188-3242 Filter Cart Group and 227-2479 Filter Cart Group{0374, 0599, 0680, 0738, 0768, 5050, 5056, 5095} Caterpillar


188-3242 Filter Cart Group and 227-2479 Filter Cart Group{0374, 0599, 0680, 0738, 0768, 5050, 5056, 5095}

Usage:

769C 01X
Caterpillar Products: All

Introduction

Important Safety Information




Illustration 1g02139237

Think Safety

European Union Compliant, CE Marked

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 can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

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.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of 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. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Section

Safety Icon Nomenclature

Personal Protection/Important Information




Illustration 2g02166423

Personal Protection/Important Information

Prohibited Action


No smoking

Hazard Avoidance


Crushing hazard (foot)


Crushing hazard (hand)


Pinch point


Fire hazard


Electrical Shock - Hazard


Fire hazard

Safety Warnings

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

At operating temperature, the hydraulic tank is hot and under pressure.

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

Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

----------------------

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

Personal injury or death can result from escaping fluid under pressure.

Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

----------------------


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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.



NOTICE

To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected.

This action also lessens the chance of oil spills.


General Information Section

Introduction

The 188-3242 and 227-2479 Filter Cart Groups are used to flush and clean hydraulic tanks or hydraulic systems which have a reservoir capacity greater than 115 L (30.0 US gal) and less than 380 L (100.0 US gal). It uses standard filtration of 25, 10, 5, or 2 micron. The filter cart can be used in any filtering application for oil contamination control. This filter cart allows oil to be filtered directly from a hydraulic tank (eliminates placing oil in separate filtering cart/container).

This manual provides general information on how to set up the filter cart, technical data, serviceable parts, and adapters.

Oil is pumped through the filter cart using an air-powered diaphragm pump. The filter cart is designed with a suction hose, 3 m (10.0 ft) long with a female quick-disconnect. The return line is 3 m (10.0 ft) long with a male quick-disconnect.

The 227-2479 Hydraulic Filter Cart in kit form includes every part needed to build the 188-3242 Filter Cart Group. The unpainted steel frame requires assembly. Prints are provided for welding and assembly.




Illustration 3g02564741

188-3242 Filter Cart Group.

The quick-disconnects permit fast and easy hose connection to a hydraulic tank when used with hydraulic tank adapters such as 193-5900 and 193-5903. Other adapters may be required depending on the particular hydraulic tank. Refer to "Contamination Control Guidelines" in Cat Systems Information System (SIS) for specific parts and procedures.




Illustration 4g02564746

Hose Ends Are Equipped With Quick-Disconnect Fittings.

  • The filter cart can filter hydraulic fluids from 5W to 90W.

  • Filter cart is easily moved around in field conditions on three pneumatic tires.

  • Oil is pumped through the filter cart using an air-powered, diaphragm pump.

  • The maximum output pressure of fluid being pumped is equal to air inlet air pressure. 414 kPa (60.0 psi) is the recommended operating or air inlet pressure.

  • The filter housing has a differential pressure gauge (dirty filter indicator) to indicate when the filter element should be changed.

  • All hose assemblies are made from Caterpillar 844 wire-reinforced hose. These hoses will not collapse when filtering hot oil.

  • Extra tall hose hook for ease of hose storage.

  • Built in storage box to hold optional adapter fittings.

  • The filter cart is European Union Compliant.

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

USA: 800-542-8665, Option 1

International: 1-309-578-7372

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

Specifications

Table 1
Specifications    
Description     Specification    
Operating pressure    
138 to 827 kPa (20.0 120. psi)    
Variable delivery    
0 to 409 L/min (0 to 90.03 US gpm)    
Supply air consumption     0.47 L/s (1 cfm) per
4.55 L/min (1.201 US gpm) of fluid pumped    
Suction lift     Up to
5.5 m (18.0 ft)    
Liters (gallons) per cycle    
1.9 L (0.50 US gal)    
Operating temperature    
0 to 93° C (2 to 200.0° F)    
Four (4) gang parallel filter head     Permits four (4) times the filter area to capture particulates and extends filter life.    
Standard filtration     10 microns    
Outlet hose (one)    
3 m (10 ft) long with a female quick disconnect end    
Inlet hose (one)    
3 m (10 ft) long with a male quick disconnect end    
Storage box    
736 x 406 x 305 mm (29.0 x 16.0 x 12.0 inch)    
Noise level     82 dB @
758 kPa (110.0 psi) air pressure    
Overall dimensions    
1295 x 889 x 1143 mm (51.0 x 35.0 x 45.0 inch) with hook bar
1956 mm (77.0 inch)    
Weight    
163 kg (360.0 lb)    

References

For more information, refer to Special Instruction, SEBF8447, "Procedure for Filtering Excavator (311-375) Hydraulic Oil" or Special Instruction, SEBF8446, "Procedure for Filtering 300 Series Excavator Hydraulic Oil". Guidelines for specific machines can also be found in Cat Systems Information System (SIS).

Installation and Setup

Typical Machine Set-Up

  1. Turn air supply ball valve (1) to the closed position. Attach an air supply to the filter cart.

    Note: A quick-disconnect coupling (not included) can be used to connect the air supply line.


    NOTICE

    An air supply in excess of 827 kPa (120.0 psi) will damage the filter cart. To prevent damage, install a 4C-7033 Regulator into the air supply line. For best results, set regulator to 414 kPa (60.0 psi).


  1. To reduce the risk of static electricity, while pumping fluids, attach one end of a ground cable (not included) to ground connection (2) and the other end to a suitable electrical ground.



    Illustration 5g02564757

    (1) Air Supply Valve. (2) Static Electricity Connection. (3) 195-3164 Muffler .

    Note: If the filter cart is used to filter different types of fluids, change the filter elements for each filtering application.

  1. If the unit is used for filtering oil from a machine:

    1. Attach a length of 25 mm (1.0 inch) ID suction hose (B) to the adapter (A). The hose length should allow the end of the hose to be within 15 cm (6.0 inch) of the bottom of the tank.



      Illustration 6g02564776

      (4) S.O.S Valve. (A) Adapter. (5) Suction Hose.

    1. Remove the filler cap and screen. Screw either the 193-5900 Adapter (4 inch diameter filler cap) or 193-5903 Adapter (2.5 inch diameter filler cap) onto the filler tube of the hydraulic tank. Other adapters are available through Cat Systems Information System (SIS).

    Note: The S·O·S valve (4) in the adapter is not used for taking an oil sample, but for releasing pressure that can build up in the hydraulic tank during the filtering procedure.

  1. Connect the suction and return hoses to the adapter and begin filtering.

  1. If the filter cart is used to filter oil from a bulk storage tote, use the following tooling from the FT3016 Contamination Control Caps and Fittings .



Illustration 7g02564784

Table 2
Threaded Suction Connection1    
Part Number     Description     Quantity    
141-1454     Coupling (2 inch NPT to 1 inch NPT)     1    
3B-7280     Close Nipple (1 inch NPT)     1    
190-8319     Male Quick Disconnect with 1 inch NPT     1    

1 For oil totes with 2 inch NPT threaded lower connection.




Illustration 8g02564789

Table 3
Cam-Lock Suction Connection2    
Part Number     Description     Quantity    
263-9602     Female Cam-Lock Quick Disconnect with 2 inch NPT     1    
141-2502     Reducer Bushing (2 inch to 1 inch NPT)     1    
3B-7280     Close Nipple (1 inch NPT)     1    
190-8319     Male Quick Disconnect with 1 inch NPT     1    

2For oil totes with quick disconnect cam-lock lower connection.




Illustration 9g02564791

Table 4
Return Connection    
Part Number     Description     Quantity    
255-4302     Screw-On Cap     1    
183-3873     Breather Assembly     1    
255-4305     Bulkhead Fitting     1    
5B-7666     Street Elbow (1-1/2 inch NPT)     1    
7X-3387     Sampling Valve (1/4 inch NPT)     1    
3B-7280     Close Nipple (1 inch NPT)     1    
8B-5774     Reducer Bushing (1-1/2 inch x 1 inch NPT)     1    
190-8316     Quick Disconnect Coupling with 1 inch NPT     1    
1H-2815     Pipe Nipple 1-1/2 inch NPT x
152 mm (6 inch)    
1    
1L-2782     Pipe Tee (1-1/2 inch NPT)     1    



Illustration 10g02564793

Table 5
Storage Cap    
Part Number     Description     Quantity    
255-4302     Screw-On Cap     1    
183-3873     Breather Assembly     1    

Checking Contamination Levels

Taking An Oil Sample Using a Portable Particle Counter

The S·O·S valve is used for taking oil samples. This valve can be used with a standard 170-8500 Particle Counter . For the most accurate test results, use the low-pressure sampling circuit.




Illustration 11g02564799

(5) S·O·S Valve.

Calculating Filtration Time If Particle Counter Is Not Available

If an on-line, portable particle counter is not available to indicate when contaminate levels have lowered to an acceptable point, refer to the following equation. This equation works with the 188-3242 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 application. Therefore, the following equation must be viewed as only a simple reference and not an absolute time or efficiency result.

Table 6
Compartment Oil Capacity (gallons) x 140     =     Approximate Filtration Time    
Cycles per Minute    

Cycles per Minute definition: Each air discharge or stroke of the air operated filter pump is considered one cycle (delivery of one pulse of oil). The internal pump shaft will slide left (one cycle), and then to the right (one cycle), delivering oil going both directions. Another way of determining one cycle is to listen for the TUK - CHUK (2 pulses). Count the number of cycles in one minute for use in the above equation.

Example: The oil capacity being filtered is 428 L (113.0 US gal) of 10W oil. The filter unit is operating at 90 cycles per minute. The approximate filtration time should be 175 minutes or 2.9 hours.

Maintenance

Filter Elements

The prefilter has a 100 mesh element for large particle removal. Also this prefilter acts as a dampening device to reduce the intensity of pressure spikes caused by the air diaphragm pump.




Illustration 12g02564806

(6) 9U-6985 Prefilter . (7) 8T-0846 Working Pressure Gauge .

The filter cart comes standard with four 10 micron filter elements. These filters should work in most filtering applications. If necessary, optional 2, 5, and 25 micron filter elements are also available.

The filter housing is equipped with a "Dirty Filter" indicator. Replace the filter whenever the indicator shows that the filter is dirty. Make sure that the fluid is at operating temperature and normal operating flow, before checking the indicator.

If the filter is being changed too frequently in a filtering application, a larger micron filter can be installed to remove all the larger contamination particles.




Illustration 13g02564811

(8) 9U-6986 Differential Pressure Gauge . (9) 9U-5870 Filter Elements

Air Pump Muffler

In some cases, the air pump muffler can freeze. If the air pump is not functioning properly, first check the muffler to make sure that it is not clogged or frozen with condensation.

For the most efficient operation of the filter cart, replace the muffler periodically.




Illustration 14g02564813

(10) 195-3164 Muffler .

188-7019 Air Pump

Repair parts are available for the 188-7019 Air Pump . A 196-9504 Air Valve Repair Kit is available for repairing the center section of the air pump. A 188-7018 Diaphragm Kit is available to replace the two diaphragms in the pump. Complete repair instruction come with each repair kit.

Serviceable Parts

Table 7
Serviceable Parts List    
Item     Part No.     Description    
(1)     188-7019     Air Pump Assembly    
(2)     9U-6985     Filter Element (100 Mesh) (prefilter)    
(3)     9U-5870     Spin-on Filter Element (10 micron) with synthetic media1 Quad Filter Assembly    
(4)     195-3164     Muffler (on air pump)    
(5)     9U-6986     Gauge (Dirty Filter)    
(6)     8T-0846     Gauge (Working Pressure)    
(7)     190-8316     Female Quick-Disconnect with 1 1/4 inch NPT    
(8)     190-8317     Male Quick-Disconnect with 1 1/4 inch NPT    
(9)     190-8318     Female Quick-Disconnect with 1 inch NPT    
(10)     190-8319     Male Quick-Disconnect with 1 inch NPT    
(11)     197-4626     Flexible Extension,
101.6 x 355.6 mm (4.00 x 14.00 inch)    
(12)     197-4627     Solid Extension,
63.5 x 330.2 mm (2.50 x 13.00 inch)    
(13)     3H-0976     O-ring (element to head)    



Illustration 15g02564817

Typical Male and Female Quick-Disconnect Fitting (All with Female NPT).

Table 8
Serviceable Parts List (cont'd)    
Optional Filter Elements for the Quad Filter Assembly    
Item     Part No.     Description    
-     9U-6983     Spin-on Filter Element (5 micron absolute) with synthetic media1    
-     9U-6984     Spin-on Filter Element (22 micron absolute) with synthetic media1    
-     188-7027     Filter Element (Water Removal)    
-     198-3188     Spin-on Filter Element (2 micron cellulose)    

1Synthetic filtering media is compatible with petroleum and water-based fluids.

Table 9
Serviceable Parts List (cont'd)    
Dust Caps/Plugs    
Item     Part No.     Description    
-     8C-3451     Rubber Cap,
13 mm (.50 inch) diameter for S.O.S port    
-     201-8057     Plastic/Rubber Plug,
66.8 mm (3 inch ), for 190-8316 and 190-8318 Quick-Disconnect Coupler, female end    
-     201-8059     Plastic/Rubber Plug,
44 mm (2 inch), for 190-8317 and 190-8319 Quick-Disconnect Coupler, male end    

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