C7.1 Industrial Engine Catalyst - Remove and Install - Diesel Oxidation Catalyst (DOC) Caterpillar

Removal Procedure

Show/hide table

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.

Show/hide table

The muffler, catalytic converter/muffler, and diesel particulate filter will become extremely hot during engine operation. A hot muffler, catalytic converter/muffler and diesel particulate filter can cause serious burns. Allow adequate cooling time before working on or near the muffler, catalytic converter/muffler and diesel particulate filter.

Show/hide table

Illustration 1	g02360116

1. If necessary, remove the Original Equipment Manufacturers (OEM) exhaust system from outlet cannister (4) of the clean emission module.

2. Make temporary alignment marks on Torca clamp (3) in Position (A) and Position (B). Loosen the nuts for Torca clamp (3) and slide the Torca clamp along the Diesel Particulate Filter (DPF).

3. Sufficiently loosen the nuts on clamp (2) in order to allow the Diesel Oxidation Catalyst (DOC) (1) to be removed.

4. Loosen the bolt on ball clamp (5) in order to allow the removal of DOC (1).
   Show/hide table

   Illustration 2	g02360117

   Show/hide table

   Illustration 3	g02360118

5. Disconnect harness assembly (7) from soot antenna (8).

6. Remove temperature sensor (6). Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.

7. Remove soot antenna (8). Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.

8. Disconnect nut (11) for tube assembly (10).

9. Slide hose clamp (9) along the hose assembly. Remove tube assembly (10).
   Show/hide table

   Illustration 4	g02360119

10. Make temporary alignment mark on DOC (1) and Diesel Particulate Filter (DPF) in Position (C).

11. Attach a suitable lifting device to DOC (1). The weight of the DOC is approximately 20 kg (44 lb).

12. Rotate the DOC in a counter clockwise direction in order to disengage pins and slots (12) from the DPF.

13. Use the suitable lifting device to remove DOC (1) from the clean emission module mounting bracket.

14. Remove Torca clamp (3).

15. Remove ball clamp (5).

Installation Procedure

1. Ensure that all components are clean and free from wear and damage. If necessary, replace any components that are worn or damaged.
   Show/hide table

   Illustration 5	g02360119

2. Position a new Torca clamp (3) onto the DPF. Ensure the correct orientation of the Torca clamp (3).

3. Position a new ball clamp (5) onto DOC (1). Ensure the correct orientation of ball clamp (5).

4. Attach a suitable lifting device to DOC (1). The weight of the DOC is approximately 20 kg (44 lb).

5. Use the suitable lifting device to position DOC (1) onto the clean emission module mounting bracket and align pins and slots (12).

6. Rotate DOC (1) in a clockwise direction in order to engage pins and slots (12) as in Position (C). Ensure that the pins and slots are fully engaged.
   Show/hide table

   Illustration 6	g02328556

   Show/hide table

   Illustration 7	g02360119

7. Position ball clamp (5) and hand tighten the bolt. Ensure that the ball clamp is correctly orientated.

8. Slide Torca clamp (3) along the DPF ensure that Torca clamp is correctly orientated.

9. Position the Torca clamp between Position (A) and Positions (B). Hand tighten the Torca clamp. Ensure that the Torca clamp is correctly aligned.
   Show/hide table

   Illustration 8	g02360116

10. Tighten the nuts on clamp (2) for DOC (1) and the DPF hand tight.

11. Tighten nuts for Torca clamp (3) to a torque of 42 N·m (31 lb ft).

12. Tighten the nuts for clamp (2) to a torque of 18 N·m (159 lb in).

13. Tighten the bolt for clamp (5) to a torque of 18 N·m (159 lb in).

14. If necessary, install the OEM exhaust system to outlet cannister (4) of the clean emission module.
    Show/hide table

    Illustration 9	g02360118

    Show/hide table

    Illustration 10	g02360117

15. Install soot antenna (8). Refer to Disassembly and Assembly, "Soot Antenna - Remove and Install" for the correct procedure.

16. Connect harness assembly (7) to soot antenna (8). Tighten the harness assembly to a torque of 1.5 N·m (13 lb in).

17. Position tube assembly (10) onto the hose assembly and connection on DOC. Connect nut (11) finger tight.

18. Slide hose clamp (9) along the hose assembly. Ensure that the hose clamp is correctly positioned.

19. Tighten nut (11) to a torque of 16 N·m (142 lb in).

20. Install temperature sensor (6) in to DOC (1). Refer to Disassembly and Assembly, "Temperature Sensor (DPF) - Remove and Install" for the correct procedure.