795F AC and 795F AC XQ Off-Highway Truck Machine Systems Caterpillar

Assembly Procedure

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Illustration 1	g06225345

1. Apply Tooling (F) onto the bearing mount areas of shaft (66).
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   Illustration 2	g06225350

2. Install bearing cover (74), with the chamfer up, onto shaft assembly (66).
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   Illustration 3	g06225349

3. Raise the temperature of bearing (73) to 142.5° ± 2.5°C (256.5° ± 4.5°F).

4. Install bearing (73) with the seal side down.

5. Install lock washer (72) and locknut (71).

   Note: Bend the tabs of lock washer (72) into the locknut.

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   Illustration 4	g06172334

6. Install roll pin (70).
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   Illustration 5	g06223087
   Old Shaft Design

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   Illustration 6	g06387820
   New Shaft Design

   Note: If the inner bore of the stator shows wear from the bearing being installed at Location (W), then install a snap ring (68) on shaft (66) at Location (X) and install bearing (69) at Location (Y). Install an additional snap ring (68) on shaft (69) at Location (Z).

7. Raise the temperature of bearing (69) to 142.5° ± 2.5°C (256.5° ± 4.5°F). Install bearing (69) onto shaft (66).

8. Install snap ring (68).
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   Illustration 7	g06224676

9. Use Tooling (C) and a suitable lifting device to install shaft assembly (66) into the stator (67).
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   Illustration 8	g06224678

10. Apply Tooling (G) to the threads of bolts (65). Install bolts (65) and tighten in an alternating pattern to a torque of 47 N·m (35 lb ft) in pattern.
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    Illustration 9	g06225638

11. Use Tooling (C) and a suitable lifting device to raise stator assembly (62) to install Tooling (J).

12. Use the following steps If installing a new stator assembly.
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    Illustration 10	g06227568

    1. Remove the damaged insulation.
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       Illustration 11	g06227581

    2. Slide on new heat shrink with adhesive and then apply heat.
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       Illustration 12	g06227588

    3. Slide on new fabric cable sleeves.
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       Illustration 13	g06227593

    4. Secure the fabric cable sleeves with fabric cable tape.

13. Clean the stator assembly with compressed air.

14. Apply Tooling (G) to the bottom of stator assembly (62).
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    Illustration 14	g06225652

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    Illustration 15	g06224297

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    Illustration 16	g06225658

15. Using Tooling (C) and the suitable lifting device, align Tooling (J) with the holes in fan housing (63). Install stator assembly (62) and guide stator leads (64) through the channel of fan housing 63 while stator assembly (62) is lowered.
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    Illustration 17	g06222845

16. Remove Tooling (J) and install stator retaining bolts (61). Tighten stator retaining bolts (61) to a torque of 111 N·m (82 lb ft).
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    Illustration 18	g06224273

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    Illustration 19	g06225673

17. Install conduit (60) over stator leads (64).
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    Illustration 20	g06172317

    Note: Remove caps or tape from the studs.

18. Install stator lead fastener (59).
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    Illustration 21	g06224267

19. Install block (58), plate (57), and nuts (56).

20. Clean the top of the fan mounting surface with a soft cloth.
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    Illustration 22	g06225358

21. Install Tooling (D) at the top of stator assembly (62).
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    Illustration 23	g06222791

    Note: Prior to installing the fan assembly, ensure that the mounting bolts of the fan blades have a torque of 111 N·m (82 lb ft).

22. Clean the top and bottom mounting surface of the fan assembly.

23. Use a suitable lifting device to raise fan assembly (55). The weight of fan assembly (55) is approximately 174 kg (384 lb).

24. Clean the inside the fan hub and apply a light coat of WD-40.

25. Install fan assembly (55).

    Note: Make certain that the fan is kept level and square to the stator assembly. The fan must not make contact with the sides of the stator coils.

26. Remove Tooling (D).
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    Illustration 24	g06222529

27. Apply a thin layer of Tooling (H) around the bolt holes and around the outside of the flange. Install retaining plate (54).

28. Apply a thin layer of Tooling (H) to the shank of bolts (53) and around the bolt holes in the plate. Install bolts (53). Tighten bolts (53), in a crisscross pattern, to the torque of 111 N·m (82 lb ft).
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    Illustration 25	g06227214

29. Attach Tooling (B) and a suitable lifting device to fan assembly (52). The weight of fan assembly (52) is approximately 704 kg (1550 lb).

    Note: Align fan assembly (52) and the electrical channel with the arrow that was made on Tooling (A).

30. Position fan assembly (52) onto Tooling (A).

31. Install nine bolts (1) to attach fan assembly (52) to Tooling (A)
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    Illustration 26	g06220175

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    Illustration 27	g06225685
    Bottom View

32. Use Tooling (B) and a suitable lifting device to install support (51). The weight of support (51) is approximately 113 kg (250 lb).

33. Install three bolts (1) and the washers at the 9 O'CLOCK, 6 O'CLOCK, AND 3 O'CLOCK positions.
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    Illustration 28	g06220164
    Top View

34. Note the location of element (45) on Tooling (A). This element is known as a Tapped Element. The element must be marked for installation purposes.

    Note: Dry fit and hand tighten the elements, the plates, and the screen before installation.

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    Illustration 29	g06220020

35. Use Tooling (B) and a suitable lifting device to install element (46). The weight of element (46) is approximately 175 kg (385 lb).

36. Install bolts (50), bolts (49), and the washers.

37. Repeat Step 35 and Step 36 for the remaining elements.

    Note: The Tapped Element (45) can be installed in the same manner as element (48), element (47), and element (46).

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    Illustration 30	g06218881

38. Position plates (44) and install bolts (43).
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    Illustration 31	g06219970

39. Install bracket assemblies (42). Install bolts (41) and the washers.
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    Illustration 32	g06218874

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    Illustration 33	g06218878

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    Illustration 34	g06225704

40. Use a suitable lifting device to install support (39). The weight of support (39) is approximately 50 kg (110 lb).

41. Install bolts (40) and the washers.

42. Install four bolts (5) and the washers.
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    Illustration 35	g06218800

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    Illustration 36	g06046985
    Bus Bar - Typical Example

43. Position cable assembly (38). Install bus bars (37), nuts (36), washers (35), and bolts (34). Tighten bolts (34) to a torque of 78 N·m (58 lb ft).
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    Illustration 37	g06218768

44. Position cover (32). Tighten cleat assembly (33). Install bolts (31) and the washers.
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    Illustration 38	g06218837

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    Illustration 39	g06046985
    Bus Bar - Typical Example

45. Insert cable assembly (30) through cleat assembly (25). Install bus bars (29), nuts (28), washers (27), and bolts (26). Tighten bolts (28) to a torque of 78 N·m (58 lb ft).
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    Illustration 40	g06218745

46. Tighten cleat assembly (25). Install cover (24), bolts (23), and the washers.
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    Illustration 41	g06220118

47. Connect clips (22).
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    Illustration 42	g06220110

48. Install bracket assembly (21), bracket assembly (20), bolts (19), and the washers.
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    Illustration 43	g06220098

49. Install cover (18), bolts (17), and the washers.
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    Illustration 44	g06218481

50. Install junction box assembly (16), bolts (15), and the washers.
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    Illustration 45	g06218479

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    Illustration 46	g06225721

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    Illustration 47	g06227174
    (CC) "IN" (DD) "IP" (EE) "RED" (FF) "WHITE" (GG) "BLUE"

51. Crimp new terminal rings 499-8740 onto to cable assemblies (14) and cable assemblies (11). Insert cable assemblies (11) and cable assemblies (14) into the junction box. Connect cable assemblies (11) at Location (CC) and Location (DD). Connect cable assemblies (14) at Location (EE), Location (FF), and Location (GG).

52. Install nuts (13), nuts (9), and the washers. Position the conduit and tighten elbow (12) and cable glands (10).
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    Illustration 48	g06220096

53. Install cover (8), bolts (7), and the washers.
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    Illustration 49	g06223981

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    Illustration 50	g06223985

54. Use two people to install outlet screen (6). The weight of outlet screen (6) is approximately 23 kg (50 lb).

    Install bolts (4) at the locations that are indicated with an (AA) and (BB).

    Note: Bolts (4) are two different sizes. Be sure to install these bolts in the same locations that the bolts were removed from.

55. Use the following steps to rotate and lower grid assembly (4).

    1. There are two possible methods for lowering the grid assembly to the ground. Use a suitable lifting device to assist Tooling (A) to rotate grid assembly (3) by 90 degrees to an upright position.
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       Illustration 51	g06224224

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       Illustration 52	g06225735

       1. Method 1 - without a fork lift

       2. Attach a suitable lifting device to Tooling (B). Attach a suitable lifting device to the link brackets on Tooling (A).

       3. Rotate grid assembly (3) onto the ground by raising one end and lowering the other.
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          Illustration 53	g06224249

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          Illustration 54	g06224231

       4. Method 2 - with a fork lift

       5. Attach a suitable lifting device to Tooling (B).

       6. Rotate grid assembly (3) by alternating between raising the lifting device and lowering the forks of the fork lift.

          Note: Ensure Tooling (A) is secured to the mast of the fork truck and cannot fall.

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    Illustration 55	g06224216

56. Remove Tooling (B).
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    Illustration 56	g06224546

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    Illustration 57	g06224202

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    Illustration 58	g06224194

57. Remove nine bolts (1) and the washers.

58. Use the suitable fork truck to remove Tooling (A) from the fan end retarder grid assembly (3). The weight of retarder grid assembly (3) is approximately 1724 kg (3800 lb).

    Note: Ensure Tooling (A) is secured to the mast of the fork truck and cannot fall.

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    Illustration 59	g06227055

59. Use two people to install screen assembly (2). The weight of screen assembly (2) is approximately 23 kg (50 lb). Install nine bolts (1) and the washers. Tighten bolts (1) to a torque of 105 ± 20 N·m (77 ± 15 lb ft)

End By:

1. Install the electric retarder. Refer to Disassembly and Assembly, "Electric Retarder - Install".