Procedure for Filtering Final Drives, Rear Axles, and Differentials on Caterpillar Machines {0680, 0768, 3258, 3260, 4050} Caterpillar

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Introduction

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes 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 this document, submit a form for feedback in the Service Information System (SIS Web)

If a Contamination Control Guideline is required, but is 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 dealer customers to benefit from cleaner hydraulic systems. The filter cart procedure is easy to use. The filter cart quickly connects to the hydraulic oil inlet ports. 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 16/13 or cleaner.

Note: If the vehicle is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this filter cart 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. Additional component cleaning and 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 cart 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 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 could change at any time: specifications, torque, pressures, measurements, 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

Illustration 3	g03414279
(C) Discharge adapter (1) 9U-7449 Nozzle (2) 3B-7749 Nipple (3) 190-8319 Coupling (4) 201-8059 Dust Cap

Illustration 4	g03414280
(B) Vent (5) 183-3873 Breather As (6) 131-9367 Adapter (7) 4C-5088 Coupling (8) 2S-4078 O-Ring Seal

Suction Adapter Fabrication

Illustration 5	g03414283
(A) Suction adapter (D11 application shown) (9) 201-8059 Dust Cap (10) 190-8319 Coupling (11) 061-9593 Reducer Bushing (12) 3H-3385 O-ring Seal (13) 1S-3888 Plug Washer (14) 5F-0304 Plug (Modified and Welded to Reducer)

1. Drill a 12.7 mm (0.5 inch) hole in the plug (14).

2. Center plug (14) on plug washer (13). Weld plug (14) onto plug washer (13). Weld 360° around the plug (14) and the washer (13) to create an air tight joint. Refer to Illustration 5.

3. Center reducer bushing (11) with the 12.7 mm (0.5 inch) NPTF end facing the opposite face of the plug washer (13). Weld 360° around the reducer bushing (11) and the plug washer (13) to create an air tight joint. Refer to Illustration 5.

4. Install O-ring seal (12) on to the 25.4 mm (1 inch) male end of the reducer bushing (modified with plug) (11). Refer to Illustration 5.

5. Thread the 25.4 mm (1 inch) National Pipe Tapered Fuel (NPTF) male end of the reducer bushing (modified with plug) (11) in to coupling (10). Refer to Illustration 5.

6. Install dust cap (9) on to coupling (10) to avoid contamination. Refer to Illustration 5.

795F AC Suction Adapter Fabrication

1. 795F AC suction adapter consists of 5P-4269 Swivel Adapter and 004-3099 Adapter.

2. Assemble the 37° flared swivel end of 5P-4269 Swivel Adapter to the 37° flared end of 004-3099 Adapter.

3. Attach suction adapter assembly to 190-8319 Coupling (10). Refer to Illustration 5.

4. Install dust cap (9) on to coupling (10) to avoid contamination. Refer to Illustration 5.

Machine Filtration Procedure

The guideline is intended for final drives, rear axles, front spindles, and differentials with 113 L (30 US gal) or less of 60W or lighter viscosity oil. The procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and mixed from operation. Warming the oil allows any contamination in the system oil to be placed in suspension and warming the oil also lowers the viscosity.

Filtration Setup

1. Operate the machine to warm the oil.

2. Park the machine on level ground.

3. Apply the service brake to stop the machine.

4. Move the directional control switch or the transmission control lever to the NEUTRAL position. Engage the transmission lock if the machine is equipped.

   Note: This procedure requires the final drives to be rotated several times throughout the procedure. Steps 3 and 4 should be performed each time the final drives are rotated.

Evacuation Procedure

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Illustration 6	g03414284
(A) Suction adapter

1. Rotate the final drive, so that the drain plug is in the UPWARD position. Refer to Illustration 6.

2. Clean the area around the drain plug. Refer to Illustration 6.

3. Remove the drain plug and install the suction adapter (A). Refer to Illustration 6.

   Note: An S·O·S sample may be taken to determine the contamination level of each final drive.

4. Store the drain plug in a clean place to avoid contamination and damage to the plug.
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   Illustration 7	g03414285
   (A) Suction adapter

5. Rotate the final drive, so the suction adapter (A) is in the DOWNWARD position. Refer to Illustration 7.
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   Illustration 8	g03414288
   (B) Vent

6. Remove the filler plug. Install the vent (B). Refer to Illustration 8.
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   Illustration 9	g03414289
   (15) Suction hose (16) Suction port

7. Connect the filter cart suction hose (15) to the filter cart suction port (16). Refer to Illustration 9.
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   Illustration 10	g03415385
   Suction valve

8. Close the suction valve. Refer to Illustration 10.
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   Illustration 11	g03415387
   Discharge valve

9. Open the discharge valve. Refer to Illustration 11.
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   Illustration 12	g03414294
   (A) Suction adapter (15) Suction hose

10. Connect the other end of the filter cart suction hose (15) to the suction adapter (A). Refer to Illustration 12.
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    Illustration 13	g03414295
    (17) Air supply valve (18) Air supply hose

11. Attach an air supply hose (18) to the 231-6284 Filter Cart Gp. Ensure that the air supply valve (17) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi). Refer to Illustration 13.

12. Slowly open the air supply valve (17) to start the filter cart pump operation. If the air supply valve (17) is a purge off style, adjust the supply air between 138 kPa (20 psi) to 345 kPa (50 psi) and turn on the air supply valve. Adjust the pressure as needed. Refer to Illustration 13.

    Note: Do not exceed 690 kPa (100 psi). The pump is a diaphragm pump. The pump is rated to pump 10W oil at 151 L/min (40 US gpm)

13. Operate the filter cart until the oil is removed from the oil compartment.

14. Turn off the air supply valve (17). Refer to Illustration 13.

15. Disconnect the filter cart suction hose (15) from the suction adapter (A). Refer to Illustration 12.

16. Remove the suction adapter (A) and install the drain plug. Refer to Illustration 12.

17. Repeat Steps 1 through 16 for the opposite final drive. Make sure that the total capacity of the filter cart tank is not exceeded by the oil capacity of the compartment.

Filtration Procedure

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Illustration 14	g03415556
Suction valve

1. Open the suction valve. Refer to Illustration 14.
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   Illustration 15	g03414298
   (15) Suction hose (16) Suction port

2. Disconnect the suction hose (15) from the suction port (16). Refer to Illustration 15.

3. Slowly open the air supply valve (17) to start the filter cart pump operation. If the air supply valve (17) is a purge off style, adjust the supply air between 138 kPa (20 psi) and 345 kPa (50 psi). Turn on the air supply valve (17). Adjust the pressure as needed. Refer to Illustration 13.

   Note: Do not exceed 690 kPa (100 psi). The pump is a diaphragm pump. The pump is rated to pump 10W oil at 151 L/min (40 US gpm)

4. During operation, check the filter element indicators on the filter cart. The filter element indicator will determine the amount of capacity left in the filter element.

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

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

   Note: Caterpillar recommends that a particle count is to be taken on the oil at the beginning of the filter cycle. The particle count is used as a baseline particle count.

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

   1. Use a portable particle analyzer for immediate results.

   2. Collect a bottle sample and send the sample to an S·O·S lab. Refer to Special Instruction, SEBF8482, "Obtaining Oil Sample for Analysis".

Portable Particle Analyzer Procedure

When using a portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual before beginning the procedure.

Illustration 16	g03414299
(18) S·O·S valve (19) 210-5530 Coupler As. (20) 220-8607 Fitting (21) 188-0639 Hose As (Low-pressure suction tube to particle analyzer)

1. Attach the fabricated particle counter "low pressure in" suction tube (21) to the S·O·S valve (18) on the filter cart.

   Note: The fabricated suction tube can be made from the parts listed in Table 3. Refer to Illustration 16.

2. 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.

Bottle Sample Procedure

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Illustration 17	g03414302
(18) S·O·S valve (22) 169-8373 Fluid Sampling Bottle

1. If collecting a bottle sample, use the same S·O·S valve (18) and a 169-8373 Fluid Sampling Bottle (22). Refer to Illustration 17.

2. Record an oil sample from the S·O·S valve (18) on the filter cart at the beginning of the filter cycle. Refer to Illustration 17.

3. Operate the filter cart until the portable particle analyzer indicates that the oil has reached a minimum ISO cleanliness level of 16/13 or cleaner. A target ISO level does not exist for non-pressurized, non-filtered compartments currently. ISO 16/13 is an acceptable contamination level for oil returned back into this type of a compartment.

   Note: Refer to "Oil Compartment Filtration Times for 231-6284 Filter Cart", located at the end of this document, when a portable particle analyzer is not available. This type of oil cleanup may require several subsequent preventative maintenance intervals. This procedure is different than the normal filtration process. The oil is filtered in a separate oil compartment. The oil that is filtered through the filter cart will be returned into a dirty compartment. The filtration procedure should be performed during several preventative maintenance intervals to maintain a clean system.

4. When the target ISO level or the time interval has been met, close the air supply valve (17). Refer to Illustration 13.

Returning Filtered Oil

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

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Illustration 18	g03415654
Oil suction valve

1. Open the suction valve. Refer to Illustration 18.
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   Illustration 19	g03415656
   Discharge valve

2. Close the discharge valve. Refer to Illustration 19.
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   Illustration 20	g03414305
   (23) Discharge port (24) Discharge hose

3. Connect the discharge hose (24) to the discharge port (23). Refer to Illustration 20.
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   Illustration 21	g03414307
   (C) Discharge nozzle (24) Discharge hose

4. Attach the discharge nozzle (C) to the discharge hose (24). Refer to Illustration 21.

5. Remove the vent (B). Refer to Illustration 8.

6. Turn on the air supply valve (17). Refer to Illustration 13.
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   Illustration 22	g01286995

7. Rotate the final drive so that the oil fill level is in the HORIZONTAL position. Refer to Illustration 22.

8. Refill the final drive with the proper amount of oil.

   Note: Refer to the Operation and Maintenance Manual, "Refill Capacities" for the proper amount of refill oil.

9. Turn off the air supply valve (17). Refer to Illustration 13.

10. Remove the suction adapter (A). Install a clean filler plug. Refer to Illustration 7.

11. Repeat Steps 7 through 10 for the opposite final drive.

12. Return the machine to service.

Oil Compartment Filtration Times for 231-6284 Filter Cart

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 231-6284 Filter Cart Gp only. Other filtration units will use different equation references. The units that use different equations will be noted when appropriate.

Illustration 23	g02977749
Oil compartment filtration equation (A) Compartment oil capacity (gal) (B) Pulses per minute (C) Approximate filtration time

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 D11R Track Type Tractor has 60.5 L (16 US gal) of SAE 60W oil. The filter cart is operating at 100 pulses per minute. The approximate filtration time should be 38 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:procurement of the sample, the sample container, and particle counting accuracy when 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. ExampleX/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

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.

Other Applications for the 231-6284 Filter Cart

This portion of the guideline is to show the various applications this cart can be used for. Due to the numerous adapters required for various machine applications, the technician will need to identify and fabricate adapters for each individual machine.

The filter cart is only effective when used on machines with 113 L (30 US gal) or less of 60W or lighter oil. Due to the capacity and flow limitations, this cart may not be effective on all machines. See the following examples of other cart applications.

When removing the drain plug from a flooded differential port, a vacuum may be required to help avoid oil leakage. A vacuum can be created with the use of a 5P-0306 Vacuum Transducer.

Illustration 24	g01287015
Wheel Loader differentials

Illustration 25	g01287017
Telehandler differentials

Illustration 26	g01287018
Articulated Truck differentials

Illustration 27	g01287019
Vibratory Compactor drums

Illustration 28	g01287020
Wheel Excavator final drives

Illustration 29	g01287022
Wheeled Excavator differentials

Illustration 30	g01287024
Off-Highway Truck spindles

Illustration 31	g01287025
Track Type Tractor final drives