Procedure for "Off-Board" Filtering Backhoe Loader and Integrated Toolcarrier Hydraulic Oil Equipped with Auxiliary Lines{0680, 0768, 5050, 5056, 5057} Caterpillar


Procedure for "Off-Board" Filtering Backhoe Loader and Integrated Toolcarrier Hydraulic Oil Equipped with Auxiliary Lines{0680, 0768, 5050, 5056, 5057}

Usage:

426C 1CR


Backhoe Loader: All
Integrated Toolcarrier: All

Introduction

Table 1
Revision     Summary of changes in SEBF8800    
03     Changes to references table listed below.
Removed PEVN4831 video canceled.
Added SEBF8726.
PEGJ5025 canceled replaced by PEGJ0045.
PEHP6001 canceled replaced by PEGJ0047.
Updated Introduction.
Added Canceled Replaced Part Numbers statement.    

© 2012 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.

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 questions or additional information concerning this guideline, submit a feedback form in the Service Information System web site. To address an urgent need, use the following to forward your request to Caterpillar Repair Process Engineering:

  • Cat Dealer Technical Communicator

  • Global Dealer Solution Network

  • Cat Technical Representative

  • Knowledge Network

If a Contamination Control Guideline is required, but not available in SIS Web, submit feedback in the Service Information System website.

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. This guideline provides directions for you to install and operate the filter cart 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 18/15 or cleaner.


NOTICE

If the machine is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this kidney loop 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 and controls. Additional component cleaning and component exchange and lines flushing will be required to remove most contaminates generated from the failure. The machine system cleaning must be performed prior to the kidney looping. This filtration procedure and subsequent particle count testing should be performed as a final step in the repair process.


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 1g01032906

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

------ 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, NENG2500, "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    
NEHS0633     Procedure for using 9U-5971 and 173-9842 Filter Cart Group    
SEBF8726     Procedure for Filtration of Hydraulic Oil in Compact Equipment    
PEGJ0045     Reporting Particle Count by ISO Code    
SEBF8482     Obtaining an Oil Sample for S·O·S Analysis    
PEGJ0047     How To Obtain A Good SOS Sample    
NEHS0799     Tool Operating Manual for S40 Portable Particle Analyzer    
NEHS0778     188-3242 Filter Cart    
SEBF8726     Procedure for Kidney Looping Compact Equipment Hydraulic Oil    
SEBF8757     Procedure for "Off-Board" Filtering 307 - 285B Excavator Hydraulic Oil with Auxiliary Hydraulic Lines    

Tooling and Equipment

Table 3
Required Tools    
Quantity     Part Number     Parts Description    
1

1    
9U-5968
Or
173-9842
Or
225-4113    
Filter As - Hydrostatic

Filter Cart

Filter Cart    
2     2S-4078     O-Ring Seal    
2     4S-6797     Connector    
2     8S-3918     Stem    
2     3S-7252     Sleeve    
All Backhoe Loader Models    
2     6V-9973     Permanent Coupling As    
2     6V-8734     Union    
3 m (10 ft)     165-0021     Hose    
Use with Quick Disconnects    
2     6V-9973     Permanent Coupling As    

3 m (10 ft)    
165-0021     Hose    
1     106-0401     Quick Disconnect Coupler    
1     106-0406     Quick Disconnect Coupler    
2     8T-8898     Connector    
Integrated Toolcarrier
IT12    
2     6V-4666     Coupling As    
2     9S-7739     Flared Union    

3 m (10 ft)    
165-0020     Hose    
IT14G    
2     6V-9945     Collet Stem    
2     6V-8730     Union    

3 m (10 ft)    
165-0017     Hose    
IT24F, IT28F, IT28G    
2     6V-9949     Coupling As    
2     6V-8731     Union    

3 m (10 ft)    
165-0017     Hose    
IT28B, IT38F, IT38G    
2     6V-9953     Collet Stem    
2     6V-8873     Union    

3 m (10 ft)    
165-0020     Hose    
IT62G    
2     6V-9957     Coupling As    
2     6V-8734     Union    

3 m (10 ft)    
165-0021     Hose    

Table 4
Option Tools    
Part Number     Part Description    
170-8500     S40 Portable Particle Analyzer    
210-5530     Quick Connect Coupler    
188-0639     Hose As    

Note: The 9U-5968 Filter Assembly or the 173-9842 Filter Cart can be used in this guideline. Both units have a 321 L/min (85 US gpm) maximum flow. Both units have a working pressure of 41368 kPa (6000 psi).

System "Off-Board" Filtration Procedure

There are three possible filtering scenarios to consider before starting this procedure.

  • Filtering machine hydraulics only. No work tools in the system.

  • Filtering machine hydraulics with work tools that have hydraulic cylinders.

  • Filtering machine hydraulics with work tools that have single direction oil flow.

This procedure is intended to filter the work tool first. Then, the procedure requires filtration of the hydraulic tank and auxiliary lines.

This guideline is intended for Backhoe Loaders and Integrated Toolcarriers. 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, NEHS0778, "188-3242 Filter Cart" before you begin the procedure.




Illustration 2g01294451

Typical filtration procedure shown on a 430D

Note: The 9U-5968 Hydrostatic Filter Group is a full bridge check valve unit. The filter group will allow oil to flow in or out either hose port. The filter group will only pass oil one direction through the filter. See Illustration 3.




Illustration 3g01294446

Schematic for the 9U-5968 Hydrostatic Filter Group

Assembling the "Off-Board" Filtering Adapters




Illustration 4g01294448

9U-5968 Filter Assembly




Illustration 5g01294452

(1) 9U-5968 Hydrostatic Filter Group

(2) 2S-4078 O-Ring Seal

(3) 4S-6797 Connector

(4) 8S-3918 Stem

(5) 3S-7252 Sleeve

(6) 165-0021 Hose - 5 feet each

  1. Assemble the filter adapter assembly first.

    1. Assemble the 165-0021 Hose (6), the 8S-3918 Stem (4) with the 3S-7252 Sleeve (5), the 4S-6797 Connector (3), the 2S-4078 O-Ring Seal (2) to the 9U-5968 Filter Housing (1) .



    Illustration 6g01294454

    (7) 6V-9973 Permanent Coupling As

    (8) 8T-8898 Connector

    (9) 106-0401 or 106-0406 Quick Disconnect Coupler

  1. Assemble the machine adapter assembly next.

    1. Connect the 6V-9973 Permanent Coupling As (7) with the 8T-9998 Adapter (8) and the 106-0401 or the 106-0406 Quick Disconnect Coupler (9) .

      Note: This procedure is a general way to assemble the adapters. Refer to Table 3 to find the adapters for a specific machine.

"Off-Board" Filtration Setup

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

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.

    Note: Do not deadhead or stall the cylinders or the work tools. Stalling either one may cause air to be ingested into the oil.

  1. Park the machine on level ground.

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

  1. Take an oil sample.

    Note: Caterpillar recommends taking a particle count before starting the kidney loop procedure. Use the sample as a baseline particle count.

  1. Turn OFF the engine.

  1. Turn the engine start key to the ON position. Move all implement functions to relieve system pressure.

Filtering Machine Hydraulics Only

Note: The following steps are intended for machine hydraulic systems with no work tools.




    Illustration 7g01294455

    (10) Attachment hose

    (11) Quick disconnect

  1. Disconnect the attachment hose (10) from the quick disconnect (11). Connect the attachment hose to one filter unit on the filter cart.

  1. Repeat Step 1 for the opposite side of the machine.

  1. Start the engine.

  1. Set the machine to "Hammer Mode" if the machine has this mode.



    Illustration 8g01294457

    Hydraulic Hammer Pedal

  1. Activate the auxiliary hydraulics to start the filtration process.

Oil Analysis Procedure

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

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

  • Use a portable particle analyzer for immediate results.

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

Portable Particle Analyzer Procedure

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




    Illustration 9g01294458

    Typical S·O·S port connection

    (12) S·O·S valve

    (13) 210-5530 Quick Connect Coupler

    (14) 220-8607 Fitting

    (15) Fabricated suction tube

  1. Attach the fabricated particle counter suction tube (15) to the S·O·S valve (12) on the machine.

    Note: The fabricated suction tube can be made with the parts listed in Table 4 and as shown in Illustration 9.

  1. 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




    Illustration 10g01294459

    Typical S·O·S port connection on a machine

    (12) S·O·S valve

    (16) 169-8373 Fluid Sampling Bottle

  1. If you collect a bottle sample, use the same S·O·S valve (12) and a 169-8373 Fluid Sampling Bottle (16) .

  1. Record an oil sample reading from the S·O·S valve (12) on the machine at the beginning and at the end of the filter cycle.

  1. At the halfway point of filtration, stop the procedure and change the machine hydraulic oil filters. Changing the filters allows the filters to assist in the 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.

    Note: Replace the machine filters only if the filters are not working at optimal performance, or scheduled to be changed.

  1. Cycle the oil until the portable particle analyzer indicates the oil has reached an acceptable contaminant level of ISO 18/15 or cleaner.

    Note: A target ISO level does not exist for nonpressurized, non-filtered compartments at this time. ISO 18/15 is an acceptable contamination level for oil returned back into this type of compartment.

  1. When the target ISO level or the time interval has been met, turn OFF the machine.

  1. Disconnect the attachment hose (10) from the filter unit on the filter cart.

  1. Reconnect the attachment hose (10) to the machine coupling (11) .

  1. Check the hydraulic tank oil level before you return the machine to service.

Oil Compartment Filtration Times

Table 5
Cycle Times for Backhoe Loader Models    
Model     Minutes for Filtration    
All Backhoe Loader models     11 minutes    

Table 6
Cycle Times for Integrated Toolcarrier Models    
Model     Minutes for Filtration    
IT12, IT14G, IT24F     13 minutes    
IT38F, IT38G, IT62G     19 minutes    
IT28F, IT28G     29 minutes    

Filtering Work Tools with Hydraulic Cylinders




    Illustration 11g01294461

    (17) Hose

    (18) Coupling

  1. Disconnect the attachment hose (17) from the coupling (18). Attach the hose (17) to one filter unit on the filter cart.

  1. Repeat Step 1 for the opposite side of the stick. Ensure that the hoses are on opposite filters. Refer to Illustration 12.

    Note: If both attachment hoses from the stick are on the same filter, the work tool will not be filtered. Only the machine hydraulics will be filters.

    Note: The hoses referred to in Steps 1 and 2 identified in Table 3, will be required to connect the attachment hoses to the filter cart.

  1. Connect a second hose from the filter cart to the coupling (18) .

  1. Repeat Step 3 for the opposite side of the stick. Ensure that the hoses are on opposite filters.

    Note: The hoses referred to in Steps 3 and 4 will need to be identified for each machine. Ensure that the fabricated hoses are pressure rated for the system being filtered.




    Illustration 12g01294462

    173-9842 Filter Cart Assembly

  1. Start the engine.

  1. Raise the work tool off the ground.

  1. Cycle the cylinders in and out 20 to 30 times to flush contaminates out of the cylinders and lines.

  1. Put the hydraulics in the HOLD position and stop the engine.

  1. Move all implement functions to relieve system pressure.

  1. Disconnect the set of lines from the second filter on the filter cart to the stick cylinder and work tool. Cap or plug the open line to the work tool.

  1. Disconnect the lines from the first filter to the work tool. Cap or plug the open line to the work tool.

  1. Refer to ""Filtering Machine Hydraulics Only" " in the front of this document to complete the rest of the filtration procedure.

Filtering Work Tools with Single-Direction Oil Flow




    Illustration 13g01294463

    (19) Hose

    (20) Coupling

    Note: When filtering hammers with this guideline, the guideline refers to Caterpillar "Oil Fired" hammers only.

  1. Disconnect the attachment hose (19) from the coupling (20). Attach the hose (19) to one filter unit on the filter cart.

  1. Repeat Step 1 for the opposite side of the stick. Ensure that the hoses are on opposite filters.

    Note: If both hoses from the stick are on the same filter, the work tool will not be filtered. Only the machine hydraulics will be filtered.

    Note: The hoses referred to in Steps 1 and 2 identified in Table 3 will be required to connect the attachment hoses to the filter cart.

  1. Connect a second hose from the filter cart to the coupling (20) .

  1. Repeat Step 3 for the opposite side of the stick. Ensure that the hoses are on opposite filters.

    Note: The hoses referred to in Steps 3 and 4 will need to be identified for each machine. Ensure that the fabricated hoses are pressure-rated for the system being filtered.




    Illustration 14g01294464

    173-9842 Filter Cart Assembly

  1. Start the engine.

  1. Raise the work tool off the ground.

  1. Set the machine to "Hammer Mode", if the machine has this mode.



    Illustration 15g01294466

    Hydraulic Hammer Pedal

  1. Activate the auxiliary hydraulics to start the filtration process.

  1. Cycle the oil for 3 to 4 minutes to flush contaminates out of the work tool and out of the hydraulic lines.

  1. Put the hydraulics in the HOLD position and stop the engine.

  1. Move all implement functions to relieve system pressures.

  1. Disconnect the set of lines from the second filters on the filter cart to the stick cylinder and the work tool. Cap or plug the open line to the work tool.

  1. Disconnect the lines from the first filter to the work tool. Cap or plug the open line to the work tool.

  1. Refer to ""Filtering Machine Hydraulics Only" " in the front of this document to complete the rest of the filtration procedure.

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 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. 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 or larger than 14 microns

At this time 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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