- Motor Grader:
- 24H (S/N: 7KK1-UP)
- 24M (S/N: B9K1-UP; B931-UP)
Introduction
This Special Instruction provides the installation procedure to add magnetic drain plugs for the differential rear axle housing group.
Important Safety Information
Note: Do not perform any procedure in this Special Instruction until you read the information and you understand the information.
Clean all surfaces and remove burrs from all areas where parts are to be installed. Chase all tapped holes used for mounting purposes.
Work safely. 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 must also have the necessary training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.
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Personal injury or death can result from improper troubleshooting and repair procedures. The following troubleshooting and repair procedures should only be performed by qualified personnel familiar with this equipment. |
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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility. |
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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210. |
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Required Tools
| Required Tools | |||
| Item | Qty | Part Number | Description |
| G | 1 | 385-1177 | Drill |
| H | 1 | Center Drill | |
| J | 1 | Counterbore Tool | |
| K | 1 | Drill Bit | |
| L | 1 | #8 Port Tool | |
| M | 1 | Hand Tap | |
Rework Procedure to Install the Final Drive Magnetic Drain Plug
| Required Parts List | |||
| Item | Qty | Part Number | Description |
| 1 | 2 | 304-8032 | Magnetic Plug |
| 2 | 2 | 3K-0360 | O-Ring Seal |
- Drain the rear axle oil.
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| Illustration 1 | g03426544 |
Ports for magnetic plugs | |
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| Illustration 2 | g03426554 |
Top arrow pointing to frame mounting face Bottom arrow pointing to ripper link (A) Dimension is 20 mm (0.8 inch) (B) Dimension is 80 mm (3.1 inch) | |
- Attach magnetic based drill (G) to the bottom of the axle housing as shown in Illustration 2.
- Place a drain pan under the magnetic based drill.
Note: When the axle is drilled into, the oil which collects in the final drive compartment will drain out.
- Use center drill (H) to start a hole in the housing.
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| Illustration 3 | g03426555 |
(C) Dimension is 17.5 mm (0.69 inch) (D) Dimension is 12 mm (0.47 inch) deep (E) Dimension is 2 mm (0.1 inch) to 5 mm (0.2 inch) deep spot face for the port (F) Counterbore dimension is 38 mm (1.5 inch) or 41 mm (1.6 inch) | |
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| Illustration 4 | g03466258 |
Body diameter is 1/2 inch Drill point diameter is 7/32 inch Drill point length is 7/32 inch Overall length is 76 mm (3.0 inch) Included angle is 60 degree End type is double Cutting edge style is plain Combination drill and countersink material is high speed steel Countersink applications are countersinking and drilling Combination drill and countersink finish/coating is bright Not a long length tool Cutting direction is right hand Not aircraft-style No insertable cutter head | |
- Use counterbore tool (J) to drill counterbore to dimension (F) and dimension (D) in the casting.
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| Illustration 5 | g03857546 |
Counterbore diameter is 1-1/2 inches Shank diameter is 1/2 inch Number of flutes are 4 Counterbore material is high speed steel Pilot shank diameter compatibility is 1/4 inch Shank type is straight Overall length is 5-1/2 inches Cutting direction is forward | |
- Use a 11/16 inch drill bit (K) to drill through the center housing.
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| Illustration 6 | g03857553 |
Shank diameter is 1/2 inch Drill bit size is 17.463 mm (0.6875 inch) Drill bit material is high speed steel Drill bit finish/coating is oxide Shank type is straight Flute length is 76 mm (3.0 inch) Drill point angle is 118 degree Overall length is 152 mm (6.0 inch) Point type is standard Flute type is spiral Spiral type is regular Cutting direction is right hand Not through coolant | |
- Allow oil to drain.
- Use #8 port tool (L) to drill a port at the bottom of the counterbore. Drill port deep enough to obtain full cleanup on port spotface. Port spotface should be of dimension (E) deep into bottom of counterbore.
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| Illustration 7 | g03463737 |
Workpiece compatibility is tubes Pilot type is reamer Port thread size is 3/4-16 inch Tube dash number is 8 Tube outside diameter compatibility is 12.700 mm (0.5000 inch) Minimum pilot diameter is 17.475 mm (0.6880 inch) Spot face diameter is 30.429 mm (1.1980 inch) Tool material is carbide-tipped Pilot length is 18.669 mm (0.7350 inch) Shank type is straight No identification groove Bright finish or coating Overall length is 93.980 mm (3.7000 inch) | |
- Use a 3/4-16 hand tap (M) to thread port.
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| Illustration 8 | g03466257 |
Thread size is 3/4-16 inches Thread limit is H5 Number of flutes are 4 Chamfer is plug Material is high speed steel Finish/coating is nitride/oxide Thread direction is right hand Thread standard is UNF Overall length is 4-1/4 inch Shank diameter is 14.986 mm (0.5900 inch) Square is 11.227 mm (0.4420 inch) Material application is aluminum or cast iron Series is 101C | |
- Deburr edges as needed. Surface finish of J-groove where magnetic plug O-ring seal will reside must be smooth and free of defects. Leading edge of J-groove must be smooth and free of burrs to prevent O-ring seal from being cut during assembly.
- Use a magnet to collect debris from inside the housing.
- Install magnetic plug (1) with O-ring seal (2) .
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| Illustration 9 | g03426556 |