COMPONENT DURABILITY

*b-_
 il
'{l

i'¿
':' t ¡:; .-:.r;.i.i:;i;:r:r;a
TABLE OF CONTENTS

ME A S URTFNG
r-UtCt
0 E A NUNrS. .S. . . . . . . 07
WHAT ISCLEAN? 07
0r¡- A NA |-Y S |S . . . . . . . . . 08

FTUID
CLEANLINESS
SÍANOABDS ll
ADD|T|VE
TNTEfiFEBENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HowMUCH 0 E B RIlS
S n E A t t yt N 0 -? . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 1 4
flLTE BS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
THE NE f t F t E CT . . . . . . . . . . . . . . . . . . .. . . . . . . . t5
fl |.]EBP E RT o B MA NCE RA T |NG
.................................... 16
DE BRT RE S -E NT RA |NMI NL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8
FITIER
CONSTRUCIION 19

BUTKfUET FITTRATION
F -T RA T T0oNt
N HEMA CHT NE
.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
0 -

30
31
MANAGING
FTUID
CI-EANTINESS 33
DBIVING
DOWNCOSTS 37
KEYSTOTONG
COMPONENT IIIE ...,,.... 39
XEEPING
OII CTEAÍ'¿ 39

TABTE
OFCONTENTS
 grealest
lhe single for ncreaslng
oppoir!nity compo¡ent fe a¡dloweringoperatngcosts
isto effectvelymanagef ! d c eannessThismeans mantan nghighevelsoffluid
clean¡nessn a mach¡¡e cor¡parlmenls thelifeofthemachlne
throLrghout ll¡derstanding
whatf Lrldc eannessis.howt is r¡easured,andho$rlo ¡¡antan l areprefequisites
for
efleclvefl! d ¡¡anag€ment

The single greatest

opportunity for
increasing component
life and lowering
operating costs is to
effectinely manage
fluid cleanliness.

The Past
Thebasic philosophyof mach a¡dservcehaschafged
nern¿ntenance dramal caly0\'e''
lastseveral decades Thefocus machines
onearly lher¡¡s faslasposs[ ;
wasto repair
order to r¡ ¡ r¡lzedowntme.fvlodestcomponenllfe was¿cceplabe as ongasfre(..
repafswerenolrequredLl¡expected fa ur€swerenol!¡cor¡mon
compofenl Theccf:.:
ol extend ngcor¡ponent ngfa ureswasa far owerprofilylhanbeng::
fe afdprevent
lo fixfalures lastand!et machifes 1owork
back

I component lifeof failre falewasnotacceptable,

lre ¿nswer ! I -:
was!sualyto redes
"moreron.'Thismeant makngcomponents orpartsb ggef,heaverandmor€exp¿:
rather
lha¡ identfyngandcoffecl nglherootca!seof theprobem
 Perhaps
oneoftheleaslLrndetstood
causesofproblems inthepastwastheirnpact
offluid
cleanliness
onreliability
anddurabiity.Filtration
wascrude ornone¡istent
bytoday s
standards.
Excessivedebris
wastheleading cause ofacceleratedcomponent
wearand
often
thecauseof repairs A good
orfailures. ex¿mplewasthe8-speed semi,automati
transmission
used inwheetfactorscrapersinthe ,l970s.
Thesefansm ssions
werebuilt
before
electronic
contrcls
existedShifting
wasaccomplished bya complex
4-layer
valve
bodycontaining
more than40spoolvalves.oneofthemost common ptoblems
withths
control
systemwasslddenlylosing
theabilityto upshift
ordownshift.

Thiswasnearlyawayscorecied whentheservicema¡disassembled
andcaref!lly
cleaned
thecomplex valvebody.A smallspeck0ldirto¡debris
causeda valve
spool
t0stickand
preve¡ted
thefansmission fromshiftng.lf today's
highquality
0ilsandLJltra-High
Effic
encyfi terswereused,therepairfrequencyofthosetransmissions
wouldprobably
havebeenreduced bya iactorof 10

I speedtnnsn¡ss¡on
contrcL

"'^'"^"iil?il3óüTilb
os
The Preaent
Thedesignphilosophy r¡achines
ol modern haschangeddrarnatically
fromdecades past
Custor¡er
demand hasdrlenmodern machines
tohave rnuch
hlgher
levelsofperformance,
reliability
anddurabil ty.Thiscustomer
demandhascausedthepefform¿nce andpower
ofe¡gines
density andpowertralñs proporl
toincrease onately
These performance evels
req!rernuch qualtylhigher
better perlormance
lluids,
much lluidfi fat on,¿nd
better
vastly
improvedfluidc eanliness
leves

lnpaslyears,there oftheneed
wasI tt e appreciation tomantain
cleanf uids.Tod¿y,
c!stor¡ers, ¿ndCaterpi
dealers gained
larhave gre¿ter
a r¡uch underslanding ol the
s gnificant
mpactoflluidc eanlnessmanagernent durabityandlle cyce
oncomponent
costs. ngisdemonstrated
Thisunderstand intherapid ofoff-board
Srowth liltr¿tion
pel0rmed duringreg0lar (preventive
Pl\,4 rnaintenance)service
andwhenmaior
components arefeplacedThere ngcustomer
isa so ncreas for
dernand
to provdesignific¿nt
Caterpillar mprovemenisinthedesgnof machine
onboard in orderto makethefiltr¿t¡on
filtraionsystems syster¡s
capabe
h
of rnaintainlng gh evels
of fl!ldcleaniness the
throughout entlre
period.
Pl\,4

Contnuousoff-boatdf¡ltraüon
 --\i
7I.i:r-\
MEASURINGFLUID CLEANLINESS

What ¡8 Clean?
Inthesrmpeslterms,
clean
fl! dsdonotconta partclesorI q! d contar¡
n loreign nants
Cleaniness
varies
depending
onwhetherthefluidisneworused.

EWtUE[0notl:
ldealynewll! dswould beperfect y cle¿nInreaity,co¡tam natonoccurs fromthree
primarysources:
. Prodtction
Metalpatticles
fnmp¡pes¡nthercfnngprccess.
. Írcnspotl
Dift,netalpanicles
andl¡qu¡d
contaninat¡on p¡pelines
frcn trucks, andshipp¡ngvessels
. Stonge
Watetfromcondensat¡on,netalfrcn thestorage
vessel,anddirtfnmunfiltered
venta¡l

Newliquids
sho!id
containverylowlevels ol partcuateorliqurd
contaminat
on.However,
conlamrnatr0n
maybesevere d!eto poortransporiation
andstoragepract
ces.Thiss
prevalent
especially inremote areasoftheworld whe¡efansportation
systemsare
extremely
crude
orwhere littleornocompetitonexstsbetween suppliers

Eulkfuelandail oftenbeconecantaninated
¡,tth d¡rt,netal andl¡qu¡dcontan¡nation
dunng

IMPBOVNG
COMPONINI
OURAs
I IY
FLUDCTEANLINESS
usED0ll-:
0 s p ckLrp ¡n ncreas ngnumber of conl¡mr¡ntstfrro!!lho!l1he I useÍulfe flüid qleanliness is a
. Eng¡neLuhe0íl relalive ternr.
Acqr¡es wear n:etals t'rDnt lhe engrne alang w¡thlarge ¿fitaurls al saallr1n tlle Acceptable cleanliness evels varybased c-
ror,Ó¡/.r¡/0,p/oaessEnll¡e Dl hasthehighest ratPaf cantantttaltan andtsby far a varietyoffactors:
tlv Íl[lteslal lhe ftve o¡ltypes . Whether theflu¡dis fuelot o¡l
. Hydnulíc 0il . Whethet o¡1¡snewú used
Acqútres $tearntalals ltut¡l hyttattlE catnpanenls. tuLJb¿rltat¡l
hases and dttt flat¡ . 0¡ltype (eng¡ne,hydtaul¡c, gear,
ertty|Éslhydtdult!. tylttúlet at¡d¡,alatsealsD¡nca alsaa lat ltDnlthea ¡losphPtP tnnsm¡ss¡an, f¡naldive oraxle)
Lhrcugh vent fthcrs n tta| f&/ sfslcDs H/d/a¡lra otl hasthe lawúl canlanttnaltan . The anount of usable l¡feleftin thec
ala atnl-¿t¡Dis lhcclealres¡ ¡r¡l/rc,vo d//lfpe.r . Contan¡nat¡on Gteprcduced bythe
. Gearoil c0npqnent
Acryitt-os \\,eat rtalalslt0t¡¡ heavtly laaded andsltnPrh¡tpast
llcdts;ttxlba¿ttttqs,
atlsp,ilsDrt i]nl t¡taAlrtc alsat¡tal crtct ,0n¡ t1¡p¿[tu]splttre lhtauaJhventltllcr:;
NL)atly all!1ca¡ atlltlhttst:rrs/slso/ ,te¡/ ,retá/s
. T¡ansn¡ssion oil
AúIintslt!)ns lt0 ¡ t'tx:titx¡ tt¡e1út¿l vr'adtj¡c1ilslt0n)l1aaled l?¿t::¿nl bt¿ttttts,
lr
¿tÍl tat ltl p¿sl ]tl sp¿ls S]n¡e (l t i nl totsltnttDy ¿lsatenle¡ l¡D¡tt
thP
¿t¡x)sphpt ! 1lt artqlt vurl Irlla)t
s
. F¡nalDive, D¡llercntial, and Axle 0ils
At\tIit)s l¿¡!la ¡itüaL1 lts t¡l t\4)¿t¡¡t\¿ls lt0t¡t h¡:¿rtlylo,t(lt\l qr¿tt; ¿rd 1)c¿ttnllt.
t¡t.ty¿l ::(ttxtl ct l tat¡t
i ¡t¡tl 5üt t lfttlt t ll) ¿ s lD tls t)¿ l sl l ü ¡ttry l l tl ttl ¿ ttl rt)t:;l Ltta
|| ¡t)¿It t n)sltl¡t t t) t ht nti!lh vt)ltt I I llt)ts
Al sanples prcparcd
be¡ng fottheautanat:

Oil Analysis
(lvcrllrcyciIs lIr 1{)llrr S[]SiS(irrrrlLr
lil[] fü r) i¡ riryss N/l,ryr]|1ltirI
srxvfl)s T r{)( r¡ 1!,r](nls
ll
u¡ (Ji S¡ rrl) rrl)lr¡s l){r{:(rrrl{r
(x)rlrpirrr|s
irrr)trrr(l
slr n:yinxlrl|f)llr01lhr)srr
it !/ (lr \r Lrsu(l
llrrr\\rr]rl(j0lf(rr
irvilr
s0rvr:usvirfylrr(Jr(lur
{)lV 0f 0
llr I lsLrrl)
(tcttrr(:
¡rl¡ yss
l:Llsl0rJltrrs
T
ys
r1 lln)(Lr¡||lyrfi rr s srrvr:r\ rllu{rl I ir0u(t1i Cirl0fp¡r.th{rllr S.fJ'SSrx\r r:rrs'h¡s
l)rf iTrir(jolr¡rkr)rlIlrr 10 rw (l ¡(isu lrl r)rs i I vilrr)Lrs 0l ¡rr¡ Vsrspr)(r{)sstrs {rlf(rr{rrl
I rourtlrS.0'SS(rvr:rrs

Srlr{r([]{r(l0 rl{)s(1rr{)(l
|s¡lrl) rr(ts¡ prrrrrrss lrrt rrrI tr(ls¡rl¡lyss a¡1¡ rltaLls¡btl
10lrep {l-"rrirly
fl0ll]r¡lr0rllr¡1c¡f l)r usrrrl rllperr(lrr{1 l¡ lLrcsbef¡re
c0rrrpurl0rrl
Pafticlecounlresultsateusuallydisplayed
1r¡l¡slr0l)hr1¡!r{rrrlrl¡ y00rL|\ Thrsrrf0nn¡l0r s Lrs0¡llr rlr¡rr¡(tc tq! prlletll
¡n(l re(lLrce 0l)rr¡tf{1c0sls I r00i ¡r¡ ysrsflorln r rs drvrl-"tlrl{rfrI I c¡tc!t0r0s
. Cat¡1lxn¡Pt¡t
WP¿iB¿tc
. L)l l)útd¡tnx¡
. A¡lÜ)nla¡¡r)a¡totr
. 0lldaitltltcdltat

COMPONENTWEAR BATE
lo r|o¡efl ,,\'ear
rate¿ r¡lysiscva!¡lcs trc $/carLlr¡1s lak¡! plat-"rnsd-"the rbfcat0d
n¡ch ne cor¡p¡rln-oriS.[].SServrrsrscsthrrcs!lsofeenreft¡ an¡ !srs¡nd p¿rlc 0
r0url trsls to ev¡ !¡t"oih-owe¡f t emefl¡ ilf¡ ys s wrlh¡ spcLlro¡teter nteas!res we¡r
p¿fll0es tllirtarc cssth¡¡l0mcrofs nsiTeP¡r1.e C¡rft ¡ r¡ ysis¡,!th itthtbockf!
iechn¡oltyfieasufrsp¡rl c rs lto¡r4 m cro¡slo 50 r¡ cfofs Trend¡n¡ yss ¿rrdpfoprl0tary
weaflabes ¡fe then!sedt0 d0tDfmrc fwrar r¡tesatefofnta or allnofr¡a
 OILCONOITION ANALYSIS
Ll Oondton¿nayss s usedto determine if iheo h¿sdegfad-"d Tests aredo¡úto look¡t
theoxd¡ t io ns, ! f ¡1o f , a ¡dv s c o siVo fih eo E s t a b ls h e d g L¡e
t dsea ¡ dt r e n da r ¡ y s i s
afelsed10deler.n fe f the¡¡ hasfeached ts !sef! if-"

OITCONTAMINATION TESTS
0i Cont¿r¡ n¡t 0ntestsareperlor¡cd t0 detefm
ne I anythl¡q
h¡fmfLr
haseftefedlheol
Tlrs ¡¡a yss re esonlherrs! ls fftlmthelollow¡! tlsts
. ctnentalat¡alysts. fueldtltni1n
autanatc pancIe counteL
. .Soo¡corlerl
. Glycalüirtlan¡nattDn

ThcC¡terparS.0.SServccspnrqramhasqudei|esfortte leve¡f c¡ntam

f¡t o| ¡ owrd
I lhevaroLis
tom¡larlm|ltts
0f C¡tfi¡chnes

0[ rDEN]tHCAT|0N
0rl dcnlif0¡t0f s ¡fot rerv"ory rmport¡|t pafi0f lheS.0.S0 ¡|¡lyss pfoqr¿ | Thewrorlrj
0 l n ¡ 0{Irp¡(mefi c¡nsevcrrly ti¡rl¡qIr¡¡J¡fco rflo|c|1s Eúre|l¡ ¡n¡lyss ¡nriv scos
ly
rcsuls¡r0 rs -ol0f la le fly
l k ry c t ¡r¡c lesrt c s 0 lllt r 0 ls
indüct¡vely PlasnallCP)analyzel
Coupled
leterntneswearnetal cantenl. Thes¡fourlypcs0f ¡firlys{rs ¡re Lrsffl
Tofixnrl(n 1lt.cIrreIt¡|¡r¡l t{lIrrxl l0r lrl c(lLpr¡eIl
rr0rd{r'l0 (lurl fy p01{)fl
;r fr0h {]l¡ss0 tlt¡l pf0¡rlvc r{)p¡r\ li¡| lxrIri¡40(l ¡|¡ ys s
r¡rl ¡lsu Lr rsr)(llr hep exle (lriOrrrpofc
tl fr)¡|(l 0w{| lr0n[)0rx] tl f0|y|{)cOsts
Q
TURNAROUNDTIME
N¡¡slS.0.S Srrvrrs¡bof¡tor0s,,!pr0r{rssIs¡lltlr{rs |74t(l4flh)urslll|]fcsLtls0llx)l)
ys
¡rr¡ s a¡ r lJc{) nir c(l0f ¿aarssul
lr0|lti]|l0 ll|0 s0LÍr:{) rrnUlc 0r¡t lIts,lrxt{)filirr
slrlrpfq¡sl¡f(]cs0fcLrsloms¡c¡y\m¡yr{xlL {)1?\['rx]ksl{rrsiIl){rln0c0ssIll

S.0.SSrrvic{rs pr0v¡-"slhe t0st¡cc(r¡10nath0rll0 ril)|rlllrwc¡r i Il llrntpllllttúlrxltt t

H0w{rv{rf,llr{)rl-"¡! belwccI I t! l|l101t{r
s¡ llllI stitkUt¡|11fr)srls r{)tLlr
Ixl 0ft{jt t{t¡|s
Autonal¡csamplehandl¡ng
systenfot the I re 0r¡chfe h¡s bu0 p ¡0c(ll)¡(ikI süv cr) C!sl0rTlrifs ¡fr)sIrJt0t[]0srli Illi tl l0rcnt0vrl
lher¡¿clirc lr0n scfvcr);rq¡n Lrnessllir S.{l'Sv fr)lx)ft re(LtresLrfllri1it|10n

DAIAVOTUMT
Tlr-"sh-"¿fvo u e 01S.0.SrOpofs10r¡ l¡rqeI rcl 0¡| l]trlrvurwhe r¡ |.1 A Tooolte|,lhc
reporls ¿res np y ficrl if ¡ c¡[] ¡-"1¡fd revrwrd ¡ftt]r¡ I¡ lLrr-"
r¡s a r-"¿dy0ccurrcdI0
¡ddressI rispfobl-"Ír, ¡ 0¡ierp ar S.0.SScfvcesreports ¡re co or rod0(l\¡/llt ¡|¡cft
rv0 Tlrrrc¡lerl eves ¿feusedtetl y0 0!,' ¡ td qf-"-"n Gree¡a erl Id calrslltirtwc¡r rs
rrorll¡ ¡rrtjconlamrnal of s ¡ot prcs0rl A y-olow ¿l"olt rs usedwh0| tlr| úrt]¡ff¡t-oll¡s
rcfe¡seds ghllyor $rheI ow l0v! s 0l coniamtf¿tto¡ ¡rc prcscIl A r0d¡ erl nalc¡1-"s
lh¡l r¡ajorla lre s kclyt! occLrf B-"d¡ ertsarc¡ssoc¡led withh qhwearr¡tesa¡d h rJh
leves 01cl:ntdnr a en levelsarevcryllc pl! |l nafaqng l¿rlevo lmesof o
fat 0 r Tlres-"
irrayss d¡ta Theclstomef c¡f seeaL¡ q ir tc-o,
thernach fes lhalfeed t lcdi¡tO ¡tlDtl 0|

" iirioi,,o*,liiiit
09
 Patticle Counting
A growlngtrendwth many fleetss to supp er¡enttheS'0'Sreport w th portab e p¿rtic:
cou¡ters.Partic e countsof fluidscanbetakenwhenthemachine is intheshopforP['
Taklng part¡c
e counts before andafterPl,4a owsthecustomer to determ neif thefiltral:-
onther¡achnelscontrongdebrls, orii addtional filtration
off-board isneeded Trend ",:
of thepadc e count datacanalsoprovdea bass to helpldentlfy a potent alfailLre wh :
ther¡achine is intheshop. A rapid countrnaybeanindcatonthatr¿É:
lurnpin pariicle
wearisoccurT ng Thiscanbeconfirmed througha more accurateS'0'Sanayss

lnrecent years,adva¡ces infiltertechnoogyhavedramatically improvedtheelfici€ncv

c'
flltersavalableforuseonmachlne systems. U traH ghEffcie¡cysynthetic medi¿ ¿.:
Advan.ed Elficencysyntheticb end med a fillersh¿vebee¡ recentlydeveloped
which 1ra:
andretain4 m cronpanicles at greaterthan987o efflciency withup10threetlmes11":
debris hodlngcapacityol o dercellllosefi ters. The ab ty to trapandhod moredebrs -
y slows
thefilt€rsignlicant therateol partic! ateaccurn!latio¡ intheoil Compartr¡enl!
gh
thatusetheseh eflic ency f ltersproduce ower partlclecou¡ts andkeepo I c e¿n.'-
thanwhena standard lilteris usedBeducing theamouni ol particles
Intheo lreduca:
abrasive wearandncreases cor¡pone¡t life

particle
Portable counters areavailabe which paltlcle
allow!sersto measuTe co!nlsIn:
whle a machneis inlorservce.fhis s thesamebasc parliclecountingtechno ogyusa:
inS.0,SlabsInsirnpe lerms,the partc e counter
shlnesa laserghtthrougha sampe :-
forshadows
ol andlooks caused byrncroscopic i¡ theoil Thes ¿ea¡dnumbe:-
debris
shadows counted
areconverted to anlS0c eanltnesscode
Portable canqu¡ckly
paniclecounters neasure _:
ofanail0tfuelsanple
thecleanliless and Portablep¿ iclecou¡tersdonothavetheab tYto te whattypes of partlcles
arecrea:
provtde
lsj data theshadows Theys mplyprovide
thenur¡berands ¿eof partic es.A growngtrends':
fleel!sersto measureparticle
countsal PN,4
and üend the rate
ofgrowih Ths canbedc-:
andons te Inrna¡ycases
irnr¡ediately where!ltra-hghefficencysyntheticfiltersare!sa:
the eves of partclesn theoi canber¡antalned at or beow lS018/15 throughoul l-:
P¡/ per¡od.

f thegrowthln particle wears Llslay nor¡alll there: :

counirer¡anslow¿ndsiable,
sudden growlh n partce colnt,rapdwear rnay
beoccurrngAnS'0'So lsamplesll'a'
taken to deterrnine wearmetals h gh.
if a particular

TURI{AEOUNDIIME
Sample are mr¡ed
res!lts ateandonstte

c0sr
Partic
e countersaresornewhat w th thecostof a typicalunt at around
expensive, $10.::':
However, thebe¡efrtof provdlngmmediate is
resulls a stro¡g incent ve to a gro\r.:
number of f eetmalnlenancemanagers.Bapid advancesin techno ogyarel¡¡proving :':
accur¿cyanddurabiliry
of portab
e parl
c e counters

DATAVOI-UME
co!ntdatac¿¡befendedbytheuserona slr¡ple
Particle spreadsfleet.
 FLUID CLEANLINESS STANDARDS

-!e slandaid
method
forexpressing
fluid TherLrnrl)rr !l p¡rl r 0s0f 0¡dt s /-o¡r-¡|¡trljrr lr¡ f¡|(essr|!!| |tlte{rlr¡rtN!10r
: ean¡ess s thro!ghS04406 1r¡l (rirtlrr¡r(t(rs1\ aelra rullrl)rr01 llrcr¡|tteTlt¡llllllrlrs I lltr |0slcl|lr¡10|
.lernational
Standards0rganizatio¡ riü(¡)sLs{r(jlr |rlllrss | | {ri t rl0ss¡re LsLt,tl I lr0 t l3 t| 24
.'ocedrre
4406)Ths standard how
deflnes
:¿11clesizeis measured
andorganies A r t)\i tt¡l ti ral ti tl vt)tl \,!t)rl tl l )t)21.19' 1/fl ¡ts\\tati l tl úrtj tr!l n)lt ) llt ) At nl)
:abrisntothrees ¿ecategor
es PA R TIC TT
S IZT IS O R A N GE N U MB E BOF P A E TIC I-EIN
S I MT
4 microns (.nd la¡get) ,1rri r)r:l ?1 |1.1t{t020.00¡
6 rrricrona (atrdrárse!) t! 2 Silit5.0!rl
1 4 fül rl i 1l ilI ttil)
14 ¡nicrons (.¡d ralgér)
Ar t\,)t)rtl t)olttxy t:tt),t t¡tlA t¡| l ¡l | t: ,¡tt¡| ¡¡Ll
l fl 1l ) l l i
ISO 4406 Chart
PA B TIC LE
S IZE IS O R A N GE N U MB E ROFP A B TIC TEIN
S 1 MI-
Numb e. ol p¿r lic les per m l
' 11 | l l l l l ] l I :l|| Tlfl(l
{ ir i ü i L r r s ti :llfl fi4{t
24 80.000 160.000 ,10 lr(l
,10000 80000 1,, )
22 20.000 40,000
10. 000
20 5.000 10.000 W lrllr r iL 1isllr,rlu rliflr i Irr 1r i iIIIr)Lr II5 I)I !ily u|, lrilllIrs, sL|tltitsll{r!LrlLlr,
2 aaj 5 000 ll,rlrr|),I Lr\r:r,rI r {r¡r rrLI,II)IIIs I trLrS0 LrLxIr ll1m,¡rvrr I r lltlrkr ! rLlrsl! rlrtr,tLI
18 1. 300 2,500
I 300 irrl Lrlnrirlrl lL rl,j ll| rLrrlnrr)l!1xy:rrrirl)i ll][rs s {r\srJtlrlIt,I IL llti Iltsrl
16 324 640 ,irsLr(l!r¡l)rrr1ü L! rr(| rrrr ,y'I r(r lI\r),]r(l|r
lr,IlL]lr s /|\ As,rr1)¡iIirlr. lll/ lti,llll
I 1i0 320
80 160 rlLr 1jl)r :rl,llrl ir\ s frtry lti 1l:l

12 2A 40
tl 2A llr{rir{rirr r{)ssrrlr) s,Ir lrlrsrfiiylJlr(l{rtlln|{r(l i I iil)1rlitlllr!
u\ rtr;S|lI:rlLrr:rl
[)
10 5 10 S,rrtrlr (
ll1SlS, rrr rllr{rlr r l r(t lr)rl¡¡ 1ll)i l L I r,ILr1t)rs Hlr\¡,'|v|rl)(rtlt
rrilrtlxrLll
2ai a
I 13 2.5 Lrslr
llrsu fr )irsI I0ralr\lr rJrc¡\LIrllrr ti 1| ¡ ll ILnl)lI |1 l)¡rl t |:t I lltlr\i ||iu
64 13
6 32 64
-henumber of partclescount€d ina mi iliter
rf fluidlsthe¡sorted ntothethree binsand
:anverted ntobroad classf cationsorcodes.
Thecodes areexpressed in a three-p¿rt
: eanness falng,such as18/16/13

ITUIDCtEANtNESS 11
 LIGHT WATIRDNOPTETS
SOURCE A PARTT.LE SmaI amouflsof waler¡re usuay present theo T fy droplelst-
I y
emusifiedwaterarec0rnmo¡10 20micro¡srl s le, wh chare ¡f:i
---1 '--------
enDUgh 10cause
shadows bythepartc e coufler:
andbe ¡lerpfeled
o " partcles

-
e
+ Waterinlerlefes
saturat
0 I N,4afy
w th thepartrc

¡bsw rüna waterclleck

€ co!ntanalys
of Ths varesbu1is typca y atlort0 07oib
s ¿taboullhep0rl1r-

p¿rt
or700ppmwaier
!\lthevery c 0 cou¡l¿rlays:
c confrn thatthecou¡treay s dueto p¡rlclesTypc¡ y labsú/ rurr"
parlicle
c0uft!f essthewalerevels hi0henough 10bev suallyollv
orthewat-"r clreckis I lh€range Walerai lhisevels nlor.
of 0 200/0
PHOTO ¿ problem forlheflud syste¡r th¿fafydetrrs irltheo lf a parlclecl
DETECTOB s |e0dedI sprleof lheh {lhwaleT coflamn¿ton.lhcsampe ca¡ I -
s 0wy Llredo¡ a hotplal-oof driedn a salee ement ove¡T"
ertclose¡
P¿ttdu Lahkxt: w0]kht:;ltm]t!¡ ¿ l¿s""tlt!¡h¡lht0!!1httu atl ar-oalsochcmcas thalfap lhewaterprorlc analysrs butthese arel¿
t:¿u t1
s¿ntpltr'¡¿ it)¿stnrt!lht rac ¿r¡tlnüntbetal sll¿lat¡\'s hazaTdous y
¡ndrarc Lrsed

ENTBAINED AIR
Partc e cou¡lersshnea l¡ser qhttlrroulh lhes¿mp e and esqe¡erated
Airtrubb if a lurbueft f u d system.Inlh-ósamp¡C pfoi.
fneasurc lhesL¿e
afdnumber 0l sh¡dOws caused bypartc es orwhileshakifglheo I a sarnp e bolle w cÍeate shadows durf.t' _
if theo I Anyoirlecl¡ lh€o thalcfeates d shallow
w I anayss afdw becounted aspartc esbylhepanclecountef cafe'
becolftedTheprobem s thalfe\,l'o rnay contan water betakenwhefpullinil
o fror¡anin ne part
c e cou¡ter10make surÉ: :
¡roplels,a r bubbles
0ralldt ves,which arefol deb¡s,yet theo s nolbecom ngeffa ¡€dw th a r Bottle sar¡pescaf bevacl.r.
theycreale shadowsdurin!thepartic e co!¡tafalysrs orsofcatedlo femovea I bubb pf
eslust orlo theanalys s
These addt o¡a componenls ¡f ¡te thelS0codereadifg
makngtheo ¿ppear dinerlhanI re¡ly s
 o o
oo
t
'----1/ O
O¡ o t?
->s!o
O
o oo o
oo

- readditivepadcles,thatlo n logelherdonolcomb neiflo ofe largepaflcle Theyact

iornewhal |ke a bufchof helumf¡ eclba oonsNalufafcrces lefdlo keeptl)ebaloofs
'-.qelhcrThcywoud separate to passthrougl)
a scrcethatwasarger lhaneachin.livirl!al
:i¡ 00f 0nceth€balloons p¡ssthrou!h thescreef,
lhef¡turaforces agsiftak-"ov-"r
and
'fe ba oofsr-"lormrftoa bo¡ch

'lr0additive
parlclesaclin thesarne
way Wl)efthelarqeaddl vepartic esstrikef fe
' termeda thef owforcesintheo oveÍcomethechernica ofthesm¿lpaficles
atf¡ction
-hesmalef partc esseparale andpassthrough
lhemedia0ncethro!gh themeda, the
rlremica
atfactoncaLses part
the c esto reform part
¡lo a larger c e

-h s problem s mostprof¡ifent wrlhfew o s Once theo hasbeenp acedntoseNce

'ora fewhours themechaf ca workfq of the¡ew o reduces theaflecloi additive
flelerenceThe pr0blem s ¡ sonotthesamefora ew oi s Thear¡ount andtype
-.fadditivesln the oi affect the severty of additive
intefefence
H gh q!a tyengine
lbe o lcoflafs theh gh€steves of addlvesafd s theworslo foraddilive
flerlerence Hydraul c o I co¡tansIeweradditvesand slessalfecled Leastaffected
s geaÍ o

¡'-.'n';r'é' l
 How Much Debris is Reauy in the Oil?
WATER There
areovomethods howmuch
lodetermrne debrs sintheol:
. Pafticle
caunting counting
lautonat¡c usingl¡ghtexttnct¡on)
. Manual paft¡cle
counting
us¡nga ncrcscope

PARTtCtEG0Ur{TEnVAnrASlLlw
A common lsthata sophlstlcaied
ass!mption parttcle
¿ndexpenstve coun::_
s i¡herenty Inlact,ther¡achines
accurate. accuracy aren::
¿ndrepeatability
Remember,
exact. theprocess y a lghtthrough
isbasicashining dirtyollar:
theszeandshadows
counting ofparticles
downtoa fewmicrons
¡nsi¿e

Inherent canbem!ltplied
varability
machine inoilsar¡pl
bydifferences -:
¿ndpartlc
lech¡iques e counter
operatio¡.
PHOTO
DETECTOF
f particle istobeused,
counti¡g it s irnportant
tofainthetechnic¡anus¡g
themachi¡e tomaximhe ofthesampling
therepeatabillty tech¡ique lt is
ln addi¡1nta debt¡s,waterdropletsandaÍ bubblesaho cause
Pan¡clecaunterscountthenunbetandsie af shadows alsorecommended totakeat2 3 samples ofthesame fluidto ins!re
shadaws.
thed¡t'ference
fheycannotefect¡velydtst¡nguish betweenshadows y.
repeatab Evenwith proper
eq!ipment operation
and samplingtechniques
caused by debns,watetar a¡ inherent tymayresult
variabi inreading ol+/-o¡elS0range
accuracy

PAST|Cr.E C0Uf{TEnS
Bece¡tadvances have
intechnology resuLted
insignificanl i¡ ¿ccuracy
ir¡prover¡ents
andrepealability of particle
counters.However,
variabllityn theequipme¡t and
sampl ngtechniq!es stilL
resuhsinsome ity.A gen€ra
variabi ruleol thumb for
lariablityisp !s orrnlnusonelS0ra¡geInaddt on,p¿rtclecounters mayalso
countentra nedairbubb es,water droplels
andadditivecl!stersalongw¡thactual
debris Asa result, partic
e c0!nterreadings
arealmost always higher thanthe
actualdebris levelintheoil Inextremecases,particle
counl readings maybe
2 4 lS0ranges higherlhanactual.

MAf{UAI- PANNCLE COUf{T fESTIf{G

Thebeslwaytodetermine howmuch variabiitymayexists topultwosamples
ol oil Useonesarnple totakethree paft
ormore clecounts to makesure the
reading isconsste¡t.Sendtheother
sar¡ple toanoill¿blora man0a partic
e counl 0¡1sanplesarc filtercdthrougha flltet patc"
test.This testmethod toperform,
issimple buts laborintensve,tirne
cons!m ng wh soiventA vacuun pullstheol ands0,:'
¿ndexpensive. Thetestproced!recons sts0fthefolowingsteps thraughthepatch and ensurcsthatthewate'
. A clean, anda¡ bubblesarcrcnaved Thedebris
1.5n¡üanorsnalletf¡ltetpatchtsused rcnain¡ngon thepatch¡s thenneasuedú.:.'
, fhea¡lsanple¡sshaken thepantcles.
wellto d¡stt¡bute
. fhesanple¡sthenpulledthrcugh thef¡lterpatchw¡tha vacuun.Thevacuum
ensuesthatall watetando¡larcrcnoved andthepatchis dry
. Thepatch¡sthen¡nspected undeta ntüoscope andthenunberandszeof
pafttclesarec,unted.

Ths tests t me-consur¡ing

andexpensve However,
it ison€waytoelimnate
the
optical
inlelerence partclecounter
ofihea0tornalic Theresulls
oftheman!al
paftlc
e count partlcle
tothea0tomatic
testcanbecor¡pared countt0deterrnlne
howmlchdirtier particle
theautomatic read
counter ng s
 . . lll: : i
illl
I lllll
lllll
l| l
i ¡¡| |
,l l l l l l l l
l

FILTERS

ir ilr . . i i , lri\,r rliL jlill \rlri i¡i lrlr,r1i, ,rir, , \ i r r l r i | i , ,r r r r Ir r r IIr r r r rl

iir 1 ,
i i l j i . i I r r r , i iI I r I I
. 1r , r l l ¡ r I I r r , . 1 i r , I I r r , i r , . r l i r , r i l r r 'i , I r r i , r i , i r , ¡ r , ri I rrrrri,r.irir rilrrirrri
i, li r , Irr rI i rII r ; i I I rrI l I .r ll, lirl rIriir¡ ,rrrri r, r 1,rt, i r i i r i , l r ,1 r i r i r i r r i i i r i

r' ,1 rL, rt Ir' , ,i r ü I l i ,, l , lr

lr ii ! r, lL rr, I l' r

The Nef Effect

I 1 1r I I rr L rrr' L r' i r tr' ,,rr ,. LI

l r!r' 1 | r, rl l ,,rl
' l l l r'
f, r lL L I !r!i tr i I I !r I I ll
I r lrr I
I rtr ' r lL L rl. tr
a fr r i! I I ,l 1 ., ! i '

!¡,i ,,1, I ..| l r| l ,,. t l ,r ll

l
a'
H0tEstzE
a

FTOW
SPEED
l, lL L Lr' r
!!r r 1.. r I r i .l tr Ll rr rr fl r.t I ,
I' I rr:t ,l ..,rr,ri tL L l L.,, lll
rL l ,rr,!: r i .r rrrL ;' , ,r ' L!,!' \L Lr , rtl r, L l r: rl rt , r L| , t t r , . r r
!,, I l t L } l \r, t.,t Lr, l ,LLf r l rI |L ,

IIL T EBI/| E D IATH IC K N E S S

l .rl I L,:rrr,r r,!,r ' r' l IrrIrl i ! !¡r,rl , I l Lrl ' r, Lr l , , il lr ', f . Ll
l L rrr.r ,rtl l l ,.r Ll l . rrr| i l rLrrLr,L ,l ,!Lr \l [ ,¡i l r]L |L nlr L, , lL
' rrr , , ,l r.rL, rL rr , \ l rr!,,l r,rl \ I rL

l l rr),j Ll ri rf l r,, r ,rl i Lr' l | \/r ,]| L L]r rL, r rrt Lr.l tl r: rl ffrl 1r r |. I I lLr '\r
l , r r' .1 rl rrrrLr l i 1,,\1, r rLr Lr' l rf i rr I \ | f | 1]. ,i,I r l Lr I Lr, r lt ll lt iif , l
I l ri l r, ' Lr Ir r :, r' Lri r! ,r' ,rl

t t -Íts
 f ilter Perforrnance Rating t att'
medium
f\,,lany a n do wq u a ily ft e f s a re -a a a
Stating a filter marketedbyusnga m cronralngonlyThs
t.t
tt at a
micron rating hasmisedmanyendusers
a 5 micfon
to belevethal
li tefsarev rtualy lhesame ..'. T --5
without the Betaraio s a lermthats virtualy ufkfown
'.at.t- '
beta rating is to moste¡d usefsSiatnga f ltefmtcfon
fatngwithout thebelafaiing ismea¡i¡gl€ss
meaningless. Theprimary method of f terfatnq s . lt a t '
effciencyof removrrrgand fetafing parlLc es
oÍ a certainsizeThetwocnlerra are
2 p¿¡ücles altt Bel¿Falng50
¡t nfiot¡s
I|easu¡ed
FuidF tefperfor¡a¡ces detefrnrnedb\. ,
Measurcd in thennnberaf patttcles manufact!rers usirtg
a¡ Ind!stry
sland¡ri:
0f tharatedsi¿eo¡lerlletentenug lhe fi lerleslForexamp e,thfee f l:-
differenl
ftllú n)edtavetsLtstltenumb¡jr Dl raledal 5 mcfonsarOtestedWh -"the
p¿rt¡cles
passng lht1ugh thcInerlta mlcron falnqmaybethcsamelheabll, '
Ihs tsreferred la as the 'betarat¡t¡tl trappartc esoflhats reafd aflefvare:
ofamal0a Y

PaÍicle ¡rrdl¡r(Jer
Size: 5 m cforrs

+
Beta 200 Raling Beia 50 Rating Beia 2 Rating
l
Filter Fillat2 F tcr3
200 c es r / I partrrl0
p¡rt olt beta200 200paftc cs | / 4 p¡ric esolt = b0ta50 200partc es ll / 100p¿nc es0!t - bel¡-

ofa fillera so rtcreases

Th0lletara1|lrrJ wfh partclesile
Thesame I terraledal thre0 d lfereflparlc e siesw hav0
tl)ree ll""Ia
d flefenl f¿llrl{ls
PABTICI-E SIZE PARTICI-ESIN & OUT BEIARATING
5 m crofs& arlt0r 200panclesin/ 4 p¡rtclssolt bela50
l0 m crofs& arqcr 200pallclesn / 2 partc esoLt bera100
1 5 r ¡ cr o n s&
ar q e r 200pances f/l partceout bera200

a'
-
t
o1
a
att'

-'a
a a
a d.'
a
. .'. T--)
a a ----'---1/ a
a
a
.s..'+)'
ta a
oa
5 microns and large¡. l0 microns and large!. 15 microns and larger.
 MEASUSING FILTEBETFICIENCY
Thef tef ndustry usesa standard test
pfoced!fetodefine the¿b il! ol a flltefto
lr¿pafd hod paftlcesof a rert¡n s re
Themr ti passlestco¡ssts¡f the
r¡ 0w ngsteps
. fhc testben.h.oñtai)sa larg-o t,1lune
0f teslfluida,d a pu p ta ctrcIlate
festduslwh¡chhasp¡ec¡sely!.at¡trallcdAl lhesamet me,¡ moreaccrr¡te
partdcsie ¡snlixedwtththetestlhiid procedLrfewasadoplrdfurme¿sLlrng
fhe nultt-passbenchis the¡ndustry tn d a0ntt0lletl
c0rtIenltdltan
standañfú measuingfihet effic¡ency
Ptec¡selycal¡brctedtestdu pan¡clesarc Ihe llurd ts thet¡puntpedthtautlltthe
nxed ¡ntestfluidandflow throughthe Itlbt tu hp lestedat ¿ staadyfl1n,tale
,het.lnl¡nepart¡clecountetscauntke
nunbetandsizeof patticlesenteingand P¿rt[]c countetiat llta rnl-"tat¡rJoutlnl
leav¡ngthef¡ltetto detern¡nef¡ltel 0f the lrllr\ ttaas|re thc,tt¡ )r\ a[
p¿tlr:bsetúennq¿ndleav tq theftJtct
FtltcrefhcLprt:y is n¡a¿sut-orl
u¡¡ttlthr
Itllc¡ he.¡t)rt0 pJu(t Whpnp|)srn t)
dta)t)a¡ct0ss
llt ftlkx tc¿tlr)s lA $t tlx)
ltllu is ün)s[lp¡cdl)hiA!]rxl.
¿tnl tht]tcsl
Themut passtestprocedlre s defi|edby
the ftcflr¡tiofa Sland¿fds
0rqanzaton1S0l
Thispr¡0edLrfe was astchanqedand
rpdaiedI Dcccrnber of 1999,whenthr
of g na sourceftlr ind!slr\rsl¡fd¡rd test
d!st d scontifredpfodLrct
0n A few h gher
qra ty testciLstw lh rn¡f-ocofsrstent
¡arl cles ¿0sw¡s id-onl
f ed ¡nd ad!ptcd
paftc e s lc llr s proc-"dLrf-"
delernrncd
lhatmoslc0m¡efca y ava alll0p¡rlirle
00urfcrs\,\'-"re y
nol c¿p¡tJc 0l ¿ccLrf¡ie
me¡sLrf fft p¡rl c cs sn¡ ef lh¡f 4 mrcrons
As a resLr
I, llrr nr| ¡Lrfi¡artcles l0
charlrtc(i
ff¡m 2 n cronsI llrcf{rrner
sl¡fdafri104 mrcros I lltc|0w st¡nd¡ral
Si¿rrrl¡r(lf(irrslrypf¡ctce whef rrp0rl {l
lasl rcs! ls rlll¡ f-"(lLrsn( tlrr S0 168{19
lcst r0lh0(lrsl¡ folow lllr ntIr0| r¡t |(l
wrlh¡ sm¡ 0tt{rlri)ifsr(lc l)f¡ckrTs Ths
rIsl1r(lLrsh.s betw-"1.Il0sl (ts! ls 0h1¡xxl
!s r(tlhc 0 (l v-orsLrs
llir cw l0slInlh0ds
¡f(ll{)sl(hrsls

Old - 5 Micron
New - 5 Micron(c)
fheb)is required
aftetthewodn¡cron
and/orthesynbolfotnicran,andthere
shauld
notbea space between thelc)and
lhewordandsfnbolfatniüan.fhelc)¡s
anndustryagreedonstandatd that
desqnatesthentingwasdetem¡ned
usngtheISA16889 flu¡dfiltertestmelhad
andndustrystandadmediuñtestdust.
ASSOTUIE RAIINGS
Anolhef 0f r¡ s!s-"rls lllc "¡bs0t|10'0ff c e|cyraTIq
leÍri,wl)clt s 0llot r¡ sunriaTslo0rl
Theleri"a¡s0ul0'sr(tn|-os¿bel¡r¡li|(t lrfl5 AIC¡lcrp ¡f fluaf lers:lrcratea¡t
''¡lrs0!tc' 1lrel¡751¡r l]r!lhcr
cff c c|c\'
Theacl!¡ rffir lfcy 0f ¡ f ter10lrapp¡rtc es car)a so b0trltfLts|q whef trsrfllbcla
ralflls
A I llerw tlr ¿rb0lar¡1fq ol 200cotrp¡rcd
l0 ¿ f t-"fw tll a bct¡ rali|q0f 75 mayseemto
bemorrllr¡flwce¿s-"ffte|l Irc¡ ty ther-ors esslh¡| l0i d ff-"fence neffcefcy
BetaRal¡ng ParliclesEnter¡ng PaliclesLeaving tilter Ell¡c¡cncy
theFilter theF¡lter
Beta75 75 l 98.6770
Bot¡200 200 l 9959ó

FTTEBS
REMOVING SMALI-ER PARTICLES
Af¿ddl¡f¿ mlsaorrept:of¡l¡rtl ters slr¡lthefe s ¡o p¡rl c e ret¡¡!¡ effcefi:r'
ai¡i¿n'r¡nlssr¡ er lranlre ¡ar¡¡r¡1fal Arflrll ¡ro I ller,,rlh ¡ bel¡ 75 r¿l '
35 rf 0ro¡sv,' ¡ sorenorre parlc es ¡s sr¡¡ ¡sJ5mrfNfswLr50o¡rflrcr ta\' fser.
rsL¡fLrsrlstunrr5rrp ¡actllhest¡¡d¡f¡ C¡lep ¡f er!rr-otr f lrr r,\,lratülLcrrf¡"
¡-"vrrtr¡1 |¡ ¡e(l trbc¡40n0r0r1lar Ho!,'e!er1r s de! l]-o,¡r¡ s ¡ r t | ¡ y¡sa
I\iir¡fredfaresre Tresaeeff-"rln'red r]llr r!s¡ra crlr¡¡4ll nfrorts r \,rahfE!
I l¡ r rr ¡f llrr t!rIJOL ¡e¡r rr!ls
r¿rr.lr..r
a
a
Debris Re-Entraintnent
Am¡ft ih-"nnsi a¡r¡finf m scofael)t r'rs f{11¡(lr!tI lcr !rrlo Jr¿rraF s TlrF¡ssLli
llrirlrflrrll¡rlr rs¡rrlr¡fperj |¡I T-or. I reyslirytr¡pf)t¡ Ll',l0rtuf¡11r,/ llrs i r'
r¡sr I lrrs 1r¡lrirr {r1¡| l]i lr rr \.rlr1]rr 10!,,'lhr)Lr(r lr(r I 1i)rrr{rl¡ r0rrri¡rs 1,i
frIrs1¡fl firw{r! r r¡ |lrs 'r 1luf ü!_rirl{rllrrlru(lrllr I l|r Ie¡ ¡ rrr)¡llrs 1
lryrlr¡Lr
IrilrLrs0rIlrIlü lrrr(¡\ rLflrfr¡f r¡Lrs(:I10r{rf¡sr ¡ r l{r r ll 1rLr ]l s 01lr¡l]pfr(l
I
li¡rlLr{r\l),rLrkrl0 lrr r|ll\¡,rfslrlr¡
Jrf T{lrillrr rl llr s rr lrir:r1r
rl lr, lrt)rrllrirrlr 1r\
flfllrr l Lrrl sIrrr¡¡r i]:rrIr{rrIrrr
rrrJr{rrI

Tlrsf¡rll{) Lslr¡iixih! I r')1r rw r(lr¡,rrfl}r ll fk rl lhrf lLl f ül,r,l\,r |¡l ri rirl

r.ír!fl I rtl:l

NOHYDRAUTIC FLOW / MEDIAREI-AXEO

VlrLrfrlrijLr \fr ryrlrlrL f lr,¡",,lr{!ill]r],rsllrirrlrll,Il IrlrlIrLrr/r ¡rl,¡r{xrillrrI
Ir f 1rwlr,rll\ll llrLr lrLr rLrLl,,Ir,rl llrLÍ ,r rlrrsls rrl

HYORAULIC TI-OW COMPRESSES MEDIA

Wlr,rlryllrirr11r!\'sli]rl,ilr,,f 1l)lrriirlrlr)rlr firl, iI r rirL\lrlrirIILrr\IIrLrnril
fr,rIr]r lrlr lr]LrsIrl!r1)rrllr, lln,r! i rlLlr lr.¡' l)Jllrs1lÍr (tlrlrLr flr ,r :ilr,rLr I
!rirr Ll lr)ur,Irl I 1r,,"il),rllIlr,r]rlLrIrs Ar 1)frl¡s1ll]Irll,,'i]1rllr1rrllr1lll]|rx ,r rLl
r,1r'r y rrfl\lir'1 llrlrllrri 11rrLr:r llr{rfirl,r ,r rrlllrlr5,{r rrlllr{rrrr¡rsirrrillrr'!¡!,I
I rir I rr irl vr V í|r!li¡fl llrlr| 111irlrrrrlr,Lrslr l r,rlr ,r r(j lr(r i l irrr[],rrrlrrrlrrLr
lrirl1

FI-OW STOPS / MEDIARELAXIS

WrLrrlrLr'stLrlslir I 1rñ|)rLr\ "{ r Lrlr Lrrrrr ir!(r ',lr rlrrr irlxIrrr1l
rr{rlllr(rrrll,(lir
Iirl][ 11]ls r)r{l rir slirlr fl rlrs ir rl l1[¡,'lr]llrshrr(rrrIlr¡r(l{rri¡ rr'"rrrr],r ir rlirrlrlr'
1ü
lrlirirlxr riri r! I irl)llr(l)¡rlr rs Hr,,!rrrrU \,-lr rrrl0!\ ll)ll]lrs,rrl
rrtlrIr lrlr rrr{)(i,l
ll¡ ll I ltli l| | ¡ I I I tLt Jl l lt

FTOW RESUMES / PARTICLES ESCAPE

\rvlrrfIr!.; rlrsu'iurIorr lrrr:f:irrtir
rirl]l0ii]-o Jr-o(l¡10,,,r'0r'rrr
)lrlrrrrr
llrurrrrr(.,
r¡rr0irprcss ilrr l0!\i L¡f l s r]l(1ús!rrrLrl tlrrlr0rc o¡seryrre¡ p¡rTa {rs,lrrll]rrl
ire r thr)LrLtlr
llren-c(l¡¡f( b¡rk il0llrr il0l"\'fslrr¡r] f Lrrúlu I rrrr s ¡ ¡rUrl
¡rofi-¡ri¡ryrlsir¡r(.le01lr¡ffcLl l¡rlcesLnl llrr)I r,,r10rürs 0 xrr rqa rL0fprrs!Ll
prOLrss
rfixj¡ ¡ r¡ llr1r 0l lr¡pp r! parlc essl¿rls0v-¡f

\¡/lrcr Llll] ted¡ sl! ! ¡¡derlw ih larl a e,,

Tlrr!,,1rslr¡sr:0i ftr rtr¡ ffrr rt O0crfs
l au/sl¡ps¡¡ll l¡e¡ fÉsl¡rls
1iilil1ilil| lllllllllllll
ri|lilililil||l ililililllll
tliltfiltmm ilililillllll
"lll[mill lffiillilllll
,ililillllll lilililillll
iltIunil ilil1ilil1

arcmanuf¿ctured
[¡oslfluidfilters usi¡ganautomated
high'volume process
manufactufing
-heprimary costdrversthat¿qeclfilte prceare
. F¡ltetmed¡a qual¡ty
. Filtetelernent qual¡ty
construct¡on

FITTENMEOIA OUATITY
Thelargest ina filtefsthefiltermeda There
costdriver types
arethreebasic off uid
fitermedia:
. Cellulase
. Synthet¡c
, Cellulose
andsyntheticblend

ED|A
cEu-urosEfltrn
Cellulosemediaisessent allypaper,a¡distheoldest, most
common, andleast expens¡v
typeoffilterrnedia.Theflbers incellulose
rnediaarewideandf at,likea fibbon.Smalle
through themedia tendtog€ttrapped onthesurface media.
ofcellulose F0rthisreason
cell!losemediafilters donothave highdebris holdingcapacity
beforeplugging.
Consequently,cellulose media isgenerallyacceptablewhen!sedforcoarse filterratlngs
Thedefi¡itlonof"coarse" filtefratings
varies Asexamples,
byapplication. coarse luelfilte
rati¡gs
areapproximately'10 microns andlarger,whilecoarse
diesel
engi¡e oiland
hydra!licoilcoarsefllterratings areapproximatey 28micronsandlarger.
Cellulose media
s usedinrnoslCaterpillarStandard filtefs.
Etficiency

Straight celuloser¡edlais notacceptabe forusen h ghflowrateapplications

whenhigh
efficiency filtration
iseitherrequestedorrequired.Anexample istheuseofa 6-micron
filterfora hydraulic
system Thehighflowratesinthesystem
applicatlon woud requrethe
media to beeithersyntheticora synthetlcblend.

tl
f ---"'*'J,ft'r'it
 FUEL

FueiSthelargest voLlme fluidusedona Poorfue qualityissocommon

m nesrte,and¡nrnoslcases,
at rnany Nearly all fuel
themost mines testhat,often.thesta¡dard
poorly managed Because fuelrepresents pfocedufe s 10install
a newsetof njectofs quality problems
thelafgest 0perating expense, the owest ateng¡ne mid-life
inordertomantan
bidder frequeftly supplies it,withitte performanc€.Thechronic costof njectorset
are the result of
regard forq!ality0rcleanliness. Inrnost replacemenl andunplanned njectorfail!res excessive water
cases,thechem calcomposition, e¡ergy canbelargely avoided wth proper f!e
conlent andl!bricty of theluelis storageandfuelfiltratonpraclces or dirt in the fuel.
acceptable t slheunintended
contar¡ nanlslhatarivein thef!ellhat Nearlyallf!elquality probemsarethe Fuel Stor¡ge
ca!seacceerated wearandfailure of lue resut ofexcessrve walerord n inthefuel. FuelqLra ty isoftenseve¡e y degraded alier
Inlectors l¡lectorlailLtresafeexpensive and Rer¡ovngthese contaminantse i¡ninates rt s d"alivefed
to theusefs storage tankdue
cause ufrnecessary dow¡lir¡e. Replacement mostfLre-reatedproblems Distilledfuel to poortankdesgnormaintenance practce!
of a setof i¡jectors ina larger¡inngtrlck leaves therelneryveryc ea¡ Fuelpicks up
maycost$10,000 to $15,000 andresult ina contamr¡ants shpment
dur¡ng andstorage TUEI. SIORAGE CAPACITY
dayormoreof downt meforfepairlf between therefinery
andthelirneil is Given adequate sett ngtirne,mlchof the
contrast, njectors n engines usingc ean placedinthemachine f!e tank drnandwatern fuelw ll sette to the
lueltypicallylastthro!gh theengine lifeto bottor¡ol thestorage tankif thefue is leh
engneover¡aul undisturbed. Fuestorage capacity at a sfe
shoud beadequale to et ne!1/de veresoJ
¡l¡netyporcont ol D¡esol troubles
aroduoto d¡nor water¡nthefusl. fuelsettlea minmumof 2 3 daysbefore
drawing suppy fue fom thetank.Newfue
sho!ld never beadded tothetankwhilethe
OFr¡n)ñ¡ Inlsucrn)¡ Inf,¡l
lanks bengused forsupply Thisofly
seflest0 sl f upthesetledcontamina¡is
CATERPILLAR
onthebottomof thetankandplt thern
backn s!spension, co¡taminating the
supply luel.

fuel cantaninatedwth d¡t andwatet¡s nate

newprcblen ThisAperctüs'lnstruct¡on 8a0k
frcn 1931identif¡edwatetanddin in thefuet
as thenalor causeof prablenswhhd¡esel
lw
lE!
|
\on.@nosue

I longe
¡an|kns

Tank Destgn
I sucTtot{
P|PE t ocaTtol{ DESICCAI{T
VEf FIIÍEBS
I lgardless
0tsize
orshape.
fueistorage Thesuction
pipeonthetanksho!ld
bewell 0arlytemperature
changes
along
wtthair

l*:::",::';".'"""
above thefloorlevelinorder toensure that orawn tntothetankasfueliswithdrawn
onlyclean fuelisdrawn in.andwater and cancause c0ndensation.
Desiccant vent
dlrtthathavesettled to thebottom
.i:,, i:
i *
::i,::,1,::
::", tankremain undisturbed 0lder
ol the filtersshould
design order
beusedonthetankventin

| . Non.conosúe hn¡ng
storage
rocated
tanlsoftenhadsuction
at 0rnearthebottom
pipes ai¡
totrapandfemove
enteÍng
oftheta¡k finitecapacity,
thetank.
a¡ymoistu¡e
These
from
filtershavea
andshould
be replacedona
fl-oor.
Thiskeptthetanklloorcleanby regUlar
| basis.
| ¡oPro TA¡IKFt-oon alowtng contam¡nants toflowoutwiththÉ
FE lankftoo¡shouJd be stoped
with a drain supply fuel.I\.4ost
newer tankdesigns use tat{(ut{tf{c
I
I E¿led at the lowest potnt.
Stncew¿ter is an elevated suction
pipe. Some highqualit\] Tanksshould
rre¿vier beepoxycoatedontheinside
I lhan fuel,
wate¡ which senlesout tanks usea floattng
suction pipe thatrises ¡norder to prevent
cotosion.
cf úe fuelwillflowlo theJowest spotIn andfallswiththefuellevel¡nrhetank.This
I
I tt l¿nkh canlhenbeeasily dr¿tnedand leature always drawsfuelfomthehighest
los0osed of Tanks should bedrained and cleanestlevel.
lñequently to mtnimr¿ethe presenceof
lEler on the tankfloor Walerprovldesa
qround forbacterial
growth whrch
lbeeding
cause severe pluggrng
filler on
lcan
ln¿cnrnes andc0rosion damage to the
l¡torage t¿nk. The frequency ofdrain
l.nervals depends on ambienttemperature
ad humidity, aswellas,thecontamination
Helof thefuelbeing delivered.

MPBOVING
COMPONENI
OURABII
TY
 sEnnl0r crÍnDcE
R€psls
smsllsrwat€rdroplsls Etn¡EuxEr¡
coatsclLc
suspondedinmovingfuelflow lib€rs
Coal€scing wstorand
attract
andpruvontsthomffomescaplng lormlsrgewar€r thstfallto
droplels
withlhecl33ndryJu8l. th€bo¡om(Visw ieexpandsd and
i€dtoillustrato
simolif JuncÍon.l

Itffoxaflcw lE¡0n
Allows
sxcssswatertodminlrom lxtc8o¡ PlrfllclJl¡ñntrB
thosumpotthounit. abr¡siv€
ns'novos pan¡clss,

GoÍn0(YAIYE
6r.u8
Slows down orsho$offlu€lllow
il th€¿mounts olw¿tffinth€lu€l
sxce€d ti6 flowcdp¿ci9otth€
wsterdnin vslveoril thep3rticul6t€ GAIEYIITI
orcoal€sc€rfiltsls$3nloPlug. ollflowto
Shuts
p€fmrtlih€f
s€rvice.

Clean,
dryluel water
Foelwith drflandwater
Fuelwith

Bulk Fuel Filttaiion

Clea¡dryfue rsabsol!tely In
essentlal A goodporlion of waierandd rt canbe Fltercoalescerfillfatlonsyslemshavebeef
order to achleve I
long¡jector fe.The removed frornsupply f!e byusl¡gprop€r thestandard method to cleanargevolumes
f llratonsyster¡s0nmachlnes aTen01 storagetanksettli¡ganddranlngpraclces offleli¡ thearrllneandpefoeumIndusf es
designed to c eanhe¿vily
contaminatedf!el ¡/ostof theremaining wateranddrrtcan formorethan40ye¿rs. ThesefiLtrat
on
berernoved byusngbulkl¡ltration or u¡itsaredesgnedto remove solidpanicLes
addingfiltratio¡andwaterseparalion andwaterlromthefue w th s nge Pass
capacty to eachr¡achl¡e inthelleet.The filtratlonTheseunilsareplaced n thefLre
rnostcostellectiveandelflcientmethod to suppy llnebetween lhefuelstorage tank
ensurecleandryfuelis delivered to andfueli¡0slationTheunltsaredesrgned
machine fu€ltañks isto usebulkfilter to meetthemaxirnum fow requireme¡ts oj
c0atescer systems thefueldelivery system
l]ompanies
thalr¡¿flfactufe pmelttypical
thistypeof eqLr y buid appicalonspecf c.
eq! pmeflbased
custor¡ onspecificat
o¡ssLppedbythecLlsto¡¡eisenqneer¡g
departmenlThere hasbee¡nost¿¡dard confgLt¡at
o¡ desgnedio meettheneeds of
Caterpar mach¡c !sers n orderto meelthese¡e0ds. C¡terplaffo,,\,0ffers
speca y
desgnedu¡ ls ¡ fruf different
capact es
50qpm
100gpnr
200gPm
300qPnr

[¿chuf t s skd mornted,selfc¡ntaned,rcq! fesno e ectrc¡ powerandhaslhe

followifqfeatLrres
' 1 n Ir0nlc] abst)lute particuJatelther
. l5A pst¡¡axt nnnptpssurc cdpdbtltty
. Filtet delta P tndQtol
. Wal|r caalcscet with tht)c¿p¿b¡lityta rc nttc 3% co tl¡|a|s watcj¡j htelby valu ¡el0
lessthan100ppt¡)
. AúlafiEltcslutlcat¡ ol valv¿to shutafl supplyI t¿rt1e qla¡¡titbst)l wdtertD thehjel
erL:eed tha¿ut1i¡¿ttc dtal¡ [apdc¡tya¡ tl tfu pattntl¿t-D
ltht!s sL¿ttto p]uq fhtsnlvL)
trtsurtsthaldeb|sat¡rl$/ítteratc notalljwtxl t0 p¿ssi)10 lltt t ¿d¡lk)

lypc¡l coslsol ünrlsr¡l(túlrom¿ho!t$2000010$50000 Whil-"tlteseuI ts rrprcseIt¡

siqflicanl rvesl¡lcl llt-"y¡r-"niotr00u|¡rnrc¿, ess ¡b0r te s ve ¡|(l n)rcr-"l¡hleiharl
rrslalnq¿rjrlnr¡ft¡ f|lr{tadal0|¡l I tf¡lr0rl¡| {r¡chm¡ch te | ¡ fkrIl TlteI terco¡es0ur
Lrrr
I0rrs!r0s lh¡l 0fyae¿nf!c r)|trtslh{rIu0l¡nk0f t¡r)rrr¡dt|0 f ¡LtI f lr¡TIt srrsü],
llrr sl¡f¡iId frlf¡1r1Ir
¡rr¡f(lcrTle l0 pf0v(jeI rj¡ ftllr¡l0rl
l0| lli{||i¡r I e rs¡rkr(lLt¡lc

[hts lrltetr0a]csc¿tIrtt eltticotly |\11lres tlnt ¿|!1ú,rtú fi0rj

tliesellLel dt flaw t¿lesrp to 2AAqallo,s petI Lrrú B|lk hn,
llttalDn tcdnolr.ll h¿sl)¿er!t!:edn tha¿vtetu| tnltntf lol
ñate thatt5Ay""¿rstta¡\t ltrie let fuei ts pun@tl trunronc
lacaü0nl0 anotlEr tt tra\/elstl)tatehd s ¡nilatt'iIet Joalc:;. ta

'.i !. ú,Íi r:,.1fi \tr rLtfi ,t i

FUEL 25
 recornmended inorder to cleanthelu€l Sta¡dard filltatronarangements 0n
Filtration on the Machine
fue f lfationarangeme¡t 0n before it reachesther¡achlne fueltank machifes var\/.A t\/Pcalstandard
Thestandard
g¡€d to actas a final f fuelis to bec ea¡ed bY the r¡achnefuei arran!ement o¡ a 3500serles machi¡e
mach ¡€s s des
y clea¡supp y system, addtionaf ltration capac must
ty engine wouJd contain thefo lowlng:
cJeaning slepformoderate
wilhwater beadded. Thisr¡cludesa waterseparator . Twa10n¡cronlc)absolutepr¡nary
l!e of lS01B/16/13 orcLeaner,
conte¡t of 0 I % or less.Thesland¿rd f!el a¡daddltrona f tersTheamount o1 f¡lters¡nparallel
l0 req!lred
tionalfiltratlon depends0nthe . TwD4 n¡crcn(c) absalute secondary
f ltration
arangeme¡t ls nolceslgne0 add
c eanverydlrtYorwater_laden luel f fue evelofcontarni¡al onof thefuela¡dthe filtetstnparallel.
rsd rt erthanlS0lB/16/13, orhasr¡ore r skof flterp uggrng betw€en schedued
than01%water, bulkflelfiJtratio¡ s PN/servce

fheslantladÍuel[¡htat]on is
at¡ntachnes
(lesqne(l fol
la actasa f¡ualclean¡tq
noderatelv cleanfuel h tsnjt destgned
to cleanfuelIhatis hearlyconantnaled

WAfER STPARATOBS
i \r111 l 1 j r,i 1 ri1il r | , r ! I 1rL ri L1r rr,i r l rrl l
lr rr rrrr, !1 1 |: l lLr llir lLr r l l,l rrl l rr rl i ,l r\r
1 ll1! r,r'!i rl {rr r ,LrI)i II i II I r : , ir ' !' ¡,!{ rr.i rl \1 r
,r , r1]¡rrI i ]!ll1iLr l) ir r iilr rlri i rl rr,rl rl Lrr rrrr'
, rrLr '\(,, l L rrl lr lllllr ll.' , r ' ll1r,llL L rrl l l l L r l
lr Lr l)fl l r l rL r ]llr r 1 ] i' r r r r r : r ' 1 1 l rl r l l l l
I Lr : rl l ,r l r1 ! Lr llr , i f ilr , l r f i I l r rl ,rr1 1 )
lrLr iir I l rL fi, lr I Lr r r lrlr lr r l r.rL rlrrl
l l I rl l
lr, r 'r L rL,r 1l lr Lrl' i r lll il' r1 'rL r,l (rl l 'lsl l l
, t I r Irr(i .¡. , LI t ( r l¡ r , l]L L stll rr{ r!,/,rl L !
I Lr (l l r l l rL rrr r Lrir
r , lL 1r , rilr l l rr rl { rl l l l l
r L rf r,rtf r)r l , r l r 1rLl, J l, lilr r l rr ,l rl l rL rr I (rl
! , , ', Ll {|rr I ri r lLr t rll( llLlr rrlllr s l l l r' J(rl l ul l l l l l
flU
*fi 'f
lrrl) i ¡l r rr1 lx lr r lnrLL, i ix r ( r I l x { i l i l r!
. i{t ) i ffl rj rs l tlulill) lll ilr lllll( 1

¡ l, r r r r r ii r r l ) r f i l 'i , r r r l i r : i r r I L 1r 1 1 'r / ¡r/l .rr,rl ,r| rl i l i i r¡l l ri \, ¡.ri ,]rJr r r ¡ [ ] iir lr I : r'
, r r ir / r ii, lilir ¡ , l l i ' , i , 'r r r I I L l l i r i i r / i ' i l i t '¡¡ r l r r l ¡,Irrrr ¡l Li ,rIi l r r /,i r' rrr1lrlil i r' liJir r '¡ lr ir lr r
i] , , I|r lt i I l r r r ',r r r r r ¡ l l r r 1 rrirrr rj rr,ri r rr r i r r s i \ ,11rii,r/rrr r1,,lrr/r,rJ:_irrrr l/rrrirliirrlrrrir rl)|I
r , r r ir , rii r r , ir r l l 1 ¡ ' l i r r ,L r l , r i i r ,I I r' i rrrr,rri ¡ ,rrJurl rr'i rr ¡r,i Jtl i rrriti r Jlri
¡riri ri /rriIrIri I l i i IIr! rr ri rl i r,rlrr rri i i iri/ i: 1r r . ! , r ir r ,
i i rtrr,,s/1i e.r1r-,xi Ji iIi,rri rl rrr,ri r , r lr r , r , ,! i i l
i Jir!|rrr.rri.rl:,r Ilir,!ri ¡l,rr ril]lri,r,! r1¡1ri¡rirr l
lri¡r¡(\ t rl iirll llir¡rir!1i¡lrrriill:rr
t¡col{DAnYFUE|FI.TEnS Thesecondary fuelfiltersremove morctha¡ machine untila lossofpower isnoticed.
The
l¡bsl3500 enginescome equipped witht\ro 98%of allpafticles 4 microns andlarqeruntil problemisthatfuelsupply pressuÍelormost
4 m¡cron(c)
absolute secondaryfiltersin filterrestriction
becomes excessive.At 3500 enginesisaround 65psi,andthe
F¿llel.This provides adequatecapacity around 18psideltaPacrcss thefilter,fuel enginewill notdemonstrate lowpoweruntil
s{le pass filtrationformostapplications.pr$sure begins t0push trapped debris fuelsupplypressure totheinjectorsis10psi
A dwgedfilterlightintheoperator's through thefiltermedia, anddownstream to orless.Thiscondition would betheresult0f
Ernpartment isactivatedwhen thefilter theinjectols.AsdeltaPacross thefilter plugged
severely filterswitha deltaPof
rcslricl¡on
isatound 15psi.h is¡mpoftant to continues torise,thevolume andsizeof around55psi.Underthese conditions,
large
Ínted¡atelyreplace thesecondary filters debris panicles pushed through thefilter amountsoftrapped dinwould bepushed
rtEn theplugged filterwaming occurs. increase rapidly.lgnoring theplugged filter throughthesecondary filters
tothe¡njectors
indicatorisa problem inmany applications Thisisa leading cause ofpremature iniector
wheie operators continue tooperate the wear0ut.

SERIES SECOf{OANY HITER

Theaddition 0fanadditional
secondary filter
inseries
downstream canhelpthisproblem
Theseriesfilterremoves
verylittledebris
parallelfilters
untilthe become plugged.lt
traps
thedebris thatispushedthroughthe
parallelfilters
byexcessive
deltaP.

H.ECTNIC P8IMI]{G PUMP

lP fuelsysteñw¡thadded
seiesf¡lterandelectr¡c
AERASIVEPARÍICLESFOFCEDTHROUGH
SECONOAFY
E
Another common problem
maintenance is
pre-filling
newfuelfilterswithdirtyfuelto
helptheengine starteasier.older
machines
wereequipped witha hand-primingpump
piningpunp.
thatwaslaborious andtimeconsuming touse.
lvanynewmachines areequipped withan
priming
electric pump. Thep mingpumpis
FUELFILTER
used when fuelfilters
a¡echanged tofillthe
secondary fuelfilterswithnewcleanfuelina
matterofa fewminutes. Theelecficpriming
pump contains ¡tsownfiltef,s0thatallfuel
suppliedt0thesystem hasbeen prejiltered

Uow 18psipressurc drcp,higheffic¡ency

fuelfilterscapture
andrctainnearly100% of
úras¡vepatt¡cles.Pressuedrops¡nexcess of 18ps¡farcedebispaft¡clesthroughthef¡lter
Ícdia anddownstrean Asrcstrictjonincreases,thes¡zeandnunberofpanciles lorcedthtouoh
llE filternediaincreases
drant¡cally.

fuelpin¡ngpump.
Electric
 t

Oil Storage
Newbulkoilmaybedelivered ofways.Large
andstoredinavariety users wil havededicated
steel
storage tanksThesetanks areusually thousand
several gallons incapactyandare
e evatedfromthegfo!nd Tank fucks y
typical new
dellver buk o l. However,theentlre
journey lo theenduser's
frorntherefinery storage mayinclude:
tanks

. Sh/ps
. lntermediate lacill¡es
storcge

Large arecommonly
tanks usedatdealer withlarge
andat rnnesites
man shops fleels

Smaleformor€ remotesites y useoildelllered

typica insteel
drurns e 1,000
ordisposab
literp asticcontainers
Theseplasiic ganlngacceptance
arerapidly
containers because
theyarec eaner,mofeeconomical,
andeas¡erto lha¡
storc steeldrur¡s

ofvessel
ofthecontalner
Fegardless used ¡ewbulkoil,theo I rafely
totranspod w¡th
arr¡ves
level
anacceptable ofcleanness.
 haverepoedsuccess l¡
Thepefcenlage of ¡ew bulkoi s €xceedr¡gA fewcuslomers
Cle aning ÜP New Oil al requlri¡g s!pplers10deliver newbulkollal
. arhashada ongsiandlng lworse th¿¡)thelS016/13speciircatron
lS016/13However' lhlsrequires a t ghtlY
ne wo l of 1S l6/13
0 foraLl de veryto theend user hasa wavsbeen
r l r o nfo r co¡lrolled fanspollat]on process and/or
, :pl engrfe l!beoll Ths nearly 100percenl Eve¡lnev!oilswere
bVthesuppLref belore delrvery
' :t o¡ $,asonginal y eslabllshedfor refnedandblended at lS0l6/13of c eaner. pre'iilterinq
w0Lll0 InthevasimajorltY ot remoie mlnlng
forfillo l!r hYdrauIc mosttl¿nsportatlon sYslems
:'e faciory app sLlpp
Lcatlons, rers afe¡ol capable i:lr
¡ new macn nes ntfoduce e¡cessive contam ¡all0¡llythe
,.erlral¡ sYslems clea¡o The
before shpr¡enl timetheoi wasdelivered Thlsproblem ¡ol w in! lo dellver
: rislemc eanllness femoteness ofthemifelocatonof a pollcY
ltwasaso !ets worse as the d s1ancean¡storage
r r : S01B/1 5 o fbetter flud sourcln!l olte¡ellmnales
'ra¡manY when oiLshad lime lncreasebetweeiherefinery a¡dtlre of low.cost
Yeafs ago pfessrfe o¡ thesuppLeft0
_. e. ¡ddtivepackalles anycompetltlve
anda00llve e¡¡ user
improve cleanness
'. .fce wasnota probem In1nepasl
Co¡lam natonduri¡q onand
transportal
,- exceeded ihe S0 16/13 r¡ theslorage
- r¡l 0n.t wasa f€l¿tvev easylob10 storage comes fromsteeLafd dlrir¡ dellver\/Newbuk 0ilmaybeiiLtered
tanksWalerand ta¡kafierdeliverY inorder 1oachevelrle
' i n La¡dachleve thedesreo pipl¡otrucksandslorage
c ea¡lnessevel However lhls
'als because lheParllcles were dirlareoltennlroduced fror¡urlflltered deslred
process req!lfes ¿dequale storage capacltY t0
ta¡kbrealhers i¡ thetrafsp0n
i . :rellfrs Jrom a clea¡ la¡k
Even ¡ew se¿edc0rllalrlers suchassleel ¡ lowo lto beconsumed
canbed rty whle anolher tanks berrgfillercd¡lonq
dnlmsa¡d plastlc corrlalrlefs
wrthcoslly bulklankmalfter)ance
prucedules N/a¡1arlLnq cLearlllness 1na
sinqe lafkLsnol possibls 1 c e¿n ¡rl ls
belnq c0¡sumed frorn i¡e lanK wn e rrew
riftyoillsbe¡q added ng
siirr !p rleDr s 0n
lheboltom ol Ülela¡K

l tahonsystens
Pe|¡nanenl naybainstalled t0
cleananl trce
nevtbull ol isdeliveted
ensurc

COMPINENT
]MPfOVING LIY
OURAS
The ¡dditive Interference Issue .D
Whalusedto bea fa f! simpe process ol f tefngn-"w0 | ¡ ordeT 10meetcleanl ¡ess \.
tar g e thsa sg otte nr
¡ u chm o red ff cut nrecenlyears The¡ b t y t o a c h e v eS 0l6 / 1 3
D-rra
w th ¡ rcasonab e amDLrnt of f lternghasneafy d sappe¿red 10addt vc ¡leference
dLle
Thearnaurt ol f llerifgtlrnehasdoubedof triped.w th somede¡ersreport ¡q lhalthey
areunab e to reach thetargelThs hassparked somedebate 0ntflccos1,/v¡ LreoTfetan ¡g
rh-"lS0l6/13Iarget

Subsequert studyh¡sder¡onstfated thaltheprobem s neafYa waysaddI ve nlerlererlcrl

rl 0rdcrto address th s ssLre,
Catefpr¡f hasdcveopedan¡ccur¡lelcstmelhod. whlch
ov-"rcomrstheeffecl ofaddI v0 nlerlerenceKfow¡ as 'samp e prelfe¡trnefl,
lh s process
ovefcomes t re ¡ddI ve pftrb
rflerference 0rllsclhala panc e 0!!rllrc¿dngLlslnga p¡(lcc
f i l u lt t {]l s r¡0 T eac c lt alu

0tl s¿ \¡lrt ¿tr (lilunxlSA'\,t!tth tl), t l¿h{¡tddl

k osetr l).tt¡rlr ú)u¡l:; ¿t"ptlItt tlatlltxl tt)
rnlx\'\rtr lot thr t|(¡ blt\|vt)ltlrt)

Wh -"th s pr!ccsslrcra¡scs lher¡o¡srlrrnrtrll¡ccLlf¡1rY bYc rrirl¡1rl(l¿(i{irlvu

SAMPU PNE.TREAIiIENT flcrference,lh s procrsss l){)ll{)r l)eúrtrtrtllrl ¡ ¡b f¡lllurlll¡rl i Thefiel(l T l0 t0sl
sample
Currently, pre-treatments the rrs! lsc¡rr bc ¿fl."cl{rd byvrr¡tr0rlsrls¿nlplrl(lltchnrqLle¡n(l cc¡lll ¡cssof lhtl
recommended waytoaccurately complete s{rvflll Scf(ii {l lllll s¡mp{)l0 ¡f 0 ¡ll r) rrrrt¡l0s lltr itb l! l0 l¡ku ¡ xi rllerp()l
thepa(iclec0unt meas!rement process c{r¡f frss rc¡¡ qs 0n s l-" Itxr0 l¡b s ¡ s0 0rl s lr, 0r rl0¡rb!w lll (ltl0kltlrrlilroLllrl
Samplepre-treatmentreq!ires
thattheoil lrile sef¡if(tlhr sampkr lo lhel¡[] s ¡ (icsrallle¿ lenlalv0 H!ü/everrlr¿rly¡bsiltl)
samplebedilltedwith50%clean kerosene. a stantlr¡m !ser srlrs ¡|d thelrnr-of-oqrrc¡ lo lransp0rl arrd¡rr¡ y/c s¡r¡l)t)srrlryll{l
Thesolventdissovestheadditiveparticles scvet¡lalavsInfenotc 0r¡lorrs,lh s n¡y nr¿kelry¡{l l0 lrl¡rl¡(lcl rc c e¡rllness0l
withoutaffect¡g thedi anddebris rxrwf ! rls npractc¡l
pafticles.
Thediluled sampleisthen
rneasuredwitha pafticle
countef Because CHANGE THECI-EANIINESS TARGTT
thesamp ewasdiluted by50%, theparticle So re b""i-"veth¡t lhc curtplexlty ¡fd I tr0 rcqutrerilerlts rf s¡nlpl0d l!l on olllweqh
co!ntinlhesample lsdoubled,a¡dthe t rr beriefts Theys(rpprrl s nrpy ¡creasrrtq lh0 larqetc earl rlessf0r rrewoil lo S0
corectlS0range determined. lB/l5toaccolnlfofLnf¡terlr0aln0sdu-"io¿rrldlve le ef-"nce Tlrcprobemwlh
lhs¿ppfOaclr istl)¡l the pafi c e colrltcr c¡n on y c0lrll slladows I carllr0ltc I I the
EXAMPLE: sh¡dows¡re ffofir¡dd t ve ¡lelefefc-o 0f rca debfs Those whusLppoltheC¿t0rpar
Theparticle
reading sample
ofthediluted s: reco¡rmefded sample d !l orlprocedrlre c0tf00ly ar0ue lh¡Id¡rlqcr of dorb ¡g lhe
andlarger200 lS0range
6 microns 15 ¡mouftol a owabe paftc eswhcf theynighl beactLra ¡ebns¿nd lOtaddlrve
14microns 30 lS0range
andlarger 12 nlerl0r0fLe, sa poteni a pf{rtr
em tl)¡l co! d imp¡cl nl¡chr¡e peformance Howevel, for
remote0c¡ti0fswlreTe ¡ew or is dehvcred ¡ J,000iterp dstc crbes lry n!1l0 I lter
thepanicle
Doubling read¡ngs afd mafageth-"cle¿flnessdolefsor even hu¡dTeds oi clrbes c¿nmakesample pfe
andlarger200x 2 = 400
6 microns impfacl
tr{ratmeft ca
lS0range16
14microns 30x 2 = 60
andl¿rger
lS0range13
 Filtering New Bulk Oil
Thefe¡re thre0d fferent¡pl]foaches
t0 f ier n! net!o
. ftlternqta Achie\P en lS0 Iatq¿t
. tlltt¡rttf a Spcatlied PDla(l
. SrJq/-"Prsst/I/a¡/o/¡

FILTEBING TOACHIEVE AN ISO]ABGET

BecrL! Jt fq f l1f¡l0rs,/slerrs r¡ I tr| rseajlo I ler ! l]t k stu¡qei¡fks !|l lltr (]0serl S0
clr¡ r rrrsss ¡ahevedllr s r¡f )-"alff cLrI lo llr¡|¡ttc\\/r-"f-" 0 s b! r]rtlrctt]||t !
¡ ,,r'llrrif¡r,/f
iron ih""l¡fk ¡|{l |!\,/ Ltnftcrel rrlJit|.Ít.Ir 0 ¡uIui

I! A]l¿ 11)'D¡l!r
l¡t lys(lir y f
llr I l|r rrrttlr-obLk L¡|k s t0 |sl¡ srJ,l lrr (l¡yt¡|ks a¡p¡he ¡i s!p! y |(t ¡
[le¿fIlrrr¡0 rsstorerl | Ofr (lityt¡ rk¡|d ¡r¡ ¡b 1rl|r usr A||1tcl
-"-"rls
1¡rrkx) (ls¡ s ¡ ¡r flLr¡f1 ly 0f lr I t¡t s l)-¡|(l li l{rr(l TltIsnr¡ vl]lLrlrrú 0l lr t¡[r)s(]s!
-"r
'|l
t'
lrrclrrl TFr¡rr1js r,rsIr llr It¡|¡(1clltilI lltr LLrkl¡|k I II),,¡,' II\,1)| ¡{rfnlxl|(10|txrs^r01
I r| (l¡\,l¡nk,llrr Ir l ,r llrlt(lIfr|0fIt1)x]!1,0l0 heI tlrrlxlil xl llllrlllrw.¡l)¡b tyl)1lllll

I il
I lrrl l|xlu|rjr{xrl Lslr(ilhllr\lLrJ{r(l llr¡l¡|l¡ lrslr,lIvitystlIlclrnly lltslrrrrr:|ss s
llr{rl){rslfr{)llr0(l
rl ürsL]l |lrlrlrin lr )Ll\tlltIrOsl itIlI tk)|s!l] llr ür ,lll(l

EIINIÍ{G FORA SPECIFIIDPENIOD

:::_erthanspendho!rsfiteringto a cleaniness
target,
an
: :a'nale
approach
hasbeendeveoped.

:':rpr arrecomm€nds theuseof theC¿lefpillar fi tercarl,

=i t 285-8095)to fiherbulkquanlitjes of n€woilsto meetf
: -¿q!rer¡ents. Th€filtersysiem combtnes a 330ga onnon,
_::: licstorage reservoirwilh¿ liltratonsystem The
:¿'!rmance of thlsfiltercarthasbeen !alid¿ted byCaterpillar
', 'amove conlaminanh n newoilsshppedto Caterpill¿r
': esa_ddedleshrpsBvloll0w_gat ol lle _str-ct ons
-: Jdedwilhtheliltralion system,newoilscanbefiltered to a
:.:fhn€ssevel0flS016/13. Caterpillar
recommends thatan
:-::l'latc partclecounter beLsedto intia ly ve¡ify the
:.-'!rmance of thef ltercartin preparingfi oils.Afterthe
- : a vaidation,
autor¡aticpancleco!ntsdonothaveto be
: -r etedevery tirne,butaudts shouldberoultn€ly cornpletedt0
:'!-re thatthefrltersystem contnLesto perforr¡ to specficaton. offersfiltet cartsto cleanportablea¡l cubes
Caterpillar
--: complete bil of rnaterials
andnstructionsforoperatingthe
- :.r syste¡Tr
are ncluded in the 'Tool0peralnglvanualforlhe
:- ( 0l Filtering
System" (NEHS0957)manla thatis ncuded
..,:. thefitr¿tio¡calr

]MPBl]VNG
COMPONENT
DURAS
L TY
ESfIMATED FI[fNATIOÍ{ TIME procedLrre
to reduce partlcle counts caused fordiffere¡t vol!mes ofo contained inthe
lf theo is beow 25'Cit rnuslbewarmed byaddltives n theoll,lS0clean ln€sseves storage tankof thefiltersystem filtercart
forthefoJlow nginstruct onsto b€vald In of 16/13orbettercanbeachieved for Once theo n thereservoirol lhe filter
order to r€ach f ll o I cleannesslevels of engneo ls,whichcontain themost systern filtercadhasbeencycled thro!gh
!S016/13 forfluid power circLts,theoi additivebyvoumeToachevethel2-14 the I ters forthe r¡inlmur¡ time interva
¡ theI hefsystern resefvorrrn!stbecycled cyclesthrough thefi ters,thefollowing specfied n Tabe 1 t is ready to beused
through theI ters12 14timesJhe processtabe of minimLrm estimated f ltrati0n ll
asa I oi lor Cat machines and engines
hasalsobeenshown to workonengrne tir¡eshasbeendeveloped SeeTable 1 fhe oilwillremain i¡ thiscondition forup
o ls Witlra proper pre treatment below,whlchiststherequredfiltratlon tr¡¡e to 14days

Requirod tiltrati0nTimo(minül6sl UsingCrtP/l{285-8119525'Coil

0il Volümo StlaiehtGr.do3 frlult¡-Gfldr¡
Gdlom Litrls ltM' tM s(ryv fltw3o 15YVO
55 208 36 B3 42
110 416 ól 71 167 48 83
165 625 107 250 1l 125
220 833 62 143 333 95 167
215 1041 7B 178 416 119 208
330 1249 94 214 500 143 250
fable I EsinatedMnlinun f¡hrattonftne lMinutes)

SINGI.E PASS FIITNANON

There aresome remote oserappcalonswhere to filterbulko issimply
the¿bility not
practlcal,
or s tooe¡pens veor abornlensive Thiss especially fue in remote applcatons
new
where bulk o is beingdelivered
and storedn 1,000 terdisposable p ast
c containers
doesofferfilfation
Caterpillar carts
lo f llerlhesecubesHowever, th s processdoes
requireI meand rn!stbe r¡¿naged.
ln cases wherea partcular typeand grade of oilis
needed, butnoI t€red cubes available, ol willoftenbe0sedralher
unfiltered lha¡waiting
forfilteri¡g
to takeplace.

Anallernat veapproach is to Lrse

singlepassser€sfi tratonto achieve a reaso¡ab e
cleannessTheminir¡um req!lrernents
areasfollows
. lnstalla nttiinumof thrcepaft¡culate
f¡herctn ser¡estn thesupplysysteñ.
. fhe filtersnust benin¡mum5 m¡cron, beta75nt¡ng or better
. Thesupplyprcssurc nust be lessthantheratedwork¡ng prcssurcof úe f¡lters,and
thesystennust nothaveanytypeof bypassvalvethatall1wsunf¡|tercd otlta bypassthe
f¡ltersWhenthe f¡ltercbegtntoplug,outletflow slows andthenst1ps. Th¡stnd¡cates
thef¡ltercnust bereplaced.
. An absorption typef¡lter¡salsorecommended ta rcnovewarcl

Ths appro¿ch will¡ot achievethesame eves ¿stherecornme¡ded

cleanli¡ess fi tetcarl
However, f fl tercartsarenotavaabe ornotpractica , th s s thernnimum fi tratlonthat
newo should recevebeforeI ing the mach necompartment f fewerfillers
are used,
off-board
filtrationshou d beused to filterthe¡ewoili¡ lhemach ¡e beforet isp aced
backln servce
 Irj

Caterpillar Global Mining KEEPING MACHINES AND FLUIDS CLEAN

Coñponent Life Strateg'y
. iu \ lr , r lr Nlyr : r )s s l s 1 )lIru r l )¡s 1 l Po¡ntl: Del¡ver
CleanMachines
Il r{ rfrs l lrr rl I l l l {)sl r¡l r)(l yl l i rsh{ !| r i r 0r{l sl ¡| l l | (l ( L¡r l \r rl r L l rrl I iTlln CiiTlI l lilr
Del¡vetCleanMach¡neSystems rrrrü )(l rTl ¡(rhrrros l l y(j r,I 1:,Ir1l IxrW Irl riIrl ])rnl l l It0r)l(| s xj sysl I ts tLr slIIII 1I {Ii III{)(i I 1l
hon the Factory(cufientmachinesl S 0 l l l ,rl l , {rrhrl l { r I)IrIrrrI r rrIi 1,\'rj l ¡c t | {)s i r) sl rt)f){)(l
l r0 rti I l i l tr)ry
Ntlrn¡rltls
r\t1J
l)t)l)Ill .x l
::' iI v t !t \ | I ) . r ¡ , ) t 1 1 I)1
l rtj
, Po¡nt2: KeepFluidsCleanThroughout the Componerts l¡fe
t,.n¡|t rt):;sI)vt, ¡ | )l I l)t!)t|ú1 t|)t¡ Tlrrscc(nr(lpr)rl I I n slr¡rlúty ir lr sl0 cln(J)cit Altlt0lqll th0rrr¡lthItsyst0 ls
ll¡s l)lrllll
¡fr 0 o¡ r{r(ilx)l(rrlr
sll IrJIIrl lxr!i/rrlr¡ | r(n¡f0l)|1sc(nrltLr{r l0 0Xp(0tr:|¡ lit¡k |
Keep fluids Clean fhrcughout the lll¡l(tenfj¡lrrs
lrrrrrriss wrirr {l{iLrs Ir0 r)f(tlr 0l llrr llr-o¡kn l]tx0(lv¡r rs l)ysystcnt¡f(l
Component'sL¡Íe (cufient nach¡nes) lir)rJiliUtUrlllrl nriryrst |0 f sr)v0¡ hL|rrlr¿al lr)sevrr¡ I t!!s¡ trlll0|rs 0 tür it ||l\,
: x¡tl)tx¡crllt\/ll apetale¿l ¿t¡ r¡r r rr s !!1 lr ,,\r0fk, I xr r¿leol rl-.br s rt|lt0'¡liuIit¡y Ix(rxrillh| ¡b l! ¡l s0rJtli
]t trtrtl¿bltcJtdt¡|||t¿ssltutl r¡rl rel lr¡laisysle rs¡o lraptlrrticLris i t( nt¡|i¡ ifualce¡|l tesseves As¡
:i,t0ultl¡aLillhui tittitr suvnn ltlu resLrll,
llLrrl r sl]r¡-o¡e\,,nracI tc syst0rIs sl¡fisc e¡ i ll|i (eis rcre¡srrJ)ra rtyoIcr thr
Iitptuve Machine 0nboaft! nr¡chr¡es ll¡ce(l rrservirrll rt frrUrly, lhe x)slrorJrJr0ri ¡lllro¿chl0 keeliIUll! d
F¡ltntionDes¡gn(Íuturcnach¡nesl ce¿rwaslolscull llu¡dl lf¡t0f(k(lfe\' ¡¡p f!)dL| fll sclred! ed PN4 s0rvL0 Tlrrrsü
itstc¡i ltlttal0, des\n an lLttue !f f lrrr¡rls frfv¡frls syslefis¡ 0!\red thesysler¡f! | lu bc lc[]p!r¡r y 0 0¡ xxll0 vrry
:r¿chnas\\/tJlLrt¡)ptortd l0 Etl hgr -"v-" s llo\¡.'ev-"fihef!d\\rour] o|cr¡qa I lr0c0fte (lrri,y'
dLtr|!l the rextPN¡fer od
.r tl t ¡¡¿tt tt¿t¡¡ |Ieh peifDit¡i¿¡¡t:p
i l¡rrlrrt-!sss¡trdr/ds
lnprcve Machi ne Bepainh¡ lity
lÍuturcnachines)
R,.patlptacctlut$at¡Llsysluüdcstqtl
,rll be npnwd t0 tnekPtl Pestcrto
aieensystpnsDackta an acceplable
ieElaltet a aantpanenl
fa||ute

FtUDCIEANt
NESS
Putting ihe Component Life l¡ orderto meettheserequiiements, unafac However, therequirementforslccesswas
Strategy to Work askedCaterpillar Global\,4inlng for just
farmorethan i¡stalngfinerfilters. The
In2004, anoppo(un tyaiose put
to the assistance in achieving thegoals setforth crtical success lactorswere:
strategytothetestandseeif it realy bythecustomer. A dedlcated teamwas . A fullunde$tand¡ng by thedealetand
worked. God Fields ls¿large
Limlted gold formed to q!ickly develop aneffectve and custonet thattheaggrcss¡velevelof
miningcor¡pany thatoperates a n!r¡ber of workable planThep anth¿temerged f¡ltnt¡onwe werc¡nstall¡nghadnevel
minesg obally.oneofther operatlons wasa ce¡ieredonexecuting Point2 of ihecGl\,4 been t¡ed befüe, andthatthere n¡ght
goldmineinGhana where a contractminer component fe strategy:KeepFludsClean besoneproblensw¡thf¡ltetplugg¡ng
hadoñgbeen used toexcavate andtransportThro!ghout theCornponent's Life. thtoughtheconponentbrcak'¡npertod.
oretotheGod Fields operated crushing . Most impottantly,theab¡lityof the
plantsa¡dheap leach 0perations ¡ 2003, Each r¡achine model inthenewfeetwas dealetto relentlesslyexecute the
God Fiedsmade thedecision toswtch stldledandonboard filtral0nmprovements planned na¡ntenance andrecord
lrombeing a contract minertoanowneT weredeflned. Thisncluded adding a few system part¡cle
countread¡ngs fol
miner Thlsmeant p!rchasingand litersonsome machi¡es where filterswerc eachnachinesystenat PM.
commissioning anentire newfleetof n0tpresent. Thefiltratio¡irnprovernents
eq!ipment Gold Fieldsapproached theocal wererelatlve y simple andconsisted ol lhe
Cat€rp llardealer, unatrac,withs0r¡e following:
demanding requTements n addition toa . Change allex¡st¡ngpowefttainfiltersta
newf eetof eq!ipmenl, theywanted a f!ll the6 m¡cranUltrc-H¡gh Efl¡c¡ency filtes
|\.4ARC
contractinwhichlJnatrac handled all . Beplacethesundardbrcathetf¡ltercon
inc!dingPN¡
repairs, maintenance. They a so thefuel,hydraul¡c andtransn¡ss¡on
wanted extended component lfe guarante€s, syste ns with 4-n ¡üon H¡gh'Effic¡ency
aggressive power traincost-per'hour
guarantees, andworld-c assavailab ¡ty
glarantees.They a soslateda sfongdesife
to make themineiheleading edgebenchmark
slteina lof Africa forcontam naton
contro andcomponent fernanagement.

MAÍ{AGIÍ{G TI.UIDCTEANTINESS
Theprimary goalwas to tryt0 acheveandmainlain S0 18/15orc eaner inallhydraulic
andpower tralnsystems (except
theengne)asqucky aspossible Ths was¿ccomplished
through thelollowngreg¡men:
. Pafticlecountswerctakenfareachhydrculicandpawertn¡n sysrcnoneachnach¡ne
aI thebeg¡nning of eachPMper¡od.
. These pat cle countswercrepeatedat theendof thePMpe odbeforcthenachtnes
wercsetu¡cedlf thepafticlecauntat theendaf thePMinteNalexceeded lS0 18/15,
theollboad f¡hntionlkidneyloop¡ng)was useddu¡ngthePMta cleansystemflu¡d
backto lS0 16/13ot betteL
. Newf¡ltercwere¡nstalledandpatt¡clecountstakenbeforcthemachnewasrcturned
to ser,/¡cefhe beforcandaftetpatt¡clecauntsallowedaccuatetnck¡ngof haweach
ñachinesystenwaspeioñtng.
, Whennach¡nesystenswereableto na¡nta¡nlS0 18/15or betterat theendof the
PMper¡odw¡ththelmprcvedonboardfiltrat¡on,add¡t¡anal off-boardf¡hratiandur¡ng
PMcouldbed¡scont¡nued
Yhai llave We l¡eatned? DoES |lWonK?
EAIHERS Theoriginal
G0ld
Fields
f eetconsisted
of
--E Jseoffuelfiltersasbreatherswereinitialy q!estioned
bya fewwhofeared thethefo owing:
:c::-tialforI terplugging
when!singa veryflnefilterandresultant
tankdamage. . 24 785C
Thts M¡n¡ng
frucks
_¿:lroven to bea ground
essconcern, s ncetherehasneverbee¡a sinqleincidence . 3 DgRÍractots
of
F-::¡er plugging.Breather
filtersaretypically
cha¡ged every
6 months. . 4 Dljñ Trcctots
. 4 16HMotoryraderc
R¡r|) FITENS . 2 844Wheel Dozers
--,.'. wassome . 2 992G WheelLoade$
p ugging
off uidfiltersduring periodThisvaries
thebreak-in bysystem . 2 9660WheelLoade5
f,: ,..as c pfoblem
nota chron
, 2 773EWatetTrucks

CIM E I Al{DSYSIEM BBEAI(-II{

PERIODS
Lt¿:-nesareusually About thefirstprojected
75%throuqh
ope¡ated
atthefactory ptiorto shprnent.
for1 2 hours Before
overhaul
cycle
of20,000
hours,pe ormance
nesareshipped,
-,¿L-- off-board
filtration
isusedtocleanassemb y debris
fomsystemsto
wasasT0ows:
,il 8115
orbetter
Pelom¡nc. Worldw¡do
Ir.¡. andrebuilt
systems
andcomponents
experience perodwhere
a b¡eak,in an tooale Benchmar
f:i eraled amount ofweardebrs iscreated. Theseperiods astdifferentamo!ntsoftime. MórnT¡mo
l{5hrs 8llhrg
Brlwrart6¡lurrs
-! -! ¿mn ngtruckasanexarnple, thefollowing
aferepresentativedifferences
insystern
r:-:(.1¡pefods Mean T¡me
4.7hrs 3-6h|s
. Steo ng Systen to neDair
Majarconponents arca piston pump,steenngvalveandsteering cylinderc.
Th¡s Avr¡lablilily 97% sÁ
systengenerctesveryltttlebreak-¡n
debisandcleansupveryfast.
. f,ansmisE¡on
154-200hourbrcak.inWiod withdebr¡s generction
pnnailylron clutchnateial
,-n¡üonliltersusuallyplugonce¡n 150houtsot less.1ncebreak-¡n debistsrenoved,
fansn¡ss¡ons shouldmaintain lS0l6/13wthoutoff-boardfiltration.
. FinalD veandD¡ltercnti.l
Uselaeegears,whichhavea break-¡n peiodthatnay lastseveÉltho\sand houts
0t lqnger.

1:ammon misconcepton0nnewmachines
s :rat0ncesystems arecleaned
atthe *4
:-d:0ry,
theystayc ean.

ItA( { PER|oDS ton MoST SYSTETiS

I'f I,OI{GE8ÍHAI{FACTORY
Of NAIIf{G/TESTIt{G IIME
1,.¡ mzingcomponent liferequreseffective
_, d c eanliness
management, where break
. lebris
isfemoved asquickly aspossible,
:_acomponents operate incleanf uid
:-oughout theirlife.

MPflOVINGCOMPONENTOURAB
L IY
FLUID
CLEANL
NESS
Sysiem CleanliBesa FleetSystomCleanl¡noaa
A goodexample of system break-in andthecleanliness thatcan be achievedand
maintained isthetransmission andtorque convener circu¡tsonthepowershift fansmiss¡on
inthe 785C trucks.
Changes to the fansmission and torque convener filtrationincludedthe
following:
. Beplace 25un transn¡ss¡on lubel¡lterw¡tha 6 umfilter
. Replace 20un transn¡ss¡on charg¡ng l¡lterw¡tha 6 un filter 785c D¡ff
. Eeplace 25un park¡ng brakerelease l¡ltetw¡tha 6 un f¡ltel
. Beplace 35un tonueconveftet f¡ltetwitha 6 un f¡lter
Inthefirst150hours, 22of24trucks plugged onefilter,whiletheremaininq twotrucks
plugged 2 filters.
Each plugged filteroccurcnce wasaddressed bysimply replacing the
filterandplacing the truckback into service. Afterthe initial
break-indebris was removed a = Befor. PM Sarvice
fÍomthesystem, nofurther filierplugging occured, andthefinerfilterswereablet0 O = Aft.r PM / Kldn.y Loop
ma¡ntain lS016/13 throughout thePl\y' period without theneed forotl-board filtration
Similarsuccess wasachieved withtheotherpowertrain systems. Thechartshows system
cleanliness levelsatthebeginning andend0fthePl\¡ period.

785CTRANSMISSION PartlcleCountlng
Betoreand After PM Servlce

.)
I
3 rs.o
o
o

'%:'%%fu%%%%%%%%'%'%%%%%'%
Hourt(Pir)

vAuoAlt{GFtutoctE t{ul{EssfrlAf{AGEMEl{T
Theongoing success0ftheGoldFields fleetdemonstratesthatfluidclea¡liness
management canwod,despite thepresence hardships.
ofsignificant Considerl
, fh¡swasthefist MABC contactexperienceforthedealer.
. TheMABC contactconta¡ned aggrcss¡ve guarcntees.
costandavailab¡l¡ty ***
. Thecustonetwanted wo d-class contan¡nat¡on contolandconponent l¡fe ln thepncess, Unatrac'sGoldFields
nanagenent. fac¡l¡ty
achievedthefi$t 3-stal
. fhe s¡tewaslocatedin thercnotejunglesof Ghana whercpattsdel¡ver¡es face
Contaninat¡on ratingin the
C1ntrol
extrcne leadt¡nesdue to sh¡pp¡ng
and custons delays: ent¡rcEurope/ Afica/ M¡ddleEast
Paftsstockorders- 40days (EAME)reg¡on.
Eneryency oñers'12days
 DRIVING DOWN COSTS

. ,., toreducifg power faina¡dhydr¿rrccomponent ifecyce costss lo ltilie a of the Effectir¡e fluid
:' 'rbLrl fto lhecomponents Thisoltenreq!ressor¡echanges i¡ theway nwhich
: fe rsoperated orrsedin prod!ction is
a¡dhow1 mantanedUnde¡standing how
cleanlinesg
:: lrts operate andwhatcalses lh€mto fa tscsse¡t ngpracl
a to elimifal cesth¡t management is
': ,race
efatedweaforprel¡aluTcfa ure
the single most
' !¡$/ngsummary lishthemalor
ca!sesol compofenl
fa ure Nolehowconlanr
nated important factor
:ttrro I quaity¡rethetwomosls gnfcanlconlrbuloTs
lo acceLerated
wearorla lre
in maximizing
component life
and lorrvering
component life
cycle costs.

PRIM.ERY C.EUSESOf PREMATURE WEAROUT .END FAILURE

BEARINGS GEARS DUO CONE SE¡,I,S

: rlpef¡sú ¿ton Nor¡a Fatigue mproper
nslaatof
.'oad (Falgue) t]verload Bendng)
lTooth (Load
Overheat FingSet)
: :¡m natedLube0 l]ontamin¿led
Lube
0i Contam
nated
Lube0

I r t r N 0L r I
DFvrNG cosTsJ,
DowN I
WATER
water,
Frst,thefuelmustbefreeofexcess which
breaks theprotective
down f mstrength
top unger
ollhefuelandleads a¡dseizure
sclffing fail!res

Remollng excess
waterbecomeseve¡more importa¡t fuelsulfur
¿sallowable evels are
reducedto nearzeroTheprocessto remove fues! fuTalsoTemoves
some 0l thelong
chaincarbonrnoecules,
whch r¡provethefi msfength olihefuelVerylowsulfurfuel
wil alsohavelower
filmstrength
andlower natural
resifance oisel¿!re.
toscuffing

¡BR¡IiIVES
Second,thef!elmusthave mlcroscopic¿bras veparticles
removed toprevent
Inlector
wearfheseabrasive
abrasive particles
leadto prernature
abrasive wearout
oftheinlector
canridge ng n
vave,resLrlt excess !e h gh'pressure inlerna
leakage.Thiseakagereduces
lueldelivery
i¡tothecylinderandres!ltsinlowpower nts.N¡any
cornpla oftheseabrasive
partlc
esarepresent n thefueasa resirll
ol lhepetrole!m on
dlsiill¿t process.
Additional
e¡terthelue tankn thelorr¡0fdusty
abrasives unlteredta¡kve¡tsorvented
airthrough
IUetca0s.

SUPPLY PRESST'RE
f!els u p p y p rc s s u re t o t h e in le c t o rmu s t b e ma in t a i¡e da t neoar dr leyrl 0 0 p s
Finally,
to achievecomplete f ingandproper operal onof theinjectorIncomp etefil ngof the
njector
cancause erralic f!el delveryandmayeventually le¿dto internacavitalion
damage to theinjector

Cavtationocc!rswhena vacuum b0bbles lormed andthenimplodes. Ths canoccur

whenluelliltersare pl!gged¿ndrestrct the flow of fuel enleringtheinjector resulting
¡n
ncomplele to prevenl
fl L lnorder cavitatlon, fuelpressure sho!d notbeallowed to drop
ps
beow 70 . lor rnoslnewerhigh presslre un t nl€ctors Contin! ngto ru¡ luellilters
untlla noticeabledropin enginepedorr¡ance is detected s notrecommended. Thefuel
pressureat wh cha dropin performance is detected is lar belowthe pressure at whlch
caviiation
damage beginsto occur.
' ,itdt'¡ltralno
¡sr]catntnendedaftertheltydraulic
systetnhasbeenopenedt0 replace
a naiu c1tnp)D¿ntsLtch
. rtL)0t cyl¡txle[lt canals)beuseddur tgPL4setvtcet0 supplenent
the]nboardftltration
andad¡ievehiqher
, i)[otlcleanliness.

KEYS TO LONG COMPONENT LIFE

L i L

rl r ! llrr
 ONBOARD FITTRATION Thoroughly Clean Debris
Whlemanyc!stomers recognlze the benefit frotn the Syste¡n After a
of offboard fi tr¿liontheres a raprdly Component failute
gfowngder¡and for mproved onboard Cor¡pone¡t fa luresge¡erale veryarge
fillraion Thegoalisto achieve thebenefltsar¡ou¡ls of abras vedebris thatc rc!lates
ofoffboard filtratrofbydevelopi¡g o¡board througho0t the system Th s debris can
systerns capable of mai¡tan nghighlevels ol cause vavesto stckandmafu¡ctiof, and
c eanliness drring oper¿tlon Thedernand s ptmps and acluat0fs t0 suneT fepeal
¡ot luslforbetter filterslt is forsyster¡s fa !res Follow th€recomme¡datlons n t¡e
designed andcapable ol reaching and service manua to femove the debris from
mar¡ta ninglS0cLean nesseves aslowas thesysfer¡ 1opreveftrepeat fai !res
16/13 througho!l thelifeol the cornpone¡t D€pend ¡g on the amount of debris n the
syslern. cleanrng maybeasslmpe as
0i cleanl nessmaybeimprov€dsome if fLushing the ta¡k afd changlng lLuids and
applcaliofs simpy byusing finerm cron filters to rnalor system disassembly and
f ltersHowever. swtchfg Io f nerli lers clean ng 0l pans
Higheff¡c¡oncyfuelf¡ltercnakeveryeflect¡ve maycause if tialfilterplugg ngdurlng th€
brcathetf¡lte9foth6l andhydrcul¡ctanks. PfVl perodas afgeamou¡ts of sma debris t s a solrnpoftanl to identrfyafdcorrecl
arelrapped r¡ lhef fer f ltersThs is theroolcalseol fa ureprorto repacnga
especi¿ y tr!ewithnewmachtnes orwhere fa Led component Neary a repeat la lures
few c0f¡pofenls havebee¡ifstaled Al a f ed u et o ln s t aI n ga ¡e whY d r a u l c
newcornp0nents cenefat€ i¡cfeased levels component w lhoulhavngcorrected the
ofweafdebrsduf¡g thebreakI process 0rg fai calseof f¿ ureTheLtse of a repar
This¡cfeased raleof debrs ge¡eTatlon check st s also st¡o¡ClY recommefded For
rnaycalsea f ter10p ugprorto the addrtiofa inforrnal onof compor)e¡t
scheduled PlVl p
perod The lggedIi ler repacerner)t, relef to thebooket:
sho!ldtrereplac€d andthemach neplaced
back¡to service Exper encehasshown
thallh s !suallyoccurs onlyofceortw ce
before lheoi c eafsLrp afdthef ¡€rf ters
lasllheduralion ol thePIVperrodThe
wofstth nga lsercando s lo change lo a
coarser f lef to avod lilterp ug!ng

Thepurpose 0f a i lteris to trapdebrrs so

Highqual¡ty hydaul¡¿filte¡sdoa beftet¡obof
trcpp¡ng andhold¡ng debr¡,.Keep¡ng0¡lvery thal I s remOved fromlhesystemllsrng
clean rcducet weat ñtes and extdlds c0arse flterslh a ta lo wd e b rttso p a s s
thelile of hldraul¡c
¿oñponents. thro!ghwitho!lp !gg nqwi lf!rther
conlaminate thesYstem andres!I n
premalufe weaforla lufe '' r¡prov
ngCompon€ft
D!rabilitl]
Componefl afd Installat
Bemova o¡.'
Form SEBFl0l7
number
 SUMMARY

than75yearshavepassed
¡,4ore sincethe
i¡1rodlction
of thef rstCaterparenglne
0ther€round breakrngir¡pTovements
were
infoduced inthefollowi¡g years.
These
technologlcalimprovements made
T¡acnrnes:
. Farnorc prcduct¡ve
. Morcreliableanddurable
. Marecoñple\andsophisticated
-'-. Thefisl pawershifttransntsson
"st Caterp¡llar
dieselenginewas was¡ntr1duced . Easierto operate
^:aJced n theD¡eselS¡xty tractor
tn 1931 ontheDgEtnclot in 1959 . Fat lessexpens¡ve to awnandoperate

Alloftheseevol!1onary changes and

mpfovernentshav€beendrvenby
cuslomer demand to conlnually improve
pefomance andreduce opefatngcosts.n
orderto remaincompet tive,it is essenti¿l
forcustomersto ut zeall of thevaluebuilt
nlohydr¿!lic
systems a¡d components to
pefofmproducl vework

''¿
-.30wheelloadetwasthelust hyüaul¡c Ihe 769wasthef¡st n¡ningtruckbutltby
:¿:.'built by Calery¡llat,
andwasntraduced Caterp¡llar,
andwas¡nttuduced in 1963
- ttg

""'"""'""Tülü'üii'Á',i
4l
 IMPBOVING COMPONENT DURABILITY

Tlrrr, r',.1 r r r 1i r r |,rIIr: rf.r' I r ,r l,r rl rrr rr I,rrrrrrr',rr l,irrrr r11rl,rr

, \ l rr,i l r, r l r n' lll. lLlr , , r r" ,ri l l rr, r l l L ' 1 1 ,1 ll l Lrl rr IIr' Li l rr i l rrr,
¡ 11rr 1 r\i tfL , lr r r r r ' LL rr ' l r, l 1 ,r ,L , l L l rl l r' rL r,I rrr,ll r rLl l i ri l ' ,rrl' rr rr !
Ilr !1 ,rrfrir L! I l, r , r! l rr r' rl ri r. rl rrr' r l r tLr\,r' r' r ' r " r,rrL
f r f , l r[,r1 .] , ir ' il r lr r r r ,r' l l ;,rrl rrL rrr , l I l i r' l rr' ,r l rl !' 1 ' r ' r' r l " ll
r r, , , ,,!fl Li1r l, , , t lr , I \' L ]N L

fUELSYSTtlrlS FINALDRIVES AND POWTRSHIFT COMPONINT REMOVAL

0rffEEENltArs IRANSMISSIONS ANDINS]ATTATION
02tNtiLlSHl
sENR9620
02BAHASA
SIINR962l] SEBFl0l5 0l tNCLSll r SFBt l0l6 tNGtlSHr stgFr0r/ ENüLISH
i
OI SPANSHi
SSBI-Il]I5 SI]BFI()]6 BAHASA BAHASA
SIIBF](J]/
36 PAGES O] BAHASA
SI]8F]l]I5 40 PAGIS 2'IPAGES
44PAGTS

ENGINIS HYONAUTICS FtUl0

IvIANAGING COMPONfNT
IIlIPROVING
CLEANTINESS DURABILITYSET
SEBFl0lSENCtSHl ENGLSH]
SEBFlOI9
EAHASA
SSBF]{]I8 CHINESE
SCBF]O]9 i ENGLSHi
SEBF1020 SEBFl021ENCtSHr
BAHASA
S8BFlO]9 EAHASA
SSBFIO2O BAHASA
S88F]021
48 PAGES
48 PAGES 44 PAGES