New Installation Procedure for Inlet Screen and Outlet Screen of the Electric Retarder Group for 795F Series AC Off-Highway Truck/Tractor{425R} Caterpillar

Off-Highway Truck/Tractor:

795F Series AC (S/N: ERM151-160)

Introduction

The special instruction will guide the user with new installation procedure for electric retarder group screens. This new installation procedure provides guidance to replace the inlet screen and outlet screen for the electric retarder group with certain lifting strategy.

The new inlet screen and new outlet screen has two holes of 25.4 mm (1.00 inch) that are located closer to the top of the electric retarder group. The service technician needs to drill two holes of 19.05 mm (0.750 inch) in inlet screen side of the grid frame and two holes of 19.05 mm (0.750 inch) in outlet screen side of the grid frame. The location of the four holes is used to lift the electric retarder group with shorter chains without any damage to the electric retarder group.

The new installation procedure applies to the original electric retarder group installed on 795F Series AC (S/N: ERM151-160) trucks only. If the entire electric retarder group needs to be replaced, then the new electric retarder group will have these provisions in place.

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Required Parts

Installation Procedure for the Screens of the Electric Retarder Group

Installation Procedure for the 336-1044 Screen (OUTLET)

Illustration 1	g02295293
The figure shows that the electric retarder group with the outlet screen in place.

1. Remove the four bolts (2) and save the bolts for installation. Install the four 9U-6238 Guide Bolts in the location of bolts (2) .

   Note: The Step 1 procedure should be done before any other bolts are removed in order to avoid the grid elements from falling inside of the support frame.

2. Remove the remaining hardware mounted in the grid frame. Save the bolts and the mounting hardware.

3. Remove and discard the outlet screen (1) .

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Illustration 2	g02295554

4. Install the four retaining bolts and tighten the four retaining bolts in the holes (3). Use the bolts that were saved in Step 2. Place the new outlet screen on the guide bolts. Refer to the Illustration 4 of the electric retarder group with the new outlet screen in place.

   Note: The new outlet screen has been drilled to fit around the retaining bolts. The retaining bolts will not be able to tightened once the new outlet screen has been installed. The retaining bolts are not used to retain the new outlet screen to the electric retarder group.

5. Install the remaining hardware that were saved in Step 2.

6. Remove the guide bolts and install bolts (2) that were saved in Step 1.

7. Mark the center of the holes in the new outlet screen and center punch the pilot holes. Remove the new outlet screen. Refer to Title ""Drilling Procedure for the Grid Frame of the Electric Retarder Group" " in this manual to drill the holes on the grid frame.

Installation Procedure for the 325-7947 Inlet Screen

Illustration 3	g02295715

1. Remove two bolts (6) and save the bolts. Install the 9U-6238 Guide Bolts in the location of bolts (6) .

2. Remove the remaining hardware for the inlet screen (4) and save the bolts that are removed.

3. Remove and discard the inlet screen (4) .

4. Install the bolts and tighten the bolts in the holes (5). Use the bolts that were saved in Step 2.

   Note: The new inlet screen has been drilled to fit around the retaining bolts. The retaining bolts will not be able to tightened once the new inlet screen has been installed. The retaining bolts are not used to retain the new inlet screen to the electric retarder group.

5. Install a new inlet screen. Refer to the Illustration 5 of the electric retarder group with the new inlet screen in place.

6. Install the remaining hardware that were saved in Step 2.

7. Remove the guide bolts and install two bolts (6) that were saved in Step 1.

8. Mark the center of the holes in the new inlet screen and center punch the pilot holes. Remove the new inlet screen. Refer to Title ""Drilling Procedure for the Grid Frame of the Electric Retarder Group" " in this manual to drill the holes on the grid frame.

Drilling Procedure for the Grid Frame of the Electric Retarder Group

Illustration 4	g02295893
Location of the lifting point holes in the new outlet screen

Illustration 5	g02295713
Location of the lifting point holes in the new inlet screen

Perform the following procedure with the new outlet screen (8) and the new inlet screen (10) in place:

1. Use the center punch to mark the center of the holes on the grid frame in the below mentioned locations:

   1. Mark the center of the holes (7) in the outlet screen.

   2. Mark the center of the holes (9) in the inlet screen.

2. Drill the pilot holes first, and drill the holes to 19.05 mm (0.750 inch) in the grid frame.

3. Use the four 189-0408 Shackle As in order to hoist the grid frame of the electric retarder group.

Note: The diameter of the shackle assembly pin is 15.875 mm (0.6250 inch). The shackle assembly pins are used to avoid the damage in the screens when the grid frame of electric retarder group is lifted.