- Articulated Truck
- 725 (S/N: B1L1-UP)
- 730 (S/N: 3F31-UP; 3T31-UP; B1M1-UP)
- 730 EJECTOR (S/N: 3F41-UP; 3T41-UP; B1W1-UP)
- 735 (S/N: 3T51-UP; 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)
- 730 (S/N: 3F31-UP; 3T31-UP; B1M1-UP)
Introduction
| Summary of Changes in SEBF8798 | |
| 09 | Added new serial number prefixes for New Product Introduction (NPI).
Updated media number for Dealer Service Tools Catalog. |
| 08 | Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2018. |
| 07 | Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2017. Removed old point of contacts. Added new point of contacts. Old Title was: Procedure for Filtering Articulated Truck Hydraulic Tank Oil. New title is: Filtration Procedure for Articulated Truck Hydraulic Oil. Updated text in: ISO 4406:1999 Method for Coding the Level of Contaminates by Solid Particles. |
| 06 | Added new serial number prefixes for New Product Introduction.
Updated copyright date to 2014. Added Caterpillar: Confidential Yellow statement. Added Repair Process Engineering point of contact. Added Think Safety graphic to Important Safety Information section. |
© 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 the 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 guideline will ensure that such changes and improvements are incorporated when applicable.
For technical questions when using this document, work with your Cat 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 the customers to benefit from cleaner hydraulic systems. The filtration process is easy to use. The filter cart connects to the steering tank oil filler neck. This guideline provides directions for installing and operating the filtration 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 16/13 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 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. Extra 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 filter procedure. 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 to be used. Confirm the safety of 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, 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. |
| 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 |
| Hydraulic Filter Cart | |
| 2 inch Filler Cap Adapter(1) | |
| 2 inch Extension Group(2) | |
| Bottle Group | |
| Optional Tools | |
| Part Number | Part Description |
| Analyzer Gp | |
| Coupler | |
| Hose | |
| 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
Filter Cart 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.
- Lower the attachment to the ground and apply slight downward pressure.
- Block the wheels.
Filtration Procedure
- Lift the access panel (1).
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Illustration 4 g01292453 (2) Filler cap - Clean the area around the hydraulic tank filler cap (2). Slowly loosen the filler cap on the hydraulic tank and release the tank pressure. Make sure that all the air pressure has been vented before removing the filler cap completely.
- Remove the strainer from the hydraulic fill neck if the machine is equipped.
- Store the filler cap (2) and store the strainer in a clean place to avoid contamination and damage.
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Illustration 5 g01292454 (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 (4.33 inch) ) - Measure the distance from the top of the hydraulic fill neck to the bottom of the hydraulic tank (Y). Subtract measurement (Z) from measurement (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 g01292455 (3) 193-5903 Filler Cap Adapter
(4) 2 in. Extension - Install a 193-5903 Two in. Filler Cap Adapter (3) on top of the
50 mm (2 inch) extension (4). Be sure that the installed suction hose reaches within25 mm (1 inch) of the bottom of the hydraulic tank. If an 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 g01292456 (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 g01292458 (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 g01292459 (9) Air supply hose
(10) Air supply valve - Attach the air supply hose (9) to the 188-3243 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) . - 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
137 kPa (20 psi) and344 kPa (50 psi) . Turn the air supply valve ON. Adjust the pressure as needed, but do not exceed690 kPa (100 psi) . The pump is a double acting diaphragm pump. The pump is rated to pump 10W oil at340 L/min (90 US gpm) . - Check the filter element indicators on the filter cart during operation. The indicators will show the amount of capacity left in the filter element.
Show/hide table
Illustration 10 g01292461 Filter cart operation Note: The filter cart pump will cavitate during start-up on various 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 connections.
- Ensure that there are no oil leaks from any of the filter cart connections.
Note: Caterpillar recommends that a particle count is taken at the beginning of the filter cycle for use as a baseline particle count.
- The oil can be particle count tested for cleanliness in one of the two following ways.
- Use a 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 for more information.
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| Illustration 3 | g01292452 |
| (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 particle counter "low pressure in" suction tube to the S·O·S valve (14) of the filter cart.
Note: The fabricated suction tube can be made with the parts listed in Table 3. The fabricated suction tube is shown in Illustration 11.
- Attach the other end of the fabricated suction tube to the "low pressure in" port on the portable particle counter as called for in the Tool Operating Manual.
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| Illustration 11 | g01292462 |
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(11) (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: Filtration can be performed while running the engine.
- At the halfway point of filtration, stop the procedure and change the filters in the machine.
Note: Changing the filters in 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 open housing becomes an inlet for contamination. The new filters can remain in place until the next scheduled filter change.
Note: The machine filters are to be changed at regularly scheduled intervals. The filters are to be replaced if the filters are not working at optimal performance.
- Operate the filter cart 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.
- When the target ISO level has been met, close the air supply valve (10) and disconnect the air supply hose (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. Refer to Illustration 9. - Disconnect the filter cart discharge hose (7) from the filler cap adapter side return port (8). Install the dust caps on the coupler and the nipple. Store the coupler and the nipple in a clean location. Refer to Illustration 8.
- Remove the 193-5903 Filler Cap Adapter (3). Refer to Illustration 6.
- Install the strainer and install the lock ring in the hydraulic fill neck.
- Install a clean filler cap (2). Refer to Illustration 4.
- Lower the access cover (1). Refer to Illustration 3.
- Check the hydraulic tank oil level.
- Unblock the wheels.
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| Illustration 12 | g01292463 |
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(14) S·O·S valve
(15) | |
Oil Compartment Filtration Times for
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 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 cycle 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 hydraulic system has
ISO 4406:1999 Method for coding the level of contaminates by solid particles
The International Organization for Standardization or ISO document ISO 4406:1999 contains specific code ranges used to define the level of particulate contaminants in hydraulic fluids with the use of devices such as automatic particle counters.
Proper care should be taken during the sample obtained is representative of the fluid circulating in the system. Live samples directly from the machine/system or particle counter on the filtration cart (if equipped) is preferred over bottle sampling as many of the sampling interferences are mitigated.
Particle counts and subsequent ISO codes are affected by various factors. These factors include the procurement of the sample, the cleanliness of the sample bottle, particle counting device maintenance, calibration, and the cleanliness of the particle count process. Extra factors include location of the sample taken from the machine/system, the purging of sample valves and the cleanliness of sample valves.
The ISO 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.