Filtration Procedure for E Series Vibratory Compactors {0680, 0768, 5050, 5056} Caterpillar

Asphalt Compactor

CB-534D (S/N: FEA1-UP; GCA1-UP)

CB64 (S/N: CB51-UP; DJM1-UP)

Paving Compactor

CP-663E (S/N: DAF1-UP; AFL1-UP)

CS-663E (S/N: ASB1-UP; AEF1-UP; DAG1-UP)

CS-683E (S/N: DAD1-UP; ASG1-UP; AGR1-UP)

Vibratory Asphalt Compactor

CB13 (S/N: LP91-UP; PWP1-UP)

CB15 (S/N: M941-UP; NPB1-UP)

CB16 (S/N: HP51-UP; KHC1-UP)

CB54 (S/N: K3J1-UP; JLM1-UP)

Vibratory Soil Compactor

CP-433E (S/N: CYE1-UP; CFK1-UP; ASN1-UP; BTY1-UP)

CP-533E (S/N: BZG1-UP; ASM1-UP; DAM1-UP)

CP-563E (S/N: BWE1-UP; CNT1-UP)

CP-573E (S/N: ASY1-UP)

CP34 (S/N: 5151-UP)

CP44B (S/N: 4P41-UP; GNB1-UP; GTT1-UP)

CP54 (S/N: C5Y1-UP)

CS-423E (S/N: EAE1-UP)

CS-433E (S/N: CFP1-UP; ASR1-UP; BTT1-UP)

CS-533E (S/N: BZE1-UP; TBE1-UP; DAK1-UP; ASL1-UP)

CS-563E (S/N: ASA1-UP; CNG1-UP)

CS-573E (S/N: CEB1-UP; CNN1-UP)

CS-583E (S/N: DAJ1-UP; CNX1-UP)

CS34 (S/N: 5141-UP)

CS433E (S/N: BWG1-UP; ASH1-UP; DCL1-UP; AST1-UP; CFX1-UP)

CS44B (S/N: CS31-UP; 4G31-UP; RGE1-UP)

Vibratory Utility Compactor

CB2.5 (S/N: R2B1-UP)

CB2.7 (S/N: R521-UP)

CB2.9 (S/N: XS31-UP)

CC2.6 (S/N: SPX1-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 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 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

This guideline enables dealers and customers to benefit from cleaner hydraulic systems. The filtration process is easy to use. The filter cart quickly connects to the hydraulic oil drain and hydraulic oil filler neck. This guideline provides directions for installing and operating the filtration system.

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.

The following procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and the oil is mixed from operation. Warming the oil causes contamination in the system to be placed in suspension and lowers the oil viscosity.

Note: If the machine is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this filter cart 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. Extra 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 before filtering the machine. This filtration procedure and subsequent particle count testing should be performed as a final step in 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 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. 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. Also ensure that the product will not be damaged or 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 information 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. Cat dealers have the most current information that is available.

Safety

Show/hide table

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.

Show/hide table

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	g03410880
Suction adapter for Vibratory Compactor systems (1) 124-1904 Permanent Coupling (2) 6B-9081 NPTF Adapter (3) 122-6871 5/8 inch 716 Hose (2 ft) (4) 9X-2488 Hose Clamp

Illustration 4	g03304817
Discharge adapter assembly for E series Vibratory Compactors. (5) 190-8318 Coupling (6) 005-8615 Union (7) 234-0218 Adapter (8) 002-5743 Elbow

Machine Filtration Procedure

This guideline is intended for Vibratory Compactors. The procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122° F) and mixed from the operation. Warming of the oil allows any contamination in the system oil to be placed in suspension and warming the oil also lowers the viscosity. Be sure to read and understand the Tool Operating Manual, NEHS0848, "204-7392 (Air Motor Driven) Filtering Cart (for use on all Caterpillar products)" before beginning the procedure.

Filter Cart Setup

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 to the NEUTRAL position.

5. Engage the parking brake.

6. Block the wheels.

Show/hide table

Activating the machine's steering and work tools can be hazardous when personnel are working around the machine. Before moving the machine, make sure the machine is on firm level ground. Engage the parking brake. Make sure the area is clear of personnel before activating any work tool. Failure to follow this instruction could result in injury or death.

Filtration Procedure for E Series Vibratory Compactors

Illustration 5	g03304821
(9) Hydraulic tank filler cap

1. Clean the area around the hydraulic tank filler cap (9). Refer to Illustration 5.

2. Remove the hydraulic tank filler cap (9). Refer to Illustration 5.
   Show/hide table

   Illustration 6	g03304916
   (10) Hydraulic tank screen

3. Remove the hydraulic tank screen (10). Refer to Illustration 6.
   Show/hide table

   Illustration 7	g03304938
   (11) Return oil adapter

4. Install the return oil adapter (11). Refer to Illustration 7.

5. Attach the filter cart discharge hose to the return oil adapter (11).

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

   Note: For machines that do not have a drain valve assembly refer to Filtration Procedure without Drain valve Assembly in this document.

   Show/hide table

   Illustration 8	g03304957
   (12) Drain valve assembly located underneath the machine

7. Locate the drain valve assembly (12). Refer to Illustration 8.
   Show/hide table

   Illustration 9	g03304976
   (13) Suction adapter

8. Connect the fabricated suction adapter (13) to the hydraulic tank drain valve. Refer to Illustration 9.
   Show/hide table

   Illustration 10	g03304978
   (14) Suction adapter (15) Suction hose

9. Connect the filter cart suction hose (15) to the fabricated suction adapter (14). Refer to Illustration 10.
   Show/hide table

   Illustration 11	g03411136
   Air supply hose and air supply valve (16) Air supply valve (17) Air supply hose

10. Attach the air supply hose (17) to the 204-7392 Filter Cart. Make sure that the air supply valve (16) is in the CLOSED position. Be sure that air supply does not exceed 690 kPa (100 psi). Refer to Illustration 11.

11. Slowly open the air supply valve (16) to start the filtration. If the air supply is adjustable, adjust the supply air between 138 kPa (20 psi) and 345 kPa (50 psi). Turn the air supply valve ON after adjusting the air supply. Do not exceed 690 kPa (100 psi). The pump is a diaphragm pump. This pump is rated to pump 10W oil at 64 L/min (17 US gpm).

12. During operation, check the filter element indicators on the filter cart. This procedure will indicate the amount of capacity left in the filter element.

    Note: The filter cart pump will cavitate during the start-up. Cavitation is due to air in the suction lines of the pump. Shut OFF the filter cart. Check the connections if the pump cavitates for more than 1 minute.

13. Make sure 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 and to use as a baseline particle count.

14. The oil can be 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 the S·O·S lab. Refer to Contamination Control Guideline, SEBF8482, "Obtaining Oil Sample for Analysis" for further information regarding the collection of oil samples for analysis.

Filtration Procedure for Machines without an Ecology Drain or Drain Valve Assembly

Vacuum Transducer Assembly procedure.

Illustration 12	g03870813
Vacuum Transducer Assembly (1) 4C-7099 Nipple (2) 4C-7156 Fitting (3) 5P-0306 Transducer (4) 8S-7169 Coupling (5) 4C-4506 Air Hose (6) 5P-3501 Adapter

Assemble the Nipple (1) to the Fitting (2) and the Vacuum Transducer (3). Assemble Coupling (4) and Adapter (6) to the Air Hose (5). Attach Coupling (4) the Vacuum Transducer (3). Refer to Illustration 12 for parts and assembly orientation.

Suction Adapter Assembly procedure.

Illustration 13	g03871222
Suction Adapter Assembly (7) 190-8319 Coupler (8) 004-3099 Connector

Assemble the Coupler (7) to the Connector (8).

1. Remove the hydraulic tank filler cap to relieve the tank pressure. Install the hydraulic tank filler cap after pressure has been released.
   Show/hide table

   Illustration 14	g03871250
   Hydraulic tank (9) 5P-4924 Elbow

2. Remove the Elbow (9) from the top of the hydraulic tank. Refer to Illustration 14.

3. Install the vacuum transducer assembly in the port that contained Elbow (9). Refer to Illustrations 14 and 12.
   Show/hide table

   Illustration 15	g06291642
   CB13 Hydraulic Tank (components removed to enhance view) (10) 183-3873 Breather

4. When the breather assembly is accessible you can remove the 183-3873 Breather (10) and install the vacuum transducer in the port that contained the breather assembly. Refer to Illustration 15.

5. Attach an air supply hose to the vacuum transducer. Operate the vacuum transducer at a minimum of 172.36 kPa (25 psi) to create a vacuum in the hydraulic tank.

6. Ensure that the vacuum transducer has achieved a vacuum.

7. Remove the drain plug on the bottom of the hydraulic tank.

8. Install the suction adapter assembly in the drain plug port. Refer to Illustration 13.

9. Turn off the air supply to the vacuum transducer. Leave the vacuum transducer installed on the hydraulic tank to aid in removal of the discharge adapter after the filtration procedure is complete.

10. Attach the suction hose to the suction adapter assembly.

11. Remove the filler cap. Install the discharge adapter assembly in the hydraulic tank filler neck. Attach the discharge hose to the discharge adapter. Refer to Illustration 6.

12. Refer to step 10 of the "Filtration Procedure for E Series Vibratory Compactors" in this document for the filter cart operation procedure.

13. When the filtration procedure is complete, reverse the steps above to remove the adapters and hoses.

Portable Particle Analyzer Procedure

When using a portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual, NEHS0799 before operating the particle counter.

Illustration 16	g03305039
Portable particle procedure (18) Fabricated suction tube (19) 220-8607 Fitting (20) 210-5530 Coupler (21) S·O·S valve

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (21) on the filter cart. Refer to Illustration 16.

   Note: The fabricated suction tube can be made with the parts listed in Table 3 and as shown in Illustration 16.

2. Attach the opposite 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.

Bottle Sample Procedure

Illustration 17	g03306078
(21) S·O·S valve (22) 169-8373 Bottle Group

1. If collecting a bottle sample, use the same S·O·S valve (21) and a 169-8373 Bottle Group (22). Refer to Illustration 17.

2. Record an oil sample from the S·O·S valve (21) on the filter cart at the beginning of the filter cycle.
   Show/hide table

   Activating the machine's steering and work tools can be hazardous when personnel are working around the machine. Before moving the machine, make sure the machine is on firm level ground. Engage the parking brake. Make sure the area is clear of personnel before activating any work tool. Failure to follow this instruction could result in injury or death.

   Note: The hydraulic system filtration can be performed while running the engine.

3. At the halfway point of filtration, stop the procedure and change the machines hydraulic oil filters. Changing the filters 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 currently avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.

   Note: The machines filters only need replaced if the filters are not working at optimal performance, or scheduled for replacement.

4. Operate the filter cart until the portable particle analyzers indicates that the oil has reached an ISO cleanliness level of 18/15 or cleaner.

   Note: A target ISO level does not exist for non-pressurized, non-filtered compartments currently. ISO 18/15 in an acceptable contamination level for oil returned back into this type of compartment.

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 (17). Refer to Illustration 11.

   Note: Refer to "Tooling and Equipment" or "Oil Compartment Filtration Times for 188-3242 Filter Cart", at the end of this document, when a portable particle analyzer is not available.

6. Disconnect the filter cart discharge hose from the return oil adapter (11). Install the dust caps on the coupler and the nipple. Store the coupler and the nipple in a clean location. Refer to Illustration 7.

7. Disconnect the filter cart suction hose (15) from the suction adapter (14). Install the dust caps on the coupler and nipple. Store the coupler and nipple in a clean location. Refer to Illustration 10.

8. Check that the hydraulic oil tank drain valve is CLOSED.

9. Check the hydraulic tank oil level.

10. 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.

11. Unblock the wheels.

Oil Compartment Filtration Times for 204-7392 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 point, refer to the following equation. This equation relates to the 204-7392 Filter Cart. Other filtration units have a different equation reference. Units that use a different equation reference will be noted when appropriate. There are various conditions that must be factored into the filtration efficiency of any filter cart and situation. The following equation must be viewed only as a simple reference and not as an absolute time or efficiency result.

Illustration 18	g01177339
Oil compartment filtration equation (A) Compartment oil capacity (gal) (B) Pulses per minute (C) Approximate filtration time (min)

Example

A 563 Vibratory Compactor has 117 L (31 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 28 minutes.

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 point, refer to the following equation. This equation relates to the 188-3242 Filter Cart. 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.

Pulses per minute definition: Each air discharge or 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), delivering oil going 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 570B has 147 L (39 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 35 minutes.

ISO 4406:1999 Standards for Oil Cleanliness

The ISO standard 4406:1999 will read in three positions ISO 20/16/12. For discussion purposes, the three positions will be called X, Y, and Z (ISO X/Y/Z). A typical particle counter readout using ISO 4406:1999 would read as follows:

• X = The number of particles equal to or larger than 4 microns.

• Y = The number of particles equal to or larger than 6 microns.

• Z = The number of particles 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 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 Filters Versus Filter Cart Filtration

After any open system repair, on-site S·O·S sampling and particle counting is required. This procedure should be accomplished by exercising the specific system until the fluid is at normal operating temperature. Exercising the specific system ensures that the oil and representative oil will be collected during the S·O·S process. 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 unnoticed 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, a second 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 filtration is required.

2. Change the machines standard filter with a high efficiency filter halfway through the filtration process explained in this guideline.

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

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