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Product: WHEEL LOADER
Model: 992K WHEEL LOADER H4C
Configuration: 992K Wheel Loader H4C00001-UP (MACHINE) POWERED BY C32 Engine
Testing and Adjusting
Air Conditioning and Heating R134a for All Caterpillar Machines
Media Number -SENR5664-26 Publication Date -01/10/2014 Date Updated -06/10/2014
i05907599
Refrigerant System - Flush
SMCS - 1809-046
Personal injury can result from contact with refrigerant.
This system is under pressure at all times, even if the engine is not
running. Heat should never be applied to a charged system.
Contact with refrigerant can cause frost bite. Keep face and hands away
to help prevent injury.
Protective goggles must always be worn when refrigerant lines are
opened, even if the gauges indicate the system is empty of refrigerant.
Always use caution when a fitting is removed. Slowly loosen the fitting.
If the system is still under pressure, evacuate the system recovering the
refrigerant before removing the fitting.
Personal injury or death can result from inhaling refrigerant through a
lit cigarette.
Inhaling air conditioner refrigerant gas through a lit cigarette or other
smoking method or inhaling fumes released from a flame contacting air
conditioner 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.
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Personal injury can result from hot coolant. Any contact with hot
coolant or with steam can cause severe burns. Allow cooling system
components to cool before the cooling system is drained.
System Contamination and Flush Procedure
NOTICE
Debris in the air conditioning refrigerant circuit can cause the
compressor to fail. Use the following procedure for cleaning and
flushing the system.
This procedure provides a method and instructions to remove
contamination from the air conditioning system refrigeration circuit
and individual components. A primary instance where a system flush is
necessary is any time a refrigerant compressor has had an internal
failure, indicated by a locked or seized condition. The air conditioning
system refrigeration circuit and components must be cleaned and
flushed to remove any particles of metal or other foreign material.
Failure to properly flush the air conditioning circuit will damage or
shorten the operating life of the replacement compressor.
A general flow chart of the flush procedure is shown in Illustration 2. The detailed procedure is
shown in Step 1 through Step 19 below.
1. Identify the refrigerant and then recover the refrigerant. Refer to the Testing and Adjusting,
"Refrigerant Recovery" section.
2. Remove the compressor. Refer to the Disassembly and Assembly, "Refrigerant Compressor
- Remove and Install" section.
3. Remove the receiver-dryer or the in-line dryer. Refer to the Disassembly and Assembly,
"Receiver-Dryer - Remove and Install" section. For in-line dryers, refer to the Disassembly
and Assembly, "In-Line Refrigerant Dryer - Remove and Install" section.
4. Remove the accumulator. Refer to the Disassembly and Assembly, "Air Conditioner
Accumulator - Remove and Install" section.
5. Remove the expansion valve or the orifice tube. Refer to the Disassembly and Assembly,
"Expansion Valve - (Air Conditioner) Remove and Install" section. Refer to the
Disassembly and Assembly, "Orifice Tube (Air Conditioner) - Remove and Install" section.
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6. If necessary, remove the quick disconnect fittings from the dryer refrigerant lines.
NOTICE
In order to avoid component damage, do not flush system components
with anything other than 153-8538 Refrigerant Flushing Solution .
7. Replace any other failed component such as coils, fittings, etc..
Illustration 1 g01519693
(1) Multichannel Extruded Tube
(2) Manifold
(3) Manifold Baffle
8. Replace condenser coils that are parallel flow or multiple flow. Refer to Illustration 1 for a
reference example. Condenser coils that are parallel flow or multiple flow have small
passages. The proper flushing out of the passages will be difficult. Failure to replace the
condenser coils may reduce the cooling performance of the air conditioner and premature
failure of the compressor.
9. Flush the remainder of the system. Flush the air conditioning system with a 153-8537 Air
Conditioner Flushing Unit . Also, a 153-8537 Air Conditioner Flushing Unit can be used in
order to flush the system. Refer to the information that is provided with the flushing unit.
Flush the system with 153-8538 Refrigerant Flushing Solution .
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10. Blow out the air conditioning system with clean dry shop air for 5 to 10 minutes. Follow the
instructions that are provided with the flushing unit.
NOTICE
It is important that all of the flushing solvent is purged from the Air
Conditioning System. Failure to purge all of the solvent will result in
premature compressor failure. Components should be positioned in
order to ensure that no solvent is trapped in the system.
11. Install a new receiver-dryer or an in-line dryer. Refer to the Disassembly and Assembly,
"Receiver-Dryer - Remove and Install" section. For in-line dryers, refer to the Disassembly
and Assembly, "In-Line Refrigerant Dryer - Remove and Install" section.
12. Install a new accumulator, if necessary. Refer to the Disassembly and Assembly, "Air
Conditioner Accumulator - Remove and Install" section.
13. Install a new expansion valve or an orifice tube. Clean the original quick couplers or replace
the original quick couplers.
Note: If the Air Conditioning System has an in-line dryer, then the new orifice tube is
already contained inside the dryer.
14. Install new quick couplers to the dryer inlet and outlet lines, if necessary.
15. Install a new compressor.
16. Refer to the Testing and Adjusting, "Refrigerant System - Evacuate" section.
17. Add additional oil to the air conditioning system, if necessary. Refer to "Oil Charge After
System Flush".
Note: New compressors are shipped with oil in the compressors. In many instances, it is not
necessary to add extra oil to the air conditioning system.
18. Refer to the Testing and Adjusting, "Refrigerant System - Charge" section.
Note: Also, Refer to Specifications, "System Capacities for Refrigerant".
19. In order to ensure proper operation of the system, refer to the Testing and Adjusting,
"Performance Test" section.
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Illustration 2 g01519747
Oil Charge After System Flush
NOTICE
The addition of oil to the air conditioning system is applicable only
after the flush of the entire air conditioning system. If an air
conditioning system is overcharged with oil, the result is a decrease of
the cooling performance and damage to the compressor may occur.
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1. Locate the correct refrigerant charge for the machine that is being serviced. Refrigerant
charge can be found on a tag inside the cab or by referencing the Specifications, "System
Capacities for Refrigerant" section.
2. Locate the part number for the a/c compressor that is being serviced in the flush procedure.
3. Refer to table 1 or table 2 below for your particular application.
4. Use proper oil charging equipment. Usually, oil charge is a function that is provided by the
refrigerant service unit. Refer to 208-1316 Refrigerant Service Unit for an example. A
portable injection tool such as 9U-6494 Refrigerant Oil Injector can also provide the oil
charge function.
Table 1 contains the recommended charges for the a/c compressors that are listed below :
• 214-4302 Refrigerant Compressor Gp
• 217-4448 Refrigerant Compressor Gp
• 218-4994 Refrigerant Compressor Gp
• 218-6833 Refrigerant Compressor Gp
• 222-2276 Refrigerant Compressor Gp
• 248-3978 Refrigerant Compressor Gp
• 272-5767 Refrigerant Compressor Gp
• 276-9875 Refrigerant Compressor Gp
• 318-4258 Refrigerant Compressor Gp
Note: The new a/c compressors that are listed above contain 150 mL (5.1 oz) to 180 mL (6.1 oz)
of oil. Table 1 is only applicable for new compressors that contain 150 mL (5.1 oz) to 180 mL (6.1
oz) of oil. The total oil charge for the air conditioning system must equal the amount from Table 1
and the oil that is already contained inside the new compressor.
Table 1
Recommended Charges for the Air Conditioning System
Refrigerant Oil (1) (2)
-80
0.5 kg (1.0 lb)
-60
0.6 kg (1.25 lb)
-30
0.7 kg (1.5 lb)
0
0.8 kg (1.75 lb)
0
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0.9 kg (2.0 lb)
0
1.0 kg (2.25 lb)
0
1.1 kg (2.5 lb)
15
1.2 kg (2.75 lb)
33
1.4 kg (3 lb)
51
1.5 kg (3.25 lb)
69
1.6 kg (3.5 lb)
88
1.7 kg (3.75 lb)
107
1.8 kg (4 lb)
126
1.9 kg (4.25 lb)
146
2.0 kg (4.5 lb)
165
2.2 kg (4.75 lb)
185
2.3 kg (5.0 lb)
206
2.4 kg (5.25 lb)
226
2.5 kg (5.5 lb)
247
2.6 kg (5.75 lb)
268
2.7 kg (6.0 lb)
289
2.8 kg (6.25 lb)
311
2.9 kg (6.5 lb)
333
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3.1 kg (6.75 lb)
355
3.2 kg (7.0 lb)
377
3.3 kg (7.25 lb)
400
3.4 kg (7.5 lb)
422
3.5 kg (7.75 lb)
446
3.6 kg (8.0 lb)
469
3.7 kg (8.25 lb)
493
3.9 kg (8.5 lb)
517
4.0 kg (8.75 lb)
541
4.1 kg (9.0 lb)
(1)
The unit is mL.
(2)
Refer to the Specifications section in order to obtain the part number for the correct type of oil.
Table 2 contains the recommended charges for the a/c compressors that are listed below:
• 3E-1906 Refrigerant Compressor Gp
• 3E-1908 Refrigerant Compressor Gp
• 106-5122 Refrigerant Compressor Gp
• 114-9484 Refrigerant Compressor Gp
• 163-0872 Refrigerant Compressor Gp
• 178-9570 Refrigerant Compressor Gp
• 183-5106 Refrigerant Compressor Gp
• 218-0324 Refrigerant Compressor Gp
• 277-7245 Refrigerant Compressor Gp
• 299-2212 Refrigerant Compressor Gp
Note: The new a/c compressors that are listed above contain 300 mL (10.2 oz) of oil. Table 2 is
applicable only for new compressors that contain 300 mL (10.2 oz) of oil. The total oil charge for
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the air conditioning system must equal the total amount from Table 2 and the oil that is already
contained inside the new compressor.
Table 2
Recommended Charges for the Air Conditioning System
Refrigerant Oil (1)
-100
0.9 kg (2.0 lb)
-80
1.0 kg (2.25 lb)
-50
1.1 kg (2.5 lb)
-30
1.2 kg (2.75 lb)
0
1.4 kg (3 lb)
0
1.5 kg (3.25 lb)
0
1.6 kg (3.5 lb)
0
1.7 kg (3.75 lb)
0
1.8 kg (4 lb)
0
1.9 kg (4.25 lb)
11
2.0 kg (4.5 lb)
30
2.2 kg (4.75 lb)
50
2.3 kg (5.0 lb)
71
2.4 kg (5.25 lb)
91
2.5 kg (5.5 lb)
112
2.6 kg (5.75 lb)
133
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2.7 kg (6.0 lb)
154
2.8 kg (6.25 lb)
176
2.9 kg (6.5 lb)
198
3.1 kg (6.75 lb)
220
3.2 kg (7.0 lb)
242
3.3 kg (7.25 lb)
265
3.4 kg (7.5 lb)
287
3.5 kg (7.75 lb)
311
3.6 kg (8.0 lb)
334
3.7 kg (8.25 lb)
358
3.9 kg (8.5 lb)
382
4.0 kg (8.75 lb)
406
4.1 kg (9.0 lb)
(1)
The unit is mL.
Note: Always use new refrigerant oil and clean equipment to avoid contamination inside the air
conditioning system.
Note: Make sure that the equipment for oil injection does not contain air in the supply line to the
air conditioning system. This prevents air from being injected into the system which can lead to
poor cooling performance and possible system damage.
Note: Oil should only be charged into the discharge service port. Failure to charge the oil
correctly can cause damage to the compressor from liquid slugging with oil.
Copyright 1993 - 2018 Caterpillar Inc. Mon Mar 26 19:30:56 UTC+0200 2018
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