Installing the 350-9036 Air Conditioner and Heater Installation Kit {7320} Caterpillar

Compact Track Loader:

299C (S/N: JSP1135-UP)

Multi Terrain Loader:

297C (S/N: GCP1657-UP)

Skid Steer Loader:

272C (S/N: RED2116-UP)

Introduction

ReferenceOperation and Maintenance, SEBU8019, "246C, 256C, 262C, and 272C Skid Steer Loader"

ReferenceDisassembly and Assembly, KENR5116, "Machine Systems - 272C Skid Steer Loader"

ReferenceDisassembly and Assembly, KENR5114, "Engine Supplement - 272C Skid Steer Loader"

ReferenceOperation and Maintenance, SEBU8020, "277C, 287C, and 297C Multi Terrain Loader"

ReferenceDisassembly and Assembly, KENR5198, "Machine Systems - 297C Multi Terrain Loader"

ReferenceDisassembly and Assembly, KENR5191, "Engine Supplement - 297C Multi Terrain Loader"

ReferenceOperation and Maintenance, SEBU8407, "279C, 289C, and 299C Compact Track Loader"

ReferenceDisassembly and Assembly, KENR8832, "Machine Systems - 299C Compact Track Loader"

ReferenceDisassembly and Assembly, KENR8828, "Engine Supplement - 299C Compact Track Loader"

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

This Special Instruction provides basic instructions for installing the 350-9036 Air Conditioner and Heater Installation Kit on the listed machines. Read the information that is provided in this publication and understand the information before you begin the installation. Also, read the information in the service manual for your machine that is referenced in this instruction.

Note: If you are installing this kit with the 258-2472 Cab Window Kit , heed the following instructions in order to facilitate the installation.

• The 350-9036 Air Conditioner and Heater Installation Kit requires the installation of electrical controls in the right control panel. The kit also requires the routing of the electrical harness behind the headliner. In order for you to maneuver the harness into position behind the headliner, the edges of the headliner must be free. Since the presence of the right window frame will make this activity difficult, install the electrical harness before you install the right window frame.

• The 350-9036 Air Conditioner and Heater Installation Kit also requires the installation of duct assemblies in the front of the cab. In order for you to install the window frames inside the cab, the duct assemblies cannot be in place. Therefore, install the window frames before you install the duct assemblies.

The 350-9036 Air Conditioner and Heater Installation Kit

Illustration 1	g02344077
Configuration of the 350-9036 Air Conditioner and Heater Installation Kit (1) Heater Lines (2) Condenser Coil (3) Compressor (4) Air Conditioner Lines (5) Accumulator (6) Heating and Air Conditioning Unit (7) Ducts (8) Harness (9) Air Conditioner and Heater Controls

Table 1

Parts List
Item	Quantity	Part Number	Description
1	Blank
2	41 cm (16 inch)	3E-8082	Seal (1)
3	24	3S-2093	Cable Strap
4	30 cm (11.8 inch)	5P-0802	Seal (1)
5	1	5P-4116	Hard Washer
6	3	6D-1641	Clip
7	2	6V-6689	Screw
8	4	6V-7357	Bolt
9	100 cm (39 inch)	6V-9334	Seal (1)
10	3	7X-2031	Retainer
11	4	8T-0154	Hose Clamp
12	12	8T-4121	Hard Washer
13	3	8T-4133	Nut
14	3	8T-4136	Bolt
15	3	8T-4196	Bolt
16	10	8T-4205	Hard Washer
17	3	8T-4223	Hard Washer
18	3	8T-4183	Bolt
19	1	8T-6685	Bolt
20	Blank
21	2	8Y-5947	Fastener
22	2	9X-7378	O-Ring Seal
23	1	9X-7380	O-Ring Seal
24	2	9X-7381	O-Ring Seal
25	1	9X-7382	O-Ring Seal
26	2	9X-7383	O-Ring Seal
27	2	9X-8250	Clip
28	1	004-6810	Elbow
29	2	101-8296	Clip
30	1	315-7790	Support
31	1	111-7899	Gasket
32	1	113-0693	Lockwasher
33	530 cm (209 inch)	136-1953	Hose
34	6	146-6371	Louver As
35	1	149-6371	Pressure Switch
36	2	163-3955	Bolt
37	7	178-3620	Strap
38	1	186-6190	Refrigerant Accumulator Gp (1)
39	1	200-6345	Mount
40	1	132-5789	Clip
41	2	206-1345	Cable Strap
42	3	206-2423	Saddle
43	1	206-9185	Bolt
44	Blank
45	3	215-6406	Screw
46	1	218-6645	Elbow
47	1	236-6923	Pressure Switch
48	1	246-9371	Relay As
49	1	258-2466	Bracket
50	1	280-8395	Bracket
51	1	258-3539	V-Belt
52	7	258-3727	Screw
53	1	258-3792	Seal
54	1	258-3793	Seal
55	1	258-3794	Insulation
56	2	258-3795	Seal
57	1	258-3796	Seal
58	1	348-4173	Heater and Air Conditioner Harness As
59	1	258-4248	Louver Cover
60	1	258-4249	Inlet Duct
61	1	258-4253	Duct Assembly
62	1	258-4254	Duct Assembly
63	1	357-8752	Duct Assembly
64	1	357-8751	Duct Assembly
65	1	258-4259	Outlet Duct Assembly
66	1	258-4263	Plate
67	1	357-8807	Cover As
68	1	258-4267	Hose As
69	1	258-4268	Hose As
70	1	258-4290	Air Conditioner Gp (1)
71	1	258-4296	Hose As
72	1	258-4309	Hose As
73	2	258-4378	Knob As
74	1	258-4379	Knob As
75	1	357-8801	Air Screen
76	1	258-4388	Bracket As
77	1	258-4408	Insulation
78	1	265-6618	Cab Air Filter
79	1	265-6619	Cab Air Filter
80	1	266-0299	Rocker Switch
81	1	266-2426	Condenser Coil As
82	1	266-2430	Air and Temperature Control Gp (1) (2)
83	2	266-3314	Bolt
84	9	266-3315	Bolt
85	1	276-9875	Refrigerant Compressor Gp
86	4	312-0131	Screw
87	1	246-9039	Information Plate
88	1	7K-1181	Cable Strap
89	1	4P-7429	Clip
90	1	5C-2890	Nut
91	1	8T-4138	Bolt
92	1	8T-4195	Bolt
93	2	9X-8256	Washer
94	2	274-3774	Connector Cap

( 2 )

See Table 2.

Table 2

266-2430 Air and Temperature Control and Wiring Gp (82)
Item	Quantity	Part Number	Description
82A	1	258-4299	Air and Temperature Control Gp
82B	1	328-2368	Control Harness As

Table 3

Miscellaneous Parts (1)
Item	Quantity	Part Number	Description
88	1	5P-3413	Pipe Sealant (50 mL Tube)
89	2	8Y-5947	Fastener

( 1 )

These parts must be provided by the customer.

Installation Instructions

During the installation of this kit, apply the following instructions:

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

• Lubricate O-ring seals with a mineral-based refrigerant oil that is compatible with the R134A refrigerant before you install the seals.

Raising the cab is necessary in order to install many of the component in this kit. Refer to Operation and Maintenance, "Tilting the Cab Upward" and to Operation and Maintenance, "Tilting the Cab Downward" for instructions.

Preparing the Machine for the Installation

1. Park the machine on a flat, level work surface.

2. Engage the parking brake.

Note: Refer to Operation and Maintenance, "Parking" for instruction.

Installing the 266-2430 Air and Temperature Control and Wiring Gp

Illustration 2	g01453577
View of the right wall inside the station for the operator (100) 9X-2044 Screw (101) 258-4034 Switch Cover (102) 258-4004 Panel (RH) (103) 258-4021 Headliner (104) 8Y-5947 Fastener (105) 280-6069 Cover (RH)

The heater kit requires the installation of air and temperature controls in panel (102) and the installation of the control harness behind headliner (103). See Illustration 2.

Note: Removal of the right cab windows and window frame are recommended to facilitate the installation of the 266-2430 Air and Temperature Control and Wiring Gp . Otherwise, the presence of the window frame will make the routing of the electrical harness much more difficult. For instructions on removing the window frame, refer to Special Instruction, REHS2796, "Installation of the 258-2472 Cab Windows Kit ".

1. Remove switch cover (101) from panel (102). Discard the switch cover.

2. Remove screw (100) that secures panel (102) to the headliner. This procedure will allow sufficient movement of panel (102) for installing the air and temperature controls with the control harness.

   Retain screw (100) for the reinstallation.

3. Remove the two fasteners (104) in order to remove cover (105). This procedure will allow sufficient movement of headliner (103) for installing the control harness behind the headliner.

   Discard the two fasteners (104). Retain cover (105) for the reinstallation.

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Illustration 3	g01453601
(80) 266-0299 Rocker Switch (82A) 258-4299 Air and Temperature Control Gp (82B) 328-2368 Control Harness As

4. Install switch (80) into the air and temperature control (82A). Then, connect the air and temperature control (82A) to the control harness (82B). See Illustration 3.

   Note: Ensure that a 111-7899 Gasket (31) is on the base of switch (80) before installing the switch in the air and temperature control (82A) .

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Illustration 4	g01453632
(82A) 258-4299 Air and Temperature Control Gp (82B) 328-2368 Control Harness As (102) 258-4004 Panel (RH) (103) 258-4021 Headliner

5. Insert the control harness connector HV-C1 into the opening in panel (102). Then, feed the remaining length of control harness (82B) into the opening. Snap the air and temperature control (82A) into the opening in panel (102) .

   Insert control harness (82B) behind headliner (103) as shown. See Illustration 4.

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Illustration 5	g01453644
(106) 258-3728 Plate (107) 266-3314 Bolt (108) 258-4211 Plate

6. Remove bolts (107). Then, remove plate (106) from the 258-4211 Plate (108). See Illustration 5.

   Discard plate (106) and discard bolts (107) .

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Illustration 6	g01453657
(41) 206-1345 Cable Strap (82B) 328-2368 Control Harness As (83) 266-3314 Bolt (108) 258-4211 Plate

Note: Headliner (103) is not shown in Illustration 6 in order to reveal the upper cable strap (41) .

7. Install the control harness connector HV-C1 into the opening in plate (108). Use the two bolts (83) in order to secure the connector to plate (108). See Illustration 6.

   Install two cable straps (41) in order to secure the control harness to the ROPS post.

   Note: Holes are provided in the ROPS post for inserting the fastener on each cable strap (41) .

8. Reinstall cover (105). Use two new 8Y-5947 Fasteners (89) for securing the cover and the headliner. See Illustration 2.

   Reinstall screw (100) in order to secure panel (102) .

9. Reinstall the right cab windows and the right window frame if the windows and the frame were removed for installation of the control harness.

   For instructions on installing the window frame, refer to Special Instruction, REHS2796, "Installation of the 258-2472 Cab Windows Kit ".

Installing the 258-4290 Air Conditioner Gp

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Illustration 7	g01453685
(57) 258-3796 Seal (63) 357-8752 Duct Assembly Inlet

1. Remove the protective paper strip from seal (57). Install the adhesive side of seal (57) onto duct (63). Refer to Illustration 7.

   Note: When you install seal (57), align the five bolt holes in the seal with the five bolt holes in the flange of the duct.

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Illustration 8	g01453697
(52) 258-3727 Screw (57) 258-3796 Seal (63) 357-8752 Duct Assembly Inlet (70) 258-4290 Air Conditioner Gp

2. Position duct (63) onto the air inlet of the air conditioner (70). Secure the duct to the air inlet with five screws (52). See Illustration 8.

   Tighten the screws to a torque of 3.0 ± 0.25 N·m (2.2 ± 0.2 lb ft).

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Illustration 9	g01453706
(8) 6V-7357 Bolt (16) 8T-4205 Hard Washer (21) 8Y-5947 Fastener (53) 258-3792 Seal (55) 258-3794 Insulation (75) 357-8801 Screen As (63) 357-8752 Duct Assembly Inlet (70) 258-4290 Air Conditioner Gp

3. Install two bolts (8) and two hard washers (16) in order to secure duct (63) to the air conditioner. See Detail A of Illustration 9.

4. Remove the protective paper strip from screen (75). Then, install the adhesive side of the screen onto duct (63). See Illustration 9.

   Secure screen (75) to duct (63) with two fasteners (21) .

5. Remove the protective paper strip from seal (53) and apply the seal around the air outlet in the top plate of air conditioner (70). Remove the protective paper strip from insulation (55) and apply the insulation to the top plate of air conditioner (70), as shown. See Illustration 9.

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Illustration 10	g01453724
(109) 266-3315 Bolt (110) 258-4042 Governor Pedal Gp (111) 8T-4138 Bolt (112) 8T-4205 Hard Washer (113) 258-4408 Insulation (114) 258-4225 Floorplate As

6. Remove the three bolts (111) and the three hard washers (112) that are used to secure foot pedal (110) to the floorplate. Retain these bolts and washers for the reinstallation. See Illustration 10.

   Remove the four bolts (109) that secure floorplate (114) to the frame. Discard these bolts.

   Then, remove the floorplate. Discard the floorplate.

   Note: Tear the seal (113) that is installed under foot pedal (110) in order to remove the floorplate from the machine. Remove any residual pieces of the seal from the plate.

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Illustration 11	g01453734
(70) 258-4290 Air Conditioner Gp (77) 258-4408 Insulation (84) 266-3315 Bolt (110) 258-4042 Governor Pedal Gp (111) 8T-4138 Bolt (112) 8T-4205 Hard Washer

7. Place air conditioner (70) in position in the lower frame. Secure air conditioner (70) to the frame with four bolts (84). See Illustration 11.

   Reposition foot pedal (110). Secure the foot pedal with the three bolts (111) and three hard washers (112) which were retained in the previous step.

   Remove the protective paper strip from insulation (77) and install the adhesive side to the plate around foot pedal (110) .

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 12	g01453922
(116) 258-2443 Belt Guard (117) 101-2867 Hard Washer (118) (119) 270-9442 Screw

3. Remove the four screws (118) and the four hard washers (117). Loosen the two screws (119). Then, slide guard (16) upward and remove the guard. See Illustration 12.

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

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Illustration 13	g01453988
(120) (122) 266-3315 Bolt (121) 258-3532 Bracket As (123) 4D-6466 Clip

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

   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 348-4170 Cab Harness As .

   2. Remove bolt (122) in order to disconnect clip (123) from the rear tower plate temporarily. See Illustration 13. Retain the bolt for the reinstallation.

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

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

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Illustration 14	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 14. Discard the bolts and the hard washers.

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Illustration 15	g01621627
(17) 8T-4223 Hard Washer (18) 8T-4183 Bolt (50) 280-8395 Bracket (89) 4P-7429 Clip

6. Install bracket (50). Use the three new bolts (18) with three new washers (17) for installing the bracket. See Illustration 15.

   Note: Install clip (89) with the installation of the front bolt and washer. Orient the clip, as shown.

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Illustration 16	g01454597
(12) 8T-4121 Hard Washer (14) 8T-4195 Bolt (30) 315-7790 Plate (68) 258-4267 Hose As (71) 258-4296 Hose As (85) 276-9875 Refrigerant Compressor Gp

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

7. Install hoses (68) and (71) to compressor (85) per Step 7.a through Step 7.c. Refer to Illustration 16.

   1. Connect hose (68) to the discharge port on the compressor.

   2. Connect hose (71) to the suction port on the compressor.

   3. Install support (30) in order to hold the hoses in place. Install the support with bolt (14) and hard washer (12). Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 17	g01454800
(12) 8T-4121 Hard Washer (13) 8T-4133 Nut (15) 8T-4196 Bolt (49) 258-2466 Bracket (85) 276-9875 Refrigerant Compressor Gp

8. Install bracket (49) to compressor (85). Use two bolts (15), four washers (12), and two nuts (13), as shown. See Illustration 17.

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Illustration 18	g01454832
(12) 8T-4121 Hard Washer (13) 8T-4133 Nut (15) 8T-4196 Bolt (19) 8T-6685 Bolt (32) 113-0693 Lockwasher (50) 280-8395 Bracket (85) 276-9875 Refrigerant Compressor Gp

9. Install compressor (85) onto bracket (50). Use bolt (19), three hard washers (12), and nut (13) in order to secure the compressor to the top of bracket (50). See Illustration 18.

   Note: Insert bolt (19) from the front of bracket (50) so that nut (13) is installed on bolt (19) from the rear of bracket (50). Only hand tighten nut (13) .

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

   Then, install bolt (15), lock washer (32), and hard washer (12) in order to secure the compressor onto the bottom of bracket (50). Only hand tighten bolt (15) .

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Illustration 19	g01621633
(88) 7K-1181 Cable Strap (89) 4P-7429 Clip (140) 258-4116 Engine Harness As

10. Secure the engine harness (140) to clip (89) with a cable strap (88). See Illustration 19.

11. Connect the electrical connector on the compressor to connector E-C16 on the 258-4115 Engine Wiring Gp . See Table 4.
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    Table 4

    Connector E-C16
    Pin	Wire Color	Wire Number
    1	Pink	E554-E9
    2	Black	200-E36

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Illustration 20	g01454928
(13) 8T-4133 Nut (15) 8T-4196 Bolt (51) 258-3539 V-Belt

12. Install belt (51). Move the air conditioner compressor until the correct tension is achieved.

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

    Tighten the adjusting locknut (15) in order to maintain belt tension. Then, tighten the mounting bolt (13) on the compressor. See Illustration 20.

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Illustration 21	g01453922
(116) 258-2443 Belt Guard (117) 101-2867 Hard Washer (118) (119) 270-9442 Screw

13. Reinstall belt guard (116) with the screws and the hard washers that were retained in Step 3. Also, tighten screws (119). See Illustration 21.

14. Reinstall the fuel/water separator that was removed in Step 4. Reconnect the electrical connector to the 348-4171 Platform Harness As and secure the electrical connector with a cable strap. See Illustration 13.

Installing the 186-6190 Refrigerant Accumulator Gp

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Illustration 22	g01454508

1. Remove the two existing 266-3315 Bolts that are installed in the lower frame. See Illustration 22.

   Discard the two existing bolts.

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Illustration 23	g01453757
(76) 258-4388 Bracket As (84) 266-3315 Bolt

2. Install bracket (76) on the left wall of the lower frame, as shown. See Illustration 23.

   Note: Use the two new bolts (84) for installing the bracket. Tighten the bolts to a torque of 15 ± 3 N·m (11 ± 2 lb ft).

   Note: Apply sealant (88) to the threads of the new bolts.

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Illustration 24	g01455012
(4) 5P-0802 Seal (29) 101-8296 Clip

3. Install a 150 mm (6.0 inch) length of seal (4) to the concave surface inside each of the two clips (29). Install the seals by removing the protective strip from the back of the seals and by pressing the seals to the clips.

   Note: Make sure that the inside of the clips is clean and free of oil before you install the seals.

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Illustration 25	g01453758
(4) 5P-5924 Seal (12) 8T-4121 Hard Washer (14) 8T-4136 Bolt (29) 101-8296 Clips (38) 186-6190 Refrigerant Accumulator Gp (76) 258-4388 Bracket As

4. Place clips (29) around accumulator (38) so that the two clips encircle the body of the accumulator. Then, mount the clips with the accumulator to the bracket (76). Use two bolts (14) and two hard washers (12). See Illustration 25.

   Note: Only hand tighten the bolts.

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Illustration 26	g01455784
(X) 32° Angle (14) 8T-4136 Bolt (22) 9X-7378 O-Ring Seal (26) 9X-7383 O-Ring Seal (29) 101-8296 Clip (35) 149-6371 Pressure Switch (38) 186-6190 Refrigerant Accumulator Gp (71) 258-4296 Hose As (72) 258-4309 Hose As

5. Make the hose connection to the inlet (side port) on the accumulator. Install the end of hose (72) with the 90° coupling to the inlet (side port) on the accumulator. Use an O-ring (26) in this connection. See Illustration 26.

   Note: Hose (72) connects the outlet on the air conditioning unit to the inlet on the accumulator. Refer to Illustration 32.

   Route the free end of hose (72) toward the front of the machine for connection to the air conditioning unit.

6. Make the hose connection to the outlet (bottom port) on the accumulator. Install the free end of hose (71) with the pressure switch port to the outlet port. Use an O-ring (26) in this connection.

   Note: Hose (71) connects the outlet on the accumulator to the suction port on the compressor. Refer to Illustration 32.

   Install pressure switch (35) in the pressure switch port in hose (71). Use an O-ring (22) in this connection. Tighten the pressure switch to a torque of 8 ± 1.5 N·m (6 ± 1 lb ft).

7. Orient the inlet on the accumulator at a 32° angle, as shown. See Detail A in Illustration 26.

   Then, tighten bolts (14) in order to secure the accumulator within clips (29). Tighten the bolts to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

Installing the 266-2426 Condenser Coil As

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Illustration 27	g01455308
(126) 216-4983 Clamp (127) 215-4012 Clamp (128) 109-5351 Hose , 216-0066 Hose , and 280-8327 Tube (129) 8T-4200 Bolt (130) 5P-4116 Hard Washer (131) 258-3269 Cover

1. Remove clamp (126) and clamp (127) in order to remove hoses (128) between the ATAAC and the turbocharger. See Illustration 27.

   Note: Cover the ATAAC inlet and the turbocharger outlet in order to prevent dirt and foreign material from entering these openings.

2. Remove the three bolts (129) and three hard washers (130). Then, remove cover (131). Retain the bolts and the hard washers for the installation of the condenser coil. Discard cover (131) .

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Illustration 28	g01455317
(2) 3E-8082 Seal (81) 266-2426 Condenser Coil As

3. Install seal (2) onto the condenser coil (81), as shown. See Illustration 28.

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Illustration 29	g01455388
(2) 3E-8082 Seal (81) 266-2426 Condenser Coil As (129) 8T-4200 Bolt (130) 5P-4116 Hard Washer

4. Install condenser (81) to the ATAAC, as shown. See Illustration 29.

   Use the three bolts (129) and the three hard washers (130) that were retained in Step 2.

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Illustration 30	g01456209
(22) 9X-7378 O-Ring Seal (23) 9X-7380 O-Ring Seal (24) 9X-7381 O-Ring Seal (47) 236-6923 Pressure Switch (68) 258-4267 Hose As (69) 258-4268 Hose As

5. Make the hose connection to the inlet on the condenser. Install the free end of hose (68) to the inlet on the condenser. Use an O-ring (24) in this connection. See Illustration 30.

   Note: Hose (68) connects the discharge port on the compressor to the inlet on the condenser. Refer to Illustration 32.

   Install pressure switch (47) in the pressure switch port in hose (68). Use an O-ring (22) in this connection. Tighten the switch to a torque of 8 ± 1.5 N·m (6 ± 1 lb ft). See Illustration 30.

6. Make the hose connection to the outlet on the condenser. Install the end of hose (69) without the charge pressure port to the outlet. Use an O-ring (23) in this connection. See Illustration 30.

   Note: Hose (69) connects the outlet on the condenser and the inlet on the air conditioning unit. Refer to Illustration 32.

   Route the free end of hose (69) toward the front of the machine to the air conditioning unit.

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Illustration 31	g01456227
(126) 216-4983 Clamp (127) 215-4012 Clamp (128) 109-5351 Hose , 216-0066 Hose , and 280-8327 Tube

7. Reinstall hoses (128), clamp (126), and clamp (127). See Illustration 31.

   Tighten the clamps to a torque of 7.5 ± 1 N·m (5.5 ± 0.7 lb ft).

Air Conditioner Hose Connections

Illustration 32	g01455561
This view shows the connections of the air conditioner hoses. (22) 9X-7378 O-Ring Seal (23) 9X-7380 O-Ring Seal (24) 9X-7381 O-Ring Seal (25) 9X-7382 O-Ring Seal (26) 9X-7383 O-Ring Seal (35) 149-6371 Pressure Switch (38) 186-6190 Refrigerant Accumulator Gp (47) 236-6923 Pressure Switch (68) 258-4267 Hose As (69) 258-4268 Hose As (70) 258-4290 Air Conditioner Gp (71) 258-4296 Hose As (72) 258-4309 Hose As (81) 266-2426 Condenser Coil As (85) 276-9875 Refrigerant Compressor Gp

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Illustration 33	g01455795
(3) 3S-2093 Cable Strap (24) 9X-7381 O-Ring Seal (25) 9X-7382 O-Ring Seal (70) 258-4290 Air Conditioner Gp (69) 258-4267 Hose As (72) 258-4309 Hose As (87) 246-9039 Information Plate

1. Make the hose connection to the inlet on the air conditioning unit. Install the free end of hose (69) to the inlet tube. Use an O-ring (24) in this connection. See Illustration 33.

   Note: Hose (69) connects between the outlet on the condenser coil and the inlet on the air conditioning unit. Refer to Illustration 32.

2. Make the hose connection to the output on the air conditioning unit. Install the free end of hose (72) to the outlet tube. Use an O-ring (25) in this connection. See Illustration 33.

   Note: Hose (72) connects between the outlet on the air conditioning unit and the inlet port on the accumulator. Refer to Illustration 32.

   Use a cable strap (3) and install instruction plate (87) near the air conditioning charging port on hose (72), as shown.

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Illustration 34	g01456710
This view shows the components that are used to secure the air conditioner hoses. (37) 178-3620 Strap (40) 132-5789 Clip (84) 266-3315 Bolt

3. Secure the air conditioner hoses per instructions in Table 5.
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   Table 5

   Location	Action Refer to Illustration 34.
   (A)	Secure hose (68) to hose (71) with one strap (37).
   (B)	Secure hose (69) to hose (71) with one strap (37).
   (C)	Secure hose (69) to hose (72) with one strap (37).
   (D)	Secure hose (69) to hose (72) with one strap (37). Then, tie the strap to the side wall with one tie anchor (40) and one bolt (84).

Installing the Heater Hoses

1. Cut hose (33) into the two lengths that are specified in Table 6.
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   Table 6

   Hose	Routing	Length
   33A	Connected between the radiator inlet and the heater outlet	2155 mm (85 inch)
   33B	Connected between the heater inlet and the engine block outlet	3111 mm (122.5 inch)

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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.

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Illustration 35	g01456296
(11) 8T-0154 Hose Clamp (33B) 3111 mm (122.5 inch) length of 136-1953 Hose (33) (46) 218-6645 Elbow

2. Remove the plug from the engine block outlet and install elbow (46) into the outlet. Use sealant (88) on the threads of elbow (46). Then, install one end of hose (33B) to elbow (46) with a hose clamp (11). See Illustration 35. Tighten the hose clamp to a torque of 4.5 ± 0.5 N·m (3.3 ± 0.4 lb ft).

   Route the free end of hose (33B) toward the front of the machine to the heater inlet.

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Illustration 36	g01456297
(11) 8T-0154 Hose Clamp (28) 004-6810 Elbow (33A) 2155 mm (85 inch) length of 136-1953 Hose (33)

3. Remove the plug from the radiator inlet and install elbow (28). Use sealant (88) on the threads of elbow (28). Then, install one end of hose (33A) to elbow (28) with a hose clamp (11). See Illustration 36. Tighten the hose clamp to a torque of 4.5 ± 0.5 N·m (3.3 ± 0.4 lb ft).

   Route the free end of hose (33A) toward the front of the machine to the heater outlet.

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Illustration 37	g01456319
(11) 8T-0154 Hose Clamp (33A) 2155 mm (85 inch) length of 136-1953 Hose (33) (33B) 3111 mm (122.5 inch) length of 136-1953 Hose (33)

4. Install the free end of hose (33B) to the heater inlet with a hose clamp (11). See Illustration 37. Tighten the hose clamp to a torque of 4.5 ± 0.5 N·m (3.3 ± 0.4 lb ft).

5. Install the free end of hose (33A) to the heater outlet with a hose clamp (11). See Illustration 37. Tighten the hose clamp to a torque of 4.5 ± 0.5 N·m (3.3 ± 0.4 lb ft).

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Illustration 38	g01455798
(6) 6D-1641 Clip (11) 8T-0154 Hose Clamp (12) 8T-4121 Hard Washer (14) 8T-4136 Bolt (27) 9X-8250 Clip (28) 004-6810 Elbow (33A) 136-1953 Hose (33) (33B) 136-1953 Hose (33) (37) 178-3620 Strap (46) 218-6645 Elbow (84) 266-3315 Bolt

6. Secure the hoses per instruction in Table 7.

   Note: Maintain the distances between fasteners that are specified in Table 8.

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   Table 7

   Location	Action Refer to Illustration 38.
   (BB), (B)	Secure hose (33A) and hose (33B) to the right side wall of the lower frame with one clip (6 ) and one bolt (84). See Illustration 39.
   (CC), (C)	Secure hose (33A) and hose (33B) to the 258-3501 Bracket As with one clip (6 ), one bolt (14) and one hard washer (12). The 258-3501 Bracket As is part of the 258-3276 Lowering Control Lines Gp .
   (DD), (D)	Secure hose (33A) and hose (33B) to the right side wall of the upper frame with one clip (6 ) and one bolt (84). See Illustration 40.
   (EE)	Secure hose (33A) to the 258-2547 Hose with one strap (37).
   (E), (F)	Secure hose (33B) to the rear frame of the 258-2549 Aftercooler Core As . Use one clip (27) with the existing 8T-4908 Bolt and the existing 5P-4116 Hard Washer for each location.
   (G), (H)	Secure hose (33B) to the 258-2546 Hose with one strap (37) at each location.

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   Table 8

   Location Refer to Illustration 38.	Distance between fasteners
   (AA) - (BB)	375 mm (14.8 inch)
   (BB) - (CC)	545 mm (21.5 inch)
   (CC) - (DD)	620 mm (24.4 inch)
   (DD) - (EE)	450 mm (17.7 inch)
   (A) - (B)	362 mm (14.3 inch)
   (B) - (C)	553 mm (21.8 inch)
   (C) - (D)	685 mm (27.0 inch)
   (D) - (E)	350 mm (13.8 inch)
   (E) - (F)	165 mm (6.5 inch)
   (F) - (G)	373 mm (14.7 inch)
   (G) - (H)	381 mm (15.0 inch)

Illustration 39	g01456357
This illustration is a view of the routing of the heater hoses along the left wall of the lower frame. (6) 6D-1641 Clip (12) 8T-4121 Hard Washer (14) 8T-4136 Bolt (33A) 136-1953 Hose (21) (33B) 136-1953 Hose (21) (84) 266-3315 Bolt

Illustration 40	g01456356
This illustration is a view of the routing of the heater hoses in the engine compartment. (6) 6D-1641 Clip (27) 9X-8250 Clip (33A) 136-1953 Hose (33) (33B) 136-1953 Hose (33) (37) 178-3620 Strap (84) 266-3315 Bolt

Installing the Harness

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Illustration 41	g02344199
(3) 3S-2093 Cable Strap (42) 206-2423 Saddle (58) 348-4173 Heater and Air Conditioner Harness As

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Illustration 42	g02344316
(3) 3S-2093 Cable Strap (42) 206-2423 Saddle (58) 348-4173 Heater and Air Conditioner Harness As

1. Route harness (58) per the harness routing that is shown in Illustration 41.

   Install harness (58) per the actions that are specified in Table 9.

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   Table 9

   Harness Connector		Action
   AC-C1	12-Pin Plug 200 BK A523 PU 124 GN 515 GY 516 GN 517 BU 520 WH	Connect to connector HV-C1 for the 266-2430 Air and Temperature Control and Wiring Gp (82)
   AC-C2	2-Pin Plug 514 PU 200 BK	This connector is not used for this kit. Tie the receptacle to the harness with a cable strap (3).
   AC-C3	2-Pin Plug 514 PU 200 BK	This connector is not used for this kit. Tie the receptacle to the harness with a cable strap (3).
   AC-C10	Delphi Relay Base A510 OR 124 GN C510 WH E554 PK	Install air conditioner control group (44) into this receptacle. Secure this component onto the top of the main control valve as shown. Use existing bolt (140) and install control group (44) in tandem with clip (141).
   AC-C5	2 Position Delphi Plug 597 PU A509 PK	Connect to pressure switch (47) which is installed in hose (68) at the inlet of the compressor.
   AC-C6	Delphi Relay Base 125 OR 520 WH 200 BK 514 PU	Insert relay assembly (48) into the base. Tie the relay to the harness with a cable strap (3).
   AC-C7	6-Pin Receptacle 124 GN 125 OR A510 OR C510 WH E554 PK	Connect to connector C-C8 in the 348-4170 Cab Harness As : 124 GN 125 OR A510 OR C510 WH E554 PK
   AC-C8	2-Pin Plug 589 GN 597 PU	Connect to pressure switch (35) which is installed in hose (71) at the outlet of the accumulator.
   AC-C9	8-Pin Plug 200 BK A523 PU 124 GN 515 GY 516 GN 517 BU 200 BK A509 PK	Connect to the air conditioning unit (70).

   Secure the harness to existing harnesses, hoses, and components with the cable straps (3) and the saddles (42) that are shown in Illustration 41. Install the cable straps (3) and the saddles (42) in the locations that are shown in Illustration 42.

   Note: Ensure that the configurations of the harness connectors match the configurations that are specified in Table 9.

Installing the Ducts

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Illustration 43	g01456528
(135) 258-4028 Cover-Duct

1. Remove two covers (135) from the floor liner. See Illustration 43.

   Discard the two covers.

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Illustration 44	g01456529
(136) 258-4027 Cover (137) 258-3727 Screw (138) 5P-4116 Hard Washer

2. Remove cover (136) from the rear liner. See Illustration 44.

   Note: In order to remove this cover, remove two screws (137) and two hard washers (138) that are installed behind the rear liner.

   Discard the screws, the hard washers, and the cover.

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Illustration 45	g01456530
(8) 6V-7357 Bolt (16) 8T-4205 Hard Washer (52) 258-3727 Screw (56) 258-3795 Seal (65) 258-4259 Outlet Duct As

3. Remove the protective paper strip from seals (56). Install the adhesive side of the seals onto duct (65). See Illustration 45.

   Position duct (65) under the floor liner. Secure the duct to the floor liner with two screws (52) and two hard washers (16). Tighten the screws to a torque of 2.25 ± 0.25 N·m (1.7 ± 0.2 lb ft).

   Then, install two bolts (8) and two hard washers (16) in order to secure the rear portion of the duct to the floor liner. Tighten the bolts to a torque of 6 ± 1 N·m (4.4 ± 0.7 lb ft).

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Illustration 46	g01456531
(34) 146-6371 Louver As (61) 258-4253 Duct As (62) 258-4254 Duct As (65) 258-4259 Outlet Duct As

4. Install three louvers (34) in duct (61) and install three louvers (34) in duct (62) .

   Note: The louvers snap into the openings that are provided on the ducts.

   Position duct (61) onto the right flange of outlet duct (65). Position duct (62) onto the left flange of outlet duct (65). See Illustration 46.

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Illustration 47	g01456532
(61) 258-4253 Duct As (62) 258-4254 Duct As (86) 312-0131 Screw

5. Secure duct (61) with two screws (86) and secure duct (62) with two screws (86), as shown. See Illustration 47.

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

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Illustration 48	g01456533
(10) 7X-2031 Retainer (45) 215-6406 Screw (64) 357-8751 Duct As (66) 258-4263 Plate (67) 357-8807 Cover As (74) 258-4379 Knob As (79) 265-6619 Cab Air Filter

6. Assemble plate (66) to duct (64) with screw (45), as shown. Tighten the screw to a torque of 6 ± 1 N·m (4.4 ± 0.7 lb ft). See Illustration 48.

   Insert air filter (79) into the opening in duct (64) .

   Assemble knob (74) onto cover (67) with a retainer (10). Then, position the top of cover (74) onto plate (66) and fasten the cover in place with knob (74). Tighten the knob hand tight.

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Illustration 49	g01456534
(7) 6V-6689 Screw (54) 258-3793 Seal (60) 258-4249 Inlet Duct (64) 357-8751 Duct As

7. Peel the protective paper strip from seal (54). Install the adhesive side around the duct flange of duct (60). Assemble duct (64) onto duct (60) .

   Drill a 2.0 mm (0.08 inch) pilot hole on each side of the duct flange that will penetrate both ducts. Then, install two screws (7) in order to fasten the two ducts together. See Illustration 49. Tighten the screws to a torque of 0.9 ± 0.1 N·m (0.66 ± 0.07 lb ft).

   Note: A small hole is provided on each side of the duct flange in order to indicate the locations for drilling the pilot holes.

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Illustration 50	g01456535
(9) 6V-9334 Seal (9A) 325 mm (12.8 inch) length of seal (9) (9B) 140 mm (5.5 inch) length of seal (9)

8. Cut two 325 mm (12.8 inch) lengths and two 140 mm (5.5 inch) lengths of seal (9) .

   Remove the protective paper strip from each length of seal (9). Install the adhesive side of the seal around the opening in the rear liner. See Illustration 50.

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Illustration 51	g01456553
(16) 8T-4205 Hard Washer (36) 163-3955 Bolt (45) 215-6406 Screw (60) 258-4249 Inlet Duct (64) 357-8751 Duct As (65) 258-4259 Outlet Duct As

9. Place the assembled ducts in position, as shown. See Illustration 51.

   Fasten duct (64) to the side wall of the cab with two screws (45). Tighten the bolts to a torque of 6 ± 1 N·m (4.4 ± 0.7 lb ft).

   Fasten duct (60) to duct (65) with two bolts (36) and two hard washers (16). Tighten bolts to a torque of 2.25 ± 0.25 N·m (1.7 ± 0.2 lb ft).

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Illustration 52	g01456554
(5) 5P-4116 Hard Washer (43) 206-9185 Bolt (60) 258-4249 Inlet Duct (64) 357-8751 Duct As

10. Also, install bolt (43) and hard washer (5) in order to secure the ducts to the back of the rear liner. Tighten the bolt to a torque of 6 ± 1 N·m (4.4 ± 0.7 lb ft). See Illustration 52.

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Illustration 53	g01456555
(10) 7X-2031 Retainer (59) 258-4248 Louver Cover (73) 258-4378 Knob As (78) 265-6618 Cab Air Filter

11. Insert filter (78) into the air duct in the rear liner. See Illustration 53.

    Assemble the two knobs (73) to cover (59) by using retainers (10). Then, place cover (59) in position over the air duct and secure the cover to the rear liner with knobs (73). Tighten the knobs hand tight.

Completing the Installation

1. Reinstall all components that were temporarily removed in order to facilitate the installation of this kit.

2. Ensure that all electrical connections have been completed.

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.

Enabling Air Conditioning in Electronic Control Module (ECM)

The air conditioning will need to be installed through Electronic Technician (ET) on machines that have ECM 361-3092 Machine Software Gp or earlier. Refer to Illustration 54 and Illustration 55 below for installation selections.

Illustration 54	g02338658

Illustration 55	g02338659

Checking the Installation

1. Refill the cooling system.

   Refer to "Coolant Recommendations", "Cooling System Level - Check", and "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 air and temperature controls for proper operation.

Appendix

Operation of the Control Panel

Illustration 56	g01456642
Air and temperature control (140) Fan control switch (141) Air conditioning control switch (142) Temperature control knob

1. The fan control switch (140) controls the three-speed blower fan motor.
   • The first switch position is OFF.

   • The second switch position is Low fan speed.

   • The third switch position is Medium fan speed.

   • The fourth switch position is High fan speed.

2. The rocker switch (141) turns the air conditioner ON and OFF.
   • Press the top portion of the rocker switch in order to turn on the air conditioner.

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

3. The temperature control knob (142) 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.

Instructions for Using Pressure Sensitive Adhesive

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

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.

Service Parts

Table 10

3E-3364 Receptacle  (1) Service Replacement
Item	Quantity	Part Number	Description
-	1	102-8802	Receptacle Kit

( 1 )

Discontinued Item

Table 11

3E-8082 Seal  (1) Service Replacement
Item	Quantity	Part Number	Description
-	41 cm (16 inch)	5P-8309	Seal

( 1 )

Discontinued Item

Table 12

5P-0802 Seal  (1) Service Replacement
Item	Quantity	Part Number	Description
-	30 cm (11.8)	5P-5924	Seal

( 1 )

Discontinued Item

Table 13

6v-9334 Seal  (1) Service Replacement
Item	Quantity	Part Number	Description
-	100 cm (39 inch)	6V-9335	Seal

( 1 )

Nonserviceable Item

Table 14

186-6190 Refrigerant Accumulator Gp  (1) Service Replacement
Item	Quantity	Part Number	Description
-	1	176-3900	Refrigerant Accumulator Gp

( 1 )

Discontinued Item

Table 15

212-2204 Air Conditioner Control Gp  (1)
Item	Quantity	Part Number	Description
-	1	155-2271	Connecting Plug Kit
-	4	186-3736	Connector Socket

( 1 )

Nonserviceable Item