Installation of Cold Climate Kit for C2.2 Engines {1071, 1090} Caterpillar

Compact Track Loader

239D (S/N: BL91-UP)

249D (S/N: GWR1-UP)

Industrial Engine

C2.2 (S/N: G431-UP; J261-UP)

Skid Steer Loader

226D (S/N: HRD1-UP)

232D (S/N: DPR1-UP)

Introduction

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

Cold climate kits for the C2.2 engine have been introduced.

Safety Section

Required Parts

For engines that have a heater connector installed, 495-3792 Breather Kit is required. 495-3792 Breather Kit contains the parts that are listed in table 1.

For engines that do not have a heater connector installed, 495-3793 Breather Kit is required. 495-3793 Breather Kit contains the parts that are listed in table 2.

In addition, a 396-9017 Connector Plug As is recommended to connect from the heated connector to the application. Obtain 158-6706 Terminal and 185-1861 Wire Seal to produce the 396-9017 Connector Plug As.

Removal Procedure (Engines with a Heated Connector)

1. Remove the existing hose assemblies and crankcase breather canister. Refer to Disassembly and Assembly, Crankcase Breather - Remove and Install for the correct procedure.

Removal Procedure (Engines without a Heated Connector)

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Illustration 1	g06073917
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Illustration 2	g06074017
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1. Loosen hose clamp (2) and hose clamp (9) for hose assembly (8). Remove clip (7) and bolt (6).

2. Disconnect hose assembly (8) from air connection (10) and crankcase breather canister (1).

3. Loosen hose clamp (3) and loosen hose clamp (5) for hose assembly (4).

4. Disconnected hose assembly (4) from crankcase breather canister (1) and engine body.

5. Open hose clip (13) and move hose clip down on hose assembly (14). Open hose clip (15) and move hose clip up onto hose assembly (14).

6. Remove hose assembly (14) from crankcase breather canister (1) and remove hose assembly from cylinder block.

7. Remove bolts (12) from crankcase breather canister (1).

8. Remove crankcase breather canister (1) from bracket (11).
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   Illustration 3	g06074030
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9. Loosen hose clamp (16) and hose clamp (18) for hose assembly (17).

10. Remove hose assembly (17) from the inlet of turbocharger and air connection (10).

Installation Procedure (Engines with a Heated Connector)

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Illustration 4	g06072746
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Illustration 5	g06072788
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1. Position new crankcase breather canister (3) onto bracket (1) and install bolts (2) hand tight.

2. Check orientation of hose assembly (9) and hose clip (10) and hose clip (8). Install hose assembly (9) to crankcase breather canister (3) and to body of engine.

3. Check orientation of hose assembly (12) and hose clip (14) and hose clip (7). Install hose assembly (12) to crankcase breather canister (3) and to breather heater connector (13).

4. Tighten bolts (2) to a torque of 7.5 N·m (66 lb in).

5. Securely tighten hose clamp (8) and hose clamp (10). Securely tighten hose clamp (7) and hose clamp (14). Install new cable tie (11).

6. Ensure the orientation of hose assembly (5) is correct. Install hose assembly (5) to crankcase breather canister (3) and install hose assembly on to cylinder block.

7. Open hose clip (4) and locate on hose assembly (5). Open hose clip (6) and locate on hose assembly (5).
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   Illustration 6	g06074036
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8. Install extra cable tie to secure both hose assemblies at Position X.

Installation Procedure (Engines without a Heated Connector)

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Illustration 7	g06072746
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1. Position new crankcase breather canister (3) onto bracket (1) and install bolts (2) hand tight.
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   Illustration 8	g06074371
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2. Ensure that hose clamp (14) and hose clamp (12) are correctly positioned onto hose assembly (13).

3. Install hose assembly (13) to the inlet for the turbocharger.

4. Install bush (10) to air connection (7).

5. Install air connection (7) to hose assembly (13).

6. Install hose clamp (11) onto air connection (7). Install heater assembly (8) into air connection (7).

7. Push connector assembly (9) onto the heater assembly (8).
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   Illustration 9	g06074387
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8. Check orientation of hose assembly (17) and hose clip (18) and hose clip (16). Install hose assembly (17) to crankcase breather canister (3) and to body of engine.

9. Check orientation of hose assembly (20) and hose clip (15) and hose clip (21). Install hose assembly (19) to crankcase breather canister (3) and to connector assembly (9).

10. Tighten bolts (2) to a torque of 7.5 N·m (66 lb in).

11. Securely tighten hose clamp (16) and hose clamp (18). Securely tighten hose clamp (15) and hose clamp (21). Securely tighten hose clamp (12) and hose clamp (14). Securely tighten hose clamp (11). Install new cable tie (19).
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    Illustration 10	g06074036
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12. Install extra cable tie to secure both hose assemblies at Position X.

Heated Connector Electrical Requirements

• The heated connection needs to be active only when the engine is in operation. It is recommended that the heated connection is powered up through the applications key switch of the application to prevent unnecessary drain on the battery.

• The heater is approved for 12 VDC and 24 VDC operation.

• No control circuitry is required. The connector can be permanently on when the application is in operation or shut down with ignition keyswitch in the ON position.

• The electrical connection is positive to one terminal and negative to the other terminal. The heater is not polarity sensitive, therefore either terminal can be used for the positive feed.

• Fuse protection for the heater circuit is recommended. The recommended fuse rating is 5A.

• When switched on the heater draws greater current (1.9A at 12 VDC, falling as the heater heats 0.6A at 12 VDC after approximately 8 minutes) where upon the heater stabilizes.

• Start up current at 24 VDC operation is 3.8A falling to 0.3A at 24 VDC after approximately 8 minutes.

• Ensure that the electrical connection and harness are protected from heat sources such as exhaust manifolds.

• Ensure that the harness to the connector is secured and cannot be snagged on other components.