5441600TP Mercruiser STERNDRIVE, Bravo-III (2.00:1 Ratio)

Diesel Particulate Filters (DPF) are not applicable to all engines. A Diesel Particulate Filter should typically not be applied to engines that are not regulated. Diesel Particulate Filters are meant for usage on only diesel engines. This technology does not apply to gas engines. Consult with Caterpillar in order to determine if a Diesel Particulate Filter can be used on your engine.
Included in this guide is a parts list and installation procedure. Each section is highlighted for your convenience.Read each section carefully prior to installing your DPF.Consult your Caterpillar dealer with questions concerning installation or warranty-related matters.Note: Ultra-Low sulfur Diesel fuel must be used. Ultra Low Sulfur Diesel (ULSD) fuel (≤ 15 ppm (mg/kg) sulfur) is required by regulation for diesel engine use in California. The United States (U.S.) Environmental Protection Agency (EPA) defines Ultra Low Sulfur Diesel (ULSD - S15) as a U.S. diesel fuel with a sulfur content not to exceed 15 parts per million (ppm (mg/kg)). Also, the sulfur content in the diesel fuel is not to exceed 0.0015 percent by weight. ULSD fuel must meet the S-15 fuels designation in the latest edition of ASTM D975 and/or conform to Caterpillar Fuel Specification.Warranty and Record Of Installation
The statement of warranty for the DPF can be found at the end of this installation manual.Be sure to record the information from the DPF housing label prior to installation.System Parts
One (1) Caterpillar DPF with data monitoring The DPF system consists of the following components:
(1) Catalyst Section
(1) Filter Section
(1) Inlet Head
(1) Outlet Head
(3) V-Band clamps
(3) Gaskets
(1) DPF Diagnostic Module to monitor the backpressure and temperature of your DPF. Refer to the DPF Diagnostic Module (DPFdm) manual for installation and operating instructions.
(1) DPF Diagnostic Module installation kit, including thermocouple, pressure sampling tube and wiring harness
(1) Remote Display Module (RDM).
One (1) packet consisting of:
Engine Label
Record Of Installation
Installation Guide
Bill of Materials
Depending on your DPF purchase, additional auxiliary items may be included such as brackets, piping and insulation. Check your bill of materials for a complete listing. System Installation Procedure
Note: Reference Special Instruction, REHS5606 for complete system installation information.
Inspect engine to ensure that it meets engine manufacturers specifications or correct the engine to meet the engine manufacturers specifications. Note: Caterpillar requires prior to installation of a DPF, each engine must be inspected by a mechanic to determine that the engine meets all of the engine manufacturers specifications. Failure to meet the correct engine specifications could void the DPF warranty. Check your warranty for details.
Remove the outlet pipe from the existing muffler.
Remove the inlet pipe from the existing muffler.
Remove the existing mounting brackets/bands.
Remove the existing muffler.
If the existing clamps and brackets are to be reused, inspect clamps and brackets to ensure that they are not fatigued or cracked. Replace these components as required.
The DPF system is shipped as a ready to install assembly, however, the t-bolt and lock-nut on the v-band clamp may need reoriented on the circumference to prevent interference with other components on the vehicle, or to allow for easier access. If the v-band clamp is loosened to reorient its location, the locknut must be tightened to the rated torque value of 16 N m (144 lb in) to prevent leakage.
On DPF units where the inlet and/or outlet pipe is eccentrically located on the section and/or if the unit has a side inlet and/or outlet, the v-band clamp may need loosened to reorient the head for installation. The v-band clamp must be tightened to the rated torque value of 16 N m (144 lb in) before the piping is installed to prevent eccentric loading that will result in leaks. Note: Care should be taken to ensure that the gaskets are not damaged during rotation of the v-band clamps, heads, or when the filter section is removed for cleaning. If the gasket is damaged, or not sealing properly, replace with Caterpillar approved gaskets.
Each DPF is shipped with 1/4 inch NPT couplings and plugs on the inlet and outlet sections. If the ports are not being utilized in the installation, check that the plugs are properly tightened.
Install the DPF system in the same location where the existing muffler was located or according to specification. Use either new clamps and brackets, if provided, or, if suitable, reuse existing clamps and brackets. When installing the DPF system, all mounting brackets must be adjusted so the inlet and outlet pipe of the DPF system line up accurately to the inlet and outlet piping of the vehicle. If properly aligned, the DPF system will have no eccentric loading on the inlet and outlet pipes. Note: The DPF can be significantly heavier than a standard muffler. If existing supports and brackets are reused, these supports and brackets must be evaluated to ensure that they can adequately support the added load of the DPF. Consult your Caterpillar dealer directly for recommendations.
Illustration 1 g01425324
Diesel Particulate Filter
(1) Inlet section
(2) Catalyst section
(3) Filter section
(4) Outlet section
Your DPF must be installed with the correct flow orientation. Verify the direction of flow by identifying the tag marked "inlet" on the DPF body. Note: The DPF system must have the catalyst section directly up-stream of the filter section in order to operate properly. The catalyst section is identified because it is the shorter section without piping. The filter section is the longer section without piping. At all times during operation the catalyst section must remain in front of the filter section in the direction of flow. Assembly should be inlet section, then catalyst section, then filter section and finally outlet section.
Reinstall the inlet and outlet pipes. Note: Any eccentric loading on the inlet and outlet piping in conjunction with the vibrations caused by vehicle operation can result in stress cracking of the DPF system where the pipe or pipe support contacts the DPF body.Note: If the DPF is mounted horizontally and the system has a vertical tailpipe, a 6.35 mm (0.25 inch) diameter water drainage hole must be drilled in the lowest point of the DPF outlet section. The drain hole shall be located 3.81 cm (1.5