794 AC Off-Highway Truck Engine Supplement Caterpillar

Removal Procedure

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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, "Prepare the Machine for Maintenance".

2. Refer to Operation and Maintenance Manual, "Electrical Shutdown and Voltage Discharge".
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   Illustration 1	g03785834

3. Disconnect harness assembly (1).
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   Illustration 2	g03785835

4. Disconnect harness assembly (2).
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   Illustration 3	g03785841

5. Open electrical box (3).
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   Illustration 4	g03785842

6. Disconnect all connection of harness assembly (4). Loosen locknut (5). Pull harness assembly (4) from the electrical box.
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   Illustration 5	g03785844

7. Disconnect clip (6).
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   Illustration 6	g03785998

8. Disconnect harness assembly (7).
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   Illustration 7	g03786001

9. Disconnect clips (8) and clips (9). Position harness assembly (4) and harness assembly (7) out of the way.
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   Illustration 8	g03786012

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   Illustration 9	g03786058

10. Remove bolts (10). Pull gauge assembly (11) from the side of the hood enough to disconnect hose assemblies (12) and remove gauge assembly (11).
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    Illustration 10	g03786065

11. Attach Tooling (A) and a suitable lifting device onto hood assembly (13). The weight of hood assembly (13) is approximately 951 kg (2097 lb).
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    Illustration 11	g03786156

12. Loosen clamp assembly (14) and position hose assemblies (15) out of the way.
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    Illustration 12	g03786460

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    Illustration 13	g03786479

13. Remove bolt (17), hard washers (18), shock mount (19), and nut (20). Record the locations and quantities of washer (18) for installation purposes. Repeat this step for the opposite side.
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    Illustration 14	g06398186

14. Remove bolt (21), hard washers (22), shock mount (23), and nut (24). Record the locations and quantities of washer (22) for installation purposes. Repeat this step for the opposite side.
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    Illustration 15	g03786478

15. Use Tooling (A) and the suitable lifting device to remove hood assembly (13). The weight of hood assembly (13) is approximately 951 kg (2097 lb).

Installation Procedure

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Illustration 16	g03786478

1. Use Tooling (A) and the suitable lifting device to install hood assembly (13). The weight of hood assembly (13) is approximately 951 kg (2097 lb).
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   Illustration 17	g06398186

2. Install bolt (21), hard washers (22), shock mount (23), and nut (24). Repeat this step for the opposite side.

3. Add or remove hard washers (22) to achieve a minimum clearance of 12 mm (0.5 inch) between hood assembly (13) and the top tank of the radiator and align the top hood surface with the superstructure.
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   Illustration 18	g03786460

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   Illustration 19	g03786479

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   Illustration 20	g06398310

4. Install bolt (17), hard washers (18), shock mount (19), and nut (20). Repeat this step for the opposite side.

5. Add or remove hard washers (18) to achieve a minimum clearance of 12 mm (0.5 inch) between hood assembly (13) and the superstructure.
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   Illustration 21	g03786156

6. Position hose assemblies (15) and tighten clamp assembly (14).
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   Illustration 22	g03786065

7. Remove Tooling (A) and the suitable lifting device from hood assembly (13).
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   Illustration 23	g03786012

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   Illustration 24	g03786058

8. Install gauge assembly (11) and hose assemblies (12). Install bolts (10).
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   Illustration 25	g03786001

9. Position harness assembly (4) and harness assembly (7). Connect clips (8) and clips (9).
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   Illustration 26	g03785998

10. Connect harness assembly (7).
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    Illustration 27	g03785844

11. Cnnect clip (6).
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    Illustration 28	g03785842

12. Insert assembly (4) into the electrical box. Connect all connection of harness assembly (4). Tighten locknut (5).
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    Illustration 29	g03785841

13. Close electrical box (3).
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    Illustration 30	g03785835

14. Connect harness assembly (2).
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    Illustration 31	g03785834

15. Connect harness assembly (1).