Filtration Procedure for Wheeled Excavator Hydraulic Oil {0680, 0768, 5050, 5056} Caterpillar

Material Handler

M325D L MH (S/N: ETE1-UP)

M325D MH (S/N: GE81-UP; EDF1-UP; KGG1-UP; KAY1-UP)

MH3022 (S/N: FM21-UP)

MH3024 (S/N: FM41-UP; FB71-UP)

MH3026 (S/N: FB91-UP)

Wheeled Excavator

M312 (S/N: 6TL1-UP)

M313C (S/N: H2A1-UP; BDR1-UP)

M313D (S/N: J3A1-UP; K3D1-UP; W3H1-UP)

M314F (S/N: F4A1-UP)

M315 (S/N: 7ML1-UP)

M315C (S/N: H2B1-UP)

M315D (S/N: J5B1-UP; K5E1-UP; W5M1-UP)

M315D2 (S/N: CA41-UP)

M315F (S/N: F4D1-UP)

M316C (S/N: H2C1-UP; BDX1-UP)

M316D (S/N: W6A1-UP; P6K1-UP; D6W1-UP)

M316F (S/N: F6N1-UP)

M317D2 (S/N: CA61-UP)

M317F (S/N: F6P1-UP)

M318 (S/N: 8AL1-UP; 6ES1-UP; 8SS1-UP)

M318C (S/N: BEB1-UP; H2D1-UP; H2F1-UP; BCZ1-UP)

M318D (S/N: P8L1-UP; P9M1-UP; W8P1-UP; W8R1-UP; D8W1-UP; D9X1-UP)

M318F (S/N: F8B1-UP)

M320 (S/N: 6WL1-UP; 9PS1-UP)

M320D2 (S/N: EN81-UP; CH91-UP)

M320F (S/N: F2W1-UP)

M322C (S/N: H2E1-UP; H2G1-UP; BDK1-UP; BDY1-UP)

M322D (S/N: W2S1-UP; P2T1-UP; W2T1-UP; D2W1-UP; P3W1-UP; D3X1-UP)

M322D 2 MH (S/N: EN91-UP)

M322D2 (S/N: EN21-UP)

M322F (S/N: F2Z1-UP)

M323F (S/N: RH31-UP)

M324D 2 MH (S/N: EN31-UP)

M325B (S/N: BGN1-UP)

M325C (S/N: XJA1-UP; PAN1-UP)

M330D (S/N: MBR1-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 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 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 customers to benefit from cleaner hydraulic systems. The filtration process is easy to use. The filter cart quickly connects to the hydraulic oil inlet ports on the top of the hydraulic tank. This guideline provides directions for installing and operating 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 need modified by the technician for use on some models.

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 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. 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 for Wheeled Excavator Hydraulic Oil

This procedure is most effective when performed immediately after the hydraulic fluid has been warmed to 50 °C (122 °F) and mixed from operation. Warming the oil places the contamination in suspension and lowers the viscosity. Be sure to read and understand Tool Operating Manual, NEHS0778, "188-3242 Hydraulic/Transmission Filter Cart" before you begin this procedure.

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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.

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 on, relieve all hydraulic system pressure by moving all hydraulic control valves through complete range of motion.
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   Illustration 3	g01272772
   (1) Access cover

3. Open the access cover (1) above the hydraulic tank. Refer to Illustration 3.
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   Illustration 4	g01272779
   (2) Breather (3) Filler Plug (4) Hydraulic hammer return line

4. Clean the area around the breather (2). Slowly loosen the breather on the hydraulic tank and release the pressure. Make sure that all air pressure has been vented before completely removing the breather. Refer to Illustration 4.

5. Replace the breather (2) once the pressure has been relieved.

6. Clean the area around the filler plug (3) and store the plug in a clean location. Refer to Illustration 4.
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   Illustration 5	g01272780
   (5) 198-1052 Plug Adapter (6) 198-8795 Suction Pipe

7. Install the 198-1052 Plug Adapter (5). Lower the suction pipe (6) within 25.4 mm (1 inch) of the bottom of the tank. Hand tighten the compression nut of the plug adapter. Refer to Illustration 5.
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   Illustration 6	g01272783
   (4) Hydraulic hammer return line

8. If the machine is equipped with hydraulic hammer lines, clean the area and remove the hydraulic hammer return line (4). Remove the cover plate if the machine is not equipped with hammer lines. Refer to Illustration 6.
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   Illustration 7	g03346538
   (7) 006-5707 Elbow (8) 190-8319 Nipple (9) 7B-9008 Pipe (10) 9X-2101 Elbow (11) 146-3661 Hydraulic Adapter

9. Assemble the 9X-2101 Elbow (10) to the 146-3661 Hydraulic Adapter (11). By using the 8T-4196 Bolts, install the assembly onto the hydraulic hammer return port. Refer to Illustration 7.
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   Illustration 8	g03346549
   (6) 198-8795 Suction Pipe (12) Suction Line

10. Connect the filter cart suction line (12) to the suction pipe (6). Refer to Illustration 8.
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    Illustration 9	g03346562
    (8) 190-8319 Nipple (13) Return line

11. Connect the filter cart return line (13) to the 190-8319 Nipple (8), as shown in Illustration 9.
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    Illustration 10	g01272789
    Air supply valve in the closed position (14) Air supply valve (15) Air supply hose

12. Attach the air supply hose (15) to the 188-3242 Filter Cart. Ensure that the air supply valve (14) is in the closed position. Be sure that the air supply does not exceed 690 kPa (100 psi). Refer to Illustration 10.
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    Illustration 11	g03346572
    Air supply valve in the open position

13. Slowly open the air supply valve (14) to start the filter cart operation. The pump is a double acting diaphragm pump. The pump is rated to pump SAE 10W oil at 341 L/min (90 US gpm). Refer to Illustration 11.

14. During the filter cart operation, check the filter element indicators on the filter cart. The 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. Shut off the filter cart and check the connections if cavitation continues for more than 1 minute.

15. 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.

16. 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.

Portable Particle Procedure

When using the 170-8500 Analyzer Gp, be sure to read and understand the tool operating manual before operating.

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Illustration 12	g03346582
(16) 220-8607 Fitting (17) 188-0639 Hose As (18) 210-5530 Quick Connect Coupler (19) S·O·S Valve

1. Attach the fabricated particle counter "low pressure in" suction tube (17) to the S·O·S valve (19) on the filter cart. Refer to Illustration 12.

   Note: The fabricated suction tube (17) can be made with the parts listed in Table 3 under the "Optional Tools" and as shown in Illustration 12.

2. Attach the other end of the fabricated suction tube (17) to the "low pressure in" port on the portable particle counter, as called for in the Tool Operating Manual.

Bottle Sample Procedure

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Illustration 13	g01272796
(19) S·O·S Valve (20) 169-8373 Bottle Group

1. If collecting a bottle sample, use the same S·O·S valve (19) and a 169-8373 Bottle Group (20). Refer to Illustration 13.

2. Record an oil sample reading from the S·O·S valve (19) on the filter cart at the beginning of the filter cycle.
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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.

3. During the filter cart operation, start the machine and cycle the boom and the stick circuit at least four times every half hour of operation. This procedure will cycle the clean tank oil into the hydraulic system and flush the more contaminated oil back into the tank.

   Note: Changing the hydraulic system filter halfway 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, the housing then becomes an inlet for contamination. The new filters can remain in place until the next scheduled filter change.

   Note: Only replace the machine filters if scheduled to be replaced, or are not working at optimal performance.

4. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an acceptable ISO code level of 18/15 or cleaner. Take a final oil sample and record the final ISO level before the machine is returned to the field.

   Note: Refer to "188-3242188-3242Oil Compartment Times for 188-3242 Filter Cart" at the end of this document when a portable particle analyzer is not available.

5. When the target ISO level or the time interval has been met, close the air supply valve (14) and disconnect the air supply hose (15). Refer to Illustration 10.
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   Personal injury can result from hot oil or hot components. At operating temperature, oil is hot and under pressure. Hot oil can cause burns. Remove the fill cap only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand. Do not allow hot oil or components to contact skin.

6. Disconnect the filter cart suction line (12) from the suction pipe (6). Refer to Illustration 8.

7. Disconnect the filter cart return line (13) from the nipple (8). Refer to Illustration 9.

8. Remove the plug adapter (5). Refer to Illustration 5.

9. Install the filler plug (3) to the top of the tank. Refer to Illustration 4.

10. Remove the nipple (8), the elbow (7), and the pipe (9). Refer to Illustration 7.
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    Illustration 14	g03346584
    (10) 9X-2101 Elbow (21) 9S-4181 Plug

11. Install the 9S-4181 Plug (21) into the elbow (10). Refer to Illustration 14.

12. Install protective caps to the adapters, the filter cart suction line, and the filter cart return line to control contamination.

13. Close the access cover (1) above the hydraulic tank. Refer to Illustration 3.

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

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

188-3242188-3242Oil Compartment 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 level, refer to the following equation. This equation relates to the 188-3242 Filter Cart and the 194-2897 Filter Carts only. Other filtration units will have different equation references. These units will be noted when appropriate.

Illustration 15	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 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). This action 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 M315 wheeled excavator hydraulic tank has 196.8 L (52 US gal) of HYDO oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 45.5 minutes or 0.75 hours.

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 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 the particle count cleanliness. Proper care should be taken during the sample procurement to 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.