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Product: TRUCK
Model: 793C TRUCK ATY
Configuration: 793C Off-Highway Truck ATY00001-UP (MACHINE) POWERED BY 3516 Engine

Special Instruction
Procedure to Improve the Fan Spider Assembly on Certain 789C and 793C Off-Highway
Trucks {1356}
Media Number -M0084791-00 Publication Date -25/09/2017 Date Updated -25/09/2017

i07079127

Procedure to Improve the Fan Spider Assembly on Certain

789C and 793C Off-Highway Trucks {1356}
SMCS - 1356

Off-Highway Truck/Tractor
789C (S/N: 2BW1-UP)
793C (S/N: 4AR1-UP; ATY1-UP; 4GZ1-UP)

Introduction
This special instruction contains information to improve the fan spider assembly on the machines
listed above.

Do not perform any procedure in this Special Instruction until you have read the information and you
understand the information.

Safety Section
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 should also have the necessary training,
skills, and tools 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

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could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that
might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all
inclusive. If the tools, or procedure is not recommended by Caterpillar, ensure that the tools and your
actions are safe for everyone.

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

Accidental engine starting can cause injury or death to personnel

working on the equipment.

To avoid accidental engine starting, disconnect the battery cable from

the negative (−) battery terminal. Completely tape all metal surfaces of
the disconnected battery cable end in order to prevent contact with
other metal surfaces which could activate the engine electrical system.

Place a Do Not Operate tag at the Start/Stop switch location to inform

personnel that the equipment is being worked on.

Before service work is begun, park the machine on a hard level surface.
Block the wheels of the machine so unexpected movement will not occur.
Unexpected movement of the machine can cause personal injury or
death.

Installation Procedure for 789C Machines (equipped with

direct drive):
Table 1
Part List
Item Qty Part Number
1 1 471-1020 Adapter
2 12 0T-0573 Bolt

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3 12 5M-2894 Hard Washer

4 1 362-7762 Fan Spider As
5 8 1A-1460 Bolt
6 8 5P-8245 Hard Washer

Illustration 1 g06226003

Illustration 2 g06226018
View of area A
(B) 110-2735 Fan Spider As

1. Remove and save the fan shroud and cooling module to access fan spider assembly (B).
Remove and discard fan spider assembly (B) and associated hardware.

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Illustration 3 g06226019
(C) Fan bracket assembly

2. Ensure that fan bracket assembly (C) is upgraded with three bolt shaft.

Reference: Refer to Service Magazine, M0064410, "A New Fan Drive Mounting Bracket
Group Is Available For Certain 3500 Machine Engines" for more information.

Reference: Refer to Service Magazine, M0064414, "New Fan Drive Components Are Used
For Certain 3500 Machine Engines" for more information.

Reference: Refer to Special Instruction, SEHS0119, "Field Installation Instructions for the 2-
bolt to 3-bolt Fan Drive Upgrade on Certain 3500 Machine Engines" for more information.

Illustration 4 g06226592
(D) Adaptor
(E) Fan belt

3. Remove and discard adapter (D) and associated hardware.

Note: Inspect fan belt (E) and replace if needed.

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Illustration 5 g06226020
(1) 471-1020 Adapter
(2) 0T-0573 Bolt
(3) 2M-2894 Washer

4. Install new adapter (1) using 12 bolts (2) and 12 washers (3) as shown in Illustration 5.

Illustration 6 g06226689
(4) 362-7762 Fan Spider As
(5) 1A-1460 Bolt
(6) 5P-8245 Hard Washer

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5. Install fan spider assembly (4) using eight bolts (5) and eight hard washers (6).

6. Install cooling module and fan shroud that were saved in Step 1.

7. Perform fan clearance inspection. Follow the procedure in Section "Post Installation Checks"
for clearance inspection.

Installation Procedure for 789C Machines (equipped with

clutch drive):
Table 2
Part List
Item Qty Part Number
1 1 174-9366 Spacer
2 1 362-7762 Fan Spider As
3 8 1D-4566 Bolt
4 8 5P-8245 Hard Washer

Illustration 7 g06226012
(F) 110-2735 Fan Spider As

1. Remove and save fan shroud and cooling module to access fan spider assembly (F). Remove
and discard fan spider assembly (F) and associated hardware.

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Illustration 8 g06226322
(G) Fan belt
(H) Spacer
(J) 163-2592 Fan Drive Gp

2. Remove and discard spacer (H) from fan drive group (J). Inspect fan belt (G) and replace if
needed.

Illustration 9 g06226013
(J) 163-2592 Fan Drive Gp

3. Inspect fan drive group (J) for replace and repair.

Note: Replace or repair fan drive group (J) only if needed.

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Illustration 10 g06226014
(J) 163-2592 Fan Drive Gp
(1) 174-9366 Spacer

4. Install spacer (1) onto fan drive group (J) as shown in Illustration 10.

Illustration 11 g06226015
(2) 362-7762 Fan Spider As
(3) 1D-4566 Bolt
(4) 5P-8245 Hard Washer

5. Install fan spider assembly (2) using eight bolts and eight washer (3) as shown in Illustration
11.

6. Install cooling module and fan shroud that were saved in Step 1.

7. Perform fan clearance inspection. Follow the procedure in Section "Post Installation Checks"
for clearance inspection.

Installation Procedure for 793C Machines (equipped with

direct drive):

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Table 3
Part List
Item Qty Part Number
1 1 471-1020 Adapter
2 12 0T-0573 Bolt
3 12 5M-2894 Hard Washer
4 1 184-3225 Spacer
5 1 362-7762 Fan Spider As
6 8 7X-0325 Bolt
7 8 5P-8245 Hard Washer

Illustration 12 g06226027
(K) 110-2735 Fan Spider As

1. Remove and save fan shroud and cooling module to access fan spider assembly (K). Remove
and discard fan spider assembly (K) and associated hardware.

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Illustration 13 g06226028
(L) Fan bracket assembly

2. Ensure that fan bracket assembly (L) is upgraded with three bolt shaft.

Reference: Refer to Service Magazine, M0064410, "A New Fan Drive Mounting Bracket
Group Is Available For Certain 3500 Machine Engines" for more information.

Reference: Refer to Service Magazine, M0064414, "New Fan Drive Components Are Used
For Certain 3500 Machine Engines" for more information.

Reference: Refer to Special Instruction, SEHS0119, "Field Installation Instructions for the 2-
bolt to 3-bolt Fan Drive Upgrade on Certain 3500 Machine Engines" for more information.

Illustration 14 g06226286
(M) Adaptor
(N) Fan belt

3. Remove and discard adapter (M) and associated hardware.

Note: Inspect fan belt (N) and replace if needed.

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Illustration 15 g06226029
(1) 471-1020 Adapter
(2) 0T-0573 Bolt
(3) 5M-2894 Hard Washer

4. Install new adapter (1) using 12 bolts (2) and 12 washers (3). Refer to Illustration 15.

Illustration 16 g06226030
(1) 471-1020 Adapter
(4) 184-3225 Spacer

5. Install spacer (4) onto adapter (1) as shown in Illustration 16.

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Illustration 17 g06226021
(5) 362-7762 Fan Spider As
(6) 7X-0325 Bolt
(7) 5P-8245 Hard Washer

6. Install fan spider assembly (5) using eight bolts (6) and eight hard washers (7).

7. Install cooling module and fan shroud that were saved in Step 1.

8. Perform fan clearance inspection. Follow the procedure in Section "Post Installation Checks"
for clearance inspection.

Installation Procedure for 793C Machines (equipped with

clutch drive):
Table 4
Part List
Item Qty Part Number
1 1 184-3225
2 1 362-7762
3 8 0S-1573
4 8 5P-8245

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Illustration 18 g06226022
(P) 110-2735 Fan Spider As

1. Remove and save fan shroud and cooling module to access the fan spider assembly (P).
Remove and discard fan spider assembly (P) and associated hardware.

Illustration 19 g06226023
(R) 174-9366 Spacer

2. Remove and save spacer (R) as shown in Illustration 19.

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Illustration 20 g06226367
(S) 163-2592 Fan Drive Gp
(T) Fan belt
(U) Compressor belt

3. Inspect fan drive group (S) for replace and repair.

Note: Replace or repair fan drive group (S) only if needed.

4. Inspect fan belt (T) and compressor belt (U) and replace if needed.

Illustration 21 g06226025
(S) 163-2592 Fan Drive Gp
(1) 184-3225 Spacer

5. Install spacer (1) and spacer (R) that was saved in Step 2 onto fan drive (S).

Illustration 22 g06226026
(2) 362-7762 Fan Spider As
(3) 0S-1573 Bolt
(4) 5P-8245 Hard Washer

6. Install fan spider assembly (2) using eight bolts (3) and eight hard washers (4).

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7. Install cooling module and fan shroud that were saved in Step 1.

8. Perform fan clearance inspection. Follow the procedure in Section "Post Installation Checks"
for clearance inspection.

Optional Rework Procedure for 793C Direct Drive and 793C

Clutch Drive
Table 5
Part List
Item Qty Part Number
1 1 439-8301 Stub Shaft
2 1 513-5989 Crankshaft Pulley Gp
3 1 9Y-8467 V-Belt Set

Illustration 23 g06226032
(V) Fan belt
(X) Compressor belt

1. Remove and discard fan belt (V). Remove and save compressor belt (X).

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Illustration 24 g06226033
(Y) Crankshaft pulley group

2. Remove and discard crankshaft pulley group (Y) from the machine. Retain the hardware.

Illustration 25 g06226034
(1) 439-8301 Stub Shaft

Illustration 26 g06226035
(2) 513-5989 Crankshaft Pulley Gp

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3. Install stub shaft (1) and crankshaft pulley group (2) using the hardware that were saved in Step
2.

Illustration 27 g06226547
(1) Compressor belt
(3) 9Y-8467 V-Belt Set

4. Inspect and install compressor belt (X) that was saved in Step 1. Install new fan V-belt set (3)
as shown in Illustration 27.

Post Installation Checks

Use the following steps for conducting post installation clearance to mitigate fan interference:

Illustration 28 g06226425

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(Y) Distance between fan leading edge to center support bar

(Z) Fan
(AA) Center support bar

1. Measure distance (Y) on the radiator. Measure at top and bottom of cooling module.

Note: Minimum allowable clearance (Y) is 20 mm (0.8 inch).

Illustration 29 g06226005
(AA) Fan
(AB) Distance between fan leading edge to center tank block
(AC) Center tank block

2. Measure distance (AB) on radiator at left and right sides of cooling module.

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Illustration 30 g06226008
(AA) Fan
(AD) Guard
(AE) Distance between rear edge of fan blade to inside of finger guard

3. Measure fan-to-finger guard distance (AA) on left, right, top, and bottom of cooling package.

Note: Minimum allowable clearance (AA) is 20 mm (0.8 inch). Shim finger guard (AD) away
from fan as needed.

Note: Ensure correct finger guards (AD) and mounting brackets are installed correctly.

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Illustration 31 g06226009
(AA) Fan
(AG) Distance between tip of fan blade to rubber ring on shroud
(AF) Rubber ring

4. Measure distance (AG) for radial clearance on shroud at eight or more locations along the
diameter of the fan.

Note: Minimum allowable clearance (AG) is 10 mm (0.4 inch). Modify rubber shroud ring
(AF) as needed to meet minimum allowable clearance (AG).

Copyright 1993 - 2017 Caterpillar Inc. Mon Oct 2 13:11:55 EST 2017
All Rights Reserved. r080cl2
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