- Compact Track Loader
- 299D2 (S/N: FD21-UP; BY41-UP)
- Multi Terrain Loader
- 297D2 (S/N: BL71-UP)
- Skid Steer Loader
- 272D2 (S/N: BL21-UP)
Introduction
| Revision History | |
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| Revision | Summary of Changes |
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This Special Instruction provides the information that is necessary to install the 435-9232 Air Conditioner Kit (Conversion) on the listed machines.
Do not begin installation of this kit until you have read the information that is contained in this instruction.
Reference
Operation and Maintenance Manual, SEBU9084, "259D, 279D, 289D, 299D, and 299D XHP Compact Track Loaders, 257D, 277D, 287D, 297D, and 297D XHP Multi-Terrain Loaders and 236D, 242D, 246D, 262D, 272D, and 272D XHP Skid Steer Loaders"
Reference: Disassembly and Assembly, UENR6555, "299D2 and 299D2 XHP Compact Track Loaders, 297D2 and 297D2 XHP Multi-Terrain Loaders and 272D2 XHP Skid Steer Loaders Machine Systems"
Safety
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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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Personal injury can result from contact with refrigerant. This system is under pressure at all times, even if the engine is not running. Heat should never be applied to a charged system. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury. Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use caution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, evacuate the system recovering the refrigerant before removing the fitting. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Before any checks of the air conditioning and heating system are made, move the machine to a smooth horizontal surface. Lower all implements to the ground. Make sure the transmission is in neutral or park and that the parking brake is engaged. Keep all other personnel away from the machine or where they can be seen. |
| NOTICE |
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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 suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. |
Prepare the Machine for Service
- Park the machine on a flat, level work surface.
- Lower all implements to the ground.
- Place the transmission in either NEUTRAL or PARK.
- Engage the parking brake.
Required Parts
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Part Name |
| 1 | 18 | Cable Strap | |
| 2 | 1 | Cable Splice Sleeve | |
| 3 | 8 | Cable Strap | |
| 4 | 1 | Pressure Switch | |
| 5 | 2 | Cable Strap | |
| 6 | 1 | Pressure Switch | |
| 7 | 1 | Rocker Switch | |
| 8 | 2 | Mount | |
| 9 | 1 | Plate | |
| 10 | 1 | Coil | |
| 11 | 1 | Refrigerant Compressor Gp | |
| 12 | 1 | Lanyard | |
| 13 | 1 | Sleeve | |
| 14 | 1 | Air Conditioner Plate | |
| 15 | 1 | Hose As | |
| 16 | 1 | Hose As | |
| 17 | 1 | Heater and Air Conditioner Harness As | |
| 18 | 1 | Clamp | |
| 19 | 1 | Jam Nut | |
| 20 | 1 | Refrigerant Accumulator Gp | |
| 21 | 1 | Air Conditioner Fitting | |
| 22 | 1 | Bracket | |
| 23 | 1 | Hose As | |
| 24 | 1 | Tube As | |
| 25 | 1 | Elbow As | |
| 26 | 1 | V-Belt | |
| 27 | 1 | Hose As | |
| 28 | 1 | Hose As | |
| 29 | 1 | Relay As | |
| 30 | 3 | Locknut | |
| 31 | 1 | Clip | |
| 32 | 3 | Stud | |
| 33 | 2 | Hex Flange Nut | |
| 34 | 4 | Strap | |
| 35 | 2 | Bolt | |
| 36 | 3 | Bolt | |
| 37 | 2 | Bolt | |
| 38 | 3 | Bolt | |
| 39 | 1 | Clip | |
| 40 | 1 | Clip | |
| 41 | 1 | Clip | |
| 42 | 1 | Nut | |
| 43 | 10 | Hard Washer | |
| 44 | 2 | Clip | |
| 45 | 1 | Washer | |
| 46 | 3 | Hard Washer | |
| 47 | 1 | Nut | |
| 48 | 1 | Bolt | |
| 49 | 1 | Bolt | |
| 50 | 2 | Hard Washer | |
| 51 | 1 | Hard Washer | |
| 52 | 1 | Nut | |
| 53 | 1 | Bolt | |
| 54 | 1 | Clip | |
| 55 | 2 | Nut | |
| 56 | 2 | O-Ring Seal | |
| 57 | 3 | O-Ring Seal | |
| 58 | 3 | O-Ring Seal | |
| 59 | 2 | O-Ring Seal | |
| 60 | 3 | O-Ring Seal | |
Installation Procedure
Note: If the machine has the 388-8275 Cab Window Kit installed, removal of the 345-6290 Cab Window Gp from the left-hand side will ease the installation of the heater and air conditioner harness as. Refer to Special Instruction, REHS8707, "Installation of the 388-8275 Cab Window Kit".
- Remove air and temperature control group (A) from console assembly (B).
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Illustration 2 g03838323 View of rocker switch installation
(A) Air and Temperature Control Gp
(C) Plug
(7)266-0299 Rocker Switch - Remove plug (C) from the center of air and temperature control group (A), and install rocker switch (7).
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Illustration 3 g03838324 View of rocker switch installation
(A) Air and Temperature Control Gp
(B) Console As
(D) Heater and Air Conditioner Harness As
(7)266-0299 Rocker Switch - Connect heater and air conditioner harness assembly (D) to air and temperature control group (A) and rocker switch (7), then reinstall air and temperature control group (A) into console assembly (B).
- Raise the lift arms. Ensure that the lift arm brace is fully ENGAGED before proceeding. Refer to Operation and Maintenance, SEBU9084, "Loader Lift Arm Brace Operation" .
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Do not go beneath cab unless cab is empty and support lever is engaged.
Failure to follow the instructions or heed the warnings could result in injury or death.
Show/hide tableDo not tilt the cab using an open door. The door must be closed and latched when lifting the cab. The door may become dislodged from its hinges and may cause serious personal injury or death.
- Raise the cab. Ensure that the cab support lever is fully ENGAGED before proceeding. Refer to Operation and Maintenance, SEBU9084, "Cab - Tilt".
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Illustration 4 g03838329 View of belt guard
(E) Belt Guard - Remove belt guard (E) from the engine. Retain guard and existing hardware.
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Illustration 5 g03838333 View of hose installation
(F) Plate
(16)435-8934 Hose As - From the engine compartment, insert hose assembly (16) into plate (F).
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Illustration 6 g03838337 View of hose installation
(16)435-8934 Hose As
(55)9S-1354 Nut - From the cab side, secure hose assembly (16) using one nut (55). Torque nut (55) to the proper specification.
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Illustration 7 g06037310 View of securing the hose
(G) Tube
(H) Hose Assembly
(5)204-2281 Cable Strap
(8)290-5562 Mount
(16)435-8934 Hose As
(34)178-3620 Strap - Secure hose assembly (16) using three clamps (34) attached to tube (G). Secure hose (H) using two straps (5) and one dual mount (8)
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Illustration 8 g03838366 View of hose routing
(H)441-4801 Platform Harness As
(1)3S-2093 Cable Strap
(17)441-4799 Heater and Air Conditioner Harness As
(29)115-1615 Relay As
(36)266-3314 Bolt - From the engine compartment, route heater and air conditioner harness assembly (17) along platform harness assembly (H). Secure the two harnesses together with six cable straps (1).
- Mount relay assembly (29) to plate and using one flange bolt (36).
Torque flange bolt (36) to
12 ± 2 N (106 ± 18 lb in) Show/hide table
Illustration 9 g03838380 View of wiring routing
(H)441-4801 Platform Harness As
(J) AR-C1 Connector
(K) C-C22 Connector
(L) Bracket
(1)3S-2093 Cable Strap
(17)441-4799 Heater and Air Conditioner Harness As - Insert connector (J) through the grommet in the bracket assembly from the engine side of the bracket.
- From the cab side, route heater and air conditioner harness assembly (17) along platform harness assembly (H). Secure the two harnesses together with three cable straps (1).
- Insert connector (J) into connector (K). Secure the two connectors to bracket (M) with one cable strap (1).
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Illustration 10 g06037329 View of accumulator
(20)468-2705 Refrigerant Accumulator Gp
(25)487-9863 Elbow As
(60)9X-7383 O-Ring Seal - Connect elbow assembly (25) to the discharge port on accumulator (20). Orient the elbow assembly at a 25 degree angle, and then seal with one O-ring (60).
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Illustration 11 g03838391 View of accumulator installation
(M) Cap
(18)441-8048 Clamp
(20)468-2705 Refrigerant Accumulator Gp
(48)8T-4139 Bolt
(50)8T-4223 Washer
(52)8T-4244 Nut - Remove cap (M) from machine and discard. Assemble accumulator assembly (20) between clamp (18). Align accumulator (20) outlet with hole in frame and secure using washer (50), nut (52) and bolt (48).
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Illustration 12 g03838398 View of bracket installation
(22)470-8335 Bracket
(41)4P-8134 Clip
(36)266-3314 Bolt - Install bracket (22) to plate using two bolts (36). Install ladder clip (41) using bolt (36).
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Illustration 13 g03838409 View of fitting installation
(19)456-8850 Jam Nut
(20)468-2705 Refrigerant Accumulator Gp
(21)470-8331 Air Conditioner Fitting
(22)470-8335 Bracket
(24)513-8075 Tube As
(55)9S-1354 Nut
(57)9X-7380 O-Ring Seal
(60)9X-7383 O-Ring Seal - Place fitting assembly (21) through hole in bracket (22) and secure using nut (55) on fitting assembly (21).
- Insert o-ring (57) into opposite end of fitting assembly (21) and tighten to proper specification.
Use
1 (0.03 oz) of mineral-based refrigerant oil on o-ring and fittings prior to assembly. - Insert end of tube assembly (24) into bracket (22) and secure using jam nut (19). Connect opposite end to outlet of accumulator (20) using one o-ring (60) to seal the connection.
Use
1 (0.03 oz) of mineral-based refrigerant oil on o-ring and fittings prior to assembly.Torque jam nut (19) to
27 ± 4 N (239 ± 35 lb in) .Show/hide table
Illustration 14 g03838426 View of orifice installation
(P) Core
(R)232-1384 Air Conditioner Orifice As
(15)535-7342 Hose As
(59)9X-7382 O-Ring Seal - Ensure that air conditioner orifice assembly (R) has been installed into the inlet side of core (P) correctly. Connect hose assembly (15) to the inlet side of core (P). Use one o-ring seal (59) to seal the connection.
Use
1 (0.03 oz) of mineral-based refrigerant oil on o-ring and fittings prior to assembly.Show/hide table
Illustration 15 g03838441 view of hose installation
(P) Core
(23)470-8336 Hose As
(58)9X-7381 O-Ring Seal - Connect hose assembly (23) to the outlet side for core (P). Use one O-ring (58) to seal the connection.
Use
1 (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.Show/hide table
Illustration 16 g06310852 View of hose routing
(S) Hoses
(V) Clip
(3)7K-1181 Cable Strap
(15)535-7342 Hose As
(23)470-8336 Hose As
(38)342-9920 Bolt
(43)5P-4116 Hard Washer
(44)7D-1553 Clip - Route hose assembly (15) and hose assembly (23) along the bundle of hoses (S) and harness assembly, which are routed along the right-hand side of the cab blower.
- Secure the hoses to the bundle using several of the cable straps (3), including one cable strap attached to clip (V).
Note: Do not distort the hoses when tightening the Cable Straps.
- Replace the existing clip and hardware with one clip (44), one washer (43), and one bolt (38). Use this clip to secure hose assembly (5), hose assembly (23) and hoses (S) to the back of the cab.
Apply Loctite 243 to bolt (38) and torque to
6 ± 1 N (53 ± 9 lb in) Show/hide table
Illustration 17 g03838451 View of hose installation
(P) Core
(S) Hose
(15)435-8930 Hose As
(21)470-8331 Air Conditioner Fitting
(23)470-8336 Hose As
(30)513-8075 Tube As
(38)342-9920 Bolt
(43)5P-4116 Hard Washer
(44)7D-1553 Clip
(57)9X-7380 O-Ring Seal
(60)9X-7383 O-Ring Seal - Connect hose assembly (15) from core (P) to tube assembly (24) using one o-ring (60) to seal the connection. Tighten to proper specification.
Use
1 (0.03 oz) of mineral-based refrigerant oil on o-ring and fittings prior to assembly. - Connect hose assembly (23) from core (P) to fitting assembly (29) using one o-ring (57) to seal the connection. Tighten to proper specification.
Use
1 (0.03 oz) of mineral-based refrigerant oil on o-ring and fittings prior to assembly. - Replace the existing clip and hardware with one clip (44), one washer (43), and one bolt (38). Use this clip to secure hose assembly (15), hose assembly (23) and hoses (S) to the back of the frame.
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Illustration 18 g03838527 View of compressor
(11)345-4547 Refrigerant Compressor Gp
(31)132-5789 Clip
(46)8T-4121 Hard Washer
(47)8T-4133 Nut
(49)8T-4195 Bolt - Attach clip (31) to refrigerant compressor group (11). Secure the clip with one bolt (59), one nut (47), and two hard washers (46).
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Illustration 19 g03838535 View of compressor install
(X) Bracket As
(11)345-4547 Refrigerant Compressor Gp
(33)175-7141 Hex Flange Nut
(46)8T-4121 Hard Washer
(53)8T-6685 Bolt - Install refrigerant compressor group (11) onto bracket assembly (X). Use one bolt (53), one hard washer (46), and one hex flange nut (33) to secure the compressor.
Note: Do not tighten the bolt now.
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Illustration 20 g03838540 View of compressor installation
(9)345-3628 Plate
(11)345-4547 Refrigerant Compressor Gp
(33)175-7141 Hex Flange Nut
(35)208-9294 Bolt
(45)7X-7729 Washer - Attach plate (9) to refrigerant compressor group (11). Secure plate (9) with one hex flange nut (33) and one bolt (35).
Note: Do not tighten the bolt now.
- Install bolt (35) and washer (45) through plate and into bracket assembly.
Note: Do not tighten the bolt now.
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Illustration 21 g03838547 View of belt installation
(AA) Fan Drive Pulley
(11)345-4547 Refrigerant Compressor Gp
(26)241-2894 V-Belt - Install the v-belt (26) around fan drive pulley (AA) and the pulley on refrigerant compressor group (11).
Move refrigerant compressor group (11) to tension v-belt (26) to the proper setting. Tighten the mounting hardware for refrigerant compressor group (11) now.
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Illustration 22 g03838549 View of hose installation
(11)345-4547 Refrigerant Compressor Gp
(28)489-2266 Hose As
(58)9X-7381 O-Ring Seal - Connect hose assembly (28) to the discharge port on refrigerant compressor group (11). Seal the connection with one o-ring seal (58).
Use
1 (0.03 oz) of mineral-based refrigerant oil on o-ring and fittings prior to assembly.Show/hide table
Illustration 23 g03838553 View of hose installation
(3)7K-1181 Cable Strap
(16)435-8934 Hose As
(28)489-2266 Hose As
(37)266-3315 Bolt
(39)4D-7733 Clip
(43)5P-4116 Hard Washer - Combine hose assembly (28) and hose assembly (16) together and secure both using two tie straps (3). Use one clip (39), one flange bolts (50) and one washer (43).
Torque flange bolts (37) to
25 ± 3 N (221 ± 26 lb in) Show/hide table
Illustration 24 g06037390 View of hose installation
(11)345-4547 Refrigerant Compressor Gp
(27)510-0020 Hose As
(59)9X-7382 O-Ring Seal - Connect hose assembly (27) to the suction port on refrigerant compressor group (11). Seal the connection with one O-ring seal (59).
Use
1 (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.Show/hide table
Illustration 25 g06037404 View of hose installation
(25)487-9863 Elbow As
(27)510-0020 Hose As
(60)9X-7383 O-Ring Seal - Connect hose (27) to elbow assembly (25), seal the connection with one O-ring seal (60).
Use
1 (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.Show/hide table
Illustration 26 g06037414 View of hose routing
(S) Hose
(3)7K-1181 Cable Strap
(8)290-5562 Mount - Use two cable straps (3) and one dual mount strap (8) to secure hoses (S).
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Illustration 27 g03838622 View of coil installation
(CC)435-9100 Engine Enclosure Gp
(12)345-4552 Lanyard
(30)131-3540 Locknut
(32)9X-2098 Stud
(38)342-9920 Bolt
(42)5C-7261 Nut
(43)5P-4116 Hard Washer
(51)8T-4224 Hard Washer - Install three studs (32) onto engine enclosure group (CC), then add two washers (43) (one on each side) to each of the three studs.
Torque studs to
22 ± 2 N (195 ± 18 lb in) - Install coil onto the studs. Secure coil with one locknut (30) and two of washers (43) on the two uppers studs.
Torque nuts to
12 ± 3 N (106 ± 27 lb in) - Install lanyard (12) onto coil and secure with one bolt (38), one washer (51), and one nut (74).
Torque bolt to
12 ± 3 N (106 ± 27 lb in) Show/hide table
Illustration 28 g03838625 View of lanyard assembly
(CC)435-9100 Engine Enclosure Gp
(12)345-4552 Lanyard
(2)5P-7958 Cable Splice Sleeve - Assemble lanyard (12) and cable splice sleeve (2) as follows:
- Loop lanyard (12) through the nearest slot on engine enclosure group (CC). Then, assemble cable splice sleeve (2) onto the Lanyard.
- Use a compression tool to attach cable splice sleeve (2) to lanyard (12). Do not allow the lanyard to extend more than
5 ± 2 (0.2 ± 0.08 inch) past the end of cable splice sleeve (2).Note: The lanyard is to help prevent injury when unbolting the condenser.
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Illustration 29 g03838635 View of hose sleeve
(13)345-6079 Sleeve
(16)435-8934 Hose As
(28)489-2266 Hose As - Slide sleeve (13) over hose assembly (16) and hose assembly (28).
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Illustration 30 g03838642 View of hose routing
(1)3S-2093 Cable Strap
(30)131-3540 Locknut
(39)4D-7733 Clip
(43)5P-4116 Hard Washer - Route the hoses and sleeve around and under coil and secure with one clip (39), one washer (43), and one locknut (30) using the existing stud.
Secure the ends of the sleeve to the hoses with two cable straps (1).
Note: Supply enough slack in the hoses to allow for the opening of engine enclosure group.
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Illustration 31 g03838649 View of hose installation
(27)510-0020 Hose As
(28)489-2266 Hose As
(34)178-3620 Strap
(57)9X-7380 O-Ring Seal
(58)9X-7381 O-Ring Seal - Connect hose assembly (27) to the lower port of coil. Seal the connection with one O-ring seal (57). Connect hose assembly (28) to the upper port of coil. Seal the connection with one o-ring seal (58). Use one strap (34) to support the two hoses.
Use
1 mL (0.03 oz) of mineral-based refrigerant oil on o-ring and fittings prior to assembly.Show/hide table
Illustration 32 g03838874 View of pressure switch installation
(4)149-6371 Pressure Switch
(6)236-6923 Pressure Switch
(27)435-8931 Hose As
(28)435-8932 Hose As
(56)9X-7378 O-Ring Seal - Install pressure switch (4) onto hose assembly (28). Seal the connection with one o-ring seal (56).
Torque to
8 ± 1 N·m (71 ± 9 lb in) Use
1 mL (0.03 oz) of mineral-based refrigerant oil on o-ring and fittings prior to assembly. - Install pressure switch (6) onto hose assembly (27). Seal the connection with one o-ring seal (56).
Torque to
8 ± 1 N·m (71 ± 9 lb in) Use
1 mL (0.03 oz) of mineral-based refrigerant oil on o-ring and fittings prior to assembly.Show/hide table
Illustration 33 g03838882 View of wiring connections
(DD) AR-C9 connector
(EE) AR-C8
(1)3S-2093 Cable Strap
(11)345-4547 Refrigerant Compressor Gp
(31)132-5789 Clip - Connect the clutch lead from refrigerant compressor group (11) to connector (DD). Ensure that arc suppressor is connected to connector (EE).
Secure both connectors to clip (31) with one cable strap (1).
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Illustration 34 g03838887 View of wiring connections
(FF)469-2944 Tube As
(GG) AR-C6
(1)3S-2093 Cable Strap
(4)149-6371 Pressure Switch - Connect the lead from pressure switch (4) to connector (GG). Secure the two connectors to tube assembly (FF) with one cable strap (1).
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Illustration 35 g03838890 View of harness connections
(HH) AR-C4
(6)236-6923 Pressure Switch - Connect connector (HH) to pressure switch (6).
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Illustration 36 g03838892 View of belt guard installation
(E) Belt Guard - Reinstall belt guard (E) to the engine with the existing hardware.
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Illustration 37 g03838894 - Connect the A/C charging equipment to the machine. The two A/C service fittings are located behind the cab heater group.
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NOTICE Do Not overcharge system. Damage to the Refrigerant Compressor Gp may result.
- Evacuate A/C system and check for leaks. Once verified that there are no leaks, charge the A/C system. Charge the system with
0.82 kg (1.8 lb) of R134a refrigerant.Verify A/C and heating systems are operating correctly. Remove service equipment. Cap both service fittings.
Note: Follow the manufacturer instructions for the A/C service equipment being used.
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| Illustration 1 | g03838316 |
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View of console assembly (A) Air and Temperature Control Gp (B) Console As | |
