- Off-Highway Truck:
- 797 (S/N: 5YW1-UP)
- 797B (S/N: JSM1-UP)
ReferenceSpecial Instruction, REHS3711, "Installation of the New Configuration for the 157-2144 Prelubrication Oil Pump Gp "
Description of Change: The plate assembly that holds the prelubrication motor has been changed. The new design of the plate has been redesigned in order to improve durability. The new design uses blocks that are not welded to the plate in order to mount the pump from the top.
Adaptable To: The 196-4689 Straps that originally held the prelubrication motor were replaced by a plate assembly that contained blocks. The straps were part of the 149-3176 Prelubrication Lines Gp (If Equipped). The 149-3176 Prelubrication Lines Gp (If Equipped) has been cancelled.
The 297-6586 Prelubrication Lines Gp is now used. The 288-3821 Plate As that contained the blocks, the 288-3822 Bracket As, and the 288-3826 Clamps were designed to provide additional support to the prelubrication pump. The redesigned configuration for the support was effective in production with machines JSM261-373. The change was adaptable back to the beginning of production on these machines.
The 297-6586 Prelubrication Lines Gp has been updated. The 288-3821 Plate As has been cancelled and replaced by one new 318-3738 Plate, two new 289-0852 Blocks, one new 9G-0028 Boss As and one new 8D-3508 Boss. The new plate, the two new blocks, the one new boss assembly and the one new boss will provide a more rugged design for the field.
The updates to the 297-6586 Prelubrication Lines Gp became effective in production with the machine JSM374-UP. The update to the prelubrication lines is adaptable back to the beginning of production of the machines.
If your machine is in the range of JSM261-373 that contains the 297-6586 Prelubrication Lines Gp (If Equipped), use the following procedure in order to update the machines to the latest configuration of the 297-6586 Prelubrication Lines Gp .
If your machine originally contained the 149-3176 Prelubrication Lines Gp (If Equipped) with the 196-4689 Straps that was upgraded to the plate assembly that contained blocks, use the following procedure in order to update the machines to the latest configuration of the 297-6586 Prelubrication Lines Gp .
If your machine contains the 149-3176 Prelubrication Lines Gp (If Equipped) that contained the 196-4689 Straps that was not upgraded to the plate assembly that contained blocks, refer to Special Instruction, REHS3711, "Installation of the New Configuration for the 157-2144 Prelubrication Oil Pump Gp " for the complete instruction in order to update your machine to the latest configuration for the prelubrication oil pump group.
| Parts Needed to Update the 297-6586 Prelubrication Lines Gp . | |||
| Item | Qty | Part Number | Description |
| 1 | 2 | 289-0852 | Blocks |
| 2 | 1 | 318-3738 | Plate |
| 3 | 1 | 9G-0028 | Boss As |
| 4 | 1 | 8D-3508 | Boss |
| 5 | 2 | 5P-9299 | Clips |
| 6 | 1 | 252-1836 | Cable As |
| 7 | 1 | 5M-3062 | Bolt |
| 8 | 1 | 7X-7729 | Washer |
| 9 | 1 | 4L-6454 | Bolt |
- Move the machine to a smooth horizontal location. Move the machine away from any machines that are working and any personnel.
- Move the transmission control to the PARK position.
- Activate the parking brakes. Stop the engine.
- Permit only one operator on the machine. Either keep other personnel away from the machine, or keep other personnel in the sight of the operator.
- Place blocks in front of the wheels and behind the wheels.
- Remove the one bolt (11), one hard washer (12) and two nuts (13) in order to remove strap (10). Save the washer and the nuts. Discard the bolt and the strap.
 | |
| Illustration 1 | g01595909 |
- Remove the four bolts (15) and four washers (16) in order to remove the two clamps (14). Save all of the parts.
Note: Leave the prelubrication pump connected to the hoses.
- For the 797 machines, remove the four bolts (17), the four hard washers (18) and the two clips (21) in order to remove plate assembly (20) and the two blocks (19). Save the bolts, hard washers and blocks. Discard the two clips (21) .
 | |
| Illustration 2 | g01595911 |
- For the 797B machines, remove the four bolts (22), the four hard washers (18) and the two clips (21) in order to remove plate assembly (20). Save the bolts and hard washers. Discard the two clips (21) .
 | |
| Illustration 3 | g01595933 |
- Remove the four bolts (23) and the four hard washers (24) in order to remove plate (20) from the prelubrication pump. Save all of the bolts and hard washers. Discard plate (20) .
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| Illustration 4 | g01595936 |
- By using the four bolts (23) and the four hard washers (24) that were saved in Step 10, attach plate (2) to the prelubrication pump.
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| Illustration 5 | g01595975 |
- By using the dimensions that are listed in Illustration 6, locate the position for the one boss (3) and the one boss (4).
By using the weld that is specified in Illustration 6, weld the two bosses into position. The weld must meet the following specifications: AWS A5.1 E7018, AWS A5.18 ER70S-2, AWS A5.18 ER70S-3, AWS A5.18 ER70S-6, AWS A5.18 ER70C-6M, AWS A5.20 E70T-1, AWS A5.20 E70T-5, AWS A5.20 E71T-1, AWS A5.17 F7A2-EM12K and AWS A5.17 F7A2-EM13K
 | |
| Illustration 6 | g01595953 |
(A) 131 mm (5.2 inch) (B) 327 mm (12.9 inch) (W1) A 4 mm (0.16 inch) fillet weld around both bosses | |
- For the 797 machines, install the plate (2) by using the four bolts (17), the four hard washers (18), the two blocks (1) and the two blocks (19). The four bolts (17), the four hard washers (18) and the two blocks (19) were saved from Step 8.
 | |
| Illustration 7 | g01595978 |
- For the 797B machines, install the plate (2) by using the four bolts (22), the four hard washers (18) and the two blocks (1). The four bolts (22) and the four hard washers (18) were saved in Step 9.
 | |
| Illustration 8 | g01595979 |
- By using the four bolts (15) and the four washers (16) that were saved in Step 7, attach the two clamps (14) to the prelubrication pump.
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| Illustration 9 | g01595982 |
- By using the two nuts (13) that were saved in Step 6, attach one end of cable assembly (6) to the prelubrication pump. By using the one bolt (7) and one washer (8), attach the second end of cable assembly (6) to boss (3) .
 | |
| Illustration 10 | g01595984 |
- By using two clips (5), one bolt (9) and one washer (12) that was saved in Step 6, attach both cable assemblies to boss (4) .