Filtration Procedure for Off-Highway Truck Transmission and Torque Converter Oil {0680, 0768, 3016, 3030, 3101} Caterpillar

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)

770 (S/N: BZZ1-UP)

770G (S/N: ECM1-UP)

772 (S/N: RLB1-UP)

772G (S/N: LTS1-UP)

773B (S/N: 63W1-UP)

773D (S/N: NBJ1-UP; 7ER1-UP; 7CS1-UP)

773E (S/N: BDA1-UP; KEG1-UP; ASK1-UP)

773F (S/N: EED1-UP; EXD1-UP)

777 (S/N: 84A1-UP)

777B (S/N: 4YC1-UP)

777C (S/N: 4XJ1-UP)

777D (S/N: AGC1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)

777F (S/N: JRP1-UP)

777G (S/N: TNM1-UP)

785 (S/N: 8GB1-UP)

785C (S/N: 1HW1-UP; APX1-UP)

785D (S/N: DMC1-UP; MSY1-UP)

785G (S/N: RTL1-UP)

789 (S/N: 9ZC1-UP)

789B (S/N: 7EK1-UP)

789C (S/N: 2BW1-UP)

789D (S/N: SPD1-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; RBT1-UP)

795FAC XQ (S/N: SNT1-UP)

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

797F (S/N: LAJ1-UP; WSP1-UP)

Quarry Truck

771C (S/N: 3BJ1-UP)

771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)

773G (S/N: MWH1-UP; JWS1-UP)

775B (S/N: 7XJ1-UP)

775D (S/N: 6KR1-UP; 8AS1-UP)

775E (S/N: BEC1-UP)

775F (S/N: EYG1-UP; DLS1-UP)

775G (S/N: RFM1-UP; MJS1-UP)

Introduction

© 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 feedback form in the Service Information System website.

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 customers to benefit from cleaner hydraulic systems. The filter cart process is easy to use. The filter cart connects to the Off-Highway Truck torque converter ecology drain and to the torque converter filler tube. This guideline provides directions for you 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 18/15 or cleaner.

Important Safety Information

Illustration 1	g02139237

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 2	g01032906

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 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, measurements, 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 you start any job. Caterpillar dealers have the most current information that is available.

Safety

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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.

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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.

References

Tooling and Equipment

Filtration Adapter Assembly

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Illustration 3	g01290626
Suction Adapter (1) 7B-9008 Pipe (2) 006-5707 Elbow (3) 190-8319 Nipple (4) 201-8059 Dust Cap

1. Assemble the 7B-9008 Pipe (1), 006-5707 Elbow (2), and the 190-8319 Nipple (3) as shown above. Install the 201-8059 Dust Cap (4). Refer to Illustration 3.

   Note: Clean inside the pipe before use. Paint only the outside surface of the pipe.

   Note: The 773E off-highway truck suction adapter requires the use of an 5P-0492 Adapter to be connected to the 773E torque converter ecology drain valve.

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   Illustration 4	g01290627
   Discharge Adapter - Rework cap

2. Fabricating the discharge adapter: Drill the center of the 7H-1447 Filler Cap to accept a 41 mm (1.6 inch) hole in the 2D-4202 Plate. Slip the plate over the 3B-6491 Coupler, and weld the plate to the middle of the coupler. Put the assembly through the hole in the 7H-1447 Filler Cap. Install the 9H-6454 Gasket inside the cap to hold the assembly in place. Refer to Illustration 4.
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   Illustration 5	g01290629
   Discharge Adapter (5) 201-8057 Dust Cap (6) 190-8319 Coupler (7) 006-5707 Elbow (8) 005-8615 Union (9) Modified 7H-1447 Filler Cap (10) 9U-7018 Male Hose Barb Coupler

3. Assemble the 005-8615 Union (8), 006-5707 Elbow (7), 190-8318 Coupler (6), and the 201-8057 Dust Cap (5). Attach the 9U-7018 Hose Barb Coupler (10) on the other end of the coupling.

Filter Cart Procedure

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Illustration 6	g01290630
188-3242 Filter Cart

Note: Before you begin, be sure to read and understand the Tool Operating Manual, NEHS0778, "Tool Operating Manual for 188-3242 227-2479 Filter Cart Group".

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Operating a power washer without proper protective equipment can result in personal injury. Wear the necessary protective equipment before operating a power washer. The necessary projective equipment includes a face shield, protective clothing and rubber gloves.

1. Clean the torque converter tank, torque converter, torque converter filter housings, and the torque converter fill tube locations with a pressure washer.

2. Operate the Off-Highway Truck to warm the oil.

3. Park the machine on level ground. Engage the parking brake and stop the engine.
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   Illustration 7	g01290632
   (11) Suction adapter assembly

4. Connect the suction adapter assembly (11) to the torque converter ecology drain valve. Refer to Illustration 7.
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   Illustration 8	g01290633

   Note: On the 797, use the drain plug in the middle of the torque converter sump. Use a 8B-5774 Reducer Bushing to attach the suction adapter assembly (11) to the torque converter sump. Refer to Illustrations 7 and 8.

   Note: The 785D has a 28.57 mm (1.125 inch) STOR drain port in the torque converter sump. Use a bushing reducer that allows you to connect the 25.4 mm (1.0 inch) suction pipe adapter to the 28.57 mm (1.125 inch) STOR port on the torque converter.

   Note: The 773E, 793F-MD, and 775F (S/N: EYG) have a 33.33750mm (1.3125 inch) drain port in the torque converter sump. Use a bushing reducer that allows you to connect the 25.4 mm (1.0 inch) suction pipe adapter to the 33.33750mm (1.3125 inch) port on the torque converter sump.

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   Illustration 9	g01290635
   (11) Suction adapter assembly (12) Suction hose

5. Connect the filter cart suction hose (12) to the suction adapter assembly (11). Refer to Illustration 9.
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   Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

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   Illustration 10	g01290636
   (13) Discharge adapter assembly

6. Remove the torque converter filler cap and remove the screen. Install the discharge adapter assembly (13) in the torque converter fill tube. Refer to Illustration 10.
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   Illustration 11	g01290637
   (13) Discharge adapter assembly (14) Discharge hose

7. Connect the filter cart discharge hose (14) to the discharge adapter assembly (13). Refer to Illustration 11.
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   Illustration 12	g01290638
   Air supply valve in the CLOSED position (15) Air supply valve (16) Air supply hose

8. Attach an air supply hose (16) to the 188-3242 Filter Cart. 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 12.
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   Illustration 13	g03668513
   Air supply valve in the OPEN position

9. Slowly open the air supply valve (15) to start the filter cart pump operation. The pump is a double acting diaphragm pump. The pump is rated to pump 10W oil at 340 L/min (90 US gpm). Refer to Illustrations 12 and 13.

10. While operating the filter cart, check the filter element indicators on the filter cart. The filter element indicator 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. When cavitation continues for more than 1 minute, shut the filter cart OFF. Check all the hydraulic connections.

11. 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 at the beginning of the filter cycle for use as a baseline particle count.

12. 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.

Portable Particle Analyzer Procedure

Note: If using the portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual before operating the particle counter.

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Illustration 14	g01290640
(17) S·O·S Valve (18) 210-5530 Coupler (19) Fabricated suction tube

1. Attach the 210-5530 Coupler (18) and fabricated suction tube (19) to the S·O·S valve (17) on the filter cart. Refer to Illustration 14.

2. Attach the other end of the fabricated suction tube to the portable particle counter as called for in the Tool Operating Manual.

   Note: Information regarding the availability of parts and fabrication instructions for the suction tube assembly can be obtained by contacting the Caterpillar Dealer Service Network. Proper fittings and instructions will be provided at no cost. A 188-0639 Hose will need to be purchased prior to assembly.

Bottle Sample Procedure

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Illustration 15	g01290641
(17) S·O·S valve (20) 169-8373 Bottle Group

1. If collecting a bottle sample, use the same S·O·S valve (17) and a 169-8373 Bottle Group (20). Refer to Illustration 15.

2. Record an oil sample from the S·O·S valve (17) on the filter cart at the beginning of the filter cycle. Refer to Illustration 15.

3. During the filtration process the engine must be run at "LOW" idle with the parking brake engaged. Running the engine will cycle the torque converter/transmission oil. Cycling the torque converter/transmission oil will flush the more contaminated oil back to the torque converter tank.

   Note: Changing the steering system filter on the machine 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 opening becomes an inlet for contamination. The new filters can remain in place until the next scheduled filter change.

4. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an ISO level of at least 18/15. The final ISO code should be recorded before the machine is returned to the field.

5. When the target ISO level has been met, close the air supply valve (15) and disconnect the air supply hose (16). Refer to Illustration 12.

Filter Cart Removal

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Illustration 16	g01290643
(13) Discharge adapter assembly (14) Discharge hose

1. Remove the discharge hose (14) and remove the discharge adapter assembly (13) from the torque converter filler tube. Install the dust cap on the nipple and the quick coupler. Store the discharge adapter in a clean place to protect the adapter from contamination. Refer to Illustration 16.
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   Illustration 17	g01290644
   Fill cap

2. Install the strainer, the retaining ring, and the filler cap to the torque converter fill neck.
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   Illustration 18	g01290646
   (11) Suction adapter assembly (12) Suction hose

3. Place a drain pan under the ecology drain, some oil will remain in the suction adapter. Remove the suction hose (12) and remove the suction adapter assembly (11) from the torque converter oil ecology drain. Install the dust caps on the suction adapter (11) and store the suction adapter in a clean place. Reinstall the drain plug. Refer to Illustration 18.

4. Check the torque converter oil level before you return the Off-Highway Truck to service.

Oil Compartment Filtration Times

In 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 have different equation references and these units will be noted when appropriate.

Illustration 19	g01177339
Oil Compartment Filtration Equation (A) Compartment Oil Capacity (gal) (B) Pulses per Minute (C) Approximate Filtration Time (minutes)

Example

A 563 Vibratory Compactor has 117 L (31 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 28 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: procurement of the sample, the sample container, particle counting accuracy, 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

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.