Filtration Procedure for Motor Grader Hydraulic Oil. {0680, 0768, 5050, 5056} Caterpillar

Motor Grader

120B (S/N: 7KB1-UP; 32C1-UP; 64U1-UP)

120G (S/N: 4HD1-UP; 1LK1-UP; 82V1-UP; 87V1-UP; 11W1-UP)

120H (S/N: 1241-UP; CAF1-UP; 4MK1-UP; 5FM1-UP; 6NM1-UP; 6TM1-UP; 2AN1-UP; 6YN1-UP; 9FN1-UP; 9YR1-UP; ALZ1-UP)

120K (S/N: SZN1-UP; JAP1-UP)

120K Series 2 (S/N: SZS1-UP)

120L (S/N: E921-UP; E961-UP; Y9A1-UP; Y9B1-UP)

120N (S/N: E941-UP; E951-UP; Y9C1-UP; Y9D1-UP)

12E (S/N: 99E1-UP)

12F (S/N: 89H1-UP; 13K1-UP; 33K1-UP)

12G (S/N: 3WC1-UP; 3PL1-UP; 61M1-UP; 26V1-UP)

12H (S/N: 1251-UP; XZJ1-UP; CBK1-UP; 4XM1-UP; 5ZM1-UP; 8MN1-UP; 2LR1-UP; 2WR1-UP; 4ER1-UP; 2GS1-UP; AMZ1-UP)

12K (S/N: SZP1-UP)

130G (S/N: 7GB1-UP; 26V1-UP; 74V1-UP; 12W1-UP)

135H (S/N: CBC1-UP; BDJ1-UP; 3YK1-UP; 7MM1-UP; 7PM1-UP; 8WN1-UP; AMX1-UP)

140 RIPPG (S/N: 26V1-UP)

140B (S/N: 33C1-UP; 61S1-UP)

140G (S/N: 5MD1-UP; 72V1-UP; 81V1-UP; 13W1-UP)

140H (S/N: 1261-UP; CCA1-UP; XZH1-UP; 2ZK1-UP; APM1-UP; 5HM1-UP; 8JM1-UP; 8KM1-UP; 9TN1-UP; 9ZN1-UP; 3AS1-UP)

140K Series 2 (S/N: SZW1-UP)

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)

143H (S/N: 1AL1-UP; APN1-UP)

14E (S/N: 72G1-UP; 12K1-UP)

14G (S/N: 96U1-UP)

14H (S/N: ASE1-UP; 7WJ1-UP)

160G (S/N: 4JD1-UP)

160H (S/N: ASD1-UP; 9EJ1-UP; XZK1-UP; 2FM1-UP; 3GM1-UP; 6WM1-UP; 9JM1-UP; CCP1-UP; 2HS1-UP)

160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9T1-UP)

163H (S/N: 5AK1-UP; ARL1-UP)

16G (S/N: 93U1-UP)

16H (S/N: 6ZJ1-UP; ATS1-UP)

24 (S/N: E9Z1-UP; N9Z1-UP)

24H (S/N: 7KK1-UP)

Introduction

© 2019 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.

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 quickly connects to the hydraulic oil filler cap. This guideline provides directions for you 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 need modified by the technician for use on some motor graders.

Important Safety Information

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 1	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 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

Motor Grader Hydraulic Oil Filtering Procedure

The following procedure is intended for all models of motor graders. The procedure is most effective when performed immediately after the hydraulic oil 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 and lowers the viscosity of the oil. Be sure to read and understand the Tool Operating Manual, NEHS0848.

1. Park the machine on level ground.

2. Lower all hydraulic implements to the ground.

3. Engage the parking brake.

4. With the engine OFF and the ignition turned ON, relieve all the hydraulic system pressure. This procedure can be accomplished by moving all the hydraulic control valves through the complete range of motion.
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   Illustration 2	g01232996
   (1) Filler cap

5. Clean the area around the hydraulic tank filler cap (1). Refer to Illustration 2.

6. Slowly loosen the filler cap (1) on the hydraulic tank and release the pressure. Make sure that all air pressure has been vented before you completely remove the cap.

7. Remove the lock-ring and remove the strainer from the hydraulic filler neck, if equipped.

8. Store the filler cap (1) and the strainer in a clean place to avoid contamination and damage.
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   Illustration 3	g01232999
   (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 neck - 110 mm (4.3 inch) (Z) 4 inch filler neck - 60 mm (2.4 inch)

9. Measure the distance from the top of the hydraulic filler neck to the bottom of the hydraulic tank (Y). Subtract (Z) from (Y) to obtain the proper hose length (X). Refer to Illustration 3.

10. Cut a length of suitable hose matching the (X) measured distance of tank depth. Install the hose on the filler cap adapter hose barb.
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    Illustration 4	g01233002
    (2) 193-5903 Filler Cap Adapter

11. Install the 193-5900 Filler Cap Adapter or the 193-5903 Filler Cap Adapter (2). If obstructions exist, the side return port can be removed for clearance and reinstalled after the main filler cap adapter is installed. Be sure that the installed suction hose reaches within 25.4 mm (1 inch) from the bottom of the tank. Refer to Illustration 4.

    Note: The 90 degree elbow fitting may be required on some motor graders. Sometimes the angle of the motor grader rear window interferes with the installation of the filter cart suction hose. The addition of the 90 degree elbow fitting (6) is pictured in Illustration 7 on the center suction port.

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    Illustration 5	g01233003
    (3) Side return port

12. Install the side return port (3). There are multiple side return inlets on the filler cap adapter to aid in the connection and orientation of the filter cart lines. Refer to Illustration 5.
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    Illustration 6	g01233009
    (4) Suction line (5) Center suction port

13. Connect the filter cart suction line (4) to the fill cap adapter center suction port (5). Refer to Illustration 6.
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    Illustration 7	g01233011
    (6) 90 degree elbow fitting (7) Return line (8) Side return port

14. Connect the filter cart return line (7) to the fill cap adapter side return port (8). Refer to Illustration 7.
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    Illustration 8	g01233012
    Air supply valve in the CLOSED position (9) Air supply hose (10) Air supply valve

15. Attach an air supply hose (9) to the 204-7392 Hydraulic Filter Cart. Ensure that the air supply valve (10) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi). Refer to Illustration 8.
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    Illustration 9	g01233013
    Air supply valve in the OPEN position

16. Slowly open the air supply valve (10) to start the filter cart pump operation. This pump is a double acting diaphragm pump. The pump is rated to pump 10W oil at 64 L/min (17 US gpm).

17. While you operate the filter cart, check the filter element indicators on the filter cart. The indicators will show 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 off the filter cart. Then, check the filter cart connections.

18. Ensure that there are no oil leaks from any of the filter cart connections.

19. Caterpillar recommends taking a particle count on the oil at the beginning of the filter cycle to use as a baseline particle count.

    • Use a 170-8500 Portable Particle Analyzer for immediate results.

    • Collect a bottle sample and send the sample to an S·O·S lab.

    Note: If you use the 170-8500 Portable Particle Analyzer for particle counting, be sure to read and understand the Tool Operating Manual, NEHS0799 before you operate the filter cart.

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    Illustration 10	g01233015
    (11) S·O·S valve (12) Fabricated suction tube (13) 210-5530 Coupler

20. When using the 170-8500 Portable Particle Analyzer, connect the "low pressure in" port to the S·O·S valve (11) on the filter cart. Use a fabricated suction tube (12) fitted with a 210-5530 Coupler (13). Refer to Illustration 10.
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    Illustration 11	g01232974
    (14) 169-8373 Bottle Group

21. If you collect a bottle sample, use the same S·O·S valve (11) and a 169-8373 Bottle Group (14). Refer to Illustration 11.

22. Record an oil sample reading from the S·O·S valve (11) 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.

23. During the filter cart operation, cycle all hydraulic cylinders at least four times every half hour. This procedure will cycle the clean tank oil into the hydraulic system and flush the more contaminated oil back into the tank. The oil filtration can be performed while running the engine.
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    Illustration 12	g01232979
    Filter cart operation on a 160H MG. (15) 240-7392 Filter Cart

24. After half an hour of filtering, stop the procedure and change the machines hydraulic filters. Changing the filters allows the filters to help with system cleaning. The new filter can remain in place until the next scheduled filter change. Changing the filters avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.

25. Operate the filter cart (15) until the 170-8500 Portable Particle Analyzer indicates that the oil has reached an acceptable ISO level of at least 18/15. The final ISO reading should be recorded before the machine is returned to the field.

    Note: Refer to "Oil Compartment Filtration Times", at the end of this document, when a 170-8500 Portable Particle Analyzer is not available.

26. When the target ISO level or time interval has been met, close the air supply valve (10). Disconnect the air supply hose (9).
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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 pilot pressure is released. Serious injury can result if this remaining pressure is not released before any service is done on the hydraulic system. Make sure that the remaining pressure has been released by utilizing the purge screws that are located on the boom, stick and bucket lines. Before any purge screw is turned, the bucket and or all of the attachments must be lowered to the ground or properly supported.

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    Illustration 13	g01232983
    (16) Probe (17) S·O·S valve (on the fill cap adapter)

27. To relieve possible tank pressure, use a probe (16) from the 169-8373 Bottle Group and depress the S·O·S valve (17) on the fill cap adapter. Refer to Illustration 13.

28. Disconnect the filter cart return line (7) from the fill cap adapter side return port (8). Refer to Illustration 7.

29. Disconnect the filter cart suction line (4) from the fill cap adapter center suction port (5). Refer to Illustration 6.

30. Remove the 193-5903 Fill Cap Adapter (2). Refer to Illustration 4.

31. Install protective caps to the fill cap adapter, the filter cart suction line, and the filter cart return line to control contamination.

32. Install the strainer and lock ring into the hydraulic fill neck.

33. Install the hydraulic oil tank fill cap (1). Refer to Illustration 2.

34. Check the oil level in the sight gauge.

35. Inspect the hydraulic system for leaks. Most hydraulic contamination is brought into the system from an external source. To provide a long-term benefit, repairs must be completed before the machine is returned 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 point, refer to the following equation. This equation relates to the 204-7392 Filter Cart only. 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.

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

Filtration Time Example

A 24H motor grader hydraulic system has 129 L (34 US gal) of 10W oil. The approximate filtration time should be about 68 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 particles cross sectional area. Particle counts are affected by various factors. These factors include procurement of the sample, the sample container, particle counting accuracy, 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. ExampleX/Y/Z.

"X" is the number of particles equal to or larger than 4 microns. "Y" is the number of particles equal to or larger than 6 microns. "Z" is the number of particles equal 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. 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

After any open system repair, an on-site S·O·S sampling and particle counting is required. This procedure should be accomplished by exercising the specific system until the fluid is at normal operating temperature. This 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. This procedure ensures that unseen system 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 machines standard filter 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.