794 AC Off-Highway Truck Power Train Caterpillar

Removal Procedure

Start By:

1. Remove the blower fan.

2. Remove the drive shaft.

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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.

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Illustration 1	g03796081

1. Remove bolts (1), washers, and lock washers. Remove cover (2). Remove gasket (3). Disconnect harness assemblies (4).
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   Illustration 2	g03796281

2. Remove bolts (5), washers, and nuts to disconnect cable assembly (6). Repeat this step for cable assembly (7) and cable assembly (8).
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   Illustration 3	g03796289

3. Remove bolts (9). Position cover (10), cable assembly (6), cable assembly (7), and cable assembly (8) out of the way. Remove gasket (11).
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   Illustration 4	g03796295

4. Disconnect clip (12), clips (13), and clips (14). Position harness assemblies (4) out of the way.
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   Illustration 5	g03796346

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   Illustration 6	g03796296

5. Remove guard (15) and guard (16).
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   Illustration 7	g03796404

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   Illustration 8	g06304249
   Typical Example

6. Remove cover (17) from the flywheel housing. Install Tooling (B).
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   Illustration 9	g03796352

7. Remove bolts (18) and the washers. Use Tooling (B) to rotate the flywheel and coupler to remove the remaining bolts (18), if necessary.
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   Illustration 10	g03796408

8. Remove bolts (19).
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   Illustration 11	g03797519

9. Attach Tooling (A) and a suitable lifting device onto power generator (20). The weight of power generator (20) is approximately 4130 kg (9105 lb).
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   Illustration 12	g03797534

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   Illustration 13	g03797537

10. Remove mounting bolts (21) and mounting bolts (22).
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    Illustration 14	g03797545

11. Use Tooling (A) and the suitable lifting device to remove power generator (20). The weight of power generator (20) is approximately 4130 kg (9105 lb).

Installation Procedure

1. Install power generator (20) in the reverse order of removal.

   1. Tighten bolts (22) and bolts (21) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).

   2. Tighten bolts (19) to a torque of 100 N·m (74 lb ft).

      Note: Do not use anti-sieze or thread lock on bolts (19).

   3. Test the stator and exciter field winding insulation. Refer to Testing and Adjusting, UENR2267, "Insulation - Test" for the correct procedure.

   4. Perform the rotating rectifier test. Refer to Testing and Adjusting, UENR2267, "Rotating Rectifier - Test" for the correct procedure.

   5. Perform the generator excitation field regulator test. Refer to Testing and Adjusting, UENR2267, "Generator Excitation Field Regulator - Test" for the correct procedure.