CAT + Caterpillar 797F Truck Operation & Maintenance Manual by Heavy Equipment Manual

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Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017

Foreword

SMCS-1000;7000

LiteratureInformation

Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatbackliterature storagearea.

Thismanualcontainssafetyinformation,operationinstructions,transportationinformation,lubrication informationandmaintenanceinformation.

Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbedifferentfrom yourmachine.Guardsandcoversmighthavebeenremovedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyourmachine whicharenotincludedinthispublication.Read,studyandkeepthismanualwiththemachine.

Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCatdealerfor thelatestavailableinformation.

Safety

Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextandlocationsof warningsignsandlabelsusedonthemachine.

Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthismachine.

Operation

s00037320

Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator.This sectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols,transportationand towinginformation.

Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting,operating andstoppingthemachine.

Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopastheoperatorgains knowledgeofthemachineanditscapabilities.

Maintenance

Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS)liststhe itemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsarelistedunderthe "WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhepagenumberforthestep-bystepinstructionsrequiredtoaccomplishthescheduledmaintenance.UsetheMaintenanceIntervalSchedule asanindexor"onesafesource"forallmaintenanceprocedures.

MaintenanceIntervals

Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)canbeusedinsteadofservicehourmeterintervalsiftheyprovidemoreconvenientservicing schedulesandapproximatetheindicatedservicehourmeterreading.Recommendedserviceshouldalwaysbe performedattheintervalthatoccursfirst.

Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecifiedinthe maintenanceintervalschartmightbenecessary.

Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500servicehoursor 3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery10service hoursordaily.

CaliforniaProposition65Warning

DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocausecancer,birth defects,andotherreproductiveharm.

Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhandsafter handling.

CertifiedEngineMaintenance

Propermaintenanceandrepairisessentialtokeeptheengineandmachinesystemsoperatingcorrectly.As theheavydutyoff-roaddieselengineowner,youareresponsiblefortheperformanceoftherequired maintenancelistedintheOwnerManual,OperationandMaintenanceManual,andServiceManual.

Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,ortrading enginesormachinestoremove,alter,orrenderinoperativeanyemissionrelateddeviceorelementofdesign

installedonorinanengineormachinethatisincompliancewiththeregulations(40CFRPart89).Certain elementsofthemachineandenginesuchastheexhaustsystem,fuelsystem,electricalsystem,intakeair systemandcoolingsystemmaybeemissionrelatedandshouldnotbealteredunlessapprovedbyCaterpillar.

MachineCapacity

Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcanadverselyaffect performancecharacteristics.Includedwouldbestabilityandsystemcertificationssuchasbrakes,steering, androlloverprotectivestructures(ROPS).ContactyourCatdealerforfurtherinformation.

CatProductIdentificationNumber

EffectiveFirstQuarter2001theCatProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Inanefforttoprovideuniformequipmentidentification,Caterpillarandotherconstruction equipmentmanufacturersaremovingtocomplywiththelatestversionoftheproductidentification numberingstandard.Non-roadmachinePINsaredefinedbyISO10261.ThenewPINformatwillapplyto allCatmachinesandgeneratorsets.ThePINplatesandframemarkingwilldisplaythe17characterPIN. Thenewformatwilllooklikethefollowing: Illustration1g00751314

Where:

1.Caterpillar'sWorldManufacturingCode(characters1-3)

2.MachineDescriptor(characters4-8)

3.CheckCharacter(character9)

4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewerepreviously referredtoastheSerialNumber.

MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8characterPINformat.

Componentssuchasengines,transmissions,axles,etc.andworktoolswillcontinuetousean8character SerialNumber(S/N).

ThuJun1711:45:26UTC+05302021

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Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017

Accumulator-Discharge

SMCS-5077

Purgealloilfromtheaccumulatorandaddprecharge.Forinformationregardingthisprocedurereferto SpecialInstruction,REHS5464,"AccumulatorDischargingandChargingProcedures"orconsultyourlocal Catdealer.

ThuJun1711:47:35UTC+05302021

i07044628

This is the sample of the manual if you need complete manual Click Here to download

PreviousScreen

Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017

Accumulator-Precharge

SMCS-5077

Checkandrefillprechargeasneeded.FormoreinformationregardingthisprocedurerefertoSpecial Instruction,REHS5464,"AccumulatorDischargingandChargingProcedures"orconsultyourlocalCat dealer.

ThuJun1711:47:46UTC+05302021

i07044642

PreviousScreen

Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017

AirConditionerFilter(WithPrecleaner)-Clean

SMCS-1054;7320;7342

NOTICE

Ifareductioninaircirculationisnoticed,cleantheradialsealairfilter fortheairconditioner.

StartBy:

a.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"PreparetheMachine forMaintenance".

i06707960

Illustration1g06084299

1.Opentheaccessdoor.

2.Removetheairconditionerfilterelement.

1.Inspecttheairconditionerfilterelementfordamagetotheseal,thepleats,andtheoutercover.

a.Ifthefilterelementisgood,cleanthefilterelementwithlow-pressurecompressedairtoremove dust.

Airpressuremustnotexceed207kPa(30psi).

Directtheairflowupanddownthepleatsfrominsidethefilterelement.Takeextreme caretoavoiddamagetothepleats.

b.Ifthefilterelementisdamaged,discardthefilterelement.

Illustration3g06084314

1.Installthecleanedorthenewairconditionerfilterelement.

2.Closetheairconditionerfilteraccessdoor.

ThuJun1711:48:00UTC+05302021

PreviousScreen

Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017 i06764999

AirConditionerFilter(WithoutPrecleaner)-Clean SMCS-7320 NOTICE

Ifareductioninaircirculationisnoticed,cleantheradialsealairfilter fortheairconditioner.

StartBy:

a.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"PreparetheMachine forMaintenance".

Illustration1g06084299

1.Opentheairconditionerfilteraccessdoor.

2.Removetheairconditionerfilterelement.

1.Inspecttheairconditionerfilterelementfordamagetotheseal,thepleats,andtheoutercover.

a.Ifthefilterelementisgood,cleanthefilterelementwithlow-pressurecompressedairtoremove dust.

Airpressuremustnotexceed207kPa(30psi).

Directtheairflowupanddownthepleatsfrominsidethefilterelement.Takeextreme caretoavoiddamagetothepleats.

b.Ifthefilterelementisdamaged,discardthefilterelement.

Illustration3g06084314

1.Installthecleanedorthenewairconditionerfilterelement.

2.Closetheairconditionerfilteraccessdoor.

ThuJun1711:48:11UTC+05302021

PreviousScreen

Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017

AirDryer-Check

SMCS-4285-535

Personalinjuryordeathcanoccurifpersonnelaretrappedbetweenthe wheelandtheframe.

Thesteeringsystemishydraulicallycontrolledandwheelscancrush personnelduringmovement.

Usecautionwhenworkingbetweenthewheelsandtheframe.Ifthe wheelsmustbeturned,ensurethatallpersonnelareclearofthe machinebeforeanymovement.

StartBy:

Theairlinestoandfromtheairdryermustbeatatmosphericpressure. Iftheairlinesarenotatatmosphericpressure,personalinjurycould result.Releasetheairpressurefromtheairsystemcompletelybefore performingmaintenance.

i06765000

a.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"PreparetheMachine forMaintenance".

Illustration1g06111932

Tireisremovedforeaseofviewing

1.Pressandholdtheairtankdrainvalve.

2.Allowtheairtankstodrain.RefertoOperationandMaintenanceManual,"AirTankMoistureand Sediment-Drain"fortheproperprocedure.

3.Releasetheairtankdrainvalve.

4.Checktheairtankformoisture.Ifmoistureispresent,proceedtoStep1A.

Note:Smallamountsofmoisturemaybepresentduetocondensationinthesystem.

Illustration2g06111933

LAJ1–616andWSP1–129

Tireisremovedforeaseofviewing

LAJ617–UpandWSP130–Up

1.Replacethedesiccantcartridgesforeachdryer.RefertoOperationandMaintenanceManual,"Air DryerDesiccant-Replace"forinformationonreplacingthedesiccantcartridges.

Note:Formoreinformationontheairdryers,refertoSystemsOperation/TestingandAdjusting, KENR8748,"797Fand797FXQOff-HighwayTruckAirSystem","AirDryer".

ThuJun1711:48:22UTC+05302021

PreviousScreen

Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017

AirDryerDesiccant-Replace

SMCS-4285-510-DSS

Personalinjuryordeathcanoccurifpersonnelaretrappedbetweenthe wheelandtheframe.

Thesteeringsystemishydraulicallycontrolledandwheelscancrush personnelduringmovement.

Usecautionwhenworkingbetweenthewheelsandtheframe.Ifthe wheelsmustbeturned,ensurethatallpersonnelareclearofthe machinebeforeanymovement.

StartBy:

Airlinestoandfromtheairdryermustbeatatmosphericpressure. Releasetheairpressurefromtheairsystemcompletelybefore performingmaintenance.

i06765001

a.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"PreparetheMachine forMaintenance".

Illustration1g06137531 Tireisremovedforeaseofviewing

1.Ifthereismoistureintheairtanks,proceedtoStep1Atoreplacethedesiccantcartridges.

Note:RefertoOperationandMaintenanceManual,"AirDryer-Check"formoreinformationon checkingformoistureintheairtanks.

Note:Smallamountsofmoisturemaybepresentduetocondensationinthesystem.

Illustration2g06111933

LAJ1-616andWSP1-129

Tireisremovedforeaseofviewing

LAJ617-UpandWSP130-Up

1.Replacethedesiccantcartridgeineachairdryerifwatercannotbeabsorbed.Toreplacethedesiccant cartridge,refertoDisassemblyandAssembly,KENR8382,"797FOff-HighwayTruckMachine Systems","AirDryer-Disassemble"and797FOff-HighwayTruckMachineSystems,"AirDryerAssemble"orconsultyourCatdealer.

PrivateNetworkForSISLicensees.

ThuJun1711:48:34UTC+05302021

PreviousScreen

Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017

AirInletSystem-Test/Inspect

SMCS-1051-040;1051-081;1054-040;1054-081;1071-040;1071-081

Anairinletsystemthatisfreeofairleaksisessentialtothehealthoftheengine.Airleaksintheairinlet systemcanallowcontaminantstoentertheengine.Theairinletsystemrequiresperiodicinspections.By reducingtheamountofdustthatgoesintotheengine,theservicelifecanbeincreased.

Thisproceduregoesbeyondsimplycheckingfortornhosesorforlooseclamps.Thisproceduredetectsthe locationofleaksbyblockingtheairintakeducts,pressurizingthesystem,andsprayingasoapsolution. Bubbleswillformatthelocationofleaks.

RecommendedScheduleforInspectionoftheAirInletSystem

Usethisproceduretoinspecttheairinletsystemifanyofthefollowingeventsoccur:

•Assemblyofthenewmachine

•Installationorremovalofanengine

•Elevatedlevelsofiron,ofchrome,orofsiliconintheS·O·Sreport

•Removalofcomponentsoftheairinletsystem

•Installationofcomponentsoftheairinletsystem

•Damagetotheaircleanergroupordamagetotheairinletsystem

•Every2000servicehoursor1year

RecommendationsforMaintenanceoftheAirInletSystem

•Installtherequirednumberofclampsonalljoints.

•Installtheclampsparalleltothetubeandtothehose.

•Ensurethatthehosesareevenateachjoint.Thiswillenableproperinstallationoftheclamps.

•Ensurethatthehosesareproperlypositionedovereachtube.

•Replaceallhosesandallhoseclampswheneveranenginecomponentisreplaced.

•Ensurethatallsupportbracketsfortheairinletsystemareproperlyinstalled.

•Replaceanycomponentsoftheairinletsystemthatarebrokenormissing.

•Checkthesealsoftheaircleanersforentryofdustandfordamage.

•Checkthefiltermediafordamage.

ProceduretoTesttheAirInletSystem

Reference:RefertothePowerTrainTestingandAdjusting,"AirInletSystemTest/Inspect".

ThuJun1711:48:45UTC+05302021

PreviousScreen

Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017

AirTank-Inspect

SMCS-4272-040;5505-040;7428-040

Whenlawsinthemachine'soperatinglocationrequiretheinspectionofairtanks,refertoSpecialInstruction, REHS2398,"AirTankInspectionfortheOff-HighwayTruck769-797".

ThuJun1711:48:56UTC+05302021

i02444297

PreviousScreen

Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017

AirTankMoistureandSediment-Drain

SMCS-4272-543-MAS

Personalinjuryordeathcanoccurifpersonnelaretrappedbetweenthe wheelandtheframe.

Thesteeringsystemishydraulicallycontrolledandwheelscancrush personnelduringmovement.

Usecautionwhenworkingbetweenthewheelsandtheframe.Ifthe wheelsmustbeturned,ensurethatallpersonnelareclearofthe machinebeforeanymovement.

StartBy:

a.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"PreparetheMachine forMaintenance".

i06765057

Illustration1g06116345

Note:Airtankdrainvalveisontheoutsideframerailinfrontoftheleftfrontsuspensioncylinder.

1.Depresstheknobtoopenthedrainvalvefortheairtank.

1.Drainthemoistureandthesedimentfromtheairtankintoasuitablecontainer. Illustration3g06116361

1.Releasetheknobtoclosethedrainvalvefortheairtank.

ThuJun1711:49:07UTC+05302021

PreviousScreen

Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017 i06756825

AutomaticLubricationReservoir-Fill

SMCS-7540-544-TNK

Note:Theautomaticlubricationreservoirprovideslubricationformanycomponents.Therearefivebanksof injectorsonthemachine.

StartBy:

a.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"PreparetheMachine forMaintenance".

Illustration1g06108309

Note:Machinesthatareequippedwiththeairstartuseanairmotorontheautomaticlubricationpump.

Note:Removeplugfortheventportifthereservoirisnotequippedwithapermanentvent.

Note:Whenthereservoirisfilledandnotproperlyvented,pressurewillcausethewipersealonthe followerassemblyinsidethereservoirtofail.Greaseonthetopsideofthefollowerassemblymay preventtheautolubesystemfromfunctioningproperly.Also,greaseonthetopsideofthefollower assemblymaydamagetheautolubesystem.

1.Filltheautolubereservoirthroughthefastfillport.

2.Fillthereservoiruntilfullorbycheckingthelevelindicator.

Note:Theventportcanalsobeusedtodeterminewhenthereservoirisfull.

Note:Thebulkcapacityofthegreasereservoiris27kg(60lb).

Note:Installtheplugintheventportifthereservoirisnotequippedwithapermanentvent.

Note:Ifanyoftheremotelinesbecomedamaged,installafittinginplaceoftheremoteline.Lubricate theitematthefittingsuntiltheremotelinecanbereplaced.

ThuJun1711:49:18UTC+05302021

PreviousScreen

Product:TRUCK

Model:797FTRUCKLAJ

Configuration:797FOff-HighwayTruckLAJ00001-UP(MACHINE)POWEREDBYC175-20Engine

OperationandMaintenanceManual

797Fand797FXQOff-HighwayTrucksVisualServiceProcedure(VSP)MaintenanceIntervals

MediaNumber-M0071306-01PublicationDate-01/12/2017DateUpdated-05/12/2017

BackupAlarm-Test

SMCS-7406-081

i06765118

Thebackupalarmalertsthepersonnelbehindthemachinethatthemachineisbackingup.Thebackupalarm isattherearofthemachine.

StartBy:

a.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,"PreparetheMachine forMaintenance".

This is the sample of the manual if you need complete manual Click Here to download