Filtration Procedure for Off-Highway Truck (769-793) Transmission Oil {0680, 0768, 3030, 3177} Caterpillar


Filtration Procedure for Off-Highway Truck (769-793) Transmission Oil {0680, 0768, 3030, 3177}

Usage:

769C 01X


Off-Highway Truck/Tractor
769 (S/N: 99F1-UP; 35W1-UP)
769B (S/N: 99F1-UP)
769C (S/N: 01X1-UP)
769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
770G (S/N: KDH1-UP; ECM1-UP; ECX1-UP)
772 (S/N: 10S1-UP; 80S1-UP)
772B (S/N: 64W1-UP)
772G (S/N: LTS1-UP; KEX1-UP; LTX1-UP)
773 (S/N: 63G1-UP)
773B (S/N: 63W1-UP)
773D (S/N: 7ER1-UP; 7CS1-UP)
773E (S/N: BDA1-UP; PRB1-UP; DJS1-UP)
773F (S/N: EED1-UP)
776 (S/N: 14H1-UP; 14W1-UP)
776B (S/N: 6JC1-UP)
776C (S/N: 2TK1-UP)
776D (S/N: 5ER1-UP; AFS1-UP)
777 (S/N: 84A1-UP)
777B (S/N: 4YC1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
777E (S/N: KDP1-UP)
777F (S/N: JRP1-UP)
777G (S/N: GT71-UP; T5A1-UP; TNM1-UP; RDR1-UP)
784B (S/N: 5RK1-UP)
784C (S/N: 2PZ1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SPD1-UP; SHH1-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)
793F (S/N: SND1-UP; SSP1-UP; D3T1-UP; RBT1-UP)
Quarry Truck
771C (S/N: 3BJ1-UP)
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
775B (S/N: 7XJ1-UP)
775D (S/N: 6KR1-UP; 8AS1-UP)
775E (S/N: BEC1-UP)
775F (S/N: DLS1-UP)

Introduction

Table 1
Revision  Summary of Changes for SEBF8445 
10  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2017.
Removed old Point of Contacts.
New Point of Contact added to the document. 
09  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2016. 
08  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2015. 
07  Added new serial number prefixes for New Product Introduction. 
06  Added serial number prefixes to document.
Insert new copyright date.
Added Caterpillar confidential yellow statement to document.
Added "Think Safety" graphic to Important Safety Information section. 

© 2017 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 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 Guideline is required, but not available in SIS Web, submit a form for feedback in the Service Information System (SIS Web) Interface.

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 customers to properly filter Off-Highway Truck transmission oil. Following 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.


NOTICE

If the vehicle is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this kidney loop 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. Additional 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 kidney looping. 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 of the information, specifications, and illustrations that are 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, NENG2500, "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 188-3242 Hydraulic/Transmission Filter Cart" 
NEHS0799  "Tool Operating Manual for 170-8500 Analyzer Group" 
NENG2500  "Dealer Service Tool Catalog" 
PEGJ0045  "Reporting Particle Count by ISO Code" 
PEGJ0047  "How to Take a Good S·O·S Sample" 
SEBF8482  "Obtaining Oil Sample for Analysis" 

Tooling and Equipment

Table 3
Required Tools 
Part Number  Part Description 
188-3242  Hydraulic/Transmission Filter Cart 
193-5903  2 in Fill Cap Adapter(1) 
001-5262  45 Degree Elbow 
3H-9690  90 Degree Elbow 
169-8373  Bottle Group 
197-4627  2 inch Extension Group 
Optional Tools 
Part Number  Part Description 
170-8500  Analyzer Gp 
188-0639  Hose 
(1) Includes entire center suction port with quick disconnect and entire side return port with quick disconnect.

Off-Highway Truck Filter Cart Procedure for Transmission Oil

The following procedure is intended for the 769 through 793 Off-Highway Truck models. Off-Highway Trucks that do not have an independent transmission tank are not applicable to this procedure. The procedure is most effective when performed immediately after the transmission oil has been warmed to 50 °C (122 °F) and mixed from operation. Warming the oil allows any contamination in the system oil to be placed in suspension and lowers the viscosity. Be sure to read and understand the Tool Operating Manual, NEHS0778, "188-3242 Hydraulic/Transmission Filter Cart" before beginning the procedure.

Procedure

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

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

At operating temperature, the engine coolant is hot and under pressure.

Steam can cause personal injury.

Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand.

Remove the cooling system pressure cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.



NOTICE

Be sure to keep all parts clean and free from contamination



NOTICE

Do not move the machine while the filter cart is connected. Moving the machine in this condition could cause machine damage.


  1. Park the machine on level ground. Engage the parking brake.


    Illustration 3g01282701
    (1) Filler cap

  2. Clean the area around the transmission filler cap (1). Slowly loosen the filler cap (1) on the transmission tank and release the pressure. Make sure that all of the air pressure has been vented before completely removing the cap. Refer to Illustration 3.

  3. Remove the lock-ring and remove the strainer from the transmission fill neck.

  4. Store the filler cap and store the strainer in a clean place to avoid contamination and to avoid damage.


    Illustration 4g01282703
    (X) Proper length of suction hose
    (Y) Distance from the top of the fill neck to the bottom of the tank
    (Z) 110 mm (4.33 inch)

  5. Measure the distance from the top of the transmission fill neck to the bottom of the transmission tank (Y). Subtract (Z) from (Y) to obtain the proper hose length (X). Refer to Illustration 4.

  6. Cut a length of suitable hose matching the (X) measured distance of the tank depth. Install the hose on the filler cap adapter hose barb.


    Illustration 5g01282704
    (2) 193-5903 Filler Cap Adapter

  7. Install the Fill Cap Adapter (2). If obstructions exist, the side return port can be removed for clearance and reinstalled after the main filler cap adapter is installed. Be sure that the installed suction hose reaches within 25.4 mm (1 inch) of the bottom of the transmission tank. Refer to Illustration 5.

    Note: The 45° or 90° elbow fitting (3) may be required on smaller trucks when the body to tank clearance is minimal. The addition of the elbow fittings will aid in the orientation of the center suction port. The 45 degree elbow fitting (3) is pictured in Illustration 6 on the center suction port.

    Note: A 197-4627 Two inch Extension Group may be needed when the air tank on top of the transmission oil tank obstructs the installation of the 193-5903 Fill Cap Adapter. The 197-4627 Two inch Extension Group will allow the fill cap adapter to be installed above the air tank.



    Illustration 6g01282705
    (3) 45 degree elbow fitting
    (4) Side return port

  8. Install the side return port fitting (4). There are multiple side return ports on the fill cap adapter that aid in the connection of the filter cart lines. Refer to Illustration 6.


    Illustration 7g01282706
    (5) Suction line
    (6) Center suction port

  9. Connect the filter cart suction line (5) to the fill cap adapter center suction port (6). Refer to Illustration 7.


    Illustration 8g01282708
    (7) Return line
    (8) Side return port

  10. Connect the filter cart return line (7) to the fill cap adapter side return port (8). Refer to Illustration 8.


    Illustration 9g01282709
    (9) Air supply hose
    (10) Air supply valve

  11. Attach an air supply hose (9) to the 188-3242 Filter Cart. Ensure that the air supply valve (10) is in the closed position. Be sure that the air supply does not exceed 690 kPa (100 psi). Refer to Illustration 9.


    Illustration 10g03318874
    Air supply valve in the open position

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

  13. While operating the filter cart, check the filter element indicators on the filter cart. The filter element indicators will indicate 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 cavitation continues for more than 1 minute, shut the filter cart OFF. Then, inspect the filter cart connections.

  14. Ensure that there are not any 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. This particle count is used as a baseline particle count.

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

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

    2. 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, be sure to read and understand the Tool Operating Manual, NEHS0799, "170-8500 Analyzer Group" before operating the particle counter.



    Illustration 11g01282714
    (11) S·O·S valve
    (12) Suction tube

  16. When using the 170-8500 Analyzer Gp, connect the "low pressure in" port to the S·O·S valve (11) on the base assembly. Refer to Illustration 11.


    Illustration 12g03318879
    (13) 169-8373 Bottle Group

  17. If collecting a bottle sample, use the same S·O·S valve (11) and a 169-8373 Bottle Group (13). Refer to Illustration 12.

  18. Record an oil sample reading from the S·O·S valve (11) on the filter cart at the beginning of the filter cycle.

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

    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.


  19. During the filter cart operation, run the engine for 5 minutes every half hour. Running the engine will cycle the clean tank oil into the transmission system and flush the more contaminated oil back into the tank. Turn off the engine. The oil can be filtered while the engine is running.

  20. Stop the procedure after 30 minutes of filtration. Change the transmission filter. Changing the filter allows the filters to assist in the cleaning of the transmission system. The new filter can remain in place until the next scheduled filter change. Changing the filter at this time avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.


    Illustration 13g01282718
    Filter cart operation on a 777D OHT
    (14) 188-3242 Filter Cart

  21. Operate the filter cart (14) until the portable particle analyzer indicates that the oil has reached an ISO level of at least 16/13. The final ISO level should be recorded before the machine is returned to the field.

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

  22. When the target ISO level or the time interval has been met, close the air supply valve (10). Disconnect the air supply hose (9). Refer to Illustration 9.

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

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

    At operating temperature, the engine coolant is hot and under pressure.

    Steam can cause personal injury.

    Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand.

    Remove the cooling system pressure cap slowly to relieve pressure.

    Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.




    Illustration 14g01282719
    (15) Probe
    (16) S·O·S valve (located on the fill cap adapter)

  23. To relieve possible tank pressure, use a probe (15) from the 169-8373 Bottle Group and depress the S·O·S valve (16) that is located on the fill cap adapter. Refer to Illustration 14.

  24. Disconnect the filter cart return line (7) from the fill cap adapter side return port (8). Refer to Illustration 8.

  25. Disconnect the filter cart suction line (5) from the fill cap adapter center suction port (6). Refer to Illustration 7.

  26. Remove the 193-5903 Fill Cap Adapter (2). Refer to Illustration 5.

  27. Install protective caps to the fill cap adapter, the filter cart suction line and the filter cart return line to control contamination.

  28. Install the strainer and install the lock-ring into the transmission fill neck.

  29. Install the transmission oil tank fill cap (1). Refer to Illustration 3.

  30. Check the oil level by viewing the transmission tank sight gauge.

  31. Inspect the transmission system for leaks. Most oil contamination is brought into the system from an external source. To provide a long-term benefit, repairs must be completed before the machine is returned to service.

Oil Compartment Times for 188-3242 Filter Cart

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 188-3242 Filter Cart and the 194-2897 Filter Cart only. Other filtration units will use different equation references. The units that use different equations will be noted when appropriate.



Illustration 15g01177339
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 stroke 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 777D Off-Highway Truck transmission system has 138 L (36.5 US gal) of SAE 30W oil. The filter cart is operating at 170 pulses per minute. The approximate filtration time should be 37 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. 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. ExampleX/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

At this time 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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