Procedure for Kidney Looping 210-215 Telescopic Handler Hydraulic Oil{0680, 0768, 5050, 5056} Caterpillar

Telehandler:

TH210 (S/N: CEC1-UP; MHT1-UP)

TH215 (S/N: CEG1-UP; MHS1-UP)

Introduction

© 2012 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.

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 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. This guideline provides directions for installing and operating the kidney loop system.

Clean fluids play a major function in the life of any fluid system. The following procedure will help reduce fluid contamination in the oil to an acceptable level of ISO 18/15 or cleaner.

Important Safety Information

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

Show/hide table

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.

Show/hide table

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.

References

Tooling and Equipment

Illustration 2	g01294900
Return oil fastener for Telescopic Handlers (1) 234-0217 Adapter

Illustration 3	g03295417
Return oil adapter for Telescopic Handlers (2) 190-8318 Coupling (3) 1L-4031 Tee (4) 1 inch Pipe (10 inches long)

Illustration 4	g03295498
Suction adapter for Telescopic Handlers (5) 6V-5258 Adapter (6) 5P-0492 Adapter (7) 005-8614 Union (8) 190-8319 Coupling

Illustration 5	g03295586
Vacuum transducer assembly for Telescopic Handlers (9) 5P-0306 Vacuum Transducer (10) 4C-7156 Fitting (11) 4C-7099 Nipple (12) 8S-7169 Union (13) 4C-4506 Air Hose (14) 8S-7169 Union (15) 131-9367 Adapter

Machine Kidney Loop Procedure

This guideline is intended for Telescopic Handlers. 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 oil viscosity. Be sure to read and understand the Tool Operation Manual, NEHS0848, "204-7392 Kidney Loop Cart", before beginning the procedure.

Show/hide table

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

1. Operate the machine to warm the oil.

2. Park the machine on level ground.

3. Apply the service brake to stop the machine.

4. Move the direction control switch or the transmission control lever to the NEUTRAL position and engage the transmission lock if the machine is equipped.

5. Engage the parking brake.

6. Lower the attachment to the ground. Apply slight downward pressure.

7. Block the wheels.

Kidney Loop Procedure

Show/hide table



Illustration 6	g03295697
(16) Access cover

1. Remove the access cover (16). Refer to Illustration 6.

   Note: If the Telescopic Handler is going to be kidney looped at every PM, add a quick disconnect to the hydraulic tank for convenience.

2. Clean the are around the filler cap (17). Refer to Illustration 7.

Show/hide table



Illustration 7	g03295736
(17) Filler cap

3. Remove the hydraulic tank filler cap (17) .

Show/hide table



Illustration 8	g03295756
(18) Filler cap assembly

4. Remove the filler cap base assembly (18) by removing the six screws. Refer to Illustration 8.

Show/hide table



Illustration 9	g03295816
(19) Return oil fastener

5. Install the return oil fastener (19). Refer to Illustration 9.

Show/hide table



Illustration 10	g03295856
(19) Return oil fastener (20) Return oil adapter (21) Vacuum transducer

6. Slide the return oil adapter (20) through the return oil fastener (19). Refer to Illustration 10.

7. Apply air pressure to the vacuum transducer assembly (21) prior to removing the drain plug.

8. Place a drain pan under the hydraulic tank drain. There could be some oil leakage.

Show/hide table



Illustration 11	g03295956
(22) Drain plug

9. Carefully remove the drain plug (22). Refer to Illustration 11.

Show/hide table



Illustration 12	g03295958
(23) Suction adapter

10. Quickly install the suction adapter (23) into the drain. Refer to Illustration 12.

11. Shut off the air supply to the vacuum transducer assembly (21). Refer to Illustration 10.

Show/hide table



Illustration 13	g03296039
(20) Return oil adapter (24) Discharge hose

12. Connect the filter cart discharge hose (24) to the return oil adapter (20). Refer to Illustration 13.

Show/hide table



Illustration 14	g03296058
(23) Suction adapter (25) Suction hose

13. Connect the filter cart suction hose (25) to the suction adapter (23). Refer to Illustration 14.

Show/hide table



Illustration 15	g03296156
Air supply hose and air supply valve (26) Air supply hose (27) Air supply valve

14. Attach an air supply hose (26) to the 204-7392 Filter Cart . Ensure that the air supply valve (27) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi). Refer to Illustration 15.

15. Slowly open the air supply valve (27) to start the filter cart pump operation. If the air supply valve (27) is a purge off style, adjust the supply air between 138 kPa (20 psi) and 345 kPa (50 psi). Turn on the air supply valve (27). Then adjust the pressure as needed. DO NOT EXCEED 690 kPa (100 psi). The pump is a diaphragm pump. The pump is rated to pump 10W oil at 64 L/min (17 US gpm).

Show/hide table



Illustration 16	g01294922
Filter cart assembly on a TH215

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

    Note: On occasion the filter cart pump will cavitate during start-up. The cavitation is due to air in the suction lines of the pump. If cavitation continues for more than 1 minute, shut the filter cart OFF. Then, check the connections.

17. Ensure that there are no oil leaks from the filter cart connections.

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

18. 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 S·O·S lab. Refer to the Contamination Control Guideline, SEBF8482, for more information.

Portable Particle Analyzer Procedure

When using a portable particle analyzer for particle counting, be sure to read and understand the Tool Operating Manual before operation.

Show/hide table



Illustration 17	g03296197
Portable Particle Procedure (28) Fabricated suction tube (29) 220-8607 Fitting (30) 210-5530 Coupler (31) S·O·S valve

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (31) on the filter cart. Refer to Illustration 17.

   Note: The fabricated suction tube can be made from parts listed in Table 3 and as shown in Illustration 17.

2. 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.

Bottle Sample Procedure

Show/hide table



Illustration 18	g03296218
(31) S·O·S valve (32) 169-8373 Bottle Group

1. If collecting a bottle sample, use the sample S·O·S valve (31) and a 169-8372 Bottle Group (32). Refer to Illustration 18.

2. Record an oil sample from the S·O·S valve (31) on the filter cart at the beginning of the filter cycle.

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

3. At the halfway point of filtration, stop the procedure and change the machines hydraulic filters. Changing the filters allows the filters to assist in system cleaning. The new filters can remain in place until the next scheduled filter change. Changing the filters at this time avoids opening the filter housing after the system has been cleaned. An open filter housing is an inlet for contamination.

   Note: The filters only need replaced if the filters are not working at optimal performance or scheduled to be changed.

4. During the filter cart operation, cycle the lift cylinders at least four times every half an hour of the cart operation. This action will cycle the clean tank oil into the hydraulic system and flush the more contaminated oil back into the tank.

5. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an ISO level of at least 18/15. The final ISO level should be recorded before the machine is returned to the field.

6. When the target ISO level or time interval has been met, close the air supply valve (27). Disconnect the air supply hose (26). Refer to Illustration 15.

   Note: Refer to ""Oil Compartment Filtration Times for 204-7392 Filter Cart" ", located at the end of this document, when a portable particle analyzer is not available.

7. Disconnect the filter cart discharge hose (24) from the return oil adapter (20). Install the dust cap on the coupler and on the nipple. Store the coupler and store the nipple in a clean location. Refer to Illustration 13.

8. Disconnect the filter cart suction hose (25) from the suction adapter (23). Install the dust caps on the coupler and nipple. Store the coupler and store the nipple in a clean location. Refer to Illustration 14.

9. Turn on the air supply to the vacuum transducer assembly (21). Refer to Illustration 10.

10. Quickly remove the suction adapter (23). Install the drain plug (22). Refer to Illustration 12 and Illustration 11.

11. Turn off the air supply to the vacuum transducer assembly (21). Refer to Illustration 10.

12. Remove the return oil adapter (20). Refer to Illustration 10.

13. Remove the return oil fastener (19). Refer to Illustration 9.

14. Install the filler cap base assembly (18). Refer to Illustration 8.

15. Install the clean filler cap (17). Refer to Illustration 7.

16. Check the hydraulic tank oil level.

17. Close the access panel (16). Refer to Illustration 6.

18. Unblock the wheels.

19. Return the machine to service.

Oil Compartment Filtration Times for 204-7392 Filter Cart

If an on-line, portable particle analyzer is not available to diagnose and track when the contaminant level has lowered to an acceptable point, refer to the following equation. This equation only relates to the 204-7392 Filter Cart only. Other filtration units will have 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.

Compartment Oil Capacity (gallons) X 2 equals the approximate filtration time.

Example: A TH215 hydraulic system has 70 L (18.5 US gal)of 10W oil. The approximate filtration time should be about 37 minutes.

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, 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. ExampleX/Y/Z.

"X" is the number of particles equal to or larger than 4 microns. "Y" is the number of particles equal to or larger than 6 microns. "Z" is the number of particles equal 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 S·O·S sampling and particle counting is required. This procedure should be accomplished by exercising the specific system until the fluid is at normal operating temperature. This action ensures that the oil and representative oil will be collected during the S·O·S process. An ISO 18/15 maximum cleanliness target has been established for most hydraulic and transmission systems. Refer to the machine system cleanliness targets to 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.