Filtration Procedure for Oil in the Motor Grader Tandem Drive {0680, 0738, 0768, 4062, 4064} Caterpillar

Motor Grader

120H (S/N: 1241-UP; CAF1-UP; 4MK1-UP; 5FM1-UP; 6NM1-UP; 6TM1-UP; 2AN1-UP; 6YN1-UP; 9YR1-UP; ALZ1-UP)

120K (S/N: SZN1-UP; JAP1-UP)

120K Series 2 (S/N: SZS1-UP)

120L (S/N: E921-UP; E931-UP; E961-UP; Y9A1-UP; Y9B1-UP)

120M (S/N: B9C1-UP; B9N1-UP; D9W1-UP)

120M Series 2 (S/N: M9C1-UP; M9H1-UP; R9N1-UP; R9W1-UP)

120N (S/N: E941-UP; E951-UP; Y9C1-UP; Y9D1-UP)

12H (S/N: 1251-UP; XZJ1-UP; CBK1-UP; 4XM1-UP; 5ZM1-UP; 8MN1-UP; 2LR1-UP; 2WR1-UP; 4ER1-UP; 2GS1-UP; AMZ1-UP)

12K (S/N: JJA1-UP; SZP1-UP)

12M (S/N: B9F1-UP)

12M Series 2 (S/N: F9B1-UP; F9M1-UP; R9P1-UP; R9S1-UP)

12M Series 3 (S/N: N9B1-UP; N9F1-UP; N9P1-UP; N9R1-UP)

12M Series II (S/N: M9F1-UP)

135H (S/N: CBC1-UP; BDJ1-UP; 3YK1-UP; 7MM1-UP; 8WN1-UP; AMX1-UP)

140 (S/N: N941-UP; N951-UP)

140H (S/N: 1261-UP; CCA1-UP; XZH1-UP; 2ZK1-UP; APM1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP; 9ZN1-UP; 3AS1-UP)

140K (S/N: JPA1-UP; SZL1-UP)

140K Series 2 (S/N: SZW1-UP)

140M (S/N: B9D1-UP; B9G1-UP; D9G1-UP)

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)

140M Series 3 (S/N: N9D1-UP; N9G1-UP; N9J1-UP; N9M1-UP)

143H (S/N: 1AL1-UP; APN1-UP)

14H (S/N: ASE1-UP; 7WJ1-UP)

14L (S/N: B941-UP)

14M (S/N: B9J1-UP; R9J1-UP)

14M Series 3 (S/N: E9S1-UP; N9S1-UP)

160H (S/N: ASD1-UP; 9EJ1-UP; XZK1-UP; 2FM1-UP; 3GM1-UP; 6WM1-UP; 9JM1-UP; CCP1-UP; 2HS1-UP)

160K (S/N: SZM1-UP; JBP1-UP)

160M (S/N: B9E1-UP; B9L1-UP; B9T1-UP; D9T1-UP)

160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)

160M Series 3 (S/N: N9E1-UP; N9K1-UP; N9L1-UP; N9T1-UP)

163H (S/N: 5AK1-UP; ARL1-UP)

16H (S/N: 6ZJ1-UP; ATS1-UP)

16M (S/N: B9H1-UP; R9H1-UP)

16M Series 3 (S/N: E9Y1-UP; N9Y1-UP)

18M Series 3 (S/N: N9A1-UP; E9W1-UP)

24 (S/N: E9Z1-UP; N9Z1-UP)

Introduction

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This guideline enables dealers and customers to benefit from cost reductions which were made possible through an established contamination control program. Fluids that are used in Caterpillar machines are highly effective unless the fluid contains damaging amounts of contaminates. Therefore, every effort must be made to reduce the contamination level within Caterpillar fluid systems. Caterpillar makes ongoing changes and improvements to the Caterpillar products. This guideline must be used with the latest technical information. Technical information is available from Caterpillar to ensure that such changes and improvements are incorporated when applicable.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) Interface.

If a Contamination Control Guideline is required, but not available in SIS web, submit a feedback form in the Service Information System web site.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Summary

The instructions that are given in this guideline will enable dealers and the customers to filter Motor Grader tandem drive oil. This procedure will reduce contamination in the oil to an acceptable ISO contamination level. This procedure may be modified by the technician for use on some machines.

Note: If the vehicle is being serviced due to a catastrophic failure, a complete system cleaning operation is required before starting this filter cart filtration procedure. If the failure is not addressed early, particles from the failed component will contaminate other system components such as valves, pumps, motors, and controls. Extra component exchange and lines flushing will be required to remove contaminates generated from the failure. The vehicle system cleaning must be performed prior to the filter cart filtration procedure. This filtration procedure and subsequent particle count testing should be performed as a final step in the repair process.

Important Safety Information

Illustration 1	g02139237

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product is dangerous. Improper methods could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair of this product, until you understand the operation, lubrication, maintenance, and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

Hazards are identified by a safety alert symbol. Safety alert symbols are followed by a signal word such as "Warning" that is shown below.

Illustration 2	g01032906

The following is the meaning of this safety alert symbol:

• Pay attention!

• Become alert!

• Your safety is involved.

The message that appears under the warning explains the hazard. The message will be written or pictorially shown.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and on the product are not all inclusive. If a tool, procedure, work method, or an operating technique, that is not recommended by Caterpillar is used, ensure the safety of all personnel around the machine. Ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance, or repair procedures.

All the information, specifications, and illustrations that are in this publication are based on information that was available at the time of publication. The following information could change at any time: specifications, torque, pressures, measurement, adjustments, illustrations, and other items. These changes can affect the service that is given to the product. Obtain the most current and complete information before you start any job. Caterpillar dealers have the most current information that is available.

Safety

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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the steering system.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

References

Tooling and Equipment

Tandem Drive Cover Plate Fabrication

1. Refer to Table 4 for the proper tandem housing cover plate part number.
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   Illustration 3	g01369690
   Adapter plate hole locations

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   Illustration 4	g06323889
   120-6156 Tandem Cover As. Sales Model 24 Hole locations

2. Drill a 41.3 mm (1.625 inch) hole in locations A and B as shown in Illustrations 3 and 4. Refer to Table 5 for the correct drilling dimensions.
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   Illustration 5	g01372785
   (1) Weld locations

3. Weld two 25.4 mm (1 inch) female pipe bushings to the adapter plate as shown in Illustration 5.

Tandem Drive Filtration Procedure

The following procedure is intended for all models of Motor Graders. The procedure is most effective when performed immediately after the hydraulic oil has been warmed to 50 °C (122 °F) and mixed from operation. This procedure allows any contamination in the oil to be placed in suspension and lowers the viscosity of the oil. Be sure to read and understand the Tool Operating Manual, NEHS0962.

1. Park the machine on level ground.

2. Lower all hydraulic implements to the ground.

3. Engage the parking brake.
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   Illustration 6	g01372786
   (2) Bolt locations for elevated work platform (3) Brake line

4. Remove the elevated work platform (if equipped) from the tandem drive housing.

5. Remove the hardware that holds the brake line (3) to the top of the tandem housing.

6. Remove the bolts that hold the front cover plate in place.

7. Remove the cover plate and install the fabricated cover plate with the same bolts.
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   Illustration 7	g01372065
   (X) Proper length of suction pipe (Y) Distance from the top of the tandem housing to the bottom of the tandem housing

8. Measure the distance from the top of the tandem housing to the bottom of the tandem housing (Y). Subtract 76.2 mm (3 inch) from the (Y) measured distance. This distance will be the length of the 25.4 mm (1 inch) suction pipe attached to the fabricated cover plate. Refer to Illustration 7.

9. Cut a length of suitable pipe matching the (X) measured distance of the housing depth. Secure the pipe to the bottom side of the suction bushing on the fabricated tandem plate.

   Note: Be sure to secure the pipe to the bushing on the side that will not interfere with the tandem chain.

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   Illustration 8	g01372077
   (4) Adapter plate bolt

10. Lower the pipe into the tandem. Bolt the cover plate to the tandem housing with the original bolts as shown in Illustration 8.
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    Illustration 9	g01372081
    (5) Suction hose

11. Attach the suction hose (5) equipped with a 190-8319 Nipple to the filter cart quick coupler.

12. Attach a suction hose (5) equipped with a 190-8318 Coupler to the suction elbow on the cover plate as shown in Illustration 9.

13. Attach the discharge hose equipped with a 190-8318 Coupler to the 190-8319 Nipple on the filter cart.
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    Illustration 10	g01372789
    (6) Discharge hose

14. Attach the discharge hose (6) equipped with a 190-8318 Coupler to the return 190-8319 Nipple on the cover plate as shown in Illustration 10.

15. To prevent the unexpected flow of oil, turn the FLOW control knob counterclockwise.

16. Push the green start button on the filter cart to start the electric pump motor.

    Note: If there is an emergency, push the red stop button to stop the oil pump.

17. Turn the pump flow control knob clockwise to increase the flow rate until the desired flow rate is achieved.

    Note: The filter cart pump flow control knob varies the pumping rate from zero to 40 L/min (10.6 US gpm).

18. While operating the filter cart, frequently check the pop-up service filter indicators near the top of the filter elements.

19. Ensure that there are no oil leaks from any of the filter cart connections.

    Note: Caterpillar recommends that a particle count is to be taken on the oil at the beginning of the filter cycle as a baseline particle count.

20. The oil can be particle count tested for cleanliness using one of the two following ways.

    • Use a 170-8500 Analyzer Gp for immediate results.

    • Collect a bottle sample and send the sample to an S·O·S lab.

21. If using the 170-8500 Analyzer Gp for particle counting, be sure to read and understand the Tool Operating Manual, NEHS0799, " 170-8500 Analyzer Gp" before operating the analyzer.
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    Illustration 11	g03447636
    (7) Fabricated suction tube (8) 210-5530 Quick Connect Coupler (9) S·O·S valve

22. Connect the low pressure in port to the S·O·S valve (9) on the top of the filter cart assembly. Use a fabricated suction tube (7) that is fitted with a 210-5530 Coupler (8). The fabricated tube (7) is required to collect an on-line sample when using the 170-8500 Analyzer Gp.
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    Illustration 12	g01373643
    (10) 169-8373 Fluid Sampling Bottle

23. Use the same S·O·S valve (9) and a 169-8373 Fluid Sampling Bottle (10) if collecting a bottle sample.

24. Record an oil sample reading from the S·O·S valve (9) on the filter cart at the start of the filter cycle.
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    Activating the machine's steering and work tools can be hazardous when personnel are working around the machine. Before moving the machine, make sure the machine is on firm level ground. Engage the parking brake. Make sure the area is clear of personnel before activating any work tool. Failure to follow this instruction could result in injury or death.

25. Operate the filter cart until the 170-8500 Analyzer Gp indicates that the oil has reached an acceptable ISO level of 16/13 or cleaner. Take a final oil sample and record the final ISO level before the machine is returned to the field.

    Note: A target ISO level does not exist for non-pressurized, non-filtered compartments currently. ISO 16/13 is an acceptable contamination level for oil returned back into this type of a compartment.

    Note: Refer to "Oil Compartment Filtration Times" at the end of this document, when a portable particle analyzer is not available.

26. When the target ISO level or the time interval has been met. Turn the pump flow control knob counterclockwise to slow the flow rate to zero.

27. Push the red stop button to shut off the power to the pump motor.

28. Disconnect the power supply cord from the power supply.

29. Disconnect the discharge hose (6) and suction hose (5) from the fabricated cover plate. Refer to Illustrations 9 and 10.

30. Disconnect the discharge hose (6) and the suction hose (5) from the 273-3273 Portable Filtration Cart.

31. Store the discharge and suction hoses in a clean location for later use.

32. Remove the bolts (4) that hold the fabricated cover plate to the tandem housing. Refer to Illustration 8.

33. Remove the fabricated cover plate.

34. Reinstall the original cover plate and the cork gasket on the tandem housing.

35. Secure the cover to the tandem housing with the original bolts.

36. Secure the brake line (3) to the top of the tandem housing. Refer to Illustration 6.

37. Reinstall the elevated work platform to the top of the tandem housing.

38. Check the oil level by viewing the tank sight gauge.

Oil Compartment Filtration Times

If an on-line, portable particle counter, is not available to diagnose and track when the contaminant level has lowered to an acceptable level, refer to the following equation. This equation relates to the 273-3273 Portable Filtration Cart only. Other filtration units will have different equation references. Filtration units with different equation references will be noted when appropriate.

Illustration 13	g01375806
Oil compartment filtration equation (A) Compartment oil capacity (gal) (B) Approximate filtration time (min.)

Example

A 16M Motor Grader tandem drive has 96.5 L (25.5 US gal) of SAE30W oil. The approximate filtration time is 20 minutes.

ISO 4406:1999 Method for Coding the Level of Contaminates by Solid Particles

ISO is a worldwide federation of national standards bodies. The ISO 4406:1999 specifies the code to be used in defining the quantity of solid particles in the fluid. This ISO code is used in any given hydraulic fluid power system. An automatic particle counter derives the equivalent size of a particle from the particle cross sectional area. Particle counts are affected by various factors. These factors include the procurement of the sample, the sample container, particle counting accuracy, where used and the particle count cleanliness. Proper care should be taken during the sample procurement to ensure that the sample obtained is representative of the fluid circulating in the system.

The code for contamination levels using automatic particle counters is composed of three scale numbers. Example X/Y/Z.

X - The number of particles that is equal to or larger than 4 microns.

Y - The number of particles that is equal to or larger than 6 microns.

Z - The number of particles that is equal to or larger than 14 microns.

Currently Caterpillar does not require the reporting of the (X) scale number. Since the hydraulic tolerances exceed the 4 micron value, therefore a (-) is used in place of the (X). For example, a particle count is read as -/Y/Z, meaning that there was no requirement to count particles equal to or larger than 4 microns.