Instructions for Installing Hydraulic Fluid Monitoring on Certain 24M Motor Graders{0113, 1439, 5095} Caterpillar

Motor Grader:

24M (S/N: B9K1-UP; B931-162)

Introduction

Illustration 1	g03794840
Parts removed for clarity. (A) Connector to fluid level sensor (B) Connector to front ECM (C) Connector to ground (D) Connector to fuse relay box

A new hydraulic fluid monitoring system is now available for 24M Motor Graders. This improvement is to support a Hydraulic Oil Level monitoring feature and an oil level warning event.

This feature is enabled using Cat ET as a Software Enabled Attachment (SEA). A factory password is required to enable this feature. The hydraulic oil level in the tank is displayed in the Cat ET Transmission Chassis ECM status screen.

ReferenceDisassembly and Assembly, "Hydraulic Tank and Filter - Remove" for your machine.

ReferenceDisassembly and Assembly, "Hydraulic Tank and Filter - Install" for your machine.

ReferenceOperation and Maintenance Manual for your machine.

ReferenceSpecial Instruction, REHS1840, "General Welding Procedures"

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the weight from the manufacturer to determine the application when you select the following items: cable, chain and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit.

Illustration 2	g03790098
Lift angles for lifting slings. (A) The load capacity is 100% of the working load limit for the sling. (B) The load capacity is 86% of the working load limit for the sling. (C) The load capacity is 70% of the working load limit for the sling. (D) The load capacity is 50% of the working load limit for the sling.

Safety

Do not perform any procedure in this Special Instruction until you read this information and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Note: Prior to welding on the hydraulic tank refer to Special Instruction, REHS1840, "General Welding Procedures" for instructions regarding the cleaning and welding process on a hydraulic tank.

Requirements

• 2014A ET or later must be used

• The following software, or a more recent version, is required to support this feature: Implement software 458-6598V00, Transmission software 458-6609V00, and M Messenger.

• Group 1 English, Portuguese, Spanish, French, German – 463-6043V00

• Group 2 English, Portuguese, Danish, Finnish, Swedish – 463-6044V00

• Group 3 English, Portuguese, Italian, Greek, Hebrew – 463-6045V00

• Group 4 English, Portuguese, Russian, Arabic– 463-6046V00

• Group 5 English, Portuguese, Romanian, Indonesian, Ukrainian– 463-6047V00

• Group 6 English, Portuguese, Dutch, Norwegian, Slovenian– 463-6048V00

• Group 7 English, Portuguese, Chinese, Turkish– 463-6049V00

To install the Software, a password will be required.

Installing the feature should be like installing other SEAs in ET. The software installation requires factory passwords.

Rework Methods

Required Parts

Required Tooling

Prepare for Rework

1. Move the machine to a hard level surface.

2. Place the transmission control in the Neutral position.

3. Lower all implements to the ground.

4. Set the parking bake and shut off the engine.

5. Set the wheel chocks.

6. Release the system pressure. Refer to Operation and Maintenance Manual, "System Pressure - Release".

Perform the Tank Rework

Illustration 3	g03787383
(A) Connection to the liquid level sensor as (B) Connection to ECM (C) Connection to ground (D) Connection to the fuse relay box (4) Sensor harness

1. Drain the hydraulic tank.

2. Remove the enclosure and the hydraulic tank using the procedure shown in Disassembly and Assembly, UENR3490, "Hydraulic Tank and Filter - Remove". Retain all parts and hardware.

3. Remove the filter base and the internal screens of the hydraulic tank. Retain parts and hardware for reassembly.

4. Remove and plug all hydraulic lines to the hydraulic tank.

5. Plug all tank ports.

Show/hide table



Illustration 4	g03824548

6. Remove tank access cover and retain the seal and hardware.

Show/hide table



Illustration 5	g03824557
(E) 45 mm (1.78 inch) hole (F) 162.5 mm (6.4 inch) (G) 120 mm (4.7 inch) (H) 145 mm (5.71 inch) (J) 267.5 mm (10.53 inch) (1) Boss location

7. Drill one hole 45 mm (1.78 inch) (E) .

8. Remove the paint from the areas to be welded.

9. Attach one boss (1) using a 3 mm (0.12 inch) fillet weld all around.

Show/hide table



Illustration 6	g03785688
(2) Flange (3) Sensor (K) 68 Degrees (L) 72 Degrees (M) 72 Degrees (N) 68 Degrees (P) 80 Degrees (R) Line that is used to mark the rotation of flange (2)

10. Place flange (2) onto sensor (3). Align the holes in sensor (3) with holes in flange (2) .

11. Place line (R) on the edge of flange (2) below the wire that comes out of the sensor.

12. Remove flange (2) from sensor (3). Place flange (2) on the hydraulic tank.

13. Verify that flange (2) is centered with hole (E) and line (R) in the direction of the boss that secures the connectors.

Show/hide table



Illustration 7	g03785865

14. Weld flange (2) in place using a 3 mm (0.12 inch) fillet weld all around.

15. Thoroughly clean the hydraulic tank after reworking and touch up the paint. Then reinstall the screens.

16. Ensure that no contamination can enter the tank during sensor installation.

Show/hide table



Illustration 8	g03785917

Show/hide table



Illustration 9	g03810745

17. Place seal (11) onto new flange (2). Carefully install sensor (3) into the new hole at flange (2) .

18. Place one washer (10) on each of five bolts (9) .

19. Place Blue Loctite on each of five bolts (9) .

Show/hide table



Illustration 10	g03808799
View of the newly installed sensor

20. Torque each of bolts (9) in an alternating pattern to 3.3 ± 0.7 N·m (29.2 ± 6.2 lb in).

21. Reinstall access cover and seal onto the hydraulic tank. Use the retained seal and hardware.

22. Reinstall the hydraulic tank onto the machine. Using the retained hardware. Refer to Disassembly and Assembly, "Hydraulic Tank and Filter - Install" for your machine.

23. Install sensor harness assembly (4) and route as shown below.

Show/hide table



Illustration 11	g03823025
View of the harness sensor connector for sensor harness assembly (4)

Show/hide table



Illustration 12	g03786079

24. Clip sensor harness assembly (4) with one clip (5), one bolt (7), and one washer (8). Connect sensor harness assembly (4) to sensor assembly (3) .

Show/hide table



Illustration 13	g03794738

25. Route sensor harness assembly (4) and secure with four cable straps (6) .

Show/hide table



Illustration 14	g03823023
Black to chassis ground (C)

Show/hide table



Illustration 15	g03824015
View of the new sensor harness assembly (4) as seen from the center line of the machine looking toward the right rail. (B) Connects to the J2 Connector (Refer to Illustration 20 for view from the RH side of the machine). (4) Sensor harness assembly (6) Cable straps

26. Route sensor harness assembly (4) as shown and secure with ten cable straps (6) .

27. Secure the black ground wire at (C) .

Show/hide table



Illustration 16	g03823027
Picture of the fuse relay box.

Show/hide table



Illustration 17	g03824062
Red wire connects to fuse relay box rear chassis at connector (D)

Show/hide table



Illustration 18	g03825497
Fuse relay box not shown in this view. For view of the fuse relay box see Illustration 16

28. Insert the red wire from the new sensor harness assembly into position (G) of the existing F-C12 179-1312 Connector Plug As (D). This process will allow the connection of the new sensor harness assembly to the fuse relay box at connection (D). A 10 amp fuse (12) should be used at this location.

Show/hide table



Illustration 19	g03824066
Blue wire connects to ECM at connector (B) .

Show/hide table



Illustration 20	g03820069
(B) J2 ECM connection

Show/hide table



Illustration 21	g03820134

29. Insert the blue wire from the new sensor harness assembly into position 42 (H) of the existing F-C21 126-1766 Connector Socket (B). This process will allow the connection of the new sensor harness assembly to the J2 transmission ECM connector.

30. Install enclosure.

Programming the Installation

Installing the feature should be like installing other SEAs in ET that require factory passwords. Connect Cat Electronic Technician.

1. Proceed to the ET configuration page. Double click on "Hydraulic Oil Level Warning System Installation Status" which will be located in the Fluid Monitoring section under the Transmission ECM.

Show/hide table



Illustration 22	g03795376

2. A pop-up window, similar to the one above, will appear and will lead to the directions on how to get the password.

3. Then go to Cat ET under "Transmission ECM Configuration". Change the configuration "Hydraulic Oil Level Warning System Installation Status" to "Installed". This configuration is a software enabled attachment (SEA) and will require a factory password. Go to Cat Electronic technician (ET) and enable the Fluid Monitoring.

4. Start the machine.

5. The oil level status can now be monitored in a Messenger display menu. To access the status in Messenger, from the main menu follow the steps below.
   • Select Service on the main screen

   • Select System Parameters

   • Select Implement

   • View the "Hydraulic Oil Level"

   When the "Hydraulic Oil Level" is viewed, the display will indicate a percentage of oil that is in the hydraulic tank. When the percentage of oil in the tank is less than 47 percent for more than 5 seconds, a Level 1, E235 (Low Hydraulic Oil Level) event will be activated. Once the oil level increases to greater than 67 percent for more than 5 seconds, the level 1 event will reset.

   When the oil level in the tank is less than 23 percent for more than 5 seconds, a Level 3, E235 event will be activated. Once the oil level increases to greater than 43 percent for more than 5 seconds, the level 3 event will reset.

6. Replace the hood following the procedure found in Disassembly and Assembly, "Hydraulic Tank and Filter - Install" for your machine. Use the retained hard ware.

Electrical

Illustration 23	g03823015
The electrical schematic for the blue connector with spare wire (G) to hook up power wire for the Hydraulic tank sensor. A 10 Amp fuse is most suitable for this application.