Filtration Procedure for Motor Grader & Paving Equipment Hydraulic Oil {0680, 0768, 5050, 5056} Caterpillar

Asphalt Compactor

CB46B (S/N: JC41-UP)

CB64B (S/N: C561-UP; 4771-UP)

CB66B (S/N: 4751-UP; B661-UP)

CB68B (S/N: 4961-UP; C681-UP)

CCS9 (S/N: C521-UP)

Asphalt Paver

AP1000F (S/N: AC41-UP)

AP1055F (S/N: TJ51-UP; RLM1-UP)

AP300D (S/N: TEN1-UP)

AP300F (S/N: YES1-UP; WHY1-UP)

AP555F (S/N: AP51-UP; M451-UP; RBM1-UP)

AP600F (S/N: AP61-UP; LR61-UP)

AP655F (S/N: 4801-UP; 4521-UP; 4531-UP; P651-UP; 6551-UP; MH61-UP; ML61-UP; 4791-UP)

AP655F L (S/N: AC61-UP)

BG500E (S/N: B5E1-UP)

BG555E (S/N: B5P1-UP)

Motor Grader

120M (S/N: B9W1-UP)

120M Series 2 (S/N: M9C1-UP; M9H1-UP; R9N1-UP; R9W1-UP)

12M (S/N: B921-UP)

12M Series 2 (S/N: F9B1-UP; F9M1-UP; R9P1-UP; R9S1-UP)

12M Series 3 (S/N: N9B1-UP; N9F1-UP; N9P1-UP; N9R1-UP)

12M Series II (S/N: M9F1-UP)

140 (S/N: N941-UP; N951-UP)

140M (S/N: B9G1-UP; D9G1-UP)

140M Series 2 (S/N: R9G1-UP; R9M1-UP)

140M Series 3 (S/N: N9D1-UP; N9G1-UP; N9J1-UP; N9M1-UP)

14L (S/N: B941-UP)

14M (S/N: B9J1-UP; R9J1-UP)

14M Series 3 (S/N: E9S1-UP; N9S1-UP)

160M (S/N: B9T1-UP; D9T1-UP)

160M Series 2 (S/N: R9L1-UP; R9T1-UP)

160M Series 3 (S/N: N9E1-UP; N9K1-UP; N9L1-UP; N9T1-UP)

16M (S/N: B9H1-UP; R9H1-UP)

16M Series 3 (S/N: E9Y1-UP; N9Y1-UP)

18M Series 3 (S/N: N9A1-UP; E9W1-UP)

Paving Compactor

CB-434D (S/N: CNH1-UP)

CB10 (S/N: MS21-UP)

CB7 (S/N: AT51-UP)

Pneumatic Compactor

CW12 (S/N: RHJ1-UP)

CW14 (S/N: LTJ1-UP)

CW16 (S/N: TL51-UP; N6J1-UP)

CW34 (S/N: AL31-UP; 3G41-UP; B7L1-UP)

Reclaimer Mixer

RM500B (S/N: MB91-UP; TAS1-UP)

Vibratory Asphalt Compactor

CB54B (S/N: LXD1-UP)

CB8 (S/N: B461-UP)

CCS7 (S/N: 4B21-UP)

CD54B (S/N: GRT1-UP)

Vibratory Soil Compactor

CP44 (S/N: MPC1-UP; M4P1-UP)

CP44B (S/N: GNB1-UP)

CP54B (S/N: 4831-UP; P541-UP; GP51-UP; PM51-UP; 5061-UP)

CP56B (S/N: 4851-UP; MP61-UP; P561-UP; 5081-UP)

CP68B (S/N: 5101-UP; CM61-UP; P681-UP; 4891-UP)

CP74B (S/N: 4911-UP; 5121-UP; P741-UP; CP71-UP)

CP76B (S/N: J761-UP)

CS-433E (S/N: MC21-UP)

CS44 (S/N: M4C1-UP; M4S1-UP)

CS44B (S/N: 4G31-UP)

CS54B (S/N: 4821-UP; G541-UP; 5M41-UP; CS51-UP; 5051-UP)

CS56B (S/N: 4841-UP; M561-UP; S561-UP; 5071-UP)

CS64B (S/N: CW61-UP; 4861-UP)

CS66B (S/N: S661-UP; 4871-UP)

CS68B (S/N: CS81-UP; M681-UP; 4881-UP; 5091-UP)

CS74B (S/N: 4901-UP; C741-UP; CS41-UP; B7M1-UP)

CS76B (S/N: 4921-UP; CB71-UP)

CS78B (S/N: 4931-UP; 5131-UP; M781-UP; S781-UP)

CS79B (S/N: C791-UP)

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 the customer of a dealer 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).

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 filter cart quickly connects to the hydraulic oil fill and drain ports. This guideline provides directions for installing and operating the filter 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. This procedure may be modified by the technician for use on some motor graders.

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 to be used, ensure that the method 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, measurements, 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

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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	g01566421
Suction Hose Assembly (1) 3B-7257 Adapter (2) 124-1907 Coupling (3) 122-6905 844 Hose (4) 8T-4983 Hose Clamp

Assemble 8C-6874 Connector, 6B-9081 Reducer Bushing, and 3B-6491 Pipe Coupling to create the suction adapter. Use suction hose assembly for Asphalt Paver. Refer to Table 5 for part numbers.

Assemble 004-5703 Pipe Adapter, 9Y-2238 Plug Bushing, and 5P-8874 Adapter to create the suction adapter. Use suction hose assembly for Asphalt Paver. Refer to Table 5 for part numbers.

Assemble the 5P-4269 Swivel Adapter and the 173-0880 Connector to create the suction adapter assembly. Use suction hose assembly for Asphalt Paver. Refer to Table 5 for part numbers.

Assemble the 284-3468 Adapter and the 6V-8634 Connector to create the suction adapter assembly. Use suction hose assembly for Asphalt Paver. Refer to Table 5 for part numbers.

Assemble the 141-7281 Adapter and the 3B-6491 Pipe Coupling to create the suction adapter assembly. Use suction hose assembly for Asphalt Paver. Refer to Table 5 for part numbers.

Assemble the 224-1375 Connector and the 5P-2244 Adapter Union to create the discharge adapter assembly. Use suction hose assembly for Asphalt Paver. Refer to Table 5 for part numbers.

Assemble the 171-4361 Connector and the 5P-4588 O-Ring Adapter to create the discharge adapter assembly. Use suction hose assembly for Asphalt Paver. Refer to Table 5 for part numbers.

Illustration 4	g03681126
Vacuum Transducer Assembly (5) 5P-0306 Vacuum Transducer (6) 297-7704 Adapter (7) 4C-4506 Air Hose (8) 8S-7169 Union (9) 4C-7099 Nipple (10) 4C-7156 Fitting

Assemble the Fitting (10) to the Nipple (9) and the Transducer (5). Assemble the Union (8) and the Adapter (6) to the Air Hose (7) and attach the assembly to the Transducer (11). Refer to Illustration 4.

Note: Vacuum Transducer is used on machines that do not have an ecology drain, gate valve drain, or a ball valve drain. Remove the breather. Install the vacuum transducer in the breather port.

Illustration 5	g03681143
(11) 124-1909 Coupling (12) 234-0218 Adapter (13) 124-1922 Coupling (14) 122-6906 844 Hose

Motor Grader Filtration Procedure

The following procedure is intended for the Paving Equipment and for all M Series motor graders except for the 24M motor grader. The procedure is most effective when performed immediately after the hydraulic oil has been warmed to 50 °C (122 °F) and mixed from operation. Warming the hydraulic oil allows any contamination in the oil to be placed in suspension and lowers the viscosity of the oil. Be sure to read and understand the Tool Operating Manual, NEHS0848.

Filtration Setup

1. Operate the machine to warm the oil.

2. Park the machine on level ground.

3. Clean around the hydraulic tank fill cap. Clean around the hydraulic tank drain valve assembly.

4. Apply the service brake to stop the machine.

5. Move the direction control switch or the transmission control lever to the NEUTRAL position. Engage the transmission lock if the machine is equipped.

6. Engage the parking brake.

7. Lower the attachment to the ground and apply slight downward pressure.

8. Block the wheels.
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   Illustration 6	g03681148
   (15) Left rear access cover

9. Open the left rear access cover to view hydraulic oil sight gauge (15).
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   Illustration 7	g03681151
   (16) Hydraulic tank fill cap

10. Slowly remove the hydraulic tank fill cap (16) to relieve the tank pressure.

11. Remove the hydraulic tank screen if the machine is equipped.
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    Illustration 8	g03681157
    (17) 3B-7257 Adapter

12. Use an Adapter (17) to connect the discharge hose assembly to the filter cart discharge port.
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    Illustration 9	g03681162
    (18) 204-7392 Filter Cart Discharge Port

13. Connect the suction hose assembly to the Filter Cart discharge port (18).
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    Illustration 10	g03681174
    (19) 234-0218 Hydraulic tank discharge adapter

14. Install the hydraulic tank discharge adapter (19) in to the hydraulic tank fill port.
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    Illustration 11	g03681177
    (20) Hydraulic tank drain hose

15. Remove the original hydraulic tank drain hose (20) from the drain valve assembly if the machine is equipped.
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    Illustration 12	g03681178
    (21) Hydraulic tank drain valve assembly (22) Filter cart suction hose assembly

16. Connect the Filter Cart suction hose assembly (22) to the hydraulic tank drain valve assembly (21) with a hose clamp.

17. Open the hydraulic tank drain valve assembly (21).
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    Illustration 13	g03681179
    (23) Air supply valve (24) Air supply hose

18. Attach an air supply hose (24) to the Filter Cart. Ensure the air supply valve (23) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi).

19. Slowly open the air supply valve (23) to start the filter cart pump operation. If the air supply valve (23) is a purge off style, adjust the air supply between 140 kPa (20 psi) and 345 kPa (50 psi). Turn the air supply valve (23) ON. Adjust the air pressure as needed, but do not exceed 690 kPa (100 psi). The pump is a diaphragm pump. The pump is rated to pump 10W oil at 64 L/min (17 US gpm).

20. During the filter cart operation, check the filter element indicators on the filter cart. Filter element indicators will determine the amount of capacity left in the filter element.

    Note: Occasionally, the filter cart pump will cavitate during startup. Cavitation is due to air in the suction lines of the pump. If cavitation continues for more than 1 minute, shut the filter cart OFF. Check all the hydraulic connections.

21. 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 as a baseline particle count.

22. 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.

Asphalt Paver and CS79B Soil Compactor Filtration Procedure

The following procedure is intended for F Series Asphalt Pavers and CS79B Soil Compactor. The procedure is most effective when performed immediately after the hydraulic oil has been warmed to 50 °C (122 °F) and mixed from operation. Warming the hydraulic oil allows any contamination in the oil to be placed in suspension and lowers the viscosity of the oil. Be sure to read and understand the Tool Operating Manual, NEHS0848.

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 the transmission control lever to the NEUTRAL position. Engage the transmission lock if the machine is equipped.

5. Engage the parking brake.

6. Lower the attachment to the ground and apply slight downward pressure.

7. Block the wheels.

8. Clean around the hydraulic tank filler neck, and the drain hose assembly. The drain hose assembly is on the right side of the machine below the pump stack under a lockable panel.
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   Illustration 14	g03883253
   396-7140 Hydraulic Tank and Mounting Gp (25) 148-8318 Connector As (26) Hydraulic Tank Filler Neck (27) 419-4904 Vented Cap

9. Clean around the 148-8318 Connector As on top of the hydraulic tank. Refer to Illustration14.

10. For the CS79B Soil Compactor, clean the area around the 183-3873 Breather.

11. Loosen the hydraulic tank fill cap (27) to relieve the tank pressure. When the pressure has been relieved, tighten the hydraulic tank fill cap (27).

12. Remove 148-8318 Connector As, gage and tube assembly (25) and install the 4Y-6112 Adapter and vacuum transducer in the same port that contained the 148-8318 Connector As, gage and tube assembly (25). Refer to Illustration 14.

13. For the CS79B Soil Compactor, remove 183-3873 Breather and install the vacuum transducer in the same port that contained the 183-3873 Breather .

    Note: Do not remove the hydraulic tank fill cap. A vacuum cannot be achieved with the fill cap removed.

14. Attach an air supply hose to the vacuum transducer, adjust the air pressure to 103.42140 kPa (15 psi). Ensure that the hydraulic tank has achieved a vacuum.

15. Remove the 164-5581 Plug As from the 423-4813 Hose As drain hose.

16. Install the suction adapter assembly for Asphalt Pavers and the filter cart suction hose. Refer to Table 6 for the parts to assemble the suction adapter.

17. For the CS79B Soil Compactor, remove 241-6185 Plug As from the bottom of the hydraulic tank.

18. For the CS79B Soil Compactor, install the suction adapter assembly for the CS79B Soil Compactor and the filter cart suction hose.

19. Remove the air supply hose from the vacuum transducer.

20. Remove the hydraulic tank fill cap.

21. Remove the hydraulic tank screen if the machine is equipped.

22. Attach the filter cart discharge hose to the hydraulic tank filler neck. Refer to Illustration 5 and Table 13 for the parts to assemble the filter cart discharge hose.

23. Attach the air supply hose to the filter cart. Ensure that the handle is in the OFF position. Ensure that the air supply does not exceed the 689.476 kPa (100 psi).

24. Refer to Step 19 of the Filtration Setup procedure for the remaining steps of the filtration procedure.

Portable Particle Analyzer Procedure

When using a portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual, NEHS0848, "Tool Operating Manual for 204-7392 Filter Cart" before operating the particle analyzer.

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Illustration 15	g03681353
(28) Fabricated suction tube. (29) 220-8607 Fitting. (30) 210-5530 Coupler. (31) S·O·S valve.

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (31) on the filter cart.

   Note: The fabricated suction tube can be made with the parts listed in Table 3 and as shown in Illustration 15.

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

Bottle Sample Procedure

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Illustration 16	g03681358
(31) S·O·S Valve (32) 169-8373 Fluid Sampling Bottle

1. If collecting a bottle sample, use the same S·O·S valve (31) and a Bottle Group (32).

2. Record an oil sample from the S·O·S valve (31) on the filter cart at the beginning of the filter cycle.

   Note: The filtration can be performed while running the engine.

3. During the filter cart operation, cycle the lift cylinders at least four times every half hour of filtration. 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.

4. At the halfway point of filtration, stop the procedure and change the machines oil filters. Changing the machines filters allows the filters to help in the system cleaning. The new filters can remain in place until the next scheduled filter change. Changing the filters now avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.

   Note: The machine filters are to be replaced if the filters are not working at optimal performance, or change the filters at scheduled interval.

5. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an ISO level of at least 18/15 or better. The final ISO should be recorded before the machine is returned to the field.

6. When the target ISO level or time interval has been met, close the air supply valve (23) and disconnect the air supply hose (24). Refer to Illustration 13.

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

7. Close the hydraulic tank drain valve assembly (21). Refer to Illustration 12.

8. Remove the filter cart discharge hose from the hydraulic tank filler port. Store the hose assembly in a clean location.

9. Install the strainer assembly in the hydraulic tank fill tube if the machine is equipped.

10. Install a clean filler cap (16). Refer to Illustration 7.

11. Disconnect the filter cart suction hose from the hydraulic tank drain assembly and cover both ends with dust caps. Store the hose assembly in a clean location.

    Note: Check the hydraulic tank drain valve assembly for leakage. Make sure that the hydraulic tank drain valve assembly is closed.

12. Install the original drain hose (20) to the hydraulic tank drain valve assembly (21). Refer to Illustration 11.

13. Close the access panel (15). Refer to Illustration 6.

14. Check the hydraulic tank oil level.

15. Unblock the wheels.

16. Return the machine to service.

Oil Compartment Filtration Times

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 204-7392 Filter Cart only. Other filtration units will have different equation references and these units will be noted when appropriate.

Compartment oil capacity (gallons) times two equals the approximate filtration time.

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). Pulsation 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 140M hydraulic system has 64 L (17.1 US gal) of SAE 10W oil. The approximate filtration time should be 35 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 the procurement of the sample, the sample container, particle counting accuracy where used 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.