R NEHS0778-02

May 2005

TOOL
OPERATING
MANUAL
188-3242 or 227-2479 Filter Cart Group
(Use on Hydraulic Tanks or Hydraulic Systems)
European Union Compliant

SMCS: 5050
Important Safety Information
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.
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.
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.
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
The message that appears under the warning
explains the hazard and can be either written
or pictorially presented.
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.
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.
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.
Failure to heed this warning can lead to
premature failures, product damage,
personal injury, or death.
Safety
WARNING
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.
To prevent possible damage to
your hearing, always wear ear
protection when using this tool
and/or working around noise-
generating tools.
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.
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.
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
WARNING
MS
In case of injury or skin irritation,
M SD
SSS
M
M SSS
DDD 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).
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.
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.
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.
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.
 WARNING Specifications
Specifications
Always wear protective Description Specification
clothing while operating Operating pressure 138 to 827 kPa (20 to 120 psi)
any machines or
Variable delivery 0 to 409 Lpm (0 to 90 gpm)
equipment. DO NOT wear
any loose clothing, jewelry, watches, gloves, Supply air consumption 0.47 L/s (1 cfm) per 4.55 Lpm
(1 gpm) of fluid pumped
or anything else that might catch on
controls, tooling, side bars, or any part of the Suction lift Up to 5.5 m (18 ft)
equipment. Liters (gallons) per cycle 1.9 l (0.5 gal)
Operating temperature 0 to 93°C (2 to 200°F)
All substances and materials
MMS SD
SSS
M
M SSS
DDD pumped through the oil filter Four (4) gang parallel Permits four (4) times the filter
cart must be handled and filter head area to capture particulates and
extends filter life.
disposed of properly. This is
very important when working with lubricants. Standard filtration 10 microns
Follow all federal, state, and local regulations on Outlet hose (one) 3 m (10 ft) long with a female
disposal of waste products. quick-disconnect end
Inlet hose (one) 3 m (10 ft) long with a male quick-
To prevent personal injury or death, disconnect end
only use the oil filter cart for the
Storage box 736 x 406 x 305 mm
intended use that it was
(29.0 x 16.0 x 12.0 in)
manufactured for, which is filtering
oil. Improper use of this equipment can Noise level 82 dB @ 758 kPa (110 psi) air
pressure
cause serious personal injury and/or
damage to the oil filter cart and other Overall dimensions 1295 x 889 x 1143 mm
property during operation procedures. (51.0 x 35.0 x 45.0 in) with hook
bar 1956 mm (77.0 in)
Weight 163 kg (360 lbs)

Contents
References
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
For more information, refer to SEBF8447
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 4 Procedure for Filtering Excavator (311-375)
References. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic Oil or SEBF8446 Procedure for
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Filtering 300 Series Excavator Hydraulic Oil.
General Information . . . . . . . . . . . . . . . . . . . . 6 Guidelines for specific machines can also be
found in Caterpillar’s Systems Information
Typical Machine Set-Up. . . . . . . . . . . . . . . 6 System (SIS).
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

4
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.
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.
188-3242 Filter Cart Group.
5
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.
Hose Ends Are Equipped With Quick-Disconnect Fittings.
• 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.
General Information
Typical Machine Set-Up
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).
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.
(1) Air Supply Valve. (2) Static Electricity Connection.
(3) 195-3164 Muffler.
6
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.
NOTE: If the filter cart is used to filter different
types of fluids, change the filter elements for
each filtering application.
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.
(4) S.O.S Valve. (A) Adapter. (B) Suction Hose
 b. Remove the filler cap and screen. 5. If the filter cart is used to filter oil from a
Screw either the 193-5900 Adapter (4 bulk storage tote, use the following tooling
inch diameter filler cap) or 193-5903 from the FT3016 Contamination Control
Adapter (2.5 inch diameter filler cap) Caps and Fittings.
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 0778-11

release pressure buildup
prior to removing adapter
Threaded Suction Connection1
assembly (in some cases
as oil heats up inside hydraulic tank, Part Number Description Quantity
pressure can build up, resulting in possible 141-1454 Coupling (2 inch NPT to 1 inch NPT) 1
hot oil spray, if pressure is not released 3B-7280 Close Nipple (1 inch NPT) 1
before adapter is removed). 190-8319 Male Quick Disconnect with 1 inch NPT 1
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 Description Quantity
263-9602 Female Cam-Lock Quick Disconnect 1
with 2 inch NPT
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
2 For oil totes with quick disconnect cam-lock lower connection.

7
 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
(5) S·O·S Valve.
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

0778-10

Storage Cap
Part Number Description Quantity
255-4302 Screw-On Cap 1
183-3873 Breather Assembly 1

8
Calculating Filtration Time If Maintenance
Particle Counter Is Not Available
Filter Elements
If an on-line, portable particle counter is not
available to indicate when contaminate levels The prefilter has a 100 mesh element for large
have lowered to an acceptable point, refer to particle removal. Also this prefilter acts as a
the following equation. This equation works dampening device to reduce the intensity of
with the 188-3242 Filter Cart only. Other pressure spikes caused by the air diaphragm
filtration units will have a different equation pump.
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 Approximate
=
Cycles per Minute 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.
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.
(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.
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.

9
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
Item Part No. Description
— 9U-6983 Spin-on Filter Element (5 micron absolute)
1 188-7019 Air Pump Assembly with synthetic media1
2 9U-6985 Filter Element (100 Mesh) (prefilter) — 9U-6984 Spin-on Filter Element (22 micron
3 9U-5870 Spin-on Filter Element (10 micron) with absolute) with synthetic media1
synthetic media1 — 188-7027 Filter Element (Water Removal)
Quad Filter Assembly
— 198-3188 Spin-on Filter Element (2 micron cellulose)
4 195-3164 Muffler (on air pump)
1Synthetic
filtering media is compatible with petroleum and
5 9U-6986 Gauge (Dirty Filter)
6 8T-0846 Gauge (Working Pressure) water based fluids.
7 190-8316 Female Quick-Disconnect with 1 1/4 inch
NPT Serviceable Parts List (cont’d)
8 190-8317 Male Quick-Disconnect with 1 1/4 inch Dust Caps/Plugs
NPT
Item Part No. Description
9 190-8318 Female Quick-Disconnect with 1 inch NPT
— 8C-3451 Rubber Cap, 13 mm (1/2 in.) diameter for
10 190-8319 Male Quick-Disconnect with 1 inch NPT
S.O.S port
11 197-4626 Flexible Extension, 101.6 x 355.6 mm
(4.00 x 14.00 in) — 201-8057 Plastic/Rubber Plug, 66.8 mm (3 in.), for
190-8316 and 190-8318 Quick-Disconnect
12 197-4627 Solid Extension, 63.5 x 330.2 mm
Coupler, female end
(2.50 x 13.00 in)
13 3H-0976 O-ring (element to head) — 201-8059 Plastic/Rubber Plug, 44 mm (2 in.), for
190-8317 and 190-8319 Quick-Disconnect
Coupler, male end

Typical Male and Female Quick-Disconnect Fitting

(All with Female NPT).

11
 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
CSTG_Hotline@cat.com

©2005 Caterpillar Inc. NEHS0778-02

All Rights Reserved Printed in U.S.A.