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Pautas de control de contaminacin

Obtaining Oil Sample for Analysis{1302, 1348, 3030, 3080, 3278, 4011, 4070, 5050, 5056, 5095, 7542}
Nmero de medio -SEBF8482-04Fecha de publicacin -24/03/2009Fecha de actu
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Obtaining Oil Sample for Analysis{1302, 1348, 3030, 3080, 3278, 4011, 4070, 5050, 5056, 5095, 7542}
SMCS - 1302; 1348; 3030; 3080; 3278; 4011; 4070; 5050; 5056; 5095; 7542 Agricultural Tractor: All Articulated Truck: All Asphalt Paver: All Backhoe Loader: All Challenger: All Cold Planer: All Combine: All Compact Track Loader: All Compact Wheel Loader: ALL Earthmoving Compactor: All Excavator: All All Wheeled Excavators Forest Products: All Integrated Toolcarrier: All Landfill Compactor: All Load Haul Dump: All
https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw... 02/10/2010
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Mini Hydraulic Excavator: All Motor Grader: All Multi Terrain Loader: All Off-Highway Truck/Tractor: All Paving Compactor: All Pipelayer: All Road Reclaimer/Soil Stabilizer: All Skid Steer Loader: All Soil Compactor: All Telehandler: All Track Feller Buncher: Caterpillar Track-Type Loader: All Track-Type Skidder: All Track-Type Tractor: All Underground Articulated Truck: All Wheel Dozer: All Wheel Feller Buncher: All Wheel Loader: All Wheel Skidder: All Wheel Tractor-Scraper: All
Introduction
This Guideline enables dealers and the dealer's 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 in order 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 in order 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 website. In order to address an urgent need, please use the following to relay your request to Caterpillar Repair Process Engineering: Cat Dealer Technical Communicator
Dealer Solution Network Cat Technical Representative Knowledge Network (on-line) If a Contatmincation 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 in order 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).
References
Table 1 References Media Number SEHS9043 PEVN4831 NEHS0799 PEEP5031 Title Valve Installation for Scheduled Oil Sampling of Engine, Transmission, Hydraulics, and Steering Count on Caterpillar Particle Analyzers Tool Operating Manual for S40 Portable Particle Analyzer Oil Analysis Bottle Label
NOTICE
Keep all parts clean and keep all parts free of contamination.
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 SOS Valves

Table 2 Parts List Quantity 1 1 1 1 (1) 1 Part Number 162-5791 170-8500 210-5530 GE06L1/4NP TA3C 188-0639 Parts Description Shop Towel S40 Particle Counter Quick Disconnect Male Connector Hose as Replacement Parts
( 1 ) These items can be obtained by contacting Caterpillar Capital Tooling Group. A
proper fitting will be provided at no cost.
Illustration 1
g01281548
170-8500 Pama On-line Particle Counter
Note: Refer to Contamination Control Guideline, PEVN4831, "Count on Caterpillar Particle Analyzers" and refer to Tool Operating Manual, NEHS0799, "Manual for S40 Portable Particle Analyzer" for proper installation and operation. Caterpillar recommends to connected the on-line particle counters directly to the SOS valve. Note: Refer to the Operation and Maintenance Manual for the SOS valve locations. Refer to the Test and Adjust Manual in order to obtain the system pressures. Prepare all equipment used to sample oil in advance in order to prevent contamination prior to taking a sample.
Illustration 2 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 (SOS valve). For proper supply hose and hardware refer to Contamination Control Guideline, PEVN4831, "Count on Caterpillar Particle Analyzers" and refer to Tool Operating Manual, NEHS0799, "Tool Operating Manual for S40 Portable Particle Analyzer". 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 of the attachments. Engage the parking brake. 4. Set the engine at low idle. All systems must be in a safe position.
Illustration 3 SOS valve dust cover
g01281551
5. Remove the dust cover from the SOS valve. Refer to the Operating and Maintenance Manual for the SOS valve locations.
Illustration 4 g01281552 162-5791 Lint Free Towel . Transmission SOS valve shown.
6. Clean the SOS valve with a clean 162-5791 Lint Free Towel .
Illustration 5 210-5530 Quick Disconnect
g01281553
7. Make sure that the 210-5530 Quick Disconnect is clean.
Illustration 6 g01281554 Typical particle counter supply hose attached to the SOS valve (low pressure hose shown)
8. Attach the particle counter supply hose to the SOS valve.
Illustration 7 Particle counter connections
g01281555
9. Secure the particle counter's 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).
NOTICE
Do not move the machine while the particle counter in connected. Moving the machine in this condition could cause damage to the machine and/or the particle counter. Note: Allow power train circuits to idle for a minimum of ten minutes prior to particle counting. This will allow 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's instructions in order to obtain an oil sample reading.
Illustration 8 Remove sampling hoses.
g01281556
12. After testing, disconnect the particle counter hose assembly from the machine. After testing, disconnect the hose assembly from the particle counter. Drain the hoses. Cap all the hose ends. Store the particle counter and store the hoses in a clean location.
Illustration 9 Replace dust cap
g01281557
13. Install the dust cap onto the SOS valve. Make sure that the cap is
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clean on the inside. 14. Properly dispose of any waste oil.
Bottle Sampling Using Oil Valve Probe and SOS Valve

Table 3 Parts List Quantity 1 2 1 1 1 Part Number 162-5791 169-8373 162-8873 8T-9208 4C-4600 Part Description Shop Towel Sample Bottle Group Sample Bottle Probe Holder Probe Assembly (1) Sample Bottle Shipping Container
( 1 ) Purging with tube
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 SOS valve locations. Refer to the Test and Adjust Manual in order 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.
Illustration 10 SOS mailing label
g01281558
1. Fill out the SOS 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.
Illustration 11 Sample bottle package
g01281559
2. Open the 169-8373 Sample Bottle package. Remove the sampling probe tube from the bag.
Illustration 12 Probe holder and probe
g01281560
3. Insert the open sampling probe tube into and through the 162-8873 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.
Illustration 13
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.
Illustration 14
g01281562
5. Return the assembled bottle and return the probe back into the package in order 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.
Illustration 15
g01281564
9. Remove the dust cover from the SOS valve.
Illustration 16
g01281565
10. Clean the SOS valve with a clean 162-5791 Lint Free Shop Towel .
Illustration 17 g01281566 Purging SOS valve with 8T-9208 Purge Probe and tube
11. Purge the SOS valve by pressing the 8T-9208 Purge Probe onto the SOS valve. Purge a minimum of one sample bottle of oil or more if it is required to ensure that all the dead volume of the fluid is purged and the sampling nipple is internally cleaned. Note: If the oil flow is slow at low idle, it may be necessary to have someone accelerate the engine.
Illustration 18 Oil disposal
g01281567
12. Properly dispose of the purged oil.
Illustration 19 Prepared bottle sample
g01281568
13. Remove the prepared sample bottle from the package.
Illustration 20 Flush sample bottle
g01281576
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.
Illustration 21 Flush sample bottle
g01281577
15. Shake the sample bottle vigorously for several seconds.
Illustration 22
g01281578
16. Then empty the oil into a waste oil container.
Illustration 23
g01281579
17. Fill the sample bottle to the "fill range" imprinted on the bottle, but do not fill beyond the fill mark. Note: Do not fill the bottle beyond the fill mark. Filling beyond the fill mark will not allow for proper lab mixing.
Illustration 24
g01281580
18. Remove the sampling probe tube from the bottle lid. Save the knurled probe holder and discard the probe tube.
Illustration 25
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.
Illustration 26
g01281583
20. If it is necessary, clean the outside of the bottle.
Illustration 27 g01281585 Mailing tube with completed label
21. Place the bottle with the completed information label into a 4C-4600 Shipping Container or take the bottle and label to the lab.
Illustration 28
g01281586
22. Wipe any oil off the sample valve.
Illustration 29
g01281588
23. Install the dust cap onto the SOS valve and check that the cap is clean on the inside.
Zero Pressure System Using a Hand Vacuum Pump

Table 4 Parts List Quantity 1 2 1 1 1 Part Number 162-5791 169-8373 1U-5718 4C-4600 1U-7648 1U-8757 Part Description Shop Towel Sample Bottle Group Oil Sampling Vacuum Pump Sample Bottle Shipping Container Tube Cutter Tube
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Note: Typical nonpressurized systems are reservoirs, differentials, final drives, or return lines (drains). The sample location should be near the middle of the reservoir's 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. Although the fluid does not enter the barrel of the pump, a small residue of glycol from the coolant remains in the pump and can contaminate the oil sample. This will indicate a "false positive" coolant leak in the oil system being sampled.
Illustration 30
g01281590
1. Fill out the SOS 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.
Illustration 31 1U-8757 Tube cut to length
g01281591
2. Measure the tubing and then cut new 1U-8757 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 1U-8757 Tube Cutter in order to prevent the tubing from being contaminated.
Illustration 32
g01281593
3. Install tubing into the 1U-5718 Vacuum Pump . The bottle end of the tubing should be approximately 25.4 mm (1 inch) beyond the base of the vacuum pump head.
Illustration 33
g01281594
4. Install a new bottle to be sampled to the vacuum pump.
Illustration 34
g01281595
5. Store the vacuum pump assembly and store 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 the machine off. Make sure that all the systems are in safe positions. Refer to the Operation and Maintenance Manual.
Illustration 35
g01281596
9. Clean the sample location using a clean 162-5791 Lint Free Shop Towel .
Illustration 36
g01281597
10. Keep the sample bottle vertical when taking samples. Pump the vacuum pump handle in order to create a vacuum. Note: If the bottle is tilted, the oil will enter into the suction of the barrel of the vacuum pump. This will cause cross contamination of subsequent samples.
Illustration 37
g01281598
11. Fill the sample bottle half full with system oil. 12. Remove the bottle from the vacuum pump.
Illustration 38
g01281577
13. Install a clean lid and shake the bottle vigorously for several seconds.
Illustration 39
g01281578
14. Empty the bottle into a waste oil container. 15. reinstall the sample bottle to the vacuum pump.
Illustration 40
g01281599
16. Take the oil sample in the same manner. Fill the bottle to the "fill range". Note: Do not fill the bottle beyond the fill mark. This will not allow for proper lab mixing.
Illustration 41
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.
Illustration 42
g01281585
19. Place the bottle with the completed information label into a 4C-4600 Shipping Container or take the bottle and the label to the lab. 20. Remove the tubing from the vacuum pump and discard the tubing in the probe location.
Illustration 43
g01281596
21. Clean any covers, caps, plates, etc that have been removed.
Copyright 1993 - 2010 Caterpillar Inc. Todos los derechos reservados. Red privada para licenciados del SIS.
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Bsqueda del medio - SEBF8482 - Obtaining Oil Sample for Analysis{1302, 1348, ...

Pautas de control de contaminacin

Nmero de medio -SEBF8482-04Fecha de publicacin -24/03/2009Fecha de actu

On-line Particle Counting using SOS Valves

( 1 ) These items can be obtained by contacting Caterpillar Capital Tooling Group. A

proper fitting will be provided at no cost.

170-8500 Pama On-line Particle Counter

Illustration 3 SOS valve dust cover

Illustration 5 210-5530 Quick Disconnect

7. Make sure that the 210-5530 Quick Disconnect is clean.

8. Attach the particle counter supply hose to the SOS valve.

Illustration 7 Particle counter connections

Illustration 8 Remove sampling hoses.

Illustration 9 Replace dust cap

clean on the inside. 14. Properly dispose of any waste oil.

Bottle Sampling Using Oil Valve Probe and SOS Valve

( 1 ) Purging with tube

Illustration 10 SOS mailing label

Illustration 11 Sample bottle package

Illustration 12 Probe holder and probe

9. Remove the dust cover from the SOS valve.

Illustration 18 Oil disposal

12. Properly dispose of the purged oil.

Illustration 19 Prepared bottle sample

13. Remove the prepared sample bottle from the package.

Illustration 20 Flush sample bottle

Illustration 21 Flush sample bottle

15. Shake the sample bottle vigorously for several seconds.

16. Then empty the oil into a waste oil container.

20. If it is necessary, clean the outside of the bottle.

Illustration 27 g01281585 Mailing tube with completed label

22. Wipe any oil off the sample valve.

Zero Pressure System Using a Hand Vacuum Pump

Illustration 31 1U-8757 Tube cut to length

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

Sat Oct 2 15:30:03 EST 2010

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