- Backhoe Loader: All
- Integrated Toolcarrier: All
Introduction
Revision     | Summary of changes in SEBF8800     |
03     | Changes to references table listed below. Removed PEVN4831 video canceled. Added SEBF8726. PEGJ5025 canceled replaced by PEGJ0045. PEHP6001 canceled replaced by PEGJ0047. Updated Introduction. Added Canceled Replaced Part Numbers statement.     |
© 2012 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.
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 questions or additional information concerning this guideline, submit a feedback form in the Service Information System web site. To address an urgent need, use the following to forward your request to Caterpillar Repair Process Engineering:
- Cat Dealer Technical Communicator
- Global Dealer Solution Network
- Cat Technical Representative
- Knowledge Network
If a Contamination Control Guideline is required, but not available in SIS Web, submit feedback in the Service Information System website.
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. This guideline provides directions for you to install and operate 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 18/15 or cleaner.
NOTICE |
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If the machine is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this kidney loop 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 and controls. Additional 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
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 of 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
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 |
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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     |
NEHS0633     | Procedure for using 9U-5971 and 173-9842 Filter Cart Group     |
SEBF8726     | Procedure for Filtration of Hydraulic Oil in Compact Equipment     |
PEGJ0045     | Reporting Particle Count by ISO Code     |
SEBF8482     | Obtaining an Oil Sample for S·O·S Analysis     |
PEGJ0047     | How To Obtain A Good SOS Sample     |
NEHS0799     | Tool Operating Manual for S40 Portable Particle Analyzer     |
NEHS0778     | 188-3242 Filter Cart     |
SEBF8726     | Procedure for Kidney Looping Compact Equipment Hydraulic Oil     |
SEBF8757     | Procedure for "Off-Board" Filtering 307 - 285B Excavator Hydraulic Oil with Auxiliary Hydraulic Lines     |
Tooling and Equipment
Required Tools     | ||
Quantity     | Part Number     | Parts Description     |
1 1     |
9U-5968 Or 173-9842 Or 225-4113     |
Filter As - Hydrostatic Filter Cart Filter Cart     |
2     | 2S-4078     | O-Ring Seal     |
2     | 4S-6797     | Connector     |
2     | 8S-3918     | Stem     |
2     | 3S-7252     | Sleeve     |
All Backhoe Loader Models     | ||
2     | 6V-9973     | Permanent Coupling As     |
2     | 6V-8734     | Union     |
3 m (10 ft)     | 165-0021     | Hose     |
Use with Quick Disconnects     | ||
2     | 6V-9973     | Permanent Coupling As     |
3 m (10 ft)     |
165-0021     | Hose     |
1     | 106-0401     | Quick Disconnect Coupler     |
1     | 106-0406     | Quick Disconnect Coupler     |
2     | 8T-8898     | Connector     |
Integrated Toolcarrier IT12     |
||
2     | 6V-4666     | Coupling As     |
2     | 9S-7739     | Flared Union     |
3 m (10 ft)     |
165-0020     | Hose     |
IT14G     | ||
2     | 6V-9945     | Collet Stem     |
2     | 6V-8730     | Union     |
3 m (10 ft)     |
165-0017     | Hose     |
IT24F, IT28F, IT28G     | ||
2     | 6V-9949     | Coupling As     |
2     | 6V-8731     | Union     |
3 m (10 ft)     |
165-0017     | Hose     |
IT28B, IT38F, IT38G     | ||
2     | 6V-9953     | Collet Stem     |
2     | 6V-8873     | Union     |
3 m (10 ft)     |
165-0020     | Hose     |
IT62G     | ||
2     | 6V-9957     | Coupling As     |
2     | 6V-8734     | Union     |
3 m (10 ft)     |
165-0021     | Hose     |
Option Tools     | |
Part Number     | Part Description     |
170-8500     | S40 Portable Particle Analyzer     |
210-5530     | Quick Connect Coupler     |
188-0639     | Hose As     |
Note: The 9U-5968 Filter Assembly or the 173-9842 Filter Cart can be used in this guideline. Both units have a 321 L/min (85 US gpm) maximum flow. Both units have a working pressure of 41368 kPa (6000 psi).
System "Off-Board" Filtration Procedure
There are three possible filtering scenarios to consider before starting this procedure.
- Filtering machine hydraulics only. No work tools in the system.
- Filtering machine hydraulics with work tools that have hydraulic cylinders.
- Filtering machine hydraulics with work tools that have single direction oil flow.
This procedure is intended to filter the work tool first. Then, the procedure requires filtration of the hydraulic tank and auxiliary lines.
This guideline is intended for Backhoe Loaders and Integrated Toolcarriers. The procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and mixed from operation. Warming the oil allows any contamination in the system oil to be placed in suspension. Warming the oil also lowers the viscosity of the oil. Be sure to read and understand the Tool Operating Manual, NEHS0778, "188-3242 Filter Cart" before you begin the procedure.
Illustration 2 | g01294451 |
Typical filtration procedure shown on a 430D |
Note: The 9U-5968 Hydrostatic Filter Group is a full bridge check valve unit. The filter group will allow oil to flow in or out either hose port. The filter group will only pass oil one direction through the filter. See Illustration 3.
Illustration 3 | g01294446 |
Schematic for the 9U-5968 Hydrostatic Filter Group |
Assembling the "Off-Board" Filtering Adapters
Illustration 4 | g01294448 |
9U-5968 Filter Assembly |
Illustration 5 | g01294452 |
(1) 9U-5968 Hydrostatic Filter Group (2) 2S-4078 O-Ring Seal (3) 4S-6797 Connector (4) 8S-3918 Stem (5) 3S-7252 Sleeve (6) 165-0021 Hose - 5 feet each |
- Assemble the filter adapter assembly first.
- Assemble the machine adapter assembly next.
Illustration 6 | g01294454 |
(7) 6V-9973 Permanent Coupling As (8) 8T-8898 Connector |
"Off-Board" Filtration Setup
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.
Note: Do not deadhead or stall the cylinders or the work tools. Stalling either one may cause air to be ingested into the oil.
- Park the machine on level ground.
- Lower the attachment to the ground. Apply slight downward pressure to the attachment.
- Take an oil sample.
Note: Caterpillar recommends taking a particle count before starting the kidney loop procedure. Use the sample as a baseline particle count.
- Turn OFF the engine.
- Turn the engine start key to the ON position. Move all implement functions to relieve system pressure.
Filtering Machine Hydraulics Only
Note: The following steps are intended for machine hydraulic systems with no work tools.
- Disconnect the attachment hose (10) from the quick disconnect (11). Connect the attachment hose to one filter unit on the filter cart.
Illustration 7 | g01294455 |
(10) Attachment hose (11) Quick disconnect |
- Repeat Step 1 for the opposite side of the machine.
- Start the engine.
- Set the machine to "Hammer Mode" if the machine has this mode.
- Activate the auxiliary hydraulics to start the filtration process.
Illustration 8 | g01294457 |
Hydraulic Hammer Pedal |
Oil Analysis Procedure
Note: Caterpillar recommends taking a particle count on the oil at the beginning of the filter cycle to be 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.
Portable Particle Analyzer Procedure
Note: When using the portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual before operating.
- Attach the fabricated particle counter suction tube (15) to the S·O·S valve (12) on the machine.
Note: The fabricated suction tube can be made with the parts listed in Table 4 and as shown in Illustration 9.
Illustration 9 | g01294458 |
Typical S·O·S port connection (12) S·O·S valve (13) 210-5530 Quick Connect Coupler (14) 220-8607 Fitting (15) Fabricated suction tube |
- 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.
Bottle Sample Procedure
- If you collect a bottle sample, use the same S·O·S valve (12) and a 169-8373 Fluid Sampling Bottle (16) .
Illustration 10 | g01294459 |
Typical S·O·S port connection on a machine (12) S·O·S valve (16) 169-8373 Fluid Sampling Bottle |
- Record an oil sample reading from the S·O·S valve (12) on the machine at the beginning and at the end of the filter cycle.
- At the halfway point of filtration, stop the procedure and change the machine hydraulic oil filters. Changing the filters allows the filters to assist in the system cleaning. The new filters can remain in place until the next scheduled filter change. Changing the filters at this time avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.
Note: Replace the machine filters only if the filters are not working at optimal performance, or scheduled to be changed.
- Cycle the oil until the portable particle analyzer indicates the oil has reached an acceptable contaminant level of ISO 18/15 or cleaner.
Note: A target ISO level does not exist for nonpressurized, non-filtered compartments at this time. ISO 18/15 is an acceptable contamination level for oil returned back into this type of compartment.
- When the target ISO level or the time interval has been met, turn OFF the machine.
- Disconnect the attachment hose (10) from the filter unit on the filter cart.
- Reconnect the attachment hose (10) to the machine coupling (11) .
- Check the hydraulic tank oil level before you return the machine to service.
Oil Compartment Filtration Times
Cycle Times for Backhoe Loader Models     | |
Model     | Minutes for Filtration     |
All Backhoe Loader models     | 11 minutes     |
Cycle Times for Integrated Toolcarrier Models     | |
Model     | Minutes for Filtration     |
IT12, IT14G, IT24F     | 13 minutes     |
IT38F, IT38G, IT62G     | 19 minutes     |
IT28F, IT28G     | 29 minutes     |
Filtering Work Tools with Hydraulic Cylinders
- Disconnect the attachment hose (17) from the coupling (18). Attach the hose (17) to one filter unit on the filter cart.
Illustration 11 | g01294461 |
(17) Hose (18) Coupling |
- Repeat Step 1 for the opposite side of the stick. Ensure that the hoses are on opposite filters. Refer to Illustration 12.
Note: If both attachment hoses from the stick are on the same filter, the work tool will not be filtered. Only the machine hydraulics will be filters.
Note: The hoses referred to in Steps 1 and 2 identified in Table 3, will be required to connect the attachment hoses to the filter cart.
- Connect a second hose from the filter cart to the coupling (18) .
- Repeat Step 3 for the opposite side of the stick. Ensure that the hoses are on opposite filters.
Note: The hoses referred to in Steps 3 and 4 will need to be identified for each machine. Ensure that the fabricated hoses are pressure rated for the system being filtered.
- Start the engine.
Illustration 12 | g01294462 |
173-9842 Filter Cart Assembly |
- Raise the work tool off the ground.
- Cycle the cylinders in and out 20 to 30 times to flush contaminates out of the cylinders and lines.
- Put the hydraulics in the HOLD position and stop the engine.
- Move all implement functions to relieve system pressure.
- Disconnect the set of lines from the second filter on the filter cart to the stick cylinder and work tool. Cap or plug the open line to the work tool.
- Disconnect the lines from the first filter to the work tool. Cap or plug the open line to the work tool.
- Refer to ""Filtering Machine Hydraulics Only" " in the front of this document to complete the rest of the filtration procedure.
Filtering Work Tools with Single-Direction Oil Flow
- Disconnect the attachment hose (19) from the coupling (20). Attach the hose (19) to one filter unit on the filter cart.
Illustration 13 | g01294463 |
(19) Hose (20) Coupling |
Note: When filtering hammers with this guideline, the guideline refers to Caterpillar "Oil Fired" hammers only.
- Repeat Step 1 for the opposite side of the stick. Ensure that the hoses are on opposite filters.
Note: If both hoses from the stick are on the same filter, the work tool will not be filtered. Only the machine hydraulics will be filtered.
Note: The hoses referred to in Steps 1 and 2 identified in Table 3 will be required to connect the attachment hoses to the filter cart.
- Connect a second hose from the filter cart to the coupling (20) .
- Repeat Step 3 for the opposite side of the stick. Ensure that the hoses are on opposite filters.
Note: The hoses referred to in Steps 3 and 4 will need to be identified for each machine. Ensure that the fabricated hoses are pressure-rated for the system being filtered.
- Start the engine.
Illustration 14 | g01294464 |
173-9842 Filter Cart Assembly |
- Raise the work tool off the ground.
- Set the machine to "Hammer Mode", if the machine has this mode.
- Activate the auxiliary hydraulics to start the filtration process.
Illustration 15 | g01294466 |
Hydraulic Hammer Pedal |
- Cycle the oil for 3 to 4 minutes to flush contaminates out of the work tool and out of the hydraulic lines.
- Put the hydraulics in the HOLD position and stop the engine.
- Move all implement functions to relieve system pressures.
- Disconnect the set of lines from the second filters on the filter cart to the stick cylinder and the work tool. Cap or plug the open line to the work tool.
- Disconnect the lines from the first filter to the work tool. Cap or plug the open line to the work tool.
- Refer to ""Filtering Machine Hydraulics Only" " in the front of this document to complete the rest of the filtration procedure.
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 cross sectional area of the particle. Particle counts are affected by various factors. These factors include: procurement of the sample, the sample container, particle counting accuracy used, 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. 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 or larger than 14 microns
At this time 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.