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Product: TRUCK Model: 793B TRUCK 1HL Configuration: 793B Off-HighwayTruck 1HL00001-UP (MACHINE) POWERED BY 3516 Engine

Contamination Control Guidelines

Procedure for Filtering Off-Highway Truck (769-793B) Transmission Oil
Media Number -SEBF8445-01 Publication Date -2003/01/06 Date Updated -2003/01/06 SEBF84450001

Procedure for Filtering Off-Highway Truck (769-793B) Transmission Oil

SMCS - 3080; 3177

SEBF8445-01 March 2002 SMCS Codes: 3080-fi, 3177

CONTAMINATION CONTROL GUIDELINES

Procedure for Filtering Off-Highway Truck (769-793B) Transmission Oil
Summary of Revisions Page No. 7 Description The "Oil Compartment Filtration Times" information has been revised.

Introduction
This guideline enables dealers and their customers to benefit from cost reductions made

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possible through an established contamination control program. The fluids used in Caterpillar machines are highly effective unless they contain damaging amounts of contamination. Therefore, every effort must be made to reduce the contamination level within Caterpillar fluid systems. Since the Company makes ongoing changes and improvements to its products, this guideline must be used with the latest technical information available from Caterpillar to ensure such changes and improvements are incorporated where applicable. For questions or additional information concerning this guideline, contact your Contamination Control representative. Information and contacts can be accessed through your Caterpillar Subsidiary s Web Site. Or contact Caterpillar Dealer Capability Department, Dealer Support (309) 675-8970.

Summary
The instructions given in this guideline will enable dealers and customers to properly filter OHT (769-793B) transmission oil. Following this procedure will reduce the contamination in the oil to an acceptable ISO contamination level. This procedure may need to be modified by the technician for use on some machines. NOTICE If the vehicle system is being serviced due to a catastrophic component failure, a complete system cleaning operation is required before initiating 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. Additional component cleaning, component exchange and lines flushing will be required to remove the majority of contaminates generated from the failure. The vehicle system cleaning MUST be performed prior to kidney looping. This filtration procedure and subsequent particle count testing should be performed as a final step in the repair process.

References
References

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NEHS0778

Tool Operating Manual for 188-3242 Hydraulic/Transmission Filter Cart Reporting Particle Count by ISO Code Count on Caterpillar Particle Analyzers Obtaining an Oil Sample for S O S Analysis Tool Operating Manual for S2 Portable Particle Analyzer

PEJT5025 PEVN4831 SEBF3116-03 NEHS0777

Tooling and Equipment

Required Tools Part Number 188-3242 193-5903 Part Description Hydraulic/Transmission Filter Cart 2 Inch Fill Cap Adapter (Includes entire center suction port w/ quick disconnect and entire side return port w/ quick disconnect) 45o Elbow 90o Elbow Bottle Group Optional Tools Part Number 188-0645 170-8505 188-0639 Part Description S2 Portable Particle Analyzer Coupler Hose

001-5262 3H-9690 169-8373

Off-Highway Truck Filter Cart Procedure for Transmission Oil

The following procedure is intended for the 769 through 793B Off-Highway Trucks models. OffHighway Trucks that do not have an independent transmission tank are not applicable to this procedure. The procedure is most effective when performed immediately after the transmission oil has been warmed to 50C (122F) and mixed from operation. This allows any contamination in the system oil to be placed in suspension and lowers the viscosity. Be sure to read and

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understand the Tool Operating Manual, NEHS0778, "188-3242 Hydraulic/Transmission Filter Cart", before beginning the procedure.

Procedure

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

NOTICE Be sure to keep all parts clean and free of contamination.

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

1. Park the machine on level ground and engage the parking brake.

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Illustration 1 (1) Fill cap

2. Clean the area around the transmissioin tank fill cap (1). Slowly loosen the fill cap (1) on the transmission tank and release the pressure. Make sure all air pressure has been vented before completely removing the cap. 3. Remove the lockring and the strainer from the transmission fill neck. 4. Store the fill cap and strainer in a clean place in order to avoid contamination and damage.

Illustration 2 (X) Proper length of suction hose (Y) Distance from the top of the fill neck to the bottom of the tank (Z) 110 mm

5. Measure the distance from the top of the transmission fill neck to the bottom of the transmission tank (Y). Subtract (Z) from from (Y) to obtain the proper hose length (X). Refer to Illustration 2. 6. Cut a length of suitable hose matching the (X) measured distance of tank depth. Install the hose on the fill cap adapter hose barb.

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Illustration 3 (2) 193-5903 Fill Cap Adapter

7. Install the 193-5903 Fill Cap Adapter (2). If obstructions exist, the side return port can be removed for clearance and reinstalled after the main fill cap adapter is installed. Be sure that the installed suction hose reaches within 1 inch of the bottom of the transmission tank. Note: The 45o elbow fitting (3) or the 90o elbow fitting may be required on smaller trucks when body-to-tank clearance is minimal. The addition of the 45o or 90o elbow fittings will aid in the necessary orientation of the center suction port. The 45o elbow fitting (3) is pictured in Illustration 4 on the center suction port.

Illustration 4 (3) 45o elbow fitting (4) Side return port fitting

8. Install the side return port fitting (4). There are multiple side return ports on the fill cap adapter to aid in the connection of the filter cart lines.

Illustration 5 (5) Suction line (6) Center suction port

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9. Connect the filter cart suction line (5) to the fill cap adapter center suction port (6).

Illustration 6 (7) Return line (8) Side return port

10. Connect the filter cart return line (7) to the fill cap adapter side return port (8).

Illustration 7 Air supply valve in the closed position. (9) Air supply hose (10) Air supply valve

11. Attach an air supply hose (9) to the 188-3242 Filter Cart, ensuring that the air supply valve (10) is in the closed position. Be sure the air supply does not exceed 689 kPa (100 psi).

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Illustration 8 Air supply valve in the open position.

12. Slowly open the air supply valve (10) to start the filter cart pump operation. This is a double acting diaphragm pump. It is rated to pump 10 W oil at 90 GPM. 13. While you operate the filter cart, check the filter element indicators on the filter cart. This will indicate the amount of capacity left in the filter element. Note: Occasionally, the filter cart pump will cavitate during start-up. This is due to air in the suction lines of the pump. If cavitation continues for more than one minute, shut the filter cart OFF and check the connections. 14. Insure there are no oil leaks from any of the filter cart connections. Note: It is recommended that a particle count be taken on the oil at the beginning of the filter cycle for use as a baseline particle count. The oil can be particle count tested for cleanliness in one of the two following ways. a. Use a 188-0645 Portable Particle Analyzer for immediate results. b. Collect a bottle sample and send the sample to an SOS lab. If using the 188-0645 Portable Particle Analyzer for particle counting, be sure to read and understand the Tool Operating Manual, NEHS0777, "S2 Portable Particle Analyzer", before operating.

Illustration 9 (11) SOS valve (12) Fabricated suction tube (13) 170-8505 Coupler

1. When using the 188-0645 Portable Particle Analyzer, connect the "low pressure in" port to the SOS valve (11) on the base assembly using a fabricated suction tube (12) fitted with a 170-8505 Coupler (13). The fabricated tube is required to properly collect an online sample when using the 188-0645 Portable Particle Analyzer.

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Note: Information regarding the availability of parts and fabrication instructions for the suction tube assembly can be obtained by contacting the Caterpillar Service Technology Group Hotline. Proper fittings and instructions will be provided at no charge. A 188-0639 Hose will need to be purchased prior to assembly.

Illustration 10 (14) 169-8373 Bottle Group

2. If collecting a bottle sample, use the same SOS valve (11) and a 169-8373 Bottle Group (14). 3. Record an oil sample reading from the SOS valve (11) on the filter cart at the beginning of the filter cycle.

Activating the machine s steering system can be hazardous when personnel are working around the machine. Failure to follow this instruction could result in injury or death.

4. During filter cart operation, run the engine for 5 minutes every hour. This will cycle the clean tank oil into the transmission system and flush the more contaminated oil back into the tank. Turn off the engine. The oil filtration can be performed while running the engine. 5. After hour of filtering, stop the procedure and change the machine s transmission filter. Changing the filter allows them to assist in system cleaning. The new filter can remain in place until the next scheduled filter change. Changing the filter at this time avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.

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Illustration 11 Filter cart operation on a 777D OHT. (15) 188-3242 Filter Cart

6. Operate the filter cart (15) until the portable particle analyzer indicates that the oil has reached an ISO level of at least 21/17. 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 188-0645 Portable Particle Counter is not available. 7. When the target ISO level or time interval has been met, close the air supply valve (10) and disconnect the air supply hose (9).

The fittings on the filter cart and Portable Particle Analyzer may be hot. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. When the hydraulic system is at operating temperature, the hydraulic oil is hot and the hydraulic oil is under pressure.

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Illustration 12 (16) Probe (17) SOS valve (located on the fill cap adapter)

8. In order to relieve possible tank pressure, use a probe (16) from the 169-8373 Bottle Group and depress the SOS valve (17) located on the fill cap adapter. 9. Disconnect the filter cart return line (7) from the fill cap adapter side return port (8). 10. Disconnect the filter cart suction line (5) from the fill cap adapter center suction port (6). 11. Remove the 193-5903 Fill Cap Adapter (2). 12. Install protective caps to the fill cap adapter, the filter cart suction line and the filter cart return line to control contamination. 13. Install the strainer and lock ring into the transmission fill neck. 14. Install the transmission oil tank fill cap (1). 15. Check the oil level by viewing the transmission tank sight gauge. 16. Inspect the transmission system for leaks. Most oil contamination is brought into the system from an external source. In order to provide a long-term benefit, repairs must be completed before the machine is returned to service.

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Oil Compartment Filtration Times

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If an on-line, portable particle counter is not available to diagnose and track when the contaminant level has lowered to an acceptable point, refer to the following equation. This equation relates to the 188-3242 and 194-2897 Filter Carts only. 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.

Compartment Oil Capacity (gal) X 140 Pulses per Minute

= Approximate Filtration Time (min)

Pulses per Minute definition: Each air discharge or 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), delivering oil going both directions. Another way of determining pulses is to listen for the TUK CHUK (2 pulses). Count the number of pulses in one minute for use in the above equation.

Example: A 777D Off- Highway Truck transmission system has 36.5 gallons of SAE30W oil. The filter cart is operating at 170 pulses per minute. The approximate filtration time should be 37 minutes.

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Fri Apr 22 14:43:44 UTC-0400 2005

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