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Special Instruction
Testing the Refrigerant Compressor Protection Module{1802}
Media Number -REHS4499-00 Publication Date -21/04/2008 Date Updated -21/04/2008

i02997442

Testing the Refrigerant Compressor Protection Module{1802}

SMCS - 1802

Off-Highway Truck/Tractor:
789C (S/N: 2BW1-UP)
784C (S/N: 2PZ1-UP)
785C (S/N: 5AZ1-UP)
785D (S/N: MSY1-UP)
793C (S/N: CBR1-UP; ATY1-UP)
797B (S/N: JSM1-UP)
Engine:
3516B (S/N: MSK1-UP)
C175-16 (S/N: A7B1-UP)
Excavator:
320C (S/N: GAD1-UP)
320D LC FOREST MACHINE HD (S/N: BZF1-UP)
320D LL FOREST MACHINE (S/N: GKS1-UP)
320D RR FOREST MACHINE (S/N: SRT1-UP)
320D LC FOREST MACHINE HD (S/N: BWW1-UP)
320D FOREST MACHINE HW (S/N: EAX1-UP)
322C FOREST MACHINE (S/N: M2H1-UP)
322C CUSTOM (S/N: BYL1-UP)
322C (S/N: C3R1-UP; LAR1-UP)
324D FOREST MACHINE (S/N: BBF1-UP)
324D LL LGP FOREST MACHINE (S/N: BXK1-UP; JGK1-UP)
324D LL FOREST MACHINE (S/N: JLS1-UP)
325C (S/N: M2K1-UP; G1L1-UP; S3M1-UP)
325D FOREST MACHINE (S/N: C7K1-UP)
325D LL FOREST MACHINE (S/N: C9M1-UP)
330C (S/N: B1K1-UP; B3M1-UP; B4N1-UP)
330D LL FOREST MACHINE (S/N: E4K1-UP; H3K1-UP)
330D FOREST MACHINE (S/N: L2K1-UP)
5130B (S/N: 4CS1-UP)
5230B (S/N: 4HZ1-UP)
Industrial Tractor:
TK371 (S/N: WBG1-UP)
TK381 (S/N: WBH1-UP)
Track Feller Buncher:
1190 (S/N: BZK1-UP; BZL1-UP; BZM1-UP)
1390 (S/N: B3F1-UP)
1490 (S/N: B4F1-UP)
1490T (S/N: B5F1-UP)
2290 (S/N: P2D1-UP)
2390 (S/N: P3H1-UP)
2391 (S/N: P4K1-UP)
2491 (S/N: P5J1-UP)
2590 (S/N: P6B1-UP)

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511 (S/N: 5111-UP)

521 (S/N: 5211-UP)
522 (S/N: 5221-UP)
532 (S/N: 5321-UP)
541 (S/N: 5411-UP)
551 (S/N: 5511-UP)
552 (S/N: 5521-UP)
TK711 (S/N: 1011-UP)
TK721 (S/N: 1021-UP)
TK722 (S/N: 1031-UP)
TK732 (S/N: 1041-UP)
TK741 (S/N: 2021-UP)
TK751 (S/N: 3011-UP)
TK752 (S/N: 3021-UP)
Wheel Feller Buncher:
533 (S/N: CDR1-UP)
543 (S/N: ASJ1-UP)
HA770 (S/N: HAB1-UP)
HA771 (S/N: HAF1-UP)
HA870 (S/N: HAE1-UP)
HA871 (S/N: HAG1-UP)
TK370 (S/N: WBD1-UP)
TK380 (S/N: WBE1-UP)
Motor Grader:
120K (S/N: JAP1-UP)
12K (S/N: JJA1-UP)
140K (S/N: JPA1-UP)
160K (S/N: JBP1-UP)
Pipelayer:
583T (S/N: CMX1-UP)
587T (S/N: FAT1-UP)
Track-Type Tractor:
D10N (S/N: 2YD1-UP; 3SK1-UP)
D10R (S/N: 3KR1-UP)
D11R (S/N: 9TR1-UP; 9XR1-UP)
D11T (S/N: GEB1-UP; TPB1-UP; DDD1-UP; RAL1-UP)
D9R PS STD (S/N: JJB1-UP)
D9R DS PS (S/N: ABK1-UP)
D9R (S/N: ACL1-UP)
Wheel Tractor-Scraper:
621G (S/N: DBB1-UP; CEN1-UP; ALP1-UP; CEP1-UP; DBX1-UP)
623G (S/N: DBC1-UP; CES1-UP; ARW1-UP; CEW1-UP; DBY1-UP)
627G (S/N: AXF1-UP; CEX1-UP; CEZ1-UP; DBZ1-UP)
631G (S/N: AWK1-UP; DEM1-UP; CLR1-UP; CMT1-UP)
637G (S/N: CEH1-UP; CEJ1-UP; AXT1-UP; DEX1-UP)
651E (S/N: 4YR1-UP; 5XR1-UP; 89Z1-UP)
657E (S/N: 5YR1-UP; 6PR1-UP; 6TR1-UP; 7KR1-UP)
657G (S/N: W1E1-UP; A4G1-UP)

Introduction
This Special Instruction will provide a procedure to perform functional tests before replacing the
169-7443 On Delay Timer Assembly . The 169-7443 On Delay Timer Assembly can also be referred
to as the compressor protection module for the compressor. The compressor protection module

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contains a delay timer in order to protect the compressor from the following conditions:

z High refrigerant pressures

z Low refrigerant pressures

z Incorrect system voltage

z Excessive current

The delay timer prevents premature wear of the compressor when the air conditioning or the
electrical system is not functioning correctly. Perform the following checks and troubleshooting
procedures before replacing any parts.

Check Electrical Connections

View Image

Illustration 1 g
Typical schematic of a circuit for a compressor

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1. Verify that the air conditioning clutch engages when the machine is turned on and the air
conditioning switch is turned to "ON". An audible click should be heard after the air
conditioning switch is turned on. This audible click should not occur until 15 to 30 seconds
after the air conditioning is turned on.

2. Ensure that the connectors are tightly connected. Also check that the connectors are secure at
the following locations:

{ Compressor protection module

{ Low pressure switch

{ High pressure switch

{ Coil for the clutch for the air conditioning compressor

3. Clean the connectors of the circuit. Refer to Illustration 1.

Check for Input Signal from a/c pressure switches and the
thermostat switch
The compressor protection module should prevent engagement of the clutch for an unlimited period
of time if the low pressure switch, the high pressure switch or the thermostat switch is open. Perform
the following tests:

1. Measure the resistance between pin 1 and pin 2. The resistance should be below 10 ohms. If
the resistance is above 10 ohms perform step 1.a and step 1.b.

a. Test for a proper ground to the compressor protection module.

b. Check the refrigerant system for the a/c and check the pressure switches for the a/c.
Refer to Testing and Adjusting, SENR5664.

Check Ground
The compressor protection module will prevent engagement of the clutch for an unlimited period if
the circuit has an inadequate ground. Test for the following condition:

1. The resistance between Pin 2 and chassis ground should be 0. A high resistance is an
indication of a bad ground. Inspect and repair the harness if the harness has a bad ground.

Check the System Voltage from the a/c switch

The compressor protection module prevents engagement of the clutch for an unlimited period under
certain electrical conditions. Test for the following conditions:

1. The voltage at pin 4 should be between 18 and 32 volts. Perform Step 1.a and Step 1.b if the
voltage to pin 4 is outside of this voltage range.

a. Verify that the a/c switch is turned on and that the circuit breaker or the fuse for the a/c
is intact.

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b. Verify the proper operation of the batteries or alternator.

Check for voltage Output from Pin 3 to Compressor Clutch

All other tests should be performed before performing this test. Test for the following conditions:

1. Start the machine. Turn the a/c switch to the "ON" position.

2. The voltage between pin 2 and pin 3 of the compressor protection module should be between
18 volts and 32 volts within 30 seconds after the a/c switch has been turned "ON". The delay
prevents rapid engagement of the clutch for the a/c compressor. This will prevent premature
failure of the compressor. If system voltage is not present after 30 seconds, the system may be
cycling normally under a low load by the thermostat. If all other function tests indicate normal
operation, the compressor protection module may have failed. Replace the module and verify
that the new module turns on the air conditioner clutch.

Note: If the equipment passes all of the functional tests then the compressor protection module is
functioning normally. The a/c is not operating due to a fault in a different part of the system for the
a/c. Some other possible faults may include the following:

z Fault in the harness between compressor clutch and the module

z Failed compressor clutch

z Excessive heat load on the a/c during machine operation

z Dirty condenser coil or air filter

z An incorrect level of charge of the refrigerant

Note: Refer to Testing and Adjusting, SENR5664 for assistance in troubleshooting the HVAC
system.

Copyright 1993 - 2008 Caterpillar Inc. Mon May 5 13:03:10 EST 2008
All Rights Reserved.
Private Network For SIS Licensees.

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