- Caterpillar Products: All
Introduction
Important Safety Information
 | |
| Illustration 1 | g02139237 |
Think Safety | |
European Union Compliant, CE marked
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 Tool Operating Manual.
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 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. The 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 the tools capabilities.
Maintenance Section
The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal
Service Parts Section
The Service Parts Section is a reference for parts identification and available part numbers.
Safety Icon Nomenclature
Personal Protection/Important Information
 | |
| Illustration 2 | g02166423 |
Personal Protection/Important Information | |
Prohibited Action
| No Smoking |
Hazard Avoidance
| Crushing Hazard (foot) |
| Crushing Hazard (hand) |
| Pinch Point |
| Fire Hazard |
| Electrical Shock - Hazard |
|
| Fire Hazard |
General Information
Introduction
This tool operating manual provides operation and maintenance information for the 319-2187 Diesel Particulate Filter Cleaner , which is used to clean after-treatment diesel particulate filters (DPFs).
The DPF cleaner is a mobile unit designed to quickly clean diesel particulate filters using compressed air (shop supplied). Adapters allow the cleaning of several different model diesel particulate filters. Pressurized air is pulsed to more effectively remove ash deposits from the DPF.
Filtered air passes through a separate, replaceable HEPA filter before being discharged from the unit.
A power cord (110V, 15 Amp) connects to shop electricity to operate the vacuum filter, on-board microprocessor, and keypad controls.
An optional printer (to be announced) can be set up to print out test results each time a cleaning cycle is completed.
Increased back pressure in the ash collection tank triggers an automatic reverse cleaning process that uses small air bursts passing backward through the cartridge filters. to remove ash from the filter media and prolong cartridge life.
The DPF cleaner features serviceable coalescing and desiccant air filters to remove oil and dry the incoming air before it enters the unit.
Additional Contact Information
DPF Technical Support Line: 1-800-822-5561
For additional product support questions concerning this tool, contact Dealer Service Tools Hotline at:
USA: 1-800-542-8665, Option 1
International: 1-309-578-7372
Operation Section
 | |
| Illustration 3 | g02728148 |
(1) On/Off Button (2) Control Panel (3) Inlet Air Fitting (4) Coalescer Filter Assembly (5) Desiccant Filter (6) Wheel Lock (7) Vacuum Cleaner Chamber (8) Air Tank (9) Hand Pump Lever (10) Table Lift Cylinder (11) Control Knob (12) Pressure Chamber Door (13) Hand Pump Fill Cap (14) Circuit Breaker Panel (15) HEPA Filter | |
Setup
- Position the cleaner in a well ventilated location close to a shop air supply and electrical power supply. Lock brakes (6) on the two caster wheels by stepping on the side of the paddle marked ON.
- Plug the power cord from the DPF cleaner into a 110V, 15 AMP outlet. If an extension cord is necessary, use the shortest possible cord with a minimum size of 14 AWG.
- Connect shop air [827 kPa (120.0 psi) minimum] to inlet sir fitting (3) located on the end of the machine.
Note: An airline pressure of 827 to 1034 kPa (120.0 to 150.0 psi) is recommended to provide an optimum tank fill rate.
- Pull out ON/OFF button (1) on control panel (2). The display briefly shows the software version of the unit.
- The unit verifies that an air supply has been connected, and the display message prompts the user to verify the air filter/dryer does not need maintenance.
Note: If the service indicator on the coalescing filter is red, or if the color indicator beads in the desiccant are pink, refer to the ""Maintenance Section" " of this manual for replacement instructions.
Control Panel (2)
- Green LED
Unit is functioning normally.
- Red LED
Process needs attention.
- Digital Display
Visual interface between operator and machine.
- STOP/NO Button
Terminate or pause a function, or answer a query.
- Number Keys
Make selections or enter data.
- MENU/Arrow Keys
Open main Menu and scroll through menu items.
- GO/YES Button
Begin or resume a function, or answer a query.
- Green LED
 | |
| Illustration 4 | g02728155 |
(a) Green LED (b) Red LED (c) Digital Display (d) STOP/NO Button (e) Number Keys (f) Arrow Keys (g) GO/YES Button | |
- Press MENU (2f) to open the Main Menu Screen. The Main menu is displayed on two screens. Press DOWN arrow (2f) to move between screens. Press keypad number key (2e) to make a specific selection.
Main Menu
 | |
| Illustration 5 | g02728164 |
- Vacuum
Allows the operator to use the vacuum for cleaning purposes. Use this selection to turn the vacuum ON or OFF.
- Setup
The Setup Menu is displayed on three screens. Press DOWN arrow (2f) to move between screens. Press keypad number key (2e) to make a specific selection.
Note: For more information on setup functions, refer to the ""Setup Menu" " section in this manual.
- Clean
Opens the cleaning protocol screens. Allows the operator to program the cleaning cycle after a DPF is loaded into the cleaner.
Note: For more information on cleaning functions, refer to the ""Cleaning Cycle" " section in this manual.
- Version
Displays the current version of software loaded on the DPF cleaner microprocessor.
Setup Menu
 | |
| Illustration 6 | g02728170 |
- Printer
Set up printer (to be announced) to print out test results each time a cleaning cycle is completed.
Note: Configure the printer DIP switches as follows: Switch 1 - all OFF, Switch 2 - 1 and 8 ON.
- Printer
Select a language for the display prompts.
- Units
Choose units of measure (English or Metric) for test result display.
- Set Date/Time
Enter the current date and time into the unit memory for printouts each time a cleaning cycle is competed.
Note: The software does not automatically adjust for Daylight Savings Time (DST).
- Edit System Text
Enter text (8 lines-20 characters per line) that will appear at the top of each printout.
Note: In order to save text that has been entered, "Save Entry?" must be answered by selecting GO/YES (2g) before moving to the next line.
- Set Contrast
Press UP or DOWN arrow (2f) to adjust brightness of text on display screen.
- Main Menu
Return to the Main Menu.
- Beeper
Use arrow keys (2f) to turn display screen beeper ON (left arrow) or OFF (right arrow).
Loading the Filter
- Remove the diesel particulate filter (DPF) from the vehicle according to appropriate OE technical manuals or bulletins regarding DPF service.
- Inspect the DPF, using appropriate OE technical procedures, to verify that it is cleanable and reusable.
- The diesel oxidation catalyst and the diesel particulate filter housing must be free of dents.
- Mounting flanges must be free of dents, cracks, or gouges in order to seal correctly with the gaskets.
- DPF filters must not be plugged as a result of excessive fluids in the exhaust system, such as coolant, fuel, or oil.
Diesel particulate filters that do not pass these criteria should be replaced and not cleaned.
- The diesel oxidation catalyst and the diesel particulate filter housing must be free of dents.
- Unlatch and open the doors on the DPF cleaner pressure chamber.
| NOTICE |
|---|
To prevent equipment damage, inspect the DPF to verify that it is not plugged with soot, oil, fuel, or any other substance which might obstruct the cleaning process. |
 | |
| Illustration 7 | g02728171 |
- Measure outer diameter (A) of the DPF V-band flange. Find that measurement in Table 1 Caterpillar DPF Sizes and Adapters to determine the correct cone and adapters for the application.
 | |
| Illustration 8 | g02728174 |
(A) Diameter of DPF V-Band Flange | |
- Make sure DPF cleaner table (16) is free of dust and debris. Place correct lower adapter (17) on the table with the edge of the adapter in the hole in the table. The adapter ring must rest on the O-ring seal in the table.
Show/hide table
Table 1 Caterpillar DPF Sizes and Adapters DPF
ModelV-Band Flange
OD mm (in)Large Cone
319-1836Medium Cone
319-1835Small Cone
319-1834Upper Adapter Ring
319-2192Lower Adapter Ring
319-1838Lower Adapter Ring
319-1839(Dim. A) (8) (8) (8) (11) (7) (7) 9.5x14
Submerged
253.1 mm (9.965 inch)X X 9.5x14
Std
279.3 mm (10.996 inch)X X 11.25x14
Submerged
279.3 mm (10.996 inch)X X 264-1556
MTB
318.2 mm (12.528 inch)X X X 11.25x14
MTB-Std
321.1 mm (12.642 inch)X X 13x17
Submerged
342.8 mm (13.496 inch)X X 12x15
342.8 mm (13.496 inch)X X 13x17
Std
368.2 mm (14.496 inch)X X
 | |
| Illustration 9 | g02728177 |
(16) DPF Cleaner Table (17) Lower Adapter | |
- Attach appropriate upper adapter cone (18) to quick disconnect coupler (19). Position cone so the pressure port is facing pressure transducing hose (20). Connect the pressure transducing hose to the pressure port on the cone.
 | |
| Illustration 10 | g02728178 |
(18) Upper Adapter Cone (19) Quick Disconnect Coupler (20) Pressure Transducer Hose | |
- Install 2F-2990 Plastic Plugs or 102-9379 Steel Plugs (M14 x 1.5 Thread), as shown, to close all open ports on the DPF.
 | |
| Illustration 11 | g02728180 |
- Place the DPF on the lower adapter ring with the arrow on the side of the DPF pointing UP (indicating the direction of the exhaust flow). The DPF must be flat on the lower adapter with no visible gaps between the DPF and adapter ring.
 | |
| Illustration 12 | g02728182 |
- If upper adapter ring (21) is necessary for the application, place it on the DPF with the rubber seal facing the DPF. The adapter ring must be flat on the DPF with no visible gaps between the DPF and adapter ring.
 | |
| Illustration 13 | g02728184 |
(21) Upper Adapter Ring | |
- Attach magnet (22) (provided) to the side of the DPF. Clamp alligator clip (23) of the DPF cleaner ground wire (24 ) to the magnet as shown.
Note: If the DPF canister is not magnetic, ground the unit by clamping the alligator clip to a protruding edge of the DPF.
 | |
| Illustration 14 | g02728186 |
(22) Magnet (23) Alligator Clip (24) Ground Wire | |
- Close and latch the doors to the pressure chamber.
Note: The DPF cleaner will not operate until the doors are securely latched.
 | |
| Illustration 15 | g02728190 |
- Verify that both cartridge filter covers are securely clamped. The handles point DOWN when the covers are correctly closed and locked into place.
 | |
| Illustration 16 | g02728192 |
 | |
| Illustration 17 | g02728193 |
Cleaning Cycle
- After a DPF has been correctly loaded into the pressure chamber, pull out ON/OFF button (1) on control panel (2) .
Note: The display briefly shows the current version of software loaded on the DPF cleaner microprocessor.
- Press MENU (2f) to open the Main Menu screen and use Keypad (2e) to select 3. Clean.
 | |
| Illustration 18 | g02728195 |
- Default cleaning parameters, listed by manufacturer, are displayed on multiple screens. Use DOWN arrow (2f) to move between screens. Use Keypad (2e) to select 2. Caterpillar
Note: To return to the Main Menu Screen, use Keypad (2e) to select 5. Main Menu.
 | |
| Illustration 19 | g02728196 |
- Once a cleaning protocol has been chosen, follow the prompts displayed on the screen to start the cleaning cycle.
Note: Parameters may include burst cycle time, burst pressure, clamp force, and number of cycles.
 | |
| Illustration 20 | g02728201 |
- The vacuum cleaner will run for 5 seconds to check the condition of the vacuum filter. If the display message indicates the vacuum filter needs to be replaced, refer to the ""Maintenance Section"
" of this manual.
Note: STOP/NO button (2d) can be pressed at any time to stop the cleaning process.
- The display will prompt the user to adjust the clamp force on the DPF. Close (CW) pump control knob (11) and operate hand pump lever (9) to raise the table and seal the DPF to the upper cone. The cone must fit uniformly on top of the upper adapter.
 | |
| Illustration 21 | g02728202 |
(9) Hand Pump Lever (11) Control Knob | |
- Watch the display, and stop pumping the lever when the clamp force value is equal to or slightly greater than the clamp force parameter.
Note: If the hand pump is over-pressurized, a fault occurs. Red LED (2b) illuminates and the display reads "REDUCE CLAMP FORCE." Release pressure by slowly opening (CCW) pump control knob (11). Once clamp force is correct, close the control knob.
- Press GO/YES Button (2g) to start the cleaning sequence. The unit builds pressure in the air tank, sounds out four "beeps" to alert the user, and completes a low pressure burst of air to verify the DPF is capable of withstanding the cleaning process.
Note: If the display indicates the DPF is NOT capable of withstanding the cleaning process, it must be repaired or replaced.
- The DPF cleaner then builds pressure in the air tank to equal the burst pressure parameter shown on the display. The unit sounds four "beeps" and completes a full pressure burst of air to remove ash from the DPF.
- The cycle will repeat according to the specified cleaning parameter.
- When the cleaning cycle is complete, green light (2a) will come ON and CYCLE COMPLETE is shown on display (2c) .
- Push in ON/OFF button (1) to turn off the machine and release pressure (vent) air tank (8) .
- Release clamp pressure on the DPF by opening (CCW) pump control knob (11) .
- Once table (16) is completely lowered, unlatch and open the pressure chamber doors and remove the clean DPF.
Automatic Reverse Cleaning Process
After a number of DPFs have been cleaned, the back pressure in the ash collection tank will increase to a level that will trigger an automatic reverse cleaning process for the internal cartridge filters. This will consist of small air bursts passing backward through the cartridge filters. This removes ash from the filter media, which will prolong cartridge life.
During the process, the display message reads "REVERSE CLEANING." After reverse cleaning is complete, the normal DPF cleaning cycle will resume.
Note: At some point, the reverse cleaning process will no longer be successful, and the 319-2194 Cartridge Filters must be replaced. When this occurs, the display message is "INTERNAL FILTERS BAD." Turn OFF the DPF Cleaner, disconnect the power cord and inlet airline, and replace the 319-2194 Cartridge Filters , as outlined in the ""Maintenance Section" " of this manual.
Maintenance Section
During operation of the DPF cleaner, the contaminated airstream is drawn into an ash collector, where the velocity is reduced by inlet baffle plates to provide even air distribution across the entire surface area of cartridge filters. This design enhances filtration efficiency by establishing a uniform dust cake on the filters. The airstream is then directed around the cartridge filters and down toward the bottom of the collector, where heavier particles accumulate.
The contaminated air then passes through the cartridge filters. The filter media strips most of the ash from the airstream, and the air then passes into the clean air plenum and through a HEPA filter before being discharged from the unit. When back pressure in the ash collector tank exceeds a preset value, and the reverse cleaning process is no longer effective, a display message will prompt the user to change the cartridge filter.
Replacement Filters
| Replacement Filters | ||
| Part No. | Description | Qty. |
| 319-1833 | Vacuum Pail/Filter | 1 |
| 319-2193 | HEPA Filter - 152.4 mm (6.0 inch) high |
1 |
| 319-2194 | Cartridge Filter 762 mm (30.0 inch) long 1 |
1 |
| 320-2679 | Desiccant (2 pkgs.) | 1 |
| 320-2680 | Coalescing Filter Element | 1 |
| 1 Two Required | ||
Replace the Vacuum Filter
This procedure describes replacing the DPF cleaner vacuum pail/filter. A canister lid to seal the dirty pail/filter is included when a new 319-1833 Vacuum Pail/Filter is purchased.
- Disconnect the shop air supply from inlet air fitting (3) located at the end of the machine.
- Push in ON/OFF button (1) to turn off the machine and release pressure (vent) air tank (8). Unplug (remove) the power cord from the outlet.
- Open door to the vacuum cleaner chamber (7) located on the front of the DPF cleaner.
 | |
| Illustration 22 | g02728203 |
(7) Vacuum Cleaner Chamber | |
- Grasp the top handle on the vacuum motor and lift the vacuum out of the chamber.
Note: It is possible to extend the life of a vacuum filter by tapping the bottom pail on the floor. This settles the contents of the filter and restores suction for a short time.
- Disconnect vacuum cleaner power cord (22) and vacuum hose (23) .
 | |
| Illustration 23 | g02728204 |
(22) Power Cord (23) Vacuum Hose (24) Rubber Latch | |
- Release three rubber latches (24) holding the vacuum motor to the pail/filter and lift the motor off the canister.
- Open the latch on white connecting band (25) and remove it from the old pail/filter.
 | |
| Illustration 24 | g02728205 |
(25) White Connecting Band | |
- The new 319-1833 Vacuum Pail/Filter is shipped with canister cover (26). Remove the cover from the box, and using a soft hammer, tap cover onto the old pail/filter canister.
 | |
| Illustration 25 | g02728206 |
(26) Canister Cover | |
- Dispose of the sealed filter canister according to all Federal, State, and Local regulations.
- Install connecting band (25) on the new pail/filter canister.
 | |
| Illustration 26 | g02728210 |
(22) Power Cord (23) Vacuum Hose (24) Rubber Latch | |
- Assemble the motor, power cord (22), and vacuum hose (23) onto the new filter. It may be necessary to adjust the connecting band to line up and reconnect rubber latches (24) .
- Place the vacuum back into the chamber, with the vacuum hose connection positioned toward the front of the unit. Close the chamber door.
Replace the Cartridge Filters
This procedure describes how to replace the cartridge filters. A "Bag-Out Kit" is included when a new 319-2194 Cartridge Filter is purchased.
- Disconnect the shop air supply from inlet air fitting (3) located at the end of the machine.
- Push in ON/OFF button (1) to turn off the machine and release pressure (vent) air tank (8). Unplug (remove) the power cord from the outlet.
- Unlock and remove the cover to the upper cartridge filter.
 | |
| Illustration 27 | g02728213 |
- Use the cinch strap provided in the Bag-Out Kit to securely attach a bag to the collar of the cartridge chamber. For easier cinch strap removal in Step 7, fasten the strap at the side of the collar.
- Pull the used filter out of the dust collector and into the bag.
 | |
| Illustration 28 | g02728216 |
- Twist the top of the bag and secure it with the cable tie provided.
 | |
| Illustration 29 | g02728217 |
- Release the cinch strap from the collar.
- Repeat Steps 3 through 7 to remove the lower cartridge filter.
- Plug in the DPF cleaner power cord and pull out ON/OFF button (1) on control panel (2) .
- Select VACUUM from the Main Menu. Use the vacuum hose and attachments to remove all ash from the cartridge door area and from inside the chamber.
 | |
| Illustration 30 | g02728220 |
- Install new 319-2194 Cartridge Filters in the dust collector with the gasket end inserted first.
- Dispose of used filters according to all Federal, State, and Local regulations regarding hazardous waste.
Replace the HEPA Filter
This procedure describes how to replace the HEPA filter located at the clean air plenum discharge.
- Disconnect the shop air supply from inlet air fitting (3) located at the end of the machine.
- Push in ON/OFF button (1) to turn off the machine and release pressure (vent) air tank (8). Unplug (remove) the power cord from the outlet.
- Use a wrench (dealer supplied) to loosen and remove four nuts (27) from z-shaped brackets (28) securing HEPA filter (15) .
 | |
| Illustration 31 | g02728221 |
(15) HEPA Filter (27) Nuts (28) Z-Shaped Brackets | |
- Lift the two z-shaped brackets off the HEPA filter.
- Remove the existing filter and replace with a new 319-2193 HEPA Filter .
- Install z-shaped brackets and nuts. Do not overtighten nuts and distort z-shaped brackets.
- Dispose of the HEPA filter according to all Federal, State, and Local regulations.
Service Air Filter/Dryer
Replace Coalescing Filter
 | |
| Illustration 32 | g02728222 |
(4) Coalescing Filter Assembly (29) Service Indicator | |
Coalescing filter assembly (4) removes oil from the incoming compressed air before it enters the DPF cleaner.
Service indicator (29) on the coalescing filter housing turns red when the filter element needs to be replaced.
- Disconnect the shop air supply from inlet air fitting (3) located at the end of the machine.
- Push in ON/OFF button (1) to turn off the machine and release pressure (vent) air tank (8). Unplug (remove) the power cord from the outlet.
- Remove bowl/guard from the coalescing filter assembly (4) housing by pushing up the bowl toward the housing body. Rotate the bowl counterclockwise to unlatch, then lower the bowl.
 | |
| Illustration 33 | g02728223 |
(4) Coalescing Filter Assembly | |
- Grasp the bottom of the used filter element, and turn counterclockwise to remove.
- Use a clean cloth to clean the bowl. Inspect the bowl for damage, and replace if necessary.
- Install the new 320-2680 Coalescing Filter Element , being careful to seat the O-ring in the groove.
- Install bowl/guard on coalescing filter assembly (4) by pushing it up toward the housing. Turn the bowl clockwise to engage the locking tabs under the retainers.
| NOTICE |
|---|
To prevent damage to the new filter element, grasp it by the end opposite the threads. Do not touch the foam cover. |
Replace Desiccant
The desiccant filter (air dryer) removes water vapor from the compressed air before it enters the DPF cleaner.
 | |
| Illustration 34 | g02728226 |
(24) Locking Tab (25) Desiccant Filter Bowl | |
The desiccant, visible through clear desiccant filter bowl (25), contains color indicator beads that change from blue (dry) to pink (wet). The pink color indicates the desiccant must be regenerated or replaced.
- Disconnect the shop air supply from inlet air fitting (3) located at the end of the machine.
- Push in ON/OFF button (1) to turn off the machine and release pressure (vent) air tank (8). Unplug (remove) the power cord from the outlet.
- Remove clear desiccant filter bowl (25) from the dryer housing by depressing locking tab (24) and rotating the locking ring counterclockwise until the bowl can be pulled down.
- Regenerate the desiccant (refer to "" Regenerate Desiccant" " Section in this manual) or replace with new 320-2679 Desiccant . Properly discard used desiccant according to all Federal, State, and Local regulations.
- Pour blue desiccant into the bowl, filling to within 13 mm (0.512 inch) of the top of the bowl. Do not allow desiccant to enter the center tube.
- Install bowl (25) on housing by rotating the locking ring clockwise until locking tab (24) can be engaged.
Regenerate Desiccant
Used (pink) desiccant can be recycled for longer use by baking it in an oven until the blue color returns.
- Preheat oven to 176° C (350.0° F).
- Pour the used, pink desiccant into a flat pan.
- Bake the pan of desiccant in the oven for approximately three hours, or until the desiccant color has changed from pink back to blue.
- Remove the desiccant from the oven and allow to cool to ambient temperature.
- Pour the desiccant back into the filter bowl, shaking, and tapping on the bowl to settle the desiccant. Do not allow desiccant to enter the center tube.
- Reinstall the filter bowl on the housing and engage locking tab to secure in place.
Drain the Air Tank
 | |
| Illustration 35 | g02728249 |
(8) Air Tank (26) Drain Plug | |
Once a month, drain water that has accumulated in DPF cleaner air tank (8) .
- Disconnect the shop air supply from inlet air fitting (3) located at the end of the machine.
- Push in ON/OFF button (1) to turn off the machine and release pressure (vent) air tank (8). Unplug (remove) the power cord from the outlet.
- Place a shallow pan under air tank drain plug (26) .
- Use an open-end wrench to remove drain plug (26). Drain the water into the pan.
- Install drain plug into the air tank pipe fitting, and tighten. Properly dispose of waste water.
Bleed The Hydraulic System
Air can accumulate in the hydraulic system, causing the table lift cylinders to respond slowly or in an unstable manner. Use the following procedure to remove the air.
- Push in ON/OFF button (1) to turn off the machine and release pressure (vent) air tank (8). Unplug (remove) the power cord from the outlet.
- Open (CCW) hand pump control knob (11) to completely lower the DPF cleaner table.
- Fully close (CW) the hand pump control knob.
- Remove bleed plug (27) from front lift cylinder (10) .
 | |
| Illustration 36 | g02728252 |
(10) Front Table Lift Cylinder (11) Pump Control Knob (27) Bleed Plug | |
- Slowly actuate the hand pump handle just until oil starts to flow from the cylinder bleed hole.
 | |
| Illustration 37 | g02728257 |
- Make sure that the bleed plug O-ring is positioned, as shown, and install the bleed plug in the table lift cylinder.
- Repeat Steps 4 through 6 to remove (bleed) air from the rear table lift cylinder (not shown).
| NOTICE |
|---|
If the O-ring is not correctly installed on the bleed plug, the O-ring could be cut, causing the cylinder to leak. |
- Open (CCW) hand pump control knob (11) to completely lower the DPF cleaner table. Close (CW) the hand pump control knob.
- Check the oil level in the pump reservoir. Remove fill cap (13) located on the end cap of the hand pump. Hydraulic oil level (28) should be 51 to 102 mm (2.0 to 4.0 inch) from the bottom of the fill hole. Add high-grade hydraulic oil, if needed.
 | |
| Illustration 38 | g02728258 |
(28) Hydraulic Oil Level 51 to 102 mm (2.0 to 4.0 inch) | |
Note: A clean wire tie can be used as a dipstick to measure the hydraulic oil level in the pump reservoir.
Troubleshooting Guide
| Symptom | Solution |
| Air dryer desiccant is a pinkish color. | 1. Replace or regenerate the desiccant. Refer to ""Maintenance Section" ". |
| Bursting does not occur. | 1. Check display screen for error message. 2. Check power connection to burst valve solenoid. |
| Cabinet doors do not close correctly. | 1. Look for damaged door hinges, seals, and latches. 2. Verify that vehicle sensors have been removed from DPF. |
| Cabinet doors open during burst process. | 1. Verify that doors are correctly latched. 2. Look for damage to door latches. 3. Check seals between DPF and adapters. |
| Clamping force cannot be obtained. | 1. Look for hydraulic fluid leaks. 2. Check fluid level in hydraulic pump. Refer to ""Maintenance Section" ". |
| Clamping force does not hold. | 1. Upon initial clamping, it is possible for clamp load to drop 689 to 1379 kPa (99.9 to 200.0 psi) within the first minute, due to temperature effects. After reclamping, the drop should be virtually zero. 2. Look for hydraulic fluid leaks. |
| Display screen is blank. | 1. Verify that machine is ON, plugged into an outlet, and power is available to the outlet. 2. Reset circuit breakers located on left side of control cabinet. |
| DPF does not line up correctly on the table. | 1. Verify that correct adapters are being used. 2. Verify DPF is correctly seated on to lower adapter. |
| DPF is damaged after cleaning process. | 1. Check DPFs for damage before cleaning. 2. Look for damage on adapters. 3. Verify that correct cleaning protocol was entered into machine. |
| DPF is not cleaned. | 1. Check orientation of DPF. Refer to ""General Information"
" Section. 2. Verify that correct cleaning protocol was entered into machine. 3. Look for other DPF conditions that may prevent successful cleaning. |
| Error message indicates cabinet doors are open. | 1. Close and latch cabinet doors. 2. Verify that sensors and/or connecting wires are not damaged or missing. |
| Error message indicates cartridge filters need to be replaced; cleaning process is halted. | 1. Replace cartridges according to instructions in ""Maintenance Section"
". 2. Check HEPA filter for possible replacement. |
| Error message indicates DPF may not be cleanable. (Process stops after initial mini-burst due to excessive back pressure in inlet cone adapter.) | 1. Verify DPF is not damaged or excessively plugged. |
| Error message indicates vacuum filter check failed. | 1. Check vacuum motor power cord connection. 2. Replace vacuum filter according to instructions in ""Maintenance Section" ". 3. Vacuum motor is overheated. Remove vacuum from cabinet and allow motor to cool. Verify that cabinet cooling fan is operating correctly. |
| Hydraulic pump does not release the table. | 1. Check table guide rods for binding. 2. Look for obstructions under table. |
| Leaks observed on inlet or outlet end of DPF. | 1. Verify that correct adapters are being used. 2. Look for damage on adapters and DPF sealing surfaces. 3. Verify all sensor ports on DPF have been plugged. |
| Leaks observed coming from ash collection tank. | 1. Verify that cartridge filter covers are securely closed and latched. Look for damage to cover seals. 2. Look for damage to cartridge filters and seals. 3. Verify ash collection tank exit (HEPA filter) is not obstructed. |
| Machine randomly shuts off or resets. | 1. Verify that machine is correctly grounded. 2. Verify DPF is correctly grounded. Refer to ""General Information" " Section. 3. Determine if there has been a power surge. |
| Pressure tank does not achieve desired pressure. (If programmed pressure is not achieved within five minutes, a time-out error occurs and an error message appears on display screen). | 1. Verify airline is connected and turned ON. 2. Verify shop air supply is 827 to 1034 kPa (120.0 to 150.0 psi) and air flow is not obstructed. 3. Look for leaks (internal/external) in air hose. |
| Pressure tank does not empty when machine is shut off. | 1. Check bleed solenoid for correct operation (normally open). |
| Reverse cartridge cleaning burst does not occur. When REVERSE CLEANING message appears, small diaphragm valves, located on control cabinet end of machine, should each burst three times in sequence. | 1. Verify that airline is connected and turned ON. 2. Verify that shop air supply is 827 to 1034 kPa (120.0 to 150.0 psi) and air flow is not obstructed. 3. Look for leaks (internal/external) in air hose. 4. Verify that power is connected to reverse pulse valve solenoids. |
Warranty Section
| Limited Warranty Statement | |
| This product is warranted to be free from defects in workmanship, materials, and components for one year from date of purchase. All parts and labor required to repair defective products covered under the warranty will be at no charge. the following restrictions apply: | |
| ° The limited warranty applies to the original purchaser only. | |
| ° The warranty applies to the product in normal usage situations only, as described in the Tool Operating Manual. The product must be serviced and maintained as specified. | |
| ° If the products fails, it will be repaired or replaced at the option of the manufacturer. | |
| ° Transportation charges for warranty service will be reimbursed by the factory upon verification of the warranty claim and submission of a freight bill for normal ground service. Approval from the manufacturer must be obtained prior to shipping to an authorized service center. | |
| ° Warranty service claims are subject to authorized inspection for product defects. | |
| ° The manufacturer shall not be responsible for any additional costs associated with a product failure including, but not limited to, loss of work time and unauthorized shipping and/or labor charges. | |
| ° All warranty service claims must be made within the specified warranty period. Proof-of-purchase date must be supplied to the manufacturer. | |
| This Limited Warranty does NOT apply if: | |
| ° The product, or product part, is broken by accident. | |
| ° The product is misused, tampered with, or modified. | |