Procedure to Retrofit a Diesel Particulate Filter (DPF) for Emissions on a IT62G Integrated Toolcarrier, and on 950F Series II, 950G, and 962G Wheel Loaders{1061, 108F, 1091} Caterpillar

Integrated Toolcarrier:

IT62G (S/N: AKP1-UP; 6PS1-UP)

Wheel Loader:

950F Series II (S/N: 4DJ2000-UP; 5SK185-UP; 8TK185-UP)

950G (S/N: 2JS1-UP; 4BS1-UP; 3JW1-UP; 5FW1-UP; 8JW1-UP)

962G (S/N: 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 7BW1-UP)

Introduction

ReferenceSpecial Instruction, REHS5606, "Installation and Operation of the Caterpillar Diesel Particulate Filter (DPF) and the Diagnostic Module for Non-Road Machine Applications (Non-California Applications)"

ReferenceSpecial Instruction, REHS1841, "General Welding Procedures"

This special instruction provides information for the installation of the Caterpillar Diesel Particulate Filter (DPF) on the machines that are listed.

Do not perform any procedure that is outlined in this special instruction, and do not order any parts, until you have a thorough understanding of the information that is contained in Special Instruction, REHS5606, "Installation and Operation of the Caterpillar Diesel Particulate Filter (DPF) and the Diagnostic Module for Non-Road Machine Applications (Non-California Applications)" which includes important installation instructions, general maintenance, testing, and cleaning information that is not included in this publication. Understanding the alarm operation and the maintenance requirements by the owner and the operator is important.

The Caterpillar Diesel Particulate Filter includes the following: a particulate exhaust filter, an exhaust monitor, a thermocouple and parts needed for the installation. The Diesel Particulate Filter replaces the muffler. The Diesel Particulate Filter requires additional brackets and modifications for the installation.

The Caterpillar DPF is used to reduce particulate matter, carbon monoxide, and hydrocarbons from diesel engine exhaust through catalytic oxidation and filtration. These filters are self-regenerating, and replacement is not necessary. The filters will periodically burn off the accumulated soot. For this application, the following requirements must be met. Refer to the EPA web site for the latest verification requirements for Caterpillar Diesel Particulate Filter installations. Refer to Special Instruction, REHS5606, "Installation and Operation of the Caterpillar Diesel Particulate Filter (DPF) and the Diagnostic Module for Non-Road Machine Applications (Non-California Applications)".

• Ultra-Low Sulfur Diesel Fuel must be used. Ultra-Low Sulfur Diesel Fuel must have an average sulfur content of 15 ppm. The maximum sulfur content of the fuel must not exceed 30 parts per million (ppm).

• The Exhaust Temperature of the engine must be greater than 240 °C (464 °F) for at least 40% of the time.

• The engine should be well maintained, and the engine should not be consuming oil at an excessive rate (a rate that is greater than the engine specification).

• The ratio of emissions of Oxides of Nitrogen (NO_x) to Particulate Matter must be a minimum of 25. This ratio should be higher for applications that involve a lower temperature. This technology is currently applicable to 1996 Tier 1 and Tier 2 engines.

Note: The Caterpillar Diesel Particulate Filter cannot be used on Tier 3 engines.

Engine oil with a high API category rating is the best engine oil. Acceptable oil grades for the Diesel Particulate Filter are CH-4, CI-4, and CJ-4. Diesel Particulate Filter CI-4 oil is superior to CH-4 oil. CJ-4 oil is superior to CI-4 oil. CJ-4 oil is highly recommended due to a low ash specification that results in better Diesel Particulate Filter performance.

Illustration 1	g01035610
Typical Operating Range for a DPF

Refer to Illustration 1 for the typical operating range of a DPF.

Note: Do not perform any procedure that is outlined in this special instruction, and do not order any parts, until you understand the information that is contained in this publication.

ReferenceSpecial Instruction, REHS5606, "Installation and Operation of the Caterpillar Diesel Particulate Filter (DPF) and the Diagnostic Module for Non-Road Machine Applications (Non-California Applications)".

Safety

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Welding on Electronically Controlled Engines

Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.

1. Set the engine control to the "STOP" mode.

2. Turn OFF the fuel supply to the engine.

3. Disconnect the negative terminal from the battery.

4. Disconnect the electronic components of the engine from the wiring harnesses: ECM, throttle actuator, turbocharger compressor bypass actuator, fuel metering valve and sensors.

5. Protect the wiring harnesses from welding debris and/or from welding spatter.

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NOTICE
Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

6. Connect the ground cable for the welder directly to the component that will be welded. Place the clamp as close as possible to the weld in order to reduce the possibility of welding current damage to the engine bearings, to the electrical components, and to other engine components.

7. Use standard welding procedures to weld the materials together.

Parts Information

Location of Parts

Illustration 2	g01760393
Exploded View (1) 7E-3870 Muffler Clamp (2) 253-4495 Clamp As (3) 277-4718 Clamp As (4) 322-7177 Bracket As (5) 322-7179 Plate (6) 322-7180 Bracket As (7) 322-9842 Diesel Particulate Filter Gp (8) 324-1454 Bracket Adapter (9) 3B-4508 Lockwasher (10) 5P-4116 Hard Washer (11) 5P-8245 Hard Washer (12) 6V-3822 Bolt (13) 6V-3823 Bolt (14) 6V-8149 Nut (15) 8T-4121 Hard Washer (16) 8T-4133 Nut (17) 8T-4196 Bolt (18) 8T-6870 Bolt

Installation Procedure

A thorough understanding of the guidelines in Special Instruction, REHS5606, "Installation and Operation of the Caterpillar Diesel Particulate Filter (DPF) and the Diagnostic Module for Non-Road Machine Applications (Non-California Applications)" is required before you attempt any part of the following installation procedure.

The installation procedure that follows is specific for the listed machines.

Diesel Particulate Filter Installation

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Illustration 3	g01898416
Rear View (a) Hood (b) Turbocharger (27) Exhaust pipe (28) Muffler assembly (29) Muffler clamp (30) Muffler support bracket

1. Remove the existing exhaust pipe (27), muffler assembly (28), muffler clamp (29), and muffler support bracket (30). Refer to the appropriate Disassembly and Assembly manual for the machine.

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Illustration 4	g01781374

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Illustration 5	g01781397

2. Relocate the ether canister to the other side. Refer to Illustration 4 and Illustration 5.

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Illustration 6	g01781413
(4) 322-7177 Bracket As (15) 8T-4121 Hard Washer (17) 8T-4196 Bolt

3. Install 322-7177 Bracket As (4) in the same location as the former muffler support bracket (30) by using four 8T-4121 Hard Washers (15), and four 8T-4196 Bolts (17). Refer to Illustration 3 and Illustration 6.

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Illustration 7	g01781434
(6) 322-7180 Bracket As (8) 324-1454 Bracket Adapter (10) 5P-4116 Hard Washer (12) 6V-3822 Bolt (15) 8T-4121 Hard Washer (18) 8T-6870 Bolt

4. Install 322-7180 Bracket As (6) by using two 8T-4121 Hard Washers (15), and two 6V-3822 Bolts (12) to the exhaust elbow mounting holes. Place 324-1454 Bracket Adapter (8) between bracket assembly (6) and the aftercooler core assembly. Secure bracket assembly (6) to bracket adapter (8), and to the aftercooler core assembly by using two 5P-4116 Hard Washers (10), and two 8T-6870 Bolts (18). Refer to Illustration 7.

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Illustration 8	g01781454
(5) 322-7179 Plate (15) 8T-4121 Hard Washer (16) 8T-4133 Nut (17) 8T-4196 Bolt

5. Install 322-7179 Plate (5) on top of bracket assembly (4), and bracket assembly (6). Secure plate (5) loosely using eight 8T-4121 Hard Washers (15), four 8T-4196 Bolts (17), four 8T-4133 Nuts (16). Refer to Illustration 8.

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Illustration 9	g01781475
(2) 253-4495 Clamp As

6. Install two 253-4495 Clamp As (2) on top of plate (5). Use eight hard washers (15), four bolts (17), and four nuts (16). Secure the brackets loosely so that you are able to make adjustments. Refer to Illustration 9.

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Illustration 10	g01781478
(c) Inlet tube (7) 322-9842 Diesel Particulate Filter Gp

7. Install 322-9842 Diesel Particulate Filter Gp (7) on top of the two bottom clamp assemblies (2). Insert inlet tube (c) on top of the exhaust elbow. The weight of the diesel particulate filter group is approximately 60 kg (132 lb). Refer to Illustration 10.

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Illustration 11	g01781493

8. Cut off material from the bracket that originally supported the ether canister (if needed), to fit the diesel particulate filter group. Refer to Illustration 11.

9. Make sure that the filter is properly placed on top of clamp assemblies (2) and the exhaust elbow. If needed, adjust plate (5), and bracket assemblies (4) and (6). Once diesel particulate filter group (7) is properly positioned, tighten the bolts between the plate and the two bracket assemblies. Also, tighten the bolts of the bottom clamp assemblies (2) .

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Illustration 12	g01781513
(d) Outlet tube (1) 7E-3870 Muffler Clamp (3) 277-4718 Clamp As (9) 3B-4508 Lockwasher (11) 5P-8245 Hard Washer (13) 6V-3823 Bolt (14) 6V-8149 Nut

10. Secure inlet tube (c) of the diesel particulate filter group to the exhaust elbow with one 7E-3870 Muffler Clamp (1). Refer to Illustration 12.

11. Position one 277-4718 Clamp As (3) over the diesel particulate filter group, and secure the clamp assembly to the bottom clamp assembly (2) using four 5P-8245 Hard Washers (11) going to the top clamp assembly (3), and four 3B-4508 Lockwasher (9) going to bottom clamp assembly (2). Use four 6V-3823 Bolts (13), and four 6V-8149 Nuts (14) to secure the top and bottom clamp assemblies together. Repeat for the other clamp assembly (3). Refer to Illustration 12.

12. Cut a hole in the support assembly above outlet tube (d) of the diesel particulate filter group. Move the exhaust pipe to the new location. Use the piece that you cut out to patch the original hole in the support assembly.

    Note: Make sure that care is taken while cutting and welding. Specific dimensions are not known and modifications will likely be required.

13. After any modifications are made, and prior to final bolt tightening, adjustments to the hood mounting may be required in order to close the hood for proper latching.

Exhaust Monitor Installation

Refer to Special Instruction, REHS5606, "Installation and Operation of the Caterpillar Diesel Particulate Filter (DPF) and the Diagnostic Module for Non-Road Machine Applications (Non-California Applications)" for information regarding the installation and the operation of the exhaust monitor.

The exhaust monitor is a device designed to monitor the Caterpillar DPF system continuously. The exhaust monitor provides critical information to the vehicle operator and maintenance staff relative to operation and performance of the Diesel Particulate Filter.

The required parts for the installation of the exhaust monitor are the following: 423-5876 Exhaust Monitor Gp (23), 216-7990 Installation Assembly (24), 282-0031 Remote Display (25), and 220-3778 Adapter Cable Assembly (INTERFACE) (26) .

Note: These parts must be installed at the same time as the DPF assembly or the DPF warranty may be voided.