A Procedure to Update the Cooling System on Certain 797F Off-Highway Trucks{1354, 1380} Caterpillar

A Procedure to Update the Cooling System on Certain 797F Off-Highway Trucks{1354, 1380}

Usage:

797F LAJ

Off-Highway Truck/Tractor:: 797F (S/N: LAJ222-223,309-309,325-325,330-330,332-332,375-375,413-413,421-421)

Introduction

The following special instruction will provide the required parts and procedure to update the cooling system on certain 797F Off-Highway Trucks. Do not order any parts or begin service work until the entire special instruction has been read and understood.

Required Parts

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Table 1
Qty	Part Number	Description
2	178-3072	Boss
1	7X-0750	Weld Boss
1	452-6600	Expansion Tank As
1	1W-3601	Gasket
8	8T-4186	Bolt
8	7X-7729	Washer
1	148-8347	Elbow As
1	452-6598	Hose As
2	452-6597	Plate As
2	067-3045	Clip
2	8T-4137	Bolt
10	8T-4121	Hard Washer
1	452-6587	Tube As
1	1P-3705	Rectangular Seal
8	8T-4910	Bolt
18	8T-4223	Hard Washer
1	452-6591	Tube
3	324-2647	Hose
12	8T-4983	Hose Clamp
1	452-6595	Bracket As
4	5P-7468	Clip
4	5P-7469	Clip
4	5P-8444	Grommet
4	8T-4956	Bolt
1	471-1231	Tube As
1	5P-1935	Seal
1	471-1232	Tube
3	132-7370	Hose
12	8T-6703	Hose Clamp
1	452-6614	Bracket As
3	5P-7470	Clip
1	5P-7471	Clip
1	5P-7703	Grommet
1	452-6596	Bracket As
1	366-4672	Connector As
1	262-2951	Strip
1	8T-4192	Bolt
2	8T-4184	Bolt
3	8T-4244	Nut
1	470-1519	Tube
1	470-1520	Tube
1	470-1515	Tube As
2	129-1609	O-Ring Seal
1	217-4195	Hose
4	230-3671	T Bolt Clamp
2	7D-8991	Hose
8	220-4126	Clamp
1	465-0340	Tube As
1	260-9171	Connector As
1	148-8378	Elbow As
2	148-8421	Tee As
1	148-8367	Elbow As
1	452-6618	Hose As
1	452-6617	Hose As
1	6V-9832	Cap As
1	425-1512	Hose As
4	293-4102	Plate
4	8M-2773	Clip
4	8T-4196	Bolt
4	8T-4133	Nut
1	5P-7464	Clip
1	5P-7465	Clip
1	6V-1249	Grommet
1	8T-4139	Bolt

Important Safety Information

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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Personal injury or death can result from fumes, gases, and ultraviolet rays from the weld arc.
Welding can cause fumes, burn skin, and produce ultraviolet rays.
Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both to keep fumes and gases from your breathing area. Wear eye, ear, and body protection before working.
Protect yourself and others by reading and understanding this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.
Read and understand the instructions of the manufacturer and the safety practices of your employer. Do not touch live electrical parts.
See "American National Standard Z49.1, Safety in Welding and Cutting" which is published by the American Welding Society.
American Welding Society
8669 NW 36 Street #130
Miami, Florida 33166-6672
1-800-443-9353

See "OSHA Safety and Health Standards, 29 CFR 1910" which is available from the U.S. Department of Labor.
U.S. Department of Labor
Washington, D.C. 20210

See applicable requirements for your local area.

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Personal injury can result from hot coolant, steam, and alkali.
At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and allow sufficient time for the cooling system to cool.
Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.

Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

Removal Procedure

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Illustration 1	g03870502
Overall view facing forwards

Use a suitable lifting device to remove the 375-4079 Expansion Tank As (A) from the machine. Retain all mounting hardware.
Note: The expansion tank assembly weighs approximately 152 kg (335 lb).

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Illustration 2	g03870542
Rear view facing forwards of the top of the radiator group

Remove 339-3256 Hose As (B), 451-7287 Hose As (C), 473-4592 Hose As (D), and 338-0053 Hose As (E). Retain mounting hardware.

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Illustration 3	g03870574
Rear view facing forwards of the center of the radiator group

Remove 291-2511 Hose As (F), 367-2360 Tube As (G), 367-2361 Tube As (H), 465-0342 Tube As (J), and 465-0344 Tube As (K) .

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Illustration 4	g03870602
Rear view facing forwards of the bottom of the radiator group

Remove tube assembly (L), tube assembly (M), hose (N), and hose (P). Retain mounting hardware.

Installation Procedure

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Table 2
Item	Qty	Part Number	Description
1	2	178-3072	Boss
2	1	7X-0750	Weld Boss
3	1	452-6600	Expansion Tank As
3a	1	1W-3601	Gasket
4	8	8T-4186	Bolt
5	8	7X-7729	Washer
6	1	148-8347	Elbow As
7	1	452-6598	Hose As
8	2	452-6597	Plate As
9	2	067-3045	Clip
10	2	8T-4137	Bolt
11	10	8T-4121	Hard Washer
12	1	452-6587	Tube As
13	1	1P-3705	Rectangular Seal
14	8	8T-4910	Bolt
15	18	8T-4223	Hard Washer
16	1	452-6591	Tube
17	3	324-2647	Hose
18	12	8T-4983	Hose Clamp
19	1	452-6595	Bracket As
20	4	5P-7468	Clip
21	4	5P-7469	Clip
22	4	5P-8444	Grommet
23	4	8T-4956	Bolt
24	1	471-1231	Tube As
25	1	5P-1935	Seal
26	1	471-1232	Tube
27	3	132-7370	Hose
28	12	8T-6703	Hose Clamp
29	1	452-6614	Bracket As
30	3	5P-7470	Clip
31	1	5P-7471	Clip
32	1	5P-7703	Grommet
33	1	452-6596	Bracket As
34	1	366-4672	Connector As
35	1	262-2951	Strip
36	1	8T-4192	Bolt
37	2	8T-4184	Bolt
38	3	8T-4244	Nut
39	1	470-1519	Tube
40	1	470-1520	Tube
41	1	470-1515	Tube As
42	2	129-1609	O-Ring Seal
43	1	217-4195	Hose
44	4	230-3671	T Bolt Clamp
45	2	7D-8991	Hose
46	8	220-4126	Clamp
47	1	465-0340	Tube As
48	1	260-9171	Connector As
49	1	148-8378	Elbow As
50	2	148-8421	Tee As
51	1	148-8367	Elbow As
52	1	452-6618	Hose As
53	1	452-6617	Hose As
54	1	6V-9832	Cap As
55	1	425-1512	Hose As
56	4	293-4102	Plate
57	4	8M-2773	Clip
58	4	8T-4196	Bolt
59	4	8T-4133	Nut
60	1	5P-7464	Clip
61	1	5P-7465	Clip
62	1	6V-1249	Grommet
63	1	8T-4139	Bolt

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Illustration 5	g03870626
Rear view facing forwards of the center of the radiator group (A) 367.9 mm (14.4842 inch) (B) 67 mm (2.68 inch)

Position two bosses (1) and weld in place using a 3 mm (0.12 inch) fillet weld for each.

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Illustration 6	g03870662
Top down view of the top-right of the radiator group and fan guard

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Illustration 7	g03870673
(D) 340 mm (13.4 inch) (E) 310 mm (12.2 inch) (F) 299.5 mm (11.8 inch) (G) Radius of 50 mm (2.0 inch) (H) 170 mm (6.7 inch) (J) 474.5 mm (18.7 inch) (K) Radius of 30 mm (1.18110 inch) (L) 55 mm (2.2 inch) (M) 805.3 mm (31.705 inch) (N) Radius of 25 mm (0.98 inch) (P) 270 mm (10.62990 inch) (R) 1194.5 mm (47.027 inch) (S) 175 mm (6.89 inch) (T) 1369.5 mm (53.917 inch) (U) 249.3 mm (9.8149 inch) (V) 279.3 mm (10.9960 inch) (W) 1454.5 mm (57.2637 inch) (X) Radius of 65 mm (2.56 inch)

Modify 288-1660 Plate (C) as shown in Illustration 7.

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Illustration 8	g03870885
Underside view of the top of the radiator group and fan guards

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Illustration 9	g03871133
(Y) 89.2 mm (3.5 inch) (Z) 28.5 mm (1.12 inch)

Weld boss (2) in place on the underside of the cowling with a 3 mm (0.12 inch) fillet weld.

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Illustration 10	g03871190
Top down view of the top-right of the radiator group

Use a suitable lifting device to install expansion tank assembly (3) using eight bolts (4) and eight hard washers (5). Use one gasket (3a) to install the existing 339-8322 Liquid Level Indicator Gp and hardware.
Note: The expansion tank assembly weighs approximately 152 kg (335 lb).

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Illustration 11	g03871352
Underside view of the expansion tank

Install elbow (6) to the underside of expansion tank assembly (3). Connect hose assembly (7) to elbow (6) and secure to boss (2) with plate assembly (8), one clip (9), one bolt (10), and one hard washer (11) .

Install tube assembly (12) to the underside of expansion tank assembly (3) using one rectangular seal (13), four bolts (14), and four hard washers (15) .

Connect tube (16) to tube assembly (12) using one hose (17) and four hose clamps (18) .
Note: Orient the two pairs of hose clamps (18) 180 degrees apart.

Secure tube (16) in place by installing one bracket assembly (19) to the fan guard with existing mounting hardware, and one clip (20), one clip (21), one grommet (22), one bolt (23), and one hard washer (15) .

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Illustration 12	g03871378
View of the center of the radiator group

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Illustration 13	g03871391
Close up of area "A-A"

Install tube assembly (24) to the underside of the expansion tank assembly (3) using one seal (25), four bolts (14), and four hard washers (15) .

Install tube (26) to tube assembly (24) using one hose (27) and four hose clamps (28) .

Secure tube (26) by installing bracket assembly (29) to the fan guard with existing mounting hardware, one clip (30), one clip (31), one grommet (32), one bolt (23), and one hard washer (15) .

Secure tube (16) by installing bracket assembly (33) to the fan guard with existing mounting hardware, one clip (20), one clip (21), one grommet (22), one bolt (23), and one hard washer (15) .

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Illustration 14	g03871409
Underside view of the expansion tank assembly

Connect hose assembly (7) to the cooling system using connector assembly (34).

Secure hose assembly (7) to tube assembly (24) using one plate assembly (8), one clip (9), one bolt (10), and one hard washer (11) .

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Illustration 15	g03871467
Rear view facing forwards of the center of the radiator group

Install strip (35) to the fan guard using one bolt (36) and one hard washer (15) .

Secure tube (16) and tube (26) to strip (35) using one bolt (37), two hard washers (15), one nut (38), one clip (20), one clip (21), one grommet (22), one clip (30), one clip (31), and one grommet (32) .

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Illustration 16	g03871519
Rear view facing forwards of the bottom of the radiator group

Connect tube (39) to tube (26) using one hose (27) and four hose clamps (28) .
Note: Orient the pairs of clamps 180 degrees apart.

Connect tube (40) to tube (16) using one hose (17) and four hose clamps (18) .
Note: Orient the pairs of clamps 180 degrees apart.

Secure tube (39) and tube (40) using one bolt (37), one hard washer (15), one clip (20), one clip (21), one grommet (22), one clip (30), one clip (31), and one grommet (32) .

Install tube assembly (41) to the radiator using the existing mounting hardware and one O-Ring seal (42). Secure tube assembly (41) to the existing cooling lines using one hose (43) and four T-Bolt clamps (44), and one hose (45) and four clamps (46) .
Note: Orient the pairs of clamps 180 degrees apart.

Install tube assembly (47) to the radiator using the existing mounting hardware and one O-Ring seal (42). Secure tube assembly (47) to the exiting cooling lines using one hose (45) and four clamps (46) .

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Illustration 17	g03872619
Close up view of the bottom of the radiator

Install connector assembly (48) and elbow assembly (49) to tube assembly (41) .

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Illustration 18	g03871799
View from below of the expansion tank

Install two tee assemblies (50) to the underside of the expansion tank.

Connect one elbow assembly (51) to tee assembly (50). Connect hose assembly (52) to elbow assembly (51) .

Connect hose assembly (53) to tee assembly (50) .

Install cap assembly (54) to the other tee assembly (50) .

Connect hose assembly (55) to tee assembly (50) .

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Illustration 19	g03871882
View looking forward towards the top of the radiator group

Install four plates (56) to the fan guard using existing mounting hardware.

Secure hose assembly (52) in four places with four clips (57) attached to the four plates (56) using four washers (5), four bolts (4), eight washers (11), four bolts (58), and four nuts (59) .

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Illustration 20	g03872029
View of the center cross tube

Secure hose assembly (53) to the center tube using existing mounting hardware, clip (60), clip (61), grommet (62), bolt (63), and hard washer (15). Connect hose assembly (53) to the existing cooling system on top of the engine.