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Introduction
Important Safety Information
Illustration 1 | g02139237 |
Think Safety |
European Union Compliant, CE marked
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 can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.
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.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of 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. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
Service Parts Section
The Service Parts section is a reference for parts identification and available part numbers.
Safety Section
Safety Icon Nomenclature
Personal Protection/Important Information
Illustration 2 | g02166423 |
Personal Protection/Important Information |
Prohibited Action
No smoking |
Hazard Avoidance
Crushing hazard (foot) |
Crushing hazard (hand) |
Pinch point |
Fire hazard |
Electrical Shock - Hazard |
Fire hazard |
Safety Warnings
At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure. |
Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
NOTICE |
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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, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
NOTICE |
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To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills. |
General Information Section
Introduction
The 204-7392 Filter Cart Group is used to flush and clean hydraulic tanks or hydraulic systems. This filter cart is similar to the 174-9158 Filter Cart , but has a CAT 844 hose with flush-face, quick disconnects. The cart is also similar to the larger 188-3242 Kidney Loop Filtering Cart and can be used in the same basic locations, however, this cart is physically smaller with pump delivery up to 64 Lpm (17 gpm).
This manual provides general information on how to set up the filter cart, technical data, serviceable parts, and adapters.
Illustration 3 | g02594192 |
Filter Cart. (1) Air Line Lubricator. (2) Air Supply Shut-Off Valve. (3) Relief Valve. (4) Hydraulic Motor. (5) Suction Filter. (6) Air Motor. (7) Inlet Quick Disconnect. (8) Outlet Quick Disconnect. (9) Outlet Filter. (10) Muffler. |
- Filter cart can be used on Caterpillar Engines with kidney loop oil systems.
- Suction hose - 3 m (10 feet) long with a female quick-disconnect coupling.
- Return line - 3 m (10 feet) long with a male quick-disconnect coupling.
- The filter cart can filter hydraulic fluids from 5W to 40W.
- Filter cart is mounted to a hand cart which is easily moved around in field conditions.
- Oil is pumped through the filter cart using an air-powered, gear pump.
- All hose assemblies are made from Caterpillar 844 wire-reinforced hose. These hoses will not collapse when filtering hot oil.
- Hose hooks on the hand cart provide convenient storage of the hose.
- Filter cart is CE Compliant.
Additional Contact Information
For additional product support questions concerning this tool, contact the Cat Dealer Service Tools Hotline at:
USA: 800-542-8665, Option 1
International: 1-309-578-7372
Email: dealerservicetool_hotline@cat.com
References
Special Instruction, SEBF8405, "The Kidney Loop Filtration Process for Rebuilt Engines"
Special Instruction, SEBF8453, "Procedure for Filtering Motor Grader (All Models) Hydraulic Oil"
Special Instruction, SEBF8455, "Procedure for Filtering Track-Type Tractor (D3-D6) Hydraulic Oil"
Note: Additional Dealer Support Information may be attained by telephoning (309) 675-5156.
Specifications
Specifications     | |
Description     | Specification     |
Pump delivery     | Variable from 0 to 63 Lpm (17 gpm) at 44 cc/r (1500 rpm)     |
System operating pressure     | 206 kPa (20 psi) maximum     |
Supply air pressure     | 7 bar (100 psi) maximum     |
Pump capability     | 70 bar (1000 psi) maximum1     |
Air motor power     | 1.7 kW max at 7 bar, 1500 rpm, 2.2 cMm (2.4 hp at 100 psi, 1500 rpm, 77 cfm)     |
Air consumption     | 0.4 cMm/Lpm (3.8 cfm/gpm) of fluid delivered     |
Operating temperature     | 16° C (60° F) minimum 65° C (150° F) maximum     |
Fluid compatibility     | Petroleum based oils with viscosity from 5W to 40W     |
Filtration (standard)     | 100-mesh suction and 2 micron on pump outlet     |
Hoses     | 25.4 mm (1.00 inch) x 3 m (10.0 feet) long Cat 844-16, single wire     |
Hose adapters     | Flush-face, quick disconnect fittings ( 190-8318 Coupler and 190-8319 Nipple )     |
Weight     | 66 kg (147 lb)     |
Overall dimensions     | 100 cm (39 inch) H x 50 cm (20 inch) L x 40 cm (16 inch) W     |
Noise level     | 72 dB at 7 bar (101 psi) 1500 rpm     |
Standards     | CE compliant     |
1 A built-in relief valve limits the pressure to 450 kPa (65 psi).
General Information
Relief valve (3) is designed to protect the cart from over-pressurization. The relief valve is set at 448 kPa (65 psi).
Illustration 4 | g02594202 |
Relief Valve (3) . |
Monitor the pressure gauge on the inlet side of the outlet filter. When pressure reaches 60 psi, both filters need to be changed. If the pressure reaches 65 psi, the system is in full bypass.
Periodically check the oil level in air line lubricator (1). Fill the lubricator with 1U-9763 Pump Oil or equivalent.
Illustration 5 | g02594207 |
Air Line Lubricator (1) . |
Operating Procedure
- Install the proper adapters on the machine or reservoir being filtered. The filter cart is equipped with flush-face quick disconnect couplings. Refer to the manuals in the References section for a specific list of adapters.
- Connect inlet coupling (7) to the suction port on the machine or reservoir. Connect outlet coupling (8) to the return port on the machine or reservoir.
Illustration 6 | g02594210 |
Flush-Face Quick Disconnect Couplings (7) And (8) . |
Note: The adapters and reference material for the 188-3242 Filter Cart can also be used on the 204-7392 Filter Cart .
- Make sure shut-off valve (2) is in the off position before connecting to the air supply.
Illustration 7 | g02594215 |
Inlet Hose (7) And Outlet Hose (8) . |
Note: If the filter cart is used to filter different types of fluids, change the filter elements for each filtering application.
- Slowly open shut-off valve (2) to start the pumping action.
NOTICE |
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An air supply in excess of 689 kPa (100 psi) will damage the filter cart. To prevent damage, install a 4C-7033 Regulator into the air supply line. |
Illustration 8 | g02594236 |
Shut-Off Valve (2) In Off Position. |
- Always close shut-off valve (2) before disconnecting inlet hose (7) and/or outlet hose (8) .
Illustration 9 | g02594256 |
Start Pumping Action By Opening Shut-Off Valve. |
Note: To vary the pumping rate, shut-off valve (2) can be partially opened or closed. A customer-supplied, 4C-7033 In-Line Regulator can also be installed.
Illustration 10 | g02594258 |
Close Shut-Off Valve Before Disconnecting Inlet And Outlet Hoses. |
Maintenance
Filter Elements
The suction filter is a 100 mesh element for large particle removal.
The filter cart comes standard with a 2 micron filter element. This filter should work in most filtering applications. If necessary, optional 5, 10, and 25 micron filter elements are also available.
If a small amount of water in the system is a problem, then the water-absorbing element may be used. Each element can remove 700 ml (1.5 pints) of water.
When pressure reaches 60 psi, both filters need to be changed. Make sure the fluid is at operating temperature and normal operating flow, before checking the pressure.
If the filter is being changed too frequently in a filtering application, a larger micron filter can be installed to first remove all the larger contamination particles.
Serviceable Parts
Serviceable Parts List     | |
Part No.     | Description     |
9U-7450     | Air Pump Assembly     |
1W-7216     | Air Motor Assembly     |
190-8319     | Quick Disconnect Nipple     |
190-8318     | Quick Disconnect Coupler     |
198-3188     | 2µm Element     |
9U-6983     | 5µm Element     |
9U-5870     | 10µm Element     |
9U-6984     | 25µm Element     |
9U-6982     | 100-mesh Element     |
188-7027     | Water Absorbent Element     |