Particulate Filter for Stationary Engines in Standby Applications{1091} Caterpillar

Usage:

Introduction

Physical Description

Installation

Operation

General Maintenance

Troubleshooting

Serviceable Parts

Reference Dimensions

Filter DPF Assembly

Silencer DPF Assembly

Diagnostic Module Description

Silencer DPF Installation

Silencer DPF Installation (Retrofit)

Filter DPF Installation

Filter DPF Installation (Retrofit)

Diagnostic Module Installation

DPF Operation

Diagnostic Module Operation

Retrieving Data from the Diagnostic Module

Testing the Diesel Particulate Filter

Regenerating the Diesel Particulate Filter

Cleaning the Diesel Particulate Filter

Excessive back pressure or the engine has lost power

Excessive blue smoke

Excessive black smoke

Excessive accumulation of soot on the filter module

Cleaning Procedure

Probable Cause

Recommended Repair

Probable Cause

Recommended Repair

Probable Cause

Recommended Repair

Probable Cause

Recommended Repair

Particulate Filter for Stationary Engines in Standby Applications{1091}

Engine:: 3406 (S/N: 90U1-UP); 3412C (S/N: 81Z1-UP); 3456 (S/N: BGA1-UP; 9BZ1-UP); 3508 (S/N: 8TL1-UP; 3LS1-UP; 23Z1-UP; 70Z1-UP); 3508B (S/N: 4GM1-UP; 6PN1-UP; 2HW1-UP); 3512 (S/N: 3MS1-UP; 24Z1-UP; 67Z1-UP); 3512B (S/N: FFG1-UP; 6WN1-UP; 4DR1-UP; 4AW1-UP; 5AW1-UP); 3516 (S/N: 7KM1-UP; 2TS1-UP; 3JS1-UP; 3NS1-UP; 25Z1-UP; 73Z1-UP); 3516B (S/N: TAK1-UP; 6HN1-UP; 7RN1-UP; 1NW1-UP; 2JW1-UP; CCX1-UP)

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

A Diesel Particulate Filter (DPF) is a filtration system for the exhaust of diesel engines that is designed to reduce the following emissions: particulates, carbon monoxide and hydrocarbons.

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Illustration 1	g01156460
Cross section of the exhaust gases through the DPF

The cross section of the DPF has a honeycomb pattern. The honeycomb pattern of the cylinder forms channels that extend from one face to the other face of the DPF. The end of every other channel is plugged on one face of the DPF. On the opposite end of the DPF, the other half of the channels are plugged. Therefore, every channel is plugged on only one end. In the exhaust pipe, the exhaust must flow into the open channels and flow through the walls of the channel of the ceramic DPF in order to exit the opposite end of the DPF.

The walls of the channel contain a coating of catalyst. As the exhaust gas contacts the catalyst, a chemical reaction occurs. The carbon monoxide is oxidized into carbon dioxide, and the hydrocarbons are oxidized into water and carbon dioxide. The walls of the channel also capture the solid particulate matter.

Particulate collection occurs continuously while the engine is operating. As the sites of particulate collection within the DPF become filled, back pressure increases. The particulates are periodically removed through a process that is called regeneration. Once the temperature of the exhaust is equal to or is greater than 300 °C (572 °F) for thirty percent of the duty cycle, the catalyst will interact with the collected particulates to burn the particulates into carbon dioxide and water vapor. The carbon dioxide and the water vapor pass through the DPF and the capacity for the particulate collection is restored.

The process of regeneration and the durability of the DPF are dependent upon the following conditions: exhaust temperature, fuel sulfur content, oil consumption and oil quality.

Exhaust Temperature - Exhaust temperatures that are greater than 300 °C (572 °F) will keep the filter performing properly. Exhaust temperature does not need to be above 300 °C (572 °F) at all times, but the DPF will not regenerate below this temperature. The DPF will continually collect particulates. If no regeneration occurs, back pressure will continue to increase and the DPF will eventually plug.

Fuel Sulfur - Ultra-low sulfur diesel fuel must be used. Ultra-low sulfur diesel must have a maximum sulfur content that does not exceed 15 parts per million (ppm). The use of a fuel with a higher sulfur content causes an increase in sulfate particulates due to the oxidation of SO₂ to SO₃. Higher sulfate levels increase the temperature for regeneration due to the sulfates inhibiting the performance of the catalyst of the filter. Increased sulfates may also reduce the filtration efficiency of the DPF. SO₃ is more corrosive than SO₂ and will result in damage to downstream components.

Oil Consumption and Oil Quality - Ensure that Caterpillar oils are used. Adhere to recommended service intervals. Refer to Engine Data Sheet, EDS 96.2 January, "Oil Consumption Data". Higher oil consumption leads to more ash production and correspondingly more nonregenerable particulates. This will necessitate cleaning of the filter more often.

The DPF is available as a filter assembly that is packaged without additional sound suppression. The DPF is also available as an exhaust silencer assembly that is packaged with additional sound suppression.

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Illustration 2	g01137071
Filter DPF assembly

The filter DPF assembly contains the filter modules without additional sound suppression. The filter DPF contains one or two filter modules determined by the engine and by the power range. The stainless steel filter DPF resembles a cylinder with an inlet and an outlet section that has a roughly conical shape. The overall length and diameter of the filter DPF varies with each part number. The cylindrical area contains the filter modules. The filter DPF is available with one or two filter modules in stainless steel only.

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Illustration 3	g01137420
Silencer DPF assembly

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Illustration 4	g01200662
Silencer DPF assembly

The silencer DPF assembly contains the filter modules with additional sound suppression. The silencer DPF contains two to seven filter modules. The number of filter modules depends on the engine's power. The silencer DPF is oval in shape along the entire length. An access panel is located on top in order to allow access to the filter modules. The designs of the silencer DPF include a bottom inlet with a top outlet or an axial inlet with an axial outlet. The silencer DPF is available in either carbon steel or stainless steel. The dimensions will vary with the part number.

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Illustration 5	g01137444
Diagnostic module group (1) Diagnostic module control box (2) Low temperature hose (3) Condenser unit (4) Warning lights (5) Thermocouple (6) High temperature hose (7) Cooling tube (8) Cooling tube

The diagnostic module is required for a DPF. The diagnostic module monitors exhaust temperature and back pressure. By downloading information from the diagnostic module, the performance of the regeneration can be monitored over time. Temperature and pressure are monitored in order to detect conditions that might exceed recommended limits. The diagnostic module contains alarm outputs that warn the operator of potential problems.

A silencer DPF generally replaces the need for another exhaust silencer. A filter DPF may be used in conjunction with an exhaust silencer. If a filter DPF is used with an exhaust silencer, the filter DPF must be installed before the exhaust silencer.

Choose a mounting location for the DPF that will minimize back pressure on the engine and the heat loss in the exhaust.

To minimize back pressure on the engine, locate the DPF as close as possible to the turbocharger outlet. The exhaust piping should have as few bends as possible. Elbows and other components in the exhaust piping will restrict the flow of the exhaust and will increase the back pressure on the engine.

To minimize the heat loss in the exhaust, minimize the length of the exhaust piping to the inlet of the DPF or insulate the exhaust pipe. A DPF that is installed further than ten feet from the engine exhaust manifold must have insulated exhaust pipes in order to maintain a temperature that is high enough to promote regeneration. Exhaust gases that enter the DPF must have a temperature above 300 to 350 °C (572 to 662 °F). In an outdoor application, insulation is very important as ten feet of uninsulated exhaust pipe may prevent the temperature from being high enough to regenerate the DPF.

The preferred mounting of a DPF is horizontal. Rain protection for the exhaust pipe is required if the DPF is mounted vertically. A rain cap or an exhaust pipe that is curved can be used for vertical applications. In a vertical application, the DPF must not be allowed to slip downward on the exhaust pipe so that the ceramic filter contacts the pipe. This will cause damage to the ceramic filter.

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NOTICE

A diagnostic module must be installed and operated with the DPF or the warranty of the DPF will be invalidated.

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NOTICE

Use only Ultra-Low Sulfur Diesel fuel with a maximum sulfur content of 15 ppm with the DPF. Also, use only the electronic program that is specified for your engine. Using incorrect fuel or using an incorrect program will cause excessive generation of soot. This will void the warranty of the DPF.

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NOTICE

Blending engine oil with the fuel is not allowed. This will void the warranty of the DPF.

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NOTICE

To protect the DPF against contamination, ensure the engine oil consumption is not above 0.00035 lb/bhp-hr

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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Moving heavy parts must be done safely and with adequate lifting capacity. Failure to do so can result in injury or death. Use caution and adequate lifting capacity when moving heavy parts.

Install the silencer DPF in a location that is easily accessible for the loading and the unloading of the filter modules during service and inspections. The access panel must have a minimum of surrounding space of one and half times the diameter of a filter module in order to service the filter modules.

A silencer DPF can only be installed with the test port connector at the inlet end or toward the engine for proper operation of the DPF. The test port connector is 1/8 inch threaded pipe.

A DPF that is installed further than ten feet from the engine exhaust manifold must have insulated exhaust pipes in order to maintain a temperature that is high enough to promote regeneration.

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Illustration 6	g01137486
Frame assembly for the silencer DPF

Support the silencer DPF. A steel frame can be used to support the silencer DPF.

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NOTICE

A silencer DPF can be significantly heavier than a standard exhaust silencer. If existing supports and brackets are reused, these supports must be examined. Ensure the supports can carry the weight of the DPF. Consult Caterpillar for verifying the strength of existing mounts.

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Illustration 7	g01137488
Flexible exhaust piping

To prevent excess stress on the DPF, place a flexible coupling between the outlet of the engine and the inlet of the DPF. This will protect the DPF and the exhaust system from vibration. Use an expansion joint whenever the DPF is installed between two fixed points.

All exhaust piping must made with one of the following forms of steel:
- Aluminum coated steel
- 409 stainless steel
- A grade above 409 stainless steel

Install the inlet and outlet pipes.

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Illustration 8	g01148925
Example of the tightening sequence for the exhaust flange

Assemble the exhaust flange for the flexible coupling. Ensure that the seals and joint surfaces are clean and dry. Evenly tighten the bolts in a crisscross pattern for the exhaust flange. Refer to illustration 8. Evenly tighten the bolts again in a crisscross pattern for the exhaust flange.

When the installation is complete, check the system for leaks. Run the engine at high idle with no load.

Take an initial back pressure reading. Refer to ""Testing the Diesel Particulate Filter" " for the proper procedure.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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Moving heavy parts must be done safely and with adequate lifting capacity. Failure to do so can result in injury or death. Use caution and adequate lifting capacity when moving heavy parts.

Install the silencer DPF in a location that is easily accessible for the loading and for the unloading of the filter modules during service and inspections. The access panel must have a minimum of surrounding space of one and half times the diameter of a filter module in order to service the filter modules.

Inspect the engine in order to ensure that the engine meets Caterpillar's specifications. Correct the engine if the engine does not meet Caterpillar's specifications.

A DPF that is installed further than ten feet from the engine exhaust manifold must have insulated exhaust pipes.

Remove the outlet pipe from the existing exhaust silencer.

Remove the inlet pipe from the existing exhaust silencer.

Remove the existing mounting brackets and bands. If the existing hardware will be reused, inspect the components. Ensure that the components are not fatigued or cracked. Replace the existing components, as needed.

Remove the existing exhaust silencer.

A silencer DPF can only be installed with the test port connector at the inlet end or toward the engine for proper operation of the DPF. The test port connector is 1/8 inch threaded pipe.

Install the silencer DPF in the location of the previous silencer. Use new clamps and brackets, when possible. The existing brackets from the silencer can be reused, if the brackets are suitable. All mounting brackets must be properly adjusted so the inlet and the outlet of the silencer DPF line up properly with the existing inlet and outlet pipes.

Support the silencer DPF. A steel frame can be used to support the silencer DPF.

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NOTICE

A silencer DPF can be significantly heavier than a standard exhaust silencer. If existing supports and brackets are reused, these supports must be examined. Ensure the supports can carry the weight of the DPF. Consult Caterpillar for verifying the strength of existing mounts.

To prevent excess stress on the silencer DPF, place a flexible coupling between the outlet of the engine and the inlet of the silencer DPF. This will protect the silencer DPF and the exhaust system from vibration. Use an expansion joint whenever the silencer DPF is installed between two fixed points.

All exhaust piping must made with one of the following forms of steel:
- Aluminum coated steel
- 409 stainless steel
- A grade above 409 stainless steel

Assemble the exhaust flange for the flexible coupling. Ensure that the seals and the joint surfaces are clean and dry. Evenly tighten the bolts in a crisscross pattern for the exhaust flange. Refer to illustration 8. Evenly tighten the bolts again in a crisscross pattern for the exhaust flange.

Reinstall the inlet and outlet pipes.

When the installation is complete, check the system for leaks. Run the engine at high idle with no load.

Take an initial back pressure reading. Refer to ""Testing the Diesel Particulate Filter" " for the proper procedure.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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Moving heavy parts must be done safely and with adequate lifting capacity. Failure to do so can result in injury or death. Use caution and adequate lifting capacity when moving heavy parts.

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Illustration 9	g01137493

A filter DPF is reversible and may be installed in the exhaust path in either direction. The filter DPF must be installed upstream of the currently installed exhaust silencer. A filter DPF that is installed further than ten feet from the engine exhaust manifold must have insulated exhaust pipes.

Install the filter DPF. All mounting brackets must be properly adjusted so the inlet and the outlet of the DPF line up properly with the existing inlet and outlet pipes.

Support the filter DPF by the use of bands around the center. Do not overtighten the bands. Bands that are overtightened will deform the metal around the center of the filter DPF. This may crack the ceramic filter and void the warranty. The filter DPF can also be supported from the connecting tubing.

To prevent excess stress on the DPF, place a flexible coupling between the outlet of the engine and the inlet of the DPF. This will protect the DPF and the exhaust system from vibration. Use an expansion joint whenever the DPF is installed between two fixed points.

All exhaust piping must made with one of the following forms of steel:
- Aluminum coated steel
- 409 stainless steel
- A grade above 409 stainless steel

In vertical applications, the filter DPF must not be allowed to slip downward on the exhaust pipe so that the ceramic filter contacts the pipe. This will cause damage to the ceramic filter.

Install the inlet and outlet pipes.

When the installation is complete, check the system for leaks by running the engine at high idle with no load.

Take an initial back pressure reading. Refer to ""Testing the Diesel Particulate Filter" " for the proper procedure.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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Moving heavy parts must be done safely and with adequate lifting capacity. Failure to do so can result in injury or death. Use caution and adequate lifting capacity when moving heavy parts.

Inspect the engine in order to ensure that the engine meets Caterpillar's specifications. Correct the engine if the engine does not meet Caterpillar's specifications.

A filter DPF is reversible and may be installed in the exhaust path in either direction. The filter DPF must be installed upstream of the currently installed exhaust silencer. A filter DPF that is installed further than ten feet from the engine exhaust manifold must have insulated exhaust pipes.

Measure the length of the filter DPF and remove that length of the exhaust piping. Include space for slip-on connections or bolt flanges and gaskets.

Install the filter DPF. All mounting brackets must be properly adjusted so the inlet and the outlet of the filter DPF line up properly with the existing inlet and outlet pipes.

Support the filter DPF by the use of bands around the center. Do not overtighten the bands. Bands that are overtightened will deform the metal around the center of the filter DPF. This may crack the ceramic filter and void the warranty. The filter DPF can also be supported from the connecting tubing.

To prevent excess stress on the filter DPF, place a flexible coupling between the outlet of the engine and the inlet of the filter DPF. This will protect the filter DPF and the exhaust system from vibration. Use an expansion joint whenever the filter DPF is installed between two fixed points.

All exhaust piping must made with one of the following forms of steel:
- Aluminum coated steel
- 409 stainless steel
- A grade above 409 stainless steel

In vertical applications, the filter DPF must not slip downward on the exhaust pipe so that the ceramic filter contacts the pipe. This will cause damage to the ceramic filter.

Install the inlet and outlet pipes.

When the installation is complete, check the system for leaks by running the engine at high idle with no load.

Take an initial back pressure reading. Refer to ""Testing the Diesel Particulate Filter" " for the proper procedure.

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Illustration 10	g01137475
Diagnostic module that is mounted to a generator

The following conditions must be met before installing the diagnostic module:

The diagnostic module must be mounted in a space that has an ambient temperature below 44 °C (111.2 °F) during normal operation. The diagnostic module must be located away from the following direct sources of heat: engine, exhaust manifolds and radiator.
The diagnostic module must be mounted in a location that is not directly exposed to the following items: the elements, splashing water and electrical discharge.
The diagnostic module must be connected to a 12 to 24 volt power supply. Polarity is extremely important. Reversing polarity will permanently damage the diagnostic module.
The diagnostic module must not be exposed to power surges that are greater than 24 volts. Ground the diagnostic module. (Negative ground is required.)
Use the thermocouple that was supplied with the diagnostic module. Also, use the wire that was supplied.
Keep the inside of the diagnostic module as clean as possible. Do not allow dirt or moisture inside the diagnostic module.

Locate the diagnostic module in an accessible area away from areas of regular maintenance. The diagnostic module must be in a location so that the wires for the thermocouple are able to connect to the diagnostic module. Mount the diagnostic module with four 3/16 inch bolts through the mounting holes. Isolate the diagnostic module from any metal that is connected to the exhaust.

Remove the 1/8 inch and 1/4 inch pipe plugs from the inlet of the DPF.

Apply anti-seize compound onto the 1/8 inch pipe nipple that was attached to the stainless steel cooling tubing. Screw the 1/8 inch pipe nipple into the port that is provided on the inlet.

Within 914.4 mm (3 ft) of the stainless steel cooling tube, locate the condenser unit. The condenser must be mounted vertically. The end that is conical needs to be pointed downward. The condenser must be within three feet of the cooling tube and higher than the inlet to the DPF. This keeps water from accumulating in the condenser by allowing drainage to the exhaust. Mount the condenser by using four 3/8 inch or 1/4 inch bolts through the 7/16 inch mounting holes.

Install the red high temperature silicone hose over the hose barb coupler onto the coiled cooling tube that is installed in the exhaust. Secure the hose to the cooling tube with a hose clamp. Measure the high temperature hose and cut the high temperature hose in order to connect the cooling tube to the inlet (bottom) of the condenser. Do not kink the hose. Position the hose away from all moving parts, sharp corners, and areas or parts with temperatures above 232 °C (450 °F). Secure the hose to the condenser with a hose clamp.

Install the clear low temperature hose onto the outlet (top) of the condenser. Secure the hose to the condenser with a hose clamp. Measure the low temperature hose and cut low temperature hose in order to connect the condenser to the diagnostic module. Do not kink the hose. Position the hose away from all moving parts, sharp corners, and areas or parts with temperatures above 65.5 °C (150 °F). Secure the hose to the diagnostic module with a hose clamp.

Install the warning lights that are yellow and red in an area that is visible to the operator. Drill two 25/64 inch holes. For the yellow warning light, pass the wires through the hole and press the light into the hole until the light snaps into position. Repeat the installation for the red warning light. Measure the wire and cut the wire in order to connect the warning lights to the diagnostic module.

Connect the red wire from the yellow warning light to the "Y (+)" terminal on the outside of the diagnostic module. Connect the black wire from the yellow warning light to the "Y (-)" terminal. The two terminals are next to each other.

Connect the red wire from the red warning light to the "R (+)" terminal on the outside of the control box. Connect the black wire from the red warning light to the "R (-)" terminal. The two terminals are next to each other.

Route the wiring for the thermocouple from the diagnostic module to the 1/8 inch pipe fitting on the DPF. Install the thermocouple into the fitting and tighten. Position the wire for the thermocouple away from all moving parts, sharp corners, and areas or parts with temperatures above 93 °C (200 °F). Do not cut or modify the thermocouple or the wire in any way. Coil excess wire and secure the wire in a location that is protected.

To use the voltage output, connect the wires to the terminals on the outside of the diagnostic module in order to utilize the 100 milliampere of available voltage. The terminals are "OUTPUT (+)" and" OUTPUT (-)". The output voltage can be used to trigger the engine ECM. The output voltage can also be used to activate an audible alarm.

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NOTICE

Use a voltage meter to ensure the power is off before connecting any wires.

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NOTICE

Do not reverse the wires for power supply. The red wire is positive (+). The black wire is negative (-). Check the labeling on the diagnostic module in order to ensure that the wires are properly connected before supplying power.

Use a 12 to 24 volt DC power source. Connect the red wire to the positive (+) terminal of the power source. Connect the black wire to the negative (-) terminal of the power source. Polarity is very important. Reversing polarity will permanently damage the diagnostic module.

Connect the red wire to the positive "POWER (+)" terminal on the outside of the diagnostic module. Connect the black to the negative "POWER (-)" terminal on the outside of the diagnostic module.

Supply power to the diagnostic module. The diagnostic module only requires power when the engine is operating.

A diesel engine and DPF are designed for optimal performance in loaded operation. The engine should not be operated at low loads for extended durations. Low load operation has lower exhaust temperatures that can cause plugging. Load must be applied within ten minutes after a cold start.

The maximum allowable back pressure is 6.7 kPa (27 inches of H₂O). Do not operate the engine if the back pressure is above this value.

A maximum of 12 cold starts followed by a regeneration is recommended. To regenerate a DPF, operate the engine at a minimum of 40 to 50 percent load for two hours. If the 40 to 50 percent load does not raise the inlet temperature to 300 to 350 °C (572 to 662 °F), the load must be increased in order to obtain a minimum inlet temperature of 300 °C (572 °F) for the two hours. This will ensure that the exhaust temperatures are high enough to continuously regenerate the DPF.

The diagnostic module has three outputs that are available for warning the operator. All warning levels are programmable and preset before the unit is delivered. The first warning is set to ten percent below the maximum recommended back pressure. This will activate the yellow warning light.

The second warning is set at the maximum recommended back pressure 6.7 kPa (27 inches of H₂O). This will activate the red warning light.

The third output is a voltage output. Depending on the configuration of the ECM software, the diagnostic module can interface with the engine ECM in order to perform the following functions: turn on an audible alarm, send a signal to a remote operator station and activate an engine derate.

Note: If the maximum recommended back pressure is reached, the red warning light and the voltage output are activated. The red warning light and the voltage output are activated while the engine is in operation until an authorized dealer services the DPF. Operation at high loads is not recommended until the DPF has been serviced. If the engine shuts down the red warning light will turn off. When the power is restored to the engine, the red warning light will illuminate until the DPF is serviced and the diagnostic module is reset. A password is required in order to reset the diagnostic module.

During engine operation, the yellow warning light may flash on and off. This will indicate that the back pressure has reached 90 percent of the maximum recommended level. The back pressure then dropped below 90 percent of the maximum recommended level. Normal engine operation can continue, but a service call to an authorized dealer is recommended.

The preprogrammed warning outputs may be changed, but only by an authorized dealer.

The data that is retrieved is in comma-delineated format. Comma-delineated format consists of four data points that are separated by commas. The first data point is the pressure in inches of water "00". The second data point is the temperature in degrees celsius "0000". The third data point is the date "dd/mm/yy". The fourth data point is the time "hr/min".

The data can be saved for analysis to a spread sheet program that accepts txt files. A computer that is using the Windows operating system can interface with the diagnostic module through a program that is called HyperTerminal. HyperTerminal is a program that is installed on all computers that are using the Windows operating system. A cable with 9-pin connectors is also required.

Start HyperTerminal.
1. Click the Start button.
1. Click Programs.
1. Click Accessories.
1. Click Communications.
1. Click HyperTerminal.

Double click on the "Hypertrm" icon in order to start a new application.

A "Connection Description" window appears. Enter a name (for example Diagnostic Module). Choose an icon, and then click on the OK button.

A "Connect To" window appears. In the "Connect using" box, click on the arrow button. Choose "COM1" and then click on the OK button. (If the serial port on the computer uses a different port, choose the correct port.)

A "COM1 Properties" window appears. The following settings must be used:
1. Within the "Bits per second" box, type 9600 or select 9600.
1. Click on the "Data bits" box, and enter the number 8.
1. Click on the "Parity" box and enter the word "None".
1. Click on the "Stop bits" box and enter the number 2.
1. Click on the "Flow control" box and enter the word "None".
1. Click the OK button.

Save the settings for future use by clicking on the word "File" at the top of the window. Click on "Save" from the drop-down menu.

The computer is ready to communicate with the diagnostic module. The diagnostic module must now be connected to the computer. Remove the power that is supplied to the diagnostic module. Remove the four phillips head screws in the lid of the diagnostic module. Remove the lid.

Connect the male end of the cable with the 9-pin connector to the diagnostic module. Connect the other end of the cable to the computer serial port.

Ensure that the power is supplied to the diagnostic module after the connections are in place.

Press the "W" key on the keyboard for the computer. The "Download data y/n" appears. Press the "Y" key on the keyboard in order to start the download. The data will appear on the screen.

Save the data to a file by pressing the "W" key on the keyboard for the computer. When "Download data y/n" appears, click on the word "Transfer" at the top of the window. From the drop-down menu, click on "Capture Text". In the window that opens, enter the destination where the data is to be stored and the name of the file. Click on "Start" and press the "Y" key on the keyboard for the computer. The data will scroll while the data is downloaded to the designated file.

Close the HyperTerminal program by clicking on the "X" in the upper right hand corner of the window.

Import the saved file for analysis to a spread sheet program.

The only required maintenance for the DPF is periodic cleaning of the filter. Refer to ""Cleaning the Diesel Particulate Filter" " for the proper procedure. The DPF collects ash from engine oil during operation. The ash is not combustible. The buildup of ash will eventually cause an increase in back pressure. Elevated back pressure above preset limits will activate the system's diagnostic module in order to indicate a service requirement. For preventive maintenance, perform a back pressure test in order to determine if the DPF needs to be cleaned. Refer to ""Testing the Diesel Particulate Filter" " for the proper procedure. Maintenance intervals will vary depending on the application. The following items are factors that will affect the required maintenance interval:

Idle time
Composition of fuel
Exhaust temperature
Emissions level of the engine
Composition of oil
Consumption of oil

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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Making contact with a running engine can cause burns from hot parts and can cause injury from rotating parts.

When working on an engine that is running, avoid contact with hot parts and rotating parts.

The DPF will become restricted with particulates that have not yet been regenerated and ash from normal engine operation. The restriction will cause the exhaust back pressure to increase. Testing the back pressure of the exhaust system will determine when the filter needs to be cleaned.

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Table 1
Required Tools
Part Number	Description
198-4240 or 1U-5470	Digital Pressure Indicator or Engine Pressure Group

Back pressure can be measured with a 198-4240 Digital Pressure Indicator . Refer to Special Instruction, NEHS0818, "Using the 198-4240 Digital Pressure Indicator".

The 1U-5470 Engine Pressure Group can also be used to measure the back pressure. Refer to Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure Group".

A back pressure measurement is required if the yellow warning light remains illuminated.

Do not test the exhaust back pressure if the red warning light for high back pressure has been activated. Clean the DPF. Refer to ""Cleaning the Diesel Particulate Filter" " for the proper procedure.

Disconnect the exhaust attachment port from the 1/8 inch test port on the inlet cone.

Connect the pressure port of the pressure gauge to the test port.

Leave the vacuum port of the differential pressure gauge open to the atmosphere.

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NOTICE

Watch the back pressure reading as the engine begins to warm up. Stop the test immediately if the back pressure exceeds 6.7 kPa (27 inches of H₂O). The filter needs to be cleaned. Refer to ""Cleaning the Diesel Particulate Filter" " for the proper procedure.

Start the engine and run the engine in the no-load condition at high idle until the engine reaches normal operating temperature.

Record the value while the engine is operating at high idle.

If the results are greater than 6.0 kPa (24 inches of H₂O) the DPF must be regenerated. Refer to ""Regenerating the Diesel Particulate Filter" " for the proper procedure.

Test the DPF again. If the results are still greater than 6.0 kPa (24 inches of H₂O), the DPF must be cleaned. Refer to ""Cleaning the Diesel Particulate Filter" " for the proper procedure.

Test the DPF again. If the results are still greater than 6.0 kPa (24 inches of H₂O), the DPF filter modules must be replaced. Refer to Table 6.

To regenerate a DPF, operate the engine at a minimum of 40 to 50 percent load for two hours. If the 40 to 50 percent load does not raise the inlet temperature to 300 to 350 °C (572 to 662 °F), the load must be increased in order to obtain a minimum inlet temperature of 300 °C (572 °F) for the two hours. This will ensure that the exhaust temperatures are high enough to continuously regenerate the DPF.

The filter modules of the DPF are serviceable. To minimize down time, extra filter modules may be stocked. Stock enough filter modules to service your largest silencer. Filter modules from this stock can be used to replace filter modules that are removed for cleaning. When the filter modules return from cleaning, they must be reinstalled in the DPF from which they were removed. The filter modules are individually identified with an identification number stamped on a plate on the exterior of the filter module. There is a plate attached to the exterior of the silencer DPF which lists the identification number of each of the filter modules contained within the silencer. The exterior of the filter DPF does not have a plate that identifies the filter modules contained within it.

Maintain a log for each DPF. List the date, engine hours, and number of hours on each filter module. Include the hours replacement filter modules were used, if any, while the original filter modules initially installed in the DPF were being cleaned. An example log is shown in Table 2.

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Table 2
Date	Engine Hours	Hours on Each Filter
Date	Engine Hours	Filter 1	Filter 2	Filter 3	Filter 4	Filter 5	Filter 6	Filter 7
01Jan 2004	250	0	0	0	0
05Apr 2004	2528	2278	2278 replaced with filter 5	2278	2278	0
19Apr 2004	2841	2591 replaced with filter 5	replaced with filter 2	2591 replaced with filter 6	2591 replaced with filter 7	313	0	0
07May 2004	3156	replaced with filter 1	2593	replaced with filter 3	replaced with filter 4	628	315	315

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NOTICE

If the red warning light has been activated do not perform a back pressure test. Clean the DPF. If the DPF is not cleaned, the filter assembly could undergo uncontrolled regeneration. This will damage the DPF.

Caterpillar recommends a log of information for the cleaning of the DPF. Refer to Table 3 for an example of a log for the cleanings. Perform a back pressure test prior to the cleaning of the DPF. Record the results. After cleaning the DPF, run the engine at high idle for 5 to 15 minutes. Perform another back pressure test and record the results.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

Follow the recommended procedure for having the DPF cleaned.

Perform a back pressure test prior to having the DPF cleaned. Record the results. Refer to ""Testing the Diesel Particulate Filter" " for the proper procedure.

Label the inlet side of the filter module for the filter DPF. The filter module must be reinstalled in the correct direction of flow.

Remove the access cover for the silencer DPF in order to access the filter modules. The silencer's filter modules do not need to be labeled since they can only be assembled in one direction.

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Illustration 11	g01258520
Top view of the DPF filter modules

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Illustration 12	g01258527
Inside the silencer DPF

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Illustration 13	g01258530
DPF filter module

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Illustration 14	g01156443
(1) V-band clamp (2) Filter module (3) Gasket (4) Sleeve

Loosen V-band clamp (1) for filter module (2). Carefully remove the filter from the filter's sleeve (4). Be careful not to damage the clamp.

Inspect the outlet side of the filter module. The outlet side should be white in color. Replace the filter if there are black deposits on the outlet side. Inspect the filter for internal damage or external damage. If there is damage, replace the filter.

Contact the Caterpillar Call Center at 309-636-8500 for shipping instructions of the filter modules that need to be cleaned.

When you reinstall the filter assembly, use a new gasket (3). When you tighten the V-band clamp, tap the clamp with a hammer for every quarter of a turn of the bolt.
Torque for the V-band clamp ... 22.6 N·m (200 lb in)

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Illustration 15	g01148968
Example of the tightening sequence for the access cover

Install the access cover on the silencer DPF. Use a new gasket. Evenly tighten the bolts in a spiral pattern for the access cover. Refer to Illustration 15. Evenly tighten the bolts again in a spiral pattern for the access cover.
Torque for the bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

Reset the diagnostic module if any alarms have been activated.

Perform a back pressure test after the DPF is cleaned. Record the results. Refer to ""Testing the Diesel Particulate Filter" " for the procedure.

The DPF is dirty.

Clean the DPF. Refer to ""Cleaning the Diesel Particulate Filter" " for the proper procedure.

Use 198-4240 Digital Pressure Indicator or 1U-5470 Engine Pressure Group in order to test the back pressure of the DPF. Refer to ""Testing the Diesel Particulate Filter" " for the proper procedure. Check the engine specifications for back pressure limits.

Smoke that is blue in color indicates that hydrocarbons are passing through the DPF. The DPF can remove most hydrocarbons under normal conditions. An engine that is not running properly or an engine that has a bad injector can produce large amounts of hydrocarbon emissions. The DPF will be unable to oxidize all of the hydrocarbon emissions.

Correct the timing and/or the injectors

Black smoke indicates that the DPF has been damaged. Remove the filter DPF from the exhaust system and inspect the outlet face of the filter modules. On a silencer DPF, remove the access panel and inspect the outlet face of the filter modules. If black spots are seen on the outlet face, then the filter modules are damaged and the filter must be replaced.

Replace the filter modules.

The excessive accumulation of soot is not a normal occurrence and the result can be from many different problems.

Check the following items if an excessive amount of soot is found on the filter module of the DPF.

Check the engine in order to ensure that an abnormal condition has not occurred.
Verify that the operating temperature is not too low.
Verify that the correct fuel type is being used.
Verify that the fuel has the correct sulfur concentration.
Verify that the emission levels are not higher than the certification of the engine.
Verify that the fuel injectors are not damaged and that the fuel injectors are functioning properly.
Verify that the turbocharger has not failed.
Verify that the turbocharger does not have any oil leaks.
Verify that the piston rings are not damaged or broken.
Verify that there are no leaks at the valve stems.

The excessive buildup of soot will cause the filter modules of the DPF to plug. Plugging of the DPF can cause damage to the system.

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Table 4
Filter Quantity Selection Table
Engine	Horsepower Rating	Exhaust Gas Flow	Recommended Filter Quantity
3508	390 to 600 kW (523 to 805 hp)	4178 to 5000 Kg/hr (1895 to 2268 lb/hr)	2
3508	610 to 900 kW (818 to 1207 hp)	5010 to 5815 Kg/hr (2273 to 2638 lb/hr)	3
3508B	520 to 600 kW (697 to 805 hp)	3830 to 5000 Kg/hr (1737 to 2268 lb/hr)	2
3508B	610 to 1050 kW (818 to 1408 hp)	5010 to 6795 Kg/hr (2272 to 3082 lb/hr)	3
3512	840 to 1050 kW (1126 to 1408 hp)	4769 to 6300 Kg/hr (2163 to 2858 lb/hr)	3
3512	1060 to 1250 kW (1421 to 1676 hp)	6310 to 7821 Kg/hr (2862 3548 lb/hr)	4
3512B	890 to 1050 kW (1193 to 1408 hp)	6107 to 7240 Kg/hr (2770 to 3284 lb/hr)	3
	1060 to 1320 kW (1421 to 1770 hp)	7250 to 9100 Kg/hr (3289 to 4128 lb/hr)	4
	1330 to 1545 kW (1784 to 2072 hp)	9100 to 10500 Kg/hr (4128 to 4763 lb/hr)	5
3516	980 to 1050 kW (1314 to 1408 hp)	6108 to 6510 Kg/hr (2771 to 2953 lb/hr)	3
	1060 to 1320 kW (1421 to 1770 hp)	6520 to 8320 Kg/hr (2957 to 3774 lb/hr)	4
	1330 to 1640 kW (1784 to 2199 hp)	8330 to 10560 Kg/hr (3778 to 4790 lb/hr)	5
	1650 to 1750 kW (2213 to 2347 hp)	10570 to 11380 Kg/hr (4794 to 5162 lb/hr)	6
3516B	1145 to 1320 kW (1535 to 1770 hp)	6789 to 7790 Kg/hr (3079 to 3533 lb/hr)	4
	1330 to 1640 kW (1784 to 2199 hp)	7800 to 9680 Kg/hr (3538 to 4391 lb/hr)	5
	1650 to 2000 kW (2213 to 2682 hp)	9690 to 11800 Kg/hr (4395 to 5352 lb/hr)	6
	2000 to 2250 kW (2682 to 3017 hp)	11810 to 13370 Kg/hr (5357 to 6065 lb/hr)	7

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Table 5
Part Number Description Table
Part Quantity	Part Number	Description
1	266-0044	Diagnostic module Required for all DPF part numbers
Filter Quantity	Part Number	Description
1	266-0040	DPF Filter Assembly 305 mm (10 inch) diameter axial inlet and outlet-SS
2	266-0039	DPF Filter Assembly 406 mm (16 inch) diameter axial inlet and outlet-SS

2	266-0038	DPF Silencer Assembly 406 mm (16 inch) diameter axial inlet and outlet-CS
2	266-0037	DPF Silencer Assembly 406 mm (16 inch) diameter axial inlet and outlet-SS
2	266-0036	DPF Silencer Assembly 406 mm (16 inch) diameter bottom inlet and top outlet-CS
2	266-0035	DPF Silencer Assembly 406 mm (16 inch) diameter bottom inlet and top outlet-SS

3	266-0034	DPF Silencer Assembly 406 mm (16 inch) diameter axial inlet and outlet-CS
3	266-0033	DPF Silencer Assembly 406 mm (16 inch) diameter axial inlet and outlet-SS
3	266-0032	DPF Silencer Assembly 406 mm (16 inch) diameter bottom inlet and top outlet-CS
3	266-0031	DPF Silencer Assembly 406 mm (16 inch) diameter bottom inlet and top outlet-SS

4	266-0030	DPF Silencer Assembly 457 mm (18 inch) diameter axial inlet and outlet-CS
4	266-0029	DPF Silencer Assembly 457 mm (18 inch) diameter axial inlet and outlet-SS
4	266-0028	DPF Silencer Assembly 457 mm (18 inch) diameter bottom inlet and top outlet-CS
4	266-0027	DPF Silencer Assembly 457 mm (18 inch) diameter bottom inlet and top outlet-SS

5	266-0026	DPF Silencer Assembly 457 mm (18 inch) diameter axial inlet and outlet-CS
5	266-0025	DPF Silencer Assembly 457 mm (18 inch) diameter axial inlet and outlet-SS
5	266-0024	DPF Silencer Assembly 457 mm (18 inch) diameter bottom inlet and top outlet-CS
5	266-0023	DPF Silencer Assembly 457 mm (18 inch) diameter bottom inlet and top outlet-SS

6	266-0022	DPF Silencer Assembly 508 mm (20 inch) diameter axial inlet and outlet-CS
6	266-0021	DPF Silencer Assembly 508 mm (20 inch) diameter axial inlet and outlet-SS
6	266-0020	DPF Silencer Assembly 508 mm (20 inch) diameter bottom inlet and top outlet-CS
6	266-0019	DPF Silencer Assembly 508 mm (20 inch) diameter bottom inlet and top outlet-SS

7	266-0018	DPF Silencer Assembly 508 mm (20 inch) diameter axial inlet and outlet-CS
7	266-0017	DPF Silencer Assembly 508 mm (20 inch) diameter axial inlet and outlet-SS
7	266-0016	DPF Silencer Assembly 508 mm (20 inch) diameter bottom inlet and top outlet-CS
7	266-0015	DPF Silencer Assembly 508 mm (20 inch) diameter bottom inlet and top outlet-SS

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Table 6
Serviceable Parts
DPF Part No	Filter Module Part No	Quantity of Filters Needed	Clamp Part No	Quantity of Clamps Needed	Gasket Part No	Quantity of Gaskets Needed	Access Panel Gasket Part No
266-0040	266-0043	1	266-0046	2	268-3898	2
266-0039	266-0043	2	266-0046	4	268-3898	4

266-0038	266-0041	2	266-0045	2	268-3897	2	273-2501
266-0037	266-0041	2	266-0045	2	268-3897	2	273-2501
266-0036	266-0041	2	266-0045	2	268-3897	2	273-2501
266-0035	266-0041	2	266-0045	2	268-3897	2	273-2501

266-0034	266-0041	3	266-0045	3	268-3897	3	273-2501
266-0033	266-0041	3	266-0045	3	268-3897	3	273-2501
266-0032	266-0041	3	266-0045	3	268-3897	3	273-2501
266-0031	266-0041	3	266-0045	3	268-3897	3	273-2501

266-0030	266-0041	4	266-0045	4	268-3897	4	273-2502
266-0029	266-0041	4	266-0045	4	268-3897	4	273-2502
266-0028	266-0041	4	266-0045	4	268-3897	4	273-2502
266-0027	266-0041	4	266-0045	4	268-3897	4	273-2502

266-0026	266-0041	5	266-0045	5	268-3897	5	273-2503
266-0025	266-0041	5	266-0045	5	268-3897	5	273-2503
266-0024	266-0041	5	266-0045	5	268-3897	5	273-2503
266-0023	266-0041	5	266-0045	5	268-3897	5	273-2503

266-0022	266-0041	6	266-0045	6	268-3897	6	273-2504
266-0021	266-0041	6	266-0045	6	268-3897	6	273-2504
266-0020	266-0041	6	266-0045	6	268-3897	6	273-2504
266-0019	266-0041	6	266-0045	6	268-3897	6	273-2504

266-0018	266-0041	7	266-0045	7	268-3897	7	273-2507
266-0017	266-0041	7	266-0045	7	268-3897	7	273-2507
266-0016	266-0041	7	266-0045	7	268-3897	7	273-2507
266-0015	266-0041	7	266-0045	7	268-3897	7	273-2507

Record of Cleaning

Model Number Of DPF

Serial Number Of Filter

Engine Identification Number

Back Pressure Before Cleaning

Back Pressure After Cleaning

Engine Hours At Cleaning

Technician's Name

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Illustration 16	g01161284
Silencer dimensions Refer to Table 7

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Table 7
Reference Dimensions of the Silencer DPF
DPF Part Number	A	B	C	D	E	F	G	H	Weight
266-0038	2692.4 mm (106 inch)	571.5 mm (22.5 inch)	1079.5 mm (42.5 inch)	1879.6 mm (74 inch)	2108.2 mm (83 inch)	330.2 mm (13 inch)	127.0 mm (5 inch)	685.8 mm (27 inch)	795 kg (1750 lb)
266-0037
266-0036	2438.4 mm (96 inch)
266-0035
266-0034	2692.4 mm (106 inch)	571.5 mm (22.5 inch)	1079.5 mm (42.5 inch)	1879.6 mm (74 inch)	2108.2 mm (83 inch)	330.2 mm (13 inch)	127.0 mm (5 inch)	685.8 mm (27 inch)	840 kg (1850 lb)
266-0033
266-0032	2438.4 mm (96 inch)
266-0031
266-0030	2997.2 mm (118 inch)	571.5 mm (22.5 inch)	1587.5 mm (62.5 inch)	2286.0 mm (90 inch)	2387.6 mm (94 inch)	355.6 mm (14 inch)	127.0 mm (5 inch)	685.8 mm (27 inch)	953 kg (2100 lb)
266-0029
266-0028	2743.2 mm (108 inch)
266-0027
266-0026	2997.2 mm (118 inch)	571.5 mm (22.5 inch)	977.9 mm (38.5 inch)	2133.6 mm (84 inch)	2387.6 mm (94 inch)	355.6 mm (14 inch)	127.0 mm (5 inch)	1143.0 mm (45 inch)	1565 kg (3450 lb)
266-0025
266-0024	2743.2 mm (108 inch)
266-0023
266-0022	2997.2 mm (118 inch)	571.5 mm (22.5 inch)	1308.1 mm (51.5 inch)	2463.8 mm (97 inch)	2362.2 mm (93 inch)	381.0 mm (15 inch)	127.0 mm (5 inch)	1143.0 mm (45 inch)	1905 kg (4200 lb)
266-0021
266-0020	2743.2 mm (108 inch)
266-0019
266-0018	4419.6 mm (174 inch)	1473.2 mm (58 inch)	571.5 mm (22.5 inch)	2438.4 mm (96 inch) ⁽¹⁾ 2590.8 mm (102 inch) ⁽²⁾	3784.6 mm (149 inch)	381.0 mm (15 inch)	127.0 mm (5 inch)	863.6 mm (34 inch)	2177 kg (4800 lb)
266-0017
266-0016	4165.6 mm (164 inch)
266-0015

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^( 1 )	Without Supports
^( 2 )	With Supports

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Illustration 17	g01161285
266-0040 One filter DPF Refer to Table 8

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Illustration 18	g01161286
266-0039 Two filter DPF Refer to Table 8

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Illustration 19	g01161289
266-0043 Filter module Refer to Table 8

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Illustration 20	g01161288
266-0041 Silencer filter module Refer to Table 8

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Table 8
Reference Dimensions
Part Number	Description	A	B
266-0040	One Filter DPF	669.1 mm (26.3 inch)	419.1 mm (16.5 inch)
266-0039	Two Filter DPF	1734.8 mm (68.3 inch)	889.0 mm (35 inch)
266-0043	Filter Module	598.6 mm (23.5 inch)	419.1 mm (16.5 inch)
266-0041	Silencer Filter Module	391.3 mm (15.4 inch)	475.5 mm (18.7 inch)