Model: NO EQUIPMENT SELECTED Configuration: NO...

Reuse And Salvage Guidelines Procedure for Kidney Looping Front Wheel Groups of 793 and 797 Off-Highway Trucks

Procedure for Kidney Looping Front Wheel Groups of 793 and 797 Off-Highway Trucks

SMCS - 0680; 0768; 3016; 3030; 3101

Introduction

This guideline enables dealers and their customers to benefit from cost reductions made possible through an established contamination control program. The fluids used in Caterpillar machines are highly effective unless they contain damaging amounts of contamination. Therefore, every effort must be made to reduce the contamination level within Caterpillar fluid systems. Since the Company makes ongoing changes and improvements to its products, this guideline must be used with the latest technical information available from Caterpillar to ensure such changes and improvements are incorporated where applicable.

For questions or additional information concerning this guideline, contact your Contamination Control representative. Information and contacts can be accessed through the Caterpillar Contamination Control Web Site, or contact Caterpillar Dealer Capability

Shutdown SIS

Previous Screen

Product: NO EQUIPMENT SELECTED

Model: NO EQUIPMENT SELECTED Configuration: NO EQUIPMENT SELECTED

Media Number -SEBF8483-00 Publication Date -2001/10/01 Date Updated -2005/01/28

SEBF84830001

GUIDELINE FOR

REUSABLE PARTS

AND SALVAGE

OPERATIONS

CAT®

Procedure for Kidney Looping Front Wheel Groups

of 793 and 797 Off-Highway Trucks

SEBF8483-00SMCS Code: 4002,

4006, 7542, 7577, 4251

October 2001

Page 1 of 21Media Search - SEBF8483 - Procedure for Kidney Looping Front Wheel Groups of 79...

15/09/2010https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/s...

Department, Dealer Support (309) 675-8970.

Summary

The instructions given in this guideline will enable dealers and customers to properly kidney loop Front Wheel Groups of 793 and 797 Off-Highway Trucks. Following this procedure will reduce the contamination in the oil to an acceptable ISO contamination level. This procedure may need to be modified by the technician for use on some machines.

NOTICE

If the vehicle system is being serviced due to a catastrophic component failure, a complete system cleaning operation is required before initiating this kidney loop filtration procedure. If the failure is not addressed early, particles from the failed component will contaminate other system components such as valves, pumps, motors and controls. Additional component cleaning, component exchange and lines flushing will be required to remove the majority of contaminates generated from the failure. The vehicle system cleaning MUST be performed prior to kidney looping. This filtration procedure and subsequent particle count testing should be performed as a final step in the repair process.



References

Tooling and Equipment

References

Media Number Title

NEHS0848 Tool Operating Manual for 204-7392 Transfer Cart

PEJT5025 Reporting Particle Count by ISO Code

PEVN4831 Count on Caterpillar Particle Analyzers

NEHS0799 Tool Operating Manual for S40

SEBF8490 Cleaning Front Wheel Groups of 793, 793B, 793C, and 797 Off-Highway Trucks

SEBF8482 Obtaining an Oil Sample for S·O·S Analysis

Required Tools

Quantity Part No. Part Description

1 204-7392 Kidney Loop Cart

4 169-8373 Bottle Group

Discharge Adapter Assembly

2 124-1920 Male Swivel-½ NPTF

1 122-6870 Caterpillar 716 Hose-3/4”-10 feet

1 190-8318 Female Coupler

1 5B-4855 Reducing Bushing

1 201-8059 Female Dust Cap

Suction Adapter Assembly

1 194-5182 793 Adapter

1 4C-5088 797 Adapter

1 005-8615 Connector

1 190-8319 Male Coupler

1 201-8057 Male Dust Cap

Non-Caterpillar Parts for Filter Cart Modification Quantity Part No. Part Description

1 C800-S-20 Parker Hannifin 170 kPa (25 psi) Relief Valve



Optional Particle Counting Tools

Quantity Part No. Part Description

1 170-8500 S40 Portable Particle Analyzer

1 188-0639 Low Pressure Hose Assembly

Filter Cart Modification Parts

Qty Part No. Part Description

1 1L-4031 1-11 ½ THD Tee

1 004-3099 1-1/16 12THD to 1-11 ½ NPTF THD Connector-37°

Flared

1 122-6872 Caterpillar 716 Hose-3/4”-Cut to length

2 124-1969 Coupling (JIC)

3 4S-6678 1-1/16 12THD to ¾-14 NPTF THD Connector

1 148-0209 Adapter3/4”NPTM to 1 1/16 37° Flared Female

1 8C-1358 ¾” Ball Valve

1 003-9163 ¾ -14 NPTF THD Elbow 90°Pipe

1 1N-8559 ¾-14 NPTF THD Tee

1 8T-0863 Pressure Gauge 0 to 240 kPa (0 to 35 psi)



Kidney Loop Procedure for Front Wheel Groups of 793 and 797 Off-Highway Trucks

The following procedure is intended for 793 and 797 Off Highway Trucks. The procedure is most effective when performed immediately after the oil has been warmed to a minimum of 50ºC (122ºF) and mixed from operation. This allows any contamination in the system oil to be placed in suspension and lowers the viscosity of the oil. Be sure to read and understand NEHS0848 204-7392, “Tool Operating Manual for 204-7392 Transfer Cart”, before beginning this procedure.

Illustration 1 Machine Setup for SEBF8483

Instructions for 170 kPa (25 psi) Relief Valve Conversion for the 204-7392 Kidney Loop Cart



Illustration 2 (1) 7X-3387 SOS Valve (2) 131-9367 Reducing Bushing (3) 2P-1306 Tee-Pipe

1. Remove 7X-3387 S·O·S Valve (1), 131-9367 Reducing Bushing (2), and 2P-1306 Tee-Pipe (3).



Illustration 3 (3) 2P-1306 Tee-Pipe (4) ¼-18 NPTF

2. Drill and tap a ¼-18 NPTF (4) in 2P-1306 Tee-Pipe (3).

Illustration 4 (1) 7X-3387 SOS Valve (2) 131-9367 Reducing Bushing (5) 1L-4031 Tee (6) 004-3099 Connector

3. S·O·S Valve Adapter Assembly-Assemble 7X-3387 S·O·S Valve (1) and 131-9367 Reducing Bushing (2) to 1L-4031 Tee (5). Attach 004-3099 Connector (6) to 1L-4031 Tee (5).



Illustration 5 (7) 4S-6678 Connector (8) C800-S-20 Parker Hannifin 170 kPa (25 psi) Relief Valve (9) 148-0209 Adapter (10) 8C-1358 Ball Valve (11) 003-9163 Elbow (12) 1N-8559 Tee

4. 170 kaPa (25 psi) Relief Valve Assembly-Attach 4S-6678 Connector (7) to C800-S-20 Parker Hannifin 170 kPa (25 psi) Relief Valve (8) to 148-0209 Adapter (9). This is then connected to 4S-6678 Connector (7), 8C-1358 Ball Valve (10), 003-9163 Elbow (11) and 1N-8559 Tee (12). Attach 4S-6678 Connector (7) to 1N-8559 Tee (12).

Illustration 6 (13) 124-1969 Coupling (14) 122-6872 Caterpillar 716 Hose-3/4”-Cut to length

5. Bypass Hose-Assemble a hose using two 124-1969 Couplings (13) and 122-6872 Caterpillar 716 Hose-cut to length (14).

Illustration 7 (15) Elbow



6. Remove elbow (15).

Illustration 8 (3) 2P-1306 Tee (16) S·O·S Valve Adapter Assembly (17) Bypass Hose (18) 8T-0863 0 to 240 kPa (0 to 35 psi) Pressure Gauge (19) Discharge Hose

7. Attach 2P-1306 Tee (3) to the filter cart. Attach S·O·S Valve Adapter Assembly (16) to 2P-1306 Tee Pipe (3) and connect bypass hose (17). Attach 8T-0863 0 to 240 kPa (0 to 35 psi) Pressure Gauge (18) into 2P-1306 (3). Attach discharge hose (19) to 2P-1306 Tee (3).

Illustration 9 (17) Bypass Hose (20) 170 kPa (25 psi) Relief Valve Assembly

8. Assemble 170 kPa (25 psi) relief valve assembly (20) to the cart. Attach bypass hose (17) to 170 kPa (25 psi) relief valve assembly (20).



Illustration 10 Final Kidney Loop Assembly

9. Final kidney loop assembly should resemble Illustration 10.

Page 10 of 21Media Search - SEBF8483 - Procedure for Kidney Looping Front Wheel Groups of ...


Kidney Loop Adapters

Illustration 11 (21) 124-1920 Male Swivel (22) 122-6870 Caterpillar 716 Hose-1/2” –10’

1. Discharge Adapter Extension-Assemble a hose using two-124-1920 Male Swivels (21) and ten feet of 122-6870 Caterpillar 716 Hose (22).

Illustration 12 (23) Discharge Adapter Extension (24) 5B-4855 Reducing Bushing (25) 190-8318 Female Coupler (26) 201-8059 Dust Cap

2. Discharge Adapter Assembly-Connect discharge adapter extension (23) to 5B-4855 Reducing Bushing (24) and 190-8318 Female Coupler (25). Attach 201-8059 Dust Cap (26) to 190-8318 Female Coupler (25).



Illustration 13

Illustration 14 (27) 194-5182 793 Coupling (28) 4C-5088 797 Coupling (29) 005-8615 Connector (30) 190-8319 Male Coupler (31) 201-8057 Male Dust Cap

3. Suction Adapter Assembly-Attach the proper coupling for your model 194-5182 793 Coupling (27) or 4C-5088 797 Coupling (28) to 190-8319 Male Coupler (30) using 005-8615 Connector (29). Attach 201-8057 Male Dust Cap (31) to 190-8319 Male Coupler (30).

Kidney Loop Setup

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.



1. Operate the machine in order to warm the front wheel oil to operating temperature.

Illustration 15 (32) Drain Plug (33) Fill Plug

Illustration 16 (34) Breather Hose

2. Thoroughly clean the wheel group around drain plug (32), fill plug (33), and breather hose (34).

NOTICE

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

NOTICE

Do not move the machine while the filter cart is connected. Moving the machine in this condition could cause machine damage.



3. Park the machine on a level surface.

Illustration 17 (32) Drain Plug

4. Refer to the OMM for the proper procedure for parking the machine.

Kidney Loop Procedure

Illustration 21 (35) Discharge Adapter Assembly

1. Remove breather hose (34) and install discharge adapter assembly (35).



Illustration 22 (36) Suction Adapter Assembly

2. Remove drain plug (32) and quickly install suction adapter assembly (36).

Illustration 23 (33) Fill Plug

Note: It is recommended that an S·O·S sample be taken before the kidney loop procedure is performed. Follow the procedures given in SEBF3116 for using vacuum extraction.

3. Remove fill plug (33) from the wheel group and take a sample as in Illustration 23.

Illustration 24 (35) Discharge Adapter Assembly (36) Suction Adapter Assembly

4. Connect both adapters to the cart. Suction adapter assembly (36) to the suction side of the filter cart and discharge adapter assembly (35) to the discharge side of the filter cart as shown in Illustration 24.

Insure there are no oil leaks from any of the connections.



Illustration 25 (10) 8C-1358 Ball Valve (37) Air Supply Hose (38) 204-7392 Filter Cart (39) Air Supply Valve

6. Attach air supply hose (37) to 204-7392 Filter Cart (38), ensuring that air supply valve (39) and 8C-1358 Ball Valve (10) are in the closed position. Be sure the air supply does not exceed 689 kPa (100 psi).

Illustration 26 (10) 8C-1358 Ball Valve

7. Open 8C-1358 Ball Valve (10).

8. Slowly open air supply valve (39) to start the filter cart pump operation. This is a gear pump. It is rated to pump 10 W oil at 17 gpm. 50W oil pumps approximately 2 to 3 gpm.

Note: Occasionally, the filter cart pump will cavitate during start-up. This is due to air in the suction lines of the pump. If cavitation continues for more than one minute, shut the filter cart OFF and check the connections. Regulate the air if necessary.

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

• Use a 170-8845 Portable Particle Analyzer for immediate results.

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

If using 170-8845 Portable Particle Analyzer (40) for particle counting, be sure to read and understand NEHS0799, “Tool Operating Manual S40 Portable Particle Analyzer”, before operation.



Illustration 27 (40) 170-8845 Portable Particle Analyzer

10. When using 170-8845 Portable Particle Analyzer (40), connect 188-0639 Hose to the “low pressure in” port.

Note: Information regarding the availability of parts and fabrication instructions for the suction tube assembly can be obtained by contacting the Caterpillar Service Technology Group Hotline. Proper fittings and instructions will be provided at no charge. A 188-0639 Hose will need to be purchased prior to assembly.

Illustration 28 (39) Air Supply Valve

11. To take the particle count test, close air supply valve (39) of the 204-7392 Filter Cart.



Illustration 29 (33) Fill Plug

12. Remove fill plug (33) from the wheel group and take a sample using vacuum extraction. Follow the procedure for vacuum extraction provided in SEBF8482.

13. Analyze the sample on 170-8845 Portable Particle Analyzer (40).

14. If the particle counter indicates:

a. A reading of ISO 18/15, the machine is ready to be returned to the field.

b. A reading greater than ISO 18/15, repeat steps 7-11.

Note: Refer to “Oil Compartment Filtration Times”, located at the end of this document, when 170-8845 Portable Particle Analyzer (40) is not available.

Illustration 30 (10) 8C-1358 Ball Valve (37) Air Supply Hose (39) Air Supply Valve

15. When the target ISO level or time interval has been met, close air supply valve (39), 8C-1358 Ball Valve (10), and disconnect air supply hose (37).

16. Disconnect the cart hoses from the adapters.



Illustration 31 (32) Drain Plug

17. Remove suction adapter assembly (36) and install drain plug (32).

Illustration 32 (35) Discharge Adapter Assembly

18. Remove discharge adapter assembly (35) and reinstall breather hose (34).

19. Check and maintain the oil level for the wheel group at the recommended oil level for each model according to the Operation and Maintenance Manual.

20. Check for any leaks in the Front Wheel Group.

21. Unblock the wheels.

22. Return the machine to service.



Oil Compartment Filtration Times

If a portable particle counter is not available to diagnose and track when the contaminant level has lowered to an acceptable point, refer to the following equation. This equation relates to the 174-9158 Filter Cart only. 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 an absolute time or efficiency result.

Compartment Oil Capacity (gallons) X 35/ Flowrate of Cart

= Approximate Filtration Time

Example: A 793 Off Highway Truck Wheel Group has 7 gallons of 50W oil. The cart pumps 50W oil at a rate of 2 to 3 gpm. The approximate filtration time should be about 120 minutes or 2 hours.

ISO 4406:1999 Method for coding the level of contamination by solid particles

ISO (International Organization of Standardization) is a worldwide federation of national standards bodies (ISO member bodies). ISO 4406:1999 specifies the code to be used in defining the quantity of solid particles in the fluid used in a given hydraulic fluid power system. An automatic particle counter derives the equivalent size of a particle from the particle’s cross-sectional area. Particle counts are affected by a variety of factors. These factors include procurement of the sample, particle counting accuracy, the sample container, where used, and its cleanliness. Proper care should be taken during sample procurement to ensure that the sample obtained is representative of the fluid circulation in the system.

The code for contamination levels using automatic particle counters comprises three scale numbers, for example X/Y/Z.

X = The number of particles equal to larger than 4 microns. Y = The number of particles equal to or larger than 6 microns. Z = The number of particles equal to or larger than 14 microns.

At this time, Caterpillar does not require the reporting of the “X” scale number since hydraulic tolerances exceed the 4 micron value, therefore a “-“ is used. 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.



SEBF8483-00 CATERPILLAR® ©2001 Caterpillar

Copyright 1993 - 2010 Caterpillar Inc. All Rights Reserved.

Private Network For SIS Licensees.

Wed Sep 15 12:46:05 UTC+0800 2010



Date post:	15-Feb-2018
Category:	Documents
Upload:	lydieu
View:	220 times
Download:	3 times

Model: NO EQUIPMENT SELECTED Configuration: NO...

Documents