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 rear tires and rims

Note: Before installing the truck body and canopy, remove the work at height handrails.

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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.

Reference: Special Instruction, REHS1841, "General Welding Procedures".

Films Install

Note: Note: Clean all surfaces with isopropyl alcohol. Thoroughly dry the surfaces before applying the film.

Note: After applying the film, ensure that the film is free of air bubbles.

Note: If no dimension is given, center the films in the space that is available.

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Illustration 1	g03881773
(45) 295-0537 Film

1. Clean the contact surface with isopropyl alcohol. Thoroughly dry the surface before applying the film. Apply film (45) to the front of the canopy.
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   Illustration 2	g03881774
   (46) 332-5861 Film (A) 0 ± 3 mm (0.00000 ± 0.12 inch)

2. Clean the contact surface with isopropyl alcohol. Thoroughly dry the surface before applying the film. Apply film (46) to the right side of the body.
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   Illustration 3	g03881775
   (47) 332-5860 Film (A) 0 ± 3 mm (0.00000 ± 0.12 inch)

3. Clean the contact surface with isopropyl alcohol. Thoroughly dry the surface before applying the film. Apply film (47) to the left side of the body.
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   Illustration 4	g03881776
   (48) 252-2156 Film

4. Clean the surfaces with isopropyl alcohol. Thoroughly dry the surfaces before applying the film. Apply films (48) to the sides of the body. Place eight films (48) to the right of each lifting location.

Truck Body Install

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Illustration 5	g03859399

1. Clean the pin bores and the mating surfaces on the truck body free of wax, dirt, debris, paint, and grease.
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   Illustration 6	g03859400

2. Clean the pin bores and the mating surfaces on the chassis and hoist cylinders free of wax, dirt, debris, paint, and grease.
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   Illustration 7	g03881777

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   Illustration 8	g03860102
   (2) 328-2251 Pin As (7) 295-4144 Pin As

3. Clean the contact and mating surfaces of two pin assemblies (2) and two pin assemblies (7) free of wax, dirt, debris, paint, and grease.
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   Illustration 9	g03860461
   (1) 290-6420 Body and Canopy As

4. Use Tooling (A) and a suitable lifting device to position truck body and canopy assembly (1) onto the chassis. The weight of truck body and canopy assembly (1) is approximately 51256 kg (113000 lb) with the liners and 44134 kg (97300 lb) without the liners.
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   Illustration 10	g03881780

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   Illustration 11	g03881781
   (2) 328-2251 Pin As (2A) 154-1808 Plate

   Note: Center the truck body on the chassis by installing shim plates (2A) , as required, on the body pivot pins between the body frame rails and the outside surface of the chassis frame rails only. Do not install the shim plates on the inboard sides of the chassis frame rails.

5. Ensure that the pin bores are aligned. Apply Tooling (B) onto pivot pin assembly (2). Use a suitable lifting device to position one pivot pin assembly (2) into the pin bore. The weight of one pivot pin assembly (2) is approximately 60 kg (132 lb). Position the required number of shim plates (2A) to center the truck body on the chassis and install one pivot pin assembly (2). Repeat this step for the opposite side of the truck body.
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   Illustration 12	g03881783
   (4) 328-2253 Plate (6A) 148-8389 Elbow As

6. Install one elbow assembly (6A) onto one retainer plate (4). Repeat this step for the three remaining retainer plates (4).
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   Illustration 13	g03881782

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   Illustration 14	g03881784
   (4) 328-2253 Plate (5) 8T-4223 Hard Washer (6) 160-8748 Bolt

7. install two O-ring seals (3), two retainer plates (4), sixteen hard washers (5), and sixteen bolts (6). Repeat this step for the remaining pin assembly on the opposite side of the truck body.

8. Repeat Step 6 through Step 7 for the opposite side of the truck body.
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   Illustration 15	g03861510

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   Illustration 16	g03861521
   (7) 295-4144 Pin As (9) 151-0888 Spacer

9. Position the hoist cylinder to align the pin bores. Apply Tooling (B) onto pin assembly (7). Install pin assembly (7) and two spacers (9). The weight of one pin assembly (7) is approximately 47 kg (104 lb)
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   Illustration 17	g03860618
   (5) 9X-8257 Washer (8) 295-6881 Plate (10) 8T-4193 Bolt

10. Install two plates (8), eight hard washers (5), and eight bolts (10). Repeat Step 9 and Step 10 for the hoist cylinder pin assembly on the opposite side of the truck body.

Mud Guards Install

Note: The mud guards can be installed at ground level.

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Illustration 18	g06358349
(12) 480-8667 Mud Flap (14) 5T-7352 Strip (15) 8T-4121 Hard Washer (16) 8T-4196 Bolt (17) 6V-7744 Nut

1. Use two people to position mud flap (12). The weight of mud flap (12) is approximately 22 kg (49 lb). Install strip (14), twelve bolts (16), twenty-four washers (15), and twelve nuts (17).

Retaining Cable Install

Note: The retaining cables can be installed at ground level.

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Illustration 19	g03881785
(18) 371-6295 Plate (21) 195-1764 Pin Kit

1. Use a suitable lifting device to install two plates (18). The weight of one plate (18) is approximately 43 kg (95 lb). Install two pin kits (21).
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   Illustration 20	g03881786
   (19) 219-5894 Pin Kit (20) 371-6297 Cable As

2. Install one cable assembly (20) and two pin kits (19).
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   Illustration 21	g03881787
   (22) 219-5893 Clevis (23) 219-6071 Pin Kit (24) 371-6296 Cable As

3. Install two cable assemblies (24), two clevises (22), and two pin kits (23).

Rock Ejector install

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Illustration 22	g03881788
(25) 195-5952 Plate As

1. Attach a string and a plumb bob to the center of one plate assembly (21) for the mounting pin of rock ejector. Use a suitable fork truck to position one plate assembly (25) onto the bottom of the truck body. The weight of one plate assembly (25) is approximately 103 kg (227 lb). Center the string between the two rear tires. Once the string is centered, mark the location of plate assembly (25) on the truck body.
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   Illustration 23	g03862366

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   Illustration 24	g03881789
   (25) 195-5952 Plate As

2. Clean the contact and mating surfaces of plate assembly (25) and the truck body free of wax, dirt, debris, paint, and grease.
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   Illustration 25	g03881788

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   Illustration 26	g03881790
   (25) 195-5952 Plate As (W1) 8 mm (0.32 inch) Fillet weld with 1.5 mm (0.06 inch) Root penetration

3. Position plate assembly (25) onto the bottom of the body and tack weld plate assembly (25) onto the truck body. The weight of one plate assembly (25) is approximately 103 kg (227 lb).

4. Weld plate assembly (25). Weld around the entire perimeter of plate assembly (25) in order to secure plate assembly (25) to the truck body. Use a grinder in order to remove any slag or debris from the affected area. Repaint the welded area.
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   Illustration 27	g03881791

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   Illustration 28	g03881792
   (25) 195-5952 Plate As (26) 175-4935 Ejector (27) 3B-4647 Cotter Pin (28) 185-6715 Pin (29) 3D-0404 Washer

5. Use a suitable fork lift or a suitable lifting device to position ejector (26) to plate assembly (25). The weight of ejector (26) is approximately 112 kg (247 lb).

6. Install one pin (28), one washer (29), and two cotter pins (27).

7. 1 and Step 6 for the opposite side of the truck body.

Rocker Install

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Illustration 29	g03881793
(36) 507-1577 Shoe (37) 8T-4192 Bolt (38) 149-1926 Plate (39) 518-9364 Pin (40) 236-5558 Plate As

1. Install plate assembly (36) onto plate assembly (40). Apply Tooling (B) onto pin (39). Install pin (39), two plates (38), and four bolts (37).
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   Illustration 30	g03881794
   (31) 7D-1649 Hard Washer (32) 8T-4184 Bolt (33) 147-5075 Pad As (34) 147-5073 Shim 2 mm (0.08 inch) (35) 147-5072 Plate 8 mm (0.32 inch) (68) Rocker Sub Assembly

2. Install two shims (34) and one plate (35) onto rocker subassembly (68). Install one pad assembly (33), three hard washers (31), and three bolts (32).

   Note: Plate (35) should be used in place of four shims (34). Use plate (35) when the gap between the truck body and pad assembly (33) is larger than 8 mm (0.32 inch).

3. Repeat Step 1 through Step 2 for the remaining rocker assembly.

4. Raise the truck body and connect the truck body retaining cables. Refer to Operation and Maintenance Manual, "Cable (Truck Body Retaining)".
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   Illustration 31	g03881795

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   Illustration 32	g03881796
   (68) Rocker Sub Assembly

5. Use a suitable lifting device to position one rocker subassembly (68) onto the crossbeam of the truck frame. The weight of rocker assembly (68) is approximately 150 kg (330 lb).
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   Illustration 33	g03881797
   (68) Rocker Sub Assembly (A) 1550 mm (61 inch)

6. Disconnect the truck body retaining cables and Lower the body. Refer to Operation and Maintenance Manual, "Cable (Truck Body Retaining)".

7. Locate rocker subassembly (68) on the crossbeam according to Dimension (A) from the centerline of the chassis. Also, position rocker subassembly (68) as far rearward on the crossbeam as possible without welding on the radius of the crossbeam.

   Note: Dimension (A) from the centerline of the chassis to the center of the rocker assembly pin is 1550 mm (61 inch)

8. Tack weld rocker subassembly (68) onto the crossbeam of the truck frame.

9. Repeat Step 5 through Step 8 for the remaining rocker subassembly.

10. Raise the truck body and connect the truck body retaining cables. Refer to Operation and Maintenance Manual, "Cable (Truck Body Retaining)".
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    Illustration 34	g03881798

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    Illustration 35	g03881799
    Grind as needed for clearance (68) Rocker Sub Assembly (W2) 25 mm (1.0 inch) Fillet weld with 1.5 mm (0.06 inch) Root penetration (W3) 10 x 35 mm (0.4 x 1.4 inch) Fillet weld with 14 mm (0.6 inch) Bevel Groove weld (W4) 10 x 27 mm (0.4 x 1.1 inch) Fillet weld with 14 mm (0.6 inch) Bevel Groove weld (N1) Grind both corners (N2) No weld from A to B

11. Weld rocker subassembly (68) to the crossbeam.

    Note: Avoid starting and stopping the weld on the corners.

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    Illustration 36	g01652994

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    Illustration 37	g01652998

12. Create additional fillet welds in order to provide a tapered transition between the original fillet weld and the main beam. Use a grinder in order to blend the additional welding area.

    Note: Perform the additional welding on the two corners of the rocker assembly that are located toward the outside edge of the chassis.

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    Illustration 38	g03881800
    (68) Rocker Sub Assembly

13. Use a grinder to blend any weld that is located by the drain opening in rocker assembly (68).

    Note: Ensure that the drain opening is free of obstructions.

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    Illustration 39	g01653036

14. Check for interference after finish welding and grinding of rocker subassemblies (68). Ensure that there is no interference between the upper rocker pad and the fillet weld on the base. If interference occurs, use a grinder to remove the excess material. Paint all affected weld areas.

15. Repeat Step 5 through Step 14 for the opposite side.

Body Pad Install

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Illustration 40	g03891867
(34) 147-5073 Shim 2 mm (0.08 inch) (41) 8T-4244 Nut (42) 173-5403 Pad As (43) 7D-1649 Hard Washer (44) 8T-4910 Bolt

1. Raise the truck body to the RAISED position and connect the truck body retaining cables. Refer to Operation and Maintenance Manual, "Cable (Truck Body Retaining)".

2. Loosely install all ten pad assemblies (42) using 30 bolts (44), 30 hard washers (43), and 30 nuts (41) to the body rails (no shims, and bolts loose).

3. Lower the body slowly until the first pad assembly fully contacts the rails. This pad assembly establishes neutral body down position and requires no additional shims.

   Note: Raise the truck body and connect the truck body retaining cables. Refer to Operation and Maintenance Manual, "Cable (Truck Body Retaining)". Or, safely block the body in position while the shims are installed.

4. As required, assemble shims (34) on the remaining pad assemblies (42) to minimize the gap between the frame rail and the body rail and maximize the contact area of pad assemblies. Use the shims to fill the gaps.

   Note: When lowering the body to establish the neutral down position, if the body landing pads contact the rocker assemblies before the body pads contact the frame rails, then add required shims to the body pad with closest clearance to minimize the gap. With this neutral position established, continue to add shims to the remaining body rail mounting pads.

5. Remove the safety device or blocks and lower the body to the DOWN position to visually check for proper shimming along the frame rails.

   Note: Check for even contact of mounting pads to frame rails, the following paint/grease transfer procedure can be used. Paint/grease the chassis frame rail body pad contact areas. While the paint/grease is wet, lower the body. Raise the body and examine the contact pattern transferred to the body pads. If needed, reshim the pads one pad at a time to achieve the most complete contact pattern possible.

6. Refer to the rocker Install section for welding rocker assemblies to position.

7. With the body in the DOWN position, finish shim the rocker assemblies.

8. Install one 8 mm (0.32 inch) shim and two 2 mm (0.08 inch) shims between pad and rocker, tighten the bolts ( this will give field adjustment for pedestals as the body pads compress during operation).

9. Place two 2 mm (0.08 inch) shims on top of the rocker pads ( this will establish initial running clearance).

10. Remove safety device or blocks. Raise and lower the body in order to ensure proper alignment and that all mounted pad assemblies have even contact with the frame.

11. At this point, remove the two shims setting on top of rocker pads from the right hand and left-hand rocker shoe and pad assemblies. Removing the shim ensure minimal load transferring to the front tower landing pads after the truck is in service.

12. Evenly tighten the rocker mounting pad assembly bolts to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

13. Evenly tighten the truck body pad assembly bolts to a torque of 105 ± 20 N·m (77 ± 15 lb ft).

14. Ensure that there is adequate clearance to the cab.

15. Inspect pad wear (footprint of pads on the frame rails) at first periodical maintenance, and reshim if required.

    Note: Verify the body frame rail to body pad contact patterns using the paint/grease transfer method at the first scheduled service interval after the truck has been in service. Reshim pads one pad at a time as needed to achieve the most complete contact pattern possible.

Truck Body Guides - Install

Note: Do not install the truck body guides until the body pads have been installed.

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Illustration 41	g03881803

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Illustration 42	g03881804
(30) 149-4621 Guide (B) 8 ± 1 mm (0.32 ± 0.04 inch) (C) 92 mm (3.6 inch)

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Illustration 43	g03881805

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Illustration 44	g03881806
(30) 149-4621 Guide (W5) 8 mm (0.32 inch) Fillet weld (W6) 10 mm (0.4 inch) Fillet weld with 10 mm (0.4 inch) Bevel Groove weld (W7) 6 mm (0.24 inch) Bevel Groove weld

1. Weld guide (30) to the crossbeam. The weight of one guide (30) is approximately 21 kg (47 lb).

2. Repeat Step 1 for the remaining guide on the opposite side.

Body Position Linkage Connect

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Illustration 45	g03881807

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Illustration 46	g03881808
(69) 8T-4195 Bolt (70) 8T-4121 Hard Washer (71) 344-5675 Nut (72) 158-0488 Rod As

1. Remove one bolt (69), two washers (70), and one nut (71) from linkage (72). Retain the hardware.

2. Position linkage (72) and install one washer (70) and one bolt (69).

3. The body position linkage is calibrated during the commissioning of the truck. Refer to Special Instruction, REHS6122, "Commissioning Procedure for the 797F and the 797F XQ Off-Highway Truck" after the truck has been assembled.

Lubrication Lines Install

Install the 351-6650 Automatic Lubrication Gp

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Illustration 47	g03884529
(73) 8T-6869 Bolt (74) 8T-4224 Hard Washer (75) 5P-4116 Hard Washer (76) 5C-7261 Nut (77) 269-5346 Lubrication Distribution Valve Gp

1. Remove four bolts (73), four washers (74), four washers (75), and four nuts (76) to disconnect grease injector assembly (77) from the mounting bracket, as a unit.
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   Illustration 48	g03884642

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   Illustration 49	g03884644
   (61) 004-6683 Fitting (77) 269-5346 Lubrication Distribution Valve Gp (78) 3J-5390 Plug (79) 203-2059 Connector As

2. Remove one plug assembly (78) from the right-hand side of grease injector assembly (77). Install one fitting assembly (61).

3. Disconnect fitting assembly (79) from the left-hand side of grease injector assembly (77). Install one fitting assembly (61).

   Note: Fitting (79) is the supply line connector.

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   Illustration 50	g03884643
   (62) 269-5346 Lubrication Distribution Valve Gp (67) 148-8389 Elbow As

4. Install four elbow assemblies (67) onto two grease injector assemblies (62).
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   Illustration 51	g03884659
   (62) 269-5346 Lubrication Distribution Valve Gp (77) 269-5346 Lubrication Distribution Valve Gp

5. Install two grease injector assemblies (62) onto grease injector assembly (77).
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   Illustration 52	g03884660
   (62) 269-5346 Lubrication Distribution Valve Gp (77) 269-5346 Lubrication Distribution Valve Gp (78) 3J-5390 Plug (79) 203-2059 Connector As

6. Connect fitting (79) to the outer grease injector assembly (62) on the left-hand side of grease injector assembly (77). Install one plug assembly (78) to the outer grease injector assembly (62) on the right-hand side of grease injector assembly (77).

   Note: Fitting (79) is the supply line connector.

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   Illustration 53	g03884661
   (63) 8T-6869 Bolt (64) 8T-4224 Hard Washer (65) 5P-4116 Hard Washer (66) 5C-7261 Nut (73) 8T-6869 Bolt (74) 8T-4224 Hard Washer (75) 5P-4116 Hard Washer (76) 5C-7261 Nut (77) 269-5346 Lubrication Distribution Valve Gp

7. Position grease injector assembly (77) onto the mounting bracket as a unit and install four bolts (73), four washers (74), four washers (75), and four nuts (76). Installinstall two bolts (63), two washers (64), two washers (65), and two nuts (66).

   Note: The washers (65) and washers (75) are on the back side of the mounting bracket.

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   Illustration 54	g03884583
   (67) 148-8389 Elbow As (67A) 148-9947 Hose As (67B) 350-3509 Hose As (67C) 4D-6466 Clip (80) 8T-4133 Nut (81) 8T-4121 Hard Washer

8. Install one hose assembly (67A) and one hose assembly (67B) onto four elbow assemblies (67).

9. Remove two nuts (80), and two washers (81). Retain the hardware.

10. Install two clips (67C), two washers (81) and two nuts (80).
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    Illustration 55	g03884639
    (67A) 148-9947 Hose As (67B) 350-3509 Hose As (67C) 4D-6466 Clip (67D) 4K-8864 Clip (80) 8T-4133 Nut (81) 8T-4121 Hard Washer

11. Remove two nuts (80), and two washers (81). Retain the hardware.

12. Route one hose assembly (67A) to the inside pin retainer plate. Route one hose assembly (67B) to the outside pin retainer plate. Install one clip (67C), one clip (67D), two washers (81) and two nuts (80).

Lubrication Lines Connect

Connect the 351-6650 Automatic Lubrication Gp and 272-3252 Central Lubrication Lines Gp

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Illustration 56	g03881809
Hoist Cylinder (57) 148-8389 Elbow As

1. Install one elbow assembly (57) onto the hoist cylinder.
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   Illustration 57	g03881810
   Hoist Cylinder (82) 216-9206 Plug As (83) 8X-8474 Hose As

2. Remove one plug assembly (82) from grease hose assembly (83).
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   Illustration 58	g03881811
   Hoist Cylinder (15) 8T-4121 Hard Washer (58) 4K-8864 Clip (59) 8T-4137 Bolt (83) 8X-8474 Hose As

3. Connect grease hose assembly (83). Install one clip (58), one hard washer (15), and one bolt (59).
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   Illustration 59	g03881812
   Body Rail (15) 8T-4121 Hard Washer (58) 4K-8864 Clip (59) 8T-4137 Bolt

4. Install five clips (58), five hard washers (15), and five bolts (59).
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   Illustration 60	g03881813
   Outside Left Hand Side (67B) 350-3509 Hose As (84) 216-9206 Plug As

5. Remove plug assembly (84) from grease hose assembly (67B).
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   Illustration 61	g03881814
   Outside Left Hand Side (67B) 350-3509 Hose As

6. Connect grease hose assembly (67B) to the elbow on the outer side pivot pin retainer plate.
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   Illustration 62	g03884640
   Inside Left Hand Side (67A) 148-9947 Hose As (84) 216-9206 Plug As

7. Remove plug assembly (84) from grease hose assembly (67A).
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   Illustration 63	g03884641
   Inside Left Hand Side (67A) 148-9947 Hose As (84) 216-9206 Plug As

8. Connect grease hose assembly (67A) to the elbow on the inner side pivot pin retainer plate.

9. Repeat Step 1 through Step 4 for the opposite side of the truck body.

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.