Filtration Procedure for Hydraulic Oil in D, E, and F Series Backhoe Loaders {0680, 0768, 5050, 5056} Caterpillar

Backhoe Loader

414E (S/N: TMS1-UP)

415F2 (S/N: HWA1-UP)

415F2 IL (S/N: PF41-UP)

416D (S/N: BKG1-UP; BGJ1-UP; BFP1-UP; CXP1-UP)

416E (S/N: SHA1-UP; C8B1-UP; BWC1-UP; CBD1-UP; MFG1-UP)

416F (S/N: KSF1-UP; LWT1-UP)

416F2 (S/N: LYA1-UP; HWB1-UP; LBF1-UP)

420D (S/N: BKC1-UP; BMC1-UP; MBH1-UP; BLN1-UP; FDP1-UP)

420E (S/N: PRA1-UP; PHC1-UP; HLS1-UP; KMW1-UP)

420F (S/N: LTG1-UP; LKH1-UP; JWJ1-UP; SKR1-UP)

420F2 (S/N: LBS1-UP)

420F2 IT (S/N: LYC1-UP; HWD1-UP)

420F2 ST (S/N: LYB1-UP; HWC1-UP)

422E (S/N: HBE1-UP; DSK1-UP; MAW1-UP)

422F (S/N: LRH1-UP)

422F2 (S/N: LYF1-UP)

424B (S/N: JRN1-UP)

424B HD (S/N: JRY1-UP)

424B2 (S/N: JTH1-UP)

424D (S/N: RXA1-UP; BGP1-UP; BKR1-UP; CJZ1-UP)

426 F2 (S/N: EJ21-UP; DJ41-UP; EJ41-UP)

427F2 (S/N: HWK1-UP)

428D (S/N: BNB1-UP; BXC1-UP; BLL1-UP; BNS1-UP; BMT1-UP; DSX1-UP)

428E (S/N: DXC1-UP; DPH1-UP; SNL1-UP)

428F (S/N: LBH1-UP; RAK1-UP; SJW1-UP)

428F2 (S/N: LYG1-UP; HWN1-UP)

430D (S/N: BML1-UP)

430D AWS (S/N: BNK1-UP)

430E (S/N: SCD1-UP; RLN1-UP; DDT1-UP; EAT1-UP)

430F (S/N: RDF1-UP; LNH1-UP; RGS1-UP; LDY1-UP)

430F2 IT (S/N: LYE1-UP; HWG1-UP)

430F2 ST (S/N: LYD1-UP; HWE1-UP)

432D (S/N: BLD1-UP; WEP1-UP; TDR1-UP)

432E (S/N: JBA1-UP; BXE1-UP; RXS1-UP)

432F (S/N: SEJ1-UP; LNR1-UP; PXR1-UP)

432F2 (S/N: LYJ1-UP; HWP1-UP)

434E (S/N: SXB1-UP; SEF1-UP; FSH1-UP; SJL1-UP)

434F (S/N: LDH1-UP; MTR1-UP; FLY1-UP)

434F2 (S/N: LYK1-UP; HWR1-UP)

438D (S/N: BPE1-UP; BPN1-UP)

442D (S/N: TBD1-UP; BRG1-UP; SMJ1-UP; BRY1-UP)

442E (S/N: EME1-UP; PCR1-UP; GKZ1-UP)

444E (S/N: NBA1-UP; HXB1-UP; LBE1-UP)

444F (S/N: LJJ1-UP; FBN1-UP; JXR1-UP)

444F2 (S/N: LYL1-UP; HWS1-UP)

450E (S/N: EBL1-UP; LYR1-UP)

450F (S/N: HJR1-UP)

Introduction

© 2017 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.

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. The filtration process is easy to use. The filter cart connects to the hydraulic oil drain and hydraulic oil filler neck. This guideline provides directions for you to install and operate the filtration system.

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 16/13 or cleaner.

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 procedure 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 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.

References

Tooling and Equipment

Illustration 3	g03549660
Return oil adapter assembly for "D" and "F"series machines. (1) 201-8057 Dust Cap (2) 190-8318 Coupler (3) 005-8615 Pipe Nipple (4) 006-5707 Pipe Elbow "D series" (4) 3L-7024 Street Elbow "F series" (5) Dealer fabricated adapter

Illustration 4	g01294184
"D" series fabricated adapter. Use 44.45 mm (1.75 inch) bar stock. (A) 44.45 mm (1.75 inch) (B) 63.5 mm (2.5 inch) (C) 38.1 mm (1.5 inch) (D) 12.7 mm (0.5 inch) (E) 6.35 mm (0.25 inch) (F) 15° (G) 1 inch NPTF 11 1/2 threads per inch (H) Drill bit size 28.981 mm (1.14 inch)

Illustration 5	g01294184
"F" series fabricated adapter. Use 44.45 mm (1.75 inch) bar stock. (A) 44.45 mm (1.75 inch) (B) 63.5 mm (2.5 inch) (C) 33 mm (1.30 inch) (D) 12.7 mm (0.5 inch) (E) 6.35 mm (0.25 inch) (F) 15° (G) 3/4 inch NPTF 14 threads per inch (H) Drill bit size 23.012 mm (0.91 inch)

Illustration 6	g03549676
Fabricated drain hose assembly for "D" and "F" series machines. (6) 124-1904 Permanent Coupling (7) 6B-9081 Reducer Bushing (8) 122-6871 Hydraulic Hose (9) 9X-2488 Hose Clamp

Machine Filtration Procedure

This guideline is intended for Backhoe Loaders. The 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. Warming the oil also lowers the viscosity of the oil. Be sure to read and understand the Tool Operating Manual, NEHS0848, "204-7392 Filter Cart Gp" before beginning the procedure.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

1. Operate the machine to warm the oil.

2. Park the machine on level ground.

3. Apply the service brake to stop the machine.

4. Move the direction control switch or move the transmission control lever to the NEUTRAL position. Engage the transmission lock if the machine is equipped with a transmission lock.

5. Engage the parking brake.

6. Lower the attachment to the ground. Apply slight downward pressure.

7. Block the wheels.

Filter Cart Procedure

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Illustration 7	g03549741
(10) Access panel (11) Release Lever

1. Pull the hood release lever (11). Remove the access panels or lift the access panels (10).
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   Illustration 8	g03549759
   (12) Filler cap

2. Clean the area around the hydraulic tank filler cap (12). Slowly loosen the filler cap on the hydraulic tank. Release the tank pressure. Make sure that all the air pressure has been vented before completely removing the filler cap.

3. Remove the lock-ring and remove the strainer from the hydraulic tank filler neck.

4. Store the filler cap (12) and the strainer in a clean place to avoid contamination and damage.
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   Illustration 9	g03549815
   (A) Return oil adapter assembly

5. Install the return oil adapter assembly (A).
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   Illustration 10	g03549899
   (13) Original drain hose

6. Remove the original drain hose (13).
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   Illustration 11	g03549916
   (B) Fabricated drain hose assembly

7. Install the fabricated drain hose assembly (B).
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   Illustration 12	g03549999
   (B) Fabricated drain hose assembly (14) Suction hose

8. Connect the filter cart suction hose (14) to the fabricated drain hose assembly (B).

9. Turn the valve to the OPEN position.
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   Illustration 13	g03550059
   (15) Discharge hose (A) Return oil adapter assembly

10. Connect the filter cart discharge hose (15) to the return oil adapter assembly (A).
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    Illustration 14	g03550118
    (16) Air supply valve (17) Air supply hose

11. Attach an air supply hose (17) to the 204-7392 Filter Cart Gp. Ensure that the air supply valve (16) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi).

12. Slowly open the air supply valve (16) to start the filter cart pump operation. The pump is a gear pump. The gear pump is rated to pump 10W oil at 64 L/min (17 US gpm).
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    Illustration 15	g01294202
    Filter cart operation on a 430D

13. During operation, check the filter element indicators on the filter cart. The filter element indicators will indicate 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 lines of the pump. When the cavitation continues for more than 1 minute, shut the filter cart OFF and inspect the connections.

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

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

15. 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. Refer to Contamination Control Guideline, SEBF8482, "Obtaining Oil Sample for Analysis" for more information.

Portable Particle Analyzer Procedure

When using a portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual before operating.

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Illustration 16	g03550135
(18) Hose assembly (19) Fitting (20) Quick disconnect coupler (21) S·O·S valve

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (21) on the filter cart.

   Note: The fabricated suction tube can be made with the parts listed in Table 3 and as shown in Illustration 16.

2. Attach the other end of the fabricated suction tube to the "low pressure in" port on the portable particle counter as called for in the Tool Operating Manual.

Bottle Sample Procedure

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Illustration 17	g03550216
(21) S·O·S valve (22) Fluid sampling bottle

1. If collecting a bottle sample, use the same S·O·S valve (21) and a 169-8373 Fluid Sampling Bottle (22).

2. Record an oil sample from the S·O·S valve (21) on the filter cart at the beginning of the filter cycle.

3. During the filter cart procedure the engine must be run at LOW idle with the parking brake engaged. Running the engine will circulate the oil in the hydraulic system. Running the engine will also flush the more contaminated oil back into the hydraulic tank.

   Note: Changing the machine hydraulic oil filters halfway through the filter process avoids opening the housing after the system has been cleaned. If the filter housing is opened after the filtration process is complete, the housing becomes an inlet for contamination. The new filters can remain in place until the next scheduled filter change.

4. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an ISO level of at least 16/13. The final ISO level should be recorded before the machine is returned to the field.

5. During the filter cart operation, cycle the lift cylinders at least four times every half an hour during the filter cart operation. Operation of the lift cylinders will cycle the clean tank oil into the hydraulic system and flush the more contaminated oil back into the tank.

   Note: The filter cart procedure can be performed while running the engine.

6. At the halfway point of filtration, stop the procedure and change the machine filters.

   Note: Refer to "Oil Compartment Filtration Times for 204-7392 Filter Cart", at the end of this document, when a portable particle analyzer is not available.

7. 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.

8. Disconnect the filter cart discharge hose (15) from the return oil adapter assembly (A). Install the dust caps on the coupler and on the nipple. Store the coupler and store the nipple in a clean location. Refer to illustration 13.

9. Disconnect the filter cart suction hose (14) from the fabricated drain hose assembly (B). Install the dust caps on the coupler and on the nipple. Store the nipple and store the coupler in a clean location. Refer to illustration 12.

10. Reinstall the original drain hose (13). Refer to illustration 10.

11. Remove the return oil adapter assembly (A). Refer to illustration 9.

12. Install the strainer and install the lock-ring in the hydraulic fill neck.

13. Install a clean filler cap (12) and lower or replace the cover (10) on the machine. Refer to illustrations 7 and 8.

14. Check the hydraulic tank oil level.

15. Unblock the wheels.

Oil Compartment Filtration Times for 204-7392 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 point, refer to the following equation: This equation relates to the 204-7392 Filter Cart. Other filtration units have a different equation reference. Units that use a different equation reference will be noted when appropriate. There are various conditions that must be factored into the filtration efficiency of any filter cart and situation. The following equation must be viewed only as a simple reference and not as an absolute time or efficiency result.

Illustration 18	g01177339
Oil compartment filtration equation (A) Compartment oil capacity (gal) (B) Pulses per minute (C) Approximate filtration time (min)

Example

A 563 Vibratory Compactor has 117 L (31 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 28 minutes.

ISO 4406:1999 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 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. Proper care will 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.