Procedures For Using: 127-8781 Transfer Filter Cart , old 9U-7361 (110V, 60 hz), 169-7159 Transfer Filter Cart , old 127-8782 (220V, 50 hz) CE, 174-9158 Transfer Filter Cart , old 129-0849 (Air Motor Driven){0374, 0599, 0680, 0738} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

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Think Safety

European Union Compliant, CE marked

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 can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.

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.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of 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. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.

Maintenance Section

The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal

Service Parts Section

The Service Parts section is a reference for parts identification and available part numbers.

Safety Icon Nomenclature

Personal Protection/Important Information

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Personal Protection/Important Information

Prohibited Action

No smoking

Hazard Avoidance

Crushing hazard (foot)

Crushing hazard (hand)

Pinch point

Fire hazard

Electrical Shock - Hazard

Fire hazard

Safety Section

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At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure.

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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.

General Information Section

Introduction

Illustration 3	g02817379
Typical Transfer Cart

This Tool Operating Manual contains two procedures. The first procedure explains how to use the transfer cart to transfer fluid from one container to another. The second procedure explains how to use the transfer cart to filter, or clean, a machines hydraulic system that contains moderate amounts of contamination.

References

Special Instruction, NEHG3961, "Tool Announcement 138-9656 Portable Contamination Monitor Group "

Tool Operating Manual, NEHS0580, " 138-9656 Particle Counter Contamination Group "

Special Instruction, SEHS9043, "Installation of Scheduled Oil Sampling Valve"

Note: Procedures for using this filter cart for specific applications can also be found in Special Instruction, SEBF8405, "Contamination Control Guidelines".

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:

Transferring Fluids from Storage to a Machine

The 127-8781 Transfer Filter Cart , 169-7159 Transfer Filter Cart , and 174-9158 Transfer Filter Cart provide an environmentally safe method to transfer oil.

Note: The tops of barrels and drums can collect water, dirt, and other airborne debris. Unless care is taken to clean the barrel openings before caps and plugs are removed, the oil can be contaminated. To use the transfer carts to transfer oil, follow these steps.

Procedure

1. Clean the top of the barrel of all water, dust, and debris, especially the area around the plug opening. The careful use of compressed air will help in cleaning the drum top without introducing contaminants into the contents of the barrel.

2. Remove the barrel plug.

3. Clean the outside of the transfer cart barrel standpipe and insert into the barrel.

4. Clean around the fill cap area of the hydraulic tank. Remove the fill cap and fill strainer from the top of the tank.

5. Store the fill cap and screen in a clean area to avoid contamination and prevent possible damage.

6. Position the discharge nozzle in the fill tube of the tank.

7. Start the motor of the transfer cart. Squeeze the handle trigger of the nozzle to start the flow of fluid. To stop the transfer of fluid, release the handle trigger. The cart is equipped with a bypass circuit to help prevent pump, motor, or filter overload when filter clogs or trigger is released.

   Note: If the oil flow does not start within a minute at startup, stop the motor and purge the air from the suction line.

8. During the transfer process, periodically check the differential pressure gauge on the discharge filter. This gauge monitors the resistance to flow through the filter and determines when to change the filter. If the indicator is not in the "GREEN" area, replace the filter.

9. When the reservoir is full, release the nozzle handle, stop the motor, and remove the nozzle/discharge hose. Store the hose on the cart.

10. Remove the standpipe from the barrel, wipe clean, and store on the cart.

11. Replace the barrel plug, hydraulic tank fill strainer, and cap. Additional protection against further oil contamination is available by using 1U-6156 Barrel Cover (55 G) to cover the oil barrel.

Filtering Hydraulic System Oil

Another use for 174-9158 Portable Transfer Carts is to clean oil in a hydraulic system. Hydraulic systems that have been carefully maintained will accumulate or generate some contaminants. In such situations, the machines hydraulic filters may not be sufficient to reduce the contamination to acceptable levels.

Note: Cleaning the machines oil using this procedure will be effective only if the machine is in good operating condition.

For questions or additional information concerning guidelines for specific applications, contact Caterpillar Service Support.

This procedure involves the continuous filtering of the oil in the machines hydraulic tank. Periodically, the filtering equipment should be disconnected and the machines implements actuated. Oil recently filtered will be exchange with contaminated oil in the hoses, tubes, and cylinders.

Note: Only the 174-9158 Air Powered Transfer Cart is recommended in this procedure.

Procedure

1. Connect the 9U-6662 Particle Counter to an appropriate test port. Refer to Tool Operating Manual, NEHS0580, " 138-9656 Particle Counter Contamination Group ".

2. Start the machine and actuate the hydraulic implements to bring the hydraulic system and oil up to normal operating temperature. Any contamination in the oil will be put into suspension.

3. Take a particle count test to establish the contamination level.

4. Shut down the machine and connect the transfer cart suction hose to the drain on the hydraulic tank

   Note: When possible, connect the suction hose to the ecology drain valve. This drain valve requires a 25.4 mm (1.00 inch) pipe be threaded in far enough to open the spring-loaded valve.

5. Clean around the hydraulic tank fill cap area. Remove the fill cap and fill strainer from the hydraulic tank.

6. Store the fill cap and strainer in a clean area to avoid contamination and prevent possible damage.

7. Position the discharge nozzle in the fill tube of the tank.

   Note: If the hydraulic tank does not have a drain valve, the suction and discharge lines must be inserted through the fill opening of the tank.

8. Start the air motor of the transfer cart. Squeeze the handle of the nozzle to start the flow of fluid. To stop the transfer of fluid, release the nozzle handle and shut off the air supply

   Note: If the transfer cart is not pumping, there may be air in the lines. This results in a no oil flow condition at start-up and can damage the pump due to cavitation. Cavitation occurs when there is air in the suction line and pump. If oil flow does not start within a minute, stop the motor and purge the air from the suction line.

9. During the filtering process, check the filter element indicators on both filters. If the indicator is not in the "GREEN" area, refer to the section ""Discharge Filter" " in this manual, on replacing the filters.

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NOTICE
Some machines cannot be operated when the cap of the hydraulic tank has been removed. Operating without using proper procedures can damage the hydraulic system. Refer to either Step 10 or 11, depending on the machines requirements.

10. While the cart is filtering the oil:
    • start the machine

    • position the throttle at medium idle

    • and actuate the implements, NOT the travel circuits

    Actuating the implements during the filtering process keeps the contaminants in suspension. The oil in remote lines, cylinders, and valves will be sent back to the tank for filtering.

11. If the implements cannot be operated with the transfer cart attached, disconnect the cart from the machine and replace the fill strainer and cap. Actuate the implements for 5 to 10 minutes to recirculate the oil throughout the implements and back into the hydraulic tank.

    Note: If the suction and discharge filtering hoses are both inserted through the fill opening, filtering a tank of oil to the same level of cleanliness will take longer. Using the tank drain valve because of the mixing of recently filtered tank oil is faster.

12. After an appropriate time of filtering (15 to 20 minutes), stop the motor of the cart. Perform another particle count analysis and compare the results to the earlier test. Industry standards suggest the minimum goal for improvement should be one ISO code. For example, from 21/17 to 20/16 as described in the Tool Operating Manual for the 138-9656 Particle Contamination Group . An improvement of one ISO code will reduce, by half, the number of contaminant particles contained in the oil. If the goal has been met, further filtering is unnecessary. Proceed to Step 16

13. Reconnect the transfer cart hoses to the machine. Filter the oil for an additional 15 to 20 minutes as in Steps 11 and 12. Perform another particle count analysis.

14. If contamination has not been reduced sufficiently, additional filtering is necessary. Before continuing, check the filter element indicators on the transfer cart. If the filters are plugged and have bypassed contaminated oil, further cleaning of the oil will not be accomplished. Change the filters as necessary and continue to run oil through the transfer cart and perform additional particle count analysis.

15. If contamination has been reduced to an acceptable level, according to the ISO guideline, disconnect the transfer cart from the machine. Replace the ecology drain valve plug, if removed, and install the hydraulic tank strainer and cap.

16. Check and fill the hydraulic oil to the proper level as specified in the Operation and Maintenance Manual for the machine. Inspect the fill cap gasket and replace. If necessary, install the fill cap.

Specifications

Serviceable Parts

Discharge Filter

Illustration 4	g02817396
Discharge Filter Indicator

The discharge filter is equipped with a bar type restriction indicator. Continue to use the discharge filter as long as the indicator is in the "GREEN" range. When the indicator begins to display a plugged condition "RED", change the filter element.

If the transfer cart is operated when the filter indicator is in the "RED", the oil is diverted through a bypass valve. No oil filtering will take place.

Suction Filter

Illustration 5	g02817398
Suction Filter Indicator

The suction filter is equipped with a dial type restriction indicator. Depending on the cleanliness of the oil being transferred, the suction filter may become plugged more quickly than the discharge filter. The suction filter is a replaceable 100 mesh screen. Replace the suction filter before the indicator is in the "RED" range using a 9U-6985 Filter Element .

Modifying the 174-9158 Filter Cart for Kidney loop Filtering of Small Hydraulic Systems

Modification Parts List

The following parts are required to modify the filter cart into a kidney loop filtering system. Specific filtering applications on specific machines may require additional parts.

Discharge Hose Modification

1. Remove the nozzle and quick disconnect assembly from the discharge hose.

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Illustration 6	g02817500
190-8319 Nipple (5) And 201-8059 Dust Cap (7)

2. Install a 190-8319 Nipple (5) and 201-8059 Dust Cap (7) on the end of the discharge hose.

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Illustration 7	g02817501
190-8319 Nipple And 201-8059 Dust Cap Added To Discharge Hose

3. Replace the filter elements with a 198-3188 Element (B) and 9U-6983 Element (A) .

Suction Hose Modification

Illustration 8	g02817502
Remove Spiral Wound Suction Hose From Filter Cart

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Illustration 9	g02817507
Install 3B-7257 Bushing (3) in Suction Port

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Illustration 10	g02817508
Install New Suction Hose In Suction Port (1) 122-6906 Hose (2) 124-1909 Hose Ends (Qty 2) (3) 3B-7257 Bushing

1. Fabricate a kidney loop suction hose from a suitable length of 122-6906 Hose , (1) and two 124-1909 Male Hose Ends (2) .

2. Install 190-8318 Female Quick Disconnect Coupling and 201-8057 Dust Cap on one end of the new suction hose.

3. Remove the clear spiral wound hose from the suction side of the filter cart.

4. Install a 3B-7257 Bushing (3) in the suction port on the filter cart.

5. Install the new suction hose in the filter cart suction port.