Instructions for Collecting Fluid Sample from Viscous Damper on Certain Cat® Engines {0645, 1000, 5569, 7542, 7571} Caterpillar

Engine

G3516 (S/N: AL71-UP; N6A1-UP; N6B1-UP; N6C1-UP)

G3516B (S/N: ZBC1-UP; N6E1-UP)

G3516C (S/N: GZC1-UP; N6R1-UP; GZZ1-UP)

G3516H (S/N: ME31-UP; NWH1-UP; NWJ1-UP; GLM1-UP; GLN1-UP)

G3516J (S/N: N6W1-UP)

G3520B (S/N: GLF1-UP)

G3520C (S/N: GZA1-UP; GZJ1-UP; GZL1-UP; GZM1-UP)

G3520J (S/N: N221-UP; N241-UP)

Generator Set

CG170-16 (S/N: KSJ1-UP)

Petroleum Engine

G3520B PETROLEUM (S/N: TPC1-UP)

Track-Type Tractor

SALES1A (S/N: NEW1-UP)

Reference: Refer to Operation and Maintenance Manual for schedule hours. As the fluid in the Viscous damper has to be sampled at the required service interval.

Reference: Refer to Disassembly and Assembly manual for the removal of damper guard.

Introduction

This Special Instruction provides instructions for collecting fluid sample from viscous damper on certain Cat^® Engines.

Note: Before collecting a fluid sample, inspect the damper for dents, cracks, leaks, and look for paint discoloring from heat. If any of these conditions exist either repair or replace damper.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.

Work safely. 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.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Turn the battery disconnect switch to the OFF position and lockout the battery disconnect switch with a safety lock. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the start switch and battery disconnect location to inform personnel that the machine is being worked on.

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Fluid Sample Collecting Instructions

Note: Fluid samples may be taken from dampers equipped with removable fill plugs. In most cases two of these plugs are positioned diametrically opposite each other in the damper.

Note: The sampling container has multiple threads on each end. Identify proper threads for the damper, the damper is reused with the old plug and a new seal. (Refer the tightening specification mentioned in Table1).

Note: Collecting a silicone fluid sample is easier from a warm damper with careful extraction of fluid, 10 samples may be taken using 1cmᵌ container.

Perform the following instructions to collect viscous damper fluid sample:

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Illustration 1	g06203468
(1) Plug

1. Collect sample of silicone fluid from a warm damper. It is recommended that the damper is rotated until the plugs are approximately vertical as shown in the illustration 1.
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   Illustration 2	g06204864

2. Remove the plug (1) using the T30 Torx bit tool.
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   Illustration 3	g06204373
   (2) Sampling Container (3) Cap Nut

3. Find the thread size on sampling container that matches damper fill hole. Prepare sample container (2) by removing the cap nut (3) from the end to be inserted in the damper.
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   Illustration 4	g06204288

4. Remove the lowest plug and screw the sample container (2) into fill hole as shown Illustration 4.
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   Illustration 5	g06204299

5. Remove the cap nut (3) from the other end of sampling container (2) as shown in Illustration 5.
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   Illustration 6	g06204303

6. Once the fluid fills the container (minimum 50% full), replace the cap nut (3).
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   Illustration 7	g06204309

7. Unscrew the container from the fill hole of the damper and immediately reinstall the plug (1) with a new seal by using T30 Torx bit tool. Torque the plug (1) to 20 ± 3 N·m (177 ± 27 lb in).

8. Close the sampling container (2) with the cap nut (3).

Fluid Sample Collecting Instructions - Damper Mounted in Reverse Direction

Perform the following instructions to collect viscous damper fluid sample, if the damper mounted in reverse direction and the sampling port is towards the front housing

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Illustration 8	g06204311

1. Rotate the damper to locate the sampling port at the bottom location.

2. Follow the Step 2to Step 8 from Section "Fluid Sample Collecting Instructions" to collect the viscous damper fluid sample.

Send the fluid sample to the below mentioned address for analysis:

Fill the information in Table 2 & Table 3 and send the information along with the fluid sample.

When the fluid sampling is completed, use the disassembly and assembly manual to reassemble the damper guard to the engine.

Use the results from the fluid test to determine next sample interval or the damper replacement.