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Procedure for Replacement of Air Conditioner Components{7320} Caterpillar


Procedure for Replacement of Air Conditioner Components{7320}

Usage:

TK1051 9HZ
Excavator:
312C (S/N: BNN1-UP)
312C (S/N: CBT1-UP)
322C (S/N: BPH1-UP)
322C (S/N: BKJ1-UP; HEK1-249; CAM1-UP; C3R1-290; LAR1-192; SLX1-UP; CBY1-UP)
325C (S/N: S2C1-142; BFE1-807; M2K1-295; G1L1-217; S3M1-322; Y4P1-400)
330C (S/N: D3C1-229; B1K1-178; B2L1-UP; B3M1-UP; B4N1-183; DKY1-1264)
Track Feller Buncher:
TK1051 (S/N: 9HZ1-110)

Introduction

The heating and air conditioning system has experienced various improvements in order to increase operator comfort. Installation of the kit that applies to your machine will increase the cooling capacity of the air conditioning system. The operator will notice a reduced cool down time at start-up.

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Table 1
237-9929 Air Conditioner Kit    
Part Number     Qty     Part Name    
2R-8159     2     Bolt    
3S-2093     3     Cable Strap    
8C-3756     1     Film    
9X-7380     1     O-Ring Seal    
9X-7381     1     O-Ring Seal    
9X-7382     2     O-Ring Seal    
177-6696     1     Grommet    
177-6698     4     Gasket    
177-6732     1     Door Assembly    
179-4674     1     Gasket    
191-0979     1     Blower Wheel    
037-4838     1     Clamp    
228-9043     1     Evaporator Coil    
228-9044     1     Expansion Valve    
228-9045     1     Motor    
228-9539     1     Plate    
231-2790     1     Control Assembly (with harness)    

The 237-9929 Air Conditioner Kit must be used for machines that have a 171-2545 Control before date code of 15Nov02.

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Table 2
237-9930 Air Conditioner Kit    
Part Number     Qty     Part Name    
2R-8159     2     Bolt    
3S-2093     3     Cable Strap    
8C-3756     2     Film    
9X-7380     1     O-Ring Seal    
9X-7381     1     O-Ring Seal    
9X-7382     2     O-Ring Seal    
177-6696     1     Grommet    
177-6698     4     Gasket    
177-6732     1     Door Assembly    
179-4674     1     Gasket    
191-0979     1     Blower Wheel    
037-4838     1     Clamp    
228-9043     1     Evaporator Coil    
228-9044     1     Expansion Valve    
228-9045     1     Motor    
228-9539     1     Plate    
232-4958 (1)     1     Test Circuit Assembly    
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( 1 ) This tool is reusable and it can be used multiple times.

The 237-9930 Air Conditioner Kit must be used for machines that have a 171-2545 Control with date code 15Nov02 or later.

Removal Procedure

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    Illustration 1g01022453

  1. Push the temperature control knob in order to disable the automatic temperature control. Rotate the temperature control knob until "8" appears on the display. This will ensure that the door is in the correct position for removal and installation.

  1. Remove the air conditioning unit from the cab.

    ReferenceRefer to Disassembly and Assembly, "Air Conditioner - Remove" for the machine that is being serviced.

Removal of the Control Assembly, the Air Inlet Housing and the Air Outlet Housing

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Illustration 2g01012353

  1. Unplug the harness connectors. Remove control assembly (9) .

  1. Remove two bolts (3). Remove two plates (4) .

  1. Remove temperature sensor (8) .

  1. Cut cable straps (7) .

  1. Remove air inlet housing (6) .

  1. Remove four bolts (1) .

  1. Cut cable straps (5) .

  1. Remove air outlet housing (2) .

Removal of Actuator, Blower Motor and Cover

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    Illustration 3g00986420

  1. Remove three screws (10). Remove actuator (11) .

  1. Remove five screws (14). Remove blower motor (15) and blower wheel (16) .

  1. Remove eight screws (11). Remove cover (12) .

Removal of Evaporator Coil

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Illustration 4g01009145

  1. Remove pressure switch (18) and pressure switch (19) .

  1. Remove screws (21) and plate (20).
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    Illustration 5g01022456

  1. Remove screws (24) and plate (25) from evaporator coil (17) .

  1. Remove tube assembly (22) and tube assembly (23) .

  1. Remove evaporator coil (17) .

Removal of Door Assembly

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    Illustration 6g01014420

  1. Remove screw (26) that holds the lever to the bottom of the door assembly.
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    Illustration 7g00994382

  1. Note the orientation of the door assembly. Remove the door assembly.

Installation Procedure

Installation of 228-9043 Evaporator Coil and the 177-6732 Door

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    Illustration 8g01009843

    (1) 177-6732 Door

    (2) 179-4674 Gasket

    (3) 177-6698 Gaskets

    (4) Tube assembly

    (5) 9X-7382 O-Ring Seal

    (6) Nut

    (7) Washer

    (8) Plate

    (9) 2R-8159 Bolts

    (10) 228-9044 Valve

    (11) 228-9539 Plate

    (12) 9X-7381 O-Ring Seals

    (13) 9X-7380 O-Ring Seal

    (14) 177-6695 Grommet

    (15) Tube assembly

    (16) 228-9043 Evaporator Coil

  1. Install the new 177-6732 Door (1) in the original orientation of the old door assembly. Ensure that the new door assembly is able to move freely.

  1. Install 228-9043 Evaporator Coil (16). The evaporator coil assembly is preassembled by the supplier. The following parts are preassembled by the supplier.

    (2) 179-4674 Gasket

    (3) 177-6698 Gasket

    (10) 228-9044 Valve

    (11) 228-9539 Plate

    (12) 9X-7381 O-Ring Seals

    (14) 177-6695 Grommet

  1. Install one 9X-7382 O-Ring Seal (5) to tube assembly (4).

  1. Install one 9X-7380 O-Ring Seal (13) to tube assembly (15) .

  1. Fasten 228-9044 Valve (10) to tube assemblies (4,13) with the existing plate (8), washer (7) and nut (6) .

    Note: Do not tighten nut (6) until the top cover and the temperature sensor have been installed.

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    Illustration 9g01010271

  1. Install plate (18) and screws (17) .

    Note: Do not tighten screws (17) until the top cover and the temperature sensor have been installed.

    Note: Ensure that the locator holes on the bottom of the evaporator coil and the heater coil are on the pins on the bottom of the case assembly.

Relocation of Evaporator Sensor

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    Illustration 10g01017368

    (A) 70 mm (2.756 inch). (B) 56 mm (2.205 inch)

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    Illustration 11g01022111

  1. Insert the probe into the coil fins at a 45° angle according to the dimensions in Illustration 10. Install the probe to depth of 82 mm (3.230 inch). At this depth, secure a cable strap to the probe. This will ensure that the probe is not inserted deeper than 82 mm (3.230 inch).
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    Illustration 12g01017417
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    Illustration 13g01019808

  1. Route the evaporator sensor wire between the filter inlet housing and the main case joint.

Installation of Cover, Actuator and 228-9045 Motor

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    Illustration 14g01009925

    (19) Screw. (20) Actuator. (21) Cover. (22) Screw. (23) 187-7719 Bolts . (24) 228-9045 Motor . (25) Ring.

  1. Install cover (21) with eight screws (22) .

    Note: Ensure that ring (26) is positioned properly.

    Note: Look through the holes of the blower motor in order to ensure that the locator holes on the heater coil are on the pins of the case assembly.

  1. Install 191-0979 Blower Wheel (25) onto 228-9045 Motor (24) with one 037-4838 Clamp .

  1. Install the 228-9045 Motor (24) with five existing 187-7719 Bolts (23) .

  1. Install the actuator (20) with three screws (19) .

Installation of Control Assembly (with harness) and 8C-3756 Film

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    Illustration 15g01010081

    (26) 8C-3756 Film . (27) 3S-2093 Cable Straps . (28) 231-2790 Control Harness .

  1. Print the following information on the 8C-3756 Film .

    Print "168-4604 chg 04" after the group number. Print "DLR code (___) AC Kit installed on DATE" after the sequence number.

  1. Apply the 8C-3756 Film (26) .

  1. The second 8C-3756 Film is used with the 237-9930 Air Conditioner Kit only. Print the following information on the second 8C-3756 Film in order to relabel the 171-2545 Control or the 233-9518 Control for the correct part identification for replacement.

    Print "231-2790" after the group number. Print "DLR code (___) AC Kit installed on DATE" after the sequence number.

  1. Apply the 8C-3756 Film to the 171-2545 Control or the 233-9518 Control .

  1. Install control assembly (28) with the existing two screws.

  1. Install three 3S-2093 Cable Straps (27) .

Reprogramming the Heating and Air Conditioning Control for Machines that Use the 237-9930 Air Conditioner Kit

Use the following procedure in order to reprogram the heating and air conditioning control.

Only a 171-2545 Control with a date code 15Nov02 or later should be reflashed. Previous control assemblies have internal circuit differences that will create problems with the new flash file.

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Table 3
Date Conversion    
Code     Number    
N     0    
U     1    
M     2    
E     3    
R     4    
A     5    
L     6    
K     7    
O     8    
D     9    

Example: Code UAUUNM equals 151102 or 15Nov02.

  1. Use the following procedure in order to remove the 168-4605 Control Panel Gp .

    1. Insert a thin blade screwdriver into the slot in order to release the spring loaded clips on each end of the control panel.

      Note: Do not force the control panel out of the opening. The panel can be removed easily when you release the clips.

  1. Unplug the 4-pin connector.

    Note: The short harness to the control panel may require the use of a screwdriver in order to release the retainer clip on the electrical DT connector.

  1. Plug the wiring harness connector that leads to the 171-2545 Control into the 232-4958 Reprogram Tool .

  1. Turn the engine start switch key to the ON position.

  1. The 232-4958 Reprogram Tool will power up the heating and air conditioning control and the blower fan. Reprogram the controller and shut off. The time that is required will be less than 15 seconds.

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

  1. Unplug the 232-4958 Reprogram Tool and reconnect the control panel to the 4-pin connector. Reinstall the control panel.

  1. Turn the engine start switch key to the ON position.
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    Illustration 16g00781373

    (1) Fan Speed Knob and Power On Switch

    (2) Automatic Temperature Control Switch

    (3) Air Outlet Selection Switch

    (4) Fresh Air Control

    (5) Temperature Control Knob

    (6) Display

  1. Use the following procedure in order to access the parameter mode.

    1. Push fan speed knob (1) to power on the system.

    1. Holding down both automatic temperature control switch (2) and the fan speed knob (1). The control panel will display the parameter codes 0 through 20 and parameter code 36 on the LCD panel.

      The LCD panel will display the codes for 2 seconds. The value of the parameter code will be displayed for 5 seconds. In order to cycle upward through the parameter codes, rotate the fan speed knob clockwise. In order to cycle downward through the parameter codes, rotate the fan speed knob counterclockwise.

  1. Check parameter value "08P". The cutoff temperature for the compressor should be −0.5 °C (31 °F).

    ReferenceSpecifications, Systems Operation, Testing and Adjusting, RENR3899, "Troubleshooting Air Conditioner Control (Parameter Codes)".

  1. Use the following procedure in order to clear all error codes.

    1. The specific error code can be displayed when the power is turned on by holding both the temperature control knob and the fan speed knob.

      The error code will be displayed for 2 seconds in the characters that are located in the last two places on the left of the LCD panel. If multiple errors exist, cycle through the errors by turning the fan speed knob.

    1. Press the fan speed knob in order to clear all error codes.

      ReferenceSpecifications, Systems Operation, Testing and Adjusting, RENR3899, "Troubleshooting Faults With Service Codes".

  1. The reprogramming is complete.

Charge the Refrigerant System

ReferenceSpecifications, Systems Operation, Testing and Adjusting, RENR3899, "Refrigerant System - Charge".

Note: Refer to Specifications, Systems Operation, Testing and Adjusting, RENR3899-11 or later for the charge capacities for your machine. The charge plate in the cab or previous versions of the manual listed in the reference may have incorrect information.

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Table 4
Model     Product Identification Number     Amount of Charge    
312C     S/N:BNN1-UP    
0.70 kg (1.5 lb)    
312C L     S/N:CBT1-UP    
0.70 kg (1.5 lb)    
322C     S/N:BPH1-UP    
1.30 kg (2.9 lb)    
322C     S/N:CAM1-UP    
1.30 kg (2.9 lb)    
322C     S/N:CBY1-UP    
1.30 kg (2.9 lb)    
322C     S/N:SLX1-UP    
1.30 kg (2.9 lb)    
322C L     S/N:BKJ1-UP    
1.40 kg (3.0 lb)    
322C L     S/N:HEK1-UP    
1.05 kg (2.3 lb)    
322C FM     S/N:C3R1-UP    
1.30 kg (2.9 lb)    
322C FM     S/N:LAR1-UP    
1.30 kg (2.9 lb)    
325C     S/N:M2K1-UP    
1.30 kg (2.9 lb)    
325C     S/N:S3M1-UP    
1.30 kg (2.9 lb)    
325C     S/N:G1L1-UP    
1.30 kg (2.9 lb)    
325C L     S/N:BFE1-UP    
1.05 kg (2.3 lb)    
325C FM     S/N:Y4P1-UP    
1.05 kg (2.3 lb)    
325C MH     S/N:S2C1-UP    
1.30 kg (2.9 lb)    
330C     S/N:B4N1-UP    
1.30 kg (2.9 lb)    
330C     S/N:B1K1-UP    
1.30 kg (2.9 lb)    
330C     S/N:B3M1-UP    
1.30 kg (2.9 lb)    
330C L     S/N:DKY1-UP    
1.05 kg (2.3 lb)    
330C FM     S/N:B2L1-UP    
1.05 kg (2.3 lb)    
330C MH     S/N:D3C1-UP    
1.30 kg (2.9 lb)    
TK1051     S/N:9HZ1-UP    
1.70 kg (3.7 lb)    

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