Installation Instructions for the Oil Renewal System on 797 Off-Highway Trucks{1348, 1349} Caterpillar


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Installation Instructions for the Oil Renewal System on 797 Off-Highway Trucks{1348, 1349} [REHS1472]
SERVICE EQUIPMENT AND SUPPLIES
LUBRICANTS & FLUIDS
Installation Instructions for the Oil Renewal System on 797 Off-Highway Trucks{1348, 1349}
1.1. Introduction
2.1. Required Materials
3.1. Installation
Off-Highway Trucks:
797 (S/N: 5YW1-UP; 3TN1-UP; 2CS1-UP; 1AW1-UP)
797B (S/N: JSM1-UP)

Introduction

This Special Instruction provides the procedure that is necessary for installing the Oil Renewal System (ORS) on the 797 Off-Highway Trucks.

The ORS has been released as an optional attachment for the 797B Off-Highway Truck. The components are released in order to update the 797 Off-Highway Trucks with the ORS.

The ORS allows a metered amount of engine oil to be automatically injected into the fuel return line to the fuel tank. The engine oil is supplied from the clean side of the engine lube system. The oil and the fuel mixture is then burned during normal engine operation. When the ORS is active the engine oil level must be checked daily. Engine oil must be added in order to replace the engine oil that was used by the ORS. A properly maintained ORS will provide the following: an increased oil change interval, improved quality of the oil and decrease in the disposal of oil.

Do not perform any procedure that is outlined in this Special Instruction until the entire Special Instruction has been read and understood.

Required Materials

Table 1
Item Number     Part Number     Description     Quantity that is Required for One Truck    
Low Altitude Arrangement (LAA) High Altitude Arrangement (HAA)    
797 with out Electric Fuel Priming Pump 797 with Electric Fuel Priming Pump 797 with out Electric Fuel Priming Pump 797 with Electric Fuel Priming Pump    
1     5P-9299     Clip     9     9     7     7    
2     0S-1591     Bolt     1     1            
3     5M-2894     Hard Washer     78     78     77     77    
4     7W-6333     Spacer     1     1            
5     168-2397     Hose As     1     1     1     1    
6     4J-5477     O-Ring Seal     4     4     4     4    
7     142-7363     Oil Metering Valve and Mounting     2     2     2     2    
8     6V-8647     Connector     1     1     1     1    
9     3J-7354     O-Ring Seal     6     6     6     6    
10     209-5255     Bracket     11     1     1     1    
11     0S-1588     Bolt     14     14     14     14    
12     030-7946     Elbow     3     3     3     3    
13     5P-9617     Adapter     4     4     4     4    
14     033-6042     O-Ring Seal     6     6     6     6    
15     0L-1352     Bolt     3     3     3     3    
16     3K-6060     Locknut     3     3     3     3    
17     6V-5048     O-Ring Seal     2     2     2     2    
18     8N-9993     Camshaft Cover     4     4     4     4    
19     162-7473     O-Ring Seal     4     4     4     4    
20     2W-0752     Gasket     4     4     4     4    
21     6V-8636     Connector     1     1     1     1    
22     4D-9517     Clip     1     1     1     1    
23     9S-4185     Plug     4     4     4     4    
24     3K-0360     O-Ring Seal     6     6     6     6    
25     209-5245     Support     2     2     2     2    
26     209-5246     Support     2     2     2     2    
27     217-7049     Hose As     1     1     1     1    
28     6V-8397     O-Ring Seal     4     4     4     4    
29     121-3954     Hose As     1     1     1     1    
30     6V-8634     Connector     1     1     1     1    
31     141-7156     Base As     2     2     2     2    
32     1R-0750     Fuel Filter     2     2     2     2    
33     1A-2029     Bolt     7     7     7     7    
34     3B-1915     Bolt     21     21     21     21    
35     9S-8752     Full Nut     14     14     14     14    
36     0S-1594     Bolt     11     11     11     11    
37     209-5247     Plate As     1     1     1     1    
38     209-5288     Hose As     1     1     1     1    
39     061-8284     Tee     1     1     1     1    
40     8C-7307     Adapter     1     1     1     1    
41     7J-9108     O-Ring Seal     4     4     4     4    
42     6V-8937     O-Ring Reducer     2     2     2     2    
43     6V-8555     Face Seal Nut     2     2     2     2    
44     209-5251     Tube As     1     1     1     1    
45     124-0174     Clip             2     2    
46     0S-1587     Bolt             1     1    
47     5P-8245     Hard Washer             1     1    
48     5K-3294     Clip             1     1    
49     9F-8885     Spacer             1     1    
50     209-5250     Tube As     1     1     1     1    
51     209-5254     Tube As     1     1     1     1    
52     209-5253     Tube As     1     1     1     1    
53     6V-8723     Elbow     1     1     1     1    
54     143-7224     Hose As     1     1     1     1    
55     132-8571     Hose As     1     1     1     1    
56     3S-8664     Clip     2     2     2     2    
57     0L-2070     Bolt     1     1     1     1    
58     127-5446     Spacer     1     1     1     1    
59     030-7941     Elbow     1     1     1     1    
60     209-5248     Plate As     1     1     1     1    
61     209-5249     Bracket     1     1     1     1    
62     6V-8628     Elbow     1     1     1     1    
63     6V-8724     Elbow     1     1     1     1    
64     0T-0065     Bolt     1     1     1     1    
65     0T-0573     Bolt     2     2     2     2    
66     153-7477     Plate     1     1     1     1    
67     205-4830     Tube As     1     1     1     1    
68     205-4829     Tube As     1         1        
69     8S-9191     Bolt     4     4     4     4    
70     4P-0692     Clamp As     4     4     4     4    
71     1A-2161     Spacer     1     1     1     1    
72     6V-9350     Bulkhead Tee     1     1     1     1    
73     209-5252     Support     1     1     1     1    
74     092-7761     Hose As     1     1     1     1    
    188-4691     Harness     1         1        
    195-3809     Harness     1         1        

Table 2
797B Parts Kits for the Oil Renewal System    
Part Number     Description     Application    
209-5236     Oil Metering Group     Tandem    
209-5234 (1)     Oil Metering Group     Front Engine    
209-5235 (1)     Oil Metering Group     Rear Engine    
( 1 ) This group is nonserviceable at this level. This group is part of 209-5236 Oil Metering Group .

Table 3
Required Engine Software    
Application     Software for Master ECM     Software for Slave ECM (2)    
797 LAA     222-9275 Electronic Software     222-9277 Electronic Software    
797B LAA     217-0760 Electronic Software     217-0761 Electronic Software    
797 HAA     226-2242 Electronic Software     226-2243 Electronic Software    
797B HAA     226-2242 Electronic Software     226-2243 Electronic Software    
( 2 ) 2 are required.

Installation




Illustration 1g00942041

Top view of engine 1




Illustration 2g00942178

View A-A

Installation of metering valve

Reinstall the crankcase pressure sensor with a new O-ring (17).




Illustration 3g00942182

View A-A

Installation of the filter




Illustration 4g00942183

Top view of View A-A




Illustration 5g00942189

Installation of the mounting plate

(A) Attach with existing hardware.




Illustration 6g00942190

Installation of the ECM

(B) Reattach existing hose.

(C) Reattach the ECM with existing hardware.




Illustration 7g00942192

View B-B




Illustration 8g00942193

View C-C

Alternate hose routing for models with HAA only




Illustration 9g00943196

Left side view of engine 2




Illustration 10g00943197

Detail D

Installation of the filter




Illustration 11g00943213

Top view of Detail D




Illustration 12g00943214

Installation of the mounting plate

(D) Attach with existing hardware.




Illustration 13g00943216

Installation of the ECM

(E) Attach with existing hardware.

(F) Reattach existing hoses.




Illustration 14g00943219

Detail E

Installation of metering valve

Reinstall the crankcase pressure sensor with a new O-ring (17).




Illustration 15g00943229

Top view of Detail E

(G) Reattach the filter with existing hardware.

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