Procedure to Install a Suction Side Pressure Switch and a Compressor Protection Module to the Air Conditioning Arrangement on Certain D8R Series II Track-Type Tractors{1805, 1808, 7320} Caterpillar


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Procedure to Install a Suction Side Pressure Switch and a Compressor Protection Module to the Air Conditioning Arrangement on Certain D8R Series II Track-Type Tractors{1805, 1808, 7320} [REHS8596]
OPERATOR STATION
AIR CONDITIONER GP
1.1. Introduction
2.1. Important Safety Information
3.1. Parts List
4.1. Installation of 149-6371 Pressure Switch for A/C Compressor
5.1. Installation Procedure of 338-1942 On Delay Timer As
Track-Type Tractor:
D8R Series II (S/N: AKA1-UP)
D8R Series II (S/N: 6YZ1-UP)

Introduction

This Special Instruction provides the procedure necessary to install a 149-6371 Pressure Switch and a 338-1942 On Delay Timer As to the air conditioning system on the machines listed above which are equipped with air conditioning.

Compressor and pressure switch life are positively impacted when both the delay timer and the suction side pressure switch are installed. The addition of this pressure switch increases the sensitivity of the compressor protection system to the low refrigerant charge situation. The delay timer limits rapid cycling of the compressor to four times per minute, delays compressor clutch engagement during engine start, and protects the compressor from incorrect refrigerant pressure, incorrect system voltage, and excessive current.

The refrigerant must be recovered and the A/C system must be evacuated and recharged to install the 149-6371 Pressure Switch .

Reference Special Instruction, REHS4499, "Testing the Refrigerant Compressor Protection Module"

Reference Special Instruction, REHS7215, "Repair Procedure for Damaged Harness Wiring"

ReferenceTesting and Adjusting, SENR5664, "Air Conditioning and Heating R-134a for All AVSpare Machines"

ReferenceTool Operating Manual, SEHS9615, "Servicing Deutsch HD and DT style connectors"

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.

Ensure that all personnel are safe when using a tool, procedure, work method, or operating technique not recommended by AVSpare. Ensure that the product will not be damaged or the product made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

------ WARNING! ------

Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

----------------------


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.

Dispose of all fluids according to local regulations and mandates.


------ WARNING! ------

Personal injury or death can result without releasing all of the hydraulic pressure.

Release all the pressure from the hydraulic system before any lines are disconnected.

----------------------

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

Parts List

Table 1
Required Parts List    
Item     Quantity     Part Number     Description    
1     2     9X-7385     O-Ring Seal    
2     1     149-6371     Pressure Switch    
3     1     9X-7378     O-Ring Seal    
4     1     9X-7382     O-Ring Seal    
5     1     292-8187     Air Conditioner Fitting    
6     1     5S-7383     Bolt    
7     3     4P-8134     Clip    
8     1     8T-4136     Bolt    
9     2     8T-4896     Hard Washer    
10     18     7K-1181     Cable Strap    
11     1     243-5821     Bracket As    
12     1     338-1942     On Delay Timer As    
13     1     347-4734     Clip    
14     1     454-2341     Harness As    
15     1     374-7463 (1)     Seal Cap    
16     1     5M-3062     Bolt    
17     2     155-2270 (2)     Connecting Plug Kit    
18     4     126-1768 (2)     Connector Socket    
19     700 mm (27.6 inch)     366-8856 (2) (3)     Wiring Harness    
-     -     4C-2959 (4)     Air Conditioner Oil    
( 1 ) Required only for S/N:6YZ1-1883 and ; S/N:AKA1-1117
( 2 ) Required only for S/N:6YZ1884-UP and ; S/N:AKA1118-UP
( 3 ) This bulk harness is braided, has three 14 gauge wires, and is sold by the decimeter (dm). 700 mm is 7.0 dm or 0.7 m. The dealer's minimum order quantity is 609dm (60.9 m) on one spool which cannot be broken or returned
( 4 ) Use as required

Installation of 149-6371 Pressure Switch for A/C Compressor

    Note: Lubricate all refrigerant system seals with 4C-2959 Air Conditioner Oil or similar Air Conditioner oil.

  1. Recover A/C system refrigerant. Refer to Testing and Adjusting, SENR5664, "Air Conditioning and Heating R-134a - for All AVSpare Machines".



    Illustration 1g03723510

    (1) 9X-7385 O-Ring Seal

    (2) 149-6371 Pressure Switch

    (3) 9X-7378 O-Ring Seal

    (4) 9X-7382 O-Ring Seal

    (5) 292-8187 Air Conditioner Fitting

  1. Assemble the 149-6371 Pressure Switch (2) to the 292-8187 Air Conditioner Fitting (5) using 9X-7378 O-Ring Seal (3). Refer to Illustration 1.

  1. Replace suction side fitting assembly with 292-8187 Air Conditioner Fitting (5) using 9X-7385 O-Ring Seal (1) and 9X-7382 O-Ring Seal (4). Replace 9X-7385 O-Ring Seal (1) in discharge side fitting. Refer to Illustration 1.

  1. Evacuate and recharge the A/C system. Refer to Testing and Adjusting, SENR5664, "Air Conditioning and Heating R-134a - for All AVSpare Machines".

Installation Procedure of 338-1942 On Delay Timer As




    Illustration 2g03723506

    (A) 106-8704 Arc Suppressor As

    (B) Compressor clutch connector

    (C) Arc suppressor connector

    (D) Discharge pressure switch connector

    (E) Lower Right Side Compressor Mounting Bolt

    (F) Existing Engine Harness

  1. Only for S/N:6YZ1-1883 and ; S/N:AKA1-1117, remove and discard 106-8704 Arc Suppressor As (A) and install 374-7463 Seal Cap (15) to engine harness connector for arc suppressor (C). Remove and discard compressor mounting bolt (E). Refer to Illustration 2.



    Illustration 3g03732096

    (A) 106-8704 Arc Suppressor As

    (E) Lower Right Side Compressor Mounting Bolt

    (G) 183-4273 Wiring Harness

    (H) Existing A/C Connector

    (F) Existing Engine Harness

  1. Only for S/N:6YZ1884-UP and ; S/N:AKA1118-UP, Remove and discard 106-8704 Arc Suppressor As (A), 183-4273 Wiring Harness (G), and Compressor mounting bolt (E). Refer to illustration 3.



    Illustration 4g03732130

    (J) A/C compressor

    (6) 5S-7383 Bolt

    (K) Existing washer

    (L) Existing nut

    (7) 4P-8134 Clip

    (M) A/C compressor mounting bracket

    (8) 8T-4136 Bolt

    (9) 8T-4896 Hard Washer

    (10) 7K-1181 Cable Strap

    (11) 243-5821 Bracket As

    (12) 338-1942 On Delay Timer As

    (13) 347-4734 Clip

  1. Use 5S-7383 Bolt (6) with existing nut (L) and washers (K) to install 4P-8134 Clip (7) and 243-5821 Bracket As (11). Refer to illustration 4 Orient bracket (11) and clip (7) as shown in illustration 5.



    Illustration 5g03723508

    (N) Compressor clutch connector

    (P) Discharge pressure switch connector

    (R) New suction pressure switch connector

    (S) New On delay timer connector

    (6) 5S-7383 Bolt

    (7) 4P-8134 Clip

    (8) 8T-4136 Bolt

    (9) 8T-4896 Hard Washer

    (10) 7K-1181 Cable Strap

    (11) 243-5821 Bracket As

    (12) 338-1942 On Delay Timer As

    (13) 347-4734 Clip

    (14) 454-2341 Wiring Harness

  1. Use 8T-4136 Bolt (8) and 8T-4896 Hard Washer (9) to install 338-1942 On Delay Timer As (12) and 347-4734 Clip (13). Refer to illustration 4. Orient clip (13) and Delay Timer (12) as shown in illustration 5.

    Note: Procedure for steps for 5 through 9 is only applicable for S/N:6YZ1-1883 and ; S/N:AKA1-1117.




    Illustration 6g03723503

    (B) Old Compressor clutch connector

    (C) Old Arc Suppressor connector

    (D) Old discharge pressure switch connector

    (F) Existing engine harness

    (10) 7K-1181 Cable Strap

    (14) 454-2341 Wiring Harness

    (15) 374-7463 Seal Cap

  1. Only for S/N:6YZ1-1883 and ; S/N:AKA1-1117, fold the air conditioner compressor pig tail and connectors (B), (C) and (D) on the existing engine harness (F) down on to the main engine harness as shown in Illustration 6.

  1. Install 454-2341 Wiring Harness (14). Connect harness connectors "A/C SWITCH HIGH" to discharge pressure switch connector (P), "A/C SWITCH LOW" to suction pressure switch connector (R), "CPS MODULE" to delay timer connector (S) "A/C Clutch Sol" to compressor clutch connector (N). Refer to illustration 5.

  1. Connect harness (14) connectors "A/C PRESS SW CONN" to engine harness (F) connector (D) and "A/C CLUTCH SOL CONN" to engine harness (F) connector (B). Refer to Illustration 6.

  1. Attach connector (S) to clip (14). Secure connectors (P), (R), and (N) to existing ladder clips using cable straps (10). Secure harness assembly (14) to 4P-8134 Clip (7) using cable strap (10). Ensure that there is no tension on the connectors. Refer to Illustration 5.

  1. Secure harness assembly (14) and connectors (B), (C), and (D) to the existing engine harness (F) using cable straps (10) as needed. Refer to Illustration 6.

    Note: Procedure for Steps 10 through 15 is only applicable for S/N:6YZ1884-UP and ; S/N:6YZ1118-UP




    Illustration 7g03732244

    (10) 7K-1181 Cable Strap

    (14) 454-2341 Wiring Harness

    (F) Existing engine harness

    (T) Fabricated Jumper Harness

    (U) Existing A/C connector on engine harness

    (V) Modified Connector on 454-2341 Wiring Harness

    (17) 155-2270 Connecting Plug Kit

    (18) 126-1768 Connector Socket

    (19) 700 mm of 366-8856 Wiring Harness

  1. Only for S/N:6YZ1884-UP and ; S/N:AKA1118-UP modify the 454-2341 Wiring Harness (14) to form connector (V). Remove the 522-WH with pin from the "A/C CLUTCH SOL CONN" connector and discard the connector. Remove the plug from position 2 of the "A/C PRESS SW CONN" connector and insert the 522-WH pin.

  1. Make a jumper harness (T) using 700 mm (27.6 inch) of 366-8856 Wiring Harness bulk braided (19), two 155-2270 Connecting Plug Kit (17), and four 126-1768 Connector Socket (18). Connect position 1 to position 1 and position 2 to position 2. Cut the third wire not being used back to the braiding.

  1. Install 454-2341 Wiring Harness (14). Connect harness connector "A/C SWITCH HIGH" to discharge pressure switch connector (P), "A/C SWITCH LOW" to suction pressure switch connector (R), "CPS MODULE" to delay timer connector (S) and "A/C CLUTCH SOL" to compressor clutch connector (N). Refer to illustration 5.

  1. Connect harness (14) modified connector (V) to one end of fabricated harness (T). Connect other end of fabricated jumper harness (T) to existing A/C connector on engine harness (U). Refer to illustration 7.

  1. Attach connector (S) to clip (13). Secure connectors (P), (R), and (N) to existing ladder clips using cable strap (10). Secure harness assembly (14) to 4P-8134 Clip (7) using cable strap (10). Ensue that there is no tension on the connectors. Refer to illustration 5.

  1. Secure harness assembly (14) , jumper harness (T), connectors (U), and (V) to the existing engine harness (F) and chain links using cable straps (10) as needed. Refer to illustration 7.



    Illustration 8g03723505

    (7) 4P-8134 Clip

    (9) 8T-4896 Hard Washer

    (10) 7K-1181 Cable Strap

    (14) 454-2341 Wiring Harness

    (16) 5M-3062 Bolt

  1. Connect harness assembly (14) to the new ground point on the block using 5M-3062 Bolt (16), and 8T-4896 Hard Washer (9). Refer to Illustration 8.

  1. Assemble two 4P-8134 Clips (7) with existing hardware and secure harness assembly (14) using cable straps (10). Refer to Illustration 8.

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