Diesel Particulate Filter Maintenance on Certain C2.4, C3.3B, and C3.8 Machine Engines {108F, 7500} Caterpillar

Compact Track Loader

259D (S/N: LW51-UP; FTK1-UP)

259D3 (S/N: CW91-UP; TE91-UP)

279D (S/N: TP51-UP; GTL1-UP)

279D3 (S/N: RB91-UP; Z9E1-UP)

289D (S/N: WE51-UP; TAW1-UP)

289D3 (S/N: BT91-UP; JX91-UP)

299D (S/N: GTC1-UP)

299D XHP (S/N: JST1-UP)

299D2 (S/N: FD21-UP; BY41-UP)

299D2 XHP (S/N: DX21-UP; DX91-UP; HLM1-UP)

299D3 XE (S/N: LB31-UP; XES1-UP)

Multi Terrain Loader

257D (S/N: D5T1-UP; EZW1-UP)

257D3 (S/N: S7E1-UP; KEZ1-UP)

277D (S/N: FMT1-UP)

287D (S/N: HMT1-UP)

297D (S/N: BE71-UP)

297D XHP (S/N: HP71-UP)

297D2 (S/N: BL71-UP)

297D2 XHP (S/N: HP21-UP)

Skid Steer Loader

236D (S/N: K2D1-UP; BGZ1-UP)

236D3 (S/N: GK61-UP; KXL1-UP)

242D (S/N: HFB1-UP; DZT1-UP)

242D3 (S/N: ME61-UP; HSX1-UP)

246D (S/N: PN51-UP; BYF1-UP)

246D3 (S/N: KC61-UP; PF61-UP)

262D (S/N: RE51-UP; DTB1-UP)

262D3 (S/N: ZB21-UP; W6E1-UP)

272D (S/N: B5W1-UP)

272D XHP (S/N: ETL1-UP)

272D2 (S/N: BL21-UP)

272D2 XHP (S/N: MD21-UP)

272D3 (S/N: HX21-UP)

272D3XHP (S/N: GJ21-UP)

299D3 (S/N: CY91-UP; DY91-UP)

299D3XHP (S/N: AN91-UP; BX91-UP)

Introduction

This Special Instruction details the Diesel Particulate Filter (DPF) maintenance on C2.4, C3.3B, and C3.8 machine engines.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Reference Section

Reference: Special Instructions , REHS7788, "Cleaning the Diesel Particulate Filter (DPF) on C2.4, C3.3B, and C3.8 Engines."

Reference: Troubleshooting , "Diesel Particulate Filter Active Regeneration Occurrence is Excessive"

Reference: Troubleshooting , "Oil Contains Fuel"

Reference: Disassembly and Assembly , "Diesel Particulate Filter- Remove and Install"

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

Maintenance Procedure

1. The C2.4, C3.3B, and C3.8 engines with a Diesel Particulate Filter (DPF) have a maintenance interval schedule for cleaning at 3000 Hrs.

2. There are three options for servicing the Diesel Particulate Filter (DPF).

   • Diesel Particulate Filter (DPF) can be cleaned by the Cat^® dealer.

   • Replaced with a certified clean Diesel Particulate Filter (DPF) from Cat^® Reman.

   • New Diesel Particulate Filter (DPF) installed.

   Note: The lowest cost option is the Diesel Particulate Filter (DPF) is cleaned by the Cat^® dealer.

3. Refer to Special Instructions , REHS7788 for cleaning procedures.

   This document has the acceptable reuse guidelines such as max number of cracked or missing end caps and minimum remaining ash pin depth as measured by a pin gauge.

   Note: The C3.8 tier 4 final (EU stage 3B) currently does not have a certified clean Diesel Particulate Filter (DPF) available from Cat^® Reman.

4. DPF cleaning is recommended to do at 3000 hrs as part of preventive maintenance, which ensures planned downtime. If the dealer and customer choose to not do this pro-actively at 3000 hrs, then Caterpillar is not responsible for any subsequent damage to the engine or emission components as a result.

5. If preventive maintenance is not done pro-actively, one of the following will occur which may indicate the Diesel Particulate Filter (DPF) is full or near full:

   • 523602-0 High Frequency Regeneration code occurs.

   • Fuel Dilution is flagged in the SOS oil sample.

   1. 523602-0 High Frequency Regeneration indicated that active regenerations (in-cylinder dosing) occurred within 30 minutes of the prior and this occurred three times in a row. This could indicate the Diesel Particulate Filter (DPF) is full and needs to be cleaned, when higher than 3,000 hrs.

      Note: 523602-0 High Frequency Regeneration code could also be caused by a different problem. Refer to Troubleshooting , "Diesel Particulate Filter Active Regeneration Occurrence is Excessive" to troubleshoot this code.

   2. Fuel dilution can be caused by many issues. If fuel dilution occurs, refer to Troubleshooting , "Oil Contains Fuel". One cause of fuel dilution can be due to a plugged Diesel Particulate Filter (DPF). This is due to the Diesel Particulate Filter (DPF) getting closer to being full, which results in more frequent the active regenerations (in-cylinder dosing). The more frequent active regeneration occurs the more fuel will get into the oil.

6. To service the Diesel Particulate Filter (DPF), refer to Disassembly and Assembly , "Diesel Particulate Filter- Remove and Install". The recommended procedures are as follows:

   • 272D, 272D XHP, 297D, 297D XHP, 299D, 299D XHP - Remove cooling package to gain access to the Diesel Particulate Filter (DPF).

   • All other models - Remove the engine to gain access to the Diesel Particulate Filter (DPF).

7. The following Table shows the amount of time it takes to remove and install (R&I) the Diesel Particulate Filter (DPF) as per Equipment Repair Labor Guidelines (ERLG) or Time Requirement Guidelines (TRG).
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   Table 2

   Remove and Install Time Sheet
   Sales Models	Engine Remove and Install	Diesel Particulate Filter Remove and Install	Total Diesel Particulate Filter Remove and Install
   236D, 242D, 257D, 259D	8.9 hrs	1.3 hr	10.2 hrs
   246D, 262D, 277D, 279D, 287D, 289D	8.5 hrs	1.3 hr	9.5 hrs
   272D, 272D XHP, 297D, 297D XHP, 299D, 299D XHP	8.0 hrs	1.3 hr	9.0 hrs
   272D2, 272D2 XHP, 297D2, 297D2 XHP, 299D2, 299D2 XHP	8.0 hrs	1.6 hr	9.6 hrs

8. Refer to ERLG or TRG for details.
   https://servicedata.cat.com/Reporting
   
   https://dealer.cat.com/en/ps/service/trg/machine.html
   

9. The above mentioned time requirements were done validated by time studies at Cat^® dealerships with Cat^® dealer technicians. The actual work times were then increased by another 30%. This uplift takes into account non-wrench time to cover technician personal time, variations, and procurement of tools and parts. The actual work time includes:

   • Wrench time.

   • Installing gaskets.

   • Inspecting parts for reusability.

   • Removing new parts from packaging.

   • Necessary adjustments and lubrication of components.

   • Getting tools out of toolbox.

   • Putting tools back in toolbox.

   • Mopping up oil and water spills in work area.

   • Looking up torque specifications.

   • Recrating exchange components.