797F Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

Illustration 1	g03869965

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Illustration 16	g03872193

Note: Verifying 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

Start By:

1. Install the cab

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.

Reference: Special Instruction, REHS1841, "General Welding Procedures".

Mud Deflector - Install

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Illustration 17	g03871689
(78) 8T-4195 Bolt (79) 8T-4222 Plated Washer

1. Remove sixteen bolts (78) and sixteen washers (79). Retain the hardware.
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   Illustration 18	g03871690
   (10) 306-7545 Mud Deflector (78) 8T-4195 Bolt (79) 8T-4222 Plated Washer

2. Position mud deflector (10) onto the platform assembly and install sixteen washers (79) and sixteen bolts (78).

Mirror Install

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Illustration 19	g03837156
(11) 383-8300 Lever (12) 384-7898 Block (13) 311-3272 Tube As (14) 7D-9969 Support (19) 8T-4182 Bolt (20) 8T-4121 Hard Washer (21) 153-4010 Mirror As

1. Position mirror assembly (21) on tube assembly (13). Install two blocks (12), two levers (11), two hard washers (20), and two bolts (19). Install two supports (14).
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   Illustration 20	g03871697
   (15) 8T-6868 Bolt (16) 7X-3391 Hard Washer (17) 479-6069 Mirror Gp (18) 7Y-5262 U-Bolt (20) 8T-4121 Hard Washer (22) 8T-4133 Nut (80) Mirror Subassembly

2. Position mirror subassembly (80) onto the handrail. Install two washers (16) and two bolts (15).

3. Position mirror assembly (17) onto the handrail. Install two U-bolts (18), two hard washers (20), and two nuts (22).
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   Illustration 21	g03837295
   (20) 8T-4121 Hard Washer (22) 8T-4133 Nut (28) 204-2281 Cable Strap (44) 353-2833 Flood Lamp Gp (44A) 353-2835 Mounting Bracket As (44B) 8T-4178 Bolt (44C) 380-8415 Lighting Harness As

4. Install flood lamp group (44), one harness assembly (44C), one bracket assembly (44A), one bolt (44B), one hard washer (20), one nut (22), and four cable straps (28).

Installation of the Cat® Detect Object Detection

Note: The information that is contained in this Special Instruction guides the user in the installation of the Caterpillar Integrated Object Detection System for Off-Highway Trucks.

Note: Do not perform any of the procedures until you have read the information in this publication.

Note: Refer to Operation and Maintenance Manual, SEBU8454, "Cat® Integrated Object Detection System for Off-Highway Trucks" for the orientation of the radar. The radar orientation is critical for the operation of the object detection system.

Note: Do not perform any of the procedures until you have read the information in this publication.

Camera Install

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Illustration 22	g03871699
(30) 336-6684 Camera Gp (81) 3T-0849 Bolt

1. Remove two mounting bolts (81) from camera group (30). Retain the hardware.

   Note: If washers are included with bolts (81), discard the washers.

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   Illustration 23	g03871701
   (29) 9X-8256 Washer (30) 336-6684 Camera Gp (31) 288-4697 Plate As (81) 3T-0849 Bolt

2. Install one camera group (30) onto bracket assembly (31). Install two hard washers (29) and two bolts (81).
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   Illustration 24	g03871705
   (26) 272-6641 Flood Lamp Gp (27) 204-8000 Cable Tie Mounting (31) 288-4697 Plate As (82) Nut (83) 5C-7261 Nut

3. Install one mount (27) and one flood lamp group (26) onto plate assembly (31). Tighten nut (82) to a torque of 9 ± 1 N·m (80 ± 9 lb in). Tighten nut (83) to a torque of 20 N·m (177 lb in) maximum.
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   Illustration 25	g03871706
   (84) 8T-4195 Bolt (85) 8T-4121 Hard Washer

4. Remove eleven bolts (84) and eleven washers (85). Retain the hardware.
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   Illustration 26	g03871708
   (89) 380-8407 Platform Harness As (88) 274-4477 Cable As

5. Remove two receptacle plugs (86) from harness assembly (87). Remove cap (88) from coaxial cable (89).
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   Illustration 27	g03871714
   (84) 8T-4195 Bolt (85) 8T-4121 Hard Washer (90) Camera Subassembly

6. Position camera subassembly (90). Install four washers (85) and four bolts (84).
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   Illustration 28	g03871718
   (26) 272-6641 Flood Lamp Gp (87) 380-8407 Platform Harness As

7. Connect harness assembly (87) to flood lamp group (26).
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   Illustration 29	g03871721
   (28) 204-2281 Cable Strap (30) 336-6684 Camera Gp (91) 274-4477 Cable As

8. Connect coaxial cable (91) to camera group (30). Install two cable straps (28).

Radar Install

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Illustration 30	g03871724
(43) 360-5282 Plate As (84) 8T-4195 Bolt (85) 8T-4121 Hard Washer

1. Position plate assembly (43) and install six hard washers (84) and six bolts (83).
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   Illustration 31	g03871726
   (27) 204-8000 Cable Tie Mounting (40) 8T-4183 Bolt (40A) 8T-4194 Bolt (41) 198-4778 Hard Washer (42) 378-7007 Plate As (84) 8T-4195 Bolt (85) 8T-4121 Hard Washer

2. Position bracket assembly (42) and install three mounts (27), four hard washers (41), two bolts (40), two bolts (40A), one hard washer (85), and one bolt (84).
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   Illustration 32	g03837580
   (25) 8T-4195 Bolt (34) 378-6997 Bracket As (37) 7X-7729 Washer

3. Position bracket assembly (34) and install two hard washers (37) and two bolts (25).
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   Illustration 33	g03837582

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   Illustration 34	g03837583
   (25) 8T-4195 Bolt (32) 347-7917 Object Detection Box Gp (35) 5P-4116 Hard Washer (37) 7X-7729 Washer (38) 265-9596 Hard Washer (39) 380-4489 Plate

4. Position object detection box group (32) and install four hard washers (38), two hard washers (37), one plate (39), and four bolts (25).
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   Illustration 35	g03871735
   (28) 204-2281 Cable Strap (33) 365-1271 Object Detection Sensor Gp (35) 5P-4116 Hard Washer (36) 8T-4189 Bolt (81) 380-8407 Platform Harness As

5. Install one cover (33) four hard washers (35), and four bolts (36). Connect harness assembly (81) and install three cable straps (28).

Payload Monitor Install

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Illustration 36	g03871769
(92) 8T-4136 Bolt (93) 8T-4121 Hard Washer (94) 277-7066 Monitor Harness As

1. Remove six bolts (92) and six washers (93). Retain the hardware. Remove receptacle plug (95) from harness assembly (94).
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   Illustration 37	g03871777
   (63) 220-8650 Payload Monitor Gp (92) 8T-4136 Bolt (93) 8T-4121 Hard Washer

2. Position payload monitor (63) and install six washers (93) and six bolts (92).
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   Illustration 38	g03871779
   (94) 277-7066 Monitor Harness As

3. Connect harness assembly (94).

Air Cleaner Install

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Illustration 39	g03871785
(45) 277-0736 Air Cleaner Gp (95A) 277-7836 Cover As

1. Remove two covers (95A) from air cleaner group (45). Retain the hardware.
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   Illustration 40	g03837773
   (45) 277-0736 Air Cleaner Gp (51) 419-9172 Air Filter Element As (52) 277-7838 Air Filter Element As

2. Install two air filter element assemblies (52) and two air filter element assemblies (51) into air cleaner group (45).
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   Illustration 41	g03872840
   (45) 277-0736 Air Cleaner Gp (95A) 277-7836 Cover As

3. Install two covers (95A) onto air cleaner group (45).
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   Illustration 42	g06013012
   (80) 8T-4193 Bolt (81) 9X-8257 Washer (82) 8T-4132 Nut (83) 338-0106 Brace

4. Remove one bolt (96), two washers (97), and one nut (98) from two brace assemblies (99).
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   Illustration 43	g03837837
   (48) 5N-7834 Clamp As (49) 2M-0879 O-Ring Seal (50) 2W-9069 Precleaner Cup Assembly

5. Install three O-ring seals (49), three clamp assemblies (48), and three precleaner cup assemblies (50).
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   Illustration 44	g03879063
   (60) 445-9370 Plate As (61) 198-4780 Hard Washer (62) 7X-2553 Bolt

6. Install one plate assembly (60), two hard washers (61), and two bolts (62).
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   Illustration 45	g06022088
   (1) 351-3812 Platform Gp, 445-9401 Fender As, 366-9968 Handrail As, 279-9495 Handrail As, 436-6128 Handrail As, 339-8213 Flood Lighting Gp, 279-2592 Monitor Wiring Gp

7. Attach a suitable lifting device onto platform assembly (1). The weight of platform assembly is approximately 2785 kg (6140 lb).
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   Illustration 46	g03871835

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   Illustration 47	g03837783

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   Illustration 48	g03837930
   (1) 351-3812 Platform Gp, 445-9401 Fender As, 366-9968 Handrail As, 279-9495 Handrail As, 436-6128 Handrail As, 339-8213 Flood Lighting Gp, 279-2592 Monitor Wiring Gp (45) 277-0736 Air Cleaner Gp (46) 8T-4139 Bolt (47) 5P-1076 Hard Washer

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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.

8. Position platform assembly (1) on top of air cleaner group (45). Install sixteen hard washers (46) and sixteen bolts (47).
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   Illustration 49	g03882025

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   Illustration 50	g03882023
   Upper Brace (96) 8T-4193 Bolt (97) 9X-8257 Washer (98) 8T-4132 Nut (99) 338-0106 Brace

9. Position one brace assembly (99) and install two washers (97), one bolt (96), and one nut (98).

Platform Install

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Illustration 51	g03836820

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Illustration 52	g03871975

1. Clean the mating surfaces of the platform free of wax, dirt, debris, paint, and grease.
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   Illustration 53	g06021744

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   Illustration 54	g06012702
   (1) 351-3812 Platform Gp, 445-9401 Fender As, 366-9968 Handrail As, 279-9495 Handrail As, 436-6128 Handrail As, 339-8213 Flood Lighting Gp, 279-2592 Monitor Wiring Gp

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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.

2. Use the suitable lifting device to position platform assembly (1) onto the truck frame. The weight of platform assembly 3103 kg (6840 lb).

   Note: Ensure that block (X) contacts the frame. Do not weld block (X) to the frame. Block (X) is used for alignment purposes.

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   Illustration 55	g06021752

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   Illustration 56	g06021755

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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.

   Note: Ensure that the platform is positioned flat, level, and square to the chassis frame.

3. Mark the locations where the supports for the right-hand platform contact the frame. Use the suitable lifting device to remove the platform assembly from the truck frame. Clean any paint, dirt, grease, or debris from the mounting surfaces on the frame.
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   Illustration 57	g06021744

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   Illustration 58	g03872049

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   Illustration 59	g03882032
   Lower Brace (1) 351-3812 Platform Gp, 445-9401 Fender As, 366-9968 Handrail As, 279-9495 Handrail As, 436-6128 Handrail As, 339-8213 Flood Lighting Gp, 279-2592 Monitor Wiring Gp (3) 198-4781 Washers (4) 7X-2563 Bolt (96) 8T-4193 Bolt (97) 9X-8257 Washer (98) 8T-4132 Nut (99) 338-0106 Brace

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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.

4. Use the suitable lifting device to position platform assembly (1) onto the truck frame. The weight of platform assembly 3103 kg (6840 lb). Install four hard washers (4) and four bolts (3).

5. Position one brace assembly (99) and install two washers (97), one bolt (96), and one nut (98).

6. Use the following steps to weld the platform to the chassis.

   Note: Ensure that the platform is positioned flat, level, and square to the chassis frame before performing the welding procedure.

   Note: Ensure that the platform supports align with the marks created in Step 3 and Block (X) is contacting the frame.

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   Illustration 60	g03871747
   (2) 384-7915 Plate As (5) 306-9540 Plate (6) 309-9101 Plate (7) 393-5254 Plate (8) 384-7928 Plate (9) 384-7913 Plate

   1. Clean the outer surface of plate assembly (2), plate (5), plates (6), plate (7), plate (8), and plate (9) free of wax, dirt, debris, paint, and grease.
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      Illustration 61	g03872076
      View of the left side of the right-hand platform

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      Illustration 62	g03838125
      (5) 306-9540 Plate (AA) 45 ± 2 mm (1.77 ± 0.0787 inch)

   2. Position plate (5) between the right-hand platform and the frame according to Dimension (AA).
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      Illustration 63	g03838126
      (5) 306-9540 Plate (W1) 6 mm (0.236 inch) fillet weld

   3. Weld plate (5) to the frame from location (A) to location (B).
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      Illustration 64	g03838127
      (5) 306-9540 Plate (W2) 6 mm (0.236 inch) Fillet weld

   4. Weld plate (5) to the right-hand platform from location (C) to location (D).
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      Illustration 65	g03838129
      View from right-hand side under right-hand platform

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      Illustration 66	g03838128
      Front view (6) 309-9101 Plate (AB) 10 mm (0.394 inch) (Approximate dimension) (AC) 10 ± 2 mm (0.394 ± 0.0787 inch)

   5. Position two plates (6) to the right-hand platform according to Dimension (AB) and Dimension (AC).

      Note: The length of dimension (AB) is an approximate length. The actual length of dimension (AB) can vary.

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      Illustration 67	g03838130
      View of the bottom of the right-hand platform (6) 309-9101 Plate (W3) 6 mm (0.236 inch) Fillet weld

   6. Weld two plates (6) from location (E) to location (F) to the right-hand platform.
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      Illustration 68	g03838131
      (6) 309-9101 Plate (W4) 6 mm (0.236 inch) Fillet weld with 1.5 mm (0.059 inch) Root penetration

   7. Weld two plates (6) from location (G) to location (H) to the frame.
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      Illustration 69	g03838135
      Side view from the top

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      Illustration 70	g03838136
      Side view from the top (W5) 6 mm (0.236 inch) Fillet weld with 1.5 mm (0.059 inch) Root penetration (W6) 6 mm (0.236 inch) Fillet weld with 1.5 mm (0.059 inch) Root penetration

   8. Weld the two support assemblies for the right-hand platform to the frame from location (J) to location (K), and from location (L) to location (M).
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      Illustration 71	g06013121

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      Illustration 72	g03838138
      View of the bottom of the right-hand platform (W7) 10 mm (0.393 inch) Fillet weld

   9. Weld the platform support from location (N) to location (P) to the frame.
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      Illustration 73	g03872027

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      Illustration 74	g03872025
      View of the rear of the right-hand platform (2) 384-7915 Plate As (7) 393-5254 Plate As (8) 384-7928 Plate (9) 384-7913 Plate

   10. Position plate assembly (2), plate (9), plate (7), and plate (8) onto the rear support for the right-hand platform.
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       Illustration 75	g06091020
       View from the right side of the right-hand platform (2) 384-7915 Plate As (7) 393-5254 Plate As (8) 384-7928 Plate (9) 384-7913 Plate (W8) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.059 inch) penetration

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       Illustration 76	g06091026
       View of the top rear of the right-hand platform (2) 384-7915 Plate As (W9) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.059 inch) penetration

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       Illustration 77	g06091029
       View of the rear of the right-hand platform (2) 384-7915 Plate As (9) 384-7913 Plate (8) 384-7928 Plate (W10) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.059 inch) penetration

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       Illustration 78	g06091031
       View of the rear of the right-hand platform (2) 384-7915 Plate As (7) 393-5254 Plate As (8) 384-7928 Plate (W) 8 mm (0.315 inch) Fillet weld with 1.5 mm (0.059 inch) penetration

   11. Weld plate assembly (2), plate (9), plate assembly (7), and plate (8) to the rear support of the right-hand platform.

   12. Paint the affected welding areas.
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   Illustration 79	g06021778
   (101) 380-8407 Platform Harness As (105) 481-9781 Chassis Harness As (103) 274-4477 Cable As (107) 283-0659 Cable As

7. Remove two receptacle plugs (100) from harness assembly (101). Remove one cap (102) from coaxial cable (103).

8. Remove two receptacle plugs (104) from harness assembly (105). Remove one cap (106) from coaxial cable (107).
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   Illustration 80	g06021760
   (101) 380-8407 Platform Harness As (105) 481-9781 Chassis Harness As (103) 274-4477 Cable As (107) 283-0659 Cable As

9. Connect harness assembly (101) to harness assembly (105). Connect coaxial cable (103) to coaxial cable (107).
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   Illustration 81	g03879065
   (20) 8T-4121 Hard Washer (58) 8T-4137 Bolt (59) 444-5220 Plate As

10. Install one plate assembly (59), five hard washers (20), and five bolts (58).

Muffler Install

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Illustration 82	g03872123
(40) 8T-4183 Bolt (66) 8T-4223 Hard Washer (72) 454-0764 Bracket As (75) 384-8690 Bracket As

1. Position one bracket assembly (72) onto one bracket assembly (75) and install four hard washers (66) and four bolts (40).
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   Illustration 83	g03872242

2. Remove two protective shipping covers (108) from the exhaust tubes.
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   Illustration 84	g03872117
   (15) 8T-6868 Bolt (67) 8T-4244 Nut (73) 198-4766 Hard Washer (74) 8T-4910 Bolt (76) 198-4778 Hard Washer (77) 7X-0550 Hard Washer (109) Bracket Subassembly

3. Install bracket subassembly (109) onto the truck chassis and install two hard washers (73), two bolts (74), one hard washer (76), one hard washer (77), one bolt (15) and one nut (67), loosely.

   Note: Do not tighten two bolts (74) or one bolt (15) to a final torque until the muffler inlet, the exhaust tubes, and the bellows are aligned.

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   Illustration 85	g03872230

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   Illustration 86	g03872238
   (53) 225-0947 Bolt (54) 260-6693 Washer (55) 3E-8017 Locknut (56) 399-3271 Bracket (57) 398-6919 Extension Pipe (64) 398-3703 Muffler

4. Install extension pipe (57) onto muffler (64). Install two brackets (56), four hard washers (54), two bolts (53), and two locknuts (55).
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   Illustration 87	g03872243

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   Illustration 88	g03872522
   (64) 398-3703 Muffler (65) 454-0766 Strap As. (68) 452-6619 Muffler Cover (69) 392-6299 Muffler Cover (70) 392-6300 Muffler Cover (71) 452-6620 Muffler Cover

5. Install three strap assemblies (65), one muffler cover (68), one muffler cover (69), one muffler cover (70), and one muffler cover (68) onto muffler (64).

   Note: Locate each of the strap assemblies within the cutout features of the muffler covers.

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   Illustration 89	g03872532
   (110) Muffler Subassembly

6. Use a suitable lifting device to position muffler subassembly (110) onto the right-hand platform. The weight of muffler subassembly (110) is approximately 1043 kg (2300 lb).
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   Illustration 90	g03872545

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   Illustration 91	g03872587
   (20) 8T-4121 Hard Washer (25) 8T-4195 Bolt (66) 8T-4223 Hard Washer (67) 8T-4244 Nut

7. Install three hard washers (66) and three nuts (67). Install six hard washers (20) and six bolts (25), loosely.

   Note: Do not tighten three nuts (67) or six bolts (25) to a final torque until the muffler inlet, the exhaust tubes, and the bellows are aligned.

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   Illustration 92	g03872603
   (111) 8T-4194 Bolt

8. Loosen twelve bolts (111). Use the suitable lifting device to align the muffler inlet with the exhaust tubes on the truck chassis.

   Note: Do not tighten twelve bolts (111) to a final torque until the muffler inlet, the exhaust tubes, and the bellows are aligned.

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   Illustration 93	g03872610
   (53) 225-0947 Bolt (54) 260-6693 Washer (55) 3E-8017 Locknut (77A) 354-4106 Bracket

9. Install four brackets (77A), eight hard washers (54), four bolts (53), and four locknuts (55).

   Note: Do not tighten four bolts (53) to a final torque until the muffler inlet, the exhaust tubes, and the bellows are aligned.

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   Illustration 94	g03872659
   (112) 8T-4172 Bolt (113) 241-8492 Band Clamp (114) 174-7926 Strap

   Note: Do not start the engine until the bellows assemblies have been aligned and the two strap assemblies and the two V- band clamps have been tightened to a final torque.

10. If necessary, loosen four bolts (112) and four V-band clamps (113). Adjust four strap assemblies (114) for optimal lateral and axial alignment of the bellows assemblies using Tooling (A). Refer to Special Instruction, SEHS0323, "Instructions for the Proper Use of the Alignment Tool For the Installation of Exhaust Bellows on Certain 797F Off-Highway Trucks".
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    NOTICE
    Any misalignment in the system can potentially shorten the life of the bellows.

11. Once the bellows, the exhaust tubes, and the muffler inlet tubes are aligned, tighten two V-band clamps (113) to a torque of 16 ± 4 Nm (142 ± 35 lb in). Tap the V-band clamps (22) all around then tighten to 16 ± 4 N·m (140 ± 35 lb in) again. Static inspection torque is a minimum of 9 N·m (80 lb in). Tighten four bolts (112) to a final torque.
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    Illustration 95	g03872770
    (111) 8T-4194 Bolt

12. Tighten twelve bolts (111) to a final torque.
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    Illustration 96	g03872695

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    Illustration 97	g03872749
    (25) 8T-4195 Bolt (67) 8T-4244 Nut

13. Tighten three nuts (67) and six bolts (25) to a final torque.
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    Illustration 98	g03872757
    (15) 8T-6868 Bolt (74) 8T-4910 Bolt

14. Tighten two bolts (74) and one bolt (15) to a final torque.
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    Illustration 99	g03872760
    (53) 225-0947 Bolt

15. Tighten four bolts (53) to a final torque.

Radar and Camera adjustment and calibration

1. After the truck has been assembled and the body has been installed, the camera and radars must be adjusted and calibrated. Refer to Testing and Adjusting, UENR2507, "Cat® Detect Object Detection System", "Object Detection Sensor - Calibrate" and Testing and Adjusting, UENR2507, "Cat® Detect Object Detection System", "Object Detection Sensor - Adjust" or Testing and Adjusting, KENR8668, "Cat® Detect Object Detection System", "Object Detection Sensor - Calibrate" and Testing and Adjusting, KENR8668, "Cat® Detect Object Detection System", "Object Detection Sensor - Adjust"for the correct procedures.