Installation of the 330-0824 Control Arrangement (Variable Pitch Fan) (Kit){1356} Caterpillar


Installation of the 330-0824 Control Arrangement (Variable Pitch Fan) (Kit){1356}

Usage:

950H K5K


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.

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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

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

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

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.

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     6V-3010     Puller Gp     1    

Parts List

Table 2
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

Table 3
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

  1. Park the machine on a hard, smooth, level surface. The location should also be dry and free of debris.

  1. Permit only one operator on the machine. All other personnel should be kept away from the machine.

  1. Connect the steering frame lock. Refer to Disassembly and Assembly, RENR8863, "Steering Frame Lock - Separate and Connect".

  1. Release the hydraulic system pressure. Refer to Disassembly and Assembly, RENR8863, "System Pressure - Release".

  1. Drain the cooling system coolant into a suitable container for storage or disposal.

  1. 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




    Illustration 1g03707290

  1. 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 2g03704140

  1. 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 3g03704276

  1. Remove the motor, motor support, fan guard, shroud, and fan blade as an assembly from the cooling system package.



    Illustration 4g03704296

  1. Remove shroud and hardware. Retain all components.



    Illustration 5g03704346

  1. Remove fan blade, spacer, and hardware. Discard all components.



    Illustration 6g03704335



    Illustration 7g03704762

  1. Remove fan adapter, nut, and washer (D). Use tooling (A) to remove adapter. Retain all components.



    Illustration 8g03704400

  1. Remove cone and hardware. Retain all components.



    Illustration 9g03704368

  1. Remove fan motor and hardware. Retain motor and hardware.



    Illustration 10g03704430

  1. Assemble the Fan Guard (12) onto the motor Support As (9). Use four Bolts (68) and four Hard Washers (69) .



    Illustration 11g03704410

  1. 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 12g03704335

  1. Install original fan adapter, nut, and washer (D) onto motor shaft.



    Illustration 13g03704428

  1. Install the Flange (13) onto the fan adapter. Use Bolts (6) to secure the flange to the adapter.



    Illustration 14g03704431

  1. Install the Fan As (10) onto the Flange (13). Secure the fan with six Bolts (8) and six Hard Washers (7)



    Illustration 15g03704868

  1. Install the original shroud to the fan group with the original hardware.



    Illustration 16g03706063

  1. 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 17g03706080

  1. Replace the baffle (E) with Baffle (11). Insert Grommet (39) into Baffle (11). Use the original hardware to secure the new baffle.



    Illustration 18g03704903

  1. 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 19g03710932

  1. 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 20g03704940

    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)

  1. 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 21g03704140

  1. Install the modified engine compartment shield onto the cooling system group. Secure the shield with the original hardware.



    Illustration 22g03711495

  1. 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




    Illustration 23g03706304

  1. 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 24g03707252

  1. 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 25g03707290

  1. 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 26g03708189

  1. 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 27g03708216

  1. 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 28g03708255

  1. 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 29g03708281

  1. 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 30g03708282

  1. 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 31g03708283

  1. 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 32g03707306

  1. 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 33g03705059

    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

  1. 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 34g03705311

  1. 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 35g03705657

  1. 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 36g03705353

  1. 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 37g03705407

  1. 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 38g03705420

  1. 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 39g03705425

  1. 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 40g03705673

  1. 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 41g03707443

  1. 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 42g03707405

  1. 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 43g03707598

  1. Using existing hardware (J) and one Clip (35), secure the Hose As (21) to the right-hand frame rail.



    Illustration 44g03707661

  1. 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 45g03707724

  1. 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 46g03709390

  1. 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 47g03709845

  1. Install the Edge Strip (45) onto the edge of the Cover (30) as shown in Illustration 47.



    Illustration 48g03709801

  1. Install the Cover (30) onto the Box As (G). Secure the cover with the original hardware (H) removed in Step 31.



    Illustration 49g03708463

  1. 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 50g03711110

  1. Remove the Cover (W) from the right, rear corner, inside the cab. Retain the cover (W) and the hardware (X) .



    Illustration 51g03711617

  1. 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) .

  1. 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.



    Illustration 52g03708498

  1. 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) .

  1. 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

  1. Reinstall the Cover (W) with the original hardware (X) removed in Step 49.



    Illustration 53g03711669

    Right-hand film location shown. Left-hand side similar.

    (A) 227 mm (8.94 inch)

    (B) 45 mm (1.77 inch)

  1. 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 .

  1. 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.

  1. 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.

  1. 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.

  1. Use a Caterpillar Electronic Technician and select the proper Electronic Control Module.

  1. Select "SERVICE" from the menu.

  1. Select "CONFIGURATION" from the menu.

  1. Double click on the desired feature on the Configuration screen.

  1. Select the desired status of the feature and click "OK".

  1. The feature will be activated on the next power cycle.

    Note: Refer to 342-8593 Standard Configuration (Variable Pitch Fan) .

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