- Integrated Toolcarrier:
- IT62H (S/N: M5G1-UP)
- Wheel Loader:
- 950H (S/N: K5K1-UP)
- 962H (S/N: K6K1-UP)
Introduction
This publication contains the information for installation of the Variable Pitch Fan. A complete listing of the parts that are contained in the kit are listed in the Parts Manual, SEBC1509.
This supplemental product support literature should be used with the appropriate Service Manual, RENR8860 and the appropriate parts manual that is available for this standard machine.
Removal instructions in this procedure should be supplemented with the Disassembly and Assembly, RENR8863.
Do not perform any procedure or order parts that are outlined in this publication until you understand the information that is contained in this document.
Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. In order to prevent possible injury, perform the following procedure before testing and adjusting any of the machine hydraulic systems. |
Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. |
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. |
Personal injury can result from hot coolant. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. |
NOTICE |
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Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components. |
NOTICE |
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Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other components. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage. |
NOTICE |
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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. |
Required Tools
Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools to perform the air conditioning service.
Required Tools     | |||
---|---|---|---|
Tool     | Part Number     | Part Description     | Qty     |
A     | 6V-3010     | Puller Gp     | 1     |
Parts List
330-0824 Fan Control Ar Parts List     | |||
Item     | Qty     | Part Number     | Description     |
1     | 2     | 225-4131     | Film     |
2     | 1     | 306-5348     | Cab Wiring Gp     |
3     | 1     | 324-0304     | Mounting Plate     |
4     | 24     | 7K-1181     | Cable Strap     |
5     | 1     | 306-5352     | Chassis Harness As     |
6     | 6     | 8T-1160     | Bolt     |
7     | 6     | 8T-4224     | Hard Washer     |
8     | 6     | 8T-4908     | Bolt     |
9     | 1     | 304-4016     | Support As     |
10     | 1     | 307-7313     | Fan     |
11     | 1     | 307-7318     | Baffle     |
12     | 1     | 308-0167     | Fan Guard     |
13     | 1     | 308-1189     | Flange     |
14     | 2     | 141-6518     | Spacer     |
15     | 1     | 165-6365     | Fitting As     |
16     | 1     | 183-7258     | Elbow As     |
17     | 1     | 188-2461     | Solenoid Valve Gp     |
18     | 1     | 1M-4543     | Grommet     |
19     | 4     | 1P-4278     | Hose Clamp     |
20     | 1     | 308-0169     | Hose As     |
21     | 1     | 319-2140     | Hose As     |
22     | 1     | 324-7874     | Hose As     |
23     | 1     | 357-4427     | Elbow As     |
24     | 1     | 365-8417     | Hose As     |
25     | 1     | 377-9582     | Elbow Adapter     |
26     | 1     | 385-8575     | Air Pump and Mounting Gp     |
27     | 1     | 386-6202     | Elbow Adapter     |
28     | 2     | 386-6203     | Elbow Adapter     |
29     | 1     | 387-9984     | Plate As     |
30     | 1     | 388-0721     | Cover     |
31     | 1     | 3S-2093     | Cable Strap     |
32     | 2     | 4B-4863     | Washer     |
33     | 1     | 4D-9517     | Clip     |
34     | 1     | 4H-6112     | Breather     |
35     | 2     | 4K-8864     | Clip     |
36     | 2     | 5K-3294     | Clip     |
37     | 2     | 5P-1076     | Hard Washer     |
38     | 1560 mm (61.42 inch) (1)     | 5P-6442     | Hose     |
39     | 1     | 5P-8440     | Grommet     |
40     | 1     | 6K-8178     | Clip     |
41     | 2     | 6V-1889     | Clip     |
42     | 1     | 7C-4354     | Clip     |
43     | 1190 mm (46.90 inch) (1)     |
7I-7439     | Hose Guard     |
44     | 8     | 7K-1181     | Cable Strap     |
45     | 80 mm (3.15 inch)     |
7X-7877     | Edge Strip     |
46     | 2     | 8T-0337     | Screw     |
47     | 7     | 8T-4121     | Hard Washer     |
48     | 1     | 8T-4133     | Nut     |
49     | 1     | 8T-4136     | Bolt     |
50     | 5     | 8T-4137     | Bolt     |
51     | 2     | 8T-4194     | Bolt     |
52     | 1     | 8T-4195     | Bolt     |
53     | 3     | 8T-4197     | Bolt     |
54     | 1     | 9M-8406     | Clip     |
55     | 3     | 9N-0869     | Hard Washer     |
56     | 2     | 9X-7381     | O-Ring Seal     |
57     | 1     | 3E-5239     | Relay As     |
58     | 1     | 262-9949     | Rocker Switch     |
59     | 1     | 306-5350     | Cab Harness As     |
60     | 1     | 5C-9553     | Bolt     |
61     | 8     | 7K-1181     | Cable Strap     |
62     | 1     | 330-3031     | Plate As     |
63     | 1     | 269-7678     | Clip     |
64     | 1     | 8T-4121     | Hard Washer     |
65     | 1     | 8T-4137     | Bolt     |
66     | 1     | 352-3964     | Clip     |
67     | 1     | 322-0931     | Bracket As     |
68     | 4     | 8T-4195     | Bolt     |
69     | 4     | 8T-4121     | Hard Washer     |
( 1 ) | Refer to Table 3 for cutting schedule |
5P-6442 Hose (38) Cutting Schedule     | |
Item     | Length     |
38a     | 1300 mm (51.18 inch)     |
38b     | 260 mm (10.24 inch)     |
7I-7439 Hose Guard (43) Cutting Schedule     | |
Item     | Length     |
43a     | 380 mm (14.96 inch)     |
43b     | 340 mm (13.39 inch)     |
43c     | 240 mm (9.45 inch)     |
43d     | 230 mm (9.06 inch)     |
Machine Preparation
- Park the machine on a hard, smooth, level surface. The location should also be dry and free of debris.
- Permit only one operator on the machine. All other personnel should be kept away from the machine.
- Connect the steering frame lock. Refer to Disassembly and Assembly, RENR8863, "Steering Frame Lock - Separate and Connect".
- Release the hydraulic system pressure. Refer to Disassembly and Assembly, RENR8863, "System Pressure - Release".
- Drain the cooling system coolant into a suitable container for storage or disposal.
- Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the correct tools.
Installation Procedure
- Remove the cooling system package (F) from the machine. Refer to Disassembly and Assembly, RENR8863, "Cooling System Package (Radiator, Fan, Aftercooler, Oil Cooler) - Remove".
Illustration 1 | g03707290 |
- Remove the engine compartment shield group. Refer to Disassembly and Assembly, RENR8863, "Engine Compartment Shield - Remove and Install".
Note: Remove the engine compartment shield (B) and the handrails (C) as an assembly. Retain all components.
Illustration 2 | g03704140 |
- Remove the motor, motor support, fan guard, shroud, and fan blade as an assembly from the cooling system package.
Illustration 3 | g03704276 |
- Remove shroud and hardware. Retain all components.
Illustration 4 | g03704296 |
- Remove fan blade, spacer, and hardware. Discard all components.
Illustration 5 | g03704346 |
- Remove fan adapter, nut, and washer (D). Use tooling (A) to remove adapter. Retain all components.
Illustration 6 | g03704335 |
Illustration 7 | g03704762 |
- Remove cone and hardware. Retain all components.
Illustration 8 | g03704400 |
- Remove fan motor and hardware. Retain motor and hardware.
Illustration 9 | g03704368 |
- Assemble the Fan Guard (12) onto the motor Support As (9). Use four Bolts (68) and four Hard Washers (69) .
Illustration 10 | g03704430 |
- Install original fan motor onto new support. Use original hardware to secure the motor. Install original cone. Use original hardware to secure the cone to the new support.
Illustration 11 | g03704410 |
- Install original fan adapter, nut, and washer (D) onto motor shaft.
Illustration 12 | g03704335 |
- Install the Flange (13) onto the fan adapter. Use Bolts (6) to secure the flange to the adapter.
Illustration 13 | g03704428 |
- Install the Fan As (10) onto the Flange (13). Secure the fan with six Bolts (8) and six Hard Washers (7)
Illustration 14 | g03704431 |
- Install the original shroud to the fan group with the original hardware.
Illustration 15 | g03704868 |
- Install the 1300 mm (51.18 inch) length of the Hose (38a) onto the tube from the Fan As (10). Insert the hose 35 ± 5 mm (1.40 ± 0.20 inch) onto the fan tube. Secure the hose with one Clamp (19) .
Note: Ensure that the fan air hose is fitted on the fan air tube without creating any tension on the tube.
Illustration 16 | g03706063 |
- Replace the baffle (E) with Baffle (11). Insert Grommet (39) into Baffle (11). Use the original hardware to secure the new baffle.
Illustration 17 | g03706080 |
- Install the assembled fan, support, and guard onto the cooling group. Use the original hardware from the old support to secure the new assembly to the cooling group except where noted. Route the Hose (38a) through Grommet (39) in Baffle (11).
Include the Plate As (29) at the right-hand lower mounting location. Use two Bolts (51) and two Hard Washers (37) to secure the plate and the fan support assembly to the cooling group.
Illustration 18 | g03704903 |
- Combine the Hose Guard (43d) and the Hose (38a). Secure the combined hose and guard with one Clip (33). Use existing hardware to secure clip to the cooling group.
Illustration 19 | g03710932 |
- Modify the engine compartment shield as shown in Illustration 20. Remove the shaded area. Refer to Illustration 20 for a dimensional representation of the material to be removed.
Illustration 20 | g03704940 |
Shield for the engine (D) 111.7 mm (4.4 inch) (E) 61.7 mm (2.4 inch) (F) 41.7 mm (1.6 inch) (G) 459.5 mm (18.1 inch) (H) 374.4 mm (14.7 inch) (J) 30 mm (1.2 inch) |
- Install the modified engine compartment shield onto the cooling system group. Secure the shield with the original hardware.
Illustration 21 | g03704140 |
- Insert the conductors from the Chassis Harness As (5) into the C-C1 connector of the 354-2734 Chassis Harness As (V) as follows.
- H746-YL conductor to the number 6 position in the C-C1 connector
- H747-BR conductor to the number 15 position in the C-C1 connector
- E947-WH conductor to the number 55 position in the C-C1 connector
- H746-YL conductor to the number 6 position in the C-C1 connector
Illustration 22 | g03711495 |
- Following the 354-2734 Chassis Harness As (V), route the Chassis Harness As (5) from the C-C1 connector (part of the V). Proceed to the left, across the rear of the cab. Continue to follow the Chassis Harness As (V), along the inside of the left-hand frame. Run across the back of the engine frame, ending in the Box As (G). Secure the harness with 24 of the Cable Strap (4) .
Illustration 23 | g03706304 |
- Connect the TH-T4 terminal (part of 5) to the ground stud (L) on the inner surface of the left-hand frame rail.
Connect the TH-C1 connector (part of 5) to the CJ-C42 connector (T) which is a part of the Chassis Harness As (V). Secure the connectors and the two harnesses together with one Cable Strap (4) .
Illustration 24 | g03707252 |
- Install the cooling system package (F) back into the machine. Refer to Disassembly and Assembly, RENR8863, "Cooling System Package (Radiator, Fan, Aftercooler, Oil Cooler) - Install".
Illustration 25 | g03707290 |
- Replace the original A/C high side discharge hose with the Hose As (22) from the kit. Seal the connection at the condenser coil with one O-Ring Seal (56) .
Secure the Hose As (22) to the machine with the original hardware (M) .
Illustration 26 | g03708189 |
- Install the Grommet (18) into the engine shield (B) Route the Hose As (22) through the grommet towards the A/C compressor.
Secure the Hose As (22) to the Support As (9) with one Clip (54), one Bolt (50), and one Hard Washer (47) .
Illustration 27 | g03708216 |
- Connect the Hose As (22) to the fitting on the discharge side of the A/C compressor (N). Seal the connection with one O-Ring Seal (56) .
Secure the Hose As (22) to the engine with the original hardware (M) .
Illustration 28 | g03708255 |
- Replace the original 247-5513 Hose As to the oil cooler core with the Hose As (20) from the kit. Seal the connection with one 6V-9746 O-Ring Seal from stock.
Secure the Hose As (20) to the radiator group with the original hardware (M) .
Illustration 29 | g03708281 |
- Route the Hose As (20) in front of the Fan Guard (12). Secure the hose to the guard with one Clip (41), one Bolt (50) and one Hard Washer (47) .
Illustration 30 | g03708282 |
- Connect the Hose As (20) to the elbow assembly (P) in the right-hand side of the engine shield (B). Seal the connection with one 6V-9746 O-Ring Seal from stock.
Illustration 31 | g03708283 |
- Remove the cover and hardware (H) from the box assembly (G) on the right, rear corner of the machine. Discard the cover and retain the hardware.
Illustration 32 | g03707306 |
- Weld Plate As (62) inside the box assembly (G) on the frame in the right, rear corner of the machine. Refer to Illustration 33 for a dimensional representation of the location of the plate.
Illustration 33 | g03705059 |
Top view of mounting plate for pump (A) 124.9 ± 1.5 mm (4.92 ± 0.06 inch) (B) 215.3 ± 1.5 mm (8.48 ± 0.06 inch) (C) 335.5 ± 1.5 mm (13.21 ± 0.06 inch) (D) 174.8 mm (6.89 inch) (E) 4 mm (0.16 inch) fillet weld |
- Install the Air Pump and Mounting Gp (26) onto the Plate As (62). Use three Bolts (53) and three Hard Washers (55) to secure the pump.
Illustration 34 | g03705311 |
- Install Clip (66) and Bracket As (67) to the Air Pump and Mounting Gp (26). Secure the hardware with one Bolt (50) and one Hard Washer (47) .
Illustration 35 | g03705657 |
- Install the Elbow As (16) into the forward port on the Air Pump and Mounting Gp (26). Install the Elbow Adapter (27) into the rear port on the Air Pump and Mounting Gp (26).
Refer to Illustration 36 for proper orientation of the elbows.
Illustration 36 | g03705353 |
- Install the Solenoid Valve Gp (17) onto the Plate As (29). Secure the solenoid with two Screws (46) and two Washers (32). Secure the solenoid harness to the plate with one Cable Strap (31) .
Install the Clip (63), Bolt (65), and Hard Washer (64). Secure the solenoid harness to the clip with one Cable Strap (31) .
Illustration 37 | g03705407 |
- Install two of the Elbow Adapters (28) into the top ports of the Solenoid Valve Gp (17). Install the Elbow Adapter (25) into the bottom port of the solenoid. Install the Breather (34) into the Elbow Adapter .
Illustration 38 | g03705420 |
- Combine a 240 mm (9.45 inch) section of the Guard (43c) and a 260 mm (10.25 inch) section of Hose (38b). Connect the hose between the rear fitting on the Air Pump and Mounting Gp (26) and the forward fitting on the Solenoid Valve Gp (17). Use two Clamps (19) to secure both the guard and hose to the fittings.
Illustration 39 | g03705425 |
- Combine the 230 mm (9.06 inch) length of the Guard (43d) and the Hose (38a). Connect the free end of the hose to the free fitting on the Solenoid Valve Gp (17). Use one Clamp (19) to secure both the guard and the hose to the fitting.
Illustration 40 | g03705673 |
- Combine a 380 mm (15.0 inch) section of the Guard (43a) and the Hose As (21). Secure the guard to the hose with one Cable Strap (44) .
Connect the Hose As (21) to the Elbow As (16) on the Air Pump and Mounting Gp (26). Seal the connection with one 4J-5477 O-Ring Seal (part of 16) .
Illustration 41 | g03707443 |
- Route the Hose As (21) along the inside of the right-hand frame rail. Secure the hose with six of the Cable Strap (44) .
Illustration 42 | g03707405 |
- Using existing hardware (J) and one Clip (35), secure the Hose As (21) to the right-hand frame rail.
Illustration 43 | g03707598 |
- Route the Hose As (21) along the hydraulic tank assembly (K). Secure the hose to the tank with one Clip (40), one Hard Washer (47), and one Bolt (49) at the lower location. Refer to Illustration 44.
Secure the hose to the tank with one Clip (35), one Hard Washer (47), and one Bolt (50) at the upper location. Refer to Illustration 44.
Illustration 44 | g03707661 |
- Replace the existing Hose As to the Air Cleaner Gp inlet with one Hose As (24) from the kit. Secure the hose with the original clamps.
Assemble the Fitting As (15) to the Hose As (24). Seal the connection with one 3J-1907 O-Ring Seal (part of 15) .
Assemble the Elbow As (23) to the Fitting As (15). Seal the connection with one 3J-1907 O-Ring Seal (part of 23). Connect the Hose As (21) to the Elbow As (23). Seal the connection with one 4J-5477 O-Ring Seal (part of 23) .
Illustration 45 | g03707724 |
- Connect the TH-C2 connector (5a) to the Solenoid Valve Gp (17). Connect the TH-C3 to the Air Pump and Mounting Gp (26). Secure all of the connectors to the Clip (66) with one Cable Strap (44) .
Secure any loose wiring from the solenoid and pump with two additional cable straps.
Illustration 46 | g03709390 |
- Install the Edge Strip (45) onto the edge of the Cover (30) as shown in Illustration 47.
Illustration 47 | g03709845 |
- Install the Cover (30) onto the Box As (G). Secure the cover with the original hardware (H) removed in Step 31.
Illustration 48 | g03709801 |
- Remove the rocker switch plug (not shown) from the upper console (U). Connect the CJ-C42 connector from the 354-2734 Chassis Harness As to the Rocker Switch (58). Install the switch into the open slot in the console.
Illustration 49 | g03708463 |
- Remove the Cover (W) from the right, rear corner, inside the cab. Retain the cover (W) and the hardware (X) .
Illustration 50 | g03711110 |
- Attach the Relay As (57) to the Plate As (Z) under the Fuse Block As (R). Secure the relay with one Bolt (60) .
Connect the Cab Harness As (59) to the Relay As (57) .
Illustration 51 | g03711617 |
- Connect the E947-WH conductor of the Chassis Harness As (59) to fuse position number 6 in the Fuse Block As (R). Ensure that there is a 10 amp fuse in the fuse panel.
- Route the Cab Harness As (59) along the Chassis Wiring Gp (S) to the CJ-C4 connector (part of S). Secure the Cab Harness As to the Chassis Wiring Gp with eight of the Cable Straps (61) .
Illustration 52 | g03708498 |
- Insert the conductors from the Cab Harness As (59) into the CJ-C4 connector (S) of the 354-2734 Chassis Wiring Gp as follows.
- H746-YL conductor to the number 6 position in the CJ-C4 connector
- H747-BR conductor to the number 15 position in the CJ-C4 connector
- E947-WH conductor to the number 55 position in the CJ-C4 connector
- H746-YL conductor to the number 6 position in the CJ-C4 connector
- Reinstall the Cover (W) with the original hardware (X) removed in Step 49.
- Apply the Film (1) to the right-hand side of the Hood Gp. Refer to Illustration 53 for placement.
Repeat this step for the left-hand side of the Hood Gp .
Illustration 53 | g03711669 |
Right-hand film location shown. Left-hand side similar. (A) 227 mm (8.94 inch) (B) 45 mm (1.77 inch) |
- Refill all machine fluids. Refer to Operation and Maintenance Manual, "Hydraulic System Oil - Change" and Operation and Maintenance Manual, "Lubricant Viscosities and Refill Capacities" for your machine.
- Evacuate and recharge the Air Conditioning System. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the correct procedure.
- Start machine and bring everything up to the normal operating temperature. Check for leaks, repair as needed.
Software Configuration and Calibration of the 330-0824 Control Arrangement (Variable Pitch Fan)
Note: This feature is configurable and must be activated with PSPS or a service tool.
- Use a Caterpillar Electronic Technician and select the proper Electronic Control Module.
- Select "SERVICE" from the menu.
- Select "CONFIGURATION" from the menu.
- Double click on the desired feature on the Configuration screen.
- Select the desired status of the feature and click "OK".
- The feature will be activated on the next power cycle.
Note: Refer to 342-8593 Standard Configuration (Variable Pitch Fan) .