793C XQ Off-Highway Truck and 793C Off-Highway Truck Engine Supplement Caterpillar

Fan Drive (Hydraulic) - Remove

Usage:

793C CBR

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Description	Qty
A	138-7573	Link Bracket	2
B	138-7575	Link Bracket	3
ZZ	6V-9832	Cap As	1
	6V-9511	Face Seal Plug	1
	7E-8716	Plug	4
	9U-7084	Cap	1
	6V-9508	Plug	1
	6V-9829	Cap As	1

Start By:

Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install".

Note: SERVICE DATA: TOOLING (ZZ) WILL NOT BE IDENTIFIED IN PHOTOGRAPHS IN THE REMOVAL OR THE INSTALLATION. THIS TOOLING IS SHOWN IN ORDER TO ASSIST THE EXPERIENCED SERVICEMAN.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

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NOTICE

Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination.

Note: Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

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Illustration 1	g00897294

Disconnect harness assembly (1) for the air temperature sensor.
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Illustration 2 g00917494
Remove bolts (2) that secure handhold (3). Remove the handhold from the truck.
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Illustration 3 g00897295

Upper RH section
Install a suitable lifting device to grill assembly (4). Weight of each section of the grill is approximately 25 kg (54 lb).
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Illustration 4 g00897296

RH side
Remove bolts (5) that secure grill assembly (4).
Repeat Step 4 for the opposite side of grill assembly.
Remove grill assembly (4) from the truck.
Repeat the following Steps in order to remove the upper left hand grill: 3, 4, 5 and 6.
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Illustration 5 g00917559

RH radiator
Position a suitable container under the drain port (6) in order to collect the coolant for storage or for disposal. Remove drain plug (7). Drain the coolant from the radiator. The cooling system has a total capacity of approximately 775 L (205 US gal).
After the radiator is completely drained, reinstall the drain plug (7).
Repeat Steps 8 and 9 for the opposite radiator.
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Illustration 6 g00917406
Remove bolts (8) from cover (9) on the expansion tank. Remove the cover.
Repeat Step 11 for the cover on the opposite side of the expansion tank (not shown).
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Illustration 7 g00917412
Disconnect hose assembly (10) from expansion tank (11).
Repeat Step 13 for the opposite side of the expansion tank (not shown).
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Illustration 8 g00917416
Loosen hose clamps (12). Disconnect hoses (13) from the expansion tank.
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Illustration 9 g00917469
Attach Tooling (A) to expansion tank (11), as shown. Attach a suitable lifting device to Tooling (A). Secure the lifting device to a suitable hoist.
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Illustration 10 g00917474
Remove the following items in order to remove the tank and hood assembly: bolts (14), nuts (18), washers (15), mounting (16) and spacers (17).
Repeat Step 17 for the opposite side of the hood assembly.
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Illustration 11 g00917484
Apply slight lift to the expansion tank and hood assembly as a unit. Remove bolts (19) from hood assembly (20).
Remove the expansion tank and hood assembly (20) from the truck. The combined weight of the expansion tank and hood assembly is approximately 227 kg (500 lb).
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Illustration 12 g00897298
Disconnect harness assembly (21) from the lamp. Pull the harness assembly through the hole in the top of cowling (22).
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Illustration 13 g00897300
Remove bolts (23) along the inside of cowling (22).
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Illustration 14 g00897307

LH side
Remove bolts (25) that secure cowling (22) to radiator module (24).
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Illustration 15 g00897308
Install Tooling (B) to the cowling. Attach a suitable lifting device to Tooling (B). Attach the lifting device to a suitable crane. The weight of the cowling and the handrail as a unit (22) is approximately 227 kg (500 lb).
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Illustration 16 g00897309
Remove bolts (26) that secure both cowlings (22) to center radiator support.
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Illustration 17 g00908144
Remove bolts (27) from the right rear of cowling.
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Illustration 18 g00908149
Lift the cowling assembly and handrail assembly (22) from the radiator module (24) as a unit. The weight of the cowling and handrail as a unit is approximately 227 kg (500 lb).
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Illustration 19 g00908219
Loosen hose clamps (28). Remove upper tubes (29) from the radiator.
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Illustration 20 g00908222
Remove top cover (31) of the box by releasing rubber latches (30).
Remove bottom cover (33) of the box. Remove bolts (32) that secure the cover to the radiator module.
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Illustration 21 g00908266
Disconnect hose assemblies (34), (35), and (36). Cap openings with Tooling (ZZ).
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Illustration 22 g00908278
Remove top cover (38) from the fan drive motor. The top cover is secured by rubber latches (40). Disconnect the harness assembly from the switch (not shown).
Disconnect drain hose from bottom cover (39). Remove bolts (37) that secure the bottom cover to the radiator module. Remove the bottom cover (41).
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Illustration 23 g00908308
Secure fan guard (43) to the support bracket (44) with cable straps (42), as shown.
Attach Tooling (B) to support bracket (44).
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Illustration 24 g00908300
Remove bolts (45) and the washers from fan guard (43).
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Illustration 25 g00908303
Disconnect harness assembly (46). Remove hose clips (49) from support bracket (44). Cut cable straps (48) that secure the harness assembly to the support bracket. Disconnect harness assembly (47) from the support bracket.
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Illustration 26 g00908319
Remove bolts (50) that secure water elbows (51). Remove water elbows from the radiator module.
Disconnect hose assembly (51). Cap hose connections with Tooling (ZZ).
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Illustration 27 g00908323
Attach a suitable lifting device to Tooling (B). Attach the lifting device to a suitable hoist.
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Illustration 28 g00908331
Disconnect outer hose assembly (53). Install Tooling (ZZ) in opening in order to prevent system contamination.
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Illustration 29 g00908326
Remove support mounting bolts (54).
Repeat Step 42 for opposite side of support bracket.
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Illustration 30 g00908362
Attach a suitable lifting device to fan drive assembly (55). Attach the lifting device to a suitable hoist. Remove fan drive assembly as a unit from the top of the radiator module, as shown. The weight of the fan drive assembly as a unit is approximately 374 kg (825 lb).