794 AC Off-Highway Truck Power Train Caterpillar

Coupler Adapter and Mounting - Remove and Install

Usage:

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	422-5474	Lifting Eye Assembly	1
B	154-6181	Forcing Screw	2
C	-	Loctite 263	-
D	-	Loctite LB 8632 Silicone Lubricant ⁽¹⁾	-
	-	Loctite LB 8104 Silicone Lubricant ⁽²⁾	-
	-	Loctite LB 8801 Silicone Lubricant ⁽³⁾	-
	-	Loctite LB Superlube ⁽⁴⁾	-
E	-	Loctite C5-A Copper Anti-Seize Lubricant	-

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⁽¹⁾	North America
⁽²⁾	EAME
⁽³⁾	Asia Pacific Division
⁽⁴⁾	South America

Start By:

Remove the power generator.

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Illustration 1	g03796807

Attach Tooling (A) and a suitable lifting device onto coupler assembly (1). The weight of coupler assembly (1) is approximately 209 kg (461 lb).
Remove bolt (2) and plate (3).
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Illustration 2 g03796824
Remove O-ring seal (4).
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Illustration 3 g03796826
Use Tooling (A) and the suitable lifting device to remove coupler assembly (1). The weight of coupler assembly (1) is approximately 209 kg (461 lb).
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Illustration 4 g03796856
Position coupler assembly (1) onto a suitable work bench.
Remove bolts (5) and bolts (6). Remove cover (7) from housing (8).
Note: The bolts (5) and bolts (6) are not serviceable if removed.
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Illustration 5 g03796867
Remove element set (9).
Note: The rubber blocks of element set (9) are serviced only as a complete set.
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Illustration 6 g03796870
Use a suitable lifting device to remove star hub (10) and drive hub (11) as a unit from housing (8). The weight of star hub (10) and drive hub (11) is approximately 77 kg (170 lb).
The weight of housing (8) is approximately 82 kg (180 lb).
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Illustration 7 g03797271

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Illustration 8 g03797276
Remove bolts (12). Use Tooling (B) to separate star hub (10) from drive hub (11).

Note: Before and after installing the coupler adaptor, check the engine crankshaft end play. Refer to Specifications, KENR9187, "C175-16 Engine for 795F Series AC Off-Highway Trucks", Crankshaft -Type 1 and Crankshaft - Type 2 for specific values.

Note: Before installing the coupler adapter, inspect the rubber blocks. Refer to Reuse And Salvage Guidelines, SEBF9338, "Inspection of Rubber Blocks for 793F AC, 794 AC, 795F AC, and MT4400D AC Off-Highway Trucks" and Disassembly and Assembly, KENR8715, Coupler Adapter and Mounting - Disassemble and Coupler Adapter and Mounting - Assemble.

Note: Prior to the drive shaft installation, make sure that the coupler adapter yoke and the power generator yoke are aligned with each other.

Install coupler assembly (1) in the reverse order of removal.
1. Prior to installation, apply Tooling (E) onto the splines of the generator rotor and the drive hub. Also apply Tooling (E) to the generator side contact surface of the drive hub
2. Tighten bolts (12) to a torque of 620 ± 80 Nm (457 ± 59 lb ft).
3. Lubricate all flanges of star hub (10) with Tooling (D) prior to assembly.
4. Tighten bolts (6) to a torque of 50 ± 5 Nm (37± 4 lb ft).
5. Tighten bolts (5) to a torque of 395 ± 35 Nm (291 ± 26 lb ft).
6. Apply Tooling (C) to the threads of bolt (2). Tighten bolt (2) to a torque of 520 ± 70 Nm (384 ± 52 lb ft).