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Oil Mist Detectors Caterpillar


Maintenance Schedule

Usage:

3616 1FN
The regular maintenance that is required for the oil mist detector is listed in Table 1. Make several copies of 1 in order to keep a record of the maintenance.

The intervals for performing the maintenance are provided as guidelines. Particular installations may require more frequent maintenance intervals.

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Table 1
Maintenance Schedule for the Oil Mist Detector    
Interval     Maintenance Procedure     Technician     Date    
When Required     Perform all of the following maintenance after the vessel has been in storage.            
Daily     Maintain the system for the compressed air.            
Every Month     Check the pressure of the vacuum in the measuring head. Adjust the pressure, if necessary. (1)            
Clean the box for the oil drain (if equipped).        
Every 3 Months     Perform the following maintenance on these items in the measuring head:
Clean the bores for the filtered air.
Replace the sintered bronze filters.
Clean the glass of the infrared filters.    		        
Every Year     Replace the sintered bronze filter for the pressure regulator.            
Clean the suction lines for sampling the atmosphere from the crankcase.        
Clean the oil drain line.        
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( 1 ) When this procedure is performed after Every Three Months, perform this procedure last.

Failure to perform the maintenance will have an adverse effect on the oil mist detector. Table 2 lists the conditions and the possible results of failure to perform the maintenance.

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Table 2
Conditions and Possible Results of Failure to Perform Maintenance for the Oil Mist Detector    
Condition     Possible Result    
The air pressure from the air pressure regulator is too low.     Fault 14 is generated because the pressure of the vacuum in the measuring head is too low.    
The box for the oil drain (if equipped) is full.    
The line for the oil drain (if equipped) to the crankcase is clogged.    
The bores for the clean air in the measuring head are clogged.    
The sintered bronze filters in the measuring head are dirty.    
The filter for the pressure regulator is dirty.    
The glass of the infrared filters is dirty.     Fault 13 is generated because the infrared filter seems to be dirty.
Fault 3 is generated because the measuring track seems to be faulty.    
The sintered bronze filters in the measuring head are dirty.    
The air pressure from the air pressure regulator is too high.     The detector can fail to detect a condition of excessive oil mist.    
The detector can activate a false alarm for oil mist.
The sintered bronze filters become fouled quickly. A number 3 fault is generated.
The lines for sampling the atmosphere from the crankcase are dirty.     The detector can activate a false alarm for oil mist.    

Most of the maintenance procedures can be performed with tools from the 132-8710 Tool Kit. See the "Service Tools" topic.

Maintenance Procedures

When Required

When the vessel is in storage, condensation can form in the oil mist detector and in the components that are associated with the detector. The condensation and any dirty deposits can activate false alarms and faults.

Before returning the vessel to service after storage, perform all of the maintenance procedures for all of the maintenance intervals: Daily, Every Month, Every 3 Months and Every Year.

Daily

Maintain the System for the Compressed Air

Good performance of the system that supplies compressed air to the detector is very important to the operation of the detector.

A worn air compressor can pump oil into the compressed air. A faulty air dryer can allow moisture to enter the detector. Leaks in the system can allow contaminants to enter the detector. These factors will cause the filters to become dirty and these factors can cause false alarms and/or faults.

For optimum performance of the detector and for optimum service life of the filters, ensure that the system that supplies compressed air to the detector is in good condition.

Service the system that supplies compressed air according to the instructions that are provided by the OEM of the system.

Every Month

Check the Pressure of the Vacuum in the Measuring Head

An increase or a decrease of the crankcase pressure during operation has an effect on the velocity of the flow of the oil mist through the system. However, the effect is mostly compensated by the internal restriction of the system.

For example, if the crankcase pressure increases by 25 mm of H2O (0.98 inches of H2O), the pressure of the flow through the piping increases by approximately 8 percent. If the crankcase pressure increases by 50 mm of H2O (1.97 inches of H2O), the pressure of the flow through the piping increases by approximately 14 percent. This is a slight effect. The restriction in the system is important because an excessive flow rate reduces the sensitivity of the detector due to increased precipitation of the oil mist.

The air pressure can be affected by the ventilation in the engine room. Make sure that the ventilation is operating properly.

    Note: Perform this procedure with the engine OFF.

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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 1g00731398

    (1) Plug

    (2) Cover

  1. Remove plug (1) and the O-ring seal from cover (2) .
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    Illustration 2g00731399

    (2) Cover

    (3) Gasket

    (4) Quick connection

    (5) Manometer

  1. Install gasket (3), quick connection (4), and manometer (5) into the exhaust port.

  1. Read the gauge on the manometer.

    The correct gauge reading is 60 mm of H2O (2.36 inches of H2O). Adjust the pressure regulator, if necessary. See "Adjustment of the Pressure Regulator".

  1. Remove manometer (5), quick connection (4), and gasket (3) from the exhaust port.

  1. Install plug (1) and the O-ring seal into cover (2) .

Adjustment of the Pressure Regulator

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    Illustration 3g00731490

    (1) Locknut

    (2) Adjusting screw

    (3) Cover

    (4) Adjusting screw

  1. Loosen locknut (1). Turn adjusting screw (2) clockwise until the screw stops in the closed position.

  1. Open cover (3). Turn adjusting screw (4) clockwise until the screw stops in the closed position.

    With adjusting screws (2) and (4) in the closed position, no pressure will be registered on the gauge of the manometer.

  1. Turn adjusting screw (4) counterclockwise until 80 mm of H2O (3.15 inches of H2O) is registered on the gauge of the manometer.

  1. Close cover (3) .

  1. Turn adjusting screw (2) counterclockwise until 60 mm of H2O (2.36 inches of H2O) is registered on the gauge of the manometer.

  1. Tighten locknut (1) .

Clean the Box for the Oil Drain (If Equipped)

If the box for the oil drain becomes full, the exhaust air from the detector cannot be vented. This will also occur if the drain line for the oil is plugged.

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    NOTICE

    Keep all parts clean from contaminants.

    Contaminants may cause rapid wear and shortened component life.

  1. Turn OFF the compressed air for the system.
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    Illustration 4g00733595

    (1) Box

    (2) Vent

    (3) Line

  1. Remove the four screws from the cover of box (1) .

  1. Clean the inside of the box and the cover of the box.

  1. Inspect the hoses for good condition.

  1. Make sure that the following components are clear of obstruction:

    • Drain line from the oil mist detector to the box

    • Vent (2) for the box

    • Drain line (3) for the box

  1. Install the cover onto the box. Secure the cover with the four screws.

  1. Turn ON the compressed air for the system.

Every 3 Months

Maintenance for the Measuring Head

Air from the air pressure regulator is filtered by two sintered bronze filters in the measuring head. The filtered air passes through two bores in order to enter the measuring track. A stream of the clean air passes between each infrared diode and the atmosphere from the crankcase. This helps to keep the oily air away from the glass of the infrared filters. The maintenance for the measuring head includes the following procedures:

  • Cleaning of the bores for the filtered air

  • Cleaning of the glass of the infrared filters

  • Replacing the sintered bronze filters

When any item of the maintenance is performed, also perform all of the other maintenance.

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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 5g00731635

    (1) Inspection cover

    (2) Retaining ring

    (3) Filter

  1. Open inspection cover (1) of the measuring head.

  1. Remove retaining rings (2) .

    Note: Do not reuse the filters. The filters cannot be effectively cleaned.

  1. Remove filters (3). Discard the filters.
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    Illustration 6g00744635

    Bores for the filtered air

    The bores for the filtered air provide a passage between the cavities for the sintered bronze filters and the spaces in front of the infrared diodes.

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    Illustration 7g00731837

    The tip of the cleaning needle is 11 mm (0.43 inch) long.

    (4) Cleaning needle

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    NOTICE

    A flow meter is located near the bore on the left side of the detector. A temperature sensor is located near the bore on the right side of the detector. If an object that is longer than 11 mm (0.43 inch) is used for cleaning the bores, the flow meter and/or the temperature sensor can be damaged. Do not use any object longer than 11 mm (0.43 inch) for cleaning the bores.

  1. Clean the two bores with cleaning needle (4) .
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    Illustration 8g00731891

    (5) Cotton swab

    Note: Only use cotton swabs that have flexible plastic sticks.

  1. Soak cotton swab (5) in alcohol. Clean the glass of the infrared filters with the cotton swab. Clean the glass at least three times. Use a different tip for each cleaning.

  1. Rub the glass dry with a clean, dry cotton swab. Make sure that no fibers remain on the glass.

    Note: When you install the new filters, make sure that the rough side of the filters are facing outward. Otherwise, the filters will quickly become clogged.

  1. Install two new 197-5464 Filters (3). Secure the filters with retaining rings (2) .

  1. Close inspection cover (1) .

  1. Check the pressure of the vacuum in the measuring head. Adjust the pressure, if necessary.

Every Year

Replace the Sintered Bronze Filter for the Pressure Regulator

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    NOTICE

    Keep all parts clean from contaminants.

    Contaminants may cause rapid wear and shortened component life.

  1. Turn OFF the compressed air supply. Purge the compressed air from the system.
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    Illustration 9g00731947

    (1) Bolt

    (2) O-ring seal

    (3) Filter

  1. Loosen bolt (1). Remove the bolt and O-ring seal (2) .

    Note: Do not reuse the filter. The filter cannot be effectively cleaned.

  1. Remove filter (3). Discard the used filter.

  1. Clean the cavity for the filter.

  1. Install a new 197-5465 Filter (3) .

  1. Inspect O-ring seal (2) for good condition. Obtain a new seal, if necessary.

  1. Install the O-ring seal and bolt (1) .

  1. Turn ON the pressurized air supply.

Clean the Suction Lines for Sampling the Atmosphere from the Crankcase

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    NOTICE

    Keep all parts clean from contaminants.

    Contaminants may cause rapid wear and shortened component life.

  1. Shut OFF the compressed air supply to the detector. Purge the compressed air from the system.

  1. Disconnect the suction lines from the detector. The procedure depends on the model of the detector.
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      Illustration 10g00744748

      191-6505 Oil Mist Detector

      (1) Connections for the suction lines

    1. For the 191-6505 Oil Mist Detector, disconnect suction lines (1) from the detector. Move the suction lines away from the detector. Discard the seals for the fittings of the suction lines. Obtain new seals for reassembly.
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      Illustration 11g00738641

      149-5143 Oil Mist Detector

    1. For the 149-5143 Oil Mist Detector, loosen two hex head bolts (not shown) from the sides of each connection block (1) and (2). Move the connection blocks and the suction lines away from the detector. A sleeve for the suction lines is inside of each connection block. Discard the sleeves. Obtain new sleeves for reassembly.

  1. Disconnect the other ends of the suction lines from the engine block.

  1. Use the 130-6061 Hose Cleaner Group to clean the suction lines. Instructions are provided with the tool group.
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    Illustration 12g00744786

    (3) Crankcase cover

    (4) Tube

    (5) Funnel

    Note: Before you clean a tube for a funnel, suspend a container under the funnel in order to catch debris. This will help to prevent contamination of the oil in the crankcase.

  1. Remove crankcase covers (3) in order to clean funnels (5) that are inside of the crankcase. Use an appropriate brush to clean the inside of tubes (4). Use absorbent towels to clean the insides of the funnels.

  1. Install the crankcase covers.

  1. Reconnect the suction lines to the engine block.

  1. Reconnect the suction lines to the oil mist detector. Use new seals or sleeves for the connections.

Clean the Oil Drain Line

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    NOTICE

    Keep all parts clean from contaminants.

    Contaminants may cause rapid wear and shortened component life.

  1. Disconnect the oil drain line from the detector.

  1. Disconnect the other end of the oil drain line from the box for the oil drain (if equipped) or from the engine block.

  1. Use the 130-6061 Hose Cleaner Group to clean the oil drain line. Instructions are provided with the tool group.

  1. Reconnect the oil drain line to the box for the oil drain (if equipped) or to the engine block.

  1. Reconnect the oil drain line to the detector.

Service Tools

The 132-8710 Tool Kit has most of the tools and some of the replacement parts that are needed for servicing the oil mist detector. The tool kit is shown in Illustration 13. The contents of the tool kit are described in Table 3.

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Illustration 13g00730660

132-8710 Tool Kit

(1) Manual

(2) Cigarette burner

(3) Quick connection

(4) Gasket

(5) Wrench

(6) Filter

(7) Spring

(8) Bolt

(9) Clamp ring

(10) Alcohol bottle

(11) Spring

(12) Bolt

(13) Gasket

(14) Cotton swab

(15) Manometer

(16) Water bottle

(17) Plate clamp

(18) Cleaning needle

(19) Plastic bag

(20) Screwdriver

(21) Pliers

(22) Screwdriver

(23) Screwdriver

(24) Hex wrench

(25) Colored glass

(26) Gasket

(27) Box wrench

(28) Rubber gasket

(29) Plug

(30) Gasket

(31) Hex wrench

(32) Gasket

(33) Fuse

(34) Flexible bellows

(35) Filter

(36) Retaining ring

The tools in Illustration 13 are described in Table 3.

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Table 3
Tools in the 132-8710 Tool Kit    
Item     Description     Function     Qty    
1     The manual has more Information about the oil mist detector.     1    
2     The cigarette burner is used for producing translucent vapor in order to test the oil mist detector.     1    
3     Gasket     The quick connection and the gasket are used with the water manometer.     1    
4     Quick connection     1
5     Wrench     The wrench is used for the removal and the installation of the electronic module.     1    
6     197-5465 Filter     The sintered bronze filter is for filtering of the air before the pressure regulator.     1    
7     Spring     The springs, bolts, and clamp rings are the upper fasteners for the measuring head.     2    
8     Bolt     2
9     Clamp ring     4
10     Alcohol bottle     The alcohol is used for cleaning the infrared filters.     1    
11     Spring     The springs and bolts are used with clamp rings (9) as the lower fasteners for the measuring head.     2    
12     Bolt     2
13     Gasket     The gasket is for the oil drain of the 191-6505 Oil Mist Detector.     1    
14     Cotton swab     The cotton swabs are used for cleaning the infrared filters.     5    
15     Manometer     The manometer is used for measuring the pressure of the vacuum in the measuring head.     1    
16     Water bottle     The water is used in the manometer. Clean tap water is acceptable for use.     1    
17     Clamp     The clamps are used for the pipe connections of the 149-5143 Oil Mist Detector.     2    
18     Cleaning needle     The cleaning needle is used to clean the bores for the fresh air in the measuring head.     1    
19     Plastic bag     The plastic bag is for holding translucent vapor from the cigarette burner.     1    
20     Screwdriver     The screwdriver is used to adjust the threshold of the oil mist alarm.     1    
21     Pliers     The pliers are for installation of the retaining rings for the sintered bronze filters in the measuring head.     1    
22     Screwdriver     The 4 mm screwdriver is used for removal and installation of the electronic module.     1    
23     Screwdriver     The screwdriver is used for removal and installation of the measuring head.     1    
24     Hex wrench     The wrench is for opening the lock of the cover on the measuring head.     1    
25     Colored glass     The glass has opacity of 5 %. The glass is used with the infrared diodes in order to verify the accuracy of the detector.     1    
26     Gasket     The gasket is installed between the measuring head and the mounting plate.     1    
27     Wrench     The box wrench is used to adjust the pressure regulator.     1    
28     Rubber gasket (sleeve)     The sleeves are installed at the connections for the pipes on the 149-5143 Oil Mist Detector.     2    
29     Plug     The plugs are for unused pipe connections on the 149-5143 Oil Mist Detector.     3    
30     Gasket     The gaskets are for the valve box of the 149-5143 Oil Mist Detector.     2    
31     Hex wrench     The wrench is used for removal and installation of the valve box.     1    
32     Gasket     The gasket is for the oil drain of a different model of oil mist detector.     0    
33     Fuse     The 2 ampere fuse is used in the measuring head.     1    
34     Flexible bellows     The flexible bellows are used for mounting between the measuring head and the base plate.     2    
35     197-5464 Filter     The sintered bronze filters are for the measuring head.     6    
36     Retaining ring     The retaining rings are used to secure the sintered bronze filters in the measuring head.     4    

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