- Agricultural Tractor
- All
- Articulated Truck
- All
- Asphalt Paver
- All
- Backhoe Loader
- All
- Challenger
- All
- Cold Planer
- All
- Combine
- All
- Compact Track Loader
- All
- Compact Wheel Loader
- All
- Earthmoving Compactor
- All
- Excavator
- All
- Forest Products
- All
- Integrated Toolcarrier
- All
- Landfill Compactor
- All
- Load Haul Dump
- All
- Mini Hydraulic Excavator
- All
- Motor Grader
- All
- Multi Terrain Loader
- All
- Off-Highway Truck/Tractor
- All
- Paving Compactor
- All
- Pipelayer
- All
- Road Reclaimer/Soil Stabilizer
- All
- Skid Steer Loader
- All
- Soil Compactor
- All
- Telehandler
- All
- Track Feller Buncher
- Caterpillar
- Track-Type Loader
- All
- Track-Type Skidder
- All
- Track-Type Tractor
- All
- Underground Articulated Truck
- All
- Wheel Dozer
- All
- Wheel Feller Buncher
- All
- Wheel Loader
- All
- Wheel Skidder
- All
- Wheel Tractor-Scraper
- All
- Wheeled Excavator
- All
Introduction
Revision | Summary of Changes in SEBF8482 |
07 | Added new serial number prefixes for New Product Introduction (NPI).
Updated copyright date to 2018. Added Caterpillar confidential yellow statement to the introduction. Added PERJ1017 , "Dealer Service Tool Catalog" to the References table. Removed NENG2500 , "Dealer Service Tool Catalog" from the References table. Added PERJ1017 , "Dealer Service Tool Catalog" to the References table. |
06 | Updated 2013 copyright paragraph, inserted "Think Safety" graphic, part number GE06L/4NP TA3C canceled and replaced by |
05 | Update 2012 copyright paragraph, insert Summary of Changes table, Important Safety Information paragraph, Safety paragraph, and Canceled Replaced by Part Numbers paragraph. Remove PEVN 8431 Count on Caterpillar Particle Analyzers, document canceled, removed part numbers from paragraphs. |
© 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 the 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 a feedback form in the Service Information System website.
Summary
A good oil sample that accurately represents the condition of the fluid system is vital for the success of any analysis program. For this reason, the oil should be at the system operating temperature or at least
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. When a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar, ensure that the tool, procedure, or work method is safe for all personnel around the machine. 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, measurements, 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. |
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. |
References
References | |
Media Number | Title |
SEHS9043 | "Valve Installation for Scheduled Oil Sampling of Engine, Transmission, Hydraulics, and Steering" |
NEHS0799 | "Tool Operating Manual for 170-8500 Analyzer Group" |
PEGJ0045 | "Reporting Particle Count by ISO code" |
PERJ1017 | "Dealer Service Tool Catalog" |
PEGJ0047 | "How to Take A Good S·O·S Sample" |
NOTICE |
---|
Keep all parts clean and keep all parts free of contamination. |
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. |
On-line Particle Counting using S·O·S Valves
Parts List | ||
Quantity | Part Number | Parts Description |
1 | Shop Towel | |
1 | S40 Particle Analyzer Gp | |
1 | Quick Disconnect | |
1 | Fluid Sampling Valve | |
1 | Hose As Replacement Parts |
Illustration 3 | g01281548 |
Pama On-line Particle Counter |
Note: Refer to Tool Operating Manual, NEHS0799, "170-8500 Analyzer Group" for proper installation and operation. Caterpillar recommends connecting the on-line particle counters directly to the S·O·S valve.
Note: Refer to the Operation and Maintenance Manual for the S·O·S valve locations. Refer to the Test and Adjust Manual to obtain the system pressures. Prepare all equipment used to sample oil in advance to prevent contamination prior to taking a sample.
Illustration 4 | g01281550 |
Left - high-pressure hose, Right - low-pressure hose |
- Determine the fluid system pressure at the location where the sample is to be taken (S·O·S valve). For proper supply hose and hardware, refer to Tool Operating Manual, NEHS0799, "170-8500 Analyzer Group".
- Exercise the machine until the sampled fluid system is up to the normal operating temperature or at a minimum of
50 °C (120 °F) . - Park the machine on level ground. Lower all the attachments. Engage the parking brake.
- Set the engine at low idle. All systems must be in a safe position.
Show/hide table
Illustration 5 g01281551 S·O·S valve dust cover - Remove the dust cover from the S·O·S valve. Refer to the Operating and Maintenance Manual for the S·O·S valve locations.
Show/hide table
Illustration 6 g01281552 Lint Free Towel. Transmission S·O·S valve shown. - Clean the S·O·S valve with a clean lint free towel.
Show/hide table
Illustration 7 g01281553 Quick Disconnect - Make sure that the quick disconnect is clean.
Show/hide table
Illustration 8 g01281554 Typical particle counter supply hose attached to the S·O·S valve (low-pressure hose shown) - Attach the particle counter supply hose to the S·O·S valve.
Show/hide table
Illustration 9 g01281555 Particle counter connections - Secure the particle counter discharge hose with a catch basin.
- If the sampled fluid system has cooled down, exercise the machine until the sampled fluid system is up to normal operating temperature or a minimum of
50 °C (120 °F) .Show/hide tableNOTICE Do not move the machine while the particle counter in connected. Moving the machine in this condition could damage the machine and/or the particle counter.
Note: Allow power train circuits to idle for a minimum of 10 minutes prior to particle counting. Allowing power train circuits to idle will permit entrapped air to escape from the sampled oil. Air trapped in the oil will distort the particle counter readings.
- Operate the particle counter according to the manufacturer instructions to obtain an oil sample reading.
Show/hide table
Illustration 10 g01281556 Remove sampling hoses. - After testing, disconnect the particle counter hose assembly from the machine. Disconnect the hose assembly from the particle counter. Drain the hoses. Cap all the hose ends. Store the particle counter and the hoses in a clean location.
Show/hide table
Illustration 11 g01281557 Replace dust cap - Install the dust cap onto the S·O·S valve. Make sure that the cap is clean on the inside.
NOTICE |
---|
Dispose of all used oil, shop towels, and oil containers according to local regulations and mandates. |
Bottle Sampling Using Oil Valve Probe and S·O·S Valve
Parts List | ||
Quantity | Part Number | Part Description |
1 | 162-5791 | Shop Towel |
2 | 169-8373 | Sample Bottle Group |
1 | 162-8873 | Sample Bottle Probe Holder |
1 | 8T-9208 | Probe Assembly(1) |
1 | 4C-4600 | Sample Bottle Shipping Container |
(1) | Purging with tube |
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. |
Note: Refer to Operation and Maintenance Manual for the S·O·S valve locations. Refer to the Test and Adjust Manual to obtain the system pressure. Only perform a bottle sample when the system pressures are below
- Fill out the S·O·S label. Pay special attention to the serial number, sample data, service meter units on the equipment, service meter units on the oil, oil type, oil brand, and the amount of oil added. Indicate if the oil was changed after the sample was taken.
Show/hide table
Illustration 13 g01281559 Sample bottle package - Open the sample bottle package. Remove the sampling probe tube from the bag.
Show/hide table
Illustration 14 g01281560 Probe holder and probe - Insert the open sampling probe tube into and through the sample bottle probe holder counter bored end. Pull the probe tube all the way through the holder until the sampling needle seats in the holder.
Show/hide table
Illustration 15 g01281561 - Remove the sampling bottle from the package. Install the cap with two holes onto the bottle. Install the probe tube into one of the holes in the cap.
Show/hide table
Illustration 16 g01281562 - Return the assembled bottle and return the probe back into the package to prevent contamination.
- Exercise the machine until the system oil to be sampled is up to normal operating temperature or at a minimum of
50 °C (120 °F) . - Park the machine on level ground. Lower all the attachments. Engage the parking brake.
- Set the engine at low idle. Make sure that all systems are in safe positions. Refer to the Operation and Maintenance Manual.
Show/hide table
Illustration 17 g01281564 - Remove the dust cover from the S·O·S valve.
Show/hide table
Illustration 18 g01281565 - Clean the S·O·S valve with a clean lint free shop towel.
Show/hide table
Illustration 19 g01281566 Purging S·O·S valve with Purge Probe and tube - Purge the S·O·S valve by pressing the purge probe onto the S·O·S valve. Purge a minimum of one sample bottle of oil or more to ensure that all the dead volume of the fluid is purged. Purging the oil will ensure that the sampling nipple is internally cleaned.
Note: If the oil flow is slow at low idle, someone may need to accelerate the engine.
Show/hide tableIllustration 20 g01281567 Oil disposal - Properly dispose of the purged oil according to local regulations and mandates.
Show/hide table
Illustration 21 g01281568 Prepared bottle sample - Remove the prepared sample bottle from the package.
Show/hide table
Illustration 22 g01281576 Flush sample bottle - Rinse the sample bottle and rinse the probe tube with the system oil. Rinse the bottle by filling the bottle half full with the system oil.
Show/hide table
Illustration 23 g01281577 Flush sample bottle - Shake the sample bottle vigorously for several seconds.
Show/hide table
Illustration 24 g01281578 - Empty the oil into a waste oil container.
Show/hide table
Illustration 25 g01281579 - Fill the sample bottle to the "fill range" imprinted on the bottle, but do not fill beyond the fill mark.
Note: Filling beyond the fill mark will not allow for proper lab mixing.
Show/hide tableIllustration 26 g01281580 - Remove the sampling probe tube from the bottle lid. Save the knurled probe holder and discard the probe tube.
Show/hide table
Illustration 27 g01281581 - Immediately replace the two-hole lid on the sample bottle with the solid lid (no hole). Dispose of the lid with two holes.
Show/hide table
Illustration 28 g01281583 - Ensure that the outside of the bottle is clean.
Show/hide table
Illustration 29 g01281585 Mailing tube with completed label - Place the bottle with the completed information label into a sample bottle shipping container, or take the bottle and label to an S·O·S lab.
Show/hide table
Illustration 30 g01281586 - Wipe any oil off the sample valve.
Show/hide table
Illustration 31 g01281588 - Install the dust cap onto the S·O·S valve and check that the cap is clean on the inside.
Illustration 12 | g01281558 |
S·O·S mailing label |
Zero Pressure System Using a Hand Vacuum Pump
Parts List | ||
Quantity | Part Number | Part Description |
1 | 162-5791 | Shop Towel |
2 | 169-8373 | Sample Bottle Group |
1 | 1U-5718 | Oil Sampling Vacuum Pump |
1 | 4C-4600 | Sample Bottle Shipping Container |
1 | 1U-7648 | Tube Cutter |
1 | 1U-8757 | Tube |
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. |
Note: Typical non-pressurized systems are reservoirs, differentials, final drives, or return lines (drains). The sample location should be near the middle of the reservoir fluid level and away from the sidewall. The sample location should be where the fluid is normally in motion, thoroughly mixed, and at normal operating temperature. The sample should be taken as soon as possible after the machine exercising has been stopped. Prepare all sampling hardware before an oil sample is taken.
Note: Never use the same vacuum pump for obtaining both oil and coolant samples. The fluid does not enter the barrel of the pump, a small residue of glycol from the coolant remains in the pump. The glycol residue can contaminate the oil sample. Glycol will indicate a "false positive" coolant leak in the oil system being sampled.
- Fill out the S·O·S label. Pay special attention to the serial number, sample data, service meter units on equipment, service meter units on oil, oil type, oil brand, and the amount of oil added. Indicate if the oil was changed after the sample was taken.
Show/hide table
Illustration 33 g01281591 Tube cut to length - Measure the tubing and then cut the new tubing to the length of the dipstick. If there is no dipstick, cut the tubing so that the tubing reaches about halfway into the oil depth of the compartment being sampled.
Note: Use a tube cutter to prevent the tubing from being contaminated.
Show/hide tableIllustration 34 g01281593 - Install tubing into the vacuum pump. The bottle end of the tubing should be approximately
25.4 mm (1 inch) beyond the base of the vacuum pump head.Show/hide tableIllustration 35 g01281594 - Install a new bottle to be sampled to the vacuum pump.
Show/hide table
Illustration 36 g01281595 - Store the vacuum pump assembly and the clean bottle cap in the plastic bag until the parts are ready for use.
- Exercise the machine fluid to be sampled until the fluid system is up to normal operating temperature. If normal operating temperature cannot be reached, then
50 °C (120 °F) is acceptable. - Park the machine on level ground. Lower all the attachments. Engage the parking brake.
- Shut off the machine . Make sure that all the systems are in safe positions. Refer to the Operation and Maintenance Manual.
Show/hide table
Illustration 37 g01281596 - Clean the sample location using a clean lint free shop towel.
Show/hide table
Illustration 38 g01281597 - Keep the sample bottle vertical when taking samples. Pump the vacuum pump handle to create a vacuum.
Note: If the bottle is tilted, the oil will enter into the suction of the barrel of the vacuum pump. Oil in the barrel will cause cross contamination of subsequent samples.
Show/hide tableIllustration 39 g01281598 - Fill the sample bottle half full with system oil.
- Remove the bottle from the vacuum pump.
Show/hide table
Illustration 40 g01281577 - Install a clean lid and shake the bottle vigorously for several seconds.
Show/hide table
Illustration 41 g01281578 - Empty the bottle into a waste oil container.
- Reattach the sample bottle to the vacuum pump.
Show/hide table
Illustration 42 g01281599 - Take the oil sample in the same manner. Fill the bottle to the "fill range". Do not fill the bottle beyond the fill mark.
Note: Filling beyond the fill mark will not allow for proper lab mixing.
Show/hide tableIllustration 43 g01281583 - When the oil bottle is filled, remove the bottle from the vacuum pump. Cap the bottle with a clean lid (no holes).
- Clean the outside of the bottle.
Show/hide table
Illustration 44 g01281585 - Place the bottle with the completed information label into a sample bottle shipping container, or take the bottle and label to an S·O·S lab.
- Remove the tubing from the vacuum pump and discard the tubing according to local regulations and mandates.
Show/hide table
Illustration 45 g01281596 - Clean any covers, caps, plates, and so on, that have been removed.
Illustration 32 | g01281590 |