Filtration Procedure for Wheel Tractor-Scraper Hydraulic Oil {0680, 0768, 5050, 5056} Caterpillar

Wheel Tractor-Scraper

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Introduction

© 2016 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 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:

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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 filler cap. This guideline provides directions 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.

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 to be used, ensure the safety for all personnel around the machine. Ensure that the product will not be damaged or the product will not 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 starting 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

Machine Filtration Procedure

The following procedure is for all models of Wheel Tractor Scrapers. The procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and mixed from operation. The warm oil allows any contamination in the system oil to be placed in suspension and lowers the viscosity of the oil. Be sure to read and understand the Tool Operating Manual, NEHS0778, "188-3242 Hydraulic Filter Cart", before operating the filter cart.

Filter Procedure

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

1. Park the machine on level ground.

2. Lower all the hydraulic implements to the ground. Be sure to engage the parking brake.

3. With the engine OFF and the ignition turned ON, relieve all system pressure. System pressure is relieved by moving all the hydraulic control valves through the complete range of motion.
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   Illustration 3	g01298894
   (1) Filler Cap

4. Clean the area around the hydraulic tank filler cap (1). Refer to Illustration 3.

5. Slowly loosen the filler cap (1) on the hydraulic tank. Relieve the pressure in the hydraulic tank. Make sure that all air pressure has been vented before removing the cap completely.

6. Remove the lock-ring from the hydraulic tank filler cap. Remove the strainer from the hydraulic filler neck.

7. Store the cap and the strainer in a clean location to avoid contamination and damage.
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   Illustration 4	g01298897
   (X) Proper length of suction hose (Y) Distance from the top of the filler neck to the bottom of the hydraulic tank (Z) 50.8 mm (2 inch) inch fill cap adapter (Z) 101.6 mm (4 inch) inch fill cap adapter

8. Measure the distance from the top of the hydraulic filler neck to the bottom of the hydraulic tank (Y). Subtract (Z) from (Y). Subtract an additional 25.4 mm (1 inch) to obtain the proper hose length (X). Refer to Illustration 4.

9. Cut a length of suitable hose matching the (X) measured distance of the tank depth. Install the hose on the fill cap adapter hose barb.
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   Illustration 5	g01298900
   (2) Fill cap adapter

10. Install the fill cap adapter (2). Refer to Illustration 5.

    Note: When obstructions exist, the side return port can be removed for clearance and reinstalled after the main fill cap adapter is installed. Be sure that the installed suction hose reaches within 25.4 mm (1 inch) from the bottom of the hydraulic tank.

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    Illustration 6	g01298901
    (3) Side return port fitting

11. Install the side return port fitting (3). There are multiple ports on the fill cap adapter. The ports will aid in the connection and the orientation of the filter cart lines. Refer to Illustration 6.
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    Illustration 7	g01298902
    (4) Suction line (5) Center suction port

12. Connect the filter cart suction hose (4) to the fill cap adapter center suction port (5). Refer to Illustration 7.
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    Illustration 8	g01298903
    (6) Return line (7) Side return port

13. Connect the filter cart return hose (6) to the fill cap adapter side return port (7). Refer to Illustration 8.
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    Illustration 9	g01298904
    (8) Air supply hose (9) Air supply valve

14. Attach the air supply hose (8) to the 188-4242 Filter Cart. Ensure that the air supply valve (9) 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	g01298905
    Air supply valve in the OPEN position. (9) Air supply valve

15. Slowly open the air supply valve (9) 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).

16. While operating the filter cart, check the filter element indicators on the filter cart. The indicator will show 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. If the cavitation continues for more than 1 minute, shut the filter cart OFF and check the connections.

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

    Note: A particle count should be taken on the oil at the beginning of the filter cart cycle for use as a baseline particle count.

18. The oil can be particle count tested for cleanliness in one of the two following ways.

    1. Use a portable particle analyzer for immediate results.

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

Portable Particle Analyzer Procedure

If using the portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual, before operating the filter cart.

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Illustration 11	g03413128
(10) S·O·S valve (11) 210-5530 Coupler (12) 220-8607 Fitting (13) Fabricated suction tube

1. Attach the fabricated particle counter "low pressure in" suction tube (13) to the S·O·S valve (10) on the filter cart. Refer to Illustration 11.

   Note: The fabricated suction tube can be made from the parts listed in Table 3 and as shown in Illustration 11.

2. Attach the other end of the fabricated suction tube (13) to the "low pressure in" port on the portable particle analyzer as called for in the Tool Operating Manual.

Bottle Sample Procedure

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Illustration 12	g01298907
(10) S·O·S valve (14) 169-8373 Bottle Group

1. If collecting a bottle sample, use the same S·O·S valve (10) and a 179-8373 Bottle Group (14). Refer to Illustration 12.

2. Record an oil sample reading from the S·O·S valve (10) on the filter cart at the beginning of the filter cycle.

3. During the filter cart operation, cycle the hydraulic cylinders at least four times each half hour. Do not cycle the steering cylinders. This process will cycle the clean tank oil into the hydraulic system and flush the more contaminated oil back into the tank.
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   Illustration 13	g01298909
   Filter cart operation on a 627F (15) 188-3242 Hydraulic Filter Cart

4. At the halfway point of filtration, stop the procedure and change the filters on the machine.

   Note: Changing the filters will assist in the system cleaning. The new filters 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.

   Note: The machine filters are to be changed at the regularly scheduled interval, or if the filters are not operating at optimal performance.

5. Operate the filter cart (15) 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.

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

6. When the target ISO level or the time interval has been met, close the air supply valve (9) and disconnect the air supply hose (8). Refer to Illustration 9.

7. Disconnect the filter cart return hose (6) from the fill cap adapter return port (7). Refer to Illustration 8.

8. Disconnect the filter cart suction hose (4) from the fill cap adapter center suction port (5). Refer to Illustration 7.

9. Remove the fill cap adapter (2). Refer to Illustration 5.

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

11. Install the strainer and install the lock-ring into the hydraulic tank filler neck.

12. Install the hydraulic oil tank filler cap (1). Refer to Illustration 3.

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

Oil Compartment Filtration Times for 188-3242 Filter Cart

If an on-line, portable particle counter is not available to measure 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 and these units will be noted when appropriate.

Illustration 14	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 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 651E wheel tractor scraper hydraulic tank has 302 L (80 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 70 minutes.

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, and the particle count cleanliness. Proper care should be taken during the sample procurement process. 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 or larger than 14 microns

Atthis 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.