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21/06/2016

777FOffHighwayTruckJRP00001UP(MACHINE)POWEREDBYC32Engine(SEBP4305121)/BasicSearch

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Welcome:k310bgb
Product:TRUCK
Model:777FTRUCKJRP
Configuration:777FOffHighwayTruckJRP00001UP(MACHINE)POWERED
BYC32Engine

SystemsOperation
AirConditioningandHeatingR134aforAllCaterpillarMachines
MediaNumberSENR566427

PublicationDate01/05/2015

DateUpdated27/05/2015

i05907559

ServiceIntervals
SMCS700073097320

Personalinjurycanresultfromcontactwithrefrigerant.
Thissystemisunderpressureatalltimes,eveniftheengineisnot
running.Heatshouldneverbeappliedtoachargedsystem.
Contactwithrefrigerantcancausefrostbite.Keepfaceandhandsaway
tohelppreventinjury.
Protectivegogglesmustalwaysbewornwhenrefrigerantlinesare
opened,evenifthegaugesindicatethesystemisemptyofrefrigerant.
Alwaysusecautionwhenafittingisremoved.Slowlyloosenthefitting.
Ifthesystemisstillunderpressure,evacuatethesystemrecoveringthe
refrigerantbeforeremovingthefitting.
Personalinjuryordeathcanresultfrominhalingrefrigerantthrougha
litcigarette.
Inhalingairconditionerrefrigerantgasthroughalitcigaretteorother
smokingmethodorinhalingfumesreleasedfromaflamecontactingair
conditionerrefrigerantgas,cancausebodilyharmordeath.
Donotsmokewhenservicingairconditionersorwhereverrefrigerant
gasmaybepresent.
Beforeanychecksoftheairconditioningandheatingsystemaremade,
movethemachinetoasmoothhorizontalsurface.Lowerallimplements
totheground.Makesurethetransmissionisinneutralorparkandthat
theparkingbrakeisengaged.Keepallotherpersonnelawayfromthe
machineorwheretheycanbeseen.

Personalinjurycanresultfromhotcoolant.Anycontactwithhot

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21/06/2016

777FOffHighwayTruckJRP00001UP(MACHINE)POWEREDBYC32Engine(SEBP4305121)/BasicSearch

Personalinjurycanresultfromhotcoolant.Anycontactwithhot
coolantorwithsteamcancausesevereburns.Allowcoolingsystem
componentstocoolbeforethecoolingsystemisdrained.
Note:Beforeperforminganymaintenance,refertoTestingandAdjusting,"MachinePreparationforTesting
andAdjusting"forthecorrectlockoutprocedure.
Regularmaintenancemustbeperformedinordertomaximizetheperformanceoftheairconditioning
system.Regularmaintenancemustbeperformedinordertominimizethedowntimeofthemachine.Failure
toinspectthesesystemswillcausepoorperformanceandprematurefailure.InspectandmaintaintheHeater
andtheAirconditionersystemperthechartbelow.Foradditionalinformationonthecomponentandsystem
maintenanceinstructions,refertoTestingandAdjustingsectionofthismanual.
Table1
ComponentorSystem

Clean/Inspect

Replace

DryerwithQuickDisconnect

Every2000hours

DryerwithTubeORingConnect

Every4000hours

RecirculationFilter

Weekly

Monthly

CondenserCoil

asneeded

FreshAirFilter

Eachshift

Weekly

HeatingandA/CMaintenancechecklist Seasonal

Performregularmaintenanceontherefrigerantserviceunitsinaccordancetotheinstructionsfromthe
manufacturer.Changetheoilthatisinthevacuumpumpsaccordingtotheinstructionsfromthe
manufacturer.
Checkthescalethatisusedforchargingforaccuracyafterevery30days.Checkafterevery30uses
accordingtotheinstructionsfromthemanufacturer.

HeatingandA/CMaintenanceChecklist
Table2
Filters
Operation

CheckifOK

CheckthecleanlinessoftheFreshAirFilter.

CheckthecleanlinessoftheRecirculationFilter.
Table3
Coils
Operation

CheckifOK

Checkthecondensercoilfordamageordebris.

Checktheevaporatorcoilfordamageordebris.
Checktheheatercoilfordamageordebris.

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777FOffHighwayTruckJRP00001UP(MACHINE)POWEREDBYC32Engine(SEBP4305121)/BasicSearch

Table4
BlowersandFans
Operation

Checkif
OK

Checktheremotecondenserfansinordertomakesurethatthefansoperatewhentheair
conditioningsystemisrunning.

Makesurethattheblowerfansforthecaboperateonallspeedsettings.

Table5
CondensateDrainLines
Operation

CheckifOK

Makesurethatthedrainlinesarecleanandthatthedrainlinesallowcondensateflow.

Makesurethatthedrainvalvesarepresentandcorrectlylocated.

Table6
Dryer
Operation

Check
ifOK

Ifthedryerhasquickdisconnects,makesurethatthedryerhasbeenreplacedwithinthelast
2000hours.Replaceaccordingtothemaintenancechart

IfthedryerhastubeconnectionsthatareanOring,makesurethatthedryerhasbeenreplaced
withinthelast4000hours.Replaceaccordingtothemaintenancechart

Table7
Compressor
Operation

Checkif
OK

Checkthecleanlinessofthewireconnectionsforthecompressorandmakesurethatthe
connectionsarefreeofdamage.

Makesurethatthedustcapsaresecurelyinstalledontheserviceports.

MakesurethattheclutchengageswhentheA/Cswitchisonandthethermostatissetto
maximumcooling.

Table8
CompressorDriveBelt
Operation

CheckifOK

Checkforwearanddamageonthecompressordrivebelt.

Makesurethattheautotensionpulleysarefunctioningcorrectly.
Makesurethatthedrivebeltisalignedwithin1/3ofadegree.

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777FOffHighwayTruckJRP00001UP(MACHINE)POWEREDBYC32Engine(SEBP4305121)/BasicSearch

Table9
HosesandConnections
Operation

CheckifOK

Checkforwearanddamageontherefrigerantlines

Checkforleaksontherefrigerantlines

Checkforwearanddamageontheheaterlines

Checkforleaksontheheaterlines

Makesurethattheheatervalvesareopenforuseinthewinter.
Table10
Performance
Operation

Checkif
OK

Makesurethataperformancecheckontheairconditioningindicatesasystemthatis
functioningproperly.

RefertoTestingandAdjusting,"PerformanceChecksfortheAirConditioningSystem".
Makesurethataperformancecheckontheheatersystemindicatesthatthesystemis
properlyfunctioning.

RefertoTestingandAdjusting,"PerformanceChecksfortheAirConditioningSystem".

AirFiltersClean
Thecabairfiltersaredesignedtoprovidecleanairtotheevaporatorandtheheatercoils.Thecabairfilters
arealsodesignedtokeepthecabpressurized.Ifthefiltersarenotproperlymaintained,thecoilswillbe
coatedwithdirt.Dirtycoilswillresultinlossofheatingandcooling.Dirtycoilscouldalsoresultinfailure
ofthecompressor.RefertoTestingandAdjusting,"CoilCleaning".

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Illustration1

777FOffHighwayTruckJRP00001UP(MACHINE)POWEREDBYC32Engine(SEBP4305121)/BasicSearch

g01517100

Cabairfiltersshouldbeinspectedregularly.Anyinspectionvariancedependsontheenvironmental
conditions.Freshairfiltersshouldbecheckedaftereveryshift(8to10hours).Freshairfiltersshouldbe
changedaftereveryweek(40to50hours).Recirculationfiltersshouldbecheckedaftereveryweek(40to50
hours).Recirculationfiltersshouldbechangedaftereverymonth(160to200hours).Inspectthefilterfor
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777FOffHighwayTruckJRP00001UP(MACHINE)POWEREDBYC32Engine(SEBP4305121)/BasicSearch

holes.Lookthroughthefiltertowardabrightlight.Checkfordamagedgasketsordentedmetalparts.Donot
usedamagedfilters.Forextremedustconditions,thefiltersshouldbeinspecteddaily,andthefiltersshould
becleanedwheneverisnecessary.

Illustration2

g01517101

Removeloosedirtwithcompressedair.Donotexceed690kPa(100psi)fromanairnozzlethatis3.18mm
(0.125inch)diameter.Keeptheairnozzleatleast51mm(2inch)fromthefilter.
Thefiltersthataremadeoffoamcanbeblownoutwithlowpressureair.Thefiltersthataremadeoffoam
canalsobegentlywashedwithamilddetergent.Afterwashingthefilters,drythefilterswithlowpressure
air.
Ifthecarbonisstillactive,thecarbonimpregnatedfiltersmaybeblownoutwithlowpressureair.Donot
washthecarbonimpregnatedfilters.
Standardfiltersorhighefficiencyfiltersmaybeblownoutwithlowpressureair.Donotwashthestandard
filtersorthehighefficiencyfilters.

CoilCleaning
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777FOffHighwayTruckJRP00001UP(MACHINE)POWEREDBYC32Engine(SEBP4305121)/BasicSearch

NOTICE
Donotusesteamtocleanthecoils,underanycircumstance.Theheat
fromthesteamwillinducethermalstressesontheconstructionofthe
componentsofthecoil.Thestresscanweakentheoverallconstruction
andpermanentlydamagingthecoil.

NOTICE
Donotuseanyotherobjectsinordertostraightenthefins,suchasa
screwdriveroraknife.Theseobjectscandamagethecoil.

InorderforanHVACcoiltofunctionproperly,airmustbeabletoflowfreelyacrossthefinswithoutany
majorobstructions.Becausethecoilsneedtostayclean,cleaningthecoilisimportantinorderforthecoils
toprovidesufficientairflow.Somejobapplicationsmaycausethecoilstobecomedirtyquickly,anddirty
coilsrequiresfrequentcleaning.Therearedifferentmethodsthatareutilizedforpropercleaning.The
differentmethodsthatareuseddependonthetypeofcoilthatisused.
Condensercoilstypicallyhaveathicker,moredurablefinstructurethatisdesignedtowithstandthe
conditionsoftheenvironment.Duetotheconstructionofthecondensercoils,condensercoilscanbewashed
withalowpressurepowerwasher.Powerwashinordertoremoveanydirtfromthecoilandanydebrisfrom
thecoil.Thecoilsshouldbecleanedfromasafedistance.However,ifthenozzleistooclosetothecoilthe
waterstillcandamagethefins.
Theevaporatorandheatercoilstypicallyresidewithinanenclosedarea.Inordertoprotecttheevaporator
andtheheatercoilsfromtheenvironmentandoutsidedirtanddebris.Therefore,theconstructionisnot
strongenoughtowithstandwashingwithdirectpressure.Inordertocleanthecoils,usealowpressureair
nozzlethatisliketheonethatisusedincleaningthefilter.Carefullyusethelowpressureairnozzleinorder
toblowoutanydirtanddebristhatispresentonthecoils.
Duringnormaloperationandroutinecleaning,thefinsmaypossiblygetbent.Thebentfinscouldcause
blockagesintheairflow,whichwillreduceoverallsystemperformance.Straightenthefinsbyusingthe
2081350RadiatorToolGp.Startatonesideofthecoilandworktowardtheotherside.Becarefulnottorip
ortearthefinsduringstraightening,asthisstraighteningwillcauseanunwantedreductioninperformance.
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