Field Installation of the 222-5721 Cab Heater and Mounting Gp {7304} Caterpillar

Introduction

Reference: Operation and Maintenance Manual, SEBU7468, "216, 226, 228, 232, 236, 242, 246, 248, 252, and 262 Skid Steer Loaders"

Reference: Operation and Maintenance Manual, SEBU7494, "247, 257, 267, 277, and 287 Multi Terrain Loaders"

This Special Instruction provides the information that is necessary for field installation of the 222-5721 Cab Heater and Mounting Gp .

Do not perform any procedure that is outlined in this publication or do not order any parts until you have read the information that is contained in this instruction.

Parts Needed

High Performance Heater

The parts that are needed for field installation of the high performance heater are identified in Table 1 and in Table 2.

Seat Belt

In order to accommodate the new high performance heater, the current seat belt must be replaced. The new seat belts that are available are listed in Table 3.

Preparing the Machine

1. Park the machine on level ground.

2. Raise the lift arms fully and engage the loader lift arm brace.

3. Turn the engine start switch key to the OFF position.

Modifying the Support Assemblies for the Joysticks

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Illustration 1	g00941494
(A) Left Hand Support Assembly (B) Right Hand Support Assembly (C) Vertical Floorplate

1. Remove the vertical floorplate (C) that is between the left hand support assembly (A) and the right hand support assembly (B). See Illustration 1.

   Retain the vertical floorplate.

   Retain the bolts and the washers.

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Illustration 2	g00944235
The left hand support assembly (A) 90 ± 1.5 mm (3.5 ± 0.06 inch) (B) 191 ± 1.5 mm (7.5 ± 0.06 inch) (C) 36 ± 1.5 mm (1.4 ± 0.06 inch) Radius (D) 4 ± 1.5 mm (0.16 ± 0.06 inch) (E) 31.5 ± 1.5 mm (1.2 ± 0.06 inch) (F) 25 ± 1.5 mm (0.9 ± 0.06 inch) Radius (G) 38.8 ± 1.5 mm (1.5 ± 0.06 inch) Radius (H) 142 ± 1.5 mm (5.6 ± 0.06 inch)

2. Cut the left hand support assembly (A) in order to provide cutout (1), cutout (2), and cutout (3), as shown. See Illustration 2.

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Illustration 3	g00948833
The right hand support assembly (J) 151 ± 1.5 mm (5.9 ± 0.06 inch) (K) 228 ± 1.5 mm (8.9 ± 0.06 inch) (L) 154 ± 1.5 mm (6.1 ± 0.06 inch) (M) 4 ± 1.5 mm (0.16 ± 0.06 inch) (N) 12.9 ± 1.5 mm (0.51 ± 0.06 inch) Radius

3. Cut the right hand support assembly (B ) in order to provide cutout (4), as shown. See Illustration 3.

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Illustration 4	g00948840
Enlarge the existing hole in the top of the right support assembly (B) in order to accommodate the new duct. (P) 8 ± 1.5 mm (0.32 ± 0.06 inch) (Q) 6 ± 1.5 mm (0.24 ± 0.06 inch) (R) 16 ± 1.5 mm (0.63 ± 0.06 inch)

4. Also, enlarge the hole in the top of the right hand support assembly (B). See Illustration 4.

   Note: Cut and remove area (5), area (6), and area (7) .

5. Perform Step 5.a through Step 5.o in order to install the ducts, the tubing, and the louvers.
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   Illustration 5	g00942195
   (8) 7K-1181 Cable Strap (15) 9X-2045 Screw (26) 218-0666 Louver As (28) 219-4359 Duct (29) 219-4360 Duct (30) 219-4361 Tubing (31) 219-4362 Cover (RH) (32) 219-4363 Cover (LH) (33) 220-8095 Support (RH) (34) 220-8096 Support (LH)

   1. Place the 231 cm (91 inch) length of 219-4361 Tubing (30) on a flat surface. Cut the tubing into the following lengths.
      • Three 31 cm (12 inch) lengths

      • Two 69 cm (27 inch) lengths

   2. Assemble two 31 cm (12 inch) lengths of tubing to the 219-4359 Duct (28). See Illustration 5.

      Secure the tubing to the duct with two 7K-1181 Cable Straps (8) .

   3. Insert the duct with the two lengths of tubing into the opening that is provided in the top of the right hand support assembly (B) .

   4. Install the 219-4362 Cover (RH) (31) on the right hand support assembly (B) .

      Install the cover with four 9X-2045 Screws (15) .

      Tighten the screws to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

   5. Pull the ends of the tubing through the openings in the cover.

   6. Install a 218-0666 Louver As (26) on the end of each length of tubing. Secure each louver assembly to the tubing with a 7K-1181 Cable Strap (8) .

      Note: Cut one coil of the tubing's helix in order to facilitate installation of the louver. Then install the cable strap beyond the cut in order to keep the cut from continuing.

   7. Seat the two louver assemblies in the openings on the 219-4362 Cover (RH) (31) .

      Note: The louver assemblies will snap into position in the openings that are provided on the cover.

   8. Assemble the three lengths of tubing that remain to the 219-4360 Duct (29). See Illustration 5.

      Secure each length of tubing to the duct with a 7K-1181 Cable Strap (8) .

   9. Insert the three lengths of tubing that are assembled on the 219-4360 Duct (29) into cutout (1) in the left hand support assembly (A) .

   10. Also, push the end of the 219-4360 Duct (29) in cutout (1) in the left hand support assembly (A) .

   11. Then, fit the opposite end of the 219-4360 Duct (29) into opening (4) in the base of the right hand support assembly (B). See Illustration 5.

       Note: This end of the 219-4360 Duct (29) will fit over the end of the 219-4359 Duct (28) which is inside the right hand support assembly (B) .

   12. Install the 219-4363 Cover (LH) (32) on the front of the left hand support assembly (A) .

       Install the cover with four 9X-2045 Screws (15) .

       Tighten the screws to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

   13. Pull the ends of the tubing through the openings in the cover.

       Note: For maximum air flow, route the tubing that is in the center position of duct (41) to the top opening in the cover, as shown. See Illustration 5.

   14. Install a 218-0666 Louver As (26) on the end of the two lengths of tubing. Secure each louver assembly to the tubing with a 7K-1181 Cable Strap (8) .

       Note: Cut one coil of the tubing's helix in order to facilitate installation of the louver. Then install the cable strap beyond the cut in order to keep the cut from continuing.

   15. Seat the two louver assemblies in the openings on the 219-4363 Cover (LH) (32) .

       Note: The louver assemblies will snap into position in the openings that are provided on the cover.

   16. Pull the end of the remaining length of tubing through cutout (3) in the left hand support assembly (A) .

   17. Install a 218-0666 Louver As (26) on the end of the tubing. Secure the louver assembly to the tubing with a 7K-1181 Cable Strap (8) .

       Note: Cut one coil of the tubing's helix in order to facilitate installation of the louver. Then install the cable strap beyond the cut in order to keep the cut from continuing.

   18. Seat the louver assembly in the cutout in the left hand support assembly (A) .

       Note: The louver assembly will snap into position in the cutout in the left hand support assembly (A) .

6. Reinstall the 154-3965 Floorplate (Vertical) (D) between the left hand support assembly and the right hand support assembly. See Illustration 1.

   Use the bolts and washers that were removed in Step 1.

Installing the Cab Air Filter

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Illustration 6	g00920073
Remove the plate.

1. If equipped, remove the plate that is indicated in Illustration 6. Remove the plate by removing the four nuts and the four washers that secure the plate to the cab. Also, remove the four studs.

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Illustration 7	g00920077
Assemble the cab air filter and install the cab air filter. (3) 5C-2890 Nut (14) 8T-4205 Hard Washer (20) 142-9290 Filter Cover (21) 142-9291 Filter (23) 152-4876 Seal

2. Assemble the 142-9290 Filter Cover (20), the 142-9291 Filter (21), and the 152-4876 Seal (23). See Illustration 7.

   Note: To install seal (23), remove the protective paper strip from the seal and press the seal firmly against the cover.

3. Install the four 199-6619 Clinch Studs (25).

   Note: Press fit the new studs from the inside of the cab.

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Illustration 8	g00920087
The cab air filter

4. Place the assembled cab air filter in position on the four 199-6619 Clinch Studs (25). See Illustration 8.

   Secure the cab air filter with four 5C-2890 Nuts (3) and four 8T-4205 Hard Washers (14) .

   Tighten the nuts to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

5. Disengage the loader lift arm brace and lower the lift arms fully.

Installing the Heater

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Illustration 9	g00920095
Remove the plate.

1. Remove the plate that is identified in Illustration 9.

   Remove the plate by removing the four screws, the four hard washers, and the four nuts that secure the plate to the cab floor.

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Illustration 10	g00927520
View of the bottom of the cab (E) Cut and remove the insulating material. (F) Remove the cable strap and the cap.

2. Cut and remove the portion of insulating material (E) from the bottom of the cab. Also remove the cable strap and remove the cap (F) from the harness connector. See Illustration 10.

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Illustration 11	g00920101
Placement of the heater inside the cab

3. Place the 220-8144 Cab Heater Gp (33) in position inside the cab. See Illustration 11.

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Illustration 12	g00920195

4. Install four 8T-4138 Bolts (4) and four 8T-4205 Hard Washers (14) in order to mount the heater to the cab floor. See Illustration 12.

   Tighten the bolts to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

   Note: The bolts are inserted from the underside of the cab floor and through the four holes in the floor of the cab.

5. Insert the connector plug for the heater into the harness connector. Secure the connectors to the bottom of the cab with cable straps, as needed.

Installing the Heater Lines

Illustration 13	g00920181
The high performance heater installation (E) Heater Inlet (F) Heater Outlet (G) Radiator Inlet (H) Engine Block Outlet

Three configurations are included in this instruction in order to show the components and the routings for all models. See Table 4 in order to identify the graphic that corresponds to your machine.

The 206-3791 Heater Lines Gp for 216 and 232 Machines

Illustration 14	g00918889
The 206-3791 Heater Lines Gp for 216 and 232 machines (1) 1L-2279 Elbow (6) 6D-1641 Clip (9) 8F-8151 Shutoff Valve (10) 8T-0154 Hose Clamp (11) 8T-4121 Hard Washer (12) 8T-4133 Nut (13) 8T-4136 Bolt (17) 004-6810 Elbow (19) 136-1953 Hose (22) 150-7568 Adapter (24) 183-7120 Hose Guard

The 190-7942 Heater Lines Gp for 226, 228, 236, 242, 247, 252, 257, and 267 Machines

Illustration 15	g00918890
The 190-7942 Heater Lines Gp for 226, 228, 236, 242, 247, 252, 257, and 267 machines (1) 1L-2279 Elbow (5) 5K-6875 Adapter (6) 6D-1641 Clip (9) 8F-8151 Shutoff Valve (10) 8T-0154 Hose Clamp (11) 8T-4121 Hard Washer (12) 8T-4133 Nut (13) 8T-4136 Bolt (17) 004-6810 Elbow (19) 136-1953 Hose (24) 183-7120 Hose Guard (27) 219-4328 Elbow

The 190-7943 Heater Lines Gp for 246, 248, 262, 277, and 287 Machines

Illustration 16	g00918891
The 190-7943 Heater Lines Gp for 246, 248, 262, 277, and 287 machines (1) 1L-2279 Elbow (2) 4S-1962 Clip (5) 5K-6875 Adapter (6) 6D-1641 Clip (9) 8F-8151 Shutoff Valve (10) 8T-0154 Hose Clamp (11) 8T-4121 Hard Washer (12) 8T-4133 Nut (13) 8T-4136 Bolt (17) 004-6810 Elbow (19) 136-1953 Hose (24) 183-7120 Hose Guard (27) 219-4328 Elbow

Installing the Heater Lines

1. Cut two lengths of the 136-1953 Hose (19) per Table 5.
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   Table 5

   Machine	Heater Outlet Hose	Heater Inlet Hose
   216	2160 mm (85 inch)	2260 mm (89 inch)
   226	2160 mm (85 inch)	2160 mm (85 inch)
   228	2160 mm (85 inch)	2160 mm (85 inch)
   232	2260 mm (89 inch)	2440 mm (96 inch)
   236	2260 mm (89 inch)	2160 mm (85 inch)
   242	2260 mm (89 inch)	2260 mm (89 inch)
   246	2260 mm (89 inch)	2160 mm (85 inch)
   247	2160 mm (85 inch)	2160 mm (85 inch)
   248	2260 mm (89 inch)	2160 mm (85 inch)
   252	2260 mm (89 inch)	2260 mm (89 inch)
   262	2260 mm (89 inch)	2260 mm (89 inch)
   257	2260 mm (89 inch)	2260 mm (89 inch)
   267	2260 mm (89 inch)	2260 mm (89 inch)
   277	2260 mm (89 inch)	2260 mm (89 inch)
   287	2260 mm (89 inch)	2260 mm (89 inch)

Note: Refer to Illustration 14, Illustration 15, or Illustration 16 for the components and for the hose routings for your machine.

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Illustration 17	g00921560
View of heater inlet hose (E) and heater outlet hose (F) Orientation of hose mountings at Location (I) and at Location (J) (A) 20° ± 5° (B) 30° ± 5°

2. Install the specified lengths of hose on the heater inlet (E) and the heater outlet (F). See Illustration 17.

   Use two 8T-0154 Hose Clamps (10) to install the hoses.

   Orient the hose clamps, as shown. Tighten the hose clamps to a torque of 6 ± 1.0 N·m (4.4 ± 0.7 lb ft).

   Note: Pull the hoses tightly between the heater connections and Location (J) .

3. Install one 183-7120 Hose Guard (24) on each length of hose. Position each hose guard on the section of the hose between the rear cab wall and the engine firewall.

4. Route both hoses up the rear wall of the cab and then route both hoses into the engine compartment.

   Secure the hoses to the mounting stud at Location (I) and at Location (J) on the back wall of the cab. See Illustration 17.

   Use a 6D-1641 Clip (6), a 8T-4121 Hard Washer (11), and a 8T-4133 Nut (12) at each location.

   Tighten each nut to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 18	g00921563
Orientation of mounting clip at Location (K) (F) 75° ± 5°

5. At Location (K), secure the hoses to the threaded boss that is provided on the back of the engine firewall. See Illustration 18.

   Use a 6D-1641 Clip (6), a 8T-4121 Hard Washer (11), and a 8T-4136 Bolt (12) at this location.

   Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

   Note: Pull the hoses tightly between Location (J) and Location (K) with the cab in the raised position. See Illustration 19.

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Illustration 19	g00921948
Pull hoses tightly between Location (J) and Location (K) with the cab in the raised position. (24) 183-7120 Hose Guard

6. Remove the plug in the radiator housing for installation of the heater outlet hose.

7. Assemble the parts for the hose connection for the radiator inlet. Refer to Illustration 14, Illustration 15, or Illustration 16 as applicable.

   Install this assembly in the radiator inlet.

   Tighten this assembly to a torque of 25 ± 6 N·m (18 ± 4 lb ft).

   Note: Use thread sealant in the assembly of the components and in the installation of this assembly.

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Illustration 20	g00921566
Orientation of hose connection at radiator inlet (G) (D) 45° ± 5° (E) 90° ± 5°

8. Route the heater outlet hose to the radiator inlet.

   Note: Route the heater outlet hose between the firewall and the hydraulic oil cooler lines.

9. Install the heater outlet hose to the elbow in the radiator inlet. See Illustration 20.

   Use a 8T-0154 Hose Clamp (10) to secure the hose.

   Orient the hose clamp, as shown. Tighten the hose clamp to a torque of 6 ± 1.0 N·m (4.4 ± 0.7 lb ft).

10. Remove the plug in the engine block for installation of the heater inlet hose.

11. Assemble the parts for the hose connection to the engine block. Refer to Illustration 14, Illustration 15, or Illustration 16 as applicable.

    Install this assembly in the engine block.

    Tighten this assembly to a torque of 25 ± 6 N·m (18 ± 4 lb ft).

    Note: Use thread sealant in the assembly of these components and in the installation of this assembly.

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Illustration 21	g00921565
Orientation of hose connection at engine block outlet (H) (C) 150° ± 5°

12. Route the heater inlet hose to the engine block outlet. Install the hose to the shutoff valve with a 8T-0154 Hose Clamp (10). See Illustration 21.

    Orient the hose clamp, as shown. Tighten the hose clamp to a torque of 6 ± 1.0 N·m (4.4 ± 0.7 lb ft).

    Note: Make sure that the shutoff valve, the hose clamp, and the elbows do not contact the coolant hose. Also, make sure that these components are at least 10 mm (0.4 inch) from the radiator fan guard when the radiator is lowered.

13. For 246, 248, 262, and 277 machines, install a 4S-1962 Clip (2) at Location (L). See Illustration 16.

    Use a 8T-4121 Hard Washer (11), a 8T-4133 Nut (12), and a 8T-4136 Bolt (13) at this location.

    Tighten the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

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Illustration 22	g00921774
Install the edging around the opening in the firewall. (16) 9X-2092 Edge Strip

14. Install the 9X-2092 Edge Strip (16) around the opening in the fire wall in order to protect the hoses from wear. See Illustration 22.

Completing and Checking the Heater Installation

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Illustration 23	g00942248

1. Install the 162-5233 Film (7) on the left side of the heater. See Illustration 23.

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Illustration 24	g00919541
Position for installing fuse (18) for heater

2. Install the 113-8492 Fuse (20 Amp) (18) in the indicated position in the fuse box. See Illustration 24.

3. Refill the cooling system.

   Refer to "Coolant Recommendations" and refer to "Cooling System Specifications" in the Operation and Maintenance Manual for your machine.

4. Start the engine. Run the engine without the radiator cap until the thermostat opens and the coolant level stabilizes. Maintain the coolant level in the sight gauge. The sight gauge is located on the right side of the radiator.

5. Stop the engine. Install the radiator cap.

6. Check the hoses and the fittings for leaks.

7. Start the engine.

8. Check the heater for proper operation.
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   Illustration 25	g00919540
   Temperature control knob

   1. The temperature control knob adjusts the output temperature. See Illustration 25.
      • Turn the temperature control knob clockwise in order to increase the temperature.

      • Turn the temperature control knob counterclockwise in order to decrease the temperature.

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   Illustration 26	g00919545
   Fan speed switch

   2. The fan speed switch controls the two-speed blower fan motor. See Illustration 26.
      • Press the rear portion of the rocker switch for low fan speed.

      • Press the front portion of the rocker switch for high fan speed.

      • Return the switch to the neutral position in order to turn off the fan.

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   Illustration 27	g00919546
   Adjustable louver

   3. The louver directs the flow of air, as needed. See Illustration 27.
      • The louver can be rotated for 360°.

      • The louver can be adjusted from a closed position to an open position.

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   Illustration 28	g00919549
   Recirculating filter

   4. To gain access to the air filter, loosen the two thumb screws and remove the grill panel. See Illustration 28.