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Introduction
Revision | Summary of changes in SEBF8448 |
7 | Added new serial number prefixes for New Product Introduction (NPI).
Added PERJ1017 , "Dealer Service Tools Catalog" to References table. Added "Think Safety" Illustration to the Important Safety Information section. Updated Introduction Information. |
06 | Changes to references table listed below.
PEGJ5025 canceled replaced by PEGJ0045. Updated Introduction. Added Safety Information. Added Canceled and 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.
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 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 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 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
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. |
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
This guideline will enable dealers and customers to add filter capability to solvent stands. Following this procedure will help maintain a solvent cleanliness target of ISO 16/13. This procedure may need modified for use on some solvent stands.
References
References | |
Media Number | Title |
PEGJ0045 | Reporting Particle Count by ISO Code |
PEVN4831 | Count on Caterpillar Particle Analyzers |
SEBF3116 | Obtaining an Oil Sample for SOS Analysis |
PERJ1017 | "Dealer Service Tools Catalog"(1) |
(1) | Visit dealer.cat.com to download or purchase the document. |
Tooling and Equipment
Required Tools | ||
Quantity | Part Number | Description |
1 | 4C-9502 | Form-A-Gasket |
1 | 169-8373 | Bottle group |
1 | 8C-3446 | Oil sample valve |
1 | 3J-7354 | O-ring |
1 | 8C-3445 | Dust cap |
1 | 1N-3789 | Base assembly |
1 | 1R-0749 | High efficiency fuel filter |
1 | 6N-4414 | Cover |
1 | 1P-0436 | Gasket |
1 | 7B-2742 | Bolt |
1 | 5P-0537 | Washer |
1 | 1B-2790 | Bolt |
1 | 9M-1974 | Washer |
2 | 0S-1591 | Bolt |
2 | 9S-8752 | Nut |
2 | 5M-2894 | Washer |
Hose(1) | ||
1 | 184-2319 | Filter bag w/o ring -25um |
1 | 2P817(2) | Filter bag w/ ring - 5um |
1 | 189-5637 | Filter bag - absorbent |
1 | 2D-7325 | Tee |
2 | 180-4796 | Valve |
1 | 1HML5 (2) | Hose barb plug |
Desired Length | 5P-0720 | Air brake hose |
1 | 1P-4278 | Hose clamp |
Optional Tools | ||
1 | 170-8500 | S40 Portable Particle Analyzer |
1 | 210-5530 | Coupler |
1 | 188-0639 | Hose |
1 | 220-8607 | Fitting group |
1 | 220-8608 | Fitting group |
(1) | Customer Supply (Must be compatible with solvents being used.) |
(2) | Grainger part number |
Adding Filtration Capability to Solvent Stands
The following procedure is applicable for various types of solvent stands. Remember to disconnect the solvent tank from a power supply before beginning this procedure.
There are three possible ways to add filtration to a solvent stand.
Adding a Fuel Filter and Pump
- Remove all parts and tools from the solvent tank and clean the tank thoroughly.
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Illustration 3 g01242154 (1) 3J-7354 O-ring
(2)8C-3445 Dust Cap
(3)8C-3446 Oil Sampling Valve - Install a 3J-7354 O-ring (1) and an 8C-3445 Dust Cap (2) on the 8C-3446 Oil Sampling Valve (3).
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Illustration 4 g01242156 (4) 1N-3789 Base Assembly - Install the 8C-3446 Oil Sampling Valve (3) on the 1N-3789 Base Assembly (4).
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Illustration 5 g01242157 (5) 1P-0436 Gasket
(6)6N-4414 Cover
(7)7B-2742 Bolt
(8)1B-2790 Bolt - Install a 1P-0436 Gasket (5) and a 6N-4414 Cover (6) to the base assembly using a 7B-2742 Bolt (7) with a 5P-0537 Washer and a 1B-2790 Bolt (8) with a 9M-1974 Washer. Tighten to
70 ± 15 Nm (52 ± 11 lb ft) .Show/hide tableIllustration 6 g01242158 (9) 1R-0749 - Install a 1R-0749 High Efficiency Fuel Filter (9) to the base assembly. Be sure to date the filter to facilitate easier maintenance.
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Illustration 7 g01242159 Installation of the 1N-3789 Base Assembly
(10)0S-1591 Bolts
(11) Inlet Port
(12) Outlet Port - Install the assembled 1N-3789 Base Assembly on the rear of the solvent tank. Installation will require drilling two
76 mm (3/8 inch) holes. - Apply 4C-9502 Form-A-Gasket to the two
76 mm (3/8 inch) holes referred to in Step 6. This procedure will prevent solvent leakage. - Attach the base assembly to the solvent tank using two 0S-1591 Bolts (10), four 5M-2894 Washers, and two 9S-8752 Nuts.
- Remove the solvent tank from the drum.
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Illustration 8 g01242160 (13) Pump discharge port
(14) Existing solvent stand hoses - Using the proper type of hose, route a hose from the pump discharge port (13) to the inlet port (11) of the filter base assembly.
- Route another hose from the outlet port (12) of the filter base assembly into the existing solvent stand hoses (14).
Adding 184-2319 or Grainger 29817 Filter Bag
- Install a filter bag over the drain portion of the solvent tank. The filter bag can be installed in one of the two following ways:
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Illustration 9 g01242161 (15) 184-2319 Filter Bag - Place a 184-2319 Filter Bag (15) over the drain portion of the solvent tank using standard electrical tie wraps.
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Illustration 10 g01242162 (16) Clips Show/hide tableIllustration 11 g01242163 (17) Grainger 2P817 Filter Bag - Install three customer-supplied clips (16) to the bottom of the solvent stand. Place a Grainger 2P-817 filter bag (17) inside the clips.
Note: The addition of a filter bag prevents the 1R-0749 High Efficiency Fuel Filter from becoming prematurely plugged with large contaminants. Therefore, the filter bag allows the fuel filter change interval to be lengthened substantially.
Show/hide tableIllustration 12 g01242165 (18) Solvent tank
(19) Drum - Return the solvent tank (18) to the drum (19). Be sure that pump is submerged in solvent when placed in the drum.
- Connect the solvent stand to a power supply.
- Begin the pump operation.
- Collect a fluid sample at least once per month from the solvent stand using the 8C-3446 SOS Valve located on the filter base assembly.
Note: The solvent stand can be particle count tested for cleanliness in one of the two following ways.
- Use a 170-8500 Portable Particle Analyzer for immediate results.
- Collect a bottle sample and send the sample to an SOS lab.
Show/hide tableIllustration 13 g01242166 (20) Fabricated suction tube
(21)220-8607 Fitting
(22)210-5530 Coupler
(23) SOS Valve - Attached the fabricated particle counter suction tube (20) to the SOS valve (23) on the filter unit.
Note: The fabricated suction tube can be made with the parts listed in table 3 and shown in Illustration 13.
- 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.
- If collecting a bottle sample, use the same SOS valve (23) and a 169-8373 Bottle Group.
- Do not allow the solvent fluid to exceed an ISO level of 16/13 consistently. If the solvent fluid does begin to exceed 16/13 regularly, all the following maintenance procedures may need performed in this order.
- Change the 1R-0749 High Efficiency Fuel Filter.
- Change the filter bag.
- Change the solvent fluid.
- Caterpillar recommends replacing the filter bag a minimum of once every 6 months and the 1R-0749 High Efficiency Fuel Filter be replaced a minimum of once every 3 months. The solvent fluid should be changed whenever the oil content in the solvent begins to reduce the cleaning capability of the solvent.
Note: Filter and fluid replacement intervals are dependent on the amount of use the solvent stand suffers over a time. Proper change intervals will need to be identified for each individual solvent stand application.
Adding 189-5637 Filter Bag
Note: All parts listed for this section in the pictures, and in table3are not designed to fill all applications. Proper parts will need to be identified for each individual application.
- Install the 2D-7325 Tee (24) between the solvent tank and the solvent tank neck (25) as shown in Illustration 14.
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Illustration 14 g01242168 (24) 2D-7325 Tee
(25) Solvent tank neck
(26)180-4796 Valves
(27) Hose Barb Plug
(28)5P-0720 Hose
(29)1P-4278 Hose Clamp - Connect the 180-4796 Valves (26) to the 2D-7325 Tee (24) as shown in Illustration 14.
- Connect the solvent tank neck (25) to one valve (26). See Illustration 14.
- Using the desired length of 5P-0720 Hose (28) and the 1P-4278 Hose Clamp (29), connect the 189-5637 Filter Bag (30) to the hose barb plug (27).
Note: The parts listed in steps 2 through 4 and shown in illustration 14 may be different for each application and will need to be identified to ensure the proper fit.
Show/hide tableIllustration 15 g01242169 (30) 189-5637 Filter Bag
(31) Protection Grill - Protect the 189-5637 Filter Bag (30) with a grill (31).
Note: The protection grill (31) is not a Caterpillar serviceable part. You may need to fabricate this part for each individual application.