- Motor Grader:
- 120M (S/N: B9C1-UP; B9N1-UP; B9W1-UP; D9W1-UP)
- 12M (S/N: B9F1-UP; B9R1-UP)
Introduction
Do not perform any procedure that is outlined in this Special Instruction and do not order any parts until the entire instruction has been read and understood.
This Special Instruction describes the rework and installation procedures for the pre-cleaner on certain 120M and 12M Motor Graders.
Whenever questions arise about this product or about this Special Instruction, contact your local Caterpillar dealer for the latest information.
Safety
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Disconnect batteries before performance of any service work. |
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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. |
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| NOTICE |
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Park on a level surface. |
Required Parts
| Quantity | Part Number | Description |
| 1 | 1W-8620 | Check Valve As |
| 1 | 224-2263 | Air Valve As |
| 2 | 228-6978 | Clamp |
| 1 | 350-5808 | Precleaner As |
| 1 | 356-5969 (1) (2) | Pipe As |
| 1 | 356-5971 (1) (2) | Pipe Adapter |
| 1 | 358-2546 (1) (2) | Bracket As |
| 3 | 5P-0597 | Hose Clamp |
| 536 mm (21 inch) | 5P-1471 | Hose |
361 mm (14 inch) |
6V-5632 | Hose |
300 mm (12 inch) |
6V-5746 | Trim |
| 6 | 8T-4121 | Hard Washer |
| 5 | 8T-4133 | Nut |
| 4 | 8T-4137 | Bolt |
| 1 | 8T-4185 | Bolt |
| 1 | 9G-7101 | Spacer |
| ( 1 ) | Dealer fabricated part |
| ( 2 ) | Dealer fabricated parts must be painted black |
Procedure
Use the following procedures in order to enhance the service life of the air filter.
Machine Preparation
- Place the transmission direction control switch in the NEUTRAL position. Engage the parking brake. Lower the work tools to the ground. Stop the engine and put chocks in front of the wheels and behind the wheels.
- Enable the ground shutoff switch.
Removal Procedure
Note: Removal of the hood is not required for this procedure.
- Loosen clamp (3). Retain clamp (3) for use in the assembly procedure. Remove and discard rain cap (1), and pipe extension (2) .
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| Illustration 1 | g02271993 |
(1) Rain cap (2) Pipe extension (3) 9X-2201 Hose Clamp | |
- Remove and discard clamps (4), and hose (5) .
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| Illustration 2 | g02272159 |
(4) Clamp (5) Hose (6) Check valve assembly | |
- Remove valve check assembly (6). Refer to Illustration 2.
- Remove nuts (7). bolts (8), and washers (9) from hose clamp (10), and tube clamp (11) .
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| Illustration 3 | g02272576 |
(7) Nuts (8) Bolts (9) Washers | |
- Remove clamp (10) and clamp (11) .
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| Illustration 4 | g02272553 |
(10) Hose clamp (11) Tube clamp | |
Rework Procedure
- Drill 4 13.5 mm (1/2 inch) holes on the 257-4911 Sheet As . Refer to Illustration 5 for the proper dimensions.
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| Illustration 5 | g02272733 |
(12) Sheet assembly of hood (A) 342.67 mm (13.5 inch) (B) 125.30 mm (4.93 inch) (C) 328.35 mm (12.93 inch) (D) 85.20 mm (3.35 inch) | |
- Create a 90 mm (3 1/2 inch) circular cut out on the 257-4910 Sheet As. . Refer to Illustration 6 for the proper dimensions.
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| Illustration 6 | g02275995 |
(12) Sheet assembly of hood (E) 534.67 mm (21 inch) (F) 227.30 mm (8.94 inch) | |
- Use a 3 mm (0.1 inch) thick piece of carbon steel, and the dimensions that are shown in Illustration 8 in order to create plate (14) .
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| Illustration 7 | g02277353 |
(13) Pipe (G) 114.3 ± 0.38 mm (4.5 ± 0.01 inch) (H) 348 ± 5 mm (13.7 ± 0.2 inch) (J) 65 ± 1 mm (2.5 ± 0.03 inch) (K) 131.7 ± 0.38 mm (5.2 ± 0.01 inch) (L) Radius of 2.5 ± 0.5 mm (0.09 ± 0.02 inch) (M) Radius of 0.74 ± 0.15 mm (0.02 ± 0.005 inch) (N) 25.4 ± 1 mm (1 ± 0.03 inch) (P) 3.2 ± 0.5 mm (0.16 ± 0.02 inch) (Q) Spacing of 60 degrees around circumference of pipe | |
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| Illustration 8 | g02283993 |
(14) Plate (R) 180.4 mm (7.1 inch) (S) 242 mm (9.5 inch) (T) 121 mm (4.7 inch) (U) 90.2 mm (3.5 inch) (V) Radius of 25.4 mm (1 inch) at each corner of plate | |
- Create a 117.5 mm (4.6 inch) hole within plate (14). Refer to Illustration 8 for the proper dimensions.
- Create 4 13.5 mm (1/2 inch) holes on plate (14). Refer to Illustration 9 for the proper dimensions.
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| Illustration 9 | g02277916 |
(14) Plate (W) 20 mm (0.7 inch) (X) 223 mm (8.7 inch) (Y) 55.2 mm (2.1 inch) (Z) 140.4 mm (5.5 inch) | |
- Use the dimensions that are shown in Illustration 7 through Illustration 9 in order to fabricate adapter and pipe.
- Use the dimensions that are listed in Illustration 10 in order to fabricate the adapter.
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| Illustration 10 | g02279094 |
(15) 356-5971 Pipe Adapter (AA) 31.8 ± 0.38 mm (1.25 ± 0.01 inch) (AB) 22.4 ± 3 mm (0.88189 ± 0.1 inch) (AC) 1.65 mm (0.06 inch) (AD) 50.8 ± 0.38 mm (2 ± 0.01 inch) (AE) 28.3 ± 3 mm (1.1 ± 0.1 inch) (AF) 69 ± 3 mm (2.7 ± 0.1 inch) (AG) 14.5 mm (0.5 inch) (AH) 4 mm (0.2 inch) (AJ) Spacing of 60 degrees around circumference of adapter (AK) Radius of 10 ± 1.5 mm (0.4 ± 0.06 inch) | |
- Use the dimensions that are listed in Illustration 11 through Illustration 14 in order to fabricate the bracket assembly.
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| Illustration 11 | g02279374 |
(16) Bracket (AK) 48.6 mm (1.9 inch) (AL) 31.8 mm (1.25 inch) (AM) 462.58 mm (18.21 inch) (AN) 402.48 mm (15.84 inch) (AP) 418.22 mm (16.46 inch) (AQ) 365.38 mm (14.38 inch) (AR) 203.02 mm (7.99 inch) (AS) 281.02 mm (11.06 inch) (AT) 448.82 mm (17.67 inch) (AU) 480.83 mm (18.93 inch) (AV) 511.02 mm (20.12 inch) (AW) 62 mm (2.4 inch) (AX) 41.23 mm (1.62 inch) (AY) 43.2 mm (1.7 inch) (AZ) 54 mm (2.13 inch) (BA) 65 mm (2.5 inch) (BB) 43.98 mm (1.73 inch) (BC) 123.96 mm (4.88 inch) (BD) 228.67 mm (9 inch) (BE) 377.17 mm (14.84 inch) (BF) 408.29 mm (16.07 inch) (BG) 448.82 mm (17.67 inch) | |
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| Illustration 12 | g02287813 |
(BH) 30.11 mm (1.18 inch) (BJ) 27.67 mm (1.09 inch) (BK) 11.52 mm (0.45 inch) (BL) 65 mm (2.6 inch) (BM) 47 mm (1.85 inch) (BN) 30 mm (1.18 inch) (BP) 17.9 mm (0.70 inch) (BQ) Radius of 59 mm (2.32 inch). (Measured from intersection of callouts (BT) and (BU) .) (BR) 62.5 mm (2.46 inch) (BS) Radius of 1.5 mm (0.06 inch) (BT) 35.2 mm (1.39 inch) (BU) 100.9 mm (3.9 inch) (BV) Radius of 12 mm (0.47244 inch) at both corners on the end of bracket (BW) Radius of 12 mm (0.47244 inch) at each corner of the bracket tabs | |
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| Illustration 13 | g02287134 |
View A-A (BX) 56 mm (2.20 inch) (BY) 59 mm (2.32 inch) (BZ) 52 mm (2.05 inch) (CA) 51 mm (2 inch) (CB) Radius of 6 mm (0.24 inch) (CC) Radius of 3 mm (0.12 inch) (CD) Radius of 6 mm (0.24 inch) | |
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| Illustration 14 | g02290953 |
View A-A (CE) 90 degrees (CF) 90 degrees (CG) 90 degrees | |
- Skip weld nuts (17) to bracket (16). Refer to Illustration 15 for the proper orientation of the nuts.
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| Illustration 15 | g02290174 |
(17) 8T-4133 Nut | |
- Install approximately 300 mm (12 inch) of trim (18) around the circular cutout created for the hose.
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| Illustration 16 | g02279479 |
(18) 6V-5746 Trim | |
- Install dust valve (21) with clamp (20) onto the air cleaner (19) .
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| Illustration 17 | g02279579 |
(19) Air cleaner (20) Clamp (21) Dust valve | |
- Install pre-cleaner assembly (22) onto the flared end of pipe (23). Tighten the hose clamp that secures the pre-cleaner to the pipe. Refer to Illustration 18.
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| Illustration 18 | g02279656 |
(22) Pre-cleaner assembly (23) Pipe (24) Plate | |
- Install bracket (16) under the hood.
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| Illustration 19 | g02288736 |
(16) 358-2546 Bracket As | |
- Install the pipe assembly (23) with pre-cleaner assembly (22) through plate (24) .
Note: Ensure that the side of the plate with a larger hole center distance from the edge is closer to the stack.
- After the pre-cleaner assembly has been installed, adjust for fit and apply a tack weld on the top side of plate (24) around the circumference of pipe (23) .
Note: Height dimensions will vary due to sum of tolerances. Plate should be welded to pipe after installing on machine.
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| Illustration 20 | g02280154 |
- Remove the pre-cleaner and apply a continuous fillet weld on the bottom side and top side of the plate around the circumference of the pipe. Once cool, clean the completed weld and paint the pipe assembly black.
- Reinstall the pre-cleaner and pipe assembly onto the hood. Install the clamp, which was retained in Step 1. This clamp secures pipe (23) to the air cleaner. Tighten the clamp.
- Drill an 11 mm (0.4 inch) hole through the hood. Refer to Illustration 21 for the proper measurements.
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| Illustration 21 | g02280794 |
(CG) 16 mm (0.6 inch) (CH) 148 mm (5.8 inch) | |
- Install bolt (25) with washer (26) through the 11 mm (0.4 inch) hole.
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| Illustration 22 | g02281033 |
(25) 8T-4185 Bolt (26) 8T-4121 Hard Washer | |
- Insert washer (27), spacer (28), check valve tab (29), and nut (30) onto the bolt. Tighten the bolt.
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| Illustration 23 | g02281054 |
(27) 8T-4121 Hard Washer (28) 9G-7101 Spacer (29) 1W-8620 Check Valve As (30) 8T-4133 Nut | |
- Cut a 536 mm (21 inch) section of 5P-1471 Hose .
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| Illustration 24 | g02281115 |
(31) 1W-8620 Check Valve As (32) 5P-0597 Hose Clamp (33) 5P-1471 Hose | |
- Install hose (33) with clamp (32) onto the back end of check valve (31). Tighten the clamp.
- Run hose (33) from the back end of check valve (31) through the 90 mm (3 1/2 inch) hole, which is located in the hood, to the bottom of the pre-cleaner assembly.
- Install hose (33) with clamp (32) to the pre-cleaner assembly. Tighten the clamp.
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| Illustration 25 | g02281198 |
(32) 5P-0597 Hose Clamp (33) 5P-1471 Hose | |
- Cut a 361 mm (14 inch) section of 6V-5632 Hose .
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| Illustration 26 | g02281234 |
(15) 356-5971 Pipe Adapter (32) 5P-0597 Hose Clamp (34) 228-6978 Clamp (35) 6V-5632 Hose | |
- Install the pipe adapter (15) with clamp (34) onto the front end of check valve (31). Tighten the clamp. Refer to Illustration 26.
- Run the hose from the adapter to the exhaust stack.
- Install hose (35) with clamp (34) onto the exhaust stack.
- Ensure that all of the connections and parts are secure before starting the engine.
- Disable the ground shutoff switch.
- Start the engine and perform a check on all connections to ensure that all of the connections are secure and not leaking.