Procedure for Kidney Looping Telescopic Handlers Hydraulic Oil{0680, 0768, 5050, 5056} Caterpillar


Procedure for Kidney Looping Telescopic Handlers Hydraulic Oil{0680, 0768, 5050, 5056}

Usage:

TH82 3JN


Telehandler:
TH103 (S/N: 3PN1-UP)
TH210 (S/N: MHT1-UP)
TH215 (S/N: MHS1-UP)
TH62 (S/N: 4TM1-UP; 3LN1-UP)
TH63 (S/N: 5WM1-UP; 3NN1-UP)
TH82 (S/N: 3JN1-UP; 3KN1-UP)
TH83 (S/N: 3RN1-UP)

Introduction

Table 1
Revision     Summary of Changes in SEBF8785    
02     Updated Introduction.
Updated Effectivity.
Changes to Reference Table listed below.
PEJT5025 canceled replaced by PEGJ0045.
PEHP6001 canceled replaced by PEGJ0047.    

© 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 form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

  • Caterpillar Dealer Technical Communicator

  • Dealer Solution Network

  • Caterpillar 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 to use. The kidney loop cart connects to the hydraulic oil filler neck and the hydraulic tank drain. 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.


NOTICE

If the machine 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 and controls. Additional component cleaning and component exchange and lines flushing will be required to remove most contaminates generated from the failure. The machine 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

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 1g01032906

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 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

------ 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    
PEGJ0045     Reporting Particle Count by ISO Code    
SEBF8482     Obtaining an Oil Sample for S·O·S Analysis    
PEGJ0047     How To Obtain A Good SOS Sample    

Tooling and Equipment

Table 3
Required Tools    
Part Number     Part Description    
288-3242     Hydraulic Filter Cart    
190-8318     Coupling    
005-8615     Union    
002-5743     Elbow    
    Fabricated Plug    
190-8319     Coupling    
005-8615     Union    
6V-3965     Pressure Tap    
6V-0301     Adapter    
6Y-2349     Connector    
5P-0306     Vacuum Transducer    
4C-7156     Fitting    
4C-7099     Nipple    
8S-7169     Union    
4C-4506     Air Hose    
2Y-4062     Adapter    
Optional Tools    
Part Number     Part Description    
170-8500     Portable Particle Analyzer    
210-5530     Coupler    
188-0639     Hose    
169-8373     Bottle Group    
220-8607     Fitting (1)    
1U-8304     Fitting (2)    
( 1 ) For low-pressure suction tube fabrication
( 2 ) Not used on all machines



Illustration 2g01296381

Return oil adapter for Telescopic Handlers

Refer to Table 4 for item identification. Refer to Illustration 5 for the fabricated plug.

Table 4
Telescopic Handler Return Oil Fabrication and Parts    
Item     Part Number     Description    
1     190-8318     Coupling    
2     005-8615     Union    
3     002-5743     Elbow    
4         Fabricated Plug    



Illustration 3g01296384

Drain adapter for Telescopic Handlers. Refer to Table 5 for item identification.

Table 5
Telescopic Handler Drain Adapter Fabrication and Parts    
Item     Part Number     Description    
1     190-8319     Coupling    
2     005-8615     Union    
3     1U-8304     Fitting (1)    
4     6V-3965     Fitting    
5     6V-0301     Adapter    
6     6Y-2349     Connector    
( 1 ) Not required on all machines



Illustration 4g01296386

Vacuum transducer assembly for Telescopic Handlers. Refer to Table 6 for item identification.

Table 6
Telescopic Handler Vacuum Transducer Assembly    
Item     Part Number     Description    
1     5P-0306     Vacuum Transducer    
2     4C-7156     Fitting    
3     4C-7099     Nipple    
4     8S-7169     Union    
5     4C-4506     Air Hose    
6     8S-7169     Union    
7     2Y-4062     Adapter    



Illustration 5g01296387

TH series fabricated plug. 44.5 mm (1.75 inch) bar stock

(A) 44.5 mm (1.75 inch)

(B) 63.5 mm (2.5 inch)

(C) 32.0 mm (1.26 inch)

(D) 12.7 mm (0.5 inch)

(E) 6.3 mm (0.25 inch)

(F) 15°

(G) 25.4 mm (1 inch) NPT thread

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 operation. Warming the oil allows any contamination in the system oil to be placed in suspension. Warming the oil also lowers the viscosity of the oil. Be sure to read and understand the Tool Operating Manual, NEHS0778, "188-3242 Kidney Loop Cart" before you begin the procedure.

Kidney Loop Setup

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

    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.

  1. Park the machine on level ground.

  1. Apply the service brake to stop the machine.

  1. Move the direction control switch or the transmission control lever to the NEUTRAL position. Engage the transmission lock if the machine is equipped.

  1. Engage the parking brake.

  1. Lower the attachment to the ground. Apply slight downward pressure on the attachment.

  1. Block the wheels.

Kidney Loop Procedure

  1. Remove the floor mat in the cab.



    Illustration 6g01296388

    (1) Access cover

  1. Remove the access cover (1). The access cover is located on the flow of the cab.



    Illustration 7g01296389

    (2) Air breather

  1. Remove the 144-8510 Air Breather (2) .



    Illustration 8g01296392

    (3) Vacuum transducer assembly

  1. Install the vacuum transducer assembly (3) in place of the air breather (2). Connect the compressed air line to the transducer.

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

  1. Apply air pressure to the vacuum transducer assembly (3) prior to removing the drain plug.

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

    Note: Be sure that the hydraulic tank has a vacuum before continuing. Do not remove the hydraulic tank filler cap before this step. If the filler cap is removed, a vacuum cannot be achieved.




    Illustration 9g01296413

    (4) Drain plug

  1. Carefully remove the drain plug (4). The hydraulic drain plug (4) is located toward the front of the machine.



    Illustration 10g01296414

    (5) New drain assembly

  1. Quickly install the drain adapter (5) into the drain.

  1. Shut off the air supply to the vacuum transducer assembly (3) .



    Illustration 11g01296415

    (6) Access panel

  1. Open the access panel (6) if the panel is on the machine.



    Illustration 12g01296417

    (7) Filler cap

  1. Clean the area around the hydraulic tank filler cap (7). Slowly loosen the filler cap on the hydraulic tank and release the tank pressure. Make sure that all the air pressure has been vented before completely removing the filler cap.

  1. Store the filler cap (7) and store the strainer in a clean location to avoid contamination and damage.



    Illustration 13g01296418

    (8) Return oil adapter

  1. Install the return oil adapter (8) .



    Illustration 14g01296420

    (8) Return oil adapter

    (9) Discharge hose

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



    Illustration 15g01296423

    (5) Drain adapter

    (10) Suction hose

  1. Connect the filter cart suction hose (10) to the drain adapter (5) .



    Illustration 16g01296424

    (11) Air supply hose

    (12) Air supply valve

  1. Attach an air supply hose (11) to the 188-3242 Filter Cart . Ensure that the air supply valve (12) is in the CLOSED position.

  1. Slowly open the air supply valve (12) to start the filter cart pump operation. If the air supply valve (12) is a purge off style, adjust the supply air between 137 kPa (20 psi) and 345 kPa (50 psi). Turn the air supply valve (12) ON. Then adjust the pressure as need, but do not exceed 690 kPa (100 psi). The pump is a diaphragm pump. The pump is rated to pump 10W oil at 340 L/min (90 US gpm).



    Illustration 17g01296425

    Filter cart assembly on a TH83.

  1. During operation, check the filter element indicators on the filter cart. This will indicate 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. Check the connections.

  1. 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 or for use as a baseline particle count.

  1. 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.

    1. Collect a bottle sample and send the sample to an S·O·S lab. Refer to Contamination Control Guideline, SEBF8482 for more information.

Portable Particle Analyzer Procedure

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




    Illustration 18g01296426

    (13) Fabricated suction tube

    (14) 220-8607 Fitting

    (15) 210-5530 Coupler

    (16) S·O·S valve

  1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (16) on the filter cart.

    Note: The fabricated suction tube can be made with the parts listed in table 3 and as shown in Illustration 18.

  1. 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




    Illustration 19g01296428

    (16) S·O·S valve

    (17) 169-8373 Bottle Group

  1. If collecting a bottle sample, use the same S·O·S valve (16) and a 169-8373 Bottle Group (17) .

  1. Record an oil sample from the S·O·S valve (17) on the filter cart at the beginning of the filter cycle.

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

  1. At the halfway point of kidney looping, stop the procedure. Change the machine filters.

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

  1. 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.

  1. 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 should be recorded before the machine is returned to the field.

  1. When the target ISO level or the time interval has been met, close the air supply valve (12) and disconnect the air supply hose (11) .

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

  1. Disconnect the filter cart discharge hose (9) from the return oil adapter (8). Install the dust cap on the coupler. Install the dust cap on the nipple. Store both parts in a clean location.

  1. Disconnect the filter cart suction hose (10) from the drain adapter (5). Install the dust cap on the coupler. Install the dust cap on the nipple. Store both of the parts in a clean location.

  1. Remove the return oil adapter (8) .

  1. Install a clean filler cap (7) .

  1. Close the access panels (6) .

  1. Turn on the air supply to the vacuum transducer assembly (3) .

  1. Quickly remove the drain adapter (5) and reinstall the drain plug (4) .

  1. Remove the vacuum transducer assembly (3) .

  1. Reinstall the air breather (2) .

  1. Close the access panel (1) .

  1. Check the hydraulic tank oil level.

  1. Unblock the wheels.

Oil Compartment Filtration Times for 188-3242 Filter Cart

If an on-line, portable particle counter is not available to diagnose and track when the contaminant level has lowered to an acceptable level, refer to the following equation. This equation relates to the 188-3242 Filter Cart and the 194-2897 Filter Carts only. Other filtration units will have different equation references and these units will be noted when appropriate.




Illustration 20g01177339

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 each 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). This delivers oil in both directions. Another way of determining pulses is to listen for the (tuk-chuk) of two pulses. Count the number of pulses in 1 minute for use in the above equation.

Example

A TH83 Telescopic Handler hydraulic system has 232 L (61.5 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 32 minutes.

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

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

The code for contamination levels using automatic particle counters is composed of three scale numbers. ExampleX/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 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 in place of the "X". 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.

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