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Product: TRUCK
Model: 793D TRUCK FDB
Configuration: 793D Off-Highway Truck FDB00001-UP (MACHINE)
POWERED BY 3516B Engine

Contamination Control Guidelines


Contamination Control of Rebuilt Engines by Using a Particle Counting Process Patent
Pending{1000, 1300}
Media Number -SEBF8442-04 Publication Date -13/11/2012 Date Updated -13/11/2012
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i05178577

Contamination Control of Rebuilt Engines by Using a Particle


Counting Process Patent Pending{1000, 1300}
SMCS - 1000; 1300

Engine: 3176 Engines 3200 3300 3400 3400 All, 3300 All, 3200 All, 3100 All, 3000 All, and D-series All All
3500 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 All C27 All C32 All C7 All

Introduction
Table 1
Revision Summary of Changes in SEBF8442
Updated Introduction.
04 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. r080crc15
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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.

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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

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 r080crc15
engine has been stopped. Serious injury can be caused if this pressure is Confidential Yellow
Caterpillar:
not released before any service is done on the hydraulic system.
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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.

Table 2
References

Media Number
Title

SEBF8405 "Kidney Loop Filtration Process For Rebuilt Engines Patent Pending"

"Valve Installation for Scheduled Oil Sampling of Engine, Transmission, Hydraulics, and
SEHS9043
Steering"

SEBF8482 "Obtaining an Oil Sample for S·O·S Analysis"

NENG2500 "Dealer Service Tool Catalog"

Tooling and Equipment


Table 3
Required Tools

Qty Part Number Part Description

1 (1) OLS Pamas OLS-2

1 (1) Cable Pamas Computer Cable r080crc15


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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
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-/Y/Z). The reason is that Caterpillar started using the ISO format when ISO cleanliness levels were reported in
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two segments (ISO Y/Z). Presently, all experience is with six and fourteen micron levels. The ISO three-segmentYellow

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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.

Table 4
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 r080crc15
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1. 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.

Illustration 2 g02385625
Typical engine oil sample valve (unfiltered engine oil).

Illustration 3 g02385637
Typical engine oil sample valve (unfiltered engine oil).

2. Drill and tap the engine oil manifold on the unfiltered side to install the oil sample port.

3. Install the oil-sampling valve. Once the dyno test is complete, install the rubber dust cover.

Particle Counting Hose Routing

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Illustration 4 g02385676
(1) 210-5530 Coupler

(2) GE06L1/4NPTA3C Male Connector

(3) 188-0639 Hose As

1. 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.

Illustration 5 g02385698
HP-IN hardware change.

(5) HP-IN port fitting

2. Remove the O-ring and the dust cap.

3. Remove the HP-IN port fitting (5) by using a 4C-9598 3/4 inch Wrench .

Illustration 6 g02385704
Install the connector

4. Install the GE06LR1/4EDA3C Male Connector into the HP-IN port.

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Illustration 7 g02385716
Hose routing during engine dyno test.

(6) Pamas On-line unit

5. Illustration 7 is a diagram that demonstrates how to run the hoses during an engine dyno test.

Illustration 8 g02385719
Switch position Red = HP to sample engine oil.

6. To run engine particle counting, the switch must be in the Red = HP position, as shown in Illustration 8.

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Illustration 9 g02385737
Hose assembly attached to the engine oil sample port.

7. Attach the hose to the engine oil sample port.

Illustration 10 g02385757
Drain hose attached to the Pamas On-line unit.

8. Attach the other end of the hose to the particle counting unit at the HP-IN port.

9. Make the drain hose by using 188-0639 Hose As and cut to length.

Illustration 11 g02385740
Hose assembly attached to the Pamas On-line unit.

10. Attach the drain hose to the particle counting unit at the HP-OUT port.

11. Place the other end of the drain hose in a drain bottle.

Connecting the Serial Port Cable and the Power Cable


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Illustration 12 g02385776
Serial port location on the Pamas particle counter

1. Connect the serial port cable to the Pamas unit. Refer to Illustration 12.

2. Connect the other end of the serial cable to computer COM1 port.

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.

Illustration 13 g02385778
Particle counter power cable connection.

3. Connect the power cable to the particle counter unit at the "Mains" connection.

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Illustration 14 g02385781
Power switch, fuse, and voltage option.

4. Turn on the power to the unit by opening the lid and switching on the power, see Illustration 14

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

1. Place the installation software disk into the disk drive. The software disk is located in the back cover of
the PMA software manual.

Illustration 15 g02385785

2. Using the mouse, RIGHT click the "Start" button to open Windows Explorer.

3. Open the drive containing the PMA disk (example A:\).

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Illustration 16 g02385806

4. Start the installation routine by double clicking the "SETUP.EXE" file.

5. 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.

Illustration 17 g02385825

1. 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.

Illustration 18 g02385836

2. Copy all sensor files to the PMA folder on the hard drive (example C:\PMA\à;). r080crc15
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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)

Illustration 19 g02385838

1. 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.

Illustration 20 g02385856

2. Copy all the system files to the PMA folder on the hard drive (example C:\PMA\à;).

Starting the PMA Program

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Illustration 21 g02385862

1. Start the PMA program by clicking "Start" and then select "Programs". Select "PMA" and then the PMA
icon.

Exiting the PMA Program

Illustration 22 g02385876

1. To exit the PMA program, open the pulldown menu "Measurement" in the menu list and select "End
program".

The PMA Main Window


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1. The upper line of the main window contains the menu bar containing the pull-down menus.
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2. 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

3. 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

4. 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

5. Field for calculating the cleanliness classes:

ISO

NAS 1638

SAE 7490

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Illustration 23 g02385916

6. 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.

Selecting the Language

Illustration 24 g02385936

1. Open the pull-down menu "System" found on the menu bar and select "Language".

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Illustration 25 g02385940

2. Select a language and click OK.

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.

Illustration 26 g02385941

1. Select "System" on the menu bar. Select the "Sensor" button, as shown in Illustration 26.

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Illustration 27 g02385956

2. 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 28 g02385958

3. Select the sensor file (*****Hni.sen) and click OK. Then click OK again.

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

1. Select "System" on the menu bar.

2. Select "Serial Ports", and the appropriate window will open.

Illustration 30 g02385996

3. Select the "Port" and highlight COM1 or COM2.

4. Select the 9600 baud rate and then click OK.

Measurement Set-up

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Illustration 31 g02386016

1. 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".

2. Open "Measurement" on the menu bar.

3. Select "Set-up".

4. The System 31 window will open.

Illustration 32 g02386038

5. Select "Load Set-up".


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Illustration 33 g02386056

6. 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.

Illustration 34 g02386076

7. Select OK.

Setting Up Diameters

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Illustration 35 g02386818

1. 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.

Illustration 36 g02386821

2. 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

3. Select OK.

Naming a New Measurement File

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Illustration 37 g02386859

1. Open "Measurement" from the menu bar and select the menu item "New". The window "Naming
Measurement File" will open.

Illustration 38 g02386896

2. Enter a name with an ".mes" extension, select a path name and confirm. The window "New Measurement"
will open.

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Illustration 39 g02386921

3. 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.

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

Illustration 40 g02386956
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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.

1. Double click on the PMA icon.

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Illustration 43 g02387036

2. Open "Measurement" from the menu bar, and select the menu item "New".

Illustration 44 g02387057

3. Type a file name. File name can only have eight spaces.

Note: This file will be saved at C:\PMA\. This file will load a predetermined test setting for rebuilt
engines.

4. Then click OK.

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Illustration 45 g02387076

5. 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 46 g02387081

6. 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 47 g02387088

7. 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\).

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.

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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.

1. 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.

Note: Caterpillars rebuilt engine roll-off target is ISO 18/15 after dyno test is complete.

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Illustration 49 g02387101
Example of a normal engine particle count.

Illustration 50 g02387105
Example of a contaminated engine particle count.

2. 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.

3. 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
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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

Illustration 51 g02387117
Cleaning procedure.

Illustration 51 diagrams how to assemble the hoses during the cleaning procedure.

Illustration 52 g02387156 r080crc15


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Switch position Black = LP for cleaning.
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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 r080crc15


Removing screens for cleaning.
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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.

Copyright 1993 - 2019 Caterpillar Inc. Sun Apr 07 2019 16:03:22 GMT-0500 (hora estándar de Perú)
All Rights Reserved.
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