Aftertreatment Filter Maintenance on Tier 4 Final Products Equipped with a Diesel Particulate Filter (DPF), Diesel Oxidation Catalyst (DOC) and a Selective Catalyst Reduction (SCR) Filter {108F} Caterpillar

Articulated Truck

725C (S/N: TFB1-UP)

730C (S/N: TFF1-UP)

730C EJECTOR (S/N: TFH1-UP)

735C (S/N: TFJ1-UP)

745C (S/N: TFK1-UP)

Electric Power Generation

XQ375 (S/N: X3F1-UP)

Engine

C13 (S/N: N3F1-UP; T4F1-UP)

C15 (S/N: N5F1-UP)

C18 (S/N: N8F1-UP; RDP1-UP)

Excavator

336F (S/N: TZA1-UP; RKB1-UP; YFD1-UP; KGH1-UP; NAJ1-UP; LCL1-UP; NBL1-UP; PFL1-UP; LTP1-UP; KFT1-UP; DSW1-UP; MTW1-UP; WTZ1-UP)

349F (S/N: BZ21-UP; KEA1-UP; HLB1-UP; HPD1-UP; TEW1-UP)

352F (S/N: WNA1-UP; YEG1-UP; A9J1-UP; KBP1-UP)

374F (S/N: DNM1-UP)

390F (S/N: MGF1-UP)

Industrial Engine

C9.3 (S/N: CS91-UP; SSE1-UP; SYE1-UP)

Landfill Compactor

826K (S/N: 2321-UP)

836K (S/N: TWZ1-UP)

Motor Grader

12M Series 3 (S/N: N9B1-UP; N9F1-UP; N9P1-UP; N9R1-UP)

140M Series 3 (S/N: N9D1-UP; N9G1-UP; N9J1-UP; N9M1-UP)

14N (S/N: N9X1-UP)

160M Series 3 (S/N: N9E1-UP; N9K1-UP; N9L1-UP; N9T1-UP)

16M Series 3 (S/N: N9Y1-UP)

Off-Highway Truck/Tractor

770G (S/N: RMA1-UP; KDH1-UP)

772G (S/N: RME1-UP; KEX1-UP)

Reclaimer Mixer

RM500B (S/N: MB91-UP)

Soil Compactor

825K (S/N: 2331-UP)

Track-Type Tractor

D6T (S/N: CR31-UP; CG81-UP; SGA1-UP; RAD1-UP; STE1-UP; MEL1-UP; WRN1-UP; KMR1-UP; WES1-UP; SGT1-UP; TMY1-UP; HTZ1-UP)

D7E (S/N: HKA1-UP; SSH1-UP)

D8T (S/N: AW41-UP; FMC1-UP)

D9T (S/N: REX1-UP)

Wheel Dozer

824K (S/N: 2341-UP)

834K (S/N: TWY1-UP)

Wheel Loader

966M (S/N: EJA1-UP; DYC1-UP; KJP1-UP)

966M Series XE (S/N: P6C1-UP)

972M (S/N: LSJ1-UP; A8P1-UP; JPR1-UP)

972M Series XE (S/N: EDW1-UP)

980M (S/N: KRS1-UP; N8T1-UP)

982M (S/N: F9A1-UP; K1Y1-UP)

988K (S/N: TWX1-UP)

Wheel Tractor-Scraper

621K (S/N: WTA1-UP; WTE1-UP)

623K (S/N: WTB1-UP)

627K (S/N: WTC1-UP)

637K (S/N: WTS1-UP; WTT1-UP)

Introduction

There are three approved processes for performing the required Diesel Particulate Filter (DPF) maintenance on Tier 4 Final products equipped with a DPF.

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

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

• Replacement of the existing DPF with a new Caterpillar DPF

• Replacement of the existing DPF with a remanufactured Caterpillar DPF

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

The DPF can be cleaned a maximum of 3 times or 20,000 total DPF hours.

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

Refer to Table 1 for the existing part number of the filter assembly being serviced along with the corresponding new and remanufactured service kits.

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

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

• Mark the DPF as shown below in Step 4

• Perform a "Manual DPF Regeneration"

• Perform the "DPF Ash Service" listed below

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

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

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

Cleaning the DPF

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

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

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

2. Connect to the "Engine # 1 Aftertreatment Controller" using Cat ET before the DPF is removed. Perform a "DPF Ash Service Regeneration". The service test could take up to an hour.

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

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

4. Mark the DPF after removing from the CEM.

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

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

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

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

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   Table 2

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

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

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

6. Clean the DPF.

   Approved Caterpillar Diesel Particulate Filter Cleaning Devices

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

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

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

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

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

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

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

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

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

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

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

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

      Note: Refer to Table 3 for the existing part number of the filter assembly being cleaned along with the clamp part number required for reassembly, and ash height measurements.

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      Table 3

      DPF Part Number	Part Number of Required Clamps	Requires cleaning if Measured Wire Depth is less than	Acceptable Cleaned Measured Wire Depth is greater than
      390-0659	375-0949	203 mm (8 inch)	317.5 mm (12.5 inch)
      390-0643	371-1871	279 mm (11 inch)	406 mm (16 inch)
      375-0945	375-0949	203 mm (8 inch)	317.5 mm (12.5 inch)
      371-1855	371-1871	279 mm (11 inch)	406 mm (16 inch)
      371-1896	375-0931	279 mm (11 inch)	406 mm (16 inch)
      390-0663	345-1839/375-0931	279 mm (11 inch)	432 mm (17 inch)
      390-0673	375-0931	279 mm (11 inch)	432 mm (17 inch)
      375-0992	345-1839/375-0931	279 mm (11 inch)	432 mm (17 inch)

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

DPF Ash Service

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

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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.

1. Connect to Cat^® Electronic Technician (Cat^® ET).
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   Illustration 4	g03390636

2. Connect to "Engine #1 Aftertreatment Controller".
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   Illustration 5	g03390638

3. Select "Service" from the top menu and select "Service Procedures".
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   Illustration 6	g03390641

4. From the "Service Procedures" menu, select "DPF Ash Service".

5. Select "Start".
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   Illustration 7	g03390644

6. Select "Ash Service Reset" to start the reset procedure.
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   Illustration 8	g03390645

7. Read the warning and select "Agree" to continue.
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   Illustration 9	g03390648

8. Choose the correct replacement type of DPF in the menu that appears. The types of replacements for the DPF are the following:

   • "Field Cleaned" A DPF that has been cleaned and reapplied.

   • "New" A new DPF replacement

   • "Remanufactured" A remanufactured DPF replacement.
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   Illustration 10	g03390663

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   Illustration 11	g03390661

9. One the reset is completed, a log of the reset is captured and visible as a new row of information in the DPF Ash Service screen. Resetting the engine ash model does not reset the soot level.

10. Perform a "Manual DPF Regeneration" with Cat^® ET to reset the soot level.

Diesel Oxidation Catalyst (DOC) Maintenance on Tier 4 Final Products

Note: Refer to Table 4 for the existing DOC part number being serviced along with the corresponding new service kit.

The Diesel Oxidation Catalyst Replacement procedure must be performed when the DOC has been replaced. This is necessary to ensure that the engine meets emissions requirements. Follow the procedure below to reset the DOC model in the aftertreatment software.

1. Connect to Cat^® Electronic Technician (Cat^® ET).
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   Illustration 12	g03390636

2. Connect to "Engine #1 Aftertreatment Controller".
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   Illustration 13	g03390638

3. Select "Service" from the top menu and select "Service Procedures".
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   Illustration 14	g03389920

4. Select "Diesel Oxidation Catalyst Replacement" and select "Start".
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   Illustration 15	g03389925

5. Select "Reset".
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   Illustration 16	g03389928

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   Illustration 17	g03389921

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   Illustration 18	g03389931

6. Read the warning and select "Accept" to continue.
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   Illustration 19	g03389947

7. Once the reset is completed, a log of the reset is captured and visible as a new row of information in the Diesel Oxidation Catalyst Replacement screen.

Selective Catalytic Reduction (SCR) Maintenance on Tier 4 Final Products

Note: Refer to Table 5 for the existing SCR catalyst part number being serviced along with the corresponding new service kit, and the clamp part number required for reassembly.

The Aftertreatment SCR Catalyst Replacement procedure must be performed when the SCR Catalyst has been replaced. This is necessary to ensure that the engine meets emissions requirements. Follow the procedure below to reset the SCR Catalyst model in the aftertreatment software.

1. Connect to Cat^® ET.
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   Illustration 20	g03390636

2. Connect to "Engine #1 Aftertreatment Controller".
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   Illustration 21	g03740190

3. Select "Service" from the top menu and select "Service Procedures".
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   Illustration 22	g03740205

4. Select "Aftertreatment #1 SCR Catalyst Replacement" and select "Start".
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   Illustration 23	g03740210

5. Select "Reset".
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   Illustration 24	g03740216

6. You must read the warning and select "Accept" to continue.

7. Enter the factory passwords to continue.
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   Illustration 25	g03740230

8. Once the reset is completed, a log of the reset is captured and visible as a new row of information in the "Aftertreatment #1 SCR Catalyst Replacement" screen.