Installing the 361-0446 Air Conditioner ; Heater Installation Kit {1405, 1802, 1805, 1808, 7174, 7304, 7320, 734D} Caterpillar

Skid Steer Loader:

242B3 (S/N: SRS1-UP)

Introduction

ReferenceOperation and Maintenance, SEBU7731, "216B, 226B, 232B, 236B, 242B, 246B, 248B, 252B, and 262B Skid Steer Loaders"

ReferenceOperation and Maintenance, SEBU8495, "216 B3, 226B3, 236B3, 242B3, and 252B3 Skid Steer Loaders, 247B3 and 257B3 Multi Terrain Loaders and 259B3 Compact Track Loaders"

ReferenceDisassembly and Assembly, RENR4898, "Machine Systems - 216B, 226B, 232B, and 242B Skid Steer Loaders"

ReferenceDisassembly and Assembly, UENR0252, "216B3, 226B3, 236B3, 242B3, and 252B3 Skid Steer Loaders 247B3 AND 257B3 Multi Terrain Loaders and 259B3 Compact Track Loader - Machine Systems"

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 226B machine and the 242B machine. 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.

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 to the condenser coil.

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

The 361-0446 Air Conditioner and Heater Installation Kit on 242B3 Machine

Illustration 1	g02317039
The configuration of the 361-0446 Air Conditioner and Heater Installation Kit on 226B3 machines (A) 218-6405 Air Conditioner Gp (B) 218-6394 Duct and Control Gp (C) 186-6190 Refrigerant Accumulator Gp (D) Refrigerant Compressor and Mounting Gp (E) 218-6348 Refrigerant Condenser and Mounting Gp (F) 326-5744 Air Conditioner Lines Gp (G) 326-5745 Heater Lines Gp

Installation Instructions

Preparing for the Installation

1. Remove the left console and the right console from the operator compartment. Discard the consoles and discard the hardware.

218-6348 Refrigerant Condenser and Mounting Gp

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Illustration 2	g02297574
Assembling the 218-6348 Refrigerant Condenser and Mounting Gp (1) 218-6060 Shroud (2) 218-6250 Fan (3) 233-5927 Coil (4) 5C-7261 Nut (M8 x 1.25 (5) 8T-4121 Hard Washer (6) 8T-4133 Nut (M10 x 1.5) (7) 8T-4189 Bolt (M8 x 1.25) (8) 8T-4224 Hard Washer

1. Assemble the 218-6348 Refrigerant Condenser and Mounting Gp per Illustration 2.

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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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat 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 bosses around the opening in the front wall of the engine compartment

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Illustration 3	g02304774
Mounting the 218-6348 Refrigerant Condenser and Mounting Gp (5) 8T-4121 Hard Washer (6) 8T-4133 Nut (M10x1.5)

3. Mount the 218-6348 Refrigerant Condenser and Mounting Gp in the opening in the front wall of the engine compartment. Use four hard washers (5) and four M10x1.5 nuts (6) .

Installing the 186-6190 Refrigerant Accumulator Gp

Illustration 4	g01056939
Installing the 186-6190 Refrigerant Accumulator Gp (1) 085-8091 Bolt (M10x1.5) (3) 101-8296 Clip (17) 186-6190 Refrigerant Accumulator Gp (51) 5P-0802 Seal (60) 8T-4121 Hard Washer (69) 9C-2741 Spacer

1. Install a 150 mm (6 inch) length of seal (51) to the concave surface of both clips (3). Install the seal by removing the protective strip from the back of the seal and by pressing the seal to the clip.

   Place clips (3) around accumulator (17) so that the two clips encircle the body of the accumulator.

2. Mount accumulator (17) to the bosses that are provided on the left wall of the lower frame. Use two spacers (69), two M10x1.5 bolts (1) and two hard washers (60). Position the accumulator, as shown. See Illustration 4.

Installing the 276-9875 Refrigerant Compressor Gp

1. Open the engine access door. Refer to Operation and Maintenance, "Engine Access Door" for operation instructions.

2. Tilt the radiator. Refer to Operation and Maintenance, "Radiator Tilting" for operation instructions.

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Illustration 5	g02299197
(116) 280-8408 Belt Guard (117) 8T-7934 Hard Washer (118) 354-6574 Special Bolt (120) 5P-4116 Hard Washer

3. Remove the four screws (118) and the four hard washers (117). Loosen the two screws (119). Then, slide guard (116) upward and remove the guard. See Illustration 5.

   Retain the guard, the screws, and the hard washers for the reinstallation.

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Illustration 6	g01453988
(120) (122) 8T-4908 Bolt (121) 326-5348 Bracket As (122) 5P-4116 Hard Washer

4. Perform Step 4.a through Step 4.c in order to remove the fuel/water separator temporarily from the frame.

   Note: Do not disconnect the hoses.

   1. Remove the cable strap that secures the electrical connector to the support clip. Then, unplug the electrical connector from the 328-2277 Engine Harness As .

   2. Remove the two bolts (120) in order to disconnect bracket (121) temporarily from the rear tower plate. Retain these bolts for the reinstallation.

   3. Then, place the bracket with the fuel/water separator on the floor of the engine compartment.

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Illustration 7	g01454537
(124) 8T-4192 Bolt (125) 8T-4223 Hard Washer

5. Remove the three bolts (124) and the three hard washers (125) that are shown in Illustration 7. Discard the bolts and the hard washers.

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Illustration 8	g02299233
(18) 8T-4223 Hard Washer (19) 8T-4183 Bolt (48) 280-8395 Bracket (90) 4P-7429 Clip

6. Install bracket (48). Use the three new bolts (19) with three new washers (18) for installing the bracket. See Illustration 8.

   Note: Install clip (90) with the installation of bolt (19) and hard washer (18). Orient the clip, as shown.

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Illustration 9	g02299299
(13) 8T-4121 Hard Washer (15) 8T-4195 Bolt (30) 315-7790 Support (64) 326-5776 Hose As (69) 326-5777 Hose As (262B3) (86) 276-9875 Refrigerant Compressor Gp

Note: Perform Step 7 and Step 8 before you install the compressor in the machine.

7. Install hoses (64) and (69) to compressor (86) per Step 7.b through Step 7.c. Refer to Illustration 9.

   1. Connect hose (64) to the compressors suction port.

   2. Connect hose (69) to the compressors discharge port.

   3. Install support (30) in order to hold the hoses in place. Install the support with bolt (15) and hard washer (13) .

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Illustration 10	g01473612
(13) 8T-4121 Hard Washer (14) 8T-4133 Nut (16) 8T-4196 Bolt (47) 258-2466 Bracket (86) 276-9875 Refrigerant Compressor Gp

8. Install bracket (47) to compressor (86). Use two bolts (16), four washers (13), and two nuts (14), as shown. See Illustration 10.

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Illustration 11	g01473632
(13) 8T-4121 Hard Washer (14) 8T-4133 Nut (16) 8T-4196 Bolt (20) 8T-6685 Bolt (31) 113-0693 Lockwasher (48) 280-8395 Bracket (86) 276-9875 Refrigerant Compressor Gp

9. Install compressor (86) onto bracket (48). Use bolt (20), three hard washers (13), and nut (14) in order to secure the compressor to the top of bracket (48). See Illustration 11.

   Note: Insert bolt (20) from the front of bracket (48). Install nut (14) on bolt (20) from the rear of bracket (48), as shown. Only hand tighten nut (14) .

   Note: Loosely route the hoses toward the front of the machine between the engine and left wall of the fuel tank.

   Then, install bolt (16), lock washer (31), and hard washer (13) in order to secure the compressor onto the bottom of bracket (48). Only hand tighten bolt (16) .

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Illustration 12	g02317113
(89) 7K-1181 Cable Strap (90) 4P-7429 Clip (150) 328-2276 Engine Wiring Gp (151) 189-3158 Arc Suppressor

10. Secure the engine harness (150) to clip (90) with a cable strap (89). See Illustration 12.

    1. Remove seal caps from connectors.

11. Connect the compressors electrical connector to connector E-C16 on the 328-2276 Engine Wiring Gp . See Table 1.

12. Connect arc suppressor (151) to connector E-C3 on 328-2276 Engine Wiring Gp .
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    Table 1

    Connector E-C16
    Pin	Wire Color	CKT ID
    1	Orange	E554
    2	Black	200

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Illustration 13	g01473672
(14) 8T-4133 Nut (16) 8T-4196 Bolt (49) 258-3539 V-Belt

13. Install belt (49). Move the air conditioner compressor until the correct belt tension is achieved.

    Refer to Operation and Maintenance, "Belts - Inspect/Adjust/Replace" for the proper belt tension.

    Tighten bolt (16) in order to maintain belt tension. Then, tighten the nut (14). See Illustration 13.

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Illustration 14	g02299197
(116) 280-8408 Belt Guard (117) 8T-7934 Hard Washer (118) 354-6574 Special Bolt (120) 5P-4116 Hard Washer

14. Reinstall belt guard (116) with the screws and the hard washers that were retained in Step 3. Also, tighten screws (119). See Illustration 14.

15. Reinstall the fuel/water separator that was removed in Step 4. Reconnect the electrical connector to the 258-4108 Chassis Harness As and secure the electrical connector with a cable strap. See Illustration 6.

Installing the 229-8747 Air Conditioner and Mounting Gp

Illustration 15	g02297654
Preparing the heating and air conditioning unit for 242B machines (F) Hose between the heater outlet and the radiator (G) Hose between the engine block and the heater inlet (H) Heater inlet (J) Heater outlet (K) Air conditioner inlet (L) Air conditioner outlet (13) 136-1953 Hose (25) 218-6405 Air Conditioner Gp (31) 218-5686 Hose As (A/C Inlet) (33) 233-5863 Hose As (A/C Outlet) (59) 8T-0154 Hose Clamp (76) 9X-7381 O-Ring Seal (77) 9X-7382 O-Ring Seal (85) 9X-2092 Edge Trim

1. Cut two lengths of hose (13) per Table 2.
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   Table 2

   Machine	Hose (F)	Hose (G)
   	Hose (F) is installed between the heater outlet and the radiator. (1)	Hose (G) is installed between the engine block and the heater inlet. (1)
   242B3	2162 mm (85 inch)	1649 mm (65 inch)

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   ( 1 )

   Use 136-1953 Hose (13)

2. Connect the specified lengths of hose to the inlet (H) and to the outlet (J) on the bottom of heater. Use a hose clamp (59) for each connection. See Illustration 15.

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

3. Connect hose assembly (31) to the air conditioner inlet (K). Use an O-ring seal (76) in this connection.

   For 242B machines, connect hose assembly (33) to the air conditioner outlet (L). Use an O-ring seal (77) in this connection.

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Illustration 16	g01056270
Installing the Air Conditioner Gp in the machine (66) 8T-4224 Hard Washer (57) 7X-2537 Bolt (M8x1.25)

4. Place heating and air conditioning unit (25) in position on the left side of the lower frame, as shown. See Illustration 16.

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

5. Secure the heating and air conditioning unit (25) to the lower frame. Use four M8x1.25 bolts (57) and four hard washers (66)

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

Installing the Air Conditioner Lines

Illustration 17	g02297755

Illustration 18	g02319976
The air conditioner lines for 242B3 machines (1) 7K-1181 Cable Strap (2) 105-9411 Support (3) 178-3620 Strap (4) 186-6190 Refrigerant Accumulator Gp (5) 189-3158 Arc Suppressor (6) 200-6345 Mount (7) 218-5686 Hose As (8) 221-3879 Heater and Air Conditioner Harness As (9) 233-5863 Hose As (10) 236-6923 Pressure Switch (11) 312-2179 Bracket As (12) 326-5776 Hose As (13) 326-5777 Hose As (14) 085-8091 Bolt (15) 095-0913 Clip (16) 101-8296 Clip (17) 234-0566 Fitting As (18) 246-9039 Information Plate (19) 3S-2093 Cable Strap (20) 6D-4246 Clip (21) 8T-4121 Hard Washer (22) 8T-4136 Bolt (23) 8T-4189 Bolt (24) 8T-4224 Hard Washer (25) 9C-2741 Spacer (26) 9X-7378 O-Ring Seal (27) 9X-7380 O-Ring Seal (28) 9X-7381 O-Ring Seal (29) 9X-7382 O-Ring Seal (30) 9X-7383 O-Ring Seal (31) 5P-0802 Seal

1. Install fitting assembly (17) to the accumulator inlet port. Use O-ring seal (30) in this connection

   1. Route the free end of hose assembly (9) to the accumulator. Connect the hose assembly to fitting assembly (17). Use O-ring seal (30) in this connection.

   2. Route free end of hose assembly (7) to condenser. Connect the hose assembly to the outlet port of the condenser (bottom port). Use 0-ring (27) in this connection.

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Illustration 19	g02317313

2. Secure Hose (12) to 328-2277 Engine Harness As . Use 178-3620 Strap in order to secure the hose

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Illustration 20	g02317314

3. Secure Hose (12) to 142-8719 Adapter Plate using one 312-2179 Bracket As and one 095-0913 Clip .

4. Ensure that bracket is oriented as shown. Loop portion of p-clip should be located ob top side to ensure that hose is constrained above oil cooler lines.

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Illustration 21	g02317315

5. Secure Hose (12) to 326-5791 Hose As . Use 2 7K-1181 Cable Straps and one 200-6345 Mounts .

   1. Attach hose (12) to accumulator (4). Install 9X-7383 O-Ring Seal into hose (12). Ensure coupling orientation as shown in Illustration 22.

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Illustration 22	g02317316

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Illustration 23	g02317317

6. Secure Hose (13) to 312-2179 Bracket As . Use one 6D-4246 Clip , one 7K-1181 Cable Strap and one 200-6345 Mount .

   1. Secure hose (13) to condenser inlet port (top) as shown in Illustration 24. Install 9X-7381 O-Ring Seal into hose c (13) .

Illustration 24	g02317318

Installing the 326-5745 Heater Lines Gp

Illustration 25	g02297909

Illustration 26	g02319977
(1) 7K-1181 Cable Strap (2) 8T-0154 Hose Clamp (3) 004-6810 Elbow (4) 178-3620 Strap (5) 218-6645 Elbow (6) 6D-1641 Clip (7) 8T-4121 Hard Washer (8) 8T-4133 Nut (9) 8T-4136 Bolt (10) 9X-8250 Clip (11) 136-1953 Hose (12) 9X-2092 Edge Trim

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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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Illustration 27	g02317738

1. Secure accumulator inlet 233-5863 Hose As . Use a 7K-1181 Cable Strap .

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Illustration 28	g02317739

2. Secure heater hoses to upper frame cross member using dual loop 6D-1641 Clip which is to be attached to boss provided on frame cross member

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Illustration 29	g02317740

3. Attach 9X-2092 Edge Trim to gusset on upper frame as shown to protect heater hoses from gusset edge.

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Illustration 30	g02317741

4. Secure heater outlet hose to 9R-1610 Threaded Boss provided on upper frame cross member using 9X-8250 Clip .

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Illustration 31	g02317742

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Illustration 32	g02317743

5. Secure heater outlet hose on stud 227-6715 Stud provided on radiator using 9X-8250 Clip .

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Illustration 33	g02317744

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Illustration 34	g02317745

6. Secure heater inlet hose on turbo inlet tube flange using 9X-8250 Clip .

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Illustration 35	g02317746

7. Secure heater inlet hose to radiator hose using 178-3620 Strap .

Installing the 221-3879 Heater and Air Conditioner Harness As

Illustration 36	g02298284
The 221-3879 Heater and Air Conditioner Harness As (38) 221-3879 Heater and Air Conditioner Harness As (47) 3S-2093 Cable Strap (48) 7K-1181 Cable Strap

1. Install harness (38) by making connections per Table 3.

2. Secure the harnesses to existing harnesses with cable straps (47) .

Installing the 218-6394 Duct and Control Gp

Illustration 37	g01056286
The 218-6394 Duct and Control Gp (14) 146-6371 Louver As (21) 218-6396 Duct (22) 218-6397 Console (RH) (23) 218-6398 Console (LH) (24) 5P-4610 Strip Insulation (26) 218-6414 Seal (27) 285-9133 Insulation (39) 285-8565 Insulation and 285-8570 Insulation (43) 240-6877 Seal (44) 240-6878 Seal (45) 240-6879 Seal (55) 6V-6689 Screw (67) 5P-3602 Seal (72) 175-0005 Screw

1. Prepare console (23) by installing seal (44) to the outside surface of the console.

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

   Next, install seal (45). Seal (45) is positioned around the pilot lines at the opening in the bottom of the console.

2. Position seal (26) 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 (72) .

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

3. Prepare console (22) by installing seal (43) to the outside surface of the console.

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

   Next, install seal (45). Seal (45) is positioned around the pilot lines at the opening in the bottom of the console.

4. Secure console (22) to the support bracket for the joystick control. Use four M6x1 screws (72) .

   Tighten the screws to a torque of 12 ± 3 N·m (9 ± 2 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 (55) 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 (14) in console (22) and install three louvers (14) in console (23) .

7. Install two 172 ± 5 mm (7 ± 0.2 inch) lengths of seal (67) under the lip of the 218-6416 Plate As (Vertical) and on either side of the 218-6417 Floorplate As .

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

8. Install insulation (27) and seal (39) to the canopy.

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

Completing 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

   • 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 electrical connector for the heater into Connector P-C32 in the 328-2275 Platform Harness As .

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 38	g02298336

   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.

Instructions for Using Pressure Sensitive Adhesive

1. Clean the 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 39	g02298373
(1) 185-4015 Clip (2) 202-2284 Rocker Switch (3) 206-7398 Control Knob (4) 218-6399 Seal (5) 218-6948 Heater and Air Conditioner Harness As (6) 231-8122 Side Housing As (7) 231-8123 Evaporator Coil As (8) 231-8124 Heater Coil As (9) 231-8126 Water Valve As (10) 231-8127 Grommet (11) 231-8132 Cab Air Filter Element (12) 231-8133 Panel (13) 231-8137 Film (14) 231-8141 Grommet (15) 232-1384 Air Conditioner Orifice As (16) 236-5067 Rocker Switch (17) 295-5440 Motor (18) 303-6658 Cab Air Filter Element (19) 305-2969 Thumb Screw (20) 312-1683 Cover Housing (21) 312-2635 Access Cover Gp (22) 119-9631 Temperature Switch (23) 236-5069 Relay As (24) 7X-2031 Retainer

Parts Information