Procedure to Retrofit a Diesel Particulate Filter (DPF) for Emissions on a 345B / 345B Series II / W345B Series II MH Excavator{108F, 1091, 7490} Caterpillar

Excavator:

345B (S/N: CFM1-UP; 9CW1-UP)

345B L (S/N: 4SS1-UP; 5WS1-UP; 9GS1-UP; 2NW1-UP; 2SW1-UP)

345B L Series II (S/N: CCC1-UP)

345B LC Series II (S/N: AGS1-UP; AKX1-UP)

345B MH Series II (S/N: APB1-UP)

W345B MH Series II (S/N: ANJ1-UP; CDY1-UP)

Introduction

Reference Special Instruction, REHS5606, "Installation Guide for Particulate Trap Exhaust Filters"

Reference Special Instruction, REHS1841, "General Welding Procedures"

Reference Special Instruction, REH5606, "Installation and Operation of the Exhaust Monitor Used in All Diesel Particulate Filter (DPF) Retrofit Emissions Applications"

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

Before performing this procedure, you must read and thoroughly understand the guidelines in Special Instruction, REHS5606, "Installation Guide for Particulate Trap Exhaust Filters" for important installation, 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, so the filters do not need to be replaced. 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 Guide for Particulate Trap Exhaust Filters".

• 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 ratio of emissions of Oxides of Nitrogen (NO_x) to Particulate Matter must be a minimum of 20. This ratio should be higher for applications that involve a lower temperature. This technology is currently applicable to 1996 and newer engines.

• 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).

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: You must read and thoroughly understand all of the instructions within this special instruction before you attempt any part of the procedure. Refer to Special Instruction, REHS5606, "Installation Guide for Particulate Trap Exhaust Filters".

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 engine's electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor's bypass, 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 welder's ground cable 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

Parts Location

Illustration 2	g01601433
(1) 308-4943 Diesel Particulate Filter Group (2) 235-3963 Clamp Assembly (3) 308-4945 Bracket Assembly (4) 8T-4183 Bolt (5) 5P-8245 Hard Washer (6) 241-9265 Muffler Clamp

Installation Procedure

Diesel Particulate Filter Installation

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Illustration 3	g01606937
Typical Example (11) Existing muffler assembly (12) Existing bracket assembly (13) Support Assembly (14) Muffler Clamp (15) Tube assembly (16) Engine lifting plate (17) Bolt (18) Hard washer (19) Bolt

1. Remove existing muffler assembly (11) and bracket assembly (12). Set aside the three 8T-4183 Bolts (17), the five 8T-4184 Bolts (19) and the eight 5P-1076 Hard Washers (18). These parts will be reused in Steps 2 and 3. Refer to Illustration 3.

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Illustration 4	g01601354
(3) 308-4945 Bracket Assembly (17) Bolt (18) Hard washer

2. Install 308-4945 Bracket Assembly (3) onto support assembly (13) by reusing three bolts (17) and three hard washers (18) that were removed in Step 1. Refer to Illustrations 3 and 4.

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Illustration 5	g01601373
(19) Bolt

3. Reuse five bolts (19) and five hard washers (18) removed in Step 1 to secure bracket assembly (3) to engine lifting plate (16). Refer to Illustrations 3 and 5.

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Illustration 6	g01601413
(2) 235-3963 Clamp Assembly (Lower half) (4) 8T-4183 Bolt (5) 5P-8245 Hard Washer

4. Remove the two bolts, two hard washers, two lock washers, and two nuts from each 235-3963 Clamp Assembly (2). Keep these parts together with the upper half of clamp assembly (2). These parts will be reinstalled in Step 8.

5. Install the lower half of 235-3963 Clamp Assembly (2) by using two 8T-4183 Bolts (4) and two 5P-8245 Hard Washers (5). Loosely secure these bolts so that the clamp assembly is adjustable. Repeat for the other clamp assembly (2). Refer to Illustration 6.

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Illustration 7	g01601473
(1) 308-4943 Diesel Particulate Filter Gp

6. Install 308-4943 Diesel Particulate Filter Group (1) onto the lower halves of clamp assemblies (2). The weight of the diesel particulate filter group is approximately 40 kg (88 lb). Make sure that the inlet tube (not shown) of the inlet module of the diesel particulate filter fits into tube assembly (15). Use a new 241-9265 Muffler Clamp (6) to secure the connection. Refer to Illustrations 3 and 7.

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Illustration 8	g01601333
(2) 235-3963 Clamp Assembly (Upper half) (2a) Bolt (2b) Hard washer (2c) Lock washer (2d) Nut

7. Once you have properly installed the tube assembly, tighten both bolts (4) to secure the bottom half of clamp assembly (2). Repeat for the other clamp assembly (4). Install the upper half of clamp assembly (2) by using two bolts (2a) and two hard washers (2b) through the upper clamp assembly, and two lock washers (2c) and two nuts (2d) on the lower clamp assembly. Repeat for the other clamp assembly. Refer to Illustration 8.

8. Reconnect the drain lines.

Exhaust Monitor Installation

Refer to Special Instruction, REHS5606, "Installation and Operation of the Exhaust Monitor Used in All Diesel Particulate Filter (DPF) Retrofit Emissions Applications" for information regarding the installation and the operation of the exhaust monitor.

The exhaust monitor is a device designed to continuously monitor the Caterpillar DPF system. 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 Group (7), 216-7990 Installation Assembly (8), 282-0031 Remote Display (9), and 220-3778 Adapter Cable Assembly (INTERFACE) (10). These parts must be installed at the same time as the DPF assembly or the DPF warranty may be voided.