Procedure for Kidney Looping Wheel Harvester and Site Prep Tractor Hydraulic Oil{0680, 0738, 0768, 3000, 5050, 5056} Caterpillar

Site Prep Tractor:

2764C (S/N: SPL1-UP)

2864C (S/N: SP41-UP)

576C (S/N: SPH1-UP)

586C (S/N: SL51-UP; SP51-UP)

Wheel Harvester:

550 (S/N: 7ZN1-UP)

550B (S/N: SAW1-UP)

560B (S/N: TRA1-UP)

570 (S/N: 4XR1-UP)

570B (S/N: CKG1-UP)

580 (S/N: 7CN1-UP)

580B (S/N: CLT1-UP)

Introduction

© 2013 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 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 that is available from Caterpillar. Updated technical information will 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

If a Contamination Control Guideline is required, but not available in SIS Web, submit a feedback for in the Service Information System website.

Summary

This guideline enables dealers and customers to benefit from cleaner hydraulic systems. This filtration process is easy to use. The hydraulic filter cart quickly connects to the hydraulic tank. This guideline provides directions to install and operate the filtration system.

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

Note: If the machine is being serviced due to a catastrophic failure, a complete system cleaning operation is required before initializing this 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. Additional component cleaning, 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 filtration procedure. This filtration procedure and subsequent particle count testing should be performed as part of the repair process.

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 is used, 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 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

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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.

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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

Hydraulic Oil Kidney Loop Procedure

This guideline is intended for Wheel Harvesters and Site Prep Tractors. 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 beginning the procedure.

Kidney Loop Adapters

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Illustration 3	g01298195
(1) 9U-7018 Fitting (2) 7X-7958 Hose Clamp (3) 122-6906 Hydraulic Hose (4) 190-8319 Coupler (5) 201-8057 Dust Cap

1. Connect the two Fittings (1), two Hose Clamps (2), 61 cm (24 inch) of Hydraulic Hose (3), Coupler (4), and a Dust Cap (5) .

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Illustration 4	g01298197
(5) 201-8059 Dust Cap (6) 190-8319 Coupler (7) 006-5707 90° Elbow (8) 144-8618 Adapter (9) 7M-8485 O-ring Seal

2. Assemble the discharge adapter by using a Dust Cap (5), Coupler (6), 90° Elbow (7), Adapter (8), and an O-ring Seal (9) .

Kidney Loop Setup

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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. Engage the parking brake.

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

5. After the attachment is lowered, relieve the pressure in the accumulator by moving the handle of the grapple control several times in different directions.

6. Turn off the engine.

Kidney Looping Procedure

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Illustration 5	g01298198
(10) Tank drain

1. Clean the area around the hydraulic tank ecology drain (10). Remove the plug. Insert the suction adapter.

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Illustration 6	g01298199
(11) Suction adapter (12) Suction hose

2. Connect the filter cart suction hose (12) to the suction adapter (11) .

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Illustration 7	g01298200
(13) Plug

3. Clean the area around the last plug (13) on the tank assembly. Remove the plug and screw in the discharge adapter.

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Illustration 8	g01298201
(14) Discharge hose (15) Discharge adapter

4. Connect the filter cart discharge hose (14) to the discharge adapter (15) .

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Illustration 9	g01298202
Air supply valve in the CLOSED position (16) Air supply valve (17) Air supply hose

5. Attach the air supply hose (17) to the 188-3242 Filter Cart . Ensure that the air supply valve (16) is in the CLOSED position. Be sure that the air supply does not exceed 690 kPa (100 psi).

6. Slowly open the air supply valve (16) to start the filter cart pump operation. The pump is a diaphragm pump. The pump is rated to pump SAE 10W oil at 340 L/min (90 US gpm).

7. While operating the filter cart, check the filter element indicators on the filter cart. Checking the filter element indicators will indicate the amount of capacity left in the filter element.

   Note: The filter cart pump may 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, turn the filter cart. Ensure that there are no oil leaks from any of the filter cart connections.

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

8. The oil can be particle count tested for cleanliness in one of the two following ways.

   1. Use a 170-8500 Analyzer Gp for immediate results.

   2. Collect a bottle sample and send the sample to an S·O·S lab.

Portable Particle Analyzer

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

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Illustration 10	g01298208
(18) Fabricated suction tube (19) 220-8607 Fitting (20) 210-5530 Quick Connect Coupler (21) S·O·S valve

1. Attach the fabricated particle counter "low pressure in" suction tube (18) to the S·O·S valve (21) on the filter cart.

Note: The fabricated suction tube (18) can be made with the parts listed in Table 2 and as shown in Illustration 10.

2. Attach the other end of the fabricated suction tube (18) to the "low pressure in" port on the portable particle analyzer as called for in the Tool Operating Manual.

Bottle Sample Procedure

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Illustration 11	g01298209
(21) S·O·S valve (22) 169-8373 Fluid Sampling Bottle

1. If collecting a bottle sample, use the same S·O·S valve (21), and a 169-8373 Fluid Sampling Bottle . Refer to Special Instruction, SEBF8482, "Obtaining an Oil Sample for S·O·S Analysis" for more information.

2. Record an oil sample from the S·O·S valve (21) on the filter cart at the beginning of the filter cycle.

3. Start the machine. Cycle the boom circuit and cycle the stick circuit every half an hour of the filter cart operation. 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. Turn the engine OFF.

Note: Stop the procedure and change the hydraulic filters after one half of an hour of filtering. Changing the filters allows the filters to assist in the 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.

4. Operate the filter cart until the portable particle analyzer indicates that the oil has reached an ISO level of 18/15 or better. Take a final oil sample and record the final ISO level before the machine is returned to the field.

   Note: 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.

5. When the target ISO level or the time interval has been met, close the air supply valve (16) and disconnect the air supply hose (17). Refer to Illustration 9.

Kidney Loop Removal

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Illustration 12	g01298210
(11) Suction adapter (12) Suction hose

1. Disconnect the filter cart suction hose (12) from the suction adapter (11). Install the dust caps on the couplers and nipples.

2. Remove the suction adapter (11). Install the drain plug (10). Refer to Illustration 5.

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Illustration 13	g01298211
(14) Discharge hose (15) Discharge adapter

3. Disconnect the filter cart discharge hose (14) from the discharge adapter (15). Install the dust caps on the couplers and nipples.

4. Reinstall the filler plug (13). Refer to Illustration 7.

5. Check the hydraulic tank oil level.

6. Inspect the hydraulic system for leaks. Most hydraulic contamination is brought into the system from an external source. To provide a long-term benefit, repairs must be completed before the machine is returned to service.

Oil Compartment Filtration Times for 188-3242 Filter Cart

In 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 14	g01177339
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 570B Wheel Harvester hydraulic system has 147 L (39 US gal) of SAE 10W oil. The filter cart is operating at 160 pulses per minute. The approximate filtration time should be 35 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. Particle counts are affected by various factors. These factors include: procurement of the sample, the sample container, particle counting accuracy, where used, 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.