Procedure for Operating Caterpillar Filter Carts {0680, 0768, 5050} 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 that are 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.

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.

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 all personnel around the machine are safe. 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 of 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 you start 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.

Summary

Portable filter carts offer a means of removing contamination from machine oil systems. Removing contamination can be accomplished without removing and replacing the oil from the machine.

Filter carts are an environmentally safe means of:

• Off-loading used oil during oil changes

• Cleaning new oil, while replenishing the fluid system.

• "Kidney loop" cleaning oil in the fluid tank.

The filter cart should be used with the recommended hydraulic system maintenance procedures. The resulting clean oil will prolong component life as well as provide smooth actuator and control movement.

There is a complete range of micron rated filter elements available for these filter carts. The choice of the micron rating depends on the contamination level and viscosity of the oil. In a heavily contaminated system (ISO code 22/19 or higher), Caterpillar recommends to begin filtering with a 20-micron absolute element. This type of filtering will eliminate the 20-micron and larger particles. After the large particles have been removed, install a standard 13-micron, or a finer 5-micron absolute element to complete the filtration to an acceptable ISO rating determined by the system. When used in a kidney loop filtration application, the 64 L/min (17 US gpm) filter cart is sized and targeted for fluid tanks less than 113.6 L (30 US gal) in fluid capacity.

The filter cart and elements will not decrease existing wear on internal parts. The filter cart will not remove, eliminate, or repair mechanical problems associated with part wear due to contamination.

Caterpillar recommends that filter cart "Kidney Loop" filtration becomes a standard part of machine maintenance. The filter cart should be used at the appropriate oil filter change intervals, typically at the 250 to 500-hour service meter reading.

References

Catastrophic Failure of Components

If components have been run to self-destructive failure, some system disassembly will be required. The amount of system disassembly will depend on the extent the metal contamination has traveled within the hydraulic system. DO NOT use the "kidney loop" filtering method until the system contamination has been removed. Removing system contamination can on be accomplished by:

• Completely draining the system fluid.

• Removal, disassembly, and cleaning of all major system components.

• Utilizing the Hose Cleaner Groups on the hoses and tubes

• Clean assembly practices

• Filling with clean ISO 16/13 oil

The 233-7191 or 233-7193 Hose Cleaner Group will help evacuate the contaminated oil left in the fluid carriers. Disassembly to valves and other major system components will still be required due to inaccessible contaminated oil.

Using one of these filter carts will provide a means of lowering contamination levels in the reservoir oil to an acceptable ISO code rating.

Obtaining Oil Samples

A hydraulic oil particle count taken from a live oil-sampling valve is always the preferred method of obtaining an oil sample. Refer to Contamination Control Guideline, SEBF8482, "Obtaining an Oil Sample for SOS Analysis" for the proper procedures. Also, refer to Special Instruction, SEHS9043 for the procedure to install a live oil-sampling valve on the machines hydraulic system.

These valves can also be used to obtain a sample when using a 170-8500 Portable Particle Counter. Portable particle counters are not a substitute for lab particle counting. Portable particle counters are intended to give an ongoing record of the reduction of contamination during the filtering process and an on-sight trending analysis tool for machine systems in remote locations.

Taking an SOS sample before and after the filtering process is still the only way to determine the actual condition of the hydraulic oil in the system. The test provides the particle count and ISO Code rating. Testing prior to filtering the oil provides a baseline to determine the length of time for filtration.

An ISO code rating of 18/15 is an acceptable operating cleanliness level for most systems. Refer to table 4 for cleanliness targets.

Values higher than the recommended target ISO code may require additional filtering of the oil.

ISO 4406 Method for coding the level of contaminates 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 particle cross sectional area. 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. 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

Atthis timeCaterpillar 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.

Cleaning Procedure

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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.

1. Take an SOS oil sample and have the sample analyzed. A live oil-sampling valve is the recommended method to obtain the require oil sample. Refer to "Obtaining Oil Samples" and Contamination Control, PEGJ0045, "Reporting Particle Count by ISO Code" for additional information.

2. Inspect the hydraulic system (hoses, cylinders, and valves) for leaks. Most hydraulic oil contamination is brought into the system from an external source. Failure to make repairs before or immediately after filtration will not provide a long-term benefit.

3. Check the sight gauge and make sure that the hydraulic tank is filled to the full level.

4. DO NOT replace the machine filters at this time. New filters should be installed at the halfway point of filtration.

   Note: After one half hour of any kidney loop filtration, stop the procedure and change the machines hydraulic filter. This procedure will allow the new filters to assist in the system clean-up, but retain enough capacity to remain in place until the next scheduled filter change. This procedure also avoids opening the filter housing after the system has been cleaned, which can provide an inlet for contamination.

   Note: Only replace machine filters if scheduled to do so, or are not operating at optimal efficiency.

5. Start the filtered machine. Exercise the fluid system until the oil reached normal operating temperature. Shut off the machine.

6. Connect the filter cart to the machine.

7. Instructions for using an Ecology Drain.

   1. Remove the fill cap from the top of the tank.

   2. Remove the screen from the fill tube, if necessary.

   3. Store the cap and screen in a clean place to avoid contamination and damage.

   4. Install the discharge adapter.

   5. Connect the filter cart discharge line to the discharge adapter.

   6. Install suction adapter.

   7. Connect the filter cart suction line to the suction adapter.

8. Instructions when using 193-5900 (4 inch) or 193-5903 2 inch Tank Cap Adapter.

   1. Remove the fill cap from the top of the tank.

   2. Remove the screen from the fill tube, if necessary.

   3. Store the cap and screen in a clean place to avoid contamination and damage.

   4. Install the fill cap adapter.

      Note: A 90° elbow fitting may be required on some machines. Sometimes, the angle of the machine frame interferes with the installation of the filter cart hoses. The additional 90° elbow fitting will alleviate this problem.

   5. Make sure that the added center hose reaches within 25.4 mm (1 inch) of the tank bottom.

   6. Wipe the cart suction and discharge quick disconnects clean to insure the parts are free of any contamination. Connect the suction side of the cart to the top/center port on the tank cap adapter. Connect the discharge side of the cart to the side port on the tank cap adapter.

9. System without ecology drain instructions.

   1. Remove the breather.

   2. Install the transducer.

   3. Turn on the air supply to the transducer.

   4. Quickly remove the drain plug and install the suction adapter.

   5. Turn off the air supply.

   6. Remove the fill cap and install the discharge adapter.

   7. Connect the filter cart suction hose to the suction adapter.

   8. Connect the filter cart discharge hose to the discharge adapter.

10. Turn the filter cart ON.

    Note: Occasionally the filter cart pump will cavitate during start-up. Cavitation is due to air in the suction line of the pump. If cavitation continues for more than 1 minute, shut the filter cart OFF. Inspect the suction line for the cause of poor oil flow.

11. Begin filtering the oil.

    1. While the cart is running, check the element indicator on the outlet side of the filter cart. This will indicate the amount of capacity left in the filter element.

    2. If the filter element quickly plugs with contamination, refer to the "Filtering Extremely Dirty Oil" section of this guideline.

    3. Continue filtering until the ISO code level is at the recommended system target or below the recommended target.

    4. Contamination ISO levels can be monitored with the use of a portable particle counter or by using bottle sampling methods.
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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.

12. Regardless of the current oil contamination level, Caterpillar recommends operating the fluid systems for 5 to 10 cycles, every half hour. This will exchange the clean tank oil to the rest of the fluid in the system. Also, the dirty system oil will be transferred to the tank for filtration.

13. If moving the implements and steering with the filter cart attached to the machine is not possible, disconnect the cart. Activate the implements and steering system and then reattach the filter cart.

14. After reaching the desired ISO code rating, remove the filter cart.

    1. Turn the machine and the filter cart OFF.

    2. Disconnect the inlet and outlet hoses.

    3. Replace the drain plug or remove the tank filler cap adapter (whichever is used) and replace the screen in the hydraulic tank filler tube.

    4. Check the oil level in the sight gauge and use the transfer cart to add hydraulic oil as needed.

    5. Inspect the filler cap gasket and replace as necessary. Clean the cap and install on the filler tube.

15. Start the machine and take a live oil sample from the machine sampling valve. Perform an SOS lab analysis of the sample to determine elemental analysis, particle count, and the ISO code level.

16. Compare the new test results with the baseline data from Step 1 and record the information for future reference.

Filtering Extremely Dirty Oil

The standard element in the filter cart has a 10-micron absolute rating. If the filter quickly plugs after only a few minutes, use the following procedure.

1. Turn the filter cart OFF and stop the machine.

2. Replace the standard filter element with a 40-micron absolute element to remove the larger particles.

3. With the machine turned OFF, filter only the hydraulic tank oil for 30 minutes.

4. Start the machine and filter the oil for a half hour or until the filter is 80 percent saturated.

5. Turn OFF the machine and filter cart.

6. Install a new standard or finer filter element and begin filtering again. If the element plugs again, repeat the 40-micron procedure. If the filter cart runs more than 2 minutes, most of the large particles will have been removed.

7. Continue filtering and monitoring the ISO contaminant level.