Procedure for Checking the Electrical Circuit that is for the Actuator and the Water Valve{1812, 7304, 7320} Caterpillar

Wheel Loader:

988G (S/N: 2TW1-UP)

988H (S/N: BXY1-UP)

Articulated Truck:

725 (S/N: B1L712-UP; AFX1233-UP)

730 (S/N: AGF1148-UP; B1M1-UP)

730 EJECTOR (S/N: B1W197-UP)

735 (S/N: B1N437-UP; AWR677-UP)

740 (S/N: AXM1489-UP; B1P1074-UP)

740 EJECTOR (S/N: B1R220-UP; AZZ351-UP)

Landfill Compactor:

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

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

Track-Type Tractor:

D10R (S/N: AKT562-UP)

D10T (S/N: RJG1-UP)

D11R (S/N: 7PZ808-UP)

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

D9T (S/N: RJS1-UP)

Wheel Dozer:

834H (S/N: BTX1-UP)

Wheel Tractor-Scraper:

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

615C Series II (S/N: 9XG1-UP)

621G (S/N: DBB1-UP; CEN1-UP)

623G (S/N: DBC1-UP; CES1-UP)

627G (S/N: DBD1-UP; AXF1-UP; CEX1-UP)

631G (S/N: DFA1-UP; CLR1-UP)

637G (S/N: CEH1-UP; DFJ1-UP; AXT1-UP)

657G (S/N: W1B1-UP; W1C1-UP)

Introduction

This Special Instruction provides information about the 245-1596 Actuator . This special instruction provides the information in order to check the operation of the actuator and the water valve.

The actuator is an electronic rotary actuator. The actuator is used in order to open and in order to close the water valve for the "Heating Ventilating and Air Conditioning" (HVAC).

Illustration 1	g01619556

Refer to Table 1 for a list the water valve assemblies.

Required Tool

Required Parts

Note: Each machine will only require a single water valve and a single actuator. Refer to Table 2 for the part that is needed for a specific machine application.

Check System Operation

1. Do not disconnect the harness from the actuator. Remove the actuator from the water valve.

2. Verify that power, signal, and ground are all present at connection (2). Refer to Illustration 2.

   Note: If needed, then refer to the Specifications, SENR5664 publication for information about testing the HVAC electrical circuit. The information will be found in the "Testing and Adjusting" section under the title "Electric Heat Control". This information provides an explanation of the electrical circuit that is to be tested.

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Illustration 2	g01622411
(1) Deutsch Connector (The pin number will vary depending on the application.) (2) Deutsch Connector (The pin number will vary depending on the application.) (3) In Line Resistor (4) Packard Six Pin Connector (5) Electronic Rotational Actuator (6) Potentiometer Assembly (Temperature Control) (7) 3 Pin Deutsch Connector

3. If there is power, ground, and signal at connection (2) and if the actuator does not move, then check for the power, signal, and ground at connector (4) .

4. If there is power, ground, and signal at connection (4), then go to Step 5.

5. Unplug the electrical connector at the actuator and then plug the connector back in. Perform this task two or three times. If the actuator begins to work due to this procedure, then use the "Repair Procedure" in order to replace the actuator. Do not throw away the faulty components. When finished with the repairs, the faulty components should be returned. Refer to Step 13 of the "Repair Procedure".

Repair Procedure

1. Cut the harness wires that are connected to the water valve actuator connector. Refer to the top picture that is shown in Illustration 1. Ensure that each of the three wires are identified and are labeled as power, ground, and signal.

2. Close the valve that is located in the engine compartment that is for the coolant lines.

3. Loosen the hose clamps that are on the coolant lines at the water valve.

4. Remove the water valve, the actuator, and the electrical connector as one assembly.

5. New connectors must be installed on the wires that were cut. Use the crimp tool in order to attach a gold socket contact to each of the wires.

6. After a gold socket contact has been installed on each wire, install each wire as follows into the plug connector.

   Note: Press each gold socket contact into the plug connector until the socket "clicks" into the correct position.

   1. Insert the power wire into position "A" of the 3 pin plug.

   2. Insert the ground wire into position "B" of the 3 pin plug.

   3. Insert the signal wire into position "C" of the 3 pin plug.

   4. Insert the appropriate wedge into the end of the plug assembly.

7. Connect the 3 pin plug into the appropriate connector of the 241-7691 Heater and Air Conditioner Harness Assembly .

8. Install the new water valve and the actuator.

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Illustration 3	g01619616

9. Move the hose clamps in to the correct position. Tighten the hose clamps.

10. Plug the unattached connector of the 241-7691 Heater and Air Conditioner Harness Assembly into the actuator.

11. Secure the connectors with a cable tie to the insulation material in order to minimize movement of the harness and the connector at the actuator. This step applies from the D8T to the D11T machines. Refer to Illustration 3.

12. Test the water valve for proper operation.

13. Inform your local dealer "Technical Communicator" if the water valve began to function after the connector was plugged back in or after the parts were replaced. Have your dealer technical communicator submit this information to the "Dealer Solution Network" (DSN) in order to obtain the information that is necessary to complete any repairs. Make sure to reference Special Instruction, REHS4644 in the service request.