R
TOOL OPERATING MANUAL 188-3242 or 227-2479 Filter Cart Group (Use on Hydraulic Tanks or Hydraulic Systems) European Union Compliant
SMCS: 5050
NEHS0778-02 May 2005
The message that appears under the warning explains the hazard and can be either written or pictorially presented.
Important Safety Information
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. The warnings in this publication and on the product are, therefore, not all-inclusive. If a tool, procedure, work method, or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.
Think Safety 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.
The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.
WARNING When replacement parts are required for this product, Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
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.
Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING”, or “CAUTION”. The Safety Alert “WARNING” label is shown below.
WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. 2
Safety
WARNING WARNING
In case of injury or skin irritation, consult the Material Safety Data Sheet for chemical hazards and first aid instructions for the fluids being used. These sheets should be available from the manufacturer/supplier of the fluid (s). MS SD M SSS DDD M SSS M
To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment or tools. Do not operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals. Contact Dealer Service Tools for replacement manuals. Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.
Contact with hot oil and components can result in severe burns. DO NOT allow any hot oil or components to contact the skin. Before opening a hydraulic tank make sure all pressure is relieved.
To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noisegenerating tools.
Personal injury can result from removing hoses or quick-disconnect fittings in a pressure system. Failure to relieve pressure can cause personal injury. Do not disconnect or remove hoses or fittings until all pressure in the system has been relieved.
To avoid eye injury, always wear protective glasses or face shield. Make sure no one can be injured by flying objects or debris when using tools or working on a component.
Check hydraulic oil lines, tubes, and hoses carefully. DO NOT use your bare hand to check for potential leaks. Always use a board or cardboard when checking for a leak. Escaping hydraulic fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.
Clean up all leaked or spilled fluids immediately. Oil, fuel, or cleaning fluid leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death. Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area and clean up all spilled fluids immediately.
Filter carts are capable of producing static electricity when pumping oil through the filter cart. This static electricity is not harmful to the filter cart, but could cause damage to other equipment which is sensitive to static electricity. The filter cart should always be grounded when working around flammable material or flammable fumes. Static electricity (sparks) can ignite these materials, resulting in serious injury or death.
Personal injuries can occur as a result of using pressurized air. Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes. Wear protective clothing, protective glasses, and a protective face shield when using pressure air.
3
Specifications
WARNING
Specifications
Always wear protective clothing while operating any machines or equipment. DO NOT wear any loose clothing, jewelry, watches, gloves, or anything else that might catch on controls, tooling, side bars, or any part of the equipment.
Description
Specification
Operating pressure
138 to 827 kPa (20 to 120 psi)
Variable delivery
0 to 409 Lpm (0 to 90 gpm)
Supply air consumption
0.47 L/s (1 cfm) per 4.55 Lpm (1 gpm) of fluid pumped
Suction lift
Up to 5.5 m (18 ft)
Liters (gallons) per cycle
1.9 l (0.5 gal)
All substances and materials pumped through the oil filter cart must be handled and disposed of properly. This is very important when working with lubricants. Follow all federal, state, and local regulations on disposal of waste products.
Operating temperature
0 to 93°C (2 to 200°F)
Four (4) gang parallel filter head
Permits four (4) times the filter area to capture particulates and extends filter life.
Standard filtration
10 microns
Outlet hose (one)
3 m (10 ft) long with a female quick-disconnect end
To prevent personal injury or death, only use the oil filter cart for the intended use that it was manufactured for, which is filtering oil. Improper use of this equipment can cause serious personal injury and/or damage to the oil filter cart and other property during operation procedures.
Inlet hose (one)
3 m (10 ft) long with a male quickdisconnect end
Storage box
736 x 406 x 305 mm (29.0 x 16.0 x 12.0 in)
Noise level
82 dB @ 758 kPa (110 psi) air pressure
Overall dimensions
1295 x 889 x 1143 mm (51.0 x 35.0 x 45.0 in) with hook bar 1956 mm (77.0 in)
Weight
163 kg (360 lbs)
MS SD M SSS DDD M SSS M
Contents
References
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 4 References. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Information . . . . . . . . . . . . . . . . . . . . 6 Typical Machine Set-Up. . . . . . . . . . . . . . . 6 Checking Contamination Levels . . . . . . . . . . 8 Taking An Oil Sample Using a Portable Particle Counter. . . . . . . . . . . . 8 Calcuating Filtration Time If Particle Counter Is Not Available . . . . . . . . . . . . 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 9 Filter Elements . . . . . . . . . . . . . . . . . . . . . . 9 Air Pump Muffler . . . . . . . . . . . . . . . . . . . 10 188-7019 Air Pump . . . . . . . . . . . . . . . . . 10 Serviceable Parts List . . . . . . . . . . . . . . . . . 11
For more information, refer to SEBF8447 Procedure for Filtering Excavator (311-375) Hydraulic Oil or SEBF8446 Procedure for Filtering 300 Series Excavator Hydraulic Oil. Guidelines for specific machines can also be found in Caterpillar’s Systems Information System (SIS).
4
The quick-disconnects permit fast and easy hose connection to a hydraulic tank when used with hydraulic tank adapters such as 193-5900 and 193-5903. Other adapters may be required depending on the particular hydraulic tank. Refer to Caterpillar’s “Contamination Control Guidelines” in Caterpillar’s Systems Information System (SIS) for specific parts and procedures.
Introduction The 188-3242 and 227-2479 Filter Cart Groups are used to flush and clean hydraulic tanks or hydraulic systems which have a reservoir capacity greater than 115 liter (30 gallon) and less than 380 liter (100 gallon). It uses standard filtration of 25, 10, 5, or 2 micron. The filter cart can be used in any filtering application for oil contamination control. This filter cart allows oil to be filtered directly from a hydraulic tank (eliminates placing oil in separate filtering cart/container). This manual provides general information on how to set up the filter cart, technical data, serviceable parts, and adapters. Oil is pumped through the filter cart using an air-powered diaphragm pump. The filter cart is designed with a suction hose, 3 m (10 ft) long with a female quick-disconnect. The return line is 3 m (10 ft) long with a male quick-disconnect.
Hose Ends Are Equipped With Quick-Disconnect Fittings.
The 227-2479 Hydraulic Filter Cart in kit form includes every part needed to build the 188-3242 Hydraulic Filter Cart. The unpainted steel frame requires assembly. Prints are provided for welding and assembly.
• The filter cart can filter hydraulic fluids from 5W to 90W. • Filter cart is easily moved around in field conditions on three pneumatic tires. • Oil is pumped through the filter cart using an air-powered, diaphragm pump. • The maximum output pressure of fluid being pumped is equal to air inlet air pressure. 414 kPa (60 psi) is the recommended operating or air inlet pressure. • The filter housing has a differential pressure gauge (dirty filter indicator) to indicate when the filter element should be changed. • All hose assemblies are made from Caterpillar 844 wire-reinforced hose. These hoses will not collapse when filtering hot oil. • Extra tall hose hook for ease of hose storage. • Built-in storage box to hold optional adapter fittings. • The filter cart is European Union Compliant.
188-3242 Filter Cart Group.
5
General Information Typical Machine Set-Up
Filter carts are capable of producing static electricity when pumping oil through the filter cart. This static electricity is not harmful to the filter cart, but could cause damage to other equipment which is sensitive to static electricity. The filter cart should always be grounded when working around flammable material or flammable fumes. Static electricity (sparks) can ignite these materials, resulting in serious injury or death.
1. Turn air supply ball valve (1) to the closed position. Attach an air supply to the filter cart. NOTE: A quick-disconnect coupling (not included) can be used to connect the air supply line.
NOTICE An air supply in excess of 827 kPa (120 psi) will damage the filter cart. To prevent damage, install a 4C-7033 Regulator into the air supply line. For best results, set regulator to 414 kPa (60 psi).
NOTE: If the filter cart is used to filter different types of fluids, change the filter elements for each filtering application.
2. To reduce the risk of static electricity, while pumping fluids, attach one end of a ground cable (not included) to ground connection (2) and the other end to a suitable electrical ground.
3. If the unit is used for filtering oil from a machine: a. Attach a length of 25 mm (1 in) ID suction hose (B) to the adapter (A). The hose length should allow the end of the hose to be within 15 cm (6 in) of the bottom of the tank.
(1) Air Supply Valve. (2) Static Electricity Connection. (3) 195-3164 Muffler.
(4) S.O.S Valve. (A) Adapter. (B) Suction Hose
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5. If the filter cart is used to filter oil from a bulk storage tote, use the following tooling from the FT3016 Contamination Control Caps and Fittings.
b. Remove the filler cap and screen. Screw either the 193-5900 Adapter (4 inch diameter filler cap) or 193-5903 Adapter (2.5 inch diameter filler cap) onto the filler tube of the hydraulic tank. Other adapters are available through Caterpillar’s Systems Information System (SIS). NOTE: The S·O·S valve (4) in the adapter is not used for taking an oil sample, but for releasing pressure that can build up in the hydraulic tank during the filtering procedure.
Use the S·O·S (4) valve to release pressure buildup prior to removing adapter assembly (in some cases as oil heats up inside hydraulic tank, pressure can build up, resulting in possible hot oil spray, if pressure is not released before adapter is removed).
0778-11
Threaded Suction Connection1 Part Number
1
Description
Quantity
141-1454
Coupling (2 inch NPT to 1 inch NPT)
1
3B-7280
Close Nipple (1 inch NPT)
1
190-8319
Male Quick Disconnect with 1 inch NPT
1
For oil totes with 2 inch NPT threaded lower connection.
4. Connect the suction and return hoses to the adapter and begin filtering.
0778-12
Cam-Lock Suction Connection2 Part Number
2
7
Description
Quantity
263-9602
Female Cam-Lock Quick Disconnect with 2 inch NPT
1
141-2502
Reducer Bushing (2 inch to 1 inch NPT)
1
3B-7280
Close Nipple (1 inch NPT)
1
190-8319
Male Quick Disconnect with 1 inch NPT
1
For oil totes with quick disconnect cam-lock lower connection.
Checking Contamination Levels Taking An Oil Sample Using a Portable Particle Counter The S·O·S valve is used for taking oil samples. This valve can be used with a standard 170-8500 Particle Counter. For the most accurate test results, use the low pressure sampling circuit.
0778-13
Return Connection Part Number
Description
Quantity
255-4302
Screw-On Cap
1
183-3873
Breather Assembly
1
255-4305
Bulkhead Fitting
1
5B-7666
Street Elbow (1-1/2 inch NPT)
1
7X-3387
Sampling Valve (1/4 inch NPT)
1
3B-7280
Close Nipple (1 inch NPT)
1
8B-5774
Reducer Bushing (1-1/2 inch x 1 inch NPT)
1
190-8316
Quick Disconnect Coupling with 1 inch NPT 1
1H-2815
Pipe Nipple 1-1/2 inch NPT x 152 mm (6 inch)
1
1L-2782
Pipe Tee (1-1/2 inch NPT)
1
(5) S·O·S Valve.
0778-10
Storage Cap Part Number
Description
Quantity
255-4302
Screw-On Cap
1
183-3873
Breather Assembly
1
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Calculating Filtration Time If Particle Counter Is Not Available
Maintenance Filter Elements
If an on-line, portable particle counter is not available to indicate when contaminate levels have lowered to an acceptable point, refer to the following equation. This equation works with the 188-3242 Filter Cart only. Other filtration units will have a different equation reference and will be noted when appropriate. There are various conditions that must be factored into the filtration efficiency of any filter cart and application. Therefore, the following equation must be viewed as only a simple reference and not an absolute time or efficiency result.
Compartment Oil Capacity (gallons) x 140 Cycles per Minute
=
The prefilter has a 100 mesh element for large particle removal. Also this prefilter acts as a dampening device to reduce the intensity of pressure spikes caused by the air diaphragm pump.
Approximate Filtration Time
Cycles per Minute definition: Each air discharge or stroke of the air operated filter pump is considered one cycle (delivery of one pulse of oil). The internal pump shaft will slide left (one cycle), and then to the right (one cycle), delivering oil going both directions. Another way of determining one cycle is to listen for the TUK - CHUK (2 pulses). Count the number of cycles in one minute for use in the above equation.
(6) 9U-6985 Prefilter. (7) 8T-0846 Working Pressure Gauge.
The filter cart comes standard with four 10 micron filter elements. These filters should work in most filtering applications. If necessary, optional 2, 5, and 25 micron filter elements are also available.
Example: The oil capacity being filtered is 428 L (113 gal) of 10W oil. The filter unit is operating at 90 cycles per minute. The approximate filtration time should be 175 minutes or 2.9 hours.
The filter housing is equipped with a “Dirty Filter” indicator. Replace the filter whenever the indicator shows the filter is dirty. Make sure the fluid is at operating temperature and normal operating flow, before checking the indicator.
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If the filter is being changed too frequently in a filtering application, a larger micron filter can be installed to first remove all the larger contamination particles.
188-7019 Air Pump Repair parts are available for the 188-7019 Air Pump. A 196-9504 Air Valve Repair Kit is available for repairing the center section of the air pump. A 188-7018 Diaphragm Kit is available to replace the two diaphragms in the pump. Complete repair instruction come with each repair kit.
(8) 9U-6986 Differential Pressure Gauge. (9) 9U-5870 Filter Elements
Air Pump Muffler In some cases, the air pump muffler can freeze. If the air pump is not functioning properly, first check the muffler to make sure it is not clogged or frozen with condensation. For the most efficient operation of the filter cart, replace the muffler periodically.
(10) 195-3164 Muffler.
10
Serviceable Parts
Serviceable Parts List (cont’d) Optional Filter Elements for the Quad Filter Assembly
Serviceable Parts List Item
Part No.
Description
1
188-7019
Air Pump Assembly
2 3
9U-6985 9U-5870
Filter Element (100 Mesh) (prefilter) Spin-on Filter Element (10 micron) with synthetic media1 Quad Filter Assembly
4
195-3164
Muffler (on air pump)
5
9U-6986
Gauge (Dirty Filter)
6 7
8T-0846 190-8316
8
190-8317
Gauge (Working Pressure) Female Quick-Disconnect with 1 1/4 inch NPT Male Quick-Disconnect with 1 1/4 inch NPT
9
190-8318
10 11
190-8319 197-4626
12
197-4627
13
3H-0976
Item —
Part No. 9U-6983
Description Spin-on Filter Element (5 micron absolute) with synthetic media1 Spin-on Filter Element (22 micron absolute) with synthetic media1
—
9U-6984
—
188-7027
Filter Element (Water Removal)
—
198-3188
Spin-on Filter Element (2 micron cellulose)
1Synthetic
filtering media is compatible with petroleum and water based fluids. Serviceable Parts List (cont’d) Dust Caps/Plugs Item
Female Quick-Disconnect with 1 inch NPT Male Quick-Disconnect with 1 inch NPT Flexible Extension, 101.6 x 355.6 mm (4.00 x 14.00 in) Solid Extension, 63.5 x 330.2 mm (2.50 x 13.00 in) O-ring (element to head)
Typical Male and Female Quick-Disconnect Fitting (All with Female NPT).
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Part No.
Description
—
8C-3451
Rubber Cap, 13 mm (1/2 in.) diameter for S.O.S port
—
201-8057
Plastic/Rubber Plug, 66.8 mm (3 in.), for 190-8316 and 190-8318 Quick-Disconnect Coupler, female end
—
201-8059
Plastic/Rubber Plug, 44 mm (2 in.), for 190-8317 and 190-8319 Quick-Disconnect Coupler, male end
For information on service tools or shop supplies, contact Dealer Service Tools on: Dealer Service Tools 501 S. W. Jefferson Peoria, IL U.S.A. 61630-2184 U.S.A.: 1-800-542-8665 Illinois: 1-800-541-8665 Canada: 1-800-523-8665 World: 1-309-675-6277 Fax: 1-309-494-1475
[email protected]
©2005 Caterpillar Inc. All Rights Reserved
NEHS0778-02 Printed in U.S.A.
