Caterpillar 797B Off-Highway Truck Parts Manual – PDF DOWNLOAD

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Caterpillar 797B Off-Highway Truck Parts Manual – PDF DOWNLOAD

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DESCRIPTION:

Caterpillar 797B Off-Highway Truck Parts Manual – PDF DOWNLOAD

Powered By 3524B Engine

JSM1-Up (Machine)
1AW559-Up (Engine)
2CS991-Up (Engine)
3TN486-Up (Engine)
5JY712-Up (Transmission)
5NT1-Up (Torque Converter)
5ST121-Up (Torque Converter)

GENERAL INFORMATION
1. MACHINE IDENTIFICATION :

Caterpillar machines are identified by Product Identification Numbers (PIN). Some components included in a machine may be identified by Serial Numbers (S/N). Typical components that will be serialized include engines, transmissions, bulldozers, and rippers.

• The machine and engine are further identified by arrangement numbers and in some cases modification numbers. These numbers are shown on the product identification plate(s) and on the master plate in the operator’s compartment. Caterpillar dealers need all of these numbers to determine accurate parts identification.
• Effective First Quarter 2001 the Caterpillar Product Identification Number (PIN) will change from 8 to 17 characters. In an effort to provide uniform equipment identification, Caterpillar and other construction equipment manufacturers are moving to comply with the latest version of the product identification numbering standard.

2. ORDERING PARTS :

• Quality Caterpillar replacement parts are available from Caterpillar dealers throughout the world. Their parts inventories are up to date and include all parts normally required to protect your investment in Caterpillar machines.
• Dealers may offer repair kits or remanufactured parts to allow selection of the most effective repair alternative for a particular situation. When ordering parts, your order should specify the quantity, part number, part name, and the serial number/product identification number of the machine for which the parts are needed.

3. PARTS MANUAL ORGANIZATION :

Product information in this manual is presented as “information elements” that represent all of the components for the specific model. Engine Arrangement and Seat Group are examples of information elements. The information elements are organized alphabetically by part name and secondarily by part number within each major section of the manual.

TABLE OF CONTENTS:

Caterpillar 797B Off-Highway Truck Parts Manual – PDF DOWNLOAD

GENERAL INFORMATION A11
REPAIR ALTERNATIVES A18
SUPPLEMENTAL COOLANT
ADDITIVES A20
MAINTENANCE PARTS A22
INDEX A38
MACHINE ARRANGEMENT 1
CHASSIS AR 1
COMMON AR-TRUCK 1
INSTALLATION AR-TRUCK 2
MACHINE AR-HIGH ALTITUDE 2
ENGINE ARRANGEMENT 3
ENGINE AR 3
ENGINE AR-FRONT 7
ENGINE AR-REAR 11
INSTALLATION AR-ENGINE 15
POWER PACK AR 16
BASIC ENGINE 17
AIR COMPRESSOR GP 17
BASE GP-VALVE COVER 20
CAMSHAFT GP 21
COUPLING AR-ENGINE 22
COUPLING GP-ENGINE 23
COVER GP-CYLINDER BLOCK 25
COVER GP-FLYWHEEL HOUSING 29
COVER GP-FRONT HOUSING 32
COVER GP-PROTECTION 35
COVER GP-REAR HOUSING 36
COVER GP-VALVE MECHANISM 38
CRANKSHAFT GP 39
CYLINDER BLOCK AS 41
CYLINDER BLOCK GP 42
CYLINDER HEAD AS 47
CYLINDER HEAD GP 51
DAMPER GP 58
DRIVE GP-ACCESSORY 63
DRIVE GP-AUXILIARY 73
FLYWHEEL GP 75
GEAR GP-FRONT 78
GEAR GP-REAR 82
GUARD GP-BELT 86
HOUSING GP-FLYWHEEL 87
HOUSING GP-FRONT 91
LIFTING GP-ENGINE 93
LINES GP-AIR COMPRESSOR 95
MOUNTING GP-ALTERNATOR 105
MOUNTING GP-ENGINE 107
PAN GP-OIL 110
PISTON & ROD GP 114
PLATE GP-REINFORCEMENT 116
SEAL GP-CRANKSHAFT 118
STEP GP 120
SUPPORT GP-ENGINE 123
TRUNNION GP-ENGINE 124
VALVE MECHANISM GP 125
LUBRICATION SYSTEM 131
BREATHER GP 131
EXTENSION GP-DRAIN 133
FILLER GP-ENGINE OIL 135
FILTER GP-ENGINE OIL 138
FUMES DISPOSAL GP 144
GAUGE GP-OIL LEVEL (DIPSTICK) 145
LINES GP-ENGINE OIL 148
LINES GP-OIL SUPPLY 154
LINES GP-PRELUBRICATION 160
LINES GP-TURBOCHARGER OIL 165
METERING GP-ENGINE OIL 193
PUMP & MTG GP-COUPLING 201
PUMP GP-ENGINE OIL 202
PUMP GP-GEAR 206
PUMP GP-PRELUBRICATION 207
PUMP GP-SCAVENGE 208
VALVE & MTG GP-OIL METERING 214
VALVE GP-SOLENOID 215
COOLING SYSTEM 216
CONNECTION GP-WATER 216
COOLER GP-ENGINE OIL 217
COOLING AR 220
CORE GP-OIL COOLER 221
COVER GP-RADIATOR CAP 225
FAN GP-SUCTION 226
GAUGE GP-COOLANT LEVEL 228
GUARD GP-FAN 229
HOUSING & REGULATOR GP 232
LINES GP-AFTERCOOLERWATER 234
LINES GP-TURBOCHARGER WATER 239
LINES GP-WATER 243
PUMP GP-AUXILIARYWATER 318
PUMP GP-WATER 320
RADIATOR GP 327
SHIELD GP-WATER MANIFOLD 332
TANK GP-COOLANT 333
AIR INLET AND EXHAUST SYSTEM 335
AFTERCOOLER GP-TREATED
WATER 335
AFTERCOOLER GP-WATER 336
AIR CLEANER GP 337
CARTRIDGE GP-TURBOCHARGER 340
GUARD GP-EXHAUST 341
LINES GP-AIR 342
SEBP4221 TABLE OF CONTENTS A1
TABLE OF CONTENTS
Name Page Name Page
MANIFOLD GP-EXHAUST 369
PIPE GP-EXHAUST 374
SUPPORT GP-TURBOCHARGER 383
TURBOCHARGER GP 387
FUEL SYSTEM 399
CONTROL GP-ACCELERATOR 399
FASTENER GP-FUEL TANK 400
FILTER GP-FUEL 403
FILTER GP-PRIMARY FUEL 405
HEATER GP-FUEL 406
INJECTOR GP-FUEL 407
LINES GP-FUEL 408
LINES GP-FUEL FILTER 411
LINES GP-FUEL INJECTION 415
MANIFOLD GP-FUEL 425
PUMP GP-FUEL INJECTION 427
PUMP GP-FUEL PRIMING 429
PUMP GP-FUEL PRM & PRIM FILTER 431
PUMP GP-FUEL TRANSFER 432
SHIELD GP-FUEL LINES 438
TANK & FILTER AR-FUEL 439
TANK AS-FUEL 440
TANK GP-FUEL 446
ELECTRICAL AND STARTING SYSTEM 453
AIR DRYER GP 453
ALARM GP 454
ALTERNATOR GP-CHARGING 456
BATTERY &WIRING GP 459
BATTERY GP 461
BUFFER GP-SENSOR 465
CONTROL & MTG GP-ELECTRONIC 466
CONTROL & MTG GP-ENGINE ELEK 472
CONTROL & MTG GP-PERSONALITY 483
CONTROL GP-AIR STARTING 484
CONTROL GP-ENGINE ELECTRONIC 490
CONTROL GP-UNPROGRAMMED 492
ELECTRONICS GP-MACHINE 494
ELECTRONICS GP-MONITOR 495
ELECTRONICS GP-POWER TRAIN 497
HEATER GP-ENGINE OIL 498
HEATER GP-JACKETWATER 499
LAMP GP-DOME 500
LAMP GP-FLOOD 501
LAMP GP-HEAD 504
LAMP GP-MARKER 510
LAMP GP-SIGNAL 512
LIGHTING GP-FLOOD 516
LIGHTING GP-SIGNAL 517
LINES GP-AIR STARTING 520
LUBRICATOR GP-AIR MOTOR 525
MOTOR GP-ELECTRIC 526
PANEL GP-CIRCUIT BREAKER 527
RELAY GP 529
SENSOR & MOUNTING GP 531
SENSOR & MTG GP-ELECTRIC 532
SENSOR GP-FUEL LEVEL 534
SENSOR GP-LIQUID LEVEL 536
SENSOR GP-POSITION 537
SENSOR GP-PRESSURE 541
SENSOR GP-SPEED 555
SENSOR GP-TEMPERATURE 558
SERVICE GP-MACHINE 561
SERVICE GP-POWER TRAIN 561
SHIM GP-GENERATOR 562
SOFTWARE GP-POWER TRAIN 562
STARTING AID GP-ETHER 563
STARTING AR-AIR 571
STARTING AR-COLDWEATHER 573
STARTING MOTOR GP-AIR 574
SWITCH GP-BYPASS 586
SWITCH GP-DISCONNECT 587
SWITCH GP-FLOW 588
SWITCH GP-LIQUID LEVEL 589
SWITCH GP-MAGNETIC 591
SWITCH GP-START 592
TRAY GP-SUPPORT 593
VALVE AS-CHECK 595
VALVE GP-SOLENOID 596
WIRING & LIGHTING GP 599
WIRING GP-CAB 604
WIRING GP-CHASSIS 609
WIRING GP-ENGINE 646
WIRING GP-ENGINE ELECTRONIC 666
WIRING GP-MONITOR 671
WIRING GP-PLATFORM 672
WIRING GP-REAR AXLE HOUSING 675
WIRING GP-SENSOR 682
POWER TRAIN 685
AXLE & MOUNTING GP 685
CASE GP-TRANSMISSION 686
CONTROL GP-TRANSMISSION 700
CONTROL GP-TRANSMISSION HYD 702
COOLER GP-REAR AXLE OIL 705
COVER GP-SHIPPING 709
COVER GP-TORQUE CONVERTER 710
COVER GP-TRANSMISSION TANK
CAP 712
DIFFERENTIAL & BEVEL GEAR GP 713
DIFFERENTIAL GP 720
DRIVE GP-PUMP 721
FASTENER GP-PUMP DRIVE 724
FASTENER GP-WHEEL & DIFF 725
FILTER & MTG GP-OIL 726
FILTER GP-OIL 731
GUARD GP-RIM 734
HOUSING AS-REAR AXLE 735
HOUSING GP-PUMP 739
A2 TABLE OF CONTENTS SEBP4221
TABLE OF CONTENTS
Name Page Name Page
HOUSING GP-REAR AXLE 741
LINES GP-POWER TRAIN COOLER 743
LINES GP-POWER TRAIN OIL 747
LINES GP-REAR AXLE LUBRICATION 757
MOTOR GP-FAN 759
MOTOR GP-GEAR 760
MOUNTING GP-RIM 762
MOUNTING GP-TORQUE
CONVERTER 765
MOUNTING GP-TRANSMISSION 768
PLANETARY GP-FINAL DRIVE 769
PLANETARY GP-TRANSMISSION 773
POWER TRAIN AR 786
PUMP & MOTOR GP-REAR AXLE
LUBE 787
PUMP & MTG GP-REAR AXLE LUBE 790
PUMP GP-GEAR 792
RIM GP 804
RIM GP-DEMOUNTABLE 804
SECTION GP-GEAR PUMP 807
SERVICE AR-DIFF & BEVEL GEAR 809
SERVICE AR-WHEEL, FDR & BRAKE 809
SHAFT GP-DRIVE 810
SLIP JOINT GP 811
TORQUE CONVERTER AR 812
TORQUE CONVERTER GP 824
TRANSMISSION AR 827
UNIVERSAL JOINT GP 828
VALVE & MTG GP-CONTROL 829
VALVE GP-MODULATING 831
VALVE GP-RELIEF 833
VALVE GP-SOLENOID 843
VALVE GP-TRACTION CONTROL 848
WHEEL GP-FINAL DRIVE & BRAKE 850
WHEEL, BRAKE & SUSPENSION GP 854
FRAME AND BODY 865
BODY & CANOPY AS 865
BUMPER GP 869
CABLE GP-RETAINING 871
COWLING GP 872
EXTENSION AS-TAIL 875
FASTENER GP-HANDHOLD 877
FENDER GP 881
FRAME AS 884
FRAME GP 894
GRILL GP-RADIATOR 896
GUARD GP-BOTTOM 897
GUARD GP-DRIVE SHAFT 898
GUARD GP-HYDRAULIC TANK 900
HANDHOLD GP 901
HOOD GP-TRUCK 906
LADDER GP 912
LATCH GP-HOOD 914
LINER GP-BODY 915
LINER GP-EXTENSION 920
LINK GP-LOWER 921
LINK GP-UPPER 923
LUBRICATION GP-AUTOMATIC 925
MIRROR GP-REAR VIEW 934
MOUNTING GP-SUSPENSION 936
MOUNTING GP-TRUCK BODY 937
PUMP GP-LUBRICATION 940
SUPPORT GP-RADIATOR 942
SUSPENSION AR-REAR 944
SUSPENSION GP-FRONT 945
SUSPENSION GP-REAR 947
TREAD GP-NONSKID 954
VALVE GP-LUBE DISTRIBUTION 955
WALKWAY GP 958
BRAKING SYSTEM 961
ACCUMULATOR GP-BRAKE 961
BRAKE GP-SERVICE & PARKING 962
CONTROL GP-FOOT BRAKE 967
CONTROL GP-SERVICE BRAKE 969
FILTER GP-OIL 992
LINES GP-BRAKE 994
LINES GP-BRAKE OIL COOLER 1001
LINES GP-SERVICE BRAKE 1006
PUMP & MOTOR GP-BRAKE
RELEASE 1019
PUMP & MTG GP-BRAKE 1021
SLACK ADJUSTER GP 1024
VALVE & MOUNTING GP 1026
VALVE & MTG GP-BRAKE 1028
VALVE GP-BRAKE CONTROL 1032
VALVE GP-CHECK 1034
VALVE GP-DIVERTER 1035
VALVE GP-RELIEF 1036
VALVE GP-SOLENOID 1038
STEERING SYSTEM 1042
ACCUMULATOR GP-STEERING 1042
ACCUMULATOR GP-HYDRAULIC 1045
CYLINDER & MTG GP-STEERING 1046
CYLINDER GP-STEERING 1048
FASTENER GP-STEERING ARM 1050
FILTER GP-OIL 1051
GEAR GP-STEERING 1052
LINES GP-STEERING 1054
LINK GP-STEERING 1078
LINKAGE GP-STEERING 1079
PUMP GP-METERING 1080
STEERING COLUMN GP 1082
VALVE GP-RELIEF 1084
VALVE GP-SOLENOID 1085
VALVE GP-SOLENOID & RELIEF 1086
VALVE GP-STEERING 1088
SEBP4221 TABLE OF CONTENTS A3
TABLE OF CONTENTS
Name Page Name Page
HYDRAULIC SYSTEM 1091
ACTUATOR GP-PILOT CONTROL 1091
ACTUATOR GP-PUMP 1093
CONTROL GP-HOIST 1094
CONTROL GP-HOIST ELECTRONIC 1096
COVER GP-HYDRAULIC TANK CAP 1097
CYLINDER GP-HOIST 1098
FILTER & MTG GP-OIL 1100
GUARD GP-OIL LINES 1102
HEAD GP-PUMP 1103
HYDRAULIC AR 1106
LINES GP-HOIST 1107
LINES GP-HYDRAULIC FAN 1116
LINES GP-HYDRAULIC OIL COOLER 1130
MANIFOLD GP-HYDRAULIC 1138
MOTOR GP-PISTON 1140
MOUNTING GP-CYLINDER 1144
MOUNTING GP-HYDRAULIC TANK 1145
PUMP & MTG GP-HYDRAULIC 1146
PUMP GP-GEAR 1147
PUMP GP-PISTON 1153
ROTATING GP-MOTOR 1157
ROTATING GP-PUMP 1161
SCREEN GP-HYDRAULIC 1167
SHAFT GP-PUMP DRIVE 1168
TANK GP-HYDRAULIC 1169
VALVE GP-CONTROL 1179
VALVE GP-MAKEUP 1185
VALVE GP-PRESSURE REDUCING 1186
VALVE GP-PUMP CONTROL 1188
VALVE GP-RELIEF 1194
VALVE GP-SHUTTLE 1197
VALVE GP-SOLENOID 1198
OPERATOR STATION 1199
ADJUSTER GP-SEAT 1199
AIR CONDITIONER & MOUNTING GP 1200
AIR CONDITIONER GP 1204
ARMREST GP 1208
BOX GP-STORAGE 1211
CAB AR 1213
CAB GP 1213
CAB GP-ROPS 1215
CLEANOUT GP-CAB 1216
COMPRESSOR & MTG GP-REFRIG 1217
COMPRESSOR GP-REFRIGERANT 1219
CONDENSER & MTG GPREFRIGERANT
1220
CONDENSER GP-REFRIGERANT 1221
DOOR GP-CAB 1223
HORN GP-AIR 1232
IDLER GP-BELT 1233
INSTALLATION GP-RADIO 1234
HEADLINER AS 1236
LINES GP-AIR CONDITIONER 1237
LINES GP-HEATER 1239
LINES GP-SEAT 1242
LITERATURE GP 1243
MODULE GP-MESSAGE CENTER 1243
MODULE GP-QUAD GAUGE 1244
MONITOR GP-PAYLOAD 1246
MOUNTING GP-CAB 1249
MOUNTING GP-PLATFORM 1251
PAN GP-BACKREST 1253
PANEL GP-INSTRUMENT 1254
PANEL GP-SOUND SUPPRESSION 1262
PLATFORM AR 1265
PLATFORM GP-RH 1266
RECLINER GP-SEAT 1267
SEAT AR 1269
SEAT BELT GP 1272
SEAT GP 1273
SEAT GP-SUSPENSION 1280
SUSPENSION GP-SEAT 1284
VISOR GP-CAB 1288
WASHER GP-WINDOW 1289
WIPER GP-WINDOW 1290
SERVICE EQUIPMENT AND SUPPLIES 1292
FILM GP 1292
PLATE & FILM GP 1295
SERVICE CENTER GP 1301
PART NUMBER INDEX B1

CATERPILLAR 797B OFF-HIGHWAY TRUCK PARTS MANUAL – PDF DOWNLOAD:

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