C15 and C18 Industrial Engines Catalyst - Remove and Install - Diesel Oxidation Catalyst, Clean Emissions Module Caterpillar

Removal Procedure

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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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.

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Illustration 1	g02198653

Note: Keep the soot antenna and harness assembly connections clean from contaminants. To prevent contaminants from entering the connections, always plug or cap the connections as they are disconnected.

1. Disconnect cable assembly (2) and remove soot antenna (1) .

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Illustration 2	g02199118

2. Loosen clamp assembly (4) and slide the clamp assembly away from catalyst (7) .

3. Disconnect temperature sensor (5) and pressure sensor (6) .

4. Position Tooling (A) around catalyst (7) . Disconnect clamp assemblies (8) and (3) , and remove the catalyst. The weight of the catalyst is approximately 21 kg (46 lb).

5. Discard clamp assembly (4) .

Installation Procedure

1. Install the diesel oxidation catalyst (7) in reverse order.

   1. Install new clamp assembly (4) . Apply Tooling (B) to the threads of clamp assembly (4) . Tighten clamp assembly (4) to a torque of 50 ± 1 N·m (37 ± 1 lb ft). Do not use power tools in order to tighten clamp assembly (4) .
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   Illustration 3	g02199213
   View from below clamp assembly (8) .

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   Illustration 4	g02199293
   Cutaway view of clamp assembly (8) in position on the assembly.

   2. Verify that the cup of the ball joint (G) does not touch the radius of the ball (F) . Position ball clamp (8) and hand tighten ball clamp (8) . Ball Clamp (8) should be in the center of the joint. Dimension (C) and Dimension (D) should be equal within 2 mm (0.08 inch). Repeat the measurements every 90° around ball clamp (8) . If necessary, adjust ball clamp (8) . Do not use power tools in order to torque clamp assembly (8) . Torque ball clamp (8) to a torque of 35 ± 2 N·m (26 ± 1 lb ft).
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   Illustration 5	g02199513

   3. Apply Tooling (B) to the threads of clamp assembly (3) for a Distance (X) . Distance (X) is 25 mm (1 inch) above the trunnion. Use hand tools in order to tighten clamp assembly (3) . Tighten clamp assembly (3) to a torque of 16.5 ± 1.5 N·m (146 ± 13 lb in).

   Note: Keep the soot antenna and cable assembly connections clean from contaminants.

   4. Apply Tooling (B) to the threads of temperature sensor (5) and soot sensor (1) . Tighten temperature sensor (5) and soot sensor (1) to a torque of 45 ± 5 N·m (33 ± 4 lb ft). Hand tighten the cable assembly (2) when connecting to soot antenna (1) .