Caterpillar TH407C DPF & EGR Cleaning

Описание: DPF Diesel Particulate Filter Removal & Flush Using Carbon Clean UK DCS-16

Caterpillar TH407C DPF & EGR Cleaning: A Telehandler Rescue Mission

Ever tackled a DPF cleaning on a Caterpillar telehandler? It's not your average car job! Jimmy from The Diesels recently faced this challenge. The mission: to clean the Diesel Particulate Filter (DPF) and Exhaust Gas Recirculation (EGR) system on a Caterpillar TH407C telehandler. The customer had already consulted with a Caterpillar mechanic. However, they needed a specialist to clean the DPF. This job wasn't without its hurdles. There were connector issues, software incompatibility, and tricky diagnostics. Keep reading to see how Jimmy and The Diesels overcame these obstacles and got the telehandler back to work.

Understanding the Challenge: Caterpillar Telehandler Diagnostics

The initial inspection of the Caterpillar TH407C revealed a few issues. A loud beeping noise and several warning lights were present. The telehandler has an on-board diagnostic system. But it wasn't providing enough information. The system did display a trouble code: 371916. This code indicated that the DPF was clogged beyond the norm. The machine also had 6,635 hours of use.

Diagnostic Connector Issues

Connecting a diagnostic tool proved difficult. Jimmy tried to connect the Launch Euro diagnostic tool. Unfortunately, the connector was incompatible. This prevented access to the telehandler's computer. A universal connector kit was ordered to solve this. But it would take a week to arrive.

The Caterpillar Mechanic's Solution

The Caterpillar mechanic suggested simply cleaning the DPF. They hoped this would resolve the fault codes. Without a working diagnostic tool, this seemed like the best first step.

Hands-On: DPF Removal and Cleaning

Cleaning the DPF required removing it first.

DPF Removal Process

The DPF is located under the telehandler. Removing it involved several steps. Skid plates needed to be removed. Temperature sensors had to be disconnected. Finally, the exhaust clamps and pins were released. Jimmy noted that the DPF removal process is similar to that of a regular vehicle.

DPF Cleaning with Carbon Clean UK DCS-16

The DPF was cleaned using a Carbon Clean UK DCS-16 [https://carbon-clean.co.uk/product/dc...]. This machine is designed for DPF cleaning.

The cleaning process involved several steps. First, the holes for the temperature sensors were blocked off. Then, a mixture of Launch DPF cleaner and water was prepared. The mixture was 2 liters of cleaner and 8 liters of water. The DPF was soaked with this solution. Finally, the DPF was flushed with the DCS-16 machine. The initial liquid that came out was black, showing a heavy blockage.

Tackling the EGR System

The EGR system also needed attention.

EGR Valve Inspection and Cleaning

The EGR valve and upstream pressure sensor were inspected. Soot blockage was found. The EGR valve was unblocked to restore proper function.

EGR Pipe Cleaning

The EGR was disconnected. The EGR pipes and attachments were cleaned. All components were flushed to remove any remaining debris.

Reassembly and Initial Testing

With the DPF and EGR system cleaned, it was time for reassembly.

Reassembly

The cleaned DPF and EGR components were reattached. All connections were checked to ensure they were secure.

Initial Startup and Smoke Clearing

After reassembly, the telehandler was started. Smoke was present initially. It needed to be cleared out before further testing.

The Diagnostic Puzzle: DPF Pressure Sensor and Resetting Fault Codes

Despite the cleaning, some questions remained.

Missing DPF Pressure Sensor

The telehandler lacked a DPF pressure sensor. This raised questions about how the system detects DPF blockages. It's possible the system uses timed regeneration. This is where the DPF is cleaned automatically after a set number of hours.

Software Limitations and Resetting Faults

The inability to connect the diagnostic tool was still a problem. Resetting the fault codes was uncertain. The customer's other mechanic might be needed for this.

The Unexpected Solution: The "Dead Switch" Trick

Sometimes, the simplest solutions are the most effective.

The Customer's Discovery

The customer used the telehandler's "dead switch". This disconnects the battery. They left it off overnight.

The Miraculous Result

The next morning, the warning lights were gone! The telehandler worked perfectly for a week. The "dead switch" trick seemed to have solved the problem.

Final Thoughts and Follow-Up

Cleaning the DPF and EGR system was crucial for restoring the telehandler's performance. The "dead switch" solution was an unexpected but effective way to reset the system. A follow-up 10 days later confirmed the fix.

Outro


CATERPILLAR TH407C Plant/Farm Machinery Telehandler