797F Off-Highway Truck Caterpillar

Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed.

The user is responsible for the performance of maintenance. All adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging are included. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals.

Note: The aftertreatment system can be expected to function properly for the useful life of the engine (emissions durability period), as defined by regulation. All prescribed maintenance requirements must be followed.

Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.

Use the service hour meter for the machine or machine system in order to determine when maintenance should be performed.

When Required

Air Conditioner Filter (Without Precleaner) - Clean
Air Tank - Inspect
Automatic Lubrication Reservoir - Fill
Battery or Battery Cable - Inspect/Replace
Brake Oil Cooler Screen - Clean
Breather (DEF Tank) - Replace
Cab Air Filter - Clean/Replace
DEF Filler Screen - Clean
Diesel Exhaust Fluid - Fill
Display and Camera - Clean
Engine Air Filter Primary Element - Clean/Replace
Engine Air Filter Secondary Element - Replace
Engine Air Precleaner - Clean
Fuel System - Fill
Fuel System - Prime
Fuel System Primary Filter (Water Separator) - Drain
Fuses, Circuit Breakers and Relays - Replace/Reset
Hoist Screens - Clean
Powered Stairway - Check
Pump Drive Return Screen - Clean
Radiator, Aftercooler and Air Conditioner Condenser - Clean
Rim - Inspect
Seat Suspension - Inspect
Traction Control System (TCS) - Test
Transmission Magnetic Screen - Clean
Window Washer Bottle - Fill
Window Wiper - Inspect/Replace
Windows - Clean

Initial 50 Service Hours

Brake Control System Oil Filter - Replace
Brake Cooling Oil Filter - Replace
Differential and Final Drive Oil Filter - Replace
Fan Drive Oil Filter (Case Drain) - Replace
Hydraulic System Oil Filter (Steering and Hydraulic Fan) - R
Link and Rear Cylinder (Suspension) - Check
Steering Pump Case Drain Filter - Replace
Torque Converter Oil Filter - Replace
Transmission Oil Filter - Replace

Initial 250 Service Hours

Engine Oil Sample - Obtain
Engine Valve Lash - Check/Adjust
Fuel Correction Factor - Set

Initial 500 Service Hours

Steering Linkage - Check
Suspension Mounting (Front) - Check

Initial 1000 Service Hours

Steering Linkage - Check
Suspension Mounting (Front) - Check

Every 10 Service Hours or Daily

Air Tank Moisture and Sediment - Drain
Backup Alarm - Test
Braking System - Test
Cooling System Coolant Level - Check
Differential and Final Drive Oil Level - Check
Engine Oil Level - Check
Front Wheel Oil Level - Check
Hoist and Brake Tank Oil Level - Check
Hydraulic Fan and Steering Tank Oil Level - Check
Indicators and Gauges - Test
Seat Belt - Inspect
Steering Accumulator - Check
Suspension Cylinder - Check
Torque Converter Sump Oil Level - Check

Every 250 Service Hours or 2 Weeks

Magnetic Plug (Wheels) - Check
Tire Inflation - Check

Every 500 Service Hours or Monthly

Air Conditioner Filter (With Precleaner) - Clean
Air Dryer - Check
Belts - Inspect/Replace
Brake Accumulator - Check
Brake Control System Oil Sample - Obtain
Breather (Fuel Tank) - Replace
Cab Air Filter - Clean/Replace
Cable (Truck Body Retaining) - Inspect
Centrifugal Oil Filter - Clean
Cooling System Coolant Sample (Level 1) - Obtain
Differential and Final Drive Oil - Inspect
Differential and Final Drive Oil and Screens - Check
Differential and Final Drive Oil Sample - Obtain
Electric Drive Pump (Powered Stairway) Oil Level - Check
Engine Oil - Change
Engine Oil Pan Sump Screen - Inspect/Clean
Engine Oil Sample - Obtain
Frame - Clean/Inspect
Frame and Body - Inspect
Front Wheel Oil - Change
Front Wheel Oil Sample - Obtain
Fuel System Primary Filter (Water Separator) - Replace
Fuel System Secondary Filter - Replace
Fuel Tank Water and Sediment - Drain
Hood Tilt Assist Spring - Lubricate
Hoist and Brake Tank Oil Sample - Obtain
Hoses and Clamps - Inspect/Replace
Magnetic Plug (High Pressure Fuel Pump) - Check
Magnetic Plug (Pump Drive, Hydraulic) - Check
Platform (Powered Stairway) - Lubricate
Secondary Steering - Check
Steering System Oil Sample - Obtain
Suspension Cylinder - Check
Torque Converter Outlet and Sump Screens - Clean
Torque Converter and Transmission Oil Sample - Obtain
Transmission Magnetic Screens - Check

Every 1000 Service Hours or 2 Months

Breather (Differential and Final Drive) - Replace
Breather (Front Axle) - Replace
Breather (Hoist and Brake Tank) - Replace
Breather (Steering Tank) - Replace
Breather (Torque Converter and Transmission) - Replace
Differential and Final Drive Oil Filter - Replace
Frame and Body Support Pads - Clean/Inspect
Manual Lowering (Powered Stairway) - Test
Rollover Protective Structure (ROPS) - Inspect
Service Brakes - Inspect
Steering Ball Stud - Inspect
Steering Linkage - Inspect

Every 2000 Service Hours or 4 Months

Air Inlet System - Test/Inspect
Brake Control System Oil Filter - Replace
Brake Cooling Oil Filter - Replace
Engine Crankcase Breather - Clean
Fan Drive Oil Filter (Case Drain) - Replace
Hydraulic System Oil Filter (Steering and Hydraulic Fan) - R
Link and Rear Cylinder (Suspension) - Check
Main Drive Shaft Universal Joint - Inspect
Steering Pump Case Drain Filter - Replace
Torque Converter and Transmission Oil - Change
Torque Converter Oil Filter - Replace
Transmission Magnetic Screen - Clean
Transmission Oil Filter - Replace

Every 3000 Service Hours or 6 Months

Accumulator - Precharge
Air Dryer Desiccant - Replace
Cooling System Pressure Cap - Clean/Replace
Cooling System Relief Valve - Clean
Engine Mounts - Inspect
Engine Water Pump - Inspect
Radiator, Aftercooler and Air Conditioner Condenser - Clean

Every 4000 Service Hours or 8 Month

Centrifugal Oil Filter (Seals) - Replace
Engine Valve Lash - Check/Adjust

Every 4000 or 6000 Service Hours or 1 Year

Differential and Final Drive Oil and Screens - Change/Clean
Hoist and Brake Tank Oil - Change
Hydraulic Tank Screen - Clean
Rear Axle Oil Filter - Replace
Steering Tank Oil - Change

Every 4500 Service Hours

Diesel Exhaust Fluid Filter - Replace

Every 6000 Service Hours or 1 Year

Accumulator - Discharge
Breather (DEF Tank) - Replace
Cooling System Coolant Extender (ELC) - Add
Cooling System Coolant Sample (Level 2) - Obtain
DEF Manifold Filters - Replace
Diesel Exhaust Fluid Injector - Replace
Electric Drive Pump (Powered Stairway) Oil - Change
Exhaust Inlet Nitrogen Oxide Sensor - Replace
Exhaust Outlet Nitrogen Oxide Sensor - Replace
Exhaust Shields - Inspect
Suspension Cylinder - Check
Wheel Adapter - Inspect

Every 12 000 Service Hours or 2 Years

Coolant Filter Screen (Pump Electronic Tank Unit) - Replace
Cooling System Coolant (ELC) - Change
Main Drive Shaft Spider and Bearing - Replace
Receiver Dryer (Refrigerant) - Replace
Steering Ball Stud - Replace

Every 15 000 Service Hours or 2.5 Years

Rim - Inspect

Every 18 000 Service Hours or 3 Years

Fan - Inspect
Seat Belt - Replace

Every 2 270 000 L (600 000 US gal) of Fuel

Clamps - Replace
Engine Components - Rebuild/Install Reman

Every 4 540 000 L (1 200 000 US gal) of Fuel

Engine Components - Clean/Inspect, Rebuild/Install Reman, Install New