Caterpillar Bulk Oil Filtration Procedure {1348, 3080, 4070, 429F, 5095, 7542} Caterpillar

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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 feedback form in the Service Information System web site.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Summary

The following explains the use of the 285-8095 Filter System to prepare bulk quantities of new Caterpillar oil to meet the fill oil requirements. The filter system combines a 1249 L (330 US gal) non-metallic storage reservoir with a filtration system. This filtration system has been validated by Caterpillar to remove contaminants that may be found in new oils shipped to Caterpillar facilities and dealerships. By following the instructions in the “Filtration Procedure” section below, new oils can be filtered to a cleanliness level of ISO 16/13. Caterpillar recommends using an automatic particle counter to verify the performance of the filter system in preparing fill oils. After the initial validation, audits should routinely be completed to ensure that the filter system continues to perform to the correct specifications.

Important Safety Information

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 1	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 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

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

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

ISO is a worldwide federation of national standards bodies. The ISO 4406: 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: procurement of the sample, the sample container, particle counting accuracy 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 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.

Filtration System Description

The complete bill of materials and instructions for operating the filter system are included in the Tool Operating Manual, NEHS0957. Following is a brief description of the major components of the filter system and why the components are important for preparing new oils to fill Caterpillar machines and engines. A schematic is also attached at the end of this guideline.

330-Gallon Non-Metallic Reservoir

Fill oils must be contained and stored in clean reservoirs during and after the filtration procedure. The best container to use is a non-metallic reservoir or tote. One tote is included with the filter system and more units may be added to meet specific needs. See the “3-Way Inlet and Outlet Valves” section below.

Centrifugal Pump

A centrifugal pump driven by a 3-phase electric motor is used to circulate the oil steadily through filters that remove debris and water contamination. Steady flow without interruptions and flow surges can be achieved by using centrifugal type pumps that maintain a uniform fluid velocity across filter elements. The steady flow of the centrifugal pump is preferred over the interrupted flow of a reciprocating pump. This uniform fluid velocity is necessary for the Filtration Procedure described below.

Ultra-High Efficiency Filter Elements

Remove fine debris down to particle sizes of 6 microns and smaller to provide the cleanest possible fill oils. This cleanliness level is accomplished with filter elements designed specifically for Caterpillar. These elements have the same quality construction and excellent dirt holding capacity as the elements used on Caterpillar machines and engines.

Water Removal Filter Element

Often new oils have been found to contain free and emulsified water. Water vapor may also be present in new oils. Depending on ambient conditions, the vapor may change phase and become emulsified in the oil. Water droplets in lubricating oil will interfere with automatic laser particle counters and should be removed if possible. In addition, water levels of 0.1 percent by volume may be harmful to Caterpillar machines and engines and must be removed from fill oils. The water removal element included in the filter system has been selected and placed in a location where the water removal element will work with the Ultra-High Efficiency filter elements to remove water contaminants.

Water Absorbing Tank Breather

The importance of water removal is addressed above. A tank breather is necessary to allow the air motion that occurs when filling a reservoir or when using the Filtration Procedure. The breather included with the filter system will remove airborne contaminants down to 4 microns. The breather will absorb some of the moisture present due to local ambient conditions. A desiccant color indicator is used to determine when the breather needs to be changed. Breather life will vary depending on the level of contamination and moisture in the air.

Filter Restriction Indicators

The filter system includes a pressure differential gauge on the ultra-high efficiency filter tank and a pop-up restriction indicator on the water removal filter housing. The indicator can be used to monitor when filter element service is required. Refer to the Tool Operating Manual, NEHS0957.

3-Way Inlet and Outlet Valves

3-way valves on the centrifugal pump inlet and the return line to the non-metallic reservoir are included with the filter system. The valves can be used to change the flow path of the oil. Oil may be drawn from or returned to an external reservoir other than the tank included with the filter system. With proper positioning, the 3-way valves can be used to fill and filter oil in an extra reservoir. If the additional reservoir is another non-metallic unit, the filtration procedure below can be used for as many of these units as desired. For instruction on the proper settings for the 3-way valves refer to the owners manual and operating instructions for the Caterpillar filter system. Refer to the Tool Operating Manual, NEHS0957.

Filtration Procedure

Oil that will be prepared to fill Caterpillar machines and engines must first be transferred to the 1249 L (330 US gal) non-metallic reservoir. The centrifugal pump of the filter system may be used if the oil temperature (viscosity) and the hose length to the storage reservoir are each low enough to prevent pump cavitation. Refer to the Tool Operating Manual, NEHS0957. During the process of transferring oil a sample bottle of the oil that will be prepared must be taken. This sample should be examined carefully with the naked eye. When visible debris or water is apparent, an automatic particle count will be required at the end of the filtration time specified in Table 1. The particle count will verify whether the oil is ready to fill Caterpillar machines and engines. Heavily contaminated oil is not to be run through the automatic particle counter.

Estimated Filtration Time

If the oil is below 25 °C (77 °F), the oil must be warmed for the following instructions to be valid. To reach fill oil cleanliness levels of ISO 16/13 for fluid power circuits, the oil in the filter system reservoir must be cycled through the filters 12 to 14 times. The process has also been shown to work on engine oils. With a proper pre-treatment procedure to reduce particle counts caused by additives in the oil, ISO cleanliness levels of 16/13 or better can be achieved for engine oils, which contain the most additive by volume. To achieve the 12 to 14 cycles through the filters, the following table of minimum estimated filtration times has been developed. See Table 4, which lists the required filtration time for different volumes of oil contained in the storage tank of the filter system filter cart. Once the oil in filter cart has been cycled through the filters for the minimum time interval specified in Table 4, the oil is ready to be used as a fill oil for Caterpillar machines and engines. The oil will remain in this condition for up to 14 days.

The content in Table 4 is the minimum filtration times. Studies have shown that oil additive levels will not be harmed if these minimum times are slightly exceeded. However, long periods of filtration are not recommended. Oil stored in the reservoir for periods longer than 14 days should be cycled through the filters again for the time interval indicated in Table 4. Do not exceed a total filtration time of 30 hours for a 1249 L (330 US gal) or smaller volume of any Caterpillar fill oil.

Automatic Laser Particle Counters

Caterpillar facilities and dealerships that want to measure the fill oil ISO cleanliness level using an automatic particle counter should use a pre-treatment procedure. This procedure offsets the possibility that oil additives may be counted by the automatic particle counter as contaminant debris. For instructions, refer to Contamination Control Guideline, SEBF9086. Caterpillar recommends using this procedure initially to verify the performance of the filter system. Use the automatic particle counter routinely to audit the cleanliness of the new oils.

Illustration 2	g01229540
(1) 330 gal reservoir (2) centrifugal pump (3) 3-phase electric motor (4) ultra-high efficiency filter elements (5) water removal element (6) moisture absorbing tank breather (7) 3-way valve