Filtration Procedure for Large Wheel Loader and Landfill Compactor Hydraulic Oil {0680, 0768, 5050, 5056} Caterpillar

Landfill Compactor

816K (S/N: WNB1-UP; WCL1-UP)

826H (S/N: AWF1-UP)

836 (S/N: 7FR1-UP)

836G (S/N: BRL1-UP; 7MZ1-UP)

836H (S/N: BXD1-UP)

836K (S/N: T6X1-UP; L6Z1-UP; LWZ1-UP; TWZ1-UP)

Soil Compactor

815K (S/N: MBB1-UP; WCS1-UP)

825H (S/N: AZW1-UP)

Wheel Dozer

814K (S/N: DMB1-UP; WCM1-UP)

834H (S/N: BTX1-UP)

834K (S/N: TW41-UP; L4Y1-UP; LWY1-UP; TWY1-UP)

844H (S/N: BTW1-UP)

844K (S/N: MBE1-UP; M4R1-UP; KLS1-UP; K4Y1-UP)

854G (S/N: A4W1-UP)

854K (S/N: 2211-UP; KK31-UP; RM31-UP; KK61-UP; RM61-UP; H9K1-UP; H8M1-UP)

Wheel Loader

938K (S/N: SWL1-UP)

986K (S/N: MH81-UP; NL81-UP)

988F (S/N: 8YG1-UP)

988G (S/N: BNH1-UP; 2TW1-UP)

988H (S/N: A7A1-UP; BXY1-UP)

988K (S/N: T8E1-UP; L8X1-UP; LWX1-UP; TWX1-UP)

988K XE (S/N: E8X1-UP; EWX1-UP)

990 (S/N: 7HK1-UP)

990 Series II (S/N: BCR1-UP)

990H (S/N: BWX1-UP)

990K (S/N: DJK1-UP; A9P1-UP; M9P1-UP; K9X1-UP)

992D (S/N: 7MJ1-UP)

992G (S/N: 7HR1-UP; ADZ1-UP)

992K (S/N: 8801-UP; KK21-UP; RM21-UP; KK41-UP; RM51-UP; H4C1-UP; ZMX1-UP)

993K (S/N: LWA1-UP; Z4D1-UP; Z8D1-UP; Z9K1-UP; Z4Z1-UP; Z8Z1-UP)

994 (S/N: 9YF1-UP)

994F (S/N: 4421-UP)

994H (S/N: DWC1-UP)

994K (S/N: MM91-UP; MRK1-UP; SMX1-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 Caterpillar 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 the customers to benefit from cleaner hydraulic systems. The filter cart process is easy to use. The filter cart connects to the hydraulic tank oil filler neck and the hydraulic tank drain. 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.

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 understanding 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 the technician 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 starting 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

K - Series Filtration Adapter Assembly

Illustration 3	g03623596
(1) 3V-7750 Adapter (2) 396-1719 Adapter (A) Weld Location

Weld the 3V-7750 Adapter to the 396-1719 Adapter at location (A). Weld 360° around location (A) to create an air tight weld. Allow adapter to cool prior to installation. Refer to Illustration 3 for adapter orientation.

Large Wheel Loader and Landfill Compactor Hydraulic Oil Filter Cart Procedure

The following procedure is for all models of large Wheel Loaders and Landfill Compactors. 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 hydraulic 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.

Illustration 4	g01299251

Filter Cart Setup

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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. Operate the machine to warm the oil.

2. Park the machine on level ground.

3. Move the direction control switch or the transmission control lever to the NEUTRAL position.

4. Engage the parking brake.

5. Lower the bucket to the ground. Apply slight downward pressure to the bucket.

6. Move the transmission lock lever to the LOCKED position if the machine is equipped.

7. Turn OFF the engine.

8. Connect the steering frame lock.

9. Chock the wheels.

Hydraulic Hose Extension Assembly (If Required)

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Illustration 5	g01299252
(1) 122-6906 Hydraulic Hose (2) 124-1909 Hose Couplings

1. Assemble two fabricated hoses. Use 4.5 m (15 ft) of Hydraulic Hose (1). Use two Hose Couplings (2) to complete one hose. Do the same for the second hose.
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   Illustration 6	g01299253
   (3) Filter cart hose (4) Extension hose (5) 3B-6491 Pipe Coupling

2. A Pipe Coupling (5) can be used to attach the extension hose (4) to the filter cart hose (3).

Filter Cart Setup and Procedure

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Illustration 7	g01299255
(6) Filler cap (7) Access panels

Note: When using the Filter Cart Group, be sure to read and understand the Special Instruction, NEHS0778, "Tool Operating Manual for 188-3242 or 227-2479 Filter Cart Group" before operating.

1. Lift the access panel (7).

2. Clean the area around the hydraulic tank filler cap (6). Slowly loosen the filler cap (6) on the hydraulic tank. Relieve all air pressure. Ensure that all the air pressure has been vented before completely removing the filler cap (6).

3. Remove the retaining ring and the strainer from the hydraulic filler neck.

4. Store the filler cap (6) and store the strainer in a clean place to avoid contamination and damage.
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   Illustration 8	g01299256

5. 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 extra 25.4 mm (1 inch) to obtain the proper hose length (X). Refer to Illustration 8.

6. 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 9	g01299257
   (8) 197-4627 2 1/2 inch Extension Gp or 197-4626 4 inch Extension Gp

7. If the 2 1/2 inch Extension Gp or the 4 inch Extension Gp (8) is needed, install on the filler neck.
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   Illustration 10	g01299258
   (9) 193-5903 Adapter Gp or 193-5900 Adapter Gp

8. Install either the 193-5903 or the 193-5900 Adapter Gp (9). Be sure that the installed suction hose reaches within 25.4 mm (1 inch) of the bottom of the hydraulic tank. If obstructions to the installation exist, the side return port can be removed for clearance and reinstalled after the main fill cap adapter is installed.
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   Illustration 11	g01299259
   (10) 3H-9690 Elbow

   Note: The Elbow (10) may be required on some models to gain added clearance. The addition of the elbow fittings will also aid in the necessary orientation of the center suction port, as seen in Illustration 11.

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   Illustration 12	g01299260
   (11) Fill cap adapter center suction port (12) Filter cart suction hose

9. Connect the filter cart suction hose (12) to the fill cap adapter center suction port (11).
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   Illustration 13	g01299263
   (13) Fill cap adapter side discharge port (14) Filter cart discharge hose

10. Connect the filter cart discharge hose (14) to the fill cap adapter side discharge port (13).
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    Illustration 14	g01299264

11. Attach the air supply hose (16) to the 188-3242 Filter Cart Gp. Ensure that the air supply valve (15) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi).
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    Illustration 15	g03640279

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

13. While operating the filter cart, check the filter element indicators on the filter cart. The filter element indicators will determine 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.

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

    Note: Caterpillar recommends taking a particle count at the beginning of the filter cart cycle for use as a baseline particle count.

15. 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 Analyzer Procedure

Note: When using the Analyzer Gp. for particle counting, be sure to read and understand the Special Instruction, NEHS0799, "Tool Operating Manual for 175-8500 Analyzer Gp." before operating the Analyzer Gp.

Illustration 16	g01299266
(17) S·O·S valve (18) 210-5530 Quick Connect Coupler (19) Fabricated suction tube

1. Attach a Quick Connect Coupler (18) and the fabricated suction tube (19) to the S·O·S valve (17) on the filter cart.

2. Attach the other end of the fabricated suction tube (19) to the Analyzer Gp. as called for in the Tool Operating Manual.

Bottle Sample Procedure

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Illustration 17	g01299267
(17) S·O·S valve (20) 169-8373 Fluid Sampling Bottle

1. If collecting a bottle sample, use the same S·O·S valve (17) and a Fluid Sampling Bottle (20). Refer to Contamination Control Guideline, SEBF8482, "Obtaining Oil Sample for Analysis" for more information.

2. Record an oil sample from the S·O·S valve (17) on the filter cart at the beginning of the filter cycle.

3. During filter cart operation, start the machine and cycle the bucket and lift arms circuit every half an hour. If the cylinders lines have been opened prior to filter cart operation, slowly cycle the cylinders between 25 and 75 percent four times to prevent dieseling before cylinders are cycled to the end of the stroke. This procedure will cycle the clean tank oil into the system and flush the more contaminated oil back into the tank. The oil filtration can be performed while cycling the machine. Turn OFF the engine.

   Note: Changing the filters half way through the filtration process allows the filters to help with 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.

4. Operate the filter cart until the Analyzer Gp. indicates that the oil has reached an ISO level of at least 18/15. 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 Gp", at the end of this document when an Analyzer Gp. is not available.

5. When the target ISO level or the time interval has been met, close the air supply valve (16) and disconnect the air supply hose (15). Refer to Illustration 14.

Filter Cart Removal

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Illustration 18	g01299268

1. To relieve possible tank pressure, use a probe from the 169-8373 Fluid Sampling Bottle (20). Relieve the tank pressure through the fill cap adapter S·O·S valve.
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   Illustration 19	g01299270

2. Disconnect the filter cart suction (12) and discharge hose (14) from the fill cap adapter. Install the dust caps on the couplers and on the nipples.

3. Remove the fill cap adapter and extension. Store the filtering adapters in a clean location.

4. Install the strainer, the retaining ring, and a clean filler cap to the hydraulic tank filler neck.
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   Illustration 20	g01299269

5. Check the hydraulic tank oil level.

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

7. Remove the chocks from the wheels.

8. Disconnect the steering frame lock and return the machine to service.

K - Series Filter Cart Procedure for Wheel Loader hydraulic Oil

Note: This procedure is for Wheel Loaders that contain the 352-5360 Hydraulic Tank and Mounting Gp.

Illustration 21	g01176237
(1) Access Cover

1. Remove the bolts that hold the access cover (1) in place. The access cover is located above the hydraulic tank. Remove the access cover. Refer to Illustration 21.
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   Illustration 22	g03621499
   (2) 352-5360 Hydraulic Tank and Mounting Gp (3) 395-4204 Breather Gp (4) 363-1242 Tank Filler Cap

2. Loosen the Tank Filler Cap (4) partially to relieve system pressure stored in the hydraulic tank. Clean the area around the Breather Gp (3). Remove the Breather Gp (3) from the hydraulic tank. Store the Breather Gp in a clean place to avoid contamination. Refer to Illustration 22.

3. Install K - Series adapter assembly on to the hydraulic tank where the Breather Gp (3) was installed.
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   Illustration 23	g03354816
   (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 = 50.8 mm (Z) 4 inch filler cap adapter = 101.6 mm

4. Measure the distance from the top of the hydraulic filler neck to the bottom of the hydraulic tank (Y). Subtract (Z) from (Y) to obtain the proper hose length (X). Refer to Illustration 23.

5. Cut a length of 122-6906 Hydraulic Suction Hose (844) that matches (X) measured distance of tank depth. Install the hose on to the filler cap adapter hose barb.
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   Illustration 24	g03624236
   (5) 193-5903 2 in Fill Cap Adapter Gp.

6. Install the 193-5903 2 in Fill Cap Adapter Gp. (5) on to the K - Series adapter assembly . Refer to Illustration 24.
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   Illustration 25	g03624299
   (6) Side discharge port with elbow fitting

   Note: The elbow fitting (6) 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 return port. The elbow fitting (6) is pictured in Illustration 25 on the side return port.

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   Illustration 26	g03624305
   (7) Suction port with elbow fitting (8) Filler cap adapter center suction port (9) Filter cart suction line

7. Connect the filter cart suction line (9) to the 2 in Fill Cap Adapter Gp. center suction port (8). Refer to Illustration 26.
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   Illustration 27	g03624379
   (10) Return line (11) Fill Cap Adapter side discharge port

8. Connect the filter cart discharge line (10) to the 2 in Fill Cap Adapter Gp. side return port (11). Refer to Illustration 27.

   Note: Refer to Step 11 of the Filter Cart Setup and Procedure for Wheel Loader Hydraulic Oil section in this document. The Filter Cart Setup and Procedure section contains the remaining steps of the filtration procedure.

9. When the filtration procedure is complete, remove the 2 in Fill Cap Adapter Gp., install the Breather Gp., and tighten the tank filler cap. Check the oil level by viewing the hydraulic tank sight gauge.

Oil Compartment Filtration Times for 188-3242 Filter Cart Gp

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 Gp and the 194-2897 Filter Cart Gp only. Other filtration units will have different equation references and these units will be noted when appropriate.

Illustration 28	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). 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 988G hydraulic tank has 378 L (100 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 88 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: 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.