- Backhoe Loader
- 414E (S/N: TMS1-UP)
- 415F2 (S/N: HWA1-UP)
- 415F2 IL (S/N: PF41-UP)
- 416D (S/N: BKG1-UP; BGJ1-UP; BFP1-UP; CXP1-UP)
- 416E (S/N: SHA1-UP; C8B1-UP; BWC1-UP; CBD1-UP; MFG1-UP)
- 416F (S/N: KSF1-UP; LWT1-UP)
- 416F2 (S/N: LYA1-UP; HWB1-UP; LBF1-UP)
- 420D (S/N: BKC1-UP; BMC1-UP; MBH1-UP; BLN1-UP; FDP1-UP)
- 420E (S/N: PRA1-UP; PHC1-UP; HLS1-UP; KMW1-UP)
- 420F (S/N: LTG1-UP; LKH1-UP; JWJ1-UP; SKR1-UP)
- 420F2 (S/N: LBS1-UP)
- 420F2 IT (S/N: LYC1-UP; HWD1-UP)
- 420F2 ST (S/N: LYB1-UP; HWC1-UP)
- 422E (S/N: HBE1-UP; DSK1-UP; MAW1-UP)
- 422F (S/N: LRH1-UP)
- 422F2 (S/N: LYF1-UP)
- 424B (S/N: JRN1-UP)
- 424B HD (S/N: JRY1-UP)
- 424B2 (S/N: JTH1-UP)
- 424D (S/N: RXA1-UP; BGP1-UP; BKR1-UP; CJZ1-UP)
- 426 F2 (S/N: EJ21-UP; DJ41-UP; EJ41-UP)
- 427F2 (S/N: HWK1-UP)
- 428D (S/N: BNB1-UP; BXC1-UP; BLL1-UP; BNS1-UP; BMT1-UP; DSX1-UP)
- 428E (S/N: DXC1-UP; DPH1-UP; SNL1-UP)
- 428F (S/N: LBH1-UP; RAK1-UP; SJW1-UP)
- 428F2 (S/N: LYG1-UP; HWN1-UP)
- 430D (S/N: BML1-UP)
- 430D AWS (S/N: BNK1-UP)
- 430E (S/N: SCD1-UP; RLN1-UP; DDT1-UP; EAT1-UP)
- 430F (S/N: RDF1-UP; LNH1-UP; RGS1-UP; LDY1-UP)
- 430F2 IT (S/N: LYE1-UP; HWG1-UP)
- 430F2 ST (S/N: LYD1-UP; HWE1-UP)
- 432D (S/N: BLD1-UP; WEP1-UP; TDR1-UP)
- 432E (S/N: JBA1-UP; BXE1-UP; RXS1-UP)
- 432F (S/N: SEJ1-UP; LNR1-UP; PXR1-UP)
- 432F2 (S/N: LYJ1-UP; HWP1-UP)
- 434E (S/N: SXB1-UP; SEF1-UP; FSH1-UP; SJL1-UP)
- 434F (S/N: LDH1-UP; MTR1-UP; FLY1-UP)
- 434F2 (S/N: LYK1-UP; HWR1-UP)
- 438D (S/N: BPE1-UP; BPN1-UP)
- 442D (S/N: TBD1-UP; BRG1-UP; SMJ1-UP; BRY1-UP)
- 442E (S/N: EME1-UP; PCR1-UP; GKZ1-UP)
- 444E (S/N: NBA1-UP; HXB1-UP; LBE1-UP)
- 444F (S/N: LJJ1-UP; FBN1-UP; JXR1-UP)
- 444F2 (S/N: LYL1-UP; HWS1-UP)
- 450E (S/N: EBL1-UP; LYR1-UP)
- 450F (S/N: HJR1-UP)
- 415F2 (S/N: HWA1-UP)
Introduction
Revision | Summary of Changes in SEBF8780 |
23 | Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2017. |
22 | Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2016. Removed old point of contacts. New point of contact added. |
21 | Added new serial number prefixes for New Product Introduction. |
20 | Added new serial number prefixes for New Product Introduction.
Updated copyright date to 2015. |
19 | Added new serial number prefixes for New Product 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. 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 (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 connects to the hydraulic oil drain and hydraulic oil filler neck. This guideline provides directions for you to install and operate the filtration 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 16/13 or cleaner.
NOTICE |
---|
If the machine is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this filter cart filtration 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. Extra component cleaning and component exchange and lines flushing will be required to remove most contaminates generated from the failure. The machine system cleaning must be performed prior to the kidney looping. 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 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 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, 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. Caterpillar dealers have the most current information that is available.
Safety
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. |
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. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
References
References | |
Media Number | Title |
NEHS0799 | " 170-8500 Analyzer Group" |
NEHS0848 | " 204-7392 Filter Cart (Air Motor Driven)" |
NENG2500 | "Dealer Service Tool Catalog" |
PEGJ0045 | "Reporting Particle Count by ISO Code" |
PEGJ0047 | "How To Obtain A Good Oil Sample" |
SEBF8482 | "Obtaining an Oil Sample for Analysis" |
Tooling and Equipment
Required Tools | |
Part Number | Parts Description |
Filter Cart Gp | |
Pipe Elbow (1) | |
Street Elbow (2) | |
Coupler | |
Dust Cap | |
Pipe Nipple | |
Permanent Coupling | |
Reducer Bushing | |
Hose Clamp | |
Hydraulic Hose | |
Fabricated Return Oil Adapter Assembly | |
Fabricated Suction Adapter Assembly | |
Optional Tools | |
Part Number | Parts Description |
S40 Portable Particle Analyzer | |
Fluid Sampling Bottle | |
Quick Connect Coupler | |
Hose As | |
Fitting(3) |
(1) | Used for the "D" series backhoe loader. |
(2) | Used for the "F" series backhoe loader. |
(3) | For the low-pressure suction tube fabrication |
Illustration 3 | g03549660 |
Return oil adapter assembly for "D" and "F"series machines. (1) (2) (3) (4) (4) (5) Dealer fabricated adapter |
Illustration 4 | g01294184 |
"D" series fabricated adapter. Use (A) (B) (C) (D) (E) (F) 15° (G) 1 inch NPTF 11 1/2 threads per inch (H) Drill bit size |
Illustration 5 | g01294184 |
"F" series fabricated adapter. Use (A) (B) (C) (D) (E) (F) 15° (G) 3/4 inch NPTF 14 threads per inch (H) Drill bit size |
Illustration 6 | g03549676 |
Fabricated drain hose assembly for "D" and "F" series machines. (6) (7) (8) (9) |
Machine Filtration Procedure
This guideline is intended for Backhoe Loaders. The procedure is most effective when performed immediately after the oil has been warmed to
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. |
- Operate the machine to warm the oil.
- Park the machine on level ground.
- Apply the service brake to stop the machine.
- Move the direction control switch or move the transmission control lever to the NEUTRAL position. Engage the transmission lock if the machine is equipped with a transmission lock.
- Engage the parking brake.
- Lower the attachment to the ground. Apply slight downward pressure.
- Block the wheels.
Filter Cart Procedure
- Pull the hood release lever (11). Remove the access panels or lift the access panels (10).
Show/hide table
Illustration 8 g03549759 (12) Filler cap - Clean the area around the hydraulic tank filler cap (12). Slowly loosen the filler cap on the hydraulic tank. Release the tank pressure. Make sure that all the air pressure has been vented before completely removing the filler cap.
- Remove the lock-ring and remove the strainer from the hydraulic tank filler neck.
- Store the filler cap (12) and the strainer in a clean place to avoid contamination and damage.
Show/hide table
Illustration 9 g03549815 (A) Return oil adapter assembly - Install the return oil adapter assembly (A).
Show/hide table
Illustration 10 g03549899 (13) Original drain hose - Remove the original drain hose (13).
Show/hide table
Illustration 11 g03549916 (B) Fabricated drain hose assembly - Install the fabricated drain hose assembly (B).
Show/hide table
Illustration 12 g03549999 (B) Fabricated drain hose assembly
(14) Suction hose - Connect the filter cart suction hose (14) to the fabricated drain hose assembly (B).
- Turn the valve to the OPEN position.
Show/hide table
Illustration 13 g03550059 (15) Discharge hose
(A) Return oil adapter assembly - Connect the filter cart discharge hose (15) to the return oil adapter assembly (A).
Show/hide table
Illustration 14 g03550118 (16) Air supply valve
(17) Air supply hose - Attach an air supply hose (17) to the 204-7392 Filter Cart Gp. Ensure that the air supply valve (16) is in the CLOSED position. Be sure that the air supply does not exceed
690 kPa (100 psi) . - Slowly open the air supply valve (16) to start the filter cart pump operation. The pump is a gear pump. The gear pump is rated to pump 10W oil at
64 L/min (17 US gpm) .Show/hide tableIllustration 15 g01294202 Filter cart operation on a 430D - During operation, check the filter element indicators on the filter cart. The filter element indicators will indicate the amount of capacity left in the filter element.
Note: Occasionally, the filter cart pump will cavitate during start-up. The cavitation is due to air in the suction lines of the pump. When the cavitation continues for more than 1 minute, shut the filter cart OFF and inspect the connections.
- Ensure that there are no oil leaks from any of the filter cart 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 used as a baseline particle count.
- The oil can 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 an S·O·S lab. Refer to Contamination Control Guideline, SEBF8482, "Obtaining Oil Sample for Analysis" for more information.
Illustration 7 | g03549741 |
(10) Access panel
(11) Release Lever |
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.
- Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (21) on the filter cart.
Note: The fabricated suction tube can be made with the parts listed in Table 3 and as shown in Illustration 16.
- Attach the other end of the fabricated suction tube to the "low pressure in" port on the portable particle counter as called for in the Tool Operating Manual.
Illustration 16 | g03550135 |
(18) Hose assembly
(19) Fitting (20) Quick disconnect coupler (21) S·O·S valve |
Bottle Sample Procedure
- If collecting a bottle sample, use the same S·O·S valve (21) and a 169-8373 Fluid Sampling Bottle (22).
- Record an oil sample from the S·O·S valve (21) on the filter cart at the beginning of the filter cycle.
- During the filter cart procedure the engine must be run at LOW idle with the parking brake engaged. Running the engine will circulate the oil in the hydraulic system. Running the engine will also flush the more contaminated oil back into the hydraulic tank.
Note: Changing the machine hydraulic oil filters halfway through the filter process avoids opening the housing after the system has been cleaned. If the filter housing is opened after the filtration process is complete, the housing becomes an inlet for contamination. The new filters can remain in place until the next scheduled filter change.
- Operate the filter cart until the portable particle analyzer indicates that the oil has reached an ISO level of at least 16/13. The final ISO level should be recorded before the machine is returned to the field.
- During the filter cart operation, cycle the lift cylinders at least four times every half an hour during the filter 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.
Note: The filter cart procedure can be performed while running the engine.
- At the halfway point of filtration, stop the procedure and change the machine filters.
Note: Refer to "Oil Compartment Filtration Times for 204-7392 Filter Cart", at the end of this document, when a portable particle analyzer is not available.
- When the target ISO level or the time interval has been met, close the air supply valve (16) and disconnect the air supply hose (17). Refer to illustration 14.
- Disconnect the filter cart discharge hose (15) from the return oil adapter assembly (A). Install the dust caps on the coupler and on the nipple. Store the coupler and store the nipple in a clean location. Refer to illustration 13.
- Disconnect the filter cart suction hose (14) from the fabricated drain hose assembly (B). Install the dust caps on the coupler and on the nipple. Store the nipple and store the coupler in a clean location. Refer to illustration 12.
- Reinstall the original drain hose (13). Refer to illustration 10.
- Remove the return oil adapter assembly (A). Refer to illustration 9.
- Install the strainer and install the lock-ring in the hydraulic fill neck.
- Install a clean filler cap (12) and lower or replace the cover (10) on the machine. Refer to illustrations 7 and 8.
- Check the hydraulic tank oil level.
- Unblock the wheels.
Illustration 17 | g03550216 |
(21) S·O·S valve
(22) Fluid sampling bottle |
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 have a different equation reference. Units that use a different equation reference will be noted when appropriate. There are various conditions that must be factored into the filtration efficiency of any filter cart and situation. The following equation must be viewed only as a simple reference and not as an absolute time or efficiency result.
Illustration 18 | g01177339 |
Oil compartment filtration equation (A) Compartment oil capacity (gal) (B) Pulses per minute (C) Approximate filtration time (min) |
Example
A 563 Vibratory Compactor has
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 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 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.