Filtration Procedure for B & D Series Telescopic Handler Hydraulic Oil {0680, 0768, 5050, 5056} Caterpillar

Telehandler

TH220B (S/N: SLA1-UP)

TH306D (S/N: TD21-UP; TD31-UP)

TH314D (S/N: MYF1-UP; MYT1-UP)

TH330B (S/N: SLB1-UP)

TH340B (S/N: SLC1-UP)

TH350B (S/N: SLD1-UP)

TH3510D (S/N: TH21-UP; TH31-UP)

TH355B (S/N: JRK1-UP)

TH357D (S/N: TD61-UP; TD71-UP)

TH360B (S/N: SLE1-UP)

TH408D (S/N: TH41-UP; TH91-UP)

TH417D (S/N: MKY1-UP; MLZ1-UP)

TH460B (S/N: SLF1-UP)

TH514D (S/N: MWG1-UP; MWY1-UP)

TH560B (S/N: SLG1-UP)

TH580B (S/N: SLH1-UP)

TL1055D (S/N: ML51-UP; MNT1-UP)

TL1255D (S/N: ML71-UP; MYW1-UP)

TL642D (S/N: ML81-UP; MLG1-UP)

TL943D (S/N: MLD1-UP; MLJ1-UP)

Introduction

© 2018 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 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 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 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 customers to benefit from cleaner hydraulic systems. This filtration process is easy to use. The hydraulic filter cart quickly connects to the machines hydraulic tank. This guideline provides directions to install and operate the filtration system.

Clean fluids play a major function in the life of any fluid system. The filtration procedure will help reduce fluid contamination in the oil to an acceptable level of ISO 18/15 or cleaner.

Note: If the machine is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this 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 most contaminates generated from the failure. The machine system cleaning must be performed prior to the filtration procedure. This filtration procedure and subsequent particle count testing should be performed as part of 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 specifications 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

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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.

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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.

References

Tooling and Equipment

Illustration 3	g01388688
Return oil adapter for telescopic handlers (1) 190-8318 Coupling (2) 1L-4031 Tee (3) 005-8615 Union (4) 234-0218 Adapter

Illustration 4	g03300638
Suction adapter for telescopic handlers (5) 5P-1042 Adapter (6) 6V-5258 Adapter (7) 5P-0492 Adapter (8) 005-8615 Union (9) 190-8319 Coupling

Illustration 5	g03300696
Vacuum transducer assembly for telescopic handlers (10) 5P-0306 Vacuum Transducer (11) 4C-7156 Fitting (12) 4C-7099 Nipple (13) 8S-7169 Union (14) 4C-4506 Air Hose (15) 8S-7169 Union (16) 131-9367 Adapter

Machine Filtration Procedure

This guideline is intended for telescopic handlers. This procedure is most effective when performed immediately after the hydraulic fluid has been warmed to 50 °C (122 °F) and mixed from operation. Warming the oil allows any contamination in the oil to be placed in suspension. Warming the oil also lowers the viscosity of the oil. Be sure to read and understand Tool Operating Manual, NEHS0778, "188-3242 or 227-2479 Hydraulic Filter Cart Tool Operating Manual" before you begin this procedure.

Filtration Setup

1. Operate the machine to warm the oil.

2. Park the machine on level ground.

3. Apply the service brake to stop the machine.

4. Move the direction control switch or the transmission control lever to the NEUTRAL position. Engage the transmission lock if the machine is equipped.

5. Engage the parking brake.

6. Lower the attachment to the group and apply slight downward pressure.

7. Block the wheels.

Filtration Procedure

Illustration 6	g03300716
(17) Access cover

1. Remove the access cover (17). Refer to Illustration 6.
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   Illustration 7	g01388693
   B series Screen washer tank

   Note: Steps 2 and 3 are for the "B" series Telescopic Handler only.

2. Remove the screen washer tank to gain access to the vent hose connection. The screen washer tank is on top of the hydraulic tank. Refer to Illustration 7.
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   Illustration 8	g01388752
   B series hydraulic tank Vent connection

3. Remove the vent hose from the connection. Plug the vent hose with a 4C-9521 Cap. Refer to Illustration 8.
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   Illustration 9	g03819461
   "D" Series hydraulic tank 473-9271 Filter

4. For the "D" Series Telescopic Handler. Remove the 473-9271 Filter, install the 9U-7197 Protective Plug in the filter port opening. Refer to Illustration 9 for location of filter.

5. Clean the area around the fill cap (18). Refer to Illustration 10.
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   Illustration 10	g03300736
   (18) Fill cap

6. Remove the hydraulic tank fill cap (18). Refer to Illustration 10.
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   Illustration 11	g03300738
   (19) Return oil adapter (20) Vacuum transducer

7. Install the return oil adapter (19). Refer to Illustration 11.

8. Apply air pressure to the vacuum transducer assembly (20) before you remove the drain plug. Refer to Illustration 11. For small plastic tanks 103.42 kPa (15 psi) is the recommended air pressure to operate the vacuum transducer.

9. Place a drain pan under the hydraulic tank drain. There could be some oil leakage.
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   Illustration 12	g03300741
   (21) Drain plug

10. Carefully remove the drain plug (21). Refer to Illustration 12.
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    Illustration 13	g03300916
    (22) Suction adapter

11. Quickly install the suction adapter (22) into the drain. Refer to Illustration 13.

12. Shut off the air supply to the vacuum transducer assembly (20). Refer to Illustration 11.
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    Illustration 14	g03300939
    (19) Return oil adapter (23) Discharge hose

13. Connect the filter cart discharge hose (23) to the return oil adapter (19). Refer to Illustration 14.
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    Illustration 15	g03300945
    (22) Suction adapter (24) Suction hose

14. Connect the filter cart suction hose (24) to the suction adapter (22). Refer to Illustration 15.
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    Illustration 16	g03300956
    (25) Air supply hose (26) Air supply valve

15. Attach an air supply hose (25) to the 204-7392 Filter Cart. Ensure that the air supply valve (26) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi). Refer to Illustration 16.

16. Slowly open the air supply valve (26) to start the filter cart pump operation. If the air supply valve (26) is a purge off style, adjust the air supply between 140 kPa (20 psi) and 345 kPa (50 psi). Turn on the air supply valve (26). Adjust the pressure as needed, but do not exceed 690 kPa (100 psi). The pump is a diaphragm pump. The pump is rated to pump 10W oil at 64 L/min (17 US gpm).
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    Illustration 17	g01388703
    Filter cart assembly on a TH360B

17. During the filter cart operation, 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 cavitation continues for more than 1 minute, shut the filter cart OFF. Check all hydraulic connections.

18. 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.

19. The oil can be particle count tested for cleanliness in one of the two following ways.

    1. Use a portable particle analyzer for immediate results.

    2. Collect a bottle sample and send the sample to an S·O·S lab. Refer to Contamination Control Guideline, SEBF8482, for more information.

Portable Particle Analyzer Procedure

When using a portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual before operating the particle analyzer.

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Illustration 18	g03300977
(27) Fabricated suction tube (28) 220-8607 Fitting (29) 210-5530 Coupler (30) S·O·S valve

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (30) on the filter cart. Refer to Illustration 18.

   Note: The fabricated suction tube can be made with the parts listed in Table 4 and as shown in Illustration 18.

2. Attach the other end of the fabricated suction tube to the "low pressure in" port on the portable particle analyzer as called for in the Tool Operating Manual.

Bottle Sample Procedure

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Illustration 19	g03301057
(30) S·O·S valve (31) 169-8373 Bottle Group

1. If you collect a bottle sample, use the same S·O·S valve (30) and a 169-8373 Bottle Group (31). Refer to Illustration 19.

2. Record an oil sample from the S·O·S valve (30) on the filter cart at the beginning of the filter cycle.

   Note: The filtration can be performed while you run the engine.

3. At the halfway point of filtration, stop the procedure and change the machines oil filters. Changing the machines filters allows the filters to help with the system cleaning. The new filters can remain in place until the next scheduled filter change. Changing the filters currently avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.

   Note: Only replace the machines filters if the filters are not working at optimal performance, or scheduled to be changed.

4. During the filter cart operation, cycle the lift cylinders at least four times every half hour of filtration. This procedure will cycle the clean tank oil into the hydraulic system and flush the more contaminated oil back into the tank.

5. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an ISO level of at least 18/15 or better. The final ISO should be recorded before the machine is returned to the field.

6. When the target ISO level or time interval has been met, close the air supply valve (26) and disconnect the air supply hose (25). Refer to Illustration 16.

   Note: Refer to"Oil Compartment Filtration Times" at the end of this document, when a portable particle analyzer is not available.

7. Disconnect the filter cart discharge hose (23) from the return oil adapter (19). Install dust caps on the coupler and on the nipple. Store the hose assembly in a clean location. Refer to Illustration 14.

8. Disconnect the filter cart suction hose (24) from the suction adapter (22). Install the dust caps on the couple and on the nipple. Store the hose assembly in a clean location. Refer to Illustration 15.

9. Turn ON the air supply to the vacuum transducer assembly (20). Refer to Illustration 11.

10. Quickly remove the suction adapter (22) and install the drain plug (21). Refer to Illustration 12 and Illustration 13.

11. Turn OFF the air supply to the vacuum transducer assembly (20). Refer to Illustration 11.

    Note: Steps 11 and 12 are for the "B" series Telescopic Handler only.

12. Remove the 4C-9521 Plug and reinstall the vent hose.

13. Install the screen washer tank, on top of the hydraulic tank. Refer to Illustration 7.

14. For the "D" Series Telescopic Handler. Remove the 9U-7197 Protective Plug, install the 473-9271 Filter in the filter port opening.

15. Remove the return oil adapter (19). Refer to Illustration 11.

16. Install a clean fill cap (18). Refer to Illustration 10.

17. Close the access panel (17). Refer to Illustration 6.

18. Check the hydraulic tank oil level.

19. Unblock the wheels.

20. Return the machine to service.

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 relates to the 204-7392 Filter Cart only. Other filtration units will have different equation references and these units will be noted when appropriate.

Compartment oil capacity (gallons) times two equals the approximate filtration time.

Pulses Per Minute Definition

Each air discharge or each 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). This action delivers oil in both directions. Another way of determining pulses is to listen for the (Tuk-Chuk) of two pulses. Count the number of pulses in 1 minute for use in the above equation.

Example

A TH260B hydraulic system has 66 L (17.4 US gal) of SAE 10W oil. The approximate filtration time should be 35 minutes.

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 particles cross sectional area. Particle counts are affected by various factors. These factors include the 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 to 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. Example X/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 to 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.