Filtration Procedure for Kidney Looping Off-Highway Truck Steering Oil {0680, 4300, 4332, 5050, 7542} Caterpillar

Off-Highway Truck/Tractor

69D (S/N: 9SS1-UP; 9XS1-UP)

73D (S/N: 9YS1-UP; 1GW1-UP)

768B (S/N: 79S1-UP)

768C (S/N: 02X1-UP)

769 (S/N: 35W1-UP)

769B (S/N: 99F1-UP)

769C (S/N: 01X1-UP)

769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)

770 (S/N: JND1-UP; M7W1-UP; BZZ1-UP)

770G (S/N: KD21-UP; RMA1-UP; TWA1-UP; RMD1-UP; KDH1-UP; ECM1-UP; ECX1-UP)

772 (S/N: RLB1-UP; RGK1-UP; J2M1-UP; 10S1-UP; 11S1-UP; 80S1-UP)

772B (S/N: 64W1-UP)

772D (S/N: 5HR1-UP)

772G (S/N: KE31-UP; TWB1-UP; RME1-UP; RMH1-UP; KEX1-UP; LTX1-UP)

773 (S/N: 63G1-UP)

773B (S/N: 5SC1-UP; 63W1-UP)

773D (S/N: NBJ1-UP; BGL1-UP; 7ER1-UP; 7CS1-UP; 7FZ1-UP)

773E (S/N: BDA1-UP; PRB1-UP; KEG1-UP; ASK1-UP; DJS1-UP)

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

773GC (S/N: RJZ1-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; 3NF1-UP)

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

777D (S/N: DCB1-UP; AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP; 6XZ1-UP)

777E (S/N: KDP1-UP; KDZ1-UP)

777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)

777G (S/N: GT71-UP; T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)

779 (S/N: 45H1-UP)

783B (S/N: 8YM1-UP)

784B (S/N: 5RK1-UP)

784C (S/N: 2PZ1-UP)

785 (S/N: 8GB1-UP)

785B (S/N: 6HK1-UP)

785C (S/N: AP21-UP; 1HW1-UP; APX1-UP; 5AZ1-UP)

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

785G (S/N: SH21-UP; MS41-UP; TRG1-UP; RTL1-UP; WHS1-UP)

786 (S/N: 01A1-UP; 80A1-UP; 81A1-UP)

787B (S/N: 9TM1-UP)

789 (S/N: 9ZC1-UP)

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

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

789D (S/N: SP21-UP; SPD1-UP; SHH1-UP; TWP1-UP)

789G (S/N: TR21-UP)

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP; 4AR1-UP)

793C (S/N: CBR1-UP; ATY1-UP; 4GZ1-UP)

793D (S/N: FDB1-UP)

793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; D3T1-UP; RBT1-UP)

793F AC (S/N: EMD1-UP)

795F AC (S/N: ERM1-UP)

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

796 (S/N: M4N1-UP; HRP1-UP; HRY1-UP; HRZ1-UP)

797 (S/N: 5YW1-UP)

797B (S/N: JSM1-UP)

797F (S/N: LAJ1-UP; WSP1-UP; LTZ1-UP)

798 (S/N: ST71-UP)

OEM POWERTRAIN (S/N: DTE1-UP; H4J1-UP)

Quarry Truck

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

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

773G (S/N: G731-UP; G771-UP; MWH1-UP; JWS1-UP; T5S1-UP; T5T1-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: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)

Introduction

© 2018 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

The instructions given in this guideline will enable dealers and customers to properly kidney loop off-highway truck steering oil. Following this procedure will reduce the contamination in the oil to an acceptable ISO contamination level. This procedure may be modified by the technician for use on some machines if needed.

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. 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. 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

Off-Highway Truck Steering Oil- Kidney Loop Procedure

The following procedure is intended for Off-Highway Trucks. The procedure is most effective when performed immediately after the oil has been warmed to normal operating temperature or a minimum of 50° C (122.0° F) and mixed from operation. This practice allows any contamination in the system oil to be placed in suspension and lowers the oil viscosity. Be sure to read and understand the Special Instruction, NEHS0778, "Tool Operating Manual for 188-3242 Hydraulic/Transmission Filter Cart", before beginning the procedure.

Illustration 3	g02401296
Typical filtration procedure (769 Shown)

Kidney Loop Setup

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

1. Operate the machine to warm the steering oil.

2. Park the machine on level ground.

3. Move the transmission control lever to the neutral position.

4. Engage the parking brake.

5. Turn off the engine.
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   NOTICE
   Activating the steering system on the machine can be hazardous when personnel are working around the machine.

6. Chock the rear wheels.

Steering Hose Extension Assembly (If Required)

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Illustration 4	g02401298
(1) 122-6906 Caterpillar 844 Hydraulic Hose ( 4.57 m (15.00 ft) length) (2) 124-1909 Hose Coupling (1 - 11 1/2 NPT)

1. Assemble a fabricated hose. Use 4.57 m (15.00 ft) of Caterpillar 844 Hydraulic Hose (1). Use two Hose Couplings (2) to complete one hose. Do the same for the second. Refer to Illustration 4.
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   Illustration 5	g02401316
   (3) Filter cart hose (4) Fabricated hose (5) 3B-6491 Pipe Coupling (1 - 11 1/2 NPT)

2. A Pipe Coupling (5) can be used to attach the extension hose (4) permanently to the filter cart hose (3). Refer to Illustration 5.

Kidney Loop Set Up and Procedure

Illustration 6	g02401318
(6) Tank filler cap (7) Breaker relief valve

1. Press the button on top of the breaker relief valve (7) to relieve the tank pressure. Remove filler cap (6). Refer to Illustration 6.

2. Remove the retaining ring and the strainer assembly from the steering tank filler neck.

3. Store the filler cap (6) and strainer in a clean place to avoid contamination and damage.
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   Illustration 7	g02401336
   (X) Proper length of suction hose (Y) Distance from the top of the filler neck to the bottom of the tank (Z) 50.8 mm (2.00 inch) Fill cap adapter = 110 mm (4.33 inch)

4. Measure the distance from the top of the steering fill neck to the bottom of the steering tank (Y). Subtract (Z) from (Y). Subtract an extra 25.4 mm (1.00 inch) from (Y)-(Z) dimension to obtain the proper hose length (X). Refer to Illustration 7.

5. Cut a length of suitable hose equal to dimension (X). Install the hose on the fill cap adapter hose barb.
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   Illustration 8	g02404359
   (8) 193-5903 Fill Cap Adapter Gp (9) 3H-9690 Elbow (90°)

6. Install the Adapter Gp (8). Be sure that the installed suction hose reaches within 25.4 mm (1.00 inch) of the bottom of the hydraulic tank. Use the Elbow (9) to gain added clearance when required. Refer to Illustration 8.
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   Illustration 9	g02404417
   (10) 797 Steering tank filler cap

   Note: On the 797 use the lower filler cap (10) shown in Illustration 9.

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   Illustration 10	g02404457
   (11) Filter cart suction hose (12) Fill cap adapter center suction port

7. Connect the filter cart suction hose (11) to the fill cap adapter center suction port (12). Refer to Illustration 10.
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   Illustration 11	g02404476
   (13) Filter cart discharge hose (14) Fill cap adapter side return port

8. Connect the filter cart discharge hose (13) to the fill cap adapter side return port (14). Refer to Illustration 11.
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   Illustration 12	g02404577
   Air supply valve in the closed position (15) Air supply valve (16) Air supply hose

9. Attach the air supply hose (16) to the 188-3242 Filter Cart Gp, ensuring the air supply valve (15) is in the closed position. Be sure that the air supply does not exceed 698 kPa (100.0 psi). Refer to Illustration 12.
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   Illustration 13	g02404556
   Air supply valve in the open position

10. Slowly open the air supply valve to start the filter cart pump operation. This pump is a double acting diaphragm-style pump and is rated to pump SAE 10W oil at 341 L/min (90.0 US gal/min).

11. While operating the filter cart, check the filter element indicators which will determine the amount of capacity left in the filter element.

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

12. Ensure that there are no oil leaks at any of the filter cart connections.

    Note: Caterpillar recommends taking a particle count on the oil at the beginning of the filter cycle as a baseline particle count.

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

    1. Use a 188-0645 Particle Analyzer Gp or 170-8500 Analyzer Gp for immediate results.

    2. Collect a bottle sample and send the sample to an S·O·S lab.

Portable Particle Analyzer Procedure

Note: When using the Portable Particle Counter for particle counting, be sure to read and understand the Tool Operating Manual before operating.

Illustration 14	g02404581
(17) S·O·S valve (18) 210-5530 Coupler (19) Fabricated suction tube

1. Attach Coupler (18) and fabricated suction tube (19) to 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 Global Dealer Solution Network. Proper fittings and instructions will be provided at no charge. A 188-0639 Hose As will need to be purchased prior to assembly.

Bottle Sample Procedure

Illustration 15	g02404596
(17) S·O·S valve (20) 169-8373 Bottle Gp

1. If collecting a bottle sample, use the same S·O·S valve (17), and a Bottle Gp (20). Reference Special Instruction, SEBF8482, "Obtaining an Oil Sample for S·O·S Analysis". 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.
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   NOTICE
   Activating the steering system on the machine can be hazardous when personnel are working around the machine. Make sure that personnel are clear of the machine before activating the steering system.

3. During filter cart operation, start the machine and turn the steering completely to the right and to the left to cycle the steering cylinders. Cycle the cylinders to the end of the stroke at least four complete cycles. This process will cycle the clean tank oil into the system and flush the more contaminated oil back into the tank. The oil filtration can be performed while cycling the machines steering system. Turn off the engine.

   Note: Changing the steering system filters on the machine half way 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.

4. Operate the filter cart until the 188-0645 Particle Analyzer Gp or 170-8500 Particle Analyzer Gp indicates that the oil has reached an acceptable ISO level of at least 18/15. Take a final oil sample and record the final ISO level before the machine is returned to the field.

   Note: Refer to Oil Compartment Filtration Times, at the end of this document, when a portable particle analyzer is not available.

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

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

Kidney Loop Removal

Illustration 16	g02404598
Relieving possible steering tank pressure

1. To relieve possible tank pressure, press the button on top of the breaker relief valve (7). Refer to Illustration 16.
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   Illustration 17	g02404617
   (11) Filter cart suction hose (13) Filter cart discharge hose

2. Disconnect the filter cart suction (11) and discharge (13) hoses from the fill cap adapter. Install the dust caps on the couplers and nipples. Refer to Illustration 17.

3. Remove the fill cap adapter. Store filtering adapters in a clean location.
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   Illustration 18	g02404636
   Cap Installation

4. Install the strainer, retaining ring, and a clean filler cap to the steering tank filler neck. Refer to Illustration 18.

5. Check the steering tank oil level.

6. Inspect the steering system for leaks. Most steering 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.

7. Remove the chocks from the rear wheels.

Oil Compartment Filtration Times

If an on-line, portable particle counter is not available to diagnose and track when the contaminant level has lowered to an acceptable point, refer to the following equation. This equation relates to the 188-3242 Filter Cart Gp and 246-1157 Filter Cart Gp only. Other filtration units will have a different equation reference and will be noted when appropriate. There are various conditions that must be factored into the filtration efficiency of any filter cart and situation. Therefore, the following equation must be viewed as only a simple reference and not an absolute time or efficiency result.

Illustration 19	g01177339
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 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), delivering oil going both directions. Another way of determining pulses is to listen for the TUK – CHUK (two pulses). Count the number of pulses in 1 minute for use in the above equation.

Example: A 797 steering tank has 235 L (62.0 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 55 minutes.

Oil Cleanliness Information

To establish a level of oil cleanliness, record an initial particle count of the bulk oil. The portable particle counting procedure is one of the techniques that can be used to determine the level of oil cleanness. The advantage to this process is that the test results are available at the time the oil sample is taken. The data can then be used as a baseline and compared to the value measured after a failure. The data can also be used whenever there is concern that debris may have contaminated the vehicle oil. A particle count unit electronically measures the count and size of the contaminant particles contained in a fluid sample. The particle count allows the operator to determine if the fluid meets the required specification.

There are two types of particle counts: laboratory and field. Cat dealers offer lab particle counting as part of the S·O·S fluids analysis program. A sample of oil should always be taken from a vehicle after repair and submitted to the Cat dealer to perform a lab particle count. This procedure establishes a "baseline" for the vehicle oil and provides a basis for future comparison among vehicles.

An on-line particle counter should be used to determine if the vehicle has been properly cleaned before the vehicle is returned to service. Caterpillar offers an on-line portable particle counter.

If an on-line particle counter is not available, a bottle oil sample must be taken. Submit the oil bottle sample to the Cat dealer S·O·S Laboratory, or use a portable particle counter.

ISO 4406:1999 Standards for Oil Cleanliness

ISO (International Organization of Standardization) 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 used, 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. 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.