Procedure for Kidney Looping Track Feller Buncher Hydraulic Oil {0680, 0738, 0768, 5050, 5056} Caterpillar


Procedure for Kidney Looping Track Feller Buncher Hydraulic Oil {0680, 0738, 0768, 5050, 5056}

Usage:

TK711 101


Industrial Tractor
TK371 (S/N: WBG1-UP)
TK381 (S/N: WBH1-UP)
Track Feller Buncher
1090 Series II (S/N: BZJ1-UP)
1190 (S/N: BZK1-UP)
1190T (S/N: BZL1-UP)
1290T (S/N: BZM1-UP)
1390 (S/N: B3F1-UP)
2491 (S/N: P5J1-UP)
2590 (S/N: P6B1-UP)
TK1051 (S/N: 9HZ1-UP)
TK711 (S/N: 1011-UP)
TK721 (S/N: 1021-UP)
TK722 (S/N: 1031-UP)
TK732 (S/N: 1041-UP)
TK741 (S/N: 2021-UP)
TK751 (S/N: 3011-UP)
TK752 (S/N: 3021-UP)
Wheel Feller Buncher
2570D (S/N: D251-UP)
2670D (S/N: D261-UP)
563D (S/N: D631-UP)
573D (S/N: D731-UP)
HA771 (S/N: HAF1-UP)
HA871 (S/N: HAG1-UP)

Introduction

Table 1
Revision  Summary of changes in SEBF8404 
04  Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2016.
Added Caterpillar: Confidential Yellow statement to the copyright paragraph.
Added "Think Safety" Graphic under Important Safety Information section.
Added "Filtration Procedure for 563D Wheel Feller Buncher with Gate Valve Drain" to the document. 
03  Changes to references table listed below.
Removed PEVN4831 video canceled.
PEGJ5025 canceled replaced by PEGJ0045.
PEHP6001 canceled replaced by PEGJ0047.
Added Canceled Replaced Part Numbers statement.
Updated Introduction.
Updated Safety Information. 

© 2016 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 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 procedure must be used with the most recent technical information available from Caterpillar Inc. to ensure that such changes and improvements are incorporated when applicable.

For questions or additional information concerning this guideline, submit a feedback form in the Service Information System web site. To address an urgent need, use the following to forward your request to Caterpillar Repair Process Engineering:

  • Cat Dealer Technical Communicator

  • Global Dealer Solution Network

  • Cat Technical Representative

  • Knowledge Network

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 kidney loop filtration process is easy. The kidney loop cart connects to the hydraulic oil system drain and hydraulic tank breather.

This guideline provides directions for installing and operating the kidney loop system. Clean fluids play a major role in the life of any fluid system. The following procedure will help reduce fluid contamination in the oil to an acceptable contamination level of ISO 16/13 or cleaner. This procedure may need to be modified by the technician for use on some machines.

The following procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and the oil is mixed from operation. This action causes contamination in the system to be placed in suspension and lowers the viscosity.


NOTICE

If the vehicle is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing 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 the kidney looping. This filtration procedure and subsequent particle count testing should be performed as a final step in the repair process.


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 the procedure is safe for all personnel around the machine. Also ensure that the product will not be damaged or 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, 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, NENG2500, "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.


References

Table 2
References 
Media Number  Title 
NEHS0778  "Tool Operating Manual for 188-3242 Filter Cart" 
NENG2500  "Dealer Service Tool Catalog" 
PEGJ0045  "Reporting Particle Count by ISO Code" 
PEGJ0047  "How to Obtain A Good S•O•S Sample" 
SEBF8482  "Obtaining an Oil Sample for S•O•S Analysis" 
NEHS0799  "Tool Operating Manual for S40 Portable Particle Analyzer" 

Tooling and Equipment

Table 3
Required Tools 
Quantity  Part Number  Part Description 
188-3242  Hydraulic Filter Cart 
190-8319  Nipple 
006-5707  90 degree Elbow 
7B-9008  Pipe 
005-8615  Union 
190-8318  Coupler 
3B-6555  45 degree Elbow 
5P-0492  Adapter 
6V-5258  Adapter 
Optional Tools 
Part Number  Parts Description 
170-8500  S40 Portable Particle Analyzer 
210-5530  Coupler 
188-0639  Hose 
169-8373  Bottle Group 
220-8607  Fitting(1) 
(1) For low-pressure suction tube fabrication.


Illustration 3g01256323
Return oil adapter for Track Feller Bunchers
(1) 6V-5258 Adapter
(2) 5P-0492 Adapter
(3) 3B-6555 45 degree Elbow
(4) 005-8615 Union
(5) 190-8318 Coupler


Illustration 4g01256352
Suction Adapter for Track Feller Buncher
(1) 190-8319 Nipple
(2) 006-5707 90 degree Elbow
(3) 7B-9008 Pipe


Illustration 5g06103728
563D Suction Adapter Hose As. for Wheel Feller Buncher
(1) 5D-1026 Hose Clamp
(2) 6B-9081 Reducer Bushing
(3) 124-1904 Permanent Coupling
(4) 122-6871 Hydraulic Hose
(Not Pictured) 190-8319 Nipple (Quick Disconnect)

Machine Kidney Loop Procedure

This guideline is intended for Feller Bunchers. The procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and mixed from the operation. Warming the oil allows any contamination in the system oil to be placed in suspension and lowers the viscosity. Be sure to read and understand Tool Operation Manual, NEHS0778, " 188-3242 Kidney Loop Cart" before beginning the procedure.

Kidney Loop Setup

------ WARNING! ------

Personal injury or death can result from sudden machine movement.

Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine.

To help prevent possible injury, perform the procedure that follows before testing and adjusting the hydraulic and steering system:


Note: Do not move the machine while the filter cart is connected. Moving the machine in this condition could cause machine damage.

  1. Operate the machine to warm the oil.

  2. Park the machine on level ground.

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

  4. Block the tracks or wheels.

Filtration Procedure for Track Feller Buncher with Ecology Drain



Illustration 6g01256361
(1) Access hood switch

  1. Hold access hood switch (1) in the open position until access hood is fully extended.


    Illustration 7g01256363
    (2) Access hood


    Illustration 8g01256364
    (3) Breather

  2. Clean the area around hydraulic tank breather (3). Relieve the tank pressure. Make sure that all air pressure has been vented before completely removing the breather.

  3. Store the breather (3) in a clean place to avoid contamination and damage.


    Illustration 9g01256365
    (4) Return oil adapter

  4. Install the return oil adapter (4).


    Illustration 10g01256368
    (5) Drain plug

  5. Remove the drain plug (5).


    Illustration 11g01256369
    (6) Suction Adapter

  6. Quickly install the suction adapter (6).


    Illustration 12g01256370
    (6) Suction adapter
    (7) Suction hose

  7. Connect the filter cart suction hose (7) to the suction adapter (6).


    Illustration 13g01256373
    (8) Discharge hose
    (9) Return oil adapter

  8. Connect the filter cart discharge hose (8) to the return oil adapter (9).


    Illustration 14g01256375
    (10) Air supply hose
    (11) Air supply valve

  9. Attach an air supply hose (10) to 188-3242 Filter Cart, ensuring that air supply valve (11) is in the closed position. Be sure that the air supply does not exceed 690 kPa (100 psi).

  10. Slowly open the air supply valve (11) to start the filter cart pump operation. The filter cart pump is a diaphragm pump. The pump is rated to pump 10W oil at 340 lpm (90 gpm).


    Illustration 15g01256377
    Filter Cart Operation on a TK732

  11. During operation, check the filter element indicators on the filter cart. The indicators will indicate the amount of capacity left in the filter element.

    Note: Occasionally, the filter cart pump will cavitate during start-up. Cavitation is due to air in the suction lines of the pump. Shut the filter cart OFF and check the connections if cavitation continues for more than 1 minute.

  12. Ensure that there are no oil leaks from any of the filter cart connections.

    Note: Caterpillar recommends taking a particle count on the oil at the beginning of the filter cycle. Use the result as a baseline particle count.

  13. 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 SOS lab. Refer to Contamination Control Guideline, SEBF8482.

Filtration Procedure for 563D Wheel Feller Buncher with Gate Valve Drain

    Note: Do not move the machine while the filter cart is connected. Moving the machine in this condition could cause machine damage.

  1. Operate the machine to warm the oil.

  2. Park the machine on level ground.

  3. Engage the parking brake.

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

  5. Turn off the engine.

  6. Block the wheels or tracks.

  7. Open the hood to access the top of the hydraulic tank.

  8. The hydraulic tank is located directly behind the cab.

    Note: Locate the filter cart on the right-hand side of the machine near the rear wheel. The Valve Assembly and Shutoff Drain are on the right-hand side of the machine.



    Illustration 16g06104007
    358-9477 Valve As (1)

  9. Clean the 358-9477 Valve As (1) and the surrounding area. Relieve the tank air pressure by pressing down on the top of the 358-9477 Valve As (1).

  10. Ensure all the tank air pressure has been vented. Remove the 358-9477 Valve As (1).


    Illustration 17g06104021
    Return Adapter Assembly (2).

  11. Install the Return Adapter Assembly (2) in the port that contained the 358-9477 Valve As (1). Refer to Illustration 17.

  12. Attach the filter cart Return Hose Assembly to the Return Adapter Assembly (2).


    Illustration 18g06104537
    508-7900 Plate (3)

  13. Remove the 508-7900 Plate (3) from the rear of the machine. Refer to Illustration 18.

    Note: The 508-7900 Plate (3) weight is 36.70 KG (80.909 LB.) use a lifting device or ask for assistance when removing the plate from the machine.



    Illustration 19g06104625
    (4) 5P-0767 Hose
    (5) 5D-1026 Hose Clamp

  14. Remove the 5P-0767 Hose (4) and the 5D-1026 Hose Clamp (5). Refer to Illustration 19.


    Illustration 20g06104631
    (6) 6V-7238 Shutoff Valve

  15. Install the Suction Adapter Hose As. for Wheel Feller Buncher on to the 6V-7238 Shutoff Valve (6). Refer to Illustration 5 for the components to assemble the Suction Adapter Hose As.

  16. Attach the Suction Adapter Hose As. for Wheel Feller Buncher to the Filter Cart suction hose.

  17. Open the 6V-7238 Shutoff Valve


    Illustration 21g06105136

  18. Attach an air supply hose (8) to the 188-3242 Filter Cart, ensuring that the air supply valve (7) 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 (7) to start the filter cart pump operation. The filter cart pump is a diaphragm pump. The pump is rated to pump 10W oil at 340 lpm (90 gpm).

    Note: Occasionally, the filter cart pump will cavitate during start-up. Cavitation is due to air in the suction lines of the pump. Shut the filter cart OFF and check the connections if cavitation continues for more than 1 minute.

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

  21. Ensure that there are no oil leaks from any of the filter cart connections.

    Note: Caterpillar recommends taking a particle count on the oil at the beginning of the filter cycle. Use the result as a baseline particle count.

  22. Start the machine. Cycle all the hydraulic implements (except the steering circuit) every half an hour of filter cart operation. Cycling the steering circuit can damage the machine or filter cart. The return and discharge hoses will need to be disconnected prior to cycling the steering circuit. Connect the return and discharge hoses after cycling the steering circuit. Cycle the cylinders to the end of the stroke at least four complete times. Cycling of the cylinders will flush the contaminated hydraulic system oil back to the tank. Cycling the cylinders will cycle the clean tank oil into the system and flush the more contaminated oil back into the tank. The filtration procedure can be performed while cycling the machine (except for the steering circuit).

  23. Turn off the machine.

  24. At the half way point of the filtration procedure, stop the filtration procedure and change the hydraulic oil filters on the machine.

    Note: Changing the hydraulic oil filters on the machine half way through the filtration procedure avoids opening the filter housing after the system has been cleaned. If the filter housing is opened after the filtration procedure is complete, the filter housing becomes an inlet for contamination. The new filters can remain in place until the next scheduled filter change.

  25. 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 SOS lab. Refer to Contamination Control Guideline, SEBF8482.

Portable Particle Analyzer Procedure

When using a portable particle analyzer for particle counting, be sure to read and understand the tool operating manual before operating.



    Illustration 22g01256384
    (12) Fabricated suction tube
    (13) 220-8607 Fitting
    (14) 210-5530 Coupler
    (15) SOS valve

  1. Attach the fabricated particle counter "low pressure in" suction tube to the SOS Valve (15) on the filter cart.

    Note: The fabricated suction tube can be made with the parts listed in Table 3 and as shown in Illustration 22.

  2. Attach the other end of the fabricated suction tube to the "low pressure in" port on the portable particle counter. Refer to the Tool Operation Manual, NEHS0778, " 188-3242 Kidney Loop Cart".

Bottle Sample Procedure

If collecting a bottle sample, use the same SOS valve (15) and a 169-8373 Bottle Group (16).



    Illustration 23g01256385
    (15) SOS valve
    (16) 169-8373 Bottle Group

  1. Record an oil sample from the SOS valve (15) on the filter cart at the beginning of the filter cycle.

  2. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an ISO level of at least 16/13. The final ISO should be recorded before the machine is returned to the field.

    Note: Kidney loop filtration can be performed while running the engine.

  3. During filter cart operation, cycle the lift cylinders at least four times per half hour of cart operation. This procedure 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 kidney looping, stop the procedure and change the filters on the machine.

    Note: Changing the hydraulic oil filters on the machine half way through the filtration procedure avoids opening the filter housing after the system has been cleaned. If the filter housing is opened after the filtration process is complete, the filter housing becomes an inlet for contamination. The new filters can remain in place until the next scheduled filter change.

    Note: Only change the hydraulic filters if scheduled to be changed or if not working at optimal performance.

  5. Refer to "Oil Compartment Filtration Times for 188-3242 Filter Cart", at the end of this document, when a portable particle analyzer is not available.

  6. When the target ISO level or time interval has been met, close the air supply valve (11) and disconnect the air supply hose (10).

    ------ WARNING! ------

    Hot oil and components can cause personal injury.

    Do not allow hot oil or components to contact skin.


  7. Disconnect the filter cart discharge hose (8) from return oil adapter port (9). Install the dust caps on the coupler and nipple. Store in a clean location.

  8. Disconnect filter cart suction hose (7) from suction adapter (6). Install the dust caps on the coupler and nipple. Store in a clean location.

  9. Remove suction adapter (6).

  10. Reinstall drain plug (5).

  11. Remove return oil adapter (4).

  12. Install a clean breather (3).

  13. Check the hydraulic tank oil level. Look at the oil level sight gauge.

  14. Close access hood (2).

  15. Unblock the tracks.

  16. Return the machine to service.

Oil Compartment Filtration Times for 188-3242 Filter Cart

If a portable particle counter is not available to diagnose and track when the contaminant level has lowered to an acceptable point, refer to the following equation. This equation relates to the 188-3242 Filter Cart. 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 situation. Therefore, the following equation must be viewed as only a simple reference and not an absolute time or efficiency result.



Illustration 24g01177339
Oil compartment filtration equation.
(A) Compartment Oil Capacity (gal)
(B) Pulses per Minute
(C) Approximate Filtration Time (min)

Pulses per Minute definition: Each air discharge or 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), delivering oil going both directions. Another way of determining pulses is to listen for the TUK – CHUK (two pulses). Count the number of pulses in 1 minute for use in the above equation.

Example: A TK711B Track Feller Buncher has 261.95 L (69.2 US gal) of oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 1 hour.

ISO 4406:1999 Method for coding the level of contamination by solid particles

ISO (International Organization of Standardization) 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 used in any given hydraulic fluid power system. An automatic particle counter derives the equivalent size of a particle from the particles cross sectional area. Particle counts are affected by various factors. These factors include procurement of the sample container, particle counting accuracy, and cleanliness. Proper care should be taken during sample procurement to ensure that the sample obtained is representative of the fluid circulation in the system.

The code for contamination levels using automatic particle counters comprises 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

At this time Caterpillar does not require the reporting of the "X" scale number since the hydraulic tolerances exceed the 4 micron value. Therefore a "-" is used instead. 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.

Clean Out Filter Vs. Kidney Loop Filtering

After any "open system" repair, on-site SOS sampling and particle counting are required. This procedure should be accomplished by exercising the specific system until the fluid is at normal operating temperature. This procedure ensures that the oil and representative oil will be collected during the SOS process. An ISO 16/13 maximum cleanliness target has been established for most hydraulic and transmission systems. Refer to the machine system cleanliness targets for your specific machine.

System Oil meets recommended cleanliness targets:

  1. Change the standard hydraulic system filter with a high efficiency filter prior to returning that machine to the customer. This procedure ensures that unseen system contamination and new part break-in debris will be properly filtered out during the initial hours after any repair.

  2. Instruct the customer that the high efficiency filter should be changed prior to 250 hours of operation.

  3. After the high efficiency filter has been removed, the filter should be cut open and the amount of captured debris should be checked. If a large amount of debris is present, another high efficiency filter should be installed and then rechecked after 100 hours. When a small amount of debris is present, a standard filter can then be installed.

System oil does not meet recommended cleanliness targets:

  1. Kidney Loop Filtering is required.

  2. Change the machines standard filter with a high efficiency filter half way through the kidney loop process explained in this guideline.

  3. Continue filtering according to the time interval at the end of this document or until the system meets the minimum recommended ISO.

  4. Leave the installed high efficiency filter on the machine. The filter should last at least 8 hours, and should be changed prior to 250 hours.

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