794 AC Off-Highway Truck Machine Systems 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, "Prepare the Machine for Maintenance".

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

3. Refer to Operation and Maintenance Manual, "Electrical Shutdown and Voltage Discharge".
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   Illustration 1	g03732926

4. Remove hand rail (1).
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   Illustration 2	g03732842

5. Remove cover assemblies (2) and shroud assembly (3).
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   Illustration 3	g03732865

6. Remove the bus bar connecting hardware (4). Remove the bolts from support (5). Position the harness assemblies (6) and support (5) out of the way.
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   Illustration 4	g03732868

7. Remove cover (6).
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   Illustration 5	g03732871

8. Remove bolts (7). Disconnect grommet assembly (8). Position harness assembly (9) out of the way.

9. Repeat Step 8 for each of the remaining harness assemblies.
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   Illustration 6	g03732884

10. Disconnect ground strap (10).
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    Illustration 7	g03732887

11. Disconnect clamps (11) and retain the hardware.
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    Illustration 8	g03732895
    Correct orientation of link brackets through weld nut

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    Illustration 9	g03732902

12. Attach Tooling (A) and a suitable lifting device onto electric retarder (12). The weight of electric retarder (12) is approximately 1724 kg (3800 lb).
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    Illustration 10	g03732905

13. Remove support bracket (13).
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    Illustration 11	g03732907

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    Illustration 12	g03732902

14. Remove mounting bolts (14) from each side of retarder grid (12). Use Tooling (A) and the suitable lifting device to remove electric retarder (12). The weight of electric retarder (12) is approximately 1724 kg (3800 lb).

Installation Procedure

1. Install electric retarder (12) in the reverse order of removal.

2. Use the following steps to install the bus bar connecting hardware.

   1. Use the following step to install the connecting hardware (4).
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      Illustration 13	g06241070
      L- Shaped Bus Bar Terminal Stack Up (AA) 6V-8188 Nut (AB) 8T-4821 Flat Washer (AC) 8T-8919 Bolt (AD) 226-2659 Belleville Washer (Cup Towards Flat Washer) (AE) 325-7956 Terminal Plate

   2. Install terminal plate (AE) onto quadrant using four bolts (AC), four belleville washers (AD), eight flat washers (AB), and four nuts (AA). Tighten bolts (AC) to a torque of 79 ± 1 N.m (58 ± 1 lb ft).

      Note: Install the terminal plate (AE) using bolt (AC), placing a belleville washer (AD) (with the cup toward the flat washer), a flat washer (AB) at L- shaped bus bar terminal and a flat washer (AB) with nut (3) on resistor quadrant terminal.