Filtration Procedure Wheel Tractor Scraper Transmission Oil {0680, 0768, 3016, 3030} Caterpillar

Wheel Scraper

621G (S/N: KLK1-UP)

637K (S/N: WTT1-UP; WTY1-UP)

Wheel Tractor

621G (S/N: KJW1-UP)

631K (S/N: WTR1-UP; WTW1-UP)

637K (S/N: WTX1-UP)

Wheel Tractor Scraper

613G (S/N: ESB1-UP)

621H (S/N: DBK1-UP; HKK1-UP; NYY1-UP; EAZ1-UP)

621K (S/N: WTA1-UP; WTE1-UP; WTL1-UP; WTP1-UP)

623H (S/N: EJD1-UP; DBF1-UP)

623K (S/N: WTB1-UP; WTM1-UP)

627H (S/N: LCT1-UP; DBW1-UP)

627K (S/N: WTC1-UP; WTN1-UP)

637K (S/N: WTS1-UP)

Introduction

© 2016 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. 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 questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

• Caterpillar Dealer Technical Communicator

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• Caterpillar Technical Representative

• Knowledge Network

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 wheel tractor scraper customers to benefit from cleaner transmissions. The filter cart process is easy to use. The filter cart quickly connects to the transmission drain and transmission oil fill tube. This guideline provides directions for installing and operating the filtration system. Clean fluids play a major role in the life of any fluid system. The following procedure will help reduce fluid contamination in wheel tractor scraper transmission oil to an acceptable ISO cleanliness level. This procedure may be modified by the technician for use on some machines. The following procedure is for wheel tractor scrapers NOT equipped with ecology drain valves. The procedure is most effective when performed immediately after the oil has been warmed to 50°C (122°F) and mixed from operation. This action causes contamination in the system to be placed in suspension in the oil and lowers the oil viscosity.

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 of the information, specifications, and illustrations that are in this publication are based on information that was available at the time of publication. The following information 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.

References

Tooling and Equipment

Note: Do not move the machine while the filter cart is connected. Moving the machine in this condition could cause machine damage or filter cart damage.

Assembling the Transmission Adapters

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Illustration 3	g01638799
Suction Adapter Weld Location

1. Drill a 28.58 mm (1.125 inch) hole in the center of 7T-2703 Drain Plug. Then weld the 7T-2703 Drain Plug to the 10 inch pipe as shown in Illustration 3. Install the 7F-8268 Seal on to the 7T-2703 Drain Plug.
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   Illustration 4	g03413171
   (1) Suction Adapter (2) 006-5707 Elbow (3) 190-8319 Nipple (4) 201-8059 Dust Cap

2. Assemble the Suction Adapter (1) to the Elbow (2), Nipple (3), and Dust Cap (4), as shown in Illustration 4.
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   Illustration 5	g01638801
   Rework 7H-1447 Cap. (A) Drill and tap 1 inch NPT. (B) Remove the tabs for this 58 mm (2.23 inch) diameter.

3. Modify 7H-1447 Cap: Machine the 7H-1447 Cap to accept a 1 inch -11.5 NPT threads, as shown in Illustration 5.
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   Illustration 6	g03413175
   613C II Discharge Adapter (5) 006-5707 Elbow (6) 190-8318 Coupler (7) 201-8057 Dust Cap (8) 005-8615 Male Union (9) 7H-1447 Modified Cap

4. Assemble the Filler Cap (9), the Male Union (8), the Pipe Elbow (5), the Coupler (6), and the Dust Cap (7), as shown in Illustration 6.
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   Illustration 7	g03413189
   611 & 615C II Discharge Adapter (5) 006-5707 Elbow (6) 190-8318 Coupler (7) 201-8057 Dust Cap (8) 1 inch diameter pipe (5-inches long)

5. Assemble the one-inch diameter pipe (8), the Elbow (5), the Coupler (6), and the Dust Cap (7), as shown in Illustration 7.
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   Illustration 8	g03413191
   Vacuum Transducer Assembly (10) 4C-7099 Nipple (11) 4C-7156 Fitting (12) 5P-0306 Vacuum Transducer

6. Assemble the Nipple (10) to the Fitting (11) and the Vacuum Transducer (12). Refer to Illustration 8.

   Note: Before beginning, be sure to read and understand the Tool Operating Manual, NEHS0848, "204-7392 Hydraulic/Transmission Filter Cart".

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   Illustration 9	g01638805
   204-7392 Filter Cart Gp

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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.

7. Pressure-wash the transmission case drain area, air breather, and the transmission fill tube location.

8. Operate the machine to warm the oil.
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   Illustration 10	g03413197
   Wheel tractor scraper with 204-7392 Filter Cart Gp

9. Park the machine on level ground. Lower the bowl to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.
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   Illustration 11	g01638808
   9G-5127 Breather

10. Remove the 9G-5127 Breather from the transmission case.
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    Illustration 12	g03413200
    (12) Vacuum transducer assembly

11. Install the vacuum transducer assembly (12) in place of the air breather on the transmission case. Connect the compressed air line to the vacuum transducer.

    Note: If the wheel tractor scraper is going to be filtered at every PM, a quick disconnect may be added to the transmission case and the breather for convenience.

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    Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressurized air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

12. Apply air pressure to the vacuum transducer before removing the transmission drain plug.

13. Place a drain pan under the transmission case. There could be some oil leakage.

    Note: Be sure that the transmission case has a vacuum before continuing. DO NOT remove the transmission fill cap before this step. If the fill cap is removed, a vacuum cannot be achieved.

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    Illustration 13	g01638811
    Typical transmission drain plug

14. Carefully remove the transmission drain plug. Refer to Illustration 13.
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    Illustration 14	g03413203
    (13) Suction adapter assembly

15. Quickly install the suction adapter assembly (13) into the transmission case. Refer to Illustration 14.
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    Illustration 15	g03413205
    (13) Suction adapter assembly (14) Suction hose

16. Connect the filter cart suction hose (14) to the suction adapter assembly (13).

17. Disconnect the vacuum transducer air supply to relieve the transmission case vacuum.

    Note: Leave the vacuum transducer connected to the transmission to complete the filter cart removal procedure later in this guideline.

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    Illustration 16	g03414155
    (15) Discharge adapter assembly

18. Remove the transmission fill cap. Install the appropriate discharge adapter assembly (15) for the scraper transmission fill tube.
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    Illustration 17	g03414162
    (15) Discharge adapter assembly (16) Discharge hose

19. Connect the filter cart discharge hose (16) to the discharge adapter assembly (15). Make sure that the hose and adapter will not dislodge during the filter cart operation.
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    Illustration 18	g03414199
    Air supply valve in the closed position. (17) Air supply valve (18) Air supply hose

20. Attach an air supply hose (18) to the 204-7392 Filter Cart Gp, ensuring that the air supply valve (17) is in the closed position. Be sure that the air supply does not exceed 689 kPa (100 psi).
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    Illustration 19	g03414200
    Air supply valve in the open position.

21. Slowly open the air supply valve (17) to start the filter cart pump operation.

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

22. 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 beginning of the filter cycle to use as a baseline particle count.

23. 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.

24. Refer to the OMM for the transmission S·O·S valve location and the transmission system pressure.
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    Illustration 20	g03414203
    (19) S·O·S valve (20) Fabricated suction tube (21) 210-5530 Coupler

25. Attach the coupler (21) and fabricated suction tube (20) to the transmission S·O·S valve (19), as shown in Illustration 20.

26. Attach the other end of the Fabricated suction tube (20) to the 170-8500 Particle Analyzer Gp as called for in the Tool Operating Manual.
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    Illustration 21	g03414205
    (22) 169-8373 Fluid Sampling Bottle

27. If collecting a bottle sample, use the same S·O·S valve (19) and a 169-8373 Fluid Sampling Bottle (22). Refer to Illustration 21.

28. Record an oil sample reading from the S·O·S valve on the filter cart at the beginning of the filter cycle.

29. During filter cart operation, run the engine with the parking brake engaged. Running the engine will cycle the clean oil into the transmission system and flush the more contaminated oil back into the case.

30. At the halfway point of filtration, stop the procedure and change the machine transmission filters. Changing the filters allows the filters to assist in system cleaning. The new filters can remain in place until the next scheduled filter change. Changing the filters at this time avoids opening the filter housing after the system has been cleaned. An opened filter housing is an inlet for contamination.

31. Operate the filter cart until the portable particle counter indicates that the oil has reached an ISO level of at least 16/13 or lower. The final ISO should be recorded before the machine is returned to the field.

    Note: Refer to "Oil Compartment Filtration Times", located at the end of this document, when a 170-8500 Particle Analyzer Gp is not available.

32. When the target ISO level or time interval has been met, close the air supply valve (17) and disconnect the air supply hose (18). Refer to Illustration 18.

33. Turn off the engine.
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    Illustration 22	g03414162
    (15) Discharge Adapter Assembly (16) Discharge Hose

34. Remove the discharge hose (16) and the discharge adapter assembly (15) from the transmission fill tube. Install the dust cap on the nipple and the quick coupler. Store the discharge adapter in a clean place for the next job.

35. Install a clean transmission fill cap.

36. Reinstall the air hose to the vacuum transducer (12). Refer to Illustration 12.

37. Operate the vacuum transducer (12) prior to removing the suction adapter.

    Note: Be sure that the transmission case has a vacuum before continuing.

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    Illustration 23	g03413205
    (13) Suction adapter assembly (14) Suction hose

38. Disconnect the filter cart suction hose (14) from the suction adapter assembly (13). Install the dust cap on the nipple and the quick coupler.

39. Place a drain pan under the transmission case. There will be some oil in the suction adapter assembly (13).
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    Illustration 24	g03413203
    (13) Suction adapter assembly

40. Remove the suction adapter assembly (13) from the transmission case. Quickly reinstall a clean transmission case drain plug. Store the suction adapter in a clean place.
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    Illustration 25	g03413200
    (12) Vacuum transducer

41. Remove the vacuum transducer assembly (12) and reinstall a clean air breather. Also, store the transducer in a clean place.

42. Check the transmission oil level before returning the wheel tractor scraper to service.

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

Illustration 26	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 stroke delivers oil in both directions. Another way to determine 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 613G hydraulic system has 128 L (33.814 gal) of SAE 10W oil. The approximate filtration time should be 1 hour and 15 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 or larger than 14 microns

At this time 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.