Cleaning Fluid-Carrying Hose and Tube Assemblies In Shop and Field Applications {0645, 5050} Caterpillar

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Introduction

© 2019 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 the 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 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.

If a Contamination Control Guideline is required but not available in SIS web, 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.

Summary

This guideline will describe the operation and safety principles required for cleaning hydraulic hoses and tubes, using the Caterpillar hose cleaning group.

This guideline will also describe the cleaning procedures of hydraulic system lines and tubes following a catastrophic failure.

This hose cleaner group is CE certified.

The three basic components required are:

1. A specially designed pneumatic launcher, which provides the pressure energy to force the projectile through the fluid carrier.

2. The nozzles that allow the unit to be utilized on varying sizes and types of hose, tube, pipe, and coupling configurations.

3. The projectile, which cleans the inside surface of the hose, tube, or pipe.

Note: Throughout this publication the word "hose" will be used to identify all types of fluid carriers pipe, tubing, and hose.

To provide cleaning, the projectile is launched through a fluid carrier by a compressed gas. This gas (air) is delivered from the launcher through the nozzle. As the projectile travels the length of the hose, a cleaning force is applied to the inside walls. This force is applied to the wall of the passage due to the compressed state of the projectile (normal compression is 20 percent). The expanding gas provides forward movement.

The contamination-absorption effectiveness of the foam projectile has been developed from extensive research and testing. The structure of the projectile must have the correct density, strength, and flexibility. These properties are critical to prevent the projectile from breaking up due to the applied cleaning and propelling forces.

The following benefits can be achieved using the 233-7191 Hose Cleaner Group or the 233-7193 Hose Cleaner Group.

• Reduce the risk of component failure due to system contamination.

• Use of the cleaners may extend component life.

• Reduced initial flushing requirements and time for the system.

• On-site hose cleaning.

• The ability to diagnose the internal condition of the hose.

• Increase the filter element service life.

• Reduced maintenance costs.

Utilizing the hose cleaner groups will provide a faster and more effective method of cleaning the machines fluid-carrying hoses. This unit will lead to increased servicing efficiency, resulting in increased productivity.

After the catastrophic failure of a component, extensive measures must be taken to restore the system to an operable condition. Complete system cleaning is an important part of any repair to reduce oil contaminants. Additional component cleaning or replacement may be necessary as well as measuring particle counts and filtering the oil. Abrasive dirt, metal particles, and other contaminants must always be removed from the system prior to operation. Contamination that is not removed can cause future inefficiencies and failures.

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 be made unsafe by the operation, lubrication, maintenance, or repair procedures.

All 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

Listed next are basic safety precautions. Read and understand these basic precautions and operating instructions contained in this guideline before installing or operating this product.

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To avoid eye injury consult shop manual before disconnecting lines, wear safety goggles. Fluid is under high pressure.

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To avoid personal injury, always wear eye and face protection when using pressurized air.

• Make sure that the faceplate is locked into the closed position before depressing the trigger. Make sure that the air supply is correctly attached and is at the correct pressure.

• Make sure that the unit is pointing in a safe direction before operating.

• Do not operate the hose cleaner group when aimed at another person.

• Make sure the end of the hose, tube, or pipe is contained within a suitable projectile catcher, which must be secured in a safe location. A secured projectile catcher will avoid injury from the contaminants and projectile when ejected from the hose or tube.

• Always turn off the air supply before disconnecting the unit.

• Use a protective mask for respiratory protection, as required.

• Use protective clothing, as required.

Hydraulic Principles

The theory of hydraulic is based on two principles:

1. The liquids are incompressible even when subjected to high pressures.

2. Pressure applied to an enclosed liquid is transmitted with undiminished force in every direction.

These two engineering principles are the concepts behind one of the simplest methods of transmitting power. Hydraulic machinery has expanded rapidly into the manufacturing and mining industries. The rapid expansion occurred mainly because of the simplicity of the components required. Also, the liquid can be carried through a pipe or hose to operate mechanisms at a distance from the main source of power, allowing great flexibility in the positioning of the working unit.

Light mineral oils or castor-based oils are now used as the preferred liquid because of the low freezing point and the lubricating and sealing properties. The type and quality of the fluid used in a hydraulic system is important. The fluid must:

• Transmit the fluid energy efficiently to the work elements on the machine.

• Lubricate the moving surfaces to reduce friction and wear in the hydraulic component.

• Seal the operating clearances between the mating surfaces to improve operating efficiency.

• Cool the system components to maintain the optimum operating temperatures at all times.

Effects of Contamination

A recent study found that 75 to 80 percent of hydraulic system failures were caused by fluid contamination. Contamination can be the downfall of even the best-designed hydraulic systems. Most component and system malfunctions are caused by solid contamination particles, ranging in size from 5 to 30 microns. Such particles can shut down expensive machinery. Contamination interferes with the fluid energy transmissions and causes:

• Increased risk of component failure, and machine downtime.

• Increased component wear, and reduced machine operating efficiency.

• Valve spools to stick, causing erratic machine operation or solenoid burn out.

• Pressure sensing passages and valve control orifices to block, resulting in the machines pressure control being unpredictable.

• Obstruction of the heat transfer mechanism, thereby hindering the fluid cooling ability, and increasing the machine maintenance costs.

Now, there is no chemical additive that either keeps dirt out of, or removes dirt from, hydraulic fluid. Keeping dirt out of a system is the function of good maintenance and repair practices. Clean fluid is the only way to achieve optimum performance from a machine.

Research has shown that reducing the solid particle count in fluids will make a major contribution to longer component life and improve functional reliability of the system.

Operation

Initial Set-up

If the hose cleaner is not properly set up using the correct air pressure, nozzle, and projectile, the hose cleaning procedure will be inefficient and the internal hose contamination will not be removed. The following sections provide the necessary set-up information that must be completed before operating the unit. Take the following items into consideration before operating the unit.

• Air pressure and air source

• Projectile selection

• Nozzle selection

• Projectile path

Note: A clean gun, clean nozzles, and clean (not degraded) projectiles must be used. Degraded projectiles can leave behind particles in the hoses.

Air Pressure and Air Source

Illustration 3	g01244647
Air Source Connection

Connect the unit to a 600 kPa (90 psi) to 800 kPa (115 psi) air source.

In most applications, the compressed gas supply to the hose cleaner group is supplied from the shop air supply. However, a standard 8 cfm to 15 cfm air compressor and receiver can be used, or a regulated bottle of inert gas (dry nitrogen or carbon dioxide) having a minimum recommended operating gas pressure for projectile launching of 620 kPa (90 psi). Select a propulsion gas compatible with the system being cleaned. Regulated gas pressure must not exceed 1034 kPa (150 psi). The hose cleaner group is supplied with an 8 mm (0.315 inch) inside diameter male coupling half.

Note: The airline and fittings connecting the air source to the unit must not have less than 8 mm (0.315 inch) inside diameter. A 12 mm (0.472 inch) inside diameter supply hose is recommended.

Projectile Selection and Nozzle Insertion

Refer to the Tool Operating Manual, NEHS0643 for projectile and nozzle selection.

Hose cleaning applications are various, but bulk hose and hose assemblies are most common. Consider the cleaning requirement of the projectile for the particular application. Possible applications are:

• Removal of large contamination particle when bulk hose cleaning.

• Removal of residual oil contained within all hoses.

• Removal of fine contamination particles after hose assembly.

• Flushing contaminated lines on a machine where a catastrophic failure has occurred.

• Applications where the projectile must go through reductions created by hose end couplings. This application is common when cleaning hose and tube assemblies while still mounted on a machine.

Illustration 4	g01244650
Nozzle Insertion

1. Open the faceplate of the unit by pressing the safety bar and release mechanism with the thumb of the hand holding the unit.

2. Drop the faceplate down.

3. Select a suitable nozzle for the application and insert the nozzle into the faceplate. For nozzle sizes less than 38 mm (1.5 inch), the 130-6062 Adapter Ring should be fitted prior to insertion of the nozzle.

Load Projectile into Unit

1. Select the type and size of projectile from the Tool Operating Manual, NEHS0643 or from NEEG2955.

2. Load the projectile into the nozzle.

Note: If the selected projectile is too large, the projectile will not leave the nozzle. If the projectile is too small, the projectile will not effectively clean the fluid passage.

Illustration 5	g01244651
Projectile Insertion

Projectile Usage

Tests have indicated that a projectile should be fired from both ends of the hose or tube. After the assembly connectors are attached, further projectiles should be utilized to make sure any introduced contamination during manufacturing (lubricants, rubber, etc.) is removed. The tests also demonstrated that projectiles remove larger size particles and absorb fluids, while coupling projectiles remove the smaller particles and go through coupling or fitting reductions.

Research has defined four standard hose cleaning procedures for the hydraulics industry. To obtain the desired cleanliness levels, Refer to the following procedures in Table 4.

Projectile Path

To clean a system successfully, be sure to identify beforehand, all intersections, changes in bore size and obstructions due to control valves, pumps, and monitoring equipment.

Run length does not matter (with a suitable air supply volume), as a projectile may travel up to 914 m (3000 ft). The number of bends or coils in the hydraulic system is not critical. Even lines crossing at right angles are not a problem. However, the hose must have both ends open to the atmosphere at the same time.

Consider the projectile path in a complex system. The projectile may travel through partially restricted hoses, connectors, and open ball valves. In some installations, however, the system will need broken into separate sections. Also, any branch hose coming from the main line must be capped.

The illustration below provides a few examples of path selection.

Illustration 6	g01244652
Select Best Path for Projectile

If more than one path is available, cap one of the paths.

Illustration 7	g01244653
Multi-path Hose

When cleaning a hose or tube configuration with multiple paths, as shown in Illustration 7, clean the closest path to the projectile starting point first. All openings down stream must be capped to allow only one path for the projectile to follow. For example, plug all hoses to the right of path #1 for proper projectile direction and cleaning. Next, plug 1 and 3 for path 2 cleaning, and finally plug 1 and 2 for path 3 cleaning.

Operating Procedure

Before operating the hose cleaner group, check to make sure all the necessary safety precautions have been taken and always observe all safety instructions.

Note: A clean gun, clean nozzles, and clean (not degraded) projectiles must be used. Degraded projectiles can leave behind particles in the hoses.

1. Select the proper nozzle and projectile for the hose to be cleaned. Refer to Tool Operating Manual, NEHS0643.
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   Illustration 8	g01244655
   Latching Faceplate

2. Close the faceplate and make sure the safety bar and release mechanism locks the faceplate into position. Refer to Illustration 8.
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   Illustration 9	g01244656
   Projectile Catcher

3. Make sure that the exit end of the hose is correctly contained in the projectile catcher (or catcher bag) and the catcher is secure. Refer to Illustration 9.

4. Use a suitable bag or container that will catch the contaminants from the hose and verify that projectile exited the hose.

   Note: Recover the used projectile so the projectile can be analyzed to determine the condition and cleanliness of the hose.

   Show/hide table

   Illustration 10	g01244657
   Firing Projectile

5. Place the nozzle firmly against the hose, making a firm seal. Obtain an airtight seal. In the event of a nozzle does not fit correctly, try reducing the nozzle size. Refer to Illustration 10.

6. Depress the trigger, making sure that the trigger remains depressed until the projectile emerges from the other end of the hose. If the trigger is released prior to the projectile emerging, the projectile will remain in the hose until the trigger is pressed again.

7. Based on cleaning level desired, repeat the procedure (with a new projectile) from the opposite end of the hose.

Projectile Storage and Disposal

New projectiles should be stored in covered boxes or contaminant free cabinets to reduce exposure to direct sunlight or florescent light.

Note: Exposure to direct sunlight or florescent light will cause discoloration and deterioration of the projectiles over time. Leave projectiles in protective shipping bags.

Do not reuse projectiles. Projectiles are discarded after one use only. Used projectiles must be disposed of properly.

Troubleshooting

Cleaning System after Catastrophic Failure

1. Manually clean the system thoroughly after any catastrophic failure. Metal particles, dirt, and other contaminants are dispersed by the oil and can be found throughout the system. Complete system disassembly and cleaning will be required in the advent of any catastrophic component failure. The amount of system disassembly will depend on the extent of the contamination throughout the hydraulic system.

2. All hydraulic components within the contaminated system should be removed, disassembled, and thoroughly cleaned.

3. Use a Hose Cleaner Group to assist in the system cleaning. At a minimum, all hoses attached to the failed component must be cleaned with the hose cleaner group. The hose cleaner group eliminates a large portion of the labor when removing all hoses and tubes from the vehicle for cleaning. These fluid-carrying devices can be cleaned while still attached to the vehicle.

4. Normal procedures when using the hose cleaner group in this type of application are:

   1. Disconnect both ends of the hose or tube from the vehicle components.

   2. Determine the smallest orifice size throughout the hose or tube assembly. Size the required projectile accordingly.

5. Select the proper nozzle for the identified projectile.

6. Blow the projectile through the hose or tube assembly. The projectiles will travel around corners, and through "T's" when the previous documented instructions are followed.

7. Direct the discharged oil, contaminants, and projectile into a waste container at the other end.

8. Continue the projectile cleaning procedure until the hose or tube is relatively clean.

After using the hose cleaner group, immediately cap or plug all open hose or tubes or reconnect to the clean system component.

The hose cleaner may not completely clean all contaminants from the fluid carrier. Caterpillar recommends kidney looping the system oil to remove the remaining contamination from the circuit. This filtering operation must be completed prior to returning the vehicle to service.