Filtration Procedure for Off-Highway Truck and Rotary Drill Hydraulic Oil {0680, 0768, 5050, 5056} Caterpillar


Filtration Procedure for Off-Highway Truck and Rotary Drill Hydraulic Oil {0680, 0768, 5050, 5056}

Usage:

769C 01X


Off-Highway Truck/Tractor
69D (S/N: 9SS1-UP; 9XS1-UP)
73D (S/N: 9YS1-UP)
768C (S/N: 02X1-UP)
769 (S/N: 99F1-UP; 35W1-UP)
769B (S/N: 99F1-UP)
769C (S/N: 01X1-UP)
769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
770 (S/N: BZZ1-UP)
770G (S/N: KDH1-UP; ECM1-UP; ECX1-UP)
772 (S/N: RLB1-UP; 10S1-UP; 11S1-UP; 80S1-UP)
772B (S/N: 64W1-UP)
772G (S/N: LTS1-UP; KEX1-UP; LTX1-UP)
773 (S/N: 63G1-UP)
773B (S/N: 63W1-UP)
773D (S/N: NBJ1-UP; 7ER1-UP; 7CS1-UP)
773E (S/N: BDA1-UP; PRB1-UP; KEG1-UP; ASK1-UP; DJS1-UP)
773F (S/N: EED1-UP)
776 (S/N: 14H1-UP; 14W1-UP)
776B (S/N: 6JC1-UP)
776C (S/N: 2TK1-UP)
776D (S/N: 5ER1-UP; AFS1-UP)
777 (S/N: 84A1-UP)
777B (S/N: 4YC1-UP)
777C (S/N: 4XJ1-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP)
777E (S/N: KDP1-UP)
777F (S/N: JRP1-UP)
777G (S/N: GT71-UP; T5A1-UP; TNM1-UP; RDR1-UP)
784B (S/N: 5RK1-UP)
784C (S/N: 2PZ1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: DMC1-UP; MSY1-UP)
785G (S/N: RTL1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SPD1-UP; SHH1-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)
793F (S/N: SND1-UP; SSP1-UP; D3T1-UP; RBT1-UP)
793F AC (S/N: EMD1-UP)
794 AC (S/N: MN51-UP; MT51-UP)
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)
797F (S/N: WSP1-UP)
MT4400D AC (S/N: MH41-UP; MT41-UP)
Quarry Truck
771C (S/N: 3BJ1-UP)
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
773G (S/N: MWH1-UP; JWS1-UP)
775B (S/N: 7XJ1-UP)
775D (S/N: 6KR1-UP; 8AS1-UP)
775E (S/N: BEC1-UP)
775F (S/N: EYG1-UP; DLS1-UP)
775G (S/N: RFM1-UP; MJS1-UP)
Rotary Drill
MD6250 (S/N: DN71-UP; DN81-UP)
MD6310 (S/N: DLK1-UP; DLZ1-UP)

Introduction

Table 1
Revision  Summary of Changes to SEBF8446 
27  Added new serial number prefixes for New Product Introduction (NPI).
Updated part numbers in table 2. 
26  Added new serial number prefixes for New Product Introduction (NPI). 
25  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2018.
Title changed from: Filtration Procedure for Off-Highway Truck Hydraulic Oil to Filtration Procedure for Off-Highway Truck and Rotary Drill Hydraulic Oil 
24  Added new serial number prefixes for New Product Introduction (NPI). 
23  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2017. 

© 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 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 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 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 the customers to benefit from cleaner hydraulic systems. The filtration process is easy to use. The filter cart quickly connects to the hydraulic tank filler cap. This guideline provides directions for installing and operating the filter cart.

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. This procedure may need modified by the technician for use on some Caterpillar Underground Mining Equipment.


NOTICE

If the vehicle 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 vehicle system cleaning MUST be performed prior to the filtration. This filtration procedure and subsequent particle count testing should be performed as a final step in the repair process.


Important Safety Information



Illustration 1g02139237

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 2g01032906

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 the safety 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 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

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

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.


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

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.



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, 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

Table 2
References 
Media Number  Title 
NEHS0778  "Tool Operating Manual for 188-3242 & 227-2479 Filter Cart" 
NEHS0799  "Tool Operating Manual for S40 Portable Particle Analyzer" 
NENG2500  "Dealer Service Tool Catalog" 
PEGJ0045  "Reporting Particle Count by ISO code" 
PEGJ0047  "How to Take A Good S·O·S Sample" 
SEBF8482  "Obtaining an Oil Sample for S·O·S Analysis" 

Tooling and Equipment

Table 3
Required Tools 
Part Number  Part Description 
188-3242  Hydraulic/Transmission Filter Cart 
193-5903  2 in. Fill Cap Adapter(1) 
193-5900  4 in. Fill Cap Adapter(2) 
001-5262  45 degree Elbow 
3H-9690  90 degree Elbow 
169-8373  Bottle Group 
9X-2514  Adapter(3) 
8T-3510  Pipe Nipple(3) 
Optional Tools 
170-8500  Analyzer Gp 
210-5530  Coupler 
188-0639  Hose 
(1) Includes entire center suction port with quick disconnect and entire side discharge port with quick disconnect.
(2) Includes entire center suction port with quick disconnect and entire side Discharge port with quick disconnect.
(3) Used on 794 AC to connect Fill Cap Adapter to the hydraulic tank.

Off-Highway Truck and Rotary Drill Filter Cart Procedure for Hydraulic Oil

The following procedure is for all models of Off-Highway Trucks and Rotary Drills. The procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and mixed from operation. The warm oil allows any contamination in the system to be placed in suspension, and lowers the viscosity of the oil. Be sure to read and understand Tool Operating Manual, NEHS0778, "188-3242 or 227-2479 Filter Cart Group" before beginning the procedure.

Filter Cart Procedure

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

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.


  1. Park the machine on level ground. Be sure to engage the parking brake.

  2. With the engine OFF and the ignition turned ON, relieve all the hydraulic system pressure. System pressure is relieved by moving all hydraulic control valves through the complete range of motion.


    Illustration 3g01262620
    (1) Filler Cap

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

  4. Remove the lock-ring and the strainer from the hydraulic filler neck.

  5. Store the filler cap, lock-ring, and strainer in a clean place to avoid contamination and damage.

  6. For 794 ACand MT4400D AC models assemble 9X-2514 Adapter and 8T-3510 Pipe Nipple to create the adapter assembly. Attach the adapter assembly to the top of the hydraulic tank in place of 9X-6138 Pipe Plug.


    Illustration 4g01262621
    (X) Proper length of suction hose
    (Y) Distance from the top of the filler neck to the bottom of the tank
    (Z) 2 inch fill cap adapter = 110 mm
    (Z) 4 inch fill cap adapter = 60 mm

  7. 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 4.

  8. Cut a length of suitable hose matching the (X) measure distance of tank depth. Install the hose on the filler cap adapter hose barb.


    Illustration 5g01262623
    (2) Fill cap adapter

  9. Install the 193-5903 Fill Cap Adapter Gp or the 193-5900 Fill Cap Adapter Gp (2). When obstructions exist, the side discharge port can be removed for clearance and reinstalled after the main fill cap adapter is installed. Be sure that the installed suction hose reaches within 25.4 mm (1 inch) of the bottom of the hydraulic tank. Refer to Illustration 5.


    Illustration 6g03399561
    (3) 90° Elbow
    (4) Side discharge port fitting

    Note: The 45 degree elbow fitting or the 90 degree elbow fitting (3) may be required on smaller trucks when the body-to-tank clearance is minimal. The addition of the 45 degree or the 90 degree elbow fittings will aid in the necessary orientation of the center suction port. The 90 degree elbow fitting (4) is pictured in Illustration 6 on the center suction port.

  10. Install the side discharge port fitting (3). There are multiple ports on the fill cap adapter to aid in the connection of the filter cart hoses. Refer to Illustration 6.


    Illustration 7g01262625
    (5) Suction hose
    (6) Center suction port

  11. Connect the filter cart suction hose (5) to the fill cap adapter center suction port (6). Refer to Illustration 7.


    Illustration 8g01262626
    (7) Discharge hose
    (8) Side discharge port

  12. Connect the filter cart discharge hose (7) to the fill cap adapter side discharge port (8). Refer to Illustration 8.


    Illustration 9g03399573
    Air supply valve in the CLOSED position
    (9) Air supply valve
    (10) Air supply hose

  13. Attach the air supply hose (10) to the 188-3242 Filter Cart. Ensure that the air supply valve (9) is in the CLOSED position. Be sure that the air supply does not exceed 689 kPa (100 psi). Refer to Illustration 9.


    Illustration 10g03399581
    (9) Air supply valve in the OPEN position

  14. Slowly open the air supply valve (9) 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 10.

  15. While operating the filter cart, check the filter element indicators on the filter cart. The indicators will determine the amount of capacity left in the filter element.

    Note: Occasionally, the filter cart pump will cavitate during start-up. The cavitation is due to air in the suction hose of the pump. If the cavitation continues for more than 1 minute, shut the filter cart OFF and check the connections.

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

    Note: A particle count should be taken on the oil at the beginning of the filter cart cycle for use as a baseline particle count.

  17. The oil can be particle count tested for cleanliness in one of the two following ways.

    1. Use a 170-8500 Analyzer Gp for immediate results.

    2. Collect a bottle sample and send the sample to an S·O·S lab.

      Note: If using the 170-8500 Analyzer Gp for particle counting, be sure to read and understand the Tool Operating Manual, NEHS0799, "170-8500 Analyzer Group" before operating the particle counter.



    Illustration 11g03399589
    (11) S·O·S valve
    (12) 210-5530 Coupler
    (13) Fabricated suction tube

  18. When using the 170-8500 Analyzer Gp, connect the "low pressure in" port to the S·O·S valve (11) on the base assembly using a fabricated suction tube (13). The fabricated suction tube is to be fitted with a 210-5530 Coupler (12). The fabricated tube is required to collect an on-line sample when using the 170-8500 Analyzer Gp. Refer to Illustration 11.


    Illustration 12g01262632
    (14) 169-8373 Bottle Group

  19. If collecting a bottle sample, use the same S·O·S valve (11) and a 169-8373 Bottle Group (14). Refer to Illustrations 11 and 12.

  20. Record an oil sample reading from the S·O·S valve (11) on the filter cart at the beginning of the filter cycle.

  21. During the filter cart operation, cycle the hoist on the Off-Highway Truck and the hydraulic circuits on the Rotary Drill at least four times each half to 1 hour. This process will cycle the clean tank oil into the hydraulic system and flush the more contaminated oil back into the tank. The oil filtration can be performed while running the engine.

  22. After half an hour of filtering, stop the procedure. Change the hydraulic filter on the machine. Changing the filters allows the filters to help with system cleaning. The new filter can remain in place until the next scheduled filter change. Changing the filter now avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.


    Illustration 13g01262633
    Filter cart operation on a 777D Off-Highway Truck.
    (15) 188-3242 Filter Cart

  23. Operate the filter cart (15) until the 170-8500 Analyzer Gp indicates that the oil has reached an ISO level of at least 18/15. The final ISO level should be recorded before the machine is returned to the field. Refer to Illustration 13.

    Note: Refer to "Oil Compartment Filtration Times for 188-3242 Filter Cart", at the end of the document, when a 170-8500 Analyzer Gp is not available.

  24. When the target ISO level or the time interval has been met, close the air supply valve (9) and disconnect the air supply hose (10). Refer to Illustration 9.

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

    Hot oil and components can cause personal injury.

    Do not allow hot oil or components to contact skin.




    Illustration 14g01262635
    (16) Probe
    (17) S·O·S valve (on the fill cap adapter)

  25. To relieve possible tank pressure, use a probe (16) from the 169-8373 Bottle Group. Use the probe supplied in the 169-8373 Bottle Group and depress the S·O·S valve (17) on the fill cap adapter. Refer to Illustration 14.

  26. Disconnect the filter cart discharge hose (7) from the fill cap adapter discharge port (8). Refer to Illustration 8.

  27. Disconnect the filter cart suction hose (5) from the fill cap adapter center suction port (6). Refer to Illustration 7.

  28. Remove the fill cap adapter (2). Refer to Illustration 5.

  29. Install protective caps to the fill cap adapter, the filter cart suction hose, and the filter cart discharge hose to control contamination.

  30. Install the strainer and the lock-ring into the hydraulic fill neck.

  31. Install the hydraulic oil tank fill cap (1). Refer to Illustration 3.

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

  33. 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.

Oil Compartment Filtration Times for 188-3242 Filter Cart

If an on-line, portable particle counter is not available to measure when the contaminant level has lowered to an acceptable point, refer to the following equation. This equation relates to the 188-3242 and 246-1157 Filter Carts 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 situation. Therefore, the following equation must be viewed as only a simple reference and not an absolute time or efficiency result.



Illustration 15g01177339
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 pump delivers one pulse of oil. The internal pump shaft will slide left (one pulse), and then to the right (one pulse). Each pulse 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 777D Off-Highway Truck hydraulic system has 416 L (110 US gal) of SAE 10W oil. The filter cart is operating at 180 pulses per minute. The approximate filtration time should be 86 minutes or an hour and a half.

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: procurement of the sample, the sample container, particle counting accuracy, 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.

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