Caterpillar Update/Refrigerants for

Off-Highway Equipment

Dan Spurgeon
Cab Climate Systems
Earthmoving Division
Caterpillar Inc.

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 1 1

Agenda

• CAT Machine Service Updates

•Quality Improvements
•Product Enhancements

• Selecting an Alternative Refrigerant for Off-

highway Machines

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 22

Agenda

• CAT Machine Service Updates

•Quality Improvements
•Product Enhancements

• Selecting an Alternative Refrigerant for Off-

highway Equipment

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 33

Quality Update – Water Valves
Issue
Cooling systems on certain machines have increased coolant
pressures. Existing water valves have lower life when exposed to
these higher coolant pressures.
Resolution
The new 521-2576 & 522-2362 water valve and mounting
assembly is replacing the former 238-8841 or 476-6335 Water
Valve Gp

Affected Models
• 120M (S/N: R9A1-126; B9C1-1430; R9C1-110; B9N1-354; B9W1-209; D9W1-513)
• 120M Series 2 (S/N: M921-107; M9C1-729; M9H1-444; R9N1-218; R9W1-197)
• 12M (S/N: B921-554; R9B1-127; B9F1-1497; B9R1-1388)
• 12M Series 2 (S/N: F9B1-220; F9M1-481; R9P1-199; R9S1-360)
• 12M Series 3 (S/N: N9B1-423; N9F1-669; N9P1-221; N9R1-280)
• 12M Series II (S/N: R9R1-105)
• 140M (S/N: B9D1-76001; B9G1-1056; D9G1-1668; B9M1-1078)
• 140M Series 2 (S/N: M9D1-1844; R9G1-372; M9J1-952; R9M1-559)
• 140M Series 3 (S/N: N9D1-758; N9G1-228; N9J1-510; N9M1-475)
• 14L (S/N: B941-228)
• 14M (S/N: B9J1-1450; R9J1-1857)
• 14M Series 3 (S/N: E9S1-250; N9S1-235)
• 160M (S/N: B9E1-1182; B9L1-506; B9T1-183; D9T1-1492)
• 160M Series 2 (S/N: M9E1-409; M9K1-425; R9L1-258; R9T1-349)
• 160M Series 3 (S/N: N9E1-110; N9K1-127; N9L1-151; N9T1-212)
• 16M (S/N: B9H1-866; R9H1-993)
• 16M Series 3 (S/N: E9Y1-235; N9Y1-230)
• 18M Series 3 (S/N: N9A1-227; E9W1-228) » EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 4 4
Quality Update – Evaporator Connection Stud

Issue
The existing 325-4416 Stud fitted to the 452-0537
Conditioner Gp can fail on certain Articulated
Trucks. If the existing 325-4416 Stud fails it can be
replaced with existing parts.
Resolution
Replace the 325-4416 Studs and joint seals with
new parts. New seal p/n’s are 327-0282 and
327-0283.

Service Letter
TEBE6219-02

Affected Models
• 725C 2 (S/N: 2L600145-00146 & 2T300241-00347)
• 730C 2 (S/N: 2L700204-00308 & 2T400426-00640)
• 730C 2 EJECTOR (S/N: EJ 2L800162 & 2T500137-00149)
• 735C (S/N: TFJ00257-00299, 301-318)
• 740C EJECTOR (S/N: LFN00277-00278 & TFN00189-00198)
• 745C (S/N: LFK00916-01096 & TFK01486-01661)

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 5 5

Quality Update – Air Filter Access Panel

Issue
Certain Articulated Trucks with 472-4671 Air Conditioner
are unable to service the fresh air filter due to clearance
issues. 443-4695 Right Panel Assembly is blocking the
wing nuts that retain the 259-3222 HVAC Fresh Air Filter.
Before

Resolution
1.Remove panel from the machine for modification
2.Trim the panel per the measurements provided
3.Ensure that the edges are smooth after performing the
modifications to panel
4.Reinstall panel and confirm that there is adequate
clearance to remove the air filter.

Affected Models After

• 725C 2 (S/N: 2L600145-00146 & 2T300241-00408)
• 730C 2 (S/N: 2L700204-00371 & 2T400426-00814)
• 730C 2 EJECTOR (S/N: EJ 2L800162 & 2T500137-00149)
• 735C (S/N: TFJ00257-00333)
• 740C EJECTOR (S/N: LFN00277-00278 & TFN00189-00202)
• 745C (S/N: LFK00916-01113 & TFK01486-01693)

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 6 6

Quality Update – Improved Accumulator

Issue
An improved accumulator assembly is now available for
select ADT. The improved accumulator has a larger orifice
hole to increase the oil circulation ratio (OCR).

Resolution
Replace the existing accumulator assembly with 513-7188
accumulator assembly. Also replace 320-0562 refrigerant
dryer due to system being open to the outside environment.

Affected Models
• 725C 2 (S/N: 2L0061-00146 & 2T0031-00314)
• 730C (S/N: T281-90106; LFF1-495; TFF1-1413)
• 730C EJECTOR (S/N: LFH1-UP; TFH1-160)
• 730C 2 (S/N: 2L00071-00293 & 2T0041-00591)
• 730C 2 EJECTOR (S/N: 2L00081-up & 2T00051-00142)
• 735B (S/N: L4D1-462; T4P1-490; E4R1-UP)
• 735C (S/N: TFJ00001-00292 & LFJ00001-00254)
• 740B (S/N: L4E1-41945; GLH1-143; E4S1-139)
• 740B EJECTOR (S/N: L4F1-530; T4S1-383)
• 740C EJECTOR (S/N: LFN00001-00278 & TFN00001-00197)
• 745C (S/N: LFK00001-01075 & TFK00001-01638)
» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 7 7
Service Update – Improved Sealing for Air
Conditioner Group
Issue
An improved design to the conditioner group
prevents dust/dirt from entering.

Resolution
Replace 302-8727 seal with a newer version,
along with adding a 520-6380 bracket.

Affected Models
• 950K (S/N: R4A1-UP; J5M1-UP; FER1-UP)
• 950M (S/N: EMB1-UP; ENE1-UP; XCJ1-UP; FTR1-UP; LCR1-UP; J1S1-UP)
• 950M Z (S/N: HE81-UP)
• 962K (S/N: T6A1-UP; FLL1-UP; X4T1-UP)
• 962M (S/N: EJB1-UP; JYD1-UP; LSE1-UP; RCL1-UP; J2S1-UP; F2T1-UP)
• 962M Z (S/N: SA81-UP)
• 966K (S/N: PBG1-UP; TFS1-UP)
• 966K Series XE (S/N: NGX1-UP)
• 966M (S/N: EJA1-UP; DYC1-UP; R8D1-UP; LMM1-UP; KJP1-UP; L8R1-UP)
• 966M Series XE (S/N: P6C1-UP; B8P1-UP)
• 972K (S/N: PEM1-UP; Z4W1-UP)
• 972M (S/N: L8E1-UP; LSJ1-UP; GGN1-UP; A8P1-UP; JPR1-UP; M8W1-UP)
• 972M Series XE (S/N: M5S1-UP; EDW1-UP)
• 980K (S/N: W7K1-UP; NEP1-UP; GTZ1-UP)
• 980M (S/N: MK21-UP; MGD1-UP; KRS1-UP; N8T1-UP)
• 982M (S/N: MK61-UP; F9A1-UP; LRS1-UP; K1Y1-UP)
» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 8 8
Quality Update – HVAC Control Panel
Issue
For certain machines using the 267-5243 control panel, the fan speed setting
may not functioning properly

Resolution
Solder is being added between the metal pathways for better connection
at the intersection of the printed circuit board.

1. If the fan speed setting is not functioning properly and the date
code is before 1638, replace the control panel.
2. If a fan speed setting is not functioning properly and the date
code is after 1638, then additional troubleshooting steps may be
required.

Affected Models Affected Models

• PL61 (S/N: 6P21-UP; S3H1-101; WGS1-727) • D6N (S/N: MG51-968; GB61-445; SC61-137; PBA1-3213; SGG1-132; NJN1-
• PL72 (S/N: P721-124; P731-127) 127; LJR297-1650; PER200-1143; GHS588-1846; P5T1-166; MLW320-1126)
• PL83 (S/N: CB21-175; DLW1-UP) • D6R2 (S/N: PPP1-161; SSS1-460; TTT1-183)
• PL87 (S/N: TEC1-155; ZAC1-153) • D6T (S/N: CR31-124; 2B31-UP; MH71-327; CG81-108; SGA1-105; RAD1-
• 953D (S/N: LBP1295-2139) 1026; STE1-121; JML1-251; MEL1-221; WRN1-582; K1R1-UP; KMR1-625;
WES1-412; SGT1-482; NDY1-202; TMY1-381; HTZ1-692)
• 953K (S/N: LJT1-104)
• D7E (S/N: HKA1-480; TJA425-1273; MDB260-297; SSH1-390; TAN403-1393;
• 963D (S/N: LCS1582-2517) LTW1-701)
• 963K (S/N: LBL1-420) • D8R (S/N: JR81-250; DWJ1-317; MEJ1-260; RJM1-468)
• 973D (S/N: LCP172-76001) • D8T (S/N: MB81-166; FMC1-760; MLN1-2026; FCT116-1643; JET1-205)
• D10T2 (S/N: RAB1-314; JJW1-208) • D9T (S/N: TWG1-757; REX1-475)
• D11T (S/N: AMA141-681; MDG1-182; JEL156-427; JNS131-134)
• D5R (S/N: D5L1-UP; D5X1-213)
• D5R2 (S/N: R5A1-158; WRE1-111)
• D6K (S/N: 6S61-101; MP71-102; DHA1572-2396; FBH1860-2810)
• D6K2 (S/N: EL71-148; MXK1-273; MGM1-137; DFR1-400; JTR1-614; WMR1-
1214; RST1-2209)
» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 9 9
Quality Update – HVAC Control Panel
Issue
Remove fasteners
For certain MG models, the control panel can see excessive and pull panel
heat due to it’s location behind the headliner and current draw assembly (B) from
through internal electronics. headliner

Resolution
The addition of a 524-2229 harness with relay will extend the
service life of the HVAC panel.
Disconnect main cab
harness (C) from
control panel, and
then install 524-2229.
Affected Models
• 120M (S/N: B9C739-807,1000-1443; R9C1-110; B9N347-354; B9W209-209; D9W195-
208,400-419,500-519)
• 120M Series 2 (S/N: M921-107; M9C1-791; M9H201-482; R9N102-218; R9W1-104,106-
197)
• 12M (S/N: B921-644; B9F1015-1121,1300-1497; B9R173-182,1388-1388)
Using two cable
• 12M Series 2 (S/N: F9B1-220; F9M1-481; R9P1-199; R9S1-360)
straps, secure relay
• 12M Series 3 (S/N: N9B1-101,103-488; N9F1-736; N9P1-229; N9R1-314)
• 140M (S/N: B9D3139-3329,3500-4959,76001-76001; D9G1158-1190,1300-1707)
tab (D) and relay (E) to
• 140M Series 2 (S/N: M9D207-310,500-1844; R9G1-372; M9J207-249,400-952; R9M1-559)
main harness bundle.
• 140M Series 3 (S/N: N9D1-848; N9G1-255; N9J1-570; N9M1-519)
• 14L (S/N: B941-188,191-204)
• 14M (S/N: R9J121-1857)
• 14M Series 3 (S/N: E9S1-206,250-257; N9S1-108,202-203,207-207,209-210,225-247)
• 160M (S/N: B9E523-570,700-1205; D9T165-182,300-311,1303-1520)
• 160M Series 2 (S/N: M9E206-213,400-409; M9K203-209,400-425; R9L1-258; R9T1-349)
• 160M Series 3 (S/N: N9E1-110; N9K1-127; N9L1-161; N9T1-236)
• 16M (S/N: R9H138-993)
• 16M Series 3 (S/N: E9Y1-206,225-245; N9Y1-108,201-203,207-209,225-231)
• 18M Series 3 (S/N: N9A1-228; E9W1-228)
• 24M (S/N: B931-206; B9K407-662,75001-75002)
» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 10 10
Quality Update – Blower Inlet Duct
Issue
The gasket can lose adhesion and be drawn into HVAC blower
inlet.

Resolution
An improved 525-4816 duct assembly for the HVAC is now
used on certain Motor Graders. The improved duct assembly
includes a flange for side support of gasket.

1. 249-0410 Gasket.
Affected Models 2. Fan housing
• 120M (S/N: R9A1-125; B9C512-1448; R9C1-110; B9N270-354; B9W188-209; D9W135-521) 3. 525-4816 Duct As
• 120M Series 2 (S/N: M921-107; M9C1-795; M9H201-488; R9N1-218; R9W1-197)
• 12M (S/N: B921-652; B9R159-1388)
• 12M Series 2 (S/N: F9B1-220; F9M1-481; R9P1-199; R9S1-360)
• 12M Series 3 (S/N: N9B1-449; N9F1-738; N9P1-233; N9R1-316)
• 12M Series II (S/N: R9R1-105)
• 140M (S/N: B9D2071-4963; B9G1001-1056; D9G1001-1714; B9M908-1078)
• 140M Series 2 (S/N: M9D1-1844; R9G1-372; M9J1-952; R9M1-558)
• 140M Series 3 (S/N: N9D1-856; N9G1-261; N9J1-582; N9M1-526)
• 14L (S/N: B941-204)
• 14M (S/N: B9J1063-1450; R9J1-1857)
• 160M (S/N: B9E388-1205; B9L478-505; B9T156-183; D9T121-1520)
• 160M Series 2 (S/N: M9E1-409; M9K1-425; R9L1-258; R9T1-349)
• 160M Series 3 (S/N: N9E1-110; N9K1-127; N9L1-167; N9T1-240)
• 16M (S/N: B9H707-866; R9H1-993)
• 16M Series 3 (S/N: E9Y1-247; N9Y1-231)
• 18M Series 3 (S/N: N9A1-228; E9W1-229)

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 11 11

Agenda

• CAT Machine Service Updates

•Quality Improvements
•Product Enhancements

• Selecting an Alternative Refrigerant for Off-

highway Equipment

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 12

12
Regulations – What’s happening?

Regulation:
– Paris agreement- Adopted by EU and
124 other countries including the US,
Canada, Australia
– Ratified Oct 2016 – EU
– Regulation (EU) No 517/2014
• The EU F-Gas Regulation will compel a
large-scale conversion to climate-
friendly technologies in new
equipment and products by 2030
• It will transform the European
economy with implications on
producers, importers, distributors,
manufacturers, operators, contractors
and consumers.
This chart is for EU only the other 124 countries have a different
methodology for implementation

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 13 13

Impact on availability of Refrigerant
• The EU quota - CO2 equivalence that can be sold or
imported into EU
• Quota is distributed to the refrigerant manufacturers per
regulation EU 517/2014
• Manufacturers can use their allotment for refrigerant sales
or sell to importers (OEM’s like Caterpillar)

Quantity of HFC Equivalent

to 10,000 tonne CO2e
HFC or Blend Global Warming Potential (tonnes)
HFC-23 14,800 0.6
HFC-404A 3,922 2.5
HFC-227ea 3,220 3.1
HFC-410A 2,088 4.7
HFC-407C 1,824 5.4
HFC-134a 1,430 6.9
HFC-32 675 14.8
HFC-152a 124 80.6
» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 14 14
Key Drivers
• Regulations
• Environmental Impact
• Performance
• Safety
• Manufacturing & Service
• Cost
– R&D
– Product Cost

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 15

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 Possible Alternative Refrigerant Options

R-134a R-1234yf R-152a R-744 (CO2) Propane

Environmental Impact (GWP) 1370 4.4 133 1 20
Safety (ASHRAE Rating) A1 A2L A2 A1 A3
Performance
Supply Base Readiness
Engineering Development Minimal Change
Available in Regulated
Availability of Refrigerant Limited in EU Countries Limited in EU
Service Tools (Mobile)
Service Training (Mobile)
Fuel Consumption Secondary Loop Secondary Loop
Final Scores

ASHRAE Safety Rating

- Letter designates toxicity rating: A (low) to B (high)
- Number designates flammability rating: 1 (low) to 3 (high)

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 16 16

ENGINEERING

1
7

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 17

3 Key Areas of Focus for Engineering

System Design
• SAE J639 – Safety Standards for Motor Vehicle Refrigerant Compression Systems
• SAE J2772 – Measurement of Passenger Compartment Refrigerant Concentrations Under System Refrigerant
Leakage Conditions
• SAE J2773 – Standard for Refrigerant Risk Analysis for Mobile Air Conditioning Systems
• SAE J2842 – R-1234yf and R744 Design Criteria and Certification for OEM Mobile Air Conditioning Evaporator
and Service Replacements

Plant Assembly Process

?????
Field Service
• SAE J2888 – R-1234yf Service Hose, Fittings and Couplers for Mobile Refrigerant Systems Service Equipment
• SAE J2845 – Technician Training for Safe Service and Containment of Refrigerants Used in Mobile A/C Systems
(R744 and R-1234yf)
• SAE J2843 – R-1234yf Recover/Recycling/Recharging Equipment for Flammable Refrigerants for Mobile Air
Conditioning Systems
• SAE J2851 – R-1234yf Refrigerant Recovery Equipment for Mobile Automotive Air Conditioning Systems
• SAE J2912 – R-1234yf Refrigerant Identification Equipment for Use with Mobile Air Conditioning Systems
• SAE J2913 – R-1234yf Refrigerant Electronic Leak Detectors, Minimum Performance Criteria

Considerable effort required to develop internal specs and standards to address gaps!

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 18 18

System Design - Performance Impact

• Automotive studies indicate up to 10% performance

degradation!

• Many automotive applications use an additional heat

exchanger to increase subcooling and boost performance

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 19 19

System Design - Performance Test

• Minimal difference in cab cool down capability

– Only minor system changes to R-1234yf compatible components

• Subcooler only provided minor improvement in

performance
– May need further design optimization

R-1234yf R-1234yf
w/subcooler
Cab Temp compared to R-134a (°C)
Machine #1 - 1.5 Not Tested
Machine #2 0.1 - 0.4
Machine #2 (high ambient) 1.1 - 0.9
Machine #4 0.5 Not Tested

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 20 20

System Design - Components

System charge amounts also

need to be determined!

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 21 21

Charge ports
R-134a HS R-1234yf HS R-1234yf LS R-134a LS

Typical Caterpillar couplings are steel vs aluminum used in automotive

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 22 22

Compressor protection
From SAE J639 - Compressor assemblies shall be designed to incorporate devices that will cut off
transmission of power to the compressor in the event of the compressor suffering catastrophic
internal failure. Such devices shall be equipped on the compressor pulley or compressor itself or
implemented in vehicle software.

One Possible Solution - Thermal fuse in clutch

Sequence of Events
1. Compressor is seized resulting in slipping clutch
2. Heat generated on clutch surface increases coil
temperature
3. Thermal fuse reacts to excessive temperature – opens
circuit and deactivates clutch
4. Compressor pulley can rotate freely preventing further
catastrophic damage

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 23 23

System Design - Safety per SAE J2772

Refrigerant Concentration in cabin

Risk Assessment
• Toxicity of refrigerant and decomposition
products
• Refrigerant flammability
– Lower & Upper Flammability Limits
– Minimum Ignition Energy (MIE)
– Auto ignition temperature
– Heat of combustion
– Burning velocity
– Hot surface ignition temperatures
– Relevant ignition source
– Refrigerant/oil mixture concentration

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 24 24

System Design - Machine Integration!

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 25 25

Summary

• Automotive standards are helpful, however gaps exist for off-

highway that need to be addressed

• Performance (to date) with R-1234yf seems to be on par with R-134a

• Due to automotive implementation, supply base is ready to handle

R-1234yf components and service tools

• Selecting R-1234yf does help reduce engineering time/cost, but

number of different machine models still makes for a daunting task

» EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 26

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 Thank You!

» CONFIDENTIAL YELLOW » EARTHMOVING DIVISION » CONFIDENTIAL YELLOW 27