- Articulated Truck
- 735 (S/N: B1N1-UP; AWR1-UP)
- 735B (S/N: L4D1-UP; T4P1-UP)
- 735C (S/N: LFJ1-UP; TFJ1-UP)
- 740 (S/N: AXM1-UP; B1P1-UP)
- 740 EJECTOR (S/N: 3F71-UP; 3T71-UP; B1R1-UP; AZZ1-UP)
- 740 GC (S/N: 3F81-UP; 3T81-UP)
- 740B (S/N: L4E1-UP; T4R1-UP)
- 740B EJECTOR (S/N: L4F1-UP; T4S1-UP)
- 740C EJECTOR (S/N: LFN1-UP; TFN1-UP)
- 745 (S/N: 3F61-UP; 3T61-UP)
- 745C (S/N: LFK1-UP; TFK1-UP)
- 735B (S/N: L4D1-UP; T4P1-UP)
Introduction
| Revision | Summary of Changes in SEBF8806 |
| 06 | Added new serial number prefixes for New Product Introduction.
Updated media number for Dealer Service Tools Catalog. |
| 05 | Added new serial number prefixes for New Product Introduction.
Updated copyright date to 2017. Removed old Point of Contacts. New Point of Contact added to the document. |
| 04 | Added new serial number prefixes for New Product Introduction.
Updated copyright date to 2014. Added Caterpillar: Confidential Yellow statement. Added Think Safety graphic to Important Safety Information section. |
| 03 | Updated Introduction.
Added Canceled Replaced Part Numbers statement. |
| 02 | Added new serial number prefixes for New Product 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 to 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
This guideline enables dealers and customers to benefit from cleaner hydraulic systems. The kidney loop filtration process is easy to use. The kidney loop cart connects to the steering tank oil filler neck. This guideline provides directions for installing and operating the kidney loop system.
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.
| NOTICE |
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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 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 kidney looping. This filtration procedure and subsequent particle count testing should be performed as a final step in the repair process. |
Important Safety Information
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| 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.
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| 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. Also, ensure that the product will not be damaged or 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, 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. Cat 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. |
| NOTICE |
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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
| References | |
| Media Number | Title |
| NEHS0778 | "Tool Operating Manual for 188-3242 Filter Cart Group or 227-2479 Filter Cart Group" |
| 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 S·O·S Sample" |
| SEBF8482 | "Obtaining an Oil Sample for S·O·S Analysis" |
Tooling and Equipment
| Required Tools | |
| Part Number | Part Description |
| 188-3242 | Hydraulic Filter Cart |
| 193-5903 | 2 inch Filler Cap Adapter(1) |
| 197-4627 | 2 inch Extension Group(2) |
| 169-8373 | Bottle Group |
| Optional Tools | |
| Part Number | Part Description |
| 170-8500 | Analyzer Gp |
| 210-5530 | Coupler |
| 188-0639 | Hose |
| 220-8607 | Fitting(3) |
| (1) | Includes entire center suction port with quick disconnect and entire side return port with quick disconnect |
| (2) | May be required on some models |
| (3) | Low-pressure suction tube fabrication |
Machine Filtration Procedure
This guideline is intended for Articulated Trucks. The procedure is most effective when performed immediately after the oil has been warmed to
Filtration Setup
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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. |
- Operate the machine to warm the oil.
- Park the machine on level ground.
- Apply the service brake to stop the machine.
- Move the direction control switch or the transmission control lever to the NEUTRAL position. Engage the transmission lock if the machine is equipped.
- Engage the parking brake.
- Block the wheels.
Filtration Procedure
- Lift the access panel (1).
Show/hide table
Illustration 4 g01292033 (2) Filler Cap - Clean the area around the steering tank filler cap (2). Loosen the filler cap on the steering tank and release the tank pressure. Make sure that all the air pressure has been vented before completely removing the filler cap.
- Remove the strainer from the filler neck.
- Store the filler cap (2) and the strainer in a clean place to avoid contamination and damage.
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Illustration 5 g01292036 (X) Proper length of suction hose
(Y) Distance from the top of the fill neck to the bottom of the tank
(Z) 2 inch filler cap adapter (110 mm (4.3 inch) - Measure the distance from the tip of the steering tank fill neck to the bottom of the steering tank (Y). Subtract (Z) from (Y). Subtract an extra
25.4 mm (1 inch) to obtain the proper hose length (X). Refer to Illustration 5. - Cut a length of suitable hose that matches the (X) measured distance of the tank depth. Install the hose on the filler cap adapter hose barb.
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Illustration 6 g01292037 (3) 193-5903 Filler Cap Adapter
(4)50 mm (2 inch) extension - Install the 193-5903 Two inch Filler Cap Adapter (3) on top of the 2 inch extension (4). Be sure that the installed suction hose reaches within
25.4 mm (1 inch) of the bottom of the steering tank. If obstruction to the installation exists, the side return port can be removed for clearance and reinstalled after the adapter is installed.Show/hide table
Illustration 7 g01292039 (5) Suction hose
(6) Suction port - Connect the filter cart suction hose (5) to the filler cap adapter center suction port (6).
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Illustration 8 g01292040 (7) Discharge hose
(8) Return port - Connect the filter cart discharge hose (7) to the filler cap adapter side return port (8).
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Illustration 9 g01292041 (9) Air supply hose
(10) Air supply valve - 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. - Slowly open the air supply valve (10) to start the filter cart pump operation. If the air supply valve (10) is a purge-off style, adjust the air supply between
138 kPa (20 psi) and345 kPa (50 psi) and turn the air supply valve (10) to the ON position. Adjust the air pressure as needed, but do not exceed690 Pa (100 psi) . The pump is a diaphragm pump. The pump is rated to pump 10W oil at340 L/min (90 US gpm) . - During operation, check the filter element indicators on the filter cart. The element indicators will determine the amount of capacity left in the filter element.
Show/hide table
Illustration 10 g01292042 Filter cart operation Note: The filter cart pump will cavitate during start-up on certain occasions. The 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 check the filter cart connections.
- Ensure that there are no oil leaks from any of the filter cart connections.
Note: Caterpillar recommends taking a particle count on the oil at the start of the filter cycle to use as a baseline particle count.
- The oil can be particle count tested for cleanliness in one of the two following ways.
- Use a 170-8500 Portable Particle Analyzer for immediate results.
- Collect a bottle sample and send the sample to an S·O·S lab. Refer to Contamination Control Guideline, SEBF8482, "Obtaining an Oil Sample for S·O·S Analysis".
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| Illustration 3 | g01292031 |
| (1) Access Panel | |
Portable Particle Analyzer Procedure
When using a portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual before operating the particle counter.
- Attach the fabricated suction tube (11) suction tube to the S·O·S valve (14) on the machine.
Note: The fabricated suction tube can be made with the parts listed in Table 3 and as shown in Illustration 11.
- Attach the other end of the fabricated suction tube (11) to the "low pressure in" port on the portable particle analyzer as called for in the Tool Operating Manual.
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| Illustration 11 | g01292043 |
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(11) Fabricated suction tube
(12) (13) (14) S·O·S valve | |
Bottle Sample Procedure
- If collecting a bottle sample, use the same S·O·S valve (14) and a 169-8373 Bottle Group (15).
- Record an oil sample from the S·O·S valve (14) on the filter cart at the beginning of the filter cycle.
Note: Kidney loop filtration can be performed while running the engine.
- At the halfway point of kidney looping, stop the procedure and change the filter on the machine.
Note: Changing the filters on the machine halfway through the filtering process avoids opening the filter housing after the system has been thoroughly cleaned. If the filter housing is opened after the filtration process is complete, the housing will become an inlet for contamination. The new filters can remain in place until the next scheduled filter change.
Note: Replace the filters on the machine if the filters are scheduled for replacement, or if the filters are not working at optimal performance.
- Operate the filter cart until the portable particle 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.
- When the target ISO level has been met, close the air supply valve (10). Disconnect the air supply hose (9). Refer to Illustration 9.
Note: Refer to "Oil Compartment Filtration Times for
188-3242 Filter Cart" at the end of this document, when a portable particle analyzer is not available. - Disconnect the filter cart discharge hose (7) from the filler cap adapter side return port (8). Install the dust caps on the coupler and on the nipple. Store the hose in a clean location. Refer to Illustration 8.
- Disconnect the filter cart suction hose (5) from the filler cap adapter center suction port (6). Install the dust caps on the coupler and on the nipple. Store the hose in a clean location. Refer to Illustration 7.
- Remove the filler cap adapter (3). Refer to Illustration 6.
- Remove the
50 mm (2 inch) extension group (4). Refer to Illustration 6. - Install the strainer and install the lock ring in the steering tank fill neck.
- Install a clean filler cap (2). Refer to Illustration 4.
- Lower the access cover (1). Refer to Illustration 3.
- Check the steering tank oil level.
- Unblock the wheels.
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| Illustration 12 | g01292044 |
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(14) S·O·S valve
(15) | |
Oil Compartment Filtration Times for
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 Carts only. Other filtration units will have different equation references and these units will be noted when appropriate.
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| Illustration 13 | g01177339 |
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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). The shifting of the pump 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 735 Articulated Truck system has
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 sectional area of the particle. 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 to 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.