861578 Mercruiser PULLEY

Introduction
Table 1
Revision History
Revision Summary of Changes
04 Added machine effectivity.
03 Made some changes in maintenance procedure section.
02 Table 2 information was updated.
01 Table 2 information was updated. This Special Instruction details the Diesel Particulate Filter (DPF) maintenance on C2.4, C3.3B, and C3.8 machine engines.Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.Reference
Reference: Special Instructions , REHS7788, "Cleaning the Diesel Particulate Filter (DPF) on C2.4, C3.3B, and C3.8 Engines."Reference: Troubleshooting , "Diesel Particulate Filter Active Regeneration Occurrence is Excessive".Reference: Troubleshooting , "Oil Contains Fuel".Reference: Disassembly and Assembly , "Diesel Particulate Filter- Remove and Install".Safety
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.
When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.
Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.
Personal injury can result from improper handling of chemicals.Make sure you use all the necessary protective equipment required to do the job.Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used.Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.
Maintenance Procedure
There are three options for servicing the Diesel Particulate Filter (DPF).
Diesel Particulate Filter (DPF) can be cleaned by the Cat® dealer.
Replaced with a certified clean Diesel Particulate Filter (DPF) from Cat® Reman.
New Diesel Particulate Filter (DPF) installed.Note: The lowest cost option is the Diesel Particulate Filter (DPF) is cleaned by the Cat® dealer.
Refer to Special Instructions , REHS7788 for cleaning procedures.This document has the acceptable reuse guidelines such as max number of cracked or missing end caps and minimum remaining ash pin depth as measured by a pin gauge.Note: The C3.8 tier 4 final (EU stage 3B) currently does not have a certified clean Diesel Particulate Filter (DPF) available from Cat® Reman.
DPF cleaning is recommended to do at 3000 hrs as part of preventive maintenance, which ensures planned downtime. If the dealer and customer choose to not do this pro-actively at 3000 hrs, then Caterpillar is not responsible for any subsequent damage to the engine or emission components as a result.
If preventive maintenance is not done pro-actively, one of the following will occur which may indicate the Diesel Particulate Filter (DPF) is full or near full:
523602-0 High Frequency Regeneration code occurs.
Fuel Dilution is flagged in the SOS oil sample.
523602-0 High Frequency Regeneration indicated that active regenerations (in-cylinder dosing) occurred within 30 minutes of the prior and this occurred three times in a row. This could indicate the Diesel Particulate Filter (DPF) is full and needs to be cleaned, when higher than 3,000 hrs.Note: 523602-0 High Frequency Regeneration code could also be caused by a different problem. Refer to Troubleshooting , "Diesel Particulate Filter Active Regeneration Occurrence is Excessive" to troubleshoot this code.
Fuel dilution can be caused by many issues. If fuel dilution occurs, refer to Troubleshooting , "Oil Contains Fuel". One cause of fuel dilution can be due to a plugged Diesel Particulate Filter (DPF). This is due to the Diesel Particulate Filter (DPF) getting closer to being full, which results in more frequent the active regenerations (in-cylinder dosing). The more frequent active regeneration occurs the more fuel will get into the oil.
To service the Diesel Particulate Filter (DPF), refer to Disassembly and Assembly , "Diesel Particulate Filter- Remove and Install". The recommended procedures are as follows:
272D, 272D XHP, 297D, 297DXHP, 299D, and 299DXHP- Remove cooling package to gain access to the Diesel Particulate Filter (DPF).
All other models - Remove the engine to gain access to the Diesel Particulate Filter (DPF).
The following Table shows the amount of time it takes to remove and install (R&I) the Diesel Particulate Filter (DPF) as per Equipment Repair Labor Guidelines (ERLG) or Time Requirement Guidelines (TRG).
Table 2
Remove and Install Time Sheet
Sales Models Engine Remove and Install Diesel Particulate Filter Remove and Install Total Diesel Particulate Filter Remove and Install
236D, 242D, 257D, an