Filtration Procedure for Load, Haul, Dump Hydraulic Oil {0680, 0768, 5050, 5056, 5068} Caterpillar

Load Haul Dump

R1300 (S/N: 6QW1-UP)

R1300G (S/N: LJB1-UP; NJB1-UP)

R1300G Series II (S/N: RSL1-UP)

R1600 (S/N: 9XP1-UP; 9EW1-UP)

R1600G (S/N: 9YZ1-UP)

R1600H (S/N: 9SD1-UP)

R1700 (S/N: KT41-UP)

R1700G (S/N: SBR1-UP; XBR1-UP; 8XZ1-UP)

R2900 (S/N: BAR1-UP; 5TW1-UP)

R2900G (S/N: GLK1-UP; JLK1-UP; NLK1-UP)

R3000H (S/N: RCM1-UP; RCY1-UP)

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 the dealer 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 relay your request to Caterpillar Repair Process Engineering:

• Cat Dealer Technical Communicator

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If a Contamination Control Guideline is required, but not available in SIS web, submit a feedback form in the Service Information System web site.

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 dealer customers to benefit from cleaner hydraulic systems. The filtration process is easy to use. The filter cart connects to the hydraulic oil filler neck. 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 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. When a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar is to be used. Ensure that the tool, procedure, or work method 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. 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 filtration 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 or 227-2479 Filter Cart Gp." before beginning the procedure.

Filter Procedure 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. Apply the service brake to stop the machine.

4. Move the direction control switch or the transmission control lever to the NEUTRAL position. Engage the transmission lock if the machine is equipped.

5. Engage the parking brake.

6. Block the wheels.

Filtration Procedure

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Illustration 3	g01343908
(1) Pressure Relief Valve (hydraulic tank)

1. Relieve the tank pressure by pressing the relief valve (1) before removing the filler cap.
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   Illustration 4	g01343909
   (2) Filler Cap (hydraulic tank)

2. Clean the area around the hydraulic tank filler cap (2). Slowly loosen the filler cap on the hydraulic tank to release the remaining tank pressure. Make sure that all the air pressure has been vented before completely removing the filler cap.

3. Remove the lock-ring and remove the strainer from the hydraulic fill neck.

4. Store the filler cap (2) and store the strainer in a clean place to avoid contamination and damage.
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   Illustration 5	g01343910

5. Measure the distance from the tip of the hydraulic fill 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 5.

6. Cut a length of suitable hose matching the (X) measured distance of tank depth. Install the hose on the filler cap adapter hose barb.
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   Illustration 6	g03394158
   (3) Suction Port (4) 3H-9690 Elbow (5) Return Port (6) Filler Cap Adapter

7. Install the Two-Inch Filler Cap Adapter (6). If an obstruction to the installation exists, the side return port can be removed for clearance and be reinstalled after the adapter is installed. Be sure that the installed suction hose reaches within 25.4 mm (1 inch) of the bottom of the hydraulic tank.

   Note: The Elbow (4) may be required on some models for the cart suction hose to reach and properly connect the filler cap adapter. The addition of the elbow fittings will also aid in the necessary orientation of the center suction port as seen in Illustration 6.

8. Connect the filter cart suction hose to the suction port (3) on the filler cap adapter (6).

9. Connect the filter cart discharge hose to the return port (5) on the filler cap adapter (6).
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   Illustration 7	g03394186
   (7) Air Supply Valve (8) Air Supply Hose

10. Attach an air supply hose (8) to the 188-3242 Filter Cart Gp. Ensure the air supply valve (7) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi).

11. Slowly open the air supply valve (7) to start the filter cart pump operation. If the air supply valve (7) is a purge off style, adjust the supply air between 137 kPa (20 psi) and 345 kPa (50 psi). Then, adjust the pressure as needed, but do not exceed 690 kPa (100 psi). The pump is a diaphragm type pump. The pump is rated to pump 10W oil at 340 L/min (90 US gpm).

12. During operation, 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 hydraulic connections.

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

    Note: Caterpillar recommends obtaining a particle count on the oil at the beginning of the filter cycle to be used as a baseline particle count.

14. 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.

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 the particle counter.

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Illustration 8	g03394205
(9) S·O·S Valve (10) 210-5530 Coupler (11) 220-8607 Fitting (12) 188-0639 Hose

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (12) of the filter cart.

   Note: The fabricated suction tube can be made with the parts listed in Table 3. Refer to Illustration 8.

2. 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, NEHS0799, "Tool Operating Manual 170-8500 Analyzer Gp.".

Bottle Sample Procedure

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Illustration 9	g03531139
(9) S·O·S Valve (13) 169-8373 Bottle Group

1. If collecting a bottle sample, use the same S·O·S valve (9) and a Bottle Group (13).

2. Record an oil sample from the S·O·S valve (9) on the filter cart at the beginning of the filter cycle.

   Note: Machine filtration can be performed while running the engine.

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

   Note: Changing the machine filters 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 open housing becomes an inlet for contamination. The new filters can remain in place until the next scheduled filter change.

   Note: The machine filters are to be replaced if the filters are not working at optimal performance, or change the filters at scheduled interval.

4. 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.

5. When the target ISO level has been met, close the air supply valve (7) and disconnect the air supply hose (8). Refer to Illustration 7.

   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. Disconnect the filter cart discharge from the return port (5) on the filler cap adapter (6). Install the dust caps on the coupler and the nipple. Refer to Illustration 6.

7. Disconnect the filter cart suction hose from the suction port (3) on the fill cap adapter (6). Install the dust caps on the coupler and the nipple. Refer to Illustration 6.

8. Remove the Filler Cap Adapter (6). Store the filler cap adapter in a clean location. Refer to Illustration 6.

9. Install the strainer and the lock-ring in the hydraulic fill neck.

10. Install a clean filler cap (2). Refer to Illustration 4.

11. Check the hydraulic tank oil level.

12. Unblock the wheels.

Oil Compartment Filtration 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 only. Other filtration units will have different equation references and these units will be noted when appropriate.

Illustration 10	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 R1600 Load Haul Dump hydraulic system has 124.9185 L (33 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 29 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 particle cross sectional area. Particle counts are affected by various factors. These factors include: procurement of the sample, the sample container, particle counting accuracy when used 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. 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 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.