Field Installation of the 223-8415 Installation Arrangement (Air Conditioner and Heater) {7304, 7320} Caterpillar

Skid Steer Loader:

242 (S/N: CMB1-UP)

Multi Terrain Loader:

257 (S/N: CMM1-UP)

Introduction

Reference: Operation and Maintenance Manual, SEBU7468, "216, 226, 228, 236, 246, 248, 252, and 262 Skid Steer Loaders"

Reference: Operation and Maintenance Manual, SEBU7494, "247, 257, 267 and 277 Multi Terrain Loaders"

Reference: Disassembly and Assembly Manual, REHR4812, "Machine Systems - 236, 246, 252, and 262 Skid Steer Loaders"

Reference: Disassembly and Assembly Manual, REHR4815, "Machine Systems - 267 and 277 Multi Terrain Loaders"

Reference: Testing and Adjusting, SENR5664, "Air Conditioning and Heating R-134a for All Caterpillar Machines"

This Special Instruction provides the information that is necessary for the installation of the 223-8415 Installation Arrangement (Air Conditioner and Heater). This kit contains all of the parts that are needed for field installation of the air conditioner and heater.

Do not perform any procedure or do not order any parts until you have read the information that is contained in this instruction.

Parts Needed

Air Conditioner and Heater

The parts that are needed for installation of the 223-8415 Installation Arrangement (Air Conditioner and Heater) are identified in Table 1 and in Table 2.

Seat Belt

In order to accommodate the new air conditioner and heater unit, the current seat belt must be replaced. The new seat belts that are available are listed in Table 3.

Preparing the Machine

1. Park the machine on level ground.

2. Raise the lift arms fully and engage the loader lift arm brace.

3. Turn the engine start switch key to the OFF position.

Modifying the Joystick Support Assemblies

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Illustration 1	g00941494
(A) Left Hand Support Assembly (B) Right Hand Support Assembly (C) Vertical Floorplate

1. Remove the vertical floorplate (C) that is between the left hand support assembly (A) and the right hand support assembly (B). See Illustration 1.

   Retain the vertical floorplate.

   Retain the two bolts and the two hard washers.

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Illustration 2	g00944235
The left hand support assembly (A) 90 ± 1.5 mm (3.5 ± 0.06 inch) (B) 191 ± 1.5 mm (7.5 ± 0.06 inch) (C) 36 ± 1.5 mm (1.4 ± 0.06 inch) Radius (D) 4 ± 1.5 mm (0.16 ± 0.06 inch) (E) 75 ± 1.5 mm (3.0 ± 0.06 inch) (F) 25 ± 1.5 mm (0.9 ± 0.06 inch) Radius (G) 38.8 ± 1.5 mm (1.5 ± 0.06 inch) Radius (H) 75 ± 1.5 mm (3.0 ± 0.06 inch)

2. Cut the left hand support assembly (A) in order to provide cutout (1), cutout (2), and cutout (3), as shown. See Illustration 2.

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Illustration 3	g00948833
The right hand support assembly (J) 151 ± 1.5 mm (5.9 ± 0.06 inch) (K) 228 ± 1.5 mm (8.9 ± 0.06 inch) (L) 154 ± 1.5 mm (6.1 ± 0.06 inch) (M) 4 ± 1.5 mm (0.16 ± 0.06 inch) (N) 12.9 ± 1.5 mm (0.51 ± 0.06 inch) Radius

3. Cut the right hand support assembly (B ) in order to provide cutout (4), as shown. See Illustration 3.

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Illustration 4	g00948840
Enlarge the existing hole in the top of the right support assembly (B) in order to accommodate the new duct. (P) 8 ± 1.5 mm (0.32 ± 0.06 inch) (Q) 6 ± 1.5 mm (0.24 ± 0.06 inch) (R) 16 ± 1.5 mm (0.63 ± 0.06 inch)

4. Also, enlarge the hole in the top of the right hand support assembly (B). See Illustration 4.

   Note: Cut and remove area (5), area (6), and area (7) per the specified dimensions.

5. Perform Step 5.a through Step 5.r in order to install the tubing, the ducts, and the louvers.
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   Illustration 5	g00946007
   (A) Left Hand Support Assembly (B) Right Hand Support Assembly (17) 7K-1181 Cable Strap (38) 9X-2045 Screw (68) 218-0666 Louver As (72) 219-4359 Duct (73) 219-4360 Duct (74) 219-4361 Tubing (75) 219-4362 Cover (RH) (76) 219-4363 Cover (LH)

   1. Place the 231 cm (91 inch) length of 219-4361 Tubing (74) on a flat surface. Cut the tubing into the following lengths.
      • Three 31 cm (12 inch) lengths

      • Two 69 cm (27 inch) lengths

   2. Assemble two 31 cm (12 inch) lengths of tubing to the 219-4359 Duct (72). See Illustration 5.

      Secure the tubing to the duct with two 7K-1181 Cable Straps (17) .

   3. Insert the duct with the two lengths of tubing into the opening that is provided in the top of the right hand support assembly (B) .

   4. Install the 219-4362 Cover (RH) (75) on the front of the right hand support assembly (B) .

      Install the cover with four 9X-2045 Screws (38) .

      Tighten the screws to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

   5. Pull the ends of the tubing through the two openings in the cover.

   6. Install a 218-0666 Louver As (68) on the end of each length of tubing. Secure each louver assembly to the tubing with a 7K-1181 Cable Strap (17) .

      Note: Cut one coil of the tubing's helix in order to facilitate installation of the louver. Then install the cable strap beyond the cut in order to keep the cut from continuing.

   7. Seat the two louver assemblies in the openings on the 219-4362 Cover (RH) (75) .

      Note: The louver assemblies will snap into position in the openings that are provided on the cover.

   8. Assemble the three lengths of tubing that remain to the 219-4360 Duct (73) .

      Note: Install the 31 cm (12 inch) length of tubing in the front position of duct (73), as shown. See Illustration 5.

      Secure each length of tubing to the duct with a 7K-1181 Cable Strap (17) .

   9. Insert the three lengths of tubing that are assembled on the 219-4360 Duct (73) into cutout (1) in the left hand support assembly (A) .

   10. Also, push the end of the 219-4360 Duct (73) into cutout (1) in the left hand support assembly (A) .

   11. Then, fit the opposite end of the 219-4360 Duct (73) into opening (4) in the base of the right hand support assembly (B). See Illustration 5.

       Note: This end of the 219-4360 Duct (73) will fit over the end of the 219-4359 Duct (72) which is inside the right hand support assembly (B) .

   12. Install the 219-4363 Cover (LH) (76) on the front of the left hand support assembly (A) .

       Install the cover with four 9X-2045 Screws (38) .

       Tighten the screws to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

   13. Pull the end of two lengths of tubing through the openings in the cover.

       Note: For maximum air flow, route the tubing that is in the center position of duct (73) to the top opening in the cover, as shown. See Illustration 5.

   14. Install a 218-0666 Louver As (68) on the end of the two lengths of tubing. Secure each louver assembly to the tubing with a 7K-1181 Cable Strap (17) .

       Note: Cut one coil of the tubing's helix in order to facilitate installation of the louver. Then install the cable strap beyond the cut in order to keep the cut from continuing.

   15. Seat the two louver assemblies in the openings on the 219-4363 Cover (LH) (76) .

       Note: The louver assemblies will snap into position in the openings that are provided on the cover.

   16. Pull the end of the remaining length of tubing through cutout (3) in the left hand support assembly (A) .

   17. Install a 218-0666 Louver As (68) on the end of the tubing. Secure the louver assembly to the tubing with a 7K-1181 Cable Strap (17) .

       Note: Cut one coil of the tubing's helix in order to facilitate installation of the louver. Then install the cable strap beyond the cut in order to keep the cut from continuing.

   18. Seat the louver assembly in the cutout in the left hand support assembly (A) .

       Note: The louver assembly will snap into position in the cutout in the left hand support assembly.

6. Reinstall the 154-3965 Floorplate (Vertical) (D) between the left hand support assembly (A) and the right hand support assembly (B). See Illustration 1.

   Use the three 8T-4205 Hard Washers and the three 5C-9553 Bolts that were removed in Step 1.

   Tighten the bolts to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

Installing the Cab Air Filter

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Illustration 6	g00920073
Remove the plate.

1. If equipped, remove the plate that is indicated in Illustration 6. Remove the plate by removing the four nuts and the four washers that secure the plate to the cab. Also, remove the four studs.

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Illustration 7	g00946020
Assemble the cab air filter and install the cab air filter. (8) 5C-2890 Nut (32) 8T-4205 Hard Washer (55) 142-9290 Filter Cover (56) 142-9291 Filter (57) 152-4876 Seal

2. Assemble the 142-9290 Filter Cover (55), the 142-9291 Filter (56), and the 152-4876 Seal (57). See Illustration 7.

   Note: To install seal (57), remove the protective paper strip from the seal and press the seal firmly against the cover.

3. Install the four 199-6619 Clinch Studs (62).

   Note: Press fit the new studs from the inside of the cab.

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Illustration 8	g00920087
The cab air filter

4. Place the assembled cab air filter in position on the four 199-6619 Clinch Studs (62). See Illustration 8.

   Secure the cab air filter with four 5C-2890 Nuts (8) and four 8T-4205 Hard Washers (32) .

   Tighten the nuts to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

5. Disengage the loader lift arm brace and lower the lift arms fully.

Installing the Air Conditioner and Heater Unit

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Illustration 9	g00920095
Remove the plate.

1. Remove the plate that is identified in Illustration 9.

   Remove the plate by removing the four screws, the four hard washers, and the four nuts that secure the plate to the cab floor.

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Illustration 10	g00927520
View of the bottom of the cab (E) Cut and remove the insulating material. (F) Remove the cable strap and the cap.

2. Cut and remove the portion of insulating material (E) from the bottom of the cab. Also remove the cable strap and the cap (F) from the harness connector. See Illustration 10.

3. Place the 219-7182 Air Conditioner Gp (81) in position inside the cab.

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Illustration 11	g00946042
(26) 8T-4138 Bolt (32) 8T-4205 Hard Washer

4. Install four 8T-4138 Bolts (26) and four 8T-4205 Hard Washers (32) in order to mount the air conditioner and heater unit to the cab floor. See Illustration 11.

   Tighten the bolts to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

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Illustration 12	g00946045
(42) 9X-7381 O-Ring Seal (86) 220-8134 Orifice Tube As

5. Install the 220-8134 Orifice Tube As (86). Use a 9X-7381 O-Ring Seal (42) in the connection. See Illustration 12.

   Note: Lubricate the O-ring seal with a mineral based refrigerant oil that is compatible with the R134a refrigerant.

   Tighten the connector to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

6. Connect the triangular shaped plug to the triangular shaped receptacle. Secure this connection with a 3S-2093 Cable Strap (5) .

   Note: The remaining connector, which is addressed later in this instruction, mates to a connector on the 220-5527 Harness (Cab) (84).

Installing the Condenser

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Illustration 13	g00946060
(16) 6V-7357 Bolt (32) 8T-4205 Hard Washer (51) 129-3178 Locknut (82) 220-0163 Suction Fan Gp (87) 220-8155 Condenser Coil As

1. Install the two 220-0163 Suction Fan Gp (82) to the 220-8155 Condenser Coil As (87). See Illustration 13.

   Use eight 6V-7357 Bolts (16), sixteen 8T-4205 Hard Washers (32), and eight 129-3178 Locknuts (51) .

   Tighten the locknuts to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

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Illustration 14	g00946061
(9) 5C-7261 Nut (33) 8T-4224 Hard Washer

2. Install the condenser in the engine compartment in the opening that is provided on the firewall. See Illustration 14.
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   Illustration 15	g00940354
   Locating dimensions for mounting holes (R) 10.5 mm (0.4 inch) (S) 80.2 mm (3.2 inch) (T) 119.6 mm (4.7 inch)

   1. Position the condenser so that the two weld studs on the left mounting flange extend through the two holes that are provided on the left side of the opening in the firewall.

      Note: For machines without holes on the left side of the firewall, drill two 9.0 mm (0.4 inch) holes per Illustration 15.

      Use three 5C-7261 Nuts (9) and three 8T-4224 Hard Washers (33) in order to mount the condenser in the firewall.

      Tighten the nuts to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

Modifying the Muffler

Illustration 16	g00935866
Rear view of the muffler

1. For machines without turbochargers, grind the rear lip of the muffler in order to provide additional clearance for the alternator wiring. Remove material between the 5 o'clock position and the 8 o'clock position, as shown. See Illustration 16.

   Note: Remove material to the end cap of the muffler. Do not penetrate the end cap.

2. Paint the area that was modified in order to prevent rusting.

3. For 236 machines, rotate the muffler clamp for 45° so that the clamp bolt is to the rear of the machine.

Installing the Compressor and the Alternator

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Disconnect batteries before performance of any service work.

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Illustration 17	g00947783
(G) Belt Guard (H) V-Belt (J) Bracket (K) Bracket (L) Alternator

1. Remove belt guard (G), V-belt (H), and alternator (L) from the engine. See Illustration 17.

   See the "Alternator Removal Procedure" in the engine section of the Disassembly and Assembly Manual for your machine.

2. Also, remove bracket (J) and bracket (K) .

   Note: Discard these components with the mounting hardware that was removed.

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Illustration 18	g00946149
(3) 2P-6818 V-Belt (13) 5P-4116 Hard Washer (19) 7X-7729 Washer (22) 8T-0342 Bolt (23) 8T-4121 Hard Washer (24) 8T-4133 Nut (28) 8T-4189 Bolt (29) 8T-4196 Bolt (34) 8T-5436 Bolt (36) 8T-7586 Bolt (37) 9R-5383 Boss (67) 216-6152 Bracket (69) 218-4994 Refrigerant Compressor Gp (77) 219-4368 Bracket (78) 219-4369 Bracket

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Illustration 19	g00946150
(13) 5P-4116 Hard Washer (23) 8T-4121 Hard Washer (24) 8T-4133 Nut (28) 8T-4189 Bolt (30) 8T-4198 Bolt (63) 203-5492 Alternator Gp (79) 219-4373 Bracket (85) 220-8129 V-Belt

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Illustration 20	g00946151
(B) 19° ± 2° (2) 1P-6356 Plate (5) 3S-2093 Cable Strap (7) 4P-8134 Clip (35) 8T-6466 Bolt (40) 9X-7378 O-Ring Seal (49) 114-5333 Pressure Switch (50) 125-2796 Fitting As (94) 225-0297 Fitting As

3. Assemble the 218-4994 Refrigerant Compressor Gp (69) .

   1. Remove the protective cap from the compressor in order to access the suction inlet port and the discharge pressure port.

   2. Place the 125-2796 Fitting As (50) in the suction inlet port and place the 225-0297 Fitting As (94) in the discharge pressure port. Then position the 1P-6356 Plate (2) over the two fittings. See Illustration 20.

   3. Assemble the 4P-8134 Clip (7) onto the 8T-6466 Bolt (35). Then install the bolt in the compressor in order to secure the two fittings and the clip.

      Tighten the bolt to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

   4. Install the 114-5333 Pressure Switch (49) in the side port of the 225-0297 Fitting As (94). See Section A-A of Illustration 20.

      Use a 9X-7378 O-Ring Seal (40) in the installation of the pressure switch.

      Note: Lubricate the O-ring seal with a mineral based refrigerant oil that is compatible with the R134a refrigerant.

      Tighten the switch assembly to a torque of 8 ± 1.5 N·m (5.9 ± 1.1 lb ft).

4. Assemble the 218-4994 Refrigerant Compressor Gp (69) to the 216-6152 Bracket (Compressor Support) (67). See Illustration 18.

   1. Insert a 8T-5436 Bolt (34) through a 8T-4121 Hard Washer (23), through the rear mounting flange on the top of the compressor, and through the boss that is provided on the 216-6152 Bracket (Compressor Support) (67) .

   2. Continue to insert the bolt through the front mounting flange on the top of the compressor and into the weld nut on the 219-4373 Bracket (Alternator Adjustment) (79). See Illustration 18 and Illustration 19.

      Note: Do not tighten the bolt fully.

5. Secure the 219-4369 Bracket (Compressor Adjustment) (78) to the two front mounting flanges on the bottom of the compressor. See Illustration 18.

   1. Insert a 8T-4196 Bolt (29) through two 8T-4121 Hard Washers (23) and through the mounting flange.

      Note: The bolt must be inserted from the rear of the mounting flange.

   2. Continue to insert the bolt through two 8T-4121 Hard Washers (23) and into the weld nut on the 219-4369 Bracket (Compressor Adjustment) (78) .

   3. Repeat Step 5.a and Step 5.b in order to secure the bracket to the remaining front mounting flange on the bottom of the compressor.

   4. Tighten the two bolts to a torque of 30 ± 3 N·m (22 ± 2 lb ft).

6. Install the 219-4368 Bracket (Alternator Support) (77) on the compressor. See Illustration 18.

   1. Insert a 8T-5436 Bolt (34) through a 8T-4121 Hard Washer (23), through the rear flange on the top of the compressor, and through the 219-4368 Bracket (Alternator Support) (77) .

   2. Continue to insert the bolt through the front flange on the top of the compressor and into the weld nut on the 219-4369 Bracket (Compressor Adjustment) (78) .

      Note: Do not tighten the bolt at this point fully.

7. Mount the compressor assembly to the engine block. See Illustration 18.

   1. Hold the compressor assembly in place on the engine. At Location (A), install a 8T-0342 Bolt (22) and a 8T-4121 Hard Washer (23) in order to secure the front of the support bracket to the engine block.

   2. At Location (B), install a 8T-4189 Bolt (28) and a 5P-4116 Hard Washer (13) in order to secure the side of the support bracket to the engine block.

   3. Raise the compressor in order to access the lower mounting hole. At Location (C), install a 8T-4189 Bolt (28) and a 5P-4116 Hard Washer (13) in order to secure the side of the support bracket to the engine block.

   4. First, tighten the front mounting bolt to a torque of 30 ± 3 N·m (22 ± 2 lb ft). Then, tighten the two side mounting bolts to a torque of 30 ± 3 N·m (22 ± 2 lb ft).

8. Install the V-belt. See Illustration 18.

   1. Position the 2P-6818 V-Belt (3) around the three pulleys.

   2. Insert a 8T-7586 Bolt (36) through a 7X-7729 Washer (19) and through the compressor adjustment bracket (78) .

   3. Then insert the bolt through the 9R-5383 Boss (37) and the hole in the timing case at Location (D) .

   4. Secure the bolt with a 5P-4116 Hard Washer (19) and a 8T-4133 Nut (24) .

      Note: Tighten the bolt so that the compressor is secure, but the compressor can be moved in order to tension the V-belt.

9. Tension the V-belt.

   Refer to the procedure for adjusting the tension of the V-Belt in the Operation and Maintenance Manual for your machine.

   The tension that is recommended for the V-belt is provided in Table 4.

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   Table 4

   Belt	Belt Tension
   	Initial (1)	Used (2)
   5L-3834 V-Belt	534 ± 22 N (120 ± 5 lb)	400 ± 44 N (90 ± 10 lb)

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   ( 1 )	A new belt
   ( 2 )	A belt is considered to be used after 30 minutes of operation.

   Note: Tension the V-belt again after 30 minutes of operation at the rated speed.

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   Table 5

   Recommended Tooling
   Part Number	Description
   144-0235	Belt Tension Gauge

   Note: When you tension the V-belt, keep the tension bar parallel to the adjustment bracket plate in order to prevent bending of the bracket.

   1. Tension the V-belt.

   2. Maintain V-belt tension and tighten the 8T-7586 Bolt (36) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

10. At Location (E), loosen the 124-6264 Hose Clamp for the radiator hose. See Illustration 19.

    Rotate the hose clamp for 90° in order to prevent interference with the new alternator. Tighten the hose clamp to a torque of 12 ± 1 N·m (9 ± 1 lb ft).

11. Install the new alternator. See Illustration 19.

    1. Place the 203-5492 Alternator Gp (63) in position. Install a 8T-4198 Bolt (30), two 8T-4121 Hard Washers (23), and a 8T-4133 Nut (24) in order to secure the alternator in position. Hand tighten the nut.

    2. Place the 220-8129 V-Belt (85) around the two pulleys.

    3. Install the 8T-4189 Bolt (28) and the 5P-4116 Hard Washer (13) in the top flange of the alternator in order to loosely secure the alternator.

    4. Adjust the tension of the alternator belt. Use a long screwdriver with a thick shaft in order to tension the V-belt. For leverage, position the screwdriver between the top of the compressor and the alternator on the engine side of the alternator adjustment bracket. See Table 4 for the recommended belt tension.

    5. Maintain belt tension. Secure the alternator by tightening the 8T-4189 Bolt (28) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

    6. Tighten the 8T-4198 Bolt (30) that secures the alternator to the alternator support bracket (77). This bolt was hand tightened in Step 11.

       Tighten the bolt to a torque of 30 ± 7 N·m (22 ± 5 lb ft).

    7. Tighten the 8T-5436 Bolt (34) into the weld nut on the alternator adjustment bracket (79). This bolt was hand tightened in Step 4.

       Tighten this bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

    8. Tighten the 8T-5436 Bolt (34) into the weld nut on the compressor adjustment bracket (78). This bolt was hand tightened in Step 6.

       Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Installing the Air Conditioner Lines

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Illustration 21	g00946173
(41) 9X-7380 O-Ring Seal (42) 9X-7381 O-Ring Seal (43) 9X-7382 O-Ring Seal (44) 9X-7383 O-Ring Seal (71) 219-4343 Hose As (88) 223-8389 Hose As (89) 223-8391 Hose As (90) 223-8401 Hose As for 242 Machines (91) 223-8407 Hose As for 257 Machines

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Illustration 22	g00946178
Assembling and mounting the accumulator for 242 machines (D) 30° ± 3° (12) 5P-0802 Seal (23) 8T-4121 Hard Washer (25) 8T-4136 Bolt (47) 101-8296 Clip (61) 186-6190 Refrigerant Accumulator (64) 215-3932 Bracket

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Illustration 23	g00948837
Assembling and mounting the accumulator for 257 machines (E) 30° ± 3° (F) 90° ± 3° (12) 5P-0802 Seal (23) 8T-4121 Hard Washer (25) 8T-4136 Bolt (47) 101-8296 Clip (61) 186-6190 Refrigerant Accumulator (64) 215-3932 Bracket

1. Assemble the 186-6190 Refrigerant Accumulator (61) to the 215-3932 Bracket (64). See Illustration 22.

   1. Install a 150 mm (6 inch) length of the 5P-0802 Seal (12) on the concave surface of both 101-8296 Clips (47) .

      Note: Remove the protective strip from the back of the seal and press the seal to the clips.

   2. Place the clips around the 186-6190 Refrigerant Accumulator (61) so that the two clips encircle the body of the accumulator.

      Note: Orient the accumulator in the clips per Section C-C of Illustration 22 for 242 machines. Orient the accumulator in the clips per Section C-C of Illustration 23 for 257 machines.

   3. Align the mounting holes in the two clips with the mounting holes in the bosses that are provided on the 215-3932 Bracket (64) .

      Secure the accumulator to the bracket with two 8T-4136 Bolts (25) and two 8T-4121 Hard Washers (23). Hand tighten the two bolts at this time.

2. Install the accumulator and the 215-3932 Bracket (64) in the machine.
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   Illustration 24	g00946574
   Locating dimensions for mounting holes for the accumulator bracket for 242 machines (AA) 95 mm (3.74 inch) (BB) 50 mm (1.97 inch) (CC) 370 mm (14.6 inch) (DD) 440 mm (17.3 inch) (EE) 510 mm (20.1 inch)

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   Illustration 25	g00946577
   Locating dimensions for mounting holes for the accumulator bracket for 257 machines (AA) 38 mm (1.5 inch) (BB) 83 mm (3.27 inch) (CC) 31.5 mm (1.24 inch) (DD) 101.5 mm (3.9 inch) (EE) 171.5 mm (6.8 inch)

   1. Place the accumulator and the 215-3932 Bracket (64) in the machine.

      For 242 machines, match the three mounting hole in the bracket with the three mounting holes in the right side of the belly plate. For 257 machines, match the three mounting holes in the bracket with the three mounting holes in the right side plate.

      Note: For machines without mounting holes, drill three 11 mm (0.4 inch) holes per Illustration 24 for 242 machines or drill three 11 mm (0.4 inch) holes per Illustration 25 for 257 machines.

   2. Install the bracket with three 8T-4136 Bolts (25) and three 8T-4121 Hard Washers (23) .

      Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

3. Install the 219-4343 Hose As (71) between the air conditioner and the condenser. See Illustration 21.
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   Illustration 26	g00946179
   Bottom view of air conditioner and heater unit (14) 6D-1641 Clip (42) 9X-7381 O-Ring Seal (43) 9X-7382 O-Ring Seal (71) 219-4343 Hose As (88) 223-8389 Hose As

   1. Connect the end of hose assembly (71) with the 90° stem to the 220-8134 Orifice Tube As (86) that is installed on the inlet of the air conditioner. See Illustration 26.

      Use a 9X-7381 O-Ring Seal (42) for this connection.

      Note: Lubricate the O-ring seal with a mineral based refrigerant oil that is compatible with the R134a refrigerant.

      Tighten the coupling to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

   2. Connect the end of hose assembly (71) with the 45° stem to the outlet of the condenser. The outlet is the bottom connector on the condenser. See Illustration 21.

      Use a 9X-7380 O-Ring Seal (41) for this connection.

      Note: Lubricate the O-ring seal with a mineral based refrigerant oil that is compatible with the R134a refrigerant.

      Tighten the coupling to a torque of 14 ± 4 N·m (10 ± 3 lb ft).

4. Install the 223-8389 Hose As (88) between the air conditioner and the accumulator. See Illustration 21.

   1. Connect the end of hose assembly (88) with the long 90° stem to the outlet for the air conditioner.

      Use a 9X-7382 O-Ring Seal (43) for this connection.

      Tighten the coupling to a torque of 40 ± 4 N·m (30 ± 3 lb ft).

   2. Connect the end of hose assembly (88) with the short 90° stem to the inlet for the accumulator. The inlet is the connection on the side of the accumulator.

      Use a 9X-7383 O-Ring Seal (44) for this connection.

      Note: Lubricate the O-ring seal with a mineral based refrigerant oil that is compatible with the R134a refrigerant.

      Tighten the coupling to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

5. Install the 223-8391 Hose As (89) between the compressor and the condenser. See Illustration 21.

   1. Connect the end of hose assembly (89) with the straight stem to the outlet for the compressor. The outlet is the smaller port on the left side of the compressor.

      Use a 9X-7381 O-Ring Seal (42) for this connection.

      Note: Lubricate the O-ring seal with a mineral based refrigerant oil that is compatible with the R134a refrigerant.

      Tighten the coupling to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

   2. Connect the end of hose assembly (89) with the 90° stem to the inlet for the condenser. The inlet is the top connection on the condenser.

      Use a 9X-7381 O-Ring Seal (42) for this connection.

      Note: Lubricate the O-ring seal with a mineral based refrigerant oil that is compatible with the R134a refrigerant.

      Tighten the coupling to a torque of 27 ± 4 N·m (20 ± 3 lb ft).

6. For 242 machines, install the 223-8401 Hose As (90) between the compressor and the accumulator. For 257 machines, install the 223-8407 Hose As (91) between the compressor and the accumulator. See Illustration 21.

   1. Connect the end of hose assembly with the 45° stem to the inlet for the compressor. The inlet is the larger port on the right side of the compressor.

      Use a 9X-7382 O-Ring Seal (43) for this connection.

      Note: Lubricate the O-ring seal with a mineral based refrigerant oil that is compatible with the R134a refrigerant.

      Tighten the coupling to a torque of 40 ± 4 N·m (30 ± 3 lb ft).

   2. Connect the end of hose assembly with the 180° stem to the connector on the bottom of the accumulator.

      Use a 9X-7383 O-Ring Seal (44) for this connection.

      Note: Lubricate the O-ring seal with a mineral based refrigerant oil that is compatible with the R134a refrigerant.

      Tighten the coupling to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

      Note: Orient the accumulator within the bracket, as shown. See Illustration 22 and Illustration 28. Tighten the 8T-4136 Bolts (20) that are used to secure the accumulator inside the clips. Tighten the bolts to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

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Illustration 27	g00946286
Securing the hose assemblies (15) 6D-4636 Clip (52) 130-9864 Bolt (54) 137-6722 Clip (59) 165-0142 Hard Washer

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Illustration 28	g00946856
(15) 6D-4636 Clip (23) 8T-4121 Hard Washer (24) 8T-4133 Nut (25) 8T-4136 Bolt (64) 215-3932 Bracket (65) 215-3933 Bracket (90) 223-8401 Hose As (91) 223-8407 Hose As

7. Secure the hose assemblies, as shown. See Illustration 27 and Illustration 28.

   1. At Location (F), use a 6D-1641 Clip (14) to secure the hose to the mounting stud on the back wall of the cab.

      Use a 8T-4133 Nut (24), and a 8T-4121 Hard Washer (23) to secure the hose.

      Note: Hand tighten the bolt at this point.

   2. At Location (G), use a 6D-4636 Clip (15) to secure the hose in tandem with the two existing hose clips. See Section D-D in Illustration 27.

      Note: The existing hose clips secure two hoses for the hydraulic oil cooler and one hose for the hydraulic fan.

      The torque for the existing 8T-4133 Nut is 55 ± 10 N·m (41 ± 7 lb ft).

   3. At Location (H), use a 137-6722 Clip (54) to secure the hose to the engine block.

      Use a 130-9864 Bolt (52) and a 165-0142 Hard Washer (59) to secure the clip.

      Tighten the bolt to a torque of 160 ± 30 N·m (118 ± 22 lb ft).

   4. At Location (J), use a 215-3933 Bracket (65) and a 6D-4636 Clip (15) to secure the hose to the front of the flywheel housing.

      Remove the two bolts and two washers that are used to secure the adapter plate, as shown. See Illustration 28.

      Install the 215-3933 Bracket (65) with the two bolts and with the two washers that were removed. Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

      Install the 6D-4636 Clip (15) in order to secure the hose. See Detail F in Illustration 28.

      Use a 8T-4136 Bolt (25), two 8T-4121 Hard Washers (23), and a 8T-4133 Nut (24) to secure the clip to the bracket. Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 29	g00946857
(4) 2W-1745 Spacer (27) 8T-4178 Bolt

8. At Location (K), install the 2W-1745 Spacer (4) in order to move the two hydraulic oil cooler lines away from the firewall. See Illustration 29.

   Use a 8T-4178 Bolt (27) to reinstall the existing hose clip with the new spacer.

   Tighten the bolt to a torque of 55 ± 10 N·m (401 ± 7 lb ft).

Installing the Heater Lines

Illustration 30	g00947189
(M) Heater Inlet (Left Connector) (N) Heater Outlet (Right Connector) (O) Radiator Inlet (P) Engine Block Outlet

The heater lines are installed between the following components. See Illustration 30.

• The engine block outlet (P) and the heater inlet (M) .

• The heater outlet (N) and the radiator inlet (O)

1. Cut two 2260 mm (89 inch) lengths of the 136-1953 Hose (53).

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Illustration 31	g00947001
(1) 1L-2279 Elbow (10) 5K-6875 Adapter (14) 6D-1641 Clip (20) 8F-8151 Shutoff Valve (21) 8T-0154 Hose Clamp (23) 8T-4121 Hard Washer (24) 8T-4133 Nut (25) 8T-4136 Bolt (45) 004-6810 Elbow (53) 136-1953 Hose (60) 183-7120 Hose Guard (70) 219-4328 Elbow

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Illustration 32	g00947813
View of heater inlet hose (M) and heater outlet hose (N) Orientation of hose mountings at Location (F) and at Location (L) (A) 20° ± 5° (B) 30° ± 5°

2. Install the two lengths of hose on the heater inlet (M) and the heater outlet (N). See Illustration 31.

   Use two 8T-0154 Hose Clamps (21) to install the hoses.

   Orient the hose clamps per Illustration 32. Tighten the hose clamps to a torque of 6 ± 1.0 N·m (4.4 ± 0.7 lb ft).

   Note: Pull the hoses tightly between the heater connections and Location (L) .

3. Install one 183-7120 Hose Guard (60) on each length of hose. Position each hose guard on the section of the hose between the rear cab wall and the engine firewall.

4. Route both hoses up the rear wall of the cab and then route both hoses into the engine compartment. See Illustration 32.

   At Location (F), install a 6D-1641 Clip (14) in tandem with the clip that was installed in order to secure the two hoses for the air conditioner.

   Note: Use the 8T-4121 Hard Washer (23) and the 8T-4133 Nut (24) that was previously installed.

   At Location (L), install a 6D-1641 Clip (14), a 8T-4121 Hard Washer (23), and a 8T-4133 Nut (24) in order to secure the hoses.

   Tighten both 8T-4133 Nuts (24) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 33	g00947807
Orientation of mounting clip at Location (M) (C) 75° ± 5°

5. At Location (M), secure the hoses with a clip to the threaded boss that is provided on the back of the engine firewall. See Illustration 33.

   Use a 6D-1641 Clip (14), a 8T-4121 Hard Washer (23), and a 8T-4136 Bolt (25) at this location.

   Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Note: Pull the hoses tightly between Location (L) and Location (M) with the cab in the raised position. See Illustration 34.

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Illustration 34	g00947203
Pull hoses tightly between Location (L) and Location (M) with the cab in the raised position. (60) 183-7120 Hose Guard

6. Remove the plug in the radiator housing for installation of the heater outlet hose.

7. Assemble the 1L-2279 Elbow (1) and the 004-6810 Elbow (45) for the hose connection for the radiator inlet. See Illustration 31.

   Install this assembly in the radiator inlet.

   Tighten this assembly to a torque of 25 ± 6 N·m (18 ± 4 lb ft).

   Note: Use thread sealant in the assembly of the components and in the installation of this assembly.

8. Route the heater outlet hose to the radiator inlet.

   Note: Route the heater outlet hose between the firewall and the hydraulic oil cooler lines.

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Illustration 35	g00947803
Orientation of hose connection at radiator inlet (O) (D) 45° ± 5° (E) 90° ± 5°

9. Install the heater outlet hose to the 004-6810 Elbow (45) at the radiator inlet. See Illustration 35.

   Use a 8T-0154 Hose Clamp (21) to secure the hose.

   Orient the hose clamp, as shown. Tighten the hose clamp to a torque of 6 ± 1.0 N·m (4.4 ± 0.7 lb ft).

10. Remove the plug in the engine block for installation of the heater inlet hose.

11. Assemble the 8F-8151 Shutoff Valve (20), the 5K-6875 Adapter (10), and the 219-4328 Elbow (70) for the hose connection to the engine block. See Illustration 31.

    Install this assembly in the engine block.

    Tighten this assembly to a torque of 25 ± 6 N·m (18 ± 4 lb ft).

    Note: Use thread sealant in the assembly of these components and in the installation of this assembly.

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Illustration 36	g00947805
Orientation of hose connection at engine block outlet (P) (F) 150° ± 5°

12. Route the heater inlet hose to the engine block outlet. Install the hose to the 8F-8151 Shutoff Valve (20) with a 8T-0154 Hose Clamp (21). See Illustration 36.

    Orient the hose clamp, as shown. Tighten the hose clamp to a torque of 6 ± 1.0 N·m (4.4 ± 0.7 lb ft).

    Note: Make sure that the shutoff valve, the hose clamp, and the elbows do not contact the coolant hose. Also, make sure that these components are at least 10 mm (0.4 inch) from the radiator fan guard when the radiator is lowered.

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Illustration 37	g00947205
Install the edging around the opening in the firewall. (39) 9X-2092 Edge Strip

13. Install the 9X-2092 Edge Strip (39) in order to protect the hoses from wear. See Illustration 37.

Installing the Belt Guard

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Illustration 38	g00947387
(18) 7X-0579 Hard Washer (31) 8T-4200 Bolt (33) 8T-4224 Hard Washer (38) 9X-2045 Screw (46) 101-2867 Hard Washer (80) 219-4392 Bracket (95) 227-5918 Belt Guard

1. Install the 219-4392 Bracket (80) on top of the engine block. See Illustration 38.

   Use two 8T-4200 Bolts (31) and two 8T-4224 Hard Washers (33) to install the bracket.

   Tighten the bolts to a torque of 15 ± 3 N·m (11 ± 2 lb ft).

2. Install the 227-5918 Belt Guard (95) .

   1. Place the 227-5918 Belt Guard (95) in position.

   2. Install a 9X-2045 Screw (38) with a 101-2867 Hard Washer (46) in the mounting hole in the top of the belt guard. Then, install two 9X-2045 Screws (38) with 101-2867 Hard Washers (46) in the mounting holes in the front of the belt guard.

   3. Install two 8T-4200 Bolts (31) with 7X-0579 Hard Washers (18) in the mounting holes in the bottom of the belt guard.

   4. Tighten the two bolts to a torque of 15 ± 3 N·m (11 ± 2 lb ft).

   5. Then, tighten the three screws to a torque of 6 ± 1 N·m (4 ± 0.7 lb ft).

Installing the Electrical Harnesses

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Illustration 39	g00947388
The electrical harnesses (83) 220-5527 Cab Harness As (84) 220-5528 Platform Harness As

1. Install the 220-5528 Platform Harness As (84) and the 220-5527 Cab Harness As (83). See Table 6 and Table 7.
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   Table 6

   220-5528 Platform Harness As (84)
   Harness Connector	Circuit	Connection
   (AC-B7)	-	Connect to Connector AA-C1 on Harness (83).
   (AC-C1)	AC Condenser Fan	Connect to the fan connector on the condenser.
   (AC-C2)	AC Condenser Fan	Connect to the fan connector on the condenser.
   (AC-T6)	AC Compressor	Connect to the bullet connector on the compressor. Secure the wiring to the clip that is provided on the rear of the compressor in order to prevent accidental grounding.
   (AC-C5)	Pressure Switch	Connect to the pressure switch connector on the compressor. Secure this harness connection to the clip that is provided on the rear of the compressor.
   (AC-T1)	AC Power (Battery +)	Connect to the circuit breaker terminal on the inside of the left tower. See View A of Illustration 40. (1)

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   ( 1 )

   Replace the existing 60 Amp circuit breaker with the 216-4970 Circuit Breaker (120 Amp) (66). Use the two 5L-4507 Screws (11) and the two 4B-4274 Washers (6) to install the circuit breaker.

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   Table 7

   220-5527 Cab Harness As (83)
   Harness Connector	Circuit	Connection
   (AA-C1)	-	Connect to Connector AC-B7 on Harness (84).
   (AA-T1)	AC Ground	Connect to the Grounding Stud on the back of the cab. See Illustration 41.
   (AA-C2)	AC Fan Motor	Connect to fan motor connector under the cab.

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Illustration 40	g00947391
The circuit breaker panel on the inside of the left tower (6) 4B-4274 Washer (11) 5L-4507 Screw (66) 216-4970 Circuit Breaker (120 Amp)

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Illustration 41	g00933471
The grounding stud on the back of cab

2. Route the harnesses with existing harness wiring. Use 3S-2093 Cable Straps (5) to secure the new harnesses to existing harnesses.

   Note: Do not route the 220-5527 Harness (HVAC Cab) (83) through the opening in the firewall. Route the harness under the torque tube.

Charging the Air Conditioner System

Use the procedure "Complete Charge of the System from a Refrigerant Tank with a Scale" to charge the air conditioner system. This procedure is part of the Testing and Adjusting, SENR5664, "Air Conditioning and Heating R-134a for All Caterpillar Machines"". This procedure can be obtained through the normal literature distribution system. This procedure can also be found on the Caterpillar Service Information System (SIS).

Note: Charge the system with 0.68 kg (1.5 lb) of R-134a refrigerant.

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Illustration 42	g00947392
(5) 3S-2093 Cable Strap (92) 223-9636 Instruction Plate

1. Install the 223-9636 Instruction Plate (92) on the suction inlet port of the compressor. Use a 3S-2093 Cable Strap (5) to tie the instruction plate on the compressor. See Illustration 42.

Checking the Air Conditioner and Heater Installation

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Illustration 43	g00947394
(58) 162-5233 Film (Work Tool Control)

1. Install the 162-5233 Film (Work Tool Control) (58) on the left side of the air conditioner and heater unit. See Illustration 43.

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Illustration 44	g00947393
Position for installation of the fuse for the air conditioner and heater unit (48) 113-8492 Fuse (20 Amp)

2. Install the 113-8492 Fuse (20 Amp) (48) in the indicated position in the fuse box. See Illustration 44.

3. Refill the cooling system.

   Refer to "Coolant Recommendations" and refer to "Cooling System Specifications" in the Operation and Maintenance Manual for your machine.

4. Start the engine. Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes. Maintain the coolant level in the sight gauge. The sight gauge is located on the right side of the radiator.

5. Stop the engine. Install the radiator cap.

6. Check the hoses and the fittings for leaks.

7. Start the engine.

8. Check the air conditioner and heater unit for proper operation.
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   Illustration 45	g00926159
   Temperature control knob

   1. The temperature control knob adjusts the output temperature. See Illustration 45.
      • Turn the temperature control knob clockwise in order to increase the temperature.

      • Turn the temperature control knob counterclockwise in order to decrease the temperature.

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   Illustration 46	g00927465

   2. The A/C switch controls the air conditioner. See Illustration 46.
      • Press the front portion of the rocker switch in order to turn on the air conditioner.

      • Press the rear portion of the rocker switch in order to turn off the air conditioner.

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   Illustration 47	g00926161
   Fan speed switch

   3. The fan speed switch controls the two-speed blower fan motor. See Illustration 47.
      • Press the rear portion of the rocker switch for low fan speed.

      • Press the front portion of the rocker switch for high fan speed.

      • Return the switch to the neutral position in order to turn off the fan.

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   Illustration 48	g00926163
   Adjustable louver

   4. The louver directs the flow of air, as needed. See Illustration 48.
      • The louver can be rotated for 360°.

      • The louver can be adjusted from a closed position to an open position.

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   Illustration 49	g00926164
   Recirculating filter

   5. To gain access to the air filter, loosen the two thumb screws and remove the grill panel. See Illustration 49.