Using the 233-7191, 233-7192, 233-7193 and 265-4959 hose cleaning groups{5050} Caterpillar

Important safety Information

Think Safety

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

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

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

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The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

AVSpare 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 recommended by AVSpare is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance, or repair procedures that you choose.

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

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When replacement parts are required for this product, AVSpare recommends using AVSpare replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material. Failure to heed this warning can lead to premature failures, product damage, personal injury, or death.

Safety

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To avoid personal injury or death, carefully read and understand all instructions before attempting to operate any equipment or tools. 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 Dealer Service Tools for replacement manuals. Proper care is your responsibility. Always follow all State and Federal health and safety laws and/or local regulations. To prevent possible damage to your hearing, always wear ear protection when using this tool and/or working around noise generating tools. To avoid eye injury, always wear protective glasses or face shield. Make sure no one can be injured by flying objects or debris when using tools or working on a component. Clean up all leaked or spilled fluids immediately. Oil, fuel, or cleaning fluid leaked or spilled onto any hot surfaces or electrical components can cause a fire, resulting in personal injury or death. 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. Personal injuries can occur as a result of using pressurized air. Maximum air pressure at the nozzle must be below 205 kPa (30 psi) for cleaning purposes. Wear protective clothing, protective glasses, and a protective face shield when using pressure air.

Introduction

This Tool Operating Manual will describe the operation and safety principles required for cleaning hydraulic hoses and tubes, using the 233-7191, 233-7192, 233-7193, and 265-4959 Hose Cleaning Groups.

All hose cleaning groups are European Union Compliant.

The three basic components required are:

1. A specially-designed pneumatic launcher, which provides the pressure energy to the projectile;

2. The nozzles that allow the unit to be used on varying sizes and types of hose, tube, pipe, and coupling configurations; and

3. The projectiles, which clean the inside surface of the hose, tube, or pipe.

NOTE: Throughout this manual the word hose will be used to identify all types of fluid conductors (pipe, tubing, hose, etc.).

The hose cleaning groups are designed for general purpose hose and tube cleaning, for new hose assemblies, or contaminated hoses on existing machines.

To provide cleaning, the projectile is launched into the hose by compressed air or nitrogen, delivered from the hose cleaning gun through the nozzle. As the projectile travels the length of the hose, force is applied to the inside walls. The cleaning force applied to the wall of the passage is due to the expansion of the compressed projectile (normal compression is 20 percent), while the forward movement is provided by the air pressure.

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 a hose cleaning group:

* Reduced risk of component failure.

* Reduced component wear.

* Reduced initial flushing requirements and time.

* On-site hose cleaning.

* Ability to diagnose the internal condition of the hose.

* Increased filter element service life.

* Reduced maintenance costs.

Using a hose cleaning group is the fastest and most effective method of cleaning the machine's hydraulic hoses. These units will lead to increased servicing efficiency, resulting in increased productivity.

233-7191 Hose Cleaning Group (Economy)

233-7191 Hose Cleaning Group (Economy)

The 233-7191 Hose Cleaning group is used to remove waste and contaminants from internal surfaces of tubes, lines, and hoses at the job site (works great in field service trucks).

This hose cleaning group is a less expensive alternative to other hose cleaning groups because of its limited size capabilities. This hose cleaning group has nozzle sizes 4 mm (.16 in) through 32 mm (1.25 in) or -04 through -20.

The 233-7191 Hose Cleaning Group has an operating pressure of 585 to 965 kPa (85 to 140 psi) and should be used with a 13 mm (.5 in) inside diameter air hose. An in-line air filter and regulator are also recommended.

233-7192 Hose Cleaning Group (Field Service)

233-7192 Hose Cleaning Group (Field Service)

The 233-7192 Hose Cleaning Group is designed for dealers wanting a portable system for servicing vehicles or mobile hose service trucks.

This hose cleaning group has nozzle sizes 4 mm (.16 in) through 32 mm (1.25 in) or -04 through -20. Optional nozzles are available for 38 mm (1.50 in) and 50 mm (2.0 in) or -24 and -32 hoses.

This hose cleaning group has an operating pressure of 585 to 760 kPa (85 to 110 psi) and should be used with a 13 mm (.5 in) inside diameter air hose. An in-line air filter and regulator are also recommended.

233-7193 Hose Cleaning Group (Dealer Shop)

233-7193 Hose Cleaning Group (Dealer Shop)

The 233-7193 Hose Cleaning Group is designed specifically for dealer and customer hose assembly areas.

This hose cleaning group includes a stand for the hose cleaning gun, a nozzle rack, and nozzle sizes 4 mm (.16 in) through 50 mm (2.0 in) or -4 through -32.

This hose cleaning group has an operating pressure of 585 to 760 kPa (85 to 110 psi). A 13 mm (.5 in) inside diameter air hose is recommended. An in-line air filter and regulator are also recommended.

265-4959 Hose Cleaning Group (Large Diameter Hose)

265-4959 Hose Cleaning Group (Large Diameter Hose)

The 265-4959 Hose Cleaning Group is designed for removing contaminants from large diameter hoses and is specifically designed for dealer and customer hose assembly areas.

This hose cleaning group includes a special hose cleaning gun, universal nozzle, quick disconnect, cleaning gun stand, and two adapters that allow the use of smaller nozzles.

The universal nozzle is designed for 63 mm (2.50 in) through 89 mm (3.50 in) or -40, -48, and -56 Hose.

This hose cleaning group has an operating pressure of 585 to 760 kPa (85 to 110 psi). A 13 mm (.5 in) inside diameter air hose should be used. An in-line air filter and regulator are recommended.

Effects Of Contamination

Studies have shown that 75 to 80 percent of hydraulic system failures were caused by fluid contamination, which can be the downfall of even the best designed hydraulic systems. The majority of component and system malfunctions are caused by solid contamination particles, ranging in size from 5 to 20 microns. Such particles can shut down expensive machinery.

The major problem with contamination is that it interferes with the fluid energy transmissions, and causes:

* Increased risk of component failure, and machine downtime.

* Increased component wear, and reduced machine operating efficiency.

* Directional control valve spools stick, causing erratic machine operation or solenoid burn out.

* Pressure sensing passages and valve control orifices block, resulting in the machine's pressure control being unpredictable.

* Obstruction of the heat transfer mechanism, thereby hindering the fluid's cooling ability, and increasing the machine's maintenance costs.

Tests have proven that cutting a hose with a steel-cutting disk followed by compressed air flushing, introduces 800 to 1200 particles of contamination with a weight of 30 to 50 milligrams in a 1 m (3.3 ft) length of hose. With abrasive cutting wheels, the hose's contamination level can increase up to 500 percent.

At present, there is no chemical additive which either keeps dirt out of, or removes dirt from, hydraulic fluid. Keeping dirt out of a system is the function of good maintenance practices. Clean fluid is the only way to achieve optimum performance from a hydraulic machine.

Research has shown that reducing the solid particle count in hydraulic fluid will make a major contribution to longer component life and improved functional reliability of the hydraulic system.

Air Source

Connect the 233-7191 Hose Cleaning Gun to a 585 to 965 (85 to 140 psi) air source.

Connect the 233-7192 or 233-7193 Hose Cleaning Gun to a 585 to 760 (85 to 110 psi) air source.

Connect the 265-4959 Hose Cleaning Gun to a 585 to 760 (85 to 110 psi) air source.

In most applications, the compressed air supply to the hose cleaning gun is supplied from a shop air supply. However, a standard 8 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 585 kPa (85 psi). You must select a propulsion gas which is compatible with the system being cleaned. Its pressure must not exceed 965 kPa (140 psi) for the 233-7191 and 760 kPa (110 psi) for the 233-7192, 233-7193, and 265-4959 groups.

NOTE: The air line and fittings connecting the air source to the unit must have a minimum 13 mm (.5 in) inside diameter.

Operating Procedure

233-7191 Hose Cleaning Group

233-7189 Hose Cleaning Gun

1. Attach air supply hose to gun.

Attach Air Supply Hose To Gun

2. Unscrew the locking ring.

Unscrew The Locking Ring

3. Select a suitable nozzle for the application and insert it into the locking ring.

Insert Nozzle Into Locking Ring

4. Selecting the size of projectile from the Hose Cleaning Projectiles Chart in this manual or the NEEG2955 Projectile Sizing Chart provided with each hose cleaning group. Load the projectile into the nozzle.

Load Projectile Into Nozzle

5. Screw the locking ring onto the gun.

Screw Locking Ring Onto Gun

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Containing the projectile that comes out of the hose is important to prevent personal injury. Projectiles and contamination, expelled during the cleaning process, can cause personal injury.

6. Make sure the exit end of the hose is inside a container that will prevent it from being forcefully ejected, causing possible injury.

Use A Container To Catch Projectile

NOTE: It is important to recover the used projectile, so it can be analyzed to determine the condition and cleanliness of the hose.

7. Place the nozzle firmly against the end of the hose, making a tight seal. It is important to obtain an air tight seal. In the event a nozzle does not fit correctly, try reducing the nozzle size.

Place Nozzle Firmly Against End Of Hose

8. Depress the trigger, making sure it remains depressed until the projectile emerges from the other end of the hose. If the trigger is released prior to the projectile emerging, it will remain in the hose until the trigger is depressed again.

9. A projectile should be fired from both ends of the hose or tube. Repeat until the necessary cleanliness is achieved. After connectors are attached, a projectile should then be fired through the assembly to make sure that any possible contamination introduced during assembly (lubricants, rubber, etc.) is removed. Repeat until the necessary cleanliness is achieved.

NOTE: Research has defined four standard hose cleaning procedures for the hydraulics industry. To obtain the desired cleanliness levels, the following procedures are recommended.

233-7192 and 233-7193 Hose Cleaning Groups

233-7190 Hose Cleaning Gun

1. Attach air supply hose to gun.

Attach Air Supply Hose To Gun

2. Open the face-plate by pressing the top of the release bar forward and then down.

Release Locking Bar

3. Drop the face-plate down. Select the correct nozzle and insert it into the face-plate.

Insert Nozzle Into Face-Plate

NOTE: For nozzle sizes less than 38 mm (1.5 in), the 130-6062 Adapter Ring should be installed prior to insertion of the nozzle.

4. Select the size of projectile from the Hose Cleaning Projectiles Chart in this manual or the NEEG2955 Projectile Sizing Chart provided with each hose cleaning group. Load the projectile into the nozzle.

Load Projectile Into Nozzle

5. Close the face-plate and make sure the release mechanism locks the face-plate into position.

Lock Face-Plate Onto Position

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Containing the projectile that comes out of the hose is important to prevent personal injury. Projectiles and contamination, expelled during the cleaning process, can cause personal injury.

6. Make sure the exit end of the hose is inside a container that will prevent it from being forcefully ejected, causing possible injury.

Use A Container To Catch Projectile

NOTE: It is important to recover the used projectile, so it can be analyzed to determine the condition and cleanliness of the hose.

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Failure to secure face-plate and safety release bar in the locked position may cause serious injury to the operator and/or damage to the launcher.

7. Make sure the release bar is locked into position, as shown.

Lock Release Bar Into Position

8. Place the nozzle firmly against the end of the hose, making a tight seal. It is important to obtain an air tight seal. In the event a nozzle does not fit correctly, try reducing the nozzle size.

Place Nozzle Firmly Against End Of Hose

9. Depress the trigger, making sure it remains depressed until the projectile emerges from the other end of the hose. If the trigger is released prior to the projectile emerging, it will remain in the hose until the trigger is depressed again.

10. A projectile should be fired from both ends of the hose or tube. Repeat until the necessary cleanliness is achieved. After connectors are attached, a projectile should then be fired through the assembly to make sure that any possible contamination introduced during assembly (lubricants, rubber, etc.) is removed. Repeat until the necessary cleanliness is achieved.

NOTE: Research has defined four standard hose cleaning procedures for the hydraulics industry. To obtain the desired cleanliness levels, the following procedures are recommended.

265-4959 Hose Cleaning Groups

265-4959 Hose Cleaning Gun

1. Attach air supply hose to the gun.

Attach Air Supply Hose To The Gun

2. Unscrew the face plate from the gun.

Unscrew Face Plate

3. Insert the universal nozzle into the face plate.

Insert Universal Nozzle

NOTE: It is recommended that the end of the 267-1527 Universal Nozzle be trimmed to the size appropriate for the hose to be cleaned. This allows the projectile to easily exit the nozzle and enter the hose being cleaned.

267-1527 Universal Nozzle Cut lines A, B, and C

NOTE: For nozzle sizes other than the universal nozzle, an adapter will allow the use of nozzles from the 233-7191, 233-7192, 233-7193, and optional nozzle groups. Snap the appropriate adapter into the face plate prior to inserting the nozzle.

Adapter Ring For 45.0 mm (1.75 in.) Diameter Nozzle

Adapter Ring For 67.0 mm (2.63 in) Diameter Nozzle

4. Select the size of projectile from the Hose Cleaning Projectiles Chart in this manual or the NEEG2955 Projectile Sizing Chart provided with each hose cleaning group. Load the projectile into the nozzle.

Load Projectile Into Nozzle

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Failure to securely thread the face plate onto the base of the gun may cause serious injury to the operator and/or damage to the launcher.

5. Thread the face plate, with the nozzle containing the projectile, onto the base of the gun. Make sure the threads are fully engaged and tighten the face plate hand-tight, to seal the face plate to the base of the gun.

Thread Face-Plate Into Locked Position

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Containing the projectile that comes out of the hose is important to prevent personal injury. Projectiles and contamination, expelled during the cleaning process, can cause personal injury.

6. Make sure the exit end of the hose is inside a container that will prevent it from being forcefully ejected, causing possible injury.

Use A Container To Catch Projectile

NOTE: It is important to recover the used projectile, so it can be analyzed to determine the condition and cleanliness of the hose.

7. Place the nozzle firmly against the end of the hose or fitting, making a tight seal. It is important to obtain an air tight seal.

Place Nozzle Firmly Against End Of Hose Or Fitting

8. Depress the trigger, making sure it remains depressed until the projectile emerges from the other end of the hose. If the trigger is released prior to the projectile emerging, it will remain in the hose until the trigger is depressed again.

9. A projectile should be fired from both ends of the hose or tube. Repeat until the necessary cleanliness is achieved. After connectors are attached, a projectile should then be fired through the assembly to make sure that any possible contamination introduced during assembly (lubricants, rubber, etc.) is removed. Repeat until the necessary cleanliness is achieved.

NOTE: Research has defined four standard hose cleaning procedures for the hydraulics industry. To obtain the desired cleanliness levels, the following procedures are recommended.

Projectiles

Path

To clean a system successfully, be careful to identify all intersections, changes in bore size, and obstructions due to control valves, pumps, and monitoring equipment.

Hose length does not matter (with a suitable air supply volume), a projectile can travel up to 1,000 m (3,000 ft). The number of bends or coils in the hydraulic system is not a factor in the distance the projectile will travel. 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.

It is, however necessary to consider the projectile's path in a complex system. It may travel through partially restricted hoses, connectors, and open ball valves. In some installations, it will be necessary to isolate the system 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.

Storage and Disposal

New projectiles should be stored in boxes so they are not exposed to direct sunlight or fluorescent light since they can cause discoloration.

Used projectiles must be disposed of properly.

Hose Cleaning Projectiles

Maintenance Recommendations

1. Keep the hose cleaning group clean.

2. The nozzle can be cleaned by using soap and warm water.

3. Periodically apply silicone or light grease to the O-rings.

4. Projectiles should not be washed or reused as they can recontaminate the system.

Troubleshooting

Parts

233-7191 Hose Cleaning Group

The 233-7191 Hose Cleaning Group comes with all the items listed in Chart B. Projectiles for the nozzles are listed in Charts C and D.

233-7192 Hose Cleaning Group

The 233-7192 Hose Cleaning Group comes with all the items listed in Chart E. Projectiles for the nozzles are listed in Charts F, G, and H.

NOTE: For couplings that jump down in size, use the nozzle that fits the head size. For couplings that jump up in size, use the nozzle that fits the hose size.

Optional Nozzles

Optional Nozzles. Refer To Chart I.

233-7193 Hose Cleaning Group

The 233-7193 Hose Cleaning Group comes with all the items listed in Chart J. Projectiles for the nozzles are listed in Charts K, L, and M.

NOTE: For couplings that jump down in size, use the nozzle that fits the head size. For couplings that jump up in size, use the nozzle that fits the hose size.

Optional Nozzles

Optional Nozzles. Refer to Chart N.

256-4959 Hose Cleaning Group

The 265-4959 Hose Cleaning Group comes with all the items listed in Chart O. Projectiles for the group are listed in Charts P and Q.

General Hose Cleaning Projectile Size Charts for Hose and Hose Assemblies

Hose

JIC/Pipe Couplings

O-Ring Face Seal Couplings

Code 61, 62, and Cat Flange Couplings

General Hose Cleaning Projectile Size Charts for Tube and Pipe

Hydraulic Tubing

Pipe

Notes