REPAIR KT-3/8" 2603764 - Caterpillar

This is a 11.0-hour job
11 Hours is allowed for an After Failure Repair.
This is to allow for back pressure valve inspection and DPF Recovery.
If replacement of the back pressure valve or DPF is required, a report of the inspection, including photographs, is required to be attached to the SIMSi claim story.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Rework Procedure for Testing the Diesel Particulate Filter (DPF) for Cracks, Leaks, and recovery from Engine Oil Contamination for C6.6 and C4.4 Engines.
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Introduction:
The following Rework Procedure must be used following contamination of the Diesel Particulate Filter (DPF) from engine oil, or to test for a crack in the DPF. Do not perform any procedure that is outlined in this Rework Procedure until you have read and understand the information that is contained in this document.
Required Tools:
Tool Part Number Part Description Qty
A 380-5200 DPF Crack Detection Kit 1
B 366-7782 Attenuator 1
Testing Procedure:
1. Do not perform any "Manual Diesel Particulate Filter Regeneration" procedures until the cause of the failure has been resolved.
2. Follow the procedure that is detailed by Step 2.a through to Step 2.l in order to clean oil from the exhaust system and DPF.
a. Remove the DPF from the bracket for the clean emission module. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove", for the correct procedure.
b. Use a suitable supporting device, position the DPF in a vertical position. Ensure that the inlet side of the DPF faces in a DOWNWARDS position.
c. Let the DPF drain overnight. The oil will collect inside the inlet face of the DPF. Position a suitable container under the inlet face of the DPF. Incline the inlet face of the DPF to drain the oil into the container.
d. Remove any excess oil from the inlet and outlet of the DPF, and from external surfaces of exhaust system with a clean cloth.
e. Install the DPF from the bracket for the clean emission module. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Install", for the correct procedure.
f. Start the engine and run for 5 minutes at low idle to ensure new turbocharger is adequately lubricated. Move the machine outside for the rest of this procedure. Operate the engine at 100 percent throttle for a MINIMUM of 20 minutes. Do not operate the application under load at this time.
g. After 20 minutes, use the electronic service tool to perform the "DPF Desulphation Procedure". The "DPF Desulphation Procedure" will last 60 minutes.
h. Once the "DPF Desulphation Procedure" has been completed, observe the soot load. If the soot load is at a value less than 80 percent, then proceed with the rest of this Rework Procedure from Step 2k. If the soot load value is at a value greater than 80 percent, repeat the DPF Desulphation Procedure.
i. If soot load remains greater than 80 percent, it could indicate a fault in the soot sensor. Refer to UENR0647, Troubleshooting, Diagnostic Functional Tests, "Soot Sensor