Senr5664 11 01 All

SENR5664-11
July 2005
Specifications
Systems Operation
Testing and Adjusting
Disassembly and
Assembly
Air Conditioning and Heating R-134a
for All Caterpillar Machines
i01658146
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SENR5664-11 3
Table of Contents
Table of Contents Testing and Adjusting

Refrigerant Recovery ............................................ 98
Manifold Gauge Set (Refrigerant) - Install .......... 100
Refrigerant System - Evacuate ........................... 101
Specifications Section Refrigerant Leakage - Test ................................. 105
Refrigerant Compressor Oil - Check ................... 106
Refrigerant Compressor ....................................... 18
Refrigerant System - Charge .............................. 108
Refrigerant Compressor - Test ............................. 115
Manifold Gauge Set (Refrigerant) - Remove ....... 117
Electronic Heat Control - Test (Type 1) ............... 120
System Capacities for Refrigerant ...................... 127
Refrigerant Compressor ....................................... 31 Disassembly and Assembly Section
Refrigerant Compressor ....................................... 33 Machine Preparation for Disassembly and
Refrigerant Compressor ....................................... 35 Assembly .......................................................... 148
Refrigerant Compressor ....................................... 36 General Information ............................................ 149
Refrigerant Compressor ....................................... 38 Refrigerant Compressor - Remove and Install .. 150
Refrigerant Compressor ....................................... 38 Refrigerant Accumulator - Remove and Install ... 151
Refrigerant Compressor ....................................... 40 Refrigerant Expansion Valve - Remove and
Refrigerant Compressor ....................................... 41 Install ................................................................. 151
Refrigerant Compressor ....................................... 42 Receiver-Dryer - Remove and Install .................. 152
Refrigerant Compressor ....................................... 45 In-Line Refrigerant Dryer - Remove and Install .. 153
Refrigerant Compressor ....................................... 46 Refrigerant Orifice Tube - Remove and Install .... 153
Refrigerant Compressor ....................................... 49 Index Section
Refrigerant Compressor ....................................... 51 Index ................................................................... 155
Systems Operation Section

General Information .............................................. 53
Identifying the Air Conditioning System ................ 53
Refrigerant Compressor Protection System ......... 56
Refrigerant Condenser ......................................... 57
Evaporator Coil ..................................................... 57
Refrigerant Expansion Valve System ................... 58
Refrigerant Expansion Valve ................................ 59
Receiver-Dryer ...................................................... 61
Refrigerant Orifice Tube System ........................... 63
Refrigerant Accumulator ....................................... 64
Heating and Air Conditioning Control System ...... 65
Heating System Schematic ................................... 66
Preparation of Air Conditioner Units for Seasonal
Use ...................................................................... 66
Cab Air Filters ....................................................... 67
Glossary of Terms ................................................. 69
Testing and Adjusting Section

Troubleshooting
Required Tools ...................................................... 71
Machine Preparation for Troubleshooting ............. 72
General Troubleshooting Information ................... 73
Visual Inspection ................................................... 74
Troubleshooting Heating and Air Conditioning Control
System ................................................................ 75
Air Conditioning System Troubleshooting ............. 83
4 SENR5664-11
Specifications Section
Specifications Section Part No.: 3E-1906

S/N: JJB1-Up
i01727129
Part No.: 3E-1906
S/N: RBB1-Up
Refrigerant Compressor Part No.: 3E-1906
SMCS Code: 1802 S/N: WMB1-Up
S/N: 2021-Up Part No.: 3E-1906

S/N: 4RC5589-Up
Part No.: 3E-1906
S/N: AKA1-Up Part No.: 3E-1906
S/N: 6FC5542-Up
Part No.: 3E-1906
S/N: ASA1-Up Part No.: 3E-1906
S/N: 7NC5527-Up
Part No.: 3E-1906
S/N: BCA1-Up Part No.: 3E-1906
S/N: 8FC5612-Up
Part No.: 3E-1906
S/N: BDA1-Up Part No.: 3E-1906
S/N: 8RC5967-Up
Part No.: 3E-1906
S/N: BEA1-Up Part No.: 3E-1906
S/N: 9TC1-Up
Part No.: 3E-1906
S/N: DDA1-Up Part No.: 3E-1906
S/N: ADC1-Up
S/N: H2A1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: AEC1-Up
S/N: RTA1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: AFC1-Up
S/N: 1AB1510-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: BDC1-Up
S/N: 1FB571-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: BEC1-Up
S/N: 4AB5532-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: BNC1-Up
S/N: 5WB5586-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: CCC1-Up
S/N: AAB1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: DAC1-Up
S/N: AFB1-Up
S/N: H2C1-Up
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S/N: ASB1-Up Part No.: 3E-1906
S/N: T4C1-Up
Part No.: 3E-1906
S/N: BBB1-Up Part No.: 3E-1906
S/N: WAC1-Up
Part No.: 3E-1906
S/N: BEB1-Up Part No.: 3E-1906
S/N: 1DD6006-Up
Part No.: 106-5122
S/N: CEB1-Up Part No.: 3E-1906
S/N: 1JD1-Up
S/N: H2B1-Up
Part No.: 3E-1906
S/N: HAB1-Up S/N: 1KD5600-Up
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Part No.: 3E-1906 S/N: HAE1-Up

S/N: 1YD5522-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: WBE1-Up
S/N: 2KD5618-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1KF1040-Up
S/N: 2SD5549-Up
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Part No.: 3E-1906 S/N: 1SF1337-Up
S/N: 3MD5594-Up
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Part No.: 3E-1906 S/N: 3ZF5736-Up
S/N: 4KD5585-Up
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Part No.: 3E-1906 S/N: 4YF5575-Up
S/N: AFD1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 5BF5690-Up
S/N: AKD1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 5HF5582-Up
S/N: BMD1-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: 6CF5565-Up
S/N: CAD1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 6ZF307-Up
S/N: DAD1-Up
Part No.: 106-5122
S/N: H2D1-Up S/N: 7ZF1-Up
Part No.: 3E-1906 Part No.: 3E-1906
S/N: WBD1-Up S/N: 8TF787-Up
S/N: AAE1-Up S/N: 9RF511-Up
S/N: ADE1-Up S/N: AAF1-Up
S/N: AME1-Up S/N: AEF1-Up
S/N: ASE1-Up S/N: AGF1-Up
S/N: BDE1-Up S/N: APF1-Up
S/N: BLE1-Up S/N: ASF1-Up
S/N: BWE1-Up S/N: AXF1-Up
S/N: BZE1-Up S/N: DAF1-Up
Part No.: 3E-1906 S/N: H2F1-Up
S/N: CYE1-Up
S/N: HAF1-Up
Part No.: 3E-1906
S/N: DAE1-Up Part No.: 3E-1906
S/N: 2RG5622-Up
Part No.: 3E-1906
S/N: EAE1-Up Part No.: 3E-1906
S/N: 2TG5593-Up
S/N: H2E1-Up
6 SENR5664-11

S/N: 3XG5515-Up S/N: DAG1-Up
Part No.: 3E-1906 S/N: H2G1-Up
S/N: 3YG5772-Up
S/N: HAG1-Up
Part No.: 3E-1906
S/N: 4FG5573-Up S/N: RJG1-Up

S/N: 4GG5632-Up S/N: WBG1-Up

S/N: 4LG5598-Up S/N: WLG1-Up

S/N: 4YG1-Up S/N: AAH1-Up

S/N: 5MG221-Up S/N: AGH1-Up
Part No.: 106-5122 Part No.: 3E-1906

S/N: 6NG234-Up S/N: ALH1-Up
Part No.: 106-5122 Part No.: 3E-1906

S/N: 6YG1-Up S/N: ASH1-Up

S/N: 86G1556-Up S/N: CEH1-Up
Part No.: 3E-1906 Part No.: 106-5122

S/N: 8BG2191-Up S/N: TGH1-Up

S/N: 8YG492-Up S/N: WBH1-Up
Part No.: 106-5122, 3E-1906 Part No.: 3E-1906

S/N: 9MG119-Up S/N: 1FJ5542-Up

S/N: 9WG1161-Up S/N: 1XJ1-Up

S/N: 9XG343-Up S/N: 2JJ100-Up

S/N: AFG1-Up S/N: 3AJ331-Up

S/N: AGG1-Up S/N: 3BJ100-Up

S/N: ASG1-Up S/N: 3TJ363-Up

S/N: BKG1-Up S/N: 3XJ1-Up

S/N: BWG1-Up S/N: 4EJ1-Up

S/N: BZG1-Up S/N: 4ZJ597-Up

S/N: CNG1-Up S/N: 5EJ1-Up
SENR5664-11 7

S/N: 5TJ1-1317 S/N: BDJ1-Up
S/N: 6XJ523-Up S/N: BGJ1-Up
S/N: 6ZJ1-Up S/N: BMJ1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 7MJ340-Up S/N: BRJ1-Up
Part No.: 3E-1906 S/N: BZJ1-Up
S/N: 7WJ1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: DAJ1-Up
S/N: 7XJ124-Up
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Part No.: 3E-1906 S/N: 1HK424-Up
S/N: 8AJ855-Up
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Part No.: 3E-1906 S/N: 1PK1-Up
S/N: 8CJ1221-Up
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Part No.: 3E-1906 S/N: 1YK2048-Up
S/N: 8LJ884-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2ZK1-Up
S/N: 8PJ533-Up
Part No.: 3E-1906
S/N: 8RJ4387-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 3SK410-Up
S/N: 8WJ77-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 3XK1909-Up
S/N: 8ZJ319-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 3YK1-Up
S/N: 9EJ1-Up
Part No.: 3E-1906
S/N: 9GJ945-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 4MK1-Up
S/N: 9KJ441-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 4NK1-Up
S/N: 9PJ1001-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 4NK147-Up
S/N: 9YJ1078-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: 4SK22-Up
S/N: 9ZJ1-166
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 5AK1-Up
S/N: ABJ1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 5KK336-Up
S/N: ACJ1-Up
Part No.: 3E-1906
S/N: AEJ1-Up
Part No.: 106-5122
S/N: ASJ1-Up
8 SENR5664-11
Part No.: 106-5122 Part No.: 3E-1906

S/N: 5SK1-Up S/N: 8LK1276-Up
S/N: 5WK1001-Up S/N: 8SK369-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 6BK33-Up S/N: 8TK816-Up
S/N: 6CK354-Up S/N: 9DK143-215
S/N: 6GK393-Up S/N: 9JK361-Up
S/N: 6KK1001-Up S/N: 9KK1359-Up
S/N: 6NK1-Up S/N: 9LK464-Up
S/N: 6SK1001-Up S/N: 9MK350-Up
S/N: 6XK89-Up S/N: 9RK308-Up
S/N: 6ZK64-Up S/N: 9ZK143-Up
S/N: 7HK28-Up S/N: ABK1-Up
S/N: 7KK1-Up S/N: AWK1-Up
S/N: 7PK135-Up S/N: BDK1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 7RK241-335 S/N: BMK1-Up
Part No.: 3E-1906 S/N: BZK1-Up
S/N: 7SK1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: CFK1-Up
S/N: 7TK1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: CMK1-Up
S/N: 7ZK349-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: DAK1-Up
S/N: 8AK1-Up
S/N: JLK1-Up
Part No.: 3E-1906
S/N: 8CK206-Up Part No.: 3E-1906
S/N: 1AL1-Up
Part No.: 3E-1906
S/N: 8FK1-Up Part No.: 3E-1906
S/N: 1DL18-Up
Part No.: 3E-1906
S/N: 8HK144-Up Part No.: 106-5122
S/N: 1JL1-Up
Part No.: 3E-1906
S/N: 8KK314-Up Part No.: 3E-1906
S/N: 1KL442-Up
SENR5664-11 9
Part No.: 3E-1906 Part No.: 106-5122

S/N: 1SL510-Up S/N: 7TL1-Up
S/N: 1YL320-Up S/N: 7WL113-Up
S/N: 2BL347-Up S/N: 8AL1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 2DL214-Up S/N: 8BL1-Up
S/N: 2EL332-Up S/N: 8CL126-Up
S/N: 2SL528-Up S/N: 8ML1-Up
S/N: 2TL346-Up S/N: 8NL78-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 2XL1-Up S/N: 8RL44-Up
S/N: 2ZL1-Up S/N: 8SL1-Up
Part No.: 106-5122 Part No.: 106-5122
S/N: 3CL751-Up S/N: 9BL1-Up
S/N: 3LL678-Up S/N: 9FL121-Up
S/N: 3ML1-Up S/N: 9JL1-Up
S/N: 3RL35-Up S/N: 9KL99-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 4CL165-Up S/N: 9ML77-Up
S/N: 4EL196-Up S/N: 9RL1-Up
S/N: 5DL167-Up S/N: 9WL87-Up
S/N: 6BL112-Up S/N: ACL1-Up
S/N: 6RL45-59 S/N: AFL1-Up
S/N: 6TL1-Up S/N: ASL1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 6WL1-Up S/N: BNL1-Up
Part No.: 106-5122 S/N: BZL1-Up
S/N: 6XL170-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: DCL1-Up
S/N: 7ML1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1AM1-Up
S/N: 7PL103-Up
10 SENR5664-11

S/N: 1FM1-Up S/N: 6KM213-Up
S/N: 1JM46-Up S/N: 6NM1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 1KM1-Up S/N: 6RM1-Up
S/N: 1XM118-Up S/N: 6WM1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 1YM181-Up S/N: 6YM254-Up
S/N: 2FM1-Up S/N: 7LM1-Up
S/N: 2HM1-Up S/N: 7PM1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 2LM348-Up S/N: 7XM1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 2PM115-Up S/N: 7YM1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 2RM1-Up S/N: 8GM299-Up
S/N: 2WM1-Up S/N: 8KM1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 2ZM1-Up S/N: 8SM142-Up
S/N: 3GM1-Up S/N: 8TM1-Up
S/N: 3ZM127-Up S/N: 8ZM1-Up
S/N: 4FM1-Up S/N: 9BM1-Up
S/N: 4MM149-Up S/N: 9CM1-Up
S/N: 4RM1-Up S/N: 9DM1-Up
S/N: 4XM1-Up S/N: 9EM1-Up
S/N: 4YM270-Up S/N: 9HM1-Up
S/N: 5FM1-Up S/N: 9WM87-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 5HM1-Up S/N: 9ZM1-Up
S/N: 5YM1-Up S/N: AEM1-Up
SENR5664-11 11

S/N: AFM1-Up S/N: 4SN1-Up
S/N: AGM1-Up S/N: 4YN75-Up
S/N: ASM1-Up S/N: 5FN1-Up
S/N: BDM1-Up S/N: 5LN1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: BPM1-Up S/N: 5NN75-Up
S/N: BZM1-Up Part No.: 3E-1906
S/N: 5TN1-Up
Part No.: 3E-1906
S/N: DAM1-Up Part No.: 3E-1906
S/N: 6DN1-Up
Part No.: 3E-1906
S/N: 1DN1-Up Part No.: 106-5122
S/N: 6FN238-Up
Part No.: 3E-1906
S/N: 1GN1-Up Part No.: 106-5122
S/N: 6GN1-Up
Part No.: 3E-1906
S/N: 1WN94-Up Part No.: 3E-1906
S/N: 6JN1-Up
Part No.: 3E-1906
S/N: 2AN1-Up Part No.: 3E-1906
S/N: 6KN51-Up
Part No.: 3E-1906
S/N: 2EN1-Up Part No.: 3E-1906
S/N: 6MN75-Up
Part No.: 106-5122
S/N: 2RN1-Up Part No.: 3E-1906
S/N: 6RN1-Up
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S/N: 2YN1-Up Part No.: 3E-1906
S/N: 6YN1-Up
Part No.: 106-5122
S/N: 2ZN1-1748 Part No.: 3E-1906
S/N: 7CN1-Up
Part No.: 3E-1906
S/N: 3DN1-Up Part No.: 3E-1906
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S/N: 3WN1-Up Part No.: 3E-1906
S/N: 7FN1-Up
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S/N: 3ZN1-Up Part No.: 3E-1906
S/N: 7KN1-Up
Part No.: 3E-1906
S/N: 4HN1-Up Part No.: 3E-1906
S/N: 7LN1-Up
Part No.: 106-5122
S/N: 4JN1-Up Part No.: 3E-1906
S/N: 7PN75-Up
Part No.: 3E-1906
S/N: 4MN1-Up Part No.: 106-5122
S/N: 7SN142-Up
Part No.: 3E-1906
S/N: 4NN51-Up Part No.: 3E-1906
S/N: 7ZN1-Up
Part No.: 3E-1906
S/N: 4RN1-Up Part No.: 3E-1906
S/N: 8FN1-Up
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S/N: 8JN1-Up S/N: ALP1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 8LN1-Up S/N: BCP1-Up
S/N: 8MN1-Up S/N: BDP1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 8WN1-Up S/N: BPP1-Up
S/N: 8XN1-Up S/N: CFP1-Up
S/N: 9HN399-Up S/N: 2HR1-Up
S/N: 9MN1-Up S/N: 2JR1-Up
S/N: 9PN1-Up S/N: 2KR1-Up
S/N: 9TN1-Up S/N: 2LR1-Up
S/N: 9ZN1-Up S/N: 2RR426-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: AAN1-Up S/N: 2SR1-Up
S/N: AGN1-Up S/N: 2WR1-Up
S/N: ASN1-Up S/N: 2YR1-Up
S/N: BBN1-Up S/N: 2ZR1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: BCN1-Up S/N: 3CR1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: CEN1-Up S/N: 3DR1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: CNN1-Up S/N: 3KR1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: KBN1-Up S/N: 3NR307-Up
S/N: 9PP1-Up S/N: 3SR1-Up
S/N: 9XP1-Up S/N: 3YR1-Up
S/N: AEP1-Up S/N: 3ZR1-Up
Part No.: 106-5122 Part No.: 106-5122
S/N: AKP1-Up S/N: 4BR1-Up
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S/N: 4ER1-Up S/N: 6ER1-Up
S/N: 4FR1-Up S/N: 6FR1-Up
S/N: 4JR1-Up S/N: 6GR1-Up
S/N: 4LR1-Up S/N: 6HR1-Up
S/N: 4NR1-Up S/N: 6JR1-Up
S/N: 4SR1-Up S/N: 6KR1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 4TR1-Up S/N: 6LR1-Up
S/N: 4WR1-Up S/N: 6MR1-Up
S/N: 4XR1-Up S/N: 6TR1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 4YR1-Up S/N: 6XR1-Up
S/N: 5BR1-Up S/N: 7AR1-Up
S/N: 5CR264-Up S/N: 7BR1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 5DR1-Up S/N: 7DR1-Up
S/N: 5LR1-Up S/N: 7ER1-Up
S/N: 5MR1-Up S/N: 7FR1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 5NR1-Up S/N: 7GR1-Up
S/N: 5PR1-Up S/N: 7HR1-Up
S/N: 5RR1-Up S/N: 7JR1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 5TR969-Up S/N: 7LR1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 5WR1-Up S/N: 7SR1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 5YR1-Up S/N: 8CR1-Up
S/N: 6CR1-Up S/N: 8GR1-461
S/N: 6DR1-Up S/N: 8JR1-Up
14 SENR5664-11

S/N: 8MR1-Up S/N: CXR1-Up
Part No.: 3E-1906 S/N: TWR1-Up
S/N: 8NR1-243
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1AS1-346
S/N: 8PR1-261
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1DS1-Up
S/N: 8RR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1ES1-Up
S/N: 8SR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1GS1-143
S/N: 8TR1-485
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1HS1-Up
S/N: 8ZR1-Up
Part No.: 3E-1906
Part No.: 106-5122 S/N: 1JS1-484
S/N: 9AR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1KS1-Up
S/N: 9GR1-412
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1XS1-Up
S/N: 9LR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1YS1-Up
S/N: 9SR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 1ZS1-Up
S/N: 9TR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2AS1-Up
S/N: 9XR1-Up
Part No.: 106-5122
Part No.: 3E-1906 S/N: 2DS1-Up
S/N: 9YR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2ES1-Up
S/N: AGR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2GS1-Up
S/N: ALR1-Up
Part No.: 106-5122
Part No.: 3E-1906 S/N: 2JS1-Up
S/N: ASR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2LS1-203
S/N: BCR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2NS1-155
S/N: BDR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2PS1-Up
S/N: BER1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2RS1-Up
S/N: CDR1-Up
Part No.: 3E-1906
Part No.: 3E-1906 S/N: 2SS1-Up
S/N: CLR1-Up
Part No.: 106-5122
S/N: 2YS1-Up
SENR5664-11 15

S/N: 3AS1-Up S/N: 5SS1-Up
Part No.: 106-5122 Part No.: 106-5122
S/N: 3BS1-Up S/N: 6AS1-Up
S/N: 3FS1-254 S/N: 6ES1-Up
S/N: 3ZS1-Up S/N: 6LS1-309
Part No.: 106-5122 Part No.: 106-5122
S/N: 4BS1-Up S/N: 6NS1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 4DS1-Up S/N: 6PS1-Up
Part No.: 106-5122 Part No.: 106-5122
S/N: 4GS1-Up S/N: 6WS1-Up
S/N: 4HS1-Up S/N: 6YS1-Up
Part No.: 106-5122 Part No.: 106-5122
S/N: 4JS1-Up S/N: 7BS1-Up
S/N: 4NS1-Up S/N: 7FS1-Up
S/N: 4PS1-Up S/N: 7LS1-Up
S/N: 4RS1-Up S/N: 8PS1-Up
Part No.: 3E-1909 Part No.: 106-5122
S/N: 4SS1-Up S/N: 8RS1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 4YS1-Up S/N: 8SS1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 5AS1-Up S/N: 9FS1-Up
S/N: 5BS1-Up S/N: 9GS1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 5CS1-Up S/N: 9HS1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 5ES1-Up S/N: 9JS1-269
Part No.: 106-5122 Part No.: 3E-1906
S/N: 5FS1-Up S/N: 9PS1-Up
S/N: 5KS1-Up S/N: 9RS1-Up
S/N: 5LS1-Up S/N: 9SS1-Up
S/N: 5MS1-Up S/N: 9WS1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 5RS1-Up S/N: 9XS1-Up
16 SENR5664-11

S/N: 9ZS1-Up S/N: 2TW1-Up
S/N: ACS1-Up S/N: 2XW1-Up
S/N: CES1-Up S/N: 3AW1-Up
Part No.: 106-5122 Part No.: 106-5122
S/N: RLS1-Up S/N: 3JW1-Up
S/N: AET1-Up S/N: 3PW1-Up
S/N: AKT1-Up S/N: 3SW1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: AST1-Up S/N: 4PW1-Up
S/N: AXT1-Up S/N: 4WW1-Up
S/N: BLT1-Up S/N: 4XW1-103
S/N: BTT1-Up S/N: 5EW1-Up
S/N: CKT1-Up S/N: 5FW1-Up
S/N: CNT1-Up S/N: 5GW1-220
Part No.: 3E-1906 Part No.: 106-5122
S/N: DBT1-Up S/N: 5MW1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: FDT1-Up S/N: 5SW1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 1CW1-Up S/N: 5TW1-Up
S/N: 1EW1-Up S/N: 5WW1-Up
S/N: 1GW1-Up S/N: 63W4011-Up
S/N: 1JW1-Up S/N: 64W195-Up
S/N: 1RW1-Up S/N: 6AW1-Up
S/N: 1SW1-214 S/N: 6EW1-Up
S/N: 2KW1-Up S/N: 6HW1-Up
S/N: 2NW1-Up S/N: 6LW1-Up
SENR5664-11 17

S/N: 6PW1-Up S/N: 02X371-Up
S/N: 6QW1-Up S/N: 85X1651-Up
S/N: 6SW1-Up S/N: 86X1104-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 6YW1-Up S/N: 87X1700-Up
S/N: 7BW1-Up S/N: AAX1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 8JW1-Up S/N: AMX1-Up
S/N: 8XW1-Up S/N: BDX1-Up
S/N: 9EW1-Up S/N: CEX1-Up
S/N: 9GW1-Up S/N: CFX1-Up
S/N: 9MW1-Up S/N: CNX1-Up
S/N: 9NW1-Up S/N: WGX1-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 9SW1-Up S/N: BDY1-Up
S/N: 9WW1-Up S/N: BMY1-Up
S/N: 9ZW1-Up S/N: BTY1-Up
S/N: AAW1-Up S/N: 15Z1413-Up
S/N: ADW1-Up S/N: 16Z368-Up
S/N: ANW1-Up S/N: 17Z1614-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: ARW1-Up S/N: 1PZ1-Up
S/N: AXW1-Up S/N: 1YZ1-Up
S/N: BLW1-Up S/N: 1ZZ1-Up
S/N: DNW1-Up S/N: 21Z5346-Up
S/N: TFW1-Up Part No.: 3E-1906
S/N: 2CZ1-Up
Part No.: 3E-1906
S/N: 01X6362-Up Part No.: 3E-1906
S/N: 2FZ1-Up
18 SENR5664-11

S/N: 2KZ1-Up S/N: 7PZ1-Up
S/N: 2RZ1-Up S/N: 7RZ1-283
S/N: 2YZ1-Up S/N: 80Z5518-Up
S/N: 3AZ1-Up S/N: 89Z271-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 3DZ1-Up S/N: 8XZ1-Up
S/N: 3GZ1-Up S/N: 90Z223-Up
S/N: 3KZ1-Up S/N: 91Z453-Up
Part No.: 106-5122 Part No.: 3E-1906
S/N: 3PZ1-Up S/N: 92Z580-Up
S/N: 3RZ1-Up S/N: BCZ1-Up
S/N: 3YZ1-Up S/N: BKZ1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 4MZ1-Up S/N: BRZ1-Up
S/N: 5CZ1-Up S/N: CBZ1-Up
Part No.: 3E-1906 Part No.: 106-5122
S/N: 5EZ253-Up S/N: CZZ1-Up
S/N: 5KZ1-Up S/N: DFZ1-Up
Part No.: 3E-1906
S/N: 5LZ1-Up
Part No.: 3E-1906
S/N: 6AZ1-Up
Part No.: 3E-1906
S/N: 6DZ1-Up
Part No.: 3E-1906
S/N: 6GZ1-Up
Part No.: 3E-1906
S/N: 6SZ1-Up
Part No.: 3E-1906 g00887217
Illustration 1
S/N: 6YZ1-Up
Part No.: 3E-1906 (1) Installation torque for pressure switch
S/N: 79Z5611-Up ...................... 8.0 ± 1.5 N·m (71.00 ± 13.00 lb in)
Part No.: 3E-1906 (2) Pressure relief valve

S/N: 7MZ1-Up
Opening pressure of pressure relief
valve ................... 3800 ± 300 kPa (551 ± 44 psi)
SENR5664-11 19
Sealing pressure of pressure relief valve ICI ........................................................... KLEA 134a

.............................................. 2900 kPa (421 psi)
Magnetic Clutch
(3) Torque for oil plug ....... 10 ± 2 N·m (89 ± 18 lb in)
Clutch 24 DCV coil resistance (Green
Note: Oil plug (3) is under pressure when the system wire) ................................................ 17.6 ± 0.6 ohms
is pressurized.
Power connection ............................... DT Connector
(4) Final installation torque .. 25 ± 7 N·m (18 ± 5 lb ft)
Minimum voltage for engagement ................ 16 DCV
(5) V-belt tension
Maximum Current ...................................... 1.42 amp
New V-belt ...................... 535 ± 22 N (120 ± 5 lb)
Used V-belt ..................... 400 ± 44 N (90 ± 10 lb)
i01976073
Note: Used belt tension is for a belt that has been
operated for at least 30 minutes at the rated speed. Refrigerant Compressor
Operate the air conditioner for 30 minutes. Then,
adjust the tension of the drive belt to 400 N (90 lb). SMCS Code: 1802
Part No.: 163-0872
Note: Use a Caterpillar 144-0235 Belt Tension S/N: 1241-Up
Gauge.
Part No.: 163-0872
Displacement per revolution .... 154.9 mL (5.20 fl oz) S/N: 1251-Up
Recommended Compressor RPM ... 2500 ± 200 rpm Part No.: 163-0872
S/N: 1261-Up
Torque for Fittings
Part No.: 218-0324
Torque for 7/8 inch threaded fitting .. 25 N·m (18 lb ft) S/N: AMA1-Up
Part No.: 163-0872
Note: The 7/8 inch threaded fitting is located on S/N: AYA1-Up
the metal tube which has an internal diameter of
15.8 mm (.62 inch). Part No.: 163-0872
S/N: BAA1-Up
Torque for 3/4 inch threaded fitting ................ 17 N·m
(150 lb in) Part No.: 163-0872
S/N: CCA1-Up
Note: The 3/4 inch threaded fitting is located on
Part No.: 163-0872
S/N: MYA1-Up
12.7 mm (.50 inch).
S/N: TRA1-Up
M10 x 1.5 retaining bolt torque ................ 25 ± 7 N·m
(18 ± 5 lb ft) Part No.: 218-0324
S/N: ALB1-Up
Note: The retaining bolt is for the block fitting.
Part No.: 218-0324
Refrigerant Oil S/N: APB1-Up
Part No.: 218-0324
Oil capacity .................................... 300 mL (10 fl oz) S/N: AXB1-Up
Note: Refer to Systems Operation, “Identifying the Part No.: 163-0872
Air Conditioning System”. S/N: AYB1-Up
Poly Alkaline Glycol Oil (PAG) Part No.: 163-0872

S/N: BAB1-Up
Cat 4C-2959 Air Conditioner Lubricant (250 mL
(8.45 Oz)) S/N: DBB1-Up
S/N: J8B1-Up
R-134a Refrigerant
Part No.: 218-0324
DuPont ........................ SUVA TRANS A/C HFC134a S/N: JMB1-Up
20 SENR5664-11
Part No.: 163-0872 Part No.: 163-0872

S/N: RTB1-Up S/N: BGF1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: AXC1-Up S/N: BKF1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: BAC1-Up S/N: CAF1-Up
Part No.: 218-0324 Part No.: 183-5106
S/N: BPC1-Up S/N: CBF1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: CBC1-Up S/N: AXG1-Up
Part No.: 218-0324 Part No.: 163-0872
S/N: CCC1-Up S/N: AYG1-Up
S/N: DBC1-Up Part No.: 218-0324
S/N: BFG1-Up
Part No.: 218-0324
S/N: AGD1-Up Part No.: 183-5106
S/N: CCG1-Up
Part No.: 218-0324
S/N: ALD1-Up Part No.: 163-0872
S/N: CKG1-Up
Part No.: 218-0324
S/N: AMD1-Up Part No.: 218-0324
S/N: PEG1-Up
Part No.: 163-0872
S/N: ASD1-Up Part No.: 218-0324
S/N: AWH1-Up
Part No.: 163-0872
S/N: AYD1-Up Part No.: 218-0324
S/N: AYH1-Up
Part No.: 163-0872
S/N: BAD1-Up Part No.: 218-0324
S/N: BNH1-Up
Part No.: 183-5106
S/N: BBD1-Up Part No.: 218-0324
S/N: BTH1-Up
S/N: BXD1-Up
Part No.: 183-5106
Part No.: 163-0872 S/N: CFH1-Up
S/N: CLD1-Up
Part No.: 218-0324
Part No.: 163-0872 S/N: AKJ1-Up
S/N: CRD1-Up
Part No.: 218-0324
S/N: DBD1-Up S/N: AMJ1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: RCD1-Up S/N: AXJ1-Up
Part No.: 163-0872 Part No.: 183-5106
S/N: ASE1-Up S/N: CBJ1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: AXE1-Up S/N: CDJ1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: AYE1-Up S/N: CFJ1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: AGF1-Up S/N: CBK1-Up
S/N: AWF1-Up
SENR5664-11 21
Part No.: 183-5106 Part No.: 163-0872

S/N: CCK1-Up S/N: CCP1-Up
Part No.: 218-0324 Part No.: 218-0324
S/N: ALL1-Up S/N: 7HR1-Up
Part No.: 163-0872 Part No.: 141-9676
S/N: ARL1-Up S/N: AWR1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: AXL1-Up S/N: AXR1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: AYL1-Up S/N: BMR1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: BKL1-Up S/N: DER1-Up
Part No.: 218-0324 Part No.: 218-0324
S/N: BRL1-Up S/N: 4SS1-Up
Part No.: 183-5106 Part No.: 218-0324
S/N: CBL1-Up S/N: 5WS1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: FDL1-Up S/N: 6XS1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: SDL1-Up S/N: 7KS1-Up
Part No.: 183-5106 Part No.: 218-0324
S/N: AKM1-Up S/N: 9GS1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: APM1-Up S/N: AGS1-Up
Part No.: 141-9676 Part No.: 163-0872
S/N: AXM1-Up S/N: ANS1-Up
Part No.: 218-0324 Part No.: 163-0872
S/N: CFM1-Up S/N: ATS1-Up
S/N: WDM1-Up Part No.: 163-0872
S/N: AXS1-Up
Part No.: 218-0324
S/N: 9TN1-Up Part No.: 163-0872
S/N: AYS1-Up
Part No.: 218-0324
S/N: AMN1-Up Part No.: 183-5106
S/N: CCS1-Up
Part No.: 163-0872
S/N: APN1-Up Part No.: 163-0872
S/N: CLS1-Up
Part No.: 163-0872
S/N: AXN1-Up S/N: JMS1-Up
Part No.: 163-0872 S/N: RJS1-Up
S/N: PHN1-Up
Part No.: 218-0324
Part No.: 141-9676 S/N: ALT1-Up
S/N: AMP1-Up
Part No.: 163-0872
Part No.: 163-0872 S/N: ANT1-Up
S/N: AWP1-Up
Part No.: 218-0324
Part No.: 163-0872 S/N: AYT1-Up
S/N: AXP1-Up
Part No.: 163-0872
S/N: CLT1-Up
22 SENR5664-11
Part No.: 218-0324 Part No.: 163-0872

S/N: DET1-Up S/N: B9Y1-Up
Part No.: 218-0324 Part No.: 163-0872
S/N: 1JW1-Up S/N: BLY1-Up
Part No.: 218-0324 S/N: BXY1-Up
S/N: 2NW1-Up
Part No.: 218-0324
Part No.: 218-0324 S/N: CTY1-Up
S/N: 2SW1-Up
Part No.: 218-0324
Part No.: 218-0324 S/N: 4XZ1-Up
S/N: 2TW1-Up
Part No.: 141-9676
Part No.: 218-0324 S/N: 6GZ1-Up
S/N: 5YW1-Up
Part No.: 141-9676
Part No.: 218-0324 S/N: 7MZ1-Up
S/N: A4W1-Up
Part No.: 218-0324
Part No.: 218-0324 S/N: 9HZ1-Up
S/N: AWW1-Up
Part No.: 218-0324
S/N: AZW1-Up S/N: 9PZ1-Up
Part No.: 218-0324 Part No.: 218-0324
S/N: DCW1-Up S/N: 9TZ1-Up
Part No.: 163-0872 Part No.: 218-0324
S/N: SAW1-Up S/N: ADZ1-Up
Part No.: 163-0872 Part No.: 163-0872
S/N: AFX1-Up S/N: ALZ1-Up
Part No.: 218-0324 Part No.: 163-0872
S/N: AKX1-Up S/N: AMZ1-Up
S/N: ASX1-Up Part No.: 163-0872
S/N: ANZ1-Up
Part No.: 163-0872
S/N: AXX1-Up Part No.: 163-0872
S/N: AWZ1-Up
Part No.: 218-0324
S/N: AZX1-Up Part No.: 218-0324
S/N: AZZ1-Up
Part No.: 183-5106
S/N: BBX1-Up S/N: KPZ1-Up
S/N: BTX1-Up
Part No.: 163-0872
S/N: CSX1-Up
Part No.: 183-5106
S/N: ALY1-Up
Part No.: 163-0872
S/N: ANY1-Up
Part No.: 163-0872
S/N: AWY1-Up
Part No.: 163-0872
S/N: AXY1-Up
SENR5664-11 23
i01976060
Refrigerant Compressor
SMCS Code: 1802
Part No.: 176-1895
S/N: BEA1-Up
Part No.: 176-1895
S/N: CBA1-Up
Part No.: 176-1895
S/N: DAA1-Up
Part No.: 176-1895
S/N: EGA1-Up
Part No.: 176-1895
S/N: FAA1-Up
g00754247
Illustration 2
Part No.: 176-1895
S/N: GLA1-Up
Part No.: 176-1895
Note: Oil plug (1) is under pressure when the system S/N: GPA1-Up
is pressurized.
Part No.: 176-1895
(2) Final installation torque .. 25 ± 7 N·m (18 ± 5 lb ft) S/N: ANB1-Up
(3) Pressure relief valve Part No.: 176-1865

S/N: BDB1-Up
Opening pressure of the relief
valve ................................ 3500 kPa to 4100 kPa Part No.: 176-1895
(508 psi to 595 psi) S/N: BGB1-Up
Sealing pressure of the relief valve ..... 2900 kPa Part No.: 176-1895
(420 psi) S/N: CFB1-Up
(4) Torque for pressure switch ............ 8.0 ± 1.5 N·m Part No.: 176-1895
(71.00 ± 13.00 lb in) S/N: MAB1-Up
Displacement per revolution .... 154.9 mL (5.20 fl oz) Part No.: 176-1895
S/N: PAB1-Up
Recommended Compressor RPM ... 2500 ± 200 rpm
Part No.: 176-1895
R-134a Refrigerant S/N: BBC1-Up
Part No.: 176-1895
DuPont ........................ SUVA TRANS A/C HFC134a S/N: CJC1-Up
ICI ........................................................... KLEA 134a Part No.: 176-1895
S/N: FBC1-Up
Refrigerant Oil
Part No.: 176-1895
Oil capacity .................................... 300 mL (10 fl oz) S/N: GAC1-Up
Part No.: 176-1895
Cat 4C-2959 Air Conditioner Lubricant (PAG)
S/N: MAC1-Up
Magnetic Clutch Part No.: 176-1895
S/N: PAC1-Up
Clutch 24 DCV coil resistance ....... 17.6 ± 0.6 ohms
Part No.: 176-1895
Minimum voltage for engagement ................ 16 DCV S/N: FED1-Up
24 SENR5664-11
S/N: GAD1-Up Part No.: 176-1895

S/N: CLM1-Up
Part No.: 176-1895
S/N: AKE1-Up Part No.: 176-1895
S/N: BCN1-Up
Part No.: 176-1895
S/N: BDE1-Up Part No.: 176-1895
S/N: BFN1-Up
Part No.: 176-1895
S/N: ANF1-Up Part No.: 176-1895
S/N: BNN1-Up
Part No.: 176-1895
S/N: BEF1-Up Part No.: 176-1895
S/N: SBN1-Up
Part No.: 176-1895
S/N: BTG1-Up Part No.: 176-1895
S/N: BLP1-Up
Part No.: 176-1895
S/N: DBG1-Up Part No.: 176-1895
S/N: BER1-Up
Part No.: 176-1895
S/N: JTG1-Up Part No.: 176-1895
S/N: BGR1-Up
Part No.: 176-1895
S/N: AKH1-Up Part No.: 176-1895
S/N: BPR1-Up
Part No.: 176-1895
S/N: BPH1-Up Part No.: 176-1895
S/N: EMR1-Up
Part No.: 176-1895
S/N: DAH1-Up Part No.: 176-1895
S/N: MAR1-Up
Part No.: 176-1895
S/N: SAH1-Up Part No.: 176-1895
S/N: TBR1-Up
Part No.: 176-1895
S/N: BKJ1-Up Part No.: 176-1895
S/N: AWS1-Up
Part No.: 176-1895
S/N: AXK1-Up Part No.: 176-1895
S/N: FDS1-Up
Part No.: 176-1895
S/N: BFK1-Up Part No.: 176-1895
S/N: CBT1-Up
Part No.: 176-1895
S/N: BKK1-Up Part No.: 176-1895
S/N: CFT1-Up
Part No.: 176-1895
S/N: BBL1-Up Part No.: 176-1895
S/N: RAW1-Up
Part No.: 176-1895
S/N: EGL1-Up Part No.: 176-1895
S/N: BFX1-Up
Part No.: 176-1895
S/N: JPL1-Up Part No.: 176-1895
S/N: BMX1-Up
S/N: KGL1-Up
Part No.: 176-1895
Part No.: 176-1895 S/N: BRX1-Up
S/N: BKM1-Up
Part No.: 176-1895
Part No.: 176-1895 S/N: SLX1-Up
S/N: BZM1-Up
Part No.: 176-1895
Part No.: 176-1895 S/N: CBY1-Up
S/N: CAM1-Up
SENR5664-11 25
Part No.: 176-1895 Voltage of magnetic clutch ............................ 24 VDC

S/N: MDY1-Up
Power consumption of a saturated magnetic
Part No.: 176-1895 clutch ................................................................ 40 W
S/N: CLZ1-Up
i01943954
SMCS Code: 1802
Part No.: 218-4994
S/N: CMB1-Up
Part No.: 218-4994
S/N: CNC1-Up
Part No.: 218-4994
S/N: CED1-Up
Part No.: 218-4994
S/N: FDG1-Up
Part No.: 218-4994
S/N: CMM1-Up
Part No.: 218-4994
g00792823 S/N: CNY1-Up
Illustration 3
Part No.: 218-4994
Refer to Specifications, “Air Conditioner Lines” for S/N: 4YZ1-Up
information concerning the torque of refrigerant lines.
Part No.: 218-4994
(1) V-belt tension S/N: 5SZ1-Up
New V-belt .................. 578 ± 111 N (130 ± 25 lb)
Used V-belt ................... 445 ± 44 N (100 ± 10 lb)

operated for at least 30 minutes at the rated speed.
adjust the tension of the drive belt to 445 N (100 lb).
Note: Use a Caterpillar 144-0235 Belt Tension

Gauge in order to test the tension of the belt.
Displacement per revolution .... 188.0 mL (6.36 fl oz)
Maximum allowable speed ........................ 6000 rpm

g01011770
Illustration 4
R-134a Refrigerant
(1) Belt tension
DuPont ........................ SUVA TRANS A/C HFC134a
New belt .......................... 534 ± 22 N (120 ± 5 lb)
ICI ........................................................... KLEA 134a Used belt ........................ 400 ± 44 N (90 ± 10 lb)
Refrigerant Oil Note: Used belt tension is for a belt that has been
Oil capacity of compressor ...... 180.0 mL (6.10 fl oz) Operate the air conditioner for 30 minutes. Then,
adjust the tension of the drive belt to 400 ± 44 N
Type of compressor oil .................. DENSO ND-OIL8 (90 ± 10 lb).
Cat 4C-2959 Air Conditioner Lubricant (PAG) Note: Use a Caterpillar 144-0235 Belt Tension
Gauge.
Magnetic Clutch
26 SENR5664-11
Type of compressor ................................... TM-13HD i01714590
Displacement per revolution ......... 131 mL (4.4 fl oz) Refrigerant Compressor

Recommended Compressor RPM ......... 700 to 6000 SMCS Code: 1802
Part No.: 191-9028
R-134a Refrigerant
S/N: DSA1-Up
DuPont ........................ SUVA TRANS A/C HFC134a Part No.: 191-9028
S/N: NAD1-Up
ICI ........................................................... KLEA 134a
S/N: DCK1-Up
Refrigerant Oil
Part No.: 191-9028
Poly Alkaline Glycol (PAG) S/N: BTN1-Up
Part No.: 191-9028
Oil capacity of compressor ...... 150.0 mL (5.07 fl oz) S/N: DCR1-Up
Magnetic Clutch S/N: DGT1-Up
Rated voltage of magnetic clutch .................. 12 VDC Part No.: 191-9028

S/N: BMW1-Up
Power consumption .............................. 45 W or less
Compressor
g00895618
Illustration 5
(1) Belt tension

New belt .......................... 800 ± 22 N (180 ± 5 lb)
Used belt ...................... 489 ± 44 N (110 ± 10 lb)

(110 ± 10 lb).
Note: Use a Caterpillar 144-1102 Belt Tightener.

SENR5664-11 27
Type of compressor .................................... TM-08 B Used V-belt ..................... 400 ± 44 N (90 ± 10 lb)
Displacement per revolution ......... 82 mL (2.77 fl oz) Note: Used belt tension is for a belt that has been
Maximum allowable continuous RPM ............... 4000 Operate the air conditioner for 30 minutes. Then,
R-134a Refrigerant (90 ± 10 lb).
DuPont ........................ SUVA TRANS A/C HFC134a Note: Use a Caterpillar 144-0235 Belt Tightener.
ICI ........................................................... KLEA 134a Displacement per revolution ...... 60.0 mL (2.03 fl oz)
Refrigerant Oil Maximum allowable continuous RPM ............... 9000
Type of compressor oil ................................ ND-OIL8 R-134a Refrigerant
Oil capacity of compressor ...... 150.0 mL (5.07 fl oz) DuPont ........................ SUVA TRANS A/C HFC134a
Magnetic Clutch ICI ........................................................... KLEA 134a
Rated voltage of magnetic clutch .................. 12 VDC Magnetic Clutch
Power consumption .............................. 45 W or less Rated voltage of magnetic clutch .................. 12 VDC
Effective pulley diameter ............ 125 mm (4.92 inch) Power consumption .............................. 36 W or less
Effective pulley diameter .......... 112.5 mm (4.43 inch)

i01712047
SMCS Code: 1802
Part No.: 163-9852
S/N: DCR1-Up
Compressor
g00881035
Illustration 6
(1) V-belt tension

New V-belt ...................... 535 ± 22 N (120 ± 5 lb)
28 SENR5664-11
i01725133 R-134a Refrigerant

Refrigerant Compressor DuPont ........................ SUVA TRANS A/C HFC134a
SMCS Code: 1802 ICI ........................................................... KLEA 134a
Part No.: 105-9362
Refrigerant Oil
S/N: 5PK1001-Up
Part No.: 105-9362 Poly Alkaline Glycol Oil (PAG)
S/N: 7DK3001-Up
Cat 4C-2959 Air Conditioner Lubricant
Part No.: 105-9362
S/N: 9ZL140-Up Oil capacity of compressor ...... 230.0 mL (7.78 fl oz)
Part No.: 105-9362 Magnetic Clutch
S/N: 2PM115-Up
S/N: 3XM213-Up
Effective pulley diameter ............ 145 mm (5.71 inch)
Part No.: 105-9362
S/N: 4JM1446-Up
i01727037
Part No.: 105-9362
S/N: 6XM217-Up Refrigerant Compressor
SMCS Code: 1802
Part No.: 117-6353
S/N: APA1-Up
Part No.: 117-6353
S/N: GHA1-Up
Part No.: 117-6353
S/N: BCB1-Up
Part No.: 117-6353
S/N: BDB1-Up
Part No.: 117-6353
g00886683
S/N: BBC1-Up
Illustration 7
Part No.: 117-6353
Refer to Specifications, “Air Conditioner Lines” for S/N: HBC1-Up
information concerning the torque of refrigerant lines.
Part No.: 117-6353
(1) V-belt tension S/N: ALF1-Up
New V-belt .................. 578 ± 111 N (130 ± 25 lb) Part No.: 117-6353
Used V-belt ................... 445 ± 44 N (100 ± 10 lb) S/N: AKH1-Up
Part No.: 117-6353
S/N: BAJ1-Up
Operate the air conditioner for 30 minutes. Then, Part No.: 117-6353
adjust the tension of the drive belt to 445 N (100 lb). S/N: KAJ1-Up
Note: Use a Caterpillar 144-0235 Belt Tension Part No.: 117-6353
Gauge in order to adjust the tension of the belt. S/N: BCM1-Up
Maximum continuous speed ...................... 7000 rpm Part No.: 117-6353

S/N: CWP1-Up
Displacement per revolution ....... 100 mL (3.72 fl oz) Part No.: 117-6353
S/N: 8HR1-Up
SENR5664-11 29
Part No.: 117-6353 Displacement per revolution .............. 90 mL (3 fl oz)

S/N: 2MS1-Up
R-134a Refrigerant
Part No.: 117-6353
S/N: 2DW1-Up DuPont ........................ SUVA TRANS A/C HFC134a
Part No.: 117-6353
ICI ........................................................... KLEA 134a
S/N: 5CW1-Up
Part No.: 117-6353 Refrigerant Oil
S/N: ALX1-Up
Poly Alkaline Glycol Oil (PAG)
Part No.: 117-6353
S/N: 6KZ1-Up Cat 9U-7551 Air Conditioner Lubricant
Oil capacity of compressor ............. 130.0 ± 10.0 mL

(4.50 ± .30 fl oz)
Magnetic Clutch
Voltage of magnetic clutch ............................ 24 VDC

clutch ................................................................ 38 W
i01526357
SMCS Code: 1802
Part No.: 171-7495
S/N: APA1-Up
Part No.: 171-7495
g00887154 S/N: FBA1-Up
Illustration 8
Part No.: 171-7495
(1) V-belt tension S/N: GAA1-Up
New V-belt ...................... 535 ± 22 N (120 ± 5 lb) Part No.: 171-7495
Used V-belt ..................... 400 ± 44 N (90 ± 10 lb) S/N: GHA1-Up
Note: Used belt tension is for a belt that has been Part No.: 171-7495
operated for at least 30 minutes at the rated speed. S/N: MAA1-Up
adjust the tension of the drive belt to 400 N (90 lb). Part No.: 171-7495
S/N: PAA1-Up
Note: Use a Caterpillar 144-0235 Belt Tension Part No.: 171-7495
Gauge in order to adjust the tension of the belt. S/N: BCB1-Up
(2) Power connection ................. 2 pin DT connector Part No.: 171-7495
S/N: BDB1-Up
(3) Refer to Specifications, “Air Conditioner Lines” for
information concerning the torque of refrigerant Part No.: 171-7495
lines. S/N: CFB1-Up
Part No.: 171-7495
Refer to Specifications, “Relief Valve (Refrigerant)”
S/N: FBB1-Up
for specified pressures.
Part No.: 171-7495
Size of 1N-4635 V-Belt ...................................... 13A S/N: GAB1-Up
Model of compressor .................................. MSC90T Part No.: 171-7495
S/N: BBC1-Up
Type of compression ........................................ Scroll
30 SENR5664-11
Part No.: 171-7495

S/N: HBC1-Up
Part No.: 171-7495
S/N: BNE1-Up
Part No.: 171-7495
S/N: CAE1-Up
Part No.: 171-7495
S/N: CKE1-Up
Part No.: 171-7495
S/N: ALF1-Up
Part No.: 171-7495
S/N: AKH1-Up
Part No.: 171-7495
S/N: BAJ1-Up
Part No.: 171-7495
S/N: KAJ1-Up
Part No.: 171-7495
S/N: CLK1-Up
Part No.: 171-7495
S/N: BTL1-Up
Part No.: 171-7495 g00792850
Illustration 9
S/N: CFL1-Up
Part No.: 171-7495 Refer to Specifications, “Air Conditioner Lines” for
S/N: BCM1-Up information concerning the torque of refrigerant lines.
Part No.: 171-7495 (1) V-belt tension

S/N: CWP1-Up
New V-belt .................. 578 ± 111 N (130 ± 25 lb)
Part No.: 171-7495 Used V-belt ................... 445 ± 44 N (100 ± 10 lb)
S/N: CFT1-Up
Part No.: 171-7495 operated for at least 30 minutes at the rated speed.
S/N: ALX1-Up Operate the air conditioner for 30 minutes. Then,

Gauge in order to adjust the tension of the belt.
Maximum continuous speed ...................... 9000 rpm
Displacement per revolution ........ 90.0 cc (3.04 fl oz)
R-134a Refrigerant
ICI ........................................................... KLEA 134a
Refrigerant Oil
Cat 4C-2959 Air Conditioner Lubricant

SENR5664-11 31
Oil capacity of compressor ...... 140.0 mL (4.73 fl oz) Note: Used belt tension is for a belt that has been
Magnetic Clutch Operate the air conditioner for 30 minutes. Then,
Voltage of magnetic clutch ............................ 24 VDC (90 ± 10 lb).
Power consumption of a saturated magnetic Note: Use a Caterpillar 144-0235 Belt Tightener.
clutch ................................................................ 34 W
Type of compressor ..................................... TM-08B
i01712086
Displacement per revolution ......... 82 mL (2.77 fl oz)
Refrigerant Compressor Maximum allowable continuous RPM ............... 4000
SMCS Code: 1802
R-134a Refrigerant
Part No.: 125-1782
S/N: KGA1-Up DuPont ........................ SUVA TRANS A/C HFC134a
Part No.: 125-1782 ICI ........................................................... KLEA 134a

S/N: AKG1-Up
Refrigerant Oil
Part No.: 125-1782
S/N: 9PR1-Up
Type of compressor oil ................................ ND-OIL8
Part No.: 125-1782
S/N: 3YS1-Up Oil capacity of compressor .. 150.0 mL (5.07 ounces)
Part No.: 125-1782 Magnetic Clutch

S/N: BAS1-Up
Rated voltage of magnetic clutch .................. 24 VDC
Part No.: 125-1782
S/N: AEX1-Up Power consumption .............................. 45 W or less
Part No.: 125-1782
Effective pulley diameter .............. 125 mm (4.9 inch)
S/N: 9CZ1-Up
Compressor
g00881048
Illustration 10
(1) Belt tension

NewV-belt ....................... 535 ± 22 N (120 ± 5 lb)
Used V-belt ..................... 400 ± 44 N (90 ± 10 lb)
32 SENR5664-11
i01711840 Note: Used belt tension is for a belt that has been
Refrigerant Compressor Operate the air conditioner for 30 minutes. Then,
SMCS Code: 1802 (90 ± 10 lb).
Part No.: 189-2746
S/N: KJA1-Up
Part No.: 189-2746 Displacement per revolution ....... 147 mL (4.97 fl oz)
S/N: PCA1-Up
Refrigerant Oil
Part No.: 189-2746
S/N: WSA1-Up Oil capacity ................................... 210 mL (7.1 fl oz)
S/N: KBB1-Up Note: Refer to Systems Operation, “Identifying the
Part No.: 189-2746 Air Conditioning System”.
S/N: KHB1-Up
Part No.: 189-2746
S/N: CPE1-Up R-134a Refrigerant
Part No.: 189-2746 DuPont ........................ SUVA TRANS A/C HFC134a

S/N: HGF1-Up
ICI ........................................................... KLEA 134a
Part No.: 189-2746
S/N: MCF1-Up
Magnetic Clutch
Part No.: 189-2746
S/N: CRW1-Up Voltage of Magnetic Clutch ........................... 24 VDC
Part No.: 189-2746 Maximum RPM .......................................... 7000 rpm

S/N: KCX1-Up
i01934402
SMCS Code: 1802
Part No.: 154-0490
S/N: BBG1-Up
Part No.: 154-0490
S/N: 8GM299-Up
Part No.: 154-0490
S/N: 7EN303-Up
Part No.: 154-0490
S/N: 9HN399-Up
Part No.: 154-0490
S/N: 2JR1-Up
Part No.: 154-0490
g00881921
S/N: 2RR426-Up
Illustration 11
Part No.: 154-0490
(1) V-belt tension S/N: 3LR1-Up
New V-belt ...................... 535 ± 22 N (120 ± 5 lb) Part No.: 154-0490
Used V-belt ..................... 400 ± 44 N (90 ± 10 lb) S/N: 3NR307-Up
Part No.: 154-0490
S/N: 4NR176-Up
SENR5664-11 33
Part No.: 154-0490 Part No.: 154-0490

S/N: 5BR1639-Up S/N: 2MS1-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 5CR264-Up S/N: 2NS156-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 6CR2902-Up S/N: 3FS255-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 6DR1-Up S/N: 6LS310-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8GR1-Up S/N: 8ES1639-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8HR1-Up S/N: 9CS2902-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8JR1008-Up S/N: 9JS270-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8MR189-Up S/N: 1SW215-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8NR244-Up S/N: 3AW1-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8PR262-Up S/N: 4XW104-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8RR1-Up S/N: 5GW221-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8SR418-Up S/N: 5EZ253-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 8TR486-Up S/N: 7KZ1-Up
Part No.: 154-0490 Part No.: 154-0490
S/N: 9GR413-Up S/N: 7RZ284-Up
Part No.: 154-0490
S/N: 1AS1-Up Compressor
Part No.: 154-0490
S/N: 1BS1-Up
Part No.: 154-0490
S/N: 1DS1-Up
Part No.: 154-0490
S/N: 1ES1-Up
Part No.: 154-0490
S/N: 1GS144-Up
Part No.: 154-0490
S/N: 1HS1-Up
Part No.: 154-0490
S/N: 1JS485-Up
Part No.: 154-0490
S/N: 1KS1-Up
Part No.: 154-0490
S/N: 2LS204-Up g00887095
Illustration 12
34 SENR5664-11
(1) V-belt tension (Table 1, contd)
New V-belt ...................... 534 ± 22 N (120 ± 5 lb) Product

V-belt
Model Identification
Used V-belt ..................... 400 ± 44 N (90 ± 10 lb) Number
(A-ribbed)
Note: Used belt tension is for a belt that has been 311B 2LS204-UP 68-5590
operated for at least 30 minutes at rated speed. 312B 9GR413-UP 68-5590
adjust the tension of the drive belt to 400 ± 44 N 312BL 8JR1008-UP 68-5590
(90 ± 10 lb). 68-5590
312B 2NS156-UP
Note: Use a 144-0235 Belt Tension Gauge. 312BL 3FS255-UP 68-5590
315B 1SW215-UP 8L-8646
(2) Power connection ................ 2 pin DT connector
315BL 3AW990-UP 8L-8646
(3) The port for charging on the low pressure side
315BL 7RZ284-UP 8L-8646
has a plastic cap.
318B 3LR1-UP 8L-8646
(4) Refer to Specifications, “Refrigerant Relief Valve”
318BN 7KZ1-UP 8L-8646
320B 5BR1639-UP 8L-8646
Type of compressor ................................... 10PA15C
320B 8ES1639-UP 8L-8646
Displacement per revolution .... 155.3 mL (5.25 fl oz) 320B 4XW104-UP 8L-8646
320BL 9CS2902-UP 8L-8646
Maximum allowable continuous RPM ............... 6000
320BL 6CR2902-UP 8L-8646
R-134a Refrigerant
320BL 5GW221-UP 8L-8646
DuPont ........................ SUVA TRANS A/C HFC134a 320BLL 6LS310-UP 8L-8646
ICI ........................................................... KLEA 134a 320BLL 9JS270-UP 8L-8646

320BN 4NR176-UP 8L-8646
Compressor Oil
322B 8MR189-UP 9L-1128
Type of compressor oil ................................ ND-OIL8 322B 3NR307-UP 9L-1128
Oil capacity of compressor ......... 180 mL (6 ounces) 322B 5CR264-UP 9L-1128

322BL 8NR244-UP 9L-1128
Magnetic Clutch
322BL 1AS347-UP 9L-1128
Type of magnetic clutch ...................................... L50 325B 8PR262-UP 5M-8135
Effective pulley diameter ..... 133.0 mm (5.20 inches) 325B 8GM299-UP 5M-8135
325B 7EN303-UP 5M-8135
325BL 8RR386-UP 5M-8135
Power consumption ................................. 14.4 Ohms 325BL 1GS144-UP 5M-8135
Maximum current ......................................... 1.2 Amp 330B 8SR418-UP 1N-4635

330B 9HN399-UP 1N-4635
V-belt 330B 2RR426-UP 1N-4635
Table 1 330BL 8TR486-UP 1N-4635
Product 330BL 1JS485-UP 1N-4635
V-belt
(A-ribbed) 330B 5EZ253-UP 1N-4635
Number
311B 8GR462-UP 68-5590
(continued)
SENR5664-11 35
i02039238 Displacement per revolution .... 188.0 mL (6.36 fl oz)

Refrigerant Compressor Maximum allowable speed ........................ 6000 rpm
SMCS Code: 1802 R-134a Refrigerant
S/N: CJC1-Up
S/N: CCD1-Up
ICI ........................................................... KLEA 134a
S/N: GAD1-Up
Refrigerant Oil
S/N: GNG1-Up
Part No.: 231-6984 Oil capacity of compressor ...... 180.0 mL (6.10 fl oz)
S/N: BWH1-Up
Type of compressor oil .................. DENSO ND-OIL8
S/N: AXK1-Up
Cat 4C-2959 Air Conditioner Lubricant (PAG)
S/N: BTL1-Up
Magnetic Clutch
S/N: KGL1-Up
S/N: DBN1-Up
S/N: HKT1-Up clutch ................................................................ 40 W
i01976068
SMCS Code: 1802
Part No.: 178-5545
S/N: 1011-Up
S/N: 3011-Up
Part No.: 178-5545
S/N: 1021-Up
S/N: 2021-Up
S/N: 3021-Up
Part No.: 178-5545
S/N: 1031-Up
Part No.: 178-5545
g01048780
Illustration 13 S/N: 1041-Up
Refer to Specifications, “Air Conditioner Lines” for Part No.: 178-5545

information concerning the torque of refrigerant lines. S/N: BLA1-Up
Part No.: 178-5545
(1) V-belt tension S/N: CYA1-Up
New V-belt .................. 578 ± 111 N (130 ± 25 lb) Part No.: 178-5545
Used V-belt ................... 445 ± 44 N (100 ± 10 lb) S/N: HAA1-Up
operated for at least 30 minutes at the rated speed. S/N: MCA1-Up
adjust the tension of the drive belt to 445 N (100 lb). Part No.: 178-5545
S/N: CRB1-Up
Gauge in order to test the tension of the belt. Part No.: 178-5545
S/N: JAB1-Up
36 SENR5664-11
S/N: D3C1-Up Part No.: 178-5545

S/N: BMM1-Up
Part No.: 178-5545
S/N: S2C1-Up Part No.: 178-5545
S/N: BTM1-Up
Part No.: 178-5545
S/N: BTD1-Up Part No.: 178-5545
S/N: MKM1-Up
Part No.: 178-5545
S/N: JCD1-Up Part No.: 178-5545
S/N: S3M1-Up
Part No.: 178-5545
S/N: JLD1-Up Part No.: 178-5545
S/N: B4N1-Up
Part No.: 178-5545
S/N: KDD1-Up Part No.: 178-5545
S/N: Y4P1-Up
Part No.: 178-5545
S/N: BFE1-Up Part No.: 178-5545
S/N: C3R1-Up
Part No.: 236-6266
S/N: BTE1-Up Part No.: 178-5545
S/N: EMR1-Up
Part No.: 178-5545
S/N: DTF1-Up Part No.: 178-5545
S/N: LAR1-Up
Part No.: 178-5545
S/N: KCF1-Up Part No.: 178-5545
S/N: MAR1-Up
Part No.: 178-5545
S/N: GAG1-Up Part No.: 178-5545
S/N: BKT1-Up
Part No.: 178-5545
S/N: AMH1-Up Part No.: 178-5545
S/N: BKW1-Up
Part No.: 178-5545
S/N: BKH1-Up Part No.: 236-6266
S/N: ADX1-Up
Part No.: 178-5545
S/N: M2H1-Up Part No.: 178-5545
S/N: BLX1-Up
Part No.: 178-5545
S/N: RBH1-Up Part No.: 178-5545
S/N: GKX1-Up
Part No.: 178-5545
S/N: CSJ1-Up Part No.: 178-5545
S/N: DKY1-Up
Part No.: 178-5545
S/N: B1K1-Up Part No.: 178-5545
S/N: CGZ1-Up
Part No.: 178-5545
S/N: HEK1-Up
Part No.: 178-5545
S/N: JNK1-Up
Part No.: 178-5545
S/N: M2K1-Up
Part No.: 178-5545
S/N: B2L1-Up
Part No.: 178-5545
S/N: G1L1-Up
Part No.: 178-5545
S/N: B3M1-Up
SENR5664-11 37
Compressor S/N: XJA1-Up

S/N: GPB1-Up
S/N: KGB1-Up
S/N: ELC1-Up
S/N: KBC1-Up
S/N: MDC1-Up
S/N: ESD1-Up
S/N: PKE1-Up
S/N: SBE1-Up
S/N: T2E1-Up
S/N: WDE1-Up
S/N: KCF1-Up
S/N: T2F1-Up
Illustration 14
g00880847 S/N: HBG1-Up
Type of 146-0894 Belt ............................. (8K)-Poly S/N: TDG1-Up

S/N: GPH1-Up
Part No.: 245-7779
Maximum allowable continuous RPM ............... 6000 S/N: TAJ1-Up
R-134a Refrigerant S/N: KKK1-Up

S/N: CJM1-Up
S/N: EAM1-Up
ICI ........................................................... KLEA 134a
S/N: JCM1-Up
Refrigerant Oil
S/N: MEM1-Up
Oil capacity of compressor ...... 180.0 mL (6.10 fl oz) S/N: FEN1-Up
Type of compressor oil ..................... Denso ND-OIL8 S/N: PAN1-Up
Caterpillar 4C-2959 Air Conditioner Lubricant (PAG) S/N: RFN1-Up
Magnetic Clutch S/N: DAP1-Up

S/N: DHP1-Up
S/N: GJR1-Up
Resistance ............................................... 14.4 Ohms
S/N: JAR1-Up
Effective pulley diameter ..... 140.0 mm (5.50 inches)
S/N: M2R1-Up
i02334021
S/N: PAR1-Up
Refrigerant Compressor S/N: D3S1-Up

S/N: MCS1-Up
SMCS Code: 1802
S/N: GLT1-Up
S/N: EDA1-Up
S/N: PJW1-Up
S/N: MMA1-Up
S/N: CPX1-Up
S/N: TBA1-Up
38 SENR5664-11
S/N: BWY1-Up i01934419
S/N: MCY1-Up Refrigerant Compressor

S/N: SRY1-Up SMCS Code: 1802
S/N: MNZ1-Up Part No.: 161-3632
S/N: AMA1-Up
Compressor S/N: CCC1-Up
Part No.: 161-3632
S/N: AGD1-Up
S/N: FEE1-Up
Part No.: 161-3632
S/N: BKF1-Up
Part No.: 161-3632
S/N: BTH1-Up
Part No.: 161-3632
S/N: CFJ1-Up
Part No.: 161-3632
S/N: ALL1-Up
Part No.: 161-3632
S/N: AYR1-Up
Part No.: 161-3632
S/N: 5WS1-Up
g00880847
Illustration 15
Part No.: 161-3632
S/N: 6XS1-Up
Type of 146-0894 Belt ............................. (8K)-Poly
Part No.: 161-3632
Displacement per revolution .... 188.0 mL (6.36 fl oz) S/N: DET1-Up
Maximum allowable continuous RPM ............... 6000 Part No.: 161-3632
S/N: 2ZW1-Up
R-134a Refrigerant
Part No.: 161-3632
DuPont ........................ SUVA TRANS A/C HFC134a S/N: 6MW1-Up
Part No.: 161-3632
ICI ........................................................... KLEA 134a S/N: 8KW1-Up
Refrigerant Oil Part No.: 161-3632
S/N: 8RW1-Up
Oil capacity of compressor ...... 200.0 mL (6.76 fl oz)
Part No.: 161-3632
Type of compressor oil ..................... Denso ND-OIL8 S/N: 9CW1-Up
Caterpillar 4C-2959 Air Conditioner Lubricant (PAG) Part No.: 161-3632

S/N: AKX1-Up
S/N: BKX1-Up
Part No.: 161-3632
Resistance ............................................... 14.4 Ohms S/N: BLY1-Up
Effective pulley diameter ..... 140.0 mm (5.50 inches) Part No.: 161-3632
S/N: 4XZ1-Up
SENR5664-11 39
Compressor Rated voltage of magnetic clutch .................. 24 VDC
Power consumption ................................. 14.4 Ohms
Effective pulley diameter ..... 140.0 mm (5.50 inches)
i01723517
SMCS Code: 1802
Part No.: 113-3499
S/N: AMA1-Up
Part No.: 113-3499
Illustration 16
g00887192 S/N: AGD1-Up
(1) Belt tension Part No.: 113-3499

S/N: ALD1-Up
New belt .......................... 800 ± 22 N (180 ± 5 lb)
Used belt ...................... 489 ± 44 N (110 ± 10 lb) Part No.: 113-3499
S/N: AMD1-Up
operated for at least 30 minutes at the rated speed. S/N: 8XG194-244
adjust the tension of the drive belt to 489 ± 44 N Part No.: 113-3499
(110 ± 10 lb). S/N: BTH1-Up
Note: Use a Caterpillar 144-1102 Belt Tightener. Part No.: 113-3499

S/N: 8WJ77-Up
Type of 146-0894 Belt ............................. (8K)-Poly
Part No.: 113-3499
S/N: AKJ1-Up
(2) Power connection ................ 2 pin DT connector
Part No.: 113-3499
(3) The port for charging on the low pressure side S/N: AMJ1-Up
has a plastic cap.
Part No.: 113-3499
(4) Refer to Specifications, “Refrigerant Relief Valve” S/N: CDJ1-Up
Part No.: 113-3499
Type of compressor ................................... 10PA15C S/N: CFJ1-Up
Part No.: 113-3499
Displacement per revolution .... 155.3 mL (5.25 fl oz) S/N: 6NK1-Up
Maximum allowable continuous RPM ............... 6000 Part No.: 113-3499
S/N: 6XK89-Up
R-134a Refrigerant
Part No.: 113-3499
DuPont ........................ SUVA TRANS A/C HFC134a S/N: 8HK144-Up
ICI ........................................................... KLEA 134a Part No.: 113-3499

S/N: 2ZL1-Up
Refrigerant Oil Part No.: 113-3499
S/N: 3ML1-Up
Type of compressor oil ................................ ND-OIL8
Part No.: 113-3499
Oil capacity of compressor .. 180.0 mL (6.10 ounces) S/N: 6RL45-59

S/N: 9FL121-Up
Type of magnetic clutch ...................................... L50
Part No.: 113-3499
S/N: 9WL87-Up
40 SENR5664-11
Part No.: 113-3499 Used V-belt ..................... 400 ± 44 N (90 ± 10 lb)

S/N: ALL1-Up
Part No.: 113-3499 operated for at least 30 minutes at rated speed.
S/N: 1JM46-Up Operate the air conditioner for 30 minutes. Then,
Part No.: 113-3499
(90 ± 10 lb).
S/N: AMN1-Up
Part No.: 113-3499 Note: Use a 144-0235 Belt Tension Gauge.
S/N: AYR1-Up
(2) Power connection ................. 2 pin DT connector
Part No.: 113-3499
S/N: 5WS1-Up (3) The port for charging on the low pressure side
has a plastic cap.
Part No.: 113-3499
S/N: 6XS1-Up (4) Refer to Specifications, “Refrigerant Relief Valve”
Part No.: 133-3499 for specified pressures.
S/N: ALT1-Up
Part No.: 113-3499
S/N: 6MW1-Up Maximum allowable continuous RPM ............... 6000
Part No.: 113-3499 R-134a Refrigerant

S/N: 8KW1-Up
Part No.: 113-3499
S/N: 8RW1-Up ICI ........................................................... KLEA 134a
Part No.: 113-3499
S/N: 9CW1-Up Compressor Oil
Part No.: 113-3499 Type of compressor oil ................................ ND-OIL8

S/N: AKX1-Up
Oil capacity of compressor ......... 180 mL (6 ounces)
Part No.: 113-3499
S/N: 4XZ1-Up Magnetic Clutch
Effective pulley diameter ................. 152 mm (6 inch)
g00887095
Illustration 17
(1) V-belt tension

New V-belt ...................... 534 ± 22 N (120 ± 5 lb)
SENR5664-11 41
i01727090 New V-belt ...................... 535 ± 22 N (120 ± 5 lb)

Used V-belt ..................... 400 ± 44 N (90 ± 10 lb)
SMCS Code: 1802 operated for at least 30 minutes at the rated speed.
Part No.: 114-9484
S/N: 8RD1-Up
Part No.: 114-9484 Note: Use a Caterpillar 144-0235 Belt Tension
S/N: 9DF1-Up Gauge.
Part No.: 114-9484 Displacement per revolution .... 154.9 mL (5.20 fl oz)
S/N: ABF1-Up
Part No.: 114-9484
S/N: 3BK1-Up Torque for Fittings
Part No.: 114-9484
S/N: 5DK1-Up Torque for 7/8 inch threaded fitting .. 25 N·m (18 lb ft)
Part No.: 114-9484 Note: The 7/8 inch threaded fitting is located on
S/N: ADK1-Up the metal tube which has an internal diameter of
15.8 mm (.62 inch).
Part No.: 114-9484
S/N: 7DM1-200 Torque for 3/4 inch threaded fitting ................ 17 N·m
(150 lb in)
Part No.: 114-9484
S/N: 6NN1-Up Note: The 3/4 inch threaded fitting is located on
Part No.: 114-9484 the metal tube which has an internal diameter of
S/N: 8DN1-Up 12.7 mm (.50 inch).
Part No.: 114-9484 M10 x 1.5 retaining bolt torque ................ 25 ± 7 N·m
S/N: AEN1-Up (18 ± 5 lb ft)
Part No.: 114-9484 Note: The retaining bolt is for the block fitting.
S/N: 1DR201-Up
Refrigerant Oil
Part No.: 114-9484
S/N: 4DZ1-Up
Oil capacity ...................................... 270 mL (9 fl oz)
Note: Refer to Systems Operation, “Identifying the

Air Conditioning System”.

(8.45 Oz))
R-134a Refrigerant
ICI ........................................................... KLEA 134a

g00887199
Illustration 18
Magnetic Clutch
Clutch 12 DCV coil resistance (Black
Note: Oil plug (1) is under pressure when the system wire) ................................................ 3.5 ± 0.15 ohms
is pressurized.
Minimum voltage for engagement ............... 7.5 DCV
(3) V-belt tension
42 SENR5664-11
i01727244 (4) Final installation torque .. 25 ± 7 N·m (18 ± 5 lb ft)

Refrigerant Compressor (5) V-belt tension
SMCS Code: 1802 New V-belt ...................... 535 ± 22 N (120 ± 5 lb)
Used V-belt ..................... 400 ± 44 N (90 ± 10 lb)
Part No.: 3E-1907
S/N: 8SG5327-Up Note: Used belt tension is for a belt that has been
Part No.: 3E-1907
S/N: 5YJ1546-Up
Part No.: 3E-1907
S/N: 6MJ650-Up Note: Use a Caterpillar 144-0235 Belt Tension
Gauge.
Part No.: 3E-1907
S/N: 7EJ2812-Up Displacement per revolution .... 154.9 mL (5.20 fl oz)
Part No.: 3E-1907 Recommended Compressor RPM ... 2500 ± 200 rpm
S/N: 3KK1136-Up
Part No.: 3E-1907 Torque for Fittings
S/N: 4KK374-Up
Torque for 7/8 inch threaded fitting .. 25 N·m (18 lb ft)
Part No.: 3E-1907
S/N: 8ZK1796-Up Note: The 7/8 inch threaded fitting is located on
Part No.: 3E-1907 15.8 mm (.62 inch).
S/N: 9TK1-Up
Part No.: 3E-1907
(150 lb in)
S/N: 4GR1-Up
12.7 mm (.50 inch).

(18 ± 5 lb ft)
Refrigerant Oil
Oil capacity .................................... 300 mL (10 fl oz)

g00887217 Air Conditioning System”.
Illustration 19

(1) Installation torque for pressure switch
...................... 8.0 ± 1.5 N·m (71.00 ± 13.00 lb in)
(8.45 Oz))
(2) Pressure relief valve
Opening pressure of pressure relief R-134a Refrigerant
valve ................... 3800 ± 300 kPa (551 ± 44 psi)
Closing pressure of pressure relief DuPont ........................ SUVA TRANS A/C HFC134a
valve ..................................... 2900 kPa (421 psi)
ICI ........................................................... KLEA 134a
Magnetic Clutch
Note: Oil plug (3) is under pressure when the system
is pressurized. Clutch 12 DCV coil resistance (Black
wire) ................................................ 3.5 ± 0.15 ohms
SENR5664-11 43
Minimum voltage for engagement ............... 7.5 DCV Part No.: 3E-1908
S/N: FDH1-Up
Part No.: 3E-1908
S/N: JMH1-Up
i01727253
Part No.: 3E-1908
Refrigerant Compressor S/N: 2ZJ375-Up
SMCS Code: 1802 Part No.: 3E-1908

S/N: 5YJ1546-Up
Part No.: 3E-1908
S/N: EAA1-Up Part No.: 3E-1908
S/N: 6MJ650-Up
Part No.: 3E-1908
S/N: FEA1-Up Part No.: 3E-1908
S/N: 7EJ2812-Up
Part No.: 3E-1908
S/N: GCA1-Up Part No.: 3E-1908
S/N: 1YK2048-Up
Part No.: 3E-1908
S/N: BNB1-Up Part No.: 3E-1908
S/N: 3KK1136-Up
Part No.: 3E-1908
S/N: WGB1-Up Part No.: 3E-1908
S/N: 8ZK1796-Up
Part No.: 3E-1908
S/N: BKC1-Up Part No.: 3E-1908
S/N: 9TK1-Up
Part No.: 3E-1908
S/N: BMC1-Up Part No.: 3E-1908
S/N: BNK1-Up
Part No.: 3E-1908
S/N: CFC1-Up Part No.: 3E-1908
S/N: 2YL1-Up
Part No.: 3E-1908
S/N: FDC1-Up Part No.: 3E-1908
S/N: 5BL386-Up
Part No.: 3E-1908
S/N: BLD1-Up Part No.: 3E-1908
S/N: 6KL1-Up
Part No.: 3E-1908
S/N: HYD1-Up Part No.: 3E-1908
S/N: 6ZL1-Up
Part No.: 3E-1908
S/N: BPE1-Up Part No.: 3E-1908
S/N: 7SL1-Up
Part No.: 3E-1908
S/N: 1KF1040-Up Part No.: 3E-1908
S/N: 7YL64-Up
Part No.: 3E-1908
S/N: 6XF1-Up Part No.: 3E-1908
S/N: 8DL35-Up
Part No.: 3E-1908
S/N: CFF1-Up Part No.: 3E-1908
S/N: 8EL57-Up
Part No.: 3E-1908
S/N: 8SG5327-Up Part No.: 3E-1908
S/N: 8FL1-Up
Part No.: 3E-1908
S/N: BRG1-Up Part No.: 3E-1908
S/N: 9CL78-Up
Part No.: 3E-1908
S/N: RKG1-Up Part No.: 3E-1908
S/N: 9DL1-Up
Part No.: 3E-1908
S/N: CNH1-Up Part No.: 3E-1908
S/N: 9EL48-Up
44 SENR5664-11

S/N: 9GL1-Up S/N: 1PR1-Up
S/N: BLL1-Up S/N: 1RR1-Up
S/N: BML1-Up S/N: 1TR1-Up
S/N: 9AM1-Up S/N: 1WR1-Up
S/N: 4ZN1-Up S/N: 1XR1-Up
S/N: 5YN1-Up S/N: 1YR1-Up
S/N: 6XN1-Up S/N: 1ZR1-Up
S/N: 7WN1-Up S/N: 2AR1-Up
S/N: 8RN1-Up S/N: 2BR1-Up
S/N: 8TN1-Up S/N: 2CR1-Up
S/N: 9JN1-Up S/N: 2DR1-Up
S/N: 9KN1-Up S/N: 4GR1-Up
S/N: BLN1-Up S/N: 5AR1-Up
S/N: BPN1-Up S/N: BKR1-Up
S/N: CFN1-Up S/N: BYR1-Up
S/N: BGP1-Up S/N: 4KS1-Up
S/N: FDP1-Up S/N: 4LS1-Up
S/N: 1CR1-Up S/N: 4TS1-Up
S/N: 1ER1-Up S/N: 5GS1-Up
S/N: 1FR1-Up S/N: 5HS1-Up
S/N: 1MR1-Up S/N: 6BS1-Up
S/N: 1NR1-Up S/N: 6CS1-Up
SENR5664-11 45
Part No.: 3E-1908 Opening pressure of pressure relief valve

S/N: 6GS1-Up ............................ 3800 ± 300 kPa (551 ± 44 psi)
Sealing pressure of pressure relief
Part No.: 3E-1908 valve ..................................... 2900 kPa (421 psi)
S/N: 6HS1-Up
Part No.: 3E-1908
S/N: 6JS1-Up
Part No.: 3E-1908 is pressurized.
S/N: 6KS1-Up
Part No.: 3E-1908
S/N: 6ZS1-Up (5) V-belt tension
Part No.: 3E-1908 New V-belt ...................... 535 ± 22 N (120 ± 5 lb)
S/N: 7PS1-Up Used V-belt ..................... 400 ± 44 N (90 ± 10 lb)
Part No.: 3E-1908 Note: Used belt tension is for a belt that has been
S/N: 8BS1-Up operated for at least 30 minutes at the rated speed.
Part No.: 3E-1908 Operate the air conditioner for 30 minutes. Then,
S/N: 8CS1-Up adjust the tension of the drive belt to 400 N (90 lb).
Part No.: 3E-1908 Note: Use a Caterpillar 144-0235 Belt Tension

S/N: 8ZS1-Up Gauge.
Part No.: 3E-1908 Displacement per revolution .... 154.9 mL (5.20 fl oz)
S/N: 9TS1-Up
Part No.: 3E-1908
S/N: BNS1-Up Torque for Fittings
Part No.: 3E-1908
S/N: BMT1-Up Torque for 7/8 inch threaded fitting .. 25 N·m (18 lb ft)
Part No.: 3E-1908 Note: The 7/8 inch threaded fitting is located on
S/N: FDW1-Up the metal tube which has an internal diameter of
15.8 mm (0.62 inch).
Part No.: 3E-1908
S/N: TLX1-Up Torque for 3/4 inch threaded fitting ................ 17 N·m
(150 lb in)
Part No.: 3E-1908
S/N: BRY1-Up
12.7 mm (.50 inch).

(18 ± 5 lb ft)
Refrigerant Oil

g00887217
Illustration 20
(1) Installation torque for pressure
switch ...................... 8.0 ± 1.5 N·m (71 ± 13 lb in) Cat 4C-2959 Air Conditioner Lubricant (250 mL
(8.45 Oz))
R-134a Refrigerant
46 SENR5664-11
DuPont ........................ SUVA TRANS A/C HFC134a New belt ...................... 578 ± 111 N (130 ± 25 lb)
Used belt ...................... 445 ± 44 N (100 ± 10 lb)
ICI ........................................................... KLEA 134a
Magnetic Clutch operated for at least 30 minutes at the rated speed.
Clutch 12 DCV coil resistance (Black adjust the tension of the drive belt to 445 ± 44 N
wire) ................................................ 3.5 ± 0.15 ohms (100 ± 10 lb).
Type of connector ............................... DT Connector Note: Use a Caterpillar 144-0235 Belt Tension
Gauge.
Minimum voltage for engagement of clutch .. 7.5 DCV
Recommended compressor RPM .... 2500 ± 200 rpm
i01935556
Maximum allowable RPM ................................. 4000
Refrigerant Compressor Refrigerant Oil
SMCS Code: 1802
Oil capacity ...................................... 180 mL (6 fl oz)
Part No.: 222-2276
S/N: 4CS130-Up Note: Refer to Systems Operation, “Identifying the
Part No.: 222-2276
S/N: 4HZ1-Up Poly Alkaline Glycol Oil (PAG)
R-134a Refrigerant
ICI ........................................................... KLEA 134a
Magnetic Clutch
Clutch 24 DCV coil resistance ............... 13.4 ohms
Maximum current ....................................... 1.79 amp
g01007514
Illustration 21

valve ................................ 3500 kPa to 4100 kPa
(508 psi to 595 psi)
Sealing pressure of the relief valve ..... 2000 kPa
(290 psi)
(3) Belt tension

SENR5664-11 47
i01941214 Note: Used belt tension is for a belt that has been
Refrigerant Compressor Operate the air conditioner for 30 minutes. Then,
SMCS Code: 1802 (110 ± 10 lb).
Part No.: 151-5270
S/N: 5531-Up
S/N: 6651-Up
Part No.: 151-5270
S/N: 7DM1-200 Refrigerant Oil
Part No.: 151-5270 Oil capacity .................................... 300 mL (10 fl oz)
S/N: 8YW1-Up
Part No.: 151-5270 Note: Refer to Systems Operation, “Identifying the
S/N: 3HZ1-Up Air Conditioning System”.

(8.45 Oz))
R-134a Refrigerant
ICI ........................................................... KLEA 134a
Magnetic Clutch

wire) ................................................ 3.5 ± 0.15 ohms
g01010215 i01727258
Illustration 22

SMCS Code: 1802
is pressurized. Part No.: 134-3997
S/N: 7NC5527-Up
Part No.: 134-3997
(3) Pressure relief valve S/N: 8FC5612-Up
Opening pressure of the relief Part No.: 134-3997
valve ................... 3800 ± 300 kPa (550 ± 44 psi) S/N: 8RC5967-Up
Sealing pressure of the relief valve ..... 2900 kPa
(420 psi) Part No.: 134-3997
S/N: 9HC5521-Up
Belt tension Part No.: 134-3997
New belt .......................... 800 ± 22 N (180 ± 5 lb) S/N: 9TC1-Up
Used belt ...................... 489 ± 44 N (110 ± 10 lb) Part No.: 134-3997
S/N: 1DD6006-Up
48 SENR5664-11
Part No.: 134-3997 Part No.: 134-3997

S/N: 1KF1040-Up S/N: 4SK22-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 1SF1337-Up S/N: 5SK1-Up
Part No.: 3E-1909 Part No.: 134-3997
S/N: 6NG234-Up S/N: 7PK135-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 8BG2191-Up S/N: 7SK1-224
Part No.: 134-3997 Part No.: 134-3997
S/N: 1XJ1-Up S/N: 7TK1-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 3BJ100-Up S/N: 8AK1-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 3TJ363-Up S/N: 8TK816-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 5TJ1317 S/N: 9JK361-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 5XJ1-Up S/N: 1JL1-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 6XJ523-Up S/N: 1SL510-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 7XJ124-Up S/N: 2XL1-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 8CJ1221-Up S/N: 3CL751-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 8PJ533-Up S/N: 4CL165-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 8RJ4387-Up S/N: 4EL196-Up
Part No.: 134-3997 Part No.: 134-3997
S/N: 9GJ945-Up S/N: 5DL167-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 9YJ1078-Up S/N: 6XL170-Up
Part No.: 3E-1909 Part No.: 134-3997
S/N: 9ZJ1-166 S/N: 7PL103-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 1YK2048-Up S/N: 1KM1-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 3SK410-Up S/N: 1YM181-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 4HK366-Up S/N: 2LM348-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 4NK1-Up S/N: 2RM1-Up
Part No.: 134-3997 Part No.: 3E-1909
S/N: 4NK147-Up S/N: 7YM1-Up
SENR5664-11 49
Part No.: 3E-1909 Opening pressure of relief valve

S/N: 8SM142-Up ............................ 3800 ± 300 kPa (551 ± 44 psi)
Sealing pressure of pressure relief valve
Part No.: 134-3997 .............................................. 2900 kPa (421 psi)
S/N: 1GN1-Up
Part No.: 134-3997
S/N: 4RN1-Up
Part No.: 3E-1909 is pressurized.
S/N: 6FN238-Up
Part No.: 134-3997
S/N: 6KN51-Up (5) V-belt tension
Part No.: 134-3997 New V-belt ...................... 535 ± 22 N (120 ± 5 lb)
S/N: 6MN75-Up Used V-belt ..................... 400 ± 44 N (90 ± 10 lb)
Part No.: 134-3997 Used belt tension is for a belt that has been operated
S/N: 7PN75-Up for at least 30 minutes at the rated speed. Operate
Part No.: 3E-1909 the air conditioner for 30 minutes. Then, adjust the
S/N: 7SN142-Up tension of the drive belt to 400 N (90 lb).
Part No.: 134-3997 Note: Use a Caterpillar 144-0235 Belt Tension

S/N: 8JN1-Up Gauge.
S/N: 2KR1-Up
Part No.: 134-3997
S/N: 2SR1-Up Torque for Fittings
Part No.: 134-3997
S/N: 8ZR1-Up Torque for 7/8 inch threaded fitting .. 25 N·m (18 lb ft)
Part No.: 134-3997 Note: The 7/8 inch threaded fitting is located on
S/N: 63W4011-Up the metal tube which has an internal diameter of
15.8 mm (.62 inch).
Part No.: 134-3997
S/N: 64W195-Up Torque for 3/4 inch threaded fitting ................ 17 N·m
(150 lb in)
Part No.: 134-3997
S/N: 21Z5346-Up
12.7 mm (.50 inch).

(18 ± 5 lb ft)
Refrigerant Oil

g00887217
Illustration 23
(1) Installation torque for pressure switch
...................... 8.0 ± 1.5 N·m (71.00 ± 13.00 lb in) Cat 4C-2959 Air Conditioner Lubricant (250 mL
(8.45 Oz))
R-134a Refrigerant
50 SENR5664-11
ICI ........................................................... KLEA 134a
Magnetic Clutch
Clutch 24 DCV coil resistance (Green

wire) ................................................ 17.6 ± 0.6 ohms
i01934063
SMCS Code: 1802
S/N: 4421-Up
Part No.: 198-4564 Illustration 24
g00887111
S/N: AGC1-Up
Part No.: 198-4564 (1) Relief valve
S/N: 4XJ376-Up Opening pressure of relief valve .......... 3309 kPa
Part No.: 198-4564 (480 psi)
S/N: 2TK79-Up Sealing pressure of relief valve .......... 2964 kPa
(430 psi)
Part No.: 198-4564
S/N: 5RK1-Up (2) Final installation torque .. 25 ± 7 N·m (18 ± 5 lb ft)
Part No.: 198-4564 (3) Oil capacity ............................... 310.0 ± 14.5 mL
S/N: 3PR1-Up (10.50 ± 0.50 fl oz)
Part No.: 198-4564
S/N: 5ER1-Up
Part No.: 198-4564 Note: Oil plug (4) is pressurized.
S/N: AFS1-Up
(5) V-belt tension
Part No.: 198-4564
S/N: AGY1-Up New V-belt ...................... 712 ± 22 N (160 ± 5 lb)
Used V-belt ..................... 489 ± 22 N (110 ± 5 lb)
Part No.: 198-4564
S/N: 2PZ1-Up Note: Used belt tension is for a belt that has been
Part No.: 198-4564 Operate the air conditioner for 30 minutes. Then,
S/N: 3TZ1-Up adjust the tension of the drive belt to 489 ± 22 N
(110 ± 5 lb). The belt should not run below 400 N
(90 lb).

Gauge.
Torque for Fittings

(150 lb in)
SENR5664-11 51
Note: The 3/4 inch fitting is located on the metal Part No.: 178-9570
tube which has an internal diameter of 12.7 mm S/N: SLB1-Up
(0.50 inch).
Part No.: 178-9570
Torque for 7/8 inch threaded fitting .. 25 N·m (18 lb ft) S/N: SLC1-Up
Part No.: 178-9570
Note: The 7/8 inch fitting is located on the metal
S/N: SLD1-Up
tube which has an internal diameter of 15.8 mm
(0.62 inch). Part No.: 178-9570
S/N: SLE1-Up
Torque for 3/8 inch retaining bolt ............. 25 ± 7 N·m
(18 ± 5 lb ft) Part No.: 178-9570
S/N: SLG1-Up
R-134a Refrigerant
S/N: SLH1-Up
ICI ........................................................... KLEA 134a
Refrigerant Oil
Cat 9U-7551 Air Conditioner Lubricant
Oil capacity ...... 310.0 ± 14.5 mL (10.50 ± 0.50 fl oz)
Magnetic Clutch
Clutch 24 DCV coil resistance ................ 12.5 ohms
i01721298
Refrigerant Compressor g00884295

Illustration 25
SMCS Code: 1802
Part No.: 178-9570
S/N: 5531-Up Note: Oil plug (1) is under pressure when the system
is pressurized.
Part No.: 178-9570
S/N: 6541-Up Belt tension
Part No.: 178-9570 New belt .......................... 800 ± 22 N (180 ± 5 lb)
S/N: 6651-Up Used belt ...................... 489 ± 44 N (110 ± 10 lb)
Part No.: 178-9570
S/N: 7651-Up Note: Used belt tension is for a belt that has been
Part No.: 178-9570 Operate the air conditioner for 30 minutes. Then,
S/N: 8661-Up adjust the tension of the drive belt to 489 ± 44 N
(110 ± 10 lb).
Part No.: 178-9570
S/N: 6571-Up Note: Use a Caterpillar 138-2514 Belt Tightener.
S/N: 7671-Up
Part No.: 178-9570 Recommended Compressor RPM ... 2500 ± 200 rpm
S/N: 8681-Up
Refrigerant Oil
Part No.: 178-9570
S/N: SLA1-Up Oil capacity .................................... 300 mL (10 fl oz)
52 SENR5664-11
Note: Refer to Systems Operation, “Identifying the Note: Oil plug (1) is under pressure when the system
Air Conditioning System”. is pressurized.
Poly Alkaline Glycol Oil (PAG) (2) Final installation torque .. 25 ± 7 N·m (18 ± 5 lb ft)
Cat 4C-2959 Air Conditioner Lubricant (250 mL (3) Pressure relief valve
(8.45 Oz))
R-134a Refrigerant valve ................................ 3500 kPa to 4100 kPa
(508 psi to 595 psi)
DuPont ........................ SUVA TRANS A/C HFC134a Sealing pressure of the relief valve ..... 2900 kPa
(420 psi)
ICI ........................................................... KLEA 134a
(4) Torque for pressure switch ............ 8.0 ± 1.5 N·m
Magnetic Clutch (71.00 ± 13.00 lb in)
Clutch 24 DCV coil resistance ....... 17.6 ± 0.6 ohms Belt tension
New belt .......................... 800 ± 22 N (180 ± 5 lb)
Used belt ...................... 489 ± 44 N (110 ± 10 lb)
i01445890 Operate the air conditioner for 30 minutes. Then,
Refrigerant Compressor (110 ± 10 lb).
SMCS Code: 1802 Note: Use a Caterpillar 138-2514 Belt Tightener.

S/N: 8YW1-Up
Part No.: 151-5270 Recommended Compressor RPM ... 2500 ± 200 rpm
S/N: 9FW1-Up
Refrigerant Oil
Part No.: 151-5270
S/N: 3HZ1-Up Oil capacity .................................... 300 mL (10 fl oz)


(8.45 Oz))
R-134a Refrigerant
ICI ........................................................... KLEA 134a
Magnetic Clutch

wire) ................................................ 3.5 ± 0.15 ohms

g00754247
Illustration 26
SENR5664-11 53

i01197494
General Information
SMCS Code: 7309
The air conditioning system is a closed circuit that

uses the refrigerant , which is under pressure, to cool
the operator compartment.
• The five components of the expansion valve

system are the compressor, the condenser coil,
g00649373
the receiver-dryer, the expansion valve and the Illustration 27
evaporator coil. (1) Compressor block fittings
(2) R-134a charging ports
• The six components of the manual orifice tube
system are the compressor, the condenser coil, If the machine has R-134a charging ports (2), a tag
the accumulator, the dryer, the orifice tube and the should identify the type of refrigerant oil that is used
evaporator coil. in the system. The tag will be located inside the cab
or near the compressor. The tag will identify the type
• The seven components of the electronic orifice of refrigerant oil that is present in the air conditioning
tube system are the compressor, the condenser system. The tag will also show the amount of
coil, the accumulator, the dryer, the orifice tube, the refrigerant that is needed in the air conditioning
evaporator coil and the heater valve. system.
Note: Some orifice tube systems use an accumulator Machines that have factory installed R-134a air
with a desiccant instead of a separate dryer. conditioning systems will contain Poly Alkaline Glycol
oil in the air conditioning system.
i01409572 If the machine has been retrofitted with a R-134a
air conditioning system, the identification tag will
Identifying the Air Conditioning indicate ESTER oil as the type of refrigerant oil. The
System identification tag will be located in the cab or near
the compressor.
SMCS Code: 1808; 7320-ZJ; 7322
When a new R-134a compressor is required in order
The type of air conditioning system must be identified to retrofit a R-134a air conditioning system onto
before the system is serviced. The refrigerant must a machine with the R12 air conditioning system,
be identified so that the correct service manual can the Poly Alkaline Glycol Oil must be replaced with
be selected. ESTER oil.
By examining charging ports (2), you can determine

if the air conditioning system contains R-134a
refrigerant.
54 SENR5664-11
g00649393
Illustration 28
(3) Receiver-dryer for the expansion valve system
g00649412
Illustration 29
(4) Accumulator for an orifice tube system
The R-134a air conditioning system must be

identified as an orifice tube system or an expansion
valve system. If the system has a receiver-dryer
(3), the system is an expansion valve system. If an
accumulator (4) is present the system is an orifice
tube system.
SENR5664-11 55
i01206480 The compressor is driven by the engine. A belt

connects the engine to the clutch and pulley
Refrigerant Compressor assembly (2). The pulley assembly is located on the
clutch. The drive plate (3) is fastened to the shaft
SMCS Code: 1802 of the compressor. The clutch and pulley assembly
(2) turns on the bearing (5). The clutch and pulley
assembly (2) are not connected to the shaft (4).
The electric current from the thermostat controls a
magnetic field in the coil assembly (6).
The magnetic field pulls the drive plate (3) against

the clutch and pulley assembly (2). The clutch and
the pulley assembly (2) turns the shaft (4) that
operates the compressor. When the current to the
coil assembly (6) is stopped, the magnetic field is
removed. This allows the drive plate (3) to move
away from the clutch and pulley assembly (2). The
clutch and the pulley assembly (2) will turn freely on
the bearing (5). The sequence of connecting and
g00466903 disconnecting the pulley to the compressor shaft (4)
Illustration 30
is called compressor cycling. The compressor cycling
(1) Compressor is controlled by the thermostat . The thermostat is
(2) Magnetic clutch and pulley assembly
controlled by the capillary tube, which is installed
between the fins of the evaporator coil.
g00645443
Illustration 31
(2) Magnetic clutch and pulley assembly
(3) Drive plate
(4) Compressor shaft
(5) Bearing
(6) Coil assembly
56 SENR5664-11
i01439520
Protection System
SMCS Code: 1802
S/N: AXF1-Up
S/N: ABK1-Up
S/N: AWK1-Up
S/N: ACL1-Up
S/N: ALP1-Up g00754249
Illustration 33
S/N: 4YR1-Up (1) Output (signal voltage)
(2) Chassis ground
S/N: 6TR1-Up (3) Compressor clutch
(4) Power supply
S/N: AKT1-Up
When the air conditioning switch is activated inside
S/N: AXT1-Up
the cab, the air conditioning switch supplies 24 volts
S/N: ARW1-Up to the on delay timer assembly through pin (4). If the
voltage at pin (4) is less than 18 volts or the voltage
at pin (4) is greater than 32 volts, the on delay timer
assembly will not engage the compressor clutch coil.
If the proper voltage is present, the on delay timer
assembly delays the engagement of the compressor
clutch for 30 seconds after the air conditioning switch
is activated. The on delay timer assembly monitors
the status of three switches by sending a signal
voltage through pin (1). The following three switches
are monitored by the on delay timer assembly:
• The high/low pressure switch on the high side of

the air conditioning system
• The low pressure switch on the low side of the air

Illustration 32
g00754063 conditioning system
On Delay Timer Assembly for the Refrigerant Compressor
• The thermostat switch
The protection system uses an on delay timer
assembly for the refrigerant compressor that monitors The three switches are connected in series to ground.
three switches in order to protect the refrigerant If any one switch creates an open circuit, the on delay
compressor. The on delay timer assembly will timer assembly detects the signal.
perform the following functions:
If any of the switches cycle on and off in rapid
• Increase the life of the refrigerant compressor if succession, the on delay timer assembly will start
the air conditioning system has a low refrigerant a time delay. The time delay limits the cycles of the
charge. refrigerant compressor to 4 times per minute.
• Delay the refrigerant compressor from engaging

during engine start-up.
• Protect the compressor clutch from low voltage

and high voltage.
SENR5664-11 57
i01215364 When the refrigerant vapor leaves the compressor,

the refrigerant vapor enters the condenser. The
Refrigerant Condenser condenser is in a location that is exposed to outside
air. In order to convert the refrigerant into a liquid, the
SMCS Code: 1805 refrigerant must lose heat. The refrigerant must reach
the temperature of saturation. At the temperature of
saturation, the refrigerant vapor will become a liquid.
The temperature of saturation of the refrigerant
depends on the pressure of the refrigerant.
As the high temperature, high pressure refrigerant

vapor passes through the condenser (1), the
condenser absorbs heat from the refrigerant vapor.
The condenser transfers the heat to the outside
air. The temperature of the refrigerant and the
pressure of the refrigerant decrease until the
temperature of saturation is reached. When the
temperature of the refrigerant vapor is equal to the
temperature of saturation, the refrigerant becomes
g00289099 a high temperature, high pressure liquid. When the
Illustration 34
refrigerant is converted into a liquid, the refrigerant
Typical Condenser leaves the condenser (1).
i01692277
Evaporator Coil
SMCS Code: 7343
g00650466
Illustration 35
Typical Condenser
When the refrigerant leaves the compressor, the

refrigerant is a vapor. The temperature of the
refrigerant is high and the pressure of the refrigerant
is high when the refrigerant leaves the compressor.
The increase in pressure of the refrigerant causes
an increase in temperature of the refrigerant. The
refrigerant vapor leaves the compressor and the
refrigerant enters the condenser (1).
The refrigerant must be converted into a liquid

g00650211
that has high temperature and high pressure. The Illustration 36
refrigerant must be converted into a liquid in order to (1) Evaporator coil
increase the efficiency of the air conditioning system.
The condenser (1) converts the refrigerant vapor into
a liquid that has high temperature and high pressure.
58 SENR5664-11
In an expansion valve system, the evaporator coil i01206586

receives liquid refrigerant from the expansion valve.
In an orifice tube system, the evaporator receives Refrigerant Expansion Valve
liquid refrigerant from the orifice tube assembly. The System
liquid refrigerant that is received by the evaporator
has low pressure and low temperature. Since SMCS Code: 7320
the pressure of the liquid refrigerant is low, the
temperature of saturation of the refrigerant is low.
At the temperature of saturation, the refrigerant
changes from a liquid into a vapor. The temperature
of saturation of a fluid increases when the pressure
of a fluid increases.
The evaporator coil is exposed to the air that is inside

of the cab. The heat from the air that is inside of the
cab is absorbed by the evaporator. The evaporator
transfers the heat to the refrigerant. The amount
of heat that is required to reach the temperature of
saturation is called the latent heat of vaporization.
When this heat is absorbed by the refrigerant,
the temperature of the refrigerant will reach the
temperature of saturation. The refrigerant will change
from a liquid into a vapor. The vaporized refrigerant
will leave the evaporator. The vaporized refrigerant
will carry away the heat from the cab. The vaporized
refrigerant will return to the compressor when the
refrigerant leaves the evaporator. This process is
repeated continuously.
g00358258
Illustration 37
Refrigerant Flow Through Air Conditioning System
(1) Compressor
(2) Condenser Coil
(3) Receiver-Dryer
(4) Expansion Valve
(5) External Equalizer Line
(6) Evaporator Coil
(A) Air conditioner refrigerant as a high pressure, high temperature
vapor
(B) Air conditioner refrigerant as a high pressure, high temperature
liquid
(C) Air conditioner refrigerant as a low pressure and low
temperature liquid
(D) Air conditioner refrigerant as a low pressure and low
temperature vapor
SENR5664-11 59
The air conditioner refrigerant begins to flow in i01206980

the air conditioning system at the air conditioning
compressor (1). The primary purpose of the Refrigerant Expansion Valve
compressor (1) is changing the air conditioner
refrigerant from a vapor that has low pressure into a SMCS Code: 7320-EV
vapor that has high pressure. Also, the compressor
(1) changes the air conditioner refrigerant to a vapor
with high temperature. An increase in the pressure
from the compressor (1) causes the increase in the
temperature of the refrigerant. The refrigerant is sent
through the condenser coil (2). In the condenser
coil, the refrigerant loses a small amount of heat.
This changes the air conditioner refrigerant to a high
temperature and high pressure liquid.
In the condenser coil (2), heat is transferred from the

refrigerant to the outside air. From the condenser coil
(2), the refrigerant moves to the receiver-dryer (3).
In the receiver-dryer, moisture is removed from the
refrigerant. The air conditioner refrigerant moves from
the receiver-dryer (3) to the expansion valve (4). In
the expansion valve, the air conditioner refrigerant is
changed from a high pressure and high temperature
liquid. The refrigerant expands in the evaporator coil
(6). The refrigerant becomes a low pressure and low
temperature liquid. When the refrigerant expands
in the evaporator coil, the refrigerant absorbs heat
from the cab. This changes the refrigerant to a low
pressure and low temperature vapor. The refrigerant
returns to the compressor (1) as a low pressure and
low temperature vapor. This marks the end of the
cycle. The cycle is repeated continuously.
Note: In an expansion valve system, frost can

be used as an indication of blockage in the air
conditioning system.
g00358258
Illustration 38
(1) Compressor
(2) Condenser Coil
(3) Receiver-Dryer
(4) Expansion Valve
(6) Evaporator Coil
vapor
liquid
temperature liquid
temperature vapor
60 SENR5664-11
The liquid refrigerant with high pressure and high

temperature enters the expansion valve (4) at the
inlet (12). Only a small amount of the liquid refrigerant
is allowed to flow through the metered restriction (10)
and into the outlet. The size of the metered restriction
(10) is controlled by a ball and rod (9). The spring
(11) moves the ball and rod (9) up the expansion
valve. This makes the restriction (10) smaller. The
diaphragm (8) moves the ball and rod (9) down the
expansion valve. This makes the restriction (10)
larger. A temperature sensing bulb with a capillary
tube (7) is connected to the evaporator coil outlet
pipe. The temperature sensing bulb measures the
temperature at the outlet of the evaporator coil. If the
temperature increases, the pressure in the capillary
tube (7) increases. The pressure in the capillary
tube (7) pushes down on the diaphragm (8). The
diaphragm pushes down on the ball and rod (9).
When the ball and rod are pushed down by the
diaphragm the size of the restriction (10) increases.
The pressure that pushes on the diaphragm allows
more liquid refrigerant to flow into the evaporator coil
(6). When the temperature decreases, the pressure
decreases on the diaphragm (8). The spring (11)
pushes up the ball and rod (9) and this makes
the restriction (10) smaller. As a result, less liquid
refrigerant flows into the evaporator coil (6).
g00645819
Illustration 39 The external equalizer line (5) connects the low
Expansion Valve in the open position (typical example) pressure from the outlet of the evaporator coil (6)
(4) Expansion valve to the underside of the expansion valve (4) and
(5) External equalizer line the diaphragm (8). The pressure from the external
(7) Capillary tube equalizer line pushes up against the bottom of the
(8) Diaphragm
diaphragm. The pressure that is created by the
(9) Ball and rod
(10) Metered restriction temperature sensing bulb in the capillary tube (7)
(11) Spring pushes down the top of the diaphragm (8). The
(12) Inlet pressures on each side of the diaphragm act against
(13) Outlet each other. The variation of pressure on each side
of the diaphragm will help to regulate the refrigerant
The expansion valve (4) converts the liquid refrigerant flow by moving the ball and rod (9) up and down.
from a high temperature and a high pressure liquid. Regulating the refrigerant flow will prevent the
The liquid refrigerant is converted to a low pressure flooding of the evaporator coil (6) with refrigerant.
and a low temperature liquid. The expansion valve
provides a metered restriction (10). The expansion
valve allows the high pressure liquid to be reduced
to a low pressure liquid. When the pressure of the
refrigerant is reduced, the boiling temperature of the
refrigerant will also be reduced. The refrigerant will
enter the evaporator coil (6). Heat from the cab will
be absorbed by the refrigerant.
SENR5664-11 61
i01533300
Receiver-Dryer
SMCS Code: 7322
g00645942
Illustration 41
Typical Receiver-Dryer
(3) Receiver-dryer
(7) Quick coupler
(8) Low pressure cutoff switch
(9) Relief valve
(10) Filter
(11) Desiccant
g00358258
Illustration 40
(1) Compressor
(2) Condenser Coil
(3) Receiver-Dryer
(4) Expansion Valve
(6) Evaporator Coil
vapor
liquid
temperature liquid
temperature vapor
62 SENR5664-11
Some receiver-dryers are equipped with quick

couplers (7). Receiver-dryers that have quick
couplers can be removed and installed without
recovering the refrigerant in the air conditioner
system. Refer to Disassembly and Assembly,
“Receiver-Dryer - Remove and Install”.
High pressure relief valve (9) is located on most

receiver-dryers. The valve allows the refrigerant to be
released to the atmosphere if the pressure increases
to approximately 3450 kPa (500 psi).
Most receiver-dryers (3) will have low pressure

cutoff switch (8). If the system pressure lowers to
approximately 175 kPa (25 psi), the switch will open.
This will open the electric circuit to the magnetic
clutch and the compressor will not operate.
Moisture Indicator
Some air conditioning systems will have moisture
indicator (12). This moisture indicator is used in order
to determine the relative moisture in the system.
In order to check for moisture, the air conditioning

system must be operated for two to three hours. The
moisture indicator may indicate a problem that is
Illustration 42
g00645970 false. The system must be operated for 2 to 3 hours
before the system is checked for moisture. Look at
Top View of Receiver-Dryer
moisture indicator (12). If the moisture indicator is
(3) Receiver-dryer blue, the system is dry. If the moisture indicator is
(7) Quick coupler
(8) Low pressure cutoff switch
pink or white, the system is full of moisture.
(9) High pressure relief valve
(12) Moisture indicator If the system is full of moisture, the moisture must
(13) Sight glass be removed. Refer to Disassembly and Assembly,
“Receiver-Dryer - Remove and Install”.
The liquid refrigerant under high pressure and
under high temperature leaves condenser coil (2)
and passes through receiver-dryer (3). The liquid i01951897
refrigerant inside the receiver-dryer passes through
filter (10) and desiccant (11). The desiccant will Refrigerant Orifice Tube
absorb a small amount of moisture. System
Receiver-dryer (3) will also store a small amount of SMCS Code: 7320-QT
refrigerant. This stored refrigerant is used in order
to compensate for the changing system demands.
The demands can result from different speeds of the
compressor and small losses of refrigerant.
Note: Receiver-dryer (3) must be replaced annually.

Receiver-dryer (3) must also be replaced whenever
the system is opened. Receiver-dryer (3) should
be replaced if moisture indicator (12) is filled with
moisture. Moisture indicator (12) will display a pink
color or white color if the receiver-dryer is full of
moisture.
SENR5664-11 63
Note: In an orifice tube system, a combination of

abnormal pressure and frost may indicate blockage
in the system.
g00647550
Illustration 44
Typical In-Line Dryer
(6) Quick coupler
(7) Orifice tube assembly
(8) Desiccant
The orifice tube system uses an orifice tube in place

of the expansion valve. The accumulator (5) and
the in-line dryer with orifice tube (3) replace the
receiver-dryer.
g00647547
Illustration 43
Typical Refrigerant Orifice Tube System The orifice tube assembly (7) is located in one end
(1) Compressor of the in-line dryer (3). The in-line dryer (3) is located
(2) Condenser coil in the line that goes from the condenser coil (2) to
(3) In-Line dryer the evaporator coil (4). Quick couplers enable the
(4) Evaporator coil in-line dryer (3) to be replaced without recovering the
(5) Accumulator
(A) Refrigerant is shown as a gas with high pressure and high
system. (6).
temperature.
(B) Refrigerant is shown as a liquid with high pressure and high Note: The dryer (3) should be replaced annually. The
temperature. dryer should also be replaced whenever the system
(C) Refrigerant is shown as a low pressure and low temperature
liquid.
is opened.
(D) Refrigerant is shown as a gas with low pressure and low
temperature. In models without an in-line dryer, the desiccant is
located in the accumulator (5). The accumulator is
Note: In an orifice tube system that is properly located in the line that extends from the evaporator
charged, frost may form between the orifice tube coil (4) to the compressor (1). The orifice tube
and the compressor. The frost may be present if assembly (7) may be located before the inlet of the
the system is operating properly and if the system evaporator coils or the orifice tube may be located at
is properly charged. the inlet of the evaporator coils.
64 SENR5664-11
i01211687
NOTICE
The orifice tube systems do not have a sight glass for
Refrigerant Accumulator
determining whether the system is low on refrigerant.
SMCS Code: 7320-ZJ
Orifice Tube
g00364412
Illustration 45
Typical Orifice Tube Assembly
(7) Orifice tube assembly
(10) Orifice tube
(11) O-Ring seal
(12) Tab
(13) Screens
The orifice tube assembly (7) has a plastic body,

two screens (13) and a small brass tube (10) that is
located in the center of the body. The O-Ring seals
(11) are positioned on the body of the orifice tube to
seal against leakage. The orifice tube assembly (7 )
is contained in the dryer. The orifice tube assembly is
used in place of the thermostatic expansion valve.
The orifice tube assembly (7) changes the refrigerant

from a high pressure and high temperature refrigerant
into a low pressure and low temperature liquid. The
orifice tube (10) has a restriction. The restriction in
the orifice tube assembly allows the liquid refrigerant
to be reduced from a high pressure to a low pressure.
The flow rate is controlled by pressure differences
across the orifice. The flow rate is also controlled by
the temperature of the liquid refrigerant that is in the
bottom of the condenser. The flow rate is sensitive to
temperature differences and pressure differences.
The flow rate is more sensitive to temperature
differences.
g00647547
Illustration 46
(1) Compressor
(2) Condenser Coil
(3) In-line dryer
(4) Evaporator Coil
(5) Accumulator
vapor
liquid
temperature liquid
temperature vapor
SENR5664-11 65
i01254073
Heating and Air Conditioning

Control System
SMCS Code: 1802; 7309; 7337; 7343
Adjustable Thermostat
An adjustable thermostat contains two temperature
control knobs. The temperature control knob for the
air conditioning system is connected to an adjustable
thermostat. A thermostat is a switch. Changes in the
temperature will open the thermostat. Changes in
the temperature will also close the thermostat. When
the temperature control knob is in the OFF position,
the electric circuit that connects the adjustable
thermostat and the magnetic clutch is OPEN. In the
OFF position, the compressor does not operate.
The temperature of the air and the position of the
g00647642 temperature control knob determines if the switch
Illustration 47
is CLOSED. When the switch is CLOSED, current
(5) Accumulator moves through the thermostat to the coil assembly
(6) Inlet
(7) Desiccant in the magnetic clutch and the compressor operates.
(8) Liquid refrigerant The temperature of the air through the evaporator
(9) Oil drain hole coil is monitored by a capillary tube that is placed
(10) Outlet between the fins of the evaporator coil.
The accumulator (5) is located at the outlet of the The temperature control knob for heating is
evaporator coil (4). The accumulator (5) separates connected to the heater control valve. The
the liquid refrigerant from the refrigerant vapor temperature of the cab is maintained by the position
that passes through the evaporator coil (4). The of the air conditioning and heating temperature
accumulator (5) retains the liquid refrigerant (8) that control knobs.
is separated. Also, the accumulator (5) releases the
vapor to the compressor (1).
Nonadjustable Thermostat (Freeze
The oil drain hole (9) is located in the bottom of Control System)
the accumulator (5). The oil drain hole will drain
refrigerant oil that is separated. The oil drain hole will
also drain some of the liquid refrigerant. This liquid
refrigerant will go back to the compressor.
The flow of refrigerant out of the accumulator (5)

to the compressor (1) is mostly vapor. The vapor
contains a small amount of liquid refrigerant. This
liquid refrigerant comes from the oil drain hole (9).
When a dryer is not used in the system, desiccants

(7) are located in the base of the accumulator (5).
The desiccant is a moisture collection agent.
In an orifice tube system that has an in-line dryer (3),

there is no desiccant (15) in the accumulator (5).
g00668537
Illustration 48
66 SENR5664-11
A nonadjustable thermostat contains one The heating system uses the coolant from the
temperature control knob. The temperature control engine cooling system. The heater control valve
knob is connected to the heater control valve, which (2) is connected to the temperature control knob in
controls the flow of coolant through the heater coil. the cab. With the temperature control knob in the
The temperature of the air across the evaporator OFF position, the heater control valve prevents the
coil is preset by the nonadjustable thermostat. The flow of the coolant through the heater coil (1). When
temperature of the cab is maintained by the position the control knob is moved from the OFF position
of the temperature control knob on the heater. the control valve (2) will open. The control valve
allows coolant that is warm to flow from the outlet
Condensation that is frozen will restrict the air flow (3) through the control valve (2) to the heater coil
through the evaporator coils. The compressor will (1). As the warm coolant flows through the heater
continue operating only if the condensation does coil, the temperature of the air flow across the heater
not freeze. In order to prevent the condensation coil increases.
from freezing, the thermostat switch opens at a
temperature of approximately −1.1°C (30°F). Also, The temperature of the heater is controlled by the
the thermostat switch closes at approximately 2.2°C amount of coolant that flows through the heater coil.
(36°F). When the switch opens, the electric circuit The increase of the coolant flow through the heater
that connects the switch to the magnetic clutch is coil will increase the temperature of the air that flows
OPEN and the compressor does not operate. When across the heater coil. The coolant from the heater
the switch is CLOSED, the current moves through coil will flow to the return connection (4). Then, the
the switch to the coil assembly in the magnetic clutch coolant is sent back through the engine cooling
and the compressor operates. system.
In order to operate the system in the correct manner,

i01719754
the heater core supply must not be closed. Also, in
order to operate the system in the correct manner,
the return coolant line valve must not be closed.
Preparation of Air Conditioner
Units for Seasonal Use
i00757731 SMCS Code: 7320
Heating System Schematic In order to improve the performance of the air
SMCS Code: 7304 conditioning units, regular maintenance must be
performed before the air conditioning units are
used. In order to decrease downtime, troubleshoot
the air conditioning units before use. Failure to
inspect the air conditioning units will cause the air
conditioning units to fail prematurely. In order for the
air conditioning unit to operate at optimum efficiency,
all inspections must be performed.
1. Clean the fresh air filters or install new fresh air

filters. Clean the recirculating air filters or install
new recirculating air filters.
2. Inspect the condenser coils. Inspect the

evaporator coils. If necessary, clean the coils. Do
not steam clean the coils. In order to straighten
Illustration 49
g00343853 the fins, use the 208-1350 Radiator Tool Gp (Fin
Heating System
Straightener).
(1) Heater coil
(2) Heater Control Valve
3. Inspect the drain lines for flow of condensate.
(3) Outlet supply connection for the coolant Check for the proper location of the drain valve. If
(4) Return connection for the coolant necessary, flush the lines with water and relocate
the valve. The valve should be located between
0.0 mm (0.00 inch) and 76 mm (3 inch) from the
end of the drain line.
SENR5664-11 67
4. Inspect the wire connections for the compressor. 8. Remember that charging an R134a system is
If necessary, clean the wire connections for the different from charging an R12 system. An R134a
compressor. To check clutch operation on systems system requires an exact charge by weight. The
with adjustable thermostats, turn the thermostat charge must be within 0.01 kg (0.022 lb) of the
on and off. On some other systems, turn the listed charge. The R12 method of determining a
A/C switch on and off. Systems that have the blockage is frost, but frost is acceptable on an
compressor protection system will need up to 30 R134a system’s low side. Frost on the R134a high
seconds before the clutch engages. side indicates that the R134a charge is low. Use
the evaporator temperatures to determine the
For systems that are not used for extended condition of the R134a system charge.
periods, run the compressor monthly for a
minimum of 30 seconds. This will keep the shaft 9. Replace the dryer annually.
seal from drying out, leaking oil, and leaking
refrigerant. 10. Inspect the dust caps in order to ensure that the
dust caps that are on the service ports are in place
5. Check the condition and tension of the compressor and that the dust caps are tight. Use 2L-1224
drive belt. For compressors that are driven by a Air Conditioner Valve Cap for the high side or
V-belt, use 144-0235 Belt Tension Gauge. 8C-5248 Air Conditioner Valve Cap for the low
side on R12 systems. Use 3E-4052 Seal Cap for
6. Check all hoses and connections for refrigerant the high side or 3E-4051 Seal Cap for the low
leaks. Leaks can be identified by the following side on R134a systems. Some Excavators require
items: accumulation of oil, accumulation of using the 150-2174 Cap and 203-7888 Cap on
dust, and accumulation of dye. Check hoses the R134a system.
for damaged areas. Replace hoses that are
damaged. As required, add protection to the
i02378010
hoses or relocate the hoses.
7. Do the performance check in this manual. The

Cab Air Filters
outside temperature needs to be at least 10 °C SMCS Code: 7342
(50 °F) for R12 systems. The outside temperature
needs to be at least 21 °C (70 °F) for R134a Most Caterpillar machines with the R134a system
systems. have two cab air filters. One type of air filter is
the fresh air filter and the other type of filter is
If the performance check shows a low charge a recirculation filter inside the cab. Some of the
and the system has been used for two or more machines have a third air filter that is made of foam.
years (R12) or one year (R134a) then perform the The third filter is designed to remove large debris
following steps: before the air reaches the fresh air filter.
a. Inspect the system for leaks. The cab air filters are designed to provide clean air to
the air conditioning and the heating coils. The cab air
b. Recover the system charge. filters are designed to pressurize the cab. If the filters
are not properly maintained, the coils will be coated
c. Change the receiver-dryer, the dryer, the in-line with dirt. Dirty coils will result in loss of heating. Dirty
dryer, and the accumulator with desiccant . coils will result in loss of cooling. Dirty coils could also
result in failure of the compressor.
d. Evacuate the system for 30 minutes.
e. Recharge the system according to the

specifications.
f. Inspect the system for leaks.
g. Do the performance check again after the

system has been charged.
68 SENR5664-11
g00884577
Illustration 51
In moderate dust conditions, the cab air filters should

be cleaned weekly. In extreme dust conditions, the
filters should be inspected daily. In extreme dust
conditions, clean the filters whenever it is necessary.
Remove loose dirt with compressed air. Do not

exceed 690 kPa (100 psi) from an air nozzle that is
an eighth inch in diameter. Keep the air nozzle at
least 2 inches away from the filter.
The filters that are made of foam can be blown

Illustration 50
g00884664 out with low pressure air. The filters can be gently
washed with a mild detergent. After washing the
Cab air filters should be inspected weekly. Inspect filters, dry the filters with low pressure air.
the filter for holes. Look through the filter toward a
bright light. Check for damaged gaskets or dented If the carbon is still active, the carbon impregnated
metal parts. Do not use damaged filters. filters may be blown out with low pressure air. Do not
wash the carbon impregnated filters.
Standard filters or high efficiency filters may be blown

out with low pressure air. Do not wash the standard
filters. Do not wash the high efficiency filters.
SENR5664-11 69
i01209937 Expansion Valve – The expansion valve is a

component in the air conditioning system that
Glossary of Terms regulates the flow of liquid refrigerants into the
evaporator.
SMCS Code: 7320
Fluid – Fluid is a liquid or a gas.
Accumulator – The accumulator is a component of
an air conditioning system that has an orifice tube. Flush – Flushing is the removal of foreign material
The accumulator separates liquid refrigerants from and oil from the air conditioning system. You must
the circuit. The accumulator is used to store a small flush the system with fluid that is approved. The fluid
amount of liquid refrigerant. The accumulator may must be approved by S.A.E. and I.S.O. standards.
also contain a desiccant which will remove moisture
from the system. Freeze – Freezing causes a liquid to become a solid.
Ambient air – Outside air Gas – A gas is a substance that contains very small
particles which float in the air. A gas does not contain
Charge – The charge is a predetermined amount of liquid or solid particles.
refrigerant that is put into the air conditioning system.
The charge is measured in units of weight. Graduated Container – A graduated container is
a glass container with markings on the side of the
Compressor – The compressor is a component container. The markings are used in order to measure
in the system that increases the pressure of the the amount of fluid in the container. The markings
refrigerant. The compressor increases the pressure normally have units of ounces or units of milliliters.
of the refrigerant in the system by pumping.
Heat – Thermal energy
Condenser – The condenser is a component in the
system that changes the refrigerant from a vapor to Identifier – The identifier is an instrument that is
a liquid. used for testing the system. The identifier is used
for determining the type of refrigerant that is in the
Contaminants – Dirt, water, and air system. The identifier is also used for determining
the percentage of air that is in the system.
Desiccant – The desiccant is used in the
receiver-dryer and in the accumulator. The desiccant In-line Dryer – The in-line dryer is a component in
removes moisture from the air conditioning system. the air conditioning system that removes moisture
from the system. The in-line dryer will have air
Detecting – Detecting is finding the source of the conditioner quick disconnect in the system. The
problem in the system. in-line dryer will have an orifice tube in the system.
Diaphragm – The diaphragm is a rubber-like Latent heat of evaporation – The quantity of heat
material. The diaphragm divides the upper chamber that is absorbed by a liquid as the liquid is changed
and the lower chamber in the thermostatic expansion from a liquid into a vapor at a constant temperature.
valve.
Leak detector – The leak detector is a device that is
Discharge – Discharge is the removal of some of used to locate leaks in the air conditioning system.
the refrigerant or the removal of all the refrigerant
from the air conditioning system. Liquid line – The liquid line is the line that connects
the condenser coil, the dryer receiver, and the
Discharge side – The discharge side is the outlet expansion valve together in an expansion valve
from the compressor to the condenser coil. system. The liquid line is also the line that connects
the condenser coil and the orifice tube together in an
Evacuating – Evacuating is the removal of air and orifice tube system.
moisture from the air conditioning system.
Magnetic clutch – The magnetic clutch is a device
Evaporation – Evaporation is the process of which is used as a coupling between the pulley
changing a liquid to a vapor. and the compressor. The magnetic clutch turns the
compressor on and off. An electric current activates
Evaporator – The evaporator is the component the clutch.
in the air conditioning system that changes the
refrigerant from a liquid to a vapor. The evaporator Manifold gauge set – The manifold gauge set
transfers heat to the liquid refrigerant in order to contains gauges and hoses that are used to measure
convert the refrigerant into a vapor. the pressures in the air conditioning system.
70 SENR5664-11
Moisture – Moisture is water that is in the air or Recycle – The recycling of the refrigerant is usually
water that is in the refrigerant. completed at the site or at the service shop. The
refrigerant can be cleaned by using oil separation.
Moisture indicator – The moisture indicator is a The refrigerant can be cleaned by passing the
device that uses color to indicate if the material in refrigerant through a filter dryer.
the dryer is fully soaked with moisture. The moisture
indicator will display a pink color or a white color Refrigerant – The refrigerant is the fluid that is
if the moisture indicator is soaked with moisture. used in the air conditioning system. The refrigerant
The moisture indicator will display a blue color if removes heat from the operator’s compartment.
the moisture indicator is capable of absorbing more
moisture. Refrigerant oil – Refrigerant oil is the oil that is
used in the air conditioning system. The refrigerant
Orifice tube – The orifice tube has a body that is oil lubricates the compressor.
plastic with a metal tube device. The orifice tube is a
metering control. The orifice tube is located between Sight glass – The sight glass is used to observe the
the high pressure side and the low pressure side in flow of refrigerant in the air conditioning system. The
the orifice tube system. sight glass is located at the top of the receiver-dryer
or in the line that is leaving the receiver-dryer.
Overcharge – A system is overcharged when an
excessive amount of refrigerant is present in the air Stabilize – If the performance of the system is
conditioning system. constant, the system is stabilized.
Partial charge – A partial charge is less than a full Stuck – Sticking will cause the prevention of free
charge of refrigerant. An air conditioning system has movement.
a partial charge when there is not enough refrigerant
in the system. Sub-cooling – The additional cooling of the
refrigerant in the bottom of the condenser after the
Performance test – The performance test is the refrigerant has changed from a vapor to a liquid.
notation of temperatures and pressures under
controlled conditions. The performance test is used Suction side – The suction side is the connection
in order to determine if the air conditioning system is that is between the evaporator coil and the
operating normally. compressor.
Refrigerant quick-check procedure – The Superheat – The additional heating of the refrigerant
refrigerant quick-check procedure is a brief inspection in the bottom of the evaporator after the refrigerant
of the system. No instruments are required in order has changed from a liquid to a vapor.
to perform a refrigerant quick-check procedure.
Temperature of saturation – At the temperature
Receiver-dryer – The receiver-dryer is the of saturation, a liquid will change into a vapor and
component in the air conditioning system that a vapor changes into a liquid. The temperature of
removes the contaminants (moisture) from the circuit. saturation depends on the pressure of the fluid.
The receiver-dryer is also a storage area for a small The temperature of saturation increases when the
amount of liquid refrigerant. The receiver-dryer may pressure of a fluid increases.
also have a pressure switch that deactivates the
compressor if the pressure of the refrigerant is lower Vapor – Gas
than approximately 175 kPa (25 psi).
Reclaim – The reclaiming and the restoring of air

conditioner refrigerant must meet the S.A.E. and the
I.S.O. specifications. The reclaiming of air conditioner
refrigerant requires processes that are available only
at a remanufacturing facility.
Recover – Recovering is the removal of the air

conditioner refrigerant from the air conditioner
system. The refrigerant must be stored in an
approved container. The refrigerant is not required
to be tested or processed when the refrigerant is
recovered from the system.
SENR5664-11 71
Testing and Adjusting (Table 2, contd)

Required Tools
Section Part Number Part Description
208-1333 Refrigerant Hose
Troubleshooting 208-1332 Refrigerant Hose
208-1340 Refrigerant Coupler (High Pressure)
i02061707 208-1339 Refrigerant Coupler (Low Pressure)
Required Tools 5P-7277 Voltage Tester
8T-0500 Continuity Tester
SMCS Code: 7320
9U-5325 Thermometer
Table 2
Refrigerant Identifier (110/220 Volt
Required Tools 138-6629
60/50 Hz)
Part Number Part Description 174-0839 Refrigerant Analyzer Tool Gp
Refrigerant Service Unit 153-8537 Air Conditioner Flushing Unit (Cart)
208-1316 (Recovery/Recyling/Recharging)(110
V / 60 Hz) 153-9032 Air Conditioner Flushing Unit (Portable)
Refrigerant Service Unit (230 V / 50/60 153-9033 Adapter Kit (Air Conditioner Flushing)
197-1915
Hz)
153-8538 Refrigerant Flushing Solution
Refrigerant Service Unit
9U-7804 O-ring Kit
208-1323 (Recovery/Recyling/Recharging)(115
V / 60 Hz) 192-4723 Dye Injection Tool Gp
Refrigerant Service Unit (Recovery/ 192-2331 Leak Detection Lamp Gp
208-1326 Recyling/Recharging)(220-240 V / 50
Hz) 192-4727 Dye Cleaning Solution
Electronic Charging Scale (115 V / 60 208-1375 Orifice Tool Gp
168-1959
Hz)
8T-9275 Radiator Tool Gp
Electronic Charging Scale (220-240 V
168-1961
/ 50 Hz)
168-1958 Electronic Charging Scale (Battery)
208-1317 Refrigerant Filter-Drier
208-1341 Manifold Gauge Set
208-1353 Thermistor Gauge
4C-2964 Refrigerant Leak Detector
9U-6494 Refrigerant Oil Injector
208-1338 Refrigerant Service Unit(Recovery)
208-1319 Refrigerant Tank (22.7 kg (50 lb))
Vacuum Pump (1.2 CFM, 110 V / 60
208-1381
Hz)
208-1556 Vacuum Pump (4 CFM, 110V / 60Hz)
Vacuum Pump (1.2 CFM, 220 V /
208-1382
50-60 Hz)
Vacuum Pump (4 CFM, 220-250 V /
208-1357
50-60 Hz)
1U-9763 Vacuum Pump Oil
1U-8085 Eye Protection Goggles (Vented)
208-1331 Refrigerant Charging Hose
(continued)
72 SENR5664-11
i01693240 • Always wear goggles when you are working on or

testing any part of the air conditioning system.
Machine Preparation for
Troubleshooting • Place a clean cloth over any valve or any
connection that is opened.
SMCS Code: 7320
• Never weld any charged components.
• Never solder any charged components.
Personal injury can result from contact with refrig- • Never steam clean any charged components.
erant.
• Do not smoke when you recover the refrigerant or
This system is under pressure at all times, even when you recycle the refrigerant.
if the engine is not running. Heat should never be
applied to a charged system. • Do not smoke when you charge the system.
Contact with refrigerant can cause frost bite. Keep • Do not smoke when you perform a leak test on the
face and hands away to help prevent injury. system.
Protective goggles must always be worn when re- • Do not smoke when you flush the system.
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant. • Do not leave refrigerant drums exposed to direct
sunlight.
Always use caution when a fitting is removed.
Slowly loosen the fitting. If the system is still • Do not carry refrigerant drums into the passenger
under pressure, evacuate the system recovering compartment of the machine.
the refrigerant before removing the fitting.
• Dispose of any oil that is poly alkaline glycol
Personal injury or death can result from inhaling (PAG) that has been opened but not used. The
refrigerant through a lit cigarette. moisture will contaminate the unused oil and the
air conditioning system.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.
Before any checks of the air conditioning and

heating system are made, move the machine to a
smooth horizontal surface. Lower all implements
to the ground. Make sure the transmission is
in neutral or park and that the parking brake is
engaged. Keep all other personnel away from the
machine or where they can be seen.
Before any problem solving procedures are

performed, read the manual for the heating and air
conditioning system. Make a visual inspection of the
complete air conditioning and heating system.
• All charging and leak testing must be done in a

well ventilated area.
• Avoid any physical contact with refrigerant. Contact

can cause frostbite.
SENR5664-11 73
i01705532 • A small amount of moisture will penetrate the

hoses that are used in R134a systems. Change the
General Troubleshooting dryer or change the accumulator and the desiccant
Information annually. Moisture causes sludge and moisture
results in plugged systems. Moisture also causes
SMCS Code: 7320 the formation of ice at the orifice tube assembly.
• Gauge readings for an undercharged R134a

system may appear as symptoms of overcharge
under certain conditions. This occurs when the
Personal injury can result from contact with refrig- ambient temperature is above 32 °C (90 °F) or in
erant. high humidity. Gauge readings that are Incorrect
lead to a loss of cooling ability and failure of the
This system is under pressure at all times, even compressor.
applied to a charged system. • Refrigerant that is removed from a system cannot
be weighed accurately. A 20 to 30% error can
Contact with refrigerant can cause frost bite. Keep occur. The error is a result of oil that is removed
face and hands away to help prevent injury. from the system and a result of the inaccuracies of
devices that are used for recovery.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges in- • Check the scale that is used for charging for
dicate the system is empty of refrigerant. accuracy after every 30 days or after every 30
uses.
Slowly loosen the fitting. If the system is still • After recovering a system, if the system pressure
under pressure, evacuate the system recovering rises above 0 kPa (0 psi) within 5 minutes, the
the refrigerant before removing the fitting. system must be recovered again until the pressure
does not increase. Recovering the system again
Personal injury or death can result from inhaling will empty the accumulator of refrigerant.
refrigerant through a lit cigarette.
• The presence of frost on the accumulator is a
Inhaling air conditioner refrigerant gas through a normal condition. The thickness of the frost will
lit cigarette or other smoking method or inhaling depend on ambient temperature and humidity.
ditioner refrigerant gas, can cause bodily harm or • Frost can appear anywhere on a R134a air
death. conditioning system. The appearance of frost does
not always indicate a failure. In order to diagnose
Do not smoke when servicing air conditioners or a blockage in the air conditioning system properly,
wherever refrigerant gas may be present. the air temperature at the evaporator must be
checked and pressure readings must be taken.
heating system are made, move the machine to a • In order to check the function of the compressor,
smooth horizontal surface. Lower all implements disconnect the hose from the inlet of the in-line
to the ground. Make sure the transmission is dryer. Measure the pressure of suction of the
in neutral or park and that the parking brake is compressor . The pressure should be a vacuum
engaged. Keep all other personnel away from the that is between 81 kPa (24 in Hg) to 95 kPa
machine or where they can be seen. (28 in Hg). Do not operate the compressor for
more than 2 minutes when the system pressure
• Low refrigerant charge will cause a loss of cooling is below vacuum.
ability and a loss of lubrication in the compressor,
which will result in failure of the compressor. • Perform regular maintenance on the refrigerant
service units and change the oil in the vacuum
• Overcharge of refrigerant will cause a loss of pumps.
cooling ability. A system that is overcharged will
contain excess liquid refrigerant, which will severely • Secure lines and wires in order to prevent damage
damage the compressor. An overcharged system to the lines and wires.
will fail two times faster than an undercharged
system. • The formation of black sludge deposits in the
system is caused by the presence of moisture in
• Too much oil in the system will contribute to a low R134a systems and by mixing charges of R134a
refrigerant charge. and R12. The black sludge deposits can cause
a blockage in the system.
74 SENR5664-11
• The presence of white foam during recovery is i01683564

normal. The foam is caused by the mixing of oil
and refrigerant. Visual Inspection
• R134a system charges must be within 0.03 kg SMCS Code: 7320
(1.000 oz) to .06 kg (2.000 oz) of the specified
charge for the machine.
• A drain line that is plugged or a drain line that is Personal injury can result from contact with refrig-
pinched may cause a backup of condensate and erant.
leakage into the cab.
This system is under pressure at all times, even
• Missing drain valves may cause a backup of if the engine is not running. Heat should never be
condensate and leakage into the cab. applied to a charged system.
• Missing drain valves will allow dust to be sucked Contact with refrigerant can cause frost bite. Keep
into the evaporator coil and the heater coil. face and hands away to help prevent injury.
A cab pressure of 0.05 kPa (0.200 inch of H2O) to Protective goggles must always be worn when re-
0.15 kPa (0.600 inch of H2O) and proper maintenance frigerant lines are opened, even if the gauges in-
of the air conditioner filter will result in the following dicate the system is empty of refrigerant.
conditions:
• Reduction of dust Slowly loosen the fitting. If the system is still
under pressure, evacuate the system recovering
• Reduction of noise the refrigerant before removing the fitting.
• More efficient HVAC performance Personal injury or death can result from inhaling
A loss of cooling ability of the system and failure of
the compressor may be caused by one or more of Inhaling air conditioner refrigerant gas through a
the following conditions. lit cigarette or other smoking method or inhaling
• Low charge ditioner refrigerant gas, can cause bodily harm or
death.
• Overcharge
• Too much oil wherever refrigerant gas may be present.
• Too little oil Before any checks of the air conditioning and
• Dirty filter or plugged filter smooth horizontal surface. Lower all implements
• Dirty condenser or plugged condenser in neutral or park and that the parking brake is
• Dirty evaporator or plugged evaporator machine or where they can be seen.
• Dirty orifice tube or plugged orifice tube

Before you conduct a performance check of the air
• Dirty expansion valve or plugged expansion valve conditioning system, the following items should be
checked:
• Too much moisture in the system
1. Check the condenser and the evaporator.
• Missing drain valves for the evaporator
a. Check for any type of restriction that will
obstruct the air flow. Check for dirt, insects,
plastic bags, etc.
SENR5664-11 75
b. For machines that are equipped with i01705544

condensers that are mounted on the roof,
always make sure that both fan motors Troubleshooting Heating
are running. Check for restrictions. A clean and Air Conditioning Control
condenser will lead to longer life for the
compressor. System
2. Clean the fresh air filters and clean the SMCS Code: 7309-035-YC
recirculation filters.
3. Check for a loose belt on the compressor.

Personal injury can result from contact with refrig-
4. Check the moisture indicator on either the erant.
receiver-dryer or the in-line dryer. If the indicator
is pink or white, there is moisture in the system. This system is under pressure at all times, even
Replace the receiver-dryer or the in-line dryer. if the engine is not running. Heat should never be
Refer to Disassembly and Assembly, “Receiver applied to a charged system.
(Refrigerant Dryer) Remove and Install” for
instructions on replacing the receiver-dryer. Contact with refrigerant can cause frost bite. Keep
Refer to Disassembly and Assembly, “In-Line face and hands away to help prevent injury.
Refrigerant Dryer- Remove and Install” for
instructions on replacing the in-line dryer. If the Protective goggles must always be worn when re-
moisture indicator is blue, the system is normal. frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
5. Check the drain tube on the evaporator. The drain
plug should not be obstructed. Always use caution when a fitting is removed.
Slowly loosen the fitting. If the system is still
6. For machines that are equipped with an under pressure, evacuate the system recovering
accumulator, start the machine. Set the air the refrigerant before removing the fitting.
conditioner on HIGH. Feel the accumulator with
the hand. In a properly charged system, the entire Personal injury or death can result from inhaling
accumulator will be cool to the touch or cold to refrigerant through a lit cigarette.
the touch.
death.


Heating System
In order to conduct a performance check of the
heating system, perform the following procedure.
1. Run the engine at 1000 rpm.
2. Adjust the temperature control knob to the setting

for maximum heating.
3. Put the fan switch in the HIGH position on heat.

76 SENR5664-11
4. When the engine coolant temperature is in the d. Check for the proper function of the fan switch
normal operating range, the temperature of the air at each setting. The evaporator blower motor
that is flowing from the louvers (air ducts) should will run at each setting. The evaporator blower
be warm. motor should be operating in the cold mode
and in the heating mode.
If the temperature of the air that is flowing is not
warm within 10 minutes of operation, refer to e. Use a 5P-7277 Voltage Tester or use a
“Problem 2” section. 9U-7330 Multimeter in order to check the
voltages in all components of the electrical
Problem 1 system. Refer to the electrical schematic
section for additional information for the
There is little warm air flow or no warm air flow machine.
when the heater control knob is set for maximum
heating. 2. If necessary, make repairs or replace the
components.
1. Perform the following procedure:
Test Procedure for Testing
a. Check the engine coolant temperature. The
temperature of the coolant must be at normal Electrical Components in the Air
operating range. Conditioning System
b. The heater control valve must be functioning The air conditioning systems on Caterpillar machines
properly. Check for the correct linkage use pressure switches in order to protect the
adjustment from the temperature control air conditioning system. Some air conditioning
lever to the heater control valve. The heater systems on Caterpillar machines use pressure
control valve must open completely when the switches and the on delay timer assembly for
temperature control knob is set for maximum the refrigerant compressor in order to protect the
heating. air conditioning system. Arc suppressors protect
other electrical components in the air conditioning
c. Check for blockage and check for bends in system. Arc suppressors are applied in order to
the heater hoses. Blockages and bends in the discharge electrical inductance when the compressor
heater hoses would stop the flow of coolant disengages. Failure of the arc suppressor can affect
through the system. the reliability of the pressure switch. Failure of the arc
suppressor may cause failure of the pressure switch.
d. Inspect the petcocks that connect the heater
hoses to the engine block. Make sure that the The following procedures are for the testing of the
petcocks are adjusted so that the petcocks are on delay timer assembly, pressure switches, and
fully open. components of the arc suppressor.
2. Make repairs to the components or replace any Table 3

damaged component. Required Tools
Part Number Part Description
Electrical System
146-4080 Digital Multimeter (RS-232)
Problem 2
On Delay Timer Assembly for the
There is no flow to the operator’s compartment.
The evaporator blower motors do not operate Refrigerant Compressor Tests
when the fan switch is activated.
In order to diagnose a faulty on delay timer assembly
1. Perform the following procedure: for the refrigerant compressor, the engine start switch
must be in the ON position and the air conditioning
a. Inspect the circuit breaker or inspect the fuses switch activated.
for an open circuit.
Note: The on delay timer assembly will delay the
b. Perform a visual inspection of all wire power supply to the compressor clutch coil for 30
connections. Use the electrical schematic for seconds after the air conditioning switch is activated.
the respective machine.
c. Check for blockages at the fan blade.

SENR5664-11 77
6. In order to check the ground path from the

compressor clutch coil to the chassis, turn off
the air conditioning switch in the cab. Set the
146-4080 Digital Multimeter OHMS. Remove
the 2-pin connector from the compressor clutch
coil. Connect the negative lead to a suitable
ground. Check each of the two pins on the two
pin connectors for continuity. One of the two pins
should display OL.
7. If both the correct voltage and ground are

present check the resistance of the compressor
clutch coil. Refer to the Service Manual, SENR
5664, “Refrigerant Compressor” section in
g00754249
Specifications.
Illustration 52
(1) Output (signal voltage)
(2) Chassis ground
Pressure Switch Tests
(3) Compressor clutch
(4) Power supply Test Procedure for 114-5333 Pressure Switch
and 114-5334 Pressure Switch (NORMALLY
1. Separate the four pin connectors from the wiring OPEN)
harness.
Pressure switches are used in order to protect the air
2. Set the 146-4080 Digital Multimeter to DC conditioning compressor. The two most commonly
voltage. Connect the positive probe to pin (4) used pressure switches are the 114-5333 Pressure
on the wiring harness and connect the negative Switch and the 114-5334 Pressure Switch. The only
probe to a suitable ground. The multimeter should difference between the two switches is the connector.
read 24 volts. Only one of these switches is used per machine. The
high pressure and low pressure switches have three
Note: If the voltage is below 18 volts or the voltage is possible switch positions which are given below:
above 32 volts the on delay timer assembly will not
supply power to the compressor. OPEN – System pressure is low.
3. Set the 146-4080 Digital Multimeter to OHMS. CLOSED – System pressure is correct.
Connect the positive probe to pin location (2) on
the wiring harness and connect the negative probe OPEN – System pressure is high.
to a suitable chassis ground. The multimeter will
display OL if the ground is not present. The two OPEN positions of the pressure switch
protect the air conditioning system. The OPEN
4. Set the 146-4080 Digital Multimeter OHMS. position prevents the compressor from actuating
Connect the positive probe to pin location (1) on when potentially harmful pressures exist in the
the wiring harness and connect the negative probe system. The CLOSED position is the normal
to a suitable chassis ground. If the multimeter operating switch position. The following table
displays OL one of the three switches are open. contains the logic for the pressure switches:
Check each of the switches if an open condition
occurs.
Note: There must be refrigerant in the air conditioning

system in order to close both of the pressure
switches.
5. In order to check that power is getting from the on

delay timer assembly to the compressor clutch
coil, reconnect the on delay timer assembly to
the wiring harness. Set the 146-4080 Digital
Multimeter to DC voltage. Remove the 2-pin
connector from the compressor clutch coil.
Connect the negative probe to a suitable chassis
ground. Check each one of the two pins on the
wiring harness for voltage. One of the two pins
should supply 24 volts.
78 SENR5664-11
Table 4 5. If the resistance that is displayed is a value of

Pressure Range Contact Contact
OL (high resistance), and the system pressure
Position Position is within acceptable limits, replace the pressure
(Pressure (Falling switch.
Rise) Pressure)
6. When the pressure switch fails, test the arc
High Above OPEN OPEN suppressor for proper operation.
Position 3 2800 kPa
(406 psi)
7. If the pressure switch is removed, make sure
Hysteresis 1750 kPa CLOSED OPEN that the wires on the new pressure switch
Band(1) (254 psi) to are tie-wrapped. Securing the pressure switch
2800 kPa prevents damage that may be caused by vibration.
(406 psi)
Middle 275 kPa CLOSED CLOSED Note: The multimeter may display OL if the contacts
(Position 2) (40 psi) to on the pressure switch are dirty. The contacts on
1750 kPa the pressure switch can become dirty if the arc
(254 psi) suppressor is no longer functioning.
Hysteresis 170 kPa OPEN CLOSED
Band(1) (25.0 psi) Note: The multimeter will display OL if the pressure
to 275 kPa switch is not threaded into the air conditioning
(40 psi) system.
Low 0 kPa (0 psi) OPEN OPEN 8T-8639 Low Pressure Switch (NORMALLY
Position 1 to 170 kPa OPEN)
(25.0 psi)
(1) Pressure must pass through the hysteresis band in order to
provide the correct conditions for the switch contact.
g00651418
Illustration 54
Table 5
g00651406
Illustration 53
Specifications for Pressure Switch
Use the following procedures in order to test the Actuation Pressure(2) 344 ± 34 kPa (50 ± 5 psi)
pressure switch:
Deactuation Pressure(3) 172 ± 21 kPa (25 ± 3 psi)
1. Disconnect the pressure switch from the machine (2) Close when pressure increases.
harness. (3) Open when pressure decreases.
2. Connect the 146-4080 Digital Multimeter to the Use the following procedures in order to test the
two connector pins. Set the multimeter to the pressure switch:
OHMS test mode.
1. Disconnect the pressure switch from the machine
3. Measure the resistance of the pressure switch. harness.
4. If the system pressure is between 275 kPa (40 psi) 2. Connect the 146-4080 Digital Multimeter to the
and 1750 kPa (254 psi), the multimeter will display two connector pins. Set the multimeter to the
a value that is less than 1 ohm. OHMS test mode.
3. Measure the resistance of the pressure switch.

SENR5664-11 79
4. If the system pressure is above 344 ± 34 kPa 3. Measure the resistance of the pressure switch.
(50 ± 5 psi), the multimeter will display less than
1 ohm. 4. If the system pressure is above 103 ± 14 kPa
5. If the resistance that is displayed is a value of OL 1 ohm.
(high resistance), and the system pressure is not
below the acceptable limit, replace the pressure 5. If the resistance that is displayed is a value of OL
switch. (high resistance), and the system pressure is not
below the acceptable limit, replace the pressure
6. When the pressure switch fails, test the arc switch.
suppressor for proper operation.
7. If the pressure switch is removed, make sure suppressor for proper operation.
that the wires on the new pressure switch
are tie-wrapped. Securing the pressure switch 7. If the pressure switch is removed, make sure
prevents damage that may be caused by vibration. that the wires on the new pressure switch
are tie-wrapped. Securing the pressure switch
Note: The multimeter may display OL if the contacts prevents damage that may be caused by vibration.
on the pressure switch are dirty. The contacts on
the pressure switch can become dirty if the arc Note: The multimeter may display OL if the contacts
suppressor is no longer functioning. on the pressure switch are dirty. The contacts on
the pressure switch can become dirty if the arc
Note: The multimeter will display OL if the pressure suppressor is no longer functioning.
switch is not threaded into the air conditioning
system. Note: The multimeter will display OL if the pressure
149-6371 Low Pressure Switch (NORMALLY system.
OPEN)
3E-6462 High Pressure Switch (NORMALLY
CLOSED)
g00651452
Illustration 55
Table 6 g00651464
Illustration 56
Table 7
Actuation Pressure(2) 103 ± 14 kPa (15 ± 2 psi)
Deactuation Pressure(3) 35 ± 7 kPa (5 ± 1 psi)
Actuation Pressure(4) 2400 ± 140 kPa
(2) Close when pressure increases. (348 ± 20 psi)
(3) Open when pressure decreases.
Deactuation Pressure(5) 1725 ± 100 kPa
(250 ± 15 psi)
Use the following procedures in order to test the
pressure switch: (4) Open when pressure increases.
(5) Close when pressure decreases.
harness. Note: A pressure switch that is NORMALLY CLOSED
will open when the system pressure increases. The
2. Connect the 146-4080 Digital Multimeter to the pressure switch will close when the system pressure
two connector pins. Set the multimeter to the decreases.
OHMS test mode.
80 SENR5664-11
Use the following procedures in order to test the Table 8

pressure switch: Specifications for Pressure Switch
1. Disconnect the pressure switch from the machine Actuation Pressure(4) 2412 ± 140 kPa
harness. (350 ± 20 psi)
Deactuation Pressure(5) 1723 ± 100 kPa
2. Connect the 146-4080 Digital Multimeter to the (250 ± 15 psi)
two connector pins. Set the multimeter to the (4) Open when pressure increases.
OHMS test mode. (5) Close when pressure decreases.

Use the following procedures in order to test the
pressure switch:
4. If the system pressure is below 2400 ± 140 kPa
1 ohm.
harness.
5. If the resistance that is displayed is a value of OL
2. Connect the 146-4080 Digital Multimeter to the
two connector pins. Set the multimeter to the
above the acceptable limit, replace the pressure
OHMS test mode.
switch.
4. If the system pressure is below 2412 ± 140 kPa
1 ohm.
5. If the resistance that is displayed is a value of OL
prevents damage that may be caused by vibration.
above the acceptable limit, replace the pressure
Note: The multimeter may display OL if the contacts
switch.
suppressor is no longer functioning.
Note: The multimeter will display OL if the pressure
system.
prevents damage that may be caused by vibration.
7X-1076 High Pressure Switch (NORMALLY
CLOSED)
Note: The multimeter may display OL if the contacts
suppressor is no longer functioning.
Note: The multimeter will display OL if the pressure

system.
g00651571
Illustration 57
SENR5664-11 81
Test Procedures for Arc Suppressors: 3E-9169 Arc Suppressor and 130-8134 Arc
Suppressor
106-8704 Arc Suppressor
g00651923
Illustration 59
g00651378
Illustration 58 Arc Suppressor with Sure Seal Connectors
106-8704 Arc Suppressor (1) Pin 1
(2) Pin 2
1. Place the multimeter in the DIODE test mode.
2. Place the red probe in the red terminal (positive

terminal) of the multimeter.
3. Place the black probe in the black terminal

(negative terminal) of the multimeter.
4. Place the red probe on Pin 2 of the connector on

the arc suppressor. Place the black probe on Pin
1 of the connector.
5. The multimeter should display a value between

0.5 VDC and 1.0 VDC.
g00651621
6. Place the red probe on Pin 1 of the connector on Illustration 60
the arc suppressor. Place the black probe on Pin Arc Suppressor with DT Connectors
2 of the connector on the arc suppressor. (1) Pin 1
(2) Pin 2
7. The multimeter should display OL.
8. If the above conditions do not exist, the component
should be considered faulty. The component will 2. Place the red probe in the red terminal (positive
not provide adequate protection if the above terminal) of the multimeter.
conditions do not exist.
9. Replace the component if the component has (negative terminal) of the multimeter.
failed.
4. Place the red probe on Pin 1 of either connector
on the arc suppressor. Place the black probe on
Pin 2 of either connector.

0.5 VDC and 1.0 VDC.

of arc suppressor. Place the black probe on Pin 1
of either connector on the arc suppressor.
7. The multimeter should display OFL or OL.

82 SENR5664-11
8. Place the red probe on pin 1 of the female 2. Place the red probe in the red terminal (plus
connector. Place the black probe on pin 1 of the terminal) of the multimeter.
male connector.
9. The multimeter should have a reading of less than (negative terminal) of the multimeter.
0.01 VDC.
10. Place the red probe on Pin 2 of the female on the arc suppressor. Place the black probe on
connector. Place the black probe on Pin 2 of the Pin 2 of either connector.
male connector.
11. The multimeter should have a reading of less 0.5 VDC and 1.0 VDC.
than 0.01 VDC.
6. Place the red probe on pin 2 of either connector of
12. The component is faulty if any of the conditions arc suppressor. Place the black probe on pin 1 of
do not exist. either connector on the arc suppressor.
13. If the component is faulty, replace the component. 7. The multimeter should display OFL or OL.
105-8827 Arc Suppressor and 130-0956 Arc 8. Place the red probe on pin 1 of the female
Suppressor connector. Place the black probe on pin 1 of the
male connector.
9. The multimeter should have a reading of less than

0.01 VDC.
10. Place the red probe on pin 2 of the female

connector. Place the black probe on pin 2 of the
male connector.
11. The multimeter should have a reading of less

than 0.01 VDC.
12. The component is faulty if any of the conditions

do not exist.
g00651923
Illustration 61 13. If the component is faulty, replace the component.
Arc Suppressor with Sure Seal Connectors
(1) Pin 1 Correct Mounting of Arc Suppressors
(2) Pin 2
Certain arc suppressors may experience failure of
the wire leads due to vibration if the arc suppressor is
not properly supported.
Use a 2U-4497 Strap to tie-wrap the arc suppressor.

The arc suppressor should be securely tie-wrapped
to a stationary support in order to prevent any motion
of the body of the arc suppressor. Additionally, the
connectors on both ends of the arc suppressor
should be secured.
A suitable bracket for supporting an arc suppressor

is the 116-6100 Plate. The addition of a 9R-2926
Plate should permit the mounting of the 116-6100
g00651621
Plate around obstacles. Use the 9R-2926 Plate if
Illustration 62 the 116-6100 Plate cannot be installed directly in an
Arc Suppressor with DT Connectors existing application.
(1) Pin 1
(2) Pin 2

SENR5664-11 83
The Sure Seal connectors on the 3E-9169 Arc i01707038

Suppressor and the 105-8827 Arc Suppressor
should be secured with two 9G-9150 Clips in order Air Conditioning System
to prevent movement of the connectors relative to the Troubleshooting
body of the arc suppressor. The DT connectors on
the 130-0956 Arc Suppressor and 130-8134 Arc SMCS Code: 7320
Suppressor should be secured with two 9U-2297
Clips. The clips should be bolted through the slotted
holes on the 116-6100 Plate.
The 106-8704 Arc Suppressor is an integral arc Personal injury can result from contact with refrig-
suppressor. The integral arc suppressor can be erant.
found on the newer machines. The 106-8704 Arc
Suppressor is lighter than the other arc suppressors. This system is under pressure at all times, even
The 106-8704 Arc Suppressor can be strapped if the engine is not running. Heat should never be
directly to the wiring harnesses that are connected to applied to a charged system.
the arc suppressor.
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.


Personal injury or death can result from inhaling


death.


System Contamination
The system must be cleaned and the system must
be flushed if any particles of metal or other foreign
material from a component failure have circulated
through the system.
Debris in the system can cause the compressor to

fail. Use the following procedure for cleaning and
flushing the system.
84 SENR5664-11
1. Identify the refrigerant and then recover the 10. Install a new accumulator. Refer to the Service
refrigerant. Refer to the Service Manual, Manual, SENR5664, “Air Conditioner Accumulator
SENR5664, “Refrigerant Recovery” section. - Remove and Install” section in Disassembly and
Assembly.
2. Remove the compressor. Refer to the Service
Manual , SERN5664, “Refrigerant Compressor - 11. Clean the original expansion valve. The orifice
Remove and Install” section. tube can not be cleaned. If necessary, replace
the original expansion valve or replace the orifice
3. Remove the receiver-dryer or the in-line dryer. tube. Clean the original quick couplers or replace
Refer to the Service Manual, SENR5664, the original quick couplers.
“Receiver-Dryer - Remove and Install” section in
Disassembly and Assembly. For in-line dryers, 12. Install a new compressor. New compressors are
refer to the Service Manual, SENR5664, “In-Line shipped with the correct amount of oil inside the
Refrigerant Dryer - Remove and Install” section in compressor. Do not add extra oil.
Disassembly and Assembly.
Note: Compressors that are new or remanufactured
4. Remove the accumulator. Refer to the Service are shipped with the correct amount of refrigerant oil
Manual, SENR5664, “Air Conditioner Accumulator in the system.
- Remove and Install” section in Disassembly and
Assembly. 13. Refer to the Service Manual, SENR5664,
“Refrigerant System - Evacuate” section in Testing
5. Remove the expansion valve or the orifice and Adjusting.
tube. Refer to the Service Manual, SENR5664,
“Expansion Valve - (Air Conditioner) Remove and 14. Refer to the Service Manual, SENR5664,
Install” section in disassembly and assembly. “Refrigerant System - Charge” section in Testing
Refer to the Service Manual, SENR5664, “Orifice and Adjusting.
Tube (Air Conditioner) - Remove and Install”
section in Disassembly and Assembly. 15. In order to ensure proper operation of the system,
refer to the Service Manual, SENR5664, “Air
6. Remove the quick couplers. Conditioning System Troubleshooting” section in
Testing and Adjusting.
NOTICE
In order to avoid component damage, do not clean False Seizure of the Compressor
system components with solvents, compressed air,
etc.. Table 9
Required Tools
7. Replace any other failed component such as Part Number Part Description
coils, fittings, etc. Flush the remainder of the
system. The air conditioning system should be 1U-8590 Spanner Wrench
flushed with a 153-8537 Air Conditioner Flushing
Unit. Also, a 153-9032 Air Conditioner Flushing On the initial start-up of the air conditioner system,
Unit can be used in order to flush the system. slipping drive belts and broken drive belts may be
Refer to the information that is provided with the experienced if the air conditioner system has not been
flushing unit. Flush the system with 153-8538 used for an extended period of time. Also, scored
Refrigerant Flushing Solution. clutch surfaces may be experienced. This would
indicate a seized compressor. However, replacement
8. Blow out the air conditioning system with dry shop of the compressor may not be necessary.
air for 5 to 10 minutes.
Changes in temperature can cause expansion of
9. Install a new receiver-dryer or an in-line dryer. the refrigerant in the compressor during extended
Refer to the Service Manual, SENR5664, periods of nonuse. Also, changes in temperature can
“Receiver-Dryer - Remove and Install” section in cause contraction of the refrigerant in the compressor
Disassembly and Assembly. For in-line dryers, during extended periods of nonuse. During this
refer to the Service Manual, SENR5664, “In-Line movement, lubricating oil that is carried by the
Refrigerant Dryer - Remove and Install” section in refrigerant migrates. The lubricating oil moves away
Disassembly and Assembly. from highly polished surfaces in the compressor.
Without lubricating oil at the polished surfaces, the
polished surfaces rub together. This can appear as a
seized compressor.
SENR5664-11 85
The compressor should be checked for seizure before • Perform a performance check. Refer to
the compressor is replaced. Use the procedures that “Performance Checks for the Air Conditioning
follow in order to check the compressor for seizure. System” section.
1. With a spanner wrench on the clutch drive plate, 2. Check for restrictions that are present in the
rock the shaft in the opposite direction of normal refrigerant lines from the compressor to the
rotation. receiver-dryer. The refrigerant lines and the
components that are high pressure and high
2. After the clutch drive plate is movable, rotate temperature come from the outlet side of the
the clutch drive plate at least three complete compressor. The lines go to the inlet side of the
revolutions in the counterclockwise direction. expansion valve or orifice tube. The outlet side
will be warm during normal operation. Heavy frost
3. Start the engine. Operate the compressor for a or a decrease in the temperature in a line or in a
minimum of one minute. component on the high pressure side may be an
indication of a restriction or blockage.
This procedure will not correct a seized
compressor. However, this procedure should be a. If there is no evidence of a restriction in the
attempted before you replace a compressor that condenser coil, the receiver-dryer or refrigerant
has been idle for a month or longer. lines from the compressor to the receiver-dryer,
use the procedure in Step 3.
Refrigerant Quick-Check Procedure b. If there is a restriction in the condenser coil,
for R-134a Expansion Valve And the receiver-dryer or refrigerant lines from the
Orifice Tube Systems compressor to the receiver-dryer, perform the
following procedures.
NOTICE • Recover the refrigerant. Refer to the Service

In an expansion valve system which uses poly alkaline Manual, SENR5664, “Refrigerant Recovery”
glycol (PAG), the sight glass is not a reliable way to section.
determine system charge.
• Remove the restriction or replace the
component.
Note: This procedure does not call for the installation
of the manifold gauge set. The procedure should
be used only as an indication of the actual • Evacuate the system. Refer to the Service
Manual, SENR5664, “Refrigerant System -
system condition. For the detailed troubleshooting
Evacuate” section in Testing and Adjusting.
procedures, refer to the “Problem Solving Procedure”
section.
• Charge the system with the correct amount
of refrigerant. Measure the refrigerant
Note: In order to use this procedure, the temperature
by weight. Refer to the Service Manual,
of the ambient air must be at least 21°C (70°F).
SENR5664, “Refrigerant System - Charge”
section in Testing and Adjusting.
1. Start the engine and run the engine at
approximately 1000 rpm. Move the control knob
on the air conditioner to the position of MAXIMUM • Perform a leak test. Refer to the Service
Manual, SENR5664, “Refrigerant Leakage -
so that cooling is at a maximum. In order to
Test”section in Testing and Adjusting.
stabilize the system, put the fan switch in the
HIGH position and operate the system for a
minimum of 10 minutes. • Perform a performance check. Refer to
“Performance Checks for the Air Conditioning
System” section.
For systems that have air conditioner quick
disconnects, the dryer can be removed without
c. If frost is present on the expansion valve, check
recovering the refrigerant.
the moisture indicator on the receiver-dryer.
If the indicator is pink or white, and the
• Replace the receiver-dryer. Refer to the receiver does not have air conditioner quick
Service Manual, SENR5664, “Receiver-Dryer
disconnects, perform the following procedures.
- Remove and Install” section in Disassembly
and Assembly.
• Recover the refrigerant. Refer to the Service
Manual, SENR5664, “Refrigerant Recovery”
• Perform a leak test. Refer to the Service section.
Test” section in Testing and Adjusting.
86 SENR5664-11
• Replace the receiver-dryer. Refer to the • Perform a performance check. Refer to

Service Manual, SENR5664, “Receiver-Dryer “Performance Checks for the Air Conditioning
- Remove and Install” section in Disassembly System” section.
and Assembly.
3. Low system charge is indicated. Perform a leak
• Evacuate the system. Refer to the Service test.
Evacuate” section in Testing and Adjusting. Note: If the system is very low on refrigerant, a
partial charge may be needed before you perform
• Charge the system with the correct amount a leak test.
of refrigerant. Measure the refrigerant
by weight. Refer to the Service Manual, • Recover the remaining refrigerant. Refer to
SENR5664, “Refrigerant System - Charge” the Service Manual, SENR5664, “Refrigerant
section in Testing and Adjusting. Recovery” section.
• Perform a leak test. Refer to the Service • Repair all leaks.

Test” section in Testing and Adjusting. • Evacuate the system. Refer to the Service
• Perform a performance check. Refer to Evacuate” section in Testing and Adjusting.
System” section. • Charge the system with the correct amount of
refrigerant. Measure the refrigerant by weight.
Refer to the Service Manual, SENR5664, Refer to the Service Manual, SENR5664,
“Receiver-Dryer - Remove and Install” section “Refrigerant System - Charge” section in Testing
if the receiver-dryer has air conditioner quick and Adjusting.
disconnects. Refer to the Service Manual,
SENR5664, “In-Line refrigerant Dryer - • Perform a performance check. Refer to
Remove and Install” section if the in-line dryer “Performance Checks for the Air Conditioning
has air conditioner quick disconnects. System” section.
d. On air conditioning systems that have a dryer 4. Feel the low pressure line and feel the high
with a moisture indicator, if the indicator is pressure line at the compressor. In order to
blue and the system is free of moisture, the indicate normal systems operation, the high
expansion valve may be blocked. pressure line to the condenser coil must be warm,
while the low pressure line to the evaporator coil
• Recover the refrigerant. Refer to the Service must be cool.
section. • The high pressure line and the low pressure line
at the compressor have a minimal temperature
• Replace the expansion valve. Refer to the difference between the two lines. Use the
Service Manual, SENR5664, “Expansion procedure in Step 5.
Valve - (Air Conditioner) Remove and Install”
section in Disassembly and Assembly. • If there is a definite temperature difference
between the high pressure line and the low
• Evacuate the system. Refer to the Service pressure line at the compressor, the system is
Manual, SENR5664, “Refrigerant System - operating correctly. The high pressure line will
Evacuate” section in Testing and Adjusting. be warm. The low pressure line will be cool. Use
the procedure in Step 6.
• Charge the system with the correct amount
of refrigerant. Measure the refrigerant 5. If the system has no refrigerant charge or if the
by weight. Refer to the Service Manual, system is nearly empty of refrigerant charge,
SENR5664, “Refrigerant System - Charge” perform the following procedure:
• Stop the engine.
• Perform a leak test. Refer to the Service
Manual, SENR5664, “Refrigerant Leakage - • Perform a partial charge of the system.
Test”section in Testing and Adjusting.
• Perform a leak test. Refer to the Service
Test” section in Testing and Adjusting.
SENR5664-11 87
• Repair leaks. • Perform a leak test. Refer to the Service Manual,

SENR5664, “Refrigerant Leakage - Test” section in
• Evacuate the system. Refer to the Service Testing and Adjusting.
Evacuate” section in Testing and Adjusting. • Perform a performance check. Refer to
• Charge the system with the correct amount of System” section.
Refer to the Service Manual, SENR5664,
“Refrigerant System - Charge” section in Testing
Performance Checks for the Air
and Adjusting. Conditioning System
• Perform a performance check. Refer to A performance check of the air conditioning system
“Performance Checks for the Air Conditioning must be made with a manifold gauge set. The
System” section. manifold gauge set must be connected to the service
ports on the compressor.
6. An overcharge of the system is possible even
though the system can have a definite difference Note: Before you conduct a performance check,
in temperature at the low pressure line and at the refer to the Service Manual, SENR5664, “Visual
high pressure line. Inspection” section.
• Recover the refrigerant. Refer to the Service Refer to the Service Manual, SENR5664, “Machine
Manual, SENR5664, “Refrigerant Recovery” Preparation for Troubleshooting” section before
section. service work is performed on the air conditioning
system.
• Evacuate the system. Refer to the Service
Manual, SENR5664, “Refrigerant System - 1. Install the manifold gauge set. Refer to the
Evacuate” section in Testing and Adjusting. Service manual, SENR5664, “Manifold Gauge Set
(Refrigerant) - Install” section.
• Charge the system with the correct amount of
refrigerant. Measure the refrigerant by weight. 2. Start the engine and operate the engine at 1000
Refer to the Service Manual, SENR5664, rpm. Move the temperature control knob to the
“Refrigerant System - Charge” section in Testing maximum cool position. Put the fan switch in
and Adjusting. the HIGH position on the AIR CONDITIONING
side. In order to stabilize the system, operate the
• Perform a performance check. Refer to the system for a minimum of ten minutes. Operate
“Performance Checks for the Air Conditioning the engine at 1000 rpm.
System” section.
During normal operation of the air conditioning
Note: For an orifice tube system, an additional system in 21°C (70°F) weather, the discharge
inspection is required. The additional inspection pressure will be 820 to 1300 kPa (120 to 190 psi).
procedure determines the level of the system charge. The pressure will be 70 to 130 kPa (10 to 20 psi).
When both the inlet of the accumulator and the outlet Refer to Table 10 for temperature range. The
of the accumulator are cool to the touch, the system outside temperature and humidity will have an
is charged correctly. effect on the pressures. If the outside temperature
is high, the discharge pressure will be high.
If the outlet is warmer than the inlet, the system may
not contain enough refrigerant. In very hot weather, the suction and the discharge
pressures will be high. In cooler weather, the
• Recover the refrigerant. Refer to the Service suction and the discharge pressure will be normal
Manual, SENR5664, “Refrigerant Recovery” or the pressure can be lower.
section.
If the suction and the discharge pressures are not
• Evacuate the system. Refer to the Service Manual, within the normal operating range, refer to the
SENR5664, “Refrigerant System - Evacuate” “Problem Solving” section.
Note: Most system failures are caused by improper
• Charge the system with the correct amount of refrigerant charge. Refrigerant charge should be
refrigerant. Measure the refrigerant by weight. measured by weight only. Do not use gauge pressure
Refer to the Service Manual, SENR5664, when you charge the system with refrigerant.
“Refrigerant System - Charge” section in testing
and adjusting.
88 SENR5664-11
Problem Solving Note: When the ambient temperature is above

21°C (70°F), a low pressure gauge reading of
The following problem solving section is provided for 70 to 138 kPa (10 to 20 psi) is a normal operating
identifying and correcting problems that may occur pressure for the air conditioning system. Also, when
in the air conditioning system. Several problems can the ambient temperature is above 21°C (70°F), a
have the same system condition or similar system high pressure gauge reading of 820 to 1300 kPa
conditions. Before you start the procedure in order to (120 to 190 psi) is a normal operating pressure for the
correct the problems, it is necessary to be complete air conditioning system. In very hot weather, the low
in the diagnosis of the problems. pressure readings and the high pressure readings
will be at the high end of the normal operating range.
The problem solving procedures are based on the In cooler weather, the low pressure reading will be
system condition during the problem. In order to in the middle to the low end of the normal operating
indicate the system pressures, the manifold gauge range, while the high pressure reading will be low.
set must be installed. The manifold gauge set is used For the correct gauge reading in relation to ambient
only in order to diagnose problems. The refrigerant temperature condition, refer to Table 10.
lines can give an indication of system operation that
is abnormal. Temperature differences between the Note: All pressures are given as a guide only.
high pressure side and the low pressure side can be Weight is the only absolute means of determining
an indication of abnormal operation in a line. This proper refrigerant charge. Improper refrigerant
can also be found by cold spots (frost) on the line. charge will cause premature failure of the
In R134a air conditioning systems, the lines can compressor .
have spots of frost and the system can be operating
normally. Frost will most often form after the orifice Table 10
and on the lower portion of the accumulator. The Pressure Range (1)
temperature of the air flow from the evaporator will
also indicate a problem with the system. Knowing the Ambient Air High Pressure Low Pressure
complete system condition is an important step in Temperature Test Fitting Test Fitting
C° (F°) kPa (psi)(2) kPa (psi)(3)
making a correct diagnosis.
21°C (70°F) 820 to 1300 kPa 70 to 138 kPa
Note: R134a air conditioning system problem (120 to 190 psi) (10 to 20 psi)
diagnosis requires a combination of symptoms or 950 to 1450 kPa 70 to 173 kPa
27°C (80°F)
indicators in order to correctly identify problems and (140 to 210 psi) (10 to 25 psi)
solve problems.
32°C (90°F) 1175 to 1650 kPa 105 to 210 kPa
(170 to 240 psi) (15 to 30 psi)
Problem Solving Procedure
38°C (100°F) 1300 to 1850 kPa 105 to 210 kPa
1. Install the manifold gauge set. Refer to the (190 to 270 psi) (15 to 30 psi)
Service Manual, SENR5664, “Manifold Gauge 43°C (110°F) 1450 to 2075 kPa 105 to 210 kPa
Set (Refrigerant) - Install” section in Testing and (210 to 300 psi) (15 to 30 psi)
Adjusting.
(1) This table is only for reference.
(2) Pressure may be slightly higher in very humid conditions and
2. Run the engine at 1000 rpm. Put the air conditioner lower in very dry conditions.
temperature control knob in the Maximum COOL (3) Pressure before clutch disengagement
position. Put the fan switch in the HIGH position
on the AIR CONDITIONING side. In order to
stabilize the system, operate the engine for a Refrigerant Circuit Problems
minimum of ten minutes.
There is no or only little cool temperature
3. Adjust the engine speed to approximately 1300 to the air flow from the evaporator.
to 1400 rpm. Record the readings on the low
pressure gauges and the high pressure gauges. System Condition 1
The gauge readings will be a partial indication of
the system condition. 1. Low pressure gauge reading is below normal.
For normal operating pressures, refer to Table 10.
2. High pressure gauge reading is below normal.

Note: Ambient temperature is above 21°C (70°F).

SENR5664-11 89
3. From the evaporator, the temperature of the air 2. High pressure gauge reading is above normal.
flow is partially cool. For normal operating pressures, refer to Table 10.
Probable Cause Note: Ambient temperature is above 21°C (70°F).
Leaks in the refrigerant circuit will cause the system 3. The temperature of the air flow from the evaporator
to be low on refrigerant. is warm.
• Perform a leak test. refer to the Service Manual, Probable Cause

SENR5664, “Refrigerant Leakage - Test” section in
Testing and Adjusting. Air or moisture (water) in the system
• If leaks are found, recover the refrigerant. Refer • Recover the refrigerant. Refer to the Service
to the Service Manual, SENR5664, “Refrigerant Manual, SENR5664, “Refrigerant Recovery”
Recovery” section. section.
• Repair leaks. • Replace the receiver-dryer or the in-line dryer. The

desiccant may be full of moisture. This will release
• If a large amount of refrigerant was lost, it is water into the system. Refer to the Service Manual,
important to check the compressor for loss of oil. SENR5664, “Receiver-Dryer - Remove and Install”
section in Disassembly and Assembly. For in-line
• Perform a partial charge of the system. dryers, refer to the Service Manual, SENR5664,
“In-Line Refrigerant Dryer - Remove and Install”
• Evacuate the system. Refer to the Service Manual, section in Disassembly and Assembly.
SENR5664, “Refrigerant System - Evacuate”
section in Testing and Adjusting. • Evacuate the system. Refer to the Service Manual,
• Charge the system with the correct amount of section in Testing and Adjusting.
Refer to the Service Manual, SENR5664, • Charge the system with the correct amount of
“Refrigerant System - Charge” section in testing refrigerant. Measure the refrigerant by weight.
and adjusting. Refer to the Service Manual, SENR5664,
• After the system is charged and operated for a and Adjusting.
minimum of ten minutes, perform a performance
check. Refer to “Performance Checks for the Air • After the system is charged and operated for a
Conditioning System” section. minimum of ten minutes, perform a performance
check. Refer to “Performance Checks for the Air
System Condition 2 Conditioning System” section.
1. Low pressure gauge reading is normal. For System Condition 4

normal operating pressures, refer to Table 10.
1. Low pressure gauge reading is below normal.
2. High pressure gauge reading bounces or the For normal operating pressures, refer to Table 10.
reading is unsteady.
2. High pressure gauge reading is normal to
Probable Cause the below normal range. For normal operating
pressures, refer to Table 10.
Air is in the system.
• Reclaim the refrigerant from the air conditioning
system. 3. The temperature of the air flow from the evaporator
is partially cool.
• Evacuate the air conditioning system.
4. The high side liquid line or the receiver-dryer
• Recharge the air conditioning system. is frosted. The high side liquid line or the
receiver-dryer is cool to the touch.
System Condition 3
1. Low pressure gauge reading is below normal.

90 SENR5664-11
Probable Cause 2. The high pressure gauge reading is normal,

but the gauge reading is below normal when
Restriction in the high pressure liquid line can cause the low pressure gauge drops into the vacuum
the refrigerant to be removed from the evaporator at range. For normal operating pressures, refer to
a faster rate. The restriction can cause the evaporator Table 10.
to be low on refrigerant from the receiver-dryer or
from the in-line dryer. Clogged filters or a failure of Note: Ambient temperature is above 21°C (70°F).
the blower motor can cause possible restrictions to
the air flow. 3. Air flow from the evaporator is very cold, but the
air flow will become warm when the low pressure
• Recover the refrigerant. Refer to the Service gauge drops into vacuum.
section. Probable Cause
• If the restriction is found at the receiver-dryer, The system has a large amount of moisture. The
replace the receiver-dryer. Refer to the Service desiccant in the receiver-dryer or the in-line dryer
Manual, SENR5664, “Receiver-Dryer - Remove is full of water. The water is released during high
and Install” section in Disassembly and Assembly. ambient temperatures. Ice collects in the orifice or
the expansion valve and the ice can block the flow of
• If the restriction is found at the in-line dryer, replace refrigerant.
the in-line dryer.
• Recover the refrigerant from the system. Refer
• If the restriction is found at the liquid line, replace to the Service Manual, SENR5664, “Refrigerant
the liquid line. Recovery” section in Testing and Adjusting.
• Cap all the open lines and fittings. • Replace the receiver-dryer or the in-line dryer.
Note: Restrictions of the refrigerant flow are identified “Receiver-Dryer - Remove and Install” section in
by frost or cold spots in the line. Also, restrictions Disassembly and Assembly. For in-line dryers,
of the refrigerant flow are identified by frost or cold refer to the Service Manual, SENR5664, “In-Line
spots in the receiver-dryer or the in-line dryer. Refrigerant Dryer - Remove and Install” section in
Disassembly and Assembly.
• Replace filters or remove any of the restrictions.
• Remove the moisture from the system. Refer to the
• Evacuate the system. Refer to the Service Manual, Service Manual, SENR5664, “Refrigerant System -
SENR5664, “Refrigerant System - Evacuate” Evacuate” section in Testing and Adjusting.
• Charge the system with the correct amount of refrigerant. Measure the refrigerant by weight.
refrigerant. Measure the refrigerant by weight. Refer to the Service Manual, SENR5664,
Refer to the Service Manual, SENR5664, “Refrigerant System - Charge” section in Testing
“Refrigerant System - Charge” section in Testing and Adjusting.
and Adjusting.
• After the system is charged and operated for a
• After the system is charged and operated for a minimum of ten minutes, perform a performance
minimum of ten minutes, perform a performance check. Refer to “Performance Checks for the Air
check. Refer to “Performance Checks for the Air Conditioning System” section.
Conditioning System” section.
Note: Low pressure (suction) drops into vacuum
System Condition 5 when ice forms in the expansion valve. High pressure
(discharge) drops when low pressure drops into
Note: The system only cools the cab in the morning vacuum.
and in the evening. The system does not cool the
cab during the hot part of the day. System Condition 6
1. Low pressure gauge reading is normal, but 1. The low pressure gauge reading does not
the gauge reading may drop into the vacuum change. The pressure should rise when the
range during the testing procedure. For normal compressor is not in operation. For normal
operating pressures, refer to Table 10. operating pressures, refer to Table 10.
SENR5664-11 91
2. High pressure gauge reading is at the high end • Recover the remaining refrigerant. Refer to
of the normal range. the Service Manual, SENR5664, “Refrigerant
Recovery” section.
3. The temperature of the air flow from the evaporator refrigerant. Measure the refrigerant by weight.
is partially cool. Refer to the Service Manual, SENR5664,
Probable Cause and Adjusting.
The system has air or moisture in the system. The • Perform a performance check. Refer to
system does not have a full charge of refrigerant. “Performance Checks for the Air Conditioning
System” section.
• Perform a leak test and carefully test around the
compressor seal. Refer to the Service Manual, Note: Perform the following procedure if the system
SENR5664, “Refrigerant Leakage - Test” section in has not been serviced for a extended period of time.
Testing and Adjusting. Perform the following procedure if the pressures of
the system are not within the correct specifications.
to the Service Manual, SENR5664, “Refrigerant • Recover the refrigerant. Refer to the Service
Recovery” section in Testing and Adjusting. Manual, SENR5664, “Refrigerant Recovery”
section.
• Repair leaks.
• Evacuate the system. Refer to the Service Manual,
• Check the compressor for loss of oil. SENR5664, “Refrigerant System - Evacuate”
section in Testing and Adjusting. If service work
• Evacuate the system. Refer to the Service Manual, has not been performed for a extended period of
SENR5664, “Refrigerant System - Evacuate” time, replace the receiver-dryer or the in-line dryer.
• Charge the system with the correct amount of refrigerant by weight. Refer to the Service Manual,
refrigerant. Measure the refrigerant by weight. SENR5664, “Refrigerant System - Charge” section
Refer to the Service Manual, SENR5664, in Testing and Adjusting.
and Adjusting. • After the system is charged and operated for a
• After the system is charged and operated for a check. Refer to “Performance Checks for the Air
minimum of ten minutes, perform a performance Conditioning System” section.
Conditioning System” section. System Condition 8
System Condition 7 1. Low pressure gauge reading is above normal.

1. Low pressure gauge reading is above normal.
For normal operating pressures, refer to Table 10. 2. High pressure gauge reading is below normal.
2. High pressure gauge reading is above normal.
For normal operating pressures, refer to Table 10. Note: Ambient temperature is above 21°C (70°F)
and the system has a refrigerant charge that is full.
3. The temperature of the air flow from the evaporator
3. High pressure (liquid line) is very hot. is partially cool.
4. The compressor may become noisy and the drive Probable Cause
belt may slip.
The compressor has internal leaks. The reed valve
Note: The compressor is not operating under ambient has leakage. The compressor piston, rings or
temperatures that are extreme. The compressor is cylinders are worn.
not operating under high humidity that is extreme.
• Check the compressor drive belt for the correct
Probable Cause tension.
The system is overcharged.

92 SENR5664-11
• Perform a leak test. Isolate the problem to System Condition 9

the compressor. Refer to the Service Manual,
SENR5664, “Refrigerant Leakage - Test” section in 1. Low pressure gauge reading is above normal.
Testing and Adjusting. For normal operating pressures, refer to Table 10.
If an internal leak is found, perform the following 2. High pressure gauge reading is normal or low.
procedure. For normal operating pressures, refer to Table 10.
• Replace the compressor. Refer to the Service Note: Ambient temperature is above 21°C (70°F)
Manual, SENR5664, “refrigerant Compressor - and the system has a refrigerant charge that is full.
remove and Install” section in Disassembly and
Assembly. 3. The temperature of the air flow from the evaporator
is warm.
• Replace the receiver-dryer. Refer to the Service
Manual, SENR5664, “Receiver-Dryer - Remove 4. The suction hose and the evaporator is covered
and Install” section in Testing and Adjusting. with moisture (sweating).
• Evacuate the system. Refer to the Service Manual, Probable Cause

section in Testing and Adjusting. Flow of refrigerant through the evaporator coil is
excessive. The expansion valve could be stuck or
• Charge the system with the correct amount of held in the OPEN position.
refrigerant by weight. Refer to the Service Manual,
SENR5664, “Refrigerant System - Charge” section 1. Test the expansion valve for the correct operation.
in Testing and Adjusting. Use the following procedure.
• After the system is charged and operated for a • Position the air conditioner temperature control
minimum of ten minutes, perform a performance knob in the maximum COOL position and the
check. Refer to “Performance Checks for the Air fan switch in the HIGH position.
• Cool the head of the expansion valve diaphragm
If an external leak such as a hose connection is chamber and the capillary tube with ice or
found, perform the following procedure. liquid nitrogen. Record the low pressure gauge
reading. The low pressure gauge should
• Recover the refrigerant. Refer to the Service indicate a vacuum.
section. • If the low pressure gauge indicates a vacuum,
place a hand over the expansion valve
• Repair leaks. diaphragm chamber. The hand will warm the
expansion valve diaphragm chamber. In order
If a large amount of refrigerant is lost, check the to ensure the correct operation of the expansion
compressor for the loss of oil. valve, cool the head of the expansion valve
diaphragm chamber and the capillary tube with
• Evacuate the system. Refer to the Service Manual, ice or liquid nitrogen again. If the operation of
SENR5664, “Refrigerant System - Evacuate” the expansion is correct, refer to Step 2.
• If the low pressure gauge does not indicate
• Charge the system with the correct amount of the proper operation of the expansion valve,
refrigerant. Measure the refrigerant by weight. recover the refrigerant from the system. Refer
Refer to the Service Manual, SENR5664, to the Service Manual, SENR5664, “Refrigerant
“Refrigerant System - Charge” section in Testing Recovery” section in Testing and Adjusting.
and Adjusting.
• Replace the expansion valve. Refer to the
• After the system is charged and operated for a Service Manual, SENR5664, “Expansion Valve
minimum of ten minutes, perform a performance - (Air Conditioner) Remove and Install” section
check. Refer to “Performance Checks for the Air in Disassembly and Assembly.
Note: The sensing bulb must be installed correctly in
order to ensure the proper operation of the expansion
valve.
SENR5664-11 93


and Adjusting.

2. If the pressure gauge indicates the correct

operation of the expansion valve, perform the
following procedure.
• Use a 8P-6355 Clip in order to hold the

sensing bulb onto the evaporator outlet pipe.
The sensing bulb should be as close to the
evaporator as possible. The bulb should be
upstream of the pressure sensing connection
on the evaporator outlet pipe. The following
items must be wound tightly with 5P-7070
Strip Insulation: the clip, the sensing bulb, and
the outlet pipe. There should be no insulation
g00409166
between the bulb and the outlet pipe. Illustration 63
Expansion valve in the open position (Typical Example)
• In order to ensure that the system operates (1) Capillary tube
correctly, perform a performance check. Refer (2) Expansion valve diaphragm chamber
to “Performance Checks for the Air Conditioning (3) Inlet
(4) Outlet
System” section.
System Condition 10
1. Low pressure gauge reading is too low. For

2. High pressure gauge reading is too low. For

3. The temperature of the air flow from the evaporator

is partially cool or warm.
4. Moisture (water) or frost is on the expansion valve

inlet or orifice tube assembly.
Probable Cause
The problems that are described in Step 1 through

Step 4 can be caused by the following faults:
Note: The following faults will cause a restriction of

the flow of refrigerant to the evaporator.
• Improper operation of the expansion valve (stuck

valve)
• Blockage at the evaporator inlet

94 SENR5664-11
• No charge in temperature sensing bulb 2. If the low pressure gauge indicates the correct
operation of the expansion valve, perform the
Note: The inlet to the expansion valve will be warm following procedure:
during normal operation.
• The sensing bulb must be in the correct position
1. If the expansion valve inlet is cool to the touch, on the evaporator outlet pipe and the sensing
perform the following procedure: bulb must be the correct distance away from the
evaporator outlet. The bulb should be upstream
• Position the air conditioner temperature control from the pressure sensing connection in the
knob to the maximum COOL position and the evaporator outlet pipe. The insulation must be
fan switch to the HIGH position. around the sensing bulb and the clip on the
evaporator outlet pipe.
• Cool the head of the expansion valve diaphragm
chamber and capillary tube with ice or liquid • In order to ensure the correct systems operation,
nitrogen. Record the low pressure gauge perform a performance check.
reading. The low pressure gauge should
indicate a vacuum. 3. Replace the in-line dryer or replace the orifice
tube.
• If a vacuum is indicated on the low pressure
gauge, place a hand over the expansion valve • Evacuate the system. Refer to the Service
diaphragm chamber. The hand will warm the Manual, SENR5664, “Refrigerant System -
expansion valve diaphragm chamber. In order Evacuate” section in Testing and Adjusting.
to ensure the correct operation of the expansion
valve, cool the head of the expansion valve • Charge the system with the correct amount of
diaphragm chamber and the capillary tube with refrigerant. Measure the refrigerant by weight.
ice or liquid nitrogen again. If the operation of Refer to the Service Manual, SENR5664,
expansion valve is correct, refer to Step 2. “Refrigerant System - Charge” section in Testing
and Adjusting.
• If the low pressure gauge does not indicate
proper operation of the expansion valve, • After the system is charged and operated for a
remove the refrigerant from the system. Refer minimum of ten minutes, perform a performance
to the Service Manual, SENR5664, “Refrigerant check. Refer to “Performance Checks for the Air
Recovery” section in Testing and Adjusting. Conditioning System” section.
• Replace the expansion valve. Refer to the

Service Manual, SENR5664, “Expansion Valve
- (Air Conditioner) Remove and Install” section
in Disassembly and Assembly.
Note: The sensing bulb must be installed correctly

in order to ensure the correct operation of the
expansion valve. Clean the location for the sensing
bulb with steel wool or emery paper. Use a 8P-6355
Clip in order to attach the sensing bulb securely to
the evaporator coil outlet pipe. Completely cover the
assembly with 5P-7070 Strip Insulation.


and Adjusting.

SENR5664-11 95
2. If a blockage is found in the condenser, remove

all blockages and perform a performance check.
The performance check will ensure proper system
operation. Refer to “Performance Checks for the
Air Conditioning System” section.
3. If the problem still exists, perform the following

procedure. Check the system for an overcharge
of refrigerant.
Note: Do not operate the engine.
• Recover the refrigerant. Refer to the Service


• Recharge the system with the correct amount of

and Adjusting.
Note: With the ambient temperature above 21°C

(70°F), the normal gauge reading for the low
g00415456
Illustration 64 pressure side is 70 to 138 kPa (10 to 20 psi) while
Expansion valve in the closed position (Typical Example) the normal gauge reading for the high pressure side
(1) Capillary tube is 820 to 1300 kPa (120 to 190 psi).
(2) Expansion valve diaphragm chamber
(3)
(4)
Inlet
Outlet
• In order to ensure the correct systems
operation, perform a performance check. Refer
to “Performance Checks for the Air Conditioning
Note: For expansion valve systems, refer to Step 1. System” section.
For orifice tube systems, refer to Step 3.
4. If the low pressure gauge reading and the high
System Condition 11 pressure gauge readings are too high, perform
the following procedure:
1. Low pressure gauge reading is too high. For
to the Service Manual, SENR5664, “Refrigerant
2. High pressure gauge reading is too high. For Recovery” section in Testing and Adjusting.

• Replace the receiver-dryer or replace the in-line
dryer. Refer to the Service Manual, SENR5664,
“Receiver-Dryer - Remove and Install” section
3. The temperature of the air flow from the evaporator in Disassembly and Assembly. For in-line
is warm. dryers, refer to the Service Manual, SENR5664,
“In-Line Refrigerant Dryer - Remove and Install”
Probable Cause section in Disassembly and Assembly.
The condenser is not functioning properly.
• If the receiver-dryer or the in-line dryer is
not equipped with quick couplers, evacuate
Note: The system may have a normal or overcharge the system. Refer to the Service Manual,
of refrigerant. SENR5664, “Refrigerant System - Evacuate”
1. Check for a blockage in the flow of air through the
condenser.
96 SENR5664-11
• Charge the system with the correct amount of 3. The wire that connects the switch to the magnetic
refrigerant. Measure the refrigerant by weight. clutch has an opening.
“Refrigerant System - Charge” section in Testing a. Check the resistance of the coil with a
and Adjusting. multimeter. Refer to the Service Manual,
SENR5664, “Refrigerant Compressor” section
• After the system is charged and operated for a in Specifications.
check. Refer to “Performance Checks for the Air b. Check for the proper electrical ground at the
Conditioning System” section. magnetic clutch.
System Condition 12 c. Touch the two wires on the switch together.

Check for the proper operation of the magnetic
• Water is in the vents. clutch.
• Water is leaking from the unit. d. In order to check the electrical components,
refer to Service Manual, SENR5664,
Probable Cause “Troubleshooting Heating and Air Conditioning
Control System” in Testing and Adjusting.
• The nonreturn valve of the drain
1. Check the nonreturn valve for proper positioning
and proper direction. If the problem is a loose wire on the switch
or a loose wire on the magnetic clutch, make
The Compressor will not Engage the repairs that are needed. If the wires to the
clutch were damaged, the damaged wires
If the machine is equipped with the protection system can cause the switch to remain open. Make
for the refrigerant compressor, Refer to the Service the needed repairs to the damaged wires. In
Manual, SENR 5664, “Troubleshooting Heating order to ensure the correct system operation,
and Air Conditioning Control Systems” in order to perform a performance check.
test the on delay timer assembly for the refrigerant
compressor. 4. The charge of refrigerant in the capillary tube has
been lost.
System Condition 13
a. If the capillary tube has no charge or the
1. Low pressure gauge reading is above normal. switch remains open, the problem is in the
For normal operating pressures, refer to Table 10. thermostatic switch.
2. High pressure gauge reading is below normal. • Replace the switch.

• In order to ensure the correct system
Note: Ambient temperature is above 21°C (70°F). operation, perform a performance check.
Refer to “Performance Checks for the Air
3. Air flow to the operator’s compartment is warm. Conditioning System” section.
Probable Cause The Compressor Continues to Cycle or

the Clutch will not Disengage.
1. The thermostatic switch is stuck open. This
does not allow the magnetic clutch to cycle the Note: The cause of the problem may be one of the
compressor. following conditions: low charge, overcharge, and
evaporator freeze-up .
a. Check the wire connectors on the thermostatic
switch and on the magnetic clutch. System Condition 14
2. The connection of wire leads on switch is 1. Low pressure gauge reading is below normal.
improper. The connection of wire leads on the For normal operating pressures, refer to Table 10.
magnetic clutch is improper.
2. High pressure gauge reading is below normal.
a. Check for insulation that is broken. The For normal operating pressures, refer to Table 10.
insulation failure can expose the wires from the
switch to the magnetic clutch.
SENR5664-11 97
Note: Ambient temperature is above 21°C (70°F). • If the low side reading is above 345 kPa
(50 psi), check for a missing orifice tube. Refer
3. The air flow to the operator’s compartment is very to Service Manual, SENR5664, “Orifice Tube
cold, or the air flow may be restricted completely (Air Conditioner) - Remove and Install” in
at times. Disassembly and Assembly.
Probable Cause • If the low side reading is into vacuum, check for
a plugged orifice tube or a restriction in the line.
The thermostat switch is held closed. There is a short
in the wire to the magnetic clutch. The magnetic • A restriction in the liquid line can be detected
clutch will not release. by running a hand along the line until there
is a change in temperature. A change in
• Check the wire that goes to the magnetic clutch. temperature in the line will usually indicate the
The wire may have an electrical short. location of the restriction.
• Replace the thermostat switch. 4. If the inlet and the outlet on the accumulator are
warm, refer to the Service Manual, SENR5664,
• Make the necessary repairs to the magnetic clutch. “Refrigerant System - Charge” section in Testing
and Adjusting. Also, refer to the Service Manual,
Additional Refrigerant Circuit SENR5664, “Refrigerant Leakage-Test” section in
Testing and Adjusting.
Problems for Orifice Tube System
System Condition 15
The compressor clutch is engaged but the system
has insufficient cooling.
Probable Cause
• The system is improperly charged.

• A compressor drive belt that is loose or a
compressor drive belt that is worn can cause
insufficient cooling.
• Restrictions, insects, foreign material in the

condenser, or any restriction of airflow can cause
• A missing or a plugged orifice tube can cause

• A restriction in a liquid line or a low amount of

refrigerant charge can cause insufficient cooling.
1. Install the manifold gauge set. Refer to the

Service manual, SENR5664, “Manifold Gauge Set
(Refrigerant) - Install” section.
2. Start the engine. Operate the engine at 1400

rpm. Move the temperature control knob to the
Maximum position and the fan to the High position.
Close all windows and doors. In order to stabilize
the system, operate the system for a minimum
of ten minutes.
3. The outlet on the accumulator should be cold

to the touch. If the outlet is not cold, check the
readings on the manifold gauges.
98 SENR5664-11
Testing and Adjusting 1. Use the refrigerant identifier. The refrigerant

identifier will detect refrigerants that are not
R134a. The refrigerant identifier will prevent
i01685825 the refrigerants from contaminating the tools
for recovery and the tools for charging. The
Refrigerant Recovery refrigerant identifier will also detect the percentage
of air that may be in the system.
SMCS Code: 1809-576

erant.

applied to a charged system.





death.


If service work is required on an air conditioning

system, the refrigerant must be recovered first before
components are removed or installed. Use the
following procedure:
SENR5664-11 99
g00389232
Illustration 65
(1) Low pressure valve. (2) High pressure valve. (3) Charging hose. (4) Low pressure hose. (5) High pressure hose. (6) Manifold gauge set.
(7) Control panel. (8) Inlet on recovery station. (9) Accumulator/oil separator. (10) Drain valve. (11) Pressure valve on accumulator. (12)
Compressor. (13) Refrigerant tank. (14) Hose (liquid). (15) Hose (vapor). (16) Refrigerant pump. (17) Filter dryer. (18) Scale. (A) Refrigerant
compressor. (B) Low pressure side (suction). (C) High pressure side (discharge).
2. Install the manifold gauge set (6). Make sure that 5. Plug the recovery station into an electrical outlet
both valves are closed. Turn the valves clockwise and turn the power switch ON. This switch is
in order to close the valves. Refer to theTesting located on the control panel (7).
and Adjusting, “Manifold Gauge Set (Refrigerant)
- Install” section. 6. Press the “Compressor Start”. The amber
“Compressor On” light will come on and
Note: Do not operate the engine. compressor (12) will start. The compressor will
automatically shut off when the recovery of
3. Attach charging hose (3) of the Manifold gauge refrigerant is complete.
set to the inlet (8) on the refrigerant service unit.
4. Slowly open valves (1) and (2) in order to release

the air from the charging hose. Ensure that the
valves on the refrigerant tank (13) are open. One
valve is for vapor and the other valve is for liquid.
100 SENR5664-11
7. Drain accumulator (9) of refrigerant oil. Open i01693224

accumulator pressurizing valve (11) long enough
so that some discharge from the compressor can Manifold Gauge Set
flow back to the accumulator. Open oil drain valve (Refrigerant) - Install
(10) slowly and drain the oil into a measuring
cup. Do not allow a complete loss of pressure in SMCS Code: 7465-012
the accumulator/oil separator. When the oil stops
draining, close oil drain valve (10).
8. If 15.0 mL (.50 fl oz) of compressor oil was lost

during the recovery process, new oil must be Personal injury can result from contact with refrig-
added to the system. Refer to the Testing and erant.
Adjusting, “Refrigerant Compressor Oil - Check”
section. This system is under pressure at all times, even





death.


1. Use the 138-6629 Refrigerant Identifier in order

to verify that the refrigerant that is in the air
conditioning system is R134a.
SENR5664-11 101
2. Connect the manifold gauge set to the service i01685841

ports near the refrigerant compressor. The service
ports for charging are located on the refrigerant Refrigerant System - Evacuate
lines. Connect the low pressure hose to the
service port on the suction side of the compressor. SMCS Code: 1809-541
Connect the high pressure hose to the service
port on the discharge side of the compressor.
Make sure that the valved couplings are turned
counterclockwise for installation. Then, turn the Personal injury can result from contact with refrig-
valved couplings clockwise in order to open the erant.
valves.
3. Turn the pressure valves clockwise and make if the engine is not running. Heat should never be
sure that both pressure valves on the manifold applied to a charged system.
gauge set are closed.
4. Place a clean rag over the charging hose fitting face and hands away to help prevent injury.
that is loosened at the manifold gauge set. This
will prevent the spraying of compressor oil. Open Protective goggles must always be worn when re-
the low pressure valve on the gauge set about 1/2 frigerant lines are opened, even if the gauges in-
turn. Keep the valve open for 2 to 3 seconds in dicate the system is empty of refrigerant.
order to flush air from the low pressure hose. This
will also flush air from the gauge set. Close the Always use caution when a fitting is removed.
low pressure valve on the gauge set. Repeat this Slowly loosen the fitting. If the system is still
process for the high pressure valve. Tighten the under pressure, evacuate the system recovering
charging hose fitting at the manifold gauge set. the refrigerant before removing the fitting.
Note: Use the refrigerant identifier. The refrigerant Personal injury or death can result from inhaling
identifier will prevent refrigerants that are not R134a refrigerant through a lit cigarette.
from contaminating the recovery and charging tools.
death.


If replacement of a component is necessary or repair

to a component is necessary, the refrigerant in
the system must be recovered. Also, if the system
has lost any charge after a long period of time, the
refrigerant in the system must be recovered. It is
necessary to perform the evacuating procedure in
order to delete the system of all air and moisture. A
complete charge must never be given to a system
without first performing the evacuating procedure.
Before evacuating the system, refer to the following
manual.
• Testing and Adjusting, “Refrigerant Leakage - Test”

• Testing and Adjusting, “Refrigerant Recovery”
102 SENR5664-11
• Testing and Adjusting, “Refrigerant Compressor

Oil - Check”
If the system has been left open for more than 1/2
hour, the system has been exposed to air or moisture
and a new receiver-dryer, an in-line dryer or a
desiccant accumulator needs to be installed. Moisture
will combine with metals in the refrigerant system and
this will produce highly corrosive by-products. The
by-products are oxides, iron hydroxide, and aluminum
hydroxide. Moisture can freeze the expansion valve
and moisture can freeze the orifice tube. If there
is water in the system the water must be removed.
Remove the water by pumping the system with a
vacuum pump and boiling the water. Refer to Table
11 that is shown below.
The time for the evacuation process will increase

under the following conditions:
• The air conditioning system has been rebuilt.

• The air conditioning system has been flushed.
• The air conditioning system has new components.
• The air conditioning system has been retrofitted.
Table 11
Boiling Point of Water Under Vacuum
Vacuum That Is Required
Temperature of Work In Order To Boil Water
Area (°C (°F)) In An Air Conditioning
System (m bar (Hg))
38 °C (100 °F) 95 kPa (28 in Hg)
32 °C (89.6000 °F) 96.5 kPa (28.50 in Hg)
27 °C (81 °F) 97.5 kPa (28.80 in Hg)
21 °C (70 °F) 98.8 kPa (29.20 in Hg)
Note: After the leak test is completed, the system

must be evacuated for a minimum of 30 minutes. In
order to correctly evacuate the system, the vacuum
gauge must be less than three inches away from the
system port. If the gauge is more than three inches
away from the system port, pull a vacuum and allow
the system to equalize for ten minutes. This will
ensure an accurate gauge reading.
NOTICE
All refrigerant must be recovered before the evacuat-
ing procedure is started. Never discharge the refrig-
erant through the vacuum pump. Never discharge the
refrigerant into the atmosphere. Always use the Re-
frigerant Identifier tool in order to ensure that contam-
ination of the system does not occur.
SENR5664-11 103
g00452649
Illustration 66
(1) Low pressure valve (6) Service valve (discharge)
(2) High pressure valve (7) Service valve (suction)
(3) Charging hose (8) Vented exhaust valve
(4) Compressor block fitting (discharge) (9) Line from condenser
(5) Compressor block fitting (suction) (10) Line from evaporator
104 SENR5664-11
1. After the refrigerant is recovered from the system, 10. After 95 kPa (28 in hg) to 98 kPa (29 in hg)
make sure that the low pressure valve (1) and the vacuum has been reached and held for an
high pressure valve (2) are closed. Disconnect the additional 90 minutes, close valve (1) and close
charging hose (3) of the manifold gauge set from valve (2) completely. Turn the power switch on the
the refrigerant service unit. vacuum pump to the OFF position. The maximum
amount of vacuum loss in five minutes must not be
2. Check the oil level in the vacuum pump. more than 7 kPa (2 in hg). Excessive vacuum loss
Refer to the Testing and Adjusting, “Refrigerant is an indication of a possible leak in the system.
Compressor Oil - Check” for the correct procedure. Refer to the Testing and Adjusting, “Refrigerant
Add oil if oil is needed. If contamination of the Leakage - Test” section. Perform the procedures
system is indicated, change the oil. that are indicated. Repair all leaks and repeat
Step 1 of the evacuating procedure.
3. Connect the electrical plug from the vacuum pump
to an approved electrical outlet. 11. If the vacuum loss does not exceed 7 kPa
(2 in hg) in five minutes, the system is then ready
4. Connect the charging hose (3) to the inlet fitting for a complete charge. Refer to the Testing and
on the vacuum pump. Refer to Illustration 66. Adjusting, “Refrigerant System - Charge” section.
Perform the procedures that are indicated.
5. Open low pressure valve (1) and open high
pressure valve (2) on the manifold gauge set
completely. Turn the valves counterclockwise.
6. In order to start the pump motor, turn the power

switch to the ON position.
7. In order to open the vented exhaust valve (8), turn

the valve counterclockwise.
Note: The vented exhaust valve (8) must be closed

until the vacuum pump has started.
8. Operate the vacuum pump until the low pressure

gauge indicates a pressure that is between 95 kPa
(28 in hg) and 98 kPa (29 in hg). After the vacuum
in the system reaches a value that is between
95 kPa (28 in hg) and 98 kPa (29 in hg), close the
vented exhaust valve (8). Operate the vacuum
pump for a minimum of 90 minutes after the
vented exhaust valve is closed. Use a 113 L/min
(4 cfm) pump. Make allowances for pumps that
are smaller than 113 L/min (4 cfm) cfm.
Note: 95 kPa (28 in hg) to 98 kPa (29 in hg) is the

required specification at sea level. For every 305 m
(1000 ft) above sea level, decrease the required
specification by 3 kPa (1 in hg). At high elevations,
less vacuum is required.
9. If the specific vacuum cannot be reached, the

system may have a leak. Refer to the Testing and
Adjusting, “Refrigerant Leakage - Test” section.
Perform the procedures that are indicated. Repair
all leaks and repeat Step 1 of the evacuating
procedure.
Note: The evacuating procedure removes air and

moisture from the system. Do not use the vacuum
pump primarily to indicate a system leak.
SENR5664-11 105
i01727454 Finding leaks and repairing leaks from refrigerant is

important since the air conditioner is a closed circuit
Refrigerant Leakage - Test system.
SMCS Code: 1809-081 The system must contain at least 0.4 kg (.88 lb)
of refrigerant. Install the manifold gauge set. The
Dye manifold gauge set can determine if pressure exists
in the system. A leak test can be performed if the
system indicates pressure.
Note: Refrigerant vapor is heavier than air. For best

Personal injury can result from contact with refrig- results, place the black light directly below possible
erant. leaks.
This system is under pressure at all times, even Note: Leaks that are in the high pressure side of the
if the engine is not running. Heat should never be system are more easily found if the air conditioner is
applied to a charged system. operated for 5 to 10 minutes. The leak test must be
performed immediately after the unit is turned OFF.
Contact with refrigerant can cause frost bite. Keep The leak test for the high pressure side is performed
face and hands away to help prevent injury. before the pressures in the system equalize. Leaks
that are in the low pressure side of the system are
Protective goggles must always be worn when re- more easily found if the air conditioner has been
frigerant lines are opened, even if the gauges in- turned OFF for 5 to 10 minutes. The leak test for the
dicate the system is empty of refrigerant. low pressure side is performed after the pressures in
the system equalize.
Slowly loosen the fitting. If the system is still 1. Move the black light along possible leak points.
under pressure, evacuate the system recovering When a leak is present, the black light will
the refrigerant before removing the fitting. illuminate the dye that is in the refrigerant.
Personal injury or death can result from inhaling Note: Leaks that are indicated by the presence
refrigerant through a lit cigarette. of dye should always be confirmed with an
electronic leak detector.
lit cigarette or other smoking method or inhaling 2. If a leak is found in the air conditioning system,
fumes released from a flame contacting air con- use a 4C-2964 Refrigerant Leak Detector in order
ditioner refrigerant gas, can cause bodily harm or to confirm the leak that was detected by the use
death. of the black light.
Do not smoke when servicing air conditioners or 3. Repair the leak In the air conditioning system
wherever refrigerant gas may be present. and clean the area with 192-4727 Dye Cleaning
Solution.
smooth horizontal surface. Lower all implements Leak Detector
in neutral or park and that the parking brake is The 208-1374 Refrigerant Leak Detectors are
engaged. Keep all other personnel away from the designed in order to detect leaks as small as 7.4 mL
machine or where they can be seen. (.25 oz) per year of refrigerant in the air conditioning
system. Perform the following procedure in order to
determine if the system has a leak.
Table 12
Required Tools The system must contain at least 0.4 kg (.88 lb)
of refrigerant. Install the manifold gauge set. The
Part Number Part Description Quantity manifold gauge set can determine if pressure exists
Leak Detection Lamp in the system. A leak test can be performed if the
192-2331 1 system indicates pressure.
Gp
Note: Refrigerant vapor is heavier than air. For best

In the middle of 1999, Caterpillar began installing dye results, place the sensor tip directly below possible
in the refrigeration systems of Caterpillar machines. leaks.
The dye is used in order to assist in identifying points
of leakage in the refrigeration system.
106 SENR5664-11
Note: Leaks in the high pressure side of the system i01934427

are more easily found if the air conditioner is operated
for a few minutes. The leak test must be performed Refrigerant Compressor Oil -
immediately after the unit is turned OFF. The leak test Check
for the high pressure side is performed before the
pressures in the system equalize. Leaks in the low SMCS Code: 1802-535-FLV
pressure side of the system are more easily found if
the air conditioner has been turned OFF for several
minutes. The leak test for the low pressure side is
performed after the pressures in the system equalize.
1. Move the sensor tip along possible leak points at erant.
a rate of one inch per second.
2. It may not be necessary to recover refrigerant if if the engine is not running. Heat should never be
a loose fitting or a loose connection is causing a applied to a charged system.
leak. Tighten the loose connection and perform the
performance check procedure. If necessary, add Contact with refrigerant can cause frost bite. Keep
refrigerant to the air conditioning system. Refer to face and hands away to help prevent injury.
the Testing and Adjusting, “Refrigerant System -
Charge” section for the proper procedure. Protective goggles must always be worn when re-
3. If the repair of a leak calls for the removal or the dicate the system is empty of refrigerant.
replacement of a component, refer to the Service
Manual, SENR5664, “Machine Preparation Always use caution when a fitting is removed.
for Disassembly and Assembly” section in Slowly loosen the fitting. If the system is still
Disassembly and Assembly. under pressure, evacuate the system recovering
Note: Under normal conditions, R134a air
conditioning systems that have P80 hoses may lose Personal injury or death can result from inhaling
as much as 0.018 kg (0.0400 lb) of refrigerant per refrigerant through a lit cigarette.
foot of hose per year.
Note: Refrigerants that are not approved by lit cigarette or other smoking method or inhaling
Caterpillar may have higher leakage rates. fumes released from a flame contacting air con-
death.


A special refrigerant oil is used in the air conditioning

system. The oil mixes completely with the refrigerant
so that all the components receive lubrication. A
check of the refrigerant oil in the compressor will give
an indication of the amount of oil that is in the system.
Reference: Refer to System Operations, “Refrigerant

Compressor” for more information.
Note: Generally, the oil in the compressor is checked

when there is evidence of a major loss of oil. The
following conditions may cause the loss of oil:
SENR5664-11 107
• Broken refrigerant hose • Metal chips

• Hose fitting (leaks) • Rubber particles
• Badly leaking compressor seal • Foreign material
• Component damage Dispose of the oil in a suitable container. Use the
following list as a guide for adding oil into the
compressor:
Complete Check of Compressor Oil
When the replacement of a component is necessary, • If the amount of oil that is drained from the
compressor is 177 mL (6 fl oz) to 237 mL
follow the procedures below. The procedure
(8 fl oz), put the same amount of new refrigerant
determines the amount of refrigerant oil (lost oil) that
is needed in the compressor. oil in the compressor. Never refill with more
than 237 mL (8 fl oz) of oil to the compressor
unless the system has been flushed.
1. Operate the engine at 1000 rpm. Set the
temperature on maximum cooling setting. Move
the fan speed switch to HIGH. The system will • If the amount of oil that is drained from the
compressor is less than 177 mL (6 fl oz), add
stabilize in a minimum of 10 minutes.
177 mL (6 fl oz) to 237 mL (8 fl oz) of new
refrigerant oil to the compressor.
2. Stop the engine. Remove the refrigerant charge
from the system. Install a plug in all open lines.
Refer to Testing and Adjusting, “Refrigerant • If a new compressor or a rebuilt compressor is
installed, drain all of the oil from the compressor
Recovery” for the proper procedure.
and add 177 mL (6 fl oz) to 237 mL (8.0 fl oz) of
3. Remove the compressor from the machine. Place new refrigerant oil in the compressor.
protective caps on all fittings and hoses.
• If the system was flushed do not remove the oil
from a new compressor.
• Refer to 13 if individual components are

replaced without charging the compressor or
without flushing the system.
Table 13
Oil Capacities for Component Replacements
Accumulator 30 mL (1 fl oz)
Compressor Refer to the Service Manual,
SENR5664, “Refrigerant Compressor
Oil-Check” section in Testing and
Adjusting.
g00296421
Illustration 67 Condenser 30 mL (1 fl oz)
(1) Pulley
(2) Hose (low pressure)
Evaporator 90 mL (3 fl oz)
(3) Hose (high pressure) In-Line Dryer(1) 30 mL (1 fl oz)
(4) Electrical harness
(5) Service valve (low pressure) Receiver-Dryer 30 mL (1 fl oz)
(6) Service valve (high pressure)
(7) Plug (oil change) (1) Refer to the Service Manual, SENR5664,
(8) Belt “In-Line-Refrigerant Dryer - Remove and Install ”
before any oil is added.
4. Place the compressor in a horizontal position so
oil plug (7) is facing downward. Remove oil plug If too much oil has been added to the system and
(7) from the compressor. Drain the oil into a clean a total of more than 325 mL (11 fl oz) of oil is in
container. Rock the compressor back and forth the system, the cooling capacity of the system will
in order to remove all of the oil. Also, rotate the be reduced. If too little oil has been added to the
compressor shaft in order to drain the rest of the system, the compressor may fail due to a lack of
oil that is in the oil sump. Record the volume of lubrication.
drained refrigerant. Inspect the oil for the following
items:
• Contaminants
108 SENR5664-11
If the failure of a component causes particles of i01934469

metal or other foreign material to be present in the
system, it is necessary to flush the system. Refer Refrigerant System - Charge
to Troubleshooting, “Air Conditioning System
Troubleshooting” for the proper diagnostics. SMCS Code: 1809-045
Note:
a. Add oil to the compressor through opening for Personal injury can result from contact with refrig-
the oil plug (7) or inject the oil through the ports erant.
that are for charging. The compressor must
be positioned so that the refrigerant oil will not This system is under pressure at all times, even
flow out of service valves (5) and (6). Do not if the engine is not running. Heat should never be
rest the compressor on the compressor shaft. applied to a charged system.
Turn the compressor shaft by hand when you
fill the compressor. The oil will slowly flow into Contact with refrigerant can cause frost bite. Keep
the compressor. Only use refrigerant oil that is face and hands away to help prevent injury.
approved and recommended.
b. Add oil to any components that are being frigerant lines are opened, even if the gauges in-
installed. dicate the system is empty of refrigerant.
c. Inject oil into the system through the ports for Always use caution when a fitting is removed.
low pressure charging. Slowly loosen the fitting. If the system is still
5. After the correct amount of refrigerant oil has the refrigerant before removing the fitting.
been added to the system, install the compressor
and the drive belt. Refer to Testing and Adjusting, Personal injury or death can result from inhaling
“Refrigerant System - Charge” for the proper refrigerant through a lit cigarette.
procedure.
death.


Table 14
Required Tools
Part
Part Description Quantity
Number
4C-4874 Heater Blanket As 1
SENR5664-11 109
Relationship Between Temperature (Table 15, contd)
and Pressure (R-134a Refrigerant) Relationship Between Temperature and Pressure

(R-134a Refrigerant)
Table 15 can be used in order to determine the Temperature °C (°F) Pressure kPa (psi)(1)
pressure level and contamination level of a container
of refrigerant. Table 15 can also be used for an 0 °C (32.0 °F) 191 kPa (27.7 psi)
air conditioning system that is not operating. This 1 °C (33.0 °F) 197 kPa (28.5 psi)
same system must be stabilized to the ambient
temperature. In order to stabilize an air conditioning 1 °C (34.0 °F) 203 kPa (29.4 psi)
system at the ambient temperature, the machine 2 °C (35.0 °F) 209 kPa (30.3 psi)
must not operate for 10 to 12 hours. The machine
must not be stored in direct sunlight. 2 °C (36.0 °F) 215 kPa (31.2 psi)
3 °C (37.0 °F) 221 kPa (32.1 psi)
If the pressure that is measured at any specific
temperature does not match the pressure that is 3 °C (38.0 °F) 228 kPa (33.0 psi)
given in the chart, the following problems may exist: 4 °C (39.0 °F) 234 kPa (34.0 psi)
• Contaminants in the system 4 °C (40.0 °F) 241 kPa (34.9 psi)

5 °C (41.0 °F) 248 kPa (35.9 psi)
• Incorrect refrigerant
6 °C (42.0 °F) 254 kPa (36.9 psi)
• Incorrect refrigerant charge 6 °C (43.0 °F) 261 kPa (37.9 psi)
Table 15 7 °C (44.0 °F) 263 kPa (38.9 psi)
Relationship Between Temperature and Pressure 7 °C (45.0 °F) 275 kPa (39.9 psi)
(R-134a Refrigerant)
8 °C (46.0 °F) 283 kPa (41.0 psi)
Temperature °C (°F) Pressure kPa (psi)(1)
8 °C (47.0 °F) 290 kPa (42.0 psi)
−18 °C (0.0 °F) 44 kPa (6.4 psi)
9 °C (48.0 °F) 297 kPa (43.1 psi)
−17° C (2.0 °F) 51 kPa (7.4 psi)
9 °C (49.0 °F) 305 kPa (44.2 psi)
−16 °C (4.0 °F) 59 kPa (8.5 psi)
10 °C (50.0 °F) 312 kPa (45.3 psi)
−14 °C (6.0 °F) 66 kPa (9.6 psi)
11 °C (51.0 °F) 320 kPa (46.4 psi)
−13 °C (8.0 °F) 74 kPa (10.7 psi)
11 °C (52.0 °F) 328 kPa (47.5 psi)
−12 °C (10.0 °F) 82 kPa (11.9 psi)
12 °C (53.0 °F) 336 kPa (48.7 psi)
−11 °C (12.0 °F) 90 kPa (13.1 psi)
12 °C (54.0 °F) 344 kPa (49.9 psi)
−10 °C (14.0 °F) 99 kPa (14.3 psi)
13 °C (55.0 °F) 352 kPa (51.0 psi)
−9 °C (16.0 °F) 108 kPa (15.6 psi)
13 °C (56.0 °F) 360 kPa (52.2 psi)
−8 °C (18.0 °F) 117 kPa (17.0 psi)
14 °C (57.0 °F) 369 kPa (53.5 psi)
−7 °C (20.0 °F) 127 kPa (18.4 psi)
14 °C (58.0 °F) 377 kPa (54.7 psi)
−6 °C (21.0 °F) 132 kPa (19.1 psi)
15 °C (59.0 °F) 385 kPa (55.9 psi)
−6 °C (22.0 °F) 137 kPa (19.8 psi)
16 °C (60.0 °F) 394 kPa (57.2 psi)
−5 °C (23.0 °F) 141 kPa (20.5 psi)
16 °C (61.0 °F) 403 kPa (58.2 psi)
−4 °C (24.0 °F) 147 kPa (21.3 psi)
17 °C (62.0 °F) 412 kPa (59.8 psi)
−4 °C (25.0 °F) 152 kPa (22.0 psi)
17 °C (63.0 °F) 421 kPa (61.1 psi)
−3 °C (26.0 °F) 157 kPa (22.8 psi)
18 °C (64.0 °F) 430 kPa (62.4 psi)
−3 °C (27.0 °F) 163 kPa (23.6 psi)
18 °C (65.0 °F) 440 kPa (63.8 psi)
−2 °C (28.0 °F) 168 kPa (24.4 psi)
19 °C (66.0 °F) 450 kPa (65.2 psi)
−2 °C (29.0 °F) 174 kPa (25.2 psi)
19 °C (67.0 °F) 459 kPa (66.8 psi)
−1 °C (30.0 °F) 179 kPa (26.0 psi)
20 °C (68.0 °F) 469 kPa (68.0 psi)
−1 °C (31.0 °F) 185 kPa (26.8 psi)
(continued)
(continued)
110 SENR5664-11
(Table 15, contd) (Table 15, contd)

Relationship Between Temperature and Pressure Relationship Between Temperature and Pressure
(R-134a Refrigerant) (R-134a Refrigerant)
Temperature °C (°F) Pressure kPa (psi)(1) Temperature °C (°F) Pressure kPa (psi)(1)
21 °C (69.0 °F) 478 kPa (69.4 psi) 41 °C (105.0 °F) 926 kPa (134.3 psi)
(1) All pressures in this table are gauge pressures.
37 °C (99.0 °F) 838 kPa (121.5 psi)
38 °C (100.0 °F) 852 kPa (123.5 psi)
38 °C (101.0 °F) 866 kPa (125.6 psi)
39 °C (102.0 °F) 881 kPa (127.8 psi)
39 °C (103.0 °F) 896 kPa (129.9 psi)
40 °C (104.0 °F) 911 kPa (132.1 psi)
(continued)
SENR5664-11 111
Procedure for Labeling (Table 16, contd)

System Capacity Part Number for Label
Attach a label to the air conditioning system that
indicates the system charge. Attaching a label 1.7 kg (3.75 lb) 114-0075
to the system will allow easy identification of the 1.8 kg (3.97 lb) 114-0076
system. Refer to Table 16 for the part number of the
appropriate label. A 8L-8413 Cable Strap may be 1.9 kg (4.19 lb) 114-0077
used in order to secure the tag to the air conditioning 2.0 kg (4.41 lb) 114-0078
system.
2.1 kg (4.63 lb) 114-0079
Table 16
2.2 kg (4.85 lb) 114-0080
System Capacity Part Number for Label
2.3 kg (5.07 lb) 114-0081
9U-7551 Air Conditioner Oil
2.4 kg (5.29 lb) 114-0082
1.5 kg (3.31 lb) 130-4677
2.5 kg (5.51 lb) 114-0083
1.8 kg (3.97 lb) 114-0050
2.6 kg (5.73 lb) 114-0084
1.9 kg (4.19 lb) 114-0051
2.7 kg (5.95 lb) 122-3301
2.0 kg (4.41 lb) 114-0052
2.8 kg (6.17 lb) 114-0085
2.1 kg (4.63 lb) 114-0053
3.0 kg (6.61 lb) 122-3302
2.2 kg (4.85 lb) 114-0054
2.3 kg (5.07 lb) 114-0055
Charging the System
2.5 kg (5.51 lb) 114-0056
114-0057
Note: An accurate refrigerant charge may only be
2.7 kg (5.95 lb)
determined by weight or by the temperature of the
3.0 kg (6.61 lb) 114-0058 evaporator core. Pressures can not be used in order
to determine if the air conditioning system is correctly
3.1 kg (6.83 lb) 140-7484
charged. Do not add or remove part of the refrigerant.
4C-2959 Air Conditioner Oil
Note: Never charge liquid or gas through the
1.6 kg (3.54 lb) 114-0059
discharge side (high side) of the system when the
1.7 kg (3.75 lb) 114-0060 engine is in operation.
1.8 kg (3.97 lb) 114-0061
NOTICE
1.9 kg (4.19 lb) 114-0062 In an expansion valve system which uses poly alkaline
2.0 kg (4.41 lb) 114-0063 glycol (PAG), the sight glass is not a reliable way to
determine the system charge.
2.1 kg (4.63 lb) 114-0064
2.2 kg (4.85 lb) 114-0065
Note: For expansion valve systems that contain
2.3 kg (5.07 lb) 114-0066 PAG oil, the sight glass can not be used for the
purpose of charging the system. In order to achieve
2.4 kg (5.29 lb) 114-0067 a full charge for the system, the refrigerant must be
2.5 kg (5.51 lb) 114-0068 recovered from the system and the system must be
evacuated. After the system has been recovered and
2.6 kg (5.73 lb) 114-0048 the system has been evacuated, the system needs
2.7 kg (5.95 lb) 114-0069 to be charged with the correct amount of refrigerant.
This is the only procedure that is recommended.
3.0 kg (6.61 lb) 114-0070 Refer to the Specifications, “System Capacities for
3.8 kg (8.38 lb) 114-0071 Refrigerant” section for the proper capacity. Also,
refer to the Service Manual, SENR5664, “Identifying
4C-2960 Air Conditioner Oil the Air Conditioning System” section.
1.1 kg (2.42 lb) 122-3300
Note: If the engine is running, charge the system with
1.4 kg (3.09 lb) 114-0072 refrigerant gas through the low pressure side. Never
1.5 kg (3.31 lb) 114-0073 charge liquid refrigerant through the suction side
(low pressure side) of the air conditioning system. If
1.6 kg (3.53 lb) 114-0074 the engine is not running, charge with liquid or gas
(continued) through the high pressure side.
112 SENR5664-11
Note: Before you charge the system, these important Complete Charge of the System
items should be checked.
from a Refrigerant Tank with a
1. Condenser and evaporator Scale
• Inspect the condenser and inspect the The use of a refrigerant tank and a scale is necessary
evaporator for foreign material that would inhibit in order to charge the system. Use the procedure that
air flow such as dirt, insects, plastic bags, etc. follows to charge the system.
• With condensers that are mounted on the roof Note: When you charge the system with a liquid,
and with remote mounted condensers, always ensure that the engine is not running.
check that both fan motors are running. Check
for restrictions. A clean condenser will lead to 1. In order to find the refrigerant capacity for the
improved life for the compressor. system that needs a refrigerant charge, refer to the
Specifications, “System Capacities for Refrigerant”
2. Check for a loose belt on the compressor. section. Also, refer to the Service Manual,
SENR5664, “Identifying the Air Conditioning
3. Clean the fresh air filter and clean the recirculation System” section.
filter.
4. Check the moisture indicator on either the

receiver-dryer or the in-line dryer. If the moisture
indicator is pink or white, there is moisture in the
system. Replace the receiver-dryer or the in-line
dryer. Refer to the Service Manual, SENR5664,
“Machine Preparation for Dissassembly and
Assembly” section. If the moisture indicator is
blue, the system is normal.
5. Check the condensate tube on the evaporator.

Make sure that the tube is not plugged and that
the valve is properly in place.
Note: Before an accurate reading for moisture can

be attained, a new receiver-dryer requires 2 to 3
hours of operation.
Refer to the Troubleshooting, “Machine

Preparation for Troubleshooting” section in testing
and adjusting before service work is performed on
the air conditioning system.
Note: The preferred method for charging the air

conditioning system is listed below.
• Recover the refrigerant.

• Evacuate the system.
Note: After the system has been recovered and the

system has been evacuated, the system needs to
be charged with the correct amount of refrigerant.
Measure the refrigerant by weight. Refer to the
Specifications, “System Capacities for Refrigerant”
section for the proper capacity. Also, refer to the
Service Manual, SENR5664, “Identifying the Air
SENR5664-11 113
g00669264
Illustration 68
(1) Low pressure valve (6) Manifold gauge set (14) Scale
(2) High pressure valve (7) Service valve (discharge) (E) Vapor
(3) Charging hose (8) Service valve (suction) (F) Liquid
(4) Low pressure hose (12) Refrigerant tank
(5) High pressure hose (13) Valve on top of refrigerant tank
114 SENR5664-11
2. Hand tighten charging hose (3) from the manifold

gauge set directly to the valve (13) on refrigerant NOTICE
tank (12). Open the valve (13) on top of refrigerant If the system has no refrigerant, evacuate the system
tank (12). This allows the flow of refrigerant before charging the system. The refrigerant charge
through the charging hose (3) to the manifold should be measured by weight.
gauge set (6).
3. Loosen the hose (3) at the manifold gauge set 1. Connect the manifold gauge set to the discharge
(6) for two to three seconds. Then tighten the and service ports on the compressor. Refer to
connection. This procedure will purge the air from the Testing and Adjusting, “Manifold Gauge Set
the line. (Refrigerant) - Install” section.
4. Place the refrigerant tank (12) on the scale (14) 2. Make sure that the low pressure valve (1) and the
so that the valve (13) is at the bottom. Check the high pressure valve (2) are closed on the manifold
weight of the tank. gauge set (6).
5. Open the high pressure valve (2) on the manifold 3. Turn the valve (13) on the tank counterclockwise.
gauge set (6). This action allows the liquid This action will release the refrigerant to the
refrigerant to charge the system through the high charging hose (3).
pressure side of the compressor.
Note: Make sure that the cylinder of refrigerant is
6. Check the weight of the refrigerant tank (12) often. in the upright position. This allows the refrigerant to
The weight will decrease as the refrigerant leaves enter the system as a gas.
the tank and the refrigerant enters the system.
When the required amount of refrigerant (system 4. Loosen the hose connection on the charging hose
capacity) has entered the system, close the valve (3) at the manifold gauge set for two to three
(13) and close the high pressure valve (2). Closing seconds. Then tighten the connection. This action
the valves stops the flow of the refrigerant. For allows air to be released from the charging hose
example, 1.8 kg (4 lb) of refrigerant has entered a (3).
system with 1.8 kg (4 lb) capacity.
5. Start the engine and operate the engine at 1000
Note: A heater blanket may be required when you rpm.
charge an air conditioning system with a partially full
refrigerant tank. 6. Move the temperature control knob to the
MAXIMUM position in the cool range. Move the
7. In order to ensure correct system operation, fan switch to the HIGH position.
disconnect charging hose (3) and conduct a
performance check. Refer to the Service Manual, Note: Recovering the refrigerant and evacuating
SENR5664, “Performance Checks for the Air the system is the preferred method for charging the
Conditioning System” section. air conditioning system. After the system has been
recovered and the system has been evacuated, the
system needs to be charged with the correct amount
Adding Additional Refrigerant to an of refrigerant. Measure the refrigerant by weight.
Air Conditioning System that Has a Refer to the Specifications, “System Capacities for
Refrigerant” section for the proper capacity. Also,
Low Charge refer to the Service Manual, SENR5664, “Identifying
the Air Conditioning System” section.
NOTICE
Failure to properly follow the procedure may cause 7. Open low pressure valve (1) on the manifold
compressor failure. The procedure that follows is not gauge set (6) in order to release the refrigerant
the preferred method for charging an air conditioning into the low pressure hose (4). The low pressure
system. The preferred method of measuring the refrig- hose (4) connects to suction service valve (8)
erant is by weight. on the compressor. Check the pressure gauge
and note the gauge reading. The gauge reading
should not exceed the normal operating ranges
Note: The procedure that follows is applicable only if during this procedure. Slowly add the refrigerant
the inlet air temperature at the condenser is between until the accumulator is cool. The temperature
21 °C (70.0 °F) and 29.5 °C (85 °F). The procedure of the louvers that are inside of the cab should
may be repeated a second time in order to achieve decrease during the procedure.
the proper charge with this method.
SENR5664-11 115
8. After the accumulator becomes cool, add 0.34 kg i02331669

(0.750 lb) of refrigerant to the system for reserve.
Measure the refrigerant by weight. Refrigerant Compressor - Test
9. In order to prevent the additional flow of refrigerant SMCS Code: 1802-081
into the compressor, close the low pressure valve
(1). Allow the system to stabilize for five minutes. The purpose of this instruction is to identify that the
The inlet and the outlet on the accumulator should compressor is functioning correctly prior to being
be cool. removed from the machine. A properly functioning
compressor should produce both high pressure and
Note: If the low pressure valve (1) is opened low pressure. If the compressor fails any one of the
completely, the low pressure gauge reading will Steps 3, 5, 7, or 8 listed below, it is then considered
appear excessively high until the system becomes a failed compressor. In the event the compressor
fully charged. is considered failed, the air conditioning system
should be further diagnosed to find and repair the
10. The gauge reading for low pressure valve (1) root cause of the failure. In the event the compressor
should be within the normal range after you is considered good additional assistance with A/C
charge the system. The gauge reading for high system diagnosis can be found in thisService Manual
pressure valve (2) should be within the normal or by contacting your Caterpillar dealer.
range after you charge the system. If the gauge
readings are within normal range, go to Step 12. If Procedures
the gauge readings are not within normal range,
go to Step 11. Refer to 17.
Table 17
Pressure Range (1)
erant.
Ambient Air High Pressure Low Pressure
Temperature Test Fitting Test Fitting This system is under pressure at all times, even
C° (F°) kPa (psi)(2) kPa (psi)(3) if the engine is not running. Heat should never be
820 to 1300 kPa 70 to 138 kPa
21°C (70°F)
(120 to 190 psi) (10 to 20 psi)
27°C (80°F) 950 to 1450 kPa 70 to 173 kPa face and hands away to help prevent injury.
(140 to 210 psi) (10 to 25 psi)
32°C (90°F) 1175 to 1650 kPa 105 to 210 kPa Protective goggles must always be worn when re-
(170 to 240 psi) (15 to 30 psi) frigerant lines are opened, even if the gauges in-
38°C (100°F) 1300 to 1850 kPa 105 to 210 kPa
(190 to 270 psi) (15 to 30 psi) Always use caution when a fitting is removed.
43°C (110°F) 1450 to 2075 kPa 105 to 210 kPa Slowly loosen the fitting. If the system is still
(210 to 300 psi) (15 to 30 psi) under pressure, evacuate the system recovering
(1) This table is only for reference.
(2) Pressure may be slightly higher in very humid conditions and
lower in very dry conditions. Personal injury or death can result from inhaling
(3) Pressure before clutch disengagement refrigerant through a lit cigarette.
11. If the pressure on the low pressure side becomes Inhaling air conditioner refrigerant gas through a
too high, the system is overcharged. If the high lit cigarette or other smoking method or inhaling
side pressure becomes too high, the system is fumes released from a flame contacting air con-
overcharged. Close the valve on the refrigerant ditioner refrigerant gas, can cause bodily harm or
tank (12) completely. Closing the valve will shut death.
off the flow of refrigerant to the charging hose (3).
Shut down the engine. Recover the charge and Do not smoke when servicing air conditioners or
evacuate the system. Recharge the system to the wherever refrigerant gas may be present.
correct charge by weight.
12. Move the air conditioning controls to the OFF heating system are made, move the machine to a
position and stop the engine. smooth horizontal surface. Lower all implements
13. Remove the manifold gauge set. in neutral or park and that the parking brake is
116 SENR5664-11
1. Check the air filters. Past experience has shown Measured Belt Tension: ________ (N) or (lb) -
that plugged air filters can cause poor cooling before adjust
inside the cab. Most air conditioning systems have
return air filters and fresh air filters. Be sure to Measured Belt Tension: ________ (N) or (lb) - after
check both the return air filters and fresh air filters. adjust
Air Filters Checked? Yes/No
2. Test the voltage. With the engine running and the

air conditioning switched ON, check if the voltage Accidental machine starting can cause injury or
at the compressor is a minimum of 11.5 VDC death to personnel working on the machine.
for a 12 VDC system or 23 volts for a 24 VDC
system. Be sure to switch ON all electrical loads To avoid accidental machine starting, turn the bat-
that the customer may be using on the machine tery disconnect switch to the OFF position and re-
on a routine basis. A customer added lighting move the key. If the machine is not equipped with
system, for example, could load the electrical a battery disconnect switch, disconnect the bat-
supply system to the point that available voltage is tery cables from the battery and tape the battery
decreased below specification. clamps.
Voltage Checked? Yes/No Place a do not operate tag at the battery discon-
nect switch location to inform personnel that the
Measured Voltage Level: ________ (volts) machine is being worked on.
Note: For A/C systems with a Compressor Protection Note: The electrical power supply to the compressor
System (CPS), there will be approximately a 30 should be switched OFF in order to perform this test.
seconds delay before a voltage signal will be detected
at the compressor after the A/C is switched ON. Air 5. Test the rotation. Rotate the compressor in the
conditioning systems with CPS can be identified by direction of belt travel by turning the nut on the
the use of either the 169-7443 On Delay Timer As end of the compressor main shaft. Rotation should
or the 212-2204 Air Conditioner Control Gp. In most be smooth with no binding.
applications the electronic control group is located
near the compressor. Rotation Checked? Yes/No
3. Test the resistance. Measure resistance of the Rotation Smooth? ________ (Yes) or (No)
clutch coil assembly at the compressor connector.
For 12 VDC models, measured resistance should 6. Check the charge level. The air conditioning
be within -0.3 to +1.1 ohms of the amount listed system must be correctly charged per Caterpillar
in the Specifications section of Service Manual, specification or an incorrect diagnosis will occur.
SENR5664, “Air Conditioning and Heating The best method to achieve the correct system
R134a for all Caterpillar Machines”, “Refrigerant refrigerant charge is by recovering, evacuating,
Compressor”. For 24 VDC models, measured and recharging with clean refrigerant to the correct
resistance should be within -1.3 to +5.5 ohms of level. Charging the A/C system must be conducted
the amount listed in the SENR5664 Specifications by weighing refrigerant with a calibrated scale to
Section. The resistance range listed above insure accuracy. Be sure to replace oil removed
compensates for the effect of temperature in the during refrigerant recovery with new oil. Reference
coil. The values listed in SENR5664 are nominal SENR5664 for refrigerant charging procedures
for 20 °C (68 °F). and capacity of CAT A/C systems.
Resistance Checked? Yes/No Charge Level Checked? Yes/No
Measured Resistance Level: ________ (ohms) Oil Removed During Recovery: ________ (ml) or
(oz)
4. Check the belt tension. For new belts and old
belts, use the 144-0235 Belt Tension Gauge. Refrigerant Charge Amount: ________ (Kg) or (lbs)
For a new belt installation, the initial belt tension
for a compressor drives system without an auto
tensioning device should be 534 N (120 lb). For
used belts, the belt tension should be 400 N
(90 lb).
Belt Tension Checked? Yes/No

SENR5664-11 117
7. Test for low pressure. This test is best performed i01693236

with the machine parked in the shade and with
ambient temperatures less than 30 °C (86 °F). Manifold Gauge Set
Close all cab doors and windows, block fresh (Refrigerant) - Remove
airflow into the cab, and bypass the low-pressure
switch (if the air conditioning system is so SMCS Code: 7465-011
equipped). Start the machine and operate at high
idle with the air conditioning switched ON and
the cab blower set on low. Measure the low-side
pressure at the refrigerant compressor after 10-15
minutes of operation. If the pressure reading is Personal injury can result from contact with refrig-
less than 69 kPa (10 psi) then the compressor erant.
inlet valves are operating correctly.
Low Pressure Checked? Yes/No if the engine is not running. Heat should never be
Record Low Pressure Reading: ________ (kPa) or
(Psig) Contact with refrigerant can cause frost bite. Keep
Note: If cab temperature is above 25 °C (77 °F)
when starting the test, the cab blower may require Protective goggles must always be worn when re-
high-speed setting to reduce the temperature before frigerant lines are opened, even if the gauges in-
starting the procedure. dicate the system is empty of refrigerant.
8. Test for high pressure. Start the engine and set Always use caution when a fitting is removed.
the speed at approximately 1200 rpm. Turn the Slowly loosen the fitting. If the system is still
air conditioner ON. Place a sheet of cardboard under pressure, evacuate the system recovering
over the condenser in order to block airflow. the refrigerant before removing the fitting.
Limiting the airflow over the condenser will cause
compressor outlet pressure to increase. Check if Personal injury or death can result from inhaling
the compressor outlet is able to increase up to refrigerant through a lit cigarette.
2414 kPa (350 psi). Once the specified pressure
is reached, immediately remove the cardboard. Inhaling air conditioner refrigerant gas through a
If the compressor passes the test, the discharge lit cigarette or other smoking method or inhaling
valves are operating correctly. fumes released from a flame contacting air con-
High Pressure Checked? Yes/No death.
Record High Pressure Reading: ________ (kPa) Do not smoke when servicing air conditioners or
or (Psig) wherever refrigerant gas may be present.
The functional test is now complete. If you feel Before any checks of the air conditioning and
that the compressor has failed, call the Refrigerant heating system are made, move the machine to a
Compressor Hotline at 1-877-598-8920. The smooth horizontal surface. Lower all implements
Refrigerant Compressor Hotline will provide you with to the ground. Make sure the transmission is
a Compressor Authorization Number for the return in neutral or park and that the parking brake is
of the compressor. engaged. Keep all other personnel away from the
The Refrigerant Compressor Hotline will require the
following information: Remove charging hoses properly. A low system
charge will result from charging hoses that are not
Machine Model: ____________________________________________ removed correctly. In order to ensure accuracy of the
refrigerant charge, the refrigerant should be removed
Serial Number: _____________________________________________ from the charging hoses. Refer to the following steps
in order to remove the refrigerant from the charging
Dealer Code: ________________________________________________ hoses:
Date: __________________________________________________________ 1. Allow the compressor to continue operating.
Close the valve on the high pressure side. The
valve is located near the charging ports on the
compressor. Disconnect the high pressure hose
from the air conditioning system.
118 SENR5664-11
2. Open the high pressure valve and open the low S/N: 7TJ1-Up
pressure valve at the gauge set . The refrigerant
that is in the hoses will be removed by the S/N: 8LJ884-Up
compressor through the low pressure hose.
S/N: ABJ1-Up
3. Close the valve on the low pressure side. This S/N: ACJ1-Up
valve is located near the charging ports on the
compressor. Disconnect the low pressure hose S/N: BMJ1-Up
from the air conditioning system. The system is
now charged. S/N: BRJ1-Up
S/N: CBJ1-Up
Note: After the manifold gauge set is removed, it is
necessary to cap the charging valves. S/N: 4HK366-Up
S/N: 4SK22-Up
i02046813
S/N: 6BK33-Up
Electronic Heat Control - Test
S/N: ABK1-Up
(Type 1)
S/N: AWK1-Up
SMCS Code: 7304-081-VL; 7309-081-VL
S/N: CCK1-Up
S/N: AKA1-Up
S/N: 1DL18-Up
S/N: DBB1-Up
S/N: 5ZL1-Up
S/N: AEC1-Up
S/N: 7LL1-85
S/N: BNC1-Up
S/N: 8PL1-Up
S/N: DBC1-Up
S/N: ACL1-Up
S/N: AFD1-Up
S/N: CBL1-Up
S/N: AKD1-Up
S/N: 2HM1-Up
S/N: CAD1-Up
S/N: 4FM1-Up
S/N: DBD1-Up
S/N: 8TM1-Up
S/N: ADE1-Up
S/N: 9BM1-Up
S/N: BLE1-Up
S/N: 9HM1-Up
S/N: DAE1-Up
S/N: 9ZM1-Up
S/N: AAF1-Up
S/N: AEM1-Up
S/N: AGF1-Up
S/N: AFM1-Up
S/N: AXF1-Up
S/N: AGM1-Up
S/N: CBF1-Up
S/N: AKM1-Up
S/N: 9XG343-Up
S/N: AXM1-Up
S/N: AFG1-Up
S/N: BPM1-Up
S/N: AGG1-Up
S/N: 2EN1-Up
S/N: CCG1-Up
S/N: 2RN1-Up
S/N: ALH1-Up
S/N: 2YN1-Up
S/N: CEH1-Up
S/N: 3DN1-Up
S/N: CFH1-Up
SENR5664-11 119
S/N: 3WN1-Up S/N: 6ER1-Up

S/N: 3ZN1-Up S/N: 6FR1-Up
S/N: 4HN1-Up S/N: 6HR1-Up
S/N: 4JN1-Up S/N: 7AR1-Up
S/N: 4MN1-Up S/N: 7DR1-Up
S/N: 5LN1-Up S/N: 7HR1-Up
S/N: 5TN1-Up S/N: 8ZR1-Up
S/N: 6GN1-Up S/N: 9TR1-Up
S/N: 6JN1-Up S/N: 9XR1-Up
S/N: 7FN1-Up S/N: ALR1-Up
S/N: 7KN1-Up S/N: AWR1-Up
S/N: 8LN1-Up S/N: BCR1-Up
S/N: 8XN1-Up S/N: CLR1-Up
S/N: 9MN1-Up S/N: 2YS1-Up
S/N: 9PN1-Up S/N: 4CS130-Up
S/N: AGN1-Up S/N: 4GS1-Up
S/N: BBN1-Up S/N: 4HS1-Up
S/N: CEN1-Up S/N: 4JS1-Up
S/N: AEP1-Up S/N: 4PS1-Up
S/N: ALP1-Up S/N: 5ES1-Up
S/N: AMP1-Up S/N: 5FS1-Up
S/N: DMP1-Up S/N: 5KS1-Up
S/N: 2HR1-Up S/N: 6AS1-Up
S/N: 3CR1-Up S/N: ACS1-Up
S/N: 3DR1-Up S/N: CCS1-Up
S/N: 3KR1-Up S/N: CES1-Up
S/N: 3ZR1-Up S/N: AKT1-Up
S/N: 4BR1-Up S/N: AXT1-Up
S/N: 4FR1-Up S/N: BLT1-Up
S/N: 4JR1-Up S/N: CKT1-Up
S/N: 4SR1-Up S/N: FDT1-Up
S/N: 4TR1-Up S/N: 1JW1-Up
S/N: 4WR1-Up S/N: 5EW1-Up
S/N: 5MR1-Up S/N: A4W1-Up
S/N: 5NR1-Up S/N: ADW1-Up
S/N: 5PR1-Up S/N: ARW1-Up
S/N: 5RR1-Up S/N: AAX1-Up
120 SENR5664-11
S/N: AFX1-Up
S/N: CEX1-Up
S/N: ALY1-Up
S/N: BMY1-Up
S/N: 2KZ1-Up
S/N: 4HZ1-Up
S/N: 6SZ1-Up
S/N: 6YZ1-Up
S/N: 7PZ1-Up
S/N: ADZ1-Up
S/N: AZZ1-Up
Electronic heat controls that only have an electronic

water valve are classified as a type 1 electronic heat
controls.
Table 18
Required Tools
Part Number Description Quantity
Digital Multimeter
146-4080 1
(RS-232)
SENR5664-11 121
g01069225
Illustration 69
Typical Electronic Control Circuit for the Heater Valve
(1) 24 VDC power supply from blower motor (5) Sure seal connector (3 pin) (9) Feedback potentiometer for the
breaker (6) Potentiometer assembly (temperature electronic water valve assembly
(2) Sure seal connector (7 pin) control) (10) Motor for the electronic water valve
(3) Sure seal connector (7 pin) (7) Board Control Assembly assembly
(4) Sure seal connector (6 pin) (8) Electronic water valve assembly
1. Turn off the power supply. 9. Connect the multimeter leads to pin (A) and
pin (B) on the sure seal connector that is on
2. Disconnect the sure seal connector (2). potentiometer assembly (6). Turn the knob on
the potentiometer assembly (6). The resistance
3. Hook the multimeter leads to pin (1) and pin (2). should vary smoothly.
Set the multimeter to DC voltage.
10. Reconnect sure seal connector (5).
4. Turn on the power supply. The multimeter should
read approximately 24 VDC. 11. Disconnect sure seal connector (4).
5. Turn off the power supply. 12. Connect the multimeter leads to pin (3) and pin
(5) on the sure seal connector that is on electronic
6. Reconnect the sure seal connector (2). water valve assembly (8). Set the multimeter to
read ohms. The multimeter should read 5000 ±
7. Disconnect the sure seal connector (5). 500 ohms.
8. Connect the multimeter leads to pin (A) and pin (C) 13. Connect the multimeter leads to pin (1) and pin (2)
on the sure seal connector that is on potentiometer on the sure seal connector that is on board control
assembly (6). Set the multimeter to read ohms. assembly (7). Set the multimeter to DC voltage.
The multimeter should read 5000 ± 500 ohms.
14. Turn on the power supply.
122 SENR5664-11
15. Turn the knob on the potentiometer assembly (6). S/N: BDP1-Up
The multimeter should read either 9 to 10 VDC or
the multimeter should read −9 to −10 VDC. S/N: 2KR1-Up
S/N: 2SR1-Up
16. Turn off the power supply.
S/N: 2JS1-Up
17. Connect two wires to a remote 12 volt DC power
supply. S/N: 3BS1-Up
Note: Do not use a power supply higher than 12 volts S/N: 3ZS1-Up
DC. If you use a power supply higher than 12 volts S/N: 4BS1-Up
DC, you may damage the water valve assembly.
S/N: 5AS1-Up
18. Connect one wire to pin (2) on the sure seal
connector that is on the electronic water valve S/N: 5RS1-Up
assembly (8).
S/N: 6NS1-Up
19. Touch the other wire to pin (1) on the sure S/N: 6PS1-Up
seal connector that is on electronic water valve
assembly (8) in order to pulse motor (10). The S/N: 7LS1-Up
motor should turn clockwise or counterclockwise.
The polarity of the power supply determines the S/N: 9RS1-Up
direction of rotation. S/N: 1EW1-Up
Note: Do not pulse motor (10) for more than a fraction S/N: 2TW1-Up
of a second. If you supply power for a longer period
of time you may damage the water valve assembly. S/N: 3JW1-Up
20. Disconnect the test equipment and reconnect S/N: 3PW1-Up

sure seal connector (4). S/N: 3SW1-Up
S/N: 4PW1-Up
i02046851
S/N: 4WW1-Up
(Type 2) S/N: 5FW1-Up
S/N: 5MW1-Up
SMCS Code: 7304-081-VL; 7309-081-VL
S/N: 6AW1-Up
S/N: AXB1-Up
S/N: 6EW1-Up
S/N: BPC1-Up
S/N: 6HW1-Up
S/N: BXD1-Up
S/N: 7BW1-Up
S/N: AWF1-Up
S/N: 8JW1-Up
S/N: AAH1-Up
S/N: 8XW1-Up
S/N: AYH1-Up
S/N: 9GW1-Up
S/N: BNH1-Up
S/N: AAW1-Up
S/N: BRL1-Up
S/N: AWW1-Up
S/N: 9CM1-Up
S/N: AZW1-Up
S/N: 4SN1-Up
S/N: ASX1-Up
S/N: 6RN1-Up
S/N: BTX1-Up
S/N: 7LN1-Up
S/N: 6GZ1-Up
S/N: AKP1-Up
SENR5664-11 123
S/N: 7MZ1-Up
Electronic heat controls that have a blend door

actuator and an electronic water valve are classified
as a type 2 electronic heat control.
Table 19
Required Tools
Digital
146-4080 Multimeter(RS- 1
232)
g01069275
Illustration 70
Typical Electronic Control Circuit for the Heater Valve
(1) Electronic controller (6) Electronic blend door actuator (9) Potentiometer assembly (temperature
(2) Deutsch connector (2 pin) (7) Motor for the electronic blend door control)
(3) Deutsch connector (6 pin) actuator (10) 24 VDC power supply from blower
(4) Deutsch connector (3 pin) (8) Feedback potentiometer for the motor breaker
(5) Electronic water valve assembly electronic blend door actuator (11) Deutsch connector (12 pin)
1. Turn off the power supply. 4. Turn on the power supply. The multimeter should
read approximately 24 VDC.
2. Disconnect Deutsch connector (11).
3. Hook the multimeter leads to pin (1) and pin (2).
Set the multimeter to DC voltage. 6. Reconnect the Deutsch connector (11) at
electronic controller (1).
124 SENR5664-11
7. Disconnect Deutsch connector (4). 22. Rotate the potentiometer assembly (9) to full
cooling.
8. Connect the multimeter leads to pin (A) and pin (C)
on the Deutsch connector that is on potentiometer Note: The actuators must be given 60 seconds in
assembly (9). Set the multimeter to read ohms. order to completely stroke.
23. Connect the multimeter leads to pin (1) and pin (2)
9. Connect the multimeter leads to pin (A) and on the Deutsch connector that is on the electronic
pin (B) on the Deutsch connector that is on water valve assembly (5). Set the multimeter to
potentiometer assembly (9). Turn the knob on read DC voltage.
the potentiometer assembly (9). The resistance
should vary smoothly. 24. Turn on the power supply.
10. Reconnect Deutsch connector (4). 25. Turn the knob on potentiometer assembly (9).
The multimeter should read −11 to −12 VDC or
11. Disconnect Deutsch connector (3). the multimeter should read 11 to 12 VDC while the
actuator is rotating. The multimeter should read 0
12. Connect the multimeter leads to pin (3) and pin VDC, after the motor has completed rotating.
(5) on the Deutsch connector that is on electronic
blend door actuator (6). Set the multimeter to read 26. Turn the knob to full cooling on the potentiometer
ohms. The multimeter should read 10000 ± 1000 assembly (9). The multimeter should read −11 to
ohms. −12 VDC or the multimeter should read 11 to 12
VDC while the actuator is rotating. The multimeter
13. Connect the multimeter leads to pin (1) and pin should read 0 VDC after the motor has completed
(2) on the Deutsch connector that is on electronic rotating.
blend door actuator (6). Set the multimeter to DC
voltage. 27. Turn off the power supply.
14. Turn on the power supply. 28. Connect two wires to a remote 12 volt DC power
supply.
15. Turn the knob on the potentiometer assembly (9).
The multimeter should read either −11 to −12 VDC 29. Connect one wire to pin (1) on Deutsch connector
or the multimeter should read 11 to 12 VDC while (2) that is on the electronic water valve assembly.
the actuator is rotating. The multimeter should
read 0 VDC after the motor has stopped rotating. 30. Touch the other wire to pin (2) on the Deutsch
connector (2) that is on electronic water valve
16. Turn off the power supply. assembly in order to pulse motor (5). The motor
should turn clockwise or counterclockwise. The
17. Connect two wires to a remote 12 volt DC power polarity of the motor determines the direction of
supply. rotation.
18. Connect one wire to pin (2) on the Deutsch Note: Do not pulse motor (5) for more than a fraction
connector that is on the electronic blend door of a second. If you supply power for a longer period
actuator (6). of time you may damage the actuator.
19. Touch the other wire to pin (1) on the Deutsch 31. Disconnect the test equipment and reconnect the
connector that is on electronic blend door actuator Deutsch connector (2).
(6) in order to pulse motor (7). The motor should
turn clockwise or counterclockwise. The polarity of
i02387491
the motor determines the direction of rotation.
Note: Do not pulse motor (7) for more than a fraction

of a second. If you supply power for a longer period (Type 3)
of time you may damage the actuator.
SMCS Code: 7304-081-VL; 7309-081-VL
20. Disconnect the test equipment and reconnect
Deutsch connector (3). S/N: AYA1-Up
S/N: BAA1-Up
21. Disconnect Deutsch connector (2).
S/N: AYB1-Up
SENR5664-11 125
S/N: BAB1-Up
S/N: AXC1-Up
S/N: BAC1-Up
S/N: AYD1-Up
S/N: BAD1-Up
S/N: AXE1-Up
S/N: AYE1-Up
S/N: AXG1-Up
S/N: AYG1-Up
S/N: AWH1-Up
S/N: AXJ1-Up
S/N: AXL1-Up
S/N: AYL1-Up
S/N: AXN1-Up
S/N: AWP1-Up
S/N: AXP1-Up
S/N: AXR1-Up
S/N: AXS1-Up
S/N: AYS1-Up
S/N: ANT1-Up
S/N: AYT1-Up
S/N: AXX1-Up
S/N: ANY1-Up
S/N: AWY1-Up
S/N: AXY1-Up
S/N: ANZ1-Up
S/N: AWZ1-Up
Electronic heat controls that have a blend air door

are classified as a Type 3 electronic heat control.
Table 20
Required Tools
Digital
146-4080 Multimeter(RS- 1
232)
126 SENR5664-11
g01191792
Illustration 71
Typical Electronic Control Circuit for the blend air door
(1) Deutsch connector (12 pin) (7) Blower motor
(2) Potentiometer assembly (temperature (8) Electronic blend door actuator
control) (9) Deutsch connector (2 pin)
(3) Resistor 6.2 kΩ (10) Packard connector (3 pin)
(4) Resistor 3.3 kΩ (11) Thermal fuse
(5) Freeze switch (12) 12 VDC power supply (converter)
(6) Blower resistor (13) Deutsch connector (3 pin)
1. Turn off the power supply. 8. Connect the multimeter leads to pin (A) and pin (C)
on the Deutsch connector that is on potentiometer
2. Disconnect Deutsch connector (1). assembly (2). Set the multimeter to read ohms.
3. Hook the multimeter leads to pin (1) and pin (8).
Set the multimeter to DC voltage. 9. Connect the multimeter leads to pin (A) and
pin (B) on the Deutsch connector that is on
4. Turn on the power supply. The multimeter should potentiometer assembly (2). Turn the knob on
read approximately 12 VDC. the potentiometer assembly (2). The resistance
should vary smoothly.
10. Reconnect Deutsch connector (13).
6. Reconnect the Deutsch connector (1).
11. Disconnect Packard connector (10) that is located
7. Disconnect Deutsch connector (13). on electronic blend door actuator (8).
12. Disconnect Deutsch connector (1) again.

SENR5664-11 127
13. Connect the multimeter leads to pin (1) and pin i02361274
(2) on the Deutsch connector. Set the multimeter
to read ohms. The multimeter should read 6200 ± System Capacities for
500 ohms for the value of resistor (3). Refrigerant
14. Disconnect Deutsch connector (9) that is located SMCS Code: 1809
on blower motor (7).
15. Connect the multimeter leads to pin (4) and pin (8)
on the Deutsch connector (1). Set the multimeter
to read ohms. The multimeter should read 3300 ± Personal injury can result from contact with refrig-
500 ohms for the value of resistor (4). erant.
16. Reconnect Deutsch connector (9). This system is under pressure at all times, even
17. Reconnect Deutsch connector (1). applied to a charged system.
18. Reconnect Packard connector (10) that is located Contact with refrigerant can cause frost bite. Keep
on electronic blend door actuator (8). face and hands away to help prevent injury.
19. Attach the positive multimeter leads to pin (D) Protective goggles must always be worn when re-
and pin (C) on thePackard connector (10). Set the frigerant lines are opened, even if the gauges in-
multimeter to DC voltage. dicate the system is empty of refrigerant.
20. Turn on the power supply. Always use caution when a fitting is removed.
21. Turn the knob on potentiometer assembly (2) to under pressure, evacuate the system recovering
full heat. The electronic blend door actuator (8) the refrigerant before removing the fitting.
should rotate counterclockwise. The multimeter
should read either −2.7 VDC or the multimeter Personal injury or death can result from inhaling
should read 2.7 VDC. refrigerant through a lit cigarette.
22. Turn the knob on potentiometer assembly (2) to Inhaling air conditioner refrigerant gas through a
full cold. The electronic blend door actuator (8) lit cigarette or other smoking method or inhaling
should rotate clockwise. The multimeter should fumes released from a flame contacting air con-
read either −7.0 VDC or the multimeter should ditioner refrigerant gas, can cause bodily harm or
read 7.0 VDC. death.
23. Turn off the power supply. Do not smoke when servicing air conditioners or

Table 21
Product
Amount of
Charge
Number
Agricultural Tractors
DV87 9AM1-Up 2 kg (4.4 lb)
Challenger 35 8DN1-Up 2.3 kg (5 lb)
Challenger 35 8RD1-Up 2.3 kg (5 lb)
Challenger 35 ADK1-Up 2.3 kg (5 lb)
(continued)
128 SENR5664-11

Product Product
Amount of Amount of
Model Identification Model Identification
Charge Charge
Number Number
Challenger 35 9DF1-Up 2.3 kg (5 lb) D350E 9LR1-Up 1.8 kg (4 lb)
Challenger 45 4DZ1-Up 2.3 kg (5 lb) D350E Series II 2XW1-Up 2 kg (4.5 lb)
Challenger 45 1DR201-Up 2.3 kg (5 lb) D400D 8TF787-Up 2 kg (4.5 lb)
Chalenger 45 ABF1-Up 2.3 kg (5 lb) D400D 4EJ1-Up 2 kg (4.5 lb)
Challenger 45 3BK1-Up 2.3 kg (5 lb) D400E 2YR1-Up 1.8 kg (4 lb)
Challenger 55 7DM1-200 2.3 kg (5 lb) D400E Series II 8PS1-Up 2 kg (4.5 lb)
Challenger 55 7DM201-Up 2.3 kg (5 lb) D400E Series
APF1-Up 2 kg (4.5 lb)
II Ejector
Challenger 55 AEN1-Up 2.3 kg (5 lb)
725 AFX1-Up 2 kg (4.5 lb)
Challenger 55 6NN1-Up 2.3 kg (5 lb)
730 AGF1-Up 2 kg (4.5 lb)
Challenger 55 5DK1-Up 2.3 kg (5 lb)
735 AWR1-Up 2 kg (4.5 lb)
Challenger 65C 2ZJ375-Up 1.9 kg (4.2 lb)
740 AXM1-Up 2 kg (4.5 lb)
Challenger 65D 2ZJ375-1964 1.9 kg (4.2 lb)
740 AZZ1-Up 2 kg (4.5 lb)
Challenger 65D 2ZJ1965-2299 1.9 kg (4.2 lb)
Underground Articulated Trucks
Challenger 65D 2ZJ2300-Up 2.1 kg (4.6 lb)
AD30 CXR1-Up 1.8 kg (4.1 lb)
Challenger 65E 6GS1-Up 1.9 kg (4.2 lb)
AD40 1YZ1-Up 2.5 kg (5.5 lb)
Challenger 70C 2YL1-Up 1.9 kg (4.2 lb)
AD45 BKZ1-Up 2.5 kg (5.5 lb)
Challenger 75C 4KK374-Up 1.9 kg (4.2 lb)
AE40 1ZZ1-Up 2.5 kg (5.5 lb)
Challenger 75D 5AR1-Up 1.9 kg (4.2 lb)
AE40 Series II BLW1-Up 2.5 kg (5.5 lb)
Challenger 75E 6HS1-Up 1.9 kg (4.2 lb)
AD55 ANW1-380 1.8 kg (4.1 lb)
Challenger 85C 9TK1-Up 1.9 kg (4.2 lb)
AD55 ANW381-Up 2.3 kg (5.0 lb)
Challenger 85D 4GR1-Up 1.9 kg (4.2 lb)
AD55 DNW1-Up 2.3 kg (5.0 lb)
Challenger 85E 6JS1-Up 1.9 kg (4.2 lb)
Backhoe Loaders
Challenger 95E 6KS1-Up 1.9 kg (4.2 lb)
416B 8SG5327-Up 2.1 kg (4.6 lb)
Articulated Trucks
416B 8ZK1769-Up 2.1 kg (4.6 lb)
D20D 9MG119-Up 2 kg (4.5 lb)
416C 4ZN1-Up 1.8 kg (4 lb)
D25D 1HK424-Up 2 kg (4.5 lb)
416C 5YN1-Up 1.8 kg (4 lb)
D30D 3AJ331-Up 2 kg (4.5 lb)
416C 1AR1-Up 1.8 kg (4 lb)
D30D 1PK1-Up 2 kg (4.5 lb)
416C 1BR1-Up 1.8 kg (4 lb)
D40D 2JJ100-Up 2 kg (4.5 lb)
416C 1KR1-Up 1.8 kg (4 lb)
D250D 6NG234-Up 2 kg (4.5 lb)
416C 1LR1-Up 1.8 kg (4 lb)
D250E 5TN1-Up 1.8 kg (4 lb)
416C 1WR1-Up 1.8 kg (4 lb)
D250E Series II 4PS1-Up 2 kg (4.5 lb)
416C 1XR1-Up 1.8 kg (4 lb)
D300D 5MG221-Up 2 kg (4.5 lb)
416D CKN1-Up 1.4 kg (3.1 lb)
D300E 7FN1-Up 1.8 kg (4 lb)
416D CBD1-Up 1.4 kg (3.1 lb)
D300E Series II 5KS1-Up 2 kg (4.5 lb)
416D CHW1-Up 1.4 kg (3.1 lb)
D350D 9RF511-Up 2 kg (4.5 lb)
(continued)
416D BFP1-Up 1.4 kg (3.1 lb)
(continued)
SENR5664-11 129

Product Product
Amount of Amount of
Charge Charge
Number Number
416D BKG1-Up 1.4 kg (3.1 lb) 428D S9D1-Up 1.4 kg (3.1 lb)
416D BGJ1-Up 1.4 kg (3.1 lb) 428D S1K1-Up 1.4 kg (3.1 lb)
420D FDP1-Up 1.4 kg (3.1 lb) 428D S3N1-Up 1.4 kg (3.1 lb)
420D BKC1-Up 1.4 kg (3.1 lb) 428D BNB1-Up 1.4 kg (3.1 lb)
420D BMC1-Up 1.4 kg (3.1 lb) 430D BML1-Up 1.4 kg (3.1 lb)
420D C2C1-Up 1.4 kg (3.1 lb) 430D BNK1-Up 1.4 kg (3.1 lb)
420D C2L1-Up 1.4 kg (3.1 lb) 430D C3J1-Up 1.4 kg (3.1 lb)
420D C4T1-Up 1.4 kg (3.1 lb) 430D C5B1-Up 1.4 kg (3.1 lb)
420D C4Y1-Up 1.4 kg (3.1 lb) 430D C7E1-Up 1.4 kg (3.1 lb)
420D C6D1-Up 1.4 kg (3.1 lb) 430D C9P1-Up 1.4 kg (3.1 lb)
420D C6R1-Up 1.4 kg (3.1 lb) 432D BLD1-Up 1.4 kg (3.1 lb)
432D S6B1-Up 1.4 kg (3.1 lb)
420D C8A1-Up 1.4 kg (3.1 lb)
432D S6H1-Up 1.4 kg (3.1 lb)
420D C8Z1-Up 1.4 kg (3.1 lb)
436 6MJ650-Up 2.1 kg (4.6 lb)
420D IT BLN1-Up 1.4 kg (3.1 lb)
436B 7FL1-Up 2.1 kg (4.6 lb)
424D BGP1-Up 1.4 kg (3.1 lb)
436C 8TN1-Up 1.8 kg (4 lb)
424D BKR1-Up 1.4 kg (3.1 lb)
436C 9JN1-Up 1.8 kg (4 lb)
424D S3G1-Up 1.4 kg (3.1 lb)
436C 1FR1-Up 1.8 kg (4 lb)
424D S5A1-Up 1.4 kg (3.1 lb)
436C 1GR1-Up 1.8 kg (4 lb)
426B 5YJ1546-Up 2.1 kg (4.6 lb)
436C 1PR1-Up 1.8 kg (4 lb)
426B 6KL1-Up 2.1 kg (4.6 lb)
436C 1RR1-Up 1.8 kg (4 lb)
426C 6XN1-Up 1.8 kg (4 lb)
436C 2AR1-Up 1.8 kg (4 lb)
426C 7WN1-Up 1.8 kg (4 lb)
436C 2BR1-Up 1.8 kg (4 lb)
426C 1CR1-Up 1.8 kg (4 lb)
438B 3KK1136-Up 2.1 kg (4.6 lb)
426C 1ER1-Up 1.8 kg (4 lb)
438C 9KN1-Up 1.8 kg (4 lb)
426C 1MR1-Up 1.8 kg (4 lb)
438C 1JR1-Up 1.8 kg (4 lb)
426C 1NR1-Up 1.8 kg (4 lb)
438C 1TR1-Up 1.8 kg (4 lb)
426C 1YR1-Up 1.8 kg (4 lb)
438C 2DR1-Up 1.8 kg (4 lb)
426C 1ZR1-Up 1.8 kg (4 lb)
438D BPN1-Up 1.4 kg (3.1 lb)
428B 7EJ2812-Up 2.1 kg (4.6 lb)
438D BPE1-Up 1.4 kg (3.1 lb)
428C 8RN1-Up 1.8 kg (4 lb)
438D S8J1-Up 1.4 kg (3.1 lb)
428C 1HR1-Up 1.8 kg (4 lb)
438D S8M1-Up 1.4 kg (3.1 lb)
428C 1SR1-Up 1.8 kg (4 lb)
442D BRY1-Up 1.4 kg (3.1 lb)
428C 2CR1-Up 1.8 kg (4 lb)
442D BRG1-Up 1.4 kg (3.1 lb)
428D BLL1-Up 1.4 kg (3.1 lb)
442D S4R1-Up 1.4 kg (3.1 lb)
428D BMT1-Up 1.4 kg (3.1 lb)
442D S4T1-Up 1.4 kg (3.1 lb)
428D BNS1-Up 1.4 kg (3.1 lb)
446B 5BL386-Up 2.2 kg (4.8 lb)
428D S7C1-Up 1.4 kg (3.1 lb)
(continued) 446B 6XF1-Up 2.2 kg (4.8 lb)
(continued)
130 SENR5664-11

Product Product
Amount of Amount of
Charge Charge
Number Number
Combines Excavators
450 8YW1-Up 1.8 kg (4 lb) 303CR CAR1-Up 0.6 kg (1.3 lb)
450 5531-Up 1.8 kg (4 lb) 304 NAD1-Up 0.6 kg (1.3 lb)
460 9FW1-Up 1.8 kg (4 lb) 304CR BTN1-Up 0.6 kg (1.3 lb)
460 6541-Up 1.8 kg (4 lb) 305 DSA1-Up 0.6 kg (1.3 lb)
460R 6651-Up 1.8 kg (4 lb) 305 DCR1-Up 0.6 kg (1.3 lb)
465 3HZ1-Up 1.8 kg (4 lb) 305CR BMW1-Up 0.6 kg (1.3 lb)
465 6571-Up 1.8 kg (4 lb) 305CR DCR1-Up 0.6 kg (1.3 lb)
470R 7651-Up 1.8 kg (4 lb) 305CR DGT1-Up 0.80 kg (1.76 lb)
475R 7671-Up 1.8 kg (4 lb) 305.5 DCK1-Up 0.60 kg (1.32 lb)
480 2BZ1-Up 1.8 kg (4 lb) 307 2WJ96-Up 1.4 kg (3.1 lb)
480R 8661-Up 1.8 kg (4 lb) 307 9ZL140-Up 1 kg (2.2 lb)
485 8ZW1-Up 1.8 kg (4 lb) 307 2PM115-Up 1 kg (2.2 lb)
485R 8681-Up 1.8 kg (4 lb)
307 2WM1-Up 1 kg (2.2 lb)
Compactors
814B 16Z368-Up 1.4 kg (3.1 lb) 307B 5CW1-Up 0.9 kg (2 lb)
815B 17Z1614-Up 1.4 kg (3.1 lb) 307B SB 6KZ1-Up 0.9 kg (2 lb)
815F BKL1-Up 1.9 kg (4.2 lb) 307B SB AFB1-Up 0.9 kg (2 lb)
815F 1GN1-Up 2.1 kg (4.6 lb) 307C BAJ1-Up 0.90 kg (1.98 lb)
816B 15Z1413-Up 2.5 kg (5.5 lb) 307C BNE1-Up 1.00 kg (2.20 lb)
816F 5FN1-Up 2.1 kg (4.6 lb) 307C BCM1-Up 1.00 kg (2.20 lb)
816F BMR1-Up 1.6 kg (3.5 lb) 308B 3YS1-Up 0.9 kg (2 lb)
824C 85X1651-Up 2.5 kg (5.5 lb) 308C CRW1-Up 0.90 kg (1.98 lb)
824G 4SN1-Up 2.5 kg (5.5 lb) 308C CPE1-Up 0.90 kg (1.98 lb)
825C 86X1104-Up 2.1 kg (4.6 lb) 308C KCX1-Up 1 kg (2.2 lb)
825G 6RN1-Up 2.5 kg (5.5 lb) 311 9LJ262-Up 1 kg (2.2 lb)
825G AXB1-Up 2.5 kg (5.5 lb) 311 5PK1001-Up 1 kg (2.2 lb)
826C 87X1700-Up 2.3 kg (5 lb) 311B 8GR1-461 1 kg (2.2 lb)
826G AYH1- Up 1.5 kg (3.3 lb) 311B 8GR462-Up 1.1 kg (2.4 lb)
826G 7LN534- Up 2.5 kg (5.5 lb) 311B 2LS1-203 1 kg (2.2 lb)
826G(1) 7LN535- Up 1.6 kg (3.5 lb) 311B 2LS204-Up 1.1 kg (2.4 lb)
834C 92Z580-Up 3 kg (6.6 lb) 311B 9MR1-Up 1 kg (2.2 lb)
836 3RL35-Up 3 kg (6.6 lb) 311B 2MS1-Up 0.9 kg (2 lb)
836 7FR1-Up 3 kg (6.6 lb) 311B 8HR1-Up 0.9 kg (2 lb)
836G BRL1-Up 1.5 kg (3.3 lb) 311C CLK1-Up 0.90 kg (1.98 lb)
836G 7MZ1-Up 1.5 kg (3.3 lb) 311C CKE1-Up 0.90 kg (1.98 lb)
(continued) (continued)
SENR5664-11 131

Product Product
Amount of Amount of
Charge Charge
Number Number
311C PAD1-Up 0.90 kg (1.98 lb) 315B 1SW1-214 1 kg (2.2 lb)
312 6GK393-Up 1 kg (2.2 lb) 315B 1SW215-Up 1.1 kg (2.4 lb)
312 7DK3001-Up 1 kg (2.2 lb) 315B 2DW1-Up 0.9 kg (2 lb)
312 6BL112-Up 1.8 kg (4 lb) 315B L 7RZ1-283 1.4 kg (3.1 lb)
312B 9GR1-412 1 kg (2.2 lb) 315B L 7RZ284-Up 1.1 kg (2.4 lb)
312B 9GR413-Up 1.1 kg (2.4 lb) 315B L 3AW1-989 1 kg (2.2 lb)
312B 9NW1-Up 1 kg (2.2 lb) 315B L 3AW990-Up 1.1 kg (2.4 lb)
312B 6SW1-Up 1 kg (2.2 lb) 315B L 5SW1-Up 1.5 kg (3.3 lb)
312B 2NS1-155 1 kg (2.2 lb) 315C CFB1-Up 0.90 kg (1.98 lb)
312B 2NS156-Up 1.1 kg (2.4 lb) 315C CFL1-Up 0.90 kg (1.98 lb)
312B L 9FS1-Up 1 kg (2.2 lb) 315C CFT1-Up 1.00 kg (2.20 lb)
312B L 8JR1-1007 1 kg (2.2 lb) 315C AKE1-Up 1.00 kg (2.20 lb)
312B L 8JR1008-Up 1.1 kg (2.4 lb) 315C BTL1-Up 0.9 kg (1.98 lb)
312B L 2KW1-Up 1 kg (2.2 lb) 315C L ANF1-Up 1.00 kg (2.20 lb)
312B L 3FS1-254 1 kg (2.2 lb) 315C L ANF1-Up 0.90 kg (1.98 lb)
312B L 3FS255-Up 1.1 kg (2.4 lb) 315C L CJC1-Up 1.0 kg (2.2 lb)
312C FDS1-Up 1.00 kg (2.20 lb) M315 7ML1-Up 1.3 kg (2.9 lb)
312C BNN1-Up 0.70 kg (1.54 lb) M315C BDM1-Up 2.20 kg (4.85 lb)
312C CAE1-Up 0.90 kg (1.98 lb) M315C H2B1-Up 2.20 kg (4.85 lb)
312C DBN1-Up 1.00 kg (2.20 lb) M316C BDX1-Up 2.20 kg (4.85 lb)
312C L BWH1-Up 1.00 kg (2.20 lb) M316C H2C1-Up 2.20 kg (4.85 lb)
312C L CBA1-Up 1.00 kg (2.20 lb) 317 4MM149-Up 1.8 kg (4 lb)
312C L CBT1-Up 0.70 kg (1.54 lb) 317 9SR1-Up 1.8 kg (4 lb)
M312 6TL1-Up 1.3 kg (2.9 lb) 317BL 9WW1-Up 1.5 kg (3.3 lb)
313B CR AEX1-Up 0.9 kg (2.0 lb) 317BLN 6DZ1-Up 1.5 kg (3.3 lb)
313B SR 9PR1-Up 0.9 kg (2.0 lb) 318B 3LR1-Up 1.1 kg (2.4 lb)
313B SR BAS1-Up 0.9 kg (2.0 lb) 318BL ADC1-Up 1.5 kg (3.3 lb)
313C SR WSA1-Up 0.90 kg (1.98 lb) 318BLN AEJ1-Up 1.5 kg (3.3 lb)
313C CR HGF1-Up 0.90 kg (1.98 lb) 318B 7KZ1-Up 1.1 kg (2.4 lb)
M313C BDR1-Up 2.20 kg (4.85 lb) 318C BTG1-Up 0.80 kg (1.76 lb)
M313C H2A1-Up 2.20 kg (4.85 lb) 318C FAA1-Up 0.80 kg (1.76 lb)
314C CR KHB1-Up 0.90 kg (1.98 lb) 318C DAH1-Up 0.80 kg (1.76 lb)
314C CR KJA1-Up 0.90 kg (1.98 lb) 318C AWS1-Up 1.00 kg (2.20 lb)
314C LCR PCA1-Up 0.90 kg (1.98 lb) 318C KAJ1-Up 0.90 kg (1.98 lb)
315 4YM270-Up 1 kg (2.2 lb) 318C CWP1-Up 0.90 kg (1.98 lb)
315 3ZM127-Up 1.8 kg (4 lb) 318C L MDY1-Up 1.00 kg (2.20 lb)
315 6XM217-Up 1 kg (2.2 lb) 318C LN GPA1-Up 1.00 kg (2.20 lb)
315 LN 6YM254-Up 1 kg (2.2 lb) M318 6ES1-Up 1.3 kg (2.9 lb)
132 SENR5664-11

Product Product
Amount of Amount of
Charge Charge
Number Number
M318 8AL1-Up 1.3 kg (2.9 lb) 320B L 9WS1-Up 1.7 kg (3.7 lb)
M318 8SS1-Up 1.3 kg (2.9 lb) 320B L 9CS1-2901 1 kg (2.2 lb)
M318 BMD1-Up 1.4 kg (3.1 lb) 320B L 9CS2902-Up 1.1 kg (2.4 lb)
M318C BCZ1-Up 2.20 kg (4.85 lb) 320B LN 3YZ1-Up 1.7 kg (3.7 lb)
M318C H2D1-Up 2.20 kg (4.85 lb) 320 N 9WG1161-Up 1.8 kg (4 lb)
M318C H2F1-Up 2.20 kg (4.85 lb) 320 N 1XM118-Up 1 kg (2.2 lb)
M318CMH BEB1-Up 2.50 kg (5.51 lb) 320B L 1DS1-Up 1 kg (2.2 lb)
319CL KGL1-Up 0.80 kg (1.76 lb) 320B N 4NR1-175 1 kg (2.2 lb)
320 4ZJ597-Up 1.8 kg (4 lb) 320B N 4NR176-Up 1.1 kg (2.4 lb)
320 8LK1276-Up 1 kg (2.2 lb) 320B S 5MS1-Up 1.7 kg (3.7 lb)
320 2DL214-Up 1 kg (2.2 lb) 320B L 6LW1-Up 1.7 kg (3.7 lb)
320 3XM213-Up 1 kg (2.2 lb) 320B LL 6LS1-309 .9 kg (2 lb)
320 9WG1-Up 1.8 kg (4 lb) 320B LL 6LS310-Up 1.1 kg (2.4 lb)
320L HKT1-Up 0.9 kg (1.98 lb) 320B LL 9JS1-269 0.9 kg (2.0 lb)
320 L 1KL442-Up 1 kg (2.2 lb) 320B LL 9JS270-Up 1.1 kg (2.4 lb)
320 L 3XK1909-Up 1.8 kg (4 lb) 320C BKK1-Up 1.40 kg (3.09 lb)
320 L 9KK1359-Up 1 kg (2.2 lb) 320C DBG1-Up 0.90 kg (1.98 lb)
320 L 4JM1446-Up 1 kg (2.2 lb) 320C AKH1-Up 0.90 kg (1.98 lb)
320 S 6KM213-Up 1.8 kg (4 lb) 320C BDC1-Up 1.00 kg (2.20 lb)
320B 1XS1-Up 1.7 kg (3.7 lb) 320C AMC1-Up 1.00 kg (2.20 lb)
320B 5BR1-1638 1 kg (2.2 lb) 320C BPR1-Up 1.00 kg (2.20 lb)
320B 5BR1639-Up 1.1 kg (2.4 lb) 320C BCN1-Up 1.00 kg (2.2 lb)
320B 4XW1-103 1 kg (2.2 lb) 320C BCB1-Up 1.00 kg (2.20 lb)
320B 4XW104-Up 1.1 kg (2.4 lb) 320C GHA1-Up 0.90 kg (1.98 lb)
320B 8ES1-1638 1 kg (2.2 lb) 320C BEF1-Up 1.00 kg (2.20 lb)
320B 8ES1639-Up 1.1 kg (2.4 lb) 320C BGB1-Up 1.40 kg (3.09 lb)
320B AED1-Up 1 kg (2.2 lb) 320C FBA1-Up 0.90 kg (1.98 lb)
320B 9KR1-Up 1 kg (2.2 lb) 320C GAA1-Up 0.90 kg (1.98 lb)
320B 5CS1-Up 1 kg (2.2 lb) 320C MAA1-Up 0.90 kg (1.98 lb)
320B L 2AS1-Up 1.7 kg (3.7 lb) 320C PAA1-Up 0.90 kg (1.98 lb)
320B L 6CR1-2901 1 kg (2.2 lb) 320C FBB1-Up 0.90 kg (1.98 lb)
320B L 6CR2902-Up 1.1 kg (2.4 lb) 320C ALF1-Up 0.90 kg (1.98 lb)
320B L 5GW1-220 1 kg (2.2 lb) 320C GAB1-Up 0.90 kg (1.98 lb)
320B L 5GW221-Up 1.1 kg (2.4 lb) 320C MAB1-Up 1.00 kg (2.20 lb)
320B L 1ES1-Up 1 kg (2.2 lb) 320C PAB1-Up 1.00 kg (2.20 lb)
320B L 7JR1-Up 1.7 kg (3.7 lb) 320C MAC1-Up 1.00 kg (2.20 lb)
SENR5664-11 133

Product Product
Amount of Amount of
Charge Charge
Number Number
320C RAW1-Up 1.00 kg (2.20 lb) 321C MCF1-Up 0.90 kg (1.98 lb)
320C SBN1-Up 1.00 kg (2.20 lb) 321C KBB1-Up 0.8 kg (1.76 lb)
320C FBC1-Up 1.00 kg (2.20 lb) 322 7WL1-Up 1 kg (2.2 lb)
320C CCD1-Up 0.9 kg ( 1.98 lb) 322 L 8CL1-Up 1 kg (2.2 lb)
320C EGA1-Up 0.90 kg (1.98 lb) 322 L 8ML1-Up 1.7 kg (3.7 lb)
320C GNA1-Up 0.90 kg (1.98 lb) 322 L 9RL1-Up 1.7 kg (3.7 lb)
320C NAE1-Up 0.90 kg (1.98 lb) 322 N 9JL1-Up 1.7 kg (3.7 lb)
320C FMHW SAH1-Up 1.00 kg (2.20 lb) 322 LN 1ZS1-Up 1.7 kg (3.7 lb)
320C FMHW SAH1-Up 1.40 kg (3.09 lb) 322 LN 4RM1-Up 1.7 kg (3.7 lb)
320C FMST TBR1-Up 1.00 kg (2.20 lb) 322B 1YS1-Up 1.7 kg (3.7 lb)
320C FMST TBR1-Up 1.40 kg (3.09 lb) 322B 8MR1-188 1 kg (2.2 lb)
320C L PAC1-Up 1.00 kg (2.20 lb) 322B 8MR189-Up 1.1 kg (2.4 lb)
320C L GLA1-Up 0.90 kg (1.98 lb) 322B 3NR307-Up 1.1 kg (2.4 lb)
320C L BER1-Up 1.00 kg (2.20 lb) 322B 5CR264-Up 1.1 kg (2.4 lb)
320C L ANB1-Up 1.00 kg (2.20 lb) 322BL 2ES1-Up 1.7 kg (3.7 lb)
320C L BRX1-Up 1.00 kg (2.20 lb) 322B L 8NR1-243 1 kg (2.2 lb)
320C L BDE1-Up 1.00 kg (2.20 lb) 322B L 8NR244-Up 1.1 kg (2.4 lb)
320C L BDB1-Up 1.00 kg (2.20 lb) 322B L 1AS1-346 1 kg (2.2 lb)
320C L BBC1-Up 1.00 kg (2.20 lb) 322B L 1AS347-Up 1.1 kg (2.4 lb)
320C L HBC1-Up 1.00 kg (2.20 lb) 322B L 1BS1-Up 1 kg (2.2 lb)
320C L GAC1-Up 1.00 kg (2.20 lb) 322BLU BBG1-Up 1.1 kg (2.4 lb)
320CLN AXK1-Up 0.90 kg (1.98 lb) 322C DAA1-Up 1.00 kg (2.20 lb)
320C LN BEA1-Up 1.00 kg (2.20 lb) 322C CAM1-Up 1.30 kg (2.87 lb)
320C LN JTG1-Up 0.90 kg (1.98 lb) 322C CBY1-Up 1.30 kg (2.87 lb)
320C LRR GAD1-Up 0.9 kg (1.98 lb) 322C BPH1-Up 1.30 kg (2.87 lb)
320C LU ALX1-Up 0.90 kg (1.98 lb) 322C BFN1-Up 1.00 kg (2.20 lb)
320C LU CLZ1-Up 1.00 kg (2.20 lb) 322C BNY1-Up 1.00 kg (2.20 lb)
320C MH JPL1-Up 0.90 kg (1.98 lb) 322C BLP1-Up 0.90 kg (1.98 lb)
320C S EGL1-Up 0.90 kg (1.98 lb) 322C ADX1-Up 1.00 kg (2.20 lb)
320C S BBL1-Up 0.90 kg (1.98 lb) 322C HBG1-Up 0.9 kg ( 1.98 lb)
320C U APA1-Up 0.90 kg (1.98 lb) 322C FM BTE1-Up 1.00 kg (2.20 lb)
320C U CLM1-Up 1.00 kg (2.20 lb) 322C FMLGP SLX1-Up 1.05 kg (2.31 lb)
320D CXY1-Up 0.80 kg (1.76 lb) 322C FMHW C3R1-Up 1.30 kg (2.87 lb)
M320 6WL1-Up 1.3 kg (2.9 lb) 322C FMHW LAR1-Up 1.30 kg (2.87 lb)
M320 9PS1-Up 1.3 kg (2.9 lb) 322C FMST M2H1-Up 1.30 kg (2.87 lb)
321B CR AKG1-Up 0.9 kg (2.0 lb) 322CL KCF1-Up 0.90 kg (1.98 lb)
321B LCR 9CZ1-Up 0.9 kg (2.0 lb) 322C L BEP1-Up 1.00 kg (2.20 lb)
321B LCR KGA1-Up 0.9 kg (2.0 lb) 322C L BMX1-Up 1.00 kg (2.20 lb)
134 SENR5664-11

Product Product
Amount of Amount of
Charge Charge
Number Number
322C L BFX1-Up 1.00 kg (2.20 lb) 325C BKT1-Up 1.00 kg (2.20 lb)
322C L BGR1-Up 0.90 kg (1.98 lb) 325C BLA1-Up 0.90 kg (1.98 lb)
322C L BKJ1-Up 1.4 kg (3.1 lb) 325C BLX1-Up 0.90 kg (1.98 lb)
322C L BKM1-Up 0.90 kg (1.98 lb) 325C BMM1-Up 0.90 kg (1.98 lb)
322C L HEK1-Up 1.05 kg (2.31 lb) 325C BKW1-Up 0.90 kg (1.98 lb)
322C L MAR1-Up 1.00 kg (2.20 lb) 325C G1L1-Up 1.05 kg (2.31 lb)
322C L FED1-Up 1.00 kg (2.20 lb) 325C JLD1-Up 1.00 kg (2.20 lb)
322C LN EMR1-Up 1.00 kg (2.20 lb) 325C MH DTF1-Up 1.00 kg (2.20 lb)
322C LN BFK1-Up 0.90 kg (1.98 lb) 325C JLC1-Up 1.00 kg (2.20 lb)
M322C BDK1-Up 2.20 kg (4.85 lb) 325C FM Y4P1-Up 1.05 kg (2.31 lb)
M322C H2E1-Up 2.20 kg (4.85 lb) 325C FMHW M2K1-Up 1.05 kg (2.31 lb)
M322C H2G1-Up 2.20 kg (4.85 lb) 325C FMHW S3M1-Up 1.05 kg (2.31 lb)
M322C MH BDY1-Up 2.50 kg (5.51 lb) 325C L BTD1-Up 0.90 kg (1.98 lb)
325 5WK1001-Up 1 kg (2.2 lb) 325C L CRB1-Up 0.90 kg (1.98 lb)
325 9ZK143-Up 1.7 kg (3.7 lb) 325C L BFE1-Up 1.05 kg (2.31 lb)
325 8NL78-Up 1 kg (2.2 lb) 325C LN CSJ1-Up 1.00 kg (2.20 lb)
325 6RM1-Up 1.7 kg (3.7 lb) 325C MH S2C1-Up 1.30 kg (2.87 lb)
325 L 6KK1001-Up 1 kg (2.2 lb) M325B BGN1-Up 1.7 kg (3.7 lb)
325 L 2SL528-Up 1.7 kg (3.7 lb) M325C T4C1-Up 2.2 kg (4.9 lb)
325 L 9KL99-Up 1 kg (2.2 lb) M325CMH XJA1-Up 1.0 kg (2.2 lb)
325 L 7LM1-Up 1.7 kg (3.7 lb) M325CMH PAN1-Up 1.0 kg (2.2 lb)
325 LN 3LL678-Up 1.7 kg (3.7 lb) 325D CJM1-Up 0.8 kg (1.76 lb)
325B 8PR1-Up 1.1 kg (2.4 lb) 325DL DAP1-Up 0.8 kg (1.76 lb)
325B 8GM299-Up 1.1 kg (2.4 lb) 325DL GPB1-Up 0.8 kg (1.76 lb)
325B 7EN303-Up 1.1 kg (2.4 lb) 325DL PKE1-Up 0.8 kg (1.76 lb)
325B L 2JR1-Up 1.7 kg (3.7 lb) 330 9PJ1001-Up 1 kg (2.2 lb)
325B L 6DN1-Up 1.7 kg (3.7 lb) 330 6ZK64-Up 1.7 kg (3.7 lb)
325B L 8FN1-Up 1.7 kg (3.7 lb) 330 8RL44-Up 1 kg (2.2 lb)
325B L 4DS1-Up 1.7 kg (3.7 lb) 330 2ZM1-Up 1.7 kg (3.7 lb)
325B L 5BS1-Up 1.7 kg (3.7 lb) 330 8FK1-Up 1 kg (2.2 lb)
325B L 8RR1-385 1 kg (2.2 lb) 330 L 6SK1001-Up 1 kg (2.2 lb)
325B L 8RR386-Up 1.1 kg (2.4 lb) 330 L 2EL332-Up 1.7 kg (3.7 lb)
325B L 1GS1-Up 1.1 kg (2.4 lb) 330 L 9ML77-Up 1 kg (2.2 lb)
325B L 1HS1-Up 1 kg (2.2 lb) 330 L 5YM1-Up 1.7 kg (3.7 lb)
325C AMH1-Up 0.90 kg (1.98 lb) 330 LN 8CK206-Up 1.7 kg (3.7 lb)
325C BKH1-Up 1.00 kg (2.20 lb) 330B 4RS1-Up 1.7 kg (3.7 lb)
SENR5664-11 135

Product Product
Amount of Amount of
Charge Charge
Number Number
330B 8SR1-417 1 kg (2.2 lb) 330C MH D3C1-Up 1.30 kg (2.87 lb)
330B 8SR418-Up 1.1 kg (2.4 lb) 345 Series II APD1-Up 2.20 kg (4.85 lb)
330B 9HN399-Up 1.1 kg (2.4 lb) 345B 6XS1-Up 1.1 kg (2.4 lb)
330B 2RR426-Up 1.1 kg (2.4 lb) 345B 8KW1-Up 1.1 kg (2.4 lb)
330B 5EZ253-Up 1.1 kg (2.4 lb) 345B 6MW1-Up 1.1 kg (2.4 lb)
330B L 8TR1-485 1 kg (2.2 lb) 345B 2ZW1-Up 1.1 kg (2.4 lb)
330B L 8TR486-Up 1.1 kg (2.4 lb) 345B AKJ1-Up 1.1 kg (2.4 lb)
330B L 1JS1-484 1 kg (2.2 lb) 345B AKX1-Up 1.1 kg (2.4 lb)
330B L 1JS485-Up 1.1 kg (2.4 lb) 345B ALD1-Up 1.1 kg (2.4 lb)
330B L 1KS1-Up 1 kg (2.2 lb) 345B ALL1-Up 1.1 kg (2.4 lb)
330B L 5LS1-Up 1.7 kg (3.7 lb) 345B ALT1-Up 1.1 kg (2.4 lb)
330B L 6DR1-Up 1.7 kg (3.7 lb) 345B CCC1-Up 2.2 kg (4.9 lb)
330B L 3YR1-Up 1.7 kg (3.7 lb)
345B AMD1-Up 1.1 kg (2.4 lb)
330B WMH AME1-Up 1.7 kg (3.7 lb)
345B AMJ1-Up 1.1 kg (2.4 lb)
330C MCA1-Up 1.00 kg (2.20 lb)
345B AMN1-Up 1.1 kg (2.4 lb)
330C AKW1-Up 1.00 kg (2.20 lb)
345B APB1-Up 2.2 kg (4.8 lb)
330C B4N1-Up 1.30 kg (2.87 lb) 345B BFG1-Up 2.2 kg (4.8 lb)
330C GAG1-Up 1.00 kg (2.20 lb) 345B AYR1-Up 1.1 kg (2.4 lb)
330C JAB1-Up 1.00 kg (2.20 lb) 345B CFM1-Up 2.2 kg (4.8 lb)
330C BTM1-Up 1.00 kg (2.20 lb) 345B DET1-Up 2.2 kg (4.8 lb)
330C JCD1-Up 1.00 kg (2.20 lb) 345B AMA1-Up 1.1 kg (2.4 lb)
330C MKM1-Up 1.00 kg (2.20 lb) 345B Series II CDJ1-Up 2.2 kg (4.9 lb)
330C JNK1-Up 1.00 kg (2.20 lb) 345B Series II DCW1-Up 2.20 kg (4.85 lb)
330C FM B2L1-Up 105 kg (2.31 lb) 345B Series II FEE1-Up 2.20 kg (4.85 lb)
330C FMHW B1K1-Up 1.30 kg (2.87 lb) 345B Series II AGS1-Up 2.20 kg (4.85 lb)
330C FMST B3M1-Up 1.30 kg (2.87 lb) 345B Series II ALB1-Up 2.20 kg (4.85 lb)
330C L GKX1-Up 1.00 kg (2.20 lb) 345BL 9CW1-Up 1.1 kg (2.4 lb)
330C L CAP1-Up 1.00 kg (2.20 lb) 345B L 5WS1-Up 1.1 kg (2.4 lb)
330C L DKY1-Up 1.05 kg (2.31 lb) 345B L 3MW1-Up 1.1 kg (2.4 lb)
330C L CYA1-Up 1.00 kg (2.20 lb) 345B L 8RW1-Up 1.1 kg (2.4 lb)
330C L KDD1-Up 1.00 kg (2.20 lb) 345B L 7KS1-Up 2.20 kg (4.85 lb)
330C L HAA1-Up 1.00 kg (2.20 lb) 345B L 2SW1-Up 2.20 kg (4.85 lb)
330C L RBH1-Up 1.00 kg (2.20 lb) 345B L 4SS1-Up 2.20 kg (4.85 lb)
330C L DXY1-Up 1.05 kg (2.31 lb) 345B L 9GS1-Up 2.20 kg (4.85 lb)
330C L DXY1-Up 0.90 kg (1.98 lb) 345B L 2NW1-Up 2.20 kg (4.85 lb)
330B LN 5LR1-Up 1.7 kg (3.7 lb) W345B ANJ1-Up 2.20 kg (4.85 lb)
330C LN CGZ1-Up 1.00 kg (2.20 lb)
W345B CDY1-Up 2.20 kg (4.85 lb)
(continued)
(continued)
136 SENR5664-11

Product Product
Amount of Amount of
Charge Charge
Number Number
345C MDC1-Up 0.9 kg (1.98 lb) 365B L Series II DER1-Up 1.5 kg (3.3 lb)
345C BWY1-Up 0.9 kg (1.98 lb) 365B L Series
SDL1-Up 1.9 kg (4.2 lb)
II MH
345C JAR1-Up 0.9 kg (1.98 lb)
365C L FEN1-Up 1.1 kg (2.42 lb)
345C CPX1-Up 0.9 kg (1.98 lb)
365C L ELC1-Up 1.1 kg (2.42 lb)
345C M2R1-Up 1.1 kg (2.42 lb)
365C L MCY1-Up 1.1 kg (2.42 lb)
345C D3S1-Up 1.1 kg (2.42 lb)
365C L MCS1-Up 1.1 kg (2.42 lb)
345CL PJW1-Up 0.9 kg (1.98 lb)
365C L PAR1-Up 1.1 kg (2.42 lb)
345CL SRY1-Up 0.9 kg (1.98 lb)
365C L TBA1-Up 1.1 kg (2.42 lb)
345CL DHP1-Up 0.9 kg (1.98 lb)
365C L MEM1-Up 1.1 kg (2.42 lb)
345CL TDG1-Up 0.9 kg (1.98 lb)
375 8XG194-244 1 kg (2.2 lb)
345CL GJR1-Up 0.9 kg (1.98 lb)
375 8XG245-Up 1 kg (2.2 lb)
345CL GPH1-Up 0.9 kg (1.98 lb)
375 8WJ77-Up 2.2 kg (4.8 lb)
345CL KBA1-Up 0.9 kg (1.98 lb)
375 6NK1-Up 2.2 kg (4.8 lb)
345CL GBH1-Up 0.9 kg (1.98 lb)
375 L 6RL45-59 1.8 kg (4 lb)
345CL RFN1-Up 0.9 kg (1.98 lb)
375 L 6RL60-Up 1 kg (2.2 lb)
345CL ESD1-Up 0.9 kg (1.98 lb)
375 L 9WL87-Up 2.2 kg (4.8 lb)
345CL WDE1-Up 0.9 kg (1.98 lb)
375 L 1JM46-Up 2.2 kg (4.8 lb)
345CL TAJ1-Up 0.9 kg (1.98 lb)
385B BKX1-Up 1.4 kg (3.1 lb)
350 7RK241-335 1.8 kg (4 lb)
385B CLS1-Up 2.2 kg (4.9 lb)
350 7RK336-Up 1 kg (2.2 lb)
385B BKF1-Up 1.4 kg (3.1 lb)
350 8HK144-Up 2.2 kg (4.8 lb)
385B RCD1-Up 2.2 kg (4.9 lb)
350 2ZL1-Up 2.2 kg (4.8 lb)
385B L ANS1-Up 2.2 kg (4.9 lb)
350 L 9DK143-215 1.8 kg (4 lb)
385B L FDL1-Up 2.2 kg (4.9 lb)
350 L 9DK216-Up 1 kg (2.2 lb)
385B L MYA1-Up 2.2 kg (4.9 lb)
350 L 3ML1-Up 2.2 kg (4.8 lb)
385B L BLY1-Up 1.4 kg (3.1 lb)
350 L 9FL121-Up 2.2 kg (4.8 lb)
385C MNZ1-Up 1.1 kg (2.42 lb)
365B BTH1-Up 1.5 kg (3.3 lb)
385C MMA1-Up 1.1 kg (2.42 lb)
365B CFJ1-Up 1.4 kg (3.1 lb)
385C KKK1-Up 1.1 kg (2.42 lb)
365B L 9TZ1-Up 1.9 kg (4.2 lb)
385C KBC1-Up 1.1 kg (2.42 lb)
365B L 9PZ1-Up 1.9 kg (4.2 lb)
385C JCM1-Up 1.1 kg (2.42 lb)
365B L 4XZ1-Up 1.5 kg (3.3 lb)
385C WAW1-Up 1.1 kg (2.42 lb)
365B L AGD1-Up 1.5 kg (3.3 lb)
385CFS EAM1-Up 1.1 kg (2.42 lb)
365B LU DER1-Up 1.9 kg (4.2 lb)
385CFS GLT1-Up 1.1 kg (2.42 lb)
365B LU JMB1-Up 1.9 kg (4.2 lb)
385CFS T2F1-Up 1.1 kg (2.42 lb)
365B LU PEG1-Up 1.9 kg (4.2 lb)
385C L SBE1-Up 1.1 kg (2.42 lb)
365B MH CTY1-Up 1.9 kg (4.2 lb)
(continued)
385CL KGB1-Up 1.1 kg (2.42 lb)
(continued)
SENR5664-11 137

Product Product
Amount of Amount of
Charge Charge
Number Number
385CL EDA1-Up 1.1 kg (2.42 lb) 574B RLS1-Up 1.14 kg (2.51 lb)
385CL T2E1-Up 1.1 kg (2.42 lb) 580 7CN1-Up 1.2 kg (2.60 lb)
5080 8SL1-Up 2.2 kg (4.8 lb) 580B CLT1-Up 1.40 kg (3.09 lb)
5080 6XK89-Up 2.2 kg (4.8 lb) HA770 HAB1-Up 1.10 kg (2.42 lb)
5090B CLD1-Up 1.4 kg (3.1 lb) HA771 HAF1-Up 1.10 kg (2.42 lb)
5110B AAA1-Up 2.7 kg (6.0 lb) HA870 HAE1-Up 1.10 kg (2.42 lb)
5110B AAT1-Up 2.7 kg (6.0 lb) HA871 HAG1-Up 1.10 kg (2.42 lb)
5110B AAK1-Up 2.7 kg (6.0 lb) TK370 WBD1-Up 1.10 kg (2.42 lb)
5130 5ZL1-Up 3 kg (6.6 lb) TK371 WBG1-Up 1.10 kg (2.42 lb)
5130 7TJ1-Up 3 kg (6.6 lb) TK380 WBE1-Up 1.10 kg (2.42 lb)
5130B 4CS130-Up 3.75 kg (8.25 lb) TK381 WBH1-Up 1.10 kg (2.42 lb)
5230 7LL1-85 3 kg (6.6 lb) TK711 1011-Up 1.70 kg (3.75 lb)
5230 7LL86-Up 3.75 kg (8.25 lb) TK721 1021-Up 1.70 kg (3.75 lb)
5230B 4HZ1-Up 3.75 kg (8.25 lb) TK722 1031-Up 1.70 kg (3.75 lb)
Forest Products TK732 1041-Up 1.70 kg (3.75 lb)
515 4LR1-Up 1.6 kg (3.50 lb) TK741 2021-Up 1.70 kg (3.75 lb)
517 5WW1-Up 1.6 kg (3.50 lb) TK751 3011-Up 1.70 kg (3.75 lb)
517 6PW1-Up 1.6 kg (3.50 lb) TK752 3021-Up 1.70 kg (3.75 lb)
525 1DN1-Up 1.6 kg (3.50 lb) TK1051 9HZ1-Up 1.70 kg (3.75 lb)
525B 3KZ1-Up 1.6 kg (3.50 lb) 1090 BZJ1-Up 1.70 kg (3.75 lb)
527 4NS1-Up 1.6 kg (3.50 lb) 1190 BZK1-Up 1.70 kg (3.75 lb)
527 2RS1-Up 1.6 kg (3.50 lb) 1190T BZL1-Up 1.70 kg (3.75 lb)
527 3DS1-Up 1.6 kg (3.50 lb) 1290T BZM1-Up 1.30 kg (2.87 lb)
533 CDR1-Up 1.1 kg (2.3 lb) Motor Graders
535B AAE1-Up 1.6 kg (3.50 lb) 120G 87V9732-Up 1.9 kg (4.2 lb)
539 1PZ1-Up 1.48 kg (3.25 lb) 120G 11W1351-Up 1.9 kg (4.2 lb)
543 ASJ1-Up 1.10 kg (2.42 lb) 120G 61M15358-Up 2.3 kg (5 lb)
545 2FZ1-Up 1.6 kg (3.50 lb) 120H 2AN1-Up 1.6 kg (3.5 lb)
550 7ZN1-Up 1.2 kg (2.60 lb) 120H 5FM1-Up 1.9 kg (4.2 lb)
550B SAW1-Up 1.40 kg (3.09 lb) 120H ES 9YR1-Up 1.6 kg (3.5 lb)
554 1AM1-Up 1.2 kg (2.60 lb) 120H NA 4MK1-Up 2 kg (4.5 lb)
554 TGH1-Up 1.10 kg (2.42 lb) 120H NA 6YN1-Up 2 kg (4.5 lb)
560B TRA1-Up 1.40 kg (3.09 lb) 120H ES 6NM1-Up 2 kg (4.5 lb)
564 KBN1-Up 1.14 kg (2.51 lb) 120H 1241-Up 2.1 kg (4.6 lb)
570 4XR1-Up 1.2 kg (2.60 lb) 120H ALZ1-Up 2.1 kg (4.6 lb)
570B CKG1-Up 1.40 kg (3.09 lb) 120H CAF1-Up 2.1 kg (4.6 lb)
574 1FM1-Up 1.2 kg (2.60 lb) 130G 74V2604-Up 2.3 kg (5 lb)
574B CZZ1-Up 1.14 kg (2.51 lb) 135H 8ZG1-Up 1.6 kg (3.5 lb)
138 SENR5664-11

Product Product
Amount of Amount of
Charge Charge
Number Number
135H 8WN1-Up 1.9 kg (4.2 lb) 160H NA 3GM1-Up 2 kg (4.5 lb)
135H 7PM1-Up 1.9 kg (4.2 lb) 160H ES 6WM1-Up 2 kg (4.5 lb)
135H AMX1-Up 1.9 kg (4.2 lb) 160H CCP1-Up 2.1 kg (4.6 lb)
135H NA 3YK1-Up 2 kg (4.5 lb) 163H NA 5AK1-Up 1.6 kg (3.5 lb)
135H NA BDJ1-Up 2 kg (4.5 lb) 163H ARL1-Up 2.1 kg (4.6 lb)
135H CBC1-Up 2.1 kg (4.6 lb) 14G 96U9075-Up 2.3 kg (5 lb)
12G 3WC1738-Up 2.3 kg (5 lb) 14H 7WJ1-2242 2 kg (4.5 lb)
12H 4ER1-Up 1.9 kg (4.2 lb) 14H 7WJ2243-Up 1.6 kg (3.5 lb)
12H 2GS1-Up 1.6 kg (3.5 lb) 14H ASE1-Up 2.1 kg (4.6 lb)
12H NA 4XM1-3131 2 kg (4.5 lb) 16G 93U3516-Up 2.3 kg (5 lb)
12H NA 4XM3132-Up 1.6 kg (3.5 lb) 16H 6ZJ1-982 2 kg (4.5 lb)
12H NA 8MN1-Up 2 kg (4.5 lb) 16H 6ZJ983-Up 1.6 kg (3.5 lb)
12H ES 2LR1-Up 2 kg (4.5 lb) 16H ATS1-Up 2.1 kg (4.6 lb)
12H NA 2WR1-Up 2 kg (4.5 lb) 24H 7KK1-Up 2.6 kg (5.7 lb)
12H 1251-Up 2.1 kg (4.6 lb) Multi-Terrain Loaders
12H AMZ1-Up 2.1 kg (4.6 lb) 247B MTL1-Up 0.8 kg (1.8 lb)
12H CBK1-Up 2.1 kg (4.6 lb) 257B SLK1-Up 0.8 kg (1.8 lb)
140G 72V15940-Up 2.3 kg (5 lb) 267B 9XS1-Up 0.8 kg (1.8 lb)
140G 13W896-Up 2.3 kg (5 lb) 277B 9XS1-Up 0.8 kg (1.8 lb)
140H 5HM1-Up 1.9 kg (4.2 lb) 287B 9XS1-Up 0.8 kg (1.8 lb)
140H 3AS1-Up 1.6 kg (3.5 lb) Off-Highway Trucks
140H APM1-Up 2.1 kg (4.6 lb) 69D 9XS1-Up 1.8 kg (4 lb)
140H NA 2ZK1-7566 2 kg (4.5 lb) 69D 9SS1-Up 1.8 kg (4 lb)
140H NA 2ZK7567-Up 1.6 kg (3.5 lb) 73D 9YS1-Up 1.8 kg (4 lb)
140H ES 8KM1-Up 2 kg (4.5 lb) 73D 1GW1-Up 1.8 kg (4 lb)
140H NA 9TN1-Up 2 kg (4.5 lb) 768C 02X371-Up 1.8 kg (4 lb)
140H NA 9ZN1-Up 2 kg (4.5 lb) 769C 01X6362-Up 1.9 kg (4.2 lb)
140H CCA1-Up 2.1 kg (4.6 lb) 769D 5TR1-969 1.8 kg (4 lb)
140H 1261-Up 2.1 kg (4.6 lb) 769D 5TR970-Up 1.8 kg (4.0 lb)
143H NA 1AL1-Up 1.6 kg (3.5 lb) 769D BBB1-Up 3.0 kg (6.6 lb)
143H APN1-Up 2.1 kg (4.6 lb) 769D 5SS1-Up 1.8 kg (4.0 lb)
160G 4JD186-Up 2.3 kg (5 lb) 771C 3BJ100-Up 1.9 kg (4.2 lb)
160H 2FM186-Up 1.9 kg (4.2 lb) 771D 6JR1-Up 1.8 kg (4 lb)
160H ASD1-Up 2.1 kg (4.6 lb) 771D BCA1-Up 3.0 kg (6.6 lb)
160H NA 9EJ1-1264 2 kg (4.5 lb) 771D 6YS1-Up 1.8 kg (4.0 lb)
160H NA 9EJ1265-Up 1.6 kg (3.5 lb) 772B 64W195-Up 1.9 kg (4.2 lb)
SENR5664-11 139

Product Product
Amount of Amount of
Charge Charge
Number Number
773B 63W4011-Up 1.9 kg (4.2 lb) CS-563D AW 1SZ1-Up 1.3 kg (2.9 lb)
773D 7ER1-Up 1.8 kg (4 lb) CS-583D 2CZ1-Up 1.3 kg (2.9 lb)
773D 7CS1-Up 1.8 kg (4.0 lb) CS-423E CFX1-Up 1.3 kg (2.9 lb)
773E BDA1-Up 3.0 kg (6.6 lb) CS-423E DCL1-Up 1.3 kg (2.9 lb)
775B 7XJ124-Up 1.9 kg (4.2 lb) CS-423E AGH1-Up 1.3 kg (2.9 lb)
775D 6KR1-Up 1.8 kg (4 lb) CS-423E ASH1-Up 1.3 kg (2.9 lb)
775D 8AS1-Up 1.8 kg (4.0 lb) CS-423E EAE1-Up 1.3 kg (2.9 lb)
775E BEC1-Up 3.0 kg (6.6 lb) CP-423E BWG1-Up 1.3 kg (2.9 lb)
776C 2TK79-Up 1.8 kg (4 lb) CP-433E CFK1-Up 1.3 kg (2.9 lb)
776D 5ER1-Up 1.8 kg (4 lb) CP-433E CYE1-Up 1.3 kg (2.9 lb)
776D AFS1-Up 1.8 kg (4 lb) CP-433E BTY1-Up 1.3 kg (2.9 lb)
777C 4XJ367-Up 1.8 kg (4 lb) CP-433E ASN1-Up 1.3 kg (2.9 lb)
777D 3PR1-Up 1.8 kg (4 lb) CS-433E CFP1-Up 1.3 kg (2.9 lb)
777D AGC1-Up 1.8 kg (4 lb) CS-433E DAC1-Up 1.3 kg (2.9 lb)
777D AGY1-Up 1.8 kg (4 lb) CS-433E BTT1-Up 1.3 kg (2.9 lb)
777D 2YW1-Up 1.8 kg (4.0 lb) CS-433E AST1-Up 1.3 kg (2.9 lb)
784B 5RK1-Up 0.5 kg (1.1 lb) CS-433E ASR1-Up 1.3 kg (2.9 lb)
784C 2PZ1-Up 0.5 kg (1.1 lb) CB-434D CNH1-Up 1.20 kg (2.65 lb)
785B 6HK265-Up 2.1 kg (4.6 lb) CS-531D 3AZ1-Up 1.3 kg (2.9 lb)
785C 5AZ1-Up 2.1 kg (4.6 lb) CS-531D 4MZ1-Up 1.3 kg (2.9 lb)
785C APX1-Up 3.0 kg (6.6 lb) CS-531D AGH1-Up 1.3 kg (2.9 lb)
789B 7EK231-Up 2.1 kg (4.6 lb) CS-533D 5CZ1-Up 1.3 kg (2.9 lb)
789C 2BW1-Up 3.0 kg (6.6 lb) CS-533D AET1-Up 1.3 kg (2.9 lb)
793B 1HL102-Up 2.4 kg (5.3 lb) CS-533E DAK1-Up 1.3 kg (2.9 lb)
793C 4AR1-Up 24 kg (5.3 lb) CS-533E ASL1-Up 1.3 kg (2.9 lb)
793C ATY1-243 2.4 kg (5.3 lb) CS-533E BZE1-Up 1.3 kg (2.9 lb)
793C ATY244-UP 3.0 kg (6.6 lb) CP-533D 6AZ1-Up 1.3 kg (2.9 lb)
793C CBR1-Up 3.0 kg (6.6 lb) CP-533D AFC1-Up 1.3 kg (2.9 lb)
793C 4GZ1-Up 2.1 kg (4.6 lb) CP-533E DAM1-Up 1.3 kg (2.9 lb)
797 5YW1-Up 2 kg (4.5 lb) CP-533E ASM1-Up 1.3 kg (2.9 lb)
797B JSM1-Up 2.7 kg (6 lb) CP-533E BZG1-Up 1.3 kg (2.9 lb)
Paving Products CB-534D FGH1-Up 1.2 kg (2.7 lb)
RR-250B 3RR1-Up 1.7 kg (3.75 lb) CB-534D GCA1-Up 1.2 kg (2.7 lb)
SS-250B 5GR1-Up 1.7 kg (3.75 lb) CB-534D XW EAA1-Up 1.2 kg (2.7 lb)
RM-350B 7FS1-Up 1.8 kg (4.0 lb) CB-534D XW FEA1-Up 1.2 kg (2.7 lb)
RM-350B AXW1-Up 1.0 kg (2.2 lb) CS-563D 2RZ1-Up 1.3 kg (2.9 lb)
CP-563D 9ZW1-Up 1.3 kg (2.9 lb) CP-563D 5LZ1-Up 1.3 kg (2.9 lb)
CS-563D AW 9MW1-Up 1.3 kg (2.9 lb) CS-563E CNG1-Up 1.3 kg (2.9 lb)
140 SENR5664-11

Product Product
Amount of Amount of
Charge Charge
Number Number
TH330B SLB1-Up 0.80 kg (1.76 lb)
CS-563E ASA1-Up 1.3 kg (2.9 lb)
TH340B SLC1-Up 0.80 kg (1.76 lb)
CP-563E CNT1-Up 1.3 kg (2.9 lb)
CP-563E BWE1-Up 1.3 kg (2.9 lb) TH350B SLD1-Up 0.80 kg (1.76 lb)
CS-573E CNN1-Up 1.3 kg (2.9 lb)
CS-573E CEB1-Up 1.3 kg (2.9 lb) TH355B JRK1-Up 0.80 kg (1.76 lb)
CS-583E CNX1-Up 1.3 kg (2.9 lb) TH360B SLE1-Up 0.80 kg (1.76 lb)
CS-583E DAJ1-Up 1.3 kg (2.9 lb) TH460B SLF1-Up 0.80 kg (1.76 lb)
CP-633E DAF1-Up 1.3 kg (2.9 lb) TH560B SLG1-Up 0.80 kg (1.76 lb)
CP-663E ASF1-Up 1.3 kg (2.9 lb) TH580B SLH1-Up
CS-663E AEF1-Up 1.3 kg (2.9 lb) Track-Type Tractors
CS-663E DAG1-Up 1.3 kg (2.9 lb) 933C 8FL70-Up 1.8 kg (4 lb)
CS-663E ASB1-Up 1.3 kg (2.9 lb) 933C 9EL48-Up 1.8 kg (4 lb)
CS-683E DAD1-Up 1.3 kg (2.9 lb) 933C 5JS1-Up 1.9 kg (4.2 lb)
CS-683E ASG1-Up 1.3 kg (2.9 lb) 933C 4MS1-Up 1.9 kg (4.2 lb)
Skid Steer Loaders 939C 9GL91-Up 1.8 kg (4 lb)
226B MJH1-Up 0.8 kg (1.8 lb) 939C 6DS1-Up 1.9 kg (4.2 lb)
236 4YZ1-Up 0.7 kg (1.5 lb) 953B 5MK1651-Up 1.6 kg (3.5 lb)
236B HEN1-Up 0.8 kg (1.8 lb) 953C 2ZN1-1748 1.1 kg (2.4 lb)
242 CMB1-Up 0.7 kg (1.5 lb) 953C 2ZN1749-Up 1.4 kg (3.0 lb)
242B BXM1-Up 0.8 kg (1.8 lb) 953C BBX1-Up 1.2 kg (2.7 lb)
246 5SZ1-Up 0.7 kg (1.5 lb) 963 21Z5346-Up 1.7 kg (3.7 lb)
246B PAT1-Up 0.8 kg (1.8 lb) 963B 9BL1-Up 1.6 kg (3.5 lb)
248B SCL1-Up 0.8 kg (1.8 lb) 963C 2DS1-Up 1.4 kg (3.0 lb)
252 FDG1-Up 0.7 kg (1.5 lb) 963C BBD1-Up 1.4 kg (3.0 lb)
252B SCP1-Up 0.8 kg (1.8 lb) 973 86G1556-Up 1.6 kg (3.5 lb)
257 CMM1-Up 0.7 kg (1.5 lb) 973C 3RZ1-Up 1.4 kg (3.0 lb)
262 CED1-Up 0.7 kg (1.5 lb) 973C BCP1-Up 1.4 kg (3.0 lb)
262B PDT1-Up 0.8 kg (1.8 lb) D3C Series lll 6SL172-Up 1.8 kg (4 lb)
268B LBA1-Up 0.8 kg (1.8 lb) D3C Series lll 7XL107-Up 1.8 kg (4 lb)
277 CNC1-Up 0.7 kg (1.5 lb) D3C Series lll 9CL78-Up 1.8 kg (4 lb)
287 CNY1-Up 0.7 kg (1.5 lb) D3C Series lll 8DL35-Up 1.8 kg (4 lb)
Telescopic Material Handlers D3C Series lll HS 4KS1-U 1.8 kg (4 lb)
TH210 CEC1-Up 1.2 kg (2.7 lb) D3C Series lll
4TS1-Up 1.8 kg (4 lb)
TH215 HS XL
CEG1-Up 1.2 kg (2.7 lb)
TH220B D3C Series lll
SLA1-Up 0.80 kg (1.76 lb) 5GS1-Up 1.8 kg (4 lb)
HS LGP
(continued)
(continued)
SENR5664-11 141

Product Product
Amount of Amount of
Charge Charge
Number Number
D3C Series lll XL 9TS1-Up 1.8 kg (4 lb) D5H Series ll 3MD5594-Up 1.6 kg (3.5 lb)
D3G CFC1-Up 1.1 kg (2.4 lb) D5H Series ll 2SD5549-Up 1.6 kg (3.5 lb)
D3G CFF1-Up 1.1 kg (2.4 lb) D5H Series ll 4KD5585-Up 1.6 kg (3.5 lb)
D3G LGP BYR1-Up 1.1 kg (2.4 lb) D5H Series ll XL 8RJ4387-Up 1.6 kg (3.5 lb)
D3G XL JMH1-Up 1.1 kg (2.4 lb) D5M 3CR1-Up 1.6 kg (3.5 lb)
D4C Series lll 6YL141-Up 1.8 kg (4 lb) D5M 3DR1-Up 1.6 kg (3.5 lb)
D4C Series lll 7SL78-Up 1.8 kg (4 lb) D5M 4BR1-Up 1.6 kg (3.5 lb)
D4C Series lll 8EL57-Up 1.8 kg (4 lb) D5M 4JS1-Up 1.6 kg (3.5 lb)
D4C Series lll 1FW1-Up 1.8 kg (4 lb) D5M 7LR1-Up 1.6 kg (3.5 lb)
D4C Series lll HS 6BS1-Up 1.8 kg (4 lb) D5M 5ES1-Up 1.6 kg (3.5 lb)
D4C Series lll D5M 5FS1-Up 1.6 kg (3.5 lb)
8CS1-Up 1.8 kg (4 lb)
HS XL
D5M 6AS1-Up 1.6 kg (3.5 lb)
D4C Series lll
4LS1-Up 1.8 kg (4 lb) D5M 6GN1-Up 1.6 kg (3.5 lb)
HS LGP
D4G CFN1-Up 1.1 kg (2.4 lb) D5N AGG1-Up 1 kg (2.2 lb)
D4G FDC1-Up 1.1 kg (2.4 lb) D5N AKD1-Up 1 kg (2.2 lb)
D4G LGP TLX1-Up 1.1 kg (2.4 lb) D5N LGP CKT1-Up 1 kg (2.2 lb)
D4G XL HYD1-Up 1.1 kg (2.4 lb) D5N XL CFH1-Up 1.8 kg (4 lb)
D4H Series ll XL 8PJ533-Up 1.6 kg (3.5 lb) D6C 8ZS1-Up 1.8 kg (4 lb)
D4H Series ll 9GJ945-Up 1.6 kg (3.5 lb) D6G 3SR1-Up 1.7 kg (3.75 lb)
D4H Series ll 4NK147-Up 1.6 kg (3.5 lb) D6H Series ll XR 4RC5589-Up 2 kg (4.5 lb)
D4H TSK Series D6H Series ll XR 6FC5542-Up 2 kg (4.5 lb)

7PK135-Up 1.6 kg (3.5 lb)
lll D6H Series ll 8FC5612-Up 2 kg (4.5 lb)
D5C Series lll 6ZL116-Up 1.8 kg (4 lb) D6H Series ll 1KD5600-Up 2 kg (4.5 lb)
D5C Series lll 7YL64-Up 1.8 kg (4 lb) D6H Series ll 2KD5618-Up 2 kg (4.5 lb)
D5C Series lll 9DL209-Up 1.8 kg (4 lb) D6H Series ll XR 3ZF5736-Up 2 kg (4.5 lb)
D5C Series lll HS 5HS1-Up 1.8 kg (4 lb) D6H Series ll XL 4YF5575-Up 2 kg (4.5 lb)
D5C Series lll D6H Series ll 5HF5582-Up 2 kg (4.5 lb)
7PS1-Up 1.8 kg (4 lb)
HS XL
D6H Series ll 6CF5565-Up 2 kg (4.5 lb)
D5C Series lll
6CS1-Up 1.8 kg (4 lb)
HS LGP D6H Series ll 2TG5593-Up 2 kg (4.5 lb)
D5G FDH1-Up 1.1 kg (2.4 lb) D6H Series ll XR 3YG5772-Up 2 kg (4.5 lb)
D5G FDW1-Up 1.1 kg (2.4 lb) D6H Series ll 4GG5632-Up 2 kg (4.5 lb)
D5G LGP RKG1-Up 1.1 kg (2.4 lb) D6H Series ll 4LG5598-Up 2 kg (4.5 lb)
D5G XL WGB1-Up 1.1 kg (2.4 lb) D6H Series ll 1FJ5542-Up 2 kg (4.5 lb)
D5H Series ll 7NC5527-Up 1.6 kg (3.5 lb) D6H Series ll XL 8ZJ319-Up 2 kg (4.5 lb)
D5H Series ll 8RC5967-Up 1.6 kg (3.5 lb) D6H Series ll XL 9KJ441-Up 2 kg (4.5 lb)
D5H Series ll 9HC5521-Up 1.6 kg (3.5 lb) D6H Series ll XR 5KK336-Up 2 kg (4.5 lb)
D5H Series ll 1DD6006-Up 1.6 kg (3.5 lb) D6H Series ll XR 6CK354-Up 2 kg (4.5 lb)
D5H Series ll 1YD5522-Up 1.6 kg (3.5 lb) D6H Series ll XR 7ZK349-Up 2 kg (4.5 lb)
142 SENR5664-11

Product Product
Amount of Amount of
Charge Charge
Number Number
D6H Series ll XL 8KK314-Up 2 kg (4.5 lb) D6R 9PN1-Up 1.6 kg (3.5 lb)
D6H Series ll XL 8SK369-Up 2 kg (4.5 lb) D6R 4WR1-Up 1.6 kg (3.5 lb)
D6H Series ll XL 9LK464-Up 2 kg (4.5 lb) D6R 5LN1-Up 1.6 kg (3.5 lb)
D6H Series ll XL 9RK308-Up 2 kg (4.5 lb) D6R 5PR1-Up 1.6 kg (3.5 lb)
D6H Series ll XR 1YL320-Up 2 kg (4.5 lb) D6R 5RR1-Up 1.6 kg (3.5 lb)
D6H Series ll XR 2BL347-Up 2 kg (4.5 lb) D6R 6FR1-Up 1.6 kg (3.5 lb)
D6H Series ll XR 2TL346-Up 2 kg (4.5 lb) D6R 6HR1-Up 1.6 kg (3.5 lb)
D6M 3WN1-Up 1.6 kg (3.5 lb) D6R 6JN1-Up 1.6 kg (3.5 lb)
D6M 4JN1-Up 1.6 kg (3.5 lb) D6R 6MR1-Up 1.6 kg (3.5 lb)
D6M 2RN1-Up 1.6 kg (3.5 lb) D6R 6GR1-Up 1.6 kg (3.5 lb)
D6M 2YS1-Up 1.6 kg (3.5 lb) D6R 7AR1-Up 1.6 kg (3.5 lb)
D6M 4GS1-Up 1.6 kg (3.5 lb) D6R 7DR1-Up 1.6 kg (3.5 lb)
D6M 4HS1-Up 1.6 kg (3.5 lb) D6R 7GR1-Up 1.6 kg (3.5 lb)
D6M 5NR1-Up 1.6 kg (3.5 lb) D6R 7KN1-Up 1.6 kg (3.5 lb)
D6M 5WR1-Up 1.6 kg (3.5 lb) D6R 8LN1-Up 1.6 kg (3.5 lb)
D6M 6LR1-Up 1.6 kg (3.5 lb) D6R 8TM1-Up 1.6 kg (3.5 lb)
D6M 9ZM1-Up 1.6 kg (3.5 lb) D6R 8XN1-Up 1.6 kg (3.5 lb)
D6N ALH1-Up 1 kg (2.2 lb) D6R 9BM1-Up 1.6 kg (3.5 lb)
D6N ALR1-Up 1 kg (2.2 lb) D6R 2HM1-Up 1.6 kg (3.5 lb)
D6N LGP ALY1-Up 1.8 kg (4 lb) D6R 9ZS1-Up 1.6 kg (3.5 lb)
D6N XL AKM1-Up 1.8 kg (4 lb) D6R Series II AEM1-Up 1.6 kg (3.5 lb)
D6N XL CCK1-Up 1.8 kg (4 lb) D6R Series II BLE1-Up 1.6 kg (3.5 lb)
D6N XL CBJ1-Up 1.8 kg (4 lb) D6R Series II AFM1-Up 1.6 kg (3.5 lb)
D6N XL CBL1-Up 1.8 kg (4 lb) D6R Series II BLT1-Up 1.6 kg (3.5 lb)
D6N LGP CCG1-Up 1.8 kg (4 lb) D6R Series II AGM1-Up 1.6 kg (3.5 lb)
D6N XL CBF1-Up 1.8 kg (4 lb) D6R BMJ1-Up 1.6 kg (3.5 lb)
D6N LGP CCS1-Up 1.8 kg (4 lb) D6R Series II AAX1-Up 1.6 kg (3.5 lb)
D6R 1RW1-Up 1.6 kg (3.5 lb) D6R BMY1-Up 1.6 kg (3.5 lb)
D6R 2YN1-Up 1.6 kg (3.5 lb) D6R Series II ACJ1-Up 1.6 kg (3.5 lb)
D6R 3ZN1-Up 1.6 kg (3.5 lb) D6R Series II ADE1-Up 1.6 kg (3.5 lb)
D6R 4FM1-Up 1.6 kg (3.5 lb) D6R Series II BNC1-Up 1.6 kg (3.5 lb)
D6R 4HN1-Up 1.6 kg (3.5 lb) D6R Series II AEP1-Up 1.6 kg (3.5 lb)
D6R 4JR1-Up 1.6 kg (3.5 lb) D6R DAE1-Up 1.6 kg (3.5 lb)
D6R 4MN1-Up 1.6 kg (3.5 lb) D6R Series II AFD1-Up 1.6 kg (3.5 lb)
D6R 4TR1-Up 1.6 kg (3.5 lb) D6R DMP1-Up 1.6 kg (3.5 lb)
D6R 9MN1-Up 1.6 kg (3.5 lb) D6R Series II FDT1-Up 1.6 kg (3.5 lb)
SENR5664-11 143

Product Product
Amount of Amount of
Charge Charge
Number Number
D6R Series II BRJ1-Up 1.6 kg (3.5 lb) D7R Series II BRM1-Up 1.6 kg (3.5 lb)
D6R Series II BPM1-Up 1.6 kg (3.5 lb) D7R Series II BRP1-Up 1.6 kg (3.5 lb)
D6R Series II CAD1-Up 1.6 kg (3.5 lb) D8N 5TJ1317-Up 1.6 kg (3.5 lb)
D6R Series II BRZ1-Up 1.6 kg (3.5 lb) D8N 7TK1-Up 1.6 kg (3.5 lb)
D6R Series II BMK1-Up 1.6 kg (3.5 lb) D8N 1XJ1-Up 1.6 kg (3.5 lb)
D6R Series II BPP1-Up 1.6 kg (3.5 lb) D8N 9TC1-Up 1.6 kg (3.5 lb)
D6R Series II BNL1-Up 1.6 kg (3.5 lb) D8R 7XM1-Up 1.6 kg (3.5 lb)
D6R Series II BRE1-Up 1.6 kg (3.5 lb) D8R 9EM1-Up 1.6 kg (3.5 lb)
D6R Series II BPS1-Up 1.6 kg (3.5 lb) D8R 6YZ1-Up 1.7 kg (3.75 lb)
D6R Series II BPZ1-Up 1.6 kg (3.5 lb) D8R(1) 6YZ1-Up 1.6 kg (3.5 lb)
D7H Series ll 4AB5532-Up 1.6 kg (3.5 lb) D8R AKA1-Up 1.7 kg (3.75 lb)
D7H Series ll 5WB5586-Up 1.6 kg (3.5 lb) D8R(1) AKA1-Up 1.6 kg (3.5 lb)
D7H Series ll 5BF5690-Up 1.6 kg (3.5 lb) D8T(1) KPZ1-Up 1.6 kg (3.53 lb)
D7H Series ll 2RG5622-Up 1.6 kg (3.5 lb) D8T KPZ1-Up 1.8 kg (4.00 lb)
D7H Series ll 3XG5515-Up 1.6 kg (3.5 lb) D8T J8B1-Up 1.8 kg (4.00 lb)
D7H Series ll 4FG5537-Up 1.6 kg (3.5 lb) D9N 5FJ1-Up 1.6 kg (3.5 lb)
D7H Series ll 79Z5611-Up 1.6 kg (3.5 lb) D9N 1JD1-Up 1.6 kg (3.5 lb)
D7H Series ll 80Z5518-Up 1.6 kg (3.5 lb) D9R 6XJ523-Up 2 kg (4.5 lb)
D7R Series II ADW1-Up 1.6 kg (3.5 lb) D9R 7TL1-Up 2 kg (4.5 lb)
D7R 2EN1-Up 1.6 kg (3.5 lb) D9R 8BL1-Up 2 kg (4.5 lb)
D7R 2HR1-Up 1.6 kg (3.5 lb) D9R JJB1-Up 2.8 kg (6.1 lb)
D7R 3DN1-Up 1.6 kg (3.5 lb) D9R(1) WDM1-Up 2.3 kg (5.07 lb)
D7R 3ZR1-Up 1.6 kg (3.5 lb) D9R WDM1-Up 2.7 kg (5.95 lb)
D7R 4SR1-Up 1.6 kg (3.5 lb) D9R Series II ACL1-Up 2.7 kg (6 lb)
D7R 5KZ1-Up 1.6 kg (3.5 lb) D9R Series II(1) ACL1-Up 2.3 kg (5 lb)
D7R 5MR1-Up 1.6 kg (3.5 lb) D9R Series II(1) ABK1-Up 2.3 kg (5 lb)
D7R 6ER1-Up 1.6 kg (3.5 lb) D9T(2) RJS1-Up 2.3 kg (5.07 lb)
D7R 9HM1-Up 1.6 kg (3.5 lb) D9T(1) RJS1-Up 2.3 kg (5.07 lb)
D7R ACS1-Up 1.6 kg (3.5 lb) D10N 3SK410-Up 2 kg (4.5 lb)
D7R AFG1-Up 1.6 kg (3.5 lb) D10N 92V410-Up 2 kg (4.5 lb)
D7R AEC1-Up 1.6 kg (3.5 lb) D10R 3KR1-Up 2 kg (4.5 lb)
D7R AGN1-Up 1.6 kg (3.5 lb) D10R(3) 3KR1-Up 2.5 kg (5.5 lb)
D7R ABJ1-Up 1.6 kg (3.5 lb) D10R(4) 3KR1-Up 2 kg (4.5 lb)
D7R CBZ1-Up 1.6 kg (3.5 lb) D10R AKT1-Up 2 kg (4.5 lb)
D7R Series II BPK1-Up 1.6 kg (3.5 lb) D10T(1) RJG1-Up 2.1 kg (4.63 lb)
D7R Series II BNM1-Up 1.6 kg (3.5 lb) D10T RJG1-Up 2.7 kg (5.95 lb)
D7R Series II BPT1-Up 1.6 kg (3.5 lb) D11N 4HK366-Up 2.5 kg (5.5 lb)
D7R Series II BNX1-Up 1.6 kg (3.5 lb) D11R 8ZR1-Up 2.5 kg (5.5 lb)
144 SENR5664-11

Product Product
Amount of Amount of
Charge Charge
Number Number
D11R(3) 8ZR1-Up 3 kg (6.8 lb) 918F 3TJ363-Up 2 kg (4.5 lb)
D11R(4) 8ZR1-Up 2 kg (4.5 lb) 918F 5DL167-Up 2 kg (4.5 lb)
D11R 9TR1-Up 2.5 kg (5.5 lb) 924F 4YN75-Up 2 kg (4.5 lb)
D11R(3) 9TR1-Up 3 kg (6.8 lb) 924F 5NN75-Up 2 kg (4.5 lb)
D11R(4) 9TR1-Up 2 kg (4.5 lb) 924F 6MN75-Up 2 kg (4.5 lb)
D11R 9XR1-Up 2.5 kg (5.5 lb) 924F 7PN75-Up 2 kg (4.5 lb)
D11R(3) 9XR1-Up 3 kg (6.8 lb) 924G 9SW1-Up 1.2 kg (2.7 lb)
D11R(4) 9XR1-Up 2 kg (4.5 lb) 924G 3PZ1-Up 1.2 kg (2.7 lb)
D11R 7PZ1-Up 2.5 kg (5.5 lb) 924G AAN1-Up 1.2 kg (2.7 lb)
D11R(3) 7PZ1-Up 3 kg (6.8 lb) 924G DFZ1-Up 1.3 kg (2.8 lb)
D11R(4) 7PZ1-Up 2 kg (4.5 lb) 924G RTA1-Up 1.3 kg (2.8 lb)
D11R AAF1-Up 2.5 kg (5.5 lb) 924G WGX1-Up 1.3 kg (2.8 lb)
D11R(3) AAF1-Up 3 kg (6.8 lb) 924G DDA1-Up 1.3 kg (2.8 lb)
D11R(4) AAF1-Up 2 kg (4.5 lb) 924G RBB1-Up 1.3 kg (2.8 lb)
Wheel Tractors 924G WMB1-Up 1.3 kg (2.8 lb)
590B 2KZ1-Up 3.9 kg (8.58 lb) 924GZ 6YW1-Up 1.2 kg (2.7 lb)
790G 1JW1-Up 2.3 kg (5.0 lb) 924GZ 3DZ1-Up 1.2 kg (2.7 lb)
814F 9DM1-Up 2.1 kg (4.6 lb) 924GZ AAB1-Up 1.2 kg (2.7 lb)
814F BGF1-Up 1.9 kg (4.2 lb) 928F 8AK1-Up 2.5 kg (5.5 lb)
824G AWW1-Up 2.5 kg (5.5 lb) 928F 2XL1-Up 2.5 kg (5.5 lb)
834B 7BR1-Up 2.8 kg (6.1 lb) 928F 7YM1-Up 2.5 kg (5.5 lb)
834G 7BR1-Up 2.8 kg (6.1 lb) 928G 6XR1-Up 1.2 kg (2.7 lb)
834G 6GZ1-Up 2.6 kg (5.7 lb) 928G 7SR1-Up 1.2 kg (2.7 lb)
834G BPC1-Up 2.6 kg (5.7 lb) 928G DJD1-Up 1.3 kg (2.8 lb)
836G 7MZ1-Up 2.6 kg (5.7 lb) 928G WLG1-Up 1.3 kg (2.8 lb)
844 BBN1-Up 2.7 kg (5.9 lb) 930G TWR1-Up 1.3 kg (2.87 lb)
854G AMP1-Up 2.6 kg (5.7 lb) 930G TFW1-Up 1.3 kg (2.87 lb)
854G AMP1-Up 2.3 kg (5.0 lb) 936F 8AJ855-Up 2.4 kg (5.3 lb)
854G A4W1-Up 2.3 kg (5.0 lb) 936F 9MK350-Up 2.4 kg (5.3 lb)
906 6ZS1-Up 1.7 kg (3.7 lb) 938F 1KM1-Up 1.8 kg (4 lb)
908 8BS1-Up 1.6 kg (3.5 lb) 938F 2RM142-Up 1.8 kg (4 lb)
910F 1SF1337-Up 1.6 kg (3.5 lb) 938F 8SM142-Up 1.8 kg (4 lb)
910F 1YK2048-Up 1.6 kg (3.5 lb) 938F 7SN142-Up 1.8 kg (4 lb)
910F 2SS1-Up 1.6 kg (3.5 lb) 938G 4YS1-Up 1.8 kg (4 lb)
910G B9X1-Up 1.3 kg (2.8 lb) 938G 6WS1-Up 1.5 kg (3.2 lb)
914G 9WM87-Up 1.2 kg (2.7 lb) 938G 8RS1-Up 1.5 kg (3.2 lb)
SENR5664-11 145

Product Product
Amount of Amount of
Charge Charge
Number Number
938G 9HS1-Up 1.5 kg (3.2 lb) 962G BDP1-Up 2.3 kg (5 lb)
938G Series ll CRD1-Up 1.5 kg (3.2 lb) 962G Series II AYE1-Up 1.7 kg (3.75 lb)
938G Series ll PHN1-Up 1.5 kg (3.2 lb) 962G Series II BAB1-Up 1.7 kg (3.75 lb)
938G Series ll RTB1-Up 1.5 kg (3.2 lb) 962G Series II AXS1-Up 1.7 kg (3.75 lb)
938G Series ll B9Y1-Up 1.5 kg (3.2 lb) 962G Series II AYG1-Up 1.7 kg (3.75 lb)
950F Series ll 4DK2240-Up 2 kg (4.5 lb) 962G Series II AXY1-Up 1.7 kg (3.75 lb)
950F Series ll 5SK745-Up 2 kg (4.5 lb) 962G Series II BAD1-Up 1.7 kg (3.75 lb)
950F Series ll 8TK816-Up 2 kg (4.5 lb) 962G Series II BAC1-Up 1.7 kg (3.75 lb)
950F Series ll 2LM348-Up 2 kg (4.5 lb) 966F 3XJ1-Up 2.1 kg (4.6 lb)
950F Series ll 6YG348-Up 2 kg (4.5 lb) 966F 4YG1-Up 2.1 kg (4.6 lb)
950F Series ll 7ZF348-Up 2 kg (4.5 lb) 966F Series ll 8BG2191-Up 2 kg (4.5 lb)
950G 2JS1-Up 2.3 kg (5 lb) 966F Series ll 9YJ1078-Up 2 kg (4.5 lb)
950G 8JW1-Up 2.3 kg (5 lb) 966F Series ll 1SL510-Up 2 kg (4.5 lb)
950G 5MW1-Up 2.3 kg (5 lb) 966G 3SW1-Up 2.4 kg (5.25 lb)
950G 3JW1-Up 2.3 kg (5 lb) 966G 9RS1-Up 2.3 kg (5 lb)
950G 8DS1-Up 2 kg (4.5 lb) 966G 3ZS1-Up 2.4 kg (5.25 lb)
950G 6NS1-Up 2 kg (4.5 lb) 966G 3PW1-Up 2.3 kg (5 lb)
950G 4BS1-Up 2 kg (4.5 lb) 966G AAH1-Up 2.1 kg (4.60 lb)
950G 5FW1-Up 2.3 kg (5 lb) 966G 8XW1-Up 2.3 kg (5 lb)
950G Series II AYD1-Up 1.7 kg (3.75 lb) 966G Series II AWY1-Up 1.9 kg (4.25 lb)
950G Series II AXX1-Up 1.7 kg (3.75 lb) 966G Series II AXJ1-Up 1.9 kg (4.25 lb)
950G Series II BAA1-Up 1.7 kg (3.75 lb) 966G Series II ANT1-Up 2.1 kg (4.6 lb)
950G Series II AYB1-Up 1.7 kg (3.75 lb) 966G Series II ANZ1-Up 2.1 kg (4.6 lb)
950G Series II AYL1-Up 1.7 kg (3.75 lb) 966G Series II AWZ1-Up 1.9 kg (4.2 lb)
950G Series II AYS1-Up 1.7 kg (3.75 lb) 966G Series II AXL1-Up 1.9 kg (4.2 lb)
950G Series II AXR1-Up 1.7 kg (3.75 lb) 970F 7SK225-Up 2 kg (4.5 lb)
960F 9ZJ167-Up 2 kg (4.5 lb) 970F 9JK361-Up 2 kg (4.5 lb)
960F 4CL165-Up 2 kg (4.5 lb) 970F 7PL103-Up 2 kg (4.5 lb)
960F 6XL170-Up 2 kg (4.5 lb) 972G 1EW1-Up 2.3 kg (5 lb)
960F 1YM181-Up 2 kg (4.5 lb) 972G 6AW1-Up 2.3 kg (5 lb)
962G 4PW1-Up 2.3 kg (5 lb) 972G 9GW1-Up 2.3 kg (5 lb)
962G 9BS1-Up 2 kg (4.5 lb) 972G 7LS1-Up 2.4 kg (5.25 lb)
962G 5RS1-Up 2 kg (4.5 lb) 972G 4WW1-Up 2.4 kg (5.25 lb)
962G 5AS1-Up 2 kg (4.5 lb) 972G AAW1-Up 2.1 kg (4.60 lb)
962G 3BS1-Up 2 kg (4.5 lb) 972G Series II AXC1-Up 1.9 kg (4.25 lb)
962G 6EW1-Up 2.3 kg (5 lb) 972G Series II AXN1-Up 1.9 kg (4.25 lb)
962G 7BW1-Up 2.3 kg (5 lb) 972G Series II ANY1-Up 2.1 kg (4.60 lb)
962G 6HW1-Up 2.3 kg (5 lb) 972G Series II AWP1-Up 2.1 kg (4.60 lb)
146 SENR5664-11

Product Product
Amount of Amount of
Charge Charge
Number Number
972G Series II AXE1-Up 1.9 kg (4.2 lb) R2900 BAR1-Up 2 kg (4.4 lb)
972G Series II AXP1-Up 1.9 kg (4.2 lb) R2900G GLK1-Up 2.3 kg (5.0 lb)
980F 8CJ1221-Up 2.3 kg (5 lb) R2900G JLK1-Up 4.8 kg (10.6 lb)
980F 8JN1-Up 2.3 kg (5 lb) Integrated Toolcarriers
980F 3HK1-Up 2.3 kg (5 lb) IT12F 1KF1040-Up 1.6 kg (3.5 lb)
980F 4RN1-Up 2.3 kg (5 lb) IT14F 4EL196-Up 1.6 kg (3.5 lb)
980F Series II 5XJ1-Up 2.3 kg (5 lb) IT14G 1WN94-Up 1.2 kg (2.7 lb)
980G 9CM1-Up 2.5 kg (5.5 lb) IT14G 8ZM1-Up 1.2 kg (2.7 lb)
980G 2KR1-Up 2.5 kg (5.5 lb) IT18F 6ZF307-Up 2 kg (4.5 lb)
980G 2SR1-Up 2.5 kg (5.5 lb) IT18F 5EJ1-Up 2 kg (4.5 lb)
980G AYT1-Up 1.9 kg (4.25 lb) IT24F 4NN51-Up 2 kg (4.5 lb)
980G Series II AWH1-Up 1.9 kg (4.25 lb) IT24F 6KN51-Up 2 kg (4.5 lb)
980G Series II AXG1-Up 1.9 kg (4.25 lb) IT28F 1JL1-Up 2.5 kg (5.5 lb)
988F 2ZR1-Up 2.8 kg (6.1 lb) IT28F 3CL751-Up 2.5 kg (5.5 lb)
988F 8YG492-Up 2.7 kg (6 lb) IT28G 8CR1-Up 1.2 kg (2.7 lb)
988G 2TW1-Up 2.6 kg (5.75 lb) IT28G 9AR1-Up 1.2 kg (2.7 lb)
988G BNH1-Up 2.6 kg (5.75 lb) IT28G DBT1-Up 1.3 kg (2.8 lb)
990 7HK28-Up 3.8 kg (8.3 lb) IT28G WAC1-Up 1.3 kg (2.8 lb)
990 4FR1-372 3.8 kg (8.3 lb) IT38F 6FN238-Up 1.8 kg (4 lb)
990 4FR373-UP 4.1 kg (9.0 lb) IT38F 5DR1-Up 2 kg (4.4 lb)
990 BCR1-Up 2.7 kg (6.0 lb) IT38G 7BS1-Up 1.5 kg (3.2 lb)
992D 7MJ340-Up 2.7 kg (6.0 lb) IT38G 1CW1-Up 1.5 kg (3.2 lb)
992G 7HR1-Up 2.3 kg (5.0 lb) IT38G CSX1-Up 1.5 kg (3.2 lb)
992G ADZ1-Up 2.3 kg (5.0 lb) IT62G 6PS1-Up 2.3 kg (5 lb)
992G AZX1-Up 2.3 kg (5.0 lb) IT62G AKP1-Up 2 kg (4.5 lb)
994 9YF83-Up 3 kg (6.6 lb) IT62G Series II AYA1-Up 1.7 kg (3.7 lb)
994D 3TZ83-Up 2.7 kg (6.0 lb) Wheel Tractor-Scrapers
Load Haul Dump 611 6SZ1-Up 1.7 kg (3.7 lb)
R1300 6QW1-Up 2 kg (4.4 lb) 613 Series ll 8LJ884-Up 1.8 kg (4 lb)
R1300G LJB1-Up 1.9 kg (4.1 lb) 615 Series ll 9XG343-Up 1.8 kg (4 lb)
R1600 9EW1-Up 2 kg (4.4 lb) 621F 4SK22-Up 1.8 kg (4 lb)
R1600 9XP1-Up 2 kg (4.4 lb) 621F 8PL1-Up 1.8 kg (4 lb)
R1600G 9PP1-Up 2 kg (4.4 lb) 621G ALP1-Up 1.8 kg (4 lb)
R1700G 8XZ1-Up 2 kg (4.4 lb) 621G CEN1-Up 1.8 kg (4 lb)
R1700 4LZ1-Up 2 kg (4.4 lb) 621G DBB1-Up 2.0 kg (4.41 lb)
R2900 5TW1-Up 2 kg (4.4 lb) 623F 6BK1-Up 1.8 kg (4 lb)
SENR5664-11 147
(Table 21, contd)

Product
Amount of
Charge
Number
623F 5EW1-Up 1.8 kg (4 lb)
623G ARW1-Up 1.8 kg (4 lb)
623G CES1-Up 1.8 kg (4 lb)
623G DBC1-Up 2.0 kg (4.41 lb)
627F 1DL18-Up 1.8 kg (4 lb)
627G AXF1-Up 1.8 kg (4 lb)
627G CEX1-Up 1.8 kg (4 lb)
627G DBD1-Up 2.0 kg (4.41 lb)
631E Series ll 1NB1-Up 1.8 kg (4 lb)
631E Series ll 1AB1510-Up 1.8 kg (4 lb)
631G AWK1-Up 1.8 kg (4 lb)
631G CLR1-Up 1.8 kg (4 lb)
633E 2PS1-Up 2 kg (4.5 lb)
637E 1JB1-Up 2.4 kg (5.3 lb)
637E Series ll 1FB571-Up 1.8 kg (4 lb)
637G AXT1-Up 1.8 kg (4 lb)
637G CEH1-Up 1.8 kg (4 lb)
651E 89Z271-Up 2.1 kg (4.6 lb)
651E 4YR1-Up 2.1 kg (4.6 lb)
657E 6TR1-Up 2.1 kg (4.6 lb)
657E 5YR1-Up 2 kg (4.5 lb)
657E 90Z223-Up 2 kg (4.5 lb)
657E 91Z453-Up 2 kg (4.5 lb)
(1) Remote condenser
(2) Fender Mount Condenser
(3) Large Accumulator
(4) Roof Mount with Large Accumulator
148 SENR5664-11
Disassembly and Assembly Section
Disassembly and Assembly When the service work is done on the air conditioning
system, it is important to keep the system clean and
Section free from contamination. Plugs and caps must be
used in order to close the components and hoses
when the components and hoses are open. The
i01707044 plugs and caps protect the system from dirt and air
Machine Preparation for (moisture). Only new refrigerant oil of the correct
viscosity and new refrigerant can be added to the
Disassembly and Assembly system. Refer to the Service Manual, SENR5664,
“Refrigerant Compressor” section in this manual
SMCS Code: 7320-017 for the correct oil. Any other material or any other
substance is considered non-condensable and the
material will contaminate the system. Keep the work
area clean.
erant. • Dust caps on the refrigerant compressor block
fitting are the primary seal on the air conditioning
This system is under pressure at all times, even system.
applied to a charged system. • All machines should have an identification tag in
the cab that specifies the proper refrigerant charge
Contact with refrigerant can cause frost bite. Keep for the machine.
When replacement or repair of components and
Protective goggles must always be worn when re- hoses are required, perform the following procedure:
dicate the system is empty of refrigerant. 1. Remove the refrigerant charge. Refer to the
Service Manual, SENR5664, “Refrigerant
Always use caution when a fitting is removed. Recovery” section in Testing and Adjusting.
under pressure, evacuate the system recovering 2. Remove the component or remove the hose that is
the refrigerant before removing the fitting. being repaired or replaced. Install protective plugs
on components or hoses that are left exposed to
Personal injury or death can result from inhaling the air.
3. Replace any damaged component or hose.
lit cigarette or other smoking method or inhaling 4. Use the following table in order to determine
fumes released from a flame contacting air con- the amount of oil that is lost during individual
ditioner refrigerant gas, can cause bodily harm or replacements of components. Add the correct
death. amount of oil to the compressor before the system
is evacuated. No additional oil should be added to
Do not smoke when servicing air conditioners or the system if the compressor is replaced at the
wherever refrigerant gas may be present. same time as other components in the system.

SENR5664-11 149
Table 22 i01707048
Oil Capacities for Component Replacements General Information

Accumulator 30 mL (1 fl oz)
SMCS Code: 1808; 7309
Compressor Refer to the Service Manual,
SENR5664, “Refrigerant Compressor
Oil-Check” section in Testing and
Adjusting.
Condenser 30 mL (1 fl oz)
erant.
Evaporator 90 mL (3 fl oz)
In-Line Dryer(1)
30 mL (1 fl oz)
Receiver-Dryer 30 mL (1 fl oz) applied to a charged system.
(1) Refer to the Service Manual, SENR5664,
“In-Line-Refrigerant Dryer - Remove and Install ” Contact with refrigerant can cause frost bite. Keep
before any oil is added. face and hands away to help prevent injury.
5. Refer to the Service Manual, SENR5664, Protective goggles must always be worn when re-
“Refrigerant System-Evacuate” section in testing frigerant lines are opened, even if the gauges in-
and adjusting. dicate the system is empty of refrigerant.
6. Refer to the Service Manual, SENR5664, Always use caution when a fitting is removed.
“Refrigerant System-Charge” section in Testing Slowly loosen the fitting. If the system is still
and Adjusting. under pressure, evacuate the system recovering


death.


• All refrigerant lines that are metal or flexible hose

must be free of sharp bends. Also, do not use
a refrigerant line that is kinked. Sharp bends
will cause a restriction in the refrigerant flow.
Restrictions in the refrigerant lines are identified
by cold spots or frost on the line at the location of
the restriction. Restrictions in the lines reduce the
performance and the efficiency of the system.
• The radius of bends in the flexible hose must never

be less than 10 times the outside diameter of the
hose.
• Do not allow the flexible hoses to come within

63.5 mm (2.50 inch) of the exhaust manifold.
150 SENR5664-11
• The hoses need to be inspected yearly for leaks i01934503

and for hardness. Conduct a leak test on all the
hoses and the lines. Refer to the Service Manual, Refrigerant Compressor -
SENR5664, “Refrigerant Leakage - Test” section Remove and Install
in testing and adjusting. Replace hoses if leaks
or hardness are in the hoses. Replace hoses with SMCS Code: 1802-010
new hose that is sealed and free of contaminants.
Removal
• The correct use of wrenches is very important
when connections are made. The type of wrench
that is used is also important. Only use wrenches
that are made for use with tube type fittings. When
a hose is connected or disconnected from the
system, use a wrench on the fitting and use a
wrench on the nut. When a metal line is connected
or disconnected from the system, use a wrench on
the fitting and use a wrench on the nut.
• Install protective plugs or protective caps on all

components and hoses that are disconnected or
removed.
• O-ring seals and O-ring seats must be in good

condition. Small cuts, scratches, or particles of dirt Illustration 72
g00742981
will cause a leak in the system. Put new refrigerant
(1) Bolt
oil on all new O-ring seals at the time of installation. (2) Drive belt
Do not use any kind of sealant on connections. (3) Suction and discharge hoses
(4) Compressor
• Dust caps on the compressor block fittings are the
primary seals on the air conditioning system. 1. Remove the refrigerant charge. Refer to the
Service Manual, SENR5664, “Refrigerant
• All machines should have an identification tag Recovery” section in Testing and Adjusting.
that specifies the refrigerant charge for the
machine. The tag should be located in the operator 2. Disconnect electrical wires from the magnetic
compartment. clutch.
• If water is in the vents check the nonreturn valve. If 3. Loosen all the mounting bolts and loosen the belt
water leaks from the air conditioning system, check tightener (if equipped). Remove drive belt (2).
the nonreturn valve. The nonreturn valve should
have the proper position and the proper direction. 4. Disconnect hoses (3) and put plugs or caps on
the hoses. Put plugs or caps on the fittings of
• If engine coolant is leaking into the operator the compressor. Put identification marks on the
compartment, check for loose clamps on the heater hoses. The marks will ensure that the hoses will
hoses. be connected correctly at a later time.
5. Remove all the mounting bolts and remove the

compressor (4). The weight of the compressor is
approximately 18 kg (40 lb).
Installation
1. Check the amount and condition of the oil in the
compressor (4). Refer to the Service Manual,
SENR5664, “Refrigerant Compressor Oil-Test”
2. Inspect the drive belt (2). If the drive belt (2) is

damaged or worn replace the belt.
SENR5664-11 151
3. Install the compressor (4). Do not tighten the Note: If the accumulator has frost on the outside, the
mounting bolts until drive belt (2) is installed and air conditioning system still contains refrigerant.
adjusted.
i00945988
4. Connect the discharge and the suction hoses
(3) to the discharge and suction ports on the
compressor.
Refrigerant Expansion Valve -
Remove and Install
5. Connect the electrical wires to the magnetic clutch.
SMCS Code: 7320-010-EV
6. Evacuate the system. Refer to the Service Manual,
SENR5664, “Refrigerant System - Evacuate” To replace the expansion valve, use the procedure
section in Testing and Adjusting. that follows. Refer to Service Manual, SENR5664,
“Troubleshooting Heating and Air Conditioning
7. Charge the system. Refer to the Service Manual, Control System” before service work is performed on
SENR5664, “Refrigerant System - Charge” the air conditioning system.
1. Recover the refrigerant.
8. For the correct system operation, refer to the
Service Manual, SENR5664, “Troubleshooting Note: Cap all disconnected lines and hoses.
Heating and Air Conditioning Control System”
section in Testing and Adjusting. 2. Remove the insulation and the clip. The insulation
and the clip hold the sensing bulb to the evaporator
Note: Refer to the Service Manual, SENR5664, outlet pipe.
“Refrigerant Compressor” in the Specifications
Section for the correct belt tension. 3. Disconnect the sensing line for pressure from the
evaporator outlet pipe.
9. For the oil level in the system, refer to Service
Manual, SENR5664, “Refrigerant Compressor 4. Loosen and remove the two connections at the
Oil - Check”. expansion valve. Remove the expansion valve.
Note: Check the O-ring seals. The seals must be

i01525664 in good condition and the seals must be properly
Refrigerant Accumulator - lubricated with the correct refrigerant oil before
assembly.
Remove and Install
5. Install the expansion valve for replacement and
SMCS Code: 1808-010-ZJ; 7320-010-ZJ tighten the two connections.
The refrigerant must be recovered before the 6. Tighten the pressure sensing connection on the
accumulator is removed. Refer to the Service evaporator outlet pipe.
Manual, SENR5664, “Refrigerant Recovery” section
in Testing and Adjusting. 7. Use a 8P-6355 Clip to hold the sensing bulb
onto the evaporator outlet pipe. The sensing bulb
Refer to the Service Manual, SENR5664, “Machine should be as close to the coil as possible. The
Preparation for troubleshooting” section in Testing bulb should be upstream of the pressure sensing
and Adjusting before service work is performed. connection on the evaporator outlet pipe. The
5P-7070 Insulation should be wrapped tightly
Remove the accumulator. The accumulator has an around the clip, the sensing bulb and the outlet
internal oil drain hole which could become plugged. pipe. There should be no insulation between the
The oil could be trapped inside the accumulator. It bulb and the outlet pipe.
is necessary to check for excessive oil when the
accumulator is changed. Add the same amount of 8. Tighten all the connections correctly.
oil that was drained from the old accumulator. Add
an additional 30 mL (1 fl oz) to the new accumulator 9. Evacuate the system. Refer to the Service Manual,
before the new accumulator is installed. Do not add SENR5664, “Refrigerant System - Evacuate”
oil if the compressor was changed also. Evacuate section in testing and adjusting.
the system and recharge the system. Refer to the
Service Manual, SENR5664, “Refrigerant System - 10. Charge the system with the correct amount of
Evacuate” section in Testing and Adjusting. Refer to refrigerant by weight. Refer to the Service Manual,
the Service Manual, SENR5664, “Refrigerant System SENR5664, “Refrigerant System - Charge”
- Charge” section in Testing and Adjusting. section in testing and adjusting.
152 SENR5664-11
i01224246 2. Disconnect the inlet hose (1) from the old

receiver-dryer at the air conditioner quick
Receiver-Dryer - Remove and disconnects.
Install
3. Connect the hose that was disconnected in Step 2
SMCS Code: 7322-010 to the inlet on the new receiver-dryer.
4. Disconnect the electrical connections on the old

receiver-dryer. Connect the electrical connections
to the new receiver-dryer.
5. Add 30 mL (1 fl oz) of refrigerant oil to the system.
Note: Do not add refrigerant oil if the compressor

was changed also.
6. Start the engine. Operate the air conditioning

system for one minute.
7. With the air conditioning system in operation,

disconnect the outlet hose (2) from the old
receiver-dryer. Disconnect the old receiver-dryer
at the air conditioner quick disconnects.
8. Stop the engine for five minutes. This allows the

air conditioning system to equalize pressure.
9. Connect the outlet hose (2) that was disconnected

in step 6 to the new receiver-dryer.
g00382493
Illustration 73
Top View of Receiver-Dryer
(1) Inlet
(2) Outlet
(3) Quick Disconnect Fittings
NOTICE
If the receiver-dryer does not have air conditioner
quick disconnects, the system must be completely
recovered, evacuated, and recharged after the re-
ceiver-dryer has been replaced.
The refrigerant that is in the system must be

recovered if the receiver-dryer does not have air
conditioner quick disconnects (3). Refer to the
Service Manual, SERN5664, “Refrigerant Recovery”
section in Testing and Adjusting before you remove
the receiver-dryer. If the receiver-dryer has air
conditioner quick disconnects (3) use the procedure
that follows.
Refer to Safety Requirements before service is

performed on the air conditioning system.
1. Stop the engine for five minutes. This allows the

air conditioning system to equalize the pressure.
SENR5664-11 153
i01224261 5. With the air conditioning system in operation,

disconnect the outlet hose (2) from the old in-line
In-Line Refrigerant Dryer - dryer.
Remove and Install
6. Stop the engine for five minutes in order to
SMCS Code: 7322-010-QT equalize the pressure in the air conditioning
system.
7. Connect the outlet hose (2) that was disconnected

in Step 5 to the outlet on the new in-line dryer.
Note: Do not add oil to the in-line dryer.
i00946003
Refrigerant Orifice Tube -

Remove and Install
SMCS Code: 7320-010-QT
The orifice tube may be located in the refrigerant line

near the evaporator inlet, or in the in-line dryer.
If the orifice tube is located in the refrigerant line near

the evaporator inlet use the procedure that follows. If
the orifice tube is located in the in-line dryer, refer to
Dryer Replacement.
Removing the Orifice Tube

Refer to Safety Requirements before service work is
performed on the air conditioning system.
g00654556
Illustration 74 The refrigerant must be recovered before removing
Typical In-Line Dryer the accumulator. Refer to the Service Manual,
(1) Inlet hose with air conditioner quick disconnects
SENR5664, “Refrigerant Recovery” section in testing
(2) Outlet hose with air conditioner quick disconnects and adjusting.
In order to replace the in-line dryer and the orifice NOTICE

tube that is in the in-line dryer, use the procedure Do not attempt to remove the orifice tube with pliers.
that follows. Do not twist or rotate the orifice tube in the tube as-
sembly.
Before any service work is performed on the
air conditioning system, refer to the Service
Manual, SENR5664, “Machine Preparation for
Troubleshooting” section in Testing and Adjusting.
1. Stop the engine for five minutes in order to

equalize the pressure in the air conditioning
system.
2. Disconnect the inlet hose (1) from the old in-line

dryer.
3. Connect the inlet hose that was disconnected in

Step 2 to the inlet on the new in-line dryer.
4. Start the engine and operate the air conditioning

system.
154 SENR5664-11
g00379603 g00381412
Illustration 75 Illustration 76
Orifice tube Removing the broken orifice tube
(1) O-Ring seals (3) Body
(2) Lugs (4) Drive screw
(3) Body (6) Extractor tip
(4) Drive screw
(5) Finger lock
6. For the removal of the orifice tube assembly, use
the extractor tip (6) on 1U-9890 Orifice Removal
1. Disconnect the high side line at the enlarged Tool. Insert the tool into the evaporator inlet tube
section of the evaporator inlet port. This will and thread the tool into the brass center of the
expose the orifice tube for removal. orifice tube.
2. Align the short fingers of the 1U-9890 Orifice 7. Repeat steps 3 and 4.
Removal Tool with the ribs of the orifice tube.
Insert the tool onto the tube until the tool bottoms 8. If only the brass center of the orifice tube is
out. removed, thread the tool into the plastic body and
repeat step 3 and 4.
3. Turn drive screw (4) clockwise. Turn far enough
to engage the lugs (2) on the orifice tube in the
finger lock (5). The finger lock (5) is part of the Orifice Tube Installation
removal tool.
1. Lubricate the O-Ring on the orifice tube with the
4. Hold the drive screw (4) stationary. Thread the proper clean refrigerant oil.
body (3) forward until the body makes contact
with the inlet port. 2. Place the orifice tube into the 1U-9890 Orifice
Removal Tool. Insert the orifice tube straight into
5. Continue holding the drive screw stationary, and the evaporator inlet tube without twisting until the
thread the body forward until the orifice tube tube is seated.
becomes free.
3. Disengage the removal tool from the orifice tube.
4. Use a new O-Ring that is lubricated with clean

refrigerant oil. Reconnect the high side line at the
enlarged section of the evaporator inlet port.
5. Do a leak test. Evacuate the system and recharge

the system. Refer to the Service Manual,
SENR5664, “Refrigerant Systems-Evacuate”
section in testing and adjusting. Also, refer to
the Service Manual, SENR5664, “Refrigerant
Systems-Charge” section in testing and adjusting.
SENR5664-11 155
Index Section
Index
A Machine Preparation for Troubleshooting ............. 72
Manifold Gauge Set (Refrigerant) - Install ........... 100
Air Conditioning System Troubleshooting ............. 83 Manifold Gauge Set (Refrigerant) - Remove ........ 117
Additional Refrigerant Circuit Problems for Orifice
Tube System .................................................... 97
False Seizure of the Compressor ...................... 84 P
Performance Checks for the Air Conditioning
System ............................................................. 87 Preparation of Air Conditioner Units for Seasonal
Problem Solving................................................. 88 Use ...................................................................... 66
Refrigerant Circuit Problems.............................. 88
Refrigerant Quick-Check Procedure for R-134a
Expansion Valve And Orifice Tube Systems .... 85 R
System Contamination....................................... 83
Receiver-Dryer ...................................................... 61
Moisture Indicator .............................................. 62
C Receiver-Dryer - Remove and Install .................. 152
Refrigerant Accumulator........................................ 64
Cab Air Filters........................................................ 67 Refrigerant Accumulator - Remove and Install.... 151
Refrigerant Compressor ....................................... 18,
22, 25–33, 35–36, 38, 40–42, 45–47, 49–52, 55
D Compressor ......................... 26–27, 31, 33, 37–39
V-belt.................................................................. 34
Disassembly and Assembly Section.................... 148 Refrigerant Compressor - Remove and Install .... 150
Refrigerant Compressor - Test ............................. 115
Procedures........................................................ 115
E Refrigerant Compressor Oil - Check ................... 106
Complete Check of Compressor Oil ................ 107
Electronic Heat Control - Test (Type 1)................ 120 Refrigerant Compressor Protection System .......... 56
Electronic Heat Control - Test (Type 2)................ 123 Refrigerant Condenser .......................................... 57
Electronic Heat Control - Test (Type 3)................ 125 Refrigerant Expansion Valve ................................. 59
Evaporator Coil...................................................... 57 Refrigerant Expansion Valve - Remove and
Install ................................................................. 151
Refrigerant Expansion Valve System .................... 58
G Refrigerant Leakage - Test .................................. 105
Dye................................................................... 105
General Information....................................... 53, 149 Leak Detector................................................... 105
General Troubleshooting Information .................... 73 Refrigerant Orifice Tube - Remove and Install .... 153
Glossary of Terms.................................................. 69 Refrigerant Orifice Tube System ........................... 63
Orifice Tube ....................................................... 64
Refrigerant Recovery............................................. 98
H Refrigerant System - Charge............................... 108
Adding Additional Refrigerant to an Air Conditioning
Heating and Air Conditioning Control System ....... 65 System that Has a Low Charge ...................... 114
Adjustable Thermostat ....................................... 65 Charging the System ........................................ 111
Nonadjustable Thermostat (Freeze Control Complete Charge of the System from a Refrigerant
System) ............................................................ 65 Tank with a Scale ............................................ 112
Heating System Schematic ................................... 66 Procedure for Labeling...................................... 111
Relationship Between Temperature and Pressure
(R-134a Refrigerant) ...................................... 109
I Refrigerant System - Evacuate............................ 101
Required Tools....................................................... 71
Identifying the Air Conditioning System................. 53
Important Safety Information ................................... 2
In-Line Refrigerant Dryer - Remove and Install ... 153 S
Specifications Section ............................................. 4

M System Capacities for Refrigerant....................... 127
Systems Operation Section ................................... 53
Machine Preparation for Disassembly and
Assembly ........................................................... 148
T
Table of Contents..................................................... 3
Testing and Adjusting ............................................ 98
Testing and Adjusting Section ............................... 71
Troubleshooting..................................................... 71
Troubleshooting Heating and Air Conditioning Control
System................................................................. 75
Electrical System ............................................... 76
Heating System.................................................. 75
Test Procedure for Testing Electrical Components
in the Air Conditioning System ......................... 76
Visual Inspection ................................................... 74
©2005 Caterpillar
All Rights Reserved Printed in U.S.A.

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Table of Contents Testing and Adjusting

Systems Operation Section

Testing and Adjusting Section

Specifications Section Part No.: 3E-1906

S/N: 2021-Up Part No.: 3E-1906

Part No.: 3E-1906 S/N: HAE1-Up

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 106-5122 Part No.: 3E-1906

Part No.: 106-5122 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 106-5122

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 106-5122, 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 106-5122 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 106-5122

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 Part No.: 3E-1906

Part No.: 3E-1906 (2) Pressure relief valve

Sealing pressure of pressure relief valve ICI ........................................................... KLEA 134a

Poly Alkaline Glycol Oil (PAG) Part No.: 163-0872

Part No.: 163-0872 Part No.: 163-0872

Part No.: 183-5106 Part No.: 163-0872

Part No.: 218-0324 Part No.: 163-0872

Maximum Current ...................................... 1.42 amp

(3) Pressure relief valve Part No.: 176-1865

S/N: GAD1-Up Part No.: 176-1895

Part No.: 176-1895 Voltage of magnetic clutch ............................ 24 VDC

Note: Used belt tension is for a belt that has been

Note: Use a Caterpillar 144-0235 Belt Tension

Displacement per revolution .... 188.0 mL (6.36 fl oz)

Maximum allowable speed ........................ 6000 rpm

Type of compressor ................................... TM-13HD i01714590

Displacement per revolution ......... 131 mL (4.4 fl oz) Refrigerant Compressor

Rated voltage of magnetic clutch .................. 12 VDC Part No.: 191-9028

(1) Belt tension

Note: Used belt tension is for a belt that has been

Note: Use a Caterpillar 144-1102 Belt Tightener.