415F2 Industrial Loader Machine Systems Air Conditioner and Heater - Remove and Install Caterpillar

Removal Procedure

Start By:

1. Remove the floor mat.

2. Remove the seat.

1. Drain the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedure
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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.

2. Recover the refrigerant. Refer to Service Manual, SENR5664, "All Products Air Conditioning and Heating R134a for All AVSpare Machines" for the recovery and charging procedure. Refer to Special Publication, NENG2500, "Air Conditioning Tools" for the correct tools.
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   Illustration 1	g06032228

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   Illustration 2	g06032233

3. Remove cover (1). Remove guard (2).
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   Illustration 3	g06032244

4. Remove bolts (3) and relocate pilot valve assembly (4).
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   Illustration 4	g06032257

5. Remove bracket (4).
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   Illustration 5	g06032265

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   Illustration 6	g06032272

6. Remove mat (5). Remove covers (6).
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   Illustration 7	g06032275

7. Remove duct (7) and cover (8).
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   Illustration 8	g06032281

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   Illustration 9	g06032304

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   Illustration 10	g06032309

8. Remove cover (9). Remove bolts (10) and inner cover assembly (11).
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   Illustration 11	g06032322

9. Remove covers (12).
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   Illustration 12	g06032326

10. Disconnect terminal assembly (13) by pulling outward on tang (14).
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    Illustration 13	g06032332

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    Illustration 14	g06032341

11. Remove set screw (15) and dial (16). Remove nut (17) and relocate switch assembly (18). Relocate cover assembly (19).
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    Illustration 15	g06032375

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    Illustration 16	g06032379

12. Disconnect heater hoses (20). Disconnect air condition hose assemblies (21).
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    Illustration 17	g06032381

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    Illustration 18	g06032388

13. Remove bolts (22) and (23). Remove air conditioner and heater assembly (24).

Installation Procedure

1. Install air conditioner and heater assembly (24) in the reverse order of removal.