Installation and Maintenance of the Powered Fumes Disposal Filter {1074} Caterpillar

Engine Commercial

G3500 Family

Introduction

The fumes disposal filter separates oil from the crankcase atmosphere.

The filter has a blower that draws the crankcase atmosphere through the breathers on the side of the engine. Large droplets of oil are trapped by the breathers. The oil in the breathers is returned to the crankcase. Small particles of oil are still entrained in the atmosphere.

Illustration 1	g00766996
Operation of the fumes disposal filter (1) Flow of the crankcase atmosphere (2) Flow of the air to the turbocharger (optional) (3) Flow of the oil that is separated from the crankcase atmosphere (4) Bypass port

Atmosphere (1) is drawn into the fumes disposal filter. The filter separates the oil from the crankcase atmosphere. The oil (3) is returned to the oil pan. Clean air (2) is sent to the air inlet of the turbocharger or other location as required by local or Cat regulations for specific products.

If power to the blower is lost during engine operation, the crankcase atmosphere is purged through bypass port (4).

The fumes disposal filter provides the following benefits:

• Reduction of pollution

• Compliance to government regulations of emissions

• Reduction of oily residue on surfaces

• Economical recirculation of oil that would otherwise be lost

• Low maintenance

Two different fumes disposal filters are available. The operation of the devices is identical.

• The 191-2303 Fumes Disposal Filter Gp is used with a single engine.

• The 191-2304 Fumes Disposal Filter Gp has a greater capacity. This filter is used with tandem engine installations.

Note: The air lines, the line for the bypass, and the fittings are supplied by the customer.

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

Components and Reference Dimensions

Illustration 2	g00767228
Components of the 191-2303 Fumes Disposal Filter Gp and the 191-2304 Fumes Disposal Filter Gp (1) Differential pressure gauge (2) Blower and motor (3) Silencer and air outlet (4) Filter element (5) Bracket with mounting holes (6) Oil drain (7) Condensation trap drain valve (8) Bypass port (9) Inlet for the fumes disposal filter

Illustration 3	g00730528
Reference dimensions of the 191-2303 Fumes Disposal Filter Gp

Illustration 4	g00730535
Reference dimensions of the 191-2304 Fumes Disposal Filter Gp

Installation

Note: The air lines, the line for the bypass, and the fittings are supplied by the customer.

Do not install the filter on the engine. Ensure that the filter is isolated from engine vibration.

The location of the filter depends on the model that will be installed. The filter must be within the specified distance from the engine to eliminate excessive pressure drop.

• Install the 191-2303 Fumes Disposal Filter Gp within 15 m (50 ft) of the engine.

• Install the 191-2304 Fumes Disposal Filter Gp within 7.5 m (25 ft) of the engine.

Before you install the unit, remove the cover and install the loose shipped filter element. Make sure that the element is properly seated in the body. Reinstall the cover.

1. Attach suitable straps and a lifting device to the filter.

   • The 191-2303 Fumes Disposal Filter Gp weighs approximately 58 kg (128 lb).

   • The 191-2304 Fumes Disposal Gp weighs approximately 86 kg (190 lb).
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   Illustration 5	g00767140
   The minimum distance from the engine oil level to the bottom of the filter is 1.5 m (5 ft). (1) Bracket

2. Lift the filter into position. The bottom of the filter must be at least 1.5 m (5 ft) above the engine oil level. Be sure to provide sufficient clearance for removal of the filter element. Refer to "Components and Reference Dimensions". Attach the filter securely to a surface that will support the weight.

   Bracket (1) has two mounting holes for installation of the filter. The fasteners are supplied by the customer.

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   Illustration 6	g00767298
   (2) Oil drain line

3. Install oil drain line (2) between the female 1/4 inch FTP oil drain and the engine oil pan. Ensure that the drain line is below the engine oil level at all times.

   If the drain line is loose, ambient air can enter the system. This reduces the performance of the system. This can also allow contaminants to enter the system. Ensure that the drain line is coupled securely.

   For proper drainage of the oil, the oil drain line must have a constant negative slope. Ensure that the oil drain line has a constant negative slope.

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   Illustration 7	g00744187
   (3) Hose from the outlet of the crankcase breathers to the inlet of the filter

4. Route hose (3) from the outlet of the crankcase breathers to the inlet of the filter. Use hose with a minimum diameter of 50.8 mm (2 inch).

   The inlet of the filter is a female 2 inch FPT fitting.

   Ensure that the hose is routed in a manner that will avoid trapped fluids.

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   Illustration 8	g00744190
   (4) Piping from the outlet of the filter to the elbow at the inlet of the turbocharger (5) Drip leg

   Note: The air lines on your engine may be different from Illustration 8.

5. Route piping (4) from the outlet of the filter to the elbow at the inlet of the turbocharger or other location away from engine.

   The outlet of the filter is a female 1 and 1/2 inch FPT fitting. The fitting on the elbow at the inlet to the turbocharger is a 1 and 1/2 inch NPTF fitting.

6. Install drip leg (5) prior to the turbocharger compressor inlet.

   Note: If power to the filter is interrupted during operation, the crankcase atmosphere is vented through the bypass.

   Note: Never install an air filter in the bypass line. Installing an air filter will increase crankcase pressure to an unacceptable level.

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   Illustration 9	g00767457

7. Route hose (6) from the bypass port to a suitable location. Venting to the outside is recommended.

   The bypass port is a female 2 inch FPT fitting.

   Size the hose and route the hose to minimize pressure drop. Route the hose in a manner that will avoid trapped fluids. Ensure that moisture cannot enter the system through the hose.

   Note: Do not connect the condensation trap drain valve to the oil drain line. Otherwise, the oil will not be removed from the air.

8. Ensure that condensation trap drain valve (7) is closed.

   Note: The wiring must be performed by a qualified service technician.

9. Connect the blower motor to an electrical source.

   The blower motor can be configured for one of the following two different power sources:

   • 208-230/460 volts

   • 220-360/415 volts

   See Illustrations 10 and 11.

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   Illustration 10	g00731513
   Wiring diagram for 220 V

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   Illustration 11	g00731561
   Wiring diagram for 380 V

   Note: Wire the blower motor to a good earth ground.

10. Wire the motor to a suitable source in accordance to the "National Electric Code" or local standards.

11. Check the rotation of the motor. Ensure that the motor is rotating in the same direction as the arrow on the housing of the blower.

    If the motor is not rotating in the correct direction, reverse the polarity at the leads for the electrical power.

Inspection Before Start-up

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Illustration 12	g00767466

1. Ensure that filter (1) is at the proper height above the engine oil level.

   The bottom of the filter must be at least 1.5 m (5 ft) above the engine oil level.

2. Ensure that oil drain line (2) remains below the engine oil level at all times. Ensure that the drain line is securely coupled and that the drain line has a constant negative slope.

3. Inspect bypass line (3). Ensure that the bypass line is not obstructed.

Initial Start-up

1. During the initial operation of the filter, use the gauge on top of the filter if equipped or install pressure gauge to check the differential pressure across the filter element.

   The restriction of a new element is approximately 1.7 kPa (7 inches of H₂O).

   The normal restriction of the element is approximately 5.7 kPa to 9.95 kPa (23 inches to 40 inches of H₂O).

2. Measure the crankcase pressure at partial load and full load.

   For a properly installed system, crankcase pressure will be within 0.25 kPa (1 inch of H₂O) of the atmospheric pressure.

Maintenance

Maintenance Schedule

Daily

Check the differential pressure across the filter element. Observe the pressure that is indicated by the pressure gauge on top of the filter. Record the measurement.

The restriction of a new element is approximately 1.7 kPa (7 inches of H₂O).

The normal restriction of the element is approximately 5.7 kPa to 9.95 kPa (23 inches to 40 inches of H₂O).

• For the 191-2303 Fumes Disposal Filter Gp, replace the filter element when the differential pressure reaches 11.2 kPa (45 inches of H₂O).

• For the 191-2304 Fumes Disposal Filter Gp, replace the filter element when the differential pressure reaches 12.4 kPa (50 inches of H₂O).

• Replace the element after every year regardless of the differential pressure.

Replacement of the Filter Element

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Note: Always disconnect power to the fumes collector prior to servicing. The motor is protected by a thermal protector. If the motor is shutdown due to excessive heat, the motor will automatically restart when the protector resets.

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 13	g00763796
(1) Nuts and washers (2) Cover (3) Body (4) Filter element

1. Remove three nuts and washers (1) to remove cover (2) from body (3).

2. Remove element (4).

3. Clean the inside of cover (2) and body (3).

4. Install new element (4) into body (3).

5. Place cover (2) in position and install three nuts and washers (1).

Every 500 Service Hours

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Note: Always disconnect power to the fumes collector prior to servicing. The motor is protected by a thermal protector. If the motor is shut down due to excessive heat, the motor will automatically restart when the protector resets.

1. Shut down the engine and the fumes disposal filter.
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   NOTICE
   Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

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   Illustration 14	g00767587
   (1) Drip leg (2) Condensation trap drain valve

2. Open drip leg (1) and drain the fluid into a suitable container.

   If the filter is installed and maintained properly, no more than 28 g (1 ounce) of fluid will be drained.

   If more than one 28 g (1 ounce) is drained, make sure that the filter is installed according to the instructions in the "Installation" section. Ensure that the system is operating properly.

3. Close the drip leg.

4. Open condensation trap drain valve (2) and drain the fluid into a suitable container.

5. Close the condensation trap drain valve.

   Resume normal operation.

Every 1000 Service Hours

Measure the crankcase pressure during normal operation.

For a properly installed system, crankcase pressure will be within 0.25 kPa (1 inch of H₂O) of the atmospheric pressure.