Procedure for Routing Air Conditioner Hoses for the Heater and Air Conditioner Group on Certain D8T, D9T, D10T, and D11T Track-Type Tractors{7304, 7309, 7320} Caterpillar

Track-Type Tractor:

D10T (S/N: RJG1840-UP)

D11T (S/N: AMA1-515; GEB598-UP; TPB184-UP; MDG1-173; JEL1-341; JNS1-UP)

D8T (S/N: J8B2329-4774; MLN1-1934; FCT1-1237; KPZ3637-UP)

D9T (S/N: TWG1-UP; RJS1263-UP)

Introduction

This Special Instruction provides the proper assembly technique to route the hose assemblies for the heater and air conditioner group on the machines listed above.

Do not perform any procedure in this Special Instruction until you read the information and you understand the information.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

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Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

Note: Cleanliness is an important factor. Before beginning the removal procedure, clean the exterior of the components thoroughly. Cleaning the components will help to prevent dirt from entering the internal mechanism.

Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies in order to prevent fluid loss, and contaminants from entering the system.

Procedure to Install New Hose Assemblies with New Heater and Air Conditioner Group

1. Recover refrigerant from the air conditioning system. Refer procedure from Testing and Adjusting, SENR5664, "Refrigerant Recovery".

2. Disconnect the air conditioning hoses connecting to air conditioning evaporator coil.

3. Disconnect hoses from heater coil, mark inlet, and outlet hoses.

   Note: Remove hose clamps, elbows, tube connectors from hoses. Save hose clamps and discard all parts.

4. Remove conditioner group and discard the part. Save all mounting hardware.

5. Disconnect and remove the air conditioning hoses connecting air conditioning evaporator coil to dryer and accumulator. Save hose clipping hardware.

6. Remove gasket from platform for inlet and outlet air from conditioner group. Discard the parts.

7. Install new gaskets on platform inlet and outlet air for mounting conditioner group.

   New 248-2929 Gasket (Inlet) is used on all machines.

   New 248-2930 Gasket (Outlet) is used on S/N:RJG, ; S/N:GEB, ; S/N:TPB, ; S/N:J8B, ; S/N:KPZ, and ; S/N:RJS machines.

   New 353-8573 Gasket (Outlet) is used on S/N:AMA, ; S/N:JEL, ; S/N:MLN, ; S/N:FCT, and ; S/N:TWG machines.

8. Remove air conditioner dryer and discard the part. If equipped with quick-disconnect coupler at dryer, remove and discard the part. Retain all mounting hardware.

9. Machines installing 418-6835 Heater and Air Conditioner Gp , install new 257-3226 Refrigerant Dryer As with hardware that was saved in Step 8. Connect inlet hose with 9X-7380 O-Ring Seal .

   Machines installing 418-6840 Heater and Air Conditioner Gp , install new 320-0562 Refrigerant Dryer As with hardware that was saved in Step 8. Connect inlet hose with 327-0282 Integral Seal .

10. Installing New Hose Assemblies

    Refer to Level ""Routing of Hose Assemblies for the 418-6835 Heater and Air Conditioner Gp " " or Level ""Routing of Hose Assemblies for the 418-6840 Heater and Air Conditioner Gp " " for new hose assembly part number to install to dryer outlet, and new hose assembly part number to install to accumulator inlet. Use hardware that were saved in Step 5 to secure the hose assemblies

11. Install new 418-6835 Heater and Air Conditioner Gp or 418-6840 Heater and Air Conditioner Gp with hardware that was saved in Step 4.

12. Connect hose from dryer to heater and air conditioner group with 327-0282 Integral Seal and 178-3336 Hex Flange Nut .

    Connect hose from accumulator to heater and air conditioner group with 327-0283 Integral Seal and 178-3336 Hex Flange Nut .

13. Identify the inlet heater coil connection and connect inlet heater hose using hose clamp that was saved in Step 3. Similarly identify the outlet heater coil connection and connect outlet heater hose.

14. For D11T machines existing heater hoses may need to be lengthened, if required use 5P-0767 Hose , 145-7125 Connector , and 9X-2488 Hose Clamp to lengthen hoses.

15. Secure the air conditioner hose assemblies with two 200-6345 Mounts and 204-2281 Cable Strap .

16. After assembly of air conditioner hose assemblies, charge the air conditioner system with the refrigerant. Refer procedure from Testing and Adjusting, SENR5664, "Refrigerant Evacuate and Charge".

Routing of Hose Assemblies for the 418-6835 Heater and Air Conditioner Gp on D8T (S/N:KPZ and ; S/N:J8B), D9T (S/N:RJS), D10T (S/N:RJG), D11T (S/N:GEB and ; S/N:TPB),

The following Illustrations shows proper routing and orientation of new hose assemblies for the 418-6835 Heater and Air Conditioner Gp on the respective machine models.

D11T (S/N:GEB598-UP and ; S/N:TPB184-UP) Hose Routing

Illustration 1	g03644163
Heater and air conditioner lines group on D11T machines

Illustration 2	g03644164
Heater and air conditioner lines group on D11T machines

Route 442-2365 Hose As (2) to accumulator, connect with 9X-7383 O-Ring Seal , route 442-2364 Hose As (3) to dryer, connect with 9X-7381 O-Ring Seal for 418-6835 Heater and Air Conditioner Gp (1). Refer to Illustration 1 and Illustration 2.

Illustration 3	g03688346

Lengthen existing heater hose assemblies (if required) using 5P-0767 Hose (8), two 145-7125 Connectors (6), and four 9X-2488 Hose Clamp (7) .

Secure the air conditioner hose assemblies with 200-6345 Mount (4) and two 204-2281 Cable Strap (5) .

The new routing of hose assembly (2) and hose assembly (3) are adaptable to machines S/N:GEB387-UP and ; S/N:TPB175-UP.

D10T (S/N:RJG1840-UP) Hose Routing

Illustration 4	g03688349
Heater and air conditioner lines group on D10T machines

Illustration 5	g03743526

Illustration 6	g03688351

Route 453-3544 Hose As (9) to accumulator, connect with 9X-7383 O-Ring Seal and 453-3545 Hose As (10) to dryer, connect with 9X-7381 O-Ring Seal for 418-6835 Heater and Air Conditioner Gp (1). Refer to Illustration 4, Illustration 5, and Illustration 6.

The new routing of 453-3544 Hose As (9) and 453-3545 Hose As (10) are adaptable to machines S/N:RJG1840-UP.

D9T (S/N:RJS1263-UP) Hose Routing

Illustration 7	g03688352
Heater and air conditioner lines group on D9T machines

Illustration 8	g03688354

Route 445-1029 Hose As (12) to dryer, connect with 9X-7381 O-Ring Seal and 445-1028 Hose As (11) to accumulator, connect with 9X-7383 O-Ring Seal for 418-6835 Heater and Air Conditioner Gp (1). Refer to Illustration 7 and Illustration 8.

The new routing of 445-1029 Hose As (12) to dryer and 445-1028 Hose As (11) are adaptable to machines S/N:RJS1263-UP.

D8T (S/N:KPZ3637-UP and ; S/N:J8B2329-UP) Hose Routing

Illustration 9	g03688356

Illustration 10	g03688358

Illustration 11	g03688360

Route 458-2087 Hose As (13) to accumulator, connect with 9X-7383 O-Ring Seal and 444-3513 Hose As (14) to dryer, connect with 9X-7381 O-Ring Seal for 418-6835 Heater and Air Conditioner Gp . Refer to Illustration 9, Illustration 10, and Illustration 11.

The new routing of 444-3512 Hose As (13) and 444-3513 Hose As (14) are adaptable to machines S/N:KPZ3236-UP and ; S/N:J8B1883-4775.

Routing of Hose Assemblies for the 418-6840 Heater and Air Conditioner Gp on D8T (S/N:MLN and ; S/N:FCT), D9T (S/N:TWG), D11T (S/N:JEL, ; S/N:JNS, ; S/N:AMA, and ; S/N:MDG)

The following Illustrations shows proper routing and orientation of new hose assemblies for the 418-6840 Heater and Air Conditioner Gp on the respective machine models.

D11T (S/N:JEL1-UP, ; S/N:JNS1-UP, ; S/N:AMA1-UP, and ; S/N:MDG1-UP) Hose Routing

Illustration 12	g03644183
Heater and air conditioner lines group on D11T machines

Illustration 13	g03675413

Route 422-6925 Hose As (2) to accumulator, connect with 327-0283 Integral Seal and 422-6924 Hose As (3) to dryer, connect with 327-0282 Integral Seal for 418-6840 Heater and Air Conditioner Gp (1). Refer to Illustration 12, Illustration 13, and Illustration 14.

Illustration 14	g03688340

Lengthen existing heater hose assemblies (if required) using 5P-0767 Hose (8), two 145-7125 Connectors (6), and four 9X-2488 Hose Clamp (7) .

Secure the air conditioner hose assemblies with 200-6345 Mount (4) and two 204-2281 Cable Strap (5) as per Illustration 14.

The new routing of 422-6925 Hose As (2) and 422-6924 Hose As (3) are adaptable to machines S/N:JEL1-341, ; S/N:JNS1-UP, ; S/N:AMA1-515, and ; S/N:MDG1-173.

D9T (S/N:TWG1-UP) Hose Routing

Illustration 15	g03688364
Heater and air conditioner lines group on D9T machines

Illustration 16	g03688367

Route 419-6942 Hose As (9) to accumulator, connect with 327-0283 Integral Seal and 445-1030 Hose As (10) to dryer, connect with 327-0282 Integral Seal for 418-6840 Heater and Air Conditioner Gp (1). Refer to Illustration 15 and Illustration 16.

The new routing of 419-6942 Hose As (9) and 445-1030 Hose As (10) are adaptable to machines S/N:TWG1-380.

D8T (S/N:MLN1-UP and ; S/N:FCT1-UP) Hose Routing

Illustration 17	g03688370
Heater and air conditioner lines group on D8T machines

Illustration 18	g03691490

Illustration 19	g03691491

Route 425-9805 Hose As (12) to accumulator, connect with 327-0283 Integral Seal and 425-9804 Hose As (11) to dryer, connect with 327-0282 Integral Seal for 418-6840 Heater and Air Conditioner Gp . Refer to Illustration 17, 18, and 5.

The new routing of 425-9805 Hose As (12) and 425-98054 Hose As (11) are adaptable to machines S/N:MLN1-1934 and ; S/N:FCT1-1237.