777E, 777F and 777G Off-Highway Truck Caterpillar

Removal Procedure

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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.

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.

2. Turn the battery disconnect switch to the OFF position in order to disconnect the battery.
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   Illustration 1	g01303147

3. Remove bolt (2). Position hose assemblies (1) out of the way.

4. Remove bolts (3). Remove guard (4).
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   Illustration 2	g01303174

5. Use Tooling (A) in order to release belt tension. Position belt (5) out of the way.
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   Illustration 3	g01303180

6. Remove bracket assembly (6).
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   Illustration 4	g01303267

7. Disconnect harness assemblies (7), (8), and (9).
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   Illustration 5	g01303275

8. Remove bolts (11). Position hose assemblies (10) out of the way.
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   Illustration 6	g01303279

9. Remove bolt (12). Remove bolts (14). Remove refrigerant compressor (13).

Installation Procedure

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Illustration 7	g01303279

1. Position refrigerant compressor (13). Install bolts (14). Install bolt (12).
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   Illustration 8	g01303275

2. Position hose assemblies (10). Install bolt (11).
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   Illustration 9	g01303267

3. Connect harness assemblies (9), (8), and (7).
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   Illustration 10	g01303180

4. Install bracket assembly (6).
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   Illustration 11	g01303174

5. Use Tooling (A) in order to position belt (5).
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   Illustration 12	g01303147

6. Install guard (4). Install bolts (3).

7. Position hose assemblies (1). Install bolt (2).

8. Turn the battery disconnect switch to the ON position in order to reconnect the battery.

9. Charge the air conditioner refrigerant into 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.