Compact DPF Cleaner{0599, 0701, 0702, 108F} Caterpillar

Caterpillar Products: All

Introduction

Important Safety Information

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Think Safety

Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.

The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.

Literature Information

This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group.

Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Cat Dealer Service Tools (DST) for the latest available information.

Safety Section

The Safety Section lists basic safety precautions.

Read and understand the basic precautions listed in the Safety Section before operating or performing maintenance and repair on this service tool.

General Information Section

The General Information Section describes tooling functions and features. This section provides useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation Section is a reference for the new operator and a refresher for the experienced operator.

Photographs and illustrations guide the operator through correct procedures for using the tool group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and tool capabilities.

Maintenance Section

The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal

Safety Section

Safety Icon Nomenclature

Personal Protection/Important Information

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Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.

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Personal Protection/Important Information

Prohibited Action

Do not drill

Do not weld

Hazard Avoidance

Crushing hazard

Electrical hazard

Pinch point

Safety alert symbol

General Information Section

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The Compact DPF Cleaner

Additional Contact Information

For additional product support questions concerning this tool, contact the Cat Dealer Service Tools Hotline at:

USA: 1-800-542-8665, Option 1

International: 1-309-578-7372

Fax: 1-309-494-1355

Email: dealerservicetool_hotline@cat.com

Note: Continuing improvement and advancement of product design can mean some photographs or illustrations in this publication will show details that are different from your service tool.

Note: Dealers ordering the 364-5971 Compact DPF Cleaner have the option of ordering the 376-4807 Vacuum and 376-4808 HEPA Filter . Customers ordering this option will have the cleaner and vacuum/filter bundled in the same shipping container. To ensure compliance with California law, customers must use a HEPA filter that collects all of the particulates. Our 376-4807 Vacuum and 376-4808 HEPA Filter meets this requirement. Other jurisdictions may require the use of a HEPA Filter or may otherwise apply additional requirements to the cleaner. Dealers and customers are responsible for obtaining their own legal advice regarding the operation of the cleaner in their respective jurisdictions and the proper disposal of ash.

Nomenclature

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The components of the control panel. (1) Ready Light (2) Complete Light (3) Fault Light (4) Stop Button (5) Start Button (6) Vacuum Button (7) Hour Meter (8) Selector Switch (9) Alarm Horn

Ready Light

The Ready Light (1) illuminates when three requirements are met.

• Electrical power is connected.

• Proper air pressure is connected.

• Interlock is connected.

The light flashes when the cleaning process is stopped before completion of program.

Complete Light

The Complete Light (2) illuminates when a program has completed.

Fault Light

The Fault Light (3) illuminates when one of the two following conditions occurs.

• The blade is obstructed and stops rotating, causing a slow flash and slow alarm pulse. Blade obstruction sensing is started 15 seconds after program starts and performed at 5 second intervals.

• Low air pressure, less than 75 psi, causing a fast flash and alarm pulse.

Alarm Horn

The Alarm Horn ( 9 ) signals a fault or the end of a program.

• Alarm Horn sounds for 30 seconds at the end of the cleaning process.

• Alarm Horn sounds when a fault is detected, continuing until stop button is pressed.

Start Button

The Start Button (5) begins a program and turns off the Ready Light.

Stop Button

The Stop Button (4) is used to perform many actions in the cleaning process.

When the button is pushed for the first time, the following actions will occur:

• Stops the cleaning process anywhere in the cycle.

• Causes the Ready Light to flash when pressed during a cleaning process.

• Resets the program at the end of a cleaning process.

• Turns off the Process Complete Light.

• Turns on the Ready Light if no fault is detected.

• Turns off the Alarm and the Fault Light after a fault is detected.

• Starts the under body air blast; one air blast for five seconds.

Pushing the Stop Button a second time will reset the cleaning program.

Vacuum Button

The Vacuum Button (6) is used at the end of a cleaning program to prevent escape of ash during filter removal.

Note: The vacuum should not be run during a cleaning program. Running the vacuum during a cleaning program will cause premature vacuum filter failure.

Pushing the button once starts a two-minute vacuum process.

Pushing the button twice will stop the vacuum process and reset the vacuum process before the process is complete.

Hour Meter

The Hour Meter (7) counts the time the DPF Cleaner runs in tenths of an hour.

Operation Section

Pre-Use Inspection

The inspection steps below should be performed before each day's operation:

1. Inspect the neoprene ring for wear and tears. Replace as needed.

2. Check for cracks and wear in all electrical cords. Replace as needed.

3. Inspect all air lines for cracks, wear, and leaks. Replace or repair as needed.

4. Inspect air filter and regulator for leaks, cracks, and water. Clean as needed.

5. Inspect straps for rips, frays, and wear. Replace as needed.

Setup Procedures

The setup of the compact DPF cleaner is as follows:

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1. Place the DPF cleaner on a sturdy and level surface.

2. Loosen the tie straps and remove the lid from the canister.

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3. Select the proper Neoprene ring seal.
   • For DPF's with a canister diameter of 400 mm - 325 mm, use the large ring.

   • For DPF's with a canister diameter of 325 mm - 235 mm, use the medium ring.

   • For DPF's with a canister diameter of 235 mm - 165 mm, use the small ring, including the metal supporting ring.

   Note: The thumb knobs holding the neoprene ring seal may become loose after time. Periodic tightening may become necessary.

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4. Gently place and center the DPF into the stretch Neoprene sealing ring with the exhaust exit end in the upward position.

   Note: Be sure that the Neoprene ring is sealing against the canister body.

5. Accurately measure the outer most diameter of the DPF using the tape measure from the case.

6. Also measure the depth of the DPF substrate from the top edge of the can. If the depth is deeper than 87.5 mm (3.44 in.), use the long reach nozzle package. (Refer to section entitled Long Reach Nozzle Package.)

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7. Assemble the legs onto the fixture and lock them into position at the distance measured with the tape measure.

   Use this edge to determine the location of the leg based on the measurement taken from the filter (A) .

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8. Set the tripod setting gauge on the top approximate center of the DPF.

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9. Set the fixture on top of the gauge and slide the feet down onto the lip of the DPF. Lock them, centered and evenly into place.

10. Remove the fixture and gauge from the DPF.

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11. Select the longest nozzle arm that will clear the legs of the fixture and connect it onto the spindle shaft using an "align, push, and twist" procedure.

    Note: Make sure that the mating parts are free from debris.

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12. Screw the nozzle onto the arm. A tool (A) is provided to fasten the nozzle into place.

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13. Snap the nozzle puck onto the nozzle.

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14. Prior to installing the upper air knife, install the neoprene shroud over the DPF. There are 2 sizes available. It is important to choose a size that fits tightly over the DPF. Select the proper size shroud based on the following DPF measurements.
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    Table 1

    DPF Measurement	Velcro Color
    400 mm - 285 mm (15.75 inch - 11.22 inch)	Beige
    285 mm - 165 mm (11.22 inch - 6.50 inch)	White

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15. Place the shroud over the DPF with the Velcro facing up and the beige/white strip toward the control box.

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16. Position the fixture on top of the DPF with connecting receptacles pointing towards the control box.

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17. Rotate the nozzle arm so the drive disc that is located on the end of the arm is off the three cam blocks. This allows the drive disk to be turned by hand to adjust the starting location of the Nozzle.

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18. Manually rotate the drive disc counterclockwise until the nozzle and puck are as far out as possible without touching the canister inner wall, flange wall, or until the puck is fully rested in the filter substrate. Insure that all areas clear by rotating the arm one full revolution.

19. Rotate the nozzle arm by hand until the arm snaps back into the spindle drive detent.

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20. Inspect the puck to ensure that there is not a bind and that it is fully rested on the filter substrate.

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21. Attach the elbow to the polycarbonate panel of the Containment Hood.

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22. Place the panel on top of the fixture.

23. Attach an ash collection source to the elbow.

    Note: We recommend purchasing the 376-4807 HEPA Vacuum Cleaning Kit from your local dealer (US and Canada), or any HEPA-Rated Vac that produces 203.2 cm (80 in) static pressure and 100 CFM air flow.

24. Measure the diameter of the filter substrate (ceramic portion of the filter). Retain this measurement for the Program Selection Guide in the Cleaning Procedure section.

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25. Pull the neoprene shroud up and attach it to the Velcro fastener on the polycarbonate panel. (A) Raise the shroud and attach the beige/white Velcro strip to the flat side of the Hood. Secure the three straps onto the fixture. (B)

    Note: Be sure that all three straps are applied with equal tension.

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26. Attach the 2-pin wire lead from the control box onto the strap buckle receptacle. This completes the interlock feature.

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27. Draw together the slots where the straps go through using the Velcro tabs. This helps seal the slots and reduces the possibility of leakage.

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28. The finished assembly should look like this illustration when complete.

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29. Attach the 4-pin wire lead from the control box onto the motor fixture (A) .

30. Attach the quick connect air line lead from the valve onto the fixture (B) .

    Note: Carefully check that all wires and hoses are out of the rotation range of the nozzle arm.

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31. Attach a compressed air line into the pneumatic filter/regulator input. Be sure that there is 100 psi sustained compressor capability. A 3/8 minimum I.D. hose size will be needed. The air must be clean and free from moisture.

32. Select the preferred input voltage cord and attach it onto the control box and into the power source.

    This completes the setup procedure.

Cleaning Procedure

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1. Open the cover of the control box. The READY light should show illuminated.

2. Select the appropriate program from the Program Selection Guide determined by the diameter size of the ceramic filter substrate.
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   Table 2

   Program Selection Guide
   Select:	When Cleaning:
   1	360 mm - 330 mm
   2	330 mm - 305 mm
   3	305 mm - 267 mm
   4	267 mm - 216 mm
   5	216 mm - 152 mm

3. Begin the cleaning procedure by activating the containment hood.

4. Press the START button on the panel.

Note: Observe the cleaning process during the first minute of operation. If there appears to be ash blowing out the top of the Diesel Particulate Filter, stop the cleaning process. The ash could be an indication that the Diesel Particulate Filter is cracked. Refer to the DPF Reuse Guide SEBF9223 or SEBF9167.

5. Press the STOP button after the program has run its process and the COMPLETE light has been illuminated.
   • To stop the process before completion, press the STOP button.

   • To resume the process at the point at which it was stopped, press the START button a second time.

   • To reset the process program to the beginning, press the STOP button twice.

Operation

Note: Upon starting a cycle, the nozzle arm will rotate at a higher rate of speed until the controller senses the correct speed. The speed will take up to 1 minute to stabilize.

Note: The procedure will stop and programs will return to default if electrical power or interlock are interrupted. Reposition the nozzle to starting point and restart the cleaning procedure.

The following action may be performed during a cleaning procedure.

• Press the Stop Button to pause the procedure at anytime.

• Press the Start Button to resume the procedure.

• Press the Stop Button a second time to reset the procedure.

• Press the Stop Button when the procedure has completed and the Complete Light is illuminated to reset program.

Panel Button and Light Functions

Ready Light

Illuminates when three requirements are met:

• Electrical power is connected

• Air pressure is connected

• Interlock is connected

Flashes when the:

• Cleaning process is manually stopped before the end of the program.

Complete Light

Illuminates when the cleaning process is complete.

Fault Light

Illuminates when the:

• Blade is obstructed and stops rotating - slow flash + alarm sound.

• Low air pressure <75psi - fast flash + alarm sound.

Stop Button

1st push:

• Stops the cleaning process anywhere in the cycle.

• Flashes the Process Ready Light when stopped in the middle of the cleaning process.

• Resets the program at the end of the cleaning process.

• Turns off the Process Complete Light.

• Turns on the Process Ready Light if no fault is detected.

• Turns off the Alarm and the Fault Light after a fault is detected.

• Starts the under body air blast - 3 times for 5 seconds.

2nd push

• Resets the cleaning program.

• Starts the under body air blast - 3 times for 5 seconds.

Start Button

One push:

• Starts the cleaning process.

• Turns off the Ready light.

Vacuum Button

1st push:

• Starts the ash control process - 2 minute duration.

2nd push:

• Stops and resets the process before the 2 minute process is finished.

Hour Meter

Begins the count when the cleaning process is running.

Selector Switch

Selects the program based on the diameter of the filter substrate:

1. 360mm - 330mm

2. 330mm - 305mm

3. 305mm - 267mm

4. 267mm - 216mm

5. 216mm - 152mm

Alarm

Sounds at the end of the cleaning process - 30 seconds.

Sounds when a fault is detected - until the stop button is pressed.

Notes of Interest

1. After the process is complete, an alarm will sound for 30 seconds and the COMPLETE light will illuminate until the STOP button is pressed.

2. During the process, the nozzle will rotate to the center of the DPF and dwell there until the program times out.

3. At the end of the process, 3 - five second blasts of compressed air will blow the underside of the filter removing any hanging ash. Any stopping of the process short of the program completion allows for this blast to take place as well.

4. The FAULT light will flash when a fault occurs.

   There are two fault detections:

   1. Blade obstruction = Slow flash

   2. Low air pressure = Fast flash

5. A fault will stop the process. Press the STOP button to reset the lights and the alarm. Once the problem is fixed, press the START button to resume the process.

6. The Low Pressure Sensor is set to 75 psi.

7. Blade obstruction sensing is engaged 15 seconds after the START button is pressed and monitored every 5 seconds thereafter.

8. The vacuum timer is set for 2 minutes. Pressing the VACUUM button once allows the operator to remove the DPF, minimizing floating ash. Pressing the VACUUM button during the 2 minute timed cycle will stop the process.

9. The canister lid may be used to protect the DPF from unexpected rain. Simply engage the pin on the underside of the lid into the pin hole that is located on the top of the motor enclosure.

10. The operation will stop and the program setting will default to its beginning when the electrical input or the interlock buckle is interrupted. Positioning the nozzle back to the beginning and starting the process again is then recommended.

11. Pressing the STOP button once during the cleaning cycle will pause the process. The READY light will show flashing. Pressing the START button will resume the process where it left off.

12. Pressing the STOP button twice during the cleaning cycle will stop the process and reset the program to its beginning. The READY light will show illuminated.

13. The thumb knobs holding the Neoprene ring seal may become loose after time. Periodic tightening may become necessary.

14. Be sure that the DPF cleaner never operates without an ash liner bag inside the canister.

15. Upon starting a cycle, the nozzle arm will rotate at a higher rate of speed until it senses its correct speed and starts a descent from there. This will take up to 1 minute to stabilize.

16. During the cycle, the nozzle puck rests directly on the filter substrate. This is intended to ensure a clean, quiet, and efficient process. Should the puck suspend itself from the substrate, seat it back onto the surface.

Teardown Procedure

1. Remove the cords and straps from the fixture.

2. Remove the containment hood from the fixture.

3. Remove the fixture from the DPF.

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4. Using a compressed air nozzle, lightly blow through the top of the DPF covering the full area of the substrate face. This exercise dislodges the ash that clings to the underside of the DPF.

5. Press the VACUUM button and remove the DPF from the cleaner within two minutes from pressing the button.

6. Wait until the vacuum function times out, or press the VACUUM button to stop short of the two-minute timeout before placing the lid onto the canister.

7. Replace the lid and secure it onto the canister with the straps to avoid escaping ash.

Maintenance Schedule

HEPA Filter Change Instructions

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366-6781 HEPA Filter Change Kit

Use the 366-6781 HEPA Filter Change Kit . Included in the kit are the HEPA Filter, Disposal Bag, and Respiratory Mask.

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1. Remove the canister from the unit by unscrewing the Retainer Nut.

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2. Slowly and gently tip the used filter into the Disposal Bag.

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3. Double seal the Disposal Bag as shown.

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4. Install the new HEPA filter with the large opening down onto the bottom of the canister.

5. Seat the canister onto the unit and screw the Retainer Nut back into place.

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6. Check for gaps between the sealing surfaces.

7. Vacuum clean the DPF Cleaner and the surrounding area as needed.

8. Dispose of the ash and used filter according to Federal, State, and local regulations.

Ash Bag Change Instructions

Use the 366-6780 Ash Bag Change Kit . Contents of the Ash Bag Kit include, Ash Bag, zip-lock bag, Sealing Cap, and respiratory mask.

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1. Disconnect the air lines from the intermediate ring and unclamp the ring from the canister.

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2. Simultaneously rotate counterclockwise and lift the intermediate ring from the canister.

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3. Remove the backing from the Sealing Cap and adhere to the top of the Ash Bag.

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4. Remove the Ash Bag from the canister.

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5. Slowly and gently press the air from the changed out Ash Bag.

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6. Insert and seal the compressed Ash Bag into the zip-lock bag.

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7. Install the new Ash Bag into the canister making sure that the bag is evenly folded around the outside edge of the canister.

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8. Reinstall the intermediate ring, hoses, and clamp onto the canister assuring a tight seal to the Ash Bag.

9. Vacuum clean the DPF Cleaner and surrounding area as needed.

10. Dispose of the Ash according to Federal, State, and local regulations.

Long Reach Nozzle Package

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• The Long Reach Nozzle Package is to be used when cleaning filters having substrate depths greater than 87.5 mm (3.44 in).

• Leg Extensions (A) affix to gauge when setting Long Reach Nozzle.

• DO NOT use on filters having substrate depths of 87.5 mm (3.44 in) and less.