Tier 4 Interim: Dealer Preparation For DPF Maintenance

Tier 4 Interim
Dealer Preparation
for DPF Maintenance
February 22, 2013
Mary Roethler
Customer Services Support
Note:
This training provides detailed product support material and is for Cat Field
Reps and Dealer personnel information purposes only. The intention of this
material is to be used for training purposes only and is not to be included in
any messaging presentations.
GENERATIONS AHEAD 1
Caterpillar Confidential: YELLOW
Dealer Preparation for Tier 4 Maintenance
1. Field Population and hours

2. DPF Maintenance Matrix
3. Cleaning
4. Reman
5. Resources on dealer.cat.com/emissionstechnology
GENERATIONS AHEAD 2
Tier 4 Production – Field population is building rapidly
U.S. & Canada

GENERATIONS AHEAD 3
Tier 4 Interim Machine Application Matrix Core Mining
BCP
Emissions 75-175 hp 175-750 hp >750 hp
Category (130-560kW) (>560kW)
(56-130kW)
Engine C3.4B C3.8L C4.4L, C6.6L C7.1L - C18L C27, C32
Models
NOx EGR* EGR* EGR* EGR* EGR*
Reduction
System
PM DOC/DPF DOC/DPF DOC/CDPF DOC/DPF DOC
Aftertreatment
Regeneration Active & Active & Passive only Active & No Regen
method Passive Passive Passive
Regen In-cylinder In-cylinder Cat Regeneration None
Technology Dosing Dosing System (burner)
DPF 3,000 hours 3,000 hours Maintenance 5,000 hours None: no DPF
Maintenance free
Fuel & Oil ULSDF ULSDF ULSDF ULSDF ULSDF
Requirements Low ash oil Low ash oil Low ash oil Low ash oil Low ash oil
Product Use PAV: CB44, SSL 272D, D3-5; 312-318, 320, MG, MTTT, WTS, D11, 992, 854, 773,
Examples CD44, 272D XHP 323, Center Pivot MWL, FP (568, 775, 777,
CD54,CW14 SSL 299D, BHL’s, SWL, D6N, 563,573), AT, HEX
299D XHP CB54, CP54,CP56, (324-349)
CP64/68,
GENERATIONS AHEAD 4
Updated as of February 4, 2014
• The Operation & Maintenance Manuals recommend that DPF ash service
be performed every 5,000 hours for the products that use the C7.1 - C18
ACERT Tier 4 Interim/Stage IIIB engines. Based on the condition of the
DPF and the application of the machines, we are seeing DPFs go well
beyond 5,000 hours before the ECM senses the need for ash servicing and
before active regenerations become more frequent.
GENERATIONS AHEAD 5
Ash Service is due (C7.1 – C18)
• There are two fault codes used to help remind the

customer his DPF is full of ash and requires a complete
cleaning.
– E997(1) – 5,000 hours have passed since the last ash service, the
amber action lamp will not be illuminated
• Stored in ET history
• Not visible in Vision Link
– E997(2) – 5,100 hours have passed and the ECM has determined
that ash loading is at 100% loading. The active lamp will be
illuminated until the DPF is cleaned and codes reset.
• Stored in ET history
• Visible in Vision Link
• Active lamp in cab illuminated until cleaned
• Many products are logging near 10,000 hrs before the code is logged
GENERATIONS AHEAD 6
This message can appear anytime after 5,100 hours when the ECM
determines that the DPF is full of ash and needs to be serviced
• Many Tier 4
Interim
machines with
the C7.1-C18
engines are
getting 8,000
to 10,000
hours before
requiring ash
service.
• This message
will not de-rate
the engine or
require a
service call.
GENERATIONS AHEAD 7
Tier 4 Interim
Machine
Applications
GENERATIONS AHEAD 8
Maintenance Points by Horse Power
• C3.4B, C3.8L (75-175 hp)
– 3,000 hour DPF cleaning
– No DOC maintenance
• C4.4 & C6.6 (75-175 hp)

– DPF is Fit for Life
– No DPF cleaning
• C7.1-C18 (175-750 hp)

– 5,000 hour DPF cleaning
– OCV filter at 2000 hrs
– Regen spark plug at 5000 hrs
– Regen head at overhaul
• C27 & C32 (>750 hp)

– No DPF, No DPF cleaning
GENERATIONS AHEAD 9
Ash in The Diesel Particulate Filter (DPF)
• Formed from lube oil additives that don’t

combust
• Removal requires cleaning process

• C7.1 ACERT – C18 ACERT
applications at 5,000 hours
• C3.4B and C3.8L applications at
3,000 hours
• Dispose per applicable regulations
• Multiple cleaning methods available

• Stationary (on-highway) tool
• Additional adapters available
• Mobile tool
• Caterpillar Reman Exchange
GENERATIONS AHEAD 10
319-2189 Diesel Particulate Filter (DPF) Ash Cleaning Tool
319-2189 DPF Cleaning Tool - $17,289.61* Dealer Net USD

Availability: Currently Available
• Cleans all Caterpillar DPF sizes
• Utilizes custom Cat software and adapters
• Accepts SD memory cards to install other OEM
DPF cleaning software
Adapters Needed for Tier 4 Machine DPF cleaning:

373-9826 Adapter Kit
Approximate Cost: $737.73* Dealer Net USD
*prices as of September 11, 2013
364-5971 Compact DPF Cleaner
• The new Compact DPF Cleaner has the best

available technology and is small enough to
transport to all servicing locations
• Cleans DPF in approximately one hour

• Is quiet, less than 72.8 dB
• Requires no expensive consumables
• Requires no specialized adapters
• Is CE Compliant
• Pricing: DN $10,802.42* USD
• Serviceable Parts
– 364-6044 - Kit-Ring & Seal (large)
– 371-3749 - Kit-Ring & Seal (med)
– 367-8959 - Kit-Ring & Seal (small)
– 366-6780 - Kit-Ash Disposal
– 366-6781 - Kit-HEPA Filter
*prices as of September 11, 2013
C3.8 DPF Cleaning
DPF Cleaning is 3,000 Hours

– Oval shaped DPF (7” X 10”) and 6” long
• DPF cleaners designed for round.
• Cleaning requires 392-3966 DPF Adapter Kit
– $685.66* USD DN
• Designed to work with other DPF cleaning manufacturers.
*prices as of September 11, 2013 Caterpillar Confidential: YELLOW
DPF Pricing D6T $1150 / 5,000 hrs = $0.23/hour
Serviced Level New Reman Part Reman Application

Filter Kit Part Customer List Number Customer List
Number
389-5370 $3,018.52 tbd tbd 272D, 299D SSL
358-3659 $1,531.80 20R0696 $ 842.48 C7.1, C9.3 (D7 only)
358-3662 $2,090.42 20R0697 $1,149.73 C7.1, C9.3
358-3664 $2,891.37 20R0698 $1,445.70 C9.3 (MWL only)

358-3667 $3,833.09 20R0699 $1,916.54 C15 (D8 only)
C9.3 (Industrial only)
358-3669 $4,181.73 20R0700 $2,090.86 C13, C15, C9.3
(Industrial only)
Caution: check prices; good as of September 11, 2013
See Reman Core Acceptance Criteria: SELD0292-02
DPF Core Acceptance Criteria SELD0292-2
https://catreman.cat.com/cda/files/2863520/7/seld0292-02_final.pdf
DPF Service Interval – Cleaning option
For Cleaning, must clean and reinstall on same machine; dealer exchange is not supported
ECM logs a code stating “Ash Service Due” @ 5000 hours

– Can only be cleared by Electronic Technician (ET)
Dealer or Customer must complete 1 hour in-chassis “Ash Service Regeneration”
– Initiated by ET
Estimated dealer cost/labor hours
1. 1 hour for in-chassis Ash Service Regen
2. 1-2 hours to cool
Anticipate Competition from
3. 1-2 hours for Remove & Install
TEPS Dealers, Cummins Dealers
4. 1 hour to clean DPF
Estimated parts costs:
Torca clamps, order quantity of 2 (~$55 x 2)
• Reference: REHS5045, DPF Maintenance on Tier 4 Products

Special Instructions
DPF Service Interval – Reman option
ECM logs a code stating “Ash Service Due” @ 5000 hours

Can only be cleared by Electronic Technician (ET)
No need to perform the 1 hour in-chassis “Ash Service Regeneration”

(initiated by ET)
Estimated dealer cost/labor hours

1-2 hours for Remove & Install
Reman DPF part number includes the Torca clamps needed
Reference: REHS5045, DPF Maintenance on Tier 4 Products,

Special Instructions
Resources for DPF Maintenance and Inspections
1. DPF Core Acceptance Criteria SELD0292-2

2. REHS5045 Special Instruction –

Maintenance on Tier 4 Products Equipped
with a Diesel Particulate Filter (DPF)
3. DPF Service Information on Dealer.cat.com/emissionstechnology

https://dealer.cat.com/cda/files/4469807/7/DPF%20Service%20Inf
ormation%20v3.doc
4. REHS5704 Special Instruction –

Testing the DPF for Cracks and Leaks
5. SEBF9223 Reuse And Salvage Guidelines –

Inspection of Diesel Particulate Filters and Diesel Oxidation
Catalysts for Tier 4 Machine and Industrial Engines
CJ-4 Oil
 Low Ash Oil

• Cat® DEO-ULS™ or oils that meet
the
Cat ECF-3, API CJ-4, and ACEA E9
specification are required.
• Use of oil with greater ash and

chemical levels can have the
following negative effects:
 Aftertreatment will accumulate
more ash sooner
 Cause aftertreatment
damage
 Increase the frequency of
ash service
 Reduce performance
DPF Core Acceptance Criteria SELD0292-2
New Maintenance Requirements for Tier 4 Interim
C9.3 ACERT – C18 ACERT
Part Estimated Parts Price Interval Labor
(Customer List)*
3rd Fuel Filter $ 42 500 hrs ~ 30 min.

Primary: 326-1643
$ 18
Secondary: (2) 1R-0749
OCV filter 2,000 hrs ~ 15 min.
Filter: 326-4689 $ 36
Engine Valve Lash (C9.3-C18) Initial valve lash set 2,500 hrs ~ 2-8 hrs.
is no longer
Reusable Valve Cover seal required
(Inspect and replace as needed)
Electric Priming Pump 5,000 hrs ~ 30-60 min.
Repair Kit: pump, CRS filter, seals (4) $351
CRS Spark Plug 5,000 hrs ~ 15 min.

Spark Plug $ 14
DPF Ash Service 5,000 hrs ~ 2-8 hrs.
Torca Clamps (if cleaning DPF) or $58 each or
Reman Filter kit $800 - $2000
Caterpillar Confidential: YELLOW See the Operations & Maintenance Manual for specific part numbers and
Caterpillar Confidential:
instructions YELLOW
*Caution: check prices; good as of January 2013
Use your Product Link to
determine your machines that
are close or overdue for their
5,000 Service Interval
Tier 4 Production – Field population is building rapidly
Use Product Link to determine your

machines that are close or
overdue for their 5,000 hour
Service Interval
Package & sell 5,000 hour PM

Service which includes:
1. DPF Ash Service,
2. electric priming pump,
3. spark plug,
4. valve lash, etc.
5. .
6. .
7. Inspection?
Resources
The quickest link to
Tier 4 information
https://dealer.cat.com/EmissionsTechnology
Tier 4 Interim Machine Application Matrix
Emissions
Category
BCP 75 - 175 hp
(56-130kW)
Engine Models C3.4B C3.8L C4.4L C6.6L
Regeneration Active & Passive Active & Passive Passive only Passive only
method
Dash Active
Regen
When
“regen *
Toggle needed”
lights / Regen
switch to
force or
light is on;
increase
Needed
Operator disable
regen
engine
RPM to
None None
Regen green zone
Interface Disabled to regen
*
Regeneration Active & Passive Active & Passive Passive only Passive only
method
DPF Maintenance 3,000 hours 3,000 hours Fit for Life Fit for Life
Product Use PAV (CB44, CD44,CD54, SSL (272D, 272D STTT (D3,D4,D5) HEX (320, 320RR,
NPI products CW14) XHP 299D, SXC (312,314,316, 318) 323)
299D XPH) BHL (416, 420, 430) SWL (924,930,938)
FP (529, 2280) MTTT (D6N, D6K)
PAV (CB54, CP54, CP56, FP (559, 579. 2384)
CP64/68, CP74, CS54, CS56,
CS64/68, CS74, CS76/78,
CW34)
*see speaker notes for more information
Caterpillar Confidential: YELLOW Caterpillar Confidential: YELLOW
Media Numbers & Description
Revised Tier 4 Interim Brochure
Tier 4 Interim Customer Brochure
 YEGT3000-01 Built for the Next Generation
 Available in English, Spanish, French
Canadian
Tier 4 Interim Regen Hard Card (7-18L)

 AMXQ0575 Two sided Regen Card
 English-Spanish
 AMXQ0576 Two sided Regen Card
 English-French
Tier 4 Interim Regen Static Cling (7-18L)

 AEXQ0681 English Static Cling
 ASXQ0681 Spanish Static Cling
 A5XQ0681 French Canadian Static Cling
Tier 4 Interim Regen Hard Card (272D & 299D)

 AEXQ0939 English Hard Card
 ASXQ0939 Spanish Hard Card 6 Minute Regen Video
 A5XQ0939 French Canadian Hard Card
Regen Hard Card
Tier 4 Interim Regen Static Cling (272D & 299D) 7L-18L
 AEXQ0953 English Static Cling
 ASXQ0953 Spanish Static Cling
 A5XQ0953 French Canadian Static Cling
Regen Window http://www.youtube.com/watch?v=gb20fcPewTI

Regen Hard Card & Static Cling
Window Static Cling 7L-18L Cat Customer Testimonial Videos
272D & 299D
980K http://www.youtube.com/watch?v=7XIf6hse_N8
D6T http://www.youtube.com/watch?v=n1AjqMMft_8
Caterpillar Confidential:
*For more information, go to https://dealer.cat.com/EmissionsTechnology YELLOW
CJ-4 Oil resources:
• PEHJ0159
DPF New, Reman and Clamp Part numbers, Dimensions & Applications

Tier 4 Interim: Dealer Preparation For DPF Maintenance

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Tier 4 Interim

1. Field Population and hours

Caterpillar Confidential: YELLOW

• There are two fault codes used to help remind the

• C4.4 & C6.6 (75-175 hp)

• C7.1-C18 (175-750 hp)

• C27 & C32 (>750 hp)

• Formed from lube oil additives that don’t

• Removal requires cleaning process

• Multiple cleaning methods available

319-2189 DPF Cleaning Tool - $17,289.61* Dealer Net USD

Adapters Needed for Tier 4 Machine DPF cleaning:

*prices as of September 11, 2013

• The new Compact DPF Cleaner has the best

• Cleans DPF in approximately one hour

• Pricing: DN $10,802.42* USD

*prices as of September 11, 2013

DPF Cleaning is 3,000 Hours

Serviced Level New Reman Part Reman Application

358-3659 $1,531.80 20R0696 $ 842.48 C7.1, C9.3 (D7 only)

358-3662 $2,090.42 20R0697 $1,149.73 C7.1, C9.3

358-3664 $2,891.37 20R0698 $1,445.70 C9.3 (MWL only)

Caution: check prices; good as of September 11, 2013

See Reman Core Acceptance Criteria: SELD0292-02

ECM logs a code stating “Ash Service Due” @ 5000 hours

• Reference: REHS5045, DPF Maintenance on Tier 4 Products

ECM logs a code stating “Ash Service Due” @ 5000 hours

No need to perform the 1 hour in-chassis “Ash Service Regeneration”

Estimated dealer cost/labor hours

Reman DPF part number includes the Torca clamps needed

Reference: REHS5045, DPF Maintenance on Tier 4 Products,

1. DPF Core Acceptance Criteria SELD0292-2

2. REHS5045 Special Instruction –

3. DPF Service Information on Dealer.cat.com/emissionstechnology

4. REHS5704 Special Instruction –

5. SEBF9223 Reuse And Salvage Guidelines –

 Low Ash Oil

• Use of oil with greater ash and

3rd Fuel Filter $ 42 500 hrs ~ 30 min.

CRS Spark Plug 5,000 hrs ~ 15 min.

Use Product Link to determine your

Package & sell 5,000 hour PM

Engine Models C3.4B C3.8L C4.4L C6.6L

Tier 4 Interim Regen Hard Card (7-18L)

Tier 4 Interim Regen Static Cling (7-18L)

Tier 4 Interim Regen Hard Card (272D & 299D)

Regen Window http://www.youtube.com/watch?v=gb20fcPewTI

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