- Off-Highway Truck/Tractor
- 797B (S/N: JSM1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
This special instruction shows the procedure to update the water lines on certain 797 and 797B Off-Highway Trucks that have had the C-175 engine retrofit performed.
Safety Section
Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.
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 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. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.
Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.
 |
|
A raised body (bed) may fall unexpectedly and without warning resulting in personal injury or death. When it is necessary to work under the truck with the body (bed) raised, install the body (bed) retaining pins through the pin bores in the frame and the retaining brackets on the body. |
|
|
Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform. |
|
|
Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility. |
|
|
Be sure all personnel are clear of the equipment while the equipment is being lowered. Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury. |
|
|
Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth and level location that is away from working machines and personnel. Ground all implements. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a "Do Not Operate" tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. |
| NOTICE |
|---|
|
Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation. |
| 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. |
| |
| Illustration 1 | g00037860 |
Use steps and handholds whenever you mount the machine. Use steps and handholds whenever you dismount the machine. Before you mount the machine, clean the step and the handholds. Inspect the step and handholds. Make all necessary repairs.
Face the machine whenever you mount the machine and whenever you dismount the machine. Maintain a three-point contact with the step and with handholds.
Note: Three-point contact can be both feet and one hand or a single foot and two hands.
Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount the machine when you carry tools or supplies. Do not try to dismount the machine when you are carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when you enter the cab or when you exit the cab.
Basic Precautions
|
|
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. |
Always observe the list of basic precautions that follows:
Safety Signs
Safety signs include the items that follow: signs, information plates, and decals. Read all “Safety” signs on the machine before operating, lubricating, or repairing the machine. Understand all “Safety” signs on the machine before operating, lubricating, or repairing the machine. Replace any safety signs that are in the conditions that follow: damage, unreadable and missing.
Protective Equipment
When you work around the machine, always wear protective equipment that is required by the job conditions. Protective equipment includes the items that follow: hard hat, protective glasses, and protective shoes. In particular, wear protective glasses when you use a hammer or when you use a sledge hammer. When you weld, use the appropriate protective equipment that is required by the job conditions. Protective equipment for welding includes the items that follow: gloves, welding hood, goggles, and apron. Do not wear loose clothing or jewelry that can catch on parts of the machine.
Mounting and Dismounting
Use steps and handholds when you mount a machine. Also, use steps and handholds when you dismount a machine. Before you mount the machine, clean any mud or debris from steps, walkways, or work platforms. Always face the machine when you use steps, handholds, and walkways. When you cannot use the accesses on the machine, use ladders, scaffolds, or work platforms to perform safe repair operations.
Specifications for Cables, Chains, and Lifting Devices
Use approved cables, chains, and lifting devices to lift components. Refer to the manufacturer's weights to determine the application when you select the following items: cable, chain, and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows to see the effect of the lift angle on the working load limit.
Note: The lifting devices that are shown in this publication are not Caterpillar parts.
Note: Ensure that the hooks are equipped with a safety latch. Do not place a side load on the lifting eyes during a lifting operation.
| |
| Illustration 2 | g00629745 |
|
Lift angles for lifting slings. (A) The load capacity is 100% of the working load limit for the sling. (B) The load capacity is 86% of the working load limit for the sling. (C) The load capacity is 70% of the working load limit for the sling. (D) The load capacity is 50% of the working load limit for the sling. | |
Hot Fluids and Parts
To avoid burns, be alert for hot parts on machines which have been stopped and hot fluids in lines, tubes and compartments.
Be careful when you remove filler caps, breathers, and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed by pressurized liquids. When the machine has been stopped, the danger of hot fluids is greater.
Corrosion Inhibitor
Corrosion inhibitor contains alkali. Avoid contact with the eyes. Do not allow corrosion inhibitor to contact the skin for extended periods of time. Avoid repeated contact with the skin. Do not drink corrosion inhibitor. If there is contact, immediately wash skin with soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.
Batteries
Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not allow battery electrolyte to contact skin or eyes. Battery electrolyte is an acid. If there is contact with battery electrolyte, immediately wash the skin with soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.
Pressurized Items
- Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
- Relieve all pressure in air, oil, or water systems before any lines, fittings, or related items are disconnected or removed. Always make sure that all raised components are blocked correctly. Be alert for possible pressure when you disconnect any device from a system that utilizes pressure.
- Fuel lines that are damaged and fuel lines that are loose can cause fires. Lubrication lines that are damaged and lubrication lines that are loose can cause fires. Hydraulic lines, tubes, and hoses that are damaged can cause fires. Loose hydraulic lines, loose tubes, and loose hoses can cause fires. Do not bend or strike high-pressure lines. Do not install lines which have been bent or damaged. Check lines, tubes, and hoses carefully. Do not use your bare hand to check for leaks. If fluids are injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
- Pressure air or water can cause personal injury. When pressure air or water is used for cleaning, wear a protective face shield, protective clothing, and protective shoes. The maximum air pressure for cleaning purposes must be below
205 kPa (30 psi) . When you use a pressure washer, keep in mind that the nozzle pressures are high. The nozzle pressures are frequently above13790 kPa (2000 psi) . Follow all the recommended practices that are provided by the manufacturer of the pressure washer.
Required Parts
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 2 | Clamp(1) | |
| 2 | 1 | Hose (1) | |
| 3 | 1 | Tube (1) | |
| 4 | 6 | Clamp (1) | |
| 5 | 4 | Bolt (1) | |
| 6 | 24 | Hard Washer (1) | |
| 7 | 4 | Bolt (1) | |
| 8 | 1 | Tube As (1) | |
| 9 | 2 | Hose (1) | |
| 10 | 8 | Clamp (1) | |
| 11 | 2 | O-Ring Seal (1) | |
| 12 | 12 | Bolt (1) | |
| 13 | 1 | O-Ring Seal (1) | |
| 14 | 1 | O-Ring Seal (1) | |
| 15 | 1 | Hose (1) | |
| 16 | 2 | Tube (1) | |
| 17 | 2 | Hose | |
| 18 | 8 | Clamp (1) | |
| 19 | 4 | Clip (1) | |
| 20 | 4 | Clip (1) | |
| 21 | 1 | Tube As (1) | |
| 22 | 4 | Boss (1) | |
| 23 | 4 | Grommet (1) | |
| 24 | 2 | Hose (1) | |
| 25 | 4 | Hose Clamp (1) | |
| (1) | Part of |
Removal Procedure
| |
| Illustration 3 | g06095084 |
|
Location of water lines | |
- Remove and retain fitting (A) and hose (B).
- Remove and retain elbow (C) and hose (D).
Show/hide table
Illustration 5 g06095092 (E) Bolt
(F) Washer
(G) Flange
(H) Hose
(J) Hose
(K) Clamp
(L) Tube
(M) Tube
(N) Clamp
(P) Hose
(R) Clamp - Remove and discard clamps (K), (N), and (R).
- Remove and discard hoses (H), (J), and (P).
- Remove and discard bolts (E) and washers (F).
- Remove and retain flanges (G).
- Remove and discard tubes (L) and (M).
Show/hide table
Illustration 6 g06095106 (S) Clamp
(T) Tube
(U) Bracket
(V) Bolt
(W) Bolt
(X) Hose
(Y) Clamps - Remove and discard bolts (V) and bolts (W)
- Remove and retain brackets (U).
- Remove and discard tube (T), clamps (L) , clamps (Y), and hose (X).
Show/hide table
Illustration 7 g06095481 (Z) Hose
(AA) Clamp
(BB) Nut
(CC) Clamp
(DD) Tube
(EE) Tube
(FF) Hose
(GG) Clamp - Remove and discard clamps (AA), clamps (GG), hose (Z), hose (FF), nuts (BB), clamps (CC), tube (DD), and tube (EE).
Show/hide table
Illustration 8 g06056136 Rear view of radiator - remove bosses - Remove the four current 9R-2821 Bosses from the radiator.
| |
| Illustration 4 | g06095088 |
|
Bottom of cooler (A) Fitting (B) Hose (C) Elbow (D) Hose | |
Installation Procedure
- Weld four 9R-9811 Boss (22) to the rear of the radiator group using a
3 mm (0.12 inch) (W1) fillet weld.Show/hide table
Illustration 10 g06095540 (U) 192-5806 Bracket
(1)226-0087 Clamp
(2)287-3172 Hose
(3)469-8903 Tube
(4)230-3671 Clamp
(5)8T-4139 Bolt
(6)8T-4223 Hard Washer
(7)8T-4192 Bolt - Connect hose (2) to tube assembly (3) with two clamps (4). Connect hose (2) to the existing thermostat tube using two clamps (1).
- Secure tube (3) in two places. In each place secure bracket assembly (U) around tube (3) using four bolts (5) and four hard washers (6). Secure bracket (U) to the frame with two bolts (7) and two hard washers (6).
Show/hide table
Illustration 11 g06095560 (C) Elbow
(D) Hose
(G) Flange
(3)469-8903 Tube
(4)230-3671 Clamp
(8)469-8900 Tube As
(6) Hard Washer
(9)444-9740 Hose
(10)220-4126 Clamp
(11)129-1609 O-Ring Seal
(12) Bolt
(13)3J-1907 O-Ring Seal
(15)217-4195 Hose - Install tube assembly (8) to the engine water pump using one hose (9) and four clamps (10).
- Install tube assembly (8) to the radiator group using one O-Ring seal (11), two flanges (G), four bolts (12), and four hard washers (6).
- Install elbow (C) to the side of tube assembly (8) with one O-Ring seal (13). Install hose (D) to elbow (C).
- Connect tube assembly (8) to tube (3) with hose (15) and four clamps (4).
Show/hide table
Illustration 12 g06095811 (6) 8T-4223 Hard Washer
(8)469-8900 Tube As
(12)8T-4956 Bolt
(16)469-8901 Tube
(17)324-2647 Hose
(18)232-4901 Clamp
(19)5P-7468 Clip
(20)5P-7469 Clip
(23)5P-8444 Grommet
(24)465-1317 Hose
(25)8T-6703 Hose Clamp - Install tube (16) to tube assembly (8) with hose (24) and four clamps (18). Secure tube (16) in place with two clips (19), two clips (20), two grommets (23), two hard washers (6), and two bolts (12).
- Connect hose (17) to the top of tube assembly (16). Use two clamps (25) to secure hose (17) to tube assembly (16) and the existing tube on the top of the cooler.
Show/hide table
Illustration 13 g06095827 (A) Fitting
(B) Hose
(G) Flange
(6)8T-4223 Hard Washer
(9)444-9740 Hose
(10)220-4126 Clamp
(11)129-1609 O-Ring Seal
(12)8T-4956 Bolt
(14)6V-8397 O-Ring Seal
(21)469-8899 Tube As - Install tube assembly (21) to the engine water pump using one hose (9) and four clamps (10).
- Install tube assembly (21) to the radiator group using one O-Ring seal (11), two flanges (G), four bolts (12), and four hard washers (6).
- Install fitting (A) to the side of tube assembly (21) with O-Ring seal (14). Connect hose (B) to fitting (A).
Show/hide table
Illustration 14 g06096197 (6) 8T-4223 Hard Washer
(12)8T-4956 Bolt
(16)469-8901 Tube
(17)324-2647 Hose
(18)232-4901 Clamp
(19)5P-7468 Clip
(20)5P-7469 Clip
(21)469-8899 Tube As
(23)5P-8444 Grommet
(24)465-1317 Hose
(25)8T-6703 Hose Clamp - Install tube (16) to tube assembly (21) with hose (24) and four clamps (18). Secure tube (16) in place with two clips (19), two clips (20), two grommets (23), two hard washers (6), and two bolts (12).
- Connect hose (17) to the top of tube assembly (16). Use two clamps (25) to secure hose (17) to tube assembly (16) and the existing tube on the top of the cooler.
|
|
Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas. |
| NOTICE |
|---|
|
Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components. |
| |
| Illustration 9 | g06095518 |
|
Rear view of radiator - Weld bosses (HH) (JJ) (KK) (LL) (W1) (22) | |
