Procedure to Relocate the Air Conditioning Pressure Switch on Certain 777E Off-Highway Trucks {1808} Caterpillar

Off-Highway Truck/Tractor

777E (S/N: KDP1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information. This Special Instruction provides the parts and procedure to replace the existing dryer and move the pressure switch from the A/C compressor to the dryer inlet coupling.

Caterpillar Channel 1 Videos

For supplemental information on this procedure, refer to the following video. The previous training has been replaced with the video below.

Note: A CWS login is required to access Caterpillar Channel 1. Scan the QR code below with a QR enabled device or copy the link that follows.

Illustration 1	g06306276

https://channel1.mediaspace.kaltura.com/media/Introduction+to+Visualization+Service+Procedures+%28VSP%29/1_92vjr92v

Safety Information

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, including human factors that can affect safety. This person should also have the necessary training, skills, and tools to perform these functions properly.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

General Information

Graphic Color Description

Color-coding of targeted components, or sections of a part, is used to communicate a required action.

The descriptions below illustrate the different colors and what is represented when used in a graphic.

(Blue) The primary component of focus for a particular step. Target or primary component to be installed or removed. Installation implied unless otherwise noted with a symbol.

(CAT® Yellow) Description of parts.

(Yellow) Components placed aside for access, but not removed. Highlighted areas of adjustment, inspection, or special attention.

(Cyan) Special tools or other equipment required for use in a particular step.

(Light Gray) Components used for reference.

(Magenta) Any fastener, retainer, or electrical connector used to install or remove the primary component.

Graphic Symbol Description

This section includes all the symbol graphics used throughout the Visual Service Procedure (VSP), along with a brief description of what the symbol represents.

Clean - To remove foreign or undesired material.

Close - To shut, as in a door. To bring into contact.

Connect - To join or fasten together. To place in an electrical circuit.

Disconnect - To separate. To remove from an electrical circuit.

Dumper Hauler - Body Float

Engine - Stop

Keep, Store - To retain for reinstallation or reuse.

Level Surface - To position a surface in a horizontal orientation. To position in vertical dimension. To align to assist positioning a surface in a horizontal orientation.

Lock - To fasten or secure by the operation of a lock.

Loosen - To make less tight. To set free. To release.

Lubricate - To apply a material to a surface to reduce friction.

Move

Off

On / Start

Open - To unseal or get access to.

Parking Brake

Position - To locate to the desired or intended location.

Protect - To cover or shield from exposure, injury, damage, or destruction.

Relieve Pressure - To eliminate the pressure or force on a part or system to reduce a pressure, load, or weight on a device.

Remove - To take off.

Replace / Install - To put back in place.

Service Indicator / Read Technical Manual - Refer to a Technical Manual.

Tighten - To make nearer to fully stretched, without slack, to apply tension or torque.

Weld - To join by heating until liquid portions of two or more pieces of metal in contact with each other and allowing the common puddle to solidify.

Wheel Chock - Wedges placed closely against the wheels of the machine to prevent accidental movement.

Torque Specifications

English (SAE) Fasteners

The following table has the recommended standard torque values.

Table 1

Nuts and Bolts
Thread Size Inch	Standard Torque
1/4	12 ± 3 N·m (9 ± 2 lb ft)
5/16	25 ± 5 N·m (18 ± 5 lb ft)
3/8	47 ± 10 N·m (35 ± 5 lb ft)
7/16	70 ± 15 N·m (50 ± 10 lb ft)
1/2	105 ± 20 N·m (75 ± 15 lb ft)
9/16	160 ± 30 N·m (120 ± 20 lb ft)
5/8	215 ± 40 N·m (160 ± 30 lb ft)
3/4	370 ± 50 N·m (275 ± 37 lb ft)
7/8	620 ± 80 N·m (460 ± 60 lb ft)
1	900 ± 100 N·m (660 ± 75 lb ft)
1 1/8	1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4	1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8	2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2	3100 ± 350 N·m (2280 ± 260 lb ft)

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

Table 2

Nuts and Bolts
Thread Size Metric	Standard Torque
M6	12 ± 3 N·m (9 ± 2 lb ft)
M8	30 ± 5 N·m (20 ± 5 lb ft)
M10	55 ± 10 N·m (40 ± 5 lb ft)
M12	100 ± 20 N·m (75 ± 15 lb ft)
M14	160 ± 30 N·m (120 ± 20 lb ft)
M16	240 ± 40 N·m (175 ± 30 lb ft)
M20	460 ± 60 N·m (340 ± 45 lb ft)
M24	800 ± 100 N·m (590 ± 75 lb ft)
M30	1600 ± 200 N·m (1180 ± 150 lb ft)
M36	2700 ± 300 N·m (2000 ± 220 lb ft)

Prepare the Machine for Maintenance

Illustration 2	g06237106
(1) Refer to Operation and Maintenance Manual, SEBU9388, Prepare the Machine for Maintenance.

Illustration 3	g06239446
(1) Refer to Operation and Maintenance Manual, SEBU9388, Use of Wheel Chocks. (2) Refer to Operation and Maintenance Manual, SEBU9388, System Pressure Release.

Illustration 4	g06239476
(1) Refer to Operation and Maintenance Manual, SEBU9388, Operator Controls.

Illustration 5	g06237132

Illustration 6	g06237146
(1) Refer to Operation and Maintenance Manual, SEBU9388, Engine Lockout Control.

Illustration 7	g06237152

Required Parts

Illustration 8	g06237612

Illustration 9	g06237618

Illustration 10	g06237630

Table 3

Item	Qty	Part Number	Part Name
1	1	533-0571(1)	Plate
2	3	9X-7383	O-Ring Seal
3	1	7K-3176	Refrigerant Coupling Assembly
4	1	7K-3304	Jam Nut
5	1	2H-3924	Lockwasher
6	1	533-0551	Hose As
7	1	9X-7380	O-Ring Seal
8	1	525-4528	Hose As
9	1	327-0282	Integral Seal
10	1	200-6345	Mount
11	18	7K-1181	Cable Strap
12	2	9X-7381	O-Ring Seal
13	1	257-3226	Refrigerant Dryer As
14	1	5P-3950	Cap
15	3	3S-2093	Cable Strap
16	1	533-0552	Hose As
17	1	5P-3948	Refrigerant Coupling Assembly
18	1	130-5300	Clip
19	2	132-5789	Clip
20	1	8T-4137	Bolt
21	1	8T-4121	Hard Washer
22	7	290-5562	Mount
23	1	274-7505	Harness As
24	1	2L-1224	Seal Cap
25	3	9X-7384(2)	O-Ring Seal
26	1	9X-7378(2)	O-Ring Seal
27	10 mL (0.34 oz)	397-7507(2)	Oil
28	1	5P-3951	Plug

(1)	Must be fabricated. Refer to "Procedure to Fabricate the 533-0571 Plate" in this manual.
(2)	Not pictured.

Procedure to Remove the Existing Dryer

Illustration 11	g06236593
(1) Refer to Testing and Adjusting, SENR5664, "Air Conditioning and Heating R134a for All Caterpillar Machines". (3) Refer to Testing and Adjusting, SENR5664, Refrigerant Recovery.

Illustration 12	g06236701

Illustration 13	g06236741

Illustration 14	g06236747

Illustration 15	g06236754

Illustration 16	g06236772

Illustration 17	g06236798

Illustration 18	g06236806

Illustration 19	g06236808

Procedure to Fabricate the 533-0571 Plate

Illustration 20	g06254943
(D1) 110 mm (4.33 inch) (D2) 15 mm (0.59 inch) (D3) 40 mm (1.57 inch) (D4) 30 mm (1.18 inch) (D5) 15 mm (0.59 inch) (D6) 40 mm (1.57 inch) (D7) 140 mm (5.51 inch) (D8) 26.75 mm (1.05 inch) (D9) 38 mm (1.49 inch) (D10) 25 mm (0.98 inch) (D11) 3 mm (0.12 inch) (D12) 90 degrees (R1) 3 ± 1 mm (0.12 ± 0.04 inch)

Procedure to Install the New Dryer

Illustration 21	g06237612

Illustration 22	g06237618

Table 4

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
1	1	533-0571(1)	Plate	Illustration 23 (1)
2	3	9X-7383	O-Ring Seal	Illustration 30 (1) Illustration 30 (2) Illustration 30 (3) Illustration 32 (1)
3	1	7K-3176	Refrigerant Coupling Assembly	Illustration 30 (3)
4	1	7K-3304	Jam Nut	Illustration 30 (4)
5	1	2H-3924	Lockwasher	Illustration 30 (4)
6	1	533-0551	Hose As	Illustration 29 (2) Illustration 30 (3)
7	1	9X-7380	O-Ring Seal	Illustration 26 (1)
8	1	525-4528	Hose As	Illustration 25 (1) Illustration 26 (2) Illustration 27 (2)
9	1	327-0282	Integral Seal	Illustration 27 (1)
10	1	200-6345	Mount	Illustration 29 (3)
11	2	7K-1181	Cable Strap	Illustration 29 (3)
12	2	9X-7381	O-Ring Seal	Illustration 29 (1) Illustration 33 (1)
13	1	257-3226	Refrigerant Dryer As	Illustration 24 (1)
15	3	3S-2093	Cable Strap	Illustration 31 (2)
16	1	533-0552	Hose As	Illustration 31 (1) Illustration 32 (3) Illustration 33 (2)
17	1	5P-3948	Refrigerant Coupling Assembly	Illustration 32 (2)
25	3	9X-7384(2)	O-Ring Seal	Illustration 35 (1) Illustration 35 (2) Illustration 36 (1)
27	10 mL (0.34 oz)	397-7507(2)	Oil	Illustration 26 (1) Illustration 27 (1) Illustration 29(1) Illustration 30 (1) Illustration 30 (2) Illustration 32 (1) Illustration 33 (1) Illustration 35 (1) Illustration 35 (2) Illustration 36 (1)

(1)	Must be fabricated. Refer to "Procedure to Fabricate the 533-0571 Plate" in this manual.
(2)	Not pictured.

Illustration 23	g06237737
(1) Refer to Special Instruction, REHS1841, "General Welding Procedures". (D1) 354 mm (13.94 inch) (D2) 127 mm (5 inch) (W1) 3 mm (0.12 inch)

Illustration 24	g06237746

Illustration 25	g06239628

Illustration 26	g06237997

Illustration 27	g06238002

Illustration 28	g06238005

Illustration 29	g06238022

Illustration 30	g06238042

Illustration 31	g06238128

Illustration 32	g06238126

Illustration 33	g06238133

Illustration 34	g06238135

Illustration 35	g06238155

Illustration 36	g06238166

Procedure to Move the Pressure Switch

Illustration 37	g06237630

Table 5

Item	Qty	Part Number	Part Name	Illustration (Sub-Step) Location
11	16	7K-1181	Cable Strap	Illustration 40 (1) Illustration 41 (1)
18	1	130-5300	Clip	Illustration 41 (1)
19	2	132-5789	Clip	Illustration 39 (2) Illustration 41 (1)
20	1	8T-4137	Bolt	Illustration 41 (1)
21	1	8T-4121	Hard Washer	Illustration 41 (1)
22	7	290-5562	Mount	Illustration 40 (1)
23	1	274-7505	Harness As	Illustration 39 (3) Illustration 39 (4) Illustration 41 (4)
24	1	2L-1224	Seal Cap	Illustration 39 (1)
26	1	9X-7378(1)	O-Ring Seal	Illustration 41 (2)
27	10 mL (0.34 oz)	397-7507(2)	Oil	Illustration 41 (2)

(1)	Not pictured.

Illustration 38	g06236786

Illustration 39	g06238180

Illustration 40	g06253556

Illustration 41	g06238199

Prepare the Refrigerant System for Use

• Refer to Testing and Adjusting, SENR5664, Refrigerant System - Evacuate.

• Refer to Testing and Adjusting, SENR5664, Refrigerant Leakage - Test.

• Refer to Testing and Adjusting, SENR5664, Refrigerant System - Charge.