Filtration Procedure for Hydraulic Oil in the Vibratory Compactor {0680, 0768, 5050, 5056} Caterpillar

Asphalt Compactor

CB-534 (S/N: 2YF1-UP; 2EG1-UP)

CB-534B (S/N: 5RN1-UP)

CB-534C (S/N: 5HN1-UP; 1WS1-UP)

CB-534D (S/N: EAA1-UP; FEA1-UP; C2B1-UP; C4B1-UP; FGH1-UP; C8M1-UP)

CB-564D (S/N: D4M1-UP)

CB36B (S/N: M361-UP; XSB1-UP)

CD10 (S/N: J6B1-UP)

Asphalt Paver

AP1000E (S/N: T1F1-UP; DKH1-UP)

AP1055E (S/N: TJF1-UP; TRS1-UP)

AP355F (S/N: NRG1-UP; NTT1-UP)

AP600D (S/N: TFZ1-UP)

AP655D (S/N: GNN1-UP; MAN1-UP)

BG1000E (S/N: RTT1-UP)

BG1055E (S/N: FRR1-UP)

Asphalt Screed

AS2302 (S/N: AYC1-UP)

Paving Compactor

CB-214B (S/N: 6LF1-UP)

CB-214C (S/N: 9XK1-UP)

CB-214D (S/N: 6FD1-UP; 1TZ1-UP)

CB-214E (S/N: 2141-UP)

CB-224 (S/N: 6GD1-UP)

CB-224B (S/N: 6LF1-UP)

CB-224C (S/N: 3AL1-UP)

CB-224D (S/N: 8RZ1-UP)

CB-224E (S/N: 2241-UP)

CB-225D (S/N: 9FZ1-UP)

CB-225E (S/N: 2251-UP)

CB-314 (S/N: 6HD1-UP)

CB-334D (S/N: DCZ1-UP; 3JZ1-UP; 4CZ1-UP)

CB-334E Series II (S/N: C3E1-UP)

CB-335D (S/N: D4E1-UP; BBW1-UP; 5PZ1-UP)

CB-335E (S/N: C5F1-UP; C5J1-UP)

CB-414 (S/N: 6KD1-UP)

CB-424 (S/N: 6LD1-UP)

CB-434 (S/N: 3TF1-UP)

CB-434B (S/N: 6AL1-UP; 7YN1-UP)

CB-434C (S/N: 4DN1-UP; 4MW1-UP)

CB-434D (S/N: CNH1-UP)

CB-514 (S/N: 6YD1-UP)

CB-521 (S/N: 6RD1-UP)

CB-522 (S/N: 6SD1-UP)

CB-523 (S/N: 6TD1-UP)

CB-523B (S/N: 7FK1-UP)

CB-524 (S/N: 6WD1-UP)

CB-525 (S/N: 6XD1-UP)

CB-525B (S/N: 1NL1-UP)

CB-535B (S/N: 3AR1-UP)

CB-544 (S/N: 8FM1-UP)

CB-545 (S/N: 2FS1-UP)

CB-551 (S/N: 6ZD1-UP)

CB-614 (S/N: 7CD1-UP)

CB-634C (S/N: 5CL1-UP; 3BR1-UP)

CB-634D (S/N: CDF1-UP)

CB10 (S/N: NPP1-UP; P8P1-UP)

CB34 (S/N: 3451-UP)

CB34XW (S/N: 3471-UP)

CB7 (S/N: NLJ1-UP)

CC34 (S/N: 3461-UP)

CD54 (S/N: C3B1-UP; J5R1-UP)

CP-323C (S/N: 6JD1-UP; 6DM1-UP; EAS1-UP)

CP-433 (S/N: 6PD1-UP)

CP-433B (S/N: 1MG1-UP)

CP-433C (S/N: 2JM1-UP; 1ZN1-UP; 4JZ1-UP)

CP-533 (S/N: 3ZL1-UP; 5AL1-UP)

CP-533C (S/N: 3XN1-UP; 3YN1-UP)

CP-533D (S/N: AFC1-UP; 6AZ1-UP)

CP-553 (S/N: 7BD1-UP)

CP-563C (S/N: 5JN1-UP; 5KN1-UP)

CP-563D (S/N: 9ZW1-UP; 5LZ1-UP)

CP-643 (S/N: 7GD1-UP)

CP-653 (S/N: 7JD1-UP)

CS-323C (S/N: 6JD1-UP; 1TM1-UP; 1EN1-UP; DAR1-UP)

CS-431 (S/N: 6MD1-UP)

CS-431C (S/N: 1XF1-UP; 9XL1-UP; 6EN1-UP; 3WZ1-UP)

CS-433 (S/N: 6ND1-UP; 6PD1-UP)

CS-433B (S/N: 4FK1-UP)

CS-433C (S/N: 3TM1-UP; 2TN1-UP; 1FS1-UP; 1XZ1-UP; 5BZ1-UP)

CS-531 (S/N: 3WM1-UP; 4KM1-UP)

CS-531C (S/N: 5ZN1-UP; 9RN1-UP)

CS-531D (S/N: AGH1-UP; 3AZ1-UP; 4MZ1-UP)

CS-533 (S/N: 3BL1-UP; 4HL1-UP)

CS-533C (S/N: 2WN1-UP; 2XN1-UP)

CS-533D (S/N: AET1-UP; 5CZ1-UP)

CS-553 (S/N: 7AD1-UP)

CS-563 (S/N: 8XF1-UP; 7GG1-UP)

CS-563C (S/N: 4KN1-UP; 4LN1-UP)

CS-563D (S/N: 9MW1-UP; 1SZ1-UP; 2RZ1-UP)

CS-573 (S/N: 8PK1-UP)

CS-573C (S/N: 6LN1-UP)

CS-573D (S/N: CMK1-UP; 2YZ1-UP)

CS-583 (S/N: 8YJ1-UP; 1EL1-UP)

CS-583C (S/N: 7MN1-UP; 7NN1-UP)

CS-583D (S/N: 2CZ1-UP; 3GZ1-UP)

CS-643 (S/N: 7FD1-UP; 7GD1-UP)

CS-653 (S/N: 7HD1-UP; 7JD1-UP)

TSF-54 (S/N: 7KD1-UP)

TSM-54 (S/N: 7LD1-UP)

Vibratory Asphalt Compactor

CB14B (S/N: 4731-UP)

CB44B (S/N: TWC1-UP; JXL1-UP)

CB54B (S/N: 4631-UP; RJN1-UP; S4P1-UP)

CB8 (S/N: JL41-UP; CB81-UP)

CD44B (S/N: 3981-UP; JXE1-UP)

CD54B (S/N: GRT1-UP; J9T1-UP)

CD8 (S/N: RH41-UP)

Vibratory Soil Compactor

CB-334E (S/N: C3A1-UP; C3D1-UP; C4F1-UP; C4J1-UP; C4X1-UP)

CB-335E Series II (S/N: C3C1-UP; C3F1-UP)

CP-563 (S/N: 1YJ1-UP; 5AJ1-UP)

CP54B (S/N: 5461-UP; P5F1-UP; PFM1-UP; CPX1-UP)

CP56B (S/N: 4381-UP; LHC1-UP; M5P1-UP)

CP68B (S/N: 6841-UP; LCF1-UP; SDT1-UP)

CP74B (S/N: 7441-UP; L7B1-UP; M7B1-UP)

CS54B (S/N: 5441-UP; M5B1-UP; P5B1-UP; MFC1-UP; L4H1-UP)

CS56B (S/N: 4371-UP; L8H1-UP; M4M1-UP)

CS64B (S/N: C641-UP; S4B1-UP)

CS66B (S/N: CS61-UP)

CS68B (S/N: 4391-UP; MBF1-UP; MMS1-UP)

CS74B (S/N: 4411-UP; LCB1-UP; E7E1-UP)

CS76B (S/N: L9H1-UP)

CS78B (S/N: 4431-UP; L8C1-UP; M8M1-UP)

Vibratory Utility Compactor

CB22 (S/N: 2201-UP)

CB22B (S/N: LR21-UP; 2B21-UP; 4191-UP)

CB24 (S/N: 2401-UP)

CB24B (S/N: 4201-UP; 2X41-UP; J2T1-UP)

CB32 (S/N: 3201-UP)

CB32B (S/N: J321-UP; 3H21-UP; 4221-UP)

CB34B (S/N: 4231-UP; XB41-UP; 3B41-UP)

CB34B XW (S/N: 4251-UP)

CC24 (S/N: 2411-UP)

CC24B (S/N: 4211-UP; C241-UP; HCB1-UP)

CC34B (S/N: CC31-UP; XC31-UP; 3241-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 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. Updated 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, 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. The filter cart filtration process is easy to use. This guideline provides directions for installing and operating the filter cart 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 or cleaner.

The following procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and the oil is mixed from operation. Warming the machine oil causes contamination in the system to be placed in suspension and also lowers the viscosity.

Note: If the vehicle is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this filter cart 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 vehicle system cleaning must be performed prior to the filter cart procedure. This filtration procedure and subsequent particle count testing should be performed as a final step in 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 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 not recommended by Caterpillar is used, ensure that all personnel around the machine are safe. 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 starting any job. Cat 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

Filter Cart Procedure

This guideline is intended for vibratory compactors. Be sure to read and understand the Tool Operation Manual, NEHS0848, "204-7392 Filter Cart (Air Motor Driven) Use on All Caterpillar Products" and Tool Operation Manual, NEHS0778, "188-3242 Filter Cart Group (Use on Hydraulic Tanks or Hydraulic Systems)" before beginning the procedure.

Filter Cart 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 and engage the transmission lock if the machine is equipped.

5. Engage the parking brake.

6. Lower the attachment to the ground and apply slight pressure.

7. Block the wheels.

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Activating the machine's steering and work tools can be hazardous when personnel are working around the machine. Before moving the machine, make sure the machine is on firm level ground. Engage the parking brake. Make sure the area is clear of personnel before activating any work tool. Failure to follow this instruction could result in injury or death.

Filtration Procedure

Illustration 3	g01188257
(1) Hood group (2) Filler cap

1. Remove the hood group (1) or lift the hood group (1). Clean the area around the hydraulic tank filler cap (2). Refer to Illustration 3.

2. Slowly loosen the filler cap on the hydraulic tank and release the tank pressure. Make sure that all air pressure has been vented before completely removing the filler cap.

3. Remove the lock-ring and the strainer from the hydraulic filler neck.

4. Store the filler cap (2) and the strainer in a clean place to avoid contamination and damage.
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   Illustration 4	g01406199
   (A) Top of filler tube (B) Hydraulic tank (C) 25.4 mm (1 inch) (X) Proper length of suction hose (Y) Distance from the top of the filler neck to the bottom of the tank (Z) 2 inch filler cap adapter = 110 mm

5. Measure the distance from the top of the hydraulic filler neck to the bottom of the hydraulic tank (Y). Subtract the (Z) measured distance from the (Y) measured distance. Subtract an extra 25.4 mm (1 inch) to obtain the proper hose length (X). Refer to Illustration 4.

6. Cut a length of suitable hose matching the (X) measured distance of the tank depth. Install the hose on the filler cap adapter hose barb coupler.
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   Illustration 5	g01188260
   (3) Filler cap adapter

7. Install the Filler Cap Adapter (3). Be sure that the installed suction hose reaches within 25.4 mm (1 inch) of the bottom of the hydraulic tank. If obstruction to the installation exists, the side return port can be removed for clearance and then reinstalled after the adapter is installed. Refer to Illustration 5.
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   Illustration 6	g01406321
   (4) Suction hose (5) Filler cap adapter suction port

8. Connect the filter cart suction hose (4) to the filler cap adapter center suction port (5). Refer to Illustration 6.
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   Illustration 7	g03374911
   (6) Filler cap adapter side return port (7) Discharge hose

9. Connect the filter cart discharge hose (7) to the filler cap adapter side return port (6). Refer to Illustration 7.
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   Illustration 8	g03374912
   (8) Air supply valve (9) Air supply hose

10. Attach the air supply hose (9) to the Filter Cart, and make sure that the air supply valve (8) is in the CLOSED position. Be sure that air supply does not exceed 689 kPa (100 psi). Refer to Illustration 8.

11. Slowly open the air supply valve (8) to start the filter cart pump operation.
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    Illustration 9	g01406378
    Filter cart operation on a 563D Vibratory Compactor. (10) Filter Cart

12. During operation, check the filter element indicators on the filter cart. The indicator will determine the amount of capacity left in the filter element. Refer to Illustration 9.

    Note: Occasionally, the filter cart pump will cavitate during start-up. The cavitation is due to air in the suction lines of the pump. Shut off the filter cart and check the filter cart connections if cavitation continues for more than 1 minute.

13. 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 as a baseline particle count.

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

    • Use a portable particle analyzer for immediate results.

    • Collect a bottle sample and send the sample to the S·O·S lab. Refer to "Bottle Sample Procedure".

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 10	g01195565
Portable particle procedure (11) 188-0639 Fabricated Suction Tube (12) 210-5530 Quick Connect Coupler (13) S·O·S valve

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (13) on the filter cart. Refer to Illustration 10.

2. Attach the opposite end of the fabricated suction tube (11) to the "low pressure in" port on the portable particle counter as called for in the Tool Operating Manual.

   Note: Information regarding the availability of parts and fabrication instructions for the suction tube assembly can be obtained by contacting the Global Dealer Solution Network at https://gdsn.cat.com/. Proper fittings and instructions will be provided at no cost. A 188-0639 Hose will need to be purchased prior to assembly.

Bottle Sample Procedure

Illustration 11	g03705440
(13) S·O·S valve (14) Bottle Group

1. If collecting a bottle sample, use the same S·O·S valve (13) and a 169-8373 Bottle Group (14).

2. Record an oil sample from the S·O·S valve (13) on the filter cart at the beginning of the filter cycle.
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   Activating the machine's steering and work tools can be hazardous when personnel are working around the machine. Before moving the machine, make sure the machine is on firm level ground. Engage the parking brake. Make sure the area is clear of personnel before activating any work tool. Failure to follow this instruction could result in injury or death.

3. Disconnect the filter cart suction hose (4). Disconnect the discharge hose (7). Refer to Illustrations 6 and 7.

4. Exercise the steering, the propel, and vibratory systems for 2 minutes or 3 minutes.

5. Reconnect the filter cart suction hose (4) and discharge hose (7). Refer to Illustrations 6 and 7.

6. At the halfway point of the filtration process, stop the procedure and change the filters on the machine.

   Note: Refer to "Oil Compartment Filtration Times for 204-7392 Filter Cart" and "Oil Compartment Filtration Times for 188-3242 Filter Cart", at the end of this document when a portable particle analyzer is not available.

   Note: Changing the filters halfway through the filtration process avoids opening the filter housing after the system has been cleaned. The housing becomes an inlet for contamination if the filter housing is opened after the filtration process is complete. The new filters can remain in place until the next scheduled filter replacement.

7. 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.

8. When the target ISO level has been met, close the air supply valve (8) and disconnect the air supply hose (9). Refer to Illustration 8.

9. Disconnect the filter cart discharge hose (7) from the filler cap adapter side port (6). Install the dust caps on the coupler and the nipple. Store the coupler and the nipple in a clean place. Refer to Illustration 7.

10. Disconnect the filter cart suction hose (4) from the fill cap adapter center suction port (5). Install the dust caps on the coupler and the nipple. Store the coupler and store the nipple in a clean location. Refer to Illustration 6.

11. Remove the Filler Cap Adapter (3). Refer to Illustration 5.

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

13. Install a clean filler cap (2) and either lower or replace the cover (1) on the machine. Refer to Illustration 3.

14. Check the hydraulic tank oil level.

15. Unblock the wheels.

Oil Compartment Filtration Times for 204-7392 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 204-7392 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 as an absolute time or efficiency result.

Compartment Oil Capacity (gallons) x 2 = Approximate Filtration Time.

Example

The hydraulic system for the CS-533D vibratory compactor hydraulic system has 80 L (21.1 US gal) of 10W oil. The approximate filtration time should be about 45 minutes.

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 12	g01177339
Oil compartment filtration equation (A) Compartment oil capacity (gal) (B) Pulses per minute (C) Approximate filtration time (min)

Pulse 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-Chuck (two pulses). Count the number of pulses in 1 minute for use in the above equation.

Example

The hydraulic system for the 563 vibratory compactor has 117 L (31 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 28 minutes.

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. The ISO 4406:1999 specifies the code to be used in defining the quantity of solid particles in the fluid used in any given hydraulic fluid power system. An automatic particle counter derives the equivalent size of a particle from the cross sectional area of the particle. Particle counts are affected by the following factors: procurement of the sample, the sample container, particle counting accuracy, where used, 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 is composed of three scale numbers. ExampleX/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 instead of a number. 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.

Clean Out Filter Versus Filter Cart Filtration Process

After any open system repair, on-site S·O·S sampling and particle counting is required. S·O·S sampling should be accomplished by exercising the specific system until the fluid is at normal operating temperature. Exercising the specific system ensures that the oil and representative oil will be collected during the S·O·S process. An ISO 18/15 maximum cleanliness target has been established for most hydraulic and transmission systems. Refer to the machine system cleanliness targets to your specific machine.

System Oil Meets Recommended Cleanliness Targets:

1. Change the standard hydraulic system filter with a high efficiency filter prior to returning that machine to the customer. The high efficiency filter ensures that unseen contamination and new part break-in debris will be properly filtered out during the initial hours after any repair.

2. Instruct the customer that the high efficiency filter should be changed prior to 250 hours of operation.

3. After the high efficiency filter has been removed, the filter should be cut open and the amount of captured debris should be checked. If a large amount of debris is present, another high efficiency filter should be installed and then rechecked after 100 hours. When a small amount of debris is present, a standard filter can then be installed.

System Oil Does Not Meet Recommended Cleanliness Targets:

1. Filter cart filtration is required.

2. Change the standard filter on the machine with a high efficiency filter half-way through the filter cart process explained in this guideline.

3. Continue filtering according to the time interval at the end of this document or until the system meets the minimum recommended ISO.

4. Leave the installed high efficiency filter on the machine. The filter should last at least 8 hours, and should be changed prior to 250 hours.