Diesel Particulate Filters At Great Prices!

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Diesel Particulate Filter (DPF) - Installation

Installation Procedure for Dieselytic SXS Diesel Particulate Filters:

1) The Dieselytic SXS diesel particulate filter (DPF) should be located as close to the outlet of the engine exhaust manifold or turbocharger as possible. The filter should be located no more than 30” (750 mm) from the engine exhaust manifold outlet or turbocharger outlet. The stock OEM muffler must be removed and replaced by the diesel particulate filter. The diesel particulate filter will also act as a muffler and reduce exhaust noise levels.

The Dieselytic SXS diesel particulate filter should be installed in a horizontal orientation. Do not allow the filter to contact any structural members of the vehicle or equipment. Avoid locating the exhaust gas purifier in close proximity to electrical components, fuel lines, fuel tanks or any combustible materials.

We strongly recommend that the full length of exhaust pipe from the engine exhaust manifold or turbocharger outlet to the filter be fully insulated with the supplied heat wrap tape.

2) To install the Dieselytic SXS diesel particulate filter, remove the stock OEM muffler from the engine exhaust system. Remove any exhaust pipe, flanges or connectors from the engine exhaust manifold outlet (or turbocharger outlet). Select a location for the diesel particulate filter and filter cradle, which is easily accessible, and close to the engine exhaust manifold (or turbocharger outlet). The filter should be located no more than 30” (760 mm) from the engine exhaust manifold outlet or turbocharger outlet. Do not allow the filter to contact any structural members of the vehicle or equipment. Avoid locating the exhaust gas purifier in close proximity to electrical components, fuel lines, fuel tanks or any combustible materials.

3) Use the directional flow arrow located on the diesel particulate filter body to correctly orient the exhaust flow direction of the Dieselytic SXS diesel particulate filter. When handling the diesel particulate filter take extra care to ensure that the filter is not damaged in any way. The filter cradle has a quantity of 4 mounting holes which are 0.430” in diameter. Mount the cradle to the secure location on the equipment chassis/body with 3/8” diameter grade 5 bolts. If you have to remove the diesel particulate filter from the filter cradle take extra care in tightening the grade 5 strap bolts. Always operate the diesel particulate filter with the filter cradle.

4) Once the Dieselytic SXS diesel particulate filter and filter cradle are safely and correctly mounted, fabricate an exhaust pipe adapter which will connect the engine exhaust manifold outlet (or turbocharger outlet) to exhaust flex hose. Modify the existing OEM parts or contact the equipment manufacturer for these components. Use aluminized steel flex hose, which has the same inside diameter as the stock OEM exhaust pipe outside diameter. Use the aluminized steel flex hose to connect the engine exhaust manifold outlet (or turbocharger outlet) to the inlet cone of the diesel particulate filter. Use the supplied accuseal flat band exhaust clamps and adapter to attach the flex hose to the filter and the engine exhaust outlet.

5) Torque the accuseal flat band exhaust clamp bolts to 45 foot pounds torque. Finished installation should measure between 1/8” and ¼” at the gap between the band curls of the accuseal flat band exhaust clamps. Start and idle the engine for a period of 5 to 10 minutes. Re-torque the band clamp bolts to the correct torque specification. Double check for any apparent exhaust leaks.

6) Insulate the aluminized steel flex hose from the engine exhaust manifold (or turbocharger outlet) to the diesel particulate filter with the supplied heat wrap tape. The heat wrap tape is approximately 2.0” wide by 1/8” thick. Wrap at least 2 layers of heat wrap tape onto the aluminized steel flex hose so the insulation thickness is at least 1/4” when finished. Use large diameter hose clamps (4.0”+diameter) to secure the heat wrap to the aluminized steel flex hose.

7) Once installation of the Dieselytic SXS exhaust particulate filter is complete, the engine exhaust backpressure restriction should be measured. Use a backpressure gauge/manometer (0 to 50” H2O range) to measure the exhaust gas flow restriction. Remove the 1/8” NPT brass plug located at the 1/8” NPT port on the inlet cone of the filter. Install the metal probe of the exhaust backpressure restriction gauge into the 1/8” NPT port. Start the engine and operate the engine at high idle and load stall conditions. Measure and record the exhaust gas restriction at both high idle and load stall conditions. The exhaust gas flow restriction of clean particulate filters will be in the order of 20” to 25” H2O.

8) Proceed to the section on “adding diesel fuel additives to the diesel fuel tank”. If you have any additional requirements, comments or questions please call the sales office at 1-(800)551-5525.

Installation Instruction for CEP Backpressure Gauge(s):

CEP backpressure gauges are designed to indicate diesel engine exhaust gas backpressure restriction, which is imposed by a diesel particulate filter or diesel oxidation catalyst/purifier and/or other exhaust system components. 2 brands of backpressure gauge are currently offered. The first brand is a Dwyer Magnehelic gauge which has a range of 0 to 50” inches water gauge. 50” inches of water gauge is equivalent to 3.7” inches mercury gauge. The second brand is a Murphy switch gauge, which also has a range of 0 to 50” inches of water gauge. The Murphy switch gauge incorporates electrical switches, which can activate a warning light or engine shutdown system. The backpressure gauges will determine if the diesel particulate filter is functioning and regenerating correctly.

Backpressure Gauge Components:

  1. Stainless steel 1/8” NPTF port and brass 1/8” NPTM plug
  2. Brass 1/8” NPTM to 1/4” I.D. tube fitting and 1/4" O.D. copper tube (60”+ length)
  3. 1/4” O.D. plastic tube (180”+ length)
  4. Brass 1/4” I.D. tube coupling
  5. Filter/water trap separator assembly
  6. Backpressure gauge assembly

Installation Procedure:

  1. Firstly drill a 15/32” diameter hole into the diesel engine exhaust pipe immediately after the engine turbocharger outlet or the exhaust manifold outlet. It is recommended that the system installer locate the 15/32” hole within 12” of the engine turbocharger outlet or exhaust manifold outlet. Weld the supplied stainless steel 1/8” NPTF port onto the 15/32” hole. Use a SS309 alloy weld filler rod to attach the 1/8” NPTF port fitting onto the 15/32” hole in the steel exhaust pipe. A brass 1/8” NPTM pipe plug is included with the 1/8” NPTF port fitting. Remove the brass 1/8” NPTM pipe plug from the 1/8” NPTF port fitting after welding. This hole location will provide the most accurate backpressure readings. If the 15/32” hole location is not practical or feasible then use the 1/8” NPTF port fitting located in the inlet cone of the diesel particulate filter or diesel oxidation catalyst/purifier. This inlet cone port location is not as accurate and will result in lower total exhaust gas backpressure restriction values.
  2. Locate the ¼” O.D. copper tube (with the brass ¼” I.D. tube coupling 1/8” NPTM fitting and the brass ¼” I.D. tube coupling). Thread the brass 1/8” NPTM fitting of the ¼” O.D. copper tube into the stainless steel 1/8” NPTF port fitting on the engine exhaust pipe or DPF inlet cone. Use a ½” wrench to torque the ½” fitting nut to a torque of 14-16 foot pounds. Use a 9/16” wrench to torque the 9/16” tube nut to a torque of 10-12 foot pounds. Please note that there are 2 small ferrules which retain the tube nut to the ¼” O.D. copper tube. Uncoil and shape the ¼” O.D. copper tube as required. We recommend that you do not shorten the length of the ¼” O.D. copper tube as it will act as a heat sink to protect the ¼” O.D. plastic line.
  3. Locate the ¼” O.D. plastic tube. Uncoil the ¼” O.D. plastic tube as required. Attach the ¼” O.D. copper tube to the ¼” O.D. plastic tube coupling with the brass ¼” I.D. tube coupling. Use a 9/16” wrench to torque the 9/16” tube nut to a torque of 10-12 foot pounds. Use a ½” wrench to support the coupling while tightening the 9/16” tube nuts. Please not that there are 2 small ferrules which retain the tube nut to the ¼” O.D. copper tube and the ¼” O.D. plastic tube.
  4. Please note that the backpressure gauge assembly and pressure switch should be located as high as possible to allow moisture to drain back to the engine exhaust pipe. The backpressure gauge assembly should therefore be the highest vertical point of the backpressure measurement system. The filter/water trap separator assembly should be located as close to the backpressure gauge assembly and pressure switch as possible. The filter/water trap separator assembly should be located at a slightly lower vertical point than the backpressure gauge assembly and pressure switch. The remaining plastic line and copper line should slope downward towards the engine exhaust pipe.
  5. Locate the filter/water trap separator assembly. Ensure that the bowl drain of the filter/water trap separator assembly is always oriented lower or downward (to allow accumulated water to drain) while the metal body of filter/water trap separator assembly is located higher. Cut the ¼” O.D. plastic tube to the required length. Attach the ¼” O.D. plastic tube into the filter/water trap separator assembly. Use a 9/16” wrench to torque the 9/16” tube nut to a torque of 10-12 foot pounds. Please not that there are 2 small ferrules which retain the tube nuts to the ¼” O.D. plastic tube. Retain the filter/water trap separator assembly to a secure location on the vehicle chassis by using heavy duty hose clamps or ty-raps, etc…
  6. Located the combination normally open/closed adjustable pressure switch. The pressure switch should be installed in an area which is free or excessive vibration, excessive oil mist, dripping water and has ambient temperatures between 20 degrees F and 120 degrees F. Cut the ¼” plastic tube to the required length. Connect the ¼” plastic tube to the brass ¼” tube fittings of the “ T fitting”. Use a 9/16” wrench to torque the 9/16” tube nut to a torque of 10-12 foot pounds. Please note that there are 2 small ferrules which retain the tube nuts to the ¼” O.D. plastic tube.
  7. Refer to the side of the pressure switch to correctly wire the pressure switch assembly. Please not that there are three wiring terminals which consist of a common terminal (denoted as CO), a normally open terminal (denoted as NO3) and a normally closed terminal (denoted as NO2). The three wiring terminals are clearly marked on the side of the pressure switch body. The pressure switch has been adjusted to close/open at 40” to 42” H2O water gauge pressure. The pressure switch close/open pressure can be adjusted by turning the allen head screw (on the pressure switch body) with a 5/64” allen wrench. To increase the pressure switch close/open pressure turn the allen head screw clockwise. To reduce the pressure switch close/open pressure turn the allen head screw counter clockwise.
  8. Located the backpressure gauge assembly in a location which is clearly visible to the operator. Locate the gauge assembly in an area which is free of excessive vibration and has ambient temperatures between 20 degrees F and 120 degrees F. Refer to the backpressure gauge installation instructions (located inside the gauge box) to install the gauge assembly in the dashboard. Cut the ¼” plastic tube to the required length. Connect the ¼” plastic tube to one leg of the “T fitting”. Connect the second leg of the “T fitting” to the outlet of the filter/water trap separator assembly. Use a 9/16” wrench to torque the 9/16” tube nut to a torque of 10/12 foot pounds. Please note that there are 2 small ferrules which retain the tube nuts to the ¼” O.D. plastic tube.
  9. Secure the ¼” O. D. copper tube and ¼” O. D. plastic tube to the vehicle chassis with plastic ty-raps or black electrical tape. We recommend that you do not shorten the ¼” O. D. copper tube as it acts as a heat sink. The plastic tube may be shortened to the correct required length for the installation. The ¼” O. D. copper tube, plastic tube, filter/water trap separator assembly and backpressure gauge assembly should be mounted in locations which should be free of hazards such as excess moisture, water, heat, vibration, dust, etc…
  10. Double check and ensure that the connections and mountings are secure and free of leaks. The engine exhaust gas backpressure restriction gauge system is ready for use.
  11. During normal engine operation the new diesel particulate filters will produce approximately 20” H2O to 25” H2O exhaust gas restriction at full load/speed conditions. Once the diesel particulate filters have acquired several days of operation, the engine exhaust gas restrictions at full engine load/speed conditions will usually cycle between 25” H2O and 40”+ H2O. If the engine exhaust gas restriction exceeds 50”+ H2O then the diesel particulate filter is not regenerating completely and corrective action must be taken. Engine manufacturers will usually specify a maximum exhaust gas restriction of between 27” H2O and 41” H2O. Refer to the diesel particulate filter installation and cleaning instructions included with the installation guide. For diesel oxidation catalyst/purifiers the usual exhaust gas restriction at full engine load/ speed conditions is in the range of 8.0” H20 to 12.0” H2O. If engine exhaust gas restriction imposed by the diesel oxidation catalyst/purifier alone exceeds 14” – 16” H2O then the diesel oxidation catalyst/ purifier core must be cleaned manually. If the total exhaust restriction exceeds the engine manufacturers recommended limit inspect the exhaust system for restrictions and clean the diesel catalyst/ purifier core. Refer to the cleaning instructions in the installation guide.
  12. The filter/water trap separator assembly should be drained of accumulated water every 40 hours of engine operation or on a weekly basis. To drain the accumulated water depress the spring clip (located at the bottom of the drain bowl). Water will begin to drain out of the of the separator drain bowl. If water does not flow, remove the drain bowl by turning the bowl with a clean cotton rag or paper towel. Re-assemble in the same manner as disassembled.
  13. The filter/water trap separator assembly should be cleaned of accumulated particulate matter every 100 hours of engine operation or once a month. To clean the accumulated particulate matter, remove the drain bowl by turning the bowl in a counterclockwise direction. Remove the drain bowl and drain the accumulated water as required. Remove the rubber o-ring and inspect for tears or damage. Remove the plastic filter retainer by turning the retainer counterclockwise. Remove the filter element. Soak the filter element in soapy warm water for 1-2 hours. Clean the drain bowl with a clean cotton rag or paper towel. Use compressed aid to remove any accumulated particulate matter. Re-assemble in the same manner as disassembled.

  14. If you have any question call the sales office at 1-(800)551-5525

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Contact

Toll free:1-800-551-5525

Fax:905-799-9771

Email:sales@catalyticexhaust.ca

Address:30 Intermodal Drive,
Units 19-22, Brampton,
Ontario, Canada L6T 5K1