797A Vs 797B

Serial Numbers
Machine / Component
Sales Model 797A 797B
Eng. Model Number RM593 RM692
PIN 5YW JSM
Engine 3TN 3TN
Front EngineModule 1AW 1AW

Rear EngineModule 2CS 2CS
Transmission 5JY 5JY
Torque Converter 5ST 5ST
797B NPI Launch Kit
DEALER SUPPORT
Contact Lists
Product Support Contacts
Name Position Location E-mail (external) Phone Number Cell Number
Larry Bradshaw Product Sevice Analyst (Help Desk) Cat Global Mining - LMT Bradshaw_Larry_L@cat.com 217-475-4934 217-433-6032
John Bauler Sr. Service Engineer Cat Global Mining - LMT Bauler_John_A@cat.com 217-475-4695 217-433-1711
Eric Ammann Product Performance Engineer Cat Global Mining - LMT Ammann_Eric_J@cat.com 217-475-5783
Gary Patrick Product Support Supervisor Cat Global Mining - LMT Patrick_Gary_B@cat.com 217-475-5613 217-454-1534
Bob Craghead PSD Supportability Consultant Product Support Div. Craghead_Bob_R@cat.com 309-494-5297 309-253-0957
George Heidenblut Industry Consultant/Canada NACD/Calgary Office Heidenblut_George_R@cat.com 780-799-1039
Sean Gladieux Technical Representative NACD/ Phoenix Office Gladieux_Sean_M@cat.com 480-774-2069
Roger Westra Technical Representative NACD/Denver Office Westra_Roger_W@cat.com 303-336-3688
Cameron McGovern SR Service Rep CACO/ Santiago Office Mcgovern_Cameron_J@cat.com 562-366-1505
Quentin Burt Field Service Rep. CAPL - Jakarta District Burt_Quentin_D@cat.com 62-21-780-2114 62-81-113-9795
David D. Smith SR Product Service Engineer Transmission Business Unit Smith_David_D@cat.com 309-494-0923
Robert J Hall Engineer Large Engine Center/Lafayette Hall_Robert_J@cat.com 765-448-2274
Ralph Butler SR Engineer-Development/Re Joliet Hydraulics Butler_Ralph_G@cat.com 815-729-6901
Charlie Grier Engineering Specialist-Dev/Res Cat Electronics Grier_Charles_M@cat.com 309-578-1201

797A to 797B Changes
Brake System
Park Brake - In order to accommodate the increased GMW, the park brake capacity has been
increased by adding 6 additional springs per front wheel, 12 total. The park brake retract
pressure was raised to compensate for the increased spring force. The increased retract
pressure is controlled by a valve in the secondary brake pedal in the cab. The park brake
accumulator has changed from a 2.5 gallon bladder accumulator to a 5 gallon piston
accumulator to resolve a PIR.
Service Brakes - Again, to accommodate the increased GMW and to provide a truck that is
10/10/20 compliant with a 400 ton payload, changes were made to the service brakes on the
797B. The slack adjusters have been simplified and an additional valve, used to allow for faster
filling of the brakes, has been added. A one gallon piston accumulator used to eliminate brake
shudder has been eliminated with the new system. The new configuration allows stopping
distances to be decreased while maintaining the same system pressure used on the 797A. The
5 gallon bladder accumulator used for service brakes on the 797A has been changed to a 5
gallon piston accumulator to resolve a PIR.
Lower Powertrain
Rim Adapters - New rim adapters were released for the 797B. The dual spacing has changed
form 1793 mm to 1780mm. The new adapters resulted in a 56 kg weight reduction. The new
adapters are compatible with all 797 trucks. The old part number has been canceled and
replaced with the new number.
Differential - A change was made to the differential to incorporate a new AETA sensor gear.
The change was made to resolve a PIR.
Steering
To allow for the higher GMW the steering system was redesigned. Larger diameter steering
cylinders were needed. The new cylinders and the larger (59/80R63) tires required changes to
be made to the linkage geometry. The geometry of the t-bar was changed for the new linkage
and to achieve a weight reduction. The steering arms were also changed for the new linkage
geometry, with both a cost and weight reduction being realized. The tie-rods are also new. The
hand metering unit (HMU) in the cab has also been changed to work with the new steering
system. A third steering accumulator has been added to the system because of the higher
cylinder volume. A new spin-on element steering filter replaces the previous steering filter. The
new filter enhances serviceability and resulted in a weight/cost reduction.
6/4/02 RWL 1 797A to 797B Changes

Air System
The air system was redesigned, eliminating the small secondary air tank. A new air dryer
system was implemented. The system switches from one dryer to the other, allowing for
increased drying capacity from the same size dryers. The removal of the secondary tank
required a change to the air compressor governor.
Engine
The engine horsepower has been increased from 3400 to 3550. This change allows the
performance of the truck to remain the same with the higher payloads. The engine mounting
rails have changed. The new rails are the permanent fix for the block cracking issues seen on
early 797 trucks. The interim fix has proven successful in the field but the new design allows for
a 1465 lb weight reduction to the engine package while maintaining structural integrity. Electric
fuel priming pumps have been added to the 797B engine, eliminating the hand pumps used
previously. Engine priming time is greatly reduced and the practice of pre-filling the filters,
which allows unfiltered fuel into the injectors, can be eliminated. A pressure sensor has been
added to the engine coupling. The sensor will trigger a VIMS event if pressure drops below a
certain limit, notifying the operator that there has been a loss of coupling oil.
Frame
The rear engine support castings have changed to allow for the mounting of the new engine
package. The front engine supports were lowered in the frame for the same reason. Changes
were also made to the ROPS tube mounting plates and the upper radiator mounts. Both of
those changes were in response to a PIR. The body slipper pad mounts were also changed to
close a PIR.
Rims
A new rim group is being used on the 797B. The new 44" rim incorporates a tapered 5.5"
flange. This change results in a weight savings over the 6.5" flange used on the final 797A
trucks.
Transmission
The transmission harness has been changed on the 797B. The change was made in response
to an Impact I PIR. The new harness will be available for the A trucks.
Torque Converter
New software changes the torque limit from 17,500 ft-lb of torque to 19,000 ft-lb. This allows
the performance-on-grade to remain the same with the higher GMW.

Body Cables and Mounting Group
A change was made to lower the hoist power down pressure. This change allows for smaller
diameter body prop cables. The new cables are lighter and should be easier for
operators/mechanics to hook up. In addition, the mounting group for the body will be using
phenolic shims rather than steel. The new shims are much lighter and should be easier to
install.

797B Off-Highway Truck Service Literature
09/11/02
English
RENR2571 Fan Drive Hydraulic System, Specifications/Sys Op/Testing & Adjusting
RENR2574 Power Train, Specifications
RENR2575 Power Train, Systems Operation
RENR2576 Power Train, Testing & Adjusting
RENR2578 Steering System, Specifications
RENR2579 Steering System, Systems Operation/Testing & Adjusting
RENR2580 Braking System, Specifications
RENR2581 Braking System, Systems Operation/Testing & Adjusting
RENR2582 Air System, Specifications/Systems Operation/Testing & Adjusting
RENR2583 Suspension Cylinders, Specifications
RENR2584 Suspension Cylinders, Systems Operation/Testing & Adjusting
RENR2585 Hydraulic Systems, Specifications
RENR2586 Hydraulic Systems, Systems Operation/Testing & Adjusting
RENR2587 Hydraulic Schematic
RENR2589 Auto Lubrication Manual
RENR2273 3524B Engine, Specifications
RENR2274 3524B Engine, Systems Operation/Testing & Adjusting
RENR2275 3524B Engine, Troubleshooting
RENR2572 3524B Engine, Disassembly & Assembly
RENR2573 3524B Engine Supplement, Disassembly & Assembly
RENR2577 Power Train, Disassembly & Assembly
RENR2588 Machine Systems, Disassembly & Assembly
1
09/11/02
SEBU7651 Operation and Maintenance Manual
RENR2676 797B Truck Chassis Electronic Control Module
RENR2677 797B Brake Cooling Electronic Control System
RENR2678 797B Transmission Electronic Control System
RENR2620 797B Electrical Schematic
RENR2630 VIMS for Off-Highway Trucks, Systems Operation
RENR2631 VIMS for Off-Highway Trucks, Testing & Adjusting
RENR2635 VIMS for Truck Payload
SEBP3432 797B Parts Manual
Spanish
RSNR2571 Fan Drive Hydraulic System, Specifications/Sys Op/Testing & Adjusting
RSNR2574 Power Train, Specifications
RSNR2575 Power Train, Systems Operation
RSNR2576 Power Train, Testing & Adjusting
RSNR2578 Steering System, Specifications
RSNR2579 Steering System, Systems Operation/Testing & Adjusting
RSNR2580 Braking System, Specifications
RSNR2581 Braking System, Systems Operation/Testing & Adjusting
RSNR2582 Air System, Specifications/Systems Operation/Testing & Adjusting
RSNR2583 Suspension Cylinders, Specifications
RSNR2584 Suspension Cylinders, Systems Operation/Testing & Adjusting
RSNR2585 Hydraulic Systems, Specifications
RSNR2586 Hydraulic Systems, Systems Operation/Testing & Adjusting
RSNR2589 Auto Lubrication Manual
2
09/11/02
RSNR2273 3524B Engine, Specifications
RSNR2274 3524B Engine, Systems Operation/Testing & Adjusting
RSNR2275 3524B Engine, Troubleshooting
RSNR2572 3524B Engine, Disassembly & Assembly
RSNR2573 3524B Engine Supplement, Disassembly & Assembly
RSNR2577 Power Train, Disassembly & Assembly
RSNR2588 Machine Systems, Disassembly & Assembly
SSBU7651 Operation and Maintenance Manual
RSNR2676 797B Truck Chassis Electronic Control Module
RSNR2677 797B Brake Cooling Electronic Control System
RSNR2678 797B Transmission Electronic Control System
RSNR2630 VIMS for Off-Highway Trucks, Systems Operation
RSNR2631 VIMS for Off-Highway Trucks, Testing & Adjusting
RSNR2635 VIMS for Truck Payload
Indonesian (Bahasa)
R8NR2571 Fan Drive Hydraulic System, Specifications/Sys Op/Testing & Adjusting
R8NR2574 Power Train, Specifications
R8NR2575 Power Train, Systems Operation
R8NR2576 Power Train, Testing & Adjusting
R8NR2578 Steering System, Specifications
R8NR2579 Steering System, Systems Operation/Testing & Adjusting
R8NR2580 Braking System, Specifications
R8NR2581 Braking System, Systems Operation/Testing & Adjusting
3
09/11/02
R8NR2582 Air System, Specifications/Systems Operation/Testing & Adjusting
R8NR2583 Suspension Cylinders, Specifications
R8NR2584 Suspension Cylinders, Systems Operation/Testing & Adjusting
R8NR2585 Hydraulic Systems, Specifications
R8NR2586 Hydraulic Systems, Systems Operation/Testing & Adjusting
R8NR2589 Auto Lubrication Manual
R8NR2273 3524B Engine, Specifications
R8NR2274 3524B Engine, Systems Operation/Testing & Adjusting
R8NR2275 3524B Engine, Troubleshooting
R8NR2572 3524B Engine, Disassembly & Assembly
R8NR2573 3524B Engine Supplement, Disassembly & Assembly
R8NR2577 Power Train, Disassembly & Assembly
R8NR2588 Machine Systems, Disassembly & Assembly
S8BU7651 Operation and Maintenance Manual
R8NR2676 797B Truck Chassis Electronic Control Module
R8NR2677 797B Brake Cooling Electronic Control System
R8NR2678 797B Transmission Electronic Control System
R8NR2630 VIMS for Off-Highway Trucks, Systems Operation
R8NR2631 VIMS for Off-Highway Trucks, Testing & Adjusting
R8NR2635 VIMS for Truck Payload
4
MANDATORY ATTACHMENTS
Part # Description Weight (lbs.) Weight (Kg)
225-3049 VIMS, ELEK {ENGLISH/SPANISH} 0
225-3050 VIMS, ELEK {ENGLISH/SPANISH} 0
192-5275 BUMPER, STANDARD 4,021 1824
186-4275 BUMPER, TOWING 4,739 2150
149-3154 SEAT, CAT, AIR SUSPENSION {C500} 0
149-3155 SEAT, ISRINGHAUSEN, AIR SUSPENSION 0
149-7766 WINDOW, PASSENGER DOOR, FIXED 0
152-7950 WINDOW, PASSENGER DOOR, ELECTRIC 0
149-3145 BATTERIES, STANDARD 138 63
196-1226 BATTERIES, HEAVY DUTY 278 126
218-0266 AIR START, VANE, INGERSOLL 891 404
218-0267 AIR START, TURBINE, TDI 778 353
218-0269 AIR START, TURBINE, INGERSOLL 792 360
149-3016 TANK, FUEL 1000 GALLONS 3,099 1406
196-9865 TANK, FUEL 1800 GALLONS 6,012 2727
177-7316 EXHAUST, SIDE 133 61
149-3120 EXHAUST, REAR THROUGH BODY 706 321
214-2298 GUARD, EXHAUST, HANDRAIL 65 30
213-8656 GUARD, EXHAUST, COVER 65 30
222-2853 PUMP, STANDARD 154 70
210-2484 OIL COOLER, REAR AXLE 228 104
221-9266 INSTRUCTIONS, ENGLISH 0
223-1699 INSTRUCTIONS, SPANISH 0
OPTIONAL ATTACHMENTS
Part # Description Weight (lbs.) Weight (Kg)
220-0000 BODY, FLAT FLOOR 104,480 47392
165-2822 LINER, PARTIAL BODY 3,986 1808
4Z-6716 LINER, ROCK BOX 4,210 1909
175-6868 HOSE, CAB CLEANOUT 15 7
149-3176 PRELUBE, ENGINE, AIR START 5 3
203-3098 GUARD, RADIATOR, OIL SANDS 1,132 514
3Z-4856 FIRE EXTINGUISHER, PORTABLE 45 21
204-4406 DISPLAY, EXTERNAL PAYLOAD LH/RH 100 46
209-5236 OIL RENEWAL SYSTEM 32 15
149-0840 GUARD, TORQUE CONVERTER 591 269
215-3636 CONTROL, ROAD ANALYSIS {RAC} 13 6
149-3172 HEATER, FUEL, LARGE TANK 39 18
149-3178 START, COLD WEATHER 207 94
217-7132 MODIFICATION, HIGH ALTITUDE 1,630 740
216-7889 SERVICE CENTER, WIGGINS 130 59
217-0767 TIRES, 59/80R63 MX XDRC4** E4 70,140 337
221-1441 SPARE RIM, 44-63 6,527 2961
207-6029 GUARD, RIM MOUNTING 156 71
797B Specific Recommended Parts
Note: These parts reflect the "new" for the 797B. Additional parts that are serviced will be in SIS/Parts Manual for the "A" Model.
SERVICED NOT SERVICED

GEAR GP - STG 192-3910 X
PUMP GP-METERING 192-3897 X
WIRING GP-CAB 220-5668 X
HARNESS AS 220-5614 X
LINES GP - AIR 192-5745 X
VALVE AS 217-4184 X
PLATE AS 217-9957 X
HOSE AS 218-7262 X
HOSE AS 218-7269 X
HOSE AS 218-7470 X
HOSE AS 218-7276 X
HOSE AS 218-7277 X
HOSE AS 218-7278 X
HOSE AS 218-7279 X
HOSE AS 218-7280 X
HOSE AS 218-7281 X
HOSE AS 218-7285 X
HOSE AS 218-7286 X
LINKAGE GP - STER 192-5690 X
ARM - CENTER 192-5691 X
ARM - STEERING 192-5692 X
LINK GP - STEERING 192-5693 X
CLAMP AS 192-5694 X
CLAMP 192-5701 X
ROD 192-5695 X
SOCKET AS 192-5696 X
BALLSTUD 192-5702 X
PLUG 192-5707 X
RING 192-5703 X
COVER-DUST 192-5704 X
RACE 199-4221 X
SOCKET AS 192-5698 X
ACCUMULATOR GP - C 192-5757 X
ACCUMULATOR GP - B 201-0708 X
ACCUMULATOR GP 214-1736 X
BLADDER 215-2449 X
BLOCK AS 217-0120 X
ACCUMULATOR GP - B 215-5764 X
BLADDER 220-2016 X
BLOCK AS 217-0120 X
PLATE AS 220-7250 X
CYL GP - MOUNTING& 192-5730 X
CYLINDER GP 194-6171 X
CONT GP - BRAKE (A) 192-5665 X
MANIFOLD GP 215-6442 X
HOSE AS 218-4471 X
HOSE AS 218-4472 X
TUBE AS 218-4474 X
HOSE AS 218-4475 X
HOSE AS 218-4477 X
HOSE AS 218-4478 X
HOSE AS 218-4479 X
HOSE AS 218-4480 X
HOSE AS 218-4481 X
HOSE AS 218-4482 X
HOSE AS 218-4483 X
HOSE AS 218-4484 X
HOSE AS 218-4485 X
HOSE AS 218-4486 X
HOSE AS 218-4487 X
HOSE AS 218-4488 X
HOSE AS 218-4489 X
HOSE AS 218-4490 X
HOSE AS 218-4491 X
HOSE AS 218-4492 X
BRACKET AS 218-4493 X
CLAMP 218-4494 X
PLATE 218-4496 X
HOSE AS 223-5974 X
PISTON AS 217-2660 X
SEAL 217-2732 X
BLOCK AS 222-9943 X
LINES GP-STER O 197-4018 X
HOSE AS 221-3017 X
HOSE AS 220-3018 X
HOSE AS 220-3019 X
WIRING GP-CHASSIS 220-5601 X
COWLING GP 149-3084 X
LINK GP 221-0751 X
SUPPORT GP-RAD 221-0335 X
PEDESTAL AS (RH) 219-6248 X
PLATE AS 221-0347 X
PLATE 221-0635 X
PEDESTAL AS (LH) 219-6250 X
PLATE AS 221-0748 X
CASE GP 140-7006 X
MTG GP-BODY 217-9662 X
SHIM-PHENOLIC 218-4424 X
PLATE 154-1808 X
EJECTOR AS 207-2832 X
PLATE 207-2831 X
CABLE GP-SAFETY 219-3074 X
PLATE 219-3310 X
SHACKLE 219-5893 X
KIT-PIN 219-6071 X
CABLE AS 219-5891 X
CABLE AS 219-5892 X
KIT-PIN 219-5894 X
PLATE 219-5896 X
LINES GP - BRAKE - F 192-5666 X
ADJUSTER GP 219-3425 X
PLATE 218-4496 X
MANIFOLD GP 215-6442 X
HOSE AS 218-4498 X
BEVEL GEAR GP 141-3126 X
GEAR AS - SENSOR 218-9978 X
CONT GP-START-B 218-3679 X
HOSE AS 218-3883 X
CONT GP-START-B 218-3680 X
CORE AS - O CLR (STD) 215-4324 X
CORE AS 218-7229 X
BONNET 218-5061 X
LINES GP - OIL COOLER (STD) 218-4466 X
MANIFOLD 219-2896 X
TUBE AS 218-4467 X
MANIFOLD 219-2894 X
MANIFOLD 219-2895 X
HOSE AS 218-4468 X
HOSE AS 218-4469 X
LUBRICANT GP - A 192-5714 X
FILM GP 220-7175 X
FILM-STRIPE 220-7176 X
INSTRUCTION-PAINT 220-7181 X
RIM GP - DMOUNT - D 217-8366 X
FLANGE 217-8365 X
WHEEL GP - SUSP& 192-5826 X
BRAKE GP-SERV 219-1633 X
ANCHOR-BRAKE 211-5048 X
PISTON-PARK 211-5192 X
SERVICE GP-WIGGINS 216-7889 X
PLATE AS 216-7890 X
PLATE AS 216-7891 X
PLATE AS 216-7892 X
HOSE AS 216-7947 X
HOSE AS 216-7949 X
HOSE AS 216-7960 X
HOSE AS 216-7966 X
HOSE AS 216-7972 X
797BPartsList.xls - LE Hook Last Updated-9/12/2002

797B Flash File
6/21/02
NAME PART NO.
Engine Master 217-0760

Engine Slave 217-0761
Transmission 218-1803
Vims 224-8501
Chassis 215-9548
Brake 200-1126
Note: If Truck is equipped with RAC use Vims Software 224-9635

797B Off Highway Truck
Reusability & Salvage/Repair Guidelines
3524B HD Engine
Form # Description
Engine Block
SEHS8869 Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal
SEBF8157 Specifications for Cylinder Blocks 3500 Family Engines
SEBF8164 Specifications for Liner Measurement and Salvage 3500 Family Engines
SEBF8219 Salvage of Cylinder Block Liner Bores 3500 Family Engines
SEBF8255 Procedure to Install Top Deck Liner Seat Inserts Into Cylinder Blocks of 3500
Engines
SEBF8263 Procedure to Repair Top Deck Pitting on Cylinder Blocks 3500 Engines
SELD0458 Cylinder Block Pitting
SEHS8792 Using CAT Replacement Thread Inserts
SEBF8226 Specifications and Salvage for Spacer Plates on 3500 Engines
SEBF8291 Top Deck Threaded Hole Repair in 3400 and 3500 Series Engines
SEBF8076 Specifications to Salvage Cylinder Block Contact Surfaces
Cylinder Head
SEBF8162 Specifications to Measure and Salvage Cylinder Head Assemblies and Related
Components
SEBF8155 Specifications for Cylinder Head Assemblies 3500 Family of Engines
SEBF8283 Reworking Cylinder Head Bolt Holes on 3500 Engines
Piston/Connecting Rods
SEBF8063 Visual Inspection of Connecting Rods
SEBF8049 Pistons
SEBF2743 Ultrasonic Contact Test Instruction Sheet Piston (3500 Engine)
SEBF8149 Specifications for Connecting Rods Used in 3500 Family of Engines
SEBF8059 Procedure to Clean and Inspect Piston in 3500 Family of Engines
SEBF8303 Procedure to Inspect Piston Pins
SEBF8242 Verification of Connecting Rod Eye Bushing Retention Using 5P-8639 Connecting
Rod Bushing Press Group
SEBF8290 Visual Inspection of Two-Piece Pistons
Fuel System
SEBD0717 Diesel Fuels and Your Engine
SEHS8884 Unit Injector Test Specifications for 1.1 Liter Engines, 1.7 Liter Engines, and 3500
Family Engines
Lubrication/Cooling System
SEBD0640 Oil and Your Engine
SEBD0970 Coolant and Your Engine
SEBF8170 Specifications for Engine Oil Pump Measurement and Salvage 3500 Family of
Engines
SEBF2162 Metal Spray Salvage for 3500 Engine
SEBF8085 Inspection and Clean of Rubber Endsheet Oil Coolers
SEBF8418 Salvage of Water Pumps in 3500 Engines
Crankshaft
SEBF8156 Specifications for Crankshaft Measurement for 3500 Family of Engines
SEBF8468 Crankshaft Cleaning Procedure
SMHS8331 Inspection of Crankshaft Main Bearings
SEBF8009 Main and Connecting Rod Bearings
SEBF8054 Procedure to Measure and Straighten Bent Crankshafts
SEBF8094 Procedure to Grind Crankshafts
SEBF8387 Main Bearing Bolt Hole Repair in 3400 and 3500 Series Engines
SEBF8043 Visual Inspection of Crankshafts
SEBF8039 Inspection of Crankshafts for Cracks
SEBF8042 Procedure to Polish Crankshafts
Turbocharger
SEBF8018 Turbochargers
Intake/Exhaust
SEBF8062 Procedure to Clean and Inspect Air Filters
Valve Mechanism
SEBF8146 Visual Inspection of Camshafts

SEBF8154 Specifications for Camshaft Measurement 3500 Family of Engines
SEBF8172 Visual Inspection of the 7N-4782 Lifter Guide Spring 3500 Family of Engines
SEBF8174 Rocker Arms, Rocker Arm Shafts, and Bridge Assemblies for 3500 Engines
SEBF8191 Camshaft Roller Followers 3500 Family of Engines
Gear Train
SEBF8045 Timing Gears For All Engines
SEBF8188 Specifications and Salvage Procedures for Rear Gear Train 3500 Family of
Engines
SEBF8377 Specifications and Salvage Procedures for Front Gear Train on 3500 Engines
Miscellaneous
SEBF8046 Cast Iron and Steel Pulleys
SEBF8301 Inspection and Reuse of Critical Fasteners Used in All Engines
SEBF8405 Kidney Loop Filtration Process for Rebuilt Engines
SEBF8186 Specifications for Trunnion Inspection 3500 Family of Engines
SEBF8175 Specifications for Damper Inspection 3500 Family of Engines
SEBF8202 Inspection of Rear Engine Mounts on 3500 Family of Engines
Hydraulic Systems
Form # Description
SELD0475 Hydraulic Repair Procedures
PEGP6025 Custom Hydraulic Service Guidebook
SEBF8383 CHS Off Highway Truck Inspection
SEBF8388 CHS Off Highway Truck Reference Information
PEVN4621 CHS Off Highway Truck Inspection Video (VHS)
PEVP4621 CHS Off Highway Truck Inspection Video (PAL)
Reminder CHS Inspection Form
NEHT6503 Procedure for Testing Hydraulic Cylinders using the 9U6803 Caterpillar Cylinder
Tester
Power Train
Form # Description
SEBF8318 Final Drive, Steering System, Wheel Braking System, Wheels and Tires Salvage
and Reuse Reference Manual
SEBF8119 Differential Components for Off-Highway Trucks
SEBF8200 Salvage of Differential Bearing Cage
SEBF8227 Salvage of Differential Housing Assembly
SEBF8225 Reusability of Final Drive Splines on 785, 789, and 793 Off-Highway Trucks
SEBF8183 Salvage of Final Drive and Differential Thrust Washer Used in Off-Highway
Trucks, Tractors, and Wheel Loaders
SEBF8093 Planetary Final Drives (Wheeled Vehicles)
SEBF8193 Reusability of Final Drive Gears in Off-Highway Trucks
SEBF8135 Repair of Web Cracks in Final Drive Planetary Carriers
SEBF8443 Procedure to Inspect and Repair Wheels Used on Off-Highway Trucks
SEBF8122 Procedure for Repairing Wheel Rims for Off-Highway Tractors and Trucks
SEBF8083 Procedure to Repair Worn Spindles and Hubs on Off-Highway Trucks
SEBF8199 Salvage of 9D-9729 and 8X-1924 Brake Housings Used on Off-Highway Trucks
SEBF8310 Transmission Salvage and Reuse Guides
SEBF8314 Torque Converter/Divider Drive Line/ Drive Axle Salvage and Reuse Guides
SEBF8272 Tool List for Power Train Components Used in 785, 789, and 793 Off-Highway
Trucks
SEBF8275 Major Non-Engine Power Train Component Receiving and Inspection Report for
785, 789, and 793 Off-Highway Trucks
SEBF8275 Procedure to Salvage Tang Slots and Reaction Dowel Holes in Transmission
Clutch Plates, Pistons, and Housings
SEBF8116 White Layer Flaking of Transfer Gears in Off-Highway Tractors and Trucks
SEBF8181 Salvage Procedure for Transmission Output Carrier for Off-Highway Trucks
RENR3640 Duo-Cone Seal Installation and Assembly Wall Chart
SEBF8126 Universal Joints and Drive Shafts
SEBF2000 Metal Spray Guide
AS3000 Arc Spray Guide
Contacts:
Jim Tyas, Engine Guidelines, (309) 636-5833
Jim McClintock, Hydraulic Systems, (309) 675-8970
Bill Franey, Power Train, (309) 675-6304
George Stenger, Undercarriage, (309) 675-6585
Maintenance and Repair Contracts
Assistance in preparing Maintenance and Repair Contracts (MARC) for mining machines
is available from the MARC coordinator at the Caterpillar Marketing Company for your
geographic area.
TDTO has passed the requirements for the
Lubricant Viscosities TO-4 oil specification. The TO-4 oil
specification includes frictional requirements
The proper oil viscosity grade is determined by and gear wear requirements.
the minimum ambient temperature at engine
start-up and during operation. In order to Note: Multigrade oils must meet the
determine the proper oil viscosity grade, refer requirements of Caterpillar TO-4M for use in
to the “Min” column and “Max” column in the transmissions. Multigrade oils that use high
table. The “Min” column indicates the coldest molecular weight polymers as viscosity index
ambient temperature condition for starting a improvers may loose the viscosity
cold machine and for operating a cold effectiveness because of temporary shear and
machine. The “Max” column indicates the oil permanent shear of the polymer viscosity
viscosity grade for operating the machine at index improver. These types of multigrade oils
the highest operating temperature that is are not recommended for Caterpillar
anticipated. Use the highest viscosity grade Transmissions. The Caterpillar TO-4M oil
that is allowed for the temperature at engine requirement includes a test for shear stability
start-up and during operation. of multigrade oil. If Caterpillar
Transmission/Drive Train Oil is not available,
Oil viscosity grade in the differential and in the use commercial oils that comply with
final drives should not be based solely on Caterpillar TO-4 or TO-4M oil specifications.
ambient temperatures. The duration of
operation and the oil temperatures during Caterpillar FDAO (Final Drive and Axle Oil) is
operation should also be considered. optimized in order to provide the maximum life
Machines that are operated continuously of gears and bearings. FDAO (Final Drive and
should use oils that have the higher oil Axle Oil) provides the maximum performance
viscosity grade in the final drives and in the and maximum protection for the following
differential. The oils that have the higher oil components: differentials, final drives, and
viscosity grade will maintain the highest front wheels.
possible film thickness. Consult your
Caterpillar dealer if additional information is Note: The oil viscosities in the final drives and
needed. differential should not be based only on
ambient temperatures. The following
Operation of the transmission with too high of conditions should be considered when the oil
an oil viscosity grade or too low of an oil viscosity is selected: duration of operation and
temperature can cause friction disc damage. oil temperature during operation. Machines
Friction disc damage is caused by extended that operate continuously should use an oil
shift time and slow clutch pressure rise. with a high viscosity in the final drives and
Thicker oil does not provide the correct differential. Oil with a high viscosity will
amount of oil flow in some areas and thicker maintain a high oil film thickness on the
oil can reduce the lube flow in some areas. components.
Note: Do NOT use Caterpillar gear oil that is

NOTICE EP (Extreme Pressure) or commercial gear oil
The brake systems on the off-highway trucks in the components for Off-Highway Trucks.
MUST use SAE 10W TDTO/TO-4 oil. Do not Gear oil is not compatible with Duo-Cone
use FDAO or TDTO/TO-4 in the engine. seals and the friction materials. Gear oil may
decrease the efficiency of the transmission
Caterpillar Transmission/Drive Train Oil and the performance of the brakes.
(TDTO) is balanced in order to provide
maximum friction material life in the following Note: Refer to Operation and Maintenance
components: power shift transmissions, Manual, SEBU5898, “Cold Weather
steering systems, body hoist systems, torque Recommendations” for the selection of oil
converters, and brake systems. Caterpillar when the machine is operated below –20 °C (-
Transmission/Drive Train Oil (TDTO) may 4 °F).
decrease brake chatter in Caterpillar machines
that are equipped with oil cooled disc brakes. Consult you Caterpillar dealer if additional
information is needed.
Table 1
Lubricant Viscosities for Ambient Temperatures

Compartment Oil Type and Oil °C °F
or System Classification Viscosity Min Max Min Max
Engine Crankcase SAE 0W20 -40 10 -40 50
and Engine Caterpillar Multigrade DEO SAE 0W30 -40 30 -40 86
Coupling (1) Global DHD-1 Multigrade SAE 5W30 -30 30 -22 86
API Multigrade CH-4 SAE 5W40 -30 40 -22 104
API Multigrade CG-4 SAE 10W30 -20 40 -4 104
SAE 15W40 -15 50 5 122
Transmission and Caterpillar TDTO SAE 30 (2) 50 122
Torque Converter Commercial TO-4
System
SAE 0W20 -40 40 -40 104
Caterpillar HYDO SAE 0W30 -40 40 -40 104
Caterpillar DEO SAE 5W30 -30 40 -22 104
Caterpillar MTO SAE 5W40 -30 40 -22 104
Caterpillar TMS SAE 10W -20 40 -4 104
Caterpillar TDTO SAE 30 10 50 50 122
Caterpillar Biodegradable SAE 10W30 -20 40 -4 104
Steering System Hydraulic Oil (HEES) SAE 15W40 -15 50 5 122
API Multigrade CH-4 Caterpillar MTO -25 40 -13 104
API Mulitgrade CG-4 Caterpillar -40 43 -40 110
API Multigrade CF-4 Biodegradable
Global Hydraulic Oil
Commercial TO-4 (HEES) (3)
TMS (4) -20 50 -4 122
Hoist and Brake Caterpillar TDTO SAE 10W (5) -20 50 -4 122
System Commercial TO-4
Differential, Final Caterpillar FDAO SAE 50 (8) (8)
32 (8)
90
Drives, and Front Commercial FD-1 oil SAE 60 (8) (8)
50 (8)
122
Wheels (Optional) (6) (7)
Suspension Caterpillar HYDO SAE 10W - - - -
Cylinders
(1)
The engine crankcase and the engine coupling should use the same oil viscosity and the same oil type.
(2)
SAE 30 oil, TDTO oil, or commercial TO-4 oil is required for all ambient temperatures in the
transmission/torque converter of the 797 Off-Highway Truck. The temperature of the transmission oil must be
above 40 °C (104 °F) before the 797 Off-Highway Truck will shift above first gear.
(3)
Commercial Biodegradable Hydraulic oil (HEES) must meet the Caterpillar BF-1 specification. The listed
ambient temperature range is for current Caterpillar Biodegradable Hydraulic oil (HEES). This temperature
range is not for commercial BF-1 oil.
(4)
Transmission Multi-Season Oil (TMS) exceeds the requirements of the specification for TO-4M multigrade
oil.
(5)
The maximum allowable viscosity at 100 °C (212 °F) is 6.6 cSt (ASTM D445).
(6)
Final Drive and Axle Oil (FDAO) meets the requirements of the specification for FD-1 oil.
(7)
TDTO or commercial TO-4 oil may be used in place of the recommended FDAO or commercial FD-1 oil.
(8)
An FDAO or commercial FD-1 oil is the preferred lubricant in most applications, particularly when the
machine is used continuously. If the ambient temperature is below –10 °C (14 °F), warm-up the oil prior to
operation. The oil must be maintained to a temperature above –10 °C (14 °F) during operation. If the ambient
temperature is below –10 °C (14 °F), perform the procedures in the Operation and Maintenance Manual,
“Differential Warm-up and Break-in” prior to operation. If the ambient temperature is below –25 ° (-13 ° C),
consult your Caterpillar dealer for instructions. Failure to warm-up the oil prior to operation will cause damage
to the machine.
Capacities (Refill)
System Capacities
Table 2
Compartment Liter US Imperial

Gallon Gallon Drain and Refill Capacities
Engine Table 3
Crankcase & 210 55 46
Filter (Each Compartment Liter US Imperial
Engine) Gallon Gallon
Engine Torque
Coupling 38 10 8 Converter 227 60 50
Sump Sump
Torque System for
Converter 303 80 67 Torque 322 85 70
Sump Converter and
System for Transmission
Torque 628 166 138 Hydraulic 1071 283 236
Converter and Tank
Transmission Steering
Hydraulic 1850 489 407 Hydraulic 235 62 52
Tank Tank
Steering Differential
Hydraulic 360 95 79 and Final 1480 391 326
Tank Drive System
Each Front 60 16 13
Wheel
Differential 1176 311 259
Each Final 185 48 40
Drive
Cooling
System 1195 315 263
(Engine and
Auxiliary)
Fuel Tank 3800 1000 835
Optional Fuel 6800 1800 1500
Tank (24 hour)
Windshield 4 1.1 0.9
Washer
Front
Suspension 104 27.5 22.9
Cylinder
Rear
Suspension 61.6 16.3 13.6
Cylinder
Maintenance Interval
Schedule
When Required
Air Conditioner Filter – Clean
Automatic Lubrication Reservoir – Fill
Battery – Recycle
Brake Accumulator Pressure – Release
Brake Oil Cooler Screen – Clean
Cab Air Filter - Clean/Replace
Circuit Breakers – Reset
Differential and Final Drive Oil and Screens -
Change/
Clean
Engine Air Filter Primary Element -
Clean/Replace
Engine Air Filter Secondary Element –
Replace
Engine Air Precleaner – Clean
Ether Starting Aid Cylinder – Replace
Frame and Body – Inspect
Fuel System – Prime
Fuel System Priming Filter – Replace
Hoist Screens – Clean
Oil Filter – Inspect
Steering Accumulator Pressure – Release
Steering Tank Screen – Clean
Traction Control System (TCS) – Test
Window – Clean
Window Washer Bottle – Fill
Window Wiper - Inspect/Replace
Every 10 Service Hours or Daily

Air Tank Moisture and Sediment – Drain
Backup Alarm – Test
Brakes, Indicators and Gauges – Test
Cooling System Level – Check
Differential and Final Drive Oil Level – Check
Engine Coupling Oil Level – Check
Engine Oil Level – Check
Engine Oil Level - Log Additions
Hydraulic Tank Oil Level – Check
Seat Belt – Inspect
Service Inspection
Steering System Oil Level – Check
Tire Inflation – Check
Torque Converter Sump Oil Level – Check
Initial 50 Service Hours

Brake Actuation Oil Filter – Replace
Brake Cooling Oil Filter – Replace
Link and Rear Cylinder (Suspension) –
Check
Pump and Motor Case Drain Oil Filter –
Replace
Steering System Oil Filter - Replace
Torque Converter Oil Filter – Replace
Transmission Oil Filter – Replace
Every 250 Service Hours or Monthly

Battery Electrolyte Level – Check
Braking System – Test
Front Wheel Oil – Inspect
Magnetic Plug (Differential) – Check
Magnetic Plug (Wheels) – Check
Initial 500 Service Hours (or at first oil

change)
Engine Coupling Oil – Change
Engine Coupling Oil Filter – Replace
Engine Valve Lash and Bridge – Adjust
Every 500 Service Hours

Engine Coupling Breather – Clean
Every 500 Service Hours or 3 Months

Air Conditioner – Test
Air Conditioner Filter – Clean
Air Dryer – Check
Automatic Lubrication Reservoir – Fill
Belts - Inspect/Adjust/Replace
Brake Actuation Oil Filter – Replace
Brake Accumulator – Check
Brake Cooling Oil Filter – Replace
Cab Air Filter - Clean/Replace
Cooling System Coolant Additive (DEAC) –
Add
Differential and Final Drive Oil – Inspect
Engine Coupling Oil Filter – Replace
Engine Crankcase Breather – Clean
Engine Oil and Filter – Change
Engine Oil Filter (Oil Renewal System) –
Change
Frame - Clean/Inspect
Front Wheel Oil – Change
Fuel Filter (Oil Renewal System) – Replace
Fuel System Primary Filter – Clean
Fuel System Secondary Filter – Replace
Fuel Tank Breather – Replace
Fuel Tank Cap and Strainer – Clean
Fuel Tank Water and Sediment – Drain
Hydraulic Tank Breather – Replace
Pump and Motor Case Drain Oil Filter –
Replace
Steering Accumulator – Check
Steering System Oil Filter – Replace
Steering Tank Breather – Replace
Suspension Cylinder – Check
Torque Converter Oil Filter – Replace
Torque Converter Outlet and Sump Screens
– Clean
Torque Converter Sump Breather – Replace
Transmission Screens – Clean
Transmission Oil Filter – Replace
Every 1000 Service Hours or 6 Months

Air Dryer Desiccant – Replace
Differential and Final Drive Oil Filter –
Replace
Engine Oil Pan Sump Screen – Clean/Inspect
Frame and Body Support Pads -
Clean/Inspect
Rollover Protective Structure (ROPS) –
Inspect
Service Brakes – Inspect
Steering Ball Stud – Inspect
Steering Linkage – Inspect
Torque Converter and Transmission Oil –
Change
Every 2000 Service Hours or 1 Year

Differential and Final Drive Breather –
Replace
Change/Clean
Engine Air Filter Primary Element -
Clean/Replace
Engine Coupling Oil - Change
Hydraulic Tank Oil - Change
Hydraulic Tank Screen - Clean
Link and Rear Cylinder (Suspension) - Check
Steering System Oil – Change
Every 3000 Service Hours or 2 Years

Auxiliary Water Pump - Inspect
Cooling System Coolant (DEAC) - Change
Cooling System Coolant Extender (ELC) -
Add
Cooling System Pressure Cap -
Clean/Replace
Cooling System Relief Valve - Clean
Radiator Core – Clean
Every 3 Years
Seat Belt – Replace
Every 4000 Service Hours

Engine Valve Lash and Bridge - Adjust
Every 4000 Service Hours or 1 Year
Change/Clean
Engine Oil (Oil Renewal System) - Change
Every 6000 Service Hours or 4 Years

Cooling System Coolant (ELC) - Change
Cooling System Water Temperature
Regulator -Replace
Engine Water Pump - Inspect
Every 1 892 700 L (500 000 US gal) of

Fuel
or 9000 Service Hours
Engine Components - Rebuild/Install Reman
Every 3 785 400 L (1 000 000 US gal) of

Fuel
or 18 000 Service Hours
Engine Components - Clean/Inspect,
Rebuild/Install
Reman, Install New
797 B
Off-Highway Truck
Service Tools
Part Part Tool

Number Name Function Qty
Air Cleaner Cover

*138-7573 Link Bracket Use to R&I the air cleaner cover. 2
Engine and Torque Converter

*4C-8563 Swivel Hose Used to drain the coolant from the oil coolers. Left and right sides. 2
Used to R&I the front pipe assemblies from the front left and front right
*138-7574 Link Bracket 2
turbochargers.
*138-7573 Link Bracket Used to R&I the filter base 1
176-6541 Reaction Clamp Used to provide the torque reaction stop for hydraulic torque wrenches. 1
176-6542 Reaction Clamp Used to provide the torque reaction stop for hydraulic torque wrenches. 1
160-1729 Spreader Bar Used to R&I the engine and engine frame rails as a unit. 1
*4C-6951 Chain Hoist Used to R&I the torque converter from the flywheel housing. 1
*138-7576 Link Bracket Used to R&I the torque converter from the flywheel housing. 2
5P-8622 Shackle Used to R&I the torque converter from the flywheel housing. 1
189-0408 Shackle Used to R&I shipping cover on the torque converter. 2
(+) 203-9603 Engine Shipping Stand Used to ship and store the 3524 engines. 1
Fan
*138-7574 Link Bracket Used to R&I the spider assembly and the support assembly as a unit. 2
Used to support the spider assembly and the support assembly as a unit on the
*(+) 195-
Radiator Cowling Support As (+) 175-7532 Radiator Support. Note Weld nuts me be added to the (+) 195-9649 1
9649
Support Assembly prior to using this tool for this application.
M10 x 50mm Guide Stud Used to locate the shield assemblies during the assembly process. 4
Hood (Front)
*138-7575 Link Bracket Used to R&I the front hood. 2
Hood (Rear)
*138-7575 Link Bracket Used to R&I the rear hood. 2
Radiator
*(+) 175-
Radiator Support Group Used to support the radiator while out of chassis. 1
7532
*138-7575 Link Bracket Multiple usage during the D&A process. 4
8S-1378 Stud Remover Set Used to R&I the stud during the D&A process. 1
*(+) 195- Used to keep the radiator supports aligned while removing and installing the radiator
Radiator Cowling Support As. 1
9649 cores.
*138-7576 Link Bracket Multiple usage during the D&A process. 2
Bar Clamp Used to seat the core assemblies into the tank assemblies. 2
Pressure Test Group Used to pressurize the radiator core assemblies, and tank assemblies in order to 1
check for leaks.
-1 -
Caterpillar: Confidential Green
Last Modified: 09/11/02
check for leaks.
Test Plate Assembly Used to cover the left and right top tank assembly for the pressure test. 2
M16 x 50mm Guide Stud Used to guide the cowling onto the radiator supports darning the assembly process. 2
Radiator Module
*138-7576 Link Bracket (M 30) Used to R&I the radiator module. 2
*(+) 175-
Radiator Support Gp Used to support the radiator while out of chassis. 1
7532
Air Dryer
185-3630 Strap Wrench Assembly Used to R&I the desiccant cartridge located on the end cover. 1
Brake Cooling Motor

176-6539 Bracket Assembly Used to make up the tooling to R&I the brake cooling motor. 1
*(+) 1U-7505 Hydraulic Jack Used to make up the tooling to R&I the brake cooling motor. 1
FT-2723 Support Stand Assembly Used to make up the tooling to R&I the brake cooling motor. 1
Center Arm (Steering)

1U-2678 Hydraulic Jack Used to support the *FT-2677 Support Stand during the R&I process. 1
*FT-2677 Support Stand Attached to 1U-2678 Hydraulic Jack during the R&I process. 1
Control Valve (Hoist)

*1P-1862 Retaining Ring Pliers Used to R&I the retaining ring located in the actuator housing. 1
*156-7100 Puller Group Used to remove the bearing from the plug. 1
*1P-0510 Driver Group Used to install the bearing into the plug. 1
Control Valve (Hoist and Brake Cooling)

*138-7574 Link Brackets Lifting device used during the D&A process. 2
*1P-1862 Retaining Ring Pliers Used to R&I the retaining ring located in the actuator housing. 1
Front Suspension (Cylinder)

Used to separate the front axle from the suspension strut rod. Must be used in the
160-5493 Puller Plate 1
horizontal disassembly process.
Front Wheel, Bearing and Duo-Cone Seal

195-3175 Front Wheel Bearing Handler Used to R&I the front wheel bearing with the front spindle in the vertical position. 1
FT-1845 Brake Release Pump and Fittings Used to release the front parking brake. 1
6K-3601 Flared Connector Used to release the front parking brake. 1
*138-7576 Link Bracket Lifting device used during the R&I and D&A process. 3
163-6455 Link Brackets Lifting device used during the R&I and D&A process. 2
*138-7575 Link Brackets Lifting device used during the R&I and D&A process. 2
9U-5344 Puller Stud (M30X3.5X200MM) Used to R&I the outer bearing cone during the R&I process. 1
*4C-6582 Seal Installer Used to install the seals during the assembly process. 1
*158-6541 Installer Extension Ring Provides extra length for deeper housings. 1
*149-0974 Duo-Cone Seal Installer As Used to install the Duo-Cone seals during the assembly process. 1
(+) 200-4533 Preload Adjuster Used to determine the correct preload during the install process. 1
-2 -
Caterpillar Confidential: Green
*132-8231 Hydraulic Pump Used to R&I the bolts during the R&I process. 1
*132-8112 Hydraulic Torque Wrench Used to R&I the bolts during the R&I process. 1
6V-9120 Socket Used to R&I the bolts during the R&I process. 1
*197-5589 Stud Installer/Remover Used to R&I the studs during the D&A process. 1
Hoist Cylinder
*127-4904 or
Hydraulic Cylinder Repair Stand Used to D&A the hoist cylinder. 1
152-4252 (1)
*136-1452 Internal Tip Pliers Used to R&I the retaining rings during the D&A process. 1
5P-3520 Spanner Wrench Used to R&I the cylinder head during the D&A process. 1
5P-8675 Extension Handle Used to R&I the cylinder head during the D&A process. 1
*138-7575 Link Bracket Used to R&I the cylinder head during the D&A process. 2
Hoist Pump
185-0622 Wrench (30 mm) Used to R&I the hydraulic hoist pump mounting bolts during the R&I process. 1
Hydraulic Tank
*4C-8563 Drain Adapter Used to drain the hydraulic oil from the hydraulic tank. 1
Manifold (Hoist)
*138-7574 Link Brackets Used to R&I the hoist control valve from the manifold during the D&A process. 2
Piston Pump (Brake Cooling Motor Drive)

*3E-3879 Eyebolts Used to place the pump onto the transmission repair stand (*1P-2420) 2
*1P-2420 Transmission Repair Stand Used to support the piston pump during the D&A process. 1
1P-1863 Retaining Ring Pliers Used to remove the snap rings during the disassembly process. 1
*1P-0510 Driver Gp Used to R&I the bearing from the head assembly during the D&A process. 1
1P-0074 Slide Hammer Puller Gp Used to remove the bearing from the housing during the disassembly process. 1
Used to determine the correct shim thickness for the lift-off limitation for the rotating
*1P-1859 Retaining Ring Pliers 1
group during the assembly process.
*171-1114 Alignment Plug 1
*171-1112 Pin (Test) 3
*129-3876 Measuring Bell 1
*171-1113 Measuring Hub 1
*6V-2013 Depth Micrometer Used to determine the correct rod length during the assembly process. 1
Piston Pump (Fan Drive)

*1P-1859 Retaining Ring Pliers Used to R&I the snap rings during the D&A process. 1
*3E-3879 Eyebolts Used to R&I the head assembly from the housing during the D&A process. 2
*1P-0510 Driver Gp Used to remove the bearings during the disassembly process. 1
*171-1114 Alignment Plug 1
*171-1112 Pin (Test) 3
*129-3876 Measuring Bell 1
*171-1113 Measuring Hub 1
*6V-2013 Depth Micrometer Used to determine the correct rod length during the assembly process. 1
-3 -
Pump Drive
1U-7600 Slide Hammer Puller Group Used to remove lip type seal during the disassembly process. 1
*1P-0520 Driver Group Used multiple times during the D&A process. 1
1P-5546 Crossblock Used to remove bottom bearing cage from the case during the disassembly process. 1
5F-7366 Forcing Screw Used to remove bottom bearing cage from the case during the disassembly process. 1
6V-5845 Bolt (M20x2.5x70mm) Used to remove bottom bearing cage from the case during the disassembly process. 2
8T-3282 Hard Washer (M20) Used to remove bottom bearing cage from the case during the disassembly process. 2
8B-7551 Bearing Puller Used to remove roller bearing cone from gears during the disassembly process. 1
1U-9895 Crossblock Used to remove roller bearing cup from case during the disassembly process. 1
1P-2322 Combination Puller Used to remove roller bearing cup from case during the disassembly process. 1
1P-0546 Jaws Used to remove roller bearing cup from case during the disassembly process. 2
Used to determine the correct amount of shims that are required for the bottom
4C-8733 Tapered Gauge 1
bearing cage during the assembly process.
8T-0447 Dial Caliper Used to measure correct shim pack thickness in the assembly process. 1
Rear Axle Housing

Used to support center frame section during the R&I of the rear axle housing and
(+) 176-9274 Center Support Assembly 1
wheel stations as a unit.
Rear Suspension (Cylinder)

*136-1452 Retaining Ring Pliers As Used to R&I the retaining rings during the D&A process. 1
*138-7574 Link Bracket Used multiple times during the D&A process. 2
*8T-5230 Torque Wrench Gp Used to tighten the bolts during the assembly process. 1
*4C-9814 Reaction Bar As Used to tighten the bolts during the assembly process. 1
200-4279 Collet Gauge Used to align the linkage pin during the installation process. 2
Service and Parking Brake (Front)

*160-1726 Plug Gauge Used to measure brake disk wear. 1
Stacking Socket (female 1 – 5/16
203-5431 Used to R&I the brake anchor bolts. 2
mm; male 36 mm)
Stacking Socket (female 1 – 1/2
203-5432 Used to R&I the brake anchor bolts. 2
mm; male 36 mm)
Stacking Socket (female 36 mm;
*203-5433 Used to R&I the brake anchor bolts. 2
male 36 mm)
male 36 mm)
male 46 mm)
*138-7576 Link Bracket Used to position the service and parking brake during the D&A process. 3
*1P-2420 Transmission Repair Stand Used to support the service and parking bake during the D&A process. 1
*154-6181 Forcing Screw Used to secure the spring guide during the D&A process. 4
*3B-4636 Cotter Pin Used to secure the spring guide during the D&A process. 4
*164-4622 Clamp Assembly Used to compress the springs during the D&A process. 1
*200-8885 Stud Remover/Installer M16 Used to R&I the taperlock studs during the D&A process. 1
*150-5492 Brake Alignment Tool Gp Used to install and align the friction disk during the assembly process. 1
-4 -
Steering Accumulator
9U-5980 Lifting Clamp Used to support the accumulator during the D&A process. 2
Steering Cylinder
*FT-2677 Support Stand Used to support the steering cylinder during the R&I process. 1
*1U-9755 Hydraulic Jack Used to support the steering cylinder during the R&I process. 1
176-6537 Spanner Wrench As Used to hold the ball studs during the R&I of the locknut. 1
*132-8231 Hydraulic Pump Used to R&I the locknut. 1
*132-8112 Hydraulic Torque Wrench Used to R&I the locknut. 1
*5P-1748 Socket Used to R&I the locknut. 1
*(+) 1U-7505 Hydraulic Jack Used to push the ball stud out of the assembly during the removal process. 1
*127-4904 or
Hydraulic Cylinder Repair Stand Used to D&A the cylinder. 1
152-4252(1)
*1P-0520 Driver Group Used multiple times during the D&A process. 1
Steering Link
*132-8231 Hydraulic Pump Used to R&I the locknuts during the R&I process. 1
*132-8112 Hydraulic Torque Wrench Used to R&I the locknuts during the R&I process. 1
*5P-1748 Socket Used to R&I the locknuts during the R&I process. 1
176-6538 Spanner Wrench As Used to R&I the locknuts during the R&I process. 1
*1U-9755 Hydraulic Jack Used to dislodge one end f the steering link during the removal process. 1
*(+) 1U-7505 Hydraulic Jack Used multiple times during the R&I process. 1
FT-2678 Support Stand Used to R&I the steering link. 1
Upper and Lower Link (Suspension)

176-6540 Pin Joint Clamp Assembly Used to tighten and loosen the linkage pin bolts for R&I of the link.
Used to remove the linkage pin bolts in minimum clearance applications (used with 1
176-6543 Modified Socket (46 mm)
inch square drive).
*4C-6951 Lever Chain Hoist Gp Used to remove the lower link during the removal process. 1
9U-7489 Lift Stand Used to support the hoist tube and rear suspension cylinder during the R&I process. 2
5H-9976 Screw Used to remove the collet during the R&I process. 3
6V-3141 Plate Used to R&I the pin during the D&A process. 1
4C-9491 Sleeve Used to R&I the pin during the D&A process. 1
*(+) 1U-7505 Hydraulic Jack Used to support the pin during the R&I process. 1
*1U-8758 Retaining Ring Pliers Used to R&I the retaining rings during the D&A process. 1
3S-6224 Electric Hydraulic Pump Gp Used to remove bearing from link during the D&A process. 1
(1)
9U-6815 Puller Stud Used to remove bearing from link during the D&A process. 1
(1)
9U-6810 Nut Used to remove bearing from link during the D&A process. 2
(1)
7X-0542 Washer Used to remove bearing from link during the D&A process. 2
(1)
6V-0014 Double Acting Cylinder Used to remove bearing from link during the D&A process. 1
5P-5212 Plate (1) Used to remove bearing from link during the D&A process. 1
124-4641 Sleeve(1) Used to remove bearing from link during the D&A process. 1
(1)
4C-9493 Sleeve Used multiple times during the R&I process. 1
196-7858 Seal Driver As Used to install link seal during the assembly process. 1
-5 -
*4C-6951 Lever Chain Hoist Gp Used to install the lower link during the installation process. 1
*(+) 1U-7505 Hydraulic Jack Used to support the pin during the installation process. 1
176-6544 Collet Gauge Used multiple times during the installation process. 1
*132-8159 Hydraulic Torque Wrench Used multiple times during the installation process. 1
*132-8231 Power Pack Used multiple times during the installation process. 1
*132-8177 Wrench Link Used multiple times during the installation process. 1
Wheel, Brake and Suspension (Front)

174-9245 Front Strut Carrier Used to support the front cylinder during the R&I process. 1
Axle Shaft
*138-7575 Link Bracket Used to R&I the axel shaft cover. 1
*FT-2676 Retainer Used to support the final drive during the R&I process. 1
188-4534 Axle Carrier Used to R&I the axel shaft. 1

(1)
160-7682 Axle Carrier Used to R&I the axel shaft. 1
Differential and Bevel Gear

190-9944 2 Inch Quick Disconnect Adapter Used to connect filter carts to the differential case. 1
*160-1831 Differential Adapter Assembly Used to R&I the differential and bevel gear. 1
*9U-5986 Eyebolt (M30x3.5-6G Thd) Used to R&I the differential and bevel gear during the D&A process. 3
(+) 195-0767 Frame Assembly Used to position the differential and bevel gear during the D&A process. 1
(+) 195-6167 Rollover Stand Gp Used to position the differential and bevel gear during the D&A process. 1
6V-0006 Governor Pliers Used to R&I the nuts on the harness assembly during the D&A process. 1
*4C-8359 Eyebolt (M12x1.75 Thd) Used multiple times during the D&A process. 3
(+) 195-4988 Hydraulic Floor Jack Gp Used to support differential during the D&A process. 1
(+) 195-0764 Rollover Frame Assembly Used to position the differential and bevel gear during the D&A process. 1
Used to support and rotate the differential carrier during the D&A process. Used with
160-1728 Bracket Adapter Assembly 2
the 4C-9832 engine rollover stand.
Used multiple times during the D&A process. Used with the 160-1728 bracket
4C-9832 Engine Rollover Stand 1
adapter assembly.
190-5624 Hydraulic Hose Gp Used to D&A the housing assemblies during the D&A process. 1
2P-5550 Electric Hydraulic Pump Gp Used multiple times during the D&A process. 1
1U-7528 Hydraulic Cylinder Used to D&A the housing assemblies during the D&A process. 2
194-3725 Bearing Puller Gp(1) Used to R&I the bearing race of the bearing puller cone during the D&A process. 1
5P-5201 Double Acting Cylinder Used to R&I the bearing race of the bearing puller cone during the D&A process. 1
(2)
194-6716 Bearing Splitter (Weld on) Used to R&I the bearing race of the bearing puller cone during the D&A process. 1
194-4809 Gear Handler Used multiple times during the D&A process. 1
(+) 195-0991 Assembly Stand Gp Used to support the spider assembly during the D&A process. 1
9U-6584 Socket (3 inch) Used to R&I the stake nut from the spider assembly during the D&A process. 1
(+) 196-1231 Bearing Puller Gp Used to R&I the spider gear during the D&A process. 1
1P-0820 Hydraulic Puller Used to R&I the spider gear during the D&A process. 1
*1P-0520 Driver Gp Used to R&I the bearing cup on the spider gear during the D&A process. 1
194-4802 Bearing Puller Gp Used to R&I the roller bearing cone during the D&A process. 1
196-0222 Hydraulic Cylinder Used to R&I the roller bearing cone during the D&A process. 1
-6 -
196-0257 Adapter Gp Used to R&I the roller bearing cone and gear during the D&A process. 1
(+) 187-2731 Lifting Bracket As Used multiple times during the D&A process. 1
196-0349 Hydraulic Puller Used to R&I the seal hub from the housing assembly during the D&A process. 1
1U-7552 Hydraulic Cylinder Used to R&I the seal hub from the housing assembly during the D&A process. 1
194-4791 Gear Handler As Used to R&I the bevel gear from the housing assembly during the D&A process. 1
(+) 195-0766 Rollover Frame As Used to position the pinion hub during the D&A process. 1
(+) 194-4803 Bearing Puller Gp Used to R&I the roller bearing cone from the pinion hub during the D&A process. 1
9U-6580 Socket (2 3/4 inch) Used to R&I the plug from the pinion hub during the D&A process. 1
(+) 199-3947 Tap (2 1/2x12 inch) Used to chase the threads of the pinion hub during the disassembly process. 1
194-4804 Bearing Puller Gp Used to R&I the roller bearing cone from the pinion hub during the D&A process. 1
Used to remove the pinion hub from the rollover frame assembly during the
(+) 187-2730 Adapter 1
disassembly process.
Used to remove the pinion hub from the rollover frame assembly during the
1P-7404 Eyebolt (5/16x18-2Z Thd) 1
(+) 194-4792 Gear Handler As Used multiple times during the D&A process. 1
Used to remove the roller bearing cup from differential carrier during the
(+) 196-1218 Bearing Puller Gp 1
FT-2747 Sleeve 1
6V-0113 Double Acting Cylinder 1
186-0350 Bearing Driver As Used to install roller bearing cup on differential carrier during the assembly process. 1
Reamer 20.268 ± 0.013mm
(+) 190-6107 Used multiple times during the assembly process. 1
(0.7980 ± 0.0005 inch)
Pan(1) Used to hold the bolts during the assembly process. 1
186-0344 Driver Cup Used to install the 147-9508 roller bearing cup into the differential. 1
195-0952 Bearing Driver As Used to seat the roller bearing cone during the assembly process. 1
194-8664 Wear Sleeve Driver As Used to install the wear sleeve onto the pinion hub during the assembly process. 1
Used to seat the roller bearing cone in the cage assembly during the assembly
186-0351 Bearing Driver As 1
process.
194-1634 Ball Driver As Used to seat balls into cage assembly during assembly process. 1
178-0344 Bearing Cage Used to determine the setting of the pinion depth during the assembly process. 1
195-0954 Guide Stud Used to determine the setting of the pinion depth during the assembly process. 2
Used to tighten nut on bolted joint of bevel pinion (used with 9U-5007 torque wrench
201-1144 Pinion Wrench
or equivalent).
(+) 194-7585 Pneumatic Wrench Gp Used multiple times during the assembly process. 1
(+) 196-1272 Rotation Gp Used multiple times during the assembly process. 1
(+) 196-1273 Pinion Cage Gp Used multiple times during the D&A process. 1
8T-1000 Electronic Position Indicator Used multiple times during the D&A process. 1
195-0953 Bearing Driver As Used to seat the roller bearing cone during the assembly process. 1
*6V-7030 Micrometer Depth Gauge Group Used multiple times during the assembly process. 1
186-0339 Seal Driver As Used to install lip type seal into cage assembly during the assembly process. 1
Used to install the cage assembly to the differential carrier assembly during the
190-6106 Seal Alignment Guide 1
assembly process.
186-0349 Seal Driver As Used to install the seal hub during the assembly process. 1
195-3168 Bearing Driver As Used to seat roller bearing cone during the assembly process. 1
(+) 1U-7461 Hydraulic Press Used to support the spider gear assembly during the assembly process. 1
194-5246 Plate Used to support the spider gear assembly during the assembly process. 1
(+) 196-0406 Guide Used to support the spider gear assembly during the assembly process. 1
-7 -
Used to install the bearing cup onto spider gear assembly during the assembly
(+) 191-7891 Bearing Driver 1
process.
Used to install the bearing cup onto spider gear assembly during the assembly
(+) 191-7886 Bearing Driver 1
process.
194-4810 Gear Handler As Attaches to the spider gear assembly during the assembly process. 1
(+) 191-7888 Bearing Driver Used to install bearing cones during the assembly process. 1
Used to install the roller bearing cone to the housing assembly during the assembly
194-4790 Bearing Handler As 1
process.
Used to seat the roller bearing cone onto the housing assembly during the assembly
186-0353 Seal Driver As 1
process.
186-0354 Differential Gauge Gp Used to seat the spider assembly during the assembly process. 1
186-0352 Bearing Driver As Used to seat the roller bearing cup in the cage during the assembly process. 1
Used to measure the backlash on the differential carrier assembly during the
194-6226 Differential Gauge Gp 1
assembly process.
(+) 194-8665 Plug Driver Used to install the orifice plug into the housing during the assembly process. 1
(+) 202-2054 Differential Shipping Stand As. Used to ship and store the differential and bevel gear. 1
Drive Shaft (Main)

*138-7573 Link Bracket Used to R&I the cover assembly during the R&I process. 1
156-8166 Metric Tap Used to recondition the bolthole threads in the drive shaft yoke. 1
Final Drive
1-1/2 Inch Quick Disconnect
190-9943 Used to connect filter cart to final drive housing. 1
Adapter
199-8231 Gear Handler 2R Used to remove first reduction sun gear. 1
199-8232 Gear Handler 1R Used to remove second reduction sun gear. 1
(+) 170-5903 Gear Inspection Stand Group Used to inspect the large final drive sun and planet gears for reusability. 1
164-4034 Hoist Ring Used to position the wheel station prior to the R&I of the final drives. 2
132-8223 Hydraulic Pump and Motor Used to R&I the bolts during the vertical R&I of the final drive housing. 1
132-8126 Torque Wrench Used to R&I the bolts during the vertical R&I of the final drive housing. 1
9U-6545 Socket Used to R&I the bolts during the vertical R&I of the final drive housing. 1
*138-7573 Link Bracket Used to support the final drive planetary group during the R&I process. 2
199-8230 Lifting Device Used to R&I the ring gear in the final drive housing during the R&I process. 1
*138-7574 Link Bracket Used to R&I the final drive housing from the wheel assembly. 3
*160-1831 Lifting Adapter Gp Used multiple times during the horizontal R&I process of the final drive. 1
*FT-2676 Sun gear retainer Used to help remove sun gear from final drive in the horizontal position. 1
153-1175 Lifting Bracket Gp Used to R&I the sun gear during the horizontal R&I process of the final drive. 1
Used to R&I the final drive planetary group from the final drive during the horizontal
152-7247 Lifting Bracket Gp 1
R&I process.
153-1174 Lifting Bracket Gp Used to place the final drive onto the workbench for D&A. 1
(+) 199-8234 Support Used multiple times in during the D&A process of the first reduction. 1
(+) 205-0595 Base Used to support the first reduction final drive during the D&A process. 1
(+) 203-6123 Plate Used to support the first reduction final drive during the D&A process. 1
203-6121 Tube Used to support the first reduction final drive during the D&A process. 2
203-7709 Locator Used to locate the carrier on the base during the Disassembly process. 2
201-1115 Pin Used to remove the shafts from the carrier during the disassembly process. 1
203-7712 Locator Used to hold the carrier in place during the disassembly process. 2
-8 -
(+) 4C-5639 Press Used to R&I the shafts of the carrier during the D&A process. 1
201-1117 Retaining Gear Use to hold gear in position during the D&A process. 2
Used to handle gear of the first reduction during the R&I of the gear during the D&A
(+) 199-8236 Gear Handler 1
process.
(+) 201-1116 Driver Used to remove the bearing cups from the gear during the D&A process. 1
(+) 199-8233 Support Used multiple times during the D&A of the second reduction. 1
(+) 203-6120 Plate Used to support the second reduction final drive during the D&A process. 1
203-6118 Shim Used to support the second reduction carrier during the D&A process. 2
203-7713 Locator Used to support the second reduction carrier during the D&A process. 2
201-1114 Pin Used to R&I the shaft in the carrier during the D&A process. 1
203-7714 Locator Used to hold the second reduction in place during the D&A process. 1
201-1118 Retaining Gear Used to hold gear of the second reduction in place during the D&A process. 2
Used to handle gear of the second reduction during the R&I of the gear during the
(+) 199-8235 Gear Handler 1
D&A process.
203-6122 Tube Used to support the first reduction carrier while pressing the shafts into position. 4
*6V-7030 Depth Gauge Used to measure depth of shaft to carrier during the assembly process. 1
6V-7059 Micrometer Used to measure shims during the assembly process. 1
206-6119 Tube Used to support the second reduction carrier while pressing the shafts into position. 4
Used to hold the second reduction carrier in position on base during the assembly
(+) 207-3631 Lifting Device 1
process.
Used to position the shafts onto the second reduction carrier during the assembly
*3E-3879 16 mm Metric Eyebolt 2
process.
Final Drive, Brake and Wheel (Rear)

173-6624 Adapter-Handling Used to R&I the wheel station as a unit from the machine. 1
(+) 202-2053 Shipping Stand Gp Used to trans port the wheel station after removal of the wheel station. 1
159-2833 Socket 55 mm Used to R&I the bolts of the final drive during the R&I process. 1
4C-9813 Socket Extension Used to R&I the bolts of the final drive during the R&I process. 1
*4C-9814 Reaction Bar Used to R&I the bolts of the final drive during the R&I process. 1
6V-6080 Torque Multiplier Used to R&I the bolts of the final drive during the R&I process. 1
*8T-5230 Air Wrench Used to R&I the bolts of the final drive during the R&I process. 1
175-6853 Guide Stud M36 Used to align the rear wheel station to differential housing. 2
Gear Pump (Torque Converter Charging and Transmission Lubrication)

*156-7100 Slide Hammer Puller Used multiple times during the R&I process. 1
Gear Pump (Transmission Charging and Scavenge)

*156-7100 Slide Hammer Puller Used multiple times during the R&I process. 1
Rear Wheel, Bearing, and Duo-Cone Seal

*138-7573 Link Bracket Used to R&I the retainer during the R&I process. 3
*138-7574 Link Bracket Used to R&I the hub during the D&A process. 2
6V-6146 Load Leveling Beam Used to R&I the wheel and to place it in position during the R&I process. 1
Bearing Loading Table(1) Used to assemble the rear wheel station during the install process. 1
*4C-6582 Duo-Cone Seal Installer Used to install the Duo-Cone seals during the assembly process. 1
*158-6541 Installer Extension Ring Provides extra length for deeper housings. 1
*197-5589 Stud Remover/Installer Used to R&I the studs if necessary. 1
-9 -
210-4885 Driver As Used to install tapered cups into the wheel assembly. 1
*149-0974 Duo-Cone Seal Installer As Used to install the Duo-Cone seals during the assembly process. 1
(+) 193-4125 Preload Adjuster Used to determine the correct preload during the install proceeds. 1
Service and Parking Brake (Rear)

*160-1726 Plug Gauge Used to measure brake disk wear. 1
male 36 mm)
male 36 mm)
male 46 mm)
*132-8159 Hydraulic Torque Wrench Gp Used to R&I the nuts and washers during the R&I process. 1
*203-5435 Stacking Socket Used to R&I the nuts and washers during the R&I process. 1
*132-8177 Wrench Link Used to R&I the nuts and washers during the R&I process. 1
132-8223 Hydraulic Pump and Motor Used to R&I the nuts and washers during the R&I process. 1
*138-7576 Link Bracket Used to position the service and parking brake during the D&A process. 3
*1P-2420 Transmission Repair Stand Used to support the service and parking bake during the D&A process. 1
5P-9736 Link Bracket Used to R&I the plate from the brake anchor during the D&A process. 2
*154-6181 Forcing Screw Used to secure the spring guide during the D&A process. 4
*3B-4636 Cotter Pin Used to secure the spring guide during the D&A process. 4
*164-4622 Clamp Assembly Used to compress the springs during the D&A process. 1
*150-5492 Brake Alignment Tool Gp Used to install and align the friction disk during the assembly process. 1
Tire and Rim (Rear)

(+) 176-3856 Stand Used to support the rear of the machine during the R&I of the tires and rims. 1
(+) 194-7592 Pneumatic Wrench Gp Used to R&I the lug nuts during the R&I process. 1
194-7591 Power Pack Used to regulate the wrench during the R&I process. 1
Extension Drive NOTE: 41 inch
194-7593 Used to R&I the lug nuts. 1
rims
Extension Drive NOTE: 44 inch
rims
Deep Well Socket (55mm, 1in
drive)
(+) 201-7602 Adapter Handler Group Used to R&I the split rings in the horizontal position while still on vehicle. 1
Used with pneumatic wrench to react against the tire and rim while removing and
194-7594 Special Reaction Arm 1
installing the lug nuts.
Torque Converter
176-6545 Swivel Hose Used to drain torque converter oil. 1
May be used in place of the 174-1397 mule to R&I the torque converter without
(+) 186-3390 Skid group, Torque Converter 1
removing one fuel tank.
(+) 174-1397 Torque Converter Mule Use to hold the torque converter during the R&I process. 1
*4C-8359 Eyebolt M12 Used multiple times during the D&A process. 3
*4C-8358 Eyebolt M10 Used to R&I the converter stator during the D&A process. 3
*3E-3880 Eyebolt M20 Used to R&I the output shaft during the D&A process. 3
- 10 -
*1U-8758 Pliers Used to R&I the retaining rings during the D&A process. 1
Driver Used multiple times during the assembly process. 1
FT-2515 Guide Bolt Used to align the impeller hub during the D&A process. 1
*1P-0520 Driver Used to R&I the sleeve bearing into the race during the assemble process. 1
Base Used to R&I the sleeve bearing into the race during the assemble process. 1
(+) 202-2057 Shipping Stand Group (Converter) Used to ship and store the torque converter. 1
Torque Converter Housing

*9U-5986 Eyebolt M30 Used multiple times during the D&A process. 2
*3E-3879 Eyebolt M16 Used multiple times during the D&A process. 2
*4C-8359 Eyebolt M12 Used to R&I the torque converter charging and transmission gear pump. 1
Driver PX1136353 Used to remove the bearings during the disassembly process. 1
*3E-3880 Eyebolt M20 Used to position the torque converter during the D&A process. 1
*138-7575 Link Bracket Used to position the torque converter during the D&A process. 2
Driver PX1130743 1
Driver PX1130623 Used to install the bearings during the assembly process. 1
Used to mesh together the oil pump gears and the torque converter gears during the
T Handle PX1133475 1
assembly process.
Driver PX1130628 Used to install the lip seal during the assembly process. 1
Driver PX1130611 Used to install the sleeve during the assembly process. 1
Transmission Hydraulic Control

1P-1853 Retaining Ring Pliers Used to R&I the rings during the D&A process. 1
Transmission Planetary
*4C-8563 Swivel Hose Used to drain the transmission during the removal process. 1
*169-3687 Transmission Bracket Attaches to the transmission during the removal process. 1
Used to disengage the input shaft splines from the output shaft splines during the
(+) 176-6536 Bolt 2
removal process.
*1P-2420 Transmission Stand Used to support the transmission during the D&A process. 1
*4C-8358 10 mm Metric Eyebolt Used multiple times during the D&A process. 3
10 mm Longer Metric Eyebolt (or
Used multiple times during the D&A process. 2
equivalent)
Used to R&I the planetary transmission during the D&A process. 4
equivalent)
Used multiple times during the D&A process. 4
equivalent)
3E-3881 24 mm Metric Eyebolt Used multiple times during the D&A process. 4
5P-5197 External Pliers Used to R&I the retaining ring during the D&A process. 1
*4C-8359 12 mm Metric Eyebolt Used multiple times during the D&A process. 3
*136-1452 Internal Pliers Used to R&I the retaining ring during the D&A process. 1
*1P-0520 Driver Group Used to R&I the bearings during the D&A process. 1
*138-7573 Link Bracket Used to R&I the sun gear during the D&A process. 2
*3E-3879 16 mm Metric Eyebolt Used to R&I the shaft assembly during the D&A process. 3
*3E-3880 20 mm Metric Eyebolt Used multiple times during the D&A process. 3
4C-3082 2-Jaw Puller Used to remove the bearings during the disassembly process. 1
Used multiple times during the assembly process. 3
equivalent)
- 11 -
Used to adjust the distance between the feeling sensor and the gear during the
1U-7234 Feeler Gauge 1
assembly process.
FT- Manifold Used multiple times during the assembly process. 1
8T-5096 Dial Indicator Gp Used multiple times during the assembly process. 1
FT- Plug Attaches to the manifold during the assembly process. 1
174-8986 Stud Used to guide the input haft splines during the installation process. 2
Used to support the primary weight of the transmission planetary during the
*169-3687 Bracket 1
installation process.
(+) 202-2056 Transmission Shipping Stand Used to ship and store the transmission. 1
Tools with the * are duplicated in this document.

(+) Indicates MAO: Made As Ordered Items. Turn around time is approximately 8-12 weeks.
- 12 -
Reman Offerings for 797B Off Highway Truck with E/Mod
Name Part# Reman# Notes
ALTERNATOR GP 3E7577 0R3615
ARM AS-ROCKER 1964793 0R1620
ARM AS-ROCKER 1546388 0R1621
CAMSHAFT 1275410 0R8494
CAMSHAFT 1275411 0R8495
CAMSHAFT 1275412 0R8496
CAMSHAFT 1334080 0R8497
CARRIER 1413140 10R1004
CARTRIDGE GP 1803948 0R1058
COMPRESSOR-GP 1170070 0R8328
CONVERTER AR-TOR 1875008 0R9812
CORE AS-OIL CLR 1940804 0R9972
COUPLING AS 1802915 0R3681
CRANKSHAFT A-UTN 2014250 0R9739
CRANKSHAFT AS 1731798 0R9740
CYLINDER AS-HYD 1503009 UNDER REVIEW
CYLINDER PACK 1720919 UNDER REVIEW
DAMPER AS 1027613 0R7847
ENGINE AR-BASIC 2136602 UNDER REVIEW
GEAR GP-DIF & 1872033 0R9815

HEAD GP-CYL 1453216 0R9472
HEAD GP-CYL-UTN 1453216 0R9473
HEAD GP-CYL-UTN 1612508 0R9471
INJECTOR GP 1504454 0R9735
MOTOR GP-HYD 1900868 10R0541
MOTOR GP-HYD 1711881 0R7321
MOTOR GP-AIR STG 7C3372 0R9851
MOTOR GP-AIR STG 1054324 0R9857
PUMP GP-ENG OIL 4P5638 0R3230
PUMP GP-ENG OIL 1069872 0R4345
PUMP GP-SCAV OIL 1W8508 0R3233
PUMP GP-SCAV OIL 8N9164 0R3860
PUMP GP-SCAV OIL 1448267 0R9250
PUMP GP-F TRF 1698615 0R9848
PUMP GP-HYD 1879682 0R7319
PUMP GP-HYD 1789181 0R7326
ROD AS-CONN 1605919 0R9963
ROD AS-HYD 1946175 UNDER REVIEW
ROD AS-HYD 2199785 UNDER REVIEW
TORQUE CONV AR 1407001 0R9812
TRANSMISSION AR 1407002 UNDER REVIEW
TURBO GP-BASIC 1980228 0R1055
WHEEL AR-FDR&BK 1872032 0R9814
WHEEL AS 1397663 0R9814
Marketer Information
Carol A. Solis, Internal Components, 4-1898
Larry E. Young, Internal Components, 5-8620
Scott M. Smith, Hydraulics, 5-6571
Wally W. Philipp, Cylinder Heads, 5-6921
Glen L. Olinger, Engines, 4-1245
Ron W. Smith, Fuel Systems, 5-5445
Gaik Ong, External Components, 5-4553
Jamie M. Gerstenkorn, Major Components, 6-5839
Vic A. Lucas, 3500 Engines, 5488
Michelle R. Monahan, NPI Integrator, 5-4809

del RM692
Marketer Initials
GO
CAS
CAS
CAS
CAS
CAS
CAS
JMG
GO
GO
JMG
LEY
LEY
LEY
GO
GLO
GLO
SMS
SMS
SMS
CAS
GO
VAL
JMG
WWP
WWP
WWP
RWS
SMS
SMS
GO
GO
LEY
LEY
LEY
LEY
LEY
RWS
SMS
SMS
CAS
SMS
SMS
JMG
JMG
GO
JMG
JMG
Machine Information
E/Model: RM692
Version: -
SNP: JSM
Engine: 3524B
797B Off Highway Truck
Contamination Control Guidelines
Contamination is anything that doesn't belong in machine fluid systems; paint flakes, rag fibers,
metals, greases, weld spatter, sealing materials, and more. When systems are contaminated,
efficiency drops, cycle times increase and component and fluid life is shortened. Eventually,
contamination can lead to catastrophic failure, unplanned downtime, and costly repairs for
customers.
Customer demand for increased productivity has produced industry trends toward electro-
hydraulics, higher system pressures and tighter internal clearances. As a result of these
trends, today's fluid systems (hydraulics, transmissions, steering, power train, engines, and
fuel) will not tolerate dirt and other contaminants like their predecessors. Fluid contamination
threatens reliability throughout the life cycle of today's machines and engines. Therefore,
Caterpillar's goal is to create a Cultural Change by educating Caterpillar Plants, Caterpillar
Dealers and Caterpillar Customers to become Leaders in Contamination Control. Servicing an
older Caterpillar machine population in the past was quite different than servicing today's
machines. The time to invest in product reliability via Contamination Control is NOW!
By addressing this very important aspect of machine operation and life cycle, you will:
· Improve component life and machine productivity

· Lower customer costs and increase customer satisfaction
· Extend product and component life
· Increase rental fleet value
· Reduce Hazardous waste generation
· Reduce service/repair redo
A partial list of the available contamination control information for this vehicle is listed below.
Visit our Contamination Control Web Site at: https://nacd.cat.com/infocast/frames/prodsupp/cc/
Contamination Control Information

Form # Description
PEGP8029 An Introduction to Contamination Control
SEBF8446 Kidney Loop Filtering 769-797 OHT Hydraulic Oil
SEBF8438 Kidney Loop Filtering 785-797 OHT Axle Oil
SEBF8483 Kidney Loop Filtering 793C & 797 OHT Front Spindle Oil
SEBF8460 Kidney Loop Filtering 769D-797 OHT Transmission Oil
SEBF8490 Field Procedures for Cleaning 793C & 797 OHT Front Spindles
SEBF8724 Kidney Loop Filtering 769-797 OHT Steering Oil
SEHS9043 Installing S.O.S Sampling Valves
PEVN4638 How to Take a Proper Oil Sample
SEBF8482 Proper S.O.S Sample Collection
SEBF8485 Cleaning Hose & Tube Assemblies w/the Caterpillar Hose Cleaning Gp.
SEBF8279 Procedure for Using Kidney Looping Filtration Carts
PERV4632 Fluid Contamination Control-The Silent Thief (Video)
PERV4632 Fluid Contamination Control-The Silent Thief (CD)
PEVN4831 Count on Caterpillar Particle Analyzers (Video)
NEXG5038 Count on Caterpillar Particle Analyzers (CD)
Contacts:
Jim McClintock, Contamination Control, (309) 675-8970
Listing of Parts Related Reports Available to Dealers
There are several recommended parts stocking lists and parts summary lists available
from Pats Distribution that can help you, provide for a good product introduction and
adequate parts coverage. It is important to order the correct report to provide you the
most value.
Parts Listings that can be ordered:

To obtain the various parts lists individualized by machine and in some cases by specific
operating hours, in NACD contact the PSD Parts PCL Analyst at 309-636-5728, 309-
636-5729, 309-5727 or 309-636-5734. For other Geographic Marketing Organizations,
contact your Parts Marketing representative at the Geographic Marketing Organization
office.
1. (PCL) Parts Consumption List:

Gives every serviceable part within a model by group level. Shows weights,
prices, returnable indicator, recommended stocking quantities, and whether the
part is a fast, medium, or slow moving item.
2. Remanufactured Parts List:

Provides a list of the remanufactured parts. Cross-references with the
remanufactured parts number and original part number. This report comes out
automatically with the PCL report.
3. Yearly Rate of Expected Replacement:

Parts are listed in alphanumeric sequence and categorized by the operating hours
in which they are expected to be replaced, i.e.: 2000 hour increments up to 22,00
total hours. Parts will show recommended quantities up through the total hours
requested.
Parts without attrition rates, or parts not projected to be replaced during the first
ten years of operation are shown in the 22,000-hour category. Parts without any
recommended quantities could be a MAO (make as ordered) part or a hardware
item. This report comes automatically with the PCL report.
4. (PCL) Maintenance List:

Consists only of maintenance items. This report comes automatically with the
PCL report.
5. (ROL) Recommends Only List:

This list shows serviceable parts within a model by group level that are
recommended.
6. (ROL) Maintenance List:

Consists only of recommended maintenance items. This report comes
automatically with the “Recommends Only List”.
7. Cross-reference List:
Serviceable items contained within the PCL in part number sequence by line item
number reference to the PCL. This report is ordered separately.
8. (PCL) Interchangeability:
A list of all serviceable parts within the PCL in alphanumeric order that can be
interchanged among different machine models. Also, sometimes called a “Pats
Commonality” report. This report can show a percentage of common parts, if
requested and lists specific parts that are interchangeable between the specified
models. Up to a maximum of 10 models can be requested on any one list. This
list must be ordered separately.
9. (PCL) Unique List:

Includes a unique list of all serviceable part numbers found only on the requested
base model when compared to other models requested. This report comes
automatically when ordering to ROL Interchangeability List.
10. (ROL) Interchangeability:

This interchangeability consists only of those parts that are recommended for
stocking for the duration specified in your request. This report must be requested
separately.
11. (ROL) Unique List:

Includes a unique recommended stocking list of serviceable part numbers found
only on the requested base model when compared to other models requested. This
report comes automatically when ordering the ROL Interchangeability List.
12. Bulk hose Stock List:

Consists of three separate reports:
A. The first report consists of a list of hose part numbers extracted from the
PCL for all types of hose.
B. The second report gives a complete breakdown of the hose information,
seals used etc., by hose assembly part number.
C. The third report gives the sum total of all hose lengths, stems and seals
included in the second report.
There is specific information required to request these reports and terminology

understanding associated with understanding the reports. This information can be
obtained from the PCL contacts when you request the needed report.
797B_Diagnostic_Advisor
With exception of Diagnostic Codes, and possibly an Engine Diagnostic, there is

currently no schedule to provide other systems DA for the 797B due to resource cutbacks
and reorganizations. Hydraulics, Power Train, Engine and Diagnostic Codes DA is
currently available for the 797 (5YW) and can be used to diagnose most 797B problems
in the meantime.
TRUCK # 1 - SPECIAL DROP DECK TRAILER
CHASISS
160,050 LBS
TRUCK # 2 - SPECIAL DROP DECK TRAILER
BANJO / FINAL DRIVE ASS’Y SKID
93,000 LBS
DATE 25 JUN 02 797B TRUCK - DOMESTIC & SKID PACK - TRUCK SHIPMENT 0P274
WITH ENGINE INSTALLED IN CHASSIS NI RADIATOR PG 1 OF3
REPLACES 20 SEP 01
TRUCK # 3- 42' (MIN) FLATBED TRAILER
LINK BOX
28”x 38”x 66”
7000 lbs.
CAB SKID FUEL TANK SKID R/H PLATFORM SKID

108”x 83”x 144” 74”x 93”x 102” 64”x 101”x 168”
7,600 lbs. 6,420 lbs. 5,000 lbs.
CAB OUTRIGGER SKID
38”x 63 ”x 77”
2,700 lbs.
28,720 LBS
CENTER LINE
TRUCK # 4 - 42' (MIN) DROPDECK TRAILER
PARTS BOX #1
37”x 48”x 88”
2,820 lbs.
RADIATOR SKID
148”HX101”WX163”L
PARTS BOX #2 14,000lbs
37”x 48”x 88”
3,660 lbs.
20,480 LBS
CENTER LINE
DATE 25 JUN 02 797B TRUCK - DOMESTIC & SKID PACK - TRUCK SHIPMENT 0P274
REPLACES
WITH ENGINE INSTALLED IN CHASSIS NI RADIATOR PG 2 OF 3
20 SEP 01
TRUCK # 5 - 42' (MIN) FLATBED TRAILER
FRONT STRUT SKID HOIST CYLINDER

HOOD/AIR CLEANER SKID REAR STRUT SKID
67”x 78”x 130” SKID
75”x 102”x 144” 31”x 48”x 72”
20,180 lbs. 24”x 48”x 114”
3,540 lbs. 3,900 lbs.
6,940 lbs.
34,560LBS
CENTER LINE
TRUCK # 6 - 42' (MIN) FLATBED TRAILER
FRONT STRUT SKID TRANSMISSION SKID

PIN BOX
67”x 78”x 130” 57”x 60”x 99”
38”HX29”WX53”L
3,175LBS
20,180 lbs. 14,720 lbs.
38,075LBS
CENTER LINE
DATE 25 JUN 02 0P274

797B TRUCK - DOMESTIC & SKID PACK - TRUCK SHIPMENT
REPLACES WITH ENGINE INSTALLED IN CHASSIS NI RADIATOR PG 3 OF 3
20 SEP 01
797B Shipping Weights
Description LBS
Chassis With Engine - Radiator Off 159,980
RAX - With Wheel Stations & Oil 93,000
Rear Struts (Each) 1,930
Front Struts with Wheels 20,180
Transmission 14,720
Engine 43,040
Cab 7,600
Fuel Tank (1800 Gallon) 6,420
Air Box & One Hood Section 2,800
Rear Wheel Station 35,180
Hoist Cylinder 3,100
Cab Out Riggers With Skid 2,700
Torque Converter 7,980
Chassis - Engine Out & Radiator On 116,940
Right Hand Platform With Skid 5,000
Radiator 11,000
Standard Body & Canopy With Liner 113,000
MSD Albian Sands Body & Canopy 92,000
Bare Frame 88,140

KGS
72,718
42,272
877
9,172
6,690
19,563
3,454
2,918
1,272 With Skid - 3,500 LBS
15,990
1,409
1,227
3,627
53,154
2,272
5,000
51,363
41,818
40,063
NPI - Preventive Maintenance Products
Groups Deliverables
1) PM Checklists
• CD Version – JERC4502
• Infocast Subscription – YERC0361
2) Wear Tables
• SOS Newsletters
4) S•O•S Coolant Sampling Intervals –
Level I – Every 500 hours or 30,000 miles for on-highway truck engines
Level II – At initial 1000 hours on new, rebuilt, or refilled cooling systems and annually
or 2000 hours thereafter or as indicated by Level 1 analysis.
S•O•S Oil Sampling Intervals –

SEBU6250-11, Caterpillar Machine Fluids Recommendations has a chart on p. 42 with
the Oil sampling intervals listed as follows:
Engine – 250 hours
Transmission – 500 hours
Hydraulics – 500 hours
Differential
and Final drives – 500 hours
21 June, 2002
797 LMT FIELD ASSEMBLY & COMMISSIONING

MCE QUALITY SERVICES DIVISION WILL PROVIDE A FACTORY REPRESENATIVE (ON SITE
COORDINATOR) TO DIRECT DEALER AND/OR CONTRACT LABOR IN THE FIELD ASSEMBLY
OF THE CHASSIS & BODY TO CHASSIS TO 100% CATERPILLAR INC. SPECIFICATIONS.
THIS ALSO INCLUDES ANY KNOWN PRODUCT SUPPORT PROGRAM UPDATE OR REWORK
THAT CAN BE COMPLETED DURING THE FIELD ASSEMBLY & COMMISSIONING PROCESS
BEFORE THE UNIT IS RELEASED TO THE CUSTOMER FOR OPERATION.
ON SITE COORDINATORS ARE ALSO RESPONSIBLE FOR COMMUNICATING FIELD

ASSEMBLY & COMMISSIONING NON CONFORMANCE ISSUES TO THE FACTORY, OTHER
BUSINESS UNITS AND PF SUPPLIERS. THEY SHALL ALSO PROVIDE FEEDBACK TO
DEALERS REGARDING THE STATUS OF THESE NON CONFORMANCE ISSUES.
MCE DECATUR WILL ALSO PROVIDE, AT NO CHARGE, A FIELD ASSEMBLY VAN

INCLUDING ALL NECESSARY SPECIAL TOOLING (LIFTING DEVICES, TORQUE EQUIPMENT,
CONTAMINATION SAMPLING & TEST EQUIPMENT, etc.).
COMMISSIONING PROCESS (BEFORE RELEASE FOR CUSTOMER OPERATION):
1. TEST & ADJUST -

THE ONSITE COORDINATOR SHALL PERFORM A FIELD PRESSURE TEST & ADJUST OF THE
COMPLETED UNIT. COMPUTERIZED TEST EQUIPMENT & TEST MANAGER SOFTWARE WILL
BE UTILIZED TO CHECK & RECORD THE FOLLOWING SYSTEMS.
ELECTRICAL
BATTERY
LIGHTS
WIPERS
ENGINE
OPERATING TEMPERATURE
IDLE, COOLANT FLOW, OIL PRESSURE, PRELUBE
TRANSMISSION TEST
CALIBRATION
NEUTRALIZER SWITCH
PUMP & LUBE PRESSURE
SHIFTING
CLUTCH ENGAGEMENT
HEATER & A/C OPERATION
HOIST PRESSURE & CYCLE TIME
STEERING PRESSURE
MAIN AIR PRESSURE
BRAKING SYSTEM PRESSURE & CYCLE
SERVICE BRAKE
PARKING BRAKE
SECONDARY BRAKE
TOWING PUMP PRESSURE
TRACTION CONTROL PRESSURE
RAX & DIVERTER VALVE PRESSURE
TORQUE CONVERTER INLET/OUTLET/LOCKUP PRESSURE
FAN/BRAKE COOLING PUMP SPEED/PRESSURE
797 LMT FIELD ASSEMBLY & COMMISSIONING (cont).
2. SIGNATURE TEST -
VIMS DOWNLOAD OF THE FIRST ACTUAL HAUL CYCLE DATA & EVENTS. THIS
ESTABLISHES A BASELINE OF VEHICLE STATUS & PERFORMANCE.
Caterpillar Versus Competitio
Caterpillar Komatsu 930E
Max Payload 380 320
Drive Mechanical Electric
Engine CAT3524B MTU/DDC 16V4000
Horse Power 3550 2700
Top Speed 42 MPH 40 MPH
GVW Max. 1,375,000 lbs. 1,059,000 lbs.
Tires 59/80R63 50/90R57
Length 47' 8" 50' 0"
Width 32' 0" 27' 8"
Height 24' 9" 21' 11"
Body up Height 50' 2" 45' 9"

on
Terex MT5500 Liebherr T1282
340 400
Electric Electric
Cummins QSK60 Cummins QSK78
3000 2750
40 MPH 40 MPH
1,125,000 lbs. 1,163,000 lbs.
55/80R63 55/80R63
48' 0" 47' 6"
29' 8" 28' 8"
23' 8" 21' 2"
43' 7" 45' 9"

797A Vs 797B

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Serial Numbers

Front EngineModule 1AW 1AW

Product Support Contacts

Name Position Location E-mail (external) Phone Number Cell Number

George Heidenblut Industry Consultant/Canada NACD/Calgary Office Heidenblut_George_R@cat.com 780-799-1039

Sean Gladieux Technical Representative NACD/ Phoenix Office Gladieux_Sean_M@cat.com 480-774-2069

Roger Westra Technical Representative NACD/Denver Office Westra_Roger_W@cat.com 303-336-3688

Cameron McGovern SR Service Rep CACO/ Santiago Office Mcgovern_Cameron_J@cat.com 562-366-1505

Robert J Hall Engineer Large Engine Center/Lafayette Hall_Robert_J@cat.com 765-448-2274

Ralph Butler SR Engineer-Development/Re Joliet Hydraulics Butler_Ralph_G@cat.com 815-729-6901

Charlie Grier Engineering Specialist-Dev/Res Cat Electronics Grier_Charles_M@cat.com 309-578-1201

6/4/02 RWL 1 797A to 797B Changes

6/4/02 RWL 2 797A to 797B Changes

6/4/02 RWL 3 797A to 797B Changes

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