Caterpillar 170-8500 Analyzer Group Tool Operating Manual - PDF DOWNLOAD

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TOOL OPERATING MANUAL 170-8500 Analyzer Group SMCS: 0784

NEHS0799-01 April 2002

Touch Screen Maps . . . . . . . . . . . . . . . . . . 27 Maintenance . . . . . . . . . . . . . . . . . . . . . . . 35 Service Problems . . . . . . . . . . . . . . . . . . . 35 Changing Printer Paper Roll . . . . . . . . . . . 35 Flow-rate and Hydrodynamic Conditions . 35 Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Flushing Procedure . . . . . . . . . . . . . . . . . 36 Hydraulic Schematic . . . . . . . . . . . . . . . . 37 Software . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Loading 170-8500 Download Software Onto a PC . . . . . . . . . . . . . . . . . . . . . . . . 38 Using the Download Software . . . . . . . . . 40 Warranty/ Service/ Repair. . . . . . . . . . . . . . 42 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . 42

Table of Contents Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 5 Specifications . . . . . . . . . . . . . . . . . . . . . . . 5 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . 6 Serviceable Parts and Accessories . . . . . . . 6 General Information . . . . . . . . . . . . . . . . . . . 6 Sample Fluid . . . . . . . . . . . . . . . . . . . . . . . . 8 Compatibility . . . . . . . . . . . . . . . . . . . . . . . 8 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Temperature. . . . . . . . . . . . . . . . . . . . . . . . 8 Recommended Sampling Temperature . . . 9 Analyzer Connections . . . . . . . . . . . . . . . . 10 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DC Power Cable . . . . . . . . . . . . . . . . . . . 10 Serial Communication . . . . . . . . . . . . . . . 11 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . 11 High-pressure Sampling. . . . . . . . . . . . . . 12 Low-pressure Sampling . . . . . . . . . . . . . . 12 Measurement Procedure . . . . . . . . . . . . . 13 Stopping the Measurement Procedure . . . 13 Shutting Down . . . . . . . . . . . . . . . . . . . . . 13 Screen Descriptions. . . . . . . . . . . . . . . . . . 14 New Sample Screen (1) . . . . . . . . . . . . . . 14 Keyboard Screen (2) . . . . . . . . . . . . . . . . 15 Hydraulic Connection Screen (3) . . . . . . . 15 Main Screen (4) . . . . . . . . . . . . . . . . . . . . 16 Sampling Screen (5) . . . . . . . . . . . . . . . . 17 System Settings Screen (1 of 3) (6) . . . . . 17 System Settings Screen (2 of 3) (7) . . . . . 18 Recalibrate Touch Screen (8) . . . . . . . . . . 18 Display Contrast Settings Screen (9) . . . . 19 System Settings Screen (3 of 3) (10) . . . . 20 Extended Systems Settings Screen (11). . 20 Date Time Settings Screen (12) . . . . . . . . 21 Pump Current Settings Screen (13) . . . . . 21 Profile Setup Screen (14) . . . . . . . . . . . . . 22 Select Profile Data Setup Screen (15). . . . 22 Profile Properties Screen (16). . . . . . . . . . 23 Profile Flow Chart Screen (17) . . . . . . . . . 24 Tolerance Range (18). . . . . . . . . . . . . . . . 25 DQ ISO 11171 (19) . . . . . . . . . . . . . . . . . 26

NOTE: Caterpillar reserves the right to make technical changes for product improvement.

This manual may contain illustrations and photographs, for demonstration purposes, which slightly deviate from the actual product design.

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Safety To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment. Do not operate or work on a machine unless you read and understand the instructions and warnings in this and all other applicable manuals.

Contact CSTG for replacement manuals.

Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations.

Personal injury can result from slips or falls. DO NOT leave tools or components laying around the work area and clean up all spilled fluids immediately.

Most accidents involving product operation, maintenance, and repair occur through failure to observe basic safety rules or operations. An accident can often be avoided by being alert and recognizing potentially hazardous situations before an accident occurs. Any individuals performing product operation, maintenance, or repair should have the necessary training, skills, and tools required to perform the functions properly and safely. The safety information in this manual serves as a basic guide in an attempt to prevent injury or death.

Check hydraulic oil lines, tubes, and hoses carefully.

DO NOT use your bare hand to check for potential leaks.

Always use a board or cardboard when checking for a leak. Escaping hydraulic fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing 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.

Personal injury can result from hydraulic oil pressure or hot oil. DO NOT remove a hydraulic tank filler cap unless it is cool enough to touch with your bare hands. Relieve all pressure in a hydraulic system before any caps, lines, fittings, or related items are disconnected or removed.

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 specifically mentioned by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. Make sure the product or machine will not be damaged or be made unsafe by any operation, lubrication, maintenance, or repair procedures that you choose.

Simultaneously exceeding the maximum fluid temperature and pressure permitted for a sample can cause an explosion, resulting from bursting hoses and/or failed connectors.

If any doubt arises about the correct, safe method of performing any steps of these procedures, DO NOT proceed. Seek out expert assistance from a qualified person.

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Personal injury or death can result from a fire.

Flammable fluid leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up all leaked or spilled flammable fluid immediately.

Sparks or open flames can cause flammable fluid to ignite. DO NOT smoke while working on or near any flammable fluid.

Personal injury can result from improperly handling any hazardous materials; such as corrosive, explosive, poisonous, flammable, or materials.

Make sure you read and understand all directions and hazards described on the labels and material safety data sheet of any product used.

Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal.

MS SD M SSS DDD M SSS M

To prevent personal injury or death, always disconnect the electrical power before opening an electrical control box.

Use extreme caution while maintaining this instrument.

When the particle analyzer is disconnected from the main power supply it is still powered by an internal AC rechargeable battery. DO NOT attempt to repair or rebuild the particle analyzer.

Make sure you use all necessary protective equipment required to do the job. Prevent sparks, flames, and smoking around dangerous substances.

Contact with batteries or electrical components may cause injury or death.

Remove all jewelry and use properly insulated tools when working on batteries or electrical components.

When preparing the particle analyzer for shipment make sure it is free of any flammable liquids.

When sending the unit in for service, it must also be free of all contamination; such as radioactive, poisonous, or bacteriological substances. Close off the input and output fittings by screwing the supplied covers into position.

Use basic precautions when working with electrical components to prevent injury or death. DO NOT touch the metal prongs on electric plugs while connecting or disconnecting electrical components with a power source.

Water and other liquids conduct electric current and can create a short circuit resulting in injury or death.

Keep all liquids away from electrical components and other sources of electricity.

DO NOT create a short circuit between a source of electricity and a liquid by being in contact with both simultaneously.

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Introduction

Specifications Chart A. 170-8500 Analyzer Group Description

Specification

Display

Backlit LCD

User Input

Touch Screen/Keypad

Measurement Capability

Pressurized (High-Pressure) 400-40000 kPa (58-5800 psi).

Non-pressurized (Low-Pressure) 0-400 kPa (0-58 psi)

Flow Rate (adjustable)

Up to 25 mL/minute

Size Range

4 - 30 microns (certified ISO-11171)

On-board Data Storage

1500 tests

The 170-8500 Analyzer Group represents up-to-date technology for effective particle contamination analysis in a portable package.

It is a self-contained system designed for analyzing particle contamination on pressurized and non-pressurized systems.

With the portability of the unit, contamination monitoring can be done in the field.

Test Run Duration

90 seconds

This particle analyzer can be used to check mineral-based fluids, such as hydraulic system oil and/or power steering fluid.

Illustration 1. 170-8500 Portable Particle Analyzer.

This particle analyzer uses red laser sensor technology to count and size particles in the fluid. This sensor technology is the same design as particle analyzers used in S·O·S Fluid Analysis and other Caterpillar factory applications.

Weight

9 kg (20 lbs)

Size

300 x 140 x 300 mm (11.8 x 5.5 x 11.8 in)

Ambient Operating Temperature

5°C to 40°C (40°F to 104°F)

Fluid Sample Temperature

71°C (160°F) (maximum recommended)

Maximum Fluid Viscosity

300 cSt

Power

Internal Battery, 100 - 240 VAC 50/60 Hz, or External Source (12 - 24 VDC)

Relative Humidity

Maximum 70%

Calibration

ISO-11171

Computer Interface

RS-232

CE Compliant

The Caterpillar portable particle analyzer performs a particle analysis in 90 seconds, so concurrent tests can be run one after another by depressing the “Start” key or setting the analyzer to continual automatic testing. The internal battery pack allows the unit to perform 60 tests per battery charge.

The unit includes a self-contained digital display and printer for viewing test results.

The particle analyzer is a complex instrument designed for reliability, simplicity, and ease of operation. The benefits for the unit will be achieved through regular use, particularly as an effective comparator and a trend analysis tool.

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Nomenclature

Serviceable Parts and Accessories Chart C. Serviceable Parts and Accessories Part No. 6V-4144

Description Coupler Assembly

9U-6754

Adapter

131-5047

Power Cable

170-8506

Hose Assembly

184-7679

Paper Roll

188-0639

Hose Assembly

210-5530

S·O·S Coupler Assembly

General Information Remove the Caterpillar portable particle analyzer from the packaging and inspect it for damage. Immediately document and report any instrument damage to the handling agent and the PAMAS GmbH. 1. Retain the original packaging material.

The packaging will be useful if the instrument must be returned for recalibration or service.

Illustration 2. 170-8500 Portable Particle Analyzer

Chart B. 170-8500 Analyzer Group Contents Item

Part No.

Description

1

–—

S40 Portable Particle Analyzer

2

131-5047

3

–—

4

NEHS0799

170-8500 Tool Operating Manual

5

184-7679

Printer Paper (5 rolls)

6

170-8506

Mini-Mess Tube (for high-pressure sampling)

7

188-0639

Plastic Tubing (for low-pressure sampling)

8

–—

Adapter

9

–—

Carrying Case

10

–—

Calibration Documentation and Download Software

NOTE: The calibration table belongs to a specific instrument and should be kept in a safe and secure location.

2. Protect the instrument from abusive handling, improper care, and harsh elements, such as: strong vibration, heavy objects placed on top of the particle analyzer, strong sunlight, high humidity, extreme temperature, and/or explosive or chemical environments.

Power Cord RS-232 Serial Cable

3. Always place the particle analyzer in a dry, clean location. Rest the analyzer on the rear or bottom feet. If needed, the carrying handle can be used to angle the analyzer for clear viewing.

To adjust the handle position, press the handle buttons simultaneously and rotate the handle to the desired position.

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4. When connecting the particle analyzer to an AC power supply, use the supplied AC power cable to connect to power socket (3) of Illustration 4.

10. Wipe off the quick-disconnect connectors and nipples with a 162-5791 Low-Lint Cloth after each use.

NOTICE

12. Run at least two pre-tests prior to running the actual sampling to flush the particle analyzer.

11. Connect the quick disconnects before starting the machine.

Make sure the electrical requirements for the particle analyzer match the supply voltage. This particle analyzer can be equipped by the manufacturer to work with various power supplies.

13. Cap all hoses and fittings when testing is complete.

14. When performing a test, monitor the flow from the discharge port. There should be a steady flow without large air bubbles.

5. Do not leave hoses connected to the analyzer when it is not in use.

15. When performing a high-pressure test, operate the “Pre-Run” cycle one minute for each meter of input hose being used.

6. Do not operate the analyzer without fluid.

Pump damage can occur under this condition.

16. When performing a low-pressure test, operate the “Pre-Run” cycle for at least one additional test cycle prior to the actual test to properly purge the system.

Use an inlet hose of 150 to 200 mm (6 to 8 in) long.

7. Do not actuate the hydraulic system while performing a test.

8. Flush the particle analyzer after each use or daily with 4C-6796 Mineral Spirits.

9. Make sure bottle sample hoses are flushed with mineral spirits before being used.

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Pressure

Sample Fluid Compatibility The 170-8500 Analyzer Group is:

Simultaneously exceeding the maximum fluid temperature and pressure permitted for a sample can cause an explosion, resulting from bursting hoses and/or failed connectors.

• NOT rust free.

• NOT compatible with esters or ketones, such as acetone.

The housing is covered with resistant polyester.

The main materials coming into contact with the sample fluids are:

Make sure the correct pressure is being used to transport the sample fluid to the system.

Use the correct input port.

• Stainless steel 1.0161 (St 37-2) and 1.4571 (V4A)

DO NOT exceed the maximum allowed pressure.

• Aluminum • Borosilicate glass • Polyamide

NOTICE

• NBR

Exceeding the maximum allowed pressure could cause bursting tubes and connections resulting in the particle analyzer being damaged or destroyed.

NOTE: These materials are compatible with most mineral oils.

Special options are available for other media such as SKYDROL or water based solutions on request.

NOTE: If any doubt exists about the compatibility of a sample fluid, contact the service department of PAMAS GmbH.

Temperature The temperature of the sample fluid must not exceed 71°C (160°F). Higher temperatures may cause erroneous results to occur.

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Recommended Sampling Temperature NOTE: The length of the hose being used to take an oil sample can cause the sampled fluid to cool.

Cooling also takes place as the fluid passes through the instrument. Cooled sampled fluid can hinder or stop the instrument from drawing fluid into the analyzer during low-pressure sampling.

Illustration 3. Recommended Sampling Temperature.

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The 170-8500 Portable Particle Analyzer may be powered by an internal (rechargeable) battery, an AC power source, or an external DC power source (4).

Analyzer Connections

The analyzer is shipped from the factory with a specific AC Voltage setting and AC power cord which is connected to port (3).

DC Power Cable A DC power cable can be fabricated using the supplied wiring diagram and parts list with a circular, three-pin connector.

Chart D. DC Power Cable Wiring Parts List

Illustration 4. Particle Analyzer (Left-Side View).

(1) Serial Port. (2) Power Switch (ON/OFF).

(3) AC Power Supply Socket Input. (4) DC Power Socket Input. (5) Rear Feet. (6) Bottom Feet. (7) Printer Cover.

(8) BNC Connector for Maintenance.

Qty.

Part No.

Mfg.

1

T641CPR

Hoffman Industries

Battery clip (+) (red)

1

T641CPB

Hoffman Industries

Battery clip (-) (black)

––1

Power

1

Description

Cable (14 -16 AWG, 2 wire) (1.5 to 2.5 mm), SO Type A3FB Switchcraft

Quick Ground Three-Pin Connector

1 Cut to desired length.

Contact with batteries or electrical components may cause injury or death.

Remove all jewelry and use properly insulated tools when working on batteries or electrical components.

1(+)

Use basic precautions when working with electrical components to prevent injury or death. DO NOT touch the metal prongs on electric plugs while connecting or disconnecting electrical components with a power source.

2 (–)

(N/C) 3 0799-07

Illustration 5. Three Pin Connector (Solder Side).

Water and other liquids conduct electric current and can create a short circuit resulting in injury or death.

Keep all liquids away from electrical components and other sources of electricity.

DO NOT create a short circuit between a source of electricity and a liquid by being in contact with both simultaneously.

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Operation

Chart E. Three Pin Connector Pin

Description

Wire Color

Pin 1

+ (Positive)

Red

Pin 2

– (Negative)

Black

Pin 3

N/C

—

Before connecting the analyzer: • determine if the input for the sample will be high-pressure or low-pressure.

• make sure the machine’s system pressure (input) will not exceed the maximum allowable pressure.

+ (RED)

NOTICE Exceeding the maximum allowed pressure could cause bursting tubes and connections resulting in the particle analyzer being damaged or destroyed.

– (BLACK) 0799-08

Illustration 6. DC Power Cable.

1. Check the output pressure at the sampling test port.

Serial Communication

2. If the pressure is between 0 and 4 bar, 400 kPa (58 psi), use the low-pressure sampling procedure.

The serial communication port of the analyzer is RS-232 compliant. It is set to a baud rate of 57,600 BPS with data being 8-bit, no parity, one stop bit, and no handshake. A straight through cable (1 to 1) is used for standard personal computer (PC) connection.

3. If the pressure is between 4 and 400 bar, 400 and 40,000 kPa (58 and 5,800 psi); use the high-pressure sampling procedure.

Illustration 7. Particle Analyzer (Front Side View).

(1) High-pressure Input/Low-pressure Output.

(2) High-pressure Output/Low-pressure Input.

(3) Keypad. (4) Touch Screen. (5) Handle.

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High-pressure Sampling

Low-pressure Sampling

High-pressure sampling should be used when the pressure is between 4 and 400 bar, 400 and 40,000 kPa (58 and 5,800 psi).

Low-pressure sampling should be used when the pressure is between 0 and 4 bar, 0 and 400 kPa (0 and 58 psi).

1. Open the high-pressure input (HP Input) port (1, Illustration 7) by unscrewing the cover.

1. Open the low-pressure input (LP Input) port (2, Illustration 7) by unscrewing the cover.

2. Install a 188-0639 Low-pressure Hose (clear hose) onto the low-pressure fitting and hand tighten.

2. Install a 170-8506 High-pressure Hose (black hose, with a Mini-Mess female connector on each end) to the high-pressure input (HP Input) port.

3. Place the loose end of the low-pressure hose into a container with the sample fluid.

3. Install and hand tighten a 9U-6794 Adapter onto the high-pressure hose.

4. Open the low-pressure output (LP Output) port (1, Illustration 7) by unscrewing the cover.

4. Connect the high-pressure hose to the quick disconnect fitting or oil sampling port.

5. Remove the Mini-Mess male fitting from the low-pressure output (LP Output) port (1) and install a 1/4 inch male fitting (Parker GE06LR1/4EDA3C).

5. Install a 6V-4144 Quick Disconnect Fitting or a 210-5530 S·O·S Quick Disconnect Fitting to the oil sample test port.

6. Attach a low-pressure hose (clear, short hose) to the high-pressure output (HP Output) port (2, Illustration 7).

NOTE: Use the OEM supplied 1/4 inch adapter or a wrench to remove the original fitting. Refer to Illustration 8 which shows the fitting installed.

7. Place the loose end of the low-pressure hose into a storage container to collect the discharged fluid sample.

6. Attach a low-pressure hose (clear, short hose) to the low-pressure output (LP Output) port.

NOTE: Secure the drain hose to the container with tape, a clip, or some other means.

7. Place the loose end of the low-pressure drain hose into a storage container to collect the discharged fluid sample.

The particle analyzer is now ready to take a high-pressure fluid sample. Refer to the “Measurement Procedure” section for taking a sample.

NOTE: Secure the drain hose to the container with tape, a clip, or some other means.

The particle analyzer in now ready to take a low-pressure fluid sample. Refer to the “Measurement Procedure” section for taking a sample.

Illustration 8. 1/4 Inch Male Fitting Installed Into LP Output Port (1).

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Refer to the Screen Descriptions and Touch Screen Maps sections for more information on these instructions.

5. Repeat the same procedure in Step 4 to include information for service hours, oil temperature, or comments. Make sure the correct button is pressed for each specific data area.

NOTICE

NOTE: Entering a sample temperature does not affect the operation of the unit. This entry is for information purposes only.

DO NOT start the particle analyzer with the input/ output covers in place. This could result in damage to the pump.

6. Press the “Start” box to enter the “Start Screen” which is shown in Diagram 3 in the “Screen Descriptions” section.

Measurement Procedure

• This screen displays the hydraulic connections for the two ports.

The oil testing requires a minimum sample size of 25.0 mL (.85 oz) per test.

• When the “Start” box is pressed the particle analyzer will pump oil through the analyzer and sampling will start after the pre-run is completed.

1. Turn on the analyzer by pressing the power switch (2, Illustration 4).

• The touch screen on the particle analyzer will turn on.

• The Sampling Screen, Diagram 5 in the “Screen Descriptions” section, will begin displaying data at this time.

• The new sample information screen will appear on the display (see Diagram 1 in the “Screen Descriptions”section).

NOTE: After starting the particle analyzer, it can take several seconds before the flow rate stabilizes, this is the reason for the “Pre-Run” cycle time. It can also take time before the measurement result stabilizes due to residual oil still in the particle analyzer from a previous sample. This is the reason for the “Measurements Run” option.

• The top button will indicate the last profile used when the unit was powered down (“Std Low Press” or “Std High Press”).

2. To select a different profile: • press the “Profile” button.

• select a profile from the drop down menu.

• The sample fluid will now be tested for contamination and counted in all 8 channels.

3. To make changes to the system or profiles: • press the ESC (Escape) button.

Stopping the Measurement Procedure

4. To enter the serial number: • press the “Serial #” button.

Press the “Stop” box once to stop the measurement procedure during a continuous sample flow.

• the Keyboard window will appear on the display.

• “Serial #” will be displayed in the upper left-hand corner of the Keyboard window.

Shutting Down

• press the appropriate buttons to match the serial number information.

Clean the system and rinse out all traces of sample material if you do not wish to make further measurements. Refer to the “Flushing Procedure” section for additional information.

• press the “OK” button to enter the serial number information into memory.

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Screen Descriptions New Sample Screen New Sample Screen

This screen appears when the unit is originally turned on and when the New Sample button on the Main Screen is pressed. This screen allows the user to enter comments and information related to the sample using the Keyboard Screen.

Diagram 1: New Sample Screen

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Keyboard Screen Select Menu Items

Press the corresponding button or function key on the keypad.

Enter Values

Use the calculator display, which opens automatically when a numeric value is required.

Enter Characters

Use the keyboard display, which opens automatically when alpha characters are required.

NOTE: If problems occur while entering data with the touch screen keys, recalibrate the response of the touch screen to your personal “touch”.

Correct Values

Use the “Back” key or the calculator display with “CE” or “C”.

Confirm Entries

Press the “OK” button.

Leave a Window without Changes

Press the “ESC” button.

Diagram 2: Keyboard Screen

Hydraulic Connection Screen Hydraulic Connection Screen

This screen appears when a new measurement can be started with the Start button. Use the ESC button to return to the New Sample Screen.

The arrows describe the function of the fittings (inlet/ outlet) in the profile.

Diagram 3: Hydraulic Connection Screen

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Main Screen NIST/AC

Toggle the display of particle numbers and ISO codes for different calibration methods (NIST=ISO11171 and AC=ISO4402).

This button is inactive during a measurement.

New Sample

Perform a standard measurement procedure (profile) or a custom measurement procedure (selected in the Info Screen).

The ESC button or the ESC key exits to the screen sequence structure.

When a measurement is in progress the Start button converts to Stop.

Setup

Access System Setup (F1), Profile Setup (F2), or Calibration Setup (F3).

Press the function key to change to subsequent screens.

This button is inactive during a measurement.

Printer NIST

Access these printer options: Printer AC – to print particle numbers and ISO codes according to ISO4402 calibration Printer NIST – to print particle numbers and ISO codes according to ISO11171 calibration.

Printer None – for no printout.

NOTE: It is possible to display AC, but print NIST results or vice versa.

Change the display by using the NIST/AC display button, because using Printer AC or Printer NIST for the printer will not change the display.

Diagram 4: Main Screen

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Sampling Screen Sampling Screen

Displays the ISO number (top) and the particle counts by size.

NOTE: Sampling can be manually stopped from this screen.

Diagram 5: Sampling Screen

System Settings Screen (1 of 3) System Settings Screen (1 of 3)

Access System Setup (F1), Profile Setup (F2), and Calibration Setup (F3, which is for OEM use only).

Diagram 6: System Settings Screen

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System Settings Screen (2 of 3) System Settings Screen (2 of 3)

Access Recalibrate Touch Screen (F1), Change display contrast (F2), Reset display to default (F3), and Get Administrator Level (F4).

Diagram 7: System Settings Screen (1)

Recalibrate Touch Screen Recalibrate Touch Screen (F1)

Recalibrate the touch screen to the specific habits of the user.

NOTE: Press the inside of the five consecutive rectangles in the same manner as a menu item is selected.

Diagram 8: Recalibrate Touch Screen

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Display Contrast Settings Screen Change Display Contrast (F2)

Increase or decrease the contrast of the display with the arrow up and arrow down keys.

NOTE: If the display is white, decrease contrast until dark lines appear.

If the display is black, increase contrast until white lines appear.

Press F6 to reset the contrast to the factory default.

Use the OK button (or key) to exit the selection box.

The actual setting (in percent of the adjustment range) is located on the lower left side of the screen.

Diagram 9: Display Contrast Settings Screen

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System Settings Screen (3 of 3) System Settings Screen (3 of 3)

Recalibrate the touch screen, change the display contrast, setup the Administrator Level, and return to the User Level.

Recalibrate Touch Screen (F1)

See Diagram 8.

Change Display Contrast (F2)

See Diagram 9.

Reset Display to Default (F3)

Resets the contrast to the factory default.

Reset to User Level (F4)

Resets the system to the user level.

Admin Setup (F5)

Set the system to ADMIN (Administration) mode after the factory password or a user-defined password has been entered.

NOTE: Contact PAMAS or CSTG for information on using passwords.

Diagram 10: System Settings Screen (2)

Extended System Settings Screen Extended System Settings Screen

Only available in the Administrator Level.

NOTE: Contact PAMAS or CSTG for entering this setting.

Diagram 11: Extended System Settings Screen

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Date Time Settings Screen Date Time Settings Screen (F1)

Change the date (mm/dd/yy) and time (hh:mm:ss).

Diagram 12: Date Time Settings Screen (from Diagram 11)

Pump Current Settings Screen Pump Current Settings Screen (F2)

Increase or decrease the power to the pump with the arrow up and arrow down keys and can be done with the pump running.

NOTE: Increase power if the pump stalls.

In the Systems Settings Screen (Diagram 7), press the Help key of the Main Screen.

Press the F6 key to reset the current to the factory default.

Press the OK button (or key) to exit the selection box.

The actual setting (in percent of the adjustment range) is located on the lower left side of the screen.

NOTE: Contact PAMAS or CSTG to make changes to the pump current, because the Pump Current Screen is password protected.

Diagram 13: Pump Current Settings Screen (from Diagram 11)

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Profile Setup Screen Profile Setup Screen

Edit a current profile, create a new profile or delete an existing profile.

NOTE: Contact PAMAS or CSTG to create or delete a profile, because the Profile Setup Screen is password protected.

Edit/View (F1)

Edit the name and/or the settings of the selected profile.

New (F2)

Create a new profile with a name consisting of the creation date and time.

In the consequent selection box, the settings of the selected profile can be copied or a new profile can be created with the default settings.

Delete (F3)

Delete profiles. At least one profile must remain in the list.

Diagram 14: Profile Setup Screen

Select Profile Data Setup Screen Select Profile Data Setup Screen

Create a new profile.

Copy Selected Profile

Copy the data values from the Profile Flow Chart of a pre-existing profile selected by the user.

Set Default Data

Copy default values into the Profile Flow Chart of the new profile.

Diagram 15: Select Profile Data Setup Screen

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Profile Properties Screen Profile Properties Screen

Change the name and settings of a profile.

NOTE: Contact PAMAS or CSTG to change the name or settings of a profile, because the Profile Editor Screen is password protected.

Profile Name (F1)

Change the profile name in a text editor.

NOTE: Changing the name of the profile does not create a new profile.

Two profiles with the same name can contain different settings and can only be distinguished by the position on the list, not by the name.

Measurement Setup (F2)

Change the sequence of the measurement.

Buttons in Save Result

Store information in particle counts (F5) or ISO codes (F4) of each measurement of the profile in the battery backed RAM. Nothing is stored in the memory when None (F6) is selected (by placing a black dot in the circle to the left of the button).

Diagram 16: Profile Properties Screen

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Profile Flow Chart Screen Profile Flow Chart Screen

Graphically shows the sequence of a measurement cycle (profile).

NOTE: Contact PAMAS or CSTG to modify the profile flow chart settings, because the Profile Flow Chart is password protected.

Diagram 17: Profile Flow Chart Screen

Rinse / Pump On Delay and Flush Flow Rate

A During this time the pump is running with the Flush Flow Rate.

If Flush Time is 0 seconds, no flushing will be performed.

If Flush Flow Rate is 0 mL/min the pump will set to Measure Flow Rate after the Flush Time has passed. Flushing is done to remove oil and other contaminants from previous samples from hoses and the particle counter system. Length of hoses/tubing and previous sample should be considered when setting the flush time.

Flow Stabilization Time

B During this time the pump is running with the Measure Flow Rate.

If the Pre-Run Time is set to 0 seconds, no stabilization time before a measurement start will be performed.

Measurement Volume C Volume of the measured sample in 0.1 mL increments.

Measure Repeat Delay D Sets the time between subsequent single measurements.

Select Stop Method

E Enters a selection box with Manual, Number of Repeats, Tolerance Range, and DQ ISO 11171.

Manual - performs endless repetitions of the measure repeat loop until the user interrupts by pressing OK. Number of Repeats – sets the number of repetitions of this loop.

Setting “Number of Repeats” at “2” will perform three measurements of a sample (the original measurement, plus “2” repeat measurements).

Tolerance Range (See Diagram 18).

DQ ISO 11171 (See Diagram 19).

Pump Mode

F Pressing the key toggles between pump on/off (the pump is switched off between the sample repeats) or pump continuous (the pump is running continuously).

Sample Repeat Delay G Sets the delay time between subsequent samples. # Sample Repeats

H Sets the number of repetitions of the sample repeat loop. (0 means no repetitions in a total of 1 sample measured).

Pump Off Delay

I Sets the time the pump is running after the last measurement of a sample in the pump on/off mode or after the last single measurement of the last sample in pump continuous mode.

Pressure Mode

J Pressing the key toggles between low-pressure and high-pressure mode. The displayed mode is the active mode.

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Tolerance Range Screen Tolerance Range Screen

Allows the user to set stabilization criteria for subsequent single measurements. Measurements are repeated until the stabilization criteria is fulfilled or maximum number of measurements is reached.

AC/NIST (F1)

Selects the set of particle counts the stabilization criteria will work with.

# Measurements for Average (F3)

Number of single measurements which must be within the given tolerance range of their mean values.

Max. # of Measurements (F4)

The sample will be finished after Maximum Number of Measurements when the stabilization criteria is not fulfilled.

Particle Size

Maximum allowed percentage deviation of all last number of measurements from their mean value. A 0.0 means that the channel is not found to be in a tolerance range. The criteria is fulfilled when the maximum allowed percentage of deviation is smaller than or equal to 100. *(Max. of last No. of Measurements – Min. of last No. of Measurements)/ Mean of last No. of measurements is true.

Diagram 18: Tolerance Range Screen

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DQ ISO 11171 Screen DQ ISO 11171 Screen

Allows the user to set stabilization criteria for five subsequent single measurements according to ISO 11171, Clause 6 (the D0 criteria will not be used). Measurements are repeated until the stabilization criteria is fulfilled or maximum number of measurements is reached.

AC/NIST (F1)

Selects the set of particle counts the stabilization criteria works with.

Set Default (F2)

Resets the DQ criteria to ISO number of valid DQs to 6.

Max. # of Measurements (F3)

Sample will be finished after Maximum Number of Measurements when the stabilization criteria is not fulfilled.

Number of Valid DQs (F4)

Minimum number of channels which have to fulfill the criteria.

The number of channels with an ISO or l>100>V must be greater or equal with the number of valid DQs.

Particle Size

ISO/ l>100>V /IGNORE: Select whether the last five counts of the channel have to: • fulfill the DQ criteria (ISO) or • fulfill the DQ criteria only if the mean of the counts is ≥ 100.

Otherwise: • the channel is regarded as having fulfilled the criteria (l>100>V) or • the channel is not examined for DQs smaller than the number of the channels that are included in the examination.

Diagram 19: DQ ISO 11171 Screen

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Touch Screen Maps

27

28

29

30

31

32

33

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Flow-rate and Hydrodynamic Conditions

Maintenance

If you cannot see bubbles in the drain tube, this does not guarantee that the flow is bubble free. When using the high-pressure input, hydrodynamic conditions are generally problem free. When in doubt consult the service department of PAMAS GmbH allowing the effects of hydrodynamic conditions can be checked experimentally beforehand.

Use extreme caution while maintaining this instrument.

When the particle analyzer is disconnected from the main power supply it is still powered by an internal AC rechargeable battery. DO NOT attempt to repair or rebuild the particle analyzer.

Check hydraulic oil lines, tubes, and hoses carefully.

DO NOT use your bare hand to check for potential leaks.

Always use a board or cardboard when checking for a leak. Escaping hydraulic fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing 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.

Service Problems If you have problems with the particle analyzer, consult the service department of PAMAS GmbH.

Changing Printer Paper Roll 1. Make sure the printing paper is compatible to thermal printers.

2. Remove the two screws on top of the printer and remove the cover.

Personal injury can result from hydraulic oil pressure or hot oil. DO NOT remove a hydraulic tank filler cap unless it is cool enough to touch with your bare hands. Relieve all pressure in a hydraulic system before any caps, lines, fittings, or related items are disconnected or removed.

3. Make sure the smoother surface of the paper is facing the print head of the printer.

4. Cut the paper of the new roll so it can be easily fed into the rubber roller. The paper is drawn in automatically.

5. Replace the cover and tighten the retaining screws.

Simultaneously exceeding the maximum fluid temperature and pressure permitted for a sample can cause an explosion, resulting from bursting hoses and/or failed connectors.

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5. Place the hose from the (LP Output) port into another clear plastic cup to capture the material flushed from the analyzer.

Faults When counts begin falling or rising, it is best to catch the problem as soon as possible.

6. Turn the particle analyzer ON, run it for eight minutes, and then turn it OFF.

False counts can be caused by water in the system. 0’s and 1’s in all counts can be caused by full or partial blockage in the optic sensor. Small amounts of water will pass through the counting sensor as drops and be counted as larger particles. If the water is substantial, it will turn the fluid into a milky color and cloud the optics of the sensor.

7. Set up the analyzer to do high-pressure (HP) testing.

8. Place the hose from the mineral spirits on the (HP Input) port. Place the hose from the (HP Output) port into a clear plastic cup to capture the fluid.

NOTE: Water will stick in different places in the system and will vary depending on the situation.

9. Turn the particle analyzer ON, run it for an additional eight minutes, and then turn it OFF.

1. Run mineral spirits through the analyzer in the opposite direction to clean the water film from the sensor. The mineral spirits will stabilize when the water is cleared.

10. Inspect the capture cup for water and other contaminants. If the particle analyzer is not clean, repeat the procedure using new filtered mineral spirits. For a dedicated rinse procedure, perform a measurement cycle with fluid and the printer switched off.

2. Make sure the particle analyzer runs long enough to clean the contaminants from the hose/tubing and allow the counts to stabilize.

Flushing Procedure

NOTICE

Portable particle analyzers should be flushed daily. Flushing should be performed after any non-filtered compartment checks, after any tests involving 50W or heavier viscosity oils, and after the last system cleanliness sample of the day. Flushing should also be performed when the operator observes any readings that appear to be abnormally high or low.

Lack of regular flushing of the particle analyzer can result in improper operation.

If the particle analyzer will not be used for an extended period of time, allow the battery to completely discharge and then recharge the battery prior to taking measurements. Allowing the battery to fully discharge can extend the life of the battery and prevent equipment damage.

Use this procedure for flushing the Caterpillar portable particle analyzer.

1. Place 200 to 300 mL (7 to 10 fl oz) of 5 micron filtered 4C-6796 Mineral Spirits or kerosene in a suitable clean container.

NOTE: A clear plastic 355 mL (12 fl oz) cup works well, because it allows inspection of the fluid at the bottom after filling.

2. Set up the analyzer to perform low-pressure (LP) testing.

3. Connect a short, clear plastic hose on the (LP Inlet) port and the other short, clear plastic hose to the (LP Output) port.

4. Place the hose from the (LP Input) port into the mineral spirits.

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Hydraulic Schematic 0799-51

T P

HP in

A

Opening Pressure 5 bar (72.5 psi)

Sensor

LP in

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P

Pump

Software

g. Press “Yes”.

Loading 170-8500 Download Software Onto a PC

h. These (2) two status boxes will appear momentarily before the “Welcome”dialog box appears.

Follow these directions to install the 170-8500 Download Software from the 3.5 inch diskette.

1. Close any applications that are running. a. Close any connections to mainframe computers or networks. b. Windows should be the only program running. c. If running Windows NT, administrative rights are required for the computer system to install the software.

2. Begin loading the 170-8500 Download software onto a computer. a. Insert the 170-8500 Download software diskette into Drive “A”.

3. Review each dialog box that appears and make the appropriate selections.

b. Press the “Start” button on the Task Bar. c. Select “Run” to display the Run dialog box.

a. The “Welcome” dialog box will appear first. Read the message and press “Next >” when ready to proceed.

d. In the text box type: A:\SETUPEX.EXE. e. Press “OK”. f. This status box will appear:

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b. The “Choose Destination Location” dialog box will appear next. If the destination is okay, press “Next >” when ready to proceed.

d. The “Start Copying Files” dialog box will appear (Windows NT). If the settings are okay, press “Next >” when ready to proceed.

c. The “Select Program Folder” dialog box will appear. If the destination is okay, press “Next >” when ready to proceed.

e. The “Setup Complete” dialog box will appear to indicate the software has been loaded onto the computer. Press finish to complete the setup.

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4. Follow these directions to complete the setup of the 170-8500 Download software.

Using the Download Software These instructions describe how to use the 170-8500 Download software from the Program Menu.

a. The first window to appear will include the DL_S40 icon. Use the computer mouse to double click the icon.

1. Launch the 170-8500 Download software. a. Select Start, Programs, and PAMAS Download S40 to launch the 170-8500 Download software.

b. This error message will be displayed, because this is the first use of the software. Press the “OK” button to continue.

b. The S40 Download Program window will appear on the screen, providing the user with two options – “System” and “S40”.

c. The “S40 Download Program” icon window will appear next. This program has now been added to the “Program” menu and it is ready to be used.

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3. Select “S40” from the function bar

2. Select “System” from the function bar.

a. A user can choose to download profile data, download measure data, or delete measured data.

a. A user can select “Serial Port” to review or change the serial port settings in the “Serial Port Settings” window.

b. These functions may be selected by using the pull down menu or by clicking on the function icon.

b. Select “Exit” to close the software.

c. The profiles and results are downloaded as text files (.txt). d. The user can name the files before they are saved to the computer’s hard drive. e. The text files can then be displayed and printed using software capable of handling text files.

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Warranty/Service/Repair

Calibration It is recommended the 170-8500 Particle Analyzer be calibrated once a year using the ISO-11171: 1999 standard. The following PAMAS facilities can be contacted in regards to calibration of this instrument:

When preparing the particle analyzer for shipment make sure it is free of any flammable liquids.

When sending the unit in for service, it must also be free of all contamination; such as radioactive, poisonous, or bacteriological substances. Close off the input and input fittings by screwing the supplied covers into position.

C & J International Inc. 6721 E. 106th St. Tulsa, OK 74133, USA Tel: 0 01 91 82 99 40 19 Fax: 0 01 91 82 99 74 10 Sintech Scientific (SEA) Pet Ltd. No. 196 Pandan Loop # 02-18 Pantech Industrial Complex Singapore 128384 Tel: 0 06 57 79 00 07 Fax: 0 06 58 72 23 92

Caterpillar warrants this instrument to be free of defects in parts and workmanship for one year from date of shipment. If it should become necessary to return the instrument for service during or beyond the warranty period, contact the particle analyzer manufacturer.

PAMAS Partikelmess- und Analysesysteme GmbH Dieselstraße 10 D-71277 Rutesheim Postfach 162 Germany Tel: + 49 7152 9 96 30 Fax: + 49 7152 5 48 62

Units in North and South America that are in need of service, repair, or calibration can be sent with an explanation to PAMAS-USA. PAMAS-USA 6721 East 106th Street Tulsa, OK 74133 USA

The Calibration Recommendations chart gives recommendations on when checks and calibrations should be done.

Chart F. Calibration Recommendations

Units in Europe and Asia that are in need of service, repair, or calibration can be sent with an explanation to PAMAS-GmbH. PAMAS-GmbH Dieselstrasse 10 D-71277 Rutesheim Postfach 1162 Germany

Sizing

Full

Calibration

Calibration

Check

Only1

Annual ISO-11171 Calibration Suspect Calibration Shift Optics Repaired or Adjusted Sensor Repaired or Adjusted Volume Measurement Repaired

X X X X X

1 A sizing calibration defines the relationship

between a detector’s change in millivolts and the size of the particles in an oil sample.

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Notes

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For information on service tools or shop supplies, contact Caterpillar Service Technology Group on: Caterpillar Service Technology 501 S.W. Jefferson Ave. Peoria, Illinois 61630-2184 1-800-542-8665 (USA) 1-800-541-8665 (Illinois) 1-800-523-8665 (Canada) 404435 (Telex) 1-309-675-6618 (Fax) CSTG_Hotline@cat.com (E-mail) or Caterpillar Service Technology Caterpillar Overseas S.A. P. O. Box 6000 1211 Geneva 6 Switzerland +41 (79) 217 27 45 (Geneva Phone) +41 (22) 849 49 29 (Geneva Fax) 36CSTG (COSA E-Mail Address)

©2002 Caterpillar Inc. All Rights Reserved

NEHS0799-01 Printed in U.S.A.