Filtration Procedure for Rebuilt Engines {0680, 0768, 1000, 1300} Caterpillar

Engine

3176 Engines

3400 All, 3300 All, 3200 All, 3100 All, 3000 All, and D-series All

3500 and G3500 Engines

All 3600 Engines

All C280 Engines

C-10 All

C-9 and C9 All

C11 All

C12 and C-12 All

C13 and C-13 All

C15 and C-15 All

C16 and C-16 All

C175 Engines

C18 and C-18 Engines

C27 Engines

C32 Engines

C7 All

Off-Highway Truck/Tractor

794 AC (S/N: MN51-UP; MT51-UP)

Introduction

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar 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 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 dealers and engine customers to attain the benefits of cleaner engines. The kidney loop filtration process is easy to use and will add only a small amount of extra time to your dyno testing. The kidney loop cart quickly connects to the engine oil ecology drain and engine oil fill tube. Most Caterpillar engines have the ecology drain so you will not need to install one.

This guideline also provides you the information needed to modify the filter cart and provides directions for installing and operating the kidney loop system. The kidney loop procedure is used with the engine dyno test and particle counting process. This procedure will remove many of the break-in particles that are in the engine. The engine roll-off target is 18/15 or better for rebuilt engines. Clean fluids play a major role in the life of any fluid system. The following procedure will help reduce fluid contamination in Wheel Loader Transmission oils to an acceptable ISO cleanliness level.

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 method 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 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, measurements, 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.

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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.

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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, PERJ1017, "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

Illustration 2	g06337818
Example of two possible return oil adapters.

Kidney Loop System Modification

Modification to the Filter Cart

Illustration 3	g02385479
204-7392 Filter Cart Gp (air pump only).

1. Remove both filters from the filter cart.
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   Illustration 4	g02385496
   Suction Filter

2. Install the 9U-6983 Oil Filter ( 5 µm (0.0002 inch) Absolute Filter to the suction side of the filter cart. Refer to Illustration 4.
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   Illustration 5	g02385497
   Discharger Filter

3. Then install the 198-3188 2 µm (0.00008 inch) Absolute Filter to the discharge side of the filter cart. Refer to Illustration 5.
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   Illustration 6	g06338184
   Suction Adapter

4. Assemble the 006-5707 Pipe Elbow, 005-8615 Pipe Nipple, 190-8319 Nipple, and 201-8059 Dust Cap. Refer to Illustration 6.
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   Illustration 7	g06338186
   Discharge Adapter, fabricated oil return adapter not pictured. Refer to Illustration 2 for the fabricated adapter.

5. Assemble the 190-8318 Coupler, 201-8057 Dust Cap, 006-5707 Pipe Elbow, 005-8615 Pipe Nipple, and fabricated adapter as shown in Illustration 2. Refer to Illustration 7.

Oil Cleanliness Information

To establish a level of oil cleanliness, record an initial particle count of the bulk oil. 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 be compared to the value measured after a failure, or whenever there is . A particle count unit electronically measures the count and size of the contaminant particles contained in a fluid sample. The 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 4406: Standards for Oil Cleanliness

ISO is a worldwide federation of national standards bodies. The ISO 4406: specifies the code to be used in defining the quantity of solid particles in the fluid. This ISO code is used in any given hydraulic fluid power system. An automatic particle counter derives the equivalent size of a particle from the particle cross sectional area. Particle counts are affected by various factors. These factors include: procurement of the sample, the sample container and particle counting accuracy, when used and the particle count cleanliness. Proper care should be taken during the sample procurement. Proper care will ensure that the sample obtained is representative of the fluid circulating in the system.

The code for contamination levels using automatic particle counters is composed of three scale numbers. Example X/Y/Z:

"X" - The number of particles that is equal to or larger than 4 microns.

"Y" - The number of particles that is equal to or larger than 6 microns.

"Z" - The number of particles that is equal or larger than 14 microns

Currently Caterpillar does not require the reporting of the "X" scale number since the hydraulic tolerances exceed the 4 micron value, therefore a "-" is used in place of the "X". For example, a particle count is read as -/Y/Z, meaning that there was no requirement to count particles equal to or larger than 4 microns.

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 5, 23/21/17 can be translated into a particle count level per 1mL.

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.

Note: The specifications are based on the number of particles per 1 mL (0.034 oz).

Filter Cart Installation

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

Illustration 8	g02385537
Engine oil ecology drain.

Illustration 9	g06338184
Suction Adapter

1. Remove the hex plug (A) and install the suction adapter in the engine oil ecology drain, on the engine oil pan. Refer to Illustration 8.

2. Connect the suction hose to the 90º suction adapter.

3. Open the ecology drain, at (B). Refer to Illustration 8.
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   Illustration 10	g02385576
   Discharge hose assembly and discharge oil adapter.

4. Connect the filter cart discharge hose to the discharge oil adapter. Refer to Illustration 10.

5. Install the oil adapter into the engine oil fill tube.

6. Fasten the adapter assembly to the fill tube.

7. Connect the shop airline to the kidney loop filter cart. Refer to Tool Operating Manual, NEHS0848, "204-7392 (Air Motor Driven) Filter Cart" for operating the filter cart.

Operation of the Kidney Loop Filter during the Dyno Testing

Note: During the kidney loop filtering process, remember to monitor the engine oil level.

• Refer to Reuse and Salvage Guideline, SEBF8442, "Contamination Control of Rebuilt Engines by Using Particle Counting Process" for instruction when to particle count during an engine dyno test.

• For filter cart operating instruction refer to Tool Operating Manual, NEHS0848, "204-7392 (Air Motor Driven) Filter Cart".

Dynamometer Test Report

Customer Name:____________________________ Date:_________________

Model: __________________ S/N: _________________ SMR: _____________

Work Order #: ___________________________ Test Number: _____________

1. Check all the bolts on the driveline to make sure that the bolts are tight.

2. Fill the crankcase _____________ US gal/L (circle units). ISO Particle Count: _____________ Fill Oil.

3. Fill the water tower.

4. Pre-lube the engine.

5. Remove valve-cover, and check for oil to the valve train.

6. Check for fuel leaks.

7. Check for oil leaks.

8. Crank the engine until the oil pressure comes up.

9. Purge the fuel lines.

10. Heat the glow plugs for 30 seconds.

11. Tighten allen plugs in the thermo adapters.

Engine Operation at Low Idle for 15 Minutes

1. Connect the particle counter oil line to the unfiltered side of the engine oil filter.

2. Run particle counter to purge the oil in the line.

3. Run kidney loop cart during low idle (10 minutes).

4. Record Oil Pressure: ______________ psi/kPa.

5. Check and tighten all bolts on the engine.

6. Inspect for oil leaks.

7. Check for fuel leaks.

8. Inspect for water leaks.

9. Set low idle: ______________ RPM.

10. Particle count _____________ ISO Particle Count.

Engine Operation 3/4 of RPM Range at 1/4 Load at 30 Minutes

1. Set the engine at 3/4 engine speed: _____________ RPM.

2. Oil pressure at 3/4 engine speed: _____________ psi/kPa.

3. Fuel pressure at 3/4 engine speed: _____________ psi/kPa.

4. Bring the engine up to operating temperature.

   Water temperature: _____________ °F/°C.

   Oil temperature: ___________ °F/°C.

5. Air inlet temperature at turbo: ___________ °F/°C.

6. Air temperature after the aftercooler: __________ °F/°C.

7. Exhaust temperature: _____________°F/°C. Location: _____________

8. Record high idle: _____________ RPM.

9. Manometer: _____________

10. Visual inspection for leaks: _____________ OK ____ Correction.

    Details of any engine leaks: _____________________________________

    _____________________________________

11. Particle count: _____________ ISO Particle Count.

Engine Operation at Full Load

1. Particle count at the following times:

   _____________ ISO Particle Count.

   _____________ ISO Particle Count.

   _____________ ISO Particle Count.

   _____________ ISO Particle Count.

   _____________ ISO Particle Count.

   _____________ ISO Particle Count.

2. High idle: _____________ RPM Engine Spec: _____________ RPM.

3. Engine speed at full load:_____________ RPM Engine Spec: _____________ RPM.

4. Power: _____________ hp/kW Engine Spec: _____________ hp/kW.

   Note: If engine speed is too low, what was done to correct the problem: _____________________________________

5. Manifold boost pressure at full load:_____________ psi/kPa.

6. Oil pressure at full load:_____________ psi/kPa and oil temperature:_____________ °F/°C.

7. Fuel pressure at full load: _____________ psi/kPa.

8. Water temperature at full load:_____________ °F/°C.

9. Torque at full load:_____________ ft-lbs/N-m.

10. Air temperature downstream of the aftercooler: _____________ °F/°C.

11. Air ratio control operation (circle one): OK Adjusted

12. Engine exhaust temperature: _____________°F/°C and at what location on the engine:_____________

13. Adjusted decelerator position: ____________________

14. Test safety shutdown: Water temperature:____°F/°C. Oil pressure:____ psi/kPa,

    Engine overspeed:_______ RPM.

15. Air inlet temperature before turbo:_____________ °F/°C.

16. Engine full load manometer reading: _____________

17. Engine final visual inspection (circle one): OK Adjusted

18. Dynamometer operator name:_____________

19. Take an S·O·S oil bottle sample: _________ done.

Check the Starting System

1. Electric starter (circle if OK) OK

2. Fill the engine and transmission with oil. OK Adjust ____

3. Test Alt. (circle if OK) OK

Engine Inspection after Dynamometer Test

1. Checked for and corrected any leaks. _______

2. Governor seals are installed. _______

3. Rack is adjusted and sealed. ______

4. Water plugs are removed and placed in the test kit. ____

5. All parts that were removed have been reinstalled. ______

6. Fan drive is okay and has been greased. ______

7. Serial number is on oil sample bottle. ______

8. Service report is completed.______

9. Flywheel bolts are torqued. ______

10. Water regulators are installed.______

Remarks:

_____________________________________

_____________________________________

_____________________________________

_____________________________________

_____________________________________

_______________________________

Signed:_______________________________

Date:_________________________________