- Off-Highway Truck/Tractor:
- 797 (S/N: 5YW1-UP)
- 797B (S/N: JSM1-UP)
Introduction
This Special Instruction contains the necessary procedures and information to install the 378-8507 Oil Filter Base As on the machines listed above. The 378-8507 Oil Filter Base As is a part of 448-1345 Oil Filter Base Gp .
Safety
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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on. |
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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. |
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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines. |
Note: Cleanliness is an important factor. Before beginning the removal procedure, clean the exterior of the components thoroughly. Cleaning the components will help to prevent dirt from entering the internal mechanism.
Note: Put identification marks on all hoses, on all hose assemblies, on all harness assemblies, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies in order to prevent fluid loss, and contaminants from entering the system.
Parts List
| Required Parts List | |||
| Item | Qty | Part Number | Specification Description |
| 1 | 1 | 378-8507 | Oil Filter Base As |
| 2 | 1 | 9S-4181 | O-Ring Plug |
| 3 | 2 | 238-5084 | O-Ring Seal |
| 4 | 2 | 134-0964 | Oil Filter Element As |
| 5 | 2 | 194-7986 | O-Ring Kit |
| 6 | 1 | 238-5080 | O-Ring Seal |
| 7 | 2 | 9S-4185 | O-Ring Plug |
| 8 | 1 | 8J-0426 | Plug |
| 9 | 8 | 8T-4136 | Bolt |
| 10 | 8 | 8T-4121 | Hard Washer |
| 11 | 1 | 448-1344 | Hose As |
| 12 | 4 | 235-2475 | Rectangular Seal |
| 13 | 1 | 448-1343 | Hose As |
| 14 | 1 | 393-5112 | Differential Pressure Switch As |
| 15 | 1 | 214-7568 | O-Ring Seal |
| 16 | 1 | 5F-9144 | O-Ring Seal |
| 17 | 1 | 116-6203 | Resistor |
Rework Procedure to Install 378-8507 Oil Filter Base As
- Remove 235-2475 Rectangular Seals (C), four 8T-4194 Bolts (D), four 8T-4223 Hard Washers (E), and two 1P-5767 Half Flanges (F). Discard rectangular seals (C) and save all the remaining hardware.
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| Illustration 1 | g03544796 |
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| Illustration 2 | g03544797 |
View of area A 195-2305 Hose As (B) | |
- Remove 195-2305 Hose As (B), 235-2475 Rectangular Seal (C), three 6V-1572 Clips (G), three 6V-1573 Clips (H), three 6V-1875 Grommets (J), two 8T-6466 Bolts (K), 8T-4195 Bolt (M), three 8T-4121 Hard Washers (L), four 8T-4194 Bolts (D), four 8T-4223 Hard Washers (E), and two 1P-5767 Half Flanges (F). Discard hose assembly (B) , rectangular seal (C), and save all the remaining hardware.
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| Illustration 3 | g03544816 |
- Remove 294-8247 Hose As (N), two 235-2475 Rectangular Seals (C), eight 8T-4194 Bolts (D), eight 8T-4223 Hard Washers (E), and four 1P-5767 Half Flanges (F). Discard hose assembly (N), rectangular seals (C), and save all the remaining hardware.
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| Illustration 4 | g03544836 |
- Remove 195-2304 Hose As (R) and discard the part.
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| Illustration 5 | g03544837 |
- Remove two 195-2303 Manifolds (S), two 7X-3166 Swivel Adapters (T), 329-5529 Elbow As (U), two 136-7032 Hydraulic Oil Filter Housing (V), two 155-6061 Oil Filter Gp (W), 329-5522 Tee As (X), 329-5527 Tee As (AA), two 244-3712 Plug As (Y), and two 238-5082 O-Ring Seals (Z). Save hydraulic oil filter housing (V) and discard all other parts.
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| Illustration 6 | g03544856 |
- The new oil filter base assembly (1) is assembled with two O-Ring plugs (2), two O-Ring seals (3), two oil filter element assemblies (4), two O-Ring kits (5), two O-Ring seals (6), and two O-Ring plugs (7). Use hydraulic oil filter housing (V) that was saved in Step 5 to pack the filter element assemblies (4) as shown in the Illustration 7.
Note: Using 9S-4181 O-Ring Plug (2) is critical due to the internal cavity which allows clearance to the internal bypass valve when installed in the port shown in Illustration 7. (Solid plug will not work).
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| Illustration 7 | g03708657 |
- Remove one of the O-Ring plug (2) from the oil filter base assembly (1). Install a new plug (8) along with O-Ring seal (3) on the oil filter base assembly (1) to allow for the assembly of the 221-3407 Pressure Sensor Gp to the end of oil filter base assembly (1). Refer to Illustration 8.
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| Illustration 8 | g03710685 |
- Mount the assembled oil filter base assembly (1) using eight bolts (9) and eight hard washers (10). Tighten bolts (9) to 45 N·m (33 lb ft).
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| Illustration 9 | g03710688 |
- Install new hose assembly (11) and new O-Ring seals (12) with parts that were saved in Step 3. Tighten eight bolts (D) to 80 N·m (59 lb ft).
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| Illustration 10 | g03710689 |
- Install new hose assembly (13) and two new O-Ring seals (12) with parts that were saved in Step 1 and Step 2. Tighten eight bolts (D) to 80 N·m (59 lb ft) and one bolt (M) to 45 N·m (33 lb ft). Refer to Illustration 11 and Illustration 12 for proper orientation and mounting location for hose assembly (13) .
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| Illustration 11 | g03710690 |
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| Illustration 12 | g03710691 |
- Install new differential pressure switch (14) with O-Ring seal (15) and O-Ring seal (16). Tighten differential switch (14) to 30 N·m (265 lb in).
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| Illustration 13 | g03710684 |
- Install resistor (17) to complete the circuit, since only one switch is required for the new manifold. Connect the ends of the switch and resistor on the top of the new oil filter base assembly as shown in the Illustration 13.