151-6617 Bracket For The Air Conditioner Refrigerant Compressor May Break Caterpillar

151-6617 Bracket For The Air Conditioner Refrigerant Compressor May Break

Usage:

EXCAVATORS315B L (7RZ284-Up) WHEN EQUIPPED WITH 149-1808 AIR CONDITIONER;
315B (1SW215-Up, 315B L (3AW990-Up);
318B L (3LR1-Up),
318B LN (7KZ1-Up) WHEN EQUIPPED WITH 154-0715 AIR CONDITIONER

Problem:

The bracket for the air conditioner refrigerant compressor may experience a break at the mounting plate for the compressor. Illustration 1 shows the location for the bracket (1) on the right side of the engine. When the bracket fails, the compressor will not be secured to the engine. This will cause damage to the belt and/or the compressor if the bracket is not repaired or replaced.

Illustration 1.

Location of the 151-6617 Bracket.

(A) 3E-1906 Compressor.

(B) Tension pulley.

(1) 151-6617 Bracket.

(2) Stiffener plate (fabricated) to be added.

Solution:

Engineering has a redesigned bracket that will provide a more durable part. Until the new bracket is available in the Parts Distribution System, the following repair procedure is recommended.

Illustration 2.

This shows a typical break to the bracket.

(D) Failed area of bracket.

Procedure to Repair Bracket

Before starting to make the repair, fabricate two plates with the dimensions shown in Illustration 3. Use ASTM A572, ASTM A565, or ASTM A808 steel for the plate material.

Illustration 3.

Dimensions for stiffener plate (2) and backing plate (3).

(E) 32 mm (1.3 in).

(F) 20 mm (.8 in).

(G) 100 mm (3.9 in).

(H) 160 mm (6.3 in).

(J) 9.0 mm (.35 in).

(K) 25 mm (1.0 in).

(L) 110 mm (4.3 in).

(M) 3.0 mm (.12 in).

(2) Stiffener plate.

(3) Backing plate.

1. Remove the 4L-6060 Compressor Belt (C). Remove the 3E-1906 Compressor (A) from the damaged bracket (1). See Illustration 1 for the locations of the components.

2. Remove the remaining sections of the bracket from the engine.

3. Prepare the surfaces of the damaged bracket by removing all paint and contaminants from areas (N) that are to be welded.

Illustration 4.

Weld instructions for the broken area.

4. Grind each edge of the area that is broken. The surface should be ground at a 30 degree angle to form a V-groove for re-welding. See Illustration 5 for the correct placement of the broken areas and the backer plate.

Illustration 5.

Detail P from Illustration 4.

(R) 30 Degree groove.

(3) Backing plate.

5. Place the two broken sections on a flat surface and clamp in position. Tack weld the pieces together.

6. Turn the bracket over and tack weld the backing plate (2) to cover the backside of the break. Finish welding the joint together as shown in Illustration 5. Use AWS E7016 or E7018 electrodes.

7. Locate the stiffener plate (2) with the bracket in the position shown in Illustration 6. Weld the stiffener plate using the electrodes listed in Step 6. After cleaning the new weld, paint the exposed surfaces.

Illustration 6.

Instruction for welding stiffener plate (2) onto bracket (1).

(S) 60 mm (2.4 in).

NOTE: Illustrations 7, 8, and 9 are views of the completed repair.

Illustration 7.

Illustration 8.

Illustration 9.

8. Install the repaired bracket in the original position on the engine. Tighten the mounting bolts to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

9. Install the compressor (A) onto the bracket (1). Tighten the mounting bolts to a torque of 28 ± 7 N·m (21 ± 5 lb ft). Inspect the V-belt (C) for abnormal wear or nicks before it is installed. Replace the belt if necessary. Refer to Illustration 1 for installing the parts again.

NOTE: Refer to the appropriate Operation and Maintenance Manual for specifications and the adjustment procedure for the V-belt.