797F Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

Illustration 1	g03863652

Illustration 2	g03864012

Note: Verify 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

Start By:

1. Install the hood

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 unprotected 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: Service Manual, KENR8749, "797F Off-Highway Truck Automatic Lubrication System for Electric Start and Air Start Equipped Trucks"

The grease tank for the autolubrication, the plate assemblies, and the control box for the fast fill are all shipped connected to each other.

Note: The grease tank is part of the 288-2628 Air Starting Lines Gp.

Note: The plate assemblies that support the grease tank and the control box are part of the 272-3252 Central Lubrication Lines Gp.

Note: The control box is part of the 293-7875 Service Center Gp or the 272-5377 Service Center Gp. The 293-7875 Service Center Gp is for machines that are equipped with the Oil Renewal System (ORS). The 272-5377 Service Center Gp is for machines that are not equipped with ORS.

Note: The grease tank, plate assemblies, and the control box for the fast fill are all shipped assembled.

Automatic Lubrication Tank Install

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Illustration 3	g03887668
(22) 290-7432 Box

1. Remove five cap assemblies (16) from service center assembly (22).

2. Remove four bolts (17), four washers (18), two half flanges (19), one cover (20), and one O-ring seal (21) from service center assembly (22).
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   Illustration 4	g03887674
   (24) (A) 334-9099 Hose As (24) (B) 344-8620 Hose As (24) (C) 314-5277 Hose As (24) (D) 342-2790 Hose As (24) (E) 334-5817 Hose As (24) (F) 322-6520 Hose As for machines that are equipped with ORS, and 308-6925 Hose As for machines that are not equipped with ORS (25) 8T-4185 Bolt (26) 8T-4223 Hard Washer (27) 1P-4582 Half Flange (29) 6V-4590 O-Ring Seal (30) 334-5817 Hose As

3. Remove five plug assemblies (23) from five hose assemblies (24).

4. Remove four bolts (25), eight washers (26), four nuts (27), one cover (28), and one O-ring seal (29) from one hose assembly (30). Retain the hardware.
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   Illustration 5	g03867323
   Left Hand Side (1) 351-2420 Lubrication Pump Gp 290-7432 Box 378-4329 Plate As 308-4280 Plate As 202-9076 Plate As

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   Illustration 6	g03867742
   (1) 351-2420 Lubrication Pump Gp 290-7432 Box 378-4329 Plate As 308-4280 Plate As 202-9076 Plate As (2) 8T-4223 Hard Washer (3) 8T-4956 Bolt

5. Use a suitable lifting device to position auto lubrication tank assembly (1) onto the chassis. The weight of auto lubrication tank assembly (1) is approximately 120 kg (265 lb)Install four hard washers (2) and four bolts (3).
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   Illustration 7	g03882216
   (24) (A) 334-9099 Hose As (24) (B) 344-8620 Hose As (24) (C) 314-5277 Hose As (24) (D) 342-2790 Hose As (24) (F) 322-6520 Hose As for machines that are equipped with ORS, and 308-6925 Hose As for machines that are not equipped with ORS

6. Connect five hose assemblies (24) to service center assembly (22).
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   Illustration 8	g03887681
   (25) 8T-4185 Bolt (26) 8T-4223 Hard Washer (27) 1P-4582 Half Flange (29) 6V-4590 O-Ring Seal (30) (E) 334-5817 Hose As

7. Position one hose assembly (30). Install one O-ring seal (29), two half flanges (27), four washers (26), and four bolts (25).

   Note: Refer to Service Manual, KENR8749, "797F Off-Highway Truck Automatic Lubrication System for Electric Start and Air Start Equipped Trucks" for additional information about the Automatic Lubrication System.

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   Illustration 9	g03887682
   (1) 351-2420 Lubrication Pump Gp 290-7432 Box 378-4329 Plate As 308-4280 Plate As 202-9076 Plate As

8. Remove two cap assemblies (31) and one receptacle plug (32) from auto lubrication tank assembly (1).
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   Illustration 10	g03887683
   (34) 468-5712 Hose As (36) 470-8499 Chassis Harness As

9. Remove one plug assembly (33) from hose assembly (34). Remove one receptacle plug (35) from harness assembly (36).
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   Illustration 11	g03867882
   (34) 468-5712 Hose As (36) 470-8499 Chassis Harness As

10. Connect hose assembly (34) to the grease tank. Connect harness assembly (36) to the grease tank.
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    Illustration 12	g02159436
    Top view of an electrically controlled grease tank (H) Liquid level switch for the tank "802-YL", Normally Open (J) Liquid level switch for the tank "674-BU", Common (K) 446-5855 Chassis Harness As

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    Illustration 13	g02159443
    Top view of an air controlled grease tank (H) Liquid level switch for the tank "AC-T8", "802-YL" Normally Open (J) Liquid level switch for the tank "AC-T4", "674-BU" Common

11. Refer to Illustration 13 for an example of the electrical connection of an air controlled grease tank. Refer to Illustration 12 for an example of the electrical connection of an electrically controlled grease tank.
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    Illustration 14	g03868016
    (38) 373-1104 Hose As

12. Remove one plug assembly (37) from hose assembly (38).
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    Illustration 15	g03868017
    (38) 373-1104 Hose As

13. Connect hose assembly (38) to the grease tank.
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    Illustration 16	g03868019
    (9) 204-2281 Cable Strap (10) 200-6345 Mount

14. Install two mounts (10) and four cable straps (9).
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    Illustration 17	g03868020
    (4) 8T-6466 Bolt (5) 9X-8250 Clip (6) 397-9301 Hard Washer (7) 6D-3479 Clip (8) 2A-2677 Spacer (9) 204-2281 Cable Strap (10) 200-6345 Mount (11) 8T-4195 Bolt (12) 8T-4136 Bolt (13) 8T-4182 Bolt (14) 8T-4121 Hard Washer (15) 204-8000 Cable Tie Mounting (15A) 8T-4186 Bolt

15. Install one mount (10) six cable straps (9), two spacers (8), two clips (5), two clips (7), one hard washer (6), six hard washers (14), one bolt (4), one bolt (15A), one bolt (13), three mounts (15), one bolt (12), and one bolt (11).