Testing the Diesel Particulate Filter (DPF) for Cracks, Leaks, and Recovery from Engine Oil Contamination for C6.6 and C4.4 Engines{108F} Caterpillar

Backhoe Loader:

416F (S/N: KSF1-UP)

420F (S/N: JWJ1-UP; SKR1-UP)

428F (S/N: RAK1-UP)

430F (S/N: RDF1-UP; RGS1-UP)

432F (S/N: PXR1-UP)

434F (S/N: MTR1-UP)

444F (S/N: JXR1-UP)

450F (S/N: HJR1-UP)

Industrial Engine:

C4.4 (S/N: 4481-UP)

C6.6 (S/N: 6671-UP)

Excavator:

312E (S/N: GAC1-UP; MJD1-UP; PZL1-UP; WEY1-UP)

314E (S/N: DKD1-UP; GMD1-UP; ECN1-UP; ZJT1-UP; YCW1-UP)

316E (S/N: DZW1-UP; WZY1-UP; YZZ1-UP)

318E (S/N: DZF1-UP; WZS1-UP)

320E (S/N: REE1-UP; SXE1-UP; DFG1-UP; TNJ1-UP; LAK1-UP; WBK1-UP; PNL1-UP; LHN1-UP; AWS1-UP; KLT1-UP; MEW1-UP; SHX1-UP; TEX1-UP; TFX1-UP; NAZ1-UP)

323E (S/N: RAP1-UP; YRP1-UP; TDW1-UP)

Knuckleboom Loader:

2384C (S/N: KAW1-UP)

2484C (S/N: KAZ1-UP)

559C (S/N: KAS1-UP)

579C (S/N: KAX1-UP)

Pneumatic Compactor:

CW34 (S/N: TLJ1-UP; CT31-UP)

Vibratory Asphalt Compactor:

CB44B (S/N: JXL1-UP; NSL1-UP)

CB54B (S/N: LXD1-UP; RJN1-UP)

Vibratory Soil Compactor:

CP54B (S/N: CPX1-UP)

CP56B (S/N: LHC1-UP)

CP68B (S/N: LCF1-UP)

CP74B (S/N: L7B1-UP)

CS54B (S/N: L4H1-UP; MJ51-UP)

CS56B (S/N: L8H1-UP)

CS64B (S/N: C641-UP)

CS66B (S/N: CS61-UP)

CS68B (S/N: MMS1-UP)

CS74B (S/N: LCB1-UP)

CS76B (S/N: L9H1-UP)

CS78B (S/N: L8C1-UP)

Track-Type Tractor:

D3K Series 2 (S/N: GAE1-UP; KFF1-UP; KLL1-UP)

D4K Series 2 (S/N: KMM1-UP; KRR1-UP)

D5K Series 2 (S/N: TRF1-UP; KWW1-UP; KYY1-UP)

D6K Series 2 (S/N: WMR1-UP; RST1-UP)

D6N (S/N: PBA1-UP; PER1-UP; SC61-UP)

Wheel Loader:

924K (S/N: PWR1-UP)

930K (S/N: RHN1-UP)

938K (S/N: SWL1-UP)

Introduction

The following special instructions must be used to test for a crack in the Diesel Particulate Filter (DPF). Do not perform any procedure that is outlined in this Special Instruction until you have read and understand the information that is contained in this document.

Required Tools

Testing Procedure

1. Perform a "Manual Diesel Particulate Filter Regeneration" using the electronic service tool. If the "Manual Diesel Particulate Filter Regeneration" procedure follows the removal of excess oil from the exhaust system, proceed to Step 2.

   1. Follow the procedure that is detailed by Step 1.b through to Step 1.m to clean oil from the exhaust system.

   2. Remove excess oil from all pipes with a clean cloth.

   3. Remove the DPF from the bracket for the clean emission module. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" for the correct procedure.

   4. Use a suitable supporting device, position the DPF in a vertical position. Ensure that the inlet side of the DPF faces in a DOWNWARDS position.

   5. Let the DPF drain overnight. The oil will collect inside the inlet face of the DPF. Position a suitable container under the inlet face of the DPF. Incline the inlet face of the DPF to drain the oil into the container.

   6. If amount drained from DPF equals less than 1 L (0.26 US gal), proceed to Step 1.g. If amount is greater than 1 L (0.26 US gal), then the DPF should be replaced.

   7. Remove excess oil from the inlet and outlet of the DPF with a clean cloth.

   8. Install the DPF from the bracket for the clean emission module. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Install" for the correct procedure.

   9. Start the engine. Operate the engine a 100 percent throttle for a MINIMUM of 20 minutes. Do not operate the application under load at this time period.

   10. After 20 minutes, use the electronic service tool to perform the "DPF Desulphation Procedure". The "DPF Desulphation Procedure" will last 60 minutes.

   11. Once the "DPF Desulphation Procedure" has been completed, observe the soot load. If the soot load is at a value less than 80 percent, then the application can be returned to service.

   12. Check the application for any signs of visible black smoke coming from the exhaust stack after the cleaning procedure has been completed. This could indicate a cracked DPF that will need to be replaced.

       Note: Black soot residue on the surface of the inside of the exhaust stack does not necessarily indicate a cracked DPF therefore should not be used in determining a problem with the DPF.

   13. If white smoke does not dissipate, contact the Technical Communicator at a Caterpillar dealer. For further assistance, the Technical Communicator can confer with the Dealer Solutions Network.

2. After the manual DPF regeneration is complete, operate the engine at 1800 rpm for a MINIMUM of 20 minutes to stabilize the DPF temperatures.

   Note: The engine must maintain a steady speed for the entire duration of the test.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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Illustration 1	g02597531
Typical example (1) DPF Outlet Cap (2) Filter Paper (3) Hose Assembly (4) Air Pump

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Illustration 2	g03655991
Typical example

3. Stop the engine. Disconnect harness assembly from both soot antennae. Remove outlet soot antenna (5). Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.

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Illustration 3	g03655207
Typical example

4. Install Tooling (B) between the inlet and outlet soot antenna connections. Refer to illustration 3.

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Illustration 4	g02599418
Typical example (6) Filter Paper

5. Install the filter in the fitting, refer to Illustration 4. Install the fitting in the DPF outlet port where the outlet soot antenna was installed. The filter must be installed in less than 10 minutes after the engine has shut down.

6. Turn the vacuum pump ON.

7. Start the engine. Operate the engine at 1800 rpm for 15 minutes.

   Note: The engine must maintain a steady speed for the entire duration of the test.

8. Stop the engine. Remove the filter assembly within 25 minutes. Use proper personal protective equipment to remove the filter assembly.

9. Allow the filter assembly time to cool down before disassembly.

10. Carefully disassemble the filter assembly to prevent contamination. Tip the fitting down on a clean surface to remove the filter paper. Handle the filter paper with clean hands and only by the edges.

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Illustration 5	g02597796
Typical example

11. Compare the stained area in the center of the filter paper to the color coded sheet provided. Refer to Illustration 5.
    • If the shade is equal to or darker than the "Color Code Sheet", then replace the DPF. Refer to Special Instruction, "Diesel Particulate Filter (DPF) Maintenance on Tier 4 Products Equipped with a Diesel Particulate Filter".

    • If the shade is lighter than the "Color Code Sheet", then the DPF can continue in service.

12. Remove Tooling (B). Install outlet soot antenna (5). Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure. Connect harness assembly to both soot antennae.

13. Return the unit to service.

14. Clean the items in Tooling (A) with a suitable cleaning solution after each application to prevent contamination.