Installation of the 509-5548 Cab Heater and Mounting Kit on Certain Compact Track Loaders, Multi-Terrain Loaders, and Skid Steer Loaders {1812, 7304, 7309, 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 Compact Track Loaders (CTL), Multi-Terrain Loaders (MTL), and Skid Steer Loaders (SSL)"

Reference: Disassembly and Assembly, UENR4243, "239D and 249D Compact Track Loaders, 232D Skid Steer Loader Engine Supplement"

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

Reference: Disassembly and Assembly, UENR6565, "239D and 249D Compact Track Loaders, 232D Skid Steer Loader Engine Supplement"

Reference: Schematic, UENR6684, "239D and 249D Compact Track Loaders, 232D Skid Steer Loader Electrical System"

Reference: Schematic, UENR6685, "239D and 249D Compact Track Loaders, 226D and 232D Skid Steer Loaders Electrical System"

Introduction

This special instruction covers the installation procedure for the 509-5548 Cab Heater and Mounting Kit on the machines listed above.

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

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 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.

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.

Required Parts

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 assembly. Refer to Special Instruction, REHS8707, "Installation of the 388-8275 Cab Window Kit".

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Illustration 1	g03832281
View of inside of the cab (1) 8Y-5947 Fastener (2) 345-6022 Cover

1. Remove fastener (1) and discard. Remove cover (2) and retain.
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   Illustration 2	g06113882
   View of panel harness assembly (1) 8Y-5947 Fastener (3) 441-4821 Panel Harness As

2. Remove fasteners (1) and discard, gently pull back headliner until panel harness assembly (3) can be accessed.
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   Illustration 3	g03883364
   View of console removal (1) 8Y-5947 Fastener (4) 345-6026 Console As (5) 258-3727 Screw

3. Remove fasteners (1) from the roof area of console assembly (4) and discard. Remove screws (5) and retain for reuse.

   Carefully pull console assembly (4) away from the roof and front pillar.

   Note: The top of the console running along the left-hand 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 4	g03883368
   View of separating the harness (A) Panel harness (6) 356-6106 Heater and Air Conditioner Harness As (8) 3S-2093 Cable Strap

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   Illustration 5	g03883381
   View of harness routing (A) Panel harness (6) 356-6106 Heater and Air Conditioner Harness As (8) 3S-2093 Cable Strap

4. Separate heater and air conditioner harness assembly (6) from air and temperature control group (7). Route heater and air conditioner harness assembly (6) behind console assembly (4) and under the headliner.

   Route heater and air conditioner harness assembly (6) along panel harness assembly (A). Secure heater and air conditioner harness assembly (6) to panel harness assembly (A) with several cable straps (8).

   Note: The 356-6106 Heater and Air Conditioner Harness Asis a part of 356-6113 Air and Temperature Control Gp.

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   Illustration 6	g03883385
   View of harness installation (6) 356-6106 Heater and Air Conditioner Harness As (8) 3S-2093 Cable Strap (9) 345-6205 Plate (10) 266-3314 Bolt

5. Secure heater and air conditioner harness assembly (6) to plate (9) with two bolts (10).

   Torque bolts (10) to 12 ± 2 N·m (106 ± 18 lb in).

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   Illustration 7	g03883500
   View of cover installation (2) 345-6022 Cover (11) 8Y-5947 Fastener

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   Illustration 8	g03883502
   View of console assembly installation (4) 345-6026 Console As (5) 258-3727 Screw (11) 8Y-5947 Fastener

6. Reinstall cover (2) and console assembly (4). Secure the cover and the upper portion of the console with new fasteners (11). Secure the lower portion of the console with screws (5).
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   Illustration 9	g03883507
   View of rocker switch installation (B) Air and temperature control group (12) 266-0299 Rocker Switch

7. Install rocker switch (12) into the center location of air and temperature control group (B).
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   Illustration 10	g03883511
   View of rocker switch installation (B) Air and temperature control group (4) 345-6026 Console As (6) 356-6106 Heater and Air Conditioner Harness As (12) 266-0299 Rocker Switch

8. Connect heater and air conditioner harness assembly (6) to rocker switch (12). Install air and temperature control group (B) into console assembly (4).
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   Illustration 11	g03883514
   View of panel removal (C) Existing panel

9. Remove panel (C) and hardware on the left-hand side of the machine right behind the cab and discard.
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   Illustration 12	g03883517
   View of grommet installation (D) Plate (13) 127-4003 Grommet

10. Install grommet (13) into the upper hole in plate (D).

    Repeat this step for the right-hand side of the machine.

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    Illustration 13	g03883519
    View of duct cover removal (E) Duct cover

11. Remove duct cover (E) from the floor.

    Discard duct cover (E) and the attaching hardware.

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    Illustration 14	g03883520
    View of cover removal (F) Existing cover

12. Remove cover (F) from the front of the cab liner assembly and discard.
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    Illustration 15	g03883523
    View of seal installation (14) 258-3795 Seal (15) 506-8061 Cab Heater Gp

13. Install two seals (14) onto cab heater group (15).

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

14. Raise the lift arms. Ensure that the lift arm brace is fully ENGAGED before proceeding. Refer to Operation and Maintenance Manual, SEBU9084, "Loader Lift Arm Brace Operation".

15. Raise the cab. Ensure that the cab support lever is fully ENGAGED before proceeding. Refer to Operation and Maintenance Manual, SEBU9084, "Cab - Tilt".
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    Illustration 16	g03883527
    View of plate installation (16) 418-5870 Plate As (17) 3E-8020 Screw (18) 9X-2038 Washer

16. Install plate assembly (16) to the cab floor by securing them with two sets of screws (17) and washers (18) along with the screw and related hardware assembled in cab floor.
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    Illustration 17	g03883528
    View of threaded inserts installation (19) 195-0936 Threaded Insert

17. Install threaded insert (19) into each of the front mounting locations in the floor.

    Note: Apply Loctite 243 to threaded inserts (19) prior to installation.

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    Illustration 18	g03883531
    View of core assembly installation (20) 345-6197 Rubber Washer (21) 114-6658 Washer (23) 435-9193 Special Bolt (24) 345-6194 Spring (25) 5P-4116 Hard Washer

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    Illustration 19	g03883532
    View of rear core assembly installation (24) 345-6194 Spring (25) 5P-4116 Hard Washer (26) 345-6196 Special Bolt

18. Install core assembly (15) with seals (14) onto the bottom of the floor with four rubber washers (20) placed between core assembly (15) and the floor. Install two washers (21) between cab heater group (22) and rubber washers (20) for both front mounting points.

    Use two bolts (23), springs (24), and washers (25) to secure forward locations of core assembly (15) to the floor.

    Use two bolts (26), springs (24), and washers (25) to secure rearward locations of core assembly (15) to the floor.

    Note: Apply Loctite 243 to bolts prior to installation.

    Torque bolts (23) to 3.5 ± 0.5 N·m (31 ± 4.4 lb in) and bolts (26) to 6 ± 1 N·m (53 ± 9 lb in)

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    Illustration 20	g03883538
    View of seal installation (27) 345-4551 Seal

19. Install seal (27) onto the cab liner assembly.

    Peel the protective paper from the seal. Install the adhesive side of the seal onto cab liner assembly.

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    Illustration 21	g03883554
    View of plenum installation (G) Plate (28) 418-5794 Cab Blower (29) 9X-2045 Screw (30) 441-0121 Panel

20. Install plenum assembly (28) onto the back of the cab liner assembly. Secure the right-hand side of plenum assembly (28) with two screws (29). Insert the screws through plate (G) and into plenum assembly (28). Secure panel (30) along with the cab plate using three screws (29).

    Note: Apply Loctite 243 to screws (29) prior to installation.

    Note: Torque screws (29) to 6 ± 1 N·m (53 ± 9 lb in).

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    Illustration 22	g03883560
    View of plenum installation (15) 506-8061 Cab Heater Gp (28) 418-5794 Cab Blower (30) 441-0121 Panel

21. Assemble plenum assembly (28) onto the back of cab heater group (15). Secure with two screws (30).
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    Illustration 23	g03883569
    View of clip installation (H) Existing bolt (25) 5P-4116 Hard Washer (28) 418-5794 Cab Blower (31) 4P-7581 Clip

22. Use existing bolt (H), washers (25), and one clip (31) to secure the right-hand side of plenum assembly (28).

    Note: Apply Loctite 243 to bolt (H) prior to installation.

    Note: Torque bolt (H) to 6 ± 1 N·m (53 ± 9 lb in).

23. Connect hose assembly (32) to the high side inlet on core (33). Use one o-ring seal (34) to seal the connection.

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

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    Illustration 24	g03883582
    View of hose installation (35) 5P-0767 Hose (36) 373-7621 Band Clamp

24. Cut two pieces of hose (35), each to a length 1730 ± 10 mm (68 ± 0.4 inch)

25. Attach one hose (35) to the outlet of the heater core and secure the hose with one clamp (36).

26. Attach the other hose (35) to the water control valve and secure the hose with one clamp (36).

27. Start to connect heater and air conditioner harness assembly (37) to the machine as follows.
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    Illustration 25	g03883599
    View of connections (38) AC-C16 (39) AC-C20 (40) AT-C2

    1. Connect AC-C16 connector (38) to water valve located on cab heater group.

    2. Connect AC-C20 connector (39) to AT-C2 connector (40).
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       Illustration 26	g03883588
       View of harness and hoses (35) 5P-0767 Hose (37) 506-8176 Heater and Air Conditioner Harness As (41) AC-17 (42) AE-C4 (43) 418-5794 Cab Blower (44) 7K-1181 Cable Strap

    3. Connect AC-C17 connector (41) from heater and air conditioner harness assembly (37) to AE-C4 connector (42) from plenum assembly (43). Secure heater and air conditioner harness assembly (37), and both hoses (35) with one tie strap (44) attached to existing ladder clip.
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    Illustration 27	g03883606
    View of hose guard installation (35) 5P-0767 Hose (45) 7Y-5074 Hose Guard

28. Install a 25 cm (9.84250 inch) section of hose guard (45) onto both hose (35) sections.

29. Route heater and air conditioner harness assembly (37), hose assembly (46), and both hoses (35) along the right-hand side of plenum assembly (43). Secure with one clip (46) mounted to the back of the cab with one bolt (47) and one hard washer (25).

    Note: Apply Loctite 243 to bolt (47) and torque to 6 ± 1 N·m (53 ± 9 lb in).

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    Illustration 28	g03883628
    View of harness and hose routing (35) 5P-0767 Hose (37) 506-8176 Heater and Air Conditioner Harness As (44) 7K-1181 Cable Strap (46) 470-8336 Hose As

30. Secure the hoses and wiring harness together with several of cable straps (44).

    Note: Do not distort the hoses when tightening the cable straps.

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    Illustration 29	g03883653
    View of connections (37) 506-8176 Heater and Air Conditioner Harness As (47) AC-C1 (48) HV-C1 (49) AC-T2

31. Continue to connect heater and air conditioner harness assembly (37) to the machine as follows:

    1. Connect AC-C1 connector (47) to HV-C1 connector (48).

    2. Connect AC-T2 terminal (49) to the cab ground stud.
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       Illustration 30	g03883660
       View of connections (I) Cab harness assembly (44) 7K-1181 Cable Strap (50) AC-C7 (51) C-C8

    3. Connect AC-C7 connector (50) to C-C8 connector (51) on cab harness assembly (I). Secure the connectors to the cab harness with one cable strap (44).
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    Illustration 31	g03883671
    View of bracket installation (44) 7K-1181 Cable Strap (52) 474-9157 Bracket As (53) 266-3314 Bolt (54) 9X-2038 Washer (55) Auxiliary lines

32. Install bracket (52) along with auxiliary lines (55) using two bolts (53) and washers (54) to the frame assembly. Secure hoses to the bracket using cable strap (44).
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    Illustration 32	g03883683
    View of connector installation (56) 457-1640 Connector (57) 266-3314 Bolt

33. Install connector (56) to the frame and secure with two bolts (57).
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    Illustration 33	g03883689
    View of hose connections (35) 5P-0767 Hose (56) 457-1640 Connector (58) 373-7621 Band Clamp

34. Working from cab side connect hose (35) to connector (56) and secure with two spring clamps (58).
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    Illustration 34	g03883706
    View of hose routing (25) 5P-4116 Hard Washer (35) 5P-0767 Hose (59) 6D-1641 Clip (60) 266-3314 Bolt

35. Secure hoses (35) to the frame assembly with one clip (59) mounted to the back of the cab with one bolt (60) and one washer (25).

36. Lower the cab and observe the hoses (35). Ensure that there is adequate clearance for the hoses as the cab is lowered. Operation and Maintenance Manual, SEBU9084, "Cab - Tilt".
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    Illustration 35	g03883719
    View of hose connection (35) 5P-0767 Hose (56) 457-1640 Connector (58) 373-7621 Band Clamp

37. Working from the engine side connect hose (35) to connector (56) and secure with two spring clamps (58).
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    Illustration 36	g03883727
    View of adapter assembly installation (J) Existing plug (60) 8T-7912 Adapter (61) 392-0808 Elbow As

38. Remove plug (J) from engine, insert adapter assembly (60), and elbow assembly (61). Orient the elbow assembly 30 degrees towards the engine enclosure group.
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    Illustration 37	g03883739
    View of hose installation (35) 5P-0767 Hose (58) 373-7621 Band Clamp (61) 392-0808 Elbow As (62) 178-3620 Strap (K) Existing hose (L) Existing Tube

39. Assemble the other end of hose (35) to elbow assembly (61) mounted on the Engine, secure with one spring clamp (58). Fasten the hose (35) to hose (K) and tube (L) using two straps (62).
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    Illustration 38	g03883747
    View of hose installation (M) Radiator Group (35) 5P-0767 Hose (58) 373-7621 Band Clamp (62) 178-3620 Strap (63) 260-9144 Connector As

40. Install adapter assembly (63) to radiator group (M). Connect other end of hose (35) to adapter assembly (63), secure with one spring clamp (58). Fasten the hose with one strap (62) to the cooler lines.
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    NOTICE
    Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

41. Drain the engine coolant into an appropriate container.
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    Illustration 39	g03883776
    View of air filter installation (65) 265-6619 Cab Air Filter Element (66) 345-4545 Cab Blower (67) 359-1585 Cover As

42. Install cab air filter element (65) into the side opening of cab blower (66). Install cover assembly (67) over cab air filter element (65). Insert the tabs on the cover into the slots in the plate that is apart of the cab blower (66). Slide cover assembly (67) down to engage the cover with the plate.
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    Illustration 40	g03883783
    View of latch assembly

43. Rotate the cover latch clockwise to hold the cover closed.

44. Lower the lift arms. Operation and Maintenance Manual, SEBU9084, "Cab - Tilt"
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    Illustration 41	g03883788
    View of air filter installation (68) 265-6618 Cab Air Filter Element (69) 345-6146 Louver Cover (70) 345-6078 Knob As

45. Install cab air filter element (68) into the opening in the cab liner group. Place louver cover (69) over the filter. Secure the louver cover (69) with two knob assemblies (70).

    Note: Tighten the knobs down until the knobs contact the cover and then tighten one more turn.

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    Illustration 42	g03883793
    View of duct installation (71) 258-3795 Seal (72) 345-6191 Duct As (73) 146-6371 Louver As

46. Install one seal (71) onto the bottom of duct assembly (72). Install three louver assemblies (73) into the openings in duct assembly (72).
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    Illustration 43	g03883804
    View of bracket installation (72) 345-6191 Duct As (74) 388-7876 Bracket As (75) 9X-2045 Screw

47. Install bracket assembly (74) onto duct assembly (72). Secure the bracket with two of screws (75).

    Note: Position bracket assembly (74) so the nut is away from duct assembly (72).

48. Repeat Step 47 for the other duct assembly.

    Note: If 345-6290 Cab Window Gp was removed previously, reinstall the window at this time. Refer Special Instruction, REHS8707, "Installation of the 388-8275 Cab Window Kit".

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    Illustration 44	g03883825
    View duct assembly installation (72) 345-6191 Duct As (73) 146-6371 Louver As (74) 388-7876 Bracket As (75) 9X-2045 Screw

49. Install duct assembly (72) down onto the exposed lip of cab heater group (73) for the left-hand side of the machine.

    Next, insert bracket assembly (74) behind the plate. Secure duct assembly (72) to plate with one screw (75).

50. Verify that the heating system is operating correctly. Check for cooling system leaks.