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Special Instruction
Installation of Oil Renewal Systems for Off-Highway Trucks{1318, 1348, 1349}
Media Number -REHS1679-02 Publication Date -13/10/2008 Date Updated -13/10/2008
i03326041
Installation of Oil Renewal Systems for Off-Highway Trucks
{1318, 1348, 1349}
SMCS - 1318; 1348; 1349
Off-Highway Truck/Tractor:
784C (S/N: 2PZ1-UP)
789C (S/N: 2BW1-UP)
776D (S/N: 5ER1-UP; AFS1-UP)
777D (S/N: AGC1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
793C (S/N: 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)
Introduction
This Special Instruction provides the procedure that is necessary for installing an oil renewal system
on the off-highway trucks that are listed above.
For information on the operation and the maintenance of the oil renewal system, refer to Systems
Operation, RENR2223, "Oil Renewal System".
Refer to Specifications, SENR3130, "Torque Specifications" for the correct torques for the threaded
fasteners.
Do not perform any procedure that is outlined in this Special Instruction until the entire Special
Instruction has been read and understood.
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Required Materials
A 135-3101 Oil Metering Group is available through the parts distribution system. The 135-3101 Oil
Metering Group contains the parts that are listed in Table 1.
Table 1
Item Number Part Number Description Quantity
1 1W-8129 Support 1
2 8T-9379 Bolt 2
3 141-7157 Bracket As 1
4 4L-9337 Bolt 2
5 8T-4896 Hard Washer 15
6 6V-8801 Nut 6
7 4L-6454 Bolt 5
8 9S-4185 Plug 2
9 3K-0360 O-Ring Seal
(1)
3
10 141-7156 Base As 1
11 1R-0750 Fuel Filter 1
12 033-6042 O-Ring Seal
(1)
3
13 5P-9617 Adapter 2
14 3J-7354 O-Ring Seal
(1)
4
15 030-7941 Elbow 1
16 6V-8723 Elbow 1
17 030-7946 Elbow 1
18 4V-3263 Hose As 1
19 6V-8724 Elbow 1
20 142-7363 Oil Metering Valve and Mounting 1
21 6V-8397 O-Ring Seal 2
22 149-0196 Hose As 1
23 153-7477 Plate 1
24 6V-8628 Elbow 2
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25 3B-4589 Stud 3
26 7K-3377 Pipe 1
27 4K-8302 Clip 1
28 8T-9377 Bolt 1
29 5P-1075 Hard Washer 2
30 5P-9299 Clip 1
31 115-3069 Connector Clip Assembly 1
32 108-7615 Hose As 1
33 4J-5477 O-Ring Seal 2
34 4P-8134 Clip 2
35 9X-6772 Cable Strap 3
36 4P-7581 Clip 1
( 1 )
Lubricate the seal lightly with clean engine oil.
Additional Materials for Trucks without a Harness Connection for the ORS
Table 2
Part Number Description Quantity
102-8802 Receptacle Kit 1
9X-3401 Connector Pin 2
5P-5677 Electrical Wire 4 m (13 ft)
Installation
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Illustration 1 g01005498
Number 7 cylinder
1. Remove the bolts and the washers from the valve cover base on the number 7 cylinder.
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Illustration 2 g01005540
Rear view
2. Install support (1) with bolts (2).
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3. Install bracket (3) on support (1) with bolts (4), washers (5), and nuts (6) .
4. Install seals (9) and plugs (8) in base (10) on the sides that are marked "OIL".
5. Install base (10) on bracket (3) with bolts (7) and washers (5) .
6. Locate the plug and seal below the camshaft cover on the number 5 cylinder. Remove the plug
and the seal from the cylinder block.
7. Install seal (12) and adapter (13) .
8. Install seal (14) and elbow (15) .
Illustration 3 g01012486
Right side view
9. Install studs (25) on the camshaft cover on the number 5 cylinder.
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Note: If the engine has a exhaust temperature sensor that is mounted to the camshaft cover the
exhaust temperature sensor must be removed and mounted between washer (5) and plate (23)
on stud (25) .
10. Install oil metering valve (20) and plate (23) on the studs by using washers (5) and nut (6).
Insert one washer between the camshaft cover and the oil metering valve and one between the
plate and the nut.
11. Install seal (9) and elbow (16) .
12. Install seal (12) and adapter (13) .
13. Install seal (14) and elbow (17) .
14. Install seal (12) and elbow (19) .
15. Install seal (14) and elbow (24) .
16. Remove the bolt and the washer from the upper center of the camshaft cover on the number 7
cylinder.
17. Install seals (21) and hose (22) from the filter base "OUT" to the valve "IN".
Illustration 4 g01012499
View B-B
18. Install clip (27) on hose (22) and connect the clip to the camshaft cover with pipe (26), bolt
(28), and washers (29). Insert one washer on each side of the clip.
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19. Install hose (18) from the side of the cylinder block to the filter base "IN".
Illustration 5 g01012509
View A-A
20. Install clip (30) on hose (18) .
21. Install connector clip (31) and clip (30) on plate (23) with bolt (7), nut (6), and washers (5) .
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Illustration 6 g01005573
Fuel manifold adapter
22. Remove the plug and the seal from the fuel manifold adapter.
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Illustration 7 g01012515
Right side view
23. Install seal (14) and elbow (24) in the fuel manifold adapter.
24. Install hose (32) and seals (33) from the "OUT" on oil metering valve (20) to elbow (24) on the
fuel manifold adapter.
25. Remove the bolt and the washer from the front outside of the valve cover on the number 1
cylinder. Reinstall the bolt and the washer with clip (34) under the washer.
26. Strap hose (32) to clip (34) with strap (35) .
27. Remove the bolt and the washer from the front outside of the valve cover on the number 3
cylinder. Reinstall the bolt and the washer with clip (34) under the washer.
28. Strap hose (32) to clip (34) with strap (35) .
29. Remove the bolt that holds the clamp for the turbocharger's oil drain. Install clip (36) under the
washer.
30. Strap hose (32) to clip (34) with strap (35) .
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Note: The 793C trucks with engines that have standard displacement do not have the oil drain
tube. Install clips for hose (34) on the rear valve cover bolt on the number 1 cylinder and on the
number 3 cylinder.
Illustration 8 g01012518
Oil metering valve
31. Connect the solenoid of valve (20) to the oil renewal system's connector in the wiring harness.
Snap the connectors in clip (31) .
Note: On early truck models that do not have a connector for the oil renewal system in the
wiring harness, the wires must be run to pin 7 and pin 13 of the ECM connector with the "D"
key. Connect pin 7 to pin 1 of the connector for the solenoid. Connect pin 13 to pin 2 of the
connector for the solenoid. If a wire is already connected to a pin, attach the new wire with a
splice. The wires must be secured. Refer to Illustration 9.
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Illustration 9 g01012552
ECM connector
(A) "D" Key
(B) Pin 7
(C) Pin 13
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Tue Feb 11 16:46:33 EST 2014
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