Installation and Maintenance of the Fumes Disposal Filter for Certain G3500 Series Engines {107F, 7500} Caterpillar

Engine

G3512H (S/N: GF41-UP; GF51-UP)

G3516H (S/N: NWH1-UP; NWJ1-UP; GLM1-UP; GLN1-UP)

G3520H (S/N: GFP1-UP; GFR1-UP)

Generator Set

CG170-16 (S/N: KSJ1-UP)

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	g06255722
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. The G3500H product requires ingesting the fumes to meet the published engine efficiencies.

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

Note: If the engine is shut down and the fumes disposal system continues to run, no damage should occur to the engine. The system will continue to maintain an atmospheric condition in the crankcase. However, the fumes disposal system is switched off.

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

The fumes disposal filter group contains a filter cartridge, blower motor, and pressure gauge which are all serviceable. Refer to the 191-2304 Fumes Disposal Filter Gp which breaks down into the following parts:

• 196-9812 Fumes Disposal Blower Gp

• 191-2373 Breather Filter Element (CRANKCASE)

• 191-2302 Oil Filter Pressure Differential Gauge Gp (FUMES DISPOSAL)

Note: The air lines and the fittings are supplied by the customer. No bypass line is needed. Leave the bypass port on bottom of the filter unit open to atmosphere without a hose attached.

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

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

Components and Reference Dimensions

Illustration 2	g06255734
Components of 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) Bypass port (8) Inlet for the fumes disposal filter

Illustration 3	g00730535
Reference dimensions of the 191-2304 Fumes Disposal Filter Gp

Installation

Note: The air lines 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 and a flexible hose is used for the final connection to the compressor inlet. Use flexible hose for the connections to the crankcase breathers.

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. For engines where temperatures can be below 15° C (59° F), the system must be insulated to minimize the risk of crankcase fumes reaching dew point temperature. If the system is too cold, water can emulsify with the oil due to condensation and damage the lube oil system.

If the engine container does not allow for enough room for the fumes disposal system, the system can be installed outdoors. The motor/blower assemblies are enclosed, so no harm can occur to electrical parts. Rust preventative epoxy paint is used on the system to help prevent rust. If installed outdoors, the ambient temperature should not get below 15° C (59° F). If there are space constraints for the engine installation and the return drain line cannot be routed to the engine oil pan, run the drain line to a customer supplied waste oil containment system. Ensure that the 5 ft pressure head requirement is met. Cover the bottom of the drain line with oil that is in the containment system for a positive seal to ensure a constant oil drain.

Note: 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 191-2304 Fumes Disposal Gp weighs approximately 86 kg (190 lb).
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   Illustration 4	g06255768
   The minimum distance from the engine oil level to the bottom of the filter (D1) 1.5 m (5 ft)

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

2. Lift the filter into position. Provide sufficient clearance for removal of the filter element. Refer to "Components and Reference Dimensions".

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

   1. Attach the filter securely to a surface that will support the weight.
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   Illustration 5	g06255787
   (1) Oil drain line (2) 390-9323 Tube As

3. Install oil drain line (1) 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 always. If the engine does not include a drain line with the tube going below the oil level, order the following parts:

   • 390-9323 Tube As

   • 3P-1155 O-Ring Seal

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

   Note: For proper drainage of the oil, the oil drain line must have a constant slope towards the oil pan.

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   Illustration 6	g06255802
   (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 a hose with a minimum diameter of 50.8 mm (2 inch) as the inlet of the filter is a female 2 inch FPT fitting.

   Note: Install lines from crankcase breathers so that pull on both sides of the engine is equal to avoid excessive contamination on one side or the other.

   1. Ensure that the hose is routed at a slight decline from CCV to crankcase breathers to avoid trapped fluids.

      Note: Although not shown in the illustrations, it is highly recommended that a drip leg be installed near the crankcase breathers exit to accumulate any oil that is condensed in the line to the CCV inlet.

   2. Make sure that all connections are tight to avoid any leakage of oil that coalesces in the lines after exiting the crankcase.
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   Illustration 7	g06255811
   (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 the illustration above.

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.

   Note: The outlet of the filter is a female 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 as close to the compressor inlet as possible. Use the orientation shown in the illustration above for the highest possibility of catching any oil that has got through the outlet of the filter.

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

7. 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

   • 220-360/415volts

   See Illustrations 8 and 9.

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   Illustration 8	g00731561
   Wiring diagram for 380 V

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   Illustration 9	g00731513
   Wiring diagram for 220 V

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

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

9. 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 10	g06255833
(1) Fumes disposal filter (2) Oil drain line (3) Bypass

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 always. Ensure that the drain line is securely coupled and that the drain line has a constant slope towards the oil pan.

3. Inspect bypass (3) to ensure that the bypass 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

1. Install a pressure gauge on top of the filter, check the differential pressure across the filter element. Observe the pressure that is indicated by the pressure gauge and 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).

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

3. 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 shut down 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 11	g06255844
(1) Nuts and washers (2) Cover (3) Body (4) Filter element

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

2. Remove element (4).

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

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

5. Place cover (2) in position and install four 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 12	g06255846
   (1) Drip leg

2. Open drip leg (1) and drain the fluid into a suitable container. If there is a second drip leg installed near the crankcase breathers to collect condensed oil flowing to the CCV inlet, this leg should also be drained.

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

   1. 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. Resume normal operation.

Every 1000 Service Hours

• Measure the crankcase pressure during normal operation.

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

Troubleshooting the Fumes Disposal System

Oil Drain Line Not Draining Oil

The bottom portion of the drain line must always be below a constant oil level to be sure that air does not leak into the drain line.

1. If the oil drain line does not seem to be moving oil, check to ensure that the line is submerged in oil.

2. Check the drain line for leaks and be sure that all fittings are tight.

   Note: Teflon tape at threaded joints is suggested.

   Note: Air leaks will create vapor lock and not allow the system to drain collected oil.

3. Make sure that the bottom of the fumes disposal system cartridge is at least 5 ft above the top of the oil level that the oil is being drained to.

   Note: This is required to overcome the static head pressure created by the fumes disposal system and depth style filter cartridge used to coalesce the oil. The 5 ft distance is essential for proper draining.

Oil Mist Exiting from Outlet of Fumes Disposal System

If smoke or oil mist is exiting from the outlet of the fumes disposal system, this likely indicates that the system is not draining properly and filling the housing.

1. Be sure that all drain fittings are tight and air is not leaking into the drain line.

2. Ensure that excessive vacuum is not on the oil system, this would indicate that oil may be sucked from the oil system and drawn up through the inlet.

Crankcase Pressure Too High

If the fumes disposal system is not pulling enough to gather the blowby fumes from the crankcase, restrict the bypass connection of the fumes disposal system in order to direct more of the blower motor pull to the crankcase inlet rather than the bypass connection.

Note: It is important not to exceed the limits of the engine (+/- 1 in. H2O crankcase pressure).

1. The best time to set butterfly valve is 1 week after the fumes disposal system has been in full operation, this ensures that the filter element is fully saturated.

2. Set the valve while monitoring the crankcase pressure.

Filter Pressure Delta Above 40 in H₂O

1. If the restriction of the element in the fumes disposal system reaches a value over 40 inches of H₂O, service the filter.

2. Replace the fumes disposal system filter canister and associated cover gaskets at least one time per year. Inspect the inside of the system to be sure it is free and clear of any foreign matter or obstructions.

Foreign Object Entry to Fumes Disposal System

Small particulate could be common depending on the environment. However the fumes disposal system cartridge will filter out any of the contaminates as it returns clean, reusable oil.

1. If debris is entering the system from the outside, verify that the bypass is angled to the most ideal position. This position is so that water and other debris do not enter the system.

2. It is required to have the bypass pointed down in outside installations of the fumes disposal system.

   Note: The system does not have enough suction to pull anything of size into the system.