REHS0883 - Installation and Maintenance of The Fumes Disposal Filter PDF

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Special Instruction
Installation and Maintenance of the Fumes Disposal Filter
Media Number -REHS0883-00 Publication Date -2001/03/01 Date Updated -2001/10/09

i01380656
Installation and Maintenance of the Fumes Disposal Filter
Engine:
G3516B (S/N: 7EZ1-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.

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Illustration 1 g00766996
Operation of the fumes disposal filter
(1) Flow of the crankcase atmosphere
(2) Flow of the air to the turbocharger
(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.
If power to the blower is lost during engine operation, the crankcase atmosphere is purged through
bypass port (4) .
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
Two different fumes disposal filters are available. The operation of the devices is identical.
The 191-2303 Fumes Disposal Filter Gp is used with a single engine.
The 191-2304 Fumes Disposal Filter Gp has a greater capacity. This filter is used with tandem
engine installations.
Note: The air lines, the line for the bypass, and the fittings are supplied by the customer.
Do not perform any procedure in this Special Instruction until you read this information and you
understand this information.
Components and Reference Dimensions


Components of the 191-2303 Fumes Disposal Filter Gp and 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) Condensation trap drain valve
(8) Bypass port
(9) Inlet for the fumes disposal filter

Reference dimensions of the 191-2303 Fumes Disposal Filter Gp
Reference dimensions of the 191-2304 Fumes Disposal Filter Gp

Installation
Note: The air lines, the line for the bypass, 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.
The location of the filter depends on the model that will be installed. The filter must be within the
specified distance from the engine in order to eliminate excessive pressure drop.
Install the 191-2303 Fumes Disposal Filter Gp within 15 m (50 ft) of the engine.
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.
Attach suitable straps and a lifting device to the filter. 1.
The 191-2303 Fumes Disposal Filter Gp weighs approximately 58 kg (128 lb).
The 191-2304 Fumes Disposal Gp weighs approximately 86 kg (190 lb).

The minimum distance from the engine oil level to the bottom of the filter is 1.5 m (5 ft).
(1) Bracket
Lift the filter into position. The bottom of the filter must be at least 1.5 m (5 ft) above the
engine oil level. Be sure to provide sufficient clearance for removal of the filter element. Refer
to ""Components and Reference Dimensions" ". Attach the filter securely to a surface that will
support the weight.
2.
Bracket (1) has two mounting holes for installation of the filter. The fasteners are supplied by
the customer.

(2) Oil drain line

Install oil drain line (2) 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 at all times.
3.
If the drain line is loose, ambient air can enter the system. This reduces the performance of the
system. This can also allow contaminants to enter the system. Ensure that the drain line is
coupled securely.
For proper drainage of the oil, the oil drain line must have a constant negative slope. Ensure
that the oil drain line has a constant negative slope.

(3) Hose from the outlet of the crankcase breathers to the inlet of the filter

Route hose (3) from the outlet of the crankcase breathers to the inlet of the filter. Use hose with
a minimum diameter of 50.8 mm (2 inch).
4.
The inlet of the filter is a female 2 inch FPT fitting.
Ensure that the hose is routed in a manner that will avoid trapped fluids.


(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 Illustration 8.
Route piping (4) from the outlet of the filter to the elbow at the inlet of the turbocharger. 5.
The outlet of the filter is a female 1 and 1/2 inch FPT fitting. The fitting on the elbow at the
inlet to the turbocharger is a 1 and 1/2 inch NPTF fitting.
Install drip leg (5) prior to the turbocharger compressor inlet. 6.
Note: If power to the filter is interrupted during operation, the crankcase atmosphere is vented
through the bypass.
Note: Never install an air filter in the bypass line. Installing an air filter will increase crankcase
pressure to an unacceptable level.


Route hose (6) from the bypass port to a suitable location. Venting to the outside is
recommended.
7.
The bypass port is a female 2 inch FPT fitting.
Size the hose and route the hose in order to minimize pressure drop. Route the hose in a manner
that will avoid trapped fluids. Ensure that moisture cannot enter the system through the hose.
Note: Do not connect the condensation trap drain valve to the oil drain line. Otherwise, the oil
will not be removed from the air.
Ensure that condensation trap drain valve (7) is closed. 8.
Note: The wiring must be performed by a qualified service technician.
Connect the blower motor to an electrical source. 9.
The blower motor can be configured for one of the following two different power sources:
208-230/460 volts
220-360/415 volts
See Illustrations 10 and 11.


Wiring diagram for 220 volts


Wiring diagram for 380 volts
Note: Wire the blower motor to a good earth ground.
Wire the motor to a suitable source in accordance to the "National Electric Code" or local
standards.
10.
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.
11.
If the motor is not rotating in the correct direction, reverse the polarity at the leads for the
electrical power.
Inspection Before Start-up


Ensure that filter (1) is at the proper height above the engine oil level. 1.
The bottom of the filter must be at least 1.5 m (5 ft) above the engine oil level.
Ensure that oil drain line (2) remains below the engine oil level at all times. Ensure that the
drain line is securely coupled and that the drain line has a constant negative slope.
2.
Inspect bypass line (3). Ensure that the bypass line is not obstructed. 3.
Initial Start-up
During the initial operation of the filter, use the gauge on top of the filter to check the
differential pressure across the filter element.
1.
The restriction of a new element is approximately 1.7 kPa (7 inches of H
2
O).
The normal restriction of the element is approximately 5.7 to 9.95 kPa (23 to 40 inches of H
2
O).
Measure the crankcase pressure at partial load and full load. 2.
For a properly installed system, crankcase pressure will be within 0.25 kPa (1 inch of H
2
O) of
the atmospheric pressure.
Maintenance
Maintenance Schedule
Maintenance Schedule for the Fumes Disposal Filter
Interval Procedure
When Required Replace the filter element.
Daily Record the differential pressure of the filter.
Every 500 Service Hours Drain the drip leg and the condensation trap drain valve.
Every 1000 Service Hours Measure the crankcase pressure.
Every Year Replace the filter element.
Table 1
Daily
Check the differential pressure across the filter element. Observe the pressure that is indicated by the
pressure gauge on top of the filter. Record the measurement.
The restriction of a new element is approximately 1.7 kPa (7 inches of H
2
O).
The normal restriction of the element is approximately 5.7 to 9.95 kPa (23 to 40 inches of H
2
O).
For the 191-2303 Fumes Disposal Filter Gp , replace the filter element when the differential
pressure reaches 11.2 kPa (45 inches of H
2
O).
For the 191-2304 Fumes Disposal Filter Gp , replace the filter element when the differential
pressure reaches 12.4 kPa (50 inches of H
2
O).
Replace the element after every year regardless of the differential pressure.
Replacement of the Filter Element
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.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

(1) Nuts and washers
(2) Cover
(3) Body
(4) Filter element

Remove three nuts and washers (1) in order to remove cover (2) from body (3) . 1.
Remove element (4) . 2.
Clean the inside of cover (2) and body (3) . 3.
Install new element (4) into body (3) . 4.
Place cover (2) in position and install three nuts and washers (1) . 5.
Every 500 Service Hours
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.
Shut down the engine and the fumes disposal filter. 1.
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, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.


(1) Drip leg
(2) Condensation trap drain valve
Open drip leg (1) and drain the fluid into a suitable container. 2.
If the filter is installed and maintained properly, no more than 28 g (1 ounce) of fluid will be
drained.
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.
Close the drip leg. 3.
Open condensation trap drain valve (2) and drain the fluid into a suitable container. 4.
Close the condensation trap drain valve. 5.
Resume normal operation.
Every 1000 Service Hours
Measure the crankcase pressure during normal operation.
For a properly installed system, crankcase pressure will be within 0.25 kPa (1 inch of H
2
O) of the
atmospheric pressure.
Copyright 1993 - 2011 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Feb 9 09:47:14 EST 2011

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