Filtration Procedure for 793F, 795F, & 797F Off-Highway Truck Steering Oil {0680, 0732, 0738, 0768, 4300, 5050, 5056} Caterpillar

Off-Highway Truck/Tractor

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)

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

This guideline enables dealers and Caterpillar customers to benefit from cleaner steering fluid systems. The filter cart process is easy to use. The filter cart connects to the Off-Highway Truck steering tank filler cap and the steering tank ecology drain valve. This guideline provides directions 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	g01990326

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 the safety 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, 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.

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Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during movement. Use caution when working between the wheels and the frame. If the wheels must be turned, ensure that all personnel are clear of the machine before any movement.

References

Tooling and Equipment

Filtration Adapter Assembly

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Illustration 3	g02012314
Weld location

1. Drill a 28.5 mm (1.125 inch) hole in a 194-7051 Plug. Then weld the 194-7051 Plug to the 25.4 cm (10 inch) pipe as shown in Illustration 3. Install a 7F-8268 Seal to the suction adapter.
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   Illustration 4	g01990321
   Suction adapter (1) 1 inch diameter pipe (2) 006-5707 Pipe Elbow (3) 190-8319 Nipple (4) 201-8059 Dust Cap

2. Assemble the 25.4 mm (1 inch) diameter pipe, to the 006-5707 Elbow, the 190-8319 Nipple, and the 201-8059 Dust Cap as shown in Illustration 4.
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   Illustration 5	g01990322
   (A) Drill and tap 1 inch NPT (B) Remove the tabs for this 58 mm (2.3 inch) diameter.

3. Modify the 7H-1447 Filler Cap by machining the cap to accept a 25.4 mm (1 inch) 11.5 NPT threads, as shown in Illustration 5.
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   Illustration 6	g03400202
   Discharge Adapter (5) 006-5707 Pipe Elbow (6) 190-8318 Coupler (7) 201-8057 Dust Cap (8) Modified Cap (9) 005-8615 Pipe Nipple

4. Assemble the 006-8615 Male Union (9) to the modified filler cap (8), the 006-5707 Pipe Elbow (5), the 190-8318 Coupler (6), and the 201-8057 Dust Cap (7), as shown in Illustration 6.

Filtration Procedure

Illustration 7	g01990324
188-3242 Filter Cart

Note: Before beginning, be sure to read and understand the Tool Operating Manual, NEHS0778, "188-3242 Hydraulic/Transmission Filter Cart".

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

2. Park the machine on level ground. Engage the parking brake and stop the engine.
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   Illustration 8	g01990260
   (10) Hydraulic tank ecology drain valve assembly

3. Place a drain pan under the steering oil tank ecology drain valve (10). There could be a small amount of oil leakage from the ecology drain valve (10). Refer to Illustration 8.

4. Carefully remove the steering tank drain plug. Refer to Illustration 8.
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   Illustration 9	g01990261
   Ecology drain valve with drain plug removed

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   Illustration 10	g01990263
   (11) Suction adapter

5. Connect the suction adapter assembly (11) to the steering tank ecology drain valve (10). Refer to Illustrations 8 and 10.
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   Illustration 11	g03668428

6. Connect the filter cart suction hose (15) to the suction adapter assembly (11).
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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 12	g02012339
   (12) Steering tank oil filler cap

7. Clean the area around the steering tank filler cap (12). Slowly loosen the filler cap (12) on the steering tank and release the pressure. Make sure that all the air pressure has been vented before completely removing the cap. Remove the lock-ring and strainer from the hydraulic tank fill neck.

8. Store the filler cap in a clean place to avoid contamination and damage.
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   Illustration 13	g02012341
   (13) Discharge adapter assembly

9. Install the discharge adapter assembly (13) in the steering tank fill tube.
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   Illustration 14	g03668436
   (13) Discharge adapter assembly (14) Filter cart discharge hose

10. Connect the filter cart discharge hose (14) to the discharge adapter assembly (13). Refer to Illustration 14.
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    Illustration 15	g01990301
    Air supply valve in the OPEN position

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

12. Slowly open the air supply valve to start the filter cart pump operation. The pump is a double action diaphragm pump. The pump will pump 10W oil at 340 L/min (90 US gpm).

13. While operating the filter cart, check the filter element indicators on the filter cart. The filter element indicators will determine the amount of capacity left in the filter element.

    Note: On occasion, the filter cart pump will cavitate during start-up. The cavitation is due to air in the suction lines of the pump. When the cavitation continues for more than 1 minute, shut the filter cart OFF and inspect the filter cart connections.

14. Ensure that there are no oil leaks from any of the filter cart connections.

    Note: Caterpillar recommends recording a particle count at the beginning of the filter cycle to be 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.

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

    When using the 170-8500 Analyzer Gp for particle counting, be sure to read and understand the Tool Operating Manual, NEHS0799, "Tool Operating Manual for S40 Portable Particle Analyzer" before operating the particle counter.

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    Illustration 16	g03400205
    (16) S·O·S valve (17) 210-5530 Quick Connect Coupler (18) 220-8607 Fitting (19) 188-0639 Hose As

17. When using the 170-8500 Analyzer Gp, connect the "low pressure in" port to the S·O·S valve on the base assembly. Use a fabricated suction tube (19) fitted with a quick connect coupler (17) to connect the port to the S·O·S valve (16). The fabricated tube is required to collect an on-line sample when using the 170-8500 Analyzer Gp.
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    Illustration 17	g03668451
    (16) S·O·S valve (20) 169-8373 Fluid Sampling Bottle

18. When collecting a bottle sample, use the same S·O·S valve (16) and a 169-8373 Fluid Sampling Bottle (20).
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    Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during movement. Use caution when working between the wheels and the frame. If the wheels must be turned, ensure that all personnel are clear of the machine before any movement.

19. During the filter cart operation, run the engine with the parking brake engaged. Operate the steering system to cycle clean tank oil in to the hydraulic system and flush the more contaminated oil back in to the tank.

20. After half an hour of filtering, stop the procedure. Change the hydraulic filters. The new filters will help in the system cleaning. The new filters can remain in place until the next scheduled filter change. Changing the filters avoids opening the filter housing after the system has been cleaned. When the filter housing is opened, the housing becomes an inlet for contamination.

21. The 170-8500 Analyzer Gp will indicate when the oil has reached an ISO level of 16/13. The final ISO level should be recorded before the machine is returned to the field.

    Note: Refer to "Oil Compartment Filtration Times", at 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. Disconnect the air supply hose.

23. Remove the discharge hose (14) and discharge adapter (13) assemblies from the steering tank filler tube. Install the dust cap on the nipple. Install the dust cap on the coupler. Store the discharge adapter in a clean place for later use. Refer to Illustrations 13 and 14.

24. Install a clean steering tank filler cap (12).

25. Disconnect the filter cart suction hose (15) from the suction adapter (11). Install the dust cap on the nipple. Install the dust cap on the coupler. Refer to Illustrations 10 and 14.

26. Place a drain pan under the steering tank ecology drain valve (10). There will be some oil in the suction adapter assembly (11). Refer to Illustrations 8 and 10.

27. Remove the suction adapter assembly (11) from the steering tank ecology drain valve assembly (10). Store the suction adapter in a clean place. Refer to Illustrations 8 and 10.

28. Install a clean drain plug in the steering tank ecology drain valve assembly (10).

29. Check the steering tank oil level before returning the off-highway truck to service.

Oil Compartment Filtration Times

When 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 Gp and the 194-2897 Filter Cart Gp only. Other filtration units will have different equation references and these units will be noted when appropriate.

Illustration 18	g01990314
Oil compartment filtration equation. (A) Compartment oil capacity (gal) (B) Pulses per minute (C) Approximate filtration time (minutes)

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 pulse 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 797F Off-Highway Truck steering oil system has 165 L (43.6 US gal) of SAE 30W oil. The filter cart is operating at 180 pulses per minute. The approximate filtration time should be 34 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 cross sectional area of the particle. 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 process. 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. 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 4 micron value. 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.