797F Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

Illustration 1	g03830079

Illustration 2	g06021639

Illustration 3	g03830195

Illustration 4	g03830198

Illustration 5	g03830204

Illustration 6	g03830227

Installation Procedure

Start By:

1. Install the wheel, brake, and suspension (front)

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 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.

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Illustration 7	g03830296

1. Remove shipping plug assemblies (43). Use Tooling (D) to clean the threads of the mounting holes on the frame.
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   Illustration 8	g03830319

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   Illustration 9	g03866570

2. Clean the mating surfaces of the mounting pads for the ROPS on the frame free of wax, dirt, debris, paint, and grease.Use Tooling (A) to measure the diameter of the dowel bores in the mounting pads for the ROPS. The dowel bores should measure 90.00 ± 0.008 mm (3.54330 ± 0.00031 inch).
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   Illustration 10	g03830323

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   Illustration 11	g03830328

3. Clean the mating surfaces and bores of support assembly (10) and support assembly (13) free of wax, dirt, debris, paint, and grease.

4. Clean two dowels (A) and two dowels (B) free of wax, dirt, debris, paint, and grease.

5. Use Tooling (A) to measure the diameter of two dowels (A) and two dowels (B). The dowels should measure 90.1 ± 0.1 mm (3.55 ± 0.004 inch).
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   Illustration 12	g03830338

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   Illustration 13	g03830378
   (10) 297-9711 Support As (13) 297-9712 Support As

6. Clean the mating surfaces and bores for the cab and walkway of support assembly (10) and support assembly (13) free of wax, dirt, debris, paint, and grease.
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   Illustration 14	g03830549
   (11) 198-4773 Hard Washer (12) 7Y-5265 Bolt (13) 297-9712 Support As

7. Use Tooling (B), Tooling (C). and a suitable lifting device to position support assembly (13) onto the truck frame. Apply Tooling (E) under the heads and on the threads of thirteen bolts (12). Install thirteen hard washers (11) and thirteen bolts (12).
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   Illustration 15	g03830384

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   Illustration 16	g03887308
   (10) 297-9711 Support As (11) 198-4773 Hard Washer (12) 7Y-5265 Bolt

8. Use Tooling (B), Tooling (C), and a suitable lifting device to position support assembly (10) onto the truck frame. Apply Tooling (E) under the heads of sixteen bolts (12). Install sixteen hard washers (11) and sixteen bolts (12). Apply Tooling (E) under the heads and on the threads of four bolts (12). Install four hard washers (11) and four bolts (12).

   Note: Clean the contact surface before installing bolts (12) and washers (11).

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   Illustration 17	g03830708

   Note: Clean the contact surfaces before installing mount assemblies (2) onto support assembly (10) and support assembly (13) free of wax, dirt, debris, paint, and grease.

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   Illustration 18	g06013484

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   Illustration 19	g06061618
   (2) 6Y-9950 Mount As. (2A) 9W-7385 Sleeve (10) 297-9711 Support As (13) 297-9712 Support As

   Note: The cab mounting hardware should always be stored at room temperature prior to assembly.

9. Install eight sleeves (2A) into eight mount assemblies (2). Install four mount assemblies (2) onto support assembly (13) and four mount assemblies (2) onto support assembly (10).

   Note: Install the eight sleeves through the top of the mount assemblies. Push the sleeve down leaving the tips of the sleeve protruding through the top of the mount assembly.

   Note: The sleeve may hold itself up or slip through the mount assembly. Ensure that the sleeve stays up in the mount assembly.

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   Illustration 20	g03830715
   (1) 467-8174 Cab Ar

10. Use a suitable lifting device to begin lowering cab assembly (1), but not completely onto the mount assemblies. The weight of cab assembly (1) is approximately 3470 kg (7650 lb).

    Note: The mount assemblies should not be in contact with the cab now. The top of the sleeve will be in contact with the cab. The cab should be low enough to engage the threads of the bolts when inserted.

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    Illustration 21	g06060619

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    Illustration 22	g06060621

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    Illustration 23	g06013490
    (3) 125-5965 Rebound Pad (4) 9W-7388 Washer (5) 8T-1482 Hard Washer (6) 8T-0672 Bolt (F) Loctite 243

    Note: The cab mounting hardware should always be stored at room temperature prior to assembly.

11. Apply Tooling (F) onto eight bolts (6). Install four pads (3), four washers (4), four hard washers (5), and four bolts (6) for the inner cab mounts. Install four pads (3), four washers (4), four hard washers (5), and four bolts (6) for the outer cab mounts. Tighten eight bolts (6) to a torque of 900 ± 100 N·m (664 ± 74 lb ft)

    Note: The sleeve should be in contact with the cab prior to applying load to prevent pinching of rubber between sleeve and abutment surface during installation.

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    Illustration 24	g03830732

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    Illustration 25	g03830738
    (7) 287-3037 Pin As (7A) 304-0299 Pin As (8) 7X-7729 Washer (9) 8T-4195 Bolt

12. Install two pin assemblies (7), two pin assemblies (7A), four washers (8), and four bolts (9).
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    Illustration 26	g03830750
    (42) 8T-4200 Bolt (43) 5P-4116 Hard Washer (44) 360-4095 Plate As (45) 315-5391 Nut (46) 348-9226 Grommet Assembly

13. Remove eight bolts (42) and eight washers (43). Position panel assembly (44) out of the way. Loosen nut (45) and remove grommet assembly (46). Retain the hardware.
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    Illustration 27	g03830804
    (48) 283-0659 Cable As, 274-4478 Cable As, and 274-4477 Cable As

14. Remove caps (47) from coaxial cable assemblies (48).
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    Illustration 28	g03830814
    (48) 283-0659 Cable As, 274-4478 Cable As, and 274-4477 Cable As (46) 348-9226 Grommet Assembly

15. Install four coaxial cable assemblies (48) through grommet assembly (46).
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    Illustration 29	g03885192

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    Illustration 30	g03830818
    (42) 8T-4200 Bolt (43) 5P-4116 Hard Washer (44) 360-4095 Plate As (45) 315-5391 Nut (46) 348-9226 Grommet Assembly (48) 283-0659 Cable As, 274-4478 Cable As, and 274-4477 Cable As (49) 261-3223 Communication Cable As

16. Install grommet assembly (46) onto panel assembly (44).

17. Connect four coaxial cable assemblies (49) from inside the cab to four coaxial cable assemblies (48).

    1. Connect the four video cables from the cameras to the four video cables from the display. Refer to Table 3.
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       Table 3

       Video Cables to Display	Video Cables to Camera	Cable Color
       1	Front	Red
       2	Right	Blue
       3	Rear	Green
       4	Left	Yellow

18. Secure the harnesses in the electronics bay using a 3S-2093 Cable Strap.

19. Position panel assembly (44) onto the cab. Install eight washers (43) and eight bolts (42). Remove any slack from the coaxial cable assemblies and tighten nut (45) to a torque of 20 ± 2 N·m (177 ± 18 lb in).
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    Illustration 31	g03887333
    (52) (D) 338-0039 Hose As (52) (E) 338-0035 Hose As (53) (F) Hose assembly with a 1V-1122 Identification Tag "SPL" (53) (G) Hose assembly with a 1V-1123 Identification Tag "RET"

20. Remove two plug assemblies (50) from two hose assemblies (52). Remove two caps (51) from two hoses (53).
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    Illustration 32	g03882161
    (52) (D) 432-6101 Hose As (52) (E) 362-8334 Hose As (53) (F) Hose assembly with a 136-1953 Identification Tag "SPL" (53) (G) Hose assembly with a 136-1953 Identification Tag "RET"

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    NOTICE
    Open the heater valves that are located on the engine after the installation of the heater hoses to the cab.

    Note: Each hose assembly has an identification tag.

    Note: Cutting the hoses to the proper length before installation may be necessary.

21. Connect two hose assemblies (52) and two hoses (53).

22. Tighten hose assembly (52) indicated with a (D) to a torque of 62 ± 1 N·m (550 ± 9 lb in).

23. Tighten hose assembly (52) indicated with an (E) to a torque of 49 ± 1 N·m (433 ± 9 lb in).

24. Tighten two band clamps (53A) to a torque of 4.5 ± 0.5 N·m (40 ± 4.5 lb in).
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    Illustration 33	g03831019
    (14) 8T-4121 Hard Washer (15) 8T-4137 Bolt (16) 470-8496 Bracket As (17) 470-8497 Bracket As

25. Install one bracket assembly (16), one bracket assembly (17), four hard washers (14), and four bolts (15).
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    Illustration 34	g03882165
    (54A) 8T-4179 Bolt (54B) 8T-4223 Hard Washer

26. Remove one bolt (54A) and one washer (54B). Retain the hardware.
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    Illustration 35	g03831040

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    Illustration 36	g03882183

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    Illustration 37	g03830983
    Section A-A (14) 8T-4121 Hard Washer (30) 6V-1249 Grommet (31) 7V-6571 Grommet (32) 8T-1890 Clip (33) 302-3908 Spacer (34) 8T-4198 Bolt (35) 8T-4178 Bolt (36) 8T-1889 Clip (37) 204-8000 Cable Tie Mounting (48) 283-0659 Cable As, 274-4478 Cable As, and 274-4477 Cable As (54) 365-7641 Cable As (54A) 8T-4179 Bolt (54B) 8T-4223 Hard Washer

27. Connect cable assembly (54) using one washer (54B) and one bolt (54A).

28. Install two spacers (33), one grommet (31), one clip (32), one clip (36), one grommet (30), one mount (37), one cable strap (29), one hard washer (14), and one bolt (34) to secure cable assembly (54) and coaxial cable assemblies (48).
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    Illustration 38	g03831040

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    Illustration 39	g03830865
    Section B-B (14) 8T-4121 Hard Washer (29) 204-2281 Cable Strap (30) 6V-1249 Grommet (31) 7V-6571 Grommet (32) 8T-1890 Clip (35) 8T-4178 Bolt (36) 8T-1889 Clip (37) 204-8000 Cable Tie Mounting (38) 091-9035 Spacer (39) 9X-8250 Clip (40) 133-6934 Spacer (48) 283-0659 Cable As, 274-4478 Cable As, and 274-4477 Cable As (54) 365-7641 Cable As

29. Install one spacer (40), two clips (39), one grommet (31), one clip (36), one clip (32), one spacer (38), one mount (37), one grommet (30), one cable strap (29), one hard washer (14), and one bolt (35) to secure cable assembly (54) and coaxial cable assemblies (48).

    Note: Before tightening the hardware, remove the slack from the harness assemblies and provide adequate strain relief.

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    Illustration 40	g03831143

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    Illustration 41	g03831059

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    Illustration 42	g03831088
    (56) 481-9781 Chassis Harness As (57) 465-9465 Engine Harness As (58) 278-7735 Chassis Harness As (59) 469-0008 Chassis Harness As

30. Remove five protective covers (55) from harness assemblies (56), (57), (58), and (59).

31. Connect harness assembly (56) and harness assembly (57).

32. Connect harness assembly (58) and harness assembly (59).
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    Illustration 43	g03831093

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    Illustration 44	g03831101
    Section C-C (14) 8T-4121 Hard Washer (18) 5P-7468 Clip (20) 5P-7469 Clip (21) 344-5675 Nut (22) 231-0336 Taperlock Stud (23) 424-2373 Plate (24) 424-2335 Block (25) 424-2322 Block (26) 424-2315 Block (27) 424-2331 Block (28) 424-2342 Block

33. Install four taper lock studs (22), two blocks (24), two blocks (25), two blocks (26), two blocks (27), two blocks (28), four plates (23), two clips (18), two clips (20), two grommets (19), four hard washers (14), and four nuts (21).

    Note: Before tightening the hardware, remove the slack from the harness assemblies and provide adequate strain relief.

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    Illustration 45	g03831107
    (14) 8T-4121 Hard Washer (15) 8T-4137 Bolt (41) 361-6723 Cover

    Note: All the connectors and adjacent wires for the harness assemblies should be free of paint, dirt, debris, or grease.

34. Install cover (41). Install eight hard washers (14) and eight bolts (15).
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    Illustration 46	g03831118

35. Remove cap assemblies (60).
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    Illustration 47	g03831147
    Brake Lines (62) (A) 345-7985 Hose As with 4J-6303 Identification Tag "3" (62) (B) 345-7986 Hose As with 4J-6302 Identification Tag "2" (62) (C) 336-8850 Hose As with 4J-6301 Identification Tag "1"

36. Remove three plug assemblies (61) from three hose assemblies (62).
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    Illustration 48	g03882208
    Brake Lines (62) (A) 345-7985 Hose As with 4J-6303 Identification Tag "3" (62) (B) 345-7986 Hose As with 4J-6302 Identification Tag "2" (62) (C) 336-8850 Hose As with 4J-6301 Identification Tag "1"

37. Connect three hose assemblies (62).

    Note: Use the identification tags that are on the hoses in order to connect the hoses to the cab.

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    Illustration 49	g03831123
    Steering Lines (64) (A) 484-2125 Hose As with 8R-4853 Identification Tag "P" (64) (B) 345-7981 Hose As with 1V-6274 Identification Tag "R" (64) (C) 345-7982 Hose As with 4J-6311 Identification Tag "11" (64) (D) 345-7980 Hose As with 1V-6276 Identification Tag "T" (64) (E) 335-6127 Hose As with 1V-6277 Identification Tag "L"

38. Remove five plug assemblies (63) from five hose assemblies (64).
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    Illustration 50	g03882209
    Steering Lines (64) (A) 484-2125 Hose As with 8R-4853 Identification Tag "P" (64) (B) 345-7981 Hose As with 1V-6274 Identification Tag "R" (64) (C) 345-7982 Hose As with 4J-6311 Identification Tag "11" (64) (D) 345-7980 Hose As with 1V-6276 Identification Tag "T" (64) (E) 335-6127 Hose As with 1V-6277 Identification Tag "L"

39. Connect five hose assemblies (64).

    Note: Use the identification tags that are on the hoses in order to connect the hoses to the cab.

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    Illustration 51	g03882196

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    Illustration 52	g03882197
    (65) 8T-4179 Bolt (66) 8T-4223 Hard Washer (67) 149-4993 Ground Strap

40. Remove one bolt (65) and one washer (66). Retain the hardware.

41. Position the cab ground strap (67). Install one washer (66) and one bolt (65).