R NEHS0799-02

November 2004

TOOL
OPERATING
MANUAL
170-8500 Analyzer Group

SMCS: 0784
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 to 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.
WARNING
The meaning of this safety alert symbol is as
follows:
Attention! Become Alert! Your Safety is
Involved.
2
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.
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 recommended by Caterpillar is
not 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 be 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.
WARNING
When replacement parts are required for this
product, Caterpillar recommends using
Caterpillar 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.
Table of Contents Pump Current Settings Screen (13). . . . . . 23
Profile Setup Screen (14). . . . . . . . . . . . . . 24
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Select Profile Data Setup Screen (15) . . . . 24
Personal Protection . . . . . . . . . . . . . . . . . . 4
Profile Properties Screen (16) . . . . . . . . . . 25
Product Hazards . . . . . . . . . . . . . . . . . . . . 4
Profile Flow Chart Screen (17). . . . . . . . . . 26
Electrical Hazards . . . . . . . . . . . . . . . . . . . 5
Tolerance Range (18) . . . . . . . . . . . . . . . . 27
Chemical Hazards . . . . . . . . . . . . . . . . . . . 5
DQ ISO 11171 (19) . . . . . . . . . . . . . . . . . . 28
Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Touch Screen Maps . . . . . . . . . . . . . . . . . . . 29
General Safety Information . . . . . . . . . . . . 5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 37
Internal Laser Radiation. . . . . . . . . . . . . . . 5
Service Problems . . . . . . . . . . . . . . . . . . . . 37
Laser Information for United States Users 6
Changing Printer Paper Roll . . . . . . . . . . . 37
Laser Safety Label . . . . . . . . . . . . . . . . . . . 6
Flow-rate and Hydrodynamic Conditions . 37
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 7
Flushing Procedure . . . . . . . . . . . . . . . . . . 38
Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic Schematic . . . . . . . . . . . . . . . . . 39
Serviceable Parts and Accessories. . . . . . . . 8
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
General Information . . . . . . . . . . . . . . . . . . . . 8
Loading 170-8500 Download Software
Sample Fluid . . . . . . . . . . . . . . . . . . . . . . . . 10 Onto a PC . . . . . . . . . . . . . . . . . . . . . . . . . 40
Compatibility . . . . . . . . . . . . . . . . . . . . . . . 10 Using the Download Software . . . . . . . . . . 42
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Warranty/ Service/ Repair . . . . . . . . . . . . . . 44
Temperature . . . . . . . . . . . . . . . . . . . . . . . . 10 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Recommended Sampling Temperature. . . 11
Analyzer Connections . . . . . . . . . . . . . . . . . 12 NOTE: Caterpillar reserves the right to make
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 technical changes for product improvement.
This manual may contain illustrations and
DC Power Cable . . . . . . . . . . . . . . . . . . . . 12
photographs, for demonstration purposes,
Serial Communication . . . . . . . . . . . . . . . . 13 which slightly deviate from the actual product
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 design.
High-pressure Sampling . . . . . . . . . . . . . . 14
Low-pressure Sampling . . . . . . . . . . . . . . . 14
Measurement Procedure . . . . . . . . . . . . . . 15
Stopping the Measurement Procedure . . . 15
Shutting Down . . . . . . . . . . . . . . . . . . . . . . 15
Screen Descriptions . . . . . . . . . . . . . . . . . . 16
New Sample Screen (1). . . . . . . . . . . . . . . 16
Keyboard Screen (2) . . . . . . . . . . . . . . . . . 17
Hydraulic Connection Screen (3) . . . . . . . 17
Main Screen (4) . . . . . . . . . . . . . . . . . . . . . 18
Sampling Screen (5) . . . . . . . . . . . . . . . . . 19
System Settings Screen (1 of 3) (6). . . . . . 19
System Settings Screen (2 of 3) (7). . . . . . 20
Recalibrate Touch Screen (8) . . . . . . . . . . 20
Display Contrast Settings Screen (9) . . . . 21
System Settings Screen (3 of 3) (10). . . . . 22
Extended Systems Settings Screen (11) . . 22
Date Time Settings Screen (12). . . . . . . . . 23

3
Safety Personal Protection (continued)
Personal Protection WARNING
WARNING
Make sure you use all
To avoid personal injury or death, necessary protective
carefully read and understand all equipment required to do
instructions before attempting to the job. Prevent sparks,
operate any equipment. Do not flames, and smoking around
operate or work on a machine unless you read dangerous substances.
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. Product Hazards
Always follow all State and Federal health and
safety laws and/or local regulations.
Personal injury can result Simultaneously
from slips or falls. DO NOT exceeding the
leave tools or components maximum fluid
laying around the work area temperature and
and clean up all spilled fluids immediately. pressure permitted for a sample can cause an
Check hydraulic oil lines, explosion, resulting from bursting hoses and/or
tubes, and hoses carefully. failed connectors.
DO NOT use your bare hand Use extreme caution while
to check for potential leaks. maintaining this instrument.
Always use a board or cardboard when When the particle analyzer
checking for a leak. Escaping hydraulic fluid is disconnected from the
under pressure, even a pinhole size leak, can main power supply it is still powered by an
penetrate body tissue, causing serious injury, internal AC rechargeable battery. DO NOT
and possible death. If fluid is injected into your attempt to repair or rebuild the particle
skin, it must be treated immediately by a doctor analyzer.
familiar with this type of injury.
Contact with batteries or
Personal injury can result electrical components may
from hydraulic oil pressure cause injury or death.
or hot oil. DO NOT remove Remove all jewelry and use
a hydraulic tank filler cap properly insulated tools when working on
unless it is cool enough to touch with your bare batteries or electrical components.
hands. Relieve all pressure in a hydraulic
system before any caps, lines, fittings, or When preparing the particle
related items are disconnected or removed. analyzer for shipment make
sure it is free of any
Personal injury or flammable liquids.
death can result When sending the unit in for
from a fire. service, it must also be free
Flammable fluid of all contamination; such as
leaked or spilled onto hot surfaces or electrical radioactive, poisonous, or
components can cause a fire. Clean up all bacteriological substances. Close off the input
leaked or spilled flammable fluid immediately. and output fittings by screwing the supplied
Sparks or open flames can cause flammable covers into position.
fluid to ignite. DO NOT smoke while working on
or near any flammable fluid.

4
Electrical Hazards
To prevent personal injury or
death, always disconnect
the electrical power before
opening an electrical control
box.
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.
Chemical Hazards
Personal injury can result from improperly
handling any hazardous materials; such as
corrosive, explosive, poisonous, flammable, or
materials.
Make sure you read and
MMS SD
SSS
M
M SSS
DDD
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.
5
Laser Safety
General Safety Information
For your own safety take
note of the following safety
precautions.
This product incorporates a sensor which
operates by means of a laser. There is no
possibility of danger from the laser, provided
that the product is operated according to the
instructions in this manual.
Since radiation emitted by the laser is
completely confined within protective housings
and external covers, the laser beam cannot
escape from the device during any phase of
user operation.
This product is certified as a Class 1 laser
product under U.S. Department of Health and
Human Services (DHHS) Radiation
Performance Standard according to the
Radiation Control for Health and Safety Act of
1968. This means that the product does not
produce hazardous laser radiation.
Internal Laser Radiation
The sensor unit, which is inside the
product, should not be opened under
any circumstances.
Maximum Average Power: 4.2 mW inside the
sensor
Wavelength: 670 nm
This product employs a Class 3R laser diode
that has a visible beam. The laser diode is
incorporated in a closed sensor unit. The
sensor unit is in the interior of the product. The
laser beam is emitted inside the long tube of
the sensor unit and cannot escape from the
sensor housing during any phase of operation.
Laser Information for United
States Users
CDRH-Regulations: This product is certified as
a Class I laser product under the Regulation
Performance Standard according to the Food,
Drug and Cosmetic Act of 1990. Compliance
is mandatory for laser products marketed in
the United States and is reported to the Center
for Devices and Radiological Health (CDRH) of
the U.S. Food and Drug Administration (FDA)
of the Department of Health and Human
Services (DHHS). This means that the product
does not produce hazardous laser radiation.
The label shown below indicates compliance
with the CDRH regulations and must be
attached to laser products marketed in the
United States.

Laser Safety Label

The laser safety label is located at the rear
panel of the product.

Use of controls, adjustments or

performance of procedures other than
those specified in this manual may
result in hazardous radiation
exposure.

This is a semiconductor laser. The maximum

power of the laser is 5 mW and the wavelength
is 670 nm.

6
Introduction Specifications
Chart A.
170-8500 Analyzer Group
Description Specification
Display Backlit LCD
User Input Touch Screen/Keypad
Measurement Pressurized (High-Pressure)
Capability 400-40000 kPa (58-5800 psi).
Non-pressurized (Low-Pressure)
0-400 kPa (0-58 psi)
Flow Rate Up to 25 mL/minute
(adjustable)

Illustration 1. 170-8500 Portable Particle Analyzer. Size Range 4 - 30 microns (certified ISO-11171)
On-board 1500 tests
Data Storage
The 170-8500 Analyzer Group represents Test Run Duration 90 seconds
up-to-date technology for effective particle Weight 9 kg (20 lbs)
contamination analysis in a portable package. Size 300 x 140 x 300 mm
It is a self-contained system designed for (11.8 x 5.5 x 11.8 in)
analyzing particle contamination on Ambient Operating 5°C to 40°C
pressurized and non-pressurized systems. Temperature (40°F to 104°F)
With the portability of the unit, contamination Fluid Sample 71°C (160°F)
monitoring can be done in the field. Temperature (maximum recommended)
This particle analyzer can be used to check Maximum Fluid 300 cSt
mineral-based fluids, such as hydraulic system Viscosity
oil and/or power steering fluid. Power Internal Battery,
100 - 240 VAC 50/60 Hz, or
This particle analyzer uses red laser sensor External Source (12 - 24 VDC)
technology to count and size particles in the
Relative Humidity Maximum 70%
fluid. This sensor technology is the same
design as particle analyzers used in S·O·S Calibration ISO-11171
Fluid Analysis and other Caterpillar factory Computer Interface RS-232
applications. 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.

7
Nomenclature Serviceable Parts and
Accessories
Chart C.
Serviceable Parts and Accessories
Part No. Description
6V-4144 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.
Illustration 2. 170-8500 Portable Particle Analyzer The packaging will be useful if the
instrument must be returned for re-
calibration or service.
Chart B.
170-8500 Analyzer Group Contents NOTE: The calibration table belongs to a
Item Part No. Description specific instrument and should be kept in a
1 –— S40 Portable Particle Analyzer safe and secure location.
2 131-5047 Power Cord 2. Protect the instrument from abusive
3 –— RS-232 Serial Cable handling, improper care, and harsh
4 NEHS0799 170-8500 Tool Operating Manual elements, such as: strong vibration, heavy
5 184-7679 Printer Paper (5 rolls)
objects placed on top of the particle
analyzer, strong sunlight, high humidity,
6 170-8506 Mini-Mess Tube
extreme temperature, and/or explosive or
(for high-pressure sampling)
chemical environments.
7 188-0639 Plastic Tubing
(for low-pressure sampling) 3. Always place the particle analyzer in a dry,
8 –— Adapter clean location. Rest the analyzer on the
9 –— Carrying Case
rear or bottom feet. If needed, the carrying
handle can be used to angle the analyzer
10 –— Calibration Documentation and
for clear viewing.
Download Software

To adjust the handle position, press the

handle buttons simultaneously and rotate
the handle to the desired position.

8
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.
NOTICE
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.
5. Do not leave hoses connected to the
analyzer when it is not in use.
6. Do not operate the analyzer without fluid.
Pump damage can occur under this
condition.
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.
9
10. Wipe off the quick-disconnect connectors
and nipples with a 162-5791 Low-Lint
Cloth after each use.
11. Connect the quick disconnects before
starting the machine.
12. Run at least two pre-tests prior to running
the actual sampling to flush the particle
analyzer.
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.
15. When performing a high-pressure test,
operate the “Pre-Run” cycle one minute
for each meter of input hose being used.
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.
Sample Fluid Pressure
Compatibility
The 170-8500 Analyzer Group is: Simultaneously
• NOT rust free. exceeding the
maximum fluid
• NOT compatible with esters or ketones, temperature and
such as acetone. pressure permitted for a sample can cause an
The housing is covered with resistant explosion, resulting from bursting hoses and/or
polyester. failed connectors.
The main materials coming into contact with
the sample fluids are: Make sure the correct pressure is being used
• Stainless steel to transport the sample fluid to the system.
1.0161 (St 37-2) and 1.4571 (V4A) Use the correct input port.
• Aluminum DO NOT exceed the maximum allowed
pressure.
• Borosilicate glass
• Polyamide
• NBR NOTICE
NOTE: These materials are compatible with Exceeding the maximum allowed pressure
most mineral oils. could cause bursting tubes and connections
resulting in the particle analyzer being damaged
Special options are available for other media or destroyed.
such as SKYDROL or water based solutions
on request.
NOTE: If any doubt exists about the Temperature
compatibility of a sample fluid, contact the
service department of PAMAS GmbH. The temperature of the sample fluid must not
exceed 71°C (160°F). Higher temperatures
may cause erroneous results to occur.

10
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.

11
Analyzer Connections 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).
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.

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

(1) Serial Port. (2) Power Switch (ON/OFF). DC Power Cable Wiring Parts List
(3) AC Power Supply Socket Input. (4) DC Power Socket Qty. Part No. Mfg. Description
Input. (5) Rear Feet. (6) Bottom Feet. (7) Printer Cover. 1 T641CPR Hoffman Battery clip (+) (red)
(8) BNC Connector for Maintenance. Industries
1 T641CPB Hoffman Battery clip (-) (black)
Industries

Power ––1 Cable (14 -16 AWG, 2 wire)

(1.5 to 2.5 mm), SO
1 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(+) 2 (–)
Use basic precautions when
working with electrical (N/C)
components to prevent 3
injury or death. DO NOT 0799-07

touch the metal prongs on electric plugs while

connecting or disconnecting electrical Illustration 5. Three Pin Connector (Solder Side).
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.

12
 Chart E. Operation
Three Pin Connector
Pin Description Wire Color
Before connecting the analyzer:
Pin 1 + (Positive) Red • determine if the input for the sample will
Pin 2 – (Negative) Black be high-pressure or low-pressure.
Pin 3 N/C — • 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
(BLACK) resulting in the particle analyzer being damaged
0799-08 or destroyed.

Illustration 6. DC Power Cable.

Serial Communication
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.
1. Check the output pressure at the sampling
test port.
2. If the pressure is between 0 and 4 bar,
400 kPa (58 psi), use the low-pressure
sampling procedure.
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.

13
High-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).
1. Open the high-pressure input (HP Input)
port (1, Illustration 7) by unscrewing the
cover.
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. Install and hand tighten a 9U-6794 Adapter
onto the high-pressure hose.
4. Connect the high-pressure hose to the
quick disconnect fitting or oil sampling
port.
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).
7. Place the loose end of the low-pressure
hose into a storage container to collect the
discharged fluid sample.
NOTE: Secure the drain hose to the container
with tape, a clip, or some other means.
The particle analyzer is now ready to take a
high-pressure fluid sample. Refer to the
“Measurement Procedure” section for taking a
sample.
14
Low-pressure Sampling
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 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.
3. Place the loose end of the low-pressure
hose into a container with the sample fluid.
4. Open the low-pressure output (LP Output)
port (1, Illustration 7) by unscrewing the
cover.
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).
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.
6. Attach a low-pressure hose (clear, short
hose) to the low-pressure output
(LP Output) port.
7. Place the loose end of the low-pressure
drain hose into a storage container to
collect the discharged fluid 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).
Measurement Procedure
Refer to the Screen Descriptions and Touch
Screen Maps sections for more information on
these instructions.
NOTICE
DO NOT start the particle analyzer with the
input/ output covers in place. This could result
in damage to the pump.
The oil testing requires a minimum sample size
of 25.0 mL (.85 oz) per test.
1. Turn on the analyzer by pressing the power
switch (2, Illustration 4).
• The touch screen on the particle analyzer
will turn on.
• The new sample information screen will
appear on the display (see Diagram 1 in
the “Screen Descriptions”section).
• 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.
3. To make changes to the system or profiles:
• press the ESC (Escape) button.
4. To enter the serial number:
• press the “Serial #” button.
• the Keyboard window will appear on the
display.
• “Serial #” will be displayed in the upper
left-hand corner of the Keyboard window.
• press the appropriate buttons to match
the serial number information.
• press the “OK” button to enter the serial
number information into memory.
15
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.
NOTE: Entering a sample temperature does
not affect the operation of the unit. This entry
is for information purposes only.
6. Press the “Start” box to enter the “Start
Screen” which is shown in Diagram 3 in the
“Screen Descriptions” section.
• This screen displays the hydraulic
connections for the two ports.
• 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.
• The Sampling Screen, Diagram 5 in the
“Screen Descriptions” section, will begin
displaying data at this time.
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 sample fluid will now be tested for
contamination and counted in all 8
channels.
Stopping the Measurement
Procedure
Press the “Stop” box once to stop the
measurement procedure during a continuous
sample flow.
Shutting Down
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.
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

16
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 Press the “ESC” button.
without Changes

Diagram 2: Keyboard Screen

Hydraulic Connection Screen

Hydraulic Connection This screen appears when a new measurement can be started with the
Screen 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

17
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

18
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 Access System Setup (F1), Profile Setup (F2), and
Screen (1 of 3) Calibration Setup (F3, which is for OEM use only).

Diagram 6: System Settings Screen

19
System Settings Screen (2 of 3)
System Settings Access Recalibrate Touch Screen (F1), Change display contrast (F2),
Screen (2 of 3) Reset display to default (F3), and Get Administrator Level (F4).

Diagram 7: System Settings Screen (1)

Recalibrate Touch Screen

Recalibrate Touch Recalibrate the touch screen to the specific habits of the user.
Screen (F1) NOTE: Press the inside of the five consecutive rectangles in the same
manner as a menu item is selected.

Diagram 8: Recalibrate Touch Screen

20
Display Contrast Settings Screen
Change Display Increase or decrease the contrast of the display with the arrow up and
Contrast (F2) 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

21
System Settings Screen (3 of 3)
System Settings Recalibrate the touch screen, change the display contrast, setup the
Screen (3 of 3) Administrator Level, and return to the User Level.
Recalibrate Touch See Diagram 8.
Screen (F1)
Change Display See Diagram 9.
Contrast (F2)
Reset Display to Resets the contrast to the factory default.
Default (F3)
Reset to Resets the system to the user level.
User Level (F4)
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 Only available in the Administrator Level.
Settings Screen NOTE: Contact PAMAS or CSTG for entering this setting.

Diagram 11: Extended System Settings Screen

22
Date Time Settings Screen
Date Time Settings Change the date (mm/dd/yy) and time (hh:mm:ss).
Screen (F1)

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

Pump Current Settings Screen

Pump Current Increase or decrease the power to the pump with the arrow up and
Settings Screen (F2) 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)

23
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 Create a new profile.
Setup Screen
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

24
Profile Properties Screen
Profile Properties Change the name and settings of a profile.
Screen 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 Change the sequence of the measurement.
Setup (F2)
Buttons in Store information in particle counts (F5) or ISO codes (F4) of each
Save Result 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

25
Profile Flow Chart Screen
Profile Flow Chart Graphically shows the sequence of a measurement cycle (profile).
Screen 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 A During this time the pump is running with the Flush Flow Rate.
Delay and Flush If Flush Time is 0 seconds, no flushing will be performed.
Flow Rate 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 B During this time the pump is running with the Measure Flow Rate.
Time 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.

26
Tolerance Range Screen
Tolerance Range Allows the user to set stabilization criteria for subsequent single
Screen 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 Number of single measurements which must be within the given tolerance
for Average (F3) range of their mean values.
Max. # of The sample will be finished after Maximum Number of Measurements
Measurements (F4) 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

27
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 Sample will be finished after Maximum Number of Measurements when
Measurements (F3) the stabilization criteria is not fulfilled.
Number of Valid Minimum number of channels which have to fulfill the criteria.
DQs (F4) 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

28
Touch Screen Maps

29
30
31
32
33
34
35
36
Maintenance
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.
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.
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.
37
Flow-rate and Hydrodynamic
Conditions
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.
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.
Simultaneously
exceeding the
maximum fluid
temperature and
pressure permitted for a sample can cause an
explosion, resulting from bursting hoses and/or
failed connectors.
Faults
When counts begin falling or rising, it is best to
catch the problem as soon as possible.
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.
NOTE: Water will stick in different places in
the system and will vary depending on the
situation.
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.
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
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.
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.
38
5. Place the hose from the (LP Output) port
into another clear plastic cup to capture the
material flushed from the analyzer.
6. Turn the particle analyzer ON, run it for
eight minutes, and then turn it OFF.
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.
9. Turn the particle analyzer ON, run it for an
additional eight minutes, and then turn it
OFF.
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.
NOTICE
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.
Hydraulic Schematic
0799-51

T
P A
HP in P

Pump
Sensor Opening
Pressure
5 bar
(72.5 psi)

LP in

39
Software g. Press “Yes”.
h. These (2) two status boxes will appear
Loading 170-8500 Download momentarily before the “Welcome”dialog
Software Onto a PC 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”.
b. Press the “Start” button on the Task Bar. 3. Review each dialog box that appears and
make the appropriate selections.
c. Select “Run” to display the Run dialog
box. a. The “Welcome” dialog box will appear
first. Read the message and press
d. In the text box type: A:\SETUPEX.EXE. “Next >” when ready to proceed.
e. Press “OK”.
f. This status box will appear:

40
b. The “Choose Destination Location” d. The “Start Copying Files” dialog box will
dialog box will appear next. If the appear (Windows NT). If the settings
destination is okay, press “Next >” are okay, press “Next >” when ready to
when ready to proceed. proceed.

c. The “Select Program Folder” dialog box e. The “Setup Complete” dialog box will
will appear. If the destination is okay, appear to indicate the software has
press “Next >” when ready to proceed. been loaded onto the computer. Press
finish to complete the setup.

41
4. Follow these directions to complete the
setup of the 170-8500 Download software.
a. The first window to appear will include
the DL_S40 icon. Use the computer
mouse to double click the icon.
Using the Download Software
These instructions describe how to use the
170-8500 Download software from the
Program Menu.
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.

42
2. Select “System” from the function bar.
a. A user can select “Serial Port” to review
or change the serial port settings in the
“Serial Port Settings” window.
b. Select “Exit” to close the software.
43
3. Select “S40” from the function bar
a. A user can choose to download profile
data, download measure data, or delete
measured data.
b. These functions may be selected by
using the pull down menu or by clicking
on the function icon.
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.
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
When preparing the particle
PAMAS facilities can be contacted in regards
analyzer for shipment make
to calibration of this instrument:
sure it is free of any
flammable liquids. C & J International Inc.
When sending the unit in for 6721 E. 106th St.
service, it must also be free Tulsa, OK 74133, USA
of all contamination; such as Tel: 0 01 91 82 99 40 19
radioactive, poisonous, or Fax: 0 01 91 82 99 74 10
bacteriological substances. Close off the input
Sintech Scientific (SEA) Pet Ltd.
and input fittings by screwing the supplied
No. 196 Pandan Loop # 02-18
covers into position.
Pantech Industrial Complex
Singapore 128384
Tel: 0 06 57 79 00 07
Caterpillar warrants this instrument to be free
Fax: 0 06 58 72 23 92
of defects in parts and workmanship for one
year from date of shipment. If it should PAMAS
become necessary to return the instrument for Partikelmess- und Analysesysteme GmbH
service during or beyond the warranty period, Dieselstraße 10
contact the particle analyzer manufacturer. D-71277 Rutesheim
Postfach 162
Units in North and South America that are in
Germany
need of service, repair, or calibration can be
Tel: + 49 7152 9 96 30
sent with an explanation to PAMAS-USA.
Fax: + 49 7152 5 48 62
PAMAS-USA
The Calibration Recommendations chart gives
6721 East 106th Street
recommendations on when checks and
Tulsa, OK 74133
calibrations should be done.
USA
Units in Europe and Asia that are in need of
service, repair, or calibration can be sent with
Chart F.
an explanation to PAMAS-GmbH. Calibration Recommendations
PAMAS-GmbH Sizing Full Check
Dieselstrasse 10 Calibration Calibration
D-71277 Rutesheim Only1
Postfach 1162 Annual ISO-11171 Calibration X
Germany Suspect Calibration Shift X
Optics Repaired or Adjusted X
Sensor Repaired or Adjusted X
Volume Measurement Repaired X

1 A sizing calibration defines the relationship

For information on service tools or shop supplies,
contact Dealer Service Tools on: between a detector’s change in millivolts and
the size of the particles in an oil sample.
Dealer Service Tools
8900 N. Pioneer Road
Peoria, IL U.S.A. 61615-1522
U.S.A.: 1-800-542-8665
Illinois: 1-800-541-8665
Canada: 1-800-523-8665
World: 1-309-675-6277
Fax: 1-309-494-1475
CSTG_Hotmail@cat.com

©2004 Caterpillar Inc. NEHS0799-02

All Rights Reserved Printed in U.S.A.