797F Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

Illustration 1	g03827831

Illustration 2	g06211968

Illustration 3	g03827848

Illustration 4	g03829904

Illustration 5	g03829564

Note: Verify that all parts are shipped and undamaged for preparation of assembly. Missing or damaged parts can be ordered prior to assembly to avoid delays during assembly.

Installation Procedure

Note: Remove all protective shipping covers, flanges, plugs, caps, clamps, cable straps, and material. Retain the bolts, washers, clamps, flanges, and O-ring seals.

Note: Clean all mounting and contact surfaces free of wax, dirt, debris, paint, and grease. Chase all unprotected threaded holes with an appropriately sized tap.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

Wheel, Brake, and Suspension Cylinder Install

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Illustration 6	g03828176
(1) 430-9719 Front Suspension Gp, 352-0598 Front Suspension Gp, or 289-8629 Front Suspension Gp and 380-6954 Wheel and Brake Gp

1. Clean the mating surfaces and the spot faces of the mounting pads on suspension cylinder, brake, and wheel assembly (1) free of wax, dirt, debris, paint, and grease.
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   Illustration 7	g03828177
   (1) 430-9719 Front Suspension Gp, 352-0598 Front Suspension Gp, or 289-8629 Front Suspension Gp and 380-6954 Wheel and Brake Gp

2. Clean the mating surfaces and the spot faces of the steering arm free of wax, dirt, debris, paint, and grease.
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   Illustration 8	g03828188

3. Remove eight bolts (36), eight washers (37), and two covers (38).
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   Illustration 9	g03828192

4. Clean the mating surfaces and the spot faces of the mounting pads on the frame free of wax, dirt, debris, paint, and grease.

   Note: Clean both sides of the mounting pads.

   Note: Clean the key way free of wax, dirt, debris, paint, and grease.

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   Illustration 10	g03828196
   (2) 156-5444 Key

5. Install key (2).

   Note: Key (2) must be set squarely into the key slot on the frame. Ensure that the holes in the key (2) are aligned with the mounting holes and the frame. Use guide studs to align the holes, if necessary.

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   Illustration 11	g06310073
   (1) 430-9719 Front Suspension Gp, 352-0598 Front Suspension Gp, or 289-8629 Front Suspension Gp and 380-6954 Wheel and Brake Gp (36A) 3E-8029 Bolt (37A) 9X-8399 Washer (38A) 8T-1583 Nut (39) 224-8961 Bolt (40) 146-1799 Washer (41) 8C-4032 Nut

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   NOTICE
   To prevent unintended movement, secure the brake and wheel assembly to the suspension cylinder assembly.

6. Use a suitable lifting device to position suspension cylinder , brake, and wheel assembly (1) onto the frame. The weight of suspension cylinder , brake, and wheel assembly (1) is approximately 9153 kg (20180 lb).
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   Do not leave the controls unattended while a load is suspended. No person shall be permitted to stand or pass under a suspended load or work tool. A suspended load or work tool may fall causing injury or death.

7. Temporarily install two bolts (36A), four washers (37A), and two nuts (38A) on each side of the suspension cylinder. Temporarily install two bolts (39), four washers (40), and two nuts (41) on each side of the suspension cylinder.

8. Use the following procedure to install the special nut assemblies, bolts, studs, and washers.

   Note: To maintain the clamping load, replace the bolts, washers, and nuts one at a time.

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   Illustration 12	g06021896
   Right-Hand Side View from the front

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   Illustration 13	g06021906
   Right-Hand Side View from the rear (3) 3E-8029 Bolt (4) 217-9902 Washer (5) 434-9585 Nut As. (6) 224-8961 Bolt (7) 217-9903 Washer (8) 434-9584 Nut As. (9) 434-9582 Special Nut (10) 434-9581 Stud (11) 434-9583 Special Nut

   Note: On the left-hand side of the machine, the top two bolts may be assembled with bolt heads facing toward the outside of the machine.

   1. Clean the mating surfaces for the mounting hardware on the back side of the frame mounting pads. Clean the front side of the suspension cylinder mounting pads.

      Note: Prior to installation of the special nut assemblies, ensure that all jack-bolts are flush or recessed with the bottom face of the nut assembly body.

   2. Apply Tooling (A) to the contact surfaces of washers, special nuts, bolts, and studs.
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      Illustration 14	g06360136
      (B) Washer (3) 3E-8029 Bolt (4) 217-9902 Washer (5) 434-9585 Nut As.

   3. Install eight bolts (3), eight washers (4), and eight special nut assemblies (5), one at a time. As each special nut is installed, back off each one by half a turn to provide a gap between the nut body and the washer.
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      Illustration 15	g06360139
      (B) Washer (6) 224-8961 Bolt (7) 217-9903 Washer (8) 434-9584 Nut As.

   4. Install six bolts (6), six washers (7), and six special nut assemblies (8), one at a time. As each special nut is installed, back off each one by half a turn to provide a gap between the nut body and the washer.
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      Illustration 16	g06360129
      (A) Washer (B) Washer (9) 434-9582 Special Nut (10) 434-9581 Stud (11) 434-9583 Special Nut

   5. Install six studs (10), six special nuts (9), and six special nut assemblies (11), one at a time. As each special nut is installed, back off each one by half a turn to provide a gap between the nut body and the washer.
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   Illustration 17	g06359587

9. For proper thread engagement of special nuts and studs provide 8 ± 2 mm (0.31 ± 0.079 inch) MAX of thread extension.

10. Tightening Sequence
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    Illustration 18	g03736470

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    Illustration 19	g03736931

    1. Use Tooling (F) to perform the following tightening sequence.

    2. Start at the top of the lower flange. Torque the four jack-bolts located at 12:00, 6:00, 2:40 and 8:40 to 38 N·m (28 lb ft) in locations E-K and R-W.

    3. Move to the upper flange. Torque the four jack-bolts located at 12:00, 6:00, 3:00 and 9:00 to 34 N·m (25 lb ft) in locations A-D and L-P.

    4. Move to the lower flange. Torque the four jack-bolts located at 12:00, 6:00, 2:40 and 8:40 to 76 N·m (56 lb ft) in locations E-K and R-W.

    5. Move to the upper flange. Torque the four jack-bolts located at 12:00, 6:00, 3:00 and 9:00 to 68 N·m (50 lb ft) in locations A-D and L-P.

    6. Move to the lower flange. Torque all jack-bolts in a circular pattern to 76 N·m (56 lb ft) in locations E-K and R-W.

    7. Move to the upper flange. Torque all jack-bolts in a circular pattern to 68 N·m (50 lb ft) in locations A-D and L-P.

    8. Repeat Step 10.f and Step 10.g until all jack-bolts rotate less than 10 degrees.

       Note: If using air tools, switch to a torque wrench for the final pass.

    9. Set torque wrench to 68 N·m (50 lb ft). Torque all jack-bolts in a circular pattern in locations A-D and L-P.

    10. Set torque wrench to 76 N·m (56 lb ft). Torque all jack-bolts in a circular pattern in locations E-K and R-W.

    11. Set torque wrench to 95 N·m (70 lb ft). Torque all jack-bolts in a circular pattern in locations H-K and U-W.

    12. Install the vinyl protective cap over the special nut assembly and secure the cap using a band clamp.

    13. Check and confirm the torque values at 500 and 1000 machine hours.
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    Illustration 20	g03888081
    (42) 5M-3062 Bolt (43) 8T-4896 Hard Washer (44) 8W-4837 Plate

11. Remove three bolts (42), three washers (43), and one guard (44). Retain the hardware.
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    Illustration 21	g03829213
    (46) 481-9781 Chassis Harness As

12. Remove plug (45) from harness assembly (46).
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    Illustration 22	g03829216
    (46) 481-9781 Chassis Harness As

13. Connect harness assembly (46).
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    Illustration 23	g03829218
    (42) 5M-3062 Bolt (43) 8T-4896 Hard Washer (44) 8W-4837 Plate

14. Install one guard (43), two washers (42), and two bolts (41).
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    Illustration 24	g03829220
    (25) 204-8000 Cable Tie Mounting (26) 204-2281 Cable Strap (33) 4D-6466 Clip (34) 8T-4121 Hard Washer (46) 481-9781 Chassis Harness As

15. Install mount (25), one washer (43), and one bolt (42). Position harness assembly (46) and install one install cable strap (26).

16. After the truck is assembled and the body has been installed, charge the suspension cylinders. Refer to Special Instruction, SEHS9411, "Servicing the Suspension Cylinders for Off-Highway Trucks" for the correct suspension cylinder charging procedure.

Brake Lines Install

Note: Use the following steps to install the 383-8856 Brake Cooling Lines Gp for the right-hand side and left-hand side of the chassis.

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Illustration 25	g03888083
(47) 8T-4184 Bolt (48) 8T-4223 Hard Washer (49) 1P-4584 Half Flange (50) 8T-4140 Bolt (51) 9X-8257 Washer (52) 1P-4585 Half Flange

1. Remove four bolts (47), four washers (48), and two flange halves (49). Retain the hardware.

2. Remove four bolts (50), four washers (51), and two flange halves (52). Retain the hardware.
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   Illustration 26	g03829239

3. Remove two covers (53), and two O-ring seals (54).
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   Illustration 27	g03829247

4. Remove eight bolts (55), eight washers (56), two covers (57), and two O-ring seals (58).

5. Repeat Step 1 through Step 4 for the left-hand side of the truck.

6. Use the following steps to install the suspension cylinder fittings.
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   Illustration 28	g06243825

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   Illustration 29	g06243828
   Left Hand Cylinder (AA) 1K-6853 Pressure Relief Fitting (BB) 5M-6214 Plug (CC) 3B-8489 Grease Fitting

   1. Install two pressure relief valves (AA) and plug (BB).

      Install grease fitting (CC) and plug (BB)

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      Illustration 30	g06244121

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      Illustration 31	g06244124
      Right Hand Cylinder (AA) 1K-6853 Pressure Relief Fitting (BB) 5M-6214 Plug (CC) 3B-8489 Grease Fitting

   2. Install grease fitting (CC) and two plugs (BB).

      Install two pressure relief valves (AA).

7. Use the following steps to install the brake cooling lines onto the right-hand side of the truck.
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   Illustration 32	g03829402
   (14) 8T-0568 O-Ring Seal (15) 6V-8001 O-Ring Seal (16) 1P-4585 Half Flange (17) 8T-4140 Bolt (18) 9X-8257 Washer (19) 487-6923 Hose As (Right-Hand Side) (20) 1P-4584 Half Flange (21) 8T-4184 Bolt (22) 8T-4223 Hard Washer (23) 487-6294 Hose As (Right-Hand Side) (35A) 148-8320 Connector As (59A) 334-8716 Hose As (CC) 3B-8489 Grease Fitting

   1. Install one O-ring seal (15) onto hose assembly (19). Position hose assembly (19) with two flange halves (16) at Location (Y). Install four bolts (17) and four washers (18).

   2. Install one O-ring seal (14) onto hose assembly (23). Position hose assembly (23) with two flange halves (20) at Location (X). Install four bolts (21) and four washers (22).

   3. Install one fitting (35A). Remove and discard grease fitting (CC). Connect grease hose assembly (59A).
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      Illustration 33	g03829421
      (14) 8T-0568 O-Ring Seal (15) 6V-8001 O-Ring Seal (19) 487-6293 Hose As (23) 487-6294 Hose As (47) 8T-4184 Bolt (48) 8T-4223 Hard Washer (49) 1P-4584 Half Flange (50) 8T-4140 Bolt (51) 9X-8257 Washer (52) 1P-4585 Half Flange

   4. Install one O-ring seal (14) onto hose assembly (23). Position hose assembly (23) with two flange halves (49) at Location (X). Install four bolts (47) and four washers (48).

   5. Install one O-ring seal (15) onto hose assembly (19). Position hose assembly (19) with two flange halves (52) at Location (Y). Install four bolts (50) and four washers (51).

8. Use the following steps to install the brake cooling lines onto the left-hand side of the truck.
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   Illustration 34	g03886796
   (14) 8T-0568 O-Ring Seal (15) 6V-8001 O-Ring Seal (16) 1P-4585 Half Flange (17) 8T-4140 Bolt (18) 9X-8257 Washer (19) 487-6296 Hose As (Left-Hand Side) (20) 1P-4584 Half Flange (21) 8T-4184 Bolt (22) 8T-4223 Hard Washer (23) 487-6295 Hose As (Left-Hand Side) (35A) 148-8320 Connector As (59A) 334-8716 Hose As

   1. Install one O-ring seal (15) onto hose assembly (19). Position hose assembly (19) with two flange halves (16) at Location (Y). Install four bolts (17) and four washers (18).

   2. Install one O-ring seal (14) onto hose assembly (23). Position hose assembly (23) with two flange halves (20) at Location (X). Install four bolts (21) and four washers (22).

   3. Install one fitting (35A). Connect grease hose assembly (59A).
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      Illustration 35	g03886801
      (14) 8T-0568 O-Ring Seal (15) 6V-8001 O-Ring Seal (19) 487-6296 Hose As (Left-Hand Side) (23) 487-6295 Hose As (Left-Hand Side) (47) 8T-4184 Bolt (48) 8T-4223 Hard Washer (49) 1P-4584 Half Flange (50) 8T-4140 Bolt (51) 9X-8257 Washer (52) 1P-4585 Half Flange

   4. Install one O-ring seal (14) onto hose assembly (23). Position hose assembly (23) with two flange halves (49) at Location (X). Install four bolts (47) and four washers (48).

   5. Install one O-ring seal (15) onto hose assembly (19). Position hose assembly (19) with two flange halves (52) at Location (Y). Install four bolts (50) and four washers (51).
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   Illustration 36	g03885895

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   Illustration 37	g03886673
   (24) 7K-2828 Clip (BB) 3S-8666 Elbow (60) 334-8995 Hose As

9. Remove one plug (AA) from the front wheel. Install one elbow (BB). Connect breather hose assembly (60) to elbow (BB). Install two clips (24). Remove two plug assemblies (61).
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   Illustration 38	g03829575
   (32) 281-5975 Elbow As

10. Install two elbow assemblies (32).
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    Illustration 39	g03829579
    (62) 344-6665 Hose As (63) 344-6666 Hose As

11. Connect hose assembly (62) marked with an (X) to Location (X). Connect hose assembly (63) marked with an (Y) to Location (Y).
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    Illustration 40	g03829590
    (27) 8T-4184 Bolt (28) 8T-4223 Hard Washer (29) 5P-7464 Clip (30) 6V-7359 Grommet (31) 5P-7465 Clip

12. Install two clips (31), two grommets (30), two clips (29), one washer (27), and one bolt (28).

13. Repeat Step 9 through Step 12 for the left-hand side of the truck.

Steering Cylinder Connect

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Illustration 41	g03829737
(73) 272-3306 Steering Cylinder and Mounting Gp (74) 438-1135 Ball Stud

1. Remove the protective shipping material from the rod end of steering cylinder (73). Clean ball stud (74) of steering cylinder (73) free of wax, dirt, debris, paint, and grease.
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   Illustration 42	g03829745
   (74) 438-1135 Ball Stud (A) Loctite Graphite 50 Anti-Seize Lubricant

2. Apply Tooling (A) onto the taper and threads of ball stud (74).
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   Illustration 43	g03829747
   (73) 272-3306 Steering Cylinder and Mounting Gp (75) 192-5692 Steering Arm

3. Use a suitable lifting device to position the rod end and ball stud of steering cylinder (73) onto steering arm (75).
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   Illustration 44	g03829752
   (76) 438-1138 Ring Retainer (77) 438-1137 Plug As

4. Remove one retaining ring (76) and one plug assembly (77). Retain the hardware.
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   Illustration 45	g06309897
   Outer Nut Assembly

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   Illustration 46	g06309909

5. Ensure that the mating surfaces and spot faces are clean and free of paint. Apply Tooling (A) on the washer faces under all nut assemblies (13) and the threads of all jack bolts (AB). Loosen set screw (AA).

6. Ensure that all jack bolts (AB) are flush or recessed with the bottom face of nut assembly (13).

7. Spin on outer nut assembly (13) by hand until the nut assemblies seat against the washer or bottoms out.

8. Back off the nut assemblies by a half turn but no more than 3/4 a turn to provide a gap between the nut assemblies and the washer.
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   Illustration 47	g06309784
   Inner Nut Assembly

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   Illustration 48	g06309899

9. Ensure that the mating surfaces and spot faces are clean and free of paint. Apply Tooling (A) on the washer faces under all nut assemblies (13A) and the threads of all jack bolts (AB). Loosen set screw (AA).

10. Ensure that all jack bolts (AB) are flush or recessed with the bottom face of nut assembly (13A).

11. Spin on outer nut assembly (13A) by hand until the nut assemblies seat against the washer or bottoms out.

12. Back off the nut assemblies by a half turn but no more than 3/4 a turn to provide a gap between the nut assemblies and the washer.
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    Illustration 49	g06309913
    Typical Example

13. Use Tooling (G) and Tooling (B) to tighten jack bolts (AB).

14. Tighten jack bolts (AB) in a 90 degree pattern to a torque of 60 ± 6 N·m (44 ± 4 lb ft).

15. Again, tighten jack bolts (AB) in a 90 degree pattern to a torque of 118 N.m (87 lb ft).

16. Check and confirm the torque values after 10 to 15 hours of operation and reapply the torque in Step 15, if necessary.
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    Illustration 50	g06309916
    Typical Example

17. Tighten two setscrews (AA) to a torque of 20 N.m (177 lb in).
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    Illustration 51	g06309923
    Typical Example

18. Install two caps (AC) over nut assembly (13) and nut assembly (13A). Secure caps (AC) with hose clamp (AD) as shown in the Illustration above.

19. Repeat Step 1 through Step 18 for the opposite side.
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    Illustration 52	g03829752
    (76) 438-1138 Ring Retainer (77) 438-1137 Plug As

20. Install one plug assembly (77) and one retaining ring (76).

Steering Link Install

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Illustration 53	g03829897
(12) 438-1130 Steering Link Gp (78) 438-1135 Ball Stud (74) 438-1135 Ball Stud (A) Loctite Graphite 50 Anti-Seize Lubricant

1. Clean ball studs (78) of steering link (12) free of wax, dirt, debris, paint, and grease.

2. Apply Tooling (A) onto the taper and threads of ball studs (78).
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   Illustration 54	g03829842
   (12) 438-1130 Steering Link Gp (75) 192-5692 Steering Arm (79) 332-7422 Arm (E) 1U-7505 Hydraulic Jack, 485-8004 Support Stand

3. Use Tooling (E) to install steering link (12) onto center arm (79) and steering arm (75). The weight of steering link (12) is approximately 198 kg (437 lb)
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   Illustration 55	g03829899
   (80) 438-1138 Ring Retainer (81) 438-1137 Plug As

4. Remove retaining ring (80) plug assembly (81). Repeat this step for the opposite end. Retain the hardware.
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   Illustration 56	g06309933

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   Illustration 57	g06309909

5. Ensure that the mating surfaces and spot faces are clean and free of paint. Apply Tooling (A) on the washer faces under nut assembly (13) and jack bolt (AB) threads.

6. Ensure that all jack bolts (AB) are flush or recessed with the bottom face of nut assembly (5).

7. Spin on nut assembly (13) by hand until nut assembly (13) seats against the washer or bottoms out.

8. Back off nut assembly (13) by a half turn but no more than 3/4 a turn to provide a gap between nut assembly (13) and the washer.
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   Illustration 58	g06309913
   Typical Example

9. Use Tooling (G) and Tooling (B) to tighten jack bolts (AB).

10. Tighten jack bolts (AB) in a 90 degree pattern to a torque of 60 ± 6 N·m (44 ± 4 lb ft).

11. Again, tighten jack bolts (AB) in a 90 degree pattern to a torque of 118 N.m (87 lb ft).

12. Check and confirm the torque values after 10 to 15 hours of operation and reapply the torque in Step 11, if necessary.
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    Illustration 59	g06309916
    Typical Example

13. Tighten two setscrews (AA) to a torque of 20 N.m (177 lb in).
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    Illustration 60	g06309923
    Typical Example

14. Install two caps (AC) over nut assembly (13). Secure caps (AC) with hose clamp (AD) as shown in the Illustration above.
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    Illustration 61	g03829899
    (80) 438-1138 Ring Retainer (81) 438-1137 Plug As

15. Install one plug assembly (81) and one retaining ring (80).

16. Repeat Step 4 through Step 15 for the opposite end of the steering link.

Lubrication Lines Connect

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Illustration 62	g03829900

1. Remove two plugs (82).
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   Illustration 63	g03829901
   (35A) 148-8320 Connector As

2. Install two connector assemblies (35A).
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   Illustration 64	g03829902
   (84) 293-7514 Hose As (85) 293-7549 Hose As

3. Remove two plug assemblies (86) from grease hose assembly (84) and grease hose assembly (85).
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   Illustration 65	g03829905

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   Illustration 66	g06309895
   (84) 293-7514 Hose As (85) 293-7549 Hose As

4. Route grease hose assembly (84) marked with an (X) to Location (X). Route grease hose assembly (85) marked with an (Y) to Location (Y). Connect grease hose assembly (84) and grease hose assembly (85).
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   Illustration 67	g03829908
   (33) 4D-6466 Clip (34) 8T-4121 Hard Washer (35) 8T-4137 Bolt

5. Install one clip (33), one washer (34), and one bolt (35).
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   Illustration 68	g03829909

6. Remove plug (87).
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   Illustration 69	g03829910
   (35B) 148-8389 Elbow As

7. Install one connector assembly (35B).
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   Illustration 70	g03829911
   (89) 323-0208 Hose As

8. Remove plug assembly (88) from grease hose assembly (89).
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   Illustration 71	g03829912
   (89) 323-0208 Hose As

9. Connect grease hose assembly (89).

10. Repeat Step 1 through Step 9 for the opposite side of the truck.

Break Wear Indicator Install

1. If equipped with a 291-4032 Brake Wear Indicator Gp, refer to Special Instruction, REHS5084, "Brake Wear Indicators Upgrade and Retrofit Now Available on Certain Off-Highway Trucks"
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   Illustration 72	g03885628

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   Illustration 73	g03885638
   (35C) 348-8324 Brake Wear Indicator As

2. Remove one plug assembly (BB). Install one brake wear indicator group (35C). Refer to Testing and Adjusting, KENR8374, "Installing and Setting the Brake Wear Indicator for the Front Brakes". Repeat this step for the opposite side of the truck.