Installation of the 508-1863 Air Conditioner and Heater Installation Kit on Certain Compact Track Loaders and Skid Steer Loaders {1405, 1802, 1805, 1808, 7174, 7304, 7320, 734D} Caterpillar

Compact Track Loader

239D (S/N: CD41-UP; BL91-UP; T9S1-UP)

249D (S/N: AH91-UP; D9E1-UP; GWR1-UP)

Skid Steer Loader

226D (S/N: HR61-UP; HRD1-UP)

232D (S/N: EH21-UP; KXC1-UP; DPR1-UP)

Reference: Operation and Maintenance Manual, SEBU9084, "D-Series and D2- Series SSL, MTL, CTL"

Reference: Disassembly and Assembly, UENR4245, "239D and 249D Compact Track Loaders and 226D and 232D Skid Steer Loaders Machine Systems"

Reference: Disassembly and Assembly, UENR4243, UENR6565, "226D and 232D Skid Steer Loaders, 239D and 249D Compact Track Loader Machine Systems"

Reference: Disassembly and Assembly, UENR6685, UENR6684, "226D and 232D Skid Steer Loaders, 239D and 249D Compact Track Loader Machine Systems."

Introduction

This special instruction covers the installation procedure for the 508-1863 Air Conditioner and Heater Installation Kit on the machines listed above.

Do not begin installation of this kit until you have read the information that is contained in this instruction.

Safety Section

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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 cooling system pressure cap slowly to relieve pressure only when engine is stopped and allow sufficient time for the cooling system to cool. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

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Personal injury can result from contact with refrigerant. 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 precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. 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. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

Required Parts

The following Table 2 breaks down the parts included in the 508-1863 Air Conditioner and Heater Installation Kit.

Prepare the Machine for Service

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

2. Lower all implements to the ground.

3. Place the transmission in either neutral or park.

4. Engage the parking brake.

5. Turn the main battery disconnect OFF.

6. Drain the engine coolant into a suitable container.

Install the Cab Switches and Wiring

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".

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Illustration 1	g03863926
(A) 345-6022 Cover (B) 8Y-5947 Fastener

1. Remove the 8Y-5947 Fastener (B) and discard the part. Remove the 345-6022 Cover (A) and save the part for reuse.
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   Illustration 2	g03863929
   (B) 8Y-5947 Fastener (C) 421-0280 Headliner (D) 441-4821 Panel Harness As

2. Remove the 8Y-5947 Fastener (B) and discard the part. Gently pull back the 421-0280 Headliner (C) until the 441-4821 Panel Harness As (D) can be accessed.
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   Illustration 3	g03863939
   (B) 8Y-5947 Fasteners (E) 345-6026 Console As (F) 258-3727 Screws

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   Illustration 4	g03863942
   (E) 345-6026 Console As

3. Remove the 8Y-5947 Fasteners (B) from the roof area of 345-6026 Console As (E) and discard the part. Remove the 258-3727 Screws (F) and save the part for reuse.

   Carefully pull the console assembly away from the roof and front pillar.

   Note: The top of the console along the left side roof is secured by clips not visible from the outside of the console. Use caution when removing the console. Do not break these retaining clips. There are also tie-straps holding the wiring harness behind the console. These tie straps will hinder console movement.

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   Illustration 5	g03863985
   (D) 441-4821 Panel Harness As (G) 3S-2093 Cable Strap (H) 356-6106 Heater and Air Conditioner Harness As

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   Illustration 6	g03864328
   (H) 356-6106 Heater and Air Conditioner Harness As

   Note: 356-6106 Heater and Air Conditioner Harness As (H) is a part of 356-6113 Air and Temperature Control Gp (77).

4. Separate the 356-6106 Heater and Air Conditioner Harness As (H) from 258-4299 Air and Temperature Control Gp (K). Route the 356-6106 Heater and Air Conditioner Harness As (H) behind the 345-6026 Console As (E) and under the 421-0280 Headliner (C).

   Route the 356-6106 Heater and Air Conditioner Harness As (H) along with the 441-4821 Panel Harness As (D). Secure the 356-6106 Heater and Air Conditioner Harness As (H) with several 3S-2093 Cable Straps (2).

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   Illustration 7	g03864375
   (H) 356-6106 Heater and Air Conditioner Harness As (J) 345-6205 Plate (2) 3S-2093 Cable Strap (62) 266-3314 Bolt

5. Secure the 356-6106 Heater and Air Conditioner Harness As (H) to 345-6205 Plate (J) with two 266-3314 Bolts (62).

   Torque the bolts to 12 ± 2 N·m (106 ± 18 lb in).

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   Illustration 8	g03864409
   (A) 345-6022 Cover (104) 8Y-5947 Fasteners

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   Illustration 9	g03864410
   (E) 345-6026 Console As (F) 258-3727 Screws (retained from Step 3 ) (104) 8Y-5947 Fasteners

6. Reinstall the 345-6022 Cover (A) and the 345-6026 Console As (E). Secure the cover and the upper portion of the console with the new 8Y-5947 Fasteners (104). Secure the lower portion of the console with the original 258-3727 Screws (F) that were saved in Step 3.
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   Illustration 10	g03864432
   (K) 258-4299 Air and Temperature Control Gp (61) 266-0299 Rocker Switch

7. Install the 266-0299 Rocker Switch (61) into the center location of the 258-4299 Air and Temperature Control Gp (K).
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   Illustration 11	g03864441
   (E) Console As (H) 356-6106 Heater and Air Conditioner Harness As (K) 258-4299 Air and Temperature Control Gp (61) 266-0299 Rocker Switch

8. Connect the 356-6106 Heater and Air Conditioner Harness As (H) to the 266-0299 Rocker Switch (61). Install the 258-4299 Air and Temperature Control Gp (K) into the Console As (E).

Exterior Cab Preparations

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Illustration 12	g03864448
(A) 441-0119 Panel

1. Remove the 441-0119 Panel (A) and the hardware on the left-hand side of the machine directly behind the cab and discard the part.
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   Illustration 13	g03864455

2. Install the 127-4003 Grommet (35) into the upper hole in the 345-6202 Plate. Repeat this step for the right-hand side of the machine.

Install the Ducts

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Illustration 14	g03864465
(A) 345-6148 Duct Cover (B) 345-6029 Floor

1. Remove the 345-6148 Duct Cover (A) from the 345-6029 Floor (B). Discard the duct cover and the secure the hardware.
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   Illustration 15	g03864482
   (C) Cab Liner As (D) 345-6147 Cover

2. Remove the 345-6147 Cover (D) from the front of the Cab Liner As (C) and discard the part.
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   Illustration 16	g03864514
   (57) 258-3795 Seals (87) 506-8061 Cab Heater Gp

3. Install the two 258-3795 Seals (57) onto the 506-8061 Cab Heater Gp (87).

   Peel the protective paper from the seals. Install the adhesive side of the seals onto the core assembly.

4. Raise the lift arms. Ensure that the lift arm brace is fully ENGAGED before proceeding. Refer to Operation and Maintenance, "Loader Lift Arm Brace Operation".

5. Raise the cab. Ensure that the cab support lever is fully ENGAGED before proceeding. Refer to Operation and Maintenance, "Cab - Tilt".
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   Illustration 17	g03864519
   (B) 345-6029 Floor (1) 3E-8020 Screw (24) 9X-2038 Washer (91) 418-5870 Plate As (105) 345-7725 Screw

6. Install the 418-5870 Plate As (91) to the cab floor (B). Use the two sets of 3E-8020 Screws (1), 9X-2038 Washers (24) and 345-7725 Screw (105).
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   Illustration 18	g03864548
   (B) 345-6029 Floor (8) 5P-4116 Washer (33) 114-6658 Washer (47) 195-0936 Threaded Insert (74) 345-6194 Spring (76) 345-6197 Rubber Washer (100) 435-9193 Bolt

7. Install the 195-0936 Threaded Insert (47) into each mounting location in the floor (B).

   Note: Apply Loctite^® 243 to 195-0936 Threaded Insert prior to installation.

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   Illustration 19	g03864562
   (8) 5P-4116 Washer (74) 345-6194 Spring (75) 345-6196 Bolt (87) 506-8061 Cab Heater Gp

8. Install the 506-8061 Cab Heater Gp (87) with the 258-3795 Seals (57) onto the bottom of 345-6029 Floor (B).

   To mount the two forward locations of the core assembly to the floor, use 435-9193 Bolts (100), 5P-4116 Washers (8) and 345-6194 Springs (74). Use 345-6197 Rubber Washers (76) and 114-6658 Washers (33) between the core assembly and the floor. Refer to Illustration 18.

   To mount the two rear locations of the core assembly to the floor, use 345-6196 Bolts (75), 5P-4116 Washers (8) and 345-6194 Springs (74). Use a 345-6197 Rubber Washer (76) placed between the Cab Heater Gp (87) and the floor. Refer to Illustration 19.

   Note: Apply Loctite^® 243 to 435-9193 Bolts and 345-6196 Bolts.

   Tighten the 435-9193 Bolts to 3.5 ± 0.5 N·m (31.0 ± 4.4 lb in).

   Tighten the 345-6196 Bolts to 6 ± 1 N·m (53 ± 9 lb in).

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   Illustration 20	g03864633
   (E) 345-6150 Liner As (67) 345-4551 Seal

9. Secure the 345-4551 Seal (67) to 345-6150 Liner As (E).

   Peel the protective paper from the seal. Install the adhesive side of the seal onto the 345-6150 Liner As (E).

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   Illustration 21	g03864873
   (E) 345-6150 Liner As (F) 345-6202 Plate (25) 9X-2045 Screw (88) 418-5794 Cab Blower (101) 441-0121 Panel

10. Install the 418-5794 Cab Blower (88) onto the back of 345-6150 Liner As (E). Secure the right-hand side of the Cab Blower with the two 9X-2045 Screws (25). Insert the screws through the 345-6202 Plate (F) and into the Cab Blower. Secure the 441-0121 Panel (101) and Plate (F) to the left side of Cab Blower using six 9X-2045 Screws (25).

    Apply Loctite^® 243 to the 9X-2045 Screws (25). Tighten the screws to 6 ± 1 N·m (53 ± 9 lb in).

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    Illustration 22	g03864893
    (56) 258-3727 Screw (87) 506-8061 Cab Heater Gp (88) 418-5794 Cab Blower

11. Secure the 418-5794 Cab Blower (88) onto the back of 506-8061 Cab Heater Gp (87). Secure with two 258-3727 Screws (56).
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    Illustration 23	g03864906
    (E) 345-6150 Liner As (G) 5P-4116 Hard Washer (H) 4P-7581 Clip (J) 206-9185 Bolt (88) 418-5794 Cab Blower

12. Use the existing 206-9185 Bolt (J), 5P-4116 Hard Washer (G) and one 4P-7581 Clip (H) to secure the right side of 418-5794 Cab Blower (88).

    Note: Apply Loctite^® 243 to the 206-9185 Bolt (J).

    Tighten the bolts to 6 ± 1 N·m (53 ± 9 lb in).

Install Cab HVAC Lines and Valves

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Illustration 24	g03864936
(28) 9X-7381 O-Ring Seal (29) 9X-7382 O-Ring Seal (85) 421-0370 Hose As (97) 421-0319 Hose As

Note: All air conditioner line connections and o-ring seals must be lubricated with 1 mL (0.03 oz) of mineral-based refrigerant oil prior to assembly.

1. Connect the 421-0319 Hose As (97) to the inlet side of 418-5866 Core As. Use one 9X-7382 O-Ring Seal (29) to seal the connection.

   Use 1 mL (0.03 oz) of mineral-based refrigerant oil on o-ring and fittings prior to assembly.

2. Connect the 421-0370 Hose As (85) to the high side inlet of the 418-5866 Core. Use one 9X-7381 O-Ring Seal (28) to seal the connection.
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   Illustration 25	g03864982
   (7) 5P-0767 Hose (78) 373-7621 Band Clamp

3. Cut two pieces of the 5P-0767 Hose (7), each to a length of 1730 ± 10 mm (68.1 ± 0.4 inch).

4. Attach the one 5P-0767 Hose (7) to the outlet of the heater core and secure the hose with one 373-7621 Band Clamp (78).

5. Attach the other 5P-0767 Hose (7) to the water control valve and secure the hose with one 373-7621 Band Clamp (78).
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   Illustration 26	g03865015
   (A) AC-C17 connector (B) AE-C4 connector (2) 3S-2093 Tie Strap (7) 5P-0767 Hose (12) 7K-1181 Tie Strap (79) 506-8176 Heater and Air Conditioner Harness As (85) 421-0370 Hose As (88) 418-5794 Cab Blower (97) 421-0319 Hose As

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   Illustration 27	g03864963
   (C) AC-C16 connector (D) Water valve (E) AT-C2 connector (F) AC-C20 connector (12) 7K-1181 Tie Strap (79) 506-8176 Heater and Air Conditioner Harness As

6. Start to connect the 506-8176 Heater and Air Conditioner Harness As (79) to the machine as follows.

   • Connect the AC-C16 connector (C) to the water valve (D).

   • Connect the AC-C20 connector (F) to the AT-C2 connector (E).

   • Connect the AC-C17 connector (A) from 506-8176 Heater and Air Conditioner Harness As (79) to the AE-C4 connector (B) from 418-5794 Cab Blower (88). Secure the 421-0370 Hose As (85) and 421-0319 Hose As (97) with one 3S-2093 Tie Strap (2). Secure the 506-8176 Heater and Air Conditioner Harness AsHarness (79) and both 5P-0767 Hoses (7) with one 7K-1181 Tie Strap (12) attached to the existing ladder clip.
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   Illustration 28	g03865049
   (7) 5P-0767 Hose (8) 5P-4116 Hard Washer (11) 7D-1553 Clip (12) 7K-1181 Cable Straps (14) 7Y-5074 Hose Guard (66) 342-9920 Bolt

7. Install a 25 cm (9.8 inch) section of the 7Y-5074 Hose Guard (14) onto both 5P-0767 Hose (7) sections.

8. Route the 506-8176 Heater and Air Conditioner Harness As (79), 421-0370 Hose As (85), 421-0319 Hose As (97), and both 5P-0767 Hose (7) along the right side of 418-5794 Cab Blower (88). Secure with one 7D-1553 Clip (11) mounted to the back of the cab with one 342-9920 Bolt (66) and one 5P-4116 Hard Washer (8). Apply Loctite^® 243 to the Bolt (66) and tighten the bolts to 6 ± 1 N·m (53 ± 9 lb in).

9. Secure the hoses and wiring harness together with several 7K-1181 Cable Straps (12).

   Note: Do not distort the hoses when tightening the Cable Straps.

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   Illustration 29	g03865200
   (G) HV-C1 connector (H) AC-C1 connector (J) AC-T2 connector (K) 470-8336 Hose As (7) 5P-0767 Hose (79) 506-8176 Heater and Air Conditioner Harness As

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   Illustration 30	g03865203
   (L) AC-C7 connector (M) C-C8 connector (N) 435-8930 Hose As (7) 5P-0767 Hose (11) 7D-1553 Clip (12) 7K-1811 Strap (14) 7Y-5074 Hose Guard (79) 506-8176 Heater and Air Conditioner Harness As

10. Continue to connect 506-8176 Heater and Air Conditioner Harness As (79) to the machine as follows.

    • Connect the AC-C1 connector (H) to the HV-C1 connector (G).

    • Connect the AC-T2 terminal (J) to the cab ground stud.

    • Connect the AC-C7 connector (L) to the C-C8 connector (M) on the Cab Harness As. Secure the connectors to the cab harness with one 7K-1811 Cable Strap (12).
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    Illustration 31	g03866077
    (P) Auxiliary Lines Gp.

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    Illustration 32	g03866095
    (Q) 421-0369 Bracket (15) 8T-4121 Hard Washer (17) 8T-4136 Bolt (48) 204-8000 Cable Tie Mounting

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    Illustration 33	g03866069
    (24) 9X-2038 washer (62) 266-3314 bolt

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    Illustration 34	g03866058
    (12) 7K-1181 strap

11. Install the 421-0369 Bracket (Q) along with auxiliary lines group (P) to the frame using two 266-3314 bolts (62) and 9X-2038 washers (24). Secure the hoses to the 204-8000 Cable Tie Mounting (48) with 7K-1181 strap (12).
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    Illustration 35	g03866161
    (62) 266-3314 bolt (102) 457-1640 Connector

12. Install the 457-1640 Connector (102) to the frame. Secure with two 266-3314 bolts (62).
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    Illustration 36	g03866216
    (3) 4B-0148 P-Clip (8) 5P-4116 Washers (62) 266-3314 Bolts (92) 421-0238 Tube As (94) 421-0297 Hose As

13. Install the 421-0238 Tube As to the frame with two sets of 4B-0148 P-Clips (3), 5P-4116 Washers (8) and 266-3314 Bolts (62).

    Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.

14. Install the 421-0297 Hose As (94) to the 421-0238 Tube As. Use 9X-7381 O-ring (28) to seal the connection.

    Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.

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    Illustration 37	g06109919
    (23) 9S-1354 Nut (27) 9x-7380 O-Ring Seal (85) 421-0370 Hose As (95) 421-0309 Hose As (104) 489-5384 Fitting As

15. From the engine compartment, insert the 421-0309 Hose As (95) into the 440-3489 Plate As. Secure the hose to the frame with 245-8842 P-Clamp (54), 5P-4116 Washer (8) and 266-3314 Bolt (62). Fasten with 178-3620 Strap, to 421-0238 Tube as (92).
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    Illustration 38	g03866233
    (8) 5P-4116 Hard Washer (45) 178-3620 Strap (54) 245-8842 Clip (62) 266-3314 Bolt (93) 421-0296 Hose As

16. Install the 421-0296 Hose As (93) to 421-0238 Tube As (92). Use 9X-7381 O-ring to seal the connection.

    Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.

17. From the cab side, secure the 421-0309 Hose As (95) using one 9S-1354 Nut (23). Insert the 9X-7380 O-Ring Seal (27) in 421-0309 Hose As (95) and in 489-5384 Fitting As (104). Install the 421-0370 Hose As (85) to the 489-5384 Fitting As (104) and install it to 421-0309 Hose As (95).

    Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring seal and fittings prior to assembly.

Install Accumulator and Associated Lines

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Illustration 39	g06110053
(A) Existing stud (18) 8T-4185 Bolt (30) 9X-7383 O-Ring Seal (31) 110-6171 Clamp (32) 110-6172 Clamp (46) 186-6190 Accumulator Gp (80) 387-1957 Air Conditioner Fitting (96) 421-0310 Hose as (97) 421-0319 Hose As

1. Install the 186-6190 Accumulator Gp (46) to the inside left area of the machine frame, just behind the cab. Use the existing stud (A). Secure the accumulator group (46) to the frame with 110-6171 Clamp (31), 110-6172 Clamp (32), and one 8T-4185 Bolt (18).

   Note: The 186-6190 Accumulator Gp must be mounted vertically.

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   Illustration 40	g03866259
   Orientation (B) of top fitting (B) 30 degrees

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   Illustration 41	g06110063
   Orientation (C) of side fitting (C) 98 degrees (30) 9X-7383 O-Ring Seal (80) 387-1957 Air Conditioner Fitting

2. Install the 387-1957 Air Conditioner Fitting (80) into the bottom port of the 186-6190 Accumulator Gp (46). Orient the fitting to 30 degree, counter clockwise viewed from the top, from the side port. Seal the connection with one 9X-7383 O-Ring Seal (30).

   Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.

3. Install the 387-1957 Air Conditioner Fitting (80) into the top port of the 186-6190 Accumulator Gp (46). Orient the fitting to 98 degree counter clockwise, viewed directly on. Seal the connection with one 9X-7383 O-Ring Seal (30).

   Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.

4. Install the 421-0310 Hose as (96) to the 387-1957 Air Conditioner Fitting (80). Seal the connection with one 9X-7383 O-Ring Seal (30).

   Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.

5. Install the 421-0319 Hose as to the 387-1957 Air Conditioner Fitting (80). Seal the connection with one 9X-7383 O-Ring Seal (30).

   Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.

Install Water Lines to Connector

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Illustration 42	g03866314
(7) 5P-0767 Hose (78) 373-7621 Band Clamp

1. Working from Cab side, install the 5P-0767 Hose (7) to the 457-1640 Connector (102). Secure with the two 373-7621 Band Clamp (78).
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   Illustration 43	g03866343
   (8) 5P-4116 Hard Washer (11) 7D-1553 Clip (62) 266-3314 Bolt

2. Secure the 5P-0767 Hose (7) and 421-0319 Hose As (97) to the frame assembly. Use one 7D-1553 Clip (11) mounted to the back of the cab with one 266-3314 Bolt (62) and one 5P-4116 Hard Washer (8).

3. Lower the cab and observe the 5P-0767 Hose (7) and 421-0319 Hose As (97). Ensure that there is adequate clearance for the hoses as the cab is lowered. Refer to Operation and Maintenance, "Cab-Tilt" for your machine.
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   Illustration 44	g03866373
   (7) 5P-0767 Hose (78) 373-7621 Band Clamp

4. Working from engine side, assemble the 5P-0767 Hose (7) to the 457-1640 Connector (102) and secure with two 373-7621 Band Clamp (78).

Engine Jacket Water Connections

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Illustration 45	g06110085
(A) Plug (22) 8T-7912 Adapter (82) 392-0808 Elbow As

1. Remove the plug (A) from Engine Gp. Install the 8T-7912 Adapter (22) and 392-0808 Elbow As (82). Orient the Elbow As (82) to 30 degree towards the engine enclosure group.
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   Illustration 46	g03866621
   Orientation (B) of Elbow As (B) 30 degrees (78) 373-7621 Band Clamp

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   Illustration 47	g03866622
   (C) 416-5683 Hose (D) 416-5684 Tube (45) 178-3620 Cable Strap

2. Assemble the other end of 5P-0767 Hose (7) to the 392-0808 Elbow As (82) mounted on the engine. Secure with one 373-7621 Band Clamp (78). Fasten the hose to 416-5683 Hose (C) and 416-5684 Tube (D) by two 178-3620 Cable Strap (45).
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   Illustration 48	g03884433
   (E) 416-5697 Radiator and Aftercooler Gp (7) 5P-0767 Hose (45) 178-3620 Strap (58) 260-9144 Adapter As (78) 373-7621 Band Clamp

3. Install the 260-9144 Adapter As (58) to 416-5697 Radiator and Aftercooler Gp (E). Connect other end of 5P-0767 Hose (7) to the adapter assembly (58). Secure with one 373-7621 Band Clamp (78). Fasten the hose with one 178-3620 Strap (45) to the Cooler Lines.

Install Refrigerant Compressor and Condenser

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Illustration 49	g03884456
(A) 388-6646 Fastener (B) 416-5771 Belt Guard

1. Remove the 416-5771 Belt Guard (B) from the engine. Retain guard and fasteners (A).
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   Illustration 50	g03884472
   (4) 4P-7581 Clip (15) 8T-4121 Hard Washer (16) 8T-4133 Nut (19) 8T-4195 Bolt (37) 132-5789 Clip

2. Install the 132-5789 Clip (37) and 4P-7581 Clip (4) to the Refrigerant Compressor Gp. Secure the clips with two set of 8T-4195 Bolt (19), 8T-4133 Nut (16) and 8T-4121 Hard Washer (15).
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   Illustration 51	g03884485
   (44) 175-7141 Hex Flange Nut (52) 208-9294 Bolt (84) 416-5844 Plate

3. Install the 416-5844 Plate (84) to the refrigerant compressor group. Secure the plate with 208-9294 Bolt (52) and 175-7141 Hex Flange Nut (44).
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   Illustration 52	g03884494
   (21) 8T-6685 Bolt (44) 175-7141 Hex Flange Nut (83) 416-5758 Bracket As

4. Install the refrigerant compressor group on to the 416-5758 Bracket As (83). Use one 8T-6685 Bolt (21) and one 175-7141 Hex Flange Nut (44) to secure the compressor.
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   Illustration 53	g03884517
   (13) 7X-7729 Washer (52) 208-9294 Bolt (63) 276-9875 Refrigerant Compressor Gp (83) 416-5758 Bracket As (84) 416-5844 Plate

5. Install the 208-9294 Bolt (52) and the 7X-7729 Washer (13) through the 416-5844 Plate (84) and into the 416-5758 Bracket As (83).

   Note: Do not tighten the bolt at this time.

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   Illustration 54	g03884522
   (C) Fan drive pulley (55) 248-3100 V-Belt (63) 276-9875 Refrigerant Compressor Gp

6. Install the 248-3100 V-Belt (55) around the fan drive pulley (C) and the pulley on the 276-9875 Refrigerant Compressor Gp (63). Move the refrigerant compressor to tension the V-Belt to the proper setting. Tighten the mounting hardware for the refrigerant compressor group at this time.
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   Illustration 55	g03885412
   (D) 435-8790 Engine Enclosure Gp (8) 5P-4116 Hard Washer (20) 8T-4224 Hard Washer (36) 131-3540 Locknut (41) 162-3148 Studs (86) 418-3550 Coil (103) 459-4695 Fan Shroud & Mounting

7. Install three 162-3148 Studs (41) onto the 435-8790 Engine Enclosure Gp (D). Use one 8T-4224 Hard Washer (20) per stud. Install one 5P-4116 Hard Washer (8) onto the end of each stud.

8. Install the 418-3550 Coil (86) and 459-4695 Fan Shroud & Mounting (103) onto the studs. Secure with one 5P-4116 Hard Washer (8) and one 131-3540 Locknut (36) per stud.
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   Illustration 56	g03885497
   (E) 5 ± 2 mm (0.2 ± 0.1 inch) (9) 5P-7958 Cable Splice Sleeve (68) 345-4552 Lanyard

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   Illustration 57	g03885499
   (6) 5C-7261 Nut (20) 8T-4224 Hard Washer (66) 342-9920 Bolt (68) 345-4552 Lanyard

9. Install e the 345-4552 Lanyard and the 5P-7958 Cable Splice Sleeve as follows:

   1. Install the 345-4552 Lanyard (68) to the nearest slot on the Engine Enclosure Gp. Use one 342-9920 Bolt (66), one 8T-4224 Hard Washer (20), and one 5C-7261 Nut (6).

   2. Install the 5P-7958 Cable Splice Sleeve (9) over the 345-4552 Lanyard (68). Loop the end of the lanyard back through the sleeve. Do not allow the lanyard cable to extend more than 5 ± 2 mm (0.2 ± 0.1 inch) past the sleeve. Refer the dimension (E) in Illustration 56. Use a compression tool to crimp the 5P-7958 Cable Splice Sleeve (9).
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   Illustration 58	g03885608
   (F) 421-0360 Tube As (12) 7K-1181 Cable Strap (49) 206-2423 Saddle (63) 276-9875 Refrigerant Compressor Gp (96) 421-0310 Hose As

10. Install the 421-0310 Hose As (96) to the suction port of the 276-9875 Refrigerant Compressor Gp (63).

11. Fasten the 421-0310 Hose As (96) to 421-0360 Tube As (F) with two 7K-1181 Cable Strap (12) and one 206-2423 Saddle (49).
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    Illustration 59	g03885627
    (63) 276-9875 Refrigerant Compressor Gp (94) 421-0297 Hose As

12. Connect the 421-0297 Hose As (94) to the discharge port of the 276-9875 Refrigerant Compressor Gp (63).
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    Illustration 60	g03885639
    (G) Engine enclosure (H) 440-6307 Tower As (2) 3S-2093 Cable Strap (8) 5P-4116 Hard Washer (54) 245-8842 Clip (62) 266-3314 Bolt (70) 345-6079 Sleeve (93) 421-0296 Hose As (95) 421-0309 Hose As

13. Secure the 421-0309 Hose As (95) to the 440-6307 Tower As (H). Use one 245-8842 Clip (54), one 5P-4116 Hard Washer (8), and one 266-3314 Bolt (62). Tighten the bolt to 25.5 ± 1.5 N·m (225.7 ± 13 lb in).

14. Combine the 421-0309 Hose As (95) and 421-0296 Hose As (93) together and slide the 345-6079 Sleeve (70) over both hoses. Secure one end of the sleeve to the hoses with one 3S-2093 Cable Strap (2).
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    Illustration 61	g03885682
    (2) 3S-2093 Cable Strap (5) 4D-7733 Clip (11) 7D-1553 Clip (43) 174-9194 Bolt (45) 178-3620 Strap (86) 418-3550 Coil (93) 421-0296 Hose As (95) 421-0309 Hose As

15. Route the hose and sleeve around and over the 418-3550 Coil (86). Secure the loose end of the sleeve with one 3S-2093 Cable Strap (2). Use one 7D-1553 Clip (11) and one 4D-7733 Clip (5) to secure the hoses to the engine enclosure. Attach clips to the engine enclosure with 174-9194 Bolts (43).

    Note: Leave enough slack in the hose to allow for the opening and closing of the engine enclosure.

16. Connect the 421-0296 Hose As (93) to the upper port of the 418-3550 Coil (86). Seal the connection with one 9X-7381 O-Ring Seal. Connect the 421-0309 Hose As (95) to the lower port of Coil (86). Seal the connection with one 9X-7380 O-Ring Seal (27). Use one 178-3620 Strap (45) to support the two hoses.

    Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring seal and fittings prior to assembly.

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    Illustration 62	g03885718
    (J) 440-6307 Tower As (2) 3S-2093 Cable Strap (34) 115-1615 Relay As (51) 208-9275 Bolt (98) 422-5523 Heater and Air Conditioner Harness As (99) 422-5567 Plate

17. Route the 422-5523 Heater and Air Conditioner Harness As (98) through the engine enclosure group. Mount the two 115-1615 Relay As (34) to the 422-5567 Plate (99). Secure the plate to the Tower As (J) weld boss by two 208-9275 Bolts (51). Use 3S-2093 Cable Straps (2) to secure the harness to the weld links.

    Tighten the 208-9275 Bolts (51) to 13 ± 1 N·m (115 ± 9 lb in).

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    Illustration 63	g03885758
    (26) 9X-7378 O-Ring Seal (53) 236-6923 Pressure Switch (63) 276-9875 Refrigerant Compressor Gp (94) 421-0297 Hose As

18. Install the 236-6923 Pressure Switch (53) onto the 421-0297 Hose As (94). Seal the connection with one 9X-7378 O-Ring Seal (26).

    Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.

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    Illustration 64	g03885794
    (26) 9X-7378 O-Ring Seal (39) 149-6371 Pressure Switch (96) 421-0310 Hose As

19. Install the 149-6371 Pressure Switch (39) onto the 421-0310 Hose As (96). Seal the connection with one 9X-7378 O-Ring Seal (26).

    Use 1 mL (0.03 oz) of mineral-based refrigerant oil on O-ring and fittings prior to assembly.

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    Illustration 65	g03885805
    (2) 3S-2093 Cable Strap (39) 149-6371 Pressure Switch (53) 236-6923 Pressure Switch (98) 422-5523 Heater and Air Conditioner Harness As

20. Connect the Heater and Air Conditioner Harness As (98) to the 236-6923 Pressure Switch (53). Secure the two unused connectors to the clip on the refrigerant compressor using one 3S-2093 Cable Strap (2).

21. Connect the lead from the 149-6371 Pressure Switch (39) to the 422-5523 Heater and Air Conditioner Harness As (98) connector.

22. Reinstall the belt guard onto the engine using fasteners retained during removal.

Install Cab Air Filter and Louvered Ducts

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Illustration 66	g03885838
(A) Cover (B) Blower (60) 265-6619 Cab Air Filter Element

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Illustration 67	g03885847
(A) Cover (B) Blower (C) Plate

1. Install the 265-6619 Cab Air Filter Element (60) into the side opening of the cab blower (B). Install the cover (A) over the air filter element. Insert the tabs on the cover into the slots in the plate (C). Slide the cover downward to engage the cover with the plate.
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   Illustration 68	g03885874
   (A) Cover (B) Blower (C) Plate (D) Latch

2. Rotate the cover latch (D) clockwise to hold the cover closed.

   Lower the lift arms. Refer to Operation and Maintenance.

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   Illustration 69	g03885885
   (E) Cab liner (59) 265-6618 Cab Air Filter Element (69) 345-6078 Knob As (71) 345-6146 Louver Cover

3. Install the 265-6618 Cab Air Filter Element (59) into the opening in the cab liner (E). Place the 345-6146 Louver Cover over the filter. Secure the louver cover with two of the 345-6078 Knob As (69).

   Note: Tighten the knobs until contact with the cover, then tighten one more turn.

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   Illustration 70	g03886134
   (38) 146-6371 Louver As (57) 258-3795 Seal (72) 345-6191 Duct As

4. Install one 258-3795 Seal (38) onto the bottom of the 345-6191 Duct As (72). Install the three 146-6371 Louver As (38) into the openings in the duct assembly.
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   Illustration 71	g03886274
   (25) 9X-2045 Screw (72) 345-6191 Duct As (81) 388-7876 Bracket As

5. Install the 388-7876 Bracket As (81) onto the 345-6191 Duct As (72). Secure the bracket with two 9X-2045 Screws (25).

   Note: Position the bracket assembly so the nut is away from the duct assembly.

   Repeat steps 4 and 5 for the 345-6192 Duct As.

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   Illustration 72	g03886335
   (A) Heater (57) 258-3795 Seal (72) 345-6191 Duct As

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   Illustration 73	g03886377
   (B) Plate (25) 9x-2045 Screw (72) 345-6191 Duct As

6. Install the 345-6191 Duct As (72) onto the exposed lip of the cab heater (A) for the left side of the machine. Insert the 388-7876 Bracket As behind the plate (B). Secure the duct to the plate with one 9X-2045 Screw (25).

   Repeat this same procedure for the 345-6192 Duct As on the right side of the machine.

   Note: If the cab window was removed previously, reinstall the window at this time. Refer to Special Instruction, REHS8707 , "Installation of the 388-8275 Cab Window Kit".

Fill the Heating and Cooling System

1. Refill the engine cooling system.

   Refer to the Operations and Maintenance Manual, "Coolant Recommendations", Operations and Maintenance Manual, "Cooling System Level - Check", Operations and Maintenance Manual, "Cooling System Specifications" for your machine.

2. Start the engine. Ensure that the temperature control is set to Full Heat. Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes. Maintain the coolant level in the sight glass. Install the radiator cap and stop the engine.
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   Illustration 74	g03886440
   (A) High side service fitting (B) Low side service fitting

3. Connect the air conditioner charging equipment to the machine. The two service fittings are located behind the Cab Heater Gp.

4. Evacuate the air conditioner system and perform a leak check. Verify that the system does not leak.

5. Charge the air conditioner system with 0.82 kg (1.81 lb) of 3E-6654 Refrigerant (R134a).

   Note: Follow the manufacturer instructions for the service equipment being used.

6. Verify the operation of the heat and air conditioning. Remove service equipment and cap the service fittings (A) and (B).