794 AC Off-Highway Truck Engine Supplement Caterpillar

Removal Procedure

Start By:

1. Remove the radiator.

2. Remove the blower fan.

3. Remove the drive shaft.

4. Remove the exhaust.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

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In order to prevent possible personal injury, release the air pressure from the air tank before disconnecting any components of the air system.

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A high pressure fuel line must be disconnected. To avoid personal injury or fire from fuel spray, the engine must be stopped before the fuel line is disconnected.

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Contact to high pressure fuel can cause personal injury or death. Do not allow high pressure fuel to contact your skin.

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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.

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

2. Refer to Operation and Maintenance Manual, "System Pressure - Release".

3. Turn the fuel supply to the OFF position.

4. Turn the power disconnect switch to the OFF position.
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   Illustration 1	g06242727

5. Remove tube assembly (1), tube assembly (2), tube assembly (3), tube assembly (4), tube assembly (5), and the connecting hardware.
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   Illustration 2	g06242729

6. Remove tube assembly (6), tube assemblies (7), tube assembly (8), tube assembly (9), tube assembly (10), and the connecting hardware.

7. If necessary, use the following steps to remove the engine platform and the exhaust pedestal.
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   Illustration 3	g06244945

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   Illustration 4	g06245154

   1. Remove bolts (AA), washers (BB), nuts (CC), and platform (DD).

   2. Remove bolts (FF), washers (GG), and strap assembly (HH). Loosen clamp assembly (EE) and remove exhaust tube assembly (JJ). Repeat this step for the opposite side.
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      Illustration 5	g06244951

   3. Remove bolts (KK) and washers (LL). Use two people to remove pedestal (MM). The weight of pedestal (MM) is approximately 43 kg (95 lb).
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   Illustration 6	g06242744

8. Disconnect cable assembly (13).
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   Illustration 7	g06243512

9. Turn oil drain plug (A) to the Closed position. Disconnect hose assembly (14) and remove the connecting hardware.
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   Illustration 8	g06243513

10. Disconnect harness assemblies (15), hose assemblies (16), and remove the connecting hardware.

    Note: Harness assemblies (15) connect to the remote start system.

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    Illustration 9	g06243514

11. Remove clamps (17).
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    Illustration 10	g06243727

12. Loosen grommet assemblies (19). Remove bolts (18) and the washers. Position cover (20) and gasket (21) out of the way.
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    Illustration 11	g06243750

13. Remove bolt (24), nut (25), washer (25), and washers (27). Disconnect cable assembly (23). Repeat this step for the remaining cable assemblies.
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    Illustration 12	g06243767

14. Disconnect harness assembly (28) and harness assembly (29). Disconnect clips (30) and clips (31).
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    Illustration 13	g06244213

15. Disconnect harness assembly (32).
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    Illustration 14	g06244238

16. Disconnect harness assembly (33).
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    Illustration 15	g06244240

17. Disconnect harness assemblies (34).
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    Illustration 16	g06244243

18. Disconnect cable assemblies (35) and cable assemblies (36).
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    Illustration 17	g06244524

19. Disconnect hose assembly (37).
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    Illustration 18	g06244532

20. Disconnect clips (38) and (39).
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    Illustration 19	g06244551

21. Disconnect clips (40).
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    Illustration 20	g06244560

22. Use two people to remove platform assembly (41). The weight of platform assembly (41) is approximately 30 kg (66 lb). Repeat this step for the two remaining platform assemblies.
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    Illustration 21	g06244587
    Rear Mount

23. Remove bolt (42), nut (43), washer (44), large washer (45), and mount (46). Repeat this step for the three remaining rear generator mounts.
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    Illustration 22	g06244653
    Front Mount

24. Remove bolt (47), nut (48), washer (49), large washer (50), and mount (51). Repeat this step for the three remaining front engine mounts.
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    Illustration 23	g06244880

25. Raise hood panels (52) and attach a suitable lifting device. The weight of hood panels (52) and cross member (56) is approximately 113 kg (250 lb). Remove bolts (53), nuts (55), and washers (54). Use the suitable lifting device to remove hood panels (52) and cross member (56).
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    Illustration 24	g06244850

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    Illustration 25	g06244885

26. Attach Tooling (A), Tooling (B), and a suitable lifting device onto engine and generator (57). The weight of engine and generator (57) is approximately 20,000 kg (44,000 lb).

27. Use Tooling (A), Tooling (B), and the suitable lifting device to remove engine and generator (57). Position engine and generator (57) onto suitable cribbing.