797F Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

Illustration 1	g03841232

Note: Verifying that 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

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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.

Hoist Cylinder Group Install

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Illustration 2	g03841496

1. Remove the tape from the trunnion. Remove any paint, rust, debris, grease, or wax from the mounting surface prior to assembly. Repeat this step for the right-hand trunnion.
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   Illustration 3	g03841521
   (5) 8T-4183 Bolt (6) 8T-4223 Hard Washer (7) 155-3718 Cover

2. Remove three bolts (5), three hard washers (6), and cover (7).
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   Illustration 4	g03841536
   (8) 6V-3532 Bolt (9) 8T-3282 Hard Washer

3. Remove and retain nine bolts (8), and nine hard washers (9) from the hoist cylinder.

4. Remove any paint, debris, rust, or grease from the mounting surface of the hoist cylinder.
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   Illustration 5	g03841695

5. Remove and discard two pugs from the hoist cylinder.
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   Illustration 6	g03841701
   (2) 297-7969 Dust Cap (3) 297-7968 Fitting (4) 319-6248 Union As

   Note: Place the loop for the chain that is already attached to cap (2) between cap (2) and union (4).

6. Assemble two caps (2), two fittings (3), and two unions (4) onto the left-hand cylinder only.
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   Illustration 7	g03841921
   (A) 422-5473 Lifting Eye Assembly

7. Use a suitable chain and Tooling (A) in order to secure the rod end of the cylinder while being lifted.
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   Illustration 8	g03841797
   (1) 289-8616 Hoist Cylinder Gp (8) 6V-3532 Bolt (9) 8T-3282 Hard Washer

8. Attach a suitable lifting device in order to lift hoist cylinder (1). The weight of the hoist cylinder (1) is approximately 1425 kg (3150 lb).

9. Mount hoist cylinder (1) onto the trunnion on the truck chassis.

10. Install nine bolts (8) and nine hard washers (9). Torque nine bolts (8) to 460 ± 60 N·m (340 ± 45 lb ft).
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    Illustration 9	g03841938
    (5) 8T-4183 Bolt (6) 8T-4223 Hard Washer (7) 155-3718 Cover

11. Install cover (7), three bolts (5), and three hard washers (6).
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    Illustration 10	g03841958

12. Use a suitable device in order to secure the hoist cylinder while the truck is being assembled.

13. Repeat Step 1 through Step 12 for the right-hand cylinder.

Hoist Oil Lines Group Connect

1. Remove and discard the shipping covers from the hoist cylinder.

2. Remove and discard the shipping covers from the hydraulic lines group.

   Note: Retain the bolts, seals, and flanges from the hydraulic lines group for installation purposes.

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   Illustration 11	g03842058

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   Illustration 12	g03888362
   (10) 293-5475 Hose As Left Hand Side (10) 220-1029 Hose As Right Hand Side (11) 214-5967 Hose As Left Hand Side (11) 293-5474 Hose As Right Hand Side (12) 8T-4140 Bolt (13) 9X-8257 Washer (14) 5P-8077 Half Flange (15) 235-2476 Rectangular Seal (16) 8T-4141 Bolt (17) 8T-4123 Washer (18) 6V-0402 Half Flange (19) 235-2480 Rectangular Seal

3. Connect hose assembly (10), four bolts (12), four hard washers (13), two half flanges (14), and rectangular seal (15).

4. Connect hose assembly (11), four bolts (16), four hard washers (17), two half flanges (18), and rectangular seal (19).

5. Repeat Step 1 through Step 4 for the right-hand cylinder.