REHS7874

5/4/23, 13:12 SIS 2.
2013/04/03 In-Chassis Replacement of the 304-2688 Oil Pan As in 797F Off-Highway Truck Engines {1302} (REHS7874-00)
SMCS - 1302 i05211210

Off-Highway Truck/Tractor
797F (S/N: LAJ1-UP; WSP1-UP)
Introduction
PIP
This Special Instruction describes how to remove and replace the 304-2688 Oil Pan As and how to install the 394-7231 Stiffener Plate in-chassis.
Safety Section -10

202 894
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
18: 3/04/0 444

12: 5
RE 14-
Do not operate or work on this machine unless you have read and understand the
instructions and warnings in the Operation and Maintenance Manuals. Failure to
HS 05:
follow the instructions or heed the warnings could result in injury or death. Contact
your Cat dealer for replacement manuals. Proper care is your responsibility.
© 2 787 00
023 4
Cat
erp
Accidental engine starting can cause injury or death to personnel working on the
illa
equipment.
r In
To avoid accidental engine starting, disconnect the battery cable from the negative (−)
battery terminal. Completely tape all metal surfaces of the disconnected battery cable
c
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.
.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
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.
Required Parts
Table 1
Required Parts
Qty Part Number
1 303-2236 Integral Seal
1 304-2688 Oil Pan As

1 312-5579 Integral Seal
1 331-8555 Gasket
1 394-7231 Stiffener Plate
1 4C-9614 Silicone Sealant
1 4C-4030 Thread Lock Compound
https://sis2.cat.com/#/print-preview/service/%257B%2522title%2522%253A%2522In-Chassis%2520Replacement%2520of%2520the%2520%25… 1/11
5/4/23, 13:12 SIS 2.0
13 6V-4249 Bolt
Preparation
1. Park the machine on a hard level surface.
2. Turn the engine start switch to the OFF position.
3. Chock the front and rear wheels. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".
4. Attach lockout tagout equipment.
5. Drain the engine oil.
Removal Procedure
Illustration 1 g03336314
Left-hand side view. Some parts have been removed for illustrative purposes.
(1) 6V-5843 Bolts
(2) 6V-5839 Washers
(3) 8T-0643 Bolts
(4) 322-7342 Tube
1. Remove the drain plug from tube (4). Allow the oil to drain form the tube.
2. Remove bolts (1) and washers (2) from the oil pan side of tube (4).
3. Remove bolts (3) and washers (2) from the oil cooler side of tube (4).
5/4/23, 13:12 SIS 2.0
(1) 6V-5843 Bolts
(2) 6V-5839 Washers
(3) 8T-0643 Bolts
(5) 332-1500 Tube As
4. Remove bolts (1) and washers (2) from the oil pan side of tube (5).
5. Remove bolts (3) and washers (2) from the oil filter side of tube (5).
Under side view of the engine oil pan.
(6) 8T-0106 Bolts
(7) 198-4767 Hard Washers
(8) 321-5955 Bracket As
(9) 6V-3303 Bolts
(11) 321-5954 Bracket As
6. Using a suitable lifting device, remove brackets (8) and (11). Each bracket weighs approximately 55 kg (120 lb).
a. Remove bolts (6) and washers (7) from bracket (8).
b. Remove bolts (9) and washers (10) from bracket (8).
c. Remove bolts (6) and washers (7) from bracket (11).
d. Remove bolts (9) and washers (10) from bracket (11).
5/4/23, 13:12 SIS 2.0
Some parts have been removed for illustration purposes.
(1) 6V-5843 Bolts
(2) 6V-5839 Washers
(12) 198-4766 Hard Washer
(13) 6V-5842 Bolts
7. Remove bolts (1) and washers (12) from the center oil pan segment.
8. Remove bolts (2) and washers (13) from the rear oil pan segment.
Underside view of the engine oil pan
(2) 6V-5839 Washers
(13) 6V-5842 Bolts
(14) 6V-8197 Bolts
(15) 5P-8245 Hard Washers
(16) 6V-7673 Bolts
(17) 6V-3823 Bolts
(18) 6V-8336 Bolts
(19) 319-7876 Oil Pan
9. Removal of the 319-7876 Oil Pan
a. Remove bolts (16), (17), (18) and washers (15).
b. Remove all of bolts (13) and washers (2) except the two outer bolts.
c. Use a suitable lifting device to support the rear oil pan segment.
d. Remove the remaining two bolts (13) , two washers (2), bolts (14) and washers (15).
e. Remove oil pan (19).
5/4/23, 13:12 SIS 2.0
(1) 6V-5843 Bolts
(13) 6V-5842 Bolts
(16) 6V-7673 Bolts
(20) 304-2688 Oil Pan As
(21) 8T-5035 Bolts
(22) 329-4762 Bracket As
10. Remove bolts (1) and washers (12).
11. Remove all bolts (16) and washers (7) except the four corner bolts.
14. Remove bracket (22).
15. Use a suitable lifting device to support oil pan (20).
16. Remove the remaining bolts (16) and washers (7).
(23) 101-2862 Dowel
(24) 303-2236 Integral Seal
17. Remove dowels (23).
5/4/23, 13:12 SIS 2.0
(A) Location of cut
(25) 378-7872 Oil Pan As
(26) 331-8555 Gasket
18. Cut gasket (26) flush with the vertical sealing surface of oil pan (25) on both sides of the cylinder block.
19. Clean the sealing surfaces of oil pan (25) and the sealing surface of the cylinder block.
Install Procedure
1. Apply 4C-9614 Silicone Sealant to all T joints (A).
5/4/23, 13:12 SIS 2.0
(7) 304-2687 Oil Pan
(13) 101-2862 Dowel
2. Remove dowels (13) from oil pan (7).
Right-hand side view
(1) 6V-7673 Bolts
(3) 378-7873 Oil Pan
(5) 6V-5843 Bolts
(7) 304-2687 Oil Pan
3. Install a new 331-8555 Gasket.

Note: Apply 4C-4030 Thread Lock Compound to bolts (1) prior to installation.
4. Install all bolts (1) and washers (2). Only torque the four corner bolts to 12 ± 3 N·m (9 ± 2 lb ft). Torquing the corner bolts help align bolts (5).
5. Install bolts (5) and washers (6).
5/4/23, 13:12 SIS 2.0
Left-hand side view
(8) 8T-5035 Bolts
(9) 6V-5842 Bolts
(10) 329-4762 Bracket As
(11) 154-2302 Spacer
(12) 360-8039 Bracket
6. Install bracket (10) to the oil pan using two bolts (8), two washers (6) and two spacers (11) behind bracket (10). Install two bolts (9) and two washers (6) into bracket (12).
7. Tighten bolts (5), (8), (9) to 55 ± 10 N·m (40 ± 7 lb ft)
8. Tighten bolts (1) to 55 ± 10 N·m (40 ± 7 lb ft).
(5) 6V-5843 Bolts
(7) 304-2687 Oil Pan
(15) 319-7876 Oil Pan
9. Install a new integral seal (14) between oil pan (7) and oil pan (15).
5/4/23, 13:12 SIS 2.0
Left hand under side view of the engine
(9) 6V-5842 Bolts
(15) 319-7876 Oil Pan
(16) 6V-5839 Washers
(17) 6V-8336 Bolt
(18) 6V-3823 Bolt
(19) 6V-7673 Bolt
(20) 6V-8197 Bolt
Right hand under side view of the engine
(5) 6V-5843 Bolts
(9) 6V-5842 Bolts
(17) 6V-8336 Bolt
(18) 6V-3823 Bolt
(19) 6V-7673 Bolt
(20) 6V-8197 Bolt
Note: Apply 4C-4030 Thread Lock Compound to bolts (9), (17), (18), (19), and (20) prior to installation.
10. Attach oil pan (15) to the cylinder block using bolts (9), (17), (18), (19), and (20) and washers (16) on all bolts. Only torque the four corner bolts to 12 ± 3 N·m (9 ± 2 lb ft).
Torquing the corner bolts help align bolts (5).
(21) 8T-0106 Bolts
(22) 321-5955 Bracket As
(23) 321-5954 Bracket As
(24) 6V-3303 Bolts
5/4/23, 13:12 SIS 2.0
11. Attach bracket assembly (22) to the oil pan using bolts (21) and washers (2). Hand tighten bolts (21).
12. Attach bracket assembly (22) to the left rear engine mount using bolts (24) and washers (25).
13. Attach bracket assembly (23) to the oil pan using bolts (21) and washers (2). Hand tighten bolts (21).
14. Attach bracket assembly (23) to the right rear engine mount using bolts (24) and washers (25).
(26) 6V-4249 Bolts
(28) 394-7231 Stiffener Plate
15. Attach stiffener plate (28) to the oil pan using bolts (26) and washers (6). Attach the center oil pan to the rear oil pan using bolts (26) and washers (27) in the top holes of
the center oil pan.
16. Tighten bolts (26) to 55 ± 10 N·m (40 ± 7 lb ft).
17. Tighten bolts (9), (17), (18), (19), (20), and (21) to 55 ± 10 N·m (40 ± 7 lb ft).
(5) 6V-5842 Bolts or 6V-5843 Bolts
(29) 259-4600 O-Ring Seals
(30) 322-7282 Flange
(31) 131-3718 O-Ring Seal
(32) 308-7220 Elbow
(33) 8T-0643 Bolts or 6V-5815 Bolts
(34) 322-7342 Tube
Note: The 6V-5842 Bolts must be used with the 344-9288 Flange only. The 6V-5843 Bolts must be used with a 371-6761 Flange only.
5/4/23, 13:12 SIS 2.0
Note: The 6V-5815 Bolts must be used with the 344-9288 Flange only. The 8T-0643 Bolts must be used with the 371-6761 Flange only.
18. Lubricate O-rings (29) with clean engine oil. Install tube (32) into flange (33).
19. Attach the tube flange to flange (34) using two bolts (5) and two washers (16).
20. Attach tube (33) to elbow (32) using two bolts (31) and two washers (16).
(5) 6V-5842 Bolts or 6V-5843 Bolts
(29) 259-4600 O-Ring Seals
(30) 322-7282 Flange
(31) 131-3718 O-Ring Seal
(33) 8T-0643 Bolts or 6V-5815 Bolts
(35) 332-1500 Tube As
(36) 348-5663 Elbow
Note: The 6V-5842 Bolts must be used with a 344-9288 Flange only. The 6V-5843 Bolts must be used with a 371-6761 Flange only.
Note: The 6V-5815 Bolts must be used with the 344-9288 Flange only. The 8T-0643 Bolts must be used with the 371-6761 Flange only.
21. Lubricate O-ring (29) with clean engine oil. Insert tube (35) into flange (30).
22. Attach tube (35) to flange (30) using two bolts (5) and two washers (16).
23. Ensure O-ring (31) is installed and attach tube (35) to elbow (36) using two bolts (33) and two washers (16).
24. Fill the engine with engine oil. Refer to the Operation and Maintenance Manual, SEBU8417 , "Capacities (Refill)".
PIP-10894444
2023/04/05
18:09:27-05:00
i05211210
© 2023 Caterpillar Inc.

REHS7874

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5/4/23, 13:12 SIS 2.

SMCS - 1302 i05211210

Safety Section -10

18: 3/04/0 444

Contaminants may cause rapid wear and shortened component life.

Dispose of all fluids according to local regulations and mandates.

1 304-2688 Oil Pan As

1 4C-4030 Thread Lock Compound

2. Turn the engine start switch to the OFF position.

4. Attach lockout tagout equipment.

5. Drain the engine oil.

a. Remove bolts (6) and washers (7) from bracket (8).

b. Remove bolts (9) and washers (10) from bracket (8).

c. Remove bolts (6) and washers (7) from bracket (11).

d. Remove bolts (9) and washers (10) from bracket (11).

9. Removal of the 319-7876 Oil Pan

a. Remove bolts (16), (17), (18) and washers (15).

e. Remove oil pan (19).

12. Remove bolts (21) and washers (12).

13. Remove bolts (13) and washers (12).

14. Remove bracket (22).

15. Use a suitable lifting device to support oil pan (20).

16. Remove the remaining bolts (16) and washers (7).

17. Remove dowels (23).

1. Apply 4C-9614 Silicone Sealant to all T joints (A).

3. Install a new 331-8555 Gasket.

5. Install bolts (5) and washers (6).

7. Tighten bolts (5), (8), (9) to 55 ± 10 N·m (40 ± 7 lb ft)

8. Tighten bolts (1) to 55 ± 10 N·m (40 ± 7 lb ft).

16. Tighten bolts (26) to 55 ± 10 N·m (40 ± 7 lb ft).

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