Solvent Pretreatment Method for Determining Additive Interference in New Bulk Oils {1348, 3080, 4070, 429F, 5095, 7542} Caterpillar


Solvent Pretreatment Method for Determining Additive Interference in New Bulk Oils {1348, 3080, 4070, 429F, 5095, 7542}

Usage:

MT700 018


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Introduction

Table 1
Revision  Summary of changes in SEBF9086 
06  Added new serial number prefixes for New Product Introduction (NPI).
Updated Introduction.
Updated Safety Section.
Added PERJ1017 , "Dealer Service Tools Catalog" to References table. 
05  Changes to references table listed below.
PEGJ5025 canceled replaced by PEGJ0045.
Updated Introduction.
Added Safety Information.
Added Canceled Replaced Part Numbers statement. 

© 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 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 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.

Important Safety Information



Illustration 1g02139237

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 2g01032906

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 all personnel around the machine are safe. 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 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 specifications 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, PERJ1017, "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.


Summary

The instructions given in this guideline will enable dealers and customers to properly kidney loop front wheel groups of 793, 795, and 797 Off-Highway Trucks. Following this procedure will reduce the contamination in the oil to an acceptable ISO contamination level. This procedure may be modified by the technician for use on some machines.


NOTICE

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


References

Table 2
References 
Media Number  Title 
PEGJ0045  Reporting Particle Count by ISO Code (1) 
NEHS0729  Portable Contamination Instructional Kit 
PERV4638  Oil Sampling...The Right Way (Training Video) 
ASTM D3699  Standard Specification for Kerosene 
PERJ1017  "Dealer Service Tools Catalog"(2) 
(1) Visit dealer.cat.com to download or purchase the document.
(2) Visit dealer.cat.com to download or purchase the document.

Table 3
ISO 4406 Hydraulic Fluid Power Solid Contamination Code 
ISO Code  Number of Particles per 1 ml (0.034 oz) of Fluid 
More Than Up to & Including 
28  1,300,000  6,000,000 
27  640,000  1,300,000 
26  320,000  640,000 
25  160,000  320,000 
24  80,000  160,000 
23  40,000  80,000 
22  20,000  40,000 
21  10,000  20,000 
20  5,000  10,000 
19  2,500  5,000 
18(1)  1,300  2,500 
17  640  1,300 
16(2)  320  640 
15(1)  160  320 
14  80  160 
13(2)  40  80 
12  20  40 
11  10  20 
10  10 
2.0 
1.3  2.5 
0.64  1.3 
0.32  0.64 
0.16  0.32 
0.08  0.16 
0.04  0.08 
0.02  0.04 
0.01  0.02 
0.00  0.01 
(1) Caterpillar specification for roll-off or in-service oil.
(2) Caterpillar specification for fill oil.

Tooling and Equipment

Table 4
Quantity  Description 
169-7372 Clean Sample Bottle 
202-2301 Portable Contamination Control Kit 
Ultrasonic Bath (1) 
100 ml (3.4 oz)  Filtered kerosene per oil sample (free of water)(2) 
0.45 micron x 25 mm (0.98 inch) filter patch(3) 
(1) See "Recommendations" at the end of this document.
(2) See Table 6 at the end of this document for common names of kerosene.
(3) Fisher Scientific part number 09-905-15

Issue

Oil additive interference, in some Caterpillar oils, has caused some difficulties in determining new bulk oil cleanliness levels with automatic particle counters. Because of the additive interference, the oil may appear dirtier than the true cleanliness level without additive interference. The oil pretreatment method below provides step-by-step instructions that will allow for the comparison of oil cleanliness results from both non-pretreated and pretreated oil samples to determine if additive interference is impacting particle counter results.

Test Procedure

  1. Filter 100 ml (3.4 oz) of kerosene through a filter patch to ensure cleanliness of the solvent using the filtering procedure described in Tool Operating Manual, NEHS0729, "Use of Portable Contamination Control Kit". Caterpillar recommends using the 0.45 micron filter patch with the portable contamination kit. Using the 5 micron patch that is included in the kit is acceptable. Each oil sample to be analyzed will be split into two separate samples. Each sample will require 50 ml (1.7 oz) of filtered kerosene.

    Note: The best way to filter the kerosene is to use a 0.45 micron patch. The patches can be ordered through Fisher Scientific. The Fisher Scientific part number is 09-905-15 for a pack of 100. If the 0.45 micron patch clogs, filter the kerosene with a 5 micron patch, followed by a 0.45 micron patch. If the clogging issue is due to water, try a different container of kerosene and start over.

  2. Fill two of the clean oil sample bottles to the top "Fill Range Line" with the oil to be tested. One sample will be tested without pretreatment and one will be tested with the pretreatment oil method. All the sample bottles should be rinsed with the oil that is being tested. Refer to Caterpillars Channel 1 for Tips and Tricks videos, along with Training Video, PERV4638, "Caterpillar Oil Sampling...The Right Way"

    Note: The source of the oil needs agitated, if possible, before the oil is sampled. For example, 3.78 L (1 US gal) and 18.9 L (5 US gal) containers should be shaken for 3 to 5 minutes before a sample is taken.

  3. Shake one of the samples vigorously for 1 minute to ensure proper agitation of the oil.

  4. Take the shaken sample and unscrew the lid one quarter of a turn. Place the bottle in the ultra sonic bath for 45 seconds to remove the air bubbles. Air bubbles remaining at the surface of the oil is acceptable.

    Note: The ultra sonic bath should be filled with enough water to cover 75-80% of the height of the bottle to allow the air bubbles to rise to the top of the bottle.

  5. Remove the sample bottle from the ultra sonic bath. Analyze the oil sample using the particle counter per the manufacturer instructions to obtain the particle count results. This sample will be used as a reference to determine if additive interference is present in the oil.

    Note: As a reminder, the three code readout represents the counts for the 4, 6, and 14 micron size particles respectively. For new oil, only look at the values for the second and third codes. These codes represent the values for the 6 micron and the 14 micron size particles.

  6. Take a third clean sample bottle and mark the 50 ml (1.7 oz) and 100 ml (3.4 oz) levels on the bottle. See the example below.


    Illustration 3g01414017
    (1) The 50 ml (1.7 oz) line is in the middle of this ridge in the bottle
    (2) The 100 ml (3.4 oz) line is just below the top of the "Fill Range" line

    Note: If you use a different type of sample bottle than the part number that is listed in Table 4, the 50 ml (1.7 oz) and 100 ml (3.4 oz) levels will need to be determined before you begin the procedure.

  7. Take the second oil sample bottle from Step 2 and shake the sample vigorously for 1 minute. Pour the oil into the empty sample bottle from Step 6 to reach the 50 ml (1.7 oz) mark on the bottle. Both sample bottles should now have 50 ml (1.7 oz) of oil. If either bottle has excess oil, discard the excess oil according to the proper disposal procedures.

  8. Add 50 ml (1.7 oz) of the filtered kerosene from Step 1 to both sample bottles. The bottles should now be filled to the 100 ml (3.4 oz) mark. Mark one of the sample bottles as "Flush" and mark the other sample as "Sample". These samples are now considered "pre-treated" or "diluted".

  9. Shake the pre-treated oil sample marked "Flush" vigorously for 30 seconds.

  10. Take the shaken sample and unscrew the lid one quarter of a turn. Place the bottle in the ultra sonic bath for 10 to 15 seconds to remove the air bubbles. Air bubbles remaining at the surface of the oil are acceptable.

  11. Remove the oil sample from the ultra sonic bath. Immediately analyze the oil sample using the particle counter per the manufacturer instructions.

  12. Repeat Steps 8 through 11 for the bottle marked "Sample".

    Note: The reason that the two pre-treated samples are run through the particle counter is that one sample is used to flush the system with the same type of fluid that is being analyzed to ensure a more accurate particle count.

  13. Correct the particle count results for the dilution factor by multiplying the counts per mL by two or by adding one number to each range of the ISO code. This is because the sample is only 50 percent oil. Therefore, the number of particles in 100 percent oil would be two times as much as what is counted in a 50 percent oil sample. Refer to Table 3 to determine the corrected ISO code from the counts per mL numbers. Determining the correct ISO code can also be accomplished by adding a value of one to each ISO code number. For example, an ISO 17/14/10 pre-treated sample has a true cleanliness of ISO 18/15/11.

  14. Compare the non-pretreated and the corrected pre-treated ISO codes. If the ISO codes are the same, there is no significant additive interference. If the sample is lower (cleaner) by at least two ISO codes, there is additive interference.

    Note: Regardless of pretreatment or non-pretreatment, always be aware that water in the oil samples will cause inaccurate readings.

Recommendations

The ultra sonic bath should meet the minimum specifications listed in Table 5. There are several different brands available and can usually be purchased at the local retail stores. For example, the specifications in Table 5 are for a Bransonic model B200 and can be purchased on-line.



Illustration 4g01414016

Table 5
Specifications for Bransonic model B200 Ultra Sonic Bath 
Model Number  B200, 117V, 60Hz  B200, 220V, 50/60Hz 
Tank Capacity  444 ml (15 oz)  444 ml (15 oz) 
Tank Dimensions  6 1/2"L x 3 1/2"W x 2 3/4"D  6 1/2"L x 3 1/2"W x 2 1/4"D 
Overall Dimensions  8 3/4"L x 4 1/2"W x 5"D  8 3/4"L x 4 1/2"W x 5"D 
Shipping Weight  13 N (3 lb)  13 N (3 lb) 
Bransonic Part Number  100-951-010  100-951-011 

Table 6
Common Names for Kerosene 
Common Name  Country 
Fotogen  Sweden 
Petrooli  Finland 
Kerosene  United States 
Kerosene or kero  Australia 
Nafta  Poland and Argentina 
Parafin  Norway 
Paraffin oil  United Kingdom and South Africa 
Petroleum  Germany and Denmark 
Petrolej or kerozin  Slovakia 
Pitch oil  Trinidad and Tobago 
Range oil   
Rockel  In western states of India 
Stove oil  Canada 
Petrolej  Czech republic 
Miti ka tail  Pakistan 
Kerosine  Netherlands 
Kaz  Syria, Lebanon, and Jordan 
Parafina  Chile 
Querosene  Brazil 

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