Filtration Procedure for Wheel Loader, Wheel Dozer, Soil Compactor, Landfill Compactor Hydraulic Oil {0680, 0768, 5056, 5068} Caterpillar

Asphalt Paver

AP555F (S/N: AP51-UP)

Landfill Compactor

816K (S/N: LT61-UP; SLL1-UP)

826K (S/N: 2321-UP; 2L31-UP; 2T61-UP; SET1-UP)

Soil Compactor

815K (S/N: SL91-UP; T1Y1-UP)

825K (S/N: 2331-UP; 2L91-UP; 2T91-UP; SEE1-UP)

Wheel Dozer

814K (S/N: LW41-UP; DMB1-UP; WCM1-UP)

824K (S/N: 2T21-UP; 2L41-UP; 2341-UP; RWB1-UP)

Wheel Loader

924H (S/N: KLN1-UP; RRS1-UP)

924HZ (S/N: WLB1-UP; JRL1-UP; JZZ1-UP)

924K (S/N: KW41-UP; SNZ1-UP)

926M (S/N: LTE1-UP)

930K (S/N: FRK1-UP; TNY1-UP)

930M (S/N: KTG1-UP; HEY1-UP)

938K (S/N: W8K1-UP; REP1-UP)

938M (S/N: J3R1-UP)

950 GC (S/N: M5K1-UP; M5T1-UP)

950L (S/N: TNS1-UP; LXX1-UP)

950M (S/N: EMB1-UP; ENE1-UP; XCJ1-UP; LCR1-UP)

950M Z (S/N: HE81-UP)

962L (S/N: MTN1-UP; SXS1-UP)

962M (S/N: EJB1-UP; JYD1-UP; LSE1-UP; RCL1-UP)

962M Z (S/N: SA81-UP)

966L (S/N: FSL1-UP)

966M (S/N: EJA1-UP; R8D1-UP; LMM1-UP; L8R1-UP)

966M Series XE (S/N: P6C1-UP; B8P1-1)

972L (S/N: YJW1-UP)

972M (S/N: L8E1-UP; LSJ1-UP; GGN1-UP; M8W1-UP)

972M Series XE (S/N: M5S1-UP; EDW1-UP)

980M (S/N: MK21-UP)

982M (S/N: MK61-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 the customer of a dealer 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 available from Caterpillar. The latest technical information will 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) interface, 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 the customer of a dealer to benefit from cleaner hydraulic systems. The filter cart quickly connects to the hydraulic oil fill and drain ports. This guideline provides directions to install and operate the filter system.

Clean fluids play a major function in the life of any fluid system. The following procedure will help reduce fluid contamination in the oil to an acceptable level of ISO 18/15 or cleaner. This procedure may be modified by the technician for use on some motor graders.

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, lubricate, maintenance, or repair of this product, until understanding 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 endorsed by Caterpillar is used, ensure that the task is safe for all personnel around the machine. Ensure that the product will not be damaged or that the product will not 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 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	g03430390
Suction Adapter Assembly (1) 8T-4983 Hose Clamp (2) 3B-7257 Reducer Bushing (3) 124-1907 Permanent Coupling (4) 122-6905 Hydraulic Hose

Illustration 4	g03429898
Discharge Adapter Assembly (5) 124-1909 Hose Coupling (6) 122-6906 Hydraulic Hose (7) 234-0218 Adapter (8) 124-1922 Permanent Coupling

Wheel Loader Filtration Procedure

The following procedure is intended for Wheel Loaders. The procedure is most effective when performed immediately after the hydraulic oil has been warmed to 50 °C (122 °F) and mixed from operation. Machine operation allows any contamination in the oil to be placed in suspension and lowers the viscosity of the oil. Be sure to read and understand the Tool Operating Manual, NEHS0848, "Tool Operating Manual for 204-7392 (Air Motor Driven) Filter Cart", before operating the filter cart.

Filtration Setup

1. Operate the machine to warm the oil.

2. Park the machine on level ground.

3. Engage the parking brake.

4. Lower the bucket to the ground and apply slight downward pressure.

5. Block the wheels.

6. Apply the service brake to stop the machine.

7. Clean around the hydraulic tank fill cap. Clean around the hydraulic drain valve assembly.
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   Illustration 5	g03429903
   (9) Hydraulic Tank Fill Cap

8. Slowly remove the hydraulic tank fill cap (9) to relieve the tank pressure.

9. Remove the hydraulic tank screen assembly if the machine is equipped.
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   Illustration 6	g03430400
   (2) 3B-7257 Reducer Bushing

10. Use a 3B-7257 Reducer Bushing (2) to connect the suction hose assembly to the filter cart suction port.
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    Illustration 7	g01622472
    (10) Filter cart suction port

11. Connect the suction hose assembly to the filter cart suction port (10).

12. Install the discharge adapter assembly in the hydraulic tank fill port.

13. Attach the filter cart discharge hose to the fill port discharge adapter.
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    Illustration 8	g01616574
    Hydraulic Tank Drain Valve

14. The location of the hydraulic tank drain valve is on a manifold near the articulation hitch on the right side of the machine.

15. Remove the original hydraulic tank drain hose from the drain valve assembly if the machine is equipped.

16. Connect the suction hose to the hydraulic tank drain assembly with a 8T-4983 Hose Clamp (1).

17. Open the hydraulic tank drain valve assembly.

18. On "K" series machines with an ecology drain valve assemble the 5P-4269 Swivel Adapter and 173-0880 Connector for the suction adapter assembly. The ecology drain valve is on the bottom of the hydraulic tank.

19. On "K" series machines with an ecology drain valve connect the suction hose to the hydraulic tank ecology drain valve suction adapter assembly.
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    Illustration 9	g01622512
    (11) Air supple hose (12) Air supply valve

20. Attach an air supply hose (11) to the 204-7392 Filter Cart Gp. Ensure the air supply valve (12) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi).

21. Slowly open the air supply valve (12) to start the filter cart pump operation. If the air supply valve (12) is a purge off style, adjust the air supply between 140 kPa (20 psi) and 345 kPa (50 psi). Turn the air supply valve (12) ON. Adjust the air 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).

22. During the filter cart operation, check the filter element indicators on the filter cart. Filter element indicators will display 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 the hydraulic connections.

23. 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.

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

    1. Use a 170-8500 Analyzer Gp for immediate results.

    2. Collect a bottle sample and send the sample to an S·O·S lab. Refer to Contamination Control Guideline, SEBF8482, "Obtaining an Oil Sample for S·O·S Analysis" 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 10	g01622514
(13) Fabricated suction tube (14) 220-8607 Fitting (15) 210-5530 Quick Connect Coupler (16) S·O·S valve

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (16) on the filter cart.

   Note: The fabricated suction tube can be made with the parts listed in Table 3 and as shown in Illustration 10.

2. Attach the other end of the fabricated suction tube (13) 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 11	g01622532
(16) S·O·S Valve (17) 169-8373 Fluid Sampling Bottle

1. If collecting a bottle sample, use the S·O·S valve (16) and a 169-8373 Fluid Sampling Bottle (17).

2. Record an oil sample from the S·O·S valve (16) on the filter cart at the beginning of the filter cycle.

   Note: The filtration can be performed although the engine is running.

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

4. At the halfway point of filtration, stop the procedure and change the oil filters on the wheel loader. Changing the machine 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 now avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.

   Note: The machine filters are to be replaced if the filters are not working at optimal performance, or the filters are scheduled for replacement.

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 level 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 (12) and disconnect the air supply hose (11). Refer to Illustration 9.

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

7. Close the hydraulic tank drain valve assembly. Refer to Illustration 8.

8. Remove the filter cart discharge hose from the hydraulic tank filler port. Store the hose assembly in a clean location.

9. Install the strainer assembly in the hydraulic tank fill tube if the machine is equipped.

10. Install a clean hydraulic tank filler cap (9). Refer to Illustration 5.

11. Disconnect the filter cart suction hose from the hydraulic tank drain assembly and cap the ends with dust caps. Store the hose assembly in a clean location. Refer to Illustration 7.

    Note: Check the hydraulic tank drain valve assembly for leakage. Make sure that the hydraulic tank drain valve assembly is closed.

12. Install the original drain hose to the hydraulic tank drain valve assembly .
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    Illustration 12	g01616575
    (18) Hydraulic Tank Sight Gauge

13. Check the hydraulic tank oil level. The hydraulic tank sight gauge (18) is located behind the cab on the front of the hydraulic tank.

14. Unblock the wheels.

15. 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 Gp 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). Pulsation 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 924H hydraulic system has 70 L (18.5 US gal) of SAE 10W oil. The approximate filtration time should be 37 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 particle 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 process. This process will 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.