- Off-Highway Truck:
- 797 (S/N: 5YW1-UP)
- 797B (S/N: JSM1-UP)
Description of Change: More lubrication lines have been added in order to increase forced lubrication of the pump drive bearings. The sizes of the drain line has increased. The drain line has been rerouted to the transmission. The increased size of the line will improve the drainage of the lubrication oil. The scavenging effect of the line to the transmission will also improve the drainage of the lubrication oil. These changes will reduce the overall temperature of the bearings. This will improve the service life of the bearings.
Adaptable To: The changes are effective with 797 (S/N: 5YW267) Off-Highway Truck and 797B (S/N: JSM1) Off-Highway Truck. The changes are adaptable to all earlier trucks with a transmission that is newer than (S/N: 5JY685) Transmission or to all earlier trucks with a remanufactured transmission that is newer than (S/N: BPL602) Transmission. Your transmission will only accept the update if there is a port for the pump drive. See Illustration 1 for the location of the port.
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| Illustration 1 | g00929629 |
Note: Do not attempt to modify an existing transmission case. The case will be damaged and the case will not seal properly.In addition to the newer transmission, the pump drive must be updated to the newer style. Use the following procedures in order to update the pump drive and the lubrication lines.
Removal of Parts
| NOTICE |
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Keep all parts clean from contaminants. Contamination of the hydraulic system with foreign material will reduce the service life of the hydraulic system components. To prevent contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. Cover any disassembled components and clean them properly before assembly. Clean the hydraulic system properly after any major component exchange or especially after a component failure, to remove any contamination. |
| NOTICE |
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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, "AVSpare Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on AVSpare products. Dispose of all fluids according to local regulations and mandates. |
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Personal injury can result from hot oil or hot components. At operating temperature, oil is hot and under pressure. Hot oil can cause burns. Remove the fill cap only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand. Do not allow hot oil or components to contact skin. |
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- Chock the wheels. Refer to the Disassembly and Assembly Manual for the proper procedures.
- Install the body retaining pin. Refer to the Disassembly and Assembly Manual for the proper procedures.
- Remove 6V-8724 Elbow (A) and 3J-1907 O-Ring Seal (B) .
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| Illustration 2 | g00929931 |
Left side view | |
- Remove the following components: 2M-9780 O-Ring Seal (C), 6V-8640 Seal Connector (D), 6V-9746 O-Ring Seal (E), 9X-2538 Elbow (F), 6V-8637 Seal Connector (G), 134-3015 Screen (H) and two 3D-2824 O-Ring Seals (J) .
- Remove the following components: 3E-2310 Tee (K), 3J-1907 O-Ring Seal (B), 159-8948 Hose As (L), 6V-8397 O-Ring Seal (M), 6V-9004 Elbow (N), two 6V-9746 O-Ring Seals (E) and 159-8947 Hose As (P) .
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| Illustration 3 | g00929940 |
Rear View | |
Update the Pump Drive
If necessary, update the pump drive. See Illustration 4 and Table 1. Refer to the Disassembly and Assembly Manual for the proper procedures.
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| Illustration 4 | g00930160 |
| Item | Qty | New Pt. No. | Description | Former Pt. No. |
|---|---|---|---|---|
| Q | 1 | 152-3851 E/C 05 | Case | 152-3851 E/C 03 |
| S | 1 | 201-0439 | Seal | 009-2895 |
| R | 2 | 200-5109 | Cage | 152-3851 |
| T | 1 | 5D-0302 | Core Plug | |
| U | 16 | 6V-4429 | Bolt | 7X-2553 |
| V | 16 | 9X-8268 | Washer | 9X-8257 |
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| Illustration 5 | g00930986 |
The change level for 152-3851 Case is cast in the case.
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| Illustration 6 | g00933689 |
The part number for 200-5109 Cage is cast in the cage.
Install the New Parts
| Item | Qty | Pt. No. | Description |
|---|---|---|---|
| 1 | 5 | 3J-1907 | O-Ring Seal |
| 2 | 3 | 6V-8781 | Face Seal Tee |
| 3 | 9 | 6V-8397 | O-Ring Seal |
| 4 | 3 | 159-8945 | Hose As |
| 5 | 2 | 6V-8636 | Connector |
| 6 | 1 | 2P-8421 | O-Ring Adapter |
| 7 | 1 | 3D-2824 | O-Ring Seal |
| 8 | 1 | 216-2249 | Hose As |
| 9 | 2 | 6K-6307 | O-Ring Seal |
| 10 | 1 | 8T-7926 | Connector |
| 11 | 1 | 8T-0315 | O-Ring Seal |
| 12 | 1 | 216-0833 | Hose As |
| 13 | 1 | 4J-0527 | O-Ring Seal |
| 14 | 8 | 8T-4223 | Hard Washer |
| 15 | 4 | 8T-4184 | Bolt |
| 16 | 2 | 1P-4582 | Half Flange |
| 17 | 1 | 105-3378 | Elbow |
| 18 | 1 | 9S-4182 | Plug |
| 19 | 1 | 3J-7354 | O-Ring Seal |
| 20 | 1 | 148-8406 | Plug |
| 21 | 4 | 8T-4176 | Bolt |
| 22 | 1 | 224-3895 | Screen As |
| 23 | 1 | 6F-8146 | O-Ring Seal |
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| Illustration 7 | g00930563 |
- Use three 3J-1907 O-Ring Seals (1) to install three 6V-8781 Face Seal Tees (2) on the pump drive.
- Use one new 6V-8397 O-Ring Seal (3) to connect the existing 159-8945 Hose As (A) to 6V-8781 Face Seal Tee (2) .
- Use four 6V-8397 O-Ring Seals (3) to install two 159-8945 Hose As (4) .
- Use one 3J-1907 O-Ring Seals (1) to install 6V-8636 Connector (5) .
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| Illustration 8 | g00931082 |
- Use two 6V-8397 O-Ring Seals (3) to install 159-8945 Hose As (4) .
- Use the following components to install 6V-8636 Connector (5) in the oil filter: one 3J-1907 O-Ring Seals (1), 2P-8421 O-Ring Adapter (6) and 3D-2824 O-Ring Seal (7) .
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| Illustration 9 | g00931161 |
- Use two 6V-8397 O-Ring Seals (3) to install 216-2249 Hose As (8) .
- Use one 6K-6307 O-Ring Seal (9) to install 8T-7926 Connector (10) to the pump drive.
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| Illustration 10 | g00931236 |
- Install 8T-0315 O-Ring Seal (11) on the 45 degree coupling of 216-0833 Hose As (12) .
- Install 4J-0527 O-Ring Seal (13) on the straight coupling of 216-0833 Hose As (12) .
- Use the following components to install 216-0833 Hose As (12) to the pump drive and to the transmission: eight 8T-4223 Hard Washers (14), four 8T-4184 Bolts (15), two 1P-4582 Half Flanges (16), 105-3378 Elbow (17), 9S-4182 Plug (18), 3J-7354 O-Ring Seal (19), 6K-6307 O-Ring Seal (9), 148-8406 Plug (20), four 8T-4176 Bolts (21), 224-3895 Screen As (22) and 6F-8146 O-Ring Seal (23) .