Installing the 233-5869 Air Conditioner and Heater Installation Kit {7304, 7320} Caterpillar

Multi Terrain Loader:

267B (S/N: CYC1-UP)

277B (S/N: MDH1-UP)

287B (S/N: ZSA1-UP)

Introduction

ReferenceOperation and Maintenance, SEBU7732, "247B, 257B, 267B, 277B and 287B Multi Terrain Loaders"

ReferenceDisassembly and Assembly, RENR4888, "Machine Systems - 267B, 277B and 287B Multi Terrain Loaders"

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

This Special Instruction provides basic instructions for installing the heater/air conditioner on the listed machines. The configuration of this kit differs between the 267B, 277B machines and the 287B machines. Therefore, read the information that is provided in this publication before you begin installation. Also, read the information in the service manual for your machine that is referenced in this instruction.

The 233-5869 Air Conditioner and Heater Installation Kit

The 233-5869 Air Conditioner and Heater Installation Kit on 267B and 277B Machines

Illustration 1	g01045154
Configuration of the 233-5869 Air Conditioner and Heater Installation Kit on 267B and 277B machines (A) 218-6405 Air Conditioner Gp (B) 218-6394 Duct and Control Gp (C) 218-6831 Refrigerant Compressor and Mounting Gp (D) 186-6190 Refrigerant Accumulator Gp (E) 218-6148 Refrigerant Condenser and Mounting Gp (F) 225-7948 Air Conditioner Wiring Gp

The 233-5869 Air Conditioner and Heater Installation Kit on 287B Machines

Illustration 2	g01045156
Configuration of the 233-5869 Air Conditioner and Heater Installation Kit on 287B machines (A) 218-6405 Air Conditioner Gp (B) 218-6394 Duct and Control Gp (C) 218-6831 Refrigerant Compressor and Mounting Gp (D) 186-6190 Refrigerant Accumulator Gp (E) 218-6148 Refrigerant Condenser and Mounting Gp (F) 225-7948 Air Conditioner Wiring Gp

Installation Instructions

Notes

Use standard values of torque for fasteners and for connectors unless a value is specified in the procedure.

To prevent damage to the condenser coil, use a wrench to support the connectors when you torque the hose connections.

Before installation, lubricate O-ring seals with a mineral based refrigerant oil that is compatible with the R134a refrigerant.

Preparing for the Installation

1. Remove the left console and the right console from the operator's compartment. Discard the consoles. Retain the eight M6x1 screws for installation of the new consoles.

Installing the 218-6148 Refrigerant Condenser and Mounting Gp

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Illustration 3	g01210046
View of the 218-6148 Refrigerant Condenser and Mounting Gp (3) 116-5763 Spring Clip (19) 218-6060 Shroud (20) 218-6250 Fan (33) 252-0348 Coil (53) 5C-7261 Nut (M8x1.25) (55) 5P-4116 Hard Washer (69) 8T-4189 Bolt (M8x1.25) (73) 8T-4224 Hard Washer (74) 8T-4908 Bolt (M8x1.25)

1. Assemble the 218-6148 Refrigerant Condenser and Mounting Gp by installing the two fans (20) to the shroud (19). Then, install the shroud (19) to the coil (33). See the details in Illustration 3.

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Illustration 4	g01045162
Mounting the 218-6148 Refrigerant Condenser and Mounting Gp (56) 6B-2882 Spacer (65) 8T-4121 Hard Washer (66) 8T-4133 Nut (M10x1.5)

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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Personal injury or death can result without releasing all of the hydraulic pressure. Release all the pressure from the hydraulic system before any lines are disconnected.

2. Temporarily remove the following components in order to facilitate installation of the condenser.
   • Hydraulic tank

   • Air cleaner and hose

   • Muffler

   • Hose clips that are fastened to the bosses around the opening in the front wall of the engine compartment

3. Mount the 218-6148 Refrigerant Condenser and Mounting Gp in the opening in the front wall of the engine compartment. Use four spacers (56), four hard washers (65), and four M10x1.5 nuts (66). See Illustration 4.

Installing the 186-6190 Refrigerant Accumulator Gp

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Illustration 5	g01211919
Installing the plate assembly (29) 218-6484 Plate As

1. Install plate assembly (29) in the engine compartment, as shown. See Illustration 5.

   For 267B and 277B machines, install the plate assembly with three 8T-4137 Bolts (68) and three 8T-4121 Hard Washers (65) .

   For 287B machines, install the plate assembly with three 8T-4136 Bolts (67) and three 8T-4121 Hard Washers (65) .

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Illustration 6	g01210236
Installing the 186-6190 Refrigerant Accumulator Gp (2) 101-8296 Clip (16) 186-6190 Refrigerant Accumulator Gp (29) 218-6484 Plate As (54) 5P-0802 Seal (65) 8T-4121 Hard Washer (72) 8T-4196 Bolt ( M10x1.5)

2. Install a 150 mm (6 inch) length of seal (54) to the concave surface of both clips (2). Install the seal by removing the protective strip from the back of the seal and by pressing the seal to the clip.

   Place clips (2) around accumulator (16) so that the two clips encircle the body of the accumulator.

3. Mount accumulator (16) to the bosses that are provided on plate assembly (29). Use two M10x1.5 bolts (72) and two hard washers (65). Position the accumulator, as shown. See Illustration 6.

Installing the 218-6832 Refrigerant Compressor and Motor Gp

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Illustration 7	g01211701
Assembling the 218-6832 Refrigerant Compressor and Motor Gp (40) 218-6833 Refrigerant Compressor Gp (41) 218-6836 Drive Coupling (41A) 276-4063 Hub (Motor) (41B) 218-6838 Hub (Compressor) (41C) 218-6837 Coupling (42) 218-6840 Gear Motor (45) 233-5590 Support Housing (51) 2D-5248 Gasket (53) 5C-7261 Nut (M8X1.25) (55) 5P-4116 Hard Washer (65) 8T-4121 Hard Washer (73) 8T-4224 Hard Washer (77) 8T-6870 Bolt (M8X1.25) (78) 9G-5127 Breather As (79) 9G-7101 Spacer (80) 233-1012 Hex Socket Setscrew (81) 9X-6032 Bolt (M10X1.5)

1. Assemble the 218-6832 Refrigerant Compressor and Motor Gp per Illustration 7.

   Note: Install the hubs for the drive coupling (41), as follows.

   • Slide hub (41A) onto the motor shaft until the hub rests against the stop. Install setscrew (80). Tighten the setscrew to a torque of 2.0 N·m (1.5 lb ft).

   • Loosen the setscrew in hub (41B). Slide hub (41B) onto the compressor hub until the hub rests against the stop. Tighten the set screw to a torque of 6 N·m (4.4 lb ft).

   Note: Before installing gasket (51), apply a continuous 3 ± 1 mm (0.12 ± 0.04 inch) bead of sealant around both sides of the gasket.

Note: The mounting locations for the 218-6832 Refrigerant Compressor and Motor Gp differ between 267B and 277B machines and 287B machines. Use the installation instructions that are appropriate for your machine.

Installing the 218-6832 Refrigerant Compressor and Motor Gp on 267B and 277B Machines

Illustration 8	g01045188
Mounting the 218-6832 Refrigerant Compressor and Motor Gp on 267B and 277B machines (14) 148-8326 Connector Gp (15) 148-8390 Elbow Gp (30) 218-6618 Hose As (40) 218-6833 Refrigerant Compressor Gp (65) 8T-4121 Hard Washer (66) 8T-4133 Nut (M10x1.5) (AA) Fabricated hose assembly (BB) Fabricated hose assembly

1. Temporarily remove the following components in order to facilitate installation of the compressor.
   • Hoses for the right drive motor

   • Supply hose for implement valve

   • Hose clips

2. Fabricate hose assembly (AA) with a 120 cm (47 inch) length of hose (4), with a coupling (5), and with a coupling (6). Refer to the fabrication drawing for the 275-8661 Hose As in the Appendix of this instruction.

3. Fabricate hose assembly (BB) with a 192 cm (76 inch) length of hose (4), with a coupling (6), and with a coupling (5). Refer to the fabrication drawing for the 218-6488 Hose As in the Appendix of this instruction.

4. Prepare the 218-6832 Refrigerant Compressor and Motor Gp (40) by installing one connector assembly (14) and one elbow assembly (15) in the bottom ports of gear motor (42), as shown. See Illustration 8.

   Also, install one elbow assembly (15) in the top port of the motor.

5. Install one end of hose assembly (AA) to elbow assembly (15) on the bottom of the motor. Install the end of hose assembly (30) with the 45° connector to connector assembly (14) on the bottom of the motor.

6. Install the end of hose assembly (BB) with the 45° connector to elbow assembly (15) on the top of the motor.

7. Place the 218-6832 Refrigerant Compressor and Motor Gp on the three mounting studs that are provided on the belly plate. Secure the compressor with three M10x1.5 nuts (66) and three hard washers (65) .

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Illustration 9	g01210409
Connecting the 218-6832 Refrigerant Compressor and Motor Gp on 267B and 277B machines (30) 218-6618 Hose As (34) 252-0356 Hose As (37) 261-7162 Hose As (58) 6V-1228 Clip (61) 7D-7233 Clip (63) 7X-7729 Washer (71) 8T-4195 Bolt (84) 9X-7381 O-Ring Seal (85) 9X-7382 O-Ring Seal (86) 9X-7383 O-Ring Seal (AA) Fabricated hose assembly (BB) Fabricated hose assembly

8. Disconnect the hose assembly that is installed between the implement pump outlet and the hydraulic fan motor. Discard the hose assembly.

9. Route the free end of hose assembly (AA) to the implement pump and connect this hose assembly to the existing connector assembly in the implement pump outlet.

10. Route the free end of hose assembly (BB) to the hydraulic fan motor and connect this hose assembly to the existing connector assembly in the hydraulic fan motor.

11. In order to connect the free end of hose assembly (30), remove the cap from the perpendicular port on the tube assembly and connect the hose assembly, as shown. See Illustration 9.

12. Install hose assembly (34) between the compressor and the condenser, as shown.
    • The end of the hose assembly with the 45° stem connects to the outlet of the compressor. Use an O-ring (84) in the connection.

    • The end of the hose assembly with the straight stem connects to the inlet of the condenser. Use an O-ring (84) in the connection.

13. Install hose assembly (37) between the compressor and the accumulator, as shown.
    • The end of the hose assembly with the male connector connects to the outlet of the accumulator. Use an O-ring (86) in the connection.

    • The end of the hose assembly with the female connector connects to the inlet of the compressor. Use an O-ring (85) in the connection.

Installing the 218-6832 Refrigerant Compressor and Motor Gp on 287B Machines

Illustration 10	g01045628
Mounting the 218-6832 Refrigerant Compressor and Motor Gp on 287B machines (12) 148-8315 Connector Gp (13) 148-8316 Connector Gp (15) 148-8390 Elbow Gp (31) 261-6086 Hose As (40) 218-6833 Refrigerant Compressor Gp (65) 8T-4121 Hard Washer (66) 8T-4133 Nut (M10x1.5) (AA) Fabricated hose assembly (BB) Fabricated hose assembly

1. Temporarily remove the following components in order to facilitate installation of the compressor.
   • Hoses for the right drive motor

   • Supply hose for implement valve

   • Hose clips

2. Fabricate hose assembly (AA) with a 48 cm (19 inch) length of hose (4), with one coupling (5), and with one coupling (8). Refer to the fabrication drawing for the 261-6084 Hose As in the Appendix of this instruction.

3. Fabricate hose assembly (BB) with a 204 cm (80 inch) length of hose (4), with one coupling (5), and with one coupling (7). Refer to the fabrication drawing for the 218-6790 Hose As in the Appendix of this instruction.

4. Prepare the 218-6832 Refrigerant Compressor and Motor Gp by installing one connector assembly (13) and one elbow assembly (15) in the bottom ports of the motor, as shown. See Illustration 10.

   Also, install one connector assembly (12) in the top port of the motor.

5. Install the end of hose assembly (AA) with the 90° connector to elbow assembly (15) on the bottom of the motor. Install the end of hose assembly (31) with the 90° connector to connector assembly (13) on the bottom of the motor.

6. Install the end of hose assembly (BB) with the 45° connector to elbow assembly (12) on the top of the motor.

7. Place the 218-6832 Refrigerant Compressor and Motor Gp on the three mounting studs that are provided on the belly plate. Secure the compressor group with three M10x1.5 nuts (66) and three hard washers (65) .

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Illustration 11	g01210410
Connecting the 218-6832 Refrigerant Compressor and Motor Gp on 287B machines (31) 261-6086 Hose As (38) 257-5872 Hose As (39) 252-0446 Hose As (58) 6V-1228 Clip (61) 7D-7233 Clip (63) 7X-7729 Washer (71) 8T-4195 Bolt (84) 9X-7381 O-Ring Seal (85) 9X-7382 O-Ring Seal (86) 9X-7383 O-Ring Seal (AA) Fabricated hose assembly (BB) Fabricated hose assembly

8. Disconnect the hose assembly that is installed between the implement pump outlet and the hydraulic fan motor. Discard the hose assembly.

9. Route the free end of hose assembly (AA) to the implement pump and connect this hose assembly to the existing connector assembly in the implement pump outlet.

10. Route the free end of hose assembly (BB) to the hydraulic fan motor and connect this hose assembly to the existing connector assembly in the hydraulic fan motor.

11. In order to connect the free end of hose assembly (31), remove the cap from the perpendicular port on the tube assembly and connect the hose assembly, as shown. See Illustration 11.

12. Install hose assembly (38) between the compressor and the condenser, as shown.
    • The end of the hose assembly with the 45° stem connects to the outlet of the compressor. Use an O-ring (84) in the connection.

    • The end of the hose assembly with the straight stem connects to the inlet of the condenser. Use an O-ring (84) in the connection.

13. Install hose assembly (39) between the compressor and the accumulator, as shown.
    • The end of the hose assembly with the male connector connects to the outlet of the accumulator. Use an O-ring (86) in the connection.

    • The end of the hose assembly with the female connector connects to the inlet of the compressor. Use an O-ring (85) in the connection.

Installing the 218-6405 Air Conditioner Gp

Illustration 12	g01046162
Preparing the 218-6405 Air Conditioner Gp (35) 218-6812 Hose As (36) 218-6813 Hose As (64) 8T-0154 Hose Clamp (84) 9X-7381 O-Ring Seal (85) 9X-7382 O-Ring Seal

1. For Hose (F), cut a 217 cm (86 inch) length of hose (10). Connect one end of Hose (F) to the heater's outlet (I). Use a hose clamp (64) for this connection. See Illustration 12.

   Tighten the hose clamp to a torque of 6 ± 1 N·m (4 ± 1 lb ft).

2. For Hose (G), cut a 170 cm (67 inch) length of hose (10). Connect one end of Hose (G) to the heater's inlet (H). Use a hose clamp (64) for this connection.

   Tighten the hose clamp to a torque of 6 ± 1 N·m (4 ± 1 lb ft).

3. Connect hose assembly (35) to the air conditioner's inlet (J). Use an O-ring seal (84) in this connection.

4. Connect hose assembly (36) to the air conditioner's outlet (K). Use an O-ring seal (85) in this connection.

Illustration 13	g01216497
Installing the air conditioning unit in the machine (25) 218-6402 Insulation As (26) 218-6405 Air Conditioner Gp (62) 7X-2537 Bolt (73) 8T-4224 Hard Washer (76) 8T-6869 Bolt

1. Place air conditioning unit (26) in position on the left side of lower frame, as shown. See Illustration 13.

   Loosely route the hoses under the torque tube and into the engine compartment.

2. For 267B and 277B machines, secure air conditioning (26) with four M8x1.25 bolts (62) and four hard washers (73). Tighten the bolts to a torque of 28 ± 7 N·m (20.6 ± 5 lb ft).

   For 287B machines, place insulation assembly (25) between air conditioning unit (26) and the side wall of the lower frame. Align all of the mounting holes and secure the air conditioning unit to the side wall with four M8x1.25 bolts (76) and four hard washers (73). Tighten the bolts to a torque of 6 ± 1 N·m (4 ± 1 lb ft).

Connecting the Hoses for the Air Conditioner Unit

Illustration 14	g01053876
Connecting the hoses on 267B and 277B Machines (35) 218-6812 Hose As (36) 218-6813 Hose As (46) 236-6923 Pressure Switch (50) 246-9039 Information Plate (52) 3S-2093 Cable Strap (82) 9X-7378 O-Ring Seal (83) 9X-7380 O-Ring Seal (86) 9X-7383 O-Ring Seal

Illustration 15	g01053877
Connecting the hoses on 287B Machines (35) 218-6812 Hose As (36) 218-6813 Hose As (46) 236-6923 Pressure Switch (50) 246-9039 Information Plate (52) 3S-2093 Cable Strap (82) 9X-7378 O-Ring Seal (83) 9X-7380 O-Ring Seal (86) 9X-7383 O-Ring Seal

1. Route the free end of hose assembly (36) to the accumulator. Connect the hose to the accumulator's inlet port. Use an O-ring seal (86) in this connection.

   Note: The accumulator's inlet port is located in the side of the accumulator's body. The inlet port faces the rear of the machine.

2. Route the free end of hose assembly (35) to the condenser. Connect the hose to the condenser's outlet port. Use an O-ring seal (83) in this hose connection.

   Note: The condenser's outlet port is the bottom port on the left side of the condenser.

3. Install pressure switch (46) in the fitting for hose assembly (35). Use an O-ring seal (82) in this connection.

   Tighten the pressure switch to a torque of 8 ± 1.5 N·m (6 ± 1 lb ft).

4. Use a cable strap (52) and install plate (50) to the 180° coupling on hose assembly (36) .

Connecting the Hoses for the Heater

Illustration 16	g01211195
The 218-5619 Heater Lines Gp (1) 004-6810 Elbow (10) 136-1953 Hose (32) 218-6645 Elbow (55) 5P-4116 Hard Washer (57) 6D-1641 Clip (59) 6V-2235 Clip (64) 8T-0154 Hose Clamp (65) 8T-4121 Hard Washer (66) 8T-4133 Nut (M10x1.5) (68) 8T-4137 Bolt (M10x1.5) (69) 8T-4189 Bolt (M8x1.25) (70) 8T-4191 Bolt (M10x1.5) (87) 9X-8250 Clip

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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide"for tools and supplies to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations.

1. Remove the plug from the radiator inlet. Then, install elbow (1) in the radiator inlet.

   Note: Use thread sealant in the installation of the connector in the radiator.

2. Route the free end of hose (F) to radiator inlet and install the hose to the connector assembly with hose clamp (64) .

   Tighten the hose clamp to a torque of 6 ± 1 N·m (4 ± 1 lb ft).

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Illustration 17	g01256572
(32) 218-6645 Elbow (A) 65°±5° Angle

3. Remove the plug from the engine block outlet. Then, install elbow (32) in the engine block outlet. Orient elbow (32), as shown. See Illustration 17.

   Note: Use thread sealant in the assembly of the components and in the installation of the assembly in the engine block outlet.

4. Route the free end of hose (G) to engine block outlet and install the hose to the elbow with a hose clamp (64) .

   Tighten the hose clamp to a torque of 6 ± 1 N·m (4 ± 1 lb ft).

5. Secure the hoses per Illustration 18 through Illustration 22. Use the parts that are called out in these illustrations.

   Note: Provide hose lengths of 60 cm (24 inch) between point A and point B, as shown. See Illustration 16.

   Note: Pull the hose tightly between the clip at point C and the clip at point D.

   Note: Secure hose (F) with the cooler is in the raised position in order to allow adequate hose length.

Illustration 18	g01053194
Securing hose assembly (35) and hose assembly (36) under the torque tube (17) 200-6345 Mount (35) 218-6812 Hose As (36) 218-6813 Hose As (52) 3S-2093 Cable Strap

Illustration 19	g01053195
Securing hose (F) and hose (G) under the torque tube (57) 6D-1641 Clip (65) 8T-4121 Hard Washer (66) 8T-4133 Nut ( M10X1.5)

Illustration 20	g01216569
Securing hose (G) inside the engine compartment (59) 6V-2235 Clip (65) 8T-4121 Hard Washer (66) 8T-4133 Nut (M10X1.5) (68) 8T-4137 Bolt (M10X1.5) (87) 9X-8250 Clip

Illustration 21	g01216604
Securing hose (G) inside the engine compartment (55) 5P-4116 Hard Washer (69) 8T-4189 Bolt ( M8X1.25) (87) 9X-8250 Clip

Illustration 22	g01210200
Securing hose (F), hose (G), and hose (BB) inside the engine compartment (3) 116-5763 Spring Clip (55) 5P-4116 Hard Washer (57) 6D-1641 Clip (58) 6V-1228 Clip (61) 7D-7233 Clip (63) 7X-7729 Washer (65) 8T-4121 Hard Washer (70) 8T-4191 Bolt ( M10X1.5) (71) 8T-4195 Bolt ( M10X1.5) (74) 8T-4908 Bolt ( M8X1.25) (87) 9X-8250 Clip

Installing the 225-7948 Air Conditioner Wiring Gp

Illustration 23	g01045204
The 225-7948 Air Conditioner Wiring Gp (9) 124-3548 Fuse (18) 202-2168 Heater and Air Conditioner Harness As (43) 221-3879 Heater and Air Conditioner Harness As (52) 3S-2093 Cable Strap

Table 1

221-3879 Heater and Air Conditioner Harness As (43)
Connector	Connection
AC-T1	Ground Stud
AC-C1	HVAC
AC-C2	Condenser Fan
AC-C3	Condenser Fan
AC-C4	Pressure Switch
AC-C5	Connector R-C2 on Harness (18)

Table 2

202-2168 Heater and Air Conditioner Harness As (18)
Connector	Connection
R-C1	Compressor
R-C2	Connector AC-C5 on Harness (43)

1. Install harness (43) by making connections per Table 1.

2. Install harness (18) by making the connections that are specified in Table 2.

3. Secure the harnesses with cable straps (52) per Illustration 23.

Installing the 218-6394 Duct and Control Gp

Illustration 24	g01256131
The 218-6394 Duct and Control Gp (11) 146-6371 Louver As (21) 218-6396 Duct (22) 218-6397 Console (RH) (23) 218-6398 Console (LH) (24) 218-6401 Seal (27) 218-6414 Seal (28) 285-9133 Insulation (44) 285-8570 Insulation (47) 240-6877 Seal (48) 240-6878 Seal (49) 240-6879 Seal (60) 6V-6689 Screw (75) 8T-5371 Seal (88) 285-8565 Insulation

1. Prepare console (23) by installing seal (48) to the outside surface of the console.

   Next, install seal (49). Seal (49) is positioned around the pilot lines at the opening in the bottom of the console. The seal is provided with a pressure sensitive adhesive. For installation instructions, see "Instructions for Using Pressure Sensitive Adhesive" in the Appendix.

2. Position seal (27) around the opening in the front of the heater. Then, place console (23) in position in front of the heater. Secure console (23) to the support bracket for the joystick control. Use the four M6X1 screws that were retained.

   Tighten the screws to a torque of 6 ± 1 N·m (4.4 ± 0.7 lb ft).

3. Prepare console (22) by installing seal (47) to the outside surface of the console.

   Next, install seal (49). Seal (49) is positioned around the pilot lines at the opening in the bottom of the console. The seal is provided with a pressure sensitive adhesive. For installation instructions, see "Instructions for Using Pressure Sensitive Adhesive" in the Appendix.

4. Secure console (22) to the support bracket for the joystick control. Use the four M6X1 screws that were retained.

   Tighten the screws to a torque of 6 ± 1 N·m (4.4 ± 0.7 lb ft).

5. Assemble seal (24) to duct (21). Install duct (21) to the heating and air conditioning unit and to console (22). Use two screws (60) to install the duct.

   Tighten the screws to a torque of 2.25 ± 0.25 N·m (1.7 ± 0.2 lb ft).

   Note: Loosening the vertical floorplate will facilitate installation of duct (21) .

6. Install three louvers (11) in console (22) and install three louvers (11) in console (23) .

7. Install two 172 ± 5 mm (7 ± 0.2 inch) lengths of seal (75) under the lip of the vertical plate on either side of the floorplate.

   Note: The seal is provided with a pressure sensitive adhesive. For installation instructions, see "Instructions for Using Pressure Sensitive Adhesive" in the Appendix.

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Illustration 25	g01256494
(28) 285-9133 Insulation (44) 285-8570 Insulation (88) 285-8565 Insulation

8. Install insulation (28), insulation (44), and insulation (88) to the housing, as shown. See Illustration 25.

   Note: The insulation is provided with a pressure sensitive adhesive. For installation instructions, see "Instructions for Using Pressure Sensitive Adhesive" in the Appendix.

Completing the Installation

1. Reinstall the following components that were temporarily removed in order to facilitate the installation of this kit.
   • Hydraulic system oil tank

   • Air cleaner and hose

   • Muffler

   • Hoses for the right drive motor

   • Supply hose for the implement valve

   • Hose clips

   • Vertical Floorplate

2. Refill the hydraulic system oil tank.

   Refer to "Lubricant Viscosities" and refer to "Refill Capacities" in the Operation and Maintenance Manual for your machine.

3. Plug the heater's electrical connector into Connector A-C8 in the 216-4702 Platform Harness As (Lower) .

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Illustration 26	g01045150
Position in the fuse block for the 20 amp fuse for the heater/air conditioner's fan

4. Ensure that a 20 amp fuse is installed in the fuse block for the air conditioner's fan. See Illustration 26.

   Note: A 124-3548 Fuse (9) is provided with the kit.

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 0.81 kg (1.8 lb) of R-134a refrigerant.

Checking the Installation

1. Refill the cooling system.

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

2. 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.

3. Stop the engine. Install the radiator cap.

4. Check the hoses and check the fittings for leaks.

5. Start the engine.

6. Check the heater for proper operation.
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   Illustration 27	g01045148

   1. The temperature control knob (H1) adjusts the output temperature.
      • Turn the temperature control knob clockwise in order to increase the temperature.

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

   2. The A/C switch (H2) controls the air conditioner.
      • 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.

   3. The fan switch (H3) controls the two-speed blower fan motor.
      • 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.

   4. The louvers (H4) direct the flow or air, as needed.
      • Each louver can be rotated for 360°.

      • Each louver can be adjusted from a fully closed position to a fully open position.

   5. In order to access the air filters (H5), see "Accessing the Cab Air Filters" in the Appendix.

Appendix

Fabrication Drawings

The 261-6084 Hose As

Illustration 28	g01050509
The 261-6084 Hose As (4) 122-6881 Hydraulic Hose (5) 124-2119 Permanent Coupling (8) 124-2168 Permanent Coupling (W) 48 cm (19 inch)

The 218-6488 Hose As

Illustration 29	g01050510
The 218-6488 Hose As (4) 122-6881 Hydraulic Hose (5) 124-2119 Permanent Coupling (6) 124-2135 Permanent Coupling (X) 192 cm (76 inch)

The 218-6790 Hose As

Illustration 30	g01050511
The 218-6877 Hose As (4) 122-6881 Hydraulic Hose (5) 124-2119 Permanent Coupling (7) 124-2150 Permanent Coupling (Y) 204 cm (80 inch)

The 275-8661 Hose As

Illustration 31	g01228385
The 275-8661 Hose As (4) 122-6881 Hydraulic Hose (5) 124-2119 Permanent Coupling (6) 124-2135 Permanent Coupling (Z) 120 cm (47 inch)

Instructions for Using Pressure Sensitive Adhesive

Note: The temperature of the adhesive and the temperature of the application surface must be between 20 °C (68 °F) to 38 °C (100 °F). The application surface must be smooth, clean, and dry.

1. Clean the application surface by wiping the surface with a 50/50 mixture of isopropyl alcohol and water. Allow the surface to dry completely.

2. Remove the protective paper from the seal and press the seal in position.

3. Use a roller or a similar device and apply a minimum of 103 kPa (15 psi) over the entire surface in order to bond the adhesive to the surface.

   Note: Pay special attention to the edges and to the corners in order to ensure that these areas are bonded securely. Avoid conditions that would apply stress to the bond for 24 hours after installation.

Accessing the Cab Air Filters

Illustration 32	g01045147
Accessing the cab air filters (S) 231-8132 Cab Air Filter (T) 231-8130 Cab Air Filter

Parts List

Table 3

The 233-5869 Air Conditioner and Heater Installation Kit
Item	Quantity	Part Number	Description
1	1	004-6810	Elbow
2	2	101-8296	Clip
3	3	116-5763	Spring Clip
4	312 cm (123 inch)	122-6881	Hydraulic Hose (1)
5	2	124-2119	Permanent Coupling
6	2	124-2135	Permanent Coupling
7	1	124-2150	Permanent Coupling
8	1	124-2168	Permanent Coupling
9	1	124-3548	Fuse
10	387 cm (153 inch)	136-1953	Hose
11	6	146-6371	Louver As
12	1	148-8315	Connector Gp (1)
-	1	2M-9780	O-Ring Seal
-	1	6V-8642	Connector
-	1	7J-9108	O-Ring Seal
13	1	148-8316	Connector (1)
-	1	3J-7354	O-Ring Seal
-	1	4J-5477	O-Ring Seal
-	1	6V-8647	Connector
14	1	148-8326	Connector Gp (1)
-	1	3J-7354	O-Ring Seal
-	1	6V-8397	O-Ring Seal
-	1	6V-9872	Connector
15	2	148-8390	Elbow Gp (1)
-	1	2M-9780	O-Ring Seal
-	1	6V-8626	Elbow
-	1	7J-9108	O-Ring Seal
16	1	186-6190	Refrigerant Accumulator Gp
17	1	200-6345	Mount
18	1	202-2168	Heater and Air Conditioner Harness As
19	1	218-6060	Shroud
20	2	218-6250	Fan
21	1	218-6396	Duct
22	1	218-6397	Console (RH)
23	1	218-6398	Console (LH)
24	1	218-6401	Seal
25	1	218-6402	Insulation As
26	1	218-6405	Air Conditioner Gp
27	1	218-6414	Seal
28	1	285-9133	Insulation
29	1	218-6484	Plate As
30	1	218-6618	Hose As (2)
31	1	261-6086	Hose As (3)
32	1	218-6645	Elbow
33	1	252-0348	Coil
34	1	252-0356	Hose As (2)
35	1	218-6812	Hose As
36	1	218-6813	Hose As
37	1	261-7162	Hose As (2)
38	1	257-5872	Hose As (3)
39	1	252-0446	Hose As (3)
40	1	218-6833	Refrigerant Compressor Gp
41	1	218-6836	Drive Coupling (1)
42	1	218-6840	Gear Motor
43	1	221-3879	Heater and Air Conditioner Harness As
44	1	285-8570	Insulation
45	1	233-5590	Support Housing
46	1	236-6923	Pressure Switch
47	1	240-6877	Seal
48	1	240-6878	Seal
49	2	240-6879	Seal
50	1	246-9039	Information Plate
51	1	2D-5248	Gasket
52	15	3S-2093	Cable Strap
53	16	5C-7261	Nut (M8X1.25)
54	30 cm (12 inch)	5P-0802	Seal
55	6	5P-4116	Hard Washer
56	4	6B-2882	Spacer
57	2	6D-1641	Clip
58	1	6V-1228	Clip
59	1	6V-2235	Clip
60	2	6V-6689	Screw
61	1	7D-7233	Clip
62	4	7X-2537	Bolt (M8X1.25)
63	1	7X-7729	Washer
64	4	8T-0154	Hose Clamp
65	20	8T-4121	Hard Washer
66	9	8T-4133	Nut (M10X1.5)
67	3	8T-4136	Bolt (M10X1.5) (3)
68	4	8T-4137	Bolt (M10X1.5) (2)
69	15	8T-4189	Bolt (M8X1.25)
70	2	8T-4191	Bolt (M10X1.5)
71	1	8T-4195	Bolt (M10X1.5)
72	2	8T-4196	Bolt (M10X1.5)
73	26	8T-4224	Hard Washer
74	3	8T-4908	Bolt (M8X1.25)
75	4	8T-5371	Seal (1)
76	4	8T-6869	Bolt (M8X1.25)
77	2	8T-6870	Bolt (M8X1.25)
78	1	9G-5127	Breather As
79	2	9G-7101	Spacer
80	1	233-1012	Setscrew
81	2	9X-6032	Bolt (M10X1.5)
82	1	9X-7378	O-Ring Seal
83	1	9X-7380	O-Ring Seal
84	3	9X-7381	O-Ring Seal
85	2	9X-7382	O-Ring Seal
86	2	9X-7383	O-Ring Seal
87	4	9X-8250	Clip
88	1	285-8565	Insulation

( 1 )	Nonserviceable item
( 3 )	This part is used on 287B machines, only.
( 2 )	This part is used on 267B and 277B machines, only.

Table 4

Miscellaneous Parts
Quantity	Part Number	Description
1	5P-3413	Pipe Sealant (50 mL Tube)
1	8T-9022	Silicone Gasket (300 mL Cartridge)

Service Parts

Table 5

Service Parts
Item	Kit Part	Service Part
4	122-6881 Hydraulic Hose	122-6871 Hydraulic Hose
16	186-6190 Refrigerant Accumulator Gp	176-3900 Refrigerant Accumulator Gp
54	5P-0802 Seal	5P-5924 Seal
75	8T-5371 Seal	8T-5372 Seal

Reference Drawings

The reference drawings that are associated with this Special Instruction are identified in Table 6.

Table 6

Reference Drawing	Change Level
218-5619 Heater Lines Gp	05
218-6148 Refrigerant Condenser and Mounting Gp	05
218-6394 Duct and Control Gp	05
218-6405 Air Conditioner Gp	03
218-6831 Refrigerant Compressor and Mounting Gp	00
225-7948 Air Conditioner Wiring Gp	02
218-6730 Air Conditioner Lines Gp  (1)	03
233-5760 Air Conditioner Lines Gp  (2)	02
233-5595 Hydraulic Fan Lines Gp  (1)	02
218-6595 Hydraulic Fan Lines Gp  (2)	03
276-5708 Drive Coupling Gp	00
233-5760 Air Conditioner Lines Gp  (2)	02
218-6832 Refrigerant Compressor and Motor Gp	03
229-8747 Air Conditioner and Mounting Gp	00
233-5869 Air Conditioner and Heater Installation Kit	07

( 1 )	267B and 277B Machines
( 2 )	287BMachines