ALTERNATOR GP-CHARGING 3893259 - Caterpillar

Removal Procedure
Start By:
Remove the storage box. Refer to Disassembly and Assembly, "Storage Box and Covers (Cab) - Remove and Install". Note: Before you begin the following procedure, swing the upper structure in order to gain access to the sheet that is mounted beneath the cab. Removing the sheet allows access to the hose connections on the heater/air conditioner unit.
Effective July 1, 1992 regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publications Service Manuals, SENR3334, SENR5664, and NEDG5065 for the proper procedure, the proper equipment, and the proper tools needed in order to reclaim refrigerant from any Caterpillar equipment.
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.
Recover the air conditioner refrigerant from the air conditioner system. The correct charge is 2.2 kg (4.8 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134a Refrigerant" for the procedure. Refer to Special Publication, NEDG5065, "Air Conditioning Tools" for the tools.
Illustration 1 g00859573
Close valves (1) and (2) to the heater hoses. The valves are located on the water pump.
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Remove bolts (3) and (4).
Remove sheet (5).
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Disconnect air conditioner hose assemblies (6) and (7). Note: Mark the air conditioner hose assemblies for installation purposes.
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Disconnect heater hoses (8) and (9). Note: Mark the heater hoses for installation purposes.
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Remove the cable straps. Disconnect harness assembly (10). Feed the harness assembly down the operator platform.
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Disconnect two harness assemblies (11) and (12). Note: Mark the harness assemblies for installation purposes.
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Peel back two rubber gaskets (13).
Remove bolt (15). Remove upper air duct (14).
Remove hose (16) and (17).
Remove air duct (18).
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Remove bolts (19). Remove heater/air conditioner unit (20).