R NEHS0819

February 2003

TOOL
OPERATING
MANUAL
Air Filter Cleaning System for Cleaning
Caterpillar Air Filters

SMCS: 0702
Contents Safety
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 4
Features and Benefits . . . . . . . . . . . . . . . . . 4
Technical Specifications. . . . . . . . . . . . . . . . 4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . 6
Filter Pre-Cleaning Instructions . . . . . . . . . . 6
Filter Cleaner Operation . . . . . . . . . . . . . . . 6
Filter Inspection . . . . . . . . . . . . . . . . . . . . . . 8
Preventive Maintenance . . . . . . . . . . . . . . . . 8
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Weekly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WARNING
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Most accidents involving product
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 9 operation, maintenance, and repair
Recommended Spare Parts . . . . . . . . . . . . 10 occur through failure to observe basic
safety rules or operations. An
Electrical Schematic . . . . . . . . . . . . . . . . . 11
accident can often be avoided by being alert
and recognizing potentially hazardous
NOTE: Caterpillar reserves the right to make situations before an accident occurs. Any
technical changes for product improvement. individuals performing product operation,
This manual may contain illustrations and maintenance, or repair should have the
photographs, for demonstration purposes, necessary training, skills, and tools required to
which slightly deviate from the actual product perform the functions properly and safely. The
design. safety information in this manual serves as a
basic guide in an attempt to prevent injury or
death.

Caterpillar cannot anticipate every possible

circumstance that might involve a potential
hazard. The warnings in this publication and on
the product are, therefore, not all inclusive. If a
tool, procedure, work method, or operating
technique that is not specifically mentioned by
Caterpillar is used, you must satisfy yourself
that it is safe for you and for others. Make sure
the product or machine will not be damaged or
be made unsafe by any operation, lubrication,
maintenance, or repair procedures that you
choose.

If any doubt arises about the correct, safe

method of performing any steps of these
procedures, DO NOT proceed. Seek out expert
assistance from a qualified person.

2
 WARNING
To avoid personal injury or
death, carefully read and
understand all instructions
contained in this manual,
the Donaldson Dust Collector manual, and the
Inspection manual before attempting to operate
any equipment. Do not operate or work on a
machine unless you read and understand the
instructions and warnings in this and all other
applicable manuals. Contact CSTG for
replacement manuals. Proper care is your
responsibility. Always follow all State and
Federal health and safety laws and/or local
regulations.
As with all shop
equipment, proper
safety gear, such
as hearing
protection, should be worn while operating this
equipment. To avoid eye injury, always wear
protective glasses or face shield. Make sure no
one can be injured by flying objects or debris
when using tools or working on a component.
Clean up all leaked or
spilled fluids immediately.
Oil or fuel leaked or spilled
onto any hot surfaces or
electrical components can cause a fire,
resulting in personal injury or death.
Personal injury can result
from slips or falls. DO NOT
leave tools or components
laying around the work area
and clean up all spilled fluids immediately.
Personal injuries
can occur as a
result of using
pressurized air.
Maximum air pressure at the nozzle must be
below 205 kPa (30 psi) for cleaning purposes.
Wear protective clothing, protective glasses,
and a protective face shield when using
pressure air.
3
WARNING
While the air coming from the air
cleaner is low volume and safe for
incidental contact, intentional contact
with air stream should be avoided.
Before any maintenance is
performed, make sure that
all shop air, electrical,
pneumatics, etc. are turned
off.
Make sure all protective covers and
lids are in place and secured before
operating.
Make sure explosion gate on dust
collector is pointed away from
personnel.
When cleaning air
filters, potentially
h a z a r d o u s
atmosphere
environments can
exist. Therefore, open flames, smoking, and
sparks should be avoided near the dust
collection/blow-o
off areas.
Carefully check all lines, tubes, and
hoses for leaks. Do not use your bare
hands to check for potential leaks.
Always position a board or cardboard
between you and the machine when
checking for leaks. Escaping fluid/air under
pressure, even a pin-h hole size leak, can
penetrate body tissue and cause serious injury. If
fluid/air is injected into your skin, it must be
treated immediately by a physician familiar with
this type of injury.
Introduction Technical Specifications
Proper cleaning of air filters will reduce Chart A provides specifications for the air filter
customer cost, increase customer awareness cleaner, which are subject to change. Please
of the need to properly maintain air filters, and consult Caterpillar Service Technology Group
therefore extend equipment life. when exact details are required.
There have been several approaches to
cleaning air filters in the past. These other Chart A.
cleaning approaches have been labor Machine Specifications
intensive, time consuming, hit or miss for Description Specification
element breaches, and inconvenient. Filter Cleaner Stage
The Caterpillar air filter cleaner system Voltage 460 VAC
provides the ability to properly clean over 40 Frequency 60 Hz
different air filters. This system provides a Phase 3 Phase
multi-stage approach to cleaning air filters.
Air Supply 90 psi shop air (minimum)
This system has been designed to efficiently
Vacuum Supplied by dust collector
clean the air filters with each stage performing
a specific task. The ultimate goal is to provide Electrical Service 40 Amp fusible disconnect
a certified clean air filter. Blower System
#1 Electric Motor 20 HP @ 3525 RPM
Overload Setting 27 Amps
Features and Benefits #2 Electric Motor 20 HP @ 3525 RPM
The filter cleaning stage provides a user safe, Overload Setting 27 Amp
high-volume, low-pressure air stream supplied Dust Collector Vacuum Unit
through a patented air slot system to
Voltage 460 VAC
effectively clean filters. Customized filter
Frequency 60 Hz
adapter rings provide “made-to-fit” fixtures for
over 40 Caterpillar air filters. Phase 3 Phase
Electric Motor 10 HP @ 3450 RPM
The filter cleaning stage is user programmable
Air Supply 90 psi shop air (minimum)
to maximize cleaning and minimize time.
Cleaning Self-Cleaning
The dust-off/blow-off stage provides a
Electrical Service 15 Amp
controlled environment to post-clean margin
Dust-off/Blow-off Stage
areas of the filter and to clean filters for
aesthetic purposes. Air Supply 90 psi shop air (minimum)
Vacuum Supplied by dust collector
Overall Sizes
Filter Cleaner 302 x 206 x 101.6 cm
(H x W x D) (119.0 x 81.0 x 40.0 in)
Dust Collector 368 x 147 x 155 cm
(H x W x D) (149.0 x 58.0 x 61.0 in)

4
Chart B provides a list of all cleanable filters.
This list is subject to change, so please
consult Caterpillar Service Technology Group
when a particular filter is not listed.
3
Chart B. DO
NE

Cleanable Air Filters -R

Pre e
ss mo
Se ve
lec Fil
t te r 7
8
Part Seal Part Seal 4
5
9
CE
1 6
Number Type Number Type 2 .
2
3
0
EN
TE
106-3969 Radial 4W-5228 Axial R

122-1674 Axial 4W-5716 Axial 4

122-1675 Axial 6I-0273 Radial EM
ER
G
ST EN
OP CY

123-6855 Radial 6I-2499 Radial 6

1
128-2686 Axial 6I-2501 Radial
131-8822 Radial 6I-2503 Radial
132-7164 Axial 6I-2505 Radial
5
132-7165 Axial 6I-2507 Radial 0819-03

132-7166 Axial 6I-2509 Radial Illustration 1. Control Panel Of Air Filter Cleaner.
132-7167 Axial 7W-5216 Axial (1) Emergency Stop button. (2) Start Push Button.
132-7168 Axial 7W-5313 Axial (3) Display, Status Lights, And Data Input Keypad.
132-7169 Axial 7W-5317 Axial (4) Left/Up Push Button. (5) Right/Down Push Button.
(6) Table Rotate Selector Switch.
132-7170 Axial 7W-5389 Axial
132-7171 Axial 7W-5495 Axial
132-7172 Axial 7W-9853 Axial The dust collector unit is controlled from a
132-7173 Axial 7W5316 Axial panel on an angle iron base which can be
134-0685 Axial 7Y-0404 Axial situated in many locations/orientations. Refer
1W-3637 Axial 9Y-7662 Axial to Illustration 2 or the actual control panel.

Controls
There are 3 distinct controls on the air filter
cleaning system; one for the air filter cleaner
stage, one for the dust collector vacuum unit,
and one for the filter inspection stage. 1
The air filter cleaner stage is controlled from a
panel on the left side of the cleaner. For 2
reference, refer to Illustration 1 or the actual
3 4
control panel.

0819-02

Illustration 2. Control Panel Of Dust Collector Vacuum

Unit.
(1) “On” Indicator Light. (2) Start Push Button.
(3) Stop Push Button. (4) Main Power Disconnect Lever.

5
Installation
The air filter cleaning system should be
located where there is access to an outside
wall and where the required power sources
(electrical/shop air) are located. Refer to
Chart A, “Machine Specifications,” for
additional information.
Initial Setup
Prior to usage, complete the following start-up
procedure to make sure that the unit is
operating properly.
1. Make sure unit is connected to the
appropriate electrical power hookups.
WARNING
DO NOT energize any of this
equipment until all of the installation is
complete and rotation on all motors
has been checked. Severe bodily
injury or death could occur.
2. Connect the unit to a shop air supply.
NOTE: Shop air is used to control the
cleaning air shunt gate, the filter hold down
weight, and the power blow gun at the
dust-off/blow-off cabinet.
3. Check for proper rotation of all electrical
motors. If motors are not rotating in the
correct direction, change the electrical
connections and recheck the rotation.
4. Energize all of the units before turning any
of them on. They are interdependent and,
to clean effectively, should not be run
alone.
6
Filter Pre-Cleaning
Instructions
1. When dirty filters are received from the
customer:
a. Inspect the air filter for structural
damage.
b. Inspect for obvious filter element
breaches.
2. Dry the air filters because:
a. Drying is essential to removal of element
contaminates.
b. Attempting to clean wet filters could
lead to damage of the air filter cleaning
system.
3. Prepare the air filter for cleaning by
removing the replaceable seals/gaskets. If
the seal is reusable, save it.
Filter Cleaner Operation
1. Make sure the correct filter adapter ring is
securely installed on the turntable.
2. Make sure the nozzle is in the proper
position; centered and pointing down. If
the nozzle is not in this position, adjust it
before proceeding.
3. Check the LCD display on the air filter
cleaner control for the status of the
machine. The display shows many types of
information depending on the cleaning
process.
NOTE: Anyone operating the machine must
become familiar with the instructions and
information provided through the LCD display.
This information helps the operator understand
the operation of the machine.
 a. If all of the filter specifications have been
WARNING entered (filter modes, input time, filter is
in place, and the door is closed), select
If at any time during the operation of cleaning a
the automatic mode. Step 10 provides a
filter, an unsafe condition develops, push the
sequence of events as the filter is
red Emergency Stop button. The Emergency
cleaned.
Stop push button will completely shut down the
Optimate display, PLC, or filter cleaner unit, but b. If the operator is unsure of any of the
will not stop the motor on the dust collector filter specifications, the filter can also be
vacuum unit. Failure to shut down the machine cleaned in the manual mode. To
in an emergency can result in bodily injury or operate the machine in the manual
death. mode, follow Step 9.
9. For manual operation, use the following
steps.
a. The LCD display should prompt the
operator to adjust the nozzle left or right.
When prompted, press the Left/Up or
Right/Down button to position the nozzle.
EM
ER
G
b. Press the scroll button.
ST EN
OP CY
c. To set the height of the nozzle measure
the inside height of the filter. Press
Left/Up or Right/Down button to position
the nozzle at this height.
0819-04
d. Place the filter on the adapter ring.
Illustration 3. Emergency Stop Button. Make sure the correct adapter ring is
installed.
e. Make sure the filter is seated properly
4. Before starting the unit, make sure the
and contacts the adapter ring squarely
Emergency Stop button is in the reset
on the bottom.
position. The machine will not start unless
the E-Stop button is rotated, in the direction f. Press the scroll button.
of the arrow, to release it from the stop
g. Position the vacuum collector so the
position.
brushes contact the outside of the filter.
5. Start the dust collector vacuum unit by Press the Left/Up or Right/Down button
pressing the “ON” button and holding it for to position the vacuum.
two seconds. The start button is located on
h. Press the scroll button.
the dust collector control panel.
i. Position the hold down weight on top of
6. Turn on the air filter cleaning unit by
the filter. Press the Left/Up or
pressing the start button on the control
Right/Down button to position the hold
panel. When the machine is started, the
down weight. When the weight touches
LCD will display the name of the device
the top of the filter, it stops automatically.
and the date of the program.
If any unusual conditions occur while
7. Input the cleaning time when prompted by lowering the hold down weight, RELEASE
the LCD display. This time is input in the push button.
SECONDS. If the filter being cleaned has
NOTE: Make sure the hold down weight is
an inside height greater than 30 cm
resting on the filter in a stable manner. Make
(12.0 in), the machine will clean the filter in
sure there is no sideways loading of the
multiple levels.
cylinder rod.
8. Select either the Manual or Automatic
j. Close the doors and press the start
cleaning cycle.
button.

7
10. For automatic operation, the following
events will occur during the cleaning
process.
a. Close the door and press the start
button. When the cleaning cycle is in
operation, the green light on the
display will flash and the LCD display
will give further instructions.
b. The table will begin to rotate and the
blowers will start.
c. The nozzle will automatically move to
preset nozzle height.
d. The display will show the time, in
seconds, for the cleaning cycle.
e. For tall filters, the nozzle will move
down to “half-height” position to clean
lower half of filter. The display will now
show the time in seconds to clean the
lower half of filter.
f. At the end of the cleaning cycle, the
hold down weight will retract upward,
the vacuum collector will move away
from the cleaned filter, and the table
will stop rotating.
11. Remove the clean air filter.
a. To repeat the cleaning process with the
same size and type of filter, place
another dirty filter on the table, shut the
door, and press the start button.
b. To clean another size or type of filter,
press the Reset button and return to
Step 1.
Filter Inspection
Clean off any excess dust. Place the filter in a
post-clean inspection fixture and perform the
inspection procedure.
1. If the filter passes the post cleaning
inspection:
a. Replace any seals/gaskets that were
removed.
b. Repackage the filter.
c. Return the filter to stock or to the
customer.
8
2. If the filter fails the post cleaning
inspection, physically damage or destroy
the filter to prevent reuse and properly
discard it.
Preventive Maintenance
As with any mechanical device, proper
preventative maintenance will ensure a longer
service life. Inspection of the air filter cleaner
system should be performed as described.
Daily
1. Make sure the table rotates properly in the
automatic mode.
2. Inspect the cable of the hold down weight
for wear.
3. Check for air leaks. There should be no
audible air leaks.
4. Check the three air sensing lines from the
dust collector control panel to the dust
collector vacuum unit. Make sure they are
not kinked or pinched.
5. Make sure the blow-tube assembly moves
freely on its guides; no binding. The rollers
should not cause binding and require no
lubrication. Binding can occur if the guides
become dirty or bent. Also, check the
guides for excessive wear.
6. Make sure the collector nozzle moves freely
on its guides. The rollers should not cause
binding and require no lubrication. Binding
can occur if the guides become dirty or
bent. Also, check the guides for excessive
wear. Check the brush for broken or
missing sections.
Weekly
Inspect or change the blower unit air filters
every 40 hours of operation or as needed.
Properly maintained air filters will ensure
maximum air flow.
NOTICE
NEVER run the blower unit without the air filters
in place. Significant blower unit damage can
result from even the smallest amount of run
time.
Monthly
Clean the dust collector air filters. Even
though these filters are self-cleaning, reduced
efficiency can be caused by filters getting
plugged.

Troubleshooting
Troubleshooting Chart
Problem Visual Indications
Dust collector vacuum will not start. No lights are visible on dust collector
control.
No vacuum. Motor is running wrong direction.
Filter cleaner unit will not function. LCD display is lighted.
LCD display is not lighted.
Possible Cause/Solution
1. Make sure power is connected.
2. Make sure disconnect on dust collector
control is in the “ON” (up) position.
Disconnect not turned on.
3. Check control fuse in dust collector control.
4. Check main fuse in dust collector control.
5. Hold start button in long enough (2 seconds).
1. Manually check rotation.
1. Make sure E-Stop button is not pressed.
2. Cleaning time is not input.
3. One of the DC motor overloads is tripped.
4. One of the AC motor overloads is tripped.
1. Power not connected.
2. Make sure disconnect on dust collector
control is in the “ON” (up) position.
3. Breaker on 24 VDC power supply is tripped.
4. Control fuse is blown on secondary of control
transformer.

NOTE: At any time during the operation of the

filter cleaner, if an error occurs, it will cause
the unit to shut down. Most of these errors will
be shown on the display.

9
Recommended Spare Parts
Chart C. Recommended Spare Parts
Qty. Part Number Description
Electrical
2 GDB-2 or equivalent Fuse, 2 Amp
1 — Proximity Switch
Mechanical
4 Donaldson - See Dust Dust Collector Vacuum
Collector Manual Unit Filters

For parts that do not have a Caterpillar part

number, contact the Caterpillar Service
Technology Group (CSTG).

10
 SLOT 0 SLOT 1 NOTES:
4 CHANNEL 0-10V INPUT 2 DC INPUT CARD
F2-04AD-2 INPUTS X20-X37 D2 16ND3-2
- NOT LOCATED IN CONTROL PANEL
COM 2 0VDC 1 *
CA - USE 14AWG WIRE UNLESS OTHERWISE INDICATED
1 24VDC
+10V 30 - USE TWISTED SHIELDED PAIR WIRE
A0 M1,M2,M3 OL'S
CH1- RIGHT/DOWN
RED GRN BRN - TERMINAL BOARD POINT
40
480V 3PH NOZZLE DOWN/UP WHT BLK BLK 79 A1 RIGHT/DOWN
L1 L2 L3 RETRACT/EXTEND CH1+ LEFT/UP FX - TERMINAL MOUNTED FUSE
XXA
BLU RED BLU
39
A2 LEFT/UP
CH2- 1 - REMOVE JUMPER AFTER E-STOP INSTALLED
OL M3 M1 RED GRN BRN DOOR
T4 L1 OL T1 31
NOZZLE LEFT/RIGHT WHT BLK BLK 89 A3 DOOR CLOSED
TABLE T5 L2 T2 NOZZLE RETRACT/EXTEND CH2+
M3 M1 BLU RED BLU 4 M4 M5 M6
T6 L3 T3 BLOWER 32
A4 DC MOTOR 0L'S
CH3- CYCLE START
M2 RED GRN BRN
L1 OL T7 37
BRUSH LEFT/RIGHT WHT BLK BLK 99 A5 CYCLE START
L2 T8 BLOW OFF RETRACT/EXTEND CH3+
M2 BLU RED BLU WEIGHT UP
L3 T9 BLOWER 33
A6 WEIGHT UP
CH4-
4 WEIGHT DOWN
CB1 36
A7 WEIGHT DOWN
CH4+

L4 L5 L6 CB 1
4 2
SIEMENS 24V-40A
POWER SUPPLY B0 MR1
Electrical Schematic

+ - GND +VDC IN -VDC IN

A2 (MOTOR ARMATURE) A1
1 2 B1
CR1 CR2 M4
24VDC 0VDC 24A 9 20 4 29 NOZZLE
B2 6 - 7 LEFT/RIGHT
2 MOTOR
AC BR2 AC CR1
8
8 J
2 B3 + 21 CR2 23
CR2 2 CR1
MR1 BRUSH LEFT 9 22 4
42 BRUSH LEFT LIMIT
F3 B4 6 I-I I-J I-K 7
WORKLIGHT +VDC
4 VIII-A VIII-B VIII-C
3A NOZZLE UP
-VDC 43 NOZZLE UP LIMIT
B5 RED YELLOW BLUE
WORKLIGHT 2 E150
MR2 *
NOZZLE RIGHT 44
ESTOP +VDC B6 NOZZLE RIGHT LIMIT
1A
MCR MASTER CONTROL 4
RELAY -VDC MANUAL ROTATE
45 MR2 M5
B7
MR3 +VDC IN -VDC IN NOZZLE
UP/DOWN
+VDC A2 (MOTOR ARMATURE) A1 MOTOR
1 2

11
D2-06BDC-1 -VDC CR3 CR4
PLC 24A 9 20 4 29
COMMUNICATION -
CABLE 6 7
2
1 2 AC BR2 AC CR1
OP1500 8
PANEL/DISPLAY + 8 J
21 CR2 23
CR4 2 CR3
9 22 4
+ - 6 I-I I-J I-K 7
ACOPIAN
24EB10E130 VIII-A VIII-B VIII-C
+ TC - SLOT 2 RED YELLOW BLUE
RELAY OUTPUT E150
4 D2-08TRS OUTPUTS Y0-Y7 2 *

+10V 0V
MCR SLOT 3 4
OL M6
50 RELAY OUTPUT MR3
NO0 M1 NOZZLE BLOWER BRUSH
D2-08TRS OUTPUTS Y10-Y17 2 +VDC IN -VDC IN
MCR LEFT/RIGHT
4 C0 MOTOR
4 A2 (MOTOR ARMATURE) A1
NC0
2 CR5 CR6
OL 57 24A 9 20 4 29
51 BLOW OFF BLOWER NO0 M6F BRUSH RIGHT/EXT 6 - 7
C1 NO1 M2
4 C0 2
AC BR2 AC CR1
OL 8
SLOT 4 52 NC0 + 8 J
C2 NO2 M3 TABLE 21 23
CR2
ANALOG OUTPUT CR6 2 CR5
F2-08DA 58 9 22 4
53 NOZZLE LEFT/RET C1 NO1 M6R BRUSH LEFT/RET 6 7
C3 NO3 M4R I-I I-J I-K
VIII-A VIII-B VIII-C
24VDC 0VDC 59 65
54 NOZZLE RIGHT/EXT C2 NO2 WEIGHT UP RED YELLOW BLUE
2 2 C4 NO4 M4F 2A
S1(-) E150
60 66 *
MR1 55 NO3 WEIGHT DOWN
NOZZLE UP/EXT C3
NH+ S2(+) C5 NO5 M5F 2A
+V1
61 67 BYPASS OPEN TO
56 NOZZLE DOWN/RET C4 NO4
NV+ 2 NO6 M5R 2A NOZZLE/BLOW OFF
+V2 S1(-)
C6 62 63 2
MR2 C5 NO5
1 BM+ NC6 2A
+V3 S2(+)
67 BYPASS CLOSED TO
2 Y17 NO6
S1(-) NO7 2A NOZZLE/BLOW OFF
+V4 C6
C7 63
MR3 NC6
NC7 2A
+V5 S2(+)
Y27
NO7
+V6 C7
NC7
+V7

+V8
 For information on service tools or shop supplies,
contact Caterpillar Service Technology Group on:

Caterpillar Service Technology

501 S.W. Jefferson Ave.
Peoria, Illinois 61630-2184
1-800-542-8665 (USA)
1-800-541-8665 (Illinois)
1-800-523-8665 (Canada)
404435 (Telex)
1-309-675-6618 (Fax)
CSTG_Hotline@cat.com (E-mail)

or

Caterpillar Service Technology

Caterpillar Overseas S.A.
P. O. Box 6000
1211 Geneva 6
Switzerland
+41 (79) 217 27 45 (Geneva Phone)
+41 (22) 849 49 29 (Geneva Fax)
36CSTG (COSA E-Mail Address)

©2003 Caterpillar NEHS0819

All Rights Reserved Printed in U.S.A.