Obtaining Oil Sample for Analysis {1302, 1348, 3030, 3080, 3278, 4011, 4070, 5050, 5056, 5095, 7542} 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 the 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.

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

Summary

A good oil sample that accurately represents the condition of the fluid system is vital for the success of any analysis program. For this reason, the oil should be at the system operating temperature or at least 50 °C (120 °F) if the normal operating temperature cannot be reached when the sample is taken. The following guideline describes the methods to obtain oil samples from machine fluid systems. Bottle sampling (pressure and suction) and portable particle counter methods are included in this guideline. These processes are used when an oil sample is taken or when an on-line particle count is taken on any fluid system such as hydraulic, steering, power train, engine, and final drive.

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. When a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar, 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 the information, specifications, and illustrations that are in this publication are based on information that was available at the time of publication. The following specifications could change at any time: specifications, torque, pressures, measurements, 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.

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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, PERJ1017, "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

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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.

On-line Particle Counting using S·O·S Valves

Illustration 3	g01281548
Pama On-line Particle Counter

Note: Refer to Tool Operating Manual, NEHS0799, "170-8500 Analyzer Group" for proper installation and operation. Caterpillar recommends connecting the on-line particle counters directly to the S·O·S valve.

Note: Refer to the Operation and Maintenance Manual for the S·O·S valve locations. Refer to the Test and Adjust Manual to obtain the system pressures. Prepare all equipment used to sample oil in advance to prevent contamination prior to taking a sample.

Illustration 4	g01281550
Left - high-pressure hose, Right - low-pressure hose

1. Determine the fluid system pressure at the location where the sample is to be taken (S·O·S valve). For proper supply hose and hardware, refer to Tool Operating Manual, NEHS0799, "170-8500 Analyzer Group".

2. Exercise the machine until the sampled fluid system is up to the normal operating temperature or at a minimum of 50 °C (120 °F).

3. Park the machine on level ground. Lower all the attachments. Engage the parking brake.

4. Set the engine at low idle. All systems must be in a safe position.
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   Illustration 5	g01281551
   S·O·S valve dust cover

5. Remove the dust cover from the S·O·S valve. Refer to the Operating and Maintenance Manual for the S·O·S valve locations.
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   Illustration 6	g01281552
   Lint Free Towel. Transmission S·O·S valve shown.

6. Clean the S·O·S valve with a clean lint free towel.
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   Illustration 7	g01281553
   Quick Disconnect

7. Make sure that the quick disconnect is clean.
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   Illustration 8	g01281554
   Typical particle counter supply hose attached to the S·O·S valve (low-pressure hose shown)

8. Attach the particle counter supply hose to the S·O·S valve.
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   Illustration 9	g01281555
   Particle counter connections

9. Secure the particle counter discharge hose with a catch basin.

10. If the sampled fluid system has cooled down, exercise the machine until the sampled fluid system is up to normal operating temperature or a minimum of 50 °C (120 °F).
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    NOTICE
    Do not move the machine while the particle counter in connected. Moving the machine in this condition could damage the machine and/or the particle counter.

    Note: Allow power train circuits to idle for a minimum of 10 minutes prior to particle counting. Allowing power train circuits to idle will permit entrapped air to escape from the sampled oil. Air trapped in the oil will distort the particle counter readings.

11. Operate the particle counter according to the manufacturer instructions to obtain an oil sample reading.
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    Illustration 10	g01281556
    Remove sampling hoses.

12. After testing, disconnect the particle counter hose assembly from the machine. Disconnect the hose assembly from the particle counter. Drain the hoses. Cap all the hose ends. Store the particle counter and the hoses in a clean location.
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    Illustration 11	g01281557
    Replace dust cap

13. Install the dust cap onto the S·O·S valve. Make sure that the cap is clean on the inside.

Bottle Sampling Using Oil Valve Probe and S·O·S Valve

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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.

Note: Refer to Operation and Maintenance Manual for the S·O·S valve locations. Refer to the Test and Adjust Manual to obtain the system pressure. Only perform a bottle sample when the system pressures are below 3450 kPa (500 psi). Prepare all equipment used to sample oil and protect the equipment from contamination.

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Illustration 12	g01281558
S·O·S mailing label

1. Fill out the S·O·S label. Pay special attention to the serial number, sample data, service meter units on the equipment, service meter units on the oil, oil type, oil brand, and the amount of oil added. Indicate if the oil was changed after the sample was taken.
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   Illustration 13	g01281559
   Sample bottle package

2. Open the sample bottle package. Remove the sampling probe tube from the bag.
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   Illustration 14	g01281560
   Probe holder and probe

3. Insert the open sampling probe tube into and through the sample bottle probe holder counter bored end. Pull the probe tube all the way through the holder until the sampling needle seats in the holder.
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   Illustration 15	g01281561

4. Remove the sampling bottle from the package. Install the cap with two holes onto the bottle. Install the probe tube into one of the holes in the cap.
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   Illustration 16	g01281562

5. Return the assembled bottle and return the probe back into the package to prevent contamination.

6. Exercise the machine until the system oil to be sampled is up to normal operating temperature or at a minimum of 50 °C (120 °F).

7. Park the machine on level ground. Lower all the attachments. Engage the parking brake.

8. Set the engine at low idle. Make sure that all systems are in safe positions. Refer to the Operation and Maintenance Manual.
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   Illustration 17	g01281564

9. Remove the dust cover from the S·O·S valve.
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   Illustration 18	g01281565

10. Clean the S·O·S valve with a clean lint free shop towel.
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    Illustration 19	g01281566
    Purging S·O·S valve with Purge Probe and tube

11. Purge the S·O·S valve by pressing the purge probe onto the S·O·S valve. Purge a minimum of one sample bottle of oil or more to ensure that all the dead volume of the fluid is purged. Purging the oil will ensure that the sampling nipple is internally cleaned.

    Note: If the oil flow is slow at low idle, someone may need to accelerate the engine.

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    Illustration 20	g01281567
    Oil disposal

12. Properly dispose of the purged oil according to local regulations and mandates.
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    Illustration 21	g01281568
    Prepared bottle sample

13. Remove the prepared sample bottle from the package.
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    Illustration 22	g01281576
    Flush sample bottle

14. Rinse the sample bottle and rinse the probe tube with the system oil. Rinse the bottle by filling the bottle half full with the system oil.
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    Illustration 23	g01281577
    Flush sample bottle

15. Shake the sample bottle vigorously for several seconds.
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    Illustration 24	g01281578

16. Empty the oil into a waste oil container.
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    Illustration 25	g01281579

17. Fill the sample bottle to the "fill range" imprinted on the bottle, but do not fill beyond the fill mark.

    Note: Filling beyond the fill mark will not allow for proper lab mixing.

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    Illustration 26	g01281580

18. Remove the sampling probe tube from the bottle lid. Save the knurled probe holder and discard the probe tube.
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    Illustration 27	g01281581

19. Immediately replace the two-hole lid on the sample bottle with the solid lid (no hole). Dispose of the lid with two holes.
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    Illustration 28	g01281583

20. Ensure that the outside of the bottle is clean.
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    Illustration 29	g01281585
    Mailing tube with completed label

21. Place the bottle with the completed information label into a sample bottle shipping container, or take the bottle and label to an S·O·S lab.
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    Illustration 30	g01281586

22. Wipe any oil off the sample valve.
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    Illustration 31	g01281588

23. Install the dust cap onto the S·O·S valve and check that the cap is clean on the inside.

Zero Pressure System Using a Hand Vacuum Pump

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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.

Note: Typical non-pressurized systems are reservoirs, differentials, final drives, or return lines (drains). The sample location should be near the middle of the reservoir fluid level and away from the sidewall. The sample location should be where the fluid is normally in motion, thoroughly mixed, and at normal operating temperature. The sample should be taken as soon as possible after the machine exercising has been stopped. Prepare all sampling hardware before an oil sample is taken.

Note: Never use the same vacuum pump for obtaining both oil and coolant samples. The fluid does not enter the barrel of the pump, a small residue of glycol from the coolant remains in the pump. The glycol residue can contaminate the oil sample. Glycol will indicate a "false positive" coolant leak in the oil system being sampled.

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Illustration 32	g01281590

1. Fill out the S·O·S label. Pay special attention to the serial number, sample data, service meter units on equipment, service meter units on oil, oil type, oil brand, and the amount of oil added. Indicate if the oil was changed after the sample was taken.
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   Illustration 33	g01281591
   Tube cut to length

2. Measure the tubing and then cut the new tubing to the length of the dipstick. If there is no dipstick, cut the tubing so that the tubing reaches about halfway into the oil depth of the compartment being sampled.

   Note: Use a tube cutter to prevent the tubing from being contaminated.

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   Illustration 34	g01281593

3. Install tubing into the vacuum pump. The bottle end of the tubing should be approximately 25.4 mm (1 inch) beyond the base of the vacuum pump head.
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   Illustration 35	g01281594

4. Install a new bottle to be sampled to the vacuum pump.
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   Illustration 36	g01281595

5. Store the vacuum pump assembly and the clean bottle cap in the plastic bag until the parts are ready for use.

6. Exercise the machine fluid to be sampled until the fluid system is up to normal operating temperature. If normal operating temperature cannot be reached, then 50 °C (120 °F) is acceptable.

7. Park the machine on level ground. Lower all the attachments. Engage the parking brake.

8. Shut off the machine . Make sure that all the systems are in safe positions. Refer to the Operation and Maintenance Manual.
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   Illustration 37	g01281596

9. Clean the sample location using a clean lint free shop towel.
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   Illustration 38	g01281597

10. Keep the sample bottle vertical when taking samples. Pump the vacuum pump handle to create a vacuum.

    Note: If the bottle is tilted, the oil will enter into the suction of the barrel of the vacuum pump. Oil in the barrel will cause cross contamination of subsequent samples.

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    Illustration 39	g01281598

11. Fill the sample bottle half full with system oil.

12. Remove the bottle from the vacuum pump.
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    Illustration 40	g01281577

13. Install a clean lid and shake the bottle vigorously for several seconds.
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    Illustration 41	g01281578

14. Empty the bottle into a waste oil container.

15. Reattach the sample bottle to the vacuum pump.
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    Illustration 42	g01281599

16. Take the oil sample in the same manner. Fill the bottle to the "fill range". Do not fill the bottle beyond the fill mark.

    Note: Filling beyond the fill mark will not allow for proper lab mixing.

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    Illustration 43	g01281583

17. When the oil bottle is filled, remove the bottle from the vacuum pump. Cap the bottle with a clean lid (no holes).

18. Clean the outside of the bottle.
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    Illustration 44	g01281585

19. Place the bottle with the completed information label into a sample bottle shipping container, or take the bottle and label to an S·O·S lab.

20. Remove the tubing from the vacuum pump and discard the tubing according to local regulations and mandates.
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    Illustration 45	g01281596

21. Clean any covers, caps, plates, and so on, that have been removed.