Filtration Procedure for Wheel Loader Transmission Oil (Equipped with an Ecology Drain) {0680, 0768, 3000, 3030, 4000} Caterpillar

Integrated Toolcarrier

IT62G (S/N: AKP1-UP; 6PS1-UP)

IT62G Series II (S/N: AYA1-UP)

IT62H (S/N: M5G1-UP)

Landfill Compactor

816K (S/N: WNB1-UP; WCL1-UP)

826G (S/N: 7LN1-UP)

826G Series II (S/N: AYH1-UP)

826K (S/N: 2321-UP; 2L31-UP; 2T61-UP; SET1-UP)

836 (S/N: 3RL1-UP; 7FR1-UP)

836G (S/N: BRL1-UP; 7MZ1-UP)

836H (S/N: BXD1-UP)

836K (S/N: T6X1-UP; L6Z1-UP)

Soil Compactor

815K (S/N: MBB1-UP; WCS1-UP)

825G (S/N: 6RN1-UP)

825G Series II (S/N: AXB1-UP)

825K (S/N: 2331-UP; 2T91-UP; SEE1-UP)

Wheel Dozer

814K (S/N: LW41-UP; DMB1-UP; WCM1-UP)

824G (S/N: 4SN1-UP)

824G Series II (S/N: AWW1-UP)

824H (S/N: ASX1-UP)

824K (S/N: 2T21-UP; 2L41-UP; 2341-UP; RWB1-UP)

834B (S/N: 7BR1-UP)

834G (S/N: BPC1-UP; 6GZ1-UP)

834H (S/N: BTX1-UP)

834K (S/N: TW41-UP; L4Y1-UP)

844K (S/N: MBE1-UP; M4R1-UP; KLS1-UP; K4Y1-UP)

854K (S/N: KK31-UP; RM31-UP; KK61-UP; RM61-UP; H9K1-UP; H8M1-UP)

Wheel Loader

950G (S/N: 2JS1-UP; 4BS1-UP; 6NS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)

950G Series II (S/N: BAA1-UP; AYB1-UP; AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)

950H (S/N: N1A1-UP; JAD1-UP; M1G1-UP; J5J1-UP; K5K1-UP; MXL1-UP; JLX1-UP)

950K (S/N: FER1-UP)

950L (S/N: TNS1-UP; LXX1-UP)

950M (S/N: EMB1-UP; ENE1-UP; XCJ1-UP; NHL1-UP; FTR1-UP; LCR1-UP; J1S1-UP)

950M Z (S/N: HE81-UP)

962G (S/N: BDP1-UP; 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)

962G Series II (S/N: BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)

962H (S/N: N4A1-UP; SSA1-UP; M3G1-UP; J6J1-UP; K6K1-UP; MAL1-UP; PCW1-UP)

962K (S/N: FLL1-UP)

962L (S/N: MTN1-UP; SXS1-UP)

962M (S/N: K881-UP; EJB1-UP; JYD1-UP; LSE1-UP; RCL1-UP; J2S1-UP; F2T1-UP)

962M Z (S/N: SA81-UP)

966G (S/N: AAH1-UP; 3ZS1-UP; 9RS1-UP; 3PW1-UP; 3SW1-UP; 8XW1-UP)

966G Series II (S/N: AXJ1-UP; AXL1-UP; ANT1-UP; AWY1-UP; ANZ1-UP; AWZ1-UP)

966H (S/N: BJ61-UP; BS61-UP; A6D1-UP; RYF1-UP; A6G1-UP; A6J1-UP; TAL1-UP)

966K (S/N: PBG1-UP; TFS1-UP)

966K Series XE (S/N: NGX1-UP)

966L (S/N: FSL1-UP; FRS1-UP)

966M (S/N: EJA1-UP; DYC1-UP; R8D1-UP; LMM1-UP; KJP1-UP; L8R1-UP)

966M Series XE (S/N: FL21-UP; P6C1-UP; B8P1-UP)

972G (S/N: 7LS1-UP; AAW1-UP; 1EW1-UP; 4WW1-UP; 6AW1-UP; 9GW1-UP)

972G Series II (S/N: AXC1-UP; AXE1-UP; AXN1-UP; AWP1-UP; AXP1-UP; ANY1-UP)

972H (S/N: GTA1-UP; LCC1-UP; A7D1-UP; NPE1-UP; A7G1-UP; A7J1-UP; WXZ1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

972L (S/N: RFB1-UP; YJW1-UP)

972M (S/N: L8E1-UP; LSJ1-UP; GGN1-UP; A8P1-UP; JPR1-UP; M8W1-UP)

972M Series XE (S/N: L9S1-UP; M5S1-UP; EDW1-UP)

980G (S/N: 9CM1-UP; 2KR1-UP; 2SR1-UP)

980G Series II (S/N: AXG1-UP; AWH1-UP; AYT1-UP)

980H (S/N: MHG1-UP; A8J1-UP; KZL1-UP; JMS1-UP)

980K (S/N: W7K1-UP; GTZ1-UP)

980L (S/N: D8Z1-UP)

980M (S/N: MK21-UP; WW31-UP; MGD1-UP; KRS1-UP; N8T1-UP)

982M (S/N: MK61-UP; F9A1-UP; WMD1-UP; LRS1-UP; K1Y1-UP)

986K (S/N: MH81-UP; NL81-UP; SWH1-UP)

988F (S/N: 8YG1-UP)

988F Series II (S/N: 2ZR1-UP)

988G (S/N: BNH1-UP; 2TW1-UP)

988H (S/N: BXY1-UP)

988K (S/N: T8E1-UP; L8X1-UP)

990H (S/N: BWX1-UP)

990K (S/N: DJK1-UP; A9P1-UP; M9P1-UP; K9X1-UP)

992K (S/N: 8801-UP; KK21-UP; RM21-UP; KK41-UP; RM51-UP; H4C1-UP; ZMX1-UP)

Introduction

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar 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. 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. Using 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 Contamination Control guideline enables dealers and the dealer customers to benefit from cleaner hydraulic systems. The filtration process is easy to use. The filter cart quickly connects to the transmission ecology drain and the transmission oil filler tube. 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 18/15 or cleaner.

Note: If the vehicle is being serviced due to a catastrophic failure, a complete system cleaning operation is required before starting 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 that were generated from the failure. The vehicle system cleaning must be performed prior to the filtration procedure. This filtration procedure and subsequent particle count testing should be performed as a final step in the repair process.

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 items 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 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.

The following procedure is to be used on wheel loaders that are equipped with a 129-0987 Ecology Drain Valve or a 138-1509 Ecology Drain Valve. The procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and the oil has been mixed from operation. This action causes any contamination in the system to be placed in suspension. Warming the oil also lowers the oil viscosity.

References

Tooling and Equipment

Assembling the Filtration Adapters

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Illustration 3	g01333064
(1) 1 inch diameter pipe (2) 006-5707 Pipe Elbow (3) 190-8319 Nipple (4) 201-8059 Dust Cap

Note: The 966H requires the use of a 5P-0492 Adapter for the suction adapter to connect to the 966H transmission case.

1. Assemble the 25.4 mm (1 inch) diameter pipe (1) to the Pipe Elbow (2), the Nipple (3), and the Dust Cap (4), as shown in Illustration 3.
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   Illustration 4	g01333065
   (A) Drill and tap 1 inch NPT (B) Remove the tabs for this 58 mm (2.3 inch) diameter.

2. Modify the 7H-1447 Filler Cap by machining the cap to except 25.4 mm (1 inch) 11.5 NPT threads, as shown in Illustration 4.
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   Illustration 5	g01333066
   (2) 006-5707 Pipe Elbow (5) Modified cap (6) 005-8615 Pipe Nipple (7) 190-8318 Coupler (8) 201-8057 Dust Cap

3. Assemble the Pipe Nipple (6) to the modified filler cap (5), the Pipe Elbow (2), the Coupler (7), and the Dust Cap (8). Refer to Illustration 5.

Filtration Procedure

Illustration 6	g01333067
188-3242 Filter Cart Gp

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

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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. Pressure-wash the transmission case drain, the transmission filter housing, and the transmission fill tube locations.

   Note: There is a possibility that the transmission guard may be removed to access the transmission drain plug. Refer to the machine Operation and Maintenance Manual for additional information.

2. Operate the machine to warm the oil.

3. Park the machine on level ground.

4. Lower the attachment to the ground. Apply slight downward pressure.

5. Engage the parking brake. Stop the engine.

6. Connect the steering frame lock when performing the filtration procedure.
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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 7	g01333069
   (A) 138-1509 Ecology Drain Gp (left) (B) 129-0987 Drain Assembly (right)

7. Place a drain pan under the transmission case. There could be a small amount of oil leakage from the ecology drain valve.

8. Carefully remove the transmission drain plug.
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   Illustration 8	g01333070
   (9) Suction adapter assembly (10) Filter cart suction hose

9. Quickly install the suction adapter assembly (9) in to the transmission case.
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   Illustration 9	g01333074
   (9) Suction adapter assembly (10) Filter cart suction hose

10. Connect the filter cart suction hose (10) to the suction adapter assembly (9).
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    Illustration 10	g01333075
    (11) Discharge adapter assembly

11. Remove the transmission filler cap. Install the discharge adapter assembly (11) in the transmission fill tube.
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    Illustration 11	g01333077
    (11) Discharge adapter assembly (12) Filter cart discharge hose

12. Connect the filter cart discharge hose (12) to the discharge adapter assembly (11).
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    Illustration 12	g01333078
    Air supply in the CLOSED position

13. Attach the 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).
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    Illustration 13	g01333079
    Air supply valve in the OPEN position

14. 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).

15. 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. If the cavitation occurs for more than 1 minute, shut OFF the filter cart and inspect the connections.

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

    Note: Caterpillar recommends taking a particle count on the oil when beginning the filter cycle to be used as a baseline particle count.

Particle Counting

1. 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.

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

      If 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 14	g01333080
   (13) 188-0639 Hose As (14) 220-8607 Fitting (15) 210-5530 Quick Connect Coupler (16) S·O·S valve

2. When using the 170-8500 Analyzer Gp, connect the "low pressure in" port to the S·O·S valve (16) on the base assembly. Use a fabricated suction tube (13) fitted with a Quick Connect Coupler (15) 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 15	g01333082
   (16) S·O·S valve (17) 169-8373 Fluid Sampling Bottle

3. If collecting a bottle sample, use the same S·O·S valve (16) and a Fluid Sampling Bottle (17).

4. Record an oil sample reading from the S·O·S valve on the filter cart before beginning the filter cycle.

5. After filtering the oil for 15 minutes, stop the procedure. Change the transmission 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. If the filter housing is opened, the housing becomes an inlet for contamination.

6. During the filtration process, the engine must be run at low idle for 5 minutes every 15 minutes. Running the engine will cycle the clean oil in the transmission sump into the transmission system and flush more contaminated oil back into the sump. With the engine at LOW idle and the parking brake ON, shift the transmission into and out of third gear forward. Shifting the transmission into and out of third gear forward will cycle the transmission oil.

   Note: This filtration process can be performed while running the engine.

7. The 170-8500 Analyzer Gp will indicate when the oil has reached an ISO level of 18/15. 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.

8. When the target ISO level or the time interval has been met, close the air supply valve. Disconnect the air supply hose. Refer to Illustration 12.
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   Illustration 16	g01333084
   (11) Discharge adapter assembly (12) Filter cart discharge hose

9. Remove the discharge hose (12) and discharge adapter assembly (11) from the transmission filler tube. Install the dust cap on the nipple. Install the dust cap on the coupler. Store the discharge adapter (11) in a clean place for later use.

10. Install a clean transmission filler cap.
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    Illustration 17	g01333085
    (9) Suction adapter assembly (10) Filter cart suction hose

11. Disconnect the filter cart suction hose (10) from the suction adapter (9). Install the dust cap on the nipple. Install the dust cap on the coupler.

12. Place a drain pan under the transmission case. There will be some oil in the suction adapter assembly.
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    Illustration 18	g01333086
    (9) Suction adapter assembly (10) Filter cart suction hose

13. Remove the suction adapter (9) from the transmission case. Store the suction adapter (9) in a clean place.

14. Install a clean drain plug in the transmission case.

15. Check the transmission oil level before returning the wheel loader to service.

16. Disconnect the steering frame lock.

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 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 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 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 990G Wheel Loader transmission system has 64 L (17 US gal) of SAE 10W oil. The filter cart is operating at 180 pulses per minute. The approximate filtration time should be 13 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 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. 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 (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.