Filtration Procedure for Mining Truck Hydraulic Oil {0113, 0680, 0768, 5050, 5095, 7000} Caterpillar

Off-Highway Truck/Tractor

69D (S/N: 9SS1-UP; 9XS1-UP)

73D (S/N: 9YS1-UP)

Underground Articulated Truck

AD22 (S/N: MW51-UP)

AD30 (S/N: DXR1-UP; GXR1-UP)

AD45B (S/N: CXM1-UP; GXM1-UP)

AD55 (S/N: DNW1-UP; GNW1-UP)

AD60 (S/N: KNW1-UP; NNW1-UP)

Introduction

© 2017 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 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 underground mining truck customers to benefit from cleaner hydraulic systems. The kidney loop filtration process is easy to use. The kidney loop cart quickly connects to the hydraulic oil filler neck.

This guideline provides directions for installing and operating the kidney loop system. Clean fluids play a major role in the life of any fluid system. The following procedure will help reduce fluid contamination in underground mining truck hydraulic system oils to an acceptable ISO cleanliness level. This procedure may be modified by the technician for use on some machines.

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 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 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

Machine Kidney Loop Procedure

The guideline is intended for Underground Mining Trucks. The procedure is most effective when performed immediately after the oil has been warmed to 50° C (122° F) and mixed from the operation. Heating and mixing of the oil allows any contamination in the system oil to be placed in suspension and lowers the viscosity. Be sure to read and understand the Tool Operation Manual, NEHS0778, "188-3242 Filter Cart Gp", before beginning the procedure.

Kidney Loop Setup

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

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 and engage the transmission lock (if equipped).

5. Engage the parking brake.
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   Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during movement. Use caution when working between the wheels and the frame. If the wheels must be turned, ensure that all personnel are clear of the machine before any movement.

6. Block the wheels.

Kidney Loop Procedure

Illustration 3	g02398977
Fill cap (typical on a 73D) (1) Fill cap

1. Clean the area around hydraulic tank fill cap (1). Slowly loosen the fill cap on the hydraulic tank and release the tank pressure. Make sure that all air pressure has been vented before completely removing the fill cap (1).

2. Remove the lock-ring and the strainer from the hydraulic fill neck.

3. Store the fill cap (1) and strainer in a clean place to avoid contamination and damage.
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   Illustration 4	g02398998
   (X) Proper length of suction hose (Y) Distance from the top of the fill neck to the bottom of the tank (Z) 2 inch Fill cap adapter = 110 mm

4. Measure the distance from the tip of the hydraulic fill neck to the bottom of hydraulic tank (Y). Subtract (Z) from (Y). Subtract an additional 1 inch to obtain the proper hose length (X). Refer to Illustration 4.

5. 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 5	g02399016
   (2) Fill cap adapter (3) Elbow (4) Suction port (5) Return port

6. Install 193-5903 Two-Inch Fill Cap Adapter (2). If obstruction to the installation exists, the side return port can be removed for clearance and reinstalled after the adapter is installed. Be sure that the installed suction hose reaches within 1 inch of the bottom of the hydraulic tank.

   Note: The 3H-9690 Elbow (3) may be required on some models. The 3H-9690 Elbow (3) allows the cart suction hose to reach and properly connect to the fill cap adapter. The addition of the 90° elbow fittings will also aid in the necessary orientation of the center suction port as seen in Illustration 5.

7. Connect filter cart suction hose to the suction port (4) on the fill cap adapter (2).

8. Connect filter cart discharge hose to the return port (5) on the fill cap adapter (2).
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   Illustration 6	g02399018
   (6) Air supply hose (7) Air supply valve

9. Attach air supply hose (6) to 188-3242 Filter Cart Gp, ensuring that air supply valve (7) is in the closed position. Be sure that the air supply does not exceed 690.0 kPa (100.08 psi)

10. Slowly open air supply valve (7) to start the filter cart pump operation. If air supply valve (7) is a purge style, adjust supply air between 20 and 50 psi and turn on the air supply valve (7). Then, adjust the pressure as needed, but DO NOT exceed 690.0 kPa (100 psi). The filter cart contains a diaphragm pump. The filter cart is rated to pump 10W oil at 90 gpm.

11. During operation, check the filter element indicators on the filter cart. The filter element indicator 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. When filter cart cavitation continues for more than 1 minute, shut the filter cart OFF. Then inspect the hydraulic hose connections.

    Note: Caterpillar recommends that a particle count is to be taken on the oil at the beginning of the filter cycle. The particle count is to be used as a baseline particle count.

12. 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 Special Instruction, SEBF8482, "Obtaining an Oil Sample for S·O·S Analysis".

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.

Illustration 7	g02399019
Portable particle procedure (8) Fabricated Suction tube (9) 220-8607 Fitting (10) 210-5530 Coupler (11) S·O·S Valve

1. Attach the fabricated particle counter “low pressure in” suction tube to the S·O·S valve (11) on the filter cart.

   Note: The fabricated suction tube (8) can be made with the parts listed in Table 3 Optional Tools chart and as shown in Illustration 7.

   Note: When using a 188-0645 Particle Analyzer Gp, the European style minimess fitting must be replaced. Replace the minimess fitting with a 220-8608 Fitting Group to allow for the suction tube connection.

2. Attach the other end of the fabricated suction tube to the “low pressure in” port on the portable particle counter. Refer to the Tool Operating Manual for the portable particle counter.

Bottle Sample Procedure

Illustration 8	g02399036
Bottle procedure (11) S·O·S valve (12) 169-8373 Bottle Group

1. If collecting a bottle sample, use the same S·O·S valve (11) and a 169-8373 Bottle Group (12).

2. Record an oil sample from the S·O·S valve (11) on the filter cart at the beginning of the filter cycle.
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   Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during movement. Use caution when working between the wheels and the frame. If the wheels must be turned, ensure that all personnel are clear of the machine before any movement.

   Note: Kidney loop filtration can be performed while running the engine.

3. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an ISO level of at least 18/15. The final ISO should be recorded before the machine is returned to the field.
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   KNOW THE MAXIMUM HEIGHT AND REACH OF YOUR MACHINE. SERIOUS INJURY OR DEATH BY ELECTROCUTION CAN OCCUR IF MACHINE OR ATTACHMENTS ARE NOT KEPT A SAFE DISTANCE FROM ELECTRICAL POWER LINES. KEEP DISTANCE AT LEAST 3 M (10 FEET) PLUS ADDITIONAL 10 MM (0.4 INCH) FOR EACH 1,000 VOLTS OVER 50,000 VOLTS.

4. During filter cart operation, cycle the lift cylinders at least four times per 1/2 hour of cart operation. Operation of the lift cylinders will cycle the clean tank oil into the hydraulic system and flush the more contaminated oil back into the tank.

5. At the halfway point of kidney looping, stop the procedure and change the machine filter.

   Note: Changing the machine hydraulic filter half way through the filtering process avoids opening the filter housing after the system has been cleaned. If the filter housing is opened after the filtration process is complete, an open filter housing becomes an inlet for contamination. The new filters can remain in place until the next scheduled filter change.

6. When the target ISO level or time interval has been met, close air supply valve (7) and disconnect air supply hose (6). Refer to Illustration 6.

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

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

7. Disconnect filter cart suction hose from the suction port (4) on the fill cap adapter (2). Install the dust caps on the coupler and nipple. Refer to Illustration 5.

8. Disconnect filter cart discharge hose from the return port (5) on the fill cap adapter center suction port (2). Install the dust caps on the coupler and nipple. Refer to Illustration 5.

9. Remove 193-5903 Fill Cap Adapter (2). Store in a clean location.

10. Install the strainer and lock ring in the hydraulic fill neck.

11. Install a clean fill cap (1). Refer to Illustration 3.

12. Check the hydraulic tank oil level.

13. Unblock the wheels.

Oil Compartment Filtration Times for 188-3242 Filter Cart

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 Filter Cart. 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.

Illustration 9	g01177339
Oil Compartment filtration equation (A) Compartment oil capacity (gal) (B) Pulses per minute (C) 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 (two pulses). Count the number of pulses in 1 minute for use in the above equation.

Example: A 69D has 257.41 L (68 US gal) gallons of SAE10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 1 hour.

ISO 4406:1999 Method for coding the level of contamination by solid particles.

ISO (International Organization of Standardization) is a worldwide federation of national standards bodies (ISO member bodies). ISO 4406:1999 specifies the code to be used in defining the quantity of solid particles in the 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 procurement of the sample, particle counting accuracy, the sample container, where used, and cleanliness. Proper care should be taken during sample procurement to ensure that the sample obtained is representative of the fluid circulation in the system.

The code for contamination levels using automatic particle counters comprises three scale numbers, for example X/Y/Z.

X = The number of particles equal to or larger than 4 microns.

Y = The number of particles equal to or larger than 6 microns.

Z = The number of particles equal to or larger than 14 microns.

At this time, Caterpillar does not require the reporting of the X scale number. Currently hydraulic tolerances exceed the 4 micron value, therefore a - is used. 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 micron.