- Articulated Truck
- 725 (S/N: AFX1-UP)
- 730 (S/N: 3F31-UP; 3T31-UP; AGF1-UP)
- 730 EJECTOR (S/N: 3F41-UP; 3T41-UP)
- 735 (S/N: 3T51-UP; AWR1-UP)
- 740 (S/N: AXM1-UP)
- 740 EJECTOR (S/N: 3F71-UP; 3T71-UP; AZZ1-UP)
- 740 GC (S/N: 3F81-UP; 3T81-UP)
- 745 (S/N: 3F61-UP; 3T61-UP)
- 745C (S/N: LFK1-UP)
- D20D (S/N: 9MG1-UP)
- D250D (S/N: 6NG1-UP)
- D250E (S/N: 5TN1-UP)
- D250E Series II (S/N: 4PS1-UP)
- D25D (S/N: 1HK1-UP)
- D300D (S/N: 5MG1-UP)
- D300E (S/N: 7FN1-UP)
- D300E Series II (S/N: 5KS1-UP)
- D30D (S/N: 3AJ1-UP)
- D350D (S/N: 9RF1-UP)
- D350E (S/N: 9LR1-UP)
- D350E Series II (S/N: 2XW1-UP)
- D400D (S/N: 8TF1-UP)
- D400E (S/N: 2YR1-UP)
- D400E Series II (S/N: APF1-UP; 8PS1-UP)
- D40D (S/N: 2JJ1-UP)
- 730 (S/N: 3F31-UP; 3T31-UP; AGF1-UP)
Introduction
Revision | Summary of Changes in SEBF8486 |
08 | Added new serial number prefix for New Product Introduction (NPI).
Updated media number for Dealer Service Tools Catalog. |
07 | Added new serial number prefix for New Product Introduction (NPI).
Updated copyright date to 2018. |
06 | Added new serial number prefix for New Product Introduction (NPI).
Section added to filter 745 machine. |
05 | Added new serial number prefix for New Product Introduction (NPI).
Updated copyright date to 2017. Removed old point of contacts. Added new point of contacts. Added "Think Safety" graphic to Important Safety Information section. |
04 | Updated Reference Table: PEHP6001 CRB PEGJ0047 also updated title of NEHS0799. |
© 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 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 that is available from Caterpillar. Updated 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 the dealers customers to benefit from cleaner transmission systems. This guideline provides directions for installing and operating the kidney loop 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.
NOTICE |
---|
If the machine is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this kidney loop 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 and component exchange and lines flushing will be required to remove most contaminates generated from the failure. The machine system cleaning must be performed prior to the kidney looping. 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. Also ensure that the product will not be damaged or 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 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
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. |
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 |
---|
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 | "188-3242 or 227-2479 Filter Cart Group" |
NEHS0848 | "Tool Operating Manual for 204-7392 Filter Cart" |
PEGJ0045 | "Reporting Particle Count by ISO Code" |
PEGJ0047 | "How To Take A Good S·O·S Sample" |
NEHS0799 | "Tool Operating Manual 170-8500 Analyzer Group" |
PERJ1017 | "Dealer Service Tool Catalog" |
SEBF8482 | "Obtaining an Oil Sample for Analysis" |
Tooling and Equipment
Parts List |
||
---|---|---|
Quantity | Part Number | Description |
1 | Filter Cart Group | |
1 | Bottle Group | |
Suction Adapter | ||
1(1) | Plug-Drain | |
1(1) | 1 In. pipe NPTM | |
1 | 90° Elbow | |
1 | Nipple | |
1 | Dust Cap | |
1(2) | 1 In. pipe coupling | |
1 | Fitting | |
1 | Nipple | |
1 | Transducer | |
1(3) | 9/16 In. STOR female to 1/4 Inch NPT Adapter | |
1 | Air Hose | |
2 | Union | |
1 (4) | O-Ring Seal | |
1 (4) | Adapter | |
1 (4) | Pipe Elbow | |
1 (4) | Coupler | |
1 (4) | Adapter | |
1 (4) | O-Ring Seal | |
1 (4) | O-Ring Seal | |
1 (4) | Adapter | |
Discharge Adapter | ||
1 | 3/4 Inch NPTM Pipe | |
1 | Reducer Bushing | |
1 | 90° Elbow | |
1 | Coupler | |
1 | Dust Cap | |
Optional Tools | ||
Part Number | Parts Description | |
S40 Portable Particle Analyzer | ||
Coupler | ||
Hose |
(1) | Used on Serial Prefix Machines: 1HK, 3AJ, 5MG, 9RF, 2JJ, 8TF, 6NG, 5TN, 4PS, 7FN, 5KS, 9MG, 2XW, 8PS, APF, 9LR and 2YR |
(2) | Use on Serial Prefix Machines AGF and AFX only. |
(3) | One 8S-7169 Union is needed for all machines. 6V-9601 adapter and two 8S-7169 unions are for Serial Prefix machines 2XW, 8PS, AWR, and APF. Does not apply for machines 3T6, 3F6, 3T7, and 3F7. |
(4) | Use on Serial Prefix Machines 3T6, 3F6, 3T7, and 3F7. |
Kidney Loop Application Reference | |||
Serial Number | Breather | Fill Tube | Drain Plug |
1HK, 3AJ, 5MG, 9RF, 2JJ, 8TF, 6NG, 5TN, 4PS, 7FN, 5KS, 9MG | Right side of machine, on top of transmission under the cab | Left side of machine, rear of the front frame | Bottom of transmission |
2XW, 8PS, APF, AWR | Right side of machine, under the top access panel, beside right staircase | Below breather | Bottom of transmission |
9LR, 2YR | On top of transmission, center rear of front frame | Next to breather | Bottom of transmission |
AFX, AGF | Left side of machine, next to fill plug, under hood | Left side of machine, under hood, front of cab | Right side of transmission, under panel by front tire |
3T6, 3F6, 3T7, 3F7, 3F4, 3T5, 3T4, 3F3, 3T3 | Left side of machine, behind cab, near hydraulic oil cooler (radiator) | Left side of machine, under hood, front of cab | Bottom of transmission oil pan |
Articulated Truck Transmission Oil Filtration Procedure
This guideline is intended for Articulated Trucks. The procedure is most effective when performed immediately after the oil has been warmed to
Illustration 3 | g01293247 |
Filter cart application on 1HK, 3AJ, 5MG, 9RF, 2JJ, 8TF, 6NG, 5TN, 4PS, 7FN, 5KS, 9MG, 2XY, 8PS, APF, 9LR and 2YR serial prefix models. |
Illustration 4 | g01293248 |
Filter cart application on AGF, AFX, LFK, 3T6, 3F6, 3T7, and 3F7 serial prefix machines. |
Suction Adapter Assembly
Suction adapter assembly for 1HK, 3AJ, 5MG, 9RF, 2JJ, 8TF, 6NG, 5TN, 4PS, 7FN, 5KS, 9MG, 2XW, 8PS, APF, 9LR, AWR, and 2YR serial prefix machines.
- Drill a
34.9 mm (1.375 inch) hole in the 7T-2703 Plug-Drain (1). Refer to Illustration 5.Show/hide tableIllustration 6 g01293250 (1) 7T-2703 Plug-Drain
(2) 1 inch pipe - 10 inches long
(3) Weld location - Assemble the 7T-2703 Plug-Drain (1) to the
25.4 mm (1 inch) pipe that is25.4 cm (10 inch) long (2). Refer to Illustration 6.Note: For serial prefix AWR, use a 9S-8010 Plug in place of the 7T-2703 Plug-Drain.
Show/hide tableIllustration 7 g01293252 (4) Suction adapter
(5)006-5707 Elbow
(6)190-8319 Nipple
(7)201-8059 Dust Cap - Assemble the suction adapter (4) to the 006-5707 Elbow (5) and the 190-8319 Nipple (6). Attach the 201-8059 Dust Cap (7) to the 190-8319 Nipple (6). Refer to Illustration 7.
Show/hide table
Illustration 8 g01293253 (6) 190-8319 Nipple
(7)201-8059 Dust Cap
(8)3B-6491 Pipe Coupling - Assemble the 3B-6491 Pipe Coupling (8) to the 190-8319 Nipple (6). Attach the 201-8059 Dust Cap (7). Refer to Illustration 8.
Show/hide table
Illustration 9 g06211251 Suction Adapter Assembly for serial numbers 3T6, 3F6, 3T7, and 3F7
(9)201-8059 Dust Cap
(10)190-8319 Coupler
(11)4J-0519 O-Ring Seal
(12)5P-0492 Adapter
(13) 1 In. pipe NPTM254 mm (10 inch) long. Threaded both end 1 inch 11-1/2 NPTF
(14)006-5707 Pipe Elbow - Install the O-Ring Seal (11) on to Adapter (12).
- Attach 1 In. pipe NPTM (13) to Adapter (12).
- Attach Pipe Elbow (14) to 1 In. pipe NPTM (13).
- Attach Dust Cap (9) to Coupler (10).
- Attach Coupler (10) to Pipe Elbow (14). Refer to Illustration 9 for the correct orientation of adapters.
Illustration 5 | g03319232 |
(1) |
Discharge Adapter Assembly
- Assemble the
19 mm (0.75 inch) pipe that is254 mm (10 inch) long (9), to the 6B-9081 Reducing Bushing (10), the 006-5707 Elbow (5), and the 190-8319 Coupler (11). Attach the 201-8057 Dust Cap (12). Refer to Illustration 10.
Illustration 10 | g01293254 |
(5) (9) 3/4 inch pipe - 10 inches long (10) (11) (12) |
Illustration 11 | g01293256 |
Fabricated Plug (A) (B) (C) (D) (E) (F) 15° (G) 3/4 Inch NPT thread |
Note: This plug is to be assembled for the end of the discharge adapter for machines with serial prefix AXM, AZZ, and AYZ. Refer to Illustration 11.
Transducer Assembly
- Assemble the 4C-7156 Fitting (13) to the 4C-7099 Nipple (14) and the 5P-0306 Transducer (15). Refer to Illustration 12.
Illustration 12 | g01293257 |
(13) (14) (15) |
Filtration Procedure Setup
- Pressure - wash the transmission case drain.
Note: There is a possibility that the transmission guard may need removing to access the transmission drain plug. Refer to the Operation and Maintenance Manual for additional information.
- Operate the machine to warm the oil.
- Park the machine on level ground.
- Apply the service brake to stop the machine.
- Move the gearshift lever to the NEUTRAL position.
Note: On 9LR and 2YR serial prefix machines move the gearshift lever to NEUTRAL and engage the neutral lock. The neutral lock engages automatically when the type 2 shift lever is moved to the NEUTRAL position.
- Engage the parking brake.
Note: On 2XW, 8PS, and APF serial prefix machines, move the parking and secondary brake control to the ENGAGED position.
- Release the service brake pedal. Ensure that the parking brake is holding the machine.
- Run the engine at low idle for 5 minutes.
- Connect the steering frame lock.
- Block the wheels.
Note: Do not move the machine when the filter cart is connected. Moving the machine in this condition could cause machine damage.
Note: Machines with serial prefix AXM, AZZ, and AYZ need to skip Steps 1 through 3, due to the presence of an ecology drain. Refer to Section: "Suction Adapter Assembly".
Show/hide tableIllustration 13 g01293258 (16) Air breather - Remove the air breather (16) from the transmission case. Refer to Table 4 and to Illustration 13.
Show/hide table
Illustration 14 g01293259 (16) Air breather
(17) Lines
(18) TeeShow/hide tableIllustration 15 g01293261 (18) Tee
(19)6V-9601 Adapter
(20)8S-7169 UnionNote: On 2XW, 8PS and APF serial prefix machines do not remove the air breather (16). Separate the two lines (17) and the tee (18). Refer to Illustration 14.
Show/hide tableIllustration 16 g01293262 (21) Transducer Assembly - Install the transducer assembly (21) in place of the air breather (16). Connect the air supply line to the transducer assembly. Refer to Illustration 14 and Illustration 16.
Show/hide table
Illustration 17 g01293263 (20) 8S-7169 Union
(21) Transducer assembly
(22)4C-4506 Air Hose
(23) Air supply hoseShow/hide tableIllustration 18 g01293275 (22) 4C-4506 Air HoseNote: A 4C-4506 Air Hose (22) may be required, depending on the breather location. Attach the 4C-4506 Air Hose (22) to the transducer assembly (21) using a 8S-7169 Coupling (20). Attach the air supply hose (23) to the transducer assembly (21). Refer to Illustration 17 and Illustration 18.
Show/hide tableIllustration 19 g01293276 (24) Drain pan - Place a drain pan (24) under the transmission case. Refer to Illustration 19.
Show/hide table
Illustration 20 g01293277 (25) Cover Note: On AGF and AFX serial prefix machines remove the cover (25).
Show/hide tableIllustration 21 g01293278 AGF and AFX serial prefix machines
(26) Drain plugShow/hide tableIllustration 22 g01293279 All other machines
(26) Drain plug - Carefully remove the transmission drain plug (26). Refer to Table 4 for drain plug location. Refer to Illustration 21 and Illustration 22.
Note: Be sure that the transmission case has a vacuum.
Show/hide tableIllustration 23 g01293280 (27) 006-5707 ElbowNote: On AGF and AFX serial prefix machines install a 006-5707 Elbow (27) as shown in illustration 23.
Show/hide tableIllustration 24 g01293281 AGF and AFX serial prefix machines only
(28) Suction adapter assemblyShow/hide tableIllustration 25 g01293282 All other machines
(28) Suction adapter assembly - Install the suction adapter assembly (28) to the transmission case.
Show/hide table
Illustration 26 g01293283 AGF and AFX serial prefix machines
(28) Suction adapter assembly
(29) Filter cart suction hoseShow/hide tableIllustration 27 g01293284 All other machines
(28) Suction adapter assembly
(29) Filter cart suction hose - Connect the filter cart suction hose (29) to the suction adapter assembly (28).
Note: Leave the transducer assembly (21) connected to complete the filter cart removal procedure.
Show/hide tableIllustration 28 g01293285 (30) Discharge adapter - Remove the transmission fill cap. Install the discharge adapter (30) to the transmission fill tube. Refer to Illustration 28.
Note: Machines with serial prefix AXM, AZZ, and AYZ need to have a fabricated plug machine to
34.3 mm (1.35 inch) to slide into the fill tube.Show/hide tableIllustration 29 g01293287 (30) Discharge adapter
(31) Filter cart discharge hose - Connect the filter cart discharge hose (31) to the discharge adapter (30). Refer to Illustration 29.
- Disconnect the air supply hose (23) from the transducer assembly (21) to relieve the transmission case vacuum.
Show/hide table
Illustration 30 g01293291 (23) Air supply hose
(32) Air supply valve - Attach an air supply hose (23) to the 204-7392 Transfer/Filter Cart. Ensure that the air supply valve (32) is in the CLOSED position. Be sure that the air supply does not exceed
690 kPa (100 psi) .Show/hide tableIllustration 31 g01293292 (32) Air supply valve - Slowly open the air supply valve (32) to start the filter cart pump operation. The filter cart pump is a gear pump. The gear pump is rated to pump 10W oil at
64 L/min (17 US gpm) . - During the filter cart operation, check the filter element indicators. The filter element indicators will determine the amount of capacity left in the filter element.
Note: Occasionally, 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 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 taking a particle count on the oil at the beginning of the filtration process for use as a baseline particle count.
- The oil can be particle count tested for cleanliness is one of the two following ways.
- Use a 170-8500 S40 Portable Particle Analyzer for immediate results.
- Collect a bottle sample and send the sample to an S·O·S lab.
- If using a 170-8500 Portable Particle Analyzer for particle counting, be sure to read and understand the Tool Operating Manual, NEHS0799, "S40 Portable Particle Analyzer" before operating the particle counter.
Show/hide table
Illustration 32 g01293293 (33) S·O·S valve
(34) Fabricated suction tube
(35)210-5530 Coupler - Use the following steps if using a 170-8500 Portable Particle Analyzer.
- Connect the "low pressure in" port to the S·O·S valve (33) on the filter cart by using the fabricated suction tube (34). Use a 210-5530 Coupler (35) to make this connection.
- The fabricated suction tube is required to collect an on-line oil sample when you use the 170-8500 Portable Particle Analyzer.
Note: Information regarding the availability of parts and fabrication instructions for the suction tube assembly can be obtained by contacting the Caterpillar Dealer Service Technology Group. Proper fittings and instructions will be provided at no cost. A 188-0639 Hose will need to be purchased prior to assembly.
- If using a 169-8373 Bottle Group for oil analysis use the following steps.
- Record an oil sample reading from the S·O·S valve (33) on the filter cart at the beginning of the filter cycle.
- After 15 minutes of filtering, stop the procedure and change the Articulated Truck transmission filters. The new filters can remain in place until the next scheduled filter change.
Note: Changing the filters avoids opening the filter housing after the system has been cleaned. If the filter housing is opened after filtration, the filter housing becomes an inlet for contamination.
- During the kidney loop process, the engine must be run at low idle for 5 minutes every half an hour. The kidney loop process will cycle the oil in the transmission through the sump. Run the engine at low idle with the parking brake ON. Next shift the Articulated Truck into and out of THIRD gear forward to cycle the transmission oil.
Note: Kidney loop filtration can be performed while running the engine.
- Operate the filter cart until the 170-8500 Portable Particle Analyzer indicates that the oil has reached an acceptable ISO level of at least 18/15. The requirement used for serial prefix machines AGF and AFX and 21/17 for all other machines. The final ISO 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 Portable Particle Analyzer is not available.
Show/hide tableIllustration 34 g01293295 (23) Air supply hose
(32) Air supply valve - When the target ISO level or the time interval has been met, close the air supply valve (32) and disconnect the air supply hose (23).
Show/hide table
Illustration 35 g01293297 (37) Transmission filler cap - Remove the filter cart discharge hose (31). Remove the discharge adapter (30) from the transmission fill tube. Install a clean transmission filler cap (37). Install dust caps on the nipple and on the coupler. Store the discharge adapter in a clean location.
- Reinstall the air supply hose (23) to the transducer assembly (21).
- Operate the 5P-0306 Transducer (15) prior to removing the suction adapter assembly (28).
Note: Be sure that the transmission case has a vacuum before removing the suction adapter assembly.
Show/hide tableIllustration 36 g01293299 AGF and AFX Serial Prefix Machines
(28) Suction adapter assembly
(29) Filter cart suction hose assemblyShow/hide tableIllustration 37 g01293300 All other machines
(28) Suction adapter assembly
(29) Filter cart suction hose - Disconnect the filter cart suction hose (29) from the suction adapter assembly (28). Install a 201-8057 Dust Cap (12) and a 190-8318 Coupler (11).
Show/hide table
Illustration 38 g01293301 AGF and AFX Serial Prefix Machines
(28) Suction adapter assemblyShow/hide tableIllustration 39 g01293302 All other machines
(28) Suction adapter assemblyShow/hide tableIllustration 40 g01293303 (27) 006-5707 ElbowNote: On AGF and AFX serial prefix machines remember to remove the 006-5707 Elbow (27) as shown in Illustration 40.
- Remove the suction adapter assembly (28) from the transmission case. Then quickly reinstall a clean transmission case drain plug (26). Install a dust cap on the nipple. Store the suction adapter assembly (28) in a clean location.
- Remove the transducer assembly (21) and reinstall a clean air breather (16). Store the transducer assembly (21) in a clean location. Refer to Illustration 16 and to Illustration 41
Show/hide table
Illustration 41 g01293304 (16) Air breather
(17) Lines
(18) TeeNote: On 2XW, 8PS and APF serial prefix machines, remove the 6V-9601 Adapter (19) and the 8S-7169 Union (20) from the tee (18). Attach two lines (17) to the air breather (16). Refer to Illustration 41.
- Check the transmission oil level before returning the Articulated Truck to service.
- Unblock the wheels.
- Disconnect the steering frame lock and return the machine to service.
745 Transducer, Suction, and Discharge Adapter Installation
This section is for serial number machines: 3T6, 3F6, 3T7, 3F7, 3F4, 3T5, 3T4, 3F3, and 3T3.
- Remove the (1) transmission guard. Refer to Illustration 42
- Pressure wash the transmission case drain.
- Operate the machine to warm the oil.
- Turn off the ignition switch.
- Park the machine on level ground. Apply the parking brake.
- Place the transmission in neutral position.
- Engage the parking brake.
- Connect the steering frame lock.
- Block the wheels.
Show/hide table
Illustration 43 g06211560 745 vacuum transducer assembly
(2)4K-1388 O-Ring Seal
(3)157-8510 Adapter
(4)3D-2824 O-Ring Seal
(5)5P-0306 Transducer
(6)4C-7099 Adapter
(7)4C-7156 Fitting
(8)7G-8478 Adapter - Attach O-Ring Seal (4) on to Adapter (3).
- Attach O-Ring Seal (2) on to Adapter (8).
- Attach Adapter (8) to Adapter (3).
- Attach Vacuum Transducer (5) to Adapter (8).
- Attach Adapter (6) to Vacuum Transducer (5).
- Attach Fitting (7) to Adapter (6). Refer to Illustration 43 for steps 10 through 15.
Show/hide table
Illustration 44 g06211578 (9) Access panel - Remove four bolts and access panel (9). To gain access to the transmission breather.
Show/hide table
Illustration 45 g06211592 - Loosen two breather mount bolts (10), do not remove the bolts.
- Loosen the lower tube nut and fully disengage the upper tube nut (11).
- Lift the breather mount and swing the tube away from the breather.
Show/hide table
Illustration 46 g06211595 Vacuum Transducer installation - Attach the Vacuum Transducer Assembly (12) pictured in Illustration in 43 to the upper tube nut (11). Tighten both tube nuts. Refer to Illustration 46
- Attach an air hose to the vacuum transducer. Operate the vacuum transducer at
172 kPa (25 psi) . - Place a drain pan under the transmission drain plug.
- Remove the transmission drain plug and install the Suction Adapter Assembly pictured in Illustration 10.
- Attach the suction hose to the Suction Adapter Assembly.
- Remove the air supply hose from the Vacuum Transducer.
- Remove the transmission oil level indicator.
- Install the Discharge Adapter Assembly pictured in Illustration 9.
- Attach the discharge hose to the Discharge Adapter Assembly.
- Refer to step 20 of the Filtration Procedure for the remainder of the Filtration Procedure.
- Reverse the above steps to remove the filter cart hoses and adapters.
Illustration 42 | g06211542 |
Transmission guard (1) |
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 related to the 204-7392 Transfer/Filter Cart. Other filtration units will have a different equation reference and will be noted when appropriate. There are various conditions that must be factored into the filtration efficiency of any filter cart and situation. Therefore, the following equation must be viewed as only a simple reference and not an absolute time or efficiency result.
Illustration 47 | g01177339 |
Oil compartment filtration equation (A) Compartment oil capacity (gal) (B) Pulses per minute (C) Approximate filtration time (min) |
Example: A D400E Ejector Articulated Truck Transmission System has
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, 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. 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.