Filtration Procedure for 5000 Series Front Shovel, Mass Excavator, 6015B Hydraulic Mining Shovel, and MH3037 Material Handler Hydraulic Oil {0680, 0768, 5050, 5056} Caterpillar

Excavator

5090B (S/N: CLD1-UP)

5110B (S/N: AAA1-UP; AAK1-UP; AAT1-UP)

5130 (S/N: 7TJ1-UP; 5ZL1-UP)

5130B (S/N: 4CS1-UP)

5230 (S/N: 7LL1-UP)

5230B (S/N: 4HZ1-UP)

Hydraulic Shovel

6015B (S/N: FKD1-UP; HLD1-UP; MKE1-UP; PZE1-UP; LWN1-UP; WSN1-UP; ZEN1-UP; LWS1-UP)

Material Handler

MH3027 (S/N: MYR1-UP)

MH3037 (S/N: JLH1-UP)

Introduction

© 2016 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 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).

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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 instructions that are given in this guideline will enable dealers and customers to properly filter 5000 Series Front Shovels, Mass Excavatorsand Material Handler hydraulic oil. This procedure will reduce contamination in the oil to an acceptable ISO contamination level. This procedure may need modified by the technician for use on some machines.

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 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 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.

References

Tooling and Equipment

Filter Cart Procedure for Excavator Hydraulic Oil

This procedure is most effective when performed immediately after the oil has been warmed to 50°C (122°F) and mixed from operation. Warming the oil allows any contamination in the system oil to be placed in suspension and lowers the viscosity. Be sure to read and understand the Tool Operating Manual, NEHS0778, "188-3242 Hydraulic/Transmission Filter Cart" before beginning the procedure.

Procedure

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

Note: On the MH3037 access the hood cover above the hydraulic tank. Refer to Step 4 of the filtration procedure for the MH3037 and Hydraulic Mining Shovel filtration procedure. Steps 1,2, and 3 do not apply to the MH3037 and Hydraulic Mining Shovel.

1. Park the machine on level ground. Lower the bucket to the ground so that the stick is vertical. Stop the engine.
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   Illustration 3	g01283760
   (1) 5130 and 5230 access door

2. Open the access door (1). Enter the left-hand enclosure on the 5130 and 5230 models.
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   Illustration 4	g01283763
   5130 and 5230 vacuum relief valve location (2) Vacuum relief valve

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   Illustration 5	g01283764
   5110B vacuum relief valve and filler cap location (2) Vacuum relief valve (3) Filler cap

3. Press the button on the vacuum relief valve (2). Relieve the tank pressure before you remove the filler cap.
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   Illustration 6	g01283765
   5130 and 5230 filler cap location (3) Filler cap

4. Clean the area around the filler cap (3). Slowly loosen the filler cap on the hydraulic tank. Release the pressure inside the hydraulic tank. Make sure that all air pressure has been vented before completely removing the filler cap. Refer to Illustration 5 for the 5110B filler cap (3) location.

5. Remove the strainer. Store the filler cap and store the strainer in a clean place to avoid contamination and to avoid damage.
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   Illustration 7	g01283766
   (X) Proper length of suction hose (Y) Distance from the top of the fill neck to the bottom of the tank. (Z) 4 inch fill cap adapter = 60mm

6. Measure the distance from the top of the hydraulic fill neck to the bottom of the hydraulic tank (Y). Subtract (Z) from (Y). Subtract an additional 25.40 mm (1 inch) to obtain the proper hose length (X). Refer to Illustration 7.

7. Cut a length of suitable hose matching the (X) measured distance of tank depth. Install the hose on the fill cap adapter hose barb.
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   Illustration 8	g01283767
   (4) 193-5900 Fill Cap Adapter (5) Suction Line (6) Return line

8. Install the 193-5900 4 inch Fill Cap Adapter (4) in place of the filler cap. Connect the filter cart suction line (5) to the suction port. Connect the return line (6) to the return port.
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   Illustration 9	g01283769
   Air supply valve in the closed position (7) Air supply valve (8) Air supply hose

9. Attach the air supply hose (8) to the 188-3242 Filter Cart. Ensure that the air supply valve (7) is in the closed position. Be sure that the air supply does not exceed 690 kPa (100 psi).
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   Illustration 10	g01283770
   Air supply valve in the open position

10. Slowly open the air supply valve (7) to start the filter cart pump operation. The filter cart pump is a double acting diaphragm pump. The pump is rated to pump SAE10W oil at 341 L/min (90 US gpm).

11. During filter cart operation, 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 cycle fast during start-up because of air in the suction lines of the pump. If this continues for more than 1 minute, shut the filter cartoff and check the filter cart connections.

12. Ensure 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 start of the filter cart cycle as a baseline particle count.

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

    1. Use a 170-8500 Portable Particle Analyzer for immediate results.

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

14. When using the Portable Particle Analyzer for particle counting, be sure to read and understand the Tool Operating Manual before operating.
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    Illustration 11	g01283771
    (9) S·O·S valve (10) 210-5530 Coupling (11) Fabricated suction tube

15. Attach a 210-5530 Coupler (10) and the fabricated suction tube (11) to the S·O·S valve (9) on the filter cart.

16. Attach the other end of the fabricated suction tube to the portable particle counter as called for in the Tool Operating Manual.

    Note: Information regarding the availability of parts and fabrication instructions for the suction tube assembly can be obtained by contacting the Dealer Service Tools Hotline. Proper fittings and instructions will be provided at no cost. A 188-0639 Hose will need to be purchased prior to assembly.

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    Illustration 12	g01283773
    (12) 169-8373 Bottle Group

17. If you collect a bottle sample, use the same S·O·S valve (9) and a 169-8373 Bottle Group (12).

18. Record an oil sample reading from the S·O·S valve (9) on the filter cart at the beginning 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.

19. During the filter cart operation, start the machine and cycle the boom and stick circuit every half an hour. Cycle the cylinders to the end of the cylinder stroke at least four complete times to flush the contaminated hydraulic system oil back to the tank. This procedure will cycle the clean tank oil into the system and flush the more contaminated oil back into the tank. The oil filtration can be performed while you cycle the machine. Turn off the engine.

20. At the halfway point of kidney looping, stop the procedure and change the machine hydraulic filters. Changing the filters allows the filters to assist in system cleaning. The new filters can remain in place until the next scheduled filter change. Changing the filters at this time avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.

21. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an acceptable ISO level of at least 16/13. Take a final oil sample and record the final ISO level before the machine is returned to the field.

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

22. When the target ISO level or the time interval has been met, close the air supply valve (7) and disconnect the air supply hose.
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    NOTICE
    The fittings on the filter cart and Portable Particle Analyzer may be hot. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. When the hydraulic system is at operating temperature, the hydraulic oil is hot and hydraulic oil is under pressure.

23. Disconnect the filter cart suction line (5) from the suction port.

24. Disconnect the filter cart return line (6) from the return port.

25. Remove the 193-5900 4 inch Fill Cap Adapter (4).

26. Ensure the strainer and filler cap are clean. Install the strainer and filler cap on the hydraulic tank.

27. Install protective caps on the filter cart suction line. Install protective caps on the filter cart return line. Store the 193-5900 4 inch Fill Cap Adapter (4) in a clean place.

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

29. 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 returns to service.

Oil Compartment 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 level, refer to the following equation. This equation relates to the 188-3242 Filter Cart and the 194-2897 Filter Carts only. Other filtration units will use different equation references. The units which use different equations will be noted when appropriate.

Illustration 13	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). This 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 5130B Excavator hydraulic system has 1601 L (423 US gal) of SAE10W oil. The filter cart is operating at 180 pulses per minute. The approximate filtration time should be 330 minutes or 5.5 hours.