i06799507
Off-Highway Truck/Tractor
69D (S/N: 9SS1-UP; 9XS1-UP)
73D (S/N: 9YS1-UP)
769 (S/N: 99F1-UP; 35W1-UP)
769B (S/N: 99F1-UP)
769C (S/N: 01X1-UP)
769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
770G (S/N: KDH1-UP; ECM1-UP; ECX1-UP)
772G (S/N: LTS1-UP; KEX1-UP; LTX1-UP)
773 (S/N: 63G1-UP)
773B (S/N: 63W1-UP)
773D (S/N: NBJ1-UP; 7ER1-UP; 7CS1-UP)
773E (S/N: BDA1-UP; PRB1-UP; KEG1-UP; DJS1-UP)
773F (S/N: EED1-UP)
776D (S/N: AFS1-UP)
777 (S/N: 84A1-UP)
777B (S/N: 4YC1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
777E (S/N: KDP1-UP)
777F (S/N: JRP1-UP)
777G (S/N: GT71-UP; TNM1-UP; RDR1-UP)
785D (S/N: MSY1-UP)
Quarry Truck
771C (S/N: 3BJ1-UP)
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
773G (S/N: MWH1-UP; JWS1-UP)
775B (S/N: 7XJ1-UP)
775D (S/N: 6KR1-UP; 8AS1-UP)
775E (S/N: BEC1-UP)
775F (S/N: DLS1-UP)
775G (S/N: RFM1-UP; MJS1-UP)
Introduction
Table 1
Revision Summary of Revisions for SEBF8454
Added new serial number prefixes for New Product Introduction (NPI).
Removed old Point of Contacts.
12
New Point of Contact added to the document.
Updated copyright date to 2016.
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11 Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2015.
© 2016 Caterpillar All Rights Reserved. This guideline is for the use of Cat 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 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 to 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 feedback form in
the Service Information System website.
Summary
The instructions that are given in this guideline will enable dealers and customers to properly filter Off-
Highway Truck axle oil. This procedure will reduce contamination in the oil to an acceptable ISO
contamination level. This procedure may be modified by the technician for use on some machines.
NOTICE
If the vehicle 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. Additional component
exchange and lines flushing will be required to remove most
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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.
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Illustration 2 g01032906
Pay Attention!
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Become Alert!
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 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 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
starting any job. Caterpillar dealers have the most current information that is available.
Safety
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.
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References
Table 2
References
170-8500 Analyzer Gp
210-5530 Coupler
188-0639 Hose
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(1) Two adapters will be needed for the procedure.
(2) Only one adapter will be needed for the procedure.
(3) For the 777F Differential Adapter Only.
(4) Install the 3B-6555 Elbow on to the filter cart return hose, then attach the quick disconnect coupler to the elbow. Refer to
Illustration 6, call out A for installation location of the elbow.
NOTICE
Be sure to keep all parts clean and free of contamination.
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Illustration 3 g01285430
(1) Air breather
2. Remove the air breather (1) that is located on top of the rear axle housing. Refer to Illustration 3.
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Illustration 4 g01285433
(2) 5P-0306 Transducer
(3) Air supply hose
3. Install the Transducer (2) in place of the air breather (1) on top of the rear axle housing. Refer to
Illustration 4.
4. Operate the vacuum transducer before removing the final drive plugs and before removing the rear
axle differential housing drain plug.
Note: Be sure that the rear axle oil system has pulled a vacuum.
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Illustration 5 g01285434
(4) Final drive magnetic plug
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Illustration 6 g01285435
(5) 190-9937 Final Dive Adapter
6. Quickly install the Final Drive Adapter (5). Inspect the magnetic plug for contaminants. Refer to
Illustration 6.
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Illustration 7 g01285437
(6) Filter cart return hoses
(7) Final drive valve
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Illustration 8 g03494135
(6) Filter cart return hoses
(7) Final drive valve
(A) Installation location of the 3B-6555 Elbow
Note: Installation of the 3B-6555Elbow will aid in orientation, reduce the length of return hose needed
and will also reduce wear on the return hose.
8. Connect the filter cart return hoses (6) to the left and right final drive adapters. Be sure that the final
drive valves (7) are in the CLOSED position. Refer to Illustration 7.
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Illustration 9 g01285438
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9. Remove the differential case drain plug and quickly install the Differential Adapter (8). Refer to
Illustration 9.
Note: The 777F differential requires the use of a 175-3623 NPT Pipe Nipple, 141-2502 Bushing
Reducer, and a 190-3222 Quick Disconnect Nipple to connect the suction hose to the 777F differential
case drain.
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Illustration 10 g03492257
(8) 190-9942 Differential Adapter
(9) Filter cart suction hose
(10) Differential valve
10. Attach the filter cart suction hose (9) to the differential adapter (8). Refer to Illustration 10.
11. Disconnect the transducer air supply to relieve the rear axle housing vacuum.
Note: Leave the transducer connected to the rear axle to complete the filter cart removal procedure.
12. Open both final drive valves (7). Open the differential valve (10). Refer to Illustration 7 and
Illustration 10.
13. Ensure that there are no oil leaks from any of the filter cart connections.
Note: This filter cart connection configuration will flush contaminants toward the center differential
housing and away from the final drive bearings. The filter cart will easily remove any contaminants
from the lower differential housing.
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Illustration 11 g03492496
(11) Air supply hose
(12) Air supply valve
14. Attach an air supply hose (11) to the246-1157 Filter Cart. Ensure that the air supply valve (12) is in the
CLOSED position. Be sure that the air supply does not exceed 690 kPa(100 psi). Refer to Illustration
11.
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Illustration 12 g01285444
(12) Air supply valve
15. Slowly open the air supply valve (12) to start the filter cart pump operation. The air pump is a double
acting diaphragm pump. The pump is rated to pump 50W to 60W oil at
approximately 114 L/min(30 US gpm) to 133 L/min(35 US gpm). Refer to Illustration 12.
16. While operating the filter cart, check the filter element indicators on the filter cart. The indicators 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 the cavitation continues for more than 1 minute, shut the filter cart off and
check the connections.
17. 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 filter cycle to
use as a baseline particle count.
18. The oil can be particle count tested for cleanliness in one of the two following ways.
19. Read Tool Operating Manual, NEHS0799, "170-8500 Analyzer Group" before operating the particle
analyzer.
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Illustration 13 g03492540
(13) S·O·S valve
(14) Fabricated suction tube
(15) 210-5530 Coupler
20. When using the 170-8500 Analyzer Gp, connect the "low pressure in" port to the S·O·S valve (13) on
the filter cart. Refer to Illustration 13.
21. Attach the opposite 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.
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Illustration 14 g03320131
(13) S·O·S valve
(16) 169-8373 Bottle Group
22. If collecting a bottle sample, use the same S·O·S valve (13) and a 169-8373 Bottle Group (16). Refer
to Illustration 14.
23. Record an oil sample reading from the S·O·S valve (13) on the filter cart at the beginning of the filter
cycle.
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Illustration 15 g01285448
(17) 246-1157 Filter Cart
24. Operate the filter cart (17) until the portable particle analyzer indicates that the oil has reached an
acceptable ISO level of at least 16/13. The final ISO level should be recorded before the machine is
returned to the field.
Note: Refer to "Oil Compartment Times for 188-3242 Filter Cart and 246-1157 Filter Cart", located at
the end of this document, when a 170-8500 Analyzer Gp is not available.
25. When the target ISO level or the time interval has been met, close the air supply valve (12).
Disconnect the air supply hose (11). Refer to Illustration 11.
Hot oil and hot components can cause personal injury. Do not allow hot
oil or hot components to contact the skin.
26. Close both final drive valves (7) and close the differential valve (10). Refer to Illustration 7 and
Illustration 10.
27. Disconnect all filter cart oil hoses from the Off-Highway Truck.
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Illustration 16 g03493836
(2) 5P-0306 Transducer
(3) Air supply hose
28. Reinstall the air supply hose (3) to the Transducer (2). Refer to Illustration 16.
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29. Operate the vacuum transducer before installing the final drive plugs and the differential case drain
plug.
Note: Be sure that the rear axle oil system has pulled a vacuum. Hot oil could cause personal injury if
a vacuum is not pulled.
30. Remove both final drive adapters (5) and the differential adapter (8). Quickly install all plugs.
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Illustration 17 g01285450
(1) Air breather
31. Remove the vacuum transducer (2) and reinstall the air breather (1). Refer to Illustration 17.
32. Check and maintain the oil level in the differential and final drives to the recommended oil level for
each truck model according to the Operation and Maintenance Manual.
33. Reinstall the protective caps to the filter cart hoses to control contamination.
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Illustration 18 g01177339
Oil compartment filtration equation
(A) Compartment oil capacity (gal)
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Example
A 777D Off-Highway Truck rear axle has227 L (60 US gal) of SAE 60W oil. The filter cart is operating at
80 pulses per minute. The approximate filtration time should be 105 minutes or 1.8 hours.
The code for contamination levels using automatic particle counters is comprised of three scale numbers, for
example X/Y/Z.
At this time, Caterpillar does not require the reporting of the "X" scale number since the hydraulic tolerances
exceed the 4 micron value. Therefore, a "-" is used instead. 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.
Copyright 1993 - 2018 Caterpillar Inc. Tue Jun 26 2018 21:13:45 GMT-0500 (hora estándar de Colombia)
Todos los derechos reservados.
Red privada para licenciados del SIS.
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