797F and 797F XQ Off-Highway Trucks Machine Systems Caterpillar

Removal Procedure

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Personal injury can result from hot oil or hot components. At operating temperature, oil is hot and under pressure. Hot oil can cause burns. Remove the fill cap only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand. Do not allow hot oil or components to contact skin.

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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

1. Install the truck body retaining cable.

2. Release the system pressure. Refer to Operation and Maintenance Manual, "System Pressure - Release".

3. Drain the hydraulic tank into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Hydraulic Tank Oil - Change - Hoist and Brake System"

4. Drain the engine coolant into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
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   Illustration 1	g06131133

5. Disconnect hose assembly (1), hose assembly (2), tube assembly (3), and manifold (4).
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   Illustration 2	g06131142

6. Disconnect hose assembly (5). Remove clamps (6). Remove tube assembly (3).
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   Illustration 3	g06130770

7. Remove clips (7). Disconnect hose assemblies (8) and position out of the way.
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   Illustration 4	g06130795

8. Remove clips (9). Loosen clamps (10). Remove clamp (11). Disconnect hose assemblies (12). Remove tube assemblies (13).
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   Illustration 5	g06130828

9. Remove clips (14). Disconnect tube assembly (15).
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   Illustration 6	g06205323

10. Remove clips (16). Loosen clamps (17). Position tube assembly (15) out of the way.
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    Illustration 7	g06130874

11. Remove bracket (18) and clips (19), Disconnect tube assembly (20).
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    Illustration 8	g06131062

12. Remove clips (21), Loosen clamps (22). Remove tube assembly (20).
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    Illustration 9	g06131148

13. Disconnect hose assembly (23) and hose assembly (24). Remove manifold (25).
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    Illustration 10	g06131092

14. Disconnect hose assembly (26) and hose assembly (27).
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    Illustration 11	g06131102

15. Remove manifold (28).
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    Illustration 12	g06131219

    Note: Place an orientation mark on oil cooler assembly (29) for installation purpose.

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    Illustration 13	g06131225

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    Illustration 14	g06131209

16. Attach Tooling (A) and a suitable lifting device onto oil cooler assembly (29). The weight of oil cooler assembly (29) is approximately 556 kg (1225 lb).

17. Remove bolts (30) and bolts (31).

18. Remove oil cooler assembly (29).

Installation Procedure

1. Install oil cooler assembly (29) in the reverse order of removal.
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   Illustration 15	g06205314

   1. Check the orientation mark on oil cooler assembly (29) marked during removal procedure. Ensure that oil cooler assembly (29) is installed in correct orientation as shown in illustration 15.