Diesel Particulate Filter (DPF) Maintenance on Certain Products Equipped with a Diesel Particulate Filter (DPF) {108F} Caterpillar

Articulated Truck

735B (S/N: T4P1-UP)

740B (S/N: T4R1-UP)

Asphalt Compactor

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

CD44B (S/N: JXE1-UP)

CD54B (S/N: GRT1-UP; J9T1-UP)

Backhoe Loader

415F2 (S/N: HWA1-UP)

427F2 (S/N: HWK1-UP)

Ejector Truck

740B EJECTOR (S/N: T4S1-UP)

Engine (Captive)

C13 (S/N: TXM1-UP; M4X1-UP)

Excavator

311F (S/N: LZF1-UP; JFT1-UP; KCW1-UP)

312F (S/N: FKE1-UP)

313F (S/N: GJD1-UP; HDK1-UP)

336E (S/N: RZA1-UP; KED1-UP; YCE1-UP; TEG1-UP; FJH1-UP; GTJ1-UP; JRJ1-UP; SSL1-UP; YEP1-UP; CMR1-UP; HDW1-UP; BZY1-UP; TMZ1-UP)

349E (S/N: FJB1-UP; DGE1-UP; SPG1-UP; TFG1-UP; RGH1-UP; KCN1-UP; MZW1-UP; KFX1-UP; MPZ1-UP; WHZ1-UP)

Forest Machine

568 (S/N: BRB1-UP; YJX1-UP)

Generator Set

C13GENSET (S/N: X3M1-UP)

C15 GEN SET (S/N: T4A1-UP; X5M1-UP)

Industrial Engine

3.4B (S/N: CJ31-UP)

C13 (S/N: KWJ1-UP)

C15 (S/N: LDN1-UP)

C18 (S/N: BDN1-UP)

C2.2 (S/N: G9P1-UP)

C3.4B (S/N: CJG1-UP)

C9.3 (S/N: C9N1-UP; D9N1-UP)

Motor Grader

12M Series 2 (S/N: F9B1-UP; F9M1-UP; R9P1-UP; R9S1-UP)

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)

160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)

Petroleum Engine

C13 PETROLEUM (S/N: A5Z1-UP)

Pneumatic Compactor

CW14 (S/N: LTJ1-UP)

Track-Type Tractor

D6T (S/N: KSB1-UP; ZJB1-UP; JZC1-UP; DTD1-UP; EJJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; TSM1-UP; WLM1-UP; PLR1-UP; JRW1-UP; RCW1-UP)

D7E (S/N: TJA1-UP; TAN1-UP)

D8T (S/N: MLN1-UP; FCT1-UP)

Wheel Loader

966K (S/N: PBG1-UP; TFS1-UP)

966K Series XE (S/N: NGX1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

980K (S/N: W7K1-UP; GTZ1-UP)

Wheel Tractor Scraper

621H (S/N: DBK1-UP; HKK1-UP)

623H (S/N: DBF1-UP)

627H (S/N: DBW1-UP)

Introduction

There are three approved processes for performing the required Diesel Particulate Filter (DPF) maintenance on products equipped with a DPF.

Do not perform any procedure in this Special Instruction until you have read this entire Special Instruction and you understand this information. Caterpillar does not recommend any equipment or process for cleaning the DPF other than the procedures listed in this Special Instruction.

Note: The approved Caterpillar DPF maintenance procedure permits any of the following actions be taken when the DPF needs to be cleaned:

• Replacement of the existing DPF with a new Caterpillar DPF

• Replacement of the existing DPF with a remanufactured Caterpillar DPF

• Replacement of the existing DPF with a similar DPF cleaned by a Caterpillar approved cleaning device.

The DPF can be cleaned a maximum of three times or 20,000 total DPF hours.

Replacement with a New or a Remanufactured Caterpillar Diesel Particulate Filter (DPF)

Refer to Table 3 for the existing part number of the filter assembly being serviced along with the corresponding new and remanufactured service kits.

Refer to Reman Core Acceptance Criteria, SELD0292 for further information.

When replacing the existing DPF with either a new or remanufactured DPF, perform the following:

• Perform a "Manual DPF Regeneration"

• Mark the DPF as shown below in Step 4

• Perform the "DPF Ash Service" listed below.

Replacement of the existing DPF with a similar DPF cleaned by a Caterpillar approved cleaning device

Inorder to maintain emissions documentationit is necessary that only the same part number DPF must be reinstalled. The cleaned DPF must have a remaining service life similar to the DPF being replaced.

Inspect the DPF for markings of a previous cleaning. Refer to Illustration 1 for a typical example of cleaning markings.

Cleaning the DPF

Follow this cleaning procedure for removal of the ash from a DPF. Refer to the Operation and Maintenance Manual for the intervals of service hours for cleaning of the DPF.

Note: Identify all engine fault codes if black soot is discovered on the outlet side of the center section on the DPF. Reference the engine Troubleshooting Manual for problem identification and the disposition of the DPF.

1. Refer to Special Instruction, REHS5704, "Testing the Diesel Particulate Filter (DPF) for Cracks and Leaks" in order to perform the crack detection test. Proceed to Step 2 if the DPF passes the crack detection test. Contact the Technical Communicator, if the DPF fails the test.

2. Connect the engine through the service port to Cat ET before the DPF is removed from the engine. Once the engine is connected to Cat ET, then perform a "DPF Ash Service Regeneration". The test could take up to an hour.

   Note: Allow the DPF to cool until the DPF can be safely removed.

3. Remove the DPF from the Clean Emissions Module (CEM).
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   Illustration 1	g03530378
   Typical example of marking the DPF.

4. Mark the DPF after removing from the CEM.

   The process for marking includes a code that will identify the first cleaning and the number of hours on the part. Engrave on a suitable location on the DPF can between the clamps in the center of the can. The 1 indicates the first cleaning and the 5 indicates that the DPF has 5000 hours on the part at the time of removal.

5. If a "DPF Ash Service Regeneration" was not performed prior to the DPF being removed the DPF must be manually regenerated. Follow the instructions listed below.

   This regeneration must be performed by a DPF Thermal Processing Unit. A DPF Thermal Processing Unit is a device which will thermally regenerate a DPF unit at a controlled, pre-programmed rate.

   This process is designed to facilitate the cleaning of dirty filters – especially filter with high amounts of wet soot, and unburned hydrocarbons. Pre-programmed thermal profile controls temperature ramp up and cool down to protect DPF from thermal shock, reducing the risk of DPF cracking. Refer to Table 2 for additional information regarding regeneration by a DPF Thermal Processing Unit.

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   Table 2

   Event	Time	Temperature		Rate
   	Minutes	° C	° F	° C/Min	° F/Min
   Ramp Up/Down	-	-	-	< 5	< 40
   Saturated (1)	60	300	572	-	-
   Preheat	60	400	752	-	-
   Regeneration (2)	480	500	932	-	-
   	360	525	977	-	-
   	240	550	1022	-	-
   Cool Down	60	300	572	-	-

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   (1)	Oil or Fuel
   (2)	Choose duration of regeneration based upon your thermal processing unit.

   Note: If the DPF inlet has been exposed to oil or fuel carry over, clean the DPF using the values listed in the "Saturated" event in the table above. After heating a saturated DPF, preheat the DPF and regenerate using the values listed above. Use only one of the regeneration procedures.

6. Clean the DPF.

   Approved Caterpillar Diesel Particulate Filter Cleaning Devices

   • Stationary Cleaning Device - 319-2189 Diesel Particulate Filter Cleaner Gp

   • Portable Cleaning Device - 364-5971 Diesel Particulate Filter Cleaner

   Refer to the Cat DPF cleaning tool Operation Manual that is included with the tool.

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   Illustration 2	g03507406
   Typical example of the 456-6048 DPF TOOL GP

7. Use the following procedure to measure the amount of ash in the DPF:

   1. Use a wire with the maximum diameter of 1.04140 mm (0.041 inch) or the 456-6048 DPF TOOL GP. Hold the wire or tool so that the end of the wire is just inside the cell approximately 6.35000 mm (0.25 inch).

   2. Drop the wire into the cell of the DPF.

   3. Mark the wire at the top of the cell where the wire exits from the DPF.

   4. Measure the depth that the wire dropped by measuring from the mark to the bottom tip of the wire.

   5. Record the measurement.
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      Illustration 3	g03021156
      Top view of DPF View of locations for recording measurements (1) Weld line

   6. Perform Steps 7.b through 7.e for all locations. Refer to Illustration 3 for the proper location for recording measurements.

   7. Average the measurements and refer to Table 3 for the acceptable measurements.
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      Table 3

      Filter Assembly Part Number	New Service Kit Part Number	Reman Service Kit Part Number - Upgrade to New	Reman Service Kit Part Number - Cat Factory Cleaned	Measured Wire Depth Requires Cleaning	Acceptable Cleaned Measured Wire Depth
      358-3658	358-3659	20R-0696	20R-5620	Less than 178 mm (7 inch)	Greater than 279 mm (11 inch)
      358-3661	358-3662	20R-0697	20R-5621	Less than 203 mm (8 inch)	Greater than 305 mm (12 inch)
      358-3663	358-3664	20R-0698	20R-5622	Less than 203 mm (8 inch)	Greater than 305 mm (12 inch)
      358-3666	358-3667	20R-0699	20R-5623	Less than 254 mm (10 inch)	Greater than 343 mm (13.5 inch)
      358-3668	358-3669	20R-0700	20R-5624	Less than 279 mm (11 inch)	Greater than 394 mm (15.5 inch)

8. The DPF is ready to be returned to service.

DPF Ash Service

Purpose

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

Cat ET Location

1. Connect to Cat ET.
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   Illustration 4	g02477962

2. Select "Service" from the top menu and highlight "Service Procedures".
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   Illustration 5	g02477961

3. From the "Service Procedures" menu, highlight "DPF Ash Service". Select "Start".
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   Illustration 6	g02495621

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   Illustration 7	g02477958

4. Select "Ash Service Reset" to start the test procedure.
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   Illustration 8	g02477960

5. Choose the correct replacement type of diesel particulate filter in the menu that appears. The types of replacements for the diesel particulate filter are the following:

   • "Field cleaned" A filter that has been cleaned and reapplied

   • "New" - A new filter replacement

   • "Remanufactured" - A remanufactured filter replacement
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   Illustration 9	g02495643

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   Illustration 10	g02478024

6. Once the reset is completed, a log of the reset is captured and visible as a new row of information in the DPF ash service screen.

7. Perform a "Manual DPF Regeneration" with Cat ET to reset the soot level