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Contamination Control Guidelines

Cleaning Fluid-Carrying Hose and Tube Assemblies In Shop and Field Applications{0645, 5050}
Media Number -SEBF8485-05 Publication Date -2012/10/19 Date Updated -2012/10/19
Caterpillar: Confidential Yellow
i05150850
Cleaning Fluid-Carrying Hose and Tube Assemblies In Shop and Field

Applications{0645, 5050}
SMCS - 0645; 5050
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
Mini Hydraulic Excavator: All
Motor Grader: All
Multi Terrain Loader: All B Series
Off-Highway Truck/Tractor: All
Paving Compactor: All
Pipelayer: All
Road Reclaimer/Soil Stabilizer: All
Skid Steer Loader: All
Soil Compactor: All
Track Feller Buncher: Caterpillar
Track-Type Loader: All
Track-Type Skidder: All
Track-Type Tractor: All
Wheel Dozer: All
Wheel Feller Buncher: Caterpillar Branded
Wheel Loader: All
Wheel Skidder: All
Wheel Tractor-Scraper: All bishosp
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Introduction
Table 1
Revision Summary of changes in SEBF8485
Updated Introduction.
05 Added Canceled Replaced Part Numbers statement.
Updated Safety Information
© 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 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 will describe the operation and safety principles required for cleaning hydraulic hoses and tubes, using
the Caterpillar hose cleaning group.
This guideline will also describe the cleaning procedures of hydraulic system lines and tubes following a catastrophic
failure.
This hose cleaner group is CE certified.
The three basic components required are:

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1. A specially designed pneumatic launcher, which provides the pressure energy to force the projectile through the
fluid carrier.
2. The nozzles that allow the unit to be utilized on varying sizes and types of hose, tube, pipe, and coupling
configurations.
3. The projectile, which cleans the inside surface of the hose, tube, or pipe.
Note: Throughout this publication the word "hose" will be used to identify all types of fluid carriers pipe, tubing and
hose.
To provide cleaning, the projectile is launched through a fluid carrier by a compressed gas. This gas (air) is delivered
from the launcher through the nozzle. As the projectile travels the length of the hose, a cleaning force is applied to the
inside walls. This force is applied to the wall of the passage due to the compressed state of the projectile (normal
compression is 20 percent). The expanding gas provides forward movement.
The contamination-absorption effectiveness of the foam projectile has been developed from extensive research and
testing. The structure of the projectile must have the correct density, strength, and flexibility. These properties are
critical to prevent the projectile from breaking up due to the applied cleaning and propelling forces.
The following benefits can be achieved using the 233-7191 Hose Cleaner Group or the 156-0058 Hose Cleaner Group .
• Reduce the risk of component failure due to system contamination.
• Use of the cleaners may extend component life.
• Reduced initial flushing requirements and time for the system.
• On-site hose cleaning.
• The ability to diagnose the internal condition of the hose.
• Increase the filter element service life.
• Reduced maintenance costs.
Utilizing the hose cleaner groups will provide a faster and more effective method of cleaning the machines fluid-
carrying hoses. This unit will lead to increased servicing efficiency, resulting in increased productivity.
After the catastrophic failure of a component, extensive measures must be taken to restore the system to an operable
condition. Complete system cleaning is an important part of any repair to reduce oil contaminants. Additional
component cleaning or replacement may be necessary as well as measuring particle counts and filtering the oil.
Abrasive dirt, metal particles, and other contaminants must always be removed from the system prior to operation.
Contamination that is not removed can cause future inefficiencies and failures.
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,
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and tools to perform these functions properly. Caterpillar: Confidential Yellow
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 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.
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.
NOTICE
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, NENG2500, "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
Table 2
References
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Media Number Title Caterpillar: Confidential Yellow
NEHS0643 Using the 233-7191, 233-7192, 233-7193 and 265-4959 Hose Cleaning Groups
NEEG2955 Hose Cleaner Projectile Size Chart for Tube and Pipe
NENG2500 Dealer Service Tool Catalog
Tooling and Equipment

Table 3
Required Tools
Tool Part Number Parts Description Qty
233-7191
A Hose Cleaner Group 1
233-7192
156-0058
B CRB Hose Cleaner Group 1
233-7193
Listed next are basic safety precautions. Read and understand these basic precautions and operating instructions
contained in this guideline before installing or operating this product.
To avoid eye injury consult shop manual before disconnecting lines,

wear safety goggles. Fluid is under high pressure.
To avoid personal injury, always wear eye and face protection when
using pressurized air.
• Make sure that the faceplate is locked into the closed position before depressing the trigger. Make sure that the
air supply is correctly attached and is at the correct pressure.
• Make sure that the unit is pointing in a safe direction before operating.
• Do not operate the hose cleaner group when aimed at another person.
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• Make sure the end of the hose, tube, or pipe is contained within a suitable projectile catcher, which must be
secured in a safe location. A secured projectile catcher will avoid injury from the contaminants and projectile
when ejected from the hose or tube.
• Always turn off the air supply before disconnecting the unit.
• Use a protective mask for respiratory protection, as required.
• Use protective clothing, as required.
Hydraulic Principles
The theory of hydraulic is based on two principles:
1. The liquids are incompressible even when subjected to high pressures.
2. Pressure applied to an enclosed liquid is transmitted with undiminished force in every direction.
These two engineering principles are the concepts behind one of the simplest methods of transmitting power. Hydraulic
machinery has expanded rapidly into the manufacturing and mining industries. The rapid expansion occurred mainly
because of the simplicity of the components required. Also, the liquid can be carried through a pipe or hose to operate
mechanisms at a distance from the main source of power, allowing great flexibility in the positioning of the working
unit.
Light mineral oils or castor-based oils are now used as the preferred liquid because of the low freezing point and the
lubricating and sealing properties. The type and quality of the fluid used in a hydraulic system is important. The fluid
must:
• Transmit the fluid energy efficiently to the work elements on the machine.
• Lubricate the moving surfaces to reduce friction and wear in the hydraulic component.
• Seal the operating clearances between the mating surfaces to improve operating efficiency.
• Cool the system components to maintain the optimum operating temperatures at all times.
Effects of Contamination
A recent study found that 75 to 80 percent of hydraulic system failures were caused by fluid contamination.
Contamination can be the downfall of even the best-designed hydraulic systems. Most component and system
malfunctions are caused by solid contamination particles, ranging in size from 5 to 30 microns. Such particles can shut
down expensive machinery. Contamination interferes with the fluid energy transmissions and causes:
• Increased risk of component failure, and machine downtime.
• Increased component wear, and reduced machine operating efficiency.
• Valve spools to stick, causing erratic machine operation or solenoid burn out.
• Pressure sensing passages and valve control orifices to block, resulting in the machines pressure control being bishosp
unpredictable. Caterpillar: Confidential Yellow
• Obstruction of the heat transfer mechanism, thereby hindering the fluid cooling ability, and increasing the
machine maintenance costs.
Now, there is no chemical additive that either keeps dirt out of, or removes dirt from, hydraulic fluid. Keeping dirt out
of a system is the function of good maintenance and repair practices. Clean fluid is the only way to achieve optimum
performance from a machine.
Research has shown that reducing the solid particle count in fluids will make a major contribution to longer component
life and improve functional reliability of the system.
Operation
Initial Set-up
If the hose cleaner is not properly set up using the correct air pressure, nozzle, and projectile, the hose cleaning
procedure will be inefficient and the internal hose contamination will not be removed. The following sections provide
the necessary set-up information that must be completed before operating the unit. Take the following items into
consideration before operating the unit.
• Air pressure and air source
• Projectile selection
• Nozzle selection
• Projectile path
Air Pressure and Air Source
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Air source connection
Connect the unit to a 600 kPa (90 psi) to 800 kPa (115 psi) air source.
In most applications, the compressed gas supply to the hose cleaner group is supplied from the shop air supply.
However, a standard 8 cfm to 15 cfm air compressor and receiver can be used, or a regulated bottle of inert gas (dry
nitrogen or carbon dioxide) having a minimum recommended operating gas pressure for projectile launching of 620
kPa (90 psi). Select a propulsion gas compatible with the system being cleaned. Regulated gas pressure must not
exceed 1034 kPa (150 psi). The hose cleaner group is supplied with an 8 mm (0.315 inch) inside diameter male
coupling half.
Note: The airline and fittings connecting the air source to the unit must not have less than 8 mm (0.315 inch) inside
diameter. A 12 mm (0.472 inch) inside diameter supply hose is recommended.
Projectile Selection and Nozzle Insertion

Refer to the Tool Operating Manual, NEHS0643 for projectile and nozzle selection.
Hose cleaning applications are various, but bulk hose and hose assemblies are most common. Consider the cleaning
requirement of the projectile for the particular application. Possible applications are:
• Removal of large contamination particle when bulk hose cleaning.
• Removal of residual oil contained within all hoses.
• Removal of fine contamination particles after hose assembly.
• Flushing contaminated lines on a machine where a catastrophic failure has occurred.
• Applications where the projectile must go through reductions created by hose end couplings. This application is
common when cleaning hose and tube assemblies while still mounted on a machine.
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Nozzle insertion
1. Open the faceplate of the unit by pressing the safety bar and release mechanism with the thumb of the hand
holding the unit.
2. Drop the faceplate down.
3. Select a suitable nozzle for the application and insert the nozzle into the faceplate. For nozzle sizes less than 38
mm (1.5 inch), the 130-6062 Adapter Ring should be fitted prior to insertion of the nozzle.
Load Projectile into Unit

1. Select the type and size of projectile from the Tool Operating Manual, NEHS0643 or from NEEG2955.
2. Load the projectile into the nozzle.
Note: If the selected projectile is too large, the projectile will not leave the nozzle. If the projectile is too small, the
projectile will not effectively clean the fluid passage.
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Projectile insertion
Projectile Usage
Tests have indicated that a projectile should be fired from both ends of the hose or tube. After the assembly connectors
are attached, further projectiles should be utilized to make sure any introduced contamination during manufacturing
(lubricants, rubber, etc.) is removed. The tests also demonstrated that projectiles remove larger size particles and
absorb fluids, while coupling projectiles remove the smaller particles and go through coupling or fitting reductions.
Research has defined four standard hose cleaning procedures for the hydraulics industry. To obtain the desired
cleanliness levels, Refer to the following procedures in Table 4.
Table 4
Example Minimum Projectile Usage
Use two projectiles through the bulk hose. Fire one projectile from
Bulk Cut Hose
each end. (one each way)
All hose assemblies. Includes hose end fittings Use two projectiles through the bulk hose (one each way) and one
on one or both ends of hose assembly. projectile through the assembly fired from the smallest end.
Projectile Path
To clean a system successfully, be sure to identify beforehand, all intersections, changes in bore size and obstructions
due to control valves, pumps and monitoring equipment.
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Run length does not matter (with a suitable air supply volume), as a projectile may travel up to 914 m (3000 ft). The
number of bends or coils in the hydraulic system is not critical. Even lines crossing at right angles are not a problem.
However, the hose must have both ends open to the atmosphere at the same time.
Consider the projectile path in a complex system. The projectile may travel through partially restricted hoses,
connectors, and open ball valves. In some installations, however, the system will need broken into separate sections.
Also, any branch hose coming from the main line must be capped.
The illustration below provides a few examples of path selection.
Select best path for projectile
If more than one path is available, cap one of the paths.
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Multi-path hose
When cleaning a hose or tube configuration with multiple paths, as shown in Illustration 6, clean the closest path to the
projectile starting point first. All openings down stream must be capped to allow only one path for the projectile to
follow. For example, plug all hoses to the right of path #1 for proper projectile direction and cleaning. Next, plug 1 and
3 for path 2 cleaning, and finally plug 1 and 2 for path 3 cleaning.
Operating Procedure
Before operating the hose cleaner group, check to make sure all the necessary safety precautions have been taken and
always observe all safety instructions.
1. Select the proper nozzle and projectile for the hose to be cleaned. Refer to Tool Operating Manual, NEHS0643.
Latching faceplate
2. Close the faceplate and make sure the safety bar and release mechanism locks the faceplate into position. Refer
to Illustration 7.
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Projectile catcher
3. Make sure that the exit end of the hose is correctly contained in the projectile catcher (or catcher bag) and the
catcher is secure. Refer to Illustration 8.
4. A 130-6422 Job Bag should be used while cleaning smaller hose assemblies in the field. Since some of these
assemblies will be disconnected, but not removed from machinery, the usage of 130-6422 Job Bag is
recommended.
Note: Recover the used projectile so the projectile can be analyzed to determine the condition and cleanliness of
the hose.
Illustration 9 g01244657 bishosp

Firing projectile
5. Place the nozzle firmly against the hose, making a firm seal. Obtain an airtight seal. In the event of a nozzle does
not fit correctly, try reducing the nozzle size. Refer to Illustration 9.
6. Depress the trigger, making sure that the trigger remains depressed until the projectile emerges from the other
end of the hose. If the trigger is released prior to the projectile emerging, the projectile will remain in the hose
until the trigger is pressed again.
7. Based on cleaning level desired, repeat the procedure (with a new projectile) from the opposite end of the hose.
Projectile Storage and Disposal

New projectiles should be stored in covered boxes or contaminant free cabinets to reduce exposure to direct sunlight or
florescent light.
Note: Exposure to direct sunlight or florescent light will cause discoloration and deterioration of the projectiles over
time. Leave projectiles in protective shipping bags.
Do not reuse projectiles. Projectiles are discarded after one use only. Used projectiles must be disposed of properly.
Troubleshooting
Table 5
Troubleshooting
Problem Solution
To clear a projectile, operate the projectile launcher from the other end of
the pipe or hose without using a projectile.
Check hose, tube, or pipe for leaks, holes, or breakages.
Check for line restriction in tube or hose. For example, inside diameter
Projectile remains lodged in the hose going from
tube, pipe, or assembly 10 mm (0.4 inch.)
Check projectiles for tear marks.
Check air pressure setting of the air source.
Check condition of hose and fittings from air source.
Determine if a smaller projectile should be used.
Try smaller projectile.
Check air pressure. Compressor unit may not have built up sufficient
pressure.
Projectile will not enter hose, tube, pipe,
Make sure quick-release coupling is correct size.
or assembly
8 mm (0.3 inch) minimum is required.
Operate unit from other end of hose.
Make sure that tube entry is not restricted.
Leaking air at hose, tube, pipe, or Hold the unit firmly against the hose, tube, pipe, or assembly, to makebishosp
assembly entry. sure that proper seal is achieved. Caterpillar: Confidential Yellow
Cleaning System after Catastrophic Failure

1. Manually clean the system thoroughly after any catastrophic failure. Metal particles, dirt, and other contaminants
are dispersed by the oil and can be found throughout the system. Complete system disassembly and cleaning will
be required in the advent of any catastrophic component failure. The amount of system disassembly will depend
on the extent of the contamination throughout the hydraulic system.
2. All hydraulic components within the contaminated system should be removed, disassembled, and thoroughly
cleaned.
3. Use a Hose Cleaner Group to assist in the system cleaning. At a minimum, all hoses attached to the failed
component must be cleaned with the hose cleaner group. The hose cleaner group eliminates a large portion of the
labor when removing all hoses and tubes from the vehicle for cleaning. These fluid-carrying devices can be
cleaned while still attached to the vehicle.
4. Normal procedures when using the hose cleaner group in this type of application are:
a. Disconnect both ends of the hose or tube from the vehicle components.
b. Determine the smallest orifice size throughout the hose or tube assembly. Size the required projectile
accordingly.
5. Select the proper nozzle for the identified projectile.
6. Blow the projectile through the hose or tube assembly. The projectiles will travel around corners, and through
"T's" when the previous documented instructions are followed.
7. Direct the discharged oil, contaminants, and projectile into a waste container at the other end.
8. Continue the projectile cleaning procedure until the hose or tube is relatively clean.
After using the hose cleaner group, immediately cap or plug all open hose or tubes or reconnect to the clean system
component.
The hose cleaner may not completely clean all contaminants from the fluid carrier. Caterpillar recommends kidney
looping the system oil to remove the remaining contamination from the circuit. This filtering operation must be
completed prior to returning the vehicle to service.
Copyright 1993 - 2013 Caterpillar Inc.

All Rights Reserved.
Private Network For SIS Licensees.
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Media Search - SEBF8485 - Cleaning Fluid-Carrying Hose and Tube Assemblies In Shop and Field Appli...

Contamination Control Guidelines

Cleaning Fluid-Carrying Hose and Tube Assemblies In Shop and Field

Agricultural Tractor: All

• Cat Dealer Technical Communicator

• Global Dealer Solution Network

• Cat Technical Representative

Canceled Part Numbers and Replaced Part Numbers

This hose cleaner group is CE certified.

The three basic components required are:

• Reduce the risk of component failure due to system contamination.

• Use of the cleaners may extend component life.

• Reduced initial flushing requirements and time for the system.

• On-site hose cleaning.

• The ability to diagnose the internal condition of the hose.

• Increase the filter element service life.

• Reduced maintenance costs.

Important Safety Information

The following is the meaning of this safety alert symbol:

• Your safety is involved.

Sudden movement of the machine or release of oil under pressure can

To prevent possible injury, perform the procedure that follows before

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all fluids according to local regulations and mandates.

Tooling and Equipment

To avoid eye injury consult shop manual before disconnecting lines,

• Use a protective mask for respiratory protection, as required.

• Use protective clothing, as required.

1. The liquids are incompressible even when subjected to high pressures.

• Increased risk of component failure, and machine downtime.

• Increased component wear, and reduced machine operating efficiency.

• Air pressure and air source

Air Pressure and Air Source

Air source connection

Projectile Selection and Nozzle Insertion

• Removal of large contamination particle when bulk hose cleaning.

• Removal of residual oil contained within all hoses.

• Removal of fine contamination particles after hose assembly.

• Flushing contaminated lines on a machine where a catastrophic failure has occurred.

2. Drop the faceplate down.

Load Projectile into Unit

2. Load the projectile into the nozzle.

The illustration below provides a few examples of path selection.

Select best path for projectile

If more than one path is available, cap one of the paths.

Illustration 9 g01244657 bishosp

Projectile Storage and Disposal

Cleaning System after Catastrophic Failure

5. Select the proper nozzle for the identified projectile.

Copyright 1993 - 2013 Caterpillar Inc.

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