204-7392 (Air Motor Driven) Filter Cart {0645, 0680, 0738, 5056, 5068} Caterpillar


204-7392 (Air Motor Driven) Filter Cart {0645, 0680, 0738, 5056, 5068}

Usage:

769C 01X
Caterpillar Products: All

Introduction

Important Safety Information




Illustration 1g02139237

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 2g02166423

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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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

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

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 3g02594192

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

Table 1
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 4g02594202

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 5g02594207

Air Line Lubricator (1) .

Operating Procedure

  1. 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.



    Illustration 6g02594210

    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 .

  1. 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 7g02594215

    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.

  1. Make sure shut-off valve (2) is in the off position before connecting to the air supply.


    NOTICE

    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 8g02594236

    Shut-Off Valve (2) In Off Position.

  1. Slowly open shut-off valve (2) to start the pumping action.



    Illustration 9g02594256

    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.

  1. Always close shut-off valve (2) before disconnecting inlet hose (7) and/or outlet hose (8) .



Illustration 10g02594258

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

Table 2
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    

Caterpillar Information System:

C18 Generator Set Maintenance Interval Schedule - Prime
3516C Generator Sets Gauges and Indicators
3512E Tier 4 Final Engines for Land Electric Drilling Inlet Manifold Temperature Sensor
C13, C15, and C18 Generator Set Engines Engine Oil Temperature Sensor
3512B and 3516B Generator Set Engines with Dynamic Gas Blending Fuel Pressure Sensor
Accumulator Discharging and Charging Procedures {0738, 4263, 4264, 4331, 5077, 5077, 5081, 7474} Accumulator Discharging and Charging Procedures {0738, 4263, 4264, 4331, 5077, 5077, 5081, 7474}
2011/11/16 An Improved Fan Assembly Is Used on Certain 3406 Generator Sets {1353, 1356}
CG137-08 and CG137-12 Generator Sets Engine Oil Lines
CG137-08 and CG137-12 Generator Sets Crankshaft Pulley
CG137-08 and CG137-12 Generator Sets Cover Group (Front Housing)
CG137-08 and CG137-12 Generator Sets Cylinder Block
Fundamentals of HVOF Spray for Reconditioning Components {0599, 0679, 1000, 7000} Fundamentals of HVOF Spray for Reconditioning Components {0599, 0679, 1000, 7000}
C18 Generator Set Maintenance Interval Schedule - Standby
TH55-E70 and TH55-E90 Petroleum Transmissions Transmission Planetary - Remove
TH55-E70 and TH55-E90 Petroleum Transmissions Transmission Planetary - Install
Cat® Grade Control Depth & Slope for E-Series and F-Series Excavators Glossary
TH55FT-E70 and TH55FT-E90 Transmissions Power Train Electronic Control System Event Codes
3516C Generator Sets Symbols
C32 Marine Generator Set Gauges and Indicators - If Equipped
C175 Cooling System Cavitation Test {1350} C175 Cooling System Cavitation Test {1350}
312E, 312F, 313F, 316E, 316F, 318E, 318F, 320E, 320F, 323E, 323F, 324E, 325F, 326F, 329E, 329F, 330F, 335F, 336E, 336F, 340F, 349E, 349F, 352F, 374F and 390F Excavators and 336E MHPU and 349E MHPU Mobile Hydraulic Power Units Air Conditioning and Hea General Information
2011/09/19 New Components and Inspection Criteria for the Oil Drain Tube Are Used for Certain 3126 and C7 Marine Engines {1052, 1307}
C32 Marine Generator Set Engine Oil Level - Check
CG137-08 and CG137-12 Generator Sets Magnetic Switch
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.