Procedure for Filtering 9U-5000 Hydraulic Test Bench Hydraulic Oil {0680, 0738, 0768, 0784, 5050, 5056} Caterpillar

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Introduction

© 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 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.

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. 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

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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.

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 quickly connects to the hydraulic test bench unit. 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 16/13 or cleaner. This procedure may need modified by the technician for use on some Hydraulic Test Benches.

The following procedure is most effective when performed immediately after the oil has been warmed to 50 °C (122 °F) and the oil is mixed from operation. Warming the machine causes contamination in the system to be placed in suspension and warming the machine also lowers the viscosity.

References

Tooling and Equipment

Illustration 3	g01175369
Test bench return oil adapter (1) FT2974 Adapter Plate (2) 140-5979 Elbow (3) 140-9462 Reducer (4) 173-4413 Bushing Reducer (5) 144-8618 Adapter

Illustration 4	g01159848

Hydraulic Test Bench Filtering Procedure

Hydraulic test benches should be particle count tested weekly. The particle count ISO level should be displayed on a maintenance sheet located on the test bench. The dealership can use an owned portable particle counter or the Caterpillar S·O·S lab services can be used. The cleanliness of the oil should be documented on the work order. This documentation is done so that the customer will see the information after a pump or a motor has been tested on the bench. The documentation should also be placed in the permanent file of the customer.

S·O·S sampling and particle count testing should be done when the test bench is at normal operating temperature. This process ensures that contaminates are suspended in the oil and the representative oil will be collected during the time of the S·O·S process. An ISO 16/13 maximum contamination level has been established for most hydraulic and transmission test benches.

This guideline is intended forCaterpillar 9U-5000 Series of Test Benches. Read Tool Operating Manual, NEHS0648, "173-8839 Kidney Loop Cart" prior to starting this procedure.

There are three separate phases of cleaning the hydraulic test bench:

• Clean the oil in the main oil reservoir.

• Clean the oil in the sump.

• Manually clean the sump.

Filtering Preparation

1. Take an S·O·S bottle sample.

Note: Taking a particle count before starting the filter procedure is recommended. This sample will be used as the base particle count.

Filter Cart Procedure

Illustration 5	g01173554

1. Pump the sump oil into the main oil reservoir. This procedure is done by manually operating the sump pumps until the sump oil level is below the sump pump intake level.

2. Remove all of the grates from the test bench sump area.
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   Illustration 6	g01159860

3. Remove the remaining sump oil with the 173-8839 Filter Cart.

   Note: Make sure that the sump debris does not flow through the 173-8839 Filter Cart.

4. Filter the oil in the 173-8839 Filter Cart according to the Tool Operating Manual, NEHS0648.

5. Remove any remaining sludge or large particles from the sump with a squeegee.
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   Illustration 7	g01159930

6. Wipe the sump and wipe the sump walls with 162-5791 Shop Towels.
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   Illustration 8	g01159932

7. Clean the grates with a pressure washer and a steam cleaner.

8. Replace the grates when the sump area is clean.

   Note: Be sure that all grates are dry before replacing the grates on the test bench. This procedure must be done since water will oxidize the oil.

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   Illustration 9	g01159934

9. Return the oil from the 173-8839 Filter Cart into the sump, as shown in Illustration 9.

   Note: Be sure that the oil is at ISO 16/13 or cleaner before returning the oil to the sump.

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   Illustration 10	g01159935

10. Install the return oil adapter, as shown in Illustration 10.
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    Illustration 11	g01173555

11. Connect a 25.4 mm (1 inch) 5p-0201 Hose from "port 2" on the test bench to the return oil adapter. Refer to Illustration 11.
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    Illustration 12	g01173559

12. Replace the sump return filters with 198-3188 Filter Element.

13. Connect a portable particle counter to the S·O·S valve on the sump oil return filter head.

    Note: See the"S·O·S Valve Installation".

S·O·S Valve Installation

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Illustration 13	g01173557
(5) 9U-6986 gauge

1. Remove the 9U-6986 gauge (5).
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   Illustration 14	g01173561
   (5) 9U-6986 gauge (6) 6K-1019 Union (7) 9B-1964 Tee (8) S·O·S Valve

2. Install the 9U-6986 gauge (5), 6K-1019 Union (6), 9B-1964 Tee (7) and S·O·S Valve (8) into the filter head.

Portable Particle Analyzer Procedure

Read the Tool Operating Manual before operating the portable particle analyzer.

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Illustration 15	g01173565
(8) S·O·S Valve (9) 210-5530 Coupler (10) 220-8607 Fitting (11) 188-0639 Suction Tube

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S Valve (8) on the test bench.

   Note: The fabricated suction tube can be made with parts listed in Table 4 and shown in Illustration 15.

2. Attach the opposite end of the fabricated suction tube to the "low pressure in" port on the portable particle counter. This procedure is called out in the Tool Operating Manual.
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   Illustration 16	g01159944

3. Start the test bench.

4. Slowly open the supply flow level (8) until the supply reaches full flow.
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   Illustration 17	g01173568

5. If the test bench is not supplying 189 L/min (50 US gpm) to 227 L/min (60 US gpm) of flow from the gear pump, adjust the supply valve pressure regulator shown as (6). Refer to Illustration 17.

6. Operate the test bench at maximum flow until the oil cleanliness level of ISO 16/13 has been met, or until the time interval has been reached.

   Note: Be sure to monitor the indicator gauge for the oil filters as the 198-3188 Filters may clog.

   Note: Refer to "Oil Filtration Time When a Portable Particle Counter is Not Available" at the end of this document to obtain estimated filtration times when a portable particle counter is not available.

   Note: The dealership S·O·S lab may also be used. Refer to Contamination Control Guideline, SEBF8482 for the correct bottle sampling procedures.

7. Once the oil is at ISO 16/13 or the time interval has been met, disconnect the 25.4 mm (1 inch) XT-5 high-pressure test hose from port (2) and disconnect the return oil adapter. Cap the hose ends for cleanliness.

8. Remove the oil adapter for the return. Store the adapter in a place free of contamination.

9. Disconnect the portable particle counter.

10. If a portable particle counter was not available, take a final S·O·S sample.

11. Remove the 198-3188 Filters. Replace the filters with 9U-5870 Filters.

Alternate Procedure using a 173-9842 Filter Cart

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Illustration 18	g01159953
Test bench return oil adapter

1. Install the return oil adapter.

2. Connect a 1 inch XT-5ES hose from port "2" to the 173-9842 Filter Cart.

3. Connect a 1 inch XT-5ES hose from the return oil adapter to the filter cart.
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   Illustration 19	g01159954

4. Refer to "Filter Cart Procedure" for operating instructions.

Oil Filtration Time When a Portable Particle Counter is Not Available

Refer to the following equation if a portable particle counter is not available to track when the contaminant level has lowered to an ISO 16/13 or lower. Use the following equation as a simple duration for the procedure. Do not use the equation as an absolute time or an efficiency result.

Illustration 20	g01173653
Filter time calculation (A) Test bench oil capacity ( 757 L (200 US gal)) (B) 208 L (55 US gal) per minute (C) Approximate filtration time (minutes)

Note: A test bench with 757 L (200 US gal) of test oil would take 127 minutes to filter.

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

ISO is a worldwide federation of national standards bodies. The ISO 4406 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 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. Example X/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 to or larger than 14 microns

Atthis 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.

Oil Compartment Filtration Times for 204-7392 Filter Cart

If an on-line, portable particle counter is not available to diagnose and track when the contaminate level has lowered to an acceptable point, refer to the following equation. This equation related to the 204-7392 Kidney Loop Cart. Other filtration units will have a 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 as an absolute time or efficiency result.

Compartment Oil Capacity (gallons) X 2 = Approximate Filtration Time