797F Tier 4 Off-Highway Truck Field Assembly Caterpillar

Parts and Specification Information

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 truck body

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

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Personal injury or death can occur from heavy components falling during removal or installation. Properly support the component with a suitable lifting device during removal or installation.

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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.

Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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 assemblies and allow adequate strain relief.

Note: Any tooling that is used for lifting the machine or for securing the machine in the raised position should be used on a concrete surface capable of supporting the weight of the machine.

439-2114 - Heated Truck Body

Note: The following procedure may be performed at ground level.

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Illustration 1	g06358823
(A) 8T-4184 Bolt (B) 329-3356 Nut (1) 158-2317 Elbow (2) 267-8821 Washer (3) 7X-2553 Bolt (4) 198-4778 Hard Washer (5) 8T-4194 Bolt

1. Install two elbows (1), eight washers (2), and eight bolts (3). Install eight washers (4) and eight bolts (5). Tighten four bolts (A) and four nuts (B).
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   Illustration 2	g06358833
   (6) 155-3569 Seal Ring (7) 155-3567 Piston

2. Install ring (6) onto piston (7).
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   Illustration 3	g06358841
   (C) Piston Assembly (8) 155-3566 Elbow (9) 538-9577 Spring

3. Install spring (9) and elbow (8) onto piston assembly (C).
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   Illustration 4	g06358867
   Exhaust Elbow Sub-Assembly (AE) ( 10) 6V-1820 Bolt (11) 6V-5839 Washer (12) 8X-3253 Lock

4. Install three locks (12), six hard washers (11), and six bolts (10). Repeat Step 2 through Step 4 for the remaining piston and elbow.

   Note: Position lock (12) to the outside of the piston.

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   Illustration 5	g06358877
   (D) Exhaust Elbow Sub-Assembly (T2) Loctite (13) 474-2507 Plate As (14) 267-8821 Washer (15) 8T-0649 Bolt (16) 8T-4132 Nut (17) 350-1640 Plate

5. Lubricate with Tooling (T2) the face of hard washers (14) and the threads of bolts (15) prior to assembly. Install two exhaust elbow subassemblies (D), four plates (17), plate assembly (13), sixteen washers (14), eight bolts (15), eight nuts (16).

6. Clean the contact surfaces free of wax, dirt, debris, paint, and grease.
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   Illustration 6	g06358888
   Truck Body (E) Exhaust Elbow Sub-Assembly (T2) Loctite (18) 350-3030 Plate (19) 9X-8257 Washer (20) 7X-2553 Bolt (21) 267-8821 Washer (22) 8T-4193 Bolt

7. Lubricate with Tooling (T2) the face of hard washers (21) and the threads of bolts (22) prior to assembly. Install plate (18), two washers (19) , and two bolts (20). Use Tooling (T1) and a suitable lifting device to install exhaust elbow subassembly (E).The weight of exhaust elbow subassembly (E) is approximately 328 kg (723 lb). Install eleven washers (21) and eleven bolts (22).

Adjustment Procedure

Note: The truck body and canopy must be installed to adjust the compression of the piston spring on the exhaust elbows. Refer to the truck body and canopy installation procedure in this document.

1. Perform the following step after the truck body and canopy has been installed.
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   Illustration 7	g06358911
   Body Down Position

   1. With the truck body in the DOWN position, install or remove plates (17) as needed to achieve an 150 ± 10 mm (6 ± 0.4 inch) Dimension (D1) compressed length of the piston spring (9).

439-2113 - Standard Truck Body

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Illustration 8	g06358924
(A) 8T-4184 Bolt (B) 329-3356 Nut (23) 517-3642 Exhaust Pipe As (24) 267-8821 Washer (25) 7X-2553 Bolt (26) 198-4778 Hard Washer (27) 8T-4194 Bolt

1. Install two exhaust pipe assemblies (23), eight washers (24), and eight bolts (25). Install eight washers (26) and eight bolts (27). Tighten four bolts (A) and four nuts (B).

Commission the Truck

1. After the truck has been fully assembled, commission the truck. Refer to Special Instruction, REHS6122, "Commissioning Procedure for the 797F and the 797F XQ Off-Highway Truck" for the correct procedure.