797F Off-Highway Truck Field Assembly Caterpillar


Walkway (Left Hand) - Install

Usage:

797F LAJ
Reference: Special Instruction, "Visual Service Procedures - Colors and Symbols"M0066576

Parts and Specification Information

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.

Table 1
Item  Part Number  Part Description  Qty  Specification  Approximate Weight 
462-7605 Truck Installation Ar 
Walkway As    3165 kg (69780 lb) 
8T-4223  Hard Washer  12     
8T-4194  Bolt  26     
8T-4121  Hard Washer  20     
8T-4195  Bolt  35     
445-9400  Fender As     
306-7555  Mud Deflector     
277-0736  Air Cleaner Gp    200 kg (441 lb) 
8T-4139  Bolt  16     
10  5P-1076  Hard Washer  16     
11  5N-7834  Clamp As     
11A  2M-0879  O-Ring Seal     
12  2W-9069  Precleaner Cup Assembly     
13  419-9172  Air Filter Element As     
14  277-7838  Air Filter Element As     
15  445-9368  Plate As     
16  479-2171  Bolt As     
17  479-2172  Bolt As     
18  505-6225  Plate As     
19  7X-2553  Bolt     
20  198-4780  Hard Washer     
21  8T-6868  Bolt     
22  8T-4223  Hard Washer     
23  7D-9969  Support     
24  311-3276  Tube As     
25  311-7058  Mirror Gp     
26  383-8300  Lever     
27  8T-4182  Bolt     
28  384-7898  Block     
29  8T-5005  Bolt     
30  302-3908  Spacer     
31  8T-4195  Bolt     
32  426-5380  Flood Lamp Gp     
33  204-8000  Cable Tie Mounting     
34  204-2281  Cable Strap  19     
35  9X-8256  Washer     
36  336-6684  Camera Gp     
37  288-4697  Plate As     
38  347-7917  Object Detection Box Gp     
39  372-9143  Plate     
40  378-6997  Bracket As     
41  5P-4116  Hard Washer     
42  8T-4189  Bolt     
43  7X-7729  Washer     
44  265-9596  Hard Washer     
45  380-4489  Plate     
46  8T-4183  Bolt     
47  198-4778  Hard Washer  16     
48  378-7007  Plate As     
49  360-5282  Plate As     
50  8T-4192  Bolt     
51  230-7732  Cable Tie Mounting     
52  204-2281  Cable Strap     
53  353-2835  Mounting Bracket As     
54  8T-4178  Bolt     
55  8T-4133  Nut     
56  380-8415  Lighting Harness As     
57  353-2833  Flood Lamp Gp     
58  291-9266  Catwalk As    92 kg (203 lb) 
59  436-6141  Guardrail As     
60  500-1338  Cover     
61  500-1337  Cover     
62  500-1334  Plate As     
63  8T-4222  Plated Washer  12     
64  479-2171  Bolt As     

Installation Procedure

Start By:

  1. Install the right hand platform


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, PERJ1017, "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.


------ WARNING! ------

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.


------ WARNING! ------

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.


Note: Remove all protective shipping covers, flanges, plugs, caps, clamps, cable straps, and material.

Note: Clean mounting and contact surfaces for major component installation free of wax, dirt, debris, paint, and grease.

Note: If necessary, chase unprotected threaded holes with an appropriately sized tap to remove paint, rust, or other debris.

Note: Unless otherwise specified, all torque requirements are Standard Torque values. Refer to the "General Information" section in this document for the correct torque values.

Note: Before tightening the cable straps (mounting hardware), remove the slack from the harness assembly(s) and allow adequate strain relief.

Fender Install



    Illustration 1g06221294
    (1) Walkway As
    (A) 8T-4195 Bolt
    (B) 8T-4121 Hard Washer

  1. Remove and retain fourteen bolts (A) and fourteen washers (B) from walkway assembly (1).


    Illustration 2g06221296
    (6) 445-9400 Fender As
    (A) 8T-4195 Bolt
    (B) 8T-4121 Hard Washer

  2. Use a suitable lifting device to position fender assembly (6) onto the walkway. Install fourteen washers (B) and fourteen bolts (A).


    Illustration 3g06221299
    (1) Walkway As
    (6) 445-9400 Fender As
    (C) 8T-4195 Bolt
    (D) 8T-4222 Plated Washer

  3. Remove and retain seventeen bolts (C) and seventeen washers (D) from fender assembly (6) and walkway assembly (1).


    Illustration 4g06221300
    (E) 479-2172 Bolt As
    (F) 305-5571 Plate As

  4. Remove and retain four bolt assemblies (E). Reposition plate assembly (F) so that the eight hole pattern is to the outside. Install four bolt assemblies (E).


    Illustration 5g06221301
    (7) 306-7555 Mud Deflector
    (C) 8T-4195 Bolt
    (D) 8T-4222 Plated Washer

  5. Position mud deflector (7) onto the fender assembly and walkway assembly. Install seventeen washers (D) and seventeen bolts (C).


    Illustration 6g06221303
    (G) 479-2171 Bolt As
    (H) 330-4316 Plate

  6. If necessary, remove and retain seven bolt assemblies (G) and one plate (H).

    Note: Removing plate (H) will allow more room to assemble the walkway over the air cleaner.



    Illustration 7g06221305
    (J) 306-7483 Brace

  7. Connect two braces (J).

    Note: Use the hardware that is included with the braces.



    Illustration 8g06221308
    (34) 204-2281 Cable Strap
    (K) 422-6726 Lighting Harness As

  8. Connect one harness assembly (K) and install twelve cable straps (34).

Mirror Install - Ground Level



    Illustration 9g03834922
    (22) 8T-4223 Hard Washer
    (23) 7D-9969 Support
    (24) 311-3276 Tube As
    (25) 311-7058 Mirror Gp
    (26) 383-8300 Lever
    (27) 8T-4182 Bolt
    (28) 384-7898 Block

  1. Position mirror group (25) onto tube assembly (24). Install two blocks (28), two hard washers (22), two bolts (27), and two levers (26). Install three supports (23) onto tube assembly (24).


    Illustration 10g06221312
    (21) 8T-6868 Bolt
    (22) 8T-4223 Hard Washer
    (25) 311-7058 Mirror Gp

  2. Install the mirror group (25) onto the handrail. Install three washers (22) and three bolts (21).


    Illustration 11g06221317
    (34) 204-2281 Cable Strap
    (L) 422-6726 Lighting Harness As

  3. Position harness assembly (L). Install cable strap (34).


    Illustration 12g06357889
    (4) 8T-4121 Hard Washer
    (22) 8T-4223 Hard Washer
    (50) 8T-4192 Bolt
    (51) 230-7732 Cable Tie Mounting
    (52) 204-2281 Cable Strap
    (53) 353-2835 Mounting Bracket As
    (54) 8T-4178 Bolt
    (55) 8T-4133 Nut
    (56) 380-8415 Lighting Harness As
    (57) 426-5380 Flood Lamp Gp

  4. Install one flood lamp group (57), one mounting bracket assembly (53), one bolt (54), one hard washer (4) and one nut (55). Install one harness assembly (56), one mount (50), one hard washer (22), one bolt (51), and six cable straps (52).

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 - Ground Level



    Illustration 13g06221319
    (36) 336-6684 Camera Gp
    (M) 3T-0849 Bolt

  1. Remove two bolts (M) from camera group (36). Retain the hardware.


    Illustration 14g06221321
    (35) 9X-8256 Washer
    (36) 336-6684 Camera Gp
    (37) 288-4697 Plate As
    (M) 3T-0849 Bolt

  2. Install one camera group (36) onto plate assembly (37). Install two hard washers (35) and two bolts (M).


    Illustration 15g06357603
    (32) 426-5380 Flood Lamp Gp
    (33) 204-8000 Cable Tie Mounting
    (37) 288-4697 Plate As
    (N) Nut
    (P) 5C-7261 Nut

  3. Install one mount (33) and one lamp group (32) onto plate assembly (37). Tighten nut (N) to a torque of 9 ± 1 N·m (80 ± 9 lb in). Tighten nut (P) to a torque of 25 ± 7 N·m (221 ± 62 lb in).


    Illustration 16g06357637


    Illustration 17g06357640
    Detail A
    (4) 8T-4121 Hard Washer
    (17) 479-2172 Bolt As
    (32) 426-5380 Flood Lamp Gp
    (29) 8T-5005 Bolt
    (30) 302-3908 Spacer
    (33) 204-8000 Cable Tie Mounting

  4. Position lamp group (32). Install three bolt assemblies (17). Install two cable tie mounts (33), spacer (30), washer (4), and bolt (29).


    Illustration 18g06357651
    (34) 204-2281 Cable Strap
    (32) 336-6684 Camera Gp
    (R) 528-7137 Lighting Harness As
    (S) 283-0657 Cable As

  5. Connect harness assembly (R) to lamp group (32). Install two cable straps (34).

  6. Connect coaxial cable (S) to camera group (32). Install cable strap (34).

Radar Install - Ground Level


NOTICE

The radar boxes contain sensors and lights. Use caution while installing.




    Illustration 19g06357663
    (T) 8T-4195 Bolt
    (V) 8T-4121 Hard Washer

  1. Remove and retain six bolts (T) and six hard washers (V).


    Illustration 20g06357665
    (49) 360-5282 Plate As
    (T) 8T-4195 Bolt
    (V) 8T-4121 Hard Washer

  2. Position plate assembly (49) and install six hard washers (V) and six bolts (T).


    Illustration 21g03835157
    (3) 8T-4194 Bolt
    (33) 204-8000 Cable Tie Mounting
    (46) 8T-4183 Bolt
    (47) 198-4778 Hard Washer
    (48) 378-7007 Plate As

  3. Position plate assembly (48) and install two mounts (33), four hard washers (47), two bolts (3), and two bolts (46).


    Illustration 22g03835159
    (31) 8T-4195 Bolt
    (40) 378-6997 Bracket As
    (43) 7X-7729 Washer

  4. Position bracket assembly (40) and install two hard washers (43) and two bolts (31).


    Illustration 23g03835093


    Illustration 24g03835160
    (31) 8T-4195 Bolt
    (38) 347-7917 Object Detection Box Gp
    (43) 7X-7729 Washer
    (44) 265-9596 Hard Washer
    (45) 380-4489 Plate

  5. Position object detection box group (38) and install four hard washers (44), two hard washers (43), one plate (45), and four bolts (31).


    Illustration 25g06357668
    (33) 204-8000 Cable Tie Mounting
    (34) 204-2281 Cable Strap
    (39) 372-9143 Plate
    (41) 5P-4116 Hard Washer
    (42) 8T-4189 Bolt
    (W) 528-7137 Lighting Harness As
    (X) 479-2171 Bolt As

  6. Install one cover (39), four hard washers (41), and four bolts (42). Install one mount (33) one bolt assembly (X). Connect harness assembly (W) and install three cable straps (34).

Air Cleaner Install



    Illustration 26g06357673
    (8) 277-0736 Air Cleaner Gp
    (Y) 277-7836 Cover As

  1. Remove and retain two covers (Y) from air cleaner group (8).


    Illustration 27g03835338
    (8) 277-0736 Air Cleaner Gp
    (13) 419-9172 Air Filter Element As
    (14) 277-7838 Air Filter Element As

  2. Install two air filter element assemblies (14) and two air filter element assemblies (13) into air cleaner group (8).


    Illustration 28g06357672
    (8) 277-0736 Air Cleaner Gp
    (Y) 277-7836 Cover As

  3. Install two covers (Y) onto air cleaner group (8).


    Illustration 29g06357676
    (AA) 8T-4193 Bolt
    (AB) 9X-8257 Washer
    (AC) 8T-4132 Nut
    (Z) 338-0106 Brace

  4. Remove bolt (AA), two washers (AB), and nut (AC) from two brace assemblies (Z).


    Illustration 30g03835343
    (8) 277-0736 Air Cleaner Gp

  5. Attach a suitable lifting device onto air cleaner group (8). The weight of air cleaner group (8) is approximately 318 kg (700 lb).


    Illustration 31g03835374
    (11) 5N-7834 Clamp As
    (11A) 2M-0879 O-Ring Seal
    (12) 2W-9069 Precleaner Cup Assembly

  6. Install three O-ring seals (11A), three clamp assemblies (11), and three precleaner cup assemblies (12).


    Illustration 32g06357679
    (AD) 8T-9393 Bolt

  7. Remove and keep nine bolts (AD) and the washers.


    Illustration 33g06220589
    (5) 8T-4195 Bolt
    (18) 444-5225 Plate As
    (19) 7X-2553 Bolt
    (20) 198-4780 Hard Washer
    (60) 500-1338 Cover
    (61) 500-1337 Cover
    (62) 500-1334 Plate As
    (63) 8T-4222 Plated Washer
    (64) 479-2171 Bolt As

  8. Install cover (60), cover (61), plate assembly (62), plate assembly (18), two hard washers (20), and two bolts (19), eight bolt assemblies (64), twelve plated washers (63), and twelve bolts (5).


    Illustration 34g06357682
    (AD) 8T-9393 Bolt

  9. Install nine bolts (AD) and the washers.


    Illustration 35g03835390


    Illustration 36g03835488


    Illustration 37g03835491
    (8) 277-0736 Air Cleaner Gp
    (9) 8T-4139 Bolt
    (10) 5P-1076 Hard Washer

    ------ WARNING! ------

    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.


  10. Position air cleaner group (8) onto the truck frame. Install sixteen hard washers (10) and sixteen bolts (9).


    Illustration 38g06357965
    Outer Brace


    Illustration 39g06357685
    Upper bracket
    (AA) 8T-4193 Bolt
    (AB) 9X-8257 Washer
    (AC) 8T-4132 Nut
    (Z) 338-0106 Brace

  11. Position outer brace assembly (Z). Install two hard washers (AB), bolt (AA), and nut (AC).

    Note: Tighten the hardware at both ends of the braces to a final torque.



    Illustration 40g06357687
    Inner Brace
    (AA) 8T-4193 Bolt
    (AB) 9X-8257 Washer
    (AC) 8T-4132 Nut
    (Z) 338-0106 Brace

  12. Position inner brace assembly (Z). Install two hard washers (AB), bolt (AA), and nut (AC).

    Note: Tighten the hardware at both ends of the braces to a final torque.

Walkway Install



    Illustration 41g06357688
    (1) 272-3329 Walkway Gp, 281-6796 Handrail As, 272-3365 Signal Lighting Gp, 323-1360 Plate As, 305-5573 Plate As, 292-5686 Handrail As
    (AE) 9X-2040 Screw
    (AF) 7X-7729 Washer
    (AG) 294-8044 Platform

  1. Remove and keep eight bolts (AE), eight washers (AF), and one plate (AG) from walkway assembly (1).


    Illustration 42g06357691
    (1) 272-3329 Walkway Gp, 281-6796 Handrail As, 272-3365 Signal Lighting Gp, 323-1360 Plate As, 305-5573 Plate As, 292-5686 Handrail As
    (AH) 8T-4186 Bolt
    (AJ) 8T-4121 Hard Washer
    (AK) 8T-4136 Bolt
    (AL) 8T-4121 Hard Washer
    (AM) 8T-4133 Nut

  2. Remove and keep six bolts (AH), six hard washers (AJ), two bolts (AK), four hard washers (AL), and two nuts (AM) from walkway assembly (1).


    Illustration 43g06021456


    Illustration 44g03836061
    (1) Walkway As
    (2) 8T-4223 Hard Washer
    (3) 8T-4194 Bolt

    ------ WARNING! ------

    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.


  3. Use a suitable lifting device to position walkway assembly (1) onto the truck frame. The weight of walkway assembly (1) is approximately 1633 kg (3600 lb).

  4. Install twelve hard washers (2) and twelve bolts (3).


    Illustration 45g03836062
    (4) 8T-4121 Hard Washer
    (5) 8T-4195 Bolt

    ------ WARNING! ------

    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.


  5. Install eighteen hard washers (4) and eighteen bolts (5).


    Illustration 46g06221656
    (15) 445-9368 Plate As
    (16) 479-2171 Bolt As

  6. Install one plate assembly (15), and seven bolt assemblies (16).


    Illustration 47g06357701
    Front Catwalk
    (1) Walkway As
    (AE) 9X-2040 Screw
    (AF) 7X-7729 Washer
    (AG) 294-8044 Platform

  7. Install platform (AG), eight washers (AF), and eight screws (AE).


    Illustration 48g06357694
    Rear Catwalk
    (58) 291-9266 Catwalk As
    (AS) 8T-4136 Bolt
    (AT) 8T-4121 Hard Washer
    (AV) 295-1055 Plate

  8. Remove and keep seven bolts (AS), seven hard washers (AT), and plate (AV) from catwalk assembly (58).


    Illustration 49g06357695
    (58) 291-9266 Catwalk As
    (AW) 8T-4136 Bolt
    (AX) 8T-4121 Hard Washer

  9. Remove and keep twelve bolts (AW) and twelve hard washers (AX) from catwalk assembly (58).


    Illustration 50g06357697
    (58) 291-9266 Catwalk As
    (59) 436-6141 Guardrail As
    (AW) 8T-4136 Bolt
    (AX) 8T-4121 Hard Washer

  10. Position one guardrail assembly (59) onto catwalk assembly (58). Install twelve hard washers (AX) and twelve bolts (AW).


    Illustration 51g06357730
    (59) 436-6141 Guardrail As
    (AY) 8T-4183 Bolt
    (AZ) 5P-1076 Hard Washer
    (BA) 8T-4244 Nut
    (BB) 5P-7469 Clip
    (BC) 5P-7468 Clip
    (BD) 8T-7087 Grommet

  11. Remove and keep two bolts (AY), four hard washers (AZ), two nuts (BA), two clips (BB), two clips (BC), and two grommets (BD) from guardrail assembly (59).


    Illustration 52g03835748


    Illustration 53g03836359


    Illustration 54g06357699
    (1) Walkway As
    (3) 8T-4194 Bolt
    (47) 198-4778 Hard Washer
    (58) 291-9266 Catwalk As
    (AH) 8T-4186 Bolt
    (AJ) 8T-4121 Hard Washer

  12. Use a suitable lifting device to position catwalk assembly (58) onto walkway assembly (1).

    ------ WARNING! ------

    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.


  13. Install twelve hard washers (47) and twelve bolts (3). Install six hard washers (AJ) and six bolts (AH).


    Illustration 55g06357700
    Rear Catwalk
    (AS) 8T-4136 Bolt
    (AT) 8T-4121 Hard Washer
    (AV) 295-1055 Plate

  14. Install one plate (AV), seven hard washers (AT), and seven bolts (AS).


    Illustration 56g06357728
    (AK) 8T-4136 Bolt
    (AL) 8T-4121 Hard Washer
    (AM) 8T-4133 Nut

  15. Install four hard washers (AL), four bolts (AK), and four nuts (AM).


    Illustration 57g06357732
    (59) 436-6141 Guardrail As
    (AY) 8T-4183 Bolt
    (AZ) 5P-1076 Hard Washer
    (BA) 8T-4244 Nut
    (BB) 5P-7469 Clip
    (BC) 5P-7468 Clip
    (BD) 8T-7087 Grommet

  16. Install two grommets (BD), two clips (BC), two clips (BB), two nuts (BA), four hard washers (AZ), and two bolts (AY) to connect guardrail assembly (59).


    Illustration 58g06357733
    (X) 479-2171 Bolt As
    (W) 272-3365 Signal Lighting Gp

  17. Remove one bolt (X). Position harness assembly (W) out of the way.


    Illustration 59g06357736
    (G) 479-2171 Bolt As
    (H) 330-4316 Plate
    (W) 272-3365 Signal Lighting Gp
    (X) 479-2171 Bolt As

  18. Install one plate (H), seven bolt assemblies (G). Position harness assembly (W) and install one bolt (X).


    Illustration 60g06221291
    (63) 8T-4222 Plated Washer
    (5) 8T-4195 Bolt

  19. Install five plated washers (63) and five bolts (5).

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.

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