Filtration Procedure for (D7- D11) Track-Type Tractor Hydraulic Oil {0680, 0738, 0768, 5050, 5056} Caterpillar

Track-Type Tractor

D10 (S/N: 84W1-UP; 76X1-UP)

D10N (S/N: 2YD1-UP; 3SK1-UP)

D10R (S/N: 3KR1-UP; AKT1-UP)

D10T (S/N: RJG1-UP)

D10T2 (S/N: RAB1-UP; JJW1-UP)

D11N (S/N: 4HK1-UP; 74Z1-UP)

D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)

D11T (S/N: AMA1-UP; GEB1-UP; TPB1-UP; MDG1-UP; JEL1-UP; JNS1-UP)

D6 (S/N: B721-UP; AG91-UP; ES91-UP; GZ91-UP; HR91-UP; LF91-UP; SA91-UP; LNC1-UP; RDC1-UP; XEC1-UP; LRG1-UP; HMH1-UP; HNK1-UP; HZL1-UP; TPL1-UP; D5M1-UP; RBP1-UP; KMT1-UP; KTW1-UP; HLY1-UP; WGY1-UP)

D6N (S/N: GB61-UP)

D6T (S/N: CR31-UP; CG81-UP; SGA1-UP; STE1-UP; MEL1-UP; SGT1-UP)

D7E (S/N: HKA1-UP; TJA1-UP; MDB1-UP; SCG1-UP; SSH1-UP; TAN1-UP)

D7F (S/N: 92E1-UP; 61G1-UP; 93N1-UP; 94N1-UP)

D7G Series 2 (S/N: 7MB1-UP; 3ZD1-UP; 3GF1-UP; 35N1-UP; 64V1-UP; 65V1-UP; 91V1-UP; 92V1-UP; 44W1-UP; 45W1-UP; 72W1-UP)

D7G Series II (S/N: X7C1-UP)

D7H (S/N: 2SB1-UP; 4AB1-UP; 5WB1-UP; 5BF1-UP; 2RG1-UP; 3XG1-UP; 4FG1-UP; 77Z1-UP; 79Z1-UP; 80Z1-UP; 82Z1-UP)

D7R (S/N: R7B1-UP; R7C1-UP; DSH1-UP; R7H1-UP; BPK1-UP; BNM1-UP; BRM1-UP; 9HM1-UP; DLN1-UP; 2EN1-UP; 3DN1-UP; BRP1-UP; DJR1-UP; 2HR1-UP; 3ZR1-UP; 4SR1-UP; 5MR1-UP; 6ER1-UP; BPT1-UP; BNX1-UP; 5KZ1-UP)

D7R Series II (S/N: AEC1-UP; AFG1-UP; ABJ1-UP; AGN1-UP; ACS1-UP; ADW1-UP)

D8 (S/N: 76V1-UP; 77V1-UP)

D8H (S/N: 36A1-UP; 46A1-UP)

D8K (S/N: 66V1-UP; 76V1-UP; 77V1-UP)

D8L (S/N: 4FB1-UP; 7YB1-UP; 7JC1-UP; 53Y1-UP)

D8N (S/N: 9TC1-UP; 1XJ1-UP; 5TJ1-UP; 7TK1-UP)

D8R (S/N: JR81-UP; DWJ1-UP; MEJ1-UP; RJM1-UP; 7XM1-UP; 9EM1-UP; T5X1-UP; 6YZ1-UP)

D8R Series II (S/N: AKA1-UP)

D8T (S/N: AW41-UP; JJ51-UP; MB81-UP; J8B1-UP; FMC1-UP; MLN1-UP; FCT1-UP; KPZ1-UP)

D9 (S/N: 66A1-UP; 91J1-UP; 90V1-UP)

D9E (S/N: 50A1-UP)

D9G (S/N: 66A1-UP; 90J1-UP; 91J1-UP)

D9H (S/N: 12U1-UP; 90V1-UP; 97V1-UP; 98V1-UP; 99V1-UP)

D9L (S/N: 14Y1-UP)

D9N (S/N: 1JD1-UP; 6XJ1-UP)

D9R (S/N: JJB1-UP; HWH1-UP; ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP)

D9T (S/N: TWG1-UP; RJS1-UP; REX1-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 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. 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 (TCC).

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 filtration process is easy to use. The filter cart quickly connects to the hydraulic tank filler cap. This guideline provides directions to install and operate the filter cart.

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 Caterpillar track-type tractors.

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. 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, measurements, 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

Track-Type Tractor & Pipelayer Hydraulic Oil Filter Cart Procedure

The following procedure is intended for the D7 through D11 track-type tractor and pipelayer models. The procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and mixed from operation. Warming 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 Tool Operating Manual, NEHS0778, "188-3242 Hydraulic/Transmission Filter Cart", before performing the procedure.

Filter Cart Procedure

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

1. Park the machine on level ground and lower all hydraulic implements to the ground. Be sure to engage the parking brake.

2. With the engine off and the ignition turned ON, relieve all hydraulic system pressure. Relieve hydraulic system pressure by moving all hydraulic control valves through the complete range of motion.
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   Illustration 3	g01267174
   (1) Filler cap

3. Clean the area around the hydraulic tank filler cap (1). Slowly loosen the filler cap (1) on the hydraulic tank and release the tank pressure. Make sure that all air pressure has been vented before completely removing the cap. Refer to Illustration 3.

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

5. Store the filler cap and the strainer in a clean place to avoid contamination and damage.
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   Illustration 4	g01262621
   (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 = 60 mm (Z) 4 inch filler cap adapter = 110 mm

6. Measure the distance from the top of the hydraulic tank filler neck to the bottom of the hydraulic tank (Y). Subtract (Z) from (Y) to obtain the proper hose length (X). Refer to Illustration 4.

7. Cut a length of suitable hose that matches (X) measured distance of tank depth. Install the hose on the filler cap adapter hose barb.
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   Illustration 5	g01267175
   (2) Filler cap adapter

8. Install the 193-5903 or the 193-5900 Filler Cap Adapter (2). When 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) of the bottom of the hydraulic tank. Refer to Illustration 5.
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   Illustration 6	g01267176
   (3) Fill Cap Adapter Gp. installed.

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   Illustration 7	g01267177
   (4) Elbow fitting (5) Filler cap adapter center suction port (6) Filter cart suction line

9. Connect the filter cart suction line (6) to the filler cap adapter center suction port (5). Refer to Illustration 7.

   Note: The elbow fitting (4) may be required on larger tractors for the filter cart suction hose to reach and connect to the filler cap adapter. The addition of the elbow fitting will aid in the necessary orientation of the center suction port. The elbow fitting (4) is pictured in Illustration 7 on the center suction port.

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   Illustration 8	g01267178
   (7) Return line (8) Side return port

10. Connect the filter cart return line (7) to the filler cap adapter side return port (8). Refer to Illustration 8.
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    Illustration 9	g01262628
    Air supply valve in the CLOSED position (9) Air supply hose (10) Air supply valve

11. Attach the air supply hose (9) to the 188-3242 Filter Cart. Make sure 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 9.
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    Illustration 10	g03375742
    (10) Air supply valve in the OPEN position.

12. Slowly open the air supply valve (10) to start the filter cart pump operation. The pump is a double acting diaphragm pump. The pump is rated to pump 10W oil at 340 L/min (90 US gpm). Refer to Illustration 10.

13. While operating the filter cart, check the filter element indicators on the filter cart. The filter cart element 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 off the filter cart and check the connections.

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

    Note: Caterpillar recommends that a particle count is taken on the oil at the beginning of the filter cycle for use as a baseline particle count.

15. Particle count test the oil cleanliness by using one of the two following ways.

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

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

    Note: If using the 170-8500 Analyzer Gp for particle counting, be sure to read and understand the Tool Operating Manual, NEHS0799, "170-8500 Analyzer Group" before operating.

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    Illustration 11	g01262630
    (11) S·O·S valve (12) Fabricated suction tube (13) 210-5530 Quick Connect Coupler

16. When using the 170-8500 Analyzer Gp, connect the "low pressure in" port to the S·O·S valve (11) on the base assembly using a fabricated suction tube (12) fitted with a 210-5530 Quick Connect Coupler (13). The fabricated tube is required to collect an on-line sample when using the 170-8500 Analyzer Gp. Refer to Illustration 11.
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    Illustration 12	g01262632
    (14) Fabricated suction tube

17. If collecting a bottle sample, use the same S·O·S Valve (11) and a 169-8373 Fluid Sampling Bottle (14). Refer to Illustration 12.

18. Record an oil sample reading from the S·O·S Valve (11) on the filter cart at the beginning of the filter cycle.

19. Cycle the hoist at least four times every 30 to 60 minutes during the filter cart operation. Operation of the hoist will cycle the clean tank oil into the hydraulic system. Cycling the hoist will also flush the more contaminated oil back into the tank. The oil filtration may be performed when then engine is running.

20. Stop the procedure after 30 minutes of filtering. Change the machine hydraulic filter. Changing the filter allows the filter to help in the cleaning of the system. The new filter can remain in place until the next scheduled filter change. Changing the filter now avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.
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    Illustration 13	g01267183
    Filter cart operation on a D11R (15) 188-3242 Filter Cart

21. Operate the filter cart (15) until the Portable Particle Analyzer indicates that the oil has reached an ISO level of 18/15. Take a final oil sample and record the final ISO level before the machine is returned to the field.

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

22. When the target ISO level or the time interval has been met, close the air supply valve (10) and disconnect the air supply hose (9). Refer to Illustration 9.
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    Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

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    Illustration 14	g01267194
    (16) Probe (17) S·O·S valve (on the filler cap adapter)

23. To relieve possible tank pressure, use a probe (16) from the 169-8373 Fluid Sampling Bottle. Use the probe used in Step 17 and depress the S·O·S valve (17) on the filler cap adapter. Refer to Illustration 14.

24. Disconnect the filter cart suction line (6) from the filler cap adapter suction port (5). Refer to Illustration 8.

25. Disconnect the filter cart return line (7) from the filler cap adapter return port (8). Refer to Illustration 7.

26. Remove the filler cap adapter (2). Refer to Illustration 5.

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

28. Install the strainer and the lock-ring into the hydraulic filler neck.

29. Install the hydraulic oil fill cap (1). Refer to Illustration 3.

30. Check the oil level by viewing the hydraulic tank sight gauge.

31. Inspect the hydraulic system for leaks. Most hydraulic contamination is brought into the system from an external source. Repairs must be completed before the machine is returned to service to provide a long-term benefit.

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 and 246-1157 Filter Carts 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.

Illustration 15	g01177339
Oil compartment filtration equation (A) Compartment oil capacity (gal) (B) Pulses per minute (C) Approximate filtration time (minutes)

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). Each pulse 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 D11R track-type tractor hydraulic system has 212 L (56 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 49 minutes.

ISO 4406 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: procurement of the sample, the sample container, particle counting accuracy, and the particle count cleanliness. Proper care should be taken during the sample procurement. Proper care will ensure that the sample obtained is representative of the fluid circulating in the system.

The code for contamination levels using automatic particle counters are composed of three scale numbers. Example X/Y/Z.

"X" - The number of particles that are 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.