Usage:
12H (4XM, 5ZM, 4ER, 8MN, 2GS, 2WR),
140H (2ZK, 8JM, 5HM, 9TN, 3AS, 9ZN, 3FR, 8KM) 143H (1AL),
160H (9EJ, 6WM, 9JM, 2FM, 3GM, 2HS, 3HR) 163H (5AK),
14H (7WJ) Motor Graders
- SUPPLEMENT: DECEMBER 14, 1998
Service Magazine SEPD0383, Article 5, Page 3, September 22, 1997; "Engine Oil Filter Access Changed For Improved Serviceability And Turbo Life".
The 147-3091 Filter Group and the 147-3092 Filter Group (Base) consist of the following:
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- SUPPLEMENT: SEPTEMBER 14, 1998
Service Magazine SEPD0383, Article 5, Page 3, September 22, 1997; "Engine Oil Filter Access Changed For Improved Serviceability And Turbo Life" for 12H (4XM, 5ZM, 4ER, 8MN, 2GS, 2WR), 140H (2ZK, 8JM, 5HM, 9TN, 3AS, 9ZN, 3FR, 8KM), 143H (1AL), 160H (9EJ, 6WM, 9JM, 2FM, 3GM, 2HS, 3HR), 163H (5AK), 14H (7WJ) Motor Graders.
When a machine has an engine with an aftercooler, a longer hose, the new 147-2069 Hose Assembly is required in place of the listed 135-8287 Hose Assembly in Chart 1 and Chart 4.
--------------- END SUPPLEMENT ---------------
Description of Change: The location of the oil filter has been changed to improve serviceability. The filter has been relocated to left front of the fuel tank. This improvement also requires a change to the turbo oil lines group. This improves flow to the turbo during cold starts, which increases turbo life.
Adaptable To: This change is effective with 12H (5ZM297, 4XM1395, 2WR641, 2GS359, 4ER499, 8MN459), 140H (8JM279, 2ZK2391, 9ZN204, 3FR151, 5HM1149, 9TN259, 3AS399), 143H (1AL407), 160H (9JM349, 9EJ509, 3HR29, 2FM399, 3GM79, 2HS349), 163H (5AK155) 14H (7WJ663), Motor Graders and is adaptable to earlier machines. Refer to the following procedure, illustrations, and charts to adapt this change to earlier machines.
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Before service work is begun, park the machine on a hard, level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.
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Do not attempt to perform any work on the oil filter housing until the engine has sufficiently cooled. Hot engine oil can cause bodily injury.
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1. Disconnect batteries on left hand side and remove support panel. Remove battery and ground stud cables from disconnect switch. Protect battery post and cable from shorting.
2. Remove disconnect switch and bracket from door hinge support. Remove diagnostic test port and bracket from air cleaner base. Both items will need to be relocated in later steps. 14H Motor Graders will require the P1 and P2 test ports to also be relocated.
3. Weld the appropriate plates (see Chart 5) to the fuel tank using Illustration 1 and Illustration 2 with the appropriate dimension chart as a reference.
NOTE: Welding dimensions and required plates will be different for different size tanks.
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Applying heat to a tank which has held flammable liquids, even when "empty", can result in residual flammable liquid or vapor igniting with explosive force. This can result in injury or death. DO NOT weld or flame cut on any tank that has held flammable liquid without taking the proper safety precautions. Read the article entitled "Welding On Fuel And Hydraulic Tanks" in the July 2, 1990 Service Magazine.
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Weld Information
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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.
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Read and understand the manufacturer's instructions 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 general area. Wear correct eye, ear, and body protection. Do not touch live electrical parts.
See 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 CRF 1910, available from U.S. Dept. of Labor, Washington, D.C. 20408.
NOTE: Welding operator personal protection should be provided to assure that total weld fume in the operators breathing zone does not exceed OSHA limits.
All repair welding operators must be qualified for groove and fillet welding, as outlined the current ANSI/AWS D14.3, or Caterpillar Manufacturing Practices MC1000-105. The qualification will be for the SMAW (Shielded Metal Arc Welding) process in the vertical welding positions. The welding operator must also have used this welding process during the last six months or be re-certified for this process before welding. Documentation must be maintained of the weld operators qualifications. The alternate process for this repair could be FCAW (Flux Cored Arc Welding).
The area to be welded and the surrounding area must be at a minimum temperature of 16° C (60° F) before and during welding.
NOTE: Since weld distortion is a possibility, minimizing the heat into the metal is important.
The SMAW process shall be used with E7018 (ANSI/AWS A5.5) welding electrode. The weld deposited by these electrodes will have the following minimum mechanical properties:
- 500 MPa (72 KSI) Tensile Strength
- 420 MPa (60 KSI) Yield Strength
- 22% elongation in 50 mm (2 in)
- 27 J (20 ft lb) Notch Toughness at -29° C (-20° F)
- 420 MPa (60 KSI) Yield Strength
These are low hydrogen electrodes and must be stored in an electrode oven at 121° C (250° F) when not in use. If the electrodes get damp, scrap or recondition them to the manufacturer's specifications.
The following chart relates to the electrodes diameter and approximate current settings for welding
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass size shall not exceed two times the electrode diameter.
As an alternate process the FCAW process may be used with E71T-1 (ANSI/A5.20) welding electrode and the manufacturer's specified shielding gas(es). The weld deposited by three electrodes will have the following minimum mechanical properties:
- 500 MPa (72 KSI) Tensile Strength
- 420 MPa (60 KSI) Yield Strength
- 22% elongation in 50 mm (2 in)
- 27 J (20 ft lb) Notch Toughness at -18° C (0° F)
- 420 MPa (60 KSI) Yield Strength
NOTE: This type of electrode has limitations if it is used to carry larger weld pass volumes in the flat welding position. Due to the fast freezing characteristics of this electrodes slag system, there is a chance of trapping evolving gases in the weld melt. Precaution should be taken by controlling weld pass size.
Welding parameters will vary due to weld position and manufacturer of the welding electrode. For 1.30 mm (.052 in) diameter electrode typical welding parameters should be:
Use the direct current electrode positive (DC reverse polarity) polarity setting and remove the slag after every pass. The weld pass size shall not exceed 8.0 mm (.31 in) fillet volume.
Clean the metal of oil, grease, paint, and dirt in the area to be welded. Attach the welding ground cable directly to the area to be welded. Protect all machined surfaces from sparks or splatter produced by the welding, chipping, and/or grinding operations.
The welds shall be free from cracks, porosity, undercut, and incomplete fusion. All weld quality shall conform to ANSI/AWS D14.3.
4. Assemble 147-3092 Filter Base group to welded plate on fuel tank (paint plates first), with three 4L-9337 Bolts and three 8T-4896 Washers. The 147-3087 Bracket Assembly is only used to secure the filter base when removing engine from unit, and bolts to the air cleaner base. (Bracket is shown in illustration 4).
5. Remove the following from existing filter base: oil filter; 2P-2537 Stud (Nipple).
6. Assemble 4P-9107 Stud (where filter stud was) with 5P-8066 Seal on it (use large nut to tightened stud in base and apply 4C-4030 Compound (Loctite) to threads). Slide 4P-9103 Adapter with 8H-7521 Seal over stud and assemble 7F-0216 Nut to stud.
NOTE: On units not equipped with turbos, omit step 7a, 7b, 7c, and 7d.
7a. Remove 8C-3446 Valve (Test) with cap from filter base. Remove four bolts from 9Y-6859 Cover. The two longest bolts will be used again.
NOTE: There are two springs and a 9Y-6860 Gasket under cover.
7b. Install the following to existing filter base: 4P-8453 Cover with two bolts previously removed; and one each 2B-2694 and 1B-9575 Bolts. Install 8C-3446 Valve (now on side) and cap
7c. Remove 7E-9302 Tube Assembly on right side of engine from turbo, and plug with 9S-4185 Plug and 3K-0360 Seal.
7d. Install 6K-3607 Connector with 2M-9780 Seal to top of oil filter base. Assemble 135-8287 Hose to connector and connect to 102-5869 Tube Assembly with 8H-9788 Gasket and bolt to turbo with existing hardware. (On DITA engines this will require a 147-2069 Hose). Clip to valve cover with 124-0174 Clip, 1C-0569 Bolt, and 3E-4352 Washer.
8. Assemble 030-7950 Elbow with 3D-2824 Seal and 030-7951 Elbow with 7M-8485 Seal to filter base adapter.
9. Assemble 147-0383 Hose Assembly and 147-0384 Hose Assembly to elbows on adapter and route to fuel tank. Assemble other end to fittings on 147-3092 Filter Base. Install new oil filter.
10. Install disconnect switch to new lower plate previously welded to fuel tank. Relocate diagnostic test port bracket to front corner of air cleaner support at a 45 degree angle with one bolt.
11. Assemble new longer 145-8713 Battery Cable to disconnect switch to negative battery post.
12. Assemble new longer 5C-6793 Cable from disconnect switch to ground stud on case.
13. Install battery support panel to unit.
14. Fill fuel tank, start unit, and check for leaks.
Illustration 1. View of Typical Tank
Illustration 2. Side View of Typical Tank
Illustration 3. Relocated Turbo Lines (Rear of Engine View)
Illustration 4. Relocated Filter Base and New Lines