770 and 772 Off-Highway Truck/Tractors Evaporator Coil - Remove and Install Caterpillar

Removal Procedure

Start By:

1. Remove the right side engine enclosure. Refer to Disassembly and Assembly, "Sound Suppression - Remove and Install".

Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. This helps to prevent fluid loss, and this helps to keep contaminants from entering the system.

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Personal injury can result from contact with refrigerant. 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 precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area. 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. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.

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, NEDG2500, "Air Conditioning Tools" for the correct tools.
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2. Remove cover (1) and filter (2).
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3. Remove bolts (3). Remove cover (4).
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4. Remove bolts (5).
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5. Remove bolts (6).
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6. Remove cover (7).
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7. Remove bolt (9). Remove panel assembly (8).
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8. Turn valves (10) to the OFF position.
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9. Loosen clamp (11) and disconnect hose (12). Disconnect harness assembly (13).
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10. Disconnect hose assemblies (14). Loosen clamp (15) and disconnect hose (16).
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11. Remove nuts (17) from both sides of air conditioner assembly (18).

12. Use two people in order to remove air conditioner assembly (18). The weight of air conditioner assembly (18) is approximately 32 kg (70 lb).
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13. Remove bolts (20). Remove plate (19).
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14. Remove bolts (21). Remove plate (22).
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15. Remove bolt (23).
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16. Mark the position of tube (25) and position tube (25) out of the way.

17. Remove bolts (26) and remove evaporator coil (24).

Installation Procedure

Note: Cleanliness is an important factor. Before you begin the installation procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

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1. Position evaporator coil (24) and install bolts (26). Reposition tube (25) into the marked locations.
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2. Install bolts (23).
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3. Position plate (22) and install bolts (21).
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4. Position plate (19) and install bolts (20).
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5. Use two people in order to position air conditioner assembly (18). The weight of air conditioner assembly (18) is approximately 32 kg (70 lb).

6. Install nuts (17) on both sides of air conditioner assembly (18).
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7. Connect hose assemblies (14). Connect hose (16) and tighten clamp (15).
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8. Connect harness assembly (13). Connect hose (12) and tighten clamp (11).
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9. Turn valves (10) to the ON position.
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10. Position panel assembly (8) and install bolt (9).
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11. Install cover (7).
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12. Install bolts (6).
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13. Install bolts (5).
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14. Position cover (4) and install bolts (3).
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15. Install filter (2) and install cover (1).

16. Charge 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, NEDG2500, "Air Conditioning Tools" for the correct tools.

End By:

1. Install the right side engine enclosure. Refer to Disassembly and Assembly, "Sound Suppression - Remove and Install".