- Excavator:
- 330D (S/N: LEM1-UP)
- 330D L (S/N: NBD1-UP; B6H1-UP; THJ1-UP; MWP1-UP; HAS1-UP)
- 330D FOREST MACHINE (S/N: L2K1-UP)
- 330D LL FOREST MACHINE (S/N: E4K1-UP; H3K1-UP)
- 330D L (S/N: NBD1-UP; B6H1-UP; THJ1-UP; MWP1-UP; HAS1-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)"
This special instruction provides information for the installation of the Caterpillar Diesel Particulate Filter (DPF) on the machines that are listed above.
Important notes regarding Engineered Solution DPF's:
- Engineered Solution DPF's have been designed only for physical fit on the specified machine, and serial number prefix. This does not mean that the temperature profile will be suitable for all like machines. Data logging is still necessary to ensure a suitable duty cycle for the DPF.
- Serial number prefix is used to design, install, and field follow an Engineered Solution DPF. Parts are designed and Special Instructions are written based only on this serial number prefix.
- Engineered Solution DPF's may fit on these other serial number prefixes with or without additional modifications and parts. CES has not installed the DPF on these other serial number prefixes, and makes no guarantee of fit of the Engineered Solution DPF on them.
Do not perform any procedure that is outlined in this special instruction or 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)" 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 Diesel Particulate Filter 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 do not need 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 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 ratio of emissions of Oxides of Nitrogen (NOx) 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 and newer engines.
- The engine should be well maintained. 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.
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| 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 and Operation of the Caterpillar Diesel Particulate Filter (DPF) and the Diagnostic Module for Non-Road Machine Applications (Non-California Applications)".
Safety
| NOTICE |
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Diesel Particulate Filters (DPF) are not applicable to all engines. A Diesel Particulate Filter should typically not be applied to engines that are not regulated. Diesel Particulate Filters are meant for usage on only diesel engines. This technology does not apply to gas engines. Consult with Caterpillar in order to determine if a Diesel Particulate Filter can be used on your engine. |
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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. |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
Parts Information
| Required Parts | |||
|---|---|---|---|
| Item | Part Number | Part Name | Qty |
| 1 | 304-1120 | Diesel Particulate Filter Gp (1) | 1 |
| 2 | 308-4936 | Bracket As | 1 |
| 3 | 308-4941 | Clamp As | 2 |
| 4 | 277-4718 | Clamp As | 2 |
| 5 | 3B-4508 | Lockwasher | 4 |
| 6 | 5P-8245 | Hard Washer | 4 |
| 7 | 6V-8149 | Nut | 4 |
| 8 | 6V-3823 | Bolt | 4 |
| 9 | 8T-4121 | Hard Washer | 4 |
| 10 | 8T-4196 | Bolt | 4 |
| 11 | 241-9265 | Muffler Clamp | 1 |
| 12 | 423-5876 | Exhaust Monitor Gp | 1 |
| 13 | 216-7990 | Installation As | 1 |
| 14 | 282-0031 | Remote Display | 1 |
| 15 | 220-3778 | Adapter Cable As (INTERFACE) | 1 |
| ( 1 ) | The diesel particulate filter group is not serviceable. However, the individual parts are serviceable. |
Parts Location
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| Illustration 2 | g01666016 |
Exploded view (1) 304-1120 Diesel Particulate Filter Gp (2) 308-4936 Bracket As (3) 308-4941 Clamp As (4) 277-4718 Clamp As (5) 3B-4508 Lockwasher (6) 5P-8245 Hard Washer (7) 6V-8149 Nut (8) 6V-3823 Bolt (9) 8T-4121 Hard Washer (10) 8T-4196 Bolt | |
Installation Procedure
Diesel Particulate Filter Installation
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| Illustration 3 | g01667275 |
(11) 241-9265 Muffler Clamp (16) Muffler Assembly (17) Bracket Assembly (18) Support Assembly (19) Exhaust Pipe Assembly (20) Clamp (21) Pipe Assembly (22) Bolt (23) Hard Washer (24) Bolt (25) Washer (26) Plate (27) Bolt (28) Hard Washer (29) Plate | |
- Remove the existing muffler assembly (16) and bracket assembly (17). Set aside exhaust pipe assembly (19), clamp (20), three bolts (22), three hard washers (23), two bolts (24), two washers (25), three bolts (27), and three hard washers (28). These parts will be reused in later steps.
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| Illustration 4 | g01601993 |
(2) 308-4936 Bracket As (22) Bolt (23) Hard washer (24) Bolt (25) Washer (27) Bolt (28) Hard washer | |
- Reuse three bolts (22), and three hard washers (23) to secure the new 308-4936 Bracket As (2) to existing support assembly (18) .
- Reuse two bolts (24), and two washers (25) to secure bracket assembly (2) to existing plate (26) .
- Reuse three bolts (27), and three hard washers (28) to secure bracket assembly (2) to existing plate (29) .
- Install the two new 308-4941 Clamp As (3) by using four 8T-4196 Bolts (10), and 8T-4121 Hard Washers (9). Loosely secure the four bolts so that the clamp assemblies are adjustable. Refer to Illustration 5.
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| Illustration 5 | g01602054 |
(3) 308-4941 Clamp As (9) 8T-4121 Hard Washer (10) 8T-4196 Bolt | |
- Install the new 304-1120 Diesel Particulate Filter Gp (1) on top of clamp assemblies (3). Make sure that inlet module tube (30) fits into existing pipe assembly (21). Use a new 241-9265 Muffler Clamp (11) to secure the joint. Refer to Illustration 6.
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| Illustration 6 | g01602115 |
(1) 304-1120 Diesel Particulate Filter Gp (30) Inlet module tube | |
- Once you have the pipe assembly installed properly, tighten the two bottom clamp assemblies (3). Install the new 277-4718 Clamp As (4) by using the four 5P-8245 Hard Washers (6), and four 6V-3823 Bolts (8). Use the four 3B-4508 Lockwashers (5), and four 6V-8149 Nuts (7) on the clamp assembly (3) side. Refer to Illustration 7.
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| Illustration 7 | g01601954 |
(4) 277-4718 Clamp As (5) 3B-4508 Lockwasher (6) 5P-8245 Hard Washer (7) 6V-8149 Nut (8) 6V-3823 Bolt (31) Outlet module tube | |
- Install the existing exhaust pipe assembly (19) to the outlet module tube of the diesel particulate filter. Secure the connection with existing clamp (20) .
- Reconnect the drain lines.
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 (12), 216-7990 Installation Assembly (13), 282-0031 Remote Display (14), and 220-3778 Adapter Cable As (INTERFACE) (15). These parts must be installed at the same time as the DPF assembly or the DPF warranty may be voided.