793F Series AC Off-Highway Truck Power Train Caterpillar

Removal Procedure

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The space between the body and the frame becomes a zero clearance area when the body is lowered. Failure to install the retaining cable can result in injury or death to personnel working in this area.

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Personal injury or death can occur from heavy components falling during removal or installation. Properly support the component with a suitable lifting device during removal or installation.

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The Power Train Electric Drive System and the Accessory Power System will contain hazardous voltage levels during machine operation and for a period of time after machine shutdown. Do not remove any covers that will expose energized electrical components while the engine is operating. Do not remove any covers that will expose the energized electrical components while the components remain energized following an engine shutdown. Do not perform any type of electrical maintenance on the orange hazardous voltage conductors, the power train components or the accessory power system components while the engine is operating. Do not perform any type of electrical maintenance on the orange hazardous voltage conductors, the power train components or the accessory power system components while the components remain energized following an engine shutdown. Always perform the safe shutdown and de-energizing procedure before performing electrical service on the Power Train Electric Drive System or the Accessory Power System. Failure to follow these instructions could result in personal injury or death.

1. Refer to Operation and Maintenance Manual, "Cable (Truck Body Retaining )".

2. Refer to Troubleshooting, "The Power Train Electrical System Service Shutdown" for the detailed procedure.
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   Illustration 1	g03432845

3. Remove clamps (1). Remove cover (2).
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   Illustration 2	g03432847

   Note: Note the location and routing of the harness assemblies for installation purposes.

4. Remove bolts (3). Loosen lock washers (5). Position cable assemblies (4) out of the way.

5. Reinstall cover (2).
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   Illustration 3	g03432850

6. Disconnect harness assemblies (6).
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   Illustration 4	g03432851

7. Disconnect harness assembly (7) and harness assembly (9). Disconnect clips (8).
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   Illustration 5	g03432852

8. Remove bolts (10) and position duct assembly (11) out of the way. Repeat this step for the opposite side of the power generator.
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   Illustration 6	g03432853

9. Disconnect ground strap (12).
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   Illustration 7	g03432854

10. Remove drive shaft guard (13).
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    Illustration 8	g03432855

11. Attach a suitable lifting device onto drive shaft (14). The weight of drive shaft (14) is approximately 218 kg (480 lb).

12. Remove bolts (15).

    Note: Bolts (15) are not reusable. Discard bolts (15).

13. Use a suitable pry bar to compress drive shaft (14).

    Note: Do not separate the universal joint and the drive shaft. The drive shafts are assembled with the universal joints in phase for balancing purposes. If the drive shaft must be separated, use a paint pen to make aligning marks on both sides of the slip joint. When reassembling the drive shaft, make sure the aligning marks match to ensure proper universal joint phasing and balance performance.

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    Illustration 9	g03432858

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    Illustration 10	g03432859

14. Remove the bolts (16) and mount (17). Remove bolt (18) and the nut. Repeat this step for the opposite side.
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    Illustration 11	g03432861

15. Use Tooling (A), Tooling (B), and Tooling (C) to remove power generator (19). The weight of power generator (19) is approximately 3856 kg (8501 lb).

Installation Procedure

1. Install power generator (18) in the reverse order of removal.

2. Use the following procedure to mate the universal joint onto the yoke of the power generator.

   Note: Prior to the drive shaft installation, make sure that the coupler adapter yoke and the power generator yoke are aligned with each other.

   Note: When installing the drive shaft, cut the weld wire that holds the slip joint together prior to seating the universal joint on the power generator.

   1. Mate the key and pilot diameter of the universal joint with the yoke of the power generator. Use a suitable rubber or wooden hammer to completely seat the universal joint.

   2. Use Tooling (D) to tighten bolts (15) to a torque of 777 ± 40 N·m (573 ± 30 lb ft) in an alternating (X) pattern.

   3. Use Tooling (D) to tighten bolts (15), again, to a torque of 777 ± 40 N·m (573 ± 30 lb ft) in an alternating (X) pattern to ensure that the correct torque has been achieved.