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Introduction
| Revision | Summary of Changes in SEBF8442 |
| 04 | Updated Introduction. Added Canceled Replaced Part Numbers statement. Added safety information. |
| 03 | Converted to SIS Authoring Format |
© 2012 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.
This guideline enables dealers and customers to benefit from cost reductions which were made possible through an established Contamination Control Program. Fluids that are used in Caterpillar machines are highly effective unless the fluid contains damaging amounts of contaminates. Therefore, every effort must be made to reduce the contamination level within Caterpillar fluid systems. Caterpillar makes ongoing changes and improvements to the Caterpillar products. This guideline must be used with the latest technical information available from Caterpillar. The latest technical information will ensure that such changes and improvements are incorporated when applicable.
For questions or additional information concerning this guideline, submit a feedback form in the Service Information System web site. To address an urgent need, use the following to forward your request to Caterpillar Repair Process Engineering:
- Caterpillar Dealer Technical Communicator
- Dealer Solution Network
- Caterpillar Technical Representative
- Knowledge Network
Canceled Part Numbers and Replaced Part Numbers
This document may 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.
Summary
This guideline enables the dealer and customers to benefit from cleaner engines. The particle counting process is used with the engine dyno test and with the kidney loop filtration process. Once the dyno operators get acquainted with the equipment, the operators will be able to detect a contaminated engine and associated engine problems before there is catastrophic damage to the engine. The particle counting equipment connects to the engine oil filter manifold.
This guideline also provides the information needed to set up a particle counting process that will work with your dyno test procedure. Additional information is provided to modify a personal computer to be used for collecting the particle data. The guideline also describes how to install a new sampling port on the engine oil manifold. The engine roll-off target is ISO 18/15 for rebuilt engines after dyno test is complete.
Important Safety Information
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 is dangerous. Improper methods could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair of this product, until you understand 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.
Hazards are identified by a safety alert symbol. Safety alert symbols are followed by a signal word such as "Warning" that is shown below.
 | |
| Illustration 1 | g01032906 |
The following is the meaning of this safety alert symbol:
- Pay Attention!
- Become Alert!
- Your Safety is Involved.
The message that appears under the warning explains the hazard. The message will be written or pictorially shown.
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. Therefore, the warnings in this publication and on the product are not all inclusive. If a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar is used, ensure that the procedure is safe for all personnel around the machine. Ensure that the product will not be damaged or that the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures.
All of the information, specifications, and illustrations that are in this publication are based on information that was available at the time of publication. The following could change at any time: specifications, torque, pressures, measurement, adjustments, illustrations and other items. These changes can affect the service that is given to the product. Obtain the most current and complete information before you start any job. Caterpillar dealers have the most current information that is available.
Safety
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Sudden movement of the machine or release of oil under pressure can cause injury to persons on or near the machine. To prevent possible injury, perform the procedure that follows before testing and adjusting the steering system. |
 |
|
Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
|
| 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. |
References
The tooling and equipment used to measure the reusability and salvage of the components listed in this Guideline are identified in the following reference material.
| References | |
| Media Number | Title |
| SEBF8405 | "Kidney Loop Filtration Process For Rebuilt Engines Patent Pending" |
| SEHS9043 | "Valve Installation for Scheduled Oil Sampling of Engine, Transmission, Hydraulics, and Steering" |
| SEBF8482 | "Obtaining an Oil Sample for S·O·S Analysis" |
| NENG2500 | "Dealer Service Tool Catalog" |
Tooling and Equipment
| Required Tools | |||
| Qty | Part Number | Part Description | |
| 1 (1) | OLS | Pamas OLS-2 | |
| 1 (1) | Cable | Pamas Computer Cable | |
| 1 | 7X-3387 | Fluid Sampling Valve As | |
| 1 | 210-5530 | Coupler | |
| 1 (2) | GE06L1/4NPTA3C | Male Connector | |
| 2 | 188-0639 | Hose As | |
| 1 (2) | GE06LR1/4EDA3C | Male Connector | |
| 1 | 4C-6796 | Mineral Spirits | |
| 1 | 4C-9598 | Wrench (3/4 inch) | |
| 1 | 1U-7565 | Wrench (6 mm) | |
| ( 1 ) | Items to be ordered by contacting Pamas, USA. The Pamas On-line unit is recommended over the Pamas S2 ( 188-0645 Particle Analyzer Gp ) for this application. The On-line unit removes the dyno operator from the dyno room during the test. |
| ( 2 ) | These items can be obtained by contacting Caterpillar Service Technology Group. |
Oil Cleanliness Information
To establish a level of oil cleanliness, recording an initial particle count of the bulk oil is necessary. The portable particle counting procedure is one of the techniques that can be used to determine the level of oil cleanness. The advantage to this process is that the test results are available at the time the oil sample is taken. The data can then be used as a baseline and compared to the value measured after a failure. A particle count unit electronically measures the count and size of the contaminant particles contained in a fluid sample. A particle count allows the operator to determine if the fluid meets the required specification.
There are two types of particle counts: laboratory and field. Cat dealers offer lab particle counting as part of the S·O·S fluids analysis program. A sample of oil should always be taken from an engine after repair and submitted to the Cat dealer to perform a lab particle count. The particle count establishes a "baseline" for the engine oil and provides a basis for future comparison among engines.
An on-line particle counter should be used to determine if the rebuilt engine has been properly cleaned before the engine is returned to service. Caterpillar offers an on-line portable particle counter.
If an on-line particle counter is not available, a bottle oil sample must be taken. Submit the oil bottle sample to the Cat dealer S·O·S Laboratory, or use a portable particle counter.
ISO Standards for Oil Cleanliness
The ISO (International Standards Organization) standard 4406:1999 will read in three positions ISO 20/16/12. For discussion purposes, the three positions will be called X, Y, and Z (ISO X/Y/Z). A typical particle counter readout using ISO 4406:1999 would read as follows:
X = Would include all particles greater than 4 µm (0.00016 inch) in size.
Y = Would include all particles greater than 6 µm (0.00024 inch) in size.
Z = Would also include all particles greater than 14 µm (0.00055 inch) in size.
Today, Caterpillar reports ISO cleanliness levels by using only the last two segments of the ISO code (ISO -/Y/Z). The reason is that Caterpillar started using the ISO format when ISO cleanliness levels were reported in two segments (ISO Y/Z). Presently, all experience is with six and fourteen micron levels. The ISO three-segment system was adopted in 1999. Caterpillar has been collecting data on the new segment (4 µm (0.00016 inch) level) since that time. When a better understanding of the four-micron level is achieved, a target value will be assigned to fill oils and filtered compartments. For the time being, the correct method of reporting cleanliness will be written as ISO -/18/15.
The particle count test provides an actual count of particles. The particle counter creates a three-position ISO number that references the quantity and size of particles contained in the oil. As an example, assume that an oil sample has a particle count reading of 23/21/17. By referring to Table 4, 23/21/17 can be translated into a particle count level per 1 mL (0.034 oz). As the range number in the ISO reading decreases, the contamination level in the oil is also decreasing (cleaner oil). Example: 20/18/14 is cleaner than 27/24/19.
| ISO 44069: 1999 Contamination Specifications | |||
| Particle Count | Range Number | ||
| More than | Up to & including | ||
| 130 x 104 | 250 x 104 | 28 | |
| 64 x 104 | 130 x 104 | 27 | |
| 32 x 104 | 64 x 104 | 26 | |
| 16 x 104 | 32 x 104 | 25 | |
| 8 x 104 | 16 x 104 | 24 | |
| 4 x 104 | 8 x 104 | 23 | |
| 2 x 104 | 4 x 104 | 22 | |
| 1 x 104 | 2 x 104 | 21 | |
| 5,000 | 10,000 | 20 | |
| 2,500 | 5,000 | 19 | |
| 1,300 | 2,500 | 18 | |
| 640 | 1,300 | 17 | |
| 320 | 640 | 16 | |
| 160 | 320 | 15 | |
| 80 | 160 | 14 | |
Note: The specifications are based on the number of particles per 1 mL (0.034 oz).
Particle Counting Setup
Installing the Oil-Sampling Valve
- Each rebuilt engine requires an oil sample valve installed in the unfiltered oil flow. Refer to Illustration 23 for examples of oil sample port placement.
- Drill and tap the engine oil manifold on the unfiltered side to install the oil sample port.
 | |
| Illustration 2 | g02385625 |
Typical engine oil sample valve (unfiltered engine oil). | |
 | |
| Illustration 3 | g02385637 |
Typical engine oil sample valve (unfiltered engine oil). | |
- Install the oil-sampling valve. Once the dyno test is complete, install the rubber dust cover.
Particle Counting Hose Routing
 | |
| Illustration 4 | g02385676 |
(1) 210-5530 Coupler (2) GE06L1/4NPTA3C Male Connector (3) 188-0639 Hose As | |
- Assemble Coupler (1), GE06L1/4NPTA3C Male Connector (2), and Hose As (3) in the order shown in Illustration 4. This end of the hose assembly will attach to the engine oil sample port.
- Remove the O-ring and the dust cap.
 | |
| Illustration 5 | g02385698 |
HP-IN hardware change. (5) HP-IN port fitting | |
- Remove the HP-IN port fitting (5) by using a 4C-9598 3/4 inch Wrench .
- Install the GE06LR1/4EDA3C Male Connector into the HP-IN port.
 | |
| Illustration 6 | g02385704 |
Install the connector | |
- Illustration 7 is a diagram that demonstrates how to run the hoses during an engine dyno test.
 | |
| Illustration 7 | g02385716 |
Hose routing during engine dyno test. (6) Pamas On-line unit | |
- To run engine particle counting, the switch must be in the Red = HP position, as shown in Illustration 8.
 | |
| Illustration 8 | g02385719 |
Switch position Red = HP to sample engine oil. | |
- Attach the hose to the engine oil sample port.
 | |
| Illustration 9 | g02385737 |
Hose assembly attached to the engine oil sample port. | |
- Attach the other end of the hose to the particle counting unit at the HP-IN port.
 | |
| Illustration 10 | g02385757 |
Drain hose attached to the Pamas On-line unit. | |
- Make the drain hose by using 188-0639 Hose As and cut to length.
- Attach the drain hose to the particle counting unit at the HP-OUT port.
 | |
| Illustration 11 | g02385740 |
Hose assembly attached to the Pamas On-line unit. | |
- Place the other end of the drain hose in a drain bottle.
Connecting the Serial Port Cable and the Power Cable
 | |
| Illustration 12 | g02385776 |
Serial port location on the Pamas particle counter | |
- Connect the serial port cable to the Pamas unit. Refer to Illustration 12.
- Connect the other end of the serial cable to computer COM1 port.
- Connect the power cable to the particle counter unit at the "Mains" connection.
Note: If COM1 is not available, install the serial port cable into COM2, and change to the PMA software listed under "Setting the Serial Port" section of this article.
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| Illustration 13 | g02385778 |
Particle counter power cable connection. | |
- Turn on the power to the unit by opening the lid and switching on the power, see Illustration 14
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| Illustration 14 | g02385781 |
Power switch, fuse, and voltage option. | |
PMA (Particle Measuring and Analysis) Software
Computer Requirements
- Personal computer with 133 MHz Pentium microprocessor or higher
- Hard disk: 30 Mb or more
- CD-ROM disk drive
- 32 Mb of RAM or more
- One unused computer serial port or USB port with serial adapter (COM)
- Printer port
- Mouse
- VGA or SVGA color monitor with a resolution of at least 800 x 600 dots
- MS-Windows 95 or higher (up to Windows 7)
Note: A powerful computer and storage unit will make the system easier to use. When working with the PMA software, the basic knowledge of the computer operating system and MS-Windows is essential.
Installing the PMA Software Using Windows 98
- Place the installation software disk into the disk drive. The software disk is located in the back cover of the PMA software manual.
- Using the mouse, RIGHT click the "Start" button to open Windows Explorer.
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| Illustration 15 | g02385785 |
- Open the drive containing the PMA disk (example A:\).
- Start the installation routine by double clicking the "SETUP.EXE" file.
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| Illustration 16 | g02385806 |
- The installation program will lead you through the installation. Be sure to use the PMA software defaults when installing the software.
Installing the Sensor Files (.SEN)
Note: The sensor files contain the calibration data needed to run the particle counter.
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| Illustration 17 | g02385825 |
- Use Windows Explorer to copy the sensor files to the hard drive. The sensor files are on the same disk as the SETUP.EXE. The sensor files are located in a folder called SENSOR.
- Copy all sensor files to the PMA folder on the hard drive (example C:\PMA\à;).
 | |
| Illustration 18 | g02385836 |
Note: The name given to the sensor file consists of the sensor serial number that belongs to the system. The serial number can be obtained by inspecting the particle counting unit. For example the serial number 6555 has the file name 6555Hac.SEN.
Installing the System Files (.S31)
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| Illustration 19 | g02385838 |
- Use Windows Explorer to copy the system files to the hard drive. The system files are on the same disk as the SETUP.EXE. The system files are located in a folder called SYSTEM.
- Copy all the system files to the PMA folder on the hard drive (example C:\PMA\à;).
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| Illustration 20 | g02385856 |
Starting the PMA Program
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| Illustration 21 | g02385862 |
- Start the PMA program by clicking "Start" and then select "Programs". Select "PMA" and then the PMA icon.
Exiting the PMA Program
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| Illustration 22 | g02385876 |
- To exit the PMA program, open the pulldown menu "Measurement" in the menu list and select "End program".
The PMA Main Window
- The upper line of the main window contains the menu bar containing the pull-down menus.
- Below the upper line of menu bar are the following icons, starting from left and moving to the right:
- Measurements
- Results
- Presentation
- Print
- System
- User
- Help
- Measurements
- The next line of menu bar contains the following icons, starting from left and moving to the right:
- Diff (Differential)
- Cum (Cumulative)
- Lin (Linear)
- Log (Logarithmic)
- Start
- Stop
- Diff (Differential)
- Below are the icons that indicate the data file shown on the screen:
- File loaded (Data file name)
- Name and sample ID
- The values entered by the operator for measurement volume
- Analyzed volume
- Dilution factor
- File loaded (Data file name)
- Field for calculating the cleanliness classes:
- ISO
- NAS 1638
- SAE 7490
- ISO
- In the lower right side of the screen is the status of the particle counter. If the particle counter is connected to the computer, the lower right box will read "System". If the box reads "No System," there is a problem with the cable connection between the two. Check the cable connections and then restart the computer.
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| Illustration 23 | g02385916 |
Selecting the Language
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| Illustration 24 | g02385936 |
- Open the pull-down menu "System" found on the menu bar and select "Language".
- Select a language and click OK.
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| Illustration 25 | g02385940 |
Loading the Sensor File (.SEN)
Note: After the PMA software has been installed on the hard drive, the sensor file must be loaded into the PMA software.
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| Illustration 26 | g02385941 |
- Select "System" on the menu bar. Select the "Sensor" button, as shown in Illustration 26.
- The sensor files will be located at C:\PMA\. To load the sensor file, click the "Load" button. For background information, see the section labeled "Installing the Sensor Files".
 | |
| Illustration 27 | g02385956 |
- Select the sensor file (*****Hni.sen) and click OK. Then click OK again.
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| Illustration 28 | g02385958 |
Note: The name given to the sensor file consists of the sensor serial number that belongs to the system. The serial number can be obtained by inspecting the particle counting unit. For example, the serial number 6555 has the file name 6555Hni.SEN.
Setting the Serial Port
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| Illustration 29 | g02385976 |
- Select "System" on the menu bar.
- Select "Serial Ports", and the appropriate window will open.
- Select the "Port" and highlight COM1 or COM2.
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| Illustration 30 | g02385996 |
- Select the 9600 baud rate and then click OK.
Measurement Set-up
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| Illustration 31 | g02386016 |
- The particle counter computer cable (COM) MUST be connected to the computer, and the computer turned on. The lower right side of the screen MUST read "System".
- Open "Measurement" on the menu bar.
- Select "Set-up".
- The System 31 window will open.
- Select "Load Set-up".
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| Illustration 32 | g02386038 |
- Select the file engine.s31. This file will be located at C:\PMA\. Then click OK. This file will load a predetermined test setting for rebuilt engines.
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| Illustration 33 | g02386056 |
- Select OK.
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| Illustration 34 | g02386076 |
Setting Up Diameters
 | |
| Illustration 35 | g02386818 |
- To set up the diameters for each individual channel, open the pull-down menu "Measurement" on the menu bar. Select "Diameters". The relevant window will then open.
- For the first diameter, enter 4.0 for the first channel. Then enter 5, 6, 10, 14, 17, 20, 25, 30, 35, 40, 45, 50, 55, 60. 70 respectively for the remaining channels
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| Illustration 36 | g02386821 |
- Select OK.
Naming a New Measurement File
 | |
| Illustration 37 | g02386859 |
- Open "Measurement" from the menu bar and select the menu item "New". The window "Naming Measurement File" will open.
- Enter a name with an ".mes" extension, select a path name and confirm. The window "New Measurement" will open.
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| Illustration 38 | g02386896 |
- Enter a sample ID, details about the customer, the user, and the sample taken. For entering other details there is a commentary field available. Then click OK.
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| Illustration 39 | g02386921 |
Note: From the window "New Measurement" you can access the buttons "Set-up" and "Diameters" directly.
General Software Information
Loading and Saving Set-up Files
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| Illustration 40 | g02386956 |
- Open "Measurement" from the menu bar and select "Set-up".
 | |
| Illustration 41 | g02386976 |
- The window "System 31" will open.
- To load a stored "set-up", open the relevant window by clicking the button "Load Set-up". Select a data file and then click OK.
- Save the set-up file by clicking the "Save Setup" button. The next window will ask for a file name and a storage location. The file name will need an extension ".s31". Examples are engine.s31 or clean.s31.
Performing the Particle Test during the Dyno Test of the Rebuilt Engine
 | |
| Illustration 42 | g02386979 |
PMA Icon. | |
- Double click on the PMA icon.
- Open "Measurement" from the menu bar, and select the menu item "New".
 | |
| Illustration 43 | g02387036 |
- Type a file name. File name can only have eight spaces.
 | |
| Illustration 44 | g02387057 |
- Then click OK.
Note: This file will be saved at C:\PMA\. This file will load a predetermined test setting for rebuilt engines.
- Enter a sample ID, details about the customer, the user, and the sample taken. For entering other details, there is a commentary field available. Then click OK.
 | |
| Illustration 45 | g02387076 |
- Select the "START" button when you are ready to start the measurement. If you need to abort the measurement, click the "STOP" button.
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| Illustration 46 | g02387081 |
- Illustration 47 represents a particle count run. A run is comprised of ten particle count measurements. The PMA software will save the particle count run as one computer file. The PMA software will save the file to the hard drive (C:\PMA\).
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| Illustration 47 | g02387088 |
Operating the Particle Counting and the Kidney Loop Process during the Dyno Test
|
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
|
 | |
| Illustration 48 | g02387095 |
Engine dyno test cycle with particle counting and kidney looping processes. | |
| NOTICE |
|---|
Engine failure may occur while an engine is operating under heavy load. This failure may cause the engine to self-destruct and produce flying objects. To prevent personal injury or death, do not enter the engine room while the engine is under heavy load. |
- Illustration 48 is a typical engine dyno test utilizing the particle counting and kidney loop filtration processes. During the engine dyno test, the engine operates through low idle (15 minutes), 1/4 load (15 minutes), full load (60 minutes), and low idle cool down (15 minutes). The two graphs show how the dyno test, particle counting, and kidney looping function together. In this example, the particle count run is 15 minutes in length. A typical engine dyno test will have seven run computer files. Refer to the Particle Counter (On-line) operation graph for more detail on this subject. The particle counting process is designed to run continually during the dyno test.
- The dyno operator will quickly learn to read the particle data. Illustration 49 and Illustration 50 are two examples of rebuilt engine particle counting data. Illustration 49 is a typical engine particle count. Notice the shape of the bar chart. This chart shows normal rebuilt engine particle count data. Illustration 50 is of a rebuilt engine that had a contaminated engine oil cooler. Notice the elevated bar on the right side of the chart. These particles are larger and the counts are too high. This engine was removed from the dyno and inspected to determine the cause of the elevated particle counts.
Note: Caterpillars rebuilt engine roll-off target is ISO 18/15 after dyno test is complete.
 | |
| Illustration 49 | g02387101 |
Example of a normal engine particle count. | |
 | |
| Illustration 50 | g02387105 |
Example of a contaminated engine particle count. | |
- The kidney loop process is only run twice, once near the beginning of the dyno, at the 10-minute mark to the 20-minute mark. The kidney loop process will remove most of the contamination that was left in the engine from the rebuild. The second time is at the 90-minute to 105- minute mark during the cool down phase. This process is designed to remove any contaminates that are the result of the engine rebuild process or from the engine break-in process.
Cleaning the Particle Counter
Flushing the Particle Counter
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| Illustration 51 | g02387117 |
Cleaning procedure. | |
Illustration 51 diagrams how to assemble the hoses during the cleaning procedure.
 | |
| Illustration 52 | g02387156 |
Switch position Black = LP for cleaning. | |
- Reverse the particle counter flow by switching to Black = LP. This procedure will run the particle counter backwards. Refer to Illustration 52.
Note: Clean the particle counter unit at the end of each shift or at the end of the dyno test.
Cleaning the Particle Counter Screens
Note: Clean the screens once a week.
 | |
| Illustration 53 | g02387177 |
- Remove both connectors (LP-IN and LP-OUT) by using a 4C-9598 3/4 inch Wrench .
 | |
| Illustration 54 | g02387201 |
Removing screens for cleaning. | |
- Remove both screens by using a 1U-7565 6mm Hex Wrench .
- Use compressed air to dislodge any particles that may be present on the screens.
- Wash the screens with mineral spirits.
- Reinstall both screens and connectors.
- Flush the particle counter by following the cleaning procedure.