Filtration Procedure for Pipelayer Hydraulic Oil Equipped with Ecology Drain Valve {0680, 0768, 5050, 5056} Caterpillar


Filtration Procedure for Pipelayer Hydraulic Oil Equipped with Ecology Drain Valve {0680, 0768, 5050, 5056}

Usage:

D6K2 6S6
Pipelayer
PL61 (S/N: WGS1-UP)
PL72 (S/N: P721-UP; P731-UP)
PL83 (S/N: CB21-UP; KSD1-UP; DLW1-UP)
PL87 (S/N: TEC1-UP; ZAC1-UP; KKJ1-UP)
Track-Type Tractor
D6K (S/N: 6S61-UP; 7P61-UP; MP71-UP)
D6K2 (S/N: MXK1-UP; DFR1-UP; JTR1-UP; RPR1-UP)

Introduction

Table 1
Revision  Summary of Changes in SEBF9176 
09  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2017.
Removed old Repair Process Engineering (RPE) point of contacts.
Added new Repair Process Engineering (RPE) point of contacts. 
08  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2016. 
07  Added new serial number prefixes for New Product Introduction (NPI). 
06  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2015. 
05  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2014. 

© 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 to 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

The instructions given in this guideline will enable dealers and customers to properly filter the hydraulic oil. Following this procedure will reduce the contamination in the oil to an acceptable ISO contamination level. This procedure may be modified by the technician for use on some machines.

Note: If the vehicle system is being serviced due to a catastrophic component failure, a complete system cleaning operation is required before starting this 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. Additional component cleaning, component exchange, and lines flushing will be required to remove most contaminates generated from the failure. The vehicle system cleaning must be performed prior to the filter cart procedure. This filtration procedure and particle count testing should be performed as a final step in the repair process.

Important Safety Information



Illustration 1g02139237

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 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 2g01032906

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 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

------ WARNING! ------

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.


------ WARNING! ------

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

Table 2
References 
Media Number  Title 
NEHS0799  "Tool Operating Manual for 170-8500 Analyzer Group" 
NEHS0848  "Tool Operating Manual for 204-7392 Filter Cart" 
NENG2500  "Dealer Service Tool Catalog" 
PEGJ0045  "Reporting Particle Count by ISO Code" 
PEGJ0047  "How To Take a Good S·O·S Sample" 
SEBF8482  "Obtaining an Oil Sample for S·O·S Analysis" 

Tooling and Equipment

Table 3
Parts List 
Quantity  Part Number  Part Description 
204-7392  Filter Cart Gp 
169-8373  Fluid Sampling Bottle 
Suction Adapter 
25.4 mm (1 inch) pipe NPT  254 mm (10 inch) long 
006-5707  Pipe Elbow 
9J-7031  Drain Plug 
190-8319  Coupler 
201-8059  Dust Cap 
Discharge Adapter 
  Fabricated Discharge adapter  69.85 mm (2.75 inch) bar stock 
201-8057  Dust Cap 
190-8318  Coupler 
005-8615  Pipe Nipple 
006-5707  Pipe Elbow 
Optional Tools 
170-8500  Analyzer Gp 
210-5530  Quick Connect Coupler 
188-0639  Hose As 
220-8607  Fitting 

Table 4
Suction Adapter Assembly 
Sales Model  Adapter  Rework  Pipe 
PL61  9J-7031  Drill 19 mm (0.75 inch) hole through the plug and weld pipe to plug  25.4 mm (1 inch) NPTF threaded one end 11-1/2 threads per inch, 254.0 mm (10 inch) length 

Assembly of the Filter Cart Adapters



    Illustration 3g03562277
    Refer to Table 4 for the correct suction adapter assembly specifications.
    (1) 201-8059 Dust Cap
    (2) 190-8319 Nipple NPT pipe
    (3) 006-5707 Pipe Elbow
    (4) 25.4 mm (1 inch)
    (5) 9J-7031 Adapter

  1. Refer to Table 4 for the suction adapter specifications.

    1. Drill the Adapter (5) to 19.05 mm (0.75 inch). Weld the 25.4 mm (1 inch) pipe (4) to the Adapter (5). Connect the Pipe Elbow (3) to the fabricated suction adapter. Connect the Nipple (2) to the Pipe Elbow (3). Be sure that a Dust Cap (1) is available for the quick disconnect fitting. Refer to Illustration 3.


    Illustration 4g01530739
    Discharge Adapter
    (A) 69.85 mm (2.75 inch)
    (B) 63.5 mm (2.5 inch)
    (C) 49 mm (1.93 inch)
    (D) 12.7 mm (0.5 inch)
    (E) 6.35 mm (0.25 inch)
    (F) 15 degrees
    (G) 25.4 mm (1 inch) NPT thread


    Illustration 5g01530739
    D6K 2 Discharge Adapter
    (A) 69.85 mm (2.75 inch)
    (B) 63.5 mm (2.5 inch)
    (C) 46 mm (1.811 inch)
    (D) 12.7 mm (0.5 inch)
    (E) 6.35 mm (0.25 inch)
    (F) 15 degrees
    (G) 25.4 mm (1 inch) NPT thread

  2. Fabricate the discharge adapter plug. Machine a 69.85 mm (2.75 inch) piece of bar stock to the specifications shown in Illustrations 4 or 5. Thread a hole in the bar stock to accept a 25.4 mm (1 inch) male elbow.


    Illustration 6g01530742
    Discharge adapter assembly
    (6) 201-8057 Dust Cap
    (7) 190-8318 Coupler
    (8) 005-8615 Pipe Nipple
    (9) 006-5707 Pipe Elbow
    (10) Fabricated plug

  3. Assemble the fabricated plug (10), the Pipe Elbow (9), the Pipe Nipple (8), the Coupler (7), and the Dust Cap (6). Refer to Illustration 6.

Filter Cart Procedure



Illustration 7g01530745
204-7392 Filter Cart Gp

  1. Before beginning the procedure, be sure to read and understand the Tool Operating Manual, NEHS0848.

  2. Operate the machine to warm the oil.

  3. Park the machine on level ground. Lower the attachment to the ground. Apply slight downward pressure. Stop the engine.


    Illustration 8g01574698
    Rear cover plate

  4. Remove the rear cover plate. Refer to Illustration 8.

  5. Pressure wash around the hydraulic tank drain port.

  6. Place a drain pan under the hydraulic tank drain valve. There could be some oil leakage.

    ------ WARNING! ------

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


  7. Remove the hydraulic tank drain plug from the hydraulic tank drain valve assembly.


    Illustration 9g01571954
    (12) Suction adapter assembly
    (13) Filter cart suction hose

  8. Install the suction adapter assembly (12).

  9. Connect the filter cart suction hose (13) to the suction adapter assembly (12). Refer to Illustration 9.


    Illustration 10g01574713
    Hydraulic tank fill location

  10. Remove the hydraulic tank filler cap. Refer to Illustration 10.

  11. Install the discharge adapter assembly in the hydraulic tank filler tube.

  12. Connect the filter cart discharge hose to the discharge adapter assembly.


    Illustration 11g01530749

  13. Attach the air supply hose to the 204-7392 Filter Cart Group. Ensure that the air supply valve is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi). Refer to Illustration 11.


    Illustration 12g01530750
    Air supply valve in the OPEN position

  14. Slowly open the air supply valve to start the filter cart pump operation. Refer to Illustration 12.

  15. While operating the filter cart, check the filter element indicators on the filter cart. The indicators will determine the amount of capacity available 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.

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

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

Portable Particle Analyzer Procedure

When using a portable particle analyzer for particle counting, be sure that you read and understand the Tool Operating Manual before operating the particle counter.



    Illustration 13g01530751
    (14) Fabricated suction tube
    (15) 220-8607 Fitting
    (16) 210-5530 Coupler
    (17) S·O·S Valve

  1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (17) on the filter cart.

    Note: The fabricated suction tube (14) can be made with the parts listed in Table 3 under the "Optional Tools" section. The fabricated tube is shown in Illustration 13.

  2. Attach the other end of the fabricated suction tube (14) to the "low pressure in" port on the particle counter as called for in the Tool Operating Manual.

Bottle Sample Procedure



    Illustration 14g01530753
    (17) S·O·S Valve
    (18) Bottle Group

  1. If collecting a bottle sample, use the same S·O·S valve (17) and a 169-8373 Fluid Sampling Bottle (18). Refer to Illustration 14.

  2. Record an oil sample reading from the S·O·S valve on the filter cart at the beginning of the procedure.

  3. At the halfway point of filtering, stop the procedure and change the hydraulic filters on the machine. 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 avoids opening the filter housing after the system has been cleaned. If the filter housing, is opened for any reason the housing becomes an inlet for contamination.

    Note: The filters on the machine are to be changed at the normal maintenance interval, or when the filters are not operating at optimal performance.

  4. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an acceptable ISO level of 18/15. The final ISO code should be recorded before the machine is returned to service.

    Note: Refer to"Oil Compartment Filtration Times for 204-7392 Filter Cart" locatedat the end of this document, when a portable particle analyzer is not available.

  5. When the target ISO level or the time interval has been met, close the air supply valve and disconnect the air supply hose.

  6. Remove the discharge hose assembly and the discharge adapter assembly from the hydraulic tank fill location. Install the dust cap on the nipple and on the quick coupler. Store the discharge adapter in a clean location.

  7. Install a clean hydraulic tank filler cap.

  8. Disconnect the filter cart suction hose (13) from the suction adapter (12). Install the dust cap on the nipple and the quick coupler. Refer to Illustration 9.

  9. Place a drain pan under the hydraulic tank drain valve assembly. There may be some oil left in the hydraulic tank suction adapter assembly.

  10. Remove the suction adapter from the hydraulic tank drain valve.

  11. Reinstall a clean hydraulic tank drain plug into the hydraulic tank drain valve assembly.

  12. Store the suction adapter in a clean location.

  13. Check the hydraulic tank oil level before returning the machine to the field.

Oil Compartment Filtration Times for 204-7392 Filter Cart

If an on-line, portable particle analyzer is not available to diagnose and track when the contaminant level has lowered to an acceptable point, refer to the following equation. This equation only relates to the 204-7392 Filter Cart only. Other filtration units will have a different equation reference and will be noted when appropriate. There are various conditions that must be factored into the filtration efficiency of any filter cart and situation. Therefore, the following equation must be viewed as only a simple reference and not an absolute time or efficiency result.

Compartment Oil Capacity (gallons) times 2 equals the approximate filtration time.

Example: A PL61 hydraulic system has 56 L (15 US gal) of 10W oil. The approximate filtration time should be about 30 minutes.

ISO 4406:1999 Method for Coding the Level of Contamination by Solid Particles

ISO (International Organization of Standardization) 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 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, where used and cleanliness. Proper care should be taken during sample procurement to ensure that the sample obtained is representative of the fluid circulation in the system.

The code for contamination levels using automatic particle counters comprises 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

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 instead. 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.

Clean Out Filter versus Filter Cart Filtering

After any "open system" repair, on-site S·O·S sampling and particle counting is required. S·O·S sampling should be accomplished by exercising the specific system until the fluid is at normal operating temperature. An ISO 18/15 maximum cleanliness target has been established for most hydraulic and transmission systems. Refer to the machine system cleanliness targets for your specific machine.

System Oil Meets Recommended Cleanliness Targets:

  1. Change the standard hydraulic system filter with a high efficiency filter prior to returning that machine to the customer. This procedure ensures that unseen system contamination and new part break-in debris will be properly filtered out during the initial hours after any repair.

  2. Instruct the customer that the high efficiency filter should be changed prior to 250 hours of operation.

  3. After the high efficiency filter has been removed, the filter should be cut open and the amount of captured debris should be checked. If a large amount of debris is present, another high efficiency filter should be installed and then rechecked after 100 hours. When a small amount of debris is present, a standard filter can then be installed.

System Oil Does Not Meet Recommended Cleanliness Targets:

  1. Filter cart filtering is required.

  2. Change the standard filter on the machine with a high efficiency filter half-way through the filtration process explained in this guideline.

  3. Continue filtering according to the time interval at the end of this document or until the system meets the minimum recommended ISO.

  4. Leave the installed high efficiency filter on the machine. The filter should last at least 8 hours, and should be changed prior to 250 hours.

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