Caterpillar Certified Procedure to Inspect and Clean Air Filters {1051, 1054} Caterpillar

Caterpillar Products

All Cat Engines

Introduction

Table 1

Revision	Summary of Changes in SEBF8062
11	Added new serial number prefixes for New Product Introduction (NPI).

© 2019 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Work safely. 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. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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 which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

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 safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. 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, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

Caterpillar no longer recommends cleaning primary air filters when the service life has been met. If a new air filter is not available for installation, follow the procedure below until a new filter can be installed. Reuse of primary air filters will cause the warranty of the filter to be voided. Do not use any cleaning method other than the one specified in this guideline.

Note: Caterpillar recommends using air in low pressure and high volume to clean air filters.

PowerCore is a registered trademark of Donaldson Company Inc.

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Do not wash air cleaner elements in any flammable solution such as diesel fuel or gasoline. Doing so can cause fire or an engine runaway and can result in personal injury.

Never install a part that does not meet the specifications in this guideline. During reconditioning, correct any conditions that might have caused the original failure.

Service Letters and Technical Information Bulletins

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NOTICE
The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.

Tooling and Equipment

Table 2

Required Tooling and Equipment
Part Number	Description
138-8448	Plastic Protectant

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

Types of Air Filter Elements

Air Filters Which Can Be Cleaned

Illustrations 34,5, and 6 show the primary elements of the air filters that can be cleaned until a new filter is installed. These filters have a folded paper design which can withstand cleaning.

Note: Air filters with axial seals and radial seals can be cleaned.

Illustration 3	g06382935
Nomenclature of panel type air filters which can be cleaned. (1) Gasket (2) Metal screen (3) Dirty side (4) Clean side

Illustration 4	g06382936
A typical example of an air filter element with an axial seal which can be cleaned. (5) Clean side (6) Axial seal (7) Metal screen (8) End cap

Illustration 5	g06382939
A typical example of an air filter element with a radial seal.

Illustration 6	g06382942
An example of a PowerCore air filter element with a radial seal.

Air Filters Which Cannot Be Cleaned

There are some types of air filters that cannot be cleaned, such as secondary air filters. The following air filters cannot be cleaned and should be replaced:

• Secondary air filters

• Filters with damage to the filter paper

• Rebuilt air filters

• Standby filters for engines

• Air filters for fire pumps

Illustration 7	g06382944
Secondary air filters cannot be washed.

Air Filter Restriction Indicator

Note: The air filter indicators need annual replacement.

Use an air filter restriction indicator (Illustrations 8 and 9) to determine when a filter should be replaced. The two types of restriction indicators are the flag type and the graduated type.

Illustration 8	g06382945
These graduated restriction indicators are found on newer engines.

Illustration 9	g06382948
A flag type air filter restriction indicator (older style).

Inspect the indicators daily for cracks, holes, or loose fittings. If the indicator is damaged, the indicator must be repaired or replaced when any of these conditions are present.

See the appropriate Operation and Maintenance Manual for further information.

Inspection

Visually inspect the filter for damage and failures in the filter seal, gasket, and outer cover before cleaning the filters. Do not use any failed filters or any damaged filters. PowerCore air filters require inspection of the beads of glue for damage and inspection of the filter paper for damage.

Illustration 10	g06382950
Typical damage to an axial air filter element

Do not use this air filter again.

Illustration 11	g06382953
Typical example of a reusable axial air filter element

Reuse this air filter until a replacement can be installed.

Illustration 12	g06382957
Typical damage to an air filter element with a radial seal.

Do not use this air filter again.

Illustration 13	g06382961
This gasket will give a good seal.

Reuse this air filter until a replacement can be installed.

Illustration 14	g06382963
This gasket is badly damaged.

Do not use this air filter again.

Illustration 15	g06382964
A typical example of a reusable gasket for an air filter with an axial seal.

Reuse this air filter until a replacement can be installed.

Illustration 16	g06382966
This gasket is badly damaged.

Do not use this air filter again.

Illustration 17	g06382968
A typical example of a reusable air filter element with an axial seal.

Reuse this air filter until a replacement can be installed.

Illustration 18	g06382970
A typical example of a reusable air filter element with a radial seal.

Reuse this air filter until a replacement can be installed.

Illustration 19	g06382974
A typical example of a reusable air filter element with a radial seal.

Reuse this air filter until a replacement can be installed.

Illustration 20	g06382977
A typical example of the beads of glue that are on a reusable PowerCore air filter with a radial seal.

Reuse this air filter until a replacement can be installed.

Recycle Center Layouts

Note: All Measurements are in meters.

Illustrations 21 through 23 show the three types of layouts for recycling centers that are recommended by Caterpillar.

Illustration 21	g06382978
This layout is used.

Illustration 22	g06382980
This layout is used.

Illustration 23	g06382981
This layout is used.

Table 3

Conversion Chart
Meters (Feet)
6.40 m (21.0 ft)
6.71 m (22.0 ft)
7.92 m (26.0 ft)
9.45 m (31.0 ft)
12.19 m (40.0 ft)
13.41 m (44.0 ft)
22.86 m (75.0 ft)

Table 1

A conversion table for converting meters into feet.

Cleaning Using Low Pressure and High Volume of Air

Illustration 24	g06382983
A flow chart for the process of cleaning air filters.

Filter Preparation

Illustration 25	g06382985
A typical example of a storage location with a machine for crushing cardboard containers and a machine that cleans seals.

Note: Make sure that you wear the correct protection for your eyes, ears, hands, and lungs.

Note: Make sure that all the customer air filter elements are cleaned together. This process will ensure that each customer will receive the original air filter elements.

(1) The air filter elements are delivered to an area to be prepared for cleaning. Remove the air filters from the pallets. Visually inspect the air filter elements for damage to the media, damage to the mesh, and damage to the seals. Discard damaged air filter elements.

Illustration 26	g06382987
A typical example of a seal for an air filter.

Note: Not all air filters are equipped with top seals.

(2) If necessary, remove the seal from the air filter.

Illustration 27	g06382989
An example of a rack for cleaning the seals.

Illustration 28	g06382992
An example of a machine that cleans parts.

(3) Fill the rack with seals. Wash the seals with a machine that washes seals with a biodegradable chemical detergent.

Illustration 29	g06382994
An example of tags with bar codes.

Illustration 30	g06382997
An example of a bar code that is positioned on an air filter element.

Illustration 31	g06382999
An example of recording an air filter element with the system that uses the certified bar codes.

Note: If the part number is not in the database, the part number must be recorded.

Note: The air filter is located in the process by using the bar codes.

Note: Check the air filter elements for previous bar codes. If a tag with a bar code is not found, place one on the air filter element.

(4) Install the tag with the bar code to the air filter element. Scan the bar code by using the database of bar codes. Record the part number, the customer number, the customer location, and the industry code. Each industry code is found below.

Industry Classification Codes

A - Agriculture

110 - Crop Production

123 - Land forming, Drainage, and Irrigation

132 - Dairy Farm

B - Building Construction

155 - Landscaping

240 - Residential Building

250 - Commercial and Public

270 - Sewer and Water

C - Heavy Construction

200 - Highways and Streets

201 - Highways, four or more lanes

209 - Dams, Levees, and Canals

220 - Airports

850 - Military

E - Rental

710 - Rental Independent

740 - Caterpillar Rental and Dealer

F - Forestry

405 - Timber Harvesting and Logging

410 - Access Road Construction and Maintenance

440 - Mill and Yard Operations

450 - General Forestry

I - Industrial

255 - Demolition

312 - Petroleum, Chemical, Rubber Products

313 - Metal Products

314 - Asphalt, Cement, Concrete

321 - Scrap Handling

322 - Recycling

331 - Utility Companies

M - Mining

510 - Coal Surface

511 - Coal and Underground

512 - Coal Surface and Coal Underground

520 - Metal Mining

557 - Quarry, Stone, Sand, and Gravel

570 - Nonmetals not classified

W - Waste

920 - Landfill Operation

Illustration 32	g06383000
A typical rack for air filters.

Illustration 33	g06383001
An example of the air filter elements as the elements are located in the process of cleaning.

Illustration 34	g06383003
Typical example of a room for drying.

Note: Designate a shelf on a rack for each customer air filters to prevent confusion.

(5) Load the air filter elements onto racks. Position the racks of filters in a room to dry the filters for 24 hours at a temperature of 41 °C (105 °F) to 43 °C (110 °F). Label the staging boards on the racks by the customer name, the received date or the inspected date, and the number of air filters.

Illustration 35	g06383006
Typical example of weighing an air filter element

Note: Caterpillar recommends using only the cleaning procedure that uses air at low pressure and high volume.

(6) Remove the filter racks from the room. Position a used air filter element on the digital scale.

(7) Scan the bar code by using the wand. Enter the weight into the database.

Illustration 36	g06382999
An example of recording the air filter element by using the bar codes.

Note: Weights of air filter elements are established by entering the weights of the air filter element into the database.

Filter Cleaning

Illustration 37	g06383008
Loosen the dirt in the filter paper.

(1) Position the air filter element according to Illustration 37. By using a wide soft faced hammer, lightly tap on the air filter screen. Continue tapping lightly until most of the particles are loose.

Illustration 38	g06383010
A Caterpillar Service Technology Group machine for cleaning air filters.

Note: Some brands and some types of filters need to be cleaned for different lengths of time. Caterpillar air filters should be cleaned for 4 minutes. Contact the manufacturer of the air filter for specifications.

Note: Some elements of the air filter may need to be cleaned again.

Note: The particles are removed with Caterpillar's by using air at high volume and low-pressure air.

(2) The air filter element is positioned according to Illustration 38 in the machine. Set the machine to the appropriate height of the air filter element. Close the door, and clean the air filter element for 4 minutes. Clean the air filter element again, if necessary

Note: You may notice a wavy appearance in the filter paper when you clean the air filter element. The wavy appearance is acceptable.

Illustration 39	g06383011
A typical example of a radial air filter with wavy filter paper.

Illustration 40	g06383012
Typical example of cleaning a PowerCore air filter with pressurized air

Use pressurized air (less than 620 kPa (90 psi)) to remove dirt from the filter. The air nozzle must be no less than 5.08 cm (2 inches) from the end of the air filter that exits the air.

Final Inspection

Illustration 41	g06383006
Weighing a cleaned air filter element

Note: Weigh three new air filter elements with the same part number. Take the average of the three air filter elements. This measurement is your standard weight for a new air filter element.

(1) The air filter element is returned to the system that uses bar codes for a second weighing. Position the cleaned air filter element on the digital scale. Weigh the cleaned air filter element. If the cleaned air filter element is within 0.27 ± 0.18 kg (0.6 ± 0.4 lb) of the standard weight for the new air filter element, the air filter element passes. If the actual weight of the cleaned air filter element exceeds 0.27 ± 0.18 kg (0.6 ± 0.4 lb), the air filter element fails. The following chart shows when an air filter element passes or an air filter element fails.

Note: Discard all failed air filter elements.

Note: The target weight is calculated by adding 0.27 ± 0.18 kg (0.6 ± 0.4 lb) to the standard weight.

Table 4

Part Number	Standard Weight (lb)	Target Weight (lb)	Actual Weight (lb)	Status
4W-5228	16	16.6	17.1	fail
6I-2499	3.4	4.0	4.0	pass
7W-5317	4.8	5.4	4.7	pass
7Y-1323	7.8	8.4	8.9	fail
9Y-7662	22.2	22.8	30.3	fail
106-3969	9.6	10.2	9.8	pass

This table shows when an air filter element passes or an air filter element fails.

Illustration 42	g06383015
An example of a box with a light.

Illustration 43	g06383018
An example of inspecting an air filter element by using a box with a light.

Note: Caterpillar recommends using a 500 W to 1000 W clear light bulb.

(2) Place the air filter element into the box to inspect the filter paper. Turn on the clear light bulb to inspect the air filter element.

Note: Finding the small holes and small tears can be difficult.

(3) Slowly spin the air filter element and move the bulb up and down. Replace an air filter element with thin filter paper or tears.

Illustration 44	g06383019
Typical damage to the element of a radial seal air filter.

Do not use this air filter again.

Illustration 45	g06383022
A typical example of a reusable element of an air filter with an axial seal.

Reuse this air filter until a replacement can be installed.

Illustration 46	g06383023
A typical example of dust on the end of the clean side of the air filter element.

Illustration 47	g06383026
An example of a hole in the air filter paper.

Do not use this air filter again.

(4) If the air filter element fails, enter the information into the certified system by using the bar code.

Illustration 48	g06383027
Putting a bar code on the air filter element

(5) Use the certified system by using the bar code to identify the air filter element.

Illustration 49	g06383028
Cleaning the air filter element with a mild cleaner

Note: Apply 138-8448 Plastic Protectant to all seals and surfaces of axial air filter elements and radial air filter elements.

Note: Do not allow the filter paper to get wet.

(6) Position the air filter element into the fixture. Visually inspect the air filter element for final acceptability. Use a rag with 138-8448 Plastic Protectant to clean the air filter element. Apply 138-8448 Plastic Protectant to all the sealing surfaces.

Note: Write the reason that the air filter element failed in your records and the customer records.

(7) Use the system of bar codes to record if the air filter element passed or if the element failed.

Illustration 50	g06383031
The label that is used to identify each air filter element that has been packaged

Note: Make sure that the correct labels for identification are placed with the corresponding air filter elements.

(8) If the air filter element passes final inspection, then print the label that identifies the air filter element.