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

Disassembly Procedure

Start By:

1. Remove the grid assembly. Refer to Disassembly and Assembly, "Electric Retarder - Remove".

Show/hide table

Illustration 1	g06224152

1. Remove nine bolts (1) and the washers. Do not remove three bolts (1) that are indicated with an (A). Use two people to remove screen assembly (2). The weight of screen assembly (2) is approximately 23 kg (50 lb).
   Show/hide table

   Illustration 2	g06216157

   Show/hide table

   Illustration 3	g06225334
   Tooling (A)

2. Tooling (A) will need to be modified before being attached to the retarder grid assembly. Refer to Illustration 2 and 3 for instruction to modify Tooling (A).
   Show/hide table

   Illustration 4	g06224194

   Show/hide table

   Illustration 5	g06224202

   Show/hide table

   Illustration 6	g06224546

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

4. Install nine bolts (1) and the washers.
   Show/hide table

   Illustration 7	g06224216
   Outlet End

5. Install Tooling (B).

6. 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 and lower to the ground.
      Show/hide table

      Illustration 8	g06224221

      Show/hide table

      Illustration 9	g06224224

      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.
         Show/hide table

         Illustration 10	g06224231

         Show/hide table

         Illustration 11	g06224249

      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.
   Show/hide table

   Illustration 12	g06223981

   Show/hide table

   Illustration 13	g06223985

7. Mark the locations of bolts (4) that are indicated with a (AA) and a (BB) for installation purposes. Remove bolts (4) and the washers. Remove bolts (5) and the washers. Use two people to remove outlet screen (6). The weight of outlet screen (6) is approximately 23 kg (50 lb)

   Note: Bolts (4) are two different sizes. Be sure to install these bolts in the same locations for assembly.

   Show/hide table

   Illustration 14	g06220096

8. Remove bolts (7), the washers, and cover (8).
   Show/hide table

   Illustration 15	g06218479

   Show/hide table

   Illustration 16	g06225721

9. Remove nuts (9), nuts (13), and the washers. Disconnect cable glands (10). Loosen elbow (12). Remove cable assemblies (11) and cable assemblies (14) with the conduit from the junction box.

10. Cut the terminal leads from cable assemblies (14) to allow the cables to be pulled through the conduit.

    Note: Cut the ring terminals off parallel to the cable to avoid loosing cable length.

    Show/hide table

    Illustration 17	g06218481

11. Remove bolts (15), the washers, and junction box assembly (16).
    Show/hide table

    Illustration 18	g06220098

12. Remove bolts (17), the washers, and cover (18).
    Show/hide table

    Illustration 19	g06220110

13. Remove bolts (19), the washers, bracket assembly (20), and bracket assembly (21).
    Show/hide table

    Illustration 20	g06220118

14. Disconnect clips (22).
    Show/hide table

    Illustration 21	g06218745

15. Remove bolts (23), the washers, and cover (24). Loosen cleat assembly (25).
    Show/hide table

    Illustration 22	g06218837

16. Remove bolts (26), washers (27), nuts (28), and bus bars (29). Pull cable assembly (30) from cleat assembly (25).
    Show/hide table

    Illustration 23	g06218768

17. Remove bolts (31) and the washers. Loosen cleat assembly (33) and position cover (32) out of the way.
    Show/hide table

    Illustration 24	g06218800

18. Remove bolts (34), washers (35), nuts (36), and bus bars (37). Position cable assembly (38) out of the way.
    Show/hide table

    Illustration 25	g06218874

    Show/hide table

    Illustration 26	g06218878

    Show/hide table

    Illustration 27	g06225704

19. Attach suitable lifting device onto support (39). The weight of support (39) is approximately 50 kg (110 lb).

20. Remove bolts (40) and the washers.

21. Remove bolts (5) and the washers.

22. Remove support (39).
    Show/hide table

    Illustration 28	g06219970

23. Remove bolts (41), the washers, and bracket assemblies (42).
    Show/hide table

    Illustration 29	g06218881

24. Remove bolts (43) and plates (44).
    Show/hide table

    Illustration 30	g06220164
    Top View

25. Mark the location of element (45) on Tooling (A). This element is known as a Tapped Element. The element must be marked for installation purposes. The Tapped Element must be installed in this location for installation.

    Note: Mark the location and alignment of element (46), element (47), and element (48) for installation purposes.

    Note: Tapped Element (45) can be removed in the same manner as the three remaining elements.

    Show/hide table

    Illustration 31	g06220020

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

27. Remove bolts (49), bolts (50), and the washers.

28. Remove element (46).

29. Repeat Step 26 through Step 28 for each of the remaining elements.
    Show/hide table

    Illustration 32	g06220175

30. Attach a suitable lifting device onto Tooling (B). Remove bolts (1). Remove support (51). The weight of support (51) is approximately 113 kg (250 lb).
    Show/hide table

    Illustration 33	g06222787

31. If necessary. use Tooling (B) and a suitable lifting device to remove fan assembly (52) from Tooling (A). The weight of fan assembly (52) is approximately 704 kg (1550 lb).

    Note: Mark the alignment of fan assembly (52) and the electrical channel on Tooling (A) for installation purposes.

    Show/hide table

    Illustration 34	g06222529

32. Remove bolts (53) and retaining plate (54).
    Show/hide table

    Illustration 35	g06222559

    Show/hide table

    Illustration 36	g06222791

33. Install Tooling (D).

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

35. Remove fan assembly (55).

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

36. Remove Tooling (D).
    Show/hide table

    Illustration 37	g06224267

37. Remove nuts (56), plate (57), and block (58).
    Show/hide table

    Illustration 38	g06172317

    Note: Install caps or tape over the studs to protect the cable leads.

38. Remove lead fastener (59).
    Show/hide table

    Illustration 39	g06224273

39. Remove conduit (60).
    Show/hide table

    Illustration 40	g06222845

40. Remove stator retaining bolts (61).
    Show/hide table

    Illustration 41	g06224297

    Show/hide table

    Illustration 42	g06225743

    Show/hide table

    Illustration 43	g06224670

41. Attach Tooling (C) and a suitable lifting device to stator assembly (62).

42. Remove stator assembly (62) from fan housing (63).

    Note: Carefully pull leads (64) through the channel of fan housing (63) while lifting stator assembly (62).

    Show/hide table

    Illustration 44	g06224678

43. Remove bolts (65).
    Show/hide table

    Illustration 45	g06224676

    Show/hide table

    Illustration 46	g06226007

44. Use Tooling (C) and a suitable lifting device to raise stator assembly (62). Strike shaft assembly (66) with a soft faced mallet to remove shaft assembly (66) from stator (67).

    Note: If necessary, use a suitable pry bar to assist the removal of shaft assembly (66).

    Show/hide table

    Illustration 47	g06223087

    Show/hide table

    Illustration 48	g06224695

45. Remove snap ring (68).

46. Use a suitable press to remove bearing (69) from shaft assembly (66).
    Show/hide table

    Illustration 49	g06223384

47. Reposition the shaft and remove roll pin (70).
    Show/hide table

    Illustration 50	g06172331

48. Remove lock nut (71) and lock washer (72).
    Show/hide table

    Illustration 51	g06224696

49. Use a suitable press to remove bearing (73) and bearing cover (74) from shaft assembly (66).