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Introduction
Diesel Particulate Filters (DPF) are not applicable to all engines. Diesel Particulate Filters intended for usage on diesel fueled engines only. This technology does not apply to engines that use any other fuel other than ultra low sulfur diesel fuel. A DPF should not be applied to any engine that does not meet all the requirements set forth in this document. The performance conditions required for installation and operation of this technology can be found on the EPA Verified Technologies List web site. Be sure to see all letters and attachments.All installations must include the Diagnostic Module. The Diagnostic Module monitors temperature and pressure conditions providing critical information to the operator. If the required temperature profile is not met, the DPF will not function properly resulting in possible Engine/DPF damage or failure. Upon initial installation of any DPF, a backpressure reading must be taken and recorded for future comparison.The DPF replaces the muffler and may require additional heavy-duty brackets and other modifications/fabrications for proper installation. Consult your Caterpillar Dealer Technical Communicator for specific installation questions.
The Caterpillar Diesel Particulate Filter System includes (see Illustration 1) the following: a diesel oxidation catalyst, a particulate filter, exhaust temperature/pressure monitor ( 423-5875 Clean Emissions Module or the 423-5876 Exhaust Monitor Gp which includes the Diagnostic Module (see "Parts List" section), thermocouple and parts needed for installation.Note: Caterpillar requires that every vehicle equipped with a Diesel Particulate Filter must install the 423-5875 Clean Emissions Module for warranty and maintenance purposes.
Illustration 1 g01917300
Typical DPF Unit (Diagnostic Module not shown)
Diesel Particulate Filter Operation
The Caterpillar Diesel Particulate Filter (DPF) is used to reduce greater than 85% of the emissions of particulate matter (soot). These emissions are reduced by filtration as the exhaust passes through the DPF wall. Carbon monoxide (CO), and Hydrocarbons (HC) are also reduced as the engine exhaust passes through the catalytic oxidation and filtration units. The DPF filter substrate uses a series of alternately blocked channels which forces exhaust gasses to flow through the channel walls. Particulates are physically captured and chemical reactions take place (see Illustration 2). Carbon monoxide and hydrocarbons are converted into carbon dioxide and water vapor. These filters are self-regenerating. Self-regenerating filters are not disposable, but, instead, will "burn off" the accumulated soot continuously if the proper exhaust temperature profile is met.
Illustration 2 g01917293
DPF Wall Flow Design
Proper DPF regeneration REQUIRES the following conditions:
Ultra Low Sulfur Diesel Fuel Must Be Used. Ultra Low Sulfur Diesel Fuel must have an average sulfur content of 15 parts per million (ppm).
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