Functional Test for the Refrigerant Dryer{7322} Caterpillar

Articulated Truck:

725 (S/N: B1L1-UP; AFX1-UP)

730 (S/N: AGF1-UP; B1M1-UP)

730 EJECTOR (S/N: B1W1-UP)

735 (S/N: B1N1-UP; AWR1-UP)

740 (S/N: AXM1-UP; B1P1-UP)

740 EJECTOR (S/N: B1R1-UP; AZZ1-UP)

Landfill Compactor:

826G Series II (S/N: AYH1-UP)

826H (S/N: AWF1-UP; ZXT1-UP)

836G (S/N: BRL1-UP)

836H (S/N: BXD1-UP)

Soil Compactor:

815F (S/N: BKL1-UP)

825G Series II (S/N: AXB1-UP)

825H (S/N: ZHC1-UP; AZW1-UP)

Excavator:

330B (S/N: 6DR1-UP)

345B Series II (S/N: ALB1-UP; APB1-UP; CCC1-UP; AGS1-UP)

365BL Series II (S/N: JMB1-UP; DER1-UP)

375L (S/N: 1JM1-UP)

385B (S/N: RCD1-UP)

5230B (S/N: 4HZ1-UP)

Motor Grader:

120H (S/N: 6YN1-UP)

12H (S/N: 4XM1-UP; 2WR1-UP; AMZ1-UP)

140H (S/N: CCA1-UP; APM1-UP; 5HM1-UP)

143H (S/N: APN1-UP)

14H (S/N: ASE1-UP)

160H (S/N: ASD1-UP)

16H (S/N: ATS1-UP)

24H (S/N: 7KK1-UP)

Off-Highway Truck/Tractor:

773E (S/N: BDA1-UP)

777D (S/N: AGC1-UP)

785C (S/N: APX1-UP)

789C (S/N: 2BW1-UP)

793C (S/N: ATY1-UP)

Quarry Truck:

771D (S/N: BCA1-UP)

775E (S/N: BEC1-UP)

Vibratory Soil Compactor:

CP-563E (S/N: CNT1-UP)

Track-Type Loader:

953C (S/N: BBX1-UP)

963C (S/N: BBD1-UP)

973C (S/N: BCP1-UP; LDX1-UP)

Track-Type Tractor:

D10R (S/N: 3KR1-UP; AKT1-UP)

D10T (S/N: RJG1-UP)

D10T2 (S/N: RAB1-UP; JJW1-UP)

D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)

D11T (S/N: AMA1-UP; GEB1-UP; TPB1-UP; MDG1-UP; JEL1-UP; JNS1-UP)

D5M (S/N: 7LR1-UP)

D5N (S/N: AKD1-UP; AGG1-UP; CKT1-UP)

D6M (S/N: 4JN1-UP)

D6N (S/N: CCG1-UP; ALH1-UP; CCK1-UP; AKM1-UP; ALY1-UP)

D6R Series II (S/N: BNC1-UP; AFD1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP; BRZ1-UP)

D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; MRT1-UP; EXW1-UP)

D6R (S/N: 2HM1-UP; 4FM1-UP; 8TM1-UP; 9BM1-UP; 2YN1-UP; 3ZN1-UP; 4HN1-UP; 4MN1-UP; 5LN1-UP; 6JN1-UP; 7KN1-UP; 8LN1-UP; 8XN1-UP; 9MN1-UP; 9PN1-UP; DMP1-UP; 4JR1-UP; 4TR1-UP; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6GR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP; 1RW1-UP)

D6T (S/N: JHB1-UP; ZEB1-UP; SMC1-UP; LBD1-UP; LAE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; LKJ1-UP; KJL1-UP; SKL1-UP; GCT1-UP; RLW1-UP; LAY1-UP; PEZ1-UP)

D7R Series II (S/N: EEA1-UP; AEC1-UP; AFG1-UP; ABJ1-UP; BPK1-UP; BNM1-UP; BRM1-UP; AGN1-UP; BRP1-UP; ACS1-UP; BPT1-UP; ADW1-UP; BNX1-UP)

D7R (S/N: 9HM1-UP; 2EN1-UP; 3DN1-UP; 2HR1-UP; 3ZR1-UP; 4SR1-UP; 5MR1-UP; 6ER1-UP; CBZ1-UP; 5KZ1-UP)

D8N (S/N: 9TC1-UP; 1XJ1-UP; 5TJ1-UP; 7TK1-UP)

D8R Series II (S/N: AKA1-UP; 6YZ1-UP)

D8R (S/N: 7XM1-UP; 9EM1-UP)

D8T (S/N: J8B1-UP; KPZ1-UP)

D9R (S/N: JJB1-UP; ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP)

D9T (S/N: RJS1-UP)

Wheel Dozer:

824G Series II (S/N: AWW1-UP)

834H (S/N: BTX1-UP)

854G (S/N: AMP1-UP)

Wheel Loader:

950G Series II (S/N: BAA1-UP; AYB1-UP; AYD1-UP; AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)

962G Series II (S/N: BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP)

966G Series II (S/N: AXJ1-UP; AXL1-UP; ANT1-UP; AWY1-UP; ANZ1-UP; AWZ1-UP)

966G (S/N: 3SW1-UP)

966H (S/N: A6D1-UP; A6G1-UP; A6J1-UP)

972G Series II (S/N: AXC1-UP; AXE1-UP; AXN1-UP; AWP1-UP; AXP1-UP; ANY1-UP)

972H (S/N: A7D1-UP; A7G1-UP; A7J1-UP)

980G Series II (S/N: AXG1-UP; AWH1-UP; AYT1-UP)

980H Series 2 (S/N: MKP1-UP)

980H (S/N: MHG1-UP; A8J1-UP; JMS1-UP)

988H (S/N: BXY1-UP)

990H (S/N: BWX1-UP)

992G (S/N: AZX1-UP; ADZ1-UP)

Wheel Tractor-Scraper:

613C Series II (S/N: 8LJ1-UP)

621G (S/N: CEN1-UP)

623G (S/N: DBC1-UP)

627G (S/N: DBD1-UP; CEX1-UP)

631G (S/N: CLR1-UP)

637G (S/N: CEH1-UP; DFJ1-UP)

657E (S/N: 5YR1-UP)

Introduction

The purpose of this instruction is to identify the Refrigerant Dryers which are functioning properly. Ice on the outlet of the dryer does not indicate a restriction within the Dryer. High discharge pressure from the Air Conditioning does not indicate a blockage inside the Dryer. These symptoms are addressed in this document.

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. Caterpillar 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. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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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.

Checklist for Dryer Service Requirements

Before removing the dryer, perform the following steps in order to diagnose the problem properly:

1. Check the following components for blockages.
   • Condenser

   • Evaporator

   • Fresh air filters

2. Check the compressor drive belt.

   1. Check the condition.

   2. Check the tension.

      The tension for a used belt should be 445 ± 22 N (100 ± 5 lb).

3. Operate the Air conditioning.

   1. Operate the engine at 1400 rpm.

   2. Place the "A/C" switch in the "ON" position.

   3. Set the blower switch to "HIGH".

   4. Open all of the louvers in the cab.

   5. Close the cab doors and close all of the cab windows.

4. Refer to Table 1 in order to ensure that the pressures are normal for the current ambient air temperature.

   For the proper test procedures, refer to Service Manual, SENR5664, "Heating and Air Conditioning System Troubleshooting".

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   Table 1

   Pressure Range (1)
   Ambient Air Temperature C° (F°)	High Pressure Test Fitting kPa (psi) (2)	Low Pressure Test Fitting kPa (psi) (3)
   21°C (70°F)	820 to 1300 kPa (120 to 190 psi)	70 to 138 kPa (10 to 20 psi)
   27°C (80°F)	950 to 1450 kPa (140 to 210 psi)	70 to 173 kPa (10 to 25 psi)
   32°C (90°F)	1175 to 1650 kPa (170 to 240 psi)	105 to 210 kPa (15 to 30 psi)
   38°C (100°F)	1300 to 1850 kPa (190 to 270 psi)	105 to 210 kPa (15 to 30 psi)
   43°C (110°F)	1450 to 2075 kPa (210 to 300 psi)	105 to 210 kPa (15 to 30 psi)

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   ( 1 )	This table is only for reference.
   ( 2 )	Pressure may be slightly higher in humid conditions and lower in dry conditions.
   ( 3 )	Pressure before clutch disengagement

5. Check for frost at the dryer outlet.

Note: Moisture on the drier outlet tube after the orifice is normal and this moisture does not indicate a failure with the dryer. Frost on the drier outlet tube after the orifice is an indicator of a low refrigerant charge.

6. If frost is indicated at the dryer outlet or if pressures are low, proceed to Step 7. Otherwise, proceed to Step 14.

7. Recover the refrigerant charge from the machine.

   Refer to Service Manual, SENR5664, "Refrigerant Recovery".

8. Record the amount of refrigerant and oil that is recovered from the Air Conditioner system.

   These values will be needed in order to calculate the amount of oil that is needed. Refer to Service Manual, SENR5664, "Refrigerant Compressor Oil - Check" in the Testing and Adjusting Section.

9. If the charge was low, check the system for leaks.

   1. Use an Ultraviolet light and use an electronic leak detector.

      Ensure that the following items are checked:

      • Quick disconnects which are on the dryer

      • Tighten the drier swivel nut to 27 ± 4 N·m (20 ± 3 lb ft).

      • All connections with O rings in the circuit

      • Hoses for rubbing, bulging, wet spots (oil leaks)

      Note: In order to help reveal leaks, simulate the vibrations which are made by the machine by moving the connections.

10. Recharge the refrigerant.

    Refer to Service Manual, SENR5664, "Refrigerant System - Charge" in the Testing and Adjusting Section.

11. Retest the system with the engine at 1400 rpm and check for frost at the dryer outlet.

12. Ensure that the pressures are normal for the current ambient temperature.

    Refer to Table 1 for the pressures which are normal for the current ambient air temperature.

13. If a component is leaking, bill the claim against the leaking component and provide details in the description.

14. End of Test

    For the correct replacement procedures, refer to Service Manual, SENR5664, "In-Line Refrigerant Dryer - Remove and Install".

Indications from the Compressor Pressures

Refer to Table 2 in order to diagnose the pressure indications.