Cost Effective Gasket and Paint Cleaning Processes

1.0 Introduction
Efficient parts cleaning processes are critical to several facets of CRC operations. Parts cleaning may be considered a non-value adding step, but it represents a substantial portion of labor and expenses in the rebuilding process. The cleaning step is an important segment in the critical path, since the last parts disassembled are the first parts needed in assembly. All other parts must wait in staging until those critical few are cleaned, rebuilt, and cleaned again before the component is ready for assembly.
There are many technologies used in the cleaning process, such as high-pressure cabinet washers, buffing, grinding, blast cleaning, and solvent washing. Ideally, the fastest and least costly process is applied to each part as needed. Automatic cleaning is typically preferred for cost control and consistent quality. Gasket removal and seal surface cleaning is difficult because it often requires extensive manual labor. Paint removal is difficult because:

• Ferrous metals require a caustic solution to remove most paints. This is expensive to buy, and the remaining wastes are expensive to dispose of.
• Non-ferrous metals require very high cost chemicals to strip paint, and these are also very expensive to dispose of in many regions.

This Best Practice will discuss paint and gasket removal without requiring such expensive chemical processes. The processes employed will provide a sufficient level of cleanliness without “over-cleaning.” These new processes will also minimize part damage and processing time/labor.


2.0 Best Practice Description
Parts cleaning is often performed by lesser-skilled employees – those with the least experience in the dealer and/or product. They are typically trained by outgoing personnel from that area, and receive little follow-up unless the rebuild technicians complain about dirty parts. Some rebuild centers will also require technicians to clean parts, with each tech being responsible for his or her own parts. Cleaners typically:

Paint & Gasket Removal Process
(Best Practice scope in green box)

• Grind and scrape all the gaskets off before the cabinet washing. This removal requires time, labor, and effort making the parts more vulnerable to damage and reducing the effectiveness of gaskets and seals. Excess grinding and scraping also creates airborne debris that will spread into the shop and require additional cleanup
• Grind/scrape all the gaskets off after the cabinet washing, typically long after the parts have cooled and gaskets have hardened, again using lots of time. This excess grinding and scraping creates the same problems mentioned above. In addition, abrasives and debris can contaminate the parts and become incorporated into the rebuilt component, and affect service life.
• Use several methods to remove paint: blast cleaning requires time and facility resources. Grinding/buffing to remove all the paint also requires significant time and labor and spreads airborne debris. Chemical removal consumes caustic, or more expensive chemicals, which add excessive disposal costs to direct expenses. Some operations don’t clean paint beyond the aluminum-safe solution washes. This omission leaves curled paint surfaces on the parts, which:

1. Creates an inferior painting surface, resulting in a low-quality product image to the customer.
2. Causes paint chips to re-enter the assembly process; contaminating bearing surfaces and blocking lubrication passages. Results can reduce service life or possibly cause early failure.
3. Creates a mess in the work bays, with paint chips breaking off the parts and flying around the shop. This adds to shop cleaning efforts and demonstrates an unprofessional image to employees and the customer.

Effective gasket and paint cleaning processes provide balance towards getting parts cleaned to a consistent quality and minimizing the time, labor, and supplies to perform the cleaning. This process follows:

• Gaskets/sealants that soften during the cabinet washer cycle should be quickly scraped off with a putty knife immediately after the wash cycle. The parts should still be hot and the gaskets should be easy to scrape off quickly. Many of the gaskets may have already fallen off the parts during the wash cycle
• Gaskets that were not softened and subsequently difficult to remove after the wash cycle, should be scraped or ground off before the second wash cycle. This will minimize post-wash grinding and further wash cycles. This is commonly required with gaskets exposed to high heat or those applied with aggressive sealing chemicals. This is common with exhaust gasket and head gasket areas those exposed to high
• Once processed by the cabinet washer, painted parts may be:

1. “Buffed” with a powered bench-mounted, or hand-held angle grinder. Although rust/corrosion should be completely removed, only the paint chips need be removed up to the point of where the paint remains adheres to the part. The sharp broken paint edge on the part should only be “feathered” to blend it into the part surface. The blend-line should disappear under a good coat of paint.
2. Blast cleaned with a automatic tumbling cleaner

• Blast clean aggressive corrosion only as needed. This may be performed manually, especially for larger/sensitive parts, or with an automatic tumbling blaster, for other parts. Blast only critical areas and blast to “feather” out paint to minimize time, labor, and supply expense. Always wash parts after blast cleaning due to the amount of abrasive carry-over.

Establish consistent and cost-effective cleaning processes:

• Perform cleaning only with specialized cleaning employees. Do not permit rebuild technician to share in the general cleaning area duties as a rule. Rebuild technicians may only clean in the general cleaning area only under special circumstances and to expedite a repair.
• Establish a training process or course to prepare the cleaning specialist. Include best-in-class visual aids and physical samples. Implement the training consistently with demonstrated qualification standards. Emphasize quality and cost effectiveness. Review performance periodically to assure quality does not drift and process improvements are documented/replicated.
• Establish cleaning equipment maintenance programs for consistent operations. Include schedules, checklists, and reliable supply delivery/inventory systems. Define individual responsibilities for equipment operators and maintainers. Enforce daily/consistently.
• Lead cleaners and disassembly technicians as a team to capitalize on the location, and opportunities to share employees between functional areas. This also allows for better parts reuse and applied failure analysis process control. Parts often must be cleaned for better reuse and AFA decisions, and a team can coordinate these processes with the least effort/ bureaucracy.

3.0 Implementation Steps

• Document as-is cleaning processes, equipment, and performance.

1. Develop practical performance metrics.
2. Document subjective observations through definitions and visual aids.
3. Account for employee experience and strategy in applying employees to function.
4. Include area equipment maintenance programs, roles/responsibilities, and adherence.

• Define future cleaning strategy based on expected product type, volume, size, etc.

1. Plan for typical rebuild volumes as well as expected peak production business cycles.
2. Investigate specialized cleaning facilities, equipment, tools and processes.
3. Utilize Cat Facility Development and Service Tools Development.
4. Visit best-in-class dealers to observe their operations.

• Apply future strategy to shop layout plans.

1. Consider staging location’s effects on product protection and flow.
2. Add changes to shop layout drawing.
3. Include shop technician teams in the review/application stages.
4. Include outside groups providing facility/equipment support functions, as needed.
5. Use Cat Facility Development and Service Tools Development expertise as required.

• Develop/document the new cleaning (and disassembly – as needed) strategy/procedure, with new roles and responsibilities.

• Establish facility/equipment maintenance strategies as needed.
• Establish adjusted repair/rebuild time requirement targets as needed.
• Establish adjusted cleaning (and disassembly) group leadership as needed.
• Present strategy to shop employees.
• Implement the staging processes, layout, and equipment changes into the shop.

1. This may occur in phases (as needed).
2. Test new processes to establish “best-fit” application for shop.

• Train employees to use the new procedures. Follow-up/enforce immediately.
• Review process and support system performance once established.
• Establish and implement adjustments as needed.

4.0 Benefits

• Increased capacity - These concepts increased cleaning stage throughput for a given amount of labor hours, by specializing and effectively training the employees. Supply control/availability minimizes production delays.
• Reduced cost – Labor hour targets per cleaning segment were reduced as mentioned above. “Over-cleaning” was almost eliminated and consistently controlled with periodic process review. Equipment is better maintained with consistent cleaners and comprehensive maintenance support. Supply control minimizes production interruptions.
• Increased quality – Reduced over-cleaning allowed time for focusing on the tough cleaning areas, and consistent cleaning methods increased the skills applied to those areas.
• Improved image – Effective processes and employees in the cleaning area promote a higher level of professionalism with the employees. A cleaner environment also promotes employee professionalism and this was immediately obvious to all customers visiting the CRC. They turned a typically “dirty corner” into a productive working area.

5.0 Resources Required

• Investment costs vary, depending on cleaning area/system related gaps found and local labor/material costs:

1. Equipment upgrades to provide product quality/consistency.
2. Facility upgrades to provide effective product flow to match new processes.
3. System development to assure facility/equipment reliability.

• Support Equipment – as needed:

1. Equipment organization aids (racks, cabinets).
2. Airborne debris containment (downdraft tables, evacuation systems, etc.).
3. Utility reels for effective facility cleaning efforts.
4. Automatic cleaning equipment (tumbling blasters, cabinet washers, etc.).

• People

1. Establish current cleaning, quality, costs, and environmental concerns with team.
2. Establish process, facility, and equipment improvements through team.
3. Establish team organization/leadership to coordinate/support contingent functions.

• Training

1. Establish the improvement benefits with the production team.
2. Define and enforce the new process and duties with the production team.
3. Define and enforce new support systems/process/duties with support teams.

6.0 Supporting Attachments / References
None.

7.0 Related Best Practices
0107-4.5-1060 -CRC Parts Buffer Enhancement
0207-4.5-1063 -CRC Material Transport Strategy
0107-4.4-1061 -CRC Parts Blasting Enhancement
0207-4.4-1066 -CRC Proper Lighting Provides Effective Working Environment

8.0 Acknowledgements
This Best Practice was written by:
Russ Young
6 Sigma Black Belt
young_russell_k@cat.com
(309) 675-4583

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3500 Engine Cylinder Head Bolt Torque Fixture

1.0 Introduction
This Best Practice is a dealer-fabricated fixture to improve the process to set 3500 engine cylinder head bolt torque. The fixture allows the use of a pneumatic torque wrench with proper alignment and engagement of the sockets on the head bolts and support of the torque wrench and reaction arm.
The fixture reduces the time required to torque all the cylinder head bolts by 20% or more, reduces technician fatigue, and improves the safety of the procedure.

2.0 Best Practice Description
The purpose of this fixture is to improve the process for setting cylinder head bolt torques on 3500 series engines. The fixture is mounted on the cylinder head with all eight sockets engaged on the head bolts. A pneumatic torque wrench is used to torque the bolts individually following the Service Manual sequence and initial torque. The reaction arm of the torque wrench is a pin that is secured in the center of the fixture. This allows easy access to all the bolts.
After initial torque, the bolt head position is marked on the fixture and the final “torque turn” is
performed.
Note: The head bolts are torqued before the fuel injector is installed in the cylinder head. Fixture
does not have spring clearance with the injector installed.

After the initial torque has been set, the operator marks the plate with a felt pen and completes the final torque turn

3.0 Implementation Steps
The first step is to fabricate the steel top plate of the fixture. Using a Caterpillar print, holes are drilled in the plate matching the cylinder head bolt hole pattern. See drawing below.
Sockets are slip fitted into the plate hole pattern and retained by a flange on the top of the socket and a snap ring on the under side of the plate. Socket diameters will need to be machined to create a flange at the top of the socket. The groove is also machined in the sockets to hold a snap ring. The sockets are slip fitted into the plate and held in position by the flange and the snap ring.
Sockets used are Cat part number 124-0662. This is a ¾ “ 12PT socket – 5” long. The diameter
of the socket is machined to provide .003-.005” clearance through the plate.

Socket has been machined leaving a shoulder on this side of the plate

Snap ring groove has been machined in to each socket to hold them in the plate

A torque wrench and a reaction arm for the torque wrench will need to be manufactured. It is best to work with your torque wrench supplier to match a reaction arm and wrench to this fixture.

Center pin slides to allow the wrench to be repositioned from one socket to the next

It may be beneficial to make several fixtures as well as spare parts (sockets, reaction arm). Keep your drawings and specifications for potential future replication of the tool if needed.

4.0 Benefits
• Reduces time required to torque head bolts 20% or more.
• Less fatigue on technician.
• Better torque accuracy.
• Less chance of socket coming off the bolt during torque – improve technician safety.

5.0 Resources Required
• Machine shop and time to fabricate. Approximate cost of the fixture is US $1500.
• Cost of pneumatic wrench, air regulator, and reaction arm approximately US$7500.

6.0 Supporting Attachments / References
None

7.0 Related Best Practices
None at this time.

8.0 Acknowledgements

Special thanks to:

Craig Priddle
OEM Remanufacturing
Craig.priddle@oemreman.com

Please contact the Subject Matter Expert with any questions:

Dale Brehm
6 Sigma Black Belt
Cat Global Mining Product Support
brehm_dale_e@cat.com
+1 309 675 6325

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3500 Engine Exhaust Manifold Salvage

1.0 Introduction
Significant cost savings can be achieved by salvaging the ends of certain 3500 engine exhaust manifolds.

2.0 Best Practice Description
The ends of the manifolds can be machined down, a fabricated repair sleeve can be installed, and the manifold can be returned to service.

3.0 Implementation Steps

CAUTION: SAFETY PROCEDURES FOR THE SHOP EQUIPMENT INVOLVED MUST BE FOLLOWED.

• Clean the exhaust manifold using a shot-peen or sandblast method.
• Inspect the manifold for cracks. If a crack is found, salvage of the manifold is not recommended, as the cracks may continue to propagate.
• Machine the end of the manifold to 4.374 ± .001 inches, 1.750 inches long.

Fabricate a sleeve from SAE 1040 grade mechanical tubing, DOM, 4-3/8 ID by 4-3/4 OD.
Saw cut to 1-7/8 length, trim one end square, with an inside chamfer of 45 degrees by .06 long. The inside diameter should be about 4.370 as delivered. There should be no requirement for additional machine work on the inside of the sleeve.

• Heat the fabricated sleeve to approximately 450 degrees F.
• Drop the heated sleeve onto the machined exhaust manifold. The sleeve material should provide .004 to .005 inches interference fit.

 
 Allow the sleeve to cool, then tack-weld it in 3 places. Use Messer MG250 nickel electrode, or equivalent.

•  Machine the outside diameter to finish size, 4.565 +.000, -.002 inches.

•  Wrap the finished manifold in shrink-wrap to protect it from rust and handling dama.

 4.0 Benefits

• The finished manifolds can be mixed along with new manifolds on the same engine bank, because the centerlines have not changed.
• To reduce turnaround time for an engine rebuild, sufficient quantities of spare manifolds can be inventoried.
• The manifold can be sleeved additional times, if inspection criteria about cracking are met.

5.0 Resources Required

• 22 inch swing lathe with cutting tools
• Band saw
• Arc welding equipment

 6.0 Supporting Attachments / References
See publication SEPD0611, page 36, “A new exhaust seal and a new exhaust manifold sleeve are used in the exhaust manifold groups.”

7.0 Related Best Practices
None at this time.

8.0 Acknowledgements
Jim Bailey
Machine Shop Manager
Wyoming Machinery Company
+1 307 472 1000
jmbailey@wyomingcat.com

Read More

In Ground Silo Rebuild Station for OHT Wheel Groups

1.0 Introduction
The size of large Off Highway Truck Wheel Groups makes rebuild difficult. Wheel group rebuild procedure requires the wheel group to be positioned vertically for disassembly and assembly. Technicians work with ladders and work platforms to rebuild the larger model Wheel Groups. A new wheel group rebuild work station concept consists of an in ground silo, a rotating platform to hold the wheel group and rotate the spindle for wheel bearing preload adjustment, and a hydraulic motor and adjustable lift to raise and lower the wheel station to any desired height. Technicians can work on wheel stations at waist height and eliminate the need for ladders and platforms for disassembly and assembly.

2.0 Best Practice Description
The common practice for Off Highway Truck wheel group rebuild is to stand the wheel station vertically on the shop floor for disassembly and assembly. Larger wheel groups are up to 12 feet tall. Disassembly and assembly requires technicians to work with ladders and work platforms in order to reach the internal parts of the wheel group.
The in ground silo concept positions the wheel station on a rotating platform mounted on a hydraulic lift which is installed in a silo or in the shop floor.
The lift can raise or lower the wheel group to any desired height, allowing mechanics to work on the wheel station at waist height without the need for ladders and platforms. The hydraulic motor also can rotate the wheel station spindle to seat and adjust the main bearing preload.

Final Drive D/A Fixture:

• Positions and secures the spindle and wheel group
• Clamp and mounting system adjusts for 777-797 rear Wheel Station
• Rotates spindle 0-4 rpm for seating and setting bearing pre-load
• Hydraulic power unit and controls included
• 40,000 lb capacity lift system available for pit installation in facilities with restricted crane hook height

 

3.0 Implementation Steps
1. A silo is constructed in the shop floor to contain the rotating platform, hydraulic motor, and lift. (See attached drawing for specifications)
2. Install hydraulic motor, platform, and lift. (See attachments for specifications)
Detailed information is available from Caterpillar Service Technology Group.

4.0 Benefits

• Significant improvement in labor efficiency, and overall less time to rebuild a wheel group.
• Improved rebuild precision in the installation of seals and other components.
• Improved precision in setting the main bearing preload.
• Improved technician comfort and work environment.
• Reduces overhead crane hook height requirement.
• Eliminates the need for platforms and steps.

5.0 Resources Required
Investment includes

• Construction of a silo work-station in the shop floor,
• Installing a rotating wheel group platform with a hydraulic motor and lift.

Cost ranges from $100,000 to $150,000 depending on the size and capacity of the work-station. Also required, technician training in the station’s proper use and safety.

6.0 Supporting Attachments

7.0 Related Best Practices
None applicable.

8.0 Acknowledgements
This Best Practice was authored by:
Dale Brehm
Caterpillar Global Mining
6 Sigma Black Belt
Brehm_Dale_E@cat.com
+1 309 675 6325

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Managing Fluid Cleanliness through Effective Measurement & Recordkeeping

1.0 Introduction
Maximizing component life and minimizing component cost-per-hour requires that fluid cleanliness be maintained at very high levels. This requires a new approach to measuring and managing fluid cleanliness. Effective fluid management requires a process to:
- Identify when fluids are dirty
- Identify when fluids are clean
- Maintain records to show how the fluids are behaving over history
This site has created a process to measure machine fluid cleanliness (particle count) at each service, both when the machine enters for service and after the service is complete. All records are maintained in a central database with results trended for variation.

2.0 Best Practice Description
Measuring Fluid Cleanliness
All fluids on the mine site are regularly checked for cleanliness. This site uses the Pamas S-40 particle counter to take particle count measurements in all filtered machine compartments at each PM.

Pamas S-40 particle counter

Data Entry
All particle-counting records are stored and analyzed in a Microsoft Access database, created by Unatrac. Data entry is simple and efficient.
Key fields include:
- Machine ID
- Sample ID
- Machine hours
- Date
- Particle count
Lube and Hyd oils: particles >6 & >14 um
Fuel: particles >4 / >16 / >14 um

Particle Count Data Screen
Data entry is quick and convenient.

Fluids Sampled

New Oils
Due to the remote location and lack of infrastructure, all hydraulic and lube oils are delivered to the site in 1,000 liter, disposable plastic cubes. Samples are taken from each cube and at the dispensing point and the cleanliness level recorded.
Many new oils have large amounts of additives, which tend to clump together in clusters, which are large enough to be recorded as particles when using a laser particle counter. This is known as “additive interference”. The combination of contamination from the new plastic container and the effects of additive interference often result in the new oil exceeding the cleanliness target of ISO 16/13 for new oil. Trying to achieve the new oil cleanliness target by kidney looping multiple grades of oil in dozens of cubes is impractical. New oil cleanliness is achieved during oil changes, by kidney looping the system, after the new oil is in the machine.

Fuel
Fuel is checked on a weekly to daily basis for compliance with the ISO 18/16/13 standard. Both, the dealership, and the fuel supplier take the measurements. Regular non-conformance is recorded in the case of future frequent fuel system problems.

Machine Fluids
On-machine fluids are checked for cleanliness at every PM service. The process followed is as follows:
1. The machine enters the PM bay and an oil sample is taken and particle counted for all major systems (example. 785C - hydraulic, steering, transmission, rear axle).
2. If the ISO reading is above 18/15, then the system is kidney loop filtered. If the particle count is 18/15 or better, then the system does not have to be kidney looped. (A flow chart of the process is shown on the following page).
3. Before the machine is returned to service, an additional oil sample is taken and particle count performed.
4. Both before PM service and after PM service particle count reading are recorded in the database.
5. SOS is also performed and these readings are matched with the particle count readings.
6. Measurements are tracked over time and particle counts are observed.
Decisions to change the PM service activities are strongly influenced by particle counts.
On new and rebuilt components, the break-in process generates additional debris, which results in higher particle counts. Systems that measure higher than ISO 18/15 at the end of the PM period are kidney looped to 16/13 during the PM to accelerate the removal of break-in debris. When the system can maintain ISO 18/15 or better at the end of the PM period, the onboard filters are maintaining system cleanliness and kidney looping can be discontinued.
A sudden and significant increase in particle count or premature filter plugging indicates abnormal component wear. This triggers an immediate SOS sample and inspection.
Machines in the fleet have been fitted with Ultra-High Efficiency (UHE) filters on powertrain and hydraulic systems. These filters are capable of maintaining high levels of fluid cleanliness once break-in debris has been removed. Kidney looping at each PM is discontinued after the onboard filtration demonstrates the ability to maintain ISO 18/15 or better through the PM period. This results in better PM efficiency.
The process map below illustrates this logic.

Measurement & Recordkeeping Process Map

3.0 Implementation Steps
Fluid cleanliness measurement and recordkeeping is part of a larger fluid cleanliness management strategy in place at this site. A critical part of this strategy is to consistently measure and record particle counts.
This requires at least two portable particle counters on site. While great strides have been made in reliability and durability of portable particle counters, they are still lab instruments used in the field. Repair of these instruments requires they be shipped back to the manufacturer for several weeks. Back-up units must be available to continue to gather data on a daily basis.

4.0 Benefits
Effective measurement, recording and trending of particle count data provides a simple and powerful management tool to improve PM efficiency and identify abnormal wear or failure quickly.

5.0 Resources Required
Cost of a typical particle is approximately $10,000 USD. A minimum of two is required. The cost of training personnel to use the equipment, take samples and record data is minimal.

6.0 Supporting Attachments / References
Improving Component Durability – Fluid Cleanliness Management booklet
• This document explains additive interference, laser particle counting, fluid filter ratings, filter media, etc.
• Available in paper only. Caterpillar literature number: SEBF1020

7.0 Related Best Practices
0806-2.1-1000 Fluid Cleanliness Management
0806-2.1-1001 Measuring Oil Cleanliness

8.0 Acknowledgments
This Best Practice was written by:
Jeff Wolffe
CGM EAME Product Support
Wolffe_Jeffrey_S@cat.com
+41-22-849-4423

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Desiccant Breathers Prevent Bulk Fluids Moisture from Damaging Machine Components

1.0 Introduction

A desiccant breather on a bulk oil tank

The best way to reduce machine powertrain cost per hour is to maximize component life and utilize all of the value built into the component. Avoiding premature component failure is essential to maximizing component life. There are many variables that contribute to premature component failure. One of those variables is corrosion damage of highly loaded precision components, such as bearings or fuel injectors.
Bearings are susceptible to corrosion damage from water in lube oils, and fuel injectors may be damaged by excess water in fuel. Keeping moisture out of bulk fluids is essential to prevent damage to machine components.

The use of desiccant breathers on bulk fluid storage tanks prevents atmospheric moisture from entering the tank and contaminating the fluid. Also preventing atmospheric moisture from entering bulk fluid storage tanks during normal fill and drain cycles will prevent failures due to corrosion. These practices will help extend component life, reduce cost per hour, and improve machine availability.

2.0 Best Practice Description

A desiccant breather beginning to change color

Many bulk fluid storage tanks at dealer and customer facilities have breathers with unfiltered tank vents. This allows both airborne dirt and moisture to enter the tank and contaminate the fluid. This can be easily corrected by installing desiccant breather filters to the tank vent. Desiccant breathers come in a wide variety of sizes and arrangements. The most common is a disposable spin-on unit that changes color as the desiccant capability is depleted. This allows for easy visual inspection to determine if the unit is functional or requires replacement.

Filter sizing is determined by:
• The maximum flow rate of air into or out of the tanks during usage or refill.
• The pipe or fitting size of the vent pipe where the breather will be attached.

3.0 Implementation Steps
Desiccant breathers are not available through the Caterpillar parts system. They are available from several outside suppliers. Two of the most common suppliers are Des-Case and Parker Hannifin.
The use of desiccant breathers should not be limited to very large tanks. Any size storage vessel, down to barrels, can introduce contamination. Desiccant breathers are recommended for any storage vessel equipped with a breather vent.

4.0 Benefits
Many dealer facilities with modern bulk fluid handling have incorporated desiccant breather filters. The actual incremental benefit is difficult to measure without a baseline of moisture and particulate contamination before the desiccant filtration was installed. However, if stored fluid is found to be contaminated with dirt or moisture, the presence of properly working desiccant breathers indicates the contamination was present in the fluid before delivery.
Operations that have endorsed the usage of desiccant breathers:
• Finning Chile Antofagasta Component Rebuild Center
• Finning Argentina – Alumbrera Mine
• Ferryros Peru – Yanococha Mine
• Western States Equipment – Simplot Smoky Canyon Mine

5.0 Resources Required
Initial installation or fitting of filters to existing vent pipes typically runs from $100 - $500 US. Cost of replacement filters range from $30 for small filters used on barrels and small tanks up to $800 for very large filters used on large bulk storage tanks.

6.0 Supporting Attachments / References
None

7.0 Related Best Practices
0806-2.1-1000 - Fluid Cleanliness Management
0806-2.1-1002 - Off-Board Machine Filtration
0806-2.1-1004 - Breather Filters
0806-2.1-1005 - Bulk Oil Filtration
0806-2.1-1006 - Bulk Fuel Filtration

8.0 Acknowledgments
This Best Practice was written by:
Richard Douglas
CGM Product Support
Douglas_richard_d@cat.com
(309 675-5699
Other contributors include:
Dave Baumann
MPSD Contamination Control
Baumann_david_l@cat.com
(309) 675-6849
Carmen Rose
MPSD Contamination Control
Rose_carmen_l@cat.com
(309) 675-8074
Kiwi Haig
CGM LACD Product Support
Haig_kevin@cat.com
+56 55 200947

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Off-Board Fluid Filtration

1.0 Introduction
The performance expectations for components and systems on modern mining machines have grown rapidly in the past two decades. This has driven the design of hydraulic systems to operate at much higher pressures, and dramatically increased the load factor on drivetrain components.
The increased performance demands also increase the rate of abrasive wear and failure of components compared to older designs, which operated at lower load factors.

2.0 Best Practice Description

2.1 Debris
In order to increase durability, it is necessary to operate components and systems in much cleaner fluids throughout the life of the component. There are three sources of debris:

2.1.1 Assembly Debris
A large amount of debris is often present in machine systems when new machines are assembled. In the past, failure to remove this debris caused a high rate of system malfunctions and component failures at the factory and in early-hour operation. As a result, portable filter carts were designed for use in the factory to clean machine systems before machines were shipped. When used properly, these carts effectively removed assembly debris and cleaned systems to a factory ship target of ISO 18/15. This cleaning of systems prior to shipment dramatically reduced the incidence of early-hour problems.

2.1.2 Break-In Debris
There is a widespread misconception that nearly all system debris is from new machine assembly, and that once systems are cleaned properly, they stay clean. This is not true. Most components produce debris as a result of the normal break-in process. The length of the break-in process and volume of debris produced varies by system. A mining truck provides a good example of how systems vary.
Steering System
Steering systems essentially consist of a small piston pump, steering cylinders and a control valve. Once assembly debris is removed from this system, it produces very little break-in debris and normally stays clean with standard machine filtration.
Transmission
Transmission clutch discs, and gears produce moderate amounts of break-in debris. This process usually takes between 100-200 hours to complete. Even if the transmission were perfectly clean after assembly, break-in debris would still be produced.
Final Drive & Differential
The rear axle produces very large amounts of break-in debris from gears. This process may last up to 8,000 hours. This debris is almost all very small abrasive particles from the hardened gears.

2.1.3 Normal Wear Debris
After the break-in process is complete, components still produce microscopic wear particles, but at a much slower rate. The rate is largely affected by how many wear particles are already in the oil. If the oil is contaminated with a high number of abrasive particles, the normal component wear process is greatly accelerated. If the oil is very clean, the normal wear process is much slower, which significantly extends component life.
On-board machine filtration on most mining machines is not capable of maintaining high levels of fluid cleanliness necessary to maximize component life. As a result, portable factory filtration carts are used during PM’s and after system repairs. This practice has grown with the increase in MARC contracts and extended component life guarantees.

2.2 Off-Board Machine Filtration (Kidney Loop)
The use of off-board filtration carts started in the factory to remove assembly debris that was causing frequent production line and early-hour problems. The practice eventually migrated to dealers where the carts were initially used to clean systems after a major repair or component replacement. This later evolved into use of carts during PM intervals. Those dealers found that consistent use of the carts for several hours during PM removed large amounts of debris and helped to achieve and maintain a much better level of oil cleanliness.
There are four basic applications of filtration carts in dealer shops and mine sites:

2.2.1 New Machine Assembly:
Large mining machines are too big to ship fully assembled, so large components such as wheel groups are assembled in the field. It is impossible to maintain system cleanliness when major components are open to contamination during assembly. Even in systems that are shipped assembled (such as hydraulics) cleanliness levels on new machines often exceed the factory roll-off spec of ISO 18/15. This has caused great debate between dealers who claim the system arrived dirty and factory personnel who claim it left clean. There are three reasons for this:

System Not Cleaned Properly
In a few cases, the system cleanliness may exceed the pre-shipment specification, due to inadequate cleaning prior to shipment.
Variability in Particle Counters
Particle counters (whether lab or portable) basically shine a small laser beam through an oil sample and count the number and size of shadows caused by particles in the oil. They also count water droplets, air bubbles and large agglomerated particles oil additives. Inherent variability in both, the particle counter and the sample treatment process, may account for elevated readings of one to two ISO codes. This is problem is even more prevalent in the field use of portable particle counters where cleaning between samples and sample treatment techniques may vary widely. It is not uncommon (due to variability in the particle counter) to deliver varied results (readings) from the same oil sample.

Additive Interference
Some new oils contain large amounts of additives. Some of these additive molecules attract and form large clusters in systems where the oil is not be used (such as new systems). These clusters may get large enough appear as a debris particle to a particle counter, and cause the particle count to be higher than it actually is. On new machines, systems should be exercised 1-2 hours to break down these additive clusters before a relatively accurate particle count can be taken.

2.2.2 PM Intervals
Many dealers or customers who are interested in maximizing component life use filtration carts for the major systems during normal PM’s. It typically takes 10-15 minutes per system to connect the carts to each system (rear axle, transmission, hydraulics, steering) at the start of the PM. Carts are then allowed to run unattended for several hours while normal PM services are completed.

2.2.3 System Oil Changes:
A long-standing spec for new oil cleanliness has been ISO 16/13. With the increasing level of additives in the oil, filtering oil to this level has become increasingly difficult. In addition, not all sites can justify the cost of permanent recirculating filtration for new oil. A viable alternative is to fill the compartment with new oil and then install and use an off-board filter cart to achieve the desired cleanliness. Machine system contamination is not a problem since the filtration process occurs before the machine is started. It also has the added benefit of removing some system contaminants that would not otherwise be removed if only new clean oil was installed.

2.2.4 Major Repairs
When major components are replaced or systems are opened up for repair, filtration carts should be used to maximize system cleanliness. A leading cause of failure of rebuilt components is failure to clean the system before the new component is put back in service. This is especially true with catastrophic failures, where the system is contaminated with failure debris.

3.0 Implementation Steps
There are several criteria for the number and size of carts required.
Cart Size
Cart filter size and flow rate is determined by the capacity of the system being filtered. As a rule of thumb, the cart should be sized to filter the volume of the system 35 times in a reasonable period of time.
Oil Type
A different cart is required for each oil type. (Example: rear axle oil cannot be mixed with hydraulic oil)
Fleet Size

The number and model of machines being maintained determine the number of carts required. For medium and large fleets, two sets of carts are often required: one set for PM and one for repair. An inadequate number of carts often results in a cart being used for PM or repair and unavailable for use on another machine when needed.

Help with determining the correct number of carts needed, cart size and required tooling is available from the Caterpillar Service Tools Group or from the Marketing and Product Support Contamination Control Group.

Service Tools Group – contact Jim Balfanz, Balfanz_James_W@cat.com
Contamination Control Group – contact Dave Baumann, Baumann_David_L@cat.com

4.0 Benefits
Maintaining oil cleanliness for major components and machine systems increases both reliability and durability. Electro-hydraulic control valves, which are widely used in transmission controls and implement hydraulics, are very intolerant of microscopic, ferrous debris. Heavily loaded wheel and final drive bearings, as well as, duo-cone seals are also easily damaged by abrasive debris commonly found in new oil. Assuring the new oil is cleaned to the desired cleanliness level, and maintaining ISO 18/15 or better significantly reduces the number of contamination induced failures and repairs and significantly extends component life.

5.0 Resources Required
The number and size of filter carts required is determined by fleet size. Carts may be purchased through Caterpillar Service Tool Group, outside suppliers, or built by the dealer. Training for maintenance and operation personnel is also required so that they fully understand the function and importance of the use of filter carts.

6.0 Supporting Attachments
“Improving Component Durability” booklet set- form # SEBF1021.
Consists of one of each of the following:
Fuel Systems SENR9620
Final Drives and Differentials SEBF1015
Powershift Transmissions SEBF1016
Component R&I SEBF1017
Engines SEBF1018
Hydraulics SEBF1019
Managing Fluid Cleanliness SEBF1020

7.0 Related Best Practices
0808-2.10-1003 -On-board Fluid Filtration
0806-2.10-1000 -Managing Fluid Cleanliness

8.0 Acknowledgements
This Off-board Fluid Filtration Best Practice was authored by:
Dick Douglas
Market Consultant
Caterpillar Global Mining
Douglas_Richard_D@cat.com
1-309-675-5699

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Measuring Oil Cleanliness

1.0 Introduction
Maximizing component life requires maintaining high levels of fluid cleanliness. The ability to effectively and consistently measure debris in fluids is a key element in catching failures before they occur. Laser particle counters are used to measure the amount of debris in oil. These units may be permanent installations in an oil analysis lab or portable units for field use.
Lab units are more repeatable and have less variability, but transportation to a lab and processing could take up to two days.
Portable units provide real-time information at the mine site but are more variable due to instrument quality and operator variability of how samples are processed. Both approaches have benefit and drawbacks.

2.0 Best Practice Description
Closely monitoring and tracking particle count data for each compartment is an effective way to manage fluid cleanliness and component performance. Particle counts before and after PM service help to identify the following;

2.1 Cleanliness at the Start of the PM Period
Compartment oil cleanliness after PM service, off-board filtration, etc. at the beginning of the PM interval.

2.2 Cleanliness at the End of the PM Period
Compartment oil cleanliness at the end of the PM interval prior to PM service. This indicates if the on-board filtration is capable of keeping the oil clean.

2.3 Break-In Period Completion
If end of PM readings exceed ISO 18/15, off-board filtration is recommended during PM to remove excess contamination. If oil cleanliness is ISO 18/15 or better, the filters are capable of maintaining fluid cleanliness and off-board filtration is not required.

2.4 Component Failure In Progress
After the break-in period is complete, particle counts will usually stabilize to +/- 1 ISO code range (due to measurement variability). If particle increase is more than the normal range of variability, a failure may be in progress. Failures almost always generate large amounts of debris that can usually be detected by particle count. SOS sample data should be used to verify if a failure is in progress.

3.0 Implementation Steps

3.1 Oil Analysis Lab
If an oil analysis lab is close, it is the lower cost option for particle count measurements. Some dealers and customers use portable counters for immediate results and oil analysis at PM or if the portable counter indicates a problem.

3.2 Portable Particle Counters
Portable counters are expensive, costing $10,000 or more per unit. However, they are rapidly gaining acceptance due to their convenience and real-time feedback. Particle counters are available with a variety of functions, including data recording.

3.3 Data Management
Looking at row after row of particle count numbers can be mind numbing. If particle count is to be used as a tool, it must be displayed in a manner which permits easy visual assessment of trends and abnormal increases. Particle count data for each compartment of each machine can be tracked using the attached software.

3.4 Develop New Wear Material Trends
If replacing standard filtration with HE or UHE filtration, more debris will be captured and wear materials in the oil will increase at a much slower rate. New trends will be much lower than traditional level. New trends will need to be developed based on the performance with the improved filtration.

4.0 Benefits
1. Trending particle data for all particles provides an easy-to-use and convenient tool to monitor component health. If particle count raises sharply, an SOS sample can be used to determine the specific wear metal showing elevated levels.
2. Lower levels of contaminants extend the duration of failures in progress and allow more time to schedule repairs before a catastrophic failure occurs.
3. Portable counters allow real time multiple samples from all machine compartments, as well as new bulk fuel and bulk oils.

5.0 Resources Required
• Oil analysis lab or portable particle counter
• Access software program that allows input of particle count data, stores information in tables and provides output reports.
o Developed and shared by Griff Jones (Unatrac).
o Obtained through Jeff Wolffe, EAME Mining Rep. Wolffe_Jeffrey_S@cat.com
(Available mid-July 2006)
• Advice on particle counter selection features and use available from Caterpillar Marketing & Product Support Division Contamination Control Group.
o Contact Dave Baumann, Baumann_David_L@cat.com or Carmen Rose. Rose_Carmen_L@cat.com

6.0 Supporting Attachments
Component Life Management Master Document PDF file. (Click on Attachments within this document to view/open file)

7.0 Related Best Practices
0806-2.10-1000 -Managing Fluid Cleanliness

8.0 Acknowledgements
This Measuring Oil Cleanliness Best Practice was authored by:
Dick Douglas
Market Consultant
Caterpillar Global Mining
Douglas_Richard_D@cat.com
1-309-675-5699

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Managing Fluid Cleanliness

1.0 Introduction

This Best Practice provides an overview of the importance of maintaining clean fluids and offers suggestions on how best to achieve that. Detailed information can be found in the specific Best Practice publications cited.

Minimizing machine operating cost is critical to minimizing cost-per-ton. Aside from the cost of tires, fuel, and operator, about 70% of total machine operating cost is the life cycle costs of machine powertrain components. On a typical large mining truck, the cost distribution is as follows:

- Engine 40%

- Transmission & Torque Converter 10%

- Final Drive & Differential 40%

- Miscellaneous 10%

Component life cycle cost is roughly defined as cost to rebuild the component divided by actual component life in hours. Example:

($100,000 rebuild cost ÷ 10,000 hour life = $10 hour life cycle cost)

Extending the life of a component is the most important factor in reducing its life cycle cost. This does not mean simply extending overhaul intervals and allowing components to wear more severely. It means implementing a strategy to reduce the rate of wear and achieve longer

component life without incurring excessive wear.

2.0 Best Practice Description

The best way to minimize power train cost per hour is to extend component life and utilize the value built into the component. The most effective way to accomplish this is to operate the component with very clean oil throughout its entire life.

Fluid cleanliness management is a strategy to:

• Remove component and/or system break-in debris as quickly as possible on new and rebuilt components.

• Maintain very clean oil in the component and/or system throughout the entire PM interval and entire component life.

3.0 Implementation Steps

3.1 Dealer & Customer Commitment

3.1.1 Understand the Causes of Component Wear and Failure

• Reference Improving Component Durability booklets

(See Section 6.0 Supporting Attachments)

• Tolerate Early-Hour Filter Plugging

• Use Off-Board Filtration to Remove Break-In Debris

3.2 Bulk Fuel Filtration

For a variety of unavoidable reasons, fuel delivered to mine sites is usually contaminated with dirt and water. Because fuel is a very low margin commodity, suppliers almost never provide adequate bulk fuel filtration or exercise recommended storage practices. As a result, mines receive and use contaminated fuel, resulting in premature injector failure and wear out. This results in excessive fuel consumption and often results in mid-life injector set replacement.

The fuel filters on the machine are designed to provide final filtration for moderately clean supply fuel. Machine filtration is not intended to clean fuel contaminated with large amounts of dirt and water. If contaminated fuel is used, the capability of the onboard filtration is overwhelmed and injectors either wear out prematurely or seize.

Bulk fuel filtration has been used in the aviation industry for more than 50 years to address the same problems. Caterpillar has now adopted this proven technology to help mining customers clean contaminated fuel.

Bulk fuel filtration consists of high capacity filters, which remove both excess dirt and water from the supply fuel before it is put into the machine.

Caterpillar has engineered a packaged system to remove both dirt and water. It requires very little maintenance and contains safeguards to prevent contaminated fuel from passing through the unit. The unit is self-contained on a skid and is located between the fuel storage tank and fueling station. It provides single pass filtration, and is offered in four sizes depending on the maximum flow rate of the fuel delivery system.

3.3 Bulk Oil Filtration

A widespread misconception is that new oil is automatically clean because of its appearance. In fact, nearly all new oil is contaminated to some degree with dirt, metal particles, plastic, water, or other foreign debris. These contaminants are introduced in the transportation and storage process from the time the oil leaves the refinery until it is used by the end-user.

Very little new bulk oil meets the recommended Caterpillar cleanliness spec for new oil of ISO16/13. This includes oil delivered in bulk tanks, steel barrels, plastic cubes, and small plastic containers.

Unfiltered new oil should never be taken directly from the container and placed into the machine.

This is true whether the oil is being used for refilling a compartment at an oil change interval or simply topping off a system.

A variety of bulk oil filtration methods are available and the best one for each situation is dictated by factors such as: volume of oil used, location, available infrastructure, and cost.

3.4 Off-Board Machine Fluid Filtration

Filtration carts can make a major contribution to extending component life. Many mines and Caterpillar dealers use filtration carts for the major systems during normal preventive maintenance. Carts are connected to major systems (rear axle, transmission, hydraulics, steering) and operate unattended while PM services are completed.

3.5 On-Board Machine Fluid Filtration

The micron rating of filters on many mining machine systems are sized so as not to plug during the initial break-in period on new machines. This does not provide optimal filtration capability to maintain very high levels of oil cleanliness after the break-in period is complete.

The most aggressive approach to removing break-in debris as quickly as possible and maintaining the highest level of fluid cleanliness is to use Ultra-High Efficiency (UHE) 6-micron filters in place of standard filters for all machine systems except the engine. Because these filters effectively trap very small particles, some filter plugging will occur during the initial PM periods.

3.6 Breather Filters

Dust entering fluid compartments through inefficient breather filters is often a source of fluid contamination. This can be easily prevented with the use of spin-on High Efficiency 4-micron fuel filters as breathers for all compartments. When used as fuel tank breathers, HE filters have reduced or eliminated premature fuel filter plugging in extremely dusty applications. HE fuel filters are also larger than standard breathers and have much greater capacity.

3.7 Measuring Oil Cleanliness

Component life is maximized when high levels of fluid cleanliness are maintained. The ability to effectively and consistently measure debris in fluids is a basic requirement of managing fluid cleanliness. Tracking fluid particle data is one way to monitor component health. If a particle count raises sharply, an SOS sample can be used to determine the specific wear metal showing elevated levels.

4.0 Benefits

Improved Durability

-Up to 1/3 longer life of powertrain and implement hydraulic components

-Does not apply to engine due to soot in lube oil.

Improved Reliability

-Reduce or eliminate repairs caused by contamination debris.

Improved Parts Reusability

-Reduced wear rates of internal parts improve reusability.

5.0 Resources Required

• Bulk Fuel Filter Coalescer

• Bulk Oil Filtration

o Permanent filtration installation (or)

o Portable filtration carts (or)

o Barrels (or)

o Cubes (or)

o On-Machine (or)

o Off-Board Filtration Carts

• Portable Particle Counters

• Particle Count Data Management Software

• Improving Component Durability Training Booklets

6.0 Supporting Attachments

See Component Life Management Strategy Document (Click on Attachments tab within this document to view attached file)

Improving Component Durability booklets

7.0 Related Best Practices

0808-2.10-1006 -Bulk Fuel Filtration

0808-2.10-1005 -Bulk Oil Filtration

0808-2.10-1002 -Off-board Fluid Filtration

0808-2.10-1002 -On-board Fluid Filtration

0808-2.10-1004 -Breather Filters

0808-2.10-1001 -Measuring Oil Cleanliness

8.0 Acknowledgments

This Managing Fluid Cleanliness Best Practice was authored by:

Dick Douglas

Market Consultant

Caterpillar Global Mining

Douglas_Richard_D@cat.com

1-309-675-5699

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Optimizing Component Removal & Installation Quality through Customer Certification

1.0 Introduction
Proper Major Component Removal and Installation (R&I) practices are vitally important for component reliability and life. Mistakes made during component removal and installations are a leading cause of early hour failures or shortened life. To ensure that component removal and installation is performed following a well-defined process, many Caterpillar dealers have provided training, and in some cases, even “Certified” customers as qualified to perform component R & I.

2.0 Best Practice Description
Caterpillar Dealers have invested considerable financial and manpower resources into creating major component rebuild capabilities that deliver cost efficient, high quality for their customers. A poorly performed removal and / or installation process can negate the efforts put into component rebuild.
Some dealers have taken steps to control the R&I process in order to protect their investment in the rebuild and also to ensure that the component delivers expected reliability and life.
Typical actions have included:
• Dealer must do the component installation.
• Dealer must supervise the installation
• Dealer trains and certifies the customer to perform component removals and installations.

3.0 Implementation Steps
Start with a process audit by the dealer to the customer. Then provide subsequent training on proper major component removal and installation. The most important success factor is a common, shared objective by customer and dealer. A shared objective will ensure component reliability and life through proper R & I practices.
Implementation Steps:
1. Customer Shop Audit / Inspection
a. Tooling
b. Contamination control practices
c. Cleaning equipment
d. R & I area
e. Component storage / staging

2. Training:
a. Failure Analysis – Determine cause for removal
b. Document removal – hours, history, oil analysis, particle count
c. System inspection and clean up process– debris removal
d. Rebuild related system: radiator, coolers, pumps, hoses, and air intake, etc.
e. Installation procedures / checklists
f. Test and brake-in procedures
g. Fluid cleanliness - ISO particle count specifications
h. Standardized installation parts kits (see example to the right)
i. Record keeping –installation checklists, parts Bill of Materials, particle count, test results.
j. Dealer feedback – completed installation checklists, initial SOS

During replacement of any major component, attention should be given to the related systems & sub-components, which may impact performance and life of the newly replaced component.

4.0 Benefits
• Improved reliability
o Improper installation is a leading cause of early hour component failures and shortened life.
o Proper installation positively impacts:
�� Machine availability, which impacts production rates at the site.
�� Maintenance costs by avoiding unnecessary costly repairs.
• Improved durability.
o Proper installation helps to maximize component life and reduce cost per ton.

5.0 Resources Required
• Dealer must have a qualified inspector and training instructor. In addition, training materials may need to be developed.
• Customer may require improved tooling or shop facility improvements.

6.0 Supporting Attachments / References
References:
See also, Improving Component Durability – Component Removal and Installation - SEBF1017

This booklet explains how problems in the component removal and installation process often cause components to fail.
The booklet contains 24 pages of high -quality, full color graphics and text, which provide an easy -to -understand explanation of:
• Common failures caused by poor R&I practices
• Importance of the R&I process
• Best practices
• Risk management in cleaning contaminated systems
 

The booklet also explains the how the component replacement process has evolved from the days of the early track-type tractors to today’s modern machines with electronically controlled engines and transmissions. A common sense approach to risk management is also discussed regarding how much time to invest in system disassembly and cleaning after a catastrophic component failure.

The booklet is intended for all levels of dealer and customer personnel involved with the operation and maintenance of earthmoving equipment. It is particularly useful to those who manage equipment operation and maintenance

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Replace Fluid Hoses During Component R & I

1.0 Introduction
When a major component is removed for a PCR rebuild, this is an ideal time to change all fluid line hoses in the major component compartment area. This is especially true for engine Removal and Installation (R&I) where hoses are very difficult to access with the engine in chassis.
This practice prevents:
- Hose failures,
- Contamination, and
- Loss of fluid and machine downtime to replace failed hoses.

2.0 Best Practice Description
This Best Practice is to replace all fluid hoses in a major component compartment area while the component is out of chassis for a PCR rebuild. Access to the compartment is greatly improved, and thus labor required is a fraction of the labor necessary to change a hose with the component in chassis. In addition, this practices provides a planned before-failure replacement schedule for the machine hoses and fluid lines.

3.0 Implementation Steps
Required process changes include:
1. Add "Replace Fluid Hoses" to the R&I checklist
2. Add hoses and clamps to the R&I parts kit and checklist,
3. Add OHT hose routing diagrams to the R&I forms kit. Hose routing diagrams are contained in the machine parts manual.

Example: Parts Book Hose Part Numbers and Routing Example
 Add OHT hose routing diagrams to the R&I forms kit.

4.0 Benefits
• Prevent unplanned hose failures
• Better machine availability
• Increased production

5.0 Resources Required
Time to identify parts and information required to perform the hose replacements.

6.0 Supporting Attachments & References
None Applicable

7.0 Related Best Practices
None applicable.

8.0 Acknowledgments
This Best Practice was authored by:
Dale Brehm
Caterpillar Global Mining
6 Sigma Black Belt
Brehm_Dale_E@cat.com
+1 309 675 6325

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Bulk Fuel Filtration

1.0 Introduction

Modern fuel systems use electronic unit injectors which deliver precise amounts of fuel at pressures up to 25,000 psi, and control injection timing to within thousandths of a second. Electronic unit injectors control the performance and fuel economy of the engine and are expensive to replace when worn. A rough estimate of injector replacement cost with parts and labor is approximately $1,000 per cylinder. And, of course, there’s the cost of taking a machine out of production.
Injectors operated on clean fuel should last through engine overhaul. The fuel filters on the machine are designed to provide final filtration for moderately clean supply fuel. Machine filtration is not intended to clean fuel contaminated with large amounts of dirt and water. If contaminated fuel is used, the capability of the onboard filtration is overwhelmed and injectors either wear out prematurely or seize.
For a variety of unavoidable reasons, fuel delivered to mine sites is usually contaminated with dirt and water. Because fuel is a very low margin commodity, suppliers almost never provide adequate bulk fuel filtration or exercise recommended storage practices. As a result, customers receive and use contaminated fuel, resulting in premature injector failure and wear out. This causes excessive fuel consumption and often results in mid-life injector set replacement.
Bulk fuel filtration has been used in the aviation industry for more than 50 years to address the same problems. Caterpillar has now adopted this proven technology to help mining customers clean contaminated fuel.

2.0 Best Practice Description

Bulk fuel filtration consists of high capacity filters, which remove both excess dirt and water from the supply fuel before it is put into the machine.
Caterpillar has engineered a packaged system to remove both dirt and water. It requires very little maintenance and contains safeguards to prevent contaminated fuel from passing through the unit. The unit is self-contained on a skid and is located between the fuel storage tank and fueling station. It provides single pass filtration and is offered in four sizes depending on the maximum flow rate of the fuel delivery system.

2.1 Dirt (Particulate Filter)

4-micron, beta 200, full synthetic particulate filter elements remove dirt in a single pass. Filter change intervals of up to one month depending on the level of fuel contamination.

2.2 Water (Coalescing Filter)

Coalescer unit contains multiple elements capable of removing up to 3% water by volume to 1,000 ppm (0.1%) or less at the rated flow. Water is automatically drained, requiring no manual intervention. Coalescing elements do not plug and usually require changing only once a year.

2.3 Flow Control Valve

An automated flow control valve slows down or stops fuel outlet flow if particulate filters plug or there are massive amounts of water in the fuel. This assures only clean fuel leaves the unit.

3.0 Implementation Steps

Technical information and pricing on these units is available from Cat Global Mining and the Cat Filters and Fluids group. Unit sizing is determined by the maximum flow rate of the fuel delivery system. Four different sizes are available:
50 &100 GPM
Small units intended for remote day tank applications or for portable use on a fuel truck where fueling is done manually.
200 GPM
Intended for fuel stations using fast-fill where maximum flow does not exceed 200 gpm. This unit will handle trucks through 793.
300 GPM
Intended for fast-fill of 797 trucks where fuel flow rates exceed 200 gpm.

4.0 Benefits

Supplying clean fuel to the machine permits the onboard fuel filters to function properly without plugging.
Most injectors should last to engine overhaul and provide improved long-term fuel economy and engine performance.

5.0 Resources Required

Permanent installation requires only a small concrete pad downstream of the bulk storage tank and supply pump. The unit is installed in series in the fuel supply line to the fueling station.
A water container is required nearby to store the waste-water removed from the fuel. No electrical power is required for the unit unless it is used in freezing climates.
An optional electric heating element is available to prevent water from freezing in the bottom of the coalescer tank.

6.0 Supporting Attachments

Component Life Management Master Document, PDF file. (Click on Attachments within this document to view)
An explanation of how the unit works, along with visuals is available in the “Managing Fluid Cleanliness” booklet form SEBF1020.

7.0 Related Best Practices
0806-2.10-1005 -Bulk Oil Filtration
0806-2.10-1000 -Managing Fluid Cleanliness

8.0 Acknowledgments
This Bulk Fuel Filtration Best Practice was authored by:
Dick Douglas
Market Consultant
Caterpillar Global Mining
Douglas_Richard_D@cat.com
1-309-675-5699

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