Caterpillar DPF Installation and Operation Guide for Diesel Engines - California Only {1000, 1091} Caterpillar


Caterpillar DPF Installation and Operation Guide for Diesel Engines - California Only {1000, 1091}

Usage:

MT700 018
Caterpillar Products
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Introduction


NOTICE

Diesel Particulate Filters (DPF) are not applicable to all engines. A Diesel Particulate Filter should typically not be applied to engines that are not regulated. Diesel Particulate Filters are meant for usage on only diesel engines. This technology does not apply to gas engines. Consult with Caterpillar in order to determine if a Diesel Particulate Filter can be used on your engine.


Included in this guide is a parts list and installation procedure. Each section is highlighted for your convenience.

Read each section carefully prior to installing your DPF.

Consult your Caterpillar dealer with questions concerning installation or warranty-related matters.

Note: Ultra-Low sulfur Diesel fuel must be used. Ultra Low Sulfur Diesel (ULSD) fuel (≤ 15 ppm (mg/kg) sulfur) is required by regulation for diesel engine use in California. The United States (U.S.) Environmental Protection Agency (EPA) defines Ultra Low Sulfur Diesel (ULSD - S15) as a U.S. diesel fuel with a sulfur content not to exceed 15 parts per million (ppm (mg/kg)). Also, the sulfur content in the diesel fuel is not to exceed 0.0015 percent by weight. ULSD fuel must meet the S-15 fuels designation in the latest edition of ASTM D975 and/or conform to Caterpillar Fuel Specification.

Warranty and Record Of Installation

The statement of warranty for the DPF can be found at the end of this installation manual.

Be sure to record the information from the DPF housing label prior to installation.

System Parts

  1. One (1) Caterpillar DPF with data monitoring

    The DPF system consists of the following components:

    1. (1) Catalyst Section

    2. (1) Filter Section

    3. (1) Inlet Head

    4. (1) Outlet Head

    5. (3) V-Band clamps

    6. (3) Gaskets

    7. (1) DPF Diagnostic Module to monitor the backpressure and temperature of your DPF. Refer to the DPF Diagnostic Module (DPFdm) manual for installation and operating instructions.

    8. (1) DPF Diagnostic Module installation kit, including thermocouple, pressure sampling tube and wiring harness

    9. (1) Remote Display Module (RDM).

  2. One (1) packet consisting of:

    1. Engine Label

    2. Record Of Installation

    3. Installation Guide

    4. Bill of Materials

  3. Depending on your DPF purchase, additional auxiliary items may be included such as brackets, piping and insulation. Check your bill of materials for a complete listing.

System Installation Procedure

    Note: Reference Special Instruction, REHS5606 for complete system installation information.

  1. Inspect engine to ensure that it meets engine manufacturers specifications or correct the engine to meet the engine manufacturers specifications.

    Note: Caterpillar requires prior to installation of a DPF, each engine must be inspected by a mechanic to determine that the engine meets all of the engine manufacturers specifications. Failure to meet the correct engine specifications could void the DPF warranty. Check your warranty for details.

  2. Remove the outlet pipe from the existing muffler.

  3. Remove the inlet pipe from the existing muffler.

  4. Remove the existing mounting brackets/bands.

  5. Remove the existing muffler.

  6. If the existing clamps and brackets are to be reused, inspect clamps and brackets to ensure that they are not fatigued or cracked. Replace these components as required.

  7. The DPF system is shipped as a ready to install assembly, however, the t-bolt and lock-nut on the v-band clamp may need reoriented on the circumference to prevent interference with other components on the vehicle, or to allow for easier access. If the v-band clamp is loosened to reorient its location, the locknut must be tightened to the rated torque value of 16 N·m (144 lb in) to prevent leakage.

  8. On DPF units where the inlet and/or outlet pipe is eccentrically located on the section and/or if the unit has a side inlet and/or outlet, the v-band clamp may need loosened to reorient the head for installation. The v-band clamp must be tightened to the rated torque value of 16 N·m (144 lb in) before the piping is installed to prevent eccentric loading that will result in leaks.

    Note: Care should be taken to ensure that the gaskets are not damaged during rotation of the v-band clamps, heads, or when the filter section is removed for cleaning. If the gasket is damaged, or not sealing properly, replace with Caterpillar approved gaskets.

  9. Each DPF is shipped with 1/4 inch NPT couplings and plugs on the inlet and outlet sections. If the ports are not being utilized in the installation, check that the plugs are properly tightened.

  10. Install the DPF system in the same location where the existing muffler was located or according to specification. Use either new clamps and brackets, if provided, or, if suitable, reuse existing clamps and brackets. When installing the DPF system, all mounting brackets must be adjusted so the inlet and outlet pipe of the DPF system line up accurately to the inlet and outlet piping of the vehicle. If properly aligned, the DPF system will have no eccentric loading on the inlet and outlet pipes.

    Note: The DPF can be significantly heavier than a standard muffler. If existing supports and brackets are reused, these supports and brackets must be evaluated to ensure that they can adequately support the added load of the DPF. Consult your Caterpillar dealer directly for recommendations.



    Illustration 1g01425324
    Diesel Particulate Filter
    (1) Inlet section
    (2) Catalyst section
    (3) Filter section
    (4) Outlet section

  11. Your DPF must be installed with the correct flow orientation. Verify the direction of flow by identifying the tag marked "inlet" on the DPF body.

    Note: The DPF system must have the catalyst section directly up-stream of the filter section in order to operate properly. The catalyst section is identified because it is the shorter section without piping. The filter section is the longer section without piping. At all times during operation the catalyst section must remain in front of the filter section in the direction of flow. Assembly should be inlet section, then catalyst section, then filter section and finally outlet section.

  12. Reinstall the inlet and outlet pipes.

    Note: Any eccentric loading on the inlet and outlet piping in conjunction with the vibrations caused by vehicle operation can result in stress cracking of the DPF system where the pipe or pipe support contacts the DPF body.

    Note: If the DPF is mounted horizontally and the system has a vertical tailpipe, a 6.35 mm (0.25 inch) diameter water drainage hole must be drilled in the lowest point of the DPF outlet section. The drain hole shall be located 3.81 cm (1.5 inch) from the center line of the filter section/outlet section V-band clamp. Failure to follow these instructions may void the mechanical warranty.

  13. When installation is complete, check for system leaks by running the engine at no load, wide open throttle.

  14. Caterpillar recommends that an initial baseline backpressure reading be taken. This reading should be recorded for warranty purposes. To accurately assess the performance of your DPF system, a backpressure reading should be taken at least every six months, or during scheduled maintenance.

  15. For backpressure measurements, use either the DPF Diagnostic Module supplied with your DPF system, or a standard pressure gauge or manometer to check and record backpressure. Follow the procedures for measuring backpressure in the "General Maintenance" section of this manual.

    Note: The DPF Diagnostic Module must be installed and operated with your DPF in order to validate the DPF warranty.

    Note: Electronically controlled engines are certified with a specific fuel and electronic program based on engine configuration and model year. Use only the fuel and electronic program specified for your engine. Using the incorrect fuel and/or electronic program will cause excessive soot generation and may void the DPF warranty.

    Note: Blending lube oil with fuel is forbidden. This action may void the DPF warranty.

    Note: Certain components in standard crankcase oil can be catalyst poisons if excessive amounts reach the catalyst. To protect against catalyst and/or filter contamination, ensure that the engine is not consuming oil at a rate higher than specified by the engine manufacturer. Fuel additives can also contain elements that can be harmful to the catalyst and/or filter. Consult with your Caterpillar dealer before using any additives.

Engine Label Requirements

Regulations require that you attach a label which states the product name and manufacturer of the emissions control device you are installing on your vehicle.

This label is included with your product.

Note: Be sure to attach the engine label to a clearly visible location on the engine or engine compartment.

System Service

Filter Cleaning

A comprehensive cleaning procedure has been developed for removal of lube oil ash from the DPF. Ash accumulates in the filter over time and results in increased backpressure. Once the specified backpressure limits are reached, the accumulated ash in the filter must be removed.

There are several options to properly clean a Caterpillar DPF. Your Caterpillar dealer may also offer a cleaning service.

In all cases, a filter must be verified clean using the Cleaned Filter Specification. Failure to do so may violate the warranty of the DPF and may significantly shorten the interval between filter cleanings.

Manual Filter Cleaning Procedure

Cleaning Interval

The following cleaning intervals/monitoring options are available to fit various operators/applications:

  1. Typical cleaning intervals for the DPF are 1,000 hours or 6 months depending on conditions.

  2. DPF systems utilizing the DPF Diagnostic Module (DPFdm) will have the backpressure limit set for notification when cleaning is required. This backpressure limit setting can increase the time between cleaning intervals on engines with low oil consumption. In addition the DPFdm provides the added protection of indicating when an early cleaning is required due to an engine upset condition.

Note: The DPF must be cleaned in accordance with this procedure and records maintained for warranty purposes. Failure to properly maintain the DPF and maintenance records could void the product warranty.

Note: The DPF backpressure must be checked prior to and after filter cleaning. Backpressure measurements must be recorded in the DPF Cleaning Record.

Filter Removal

Remove the filter section of the DPF by opening the clamps holding the filter section in place. The filter section is between the two clamps closest to the outlet side of the DPF. Check the nameplate on the section for identification. Separate the mating sections by approximately 12.7 mm (0.5 inch) to allow removal over the gasket retainer rings. Note the orientation of the filter in the exhaust flow because the filter will be reinstalled in the same direction, with the dirty side closest to the catalyst section. Caterpillar recommends replacing gaskets at each filter-cleaning interval.



Illustration 2g01425424
Diesel Particulate Filter
(1) Inlet section
(2) Catalyst section
(3) Filter section
(4) Outlet section

Note: The filter and catalyst are made of ceramic material which requires care when handling. Use caution to ensure that the filter and/or catalyst do not get chipped or cracked. If chipped or cracked, contact your Caterpillar dealer for recommendations.

Section Design

  1. The DPF is unique in its section design, which allows for complete access to the filter face to ensure thorough cleaning.

  2. Because the DPF is sectional and the sections are interchangeable, the operator has the option to maintain a small stock of filter sections that can be used to replace filters being removed from service at the cleaning interval. The filters that have been removed can then be cleaned and returned for installation in the next vehicle to be cleaned. This rolling stock process can significantly reduce vehicle down time. Consult your Caterpillar dealer for recommended approach.

Distributor cleaning service

Caterpillar dealers, offer the option of returning filters to the dealer for cleaning. The operator can maintain a small stock of filter sections that can be used to replace filters in service at the cleaning interval. The removed filters can be cleaned at the dealer's facility and returned for installation in the next vehicle to be cleaned. The operator should remove the dirty filter, place the dirty filter in a sealed bag or container and give the dirty filter to the dealer. The operator would install a filter from stock while the dealer cleans the dirty filter and returns the filter to the operators inventory.

Cleaning

Refer to Special Instruction, REHS5606 for details on cleaning the filter.

Inspection

  1. During the cleaning interval, all installation mounts and brackets should be inspected for fatigue or cracks. Replace components as required.

  2. Check the v-band clamps, t-bolts, nuts and gaskets for damage. Replace damaged parts as required using genuine replacement parts. Caterpillar recommends replacing the gaskets at either end of the filter section at each cleaning interval to ensure proper sealing. Gaskets are available through your Caterpillar dealer.

  3. Inspect the outlet (clean) side of the filter for signs of soot leakage. If more than 20 cells are black, the filter needs replaced because the filter has been damaged. Contact your Caterpillar dealer for replacement parts.

  4. Inspect both filter faces for signs of cracking and for gouges. If cracks are noted or a gouge is deeper than 3.81 mm (0.15 inch), the filter should be replaced. Contact your Caterpillar dealer for replacement parts.

Assembly

  1. Check that the filter section flanges and mating flanges are clean from debris. Clean as required.

  2. Orient the filter section in the same way it was removed with the dirty face nearest the catalyst section.

    Note: Caterpillar does not recommend flipping the filter after cleaning because the clean filter face will get contaminated with soot and ash making it very difficult to determine if the filter has been damaged when maintenance is required again.

  3. Install a gasket on the catalyst gasket retainer ring and connect the filter section using a v-band clamp. Tighten the v-band clamp lock nut to 16 N·m (144 lb in). Do not over tighten.

  4. Install a gasket on the outlet head gasket retainer ring and connect to the filter section using a v-band clamp. Tighten the v-band clamp lock nut to 16 N·m (144 lb in). Do not over tighten.

    Note: The DPF outlet head may require rotation to align with the vehicle piping or to orient the test port.

  5. Check all brackets and fasteners connecting the DPF to the exhaust piping and body frame.

  6. Start the engine and examine the clamps for leaks.

  7. Run the engine under normal operating conditions for a period of 15 minutes then check for proper operation of the DPFdm or perform a backpressure test per the procedure in the installation guide.

Cleaned Filter Specification

Required Equipment

  1. Stainless steel probe per specification.

    • 38 cm (15 inch) long by 0.89 mm (0.035 inch) thick for 200 cpsi filters

  2. Tape measure.

Procedure

  1. Evaluation of a cleaned filter.

    Note: A filter MUST meet all criteria laid out in this section to be considered clean.

    1. Inspect substrate (filter) for gouges, cracks, and if it appears to be slipping from the banding.

      • Gouges may not be deeper than 3.81 mm (0.15 inch) deep.

      • No cracks may be visible.

      • The filter (5) must not appear to have moved within its banding, defined as the substrate moving past the bent over flange (4). Inspect both inlet and outlet. The filter (5) must be even or below the bent over flange (4). There must not be any signs of the steel fiber ring (3) coming loose or any mat material (1) (cottony gauze) slipping past the filter (5). See Illustration 3.


      Illustration 3g01425469
      Proper placement of the filter (5) within the banding. Filter (5) must be below bent over flange (4).
      (1) Mat material
      (2) Outer can
      (3) Steel fiber ring
      (4) Bent over flange
      (5) Filter

    2. The flanges are not damaged beyond repair.

    3. There are no dents deeper than 6.35 mm (0.25 inch) in the outer can of the filter and the outer can is not cracked, torn or otherwise breached.


      Illustration 4g01425565
      Acceptable filter with less than 20 damaged cells


      Illustration 5g01425553
      Unacceptable filter, too many damaged cells


      Illustration 6g01425579
      Locations to check cell depth

    4. No more than 20 cells are allowed to be damaged (showing soot) on the outlet face of the filter. Refer to Illustrations 4 and 5. Check cell depth by dropping the stainless steel probe into a cell location noted by a dot in Illustration 6. Lightly tap the probe with a finger until the probe does not travel into the cell any further. Measure the distance from the tip of the probe which entered the cell to the mark you made on the probe. This is the cell depth. Repeat this step 17 times per Illustration 6.

      • If the probe travels a minimum of 28.50 cm (11.25 inch) in all cells, the filter is considered CLEAN.

      • If the probe encounters heavy resistance in one or two cells, proceed to Step 1.e, Evaluation of a filter with hardened ash.

      • If the probe encounters heavy resistance in three or more cells, the filter is NOT CONSIDERED CLEAN AND MUST NOT RETURN TO SERVICE UNTIL IT IS CLEANED PROPERLY.

    5. Evaluation of a filter with hardened ash.

      • Draw a two 5.08 cm (2 inch) square around the cell with the hardened ash per illustration 7.

      • At the locations noted in Illustration 7, recheck the cell depth per section d.

      • If hardened ash is noted at any of the locations around the edge of the square, the filter IS NOT CLEAN AND MUST NOT RETURN TO SERVICE UNTIL IT IS CLEANED PROPERLY.


Illustration 7g01425670
Checking for hardened ash
(1) Cell noted with hardened ash during cell depth check
(2) Draw a 50.8 mm (2 inch) square around the cell noted with hardened ash and check cell depth at the dots.

General Maintenance

Periodic Maintenance

During routine maintenance and backpressure checks, make sure to inspect all brackets and fasteners connecting the DPF to the exhaust piping and body frame.

Replace all worn or fatigued parts as required to ensure the proper stability of your DPF.

Backpressure

Stable backpressure is a good indication of the proper operation of the DPF. Backpressure can be affected by:

  • Accumulation of lube oil ash

  • Mis-operation and/or poor maintenance

  • Use of improper fuel (high sulfur fuel)

If high backpressure is observed with the DPF, immediate steps must be taken to correct the situation.

Indication of high backpressure can be obtained from the DPFdm, which can be supplied with your DPF. The DPFdm continuously monitors the system backpressure and an alarm is triggered when the backpressure limits are exceeded. Refer to the DPFdm manual for specific information regarding its operation.

Caterpillar requires that periodic backpressure measurements are taken using the DPFdm or an approved Caterpillar backpressure monitoring device or, alternatively, a simple pressure gauge or monitor. Refer to the DPFdm manual or "Checking Backpressure with Manometer/Gauge" section below.

Checking Backpressure with Manometer/Gauge

  1. Remove the plug from the pressure tap coupling located on the manifold immediately after the engine and install a manometer or pressure gauge. Use a gauge with a minimum range of 0 to 20 kpa (0 to 80 inch of H2O).

  2. After completely warming up the engine, run at no load, wide open throttle (W.O.T.) for 2 to 3 minutes. Record the pressure reading while the engine is running at no load, W.O.T.

    Repeat 2 to 3 times.

  3. If the observed backpressure is less than 10.20 kPa (41 inch of H2O), the DPF can continue to be operated without further maintenance.

  4. If the backpressure is greater than 10.20 kPa (41 inch of H2O) at the time of installation, contact your Caterpillar dealer. If the backpressure is greater than 10.20 kPa (41 inch of H2O) during a maintenance check, contact your Caterpillar dealer.

Your Warranty Rights And Obligations

VERIFIED PRODUCT WARRANTY

Caterpillar Inc. warrants the diesel emission control system in the application for which it is sold or leased to be free from defects in design, materials, workmanship, or operation of the diesel emission control system which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your diesel emission control system, vehicle or equipment, as specified in the owners manuals. Where a warrantable condition exists, this warranty also covers the engine from damage caused by the diesel emission control system, subject to the same exclusions for abuse, neglect or improper maintenance of your vehicle or equipment. Please review your owners manual for other warranty information. Your diesel emission control system may include a core part (e.g., particulate filter, diesel oxidation catalyst, selective catalytic reduction converter) as well as hoses, connectors, a backpressure monitor (if applicable), and other emission-related assemblies. Where a warrantable condition exists, Caterpillar will repair or replace your diesel emission control system at no cost to you including diagnosis, parts, and labor.

WARRANTY COVERAGE

For engines used in verified applications, the warranty period will be in years or hours or miles of operation, whichever occurs first, based on the following chart:

Table 1
Engine Type  Engine Size  Minimum Warranty Period 
On-Road  Light heavy-duty, 70 to 170 hp, Gross Vehicle Weight Rating (GVWR) less than 19,500 lbs.  5 years or 60,000 miles 
Medium heavy-duty, 170 to 250 hp, GVWR from 19,500 lbs. to 33,000 lbs. 5 years or 100,000 miles 
Heavy heavy-duty, exceeds 250 hp, GVWR exceeds 33,000 lbs. 5 years or 150,000 miles 
Heavy heavy-duty, exceeds 250 hp, GVWR exceeds 33,000 lbs., and trucks are:
1. Typically driven over 100,000 miles per year, and
2. Have less than 300,000 miles on the odometer at the time of installation.
2 years, unlimited miles 
Off-Road (includes portable engines) and Stationary  Under 25 hp, and for constant speed engines rated under 50 hp with rated speeds greater than or equal to 3,000 rpm  3 years or 1,600 hours 
At or above 25 hp and under 50 hp 4 years or 2,600 hours 
At or above 50 hp 5 years or 4,200 hours 

If any emission-related part of your diesel emission control system is defective in design, materials, workmanship, or operation of the diesel emission control system thus causing the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, within the warranty period, as defined above, Caterpillar will repair or replace the diesel emission control system, including parts and labor; provided that the following items are excluded from this warranty: (1) gaskets, (2) clamps, and (3) the batteries for the diagnostic module.

In addition, Caterpillar will replace or repair the engine components to the condition they were in prior to the failure, including parts and labor, for damage to the engine proximately caused by the verified diesel emission control strategy. This also includes those relevant diagnostic expenses in the case in which a warranty claim is valid. Caterpillar Inc. may, at its option, instead pay the fair market value of the engine prior to the time the failure occurs.

INSTALLATION OF VERIFIED PRODUCTS WARRANTY

Your Caterpillar dealer warrants that the installation of a diesel emission control system is free from defects in workmanship or materials which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the Requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706. The warranty period and the extent of the warranty coverage provided by your Caterpillar dealer is the same as the warranty provided by Caterpillar Inc. on the diesel emission control system, and the same exclusions apply.

OWNERS WARRANTY RESPONSIBILITY

As the (vehicle, engine, equipment) owner, you are responsible for performing the required maintenance described in your owners manual. Caterpillar recommends that you retain all maintenance records and receipts for maintenance expenses for your vehicle, engine, or equipment, and diesel emission control system. If you do not keep your receipts or fail to perform all scheduled maintenance, Caterpillar may have grounds to deny warranty coverage. You are responsible for presenting your vehicle, equipment, or engine, and diesel emission control system to a Caterpillar dealer as soon as a problem is detected. The warranty repair or replacement should be completed in a reasonable amount of time, not to exceed 30 days. If a replacement is needed, this may be extended to 90 days should a replacement not be available, but must be performed as soon as a replacement becomes available.

If you have questions regarding your warranty rights and responsibilities, you should contact Caterpillar Inc. at 1-877-CAT-0909 or the California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731, or (800) 363-7664, or electronic mail: helpline@arb.ca.gov.

CATERPILLAR EXCLUSIONS AND LIMITATIONS (WHICH DO NOT LIMIT OR MODIFY THE PROVISIONS OF THE ABOVE WARRANTY IN ANY WAY)

THIS IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY CATERPILLAR. CATERPILLAR MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. FURTHER, THE WARRANTY SET FORTH ABOVE MAY NOT APPLY TO THE RESULTS OF ACCIDENT, ABUSE, NEGLECT, VANDALISM, ACT OF GOD, USE CONTRARY TO CATERPILLAR'S INSTRUCTIONS, IMPROPER INSTALLATION, REPAIR, REPLACEMENT OR MODIFICATION BY ANYONE OTHER THAN CATERPILLAR (EXCEPT WITH CATERPILLAR'S WRITTEN APPROVAL). CATERPILLAR does not warrant against infringement under the uniform commercial code by reason of the use of such verified products by Buyer in combination with other materials or in the operations of any process. Except to the extent otherwise provided in the Warranty above, CATERPILLAR SHALL NOT BE LIABLE FOR LOSS OF PROFITS, DIRECT, INDIRECT, INCIDENTAL, SPECIAL, CONSEQUENTIAL OR OTHER DAMAGES ARISING OUT OF OR RESULTING IN ANY WAY FORM ANY DIESEL EMISSION CONTROL SYSTEM OR FORM ANY CAUSE WHATSOEVER, REGARDLESS WHETHER BUYER'S CLAIM IS BASED ON, WITHOUT LIMITATION, CONTRACT, TORT, NEGLIGENCE, PRODUCTS, LIABILITY, OR ANY OTHER CAUSE. Except to the extent provided otherwise in the Warranty above, CATERPILLAR's total, complete and exclusive liability hereunder shall be limited to repair of replacement of the verified device, repair or replacement of the engine or payment for the market value of the engine prior to the failure as provided above. Further, CATERPILLAR is not responsible for repair or replacement of gaskets, clamps or diagnostic module batteries.

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