Filtration Procedure for Excavator Hydraulic Oil {0680, 0768, 5050, 5056} Caterpillar

Agricultural Tractor

All

Articulated Truck

All

Asphalt Paver

All

Backhoe Loader

All

Challenger

All

Cold Planer

All

Combine

All

Compact Track Loader

All

Compact Wheel Loader

All

Earthmoving Compactor

All

Excavator

All

All Mining Shovels

311F (S/N: LZF1-UP; JFT1-UP; KCW1-UP)

312D2 (S/N: KLE1-UP; HBF1-UP; MGJ1-UP; GWN1-UP; MPP1-UP; RXZ1-UP)

312E (S/N: GAC1-UP; MJD1-UP; PZL1-UP; WEY1-UP)

312F (S/N: NLG1-UP; KMK1-UP)

312F GC (S/N: FKE1-UP)

313D2 (S/N: FEB1-UP; PLD1-UP; GAJ1-UP; RKN1-UP; FAP1-UP; GAP1-UP; MES1-UP; LCY1-UP)

313F (S/N: DJE1-UP; PRG1-UP)

313F GC (S/N: GJD1-UP; HDK1-UP)

314E (S/N: DKD1-UP; ECN1-UP; ZJT1-UP; YCW1-UP)

314F (S/N: LFC1-UP; RAF1-UP; MFR1-UP)

315F (S/N: TDY1-UP)

316E (S/N: DZW1-UP; WZY1-UP; YZZ1-UP)

316F (S/N: XAD1-UP; YDL1-UP; ZCR1-UP; ECZ1-UP)

318D2 (S/N: SGB1-UP; XAH1-UP; DPJ1-UP; HBP1-UP; WGR1-UP; TZS1-UP)

318E (S/N: DZF1-UP; WZS1-UP)

318F (S/N: HCP1-UP; FFT1-UP; GNX1-UP)

319D (S/N: KRM1-UP)

320 (S/N: BR61-UP; EBB1-UP; DJH1-UP; ZBN1-UP; YBP1-UP; HEX1-UP)

320 GC (S/N: BR41-UP; DKJ1-UP; KTN1-UP; ZBT1-UP)

320D (S/N: JPD1-UP; A6F1-UP; A9F1-UP; KZF1-UP)

320D2 (S/N: GBA1-UP; LMA1-UP; YEA1-UP; XBB1-UP; ZBD1-UP; PFE1-UP; TMF1-UP; DGH1-UP; NBH1-UP; ZBH1-UP; YBJ1-UP; FKK1-UP; XAK1-UP; EAL1-UP; DFM1-UP; HDM1-UP; JFM1-UP; DNP1-UP; KHR1-UP; ZCS1-UP; EKT1-UP; NBT1-UP)

320D3 (S/N: ESX1-UP)

320E (S/N: SXE1-UP; DFG1-UP; NEH1-UP; LAK1-UP; WBK1-UP; PNL1-UP; LHN1-UP; MEW1-UP; SHX1-UP; TFX1-UP; NAZ1-UP)

320F (S/N: ZRC1-UP; NHD1-UP; WJJ1-UP; YBM1-UP; TET1-UP; REW1-UP; SFX1-UP)

323 (S/N: BR91-UP; DWF1-UP; ZBK1-UP; YBL1-UP; RAZ1-UP)

323D (S/N: NZF1-UP)

323D2 (S/N: KCE1-UP; JEG1-UP; XBK1-UP; HCM1-UP; GYN1-UP; PJP1-UP; YCR1-UP; TDT1-UP; JEX1-UP; KBX1-UP)

323D3 (S/N: FEY1-UP)

323E (S/N: PJD1-UP; RGL1-UP; RAP1-UP; TDW1-UP)

323F (S/N: FA21-UP; PLB1-UP; YEC1-UP; XCF1-UP; YEJ1-UP; LMK1-UP; MDL1-UP; NCW1-UP)

324E (S/N: KTE1-UP; TLF1-UP; LDG1-UP; PNW1-UP; JCZ1-UP)

325F (S/N: XAA1-UP; YCA1-UP)

326D (S/N: PJM1-UP)

326D2 (S/N: JFL1-UP; MGW1-UP; NBX1-UP; KGY1-UP)

326F (S/N: TPG1-UP; HCJ1-UP; SGK1-UP; XFK1-UP; WGL1-UP; TMR1-UP)

329D (S/N: MNB1-UP; TAY1-UP)

329D2 (S/N: RGA1-UP; KJB1-UP; TMJ1-UP; WDT1-UP)

329E (S/N: RLD1-UP; WJK1-UP; TST1-UP; PLW1-UP; RDX1-UP; PTY1-UP)

329F (S/N: YHA1-UP; GKK1-UP; ERL1-UP; RCN1-UP; ZNN1-UP)

330 (S/N: WCH1-UP; KEL1-UP; PFN1-UP)

330 GC (S/N: NDH1-UP; FEK1-UP; GDW1-UP)

330D2 (S/N: ZBF1-UP)

330F (S/N: WBA1-UP; LBN1-UP)

335F (S/N: KNE1-UP; JJR1-UP)

336 (S/N: SP91-UP; JHD1-UP; TPK1-UP; YBN1-UP; DKS1-UP; ZBS1-UP; GDY1-UP)

336 GC (S/N: GSF1-UP; EBJ1-UP; JFW1-UP)

336D2 (S/N: GJA1-UP; MFA1-UP; WDC1-UP; JED1-UP; YCF1-UP; HBH1-UP; LAH1-UP; MEH1-UP; NAH1-UP; XBH1-UP; FAJ1-UP; HBK1-UP; NBN1-UP; MBP1-UP; FAR1-UP; EFT1-UP; FBT1-UP; ZCT1-UP; LBX1-UP; TLY1-UP)

336E (S/N: RZA1-UP; BMH1-UP; SSL1-UP; DPX1-UP)

336F (S/N: RKB1-UP; YFD1-UP; KGH1-UP; NAJ1-UP; ZBJ1-UP; NBL1-UP; PFL1-UP; SSN1-UP; LTP1-UP; KFT1-UP; DSW1-UP; MTW1-UP; WTZ1-UP)

340 (S/N: TYH1-UP; TMK1-UP; WDN1-UP; SZT1-UP)

340D2 (S/N: JEE1-UP; HHK1-UP)

340F (S/N: XBD1-UP; YBF1-UP; WBX1-UP)

345 GC (S/N: KEF1-UP)

349 (S/N: LKG1-UP; RYG1-UP; RBY1-UP)

349D (S/N: FLA1-UP; JGB1-UP; GKF1-UP; KLH1-UP)

349D2 (S/N: XAC1-UP; PFD1-UP; YAE1-UP; TAH1-UP; SDM1-UP; RAN1-UP; GAX1-UP)

349E (S/N: FJB1-UP; ETC1-UP; DGE1-UP; SPG1-UP; RGH1-UP; FEJ1-UP; MZW1-UP; MPZ1-UP)

349F (S/N: BZ21-UP; KEA1-UP; HLB1-UP; HPD1-UP; SFG1-UP; TEW1-UP; RAX1-UP)

352 (S/N: MGR1-UP; KZY1-UP)

352F (S/N: SD21-UP; WNA1-UP; YEG1-UP; A9J1-UP; XAJ1-UP; XAL1-UP; KBP1-UP)

374F (S/N: AT21-UP; AP41-UP; NFJ1-UP; MFL1-UP; DNM1-UP)

385C (S/N: EDA1-UP)

390D (S/N: WBT1-UP)

390F (S/N: HJD1-UP; TYE1-UP; MGF1-UP; HSM1-UP; GAY1-UP)

Forest Machine

320D2 FM (S/N: BW21-UP; CY21-UP)

538 (S/N: KBJ1-UP; GMY1-UP)

548 (S/N: WRA1-UP; SFZ1-UP)

558 (S/N: F5G1-UP; F5L1-UP; RHS1-UP; LRT1-UP)

568 (S/N: GF81-UP; L681-UP)

Forest Products

All

Hydraulic Shovel

All

Integrated Toolcarrier

All

Landfill Compactor

All

Load Haul Dump

All

Material Handler

All

MH3022 (S/N: FB31-UP)

MH3024 (S/N: FB51-UP; FB71-UP)

MH3026 (S/N: FB91-UP)

MH3037 (S/N: JPB1-UP; KPM1-UP)

MH3049 (S/N: HPB1-UP)

MH3059 (S/N: RBR1-UP)

MH3295 (S/N: PA91-UP)

Mini Hydraulic Excavator

All

307.5 (S/N: GW71-UP)

308 (S/N: GG81-UP; GK81-UP; GW81-UP; GX81-UP)

308.5 (S/N: GZ81-UP)

309 (S/N: GG91-UP; GW91-UP)

310 (S/N: GWT1-UP)

Motor Grader

All

Multi Terrain Loader

All

Off-Highway Truck/Tractor

All

797F (S/N: LAJ1-UP)

Paving Compactor

All

CB-536D (S/N: FEB1-UP)

Pipelayer

All

Skid Steer Loader

All

Soil Compactor

All

Telehandler

All

Track-Type Loader

All

Track-Type Skidder

All

Track-Type Tractor

All

Underground Articulated Truck

All

Wheel Dozer

All

Wheel Feller Buncher

All

Wheel Loader

All

924K (S/N: HJF1-UP)

Wheel Skidder

All

Wheel Tractor-Scraper

All

Wheeled Excavator

All

M314F (S/N: FB41-UP)

M316F (S/N: FB61-UP)

M318F (S/N: FB81-UP)

M320F (S/N: FB21-UP)

M322F (S/N: FBW1-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 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 that is available from Caterpillar. Updated 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 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. This filtration process is easy to use. The hydraulic filter cart quickly connects to the excavator 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. 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 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 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 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 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 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.

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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, PERJ1017, "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

Tooling and Equipment

Filter Cart Procedure for Excavator Hydraulic Oil

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, NEHS0778, "188-3242 Hydraulic/Transmission Filter Cart" before beginning this procedure.

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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.

Procedure

Note: Be sure to keep all parts clean and free of contamination throughout the procedure.

1. Position the machine on level ground.
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   Illustration 3	g02190776

2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the ground. Lower the boom until the bucket is flat on the ground. Refer to Illustration 3.

3. Shut off the engine.

4. Turn the engine start switch to the ON position without starting the engine.

5. Place the hydraulic activation control lever in the UNLOCKED position.

6. Move the joysticks or the pedals of the hydraulic circuit that requires service to the FULL STROKE positions. Movement of the joysticks or pedals will release the high pressure only in that circuit.

   Note: If the hydraulic circuit requires the activation of a switch for operation, activate the necessary switches for the operation of the hydraulic circuit.

7. After releasing the hydraulic pressure in each of the desired hydraulic circuits, place the hydraulic activation control lever in the LOCKED position.

8. Turn the engine switch to the OFF position.
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   Illustration 4	g01176237
   (1) Access cover

9. Remove the bolts that hold the access cover in place. The access cover is located above the hydraulic tank. Remove the access cover (1). Refer to Illustration 4.
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   Illustration 5	g01176239
   (2) Pressure cap

10. Clean the area around the pressure cap (2). Slowly loosen the pressure cap (2) on the hydraulic tank and release the pressure. Make sure that all air pressure has been vented before completely removing the pressure cap. Refer to Illustration 5.

11. Store the pressure cap in a clean place to avoid contamination and damage.
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    Illustration 6	g01176242
    (3) 199-1003 Bushing

12. Install a Bushing (3) in place of the pressure cap to be used as a spacer for the pressure cap adapter. Refer to Illustration 6.
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    Illustration 7	g03377587
    (4) 198-8796 Return Pipe (5) 198-1051 Pressure Cap Adapter

13. Install the Pressure Cap Adapter (5) onto the pressure cap port. Lower the Return Pipe (4) until the quick disconnect is within 50.8 mm (2 inch) of the compression nut. Hand tighten the compression nut of the Pressure Cap Adapter (5). Refer to Illustration 7.

    Note: For models that do not have a pressure cap, steps 14 through 16 will explain how to replace the cover plate with an adapter to create a connection for the return pipe.

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    Illustration 8	g01176249
    (6) Cover plate

14. Clean the area around the cover plate (6). Remove the bolts that hold the cover plate (6) to the hydraulic tank. Remove the cover plate (6) and store in a clean place to avoid contamination. Refer to Illustration 8.
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    Illustration 9	g01176250
    (7) Cover Plate Adapter (8) 4I-0722 Plug

15. Install the Cover Plate Adapter (7) and remove the Plug (8). Refer to Illustration 9.

    Note: The Plug (8) from the Cover Plate Adapter (7) is the same size as the tank filler plug (9). Refer to Illustration 9.

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    Illustration 10	g03377591
    (9) Filler Plug (10) 198-1052 Adapter As (11) 198-8796 Return Pipe

16. Install the Adapter As (10) on the cover plate adapter (7). Lower the Return Pipe (11) until the quick disconnect is within 50.8 mm (2 inch) of the compression nut. Hand tighten the compression nut of the plug adapter. Refer to Illustration 10.

17. Clean the area around the filler plug (9). Remove the filler plug (9) that is on top of the hydraulic tank. Store the filler plug (9) in a clean place. Refer to Illustration 10.
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    Illustration 11	g03377602
    (12) 198-8795 Suction Adapter (13) 198-1052 Adapter As

18. Install the Adapter As (13). Lower the suction pipe (12) within 25.4 mm (1 inch) of the bottom of the tank. Hand tighten the compression nut on the plug adapter. Refer to Illustration 11.
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    Illustration 12	g01176285
    (14) Suction line

19. Connect the filter cart suction hose (14) to the suction pipe (13). Refer to Illustration 12.
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    Illustration 13	g01176289
    (15) Return line

20. Connect the filter cart return line (15) to the discharge hose (4). Connect the filter cart to the return pipe on the 345 and 365 excavator models. Refer to Illustration 13.
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    Illustration 14	g03377606
    The air supply valve is in the CLOSED position. (16) Air supply valve (17) Air supply hose

21. Attach the air supply hose (17) to the Filter Cart Gp. Ensure the air supply valve (16) is in the CLOSED position. Be sure that the air supply does not exceed 689 kPa (100 psi). Refer to Illustration 14.
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    Illustration 15	g03377609
    Air supply valve in the OPEN position

22. Slowly open the air supply valve (16) to start the filter cart pump operation. The pump is a double acting diaphragm pump. The pump is rated to pump 10W oil at 340 L/min (90 US gpm). Refer to Illustration 15.

23. When operating the filter cart, check the filter element indicators on the filter cart. Checking the filter element indicators will determine the amount of capacity left in the filter element.

24. The filter cart pump will occasionally cavitate during start-up. If cavitation continues for more than 1 minute, turn off the filter cart. Ensure that there are no oil leaks from any of the filter cart connections.

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

25. 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.

26. If using the Portable Particle Analyzer for particle counting, be sure to read and understand Tool Operating Manual, NEHS0799, "Tool Operating Manual for 170-8500 Analyzer Gp" before operating the Portable Particle Analyzer.
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    Illustration 16	g03377611
    (18) S·O·S valve (19) 210-5530 Quick Connect Coupler (20) Fabricated suction tube

27. Connect the low pressure IN port to the S·O·S valve (18) on the base assembly with a fabricated suction tube (20) that is fitted with a Quick Connect Coupler (19). The fabricated tube is required to collect an on-line sample when using the Portable Particle Analyzer. Refer to Illustration 16.
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    Illustration 17	g01176977
    (21) 169-8373 Bottle Group

28. Use the same S·O·S valve (18) and a Fluid Sampling Bottle (21) if collecting a bottle sample. Refer to Illustrations 16 and 17.

29. Record an oil sample reading from the S·O·S valve (18) on the filter cart at the start of the filter cycle.
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    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.

30. Start the machine. Cycle the boom circuit and cycle the stick circuit every half an hour of the filter cart operation. Cycle the cylinders to the end of the stroke at least four complete times. Cycling of the cylinders will flush the contaminated hydraulic system oil back to the tank. Cycling the cylinders will cycle the clean tank oil into the system and flush the more contaminated oil back into the tank. The filtration procedure can be performed while cycling the machine.

31. Turn off the engine.

32. Stop the procedure and change the hydraulic filters after one half of an hour of filtering. Changing the 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.
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    Illustration 18	g01177013
    Filter cart operation on a 330B L Excavator. (22) 188-3242 Filter Cart Gp

33. Operate the filter cart (22) until the Portable Particle Analyzer indicates that the oil has reached an acceptable ISO level of at least 18/15. Take a final oil sample and record the final ISO level before the machine is returned to the field. Refer to Illustration 18.

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

34. 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 14.
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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 pilot pressure is released. Serious injury can result if this remaining pressure is not released before any service is done on the hydraulic system. Make sure that the remaining pressure has been released by utilizing the purge screws that are located on the boom, stick and bucket lines. Before any purge screw is turned, the bucket and or all of the attachments must be lowered to the ground or properly supported.

35. Disconnect the filter cart suction hose (14) from the suction pipe. Refer to Illustration 12.

36. Disconnect the filter cart discharge hose (15) from the return pipe (4). Disconnect the filter cart return pipe (11) on the 345 and 365 Excavators.

37. Remove the Adapter As (13). Refer to Illustration 11.

38. Install the filler plug (9) to the top of the tank. Refer to Illustration 10.

39. Remove the plug adapter (10) from the cover plate adapter (7). Install the plug (8) on the cover plate adapter. Refer to Illustrations 9 and 10.

40. Remove the pressure cap adapter (5) and remove the bushing (3). Refer to Illustrations 6 and 7.

41. Install protective caps to the adapter, the filter cart suction hose, and the filter cart discharge line to control contamination.

42. Install the pressure cap (2) on the top of the tank. Refer to Illustration 5.

43. Install the access cover (1) and install the bolts that secure the access cover to the hydraulic tank.

44. Check the oil level by viewing the hydraulic tank sight gauge.

45. 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.

E, F, & Next Gen Hex - Series Filter Cart Procedure for Excavator Hydraulic Oil

The procedure encompasses tracked, wheeled, and trailer or truck mounted E - Series excavators.

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Illustration 19	g01176237
(1) Access Cover

1. Remove the bolts that hold the access cover (1) in place. The access cover is located above the hydraulic tank. Remove the access cover. Refer to Illustration 19.
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   Illustration 20	g02704617
   (2) 278-6501 Cover As (7) 363-2518 Breather Gp

2. Loosen the Breather Gp (7) cap partially to relieve system pressure stored in the hydraulic tank. An ignition key is needed to remove the breather group. Clean the area around Cover As (2). Remove the bolts that mount the Cover As (2) to the hydraulic tank. Remove the Cover As (2) and store the Cover Assembly in a clean place to avoid contamination. Refer to Illustration 20.
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   Illustration 21	g02705417
   (3) Cover As (4) 207-6403 Plug

3. Install the Cover As (3) onto the hydraulic tank and remove the Plug (4). Refer to Illustration 21.
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   Illustration 22	g02705557
   (3) Cover As (5) 198-1052 Adapter As (6) 198-8796 Return Pipe

4. Install the Adapter As (5) on the Cover Plate Adapter (3). Lower the Return Pipe (6) until the quick disconnect is within 50.8 mm (2 inch) of the compression nut. Hand tighten the compression nut of the plug adapter. Refer to Illustration 22.
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   Illustration 23	g02705876
   (7) 363-2518 Breather Gp

5. Clean the area around the Breather Gp (7). Remove the Breather Gp (7) that is on top of the hydraulic tank. Store the breather group in a clean place to avoid contamination. Refer to Illustration 23.
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   Illustration 24	g02708456
   (8) 381-8839 Pressure Cap Adapter (9) 198-1052 Adapter As

6. Install the Pressure Cap Adapter (8) on the hydraulic tank. Attach the Adapter As (9) to the Pressure Cap Adapter (8). Lower the suction pipe within 25.4 mm (1 inch) of the bottom of the tank. Hand tighten the compression nut on the plug adapter. Refer to Illustration 24.

Note: Refer to Step 19 of the Filter Cart Procedure for Excavator Hydraulic Oil section in this document for the remaining steps of the filtration procedure.

Filter Cart Procedure for MH3049 and MH3059 Material Handler

1. Park the machine on level ground and lower all hydraulic implements to the ground. Be sure to engage the parking brake.

2. Shut off the engine. With the ignition turned ON, relieve all hydraulic system pressure by moving all hydraulic control valves through the complete range of motion.
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   Illustration 25	g03354408
   (1) Cover As (2) Filler cap

3. Clean the area around the hydraulic tank Filler Cap (2) and Cover As (1). Slowly loosen the filler cap (2) on the hydraulic tank and release the tank pressure. Make sure that all air pressure has been vented before completely removing the cap. Refer to Illustration 25.

4. Remove Cover As (1) from the hydraulic tank. When removing the Cover As (1) from the hydraulic tank, keep the Cover As (1) parallel to the hydraulic tank to prevent damage to the hydraulic tank filler screen. Refer to Illustration 25.
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   Illustration 26	g03354452
   (1) Cover As (3) Hole location

5. Cut a 63.50 mm (2.5 inch) hole (3) in the center of the Cover As (1). Refer to Illustration 26.

6. Insert the 37° angle of the 7X-7678 Connector into the hole (3) cut in the Cover As (1). Weld the connector to the Cover As (1).

7. Install a 228-7097 O-Ring Seal onto the connector over the threads down to the hex nut portion of the connector to create a seal between the connector and the fill cap adapter.

8. Install the Cover As (1) on to the hydraulic tank.
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   Illustration 27	g03354816
   (X) Proper length of suction hose (Y) Distance from the top of the filler neck to the bottom of the tank (Z) 2 inch filler cap adapter = 50.8 mm (Z) 4 inch filler cap adapter = 101.6 mm

9. Measure the distance from the top of the hydraulic filler neck to the bottom of the hydraulic tank (Y). Subtract (Z) from (Y) to obtain the proper hose length (X). Refer to Illustration 27.

10. Cut a length of 122-6906 Hydraulic Suction Hose (844) that matches (X) measured distance of tank depth. Install the hose on the filler cap adapter hose barb.
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    Illustration 28	g03354821
    (4) Filler cap adapter

11. Install the 193-5900 Filler Cap Adapter (4) on to the 7X-7678 Connector. Be sure that the installed suction hose reaches within 25.4 mm (1 inch) of the bottom of the hydraulic tank. Refer to Illustration 28.
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    Illustration 29	g03354873
    (5) Side return port with elbow fitting

    Note: The elbow fitting (5) may be required on larger tractors for the filter cart suction hose to reach and connect to the filler cap adapter. The addition of the elbow fitting will aid in the necessary orientation of the return port. The elbow fitting (5) is pictured in Illustration 29 on the side report port.

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    Illustration 30	g03354879
    (6) Suction port with elbow fitting (7) Filler cap adapter center suction port (8) Filter cart suction hose

12. Connect the filter cart suction hose (8) to the Fill Cap Adapter center suction port (7). Refer to Illustration 30.
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    Illustration 31	g03354882
    (9) Return line (10) Fill Cap Adapter side return port

13. Connect the filter cart discharge hose (9) to the Fill Cap Adapter side return port (10). Refer to Illustration 31.

    Note: Refer to Step 19 of the Filter Cart Procedure for Excavator Hydraulic Oil section in this document for the remaining steps of the filtration procedure.

14. When the filtration procedure is complete, remove the 193-5900 Filler Cap Adapter and install the 103-6343 Cap.

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 188-3242 Filter Cart Gp and the 194-2897 Filter Cart only. Other filtration units will have different equation references and these units will be noted when appropriate.

Illustration 32	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). The two pulses will deliver 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 330B Excavator hydraulic tank has 401.25 L (106 US gal) of SAE 10W oil. The filter cart is operating at 180 pulses per minute. The approximate filtration time should be 84 minutes or 1.4 hours.

ISO 4406 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. 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

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.