Procedure for Kidney Looping Forwarder Power Train and Hydraulic Oil{0680, 0768, 3016, 5056} Caterpillar

Forwarder:

554 (S/N: 1AM1-UP)

564 (S/N: KBN1-UP)

574 (S/N: 1FM1-UP)

574B (S/N: RLS1-UP; CZZ1-UP)

Introduction

© 2012 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 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 to 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

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 enables dealers and the customers to benefit from cleaner hydraulic systems. The kidney loop filtration process is easy to use. The kidney loop cart connects to the hydraulic oil drain and hydraulic oil filler neck. 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 18/15 or cleaner.

Important Safety Information

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 1	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 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

Forwarder Hydraulic Oil Kidney Loop Procedure

This guideline is intended for Forwarders. 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, NEHS0848, "204-7392 Kidney Loop Cart" before you begin the procedure.

Kidney Loop Adapters

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Illustration 2	g01295168
Suction Adapter (1) 19 mm (0.75 inch) Pipe (2) 7M-8485 O-ring Seal (3) 6B-9081 Bushing - Pipe Reducing (4) 006-5707 Elbow (5) 190-8319 Nipple (6) 201-8057 Dust Cap

1. Assemble the suction adapter by using a 19 mm (0.75 inch) pipe (1), O-ring Seal (2), Bushing - Pipe Reducing (3), 90° Elbow (4), Nipple (5) and a Dust Cap (6). Refer to Illustration 2.

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Illustration 3	g01295169
Suction Fastener (7) 228-6507 Suction Fastener

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Illustration 4	g01295170
Discharge Adapter (8) 161-5544 Coupler (9) 6V-3526 Fitting (10) 8C-8552 Union (11) 002-6454 Nipple (12) 163-5972 Bushing - Reducing (13) 006-5707 Elbow (14) 190-8318 Coupling

2. Assemble the discharge adapter by using a Coupler (8), Fitting (9), Union (10), Nipple (11), Bushing - Reducing (12), 90° Elbow (13) and a Coupling (14). Refer to Illustration 4.

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.

Note: Be sure to keep all parts clean and free of contamination.

1. Operate the machine to warm the oil.

2. Park the machine on level ground.

3. Move the direction selector switch to the NEUTRAL position.

4. Place the machine in the "roading" mode.

5. Place the boom in the STORED position.

6. Turn off the engine.

Kidney Loop Setup and Procedure

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Illustration 5	g01295171
(15) Breather

1. Clean the area around the breather (15) on top of the power train tank. Remove the breather. Remove the adapter located underneath the breather. Refer to Illustration 5.

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Illustration 6	g01295173
(7) Suction Fastener (16) Suction Adapter

2. Install the suction fastener (7), and slide the suction adapter (16) through the Suction Fastener (7) .Refer to Illustration 6.

   Note: The 574B will use the 236-2516 Suction Fastener .

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Illustration 7	g01295174
(16) Suction adapter (17) Suction hose

3. Connect the filter cart suction hose (17) to the suction adapter (16). Refer to Illustration 7.

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Illustration 8	g01295175
(18) Fill coupling

4. Clean the area around the fill coupling (18). Connect the discharge adapter (19) to the fill coupling (18). Refer to Illustration 8 and Illustration 9.

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Illustration 9	g01295176
(19) Discharge adapter (20) Discharge hose

5. Connect the filter cart discharge hose (20) to the discharge adapter (19). Refer to Illustration 9.

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Illustration 10	g01295178
(21) Air supply valve (22) Air supply hose

6. Attach the air supply hose (22) to the 204-7392 Filter Cart . Ensure that the air supply valve (21) is in the CLOSED position. BE SURE THAT THE AIR SUPPLY DOES NOT EXCEED 690 kPa (100 psi). Refer to Illustration 10.

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Illustration 11	g01295179
Filter cart operation

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Illustration 12	g01295180
Air supply valve in the OPEN position

7. Slowly open the air supply valve to start the filter cart pump operation. The pump is a gear pump. The pump is rated to pump SAE10W oil at 64 L/min (17 US gpm).

8. While operating the filter cart, check the filter element indicators. The indicators will indicate the amount of capacity left in the filter element.

   Note: On occasion, the filter cart pump will cavitate during start-up. The cavitation is due to air in the suction lines of the pump. Shut the filter cart OFF and check the connections if cavitation continues for more than 1 minute.

9. Ensure that there are no oil leaks at any of the filter cart connections.

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

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

   1. Use a portable particle analyzer for immediate results.

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

Portable Particle Analyzer Procedure

When using the portable particle counter for particle counting, be sure to read and understand the Tool Operating Manual before operating the particle counter.

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Illustration 13	g01295181
(23) 188-0639 Suction Tube (24) 220-8607 Fitting (25) 210-5530 Coupler (26) S·O·S valve

1. Attach the fabricated particle counter "low pressure in" suction tube to the S·O·S valve (26) on the filter cart. Refer to Illustration 13.

   Note: The fabricated suction tube can be made with the parts listed in Table 2 and as shown in Illustration 13.

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

Bottle Sample

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Illustration 14	g01295182
(26) S·O·S valve (27) 169-8373 Bottle Group

1. If collecting a bottle sample, use the same S·O·S valve (26) and use a 169-8373 Bottle Group . Refer to Contamination Control Guideline, SEBF8482 for more information.

2. Record an oil sample from the S·O·S valve (26) on the filter cart at the beginning of the filter cycle.

3. During the filter cart operation, start the machine and cycle the implement and lift arms circuit every 20 minutes. Cycle the cylinders to the end of the stroke at least four times. While the machine is elevated off the ground, run the power train in FORWARD and REVERSE. This procedure will cycle the clean tank oil into the system and flush the more contaminated oil back in the tank. The oil filtration can be performed while cycling the machine.

4. Turn OFF the engine.

Note: Change the machine hydraulic system filters halfway through the filter process. This procedure avoids opening the filter housing after the system has been cleaned. If the filter housing in opened after the filtration process is complete, the filter housing becomes an inlet for contamination. The new filters can remain in place until the next schedule filter change.

Note: The machine filters only need changed if the filters are not working at optimal performance or the filters scheduled for replacement.

5. Operate the filter cart until the portable particle analyzer indicated that the oil has reached an acceptable ISO level of at least 18/15. 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 204-7392 Filter Cart" " at the end of this document, when a portable particle analyzer is not available.

6. When the target ISO level or time interval has been met, close the air supply valve (21) and disconnect the air supply hose (22). Refer to Illustration 10.

7. Disconnect the discharge hose (20) from the discharge adapter (19). Refer to Illustration 9.

8. Disconnect the suction hose (17) from the suction adapter (16). Refer to Illustration 7

9. Remove the discharge adapter (19) .

10. Remove the suction adapter (16) .

11. Remove the suction fastener (7) .

12. Install the breather (15) and install the adapter. Refer to Illustration 5.

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Illustration 15	g01295183
Hydraulic Tank

13. Repeat this procedure for the hydraulic side of the tank.

    Note: A 574B has a common power train and hydraulic tank. The procedure does not need repeated on the 574B.

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 contaminant level has lowered to an acceptable level, refer to the following equation. This equation relates to the 204-7392 Filter Cart only. Other filtration units will have different equation references and these units will be noted when appropriate.

Multiply the compartment oil capacity (gallons) by two. The product of this equation will equal the approximate filtration time in minutes.

Example

A 554 Forwarder hydraulic system has 79 L (21 US gal) of SAE 10W oil. The approximate filtration time should be 42 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 particles cross sectional area. 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. 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.