Filtration Procedure For Cold Planer Hydraulic Oil {0680, 0738, 0768, 5050, 5056} Caterpillar

Cold Planer

PM-200 (S/N: P1M1-UP)

PM310 (S/N: RH81-UP; KWA1-UP; NMA1-UP)

PM312 (S/N: NA91-UP; NJ91-UP)

PM313 (S/N: J631-UP; DK91-UP; JH91-UP; JHZ1-UP)

PM620 (S/N: FG41-UP; JB91-UP; LH91-UP; 8RF1-UP)

PM622 (S/N: EL61-UP; XS61-UP; JFC1-UP; JCF1-UP; TPH1-UP)

PM820 (S/N: RL31-UP; AK51-UP; AN81-UP; TLZ1-UP)

PM822 (S/N: EE21-UP; SL81-UP; E8S1-UP; H6S1-UP)

PM825 (S/N: 6261-UP; 6271-UP; ESE1-UP)

Introduction

© 2019 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 customers to benefit from cost reductions which were made possible through an established Contamination Control Program . Fluids 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 that is 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 feedback form 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. This filtration process is easy to use. The hydraulic filter cart quickly connects to the machine hydraulic tank. 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 filtration procedure will help reduce fluid contamination in the oil to an acceptable level of ISO 18/15 or cleaner.

Note: If the machine is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing 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. More component cleaning, 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 filtration procedure. This filtration procedure and subsequent particle count testing should be performed as part of the repair process.

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, lubricate, 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 used, ensure that all personnel around the machine are safe. 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 specifications 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

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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

Illustration 3	g01652645

Discharge adapter for cold planers. Refer to Table 5 for item identification.

Illustration 4	g01654954
Discharge Hose Assembly for Cold Planer. Refer to Table 6 for item identification

Illustration 5	g01654914

Fabricated Suction Tee Assembly for Cold Planer. Refer to Table 7 for item identification.

Illustration 6	g01652634
Vacuum transducer assembly for cold planers. Refer to Table 8 for item identification.

Assemble two 124-1922 Permanent Couplings and 4.57 m (15 ft) of 122-6906 Hydraulic Hose on a hose press. After hose is assembled, attach the 234-0218 Adapter - Hydraulic Tank to one end of the assembled hose.

Assemble two 124-1922 Permanent Couplings and 4.57 m (15 ft) of 122-6906 Hydraulic Hose on a hose press. After hose is assembled, attach 173-0880 Connector to the hydraulic hose. Attach 5P-4269 Swivel Adapter to the 173-0880 Connector that is attached to the hose assembly.

Machine Filtration Procedure

This guideline is intended for cold planers. This procedure is most effective when performed immediately after the hydraulic fluid has been warmed to 50 °C (122 °F) and mixed from operation. Warming the oil allows any contamination in the oil to be placed in suspension. Warming the oil also lowers the viscosity of the oil. Be sure to read and understand Tool Operating Manual, NEHS0848, "207-7392 Hydraulic Filter Cart" before you begin this procedure.

Filtration Setup for all Cold Planers

Illustration 7	g01652693

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. Lower the attachment to the ground and apply slight downward pressure.

7. Block the wheels.

Filtration Procedure for PM200

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Illustration 8	g01652673
Hydraulic tank drain

1. Clean the area around the hydraulic tank fill cap and drain assembly.
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   Illustration 9	g01655075
   (1) Hydraulic filter cart suction port

2. Connect the Fabricated Suction Tee Assembly to the Hydraulic Filter Cart Suction Port.
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   Illustration 10	g01652814
   Hydraulic filter cart discharge port (2) 3B-7257 Adapter

3. Connect the discharge hose assembly to the 204-7392 Hydraulic Filter Cart discharge port using a 3B-7257 Adapter.

4. Remove the hydraulic tank fill cap.
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   Illustration 11	g01657273

5. Install the fabricated discharge adapter in place of the hydraulic tank fill cap.

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

7. Apply air pressure to the vacuum transducer assembly before you remove the drain plug.
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   Illustration 12	g01652677
   (3) Hydraulic tank drain assembly

8. Carefully remove the drain hose assembly (3).
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   Illustration 13	g01655133
   Fabricated Suction Tee Assembly

9. Quickly install the Fabricated Suction Tee Assembly onto the drain nipple.

10. Reinstall the drain hose assembly in the bottom of the 6V-9839 Tee .

11. When adapter installation is complete, shut off the air supply to the vacuum transducer assembly.
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    Illustration 14	g01652716
    (4) Air supply hose (5) Air supply valve

12. Attach an air supply hose (4) to the 204-7392 Filter Cart. Ensure the air supply valve (5) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi).

13. Slowly open the air supply valve (5) to start the filter cart pump operation. If the air supply valve (5) is a purge off style, adjust the air supply between 140 kPa (20 psi) and 345 kPa (50 psi). Turn on the air supply valve (5). Adjust the pressure as needed, but do not exceed 690 kPa (100 psi). The pump is a diaphragm pump. The pump is rated to pump 10W oil at 64 L/min (17 US gpm).

14. During the filter cart operation, check the filter element indicators on the filter cart. The indicators will show the amount of capacity left in the filter element.

    Note: Occasionally, the filter cart pump will cavitate during start-up. Cavitation is due to air in the suction lines of the pump. If cavitation continues for more than 1 minute, shut the filter cart OFF. Check all hydraulic connections.

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

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

16. 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. Refer to Contamination Control Guideline, SEBF8482 for more information.

Filtration Procedure for PM310, PM312, PM313, PM620, PM622, PM820, PM822, and PM825

Illustration 15	g06059731
Access panel locations (A) Access panel for hydraulic tank drain assembly (B) Access panel for hydraulic tank filler neck assembly

1. Open access panels A and B to gain access to the hydraulic tank filler neck and drain assembly.

2. Clean the areas around the filler neck and drain assembly.
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   Illustration 16	g06061259
   (1) Hydraulic tank drain assembly

3. The hydraulic tank drain assembly (1) is located under access panel A. Refer to Illustration 16.

4. Ensure the 377-9629 Ball Valve (3) is in the closed position. Refer to Illustration 16.
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   Illustration 17	g06061288
   (1) Hydraulic tank drain assembly components (2) 148-8408 Plug As (3) 377-9629 Ball Valve

5. Remove the 148-8408 Plug As (2) from the 377-9629 Ball Valve (3). Refer to Illustration 17.

6. Attach the suction hose assembly to the 377-9629 Ball Valve (3) and the suction port of the filter cart. Refer to Illustration 17.

7. The hydraulic tank filler neck is located under access panel B. Refer to Illustration 15.
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   Illustration 18	g06061340
   Filler cap assembly (4) 142-8937 Filler Cap As

8. Remove the 142-8937 Filler Cap As (4). Refer to Illustration 18.
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   Illustration 19	g06061382
   Discharge hose assembly with Adapter - hydraulic tank (5) 234-0218 Adapter - hydraulic tank (6) 124-1922 Permanent Coupling (7) 122-6906 Hydraulic Hose

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   Illustration 20	g06061403
   Hydraulic tank adapter (5) 234-0218 Adapter - Hydraulic Tank

9. Attach the 234-0218 Adapter - Hydraulic Tank (5) and discharge hose assembly to the filler neck and the discharge port of the filter cart.

10. Open the 377-9629 Ball Valve. Refer to Illustration 17.

11. Refer to step 12 of the Filtration Procedure for PM600 for the remaining steps of the procedure.

Portable Particle Analyzer Procedure

When you use a portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual before you operate the particle analyzer.

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Illustration 21	g01652719
(6) Fabricated suction tube (7) 220-8607 Fitting (8) 210-5530 Coupler (9) S·O·S valve

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (9) on the filter cart.

   Note: The fabricated suction tube can be made with the parts listed in Table 4 and as shown in Illustration 21.

2. Attach the other end of the fabricated suction tube 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 22	g01652720
(9) S·O·S valve (10) 169-8373 Bottle Group

1. If you collect a bottle sample, use the same S·O·S valve (9) and a 169-8373 Bottle Group (10).

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

   Note: The filtration can be performed with the engine running.

3. At the halfway point of filtration, stop the procedure and change the machine oil filters. Changing the machines filters allows the filters to help in the system cleaning. The new filters can remain in place until the next scheduled filter change. Changing the filters now avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.

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

4. During the filter cart operation, cycle the lift cylinders at least four times every half hour of filtration. Activation of the cylinders will cycle the clean tank oil into the hydraulic system and flush the more contaminated oil back into the tank.

5. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an ISO level of at least 18/15 or better. The final ISO should be recorded before the machine is returned to the field.

6. When the target ISO level or time interval has been met, close the air supply valve (5) and disconnect the air supply hose (4).

   Note: Refer to Oil Compartment Filtration Times "Oil Compartment Filtration Times" at the end of this document, when a portable particle analyzer is not available.

7. Disconnect the filter cart discharge hose male coupling from the discharge oil adapter female coupling. Install dust caps on the coupler and on the nipple. Store the hose assembly in a clean location.

8. Turn ON the air supply (5) to the vacuum transducer assembly .

9. Quickly remove the suction adapter and install the hydraulic tank drain assembly.

10. Turn OFF the air supply to the vacuum transducer assembly.
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    Illustration 23	g01657273

11. Remove the fabricated discharge oil adapter.

12. Install a clean fill cap.

13. Check the hydraulic tank oil level.

14. Unblock the wheels.

15. Return the machine to service.

Oil Compartment Filtration Times

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 204-7392 Filter Cart only. Other filtration units will have different equation references and these units will be noted when appropriate.

Compartment oil capacity (gallons) times two equals the approximate filtration time.

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), which 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 PM200 hydraulic system has 180 L (47.5 US gal) of SAE 10W oil. The approximate filtration time should be 1 hour and 40 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 the procurement of the sample, the sample container, particle counting accuracy where 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 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.