C15 On-Highway Engine Caterpillar

Assembly Procedure (Horizontally Mounted Particulate Filter)

Note: When the sections are installed, maintain the original direction of the flow of exhaust. The sections must maintain the original direction of the flow of exhaust in order to comply with emissions standards.

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Illustration 1	g01458222

Note: Install new gasket. Refer to Special Instructions, "Procedure for cleaning ash from the Diesel Particulate Filter (DPF)".

1. Position the new gasket (not shown) and connect inlet section (9) onto filter section (7) .

2. Position the new gasket (not shown) and connect outlet section (6) onto filter section (7) .

3. Install band clamps (8) and hand tighten the band clamps.

4. Align the marks at Point (E) on the filter section and the exterior of the inlet and outlet sections.

5. Use Tooling (B) in order to tap gently band clamps (8) around the diesel particulate filter in one full rotation. This process is used to seat the band clamps.

Note: Verify that sections (6) , (7) , and (9) remain in original positions.

6. Position band clamps (8) into original positions. Tighten band clamps (8) to a torque of 11 ± 1 N·m (100 ± 10 lb in).

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Illustration 2	g01454590

7. Apply Tooling (A) to the threads on fittings (3) , (4) , and (5) .

8. Install fittings (5) and tighten the fittings to a torque of 24 ± 4 N·m (208 ± 35 lb in).

9. Position temperature sensor (2) into the original position.

10. Tighten fitting (3) to a torque of 45 ± 5 N·m (33 ± 4 lb ft). Repeat this step for the opposite side.

11. Tighten fitting (4) to a torque of 8 ± 2 N·m (71 ± 18 lb in). Repeat this step for the opposite side.

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Illustration 3	g01458162

12. Position clamps (1) , as shown. Tighten clamps (1) to a torque of 8.5 ± 1 N·m (75 ± 10 lb in).

13. Reset the engine ash model. Refer to the section "Ash Service Reset".

Assembly Procedure (Vertically Mounted Particulate Filter)

Note: When the sections are installed, maintain the original direction of the flow of exhaust. The sections must maintain the original direction of the flow of exhaust in order to comply with the emissions standards.

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Illustration 4	g01460747

Note: Install new gasket. Refer to Special Instructions, "Procedure for cleaning ash from the Diesel Particulate Filter (DPF)".

1. Position the new gasket (not shown) and connect inlet section (18) onto filter section (11) .

2. Install band clamp (19) and hand tighten the band clamp.

3. Position mounting assemblies (16) and clamp assemblies (17) at Point (H) .

4. Tighten clamp assemblies (17) to a torque of 11 ± 1 N·m (100 ± 10 lb in).

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Illustration 5	g01459892

Note: Install new gasket. Refer to Special Instructions, "Procedure for cleaning ash from the Diesel Particulate Filter (DPF)".

5. Position the new gasket (not shown) and connect outlet section (15) onto filter section (11) .

6. Install band clamp (12) and hand tighten the band clamp.

7. Position mounting assembly (14) and clamp assembly (13) at Point (G) .

8. Tighten clamp assembly (13) to a torque of 11 ± 1 N·m (100 ± 10 lb in).

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Illustration 6	g01460767

9. Align the marks at Point (F) on filter section (11) , inlet section (18) , and outlet section (15) .

10. Use Tooling (B) in order to tap gently band clamps (19) and (12) around the diesel particulate filter in one full rotation. This process is used to seat the band clamps.

Note: Verify that sections (18) , (11) , and (15) remain in original positions.

11. Position band clamps (19) and (12) into original positions. Tighten the band clamps to a torque of 11 ± 1 N·m (100 ± 10 lb in).

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Illustration 7	g01459864

12. Apply Tooling (A) to the threads on fittings (8) , (9) , and (10) .

13. Install fittings (8) , (9) , and (10) and tighten the fittings to a torque of 24 ± 4 N·m (208 ± 35 lb in).

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Illustration 8	g01459826

14. Apply Tooling (A) to the threads on fittings (1) , (2) , (5) , and (6) .

15. Position temperature sensor (7) into the original position.

16. Tighten fittings (1) and (6) to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

17. Tighten fittings (2) and (5) to a torque of 8 ± 2 N·m (71 ± 18 lb in).

18. Position clamps (4) , as shown. Install bolt (3) and tighten clamp assemblies (4) to a torque of 8.5 ± 1 N·m (75 ± 10 lb in).

19. Reset the engine ash model. Refer to the section "Ash Service Reset".

Assembly Procedure (Horizontally Mounted Dual Particulate Filter)

Note: When the sections are installed, maintain the original direction of the flow of exhaust. The sections must maintain the original direction of the flow of exhaust in order to comply with the emissions standards.

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Illustration 9	g01458388

1. Position particulate filter sections (10) .

2. Install outlet section (8) and the new gaskets (not shown) onto particulate filter sections (10) .

3. Align the marks at Point (K) on the filter sections and the exterior of the inlet and outlet sections.

4. Install band clamps (9) finger tight.

5. Use Tooling (B) and gently tap band clamps (9) around the diesel particulate filter in one full rotation. This process is used to seat the band clamps.

Note: Verify that sections (8) and (10) remain in original positions.

6. Position band clamps (9) into original positions. Tighten band clamps (9) to a torque of 11 ± 1 N·m (100 ± 10 lb in).

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Illustration 10	g01458393

Note: Install new gasket. Refer to Special Instructions, "Procedure for cleaning ash from the Diesel Particulate Filter (DPF)".

7. Install outlet section (6) and the new gaskets (not shown) onto the particulate filter sections.

8. Align the marks at Point (J) on the filter sections and the exterior of the inlet and outlet sections.

9. Install band clamps (7) finger tight.

10. Use Tooling (B) and gently tap band clamps (7) around the diesel particulate filters in one full rotation. This process is used to seat the band clamps.

Note: Position section (6) in the original position.

11. Position band clamps (7) into original positions. Tighten band clamps (7) to a torque of 11 ± 1 N·m (100 ± 10 lb in).

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Illustration 11	g01456632

12. Apply Tooling (A) to the threads of fittings (2) , (3) , and (5) .

13. Install fittings (5) and tighten the fittings to a torque of 24 ± 4 N·m (208 ± 35 lb in). Repeat this step for the opposite side.

14. Position temperature sensor (1) into the original position.

15. Tighten fitting (2) to a torque of 45 ± 5 N·m (33 ± 4 lb ft). Repeat this step for the opposite side.

16. Tighten fitting (3) to a torque of 8 ± 2 N·m (71 ± 18 lb in). Repeat this step for the opposite side.

17. Position clamp assemblies (4) into the original position. Tighten clamps (4) to a torque of 8.5 ± 1 N·m (75 ± 10 lb in).

18. Repeat Steps 12 through Step 17 for the opposite side.

19. Reset the engine ash model. Refer to the section "Ash Service Reset".

Ash Service Reset

The engine ash model must be reset whenever the filter is cleaned or replaced. Reset the DPF volume back to the "Clean State". The resetting will allow the regeneration of the DPF to function properly.

1. Use Cat ET to access the configuration parameters. In the "System Settings" group of parameters, highlight the" Diesel Particulate Filter Ash Service Reset". Refer to Illustration 12 for the location of the "Diesel Particulate Filter Ash Service Reset". The value of the parameter should be "Not Reset".

2. Click the "Change" button at the bottom of the screen. The change will require the Factory Passwords to be reset. Enter either "Reason code 67 or 68".

3. Contact the Global Highway Call Center at 1-800-447-4986 and select Option 1. The analyst will collect the necessary information in order to make a Call Record. The analyst will enter the following information into the call history space: serial number of the DPF, mileage and hours. The analyst will provide the factory passwords that are needed to reset the engine ash model.

4. Enter the factory passwords. The value of the parameter will change to "Reset". This will indicates that the engine ash model was reset to "Zero Ash".

Illustration 12	g01726174
(1) Location of " Diesel Particulate Filter Ash Service Reset"