Installing the 361-0444 Air Conditioner Installation Kit Caterpillar

Skid Steer Loader:

236B3 (S/N: A9H1-UP)

Introduction

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

ReferenceDisassembly and Assembly, RENR4868, "Machine Systems - 236B, 246B, 252B, and 262B Skid Steer 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 236B, 246B, 252B and 262B machines and the 248B and 268B 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.

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

In order to prevent damage to the condenser coil, use a wrench to support the connectors when torquing 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 361-0444 Air Conditioner Installation Kit

The 361-0444 Air Conditioner Installation Kit on 236B3 Machines

Illustration 1	g02326334
The configuration of the kit on 236B3 machines (A) 218-6405 Air Conditioner Gp (B) 186-6190 Refrigerant Accumulator Gp (C) 326-5377 Air Conditioner Lines Gp (D) () 326-5357 Refrigerant Compressor Gp (E) 218-6148 Refrigerant Condenser and Mounting Gp

Installation Instructions

Preparing for the Installation

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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 four 8T-6869 Bolts bolts and the four hard washers that secure the heater to the left sidewall of the lower frame. Discard the bolts and washers.

2. Separate the heater from the duct. Remove the two 6V-6689 Screws that secure the duct to the heater and to the right console. Retain these screws for reinstallation.

3. Separate the heater from the left console. Retain the seal that is installed between the front of the heater and the left console for installation of the heating and air conditioning unit.

4. Disconnect the heater hoses from the heater inlet and the heater outlet. Retain the hose clamps for reinstalling the hoses to the heating and air conditioning unit.

Note: Temporarily remove the following components in order to facilitate installation of the kit.

• Duct

• Left Console

• Right Console

• Vertical Floorplate

Installing the 218-6148 Refrigerant Condenser and Mounting Gp

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Illustration 2	g02336176
(15) 218-6060 Shroud (16) 218-6250 Fan (18) 116-5763 Spring Clip (21) 8T-4224 Hard Washer (22) 8T-4189 Bolt (34) 8T-4121 Hard Washer (35) 5C-7261 Nut (38) 252-0348 Coil (40) 8T-4133 Nut (42) 5P-4116 Hard Washer (43) 6B-2882 Spacer (44) 8T-4908 Bolt

1. Assemble the 218-6148 Refrigerant Condenser and Mounting Gp .

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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 system oil 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	g02336228
Mounting the 218-6148 Refrigerant Condenser and Mounting Gp (34) 8T-4121 Hard Washer (40) 8T-4133 Nut (M10x1.5) (43) 6B-2882 Spacer

3. Mount the 218-6148 Refrigerant Condenser and Mounting Gp in the opening in the front wall of the engine compartment. Use four spacers (43), four hard washers (34), and four M10x1.5 nuts (40) .

Installing the 186-6190 Refrigerant Accumulator Gp

Illustration 4	g02336238
Installing the 186-6190 Refrigerant Accumulator Gp (1) 101-8296 Clip (10) 186-6190 Refrigerant Accumulator Gp (14) 085-8091 Bolt (M10x1.5) (34) 8T-4121 Hard Washer (41) 9C-2741 Spacer (51) 5P-0802 Seal

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

   Place clips (1) around accumulator (10) so that the two clips encircle the body of the accumulator.

2. Mount accumulator (10) to the bosses that are provided on the left wall of the lower frame. Use two spacers (41), two bolts (14) and two hard washers (34). Position the accumulator (10), as shown.

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.

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

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Illustration 6	g02332036

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	g02332053
(23) 8T-4223 Hard Washer (124) 8T-4192 Bolt

5. Remove the three bolts (124) and the three hard washers (23). Discard the bolts and the hard washers.

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Illustration 8	g02336405
(23) 8T-4223 Hard Washer (33) 8T-4183 Bolt (36) 280-8395 Bracket (52) 4P-7429 Clip

6. Install bracket (36). Use the three new bolts (33) with three new washers (23) for installing the bracket.

   Note: Install clip (42) with the installation of bolt (33) and hard washer (23). Orient the clip, as shown.

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Illustration 9	g02328074
(2) 315-7790 Plate (12) 326-5379 Hose As (13) 326-5378 Hose As (25) 276-9875 Refrigerant Compressor Gp (32) 8T-4195 Bolt (34) 8T-4121 Hard Washer

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

7. Install hoses (12) and (13) to compressor (25) per Step 7.b through Step 7.c.

   1. Connect hose (12) to the compressors suction port.

   2. Connect hose (13) to the compressors discharge port.

   3. Install plate (2) in order to hold the hoses in place. Install the plate with bolt (32) and hard washer (34) .

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Illustration 10	g02336276
(25) 276-9875 Refrigerant Compressor Gp (31) 8T-4196 Bolt (34) 8T-4121 Hard Washer (37) 258-2466 Bracket (40) 8T-4133 Nut

8. Install bracket (37) to compressor (25). Use two bolts (31), four washers (34), and two nuts (40), as shown.

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Illustration 11	g02332133
(25) 276-9875 Refrigerant Compressor Gp (29) 113-0693 Lockwasher (30) 8T-6685 Bolt (31) 8T-4196 Bolt (34) 8T-4121 Hard Washer (36) 280-8395 Bracket (40) 8T-4133 Nut

9. Install compressor (25) onto bracket (48). Use bolt (30), three hard washers (34), and nut (40) in order to secure the compressor to the top of bracket (36).

   Note: Insert bolt (30) from the front of bracket (36). Insert the bolt so that nut (40) is installed on bolt (30) from the rear of bracket (36), as shown. Only hand tighten nut (40) in this part of the procedure.

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

   Then, install bolt (31), lock washer (29), and hard washer (34) in order to secure the compressor onto the bottom of bracket (36). Only hand tighten bolt (31) in this part of the procedure.

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Illustration 12	g02336317
(5) 189-3158 Arc Suppressor (7) 7K-1181 Cable Strap (42) 4P-7429 Clip (150) 328-2276 Engine Wiring Gp

10. Secure the engine harness (150) to clip (42) with a cable strap (7).

    1. Remove seal caps from the 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 (5) to the 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	g02341556
(14) 8T-4133 Nut (16) 8T-4196 Bolt (39) 258-3539 V-Belt

13. Install belt (39). 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).

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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) .

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.

Installing the 218-6405 Air Conditioner Gp

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Illustration 15	g02337997
Preparing the heating and air conditioning unit (H) Heater inlet (J) Heater outlet (K) Air conditioner inlet (L) Air conditioner outlet (9) 218-5685 Hose As (17) 218-5686 Hose As (45) 9X-7381 O-Ring Seal (46) 9X-7382 O-Ring Seal (53) 218-6405 Air Conditioner Gp (55) 218-6402 Insulation As

1. Connect hose assembly (17) to the air conditioner inlet (K). Use an O-ring seal (45) in this connection.

2. Connect hose assembly (9) to the air conditioner outlet (L). Use an O-ring seal (46) in this connection.

3. Attach insulation (55) to the side of the air conditioning box. Ensure that the inserts in the insulation are facing the outside. Place the Air Conditioner Gp (53) in position on the left side of the lower frame.

4. Connect the two heater hoses to the heater inlet (H) and to the heater outlet (I) on the bottom of heater. Use the two hose clamps that were previously removed for these connections.

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

   Note: The free end of the hose that is connected to the engine block connects to the heater inlet. The free end of the hose that is connected to the radiator connects to the heater outlet.

5. Mount the heating and air conditioning unit to the lower frame. Use the four bolts 8T-6869 (54) and the four hard washers 8T-4224 (21) that were previously removed.

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

Installing the 326-5377 Air Conditioner Lines Gp Air Conditioner Lines

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

2. In order to prevent damage to the condenser coil, use a wrench to support the connectors when torquing the hose connections to the condenser coil

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

Illustration 16	g02338688
(1) 101-8296 Clip (2) 315-7790 Plate (3) 178-3620 Strap (4) 095-0913 Clip (5) 189-3158 Arc Suppressor (6) 200-6345 Mount (7) 7K-1181 Cable Strap (8) 221-3879 Heater and Air Conditioner Harness As (9) 218-5685 Hose As (10) 186-6190 Refrigerant Accumulator Gp (11) 312-2179 Bracket As (12) 326-5378 Hose As (13) 326-5379 Hose As (14) 085-8091 Bolt (17) 218-5686 Hose As (19) 3s-2093 Cable Strap (20) 6D-4246 Clip (21) 8T-4224 Hard Washer (22) 8T-4189 Bolt (26) 234-0566 Fitting As (27) 236-6923 Pressure Switch (28) 246-9039 Information Plate (34) 8T-4121 Hard Washer (41) 9C-2741 Spacer (45) 9X-7378 O-Ring Seal (46) 9X-7380 O-Ring Seal (47) 9X-7381 O-Ring Seal (48) 9X-7382 O-Ring Seal (49) 9X-7383 O-Ring Seal (50) 5P-0802 Seal

1. Route the free end of hose assembly (9) to the accumulator. Connect the hose to fitting assembly (26). Use an O-ring seal (49) in this connection.

2. Route the free end of hose assembly (17) to the condenser. Connect the hose assembly to the condenser outlet port. Use an O-ring seal (46) in this hose connection.

3. Secure hose (12) to engine harness assembly (60) using strap (3) .

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Illustration 17	g02340058
(25) 276-9875 Refrigerant Compressor Gp

4. Instructions for the installation of compressor (25) follow.

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Illustration 18	g02338697
(62) 142-8719 Adapter Plate

5. Secure hose (13) to the flywheel adapter plate (62) using one bracket assembly (11), one clip (4), one washer (21), and one bolt (22). Note the orientation of the bracket and loop portion of the clip (4) .

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Illustration 19	g02338699

6. Secure hose (13) to the hydrostatic lines using two cable straps (7) and one mount (6). Ensure that the air conditioner hose passes between the hydrostatic hoses and the hydrostatic pump.-

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Illustration 20	g02338717

7. Connect the free end of hose (12) to accumulator (10). Use o-ring (49) in this connection. Ensure that the hose coupling orientation, with respect to the frame side sheet is as shown in the illustration that is above.

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Illustration 21	g02340116

8. Secure hose (12) to rear engine mount using bracket assembly (11) and clip (20) .

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Illustration 22	g02339337
(F) Condenser inlet port

9. Attach the free end of hose (12) to the condenser inlet port (top port) (F). Use o-ring (47) in this connection.

10. Install pressure switch (27) in the fitting for hose assembly (17). Use an o-ring seal (45) in this connection.

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

11. Use a cable strap (19) and install plate (28) to fitting assembly (26) .

Installing the Air Conditioner Wiring Group

Illustration 23	g02331333
The 221-3879 Heater and Air Conditioner Harness As (7) 7K-1181 Cable Strap (8) 221-3879 Heater and Air Conditioner Harness As (13) 3S-2093 Cable Strap (AC-T1) Ground Stud (AC-C1) HVAC (AC-C2) Condenser Fan (AC-C3) Condenser Fan (AC-C4) Pressure Switch (AC-C5) Connector P-C32 on platform harness (513-OR wire)

Table 2

221-3879 Heater and Air Conditioner Harness As
Connector ID	Connection
AC-T1	Ground stud
AC-C1	HVAC
AC-C2	Condenser Fan
AC-C3	Condenser Fan
AC-C4	Pressure switch
AC-C5	Connector P-C32 on platform harness (513-OR wire)

1. Install harness (25) by making the connections.

2. Install harness (12) by making the connections that are specified in the table that is above.

3. Secure the harnesses to existing harnesses with cable straps (30) .

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

   • Duct

   • Left Console

   • Right Console

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 A-C8 in the 216-4702 Platform Harness As (Lower) .

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Illustration 24	g01043405
Position in the fuse block for the 20 amp fuse for the heater/air conditioner fan

4. Replace the 20 amp fuse that is installed in the fuse block for the heater/air conditioner fan with the 30 amp fuse (7) .

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 25	g01043401

   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

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.

Accessing the Cab Air Filters

Illustration 26	g01043399
Accessing the cab air filters (S) 231-8132 Cab Air Filter (T) 231-8130 Cab Air Filter

Parts List

Table 3

The 361-0444 Air Conditioner Installation Kit
Item	Quantity	Part Number	Description
1	2	101-8296	Clip
2	1	315-7790	Plate
3	1	178-3620	Strap
4	1	095-0913	Clip
5	1	189-3158	Arc Suppressor
6	2	200-6345	Mount
7	5	7K-1181	Cable Strap
8	1	221-3879	Heater and Air Conditioner Harness As
9	1	218-5685	Hose As
10	1	186-6190	Accumulator Gp (3)
11	2	312-2179	Bracket As
12	1	326-5378	Hose As
13	1	326-5379	Hose As
14	2	085-8091	Bolt
15	1	218-6060	Shroud
16	2	218-6250	Fan
17	1	218-5686	Hose As
18	2	116-5763	Spring Clip
19	7	3S-2093	Cable Strap
20	1	6D-4246	Clip
21	26	8T-4224	Hard Washer
22	16	8T-4189	Bolt
23	3	8T-4223	Hard Washer
24	1	233-5927	Coil
25	1	276-9875	Refrigerant Compressor Gp
26	1	234-0566	Fitting As
27	1	236-6923	Pressure Switch
28	1	246-9039	Information Plate
29	1	113-0693	Lockwasher
30	1	8T-6685	Bolt
31	3	8T-4196	Bolt
32	1	8T-4195	Bolt
33	3	8T-4183	Bolt
34	15	8T-4121	Hard Washer
35	14	5C-7261	Nut
36	1	280-8395	Bracket
37	1	258-2466	Bracket
38	1	252-0348	Coil
39	1	258-3539	V-Belt
40	7	8T-4133	Nut
41	2	9C-2741	Spacer
42	3	5P-4116	Hard Washer
43	4	6B-2882	Spacer
44	3	8T-4908	Bolt
45	1	9X-7378	O-Ring Seal
46	1	9X-7380	O-Ring Seal
47	2	9X-7381	O-Ring Seal
48	1	9X-7382	O-Ring Seal
49	3	9X-7383	O-Ring Seal
50	3	5P-0802	Seal
52	1	4P-7429	Clip
53	1	218-6405	Air Conditioner Gp
54	4	8T-6869	Bolt
55	1	218-6402	Insulation As

( 3 )

.

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

5P-0802 Seal (32)
Item	Quantity	Part Number	Description
-	1	5P-5924	Seal

Table 6

122-6881 Hydraulic Hose (4)
Item	Quantity	Part Number	Description
-	1	122-6871	Hydraulic Hose

Table 7

186-6190 Refrigerant Accumulator Gp (10)
Item	Quantity	Part Number	Description
-	1	176-3900	Refrigerant Accumulator Gp