Filtration Procedure for Transmission Oil on Motor Graders Without Ecology Drain {0680, 0768, 3030} Caterpillar


Filtration Procedure for Transmission Oil on Motor Graders Without Ecology Drain {0680, 0768, 3030}

Usage:

120H 124


Motor Grader
120H (S/N: 1241-UP; CAF1-UP; 5FM1-UP; 6NM1-UP; 6TM1-UP; 2AN1-UP; 9FN1-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; AMZ1-UP)
12K (S/N: JJA1-UP; SZP1-UP)
12M (S/N: B9F1-UP; B9R1-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; 7PM1-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)
160H (S/N: ASD1-UP; 9EJ1-UP; XZK1-UP; 2FM1-UP; 3GM1-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)
24H (S/N: 7KK1-UP)

Introduction

Table 1
Revision  Summary of Changes in SEBF8461 
20  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2019. 
19  Added new serial number prefixes for New Product Introduction (NPI).
Updated media number for Dealer Service Tools Catalog. 
18  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2018.
Removed old Repair Process Engineering point of contacts.
Added new Process Engineering point of contact. 
17  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2016.
Added 12M 3 AWDsales model to table # 5. 
16  Added new serial number prefixes for New Product Introduction.
Updated copyright date to 2014.
Added Caterpillar: Confidential Yellow statement. 

© 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 the customers to benefit from cost reductions which were made possible through an established Contamination Control Program. Fluids 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 available from Caterpillar. The latest technical information will 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 Guidelines 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

This guideline enables dealers and the customers to benefit from cleaner transmission systems. The filtration process is easy to use. The filter cart quickly connects to the transmission oil inlet port and the transmission case drain. This guideline provides directions to install and operate the filter cart.

Clean fluids play a major function in the life of any fluid system. The following procedure will help reduce fluid contamination in the oil to an acceptable level of ISO 16/13 or cleaner.


NOTICE

If the vehicle is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this filtration procedure. If the failure is not addressed early, particles from the failed component will contaminate other system components such as valves, pumps, motorsandcontrols. Additional component cleaning, component exchange, and lines flushing will be required to remove most contaminates generated from the failure. The vehicle system cleaning MUST be performed prior to the 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 1g02139237

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 2g01032906

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, a procedure, a work method, or an operating technique that is not recommended by Caterpillar is used, ensure that the procedure is safe for all personnel around the machine. Ensure that the product will not be damaged or that the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures.

All information, specifications, and illustrations in this publication are based on information that was available at the time of publication. The following 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 starting any job. Caterpillar dealers have the most current information that is available.

Safety

------ WARNING! ------

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.


------ WARNING! ------

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.



NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.

Dispose of all fluids according to local regulations and mandates.


References

Table 2
References 
Media Number  Title 
NEHS0778  "Tool Operating Manual for 188-3243 Hydraulic/Transmission Filter Cart" 
NEHS0799  "Tool Operating Manual for 170-8500 Analyzer Group" 
PERJ1017  "Dealer Service Tool Catalog" 
PEGJ0045  "Reporting Particle Count by ISO Code" 
PEGJ0047  "How To Take A Good Oil S·O·S Sample" 
SEBF8482  "Obtaining an Oil Sample for S·O·S Analysis" 

Tooling and Equipment

Table 3
Parts List 
Quantity  Part Number  Part Description 
188-3242  Filter Cart Gp 
169-8373  Fluid Sampling Bottle 
Suction Adapter 
1(1)  Pipe NPT  254 mm (10 inch) in length 
006-5707  Pipe Elbow 
190-8319  Coupler 
201-8059  Dust Cap 
4C-7156  Fitting 
4C-7099  Nipple 
5P-0306  Vacuum Transducer 
Discharge Adapter 
1(1)  25.4 mm (1 inch) pipe NPT  127 mm (5 inch) 1 inch - 12 NPT one end 
006-5707  Pipe Elbow 
190-8318  Coupler 
201-8057  Dust Cap 
(1) See Table 4.

Table 4
Optional Tooling 
Part Number  Parts Description 
170-8500  Analyzer Gp 
210-5530  Quick Connect Coupler 
188-0639  Hose As 
220-8607  Fitting 

Table 5
Suction Adapter Assembly 
Sales Model  Adapter  Seal  Rework  254 mm (10 inch) Long Pipe 
14H
16H 
4T-2069  2H-3932  Drill 5/8 inch hole & weld pipe to adapter
Next weld the 6B-9081 bushing to the opposite end of the pipe. 
3/4 inch NPTF(1)
One end 
12H
12K
12M
12M
12M 3 AWD
14L AWD
120H
120K
120M
120N
135H
140H
140M
140M 3
140K
143H
160H
160K
163H
14M
16M
160M 
5P-0492  7M-8485  Weld pipe to the adapter  1 inch NPTF(1)
Both ends 
(1) Clean the insideof the pipe before use. Paint only the outside surface of the pipe.

Filter Cart Adapter Assembly



    Illustration 3g01274823
    Suction Adapter
    Weld locations

  1. Refer to Table 5 to determine the correct adapter and pipe. Weld the adapters to the pipe, as shown in Illustration 3.


    Illustration 4g01274825
    (1) Suction adapter
    (2) 006-5707 Pipe Elbow
    (3) 190-8319 Nipple
    (4) 201-8059 Dust Cap

  2. Assemble the proper suction adapter (1) to the Elbow (2), Nipple (3), and the Dust Cap (4), as shown in Illustration 4.


    Illustration 5g03448490
    Discharge Adapter
    (2) 006-5707 Elbow
    (5) 1 inch diameter pipe (5 inches long)
    (6) 201-8057 Dust Cap
    (7) 190-8319 Coupler

  3. Assemble the 25.4 mm (1 inch) diameter pipe (5), the Elbow (2), Coupler (7), and Dust Cap (6), as shown in Illustration 5.

Filtration Procedure

This procedure is most effective when performed immediately after the transmission fluid has been warmed to 50 °C (122 °F) and mixed from operation. Warming the oil 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, NEHS0778, "188-3242 Hydraulic/Transmission Filter Cart" before beginning this procedure.

Note: Be sure to keep all parts clean and free of contamination.

  1. Install the frame lock pins, if the machine is equipped with an articulated frame.

  2. Clean the transmission case drain area, case, air breather, and the transmission fill tube locations with a pressure washer.

  3. Operate the machine to warm the oil.


    Illustration 6g01274830
    Motor grader with 188-3242 Filter Cart

  4. Park the machine on level ground.

  5. Lower the attachment to the ground and apply slight downward pressure.

  6. Engage the parking brake and stop the engine.

  7. Install the frame lock pins when performing filtration work.

    ------ WARNING! ------

    Hot oil and components can cause personal injury.

    Do not allow hot oil or components to contact the skin.

    Be sure that the engine and components are cool enough to touch with your bare hand prior to performing any service work.




    Illustration 7g01274834
    9G-5127 Breather

  8. Remove the 9G-5127 Breather from the transmission case.


    Illustration 8g01274835
    (8) 4C-7099 Nipple
    (9) 4C-7156 Fitting
    (10) 5P-0306 Vacuum Transducer

  9. Assemble the Fitting (9) to the Nipple (8) and the Vacuum Transducer (10). An air hose extension attached to the transducer may be helpful. Refer to Illustration 8.

  10. Install the transducer assembly in place of the air breather on the transmission case. Connect the compressed air line to the transducer.

    Note: If the motor grader is going to be filtered at every preventive maintenance, a quick disconnect can be connected to the transmission case and the breather for the convenience.

  11. Apply air pressure to the vacuum transducer before removing the transmission drain plug.

  12. Place a drain pan under the transmission case. There could be some oil leakage.

    Note: Be sure that the transmission case has a vacuum before continuing. Do not remove the transmission filler cap before this step. If the filler cap is removed, the vacuum cannot be achieved.



    Illustration 9g03321400
    Typical transmission drain plug

  13. Carefully remove the transmission drain plug. Refer to Illustration 9.


    Illustration 10g01274838
    (11) Suction adapter assembly

  14. Quickly install the suction adapter assembly (11) into the transmission case. Refer to Illustration 10.


    Illustration 11g01274839
    (11) Suction adapter assembly
    (12) Suction hose

  15. Connect the filter cart suction hose (12) to the suction adapter assembly (11).

  16. Disconnect the air supply of the transducer to relieve the transmission case vacuum.

    Note: Leave the transducer connected to the transmission to complete the filter cart removal procedure later in this guideline.



    Illustration 12g01274840
    (13) Discharge adapter assembly

  17. Remove the transmission filler cap. Install the discharge adapter assembly (13) in the transmission fill tube. Refer to Illustration 12.


    Illustration 13g01274841
    (13) Discharge adapter assembly
    (14) Discharge hose

  18. Connect the filter cart discharge hose (14) to the discharge adapter assembly (13). Make sure that the hose and the adapter will not dislodge during the filter cart operation. Refer to Illustration 13.


    Illustration 14g03448897
    Air supply valve in the CLOSED position
    (15) Air supply valve
    (16) Air supply hose

  19. Attach an air supply hose (16) to the 188-3242 Filter Cart Gp. Ensure that the air supply valve (15) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi). Refer to Illustration 14.


    Illustration 15g03448916
    Air supply valve in the OPEN position

  20. Slowly open the air supply valve (15) to start the filter cart operation. The pump is a double acting diaphragm pump. The pump is rated to pump 10W oil at 341 L/min (90 US gpm).

  21. While operating the filter cart, check the filter element indicators on the filter cart. The filter element indicators will determine the amount of capacity left in the filter element.

    Note: Occasionally, the filter cart pump will cavitate during start-up. Cavitation is due to air in the suction lines of the pump. If the cavitation continues for more than 1 minute, shut the filter cart OFF and inspect the connections.

  22. 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. The particle count is used as a baseline particle count.

  23. The oil can be particle count tested for cleanliness in 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.

    Note: If using the 170-8500 Analyzer Gp for particle counting, read and understand the Tool Operating Manual, NEHS0799, before operating the particle counter.



    Illustration 16g03448940
    (17) 220-8607 Fitting
    (18) Fabricated suction tube
    (19) 210-5530 Quick Connect Coupler
    (20) S·O·S Valve

  24. When using the 170-8500 Analyzer Gp, connect the "low pressure in" port to the S·O·S valve (20) on the base assembly using a fabricated suction tube (18) fitted with a Quick Connect Coupler (19). Refer to Illustration 16.


    Illustration 17g03448943
    (20) S·O·S Valve
    (21) 169-8373 Fluid Sampling Bottle

  25. If collecting a bottle sample, use the same S·O·S valve (20) and a 169-8373 Fluid Sampling Bottle (21). Refer to Illustration 17.

  26. Record an oil sample reading from the S·O·S valve (20) on the filter cart at the beginning of the filter cycle.

  27. During filter cart operation, run the engine. Running the engine will cycle the clean oil into the transmission system and flush the more contaminated oil back into the case.

  28. During the filter cart operation, start the machine and cycle the hydraulic circuits at least four times every half hour. Operation of the hydraulic circuits will cycle the clean tank oil into the hydraulic system and flush the more contaminated oil back into the tank.

    Note: Changing the hydraulic system filters halfway through the filtering process avoids opening the filter housing after the system has been cleaned. If the filter housing is opened after the filtration process is complete, the housing becomes an inlet for contamination. The new filters can remain in place until the next scheduled filter change.

    Note: The machine filters should be replaced at regularly scheduled intervals, or if the filters are not working at optimal performance.

  29. Operate the filter cart until the Analyzer Gp indicates that the oil has reached an ISO level of at least 16/13 or lower. The final ISO should be recorded before the machine is returned to the field.

    Note: Refer to "Oil Compartment Times for 188-3242 Filter Cart Gp" at the end of this guideline, when a 170-8500 Analyzer Gp is not available.

  30. When the target ISO level or the time interval has been met, close the air supply valve (15) and disconnect the air supply hose (16). Refer to Illustration 14.

    ------ WARNING! ------

    Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.


  31. Remove the discharge hose (14) and the discharge adapter assembly (13) from the transmission fill tube. Install the dust cap on the nipple and the quick coupler. Store the discharge adapter in a clean place for the next job. Refer to Illustration 13.

  32. Install a clean transmission filler cap.

  33. Reinstall the airline to the 5P-0306 Vacuum Transducer (10). Refer to Illustration 8.

  34. Operate the vacuum transducer prior to removing the suction adapter (1). Refer to Illustration 4.

    Note: Be sure that the transmission case has a vacuum before removing the suction adapter assembly.

  35. Disconnect the filter cart suction hose (12) from the suction adapter assembly (11). Install the dust cap on the nipple and the quick coupler. Refer to Illustration 11.

  36. Place a drain pan under the transmission case. There will be some oil in the suction adapter assembly (11).

  37. Remove the suction adapter assembly (11) from the transmission case. Then quickly reinstall a clean transmission case drain plug. Also store the suction adapter in a clean place. Refer to Illustrations 9 and 10.

  38. Remove the vacuum transducer and reinstall a clean air breather. Also store the transducer in a clean place.

  39. Check the transmission oil level before returning the motor grader to service.

  40. Remove the frame lock pins, if the machine is equipped with an articulated frame.

Oil Compartment Times for 188-3242 Filter Cart Gp

Ifan on-line Analyzer Gp, 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 188-3242 Filter Cart Gp and the 194-2897 Filter Cart Gp. only. Other filtration units will have different equation references and these units will be noted when appropriate.



Illustration 18g01177339
Oil compartment filtration equation
(A) Compartment oil capacity (gal)
(B) Pulses per minute
(C) Approximate filtration time (min)

Pulses Per Minute Definition

Each air discharge or each stroke of the air operated filter pump delivers one pulse of oil. The internal pump shaft will slide left (one pulse), and then to the right (one pulse). Each pulse delivers oil in both directions. Another way of determining pulses is to listen for the “tuk-chuk” of two pulses. Count the number of pulses in 1 minute for use in the above equation.

Example

A 12H motor grader transmission system has 45 L (12 US gal) of SAE 10W oil. The filter cart is operating at 180 pulses per minute. The approximate filtration time should be 9 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 cross section area of the particle. Particle counts are affected by various factors. These factors include: 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. Proper care will 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.

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