794 AC Off-Highway Truck Machine Systems Caterpillar

Disassembly Procedure

Start By:

1. Remove the front service and parking brake

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Illustration 1	g03731377

1. Use Tooling (A) and a suitable lifting device in order to position service and parking brake (1) onto Tooling (B). The weight of service and parking brake (1) is approximately 1581 kg (3486 lb).

2. Remove bolts (2).
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   Illustration 2	g02152464

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   Possible injury can result from spring force released when removing the nuts. Spring force will be released when the nuts and the brake anchor are removed. Loosen the nuts evenly, one turn at a time in order to release the spring force.

3. Loosen nuts (3) by one-half turn at a time until the spring tension has been released.
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   Illustration 3	g03731389

4. Attach Tooling (C) and a suitable lifting device onto to plate (4). The weight of plate (4) is approximately 231 kg (510 lb). Continue Loosening nuts (3) until plate (4) can be removed.

5. Remove plate (4). Remove nuts (3).
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   Illustration 4	g03897802

6. Remove O-ring seal (5). Remove damper assembly (6).
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   Illustration 5	g03897803

7. Remove discs (7) and plates (8).

   Note: Note the order of the discs and plates for installation purposes.

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   Illustration 6	g03897807

8. Remove damper assembly (9).
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   Illustration 7	g02152483

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   Illustration 8	g02152492

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   Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

9. Install Tooling (D) onto piston (10). Tighten Tooling (D) in order to compress the guide springs.

10. Install Tooling (E) into guide (11). Repeat this step for the remaining guides (11).

11. Remove Tooling (D).
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    Illustration 9	g03731450

12. Press down piston (10). Remove pin (12) from guide (11).
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    Illustration 10	g03731396

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    Illustration 11	g02152508

13. Use Tooling (C) and a suitable lifting device in order to remove piston (10). The weight of piston (10) is approximately 98 kg (215 lb).

14. Remove seal rings (13) and seal rings (14) from piston (10).
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    Illustration 12	g02152511

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    Possible injury can result from spring force released when removing the nuts. Spring force will be released when the nuts and the brake anchor are removed. Loosen the nuts evenly, one turn at a time in order to release the spring force.

15. Loosen nuts (15) by one-half turn at a time until the spring tension has been released.
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    Illustration 13	g03731411

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    Illustration 14	g02152532

16. Attach Tooling (C) and a suitable lifting device onto housing (16). Continue loosening nuts (15) until the nuts until housing (16) can be removed. The weight of housing (16) is approximately 57 kg (126 lb).

17. Remove seal rings (17) and seal rings (18) from the housing (16).

18. Remove nuts (15).
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    Illustration 15	g03731416

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    Illustration 16	g02152537

19. Use Tooling (C) and a suitable lifting device in order to remove piston (19). The weight of piston (19) is approximately 121 kg (267 lb).

20. Remove D-ring seal (20) from piston (19).
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    Illustration 17	g03731424

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    Illustration 18	g02152544

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

21. Use Tooling (F) in order to compress guide spring (21). Remove Tooling (E), guide (11), and guide spring (21). Repeat this step for the remaining Tooling (E), guides (11), and guide springs (21).
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    Illustration 19	g02152549

    Note: Note the location of the springs that are marked with an X.

22. Remove inner springs (22) and outer springs (23) from brake anchor (24).
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    Illustration 20	g02152554

23. Remove O-ring seals (25).
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    Illustration 21	g02152558

24. Remove studs (26) and studs (27), if necessary.