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A Truck Driver’s Guide to Care and Maintenance of
Diesel Particulate Filters (DPFs)
Disclaimer: This handbook is not a substitute for the detailed instructions/warranty limitations supplied by the manufacturer or the conditions contained in the applicable Air Resources Board (ARB) executive order.
Don’t Let Your Filter Get Out of Kilter!
• YourtruckisretrofittedwithaDieselParticulateFilter(DPF).TheemissionsperformanceofthisretrofithasbeenverifiedbyARBthroughrigoroustesting.
• KeepinmindthataDPFisnota“fitandforget”device.Protectyourinvestmentbyunderstandingtheneedsofyournewsystem.
• ImpropercareofyourengineandDPFcanleadto:
− Expensiverepairsandreplacementparts
− Voidedwarranty
− Enginemalfunctionorbreakdown
− Non-compliancewithairpollutionlaws
• Maintainengineinitsoriginalconfiguration.
• DonotexchangefilterpartsunlessallowedbytheDPFmanufacturer.
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Vehicle Maintenance is Critical
Topnotchvehicleenginemaintenanceisrequired.Lossoflubeoilcontrolorover-fuelingcandamageordestroyyourDPFleadingtoexpensiverepairs.ADPFcapturessootfromtheengineandcanmaskengineproblemsthatwereformerlydetectablebyobservingexhaustsmokecharacteristics.Beproactive.Reducingsootfromyourenginereducesfilterpluggingandcleaning.
Fuel injectors:Repairandreplaceatintervalsrequiredbytheenginemanufacturer’smaintenanceschedule.Wornfuelinjectorscanleadtoexcessivefuelingandmoresootgenerationandaccumulationinthefilter.Fixwornhydraulicinjectorstostoplubeoilleaksintothefuel.
Air filters:Replaceatintervalsrequiredbytheenginemanufacturer.Dirtyairfiltersreduceairflowtotheengineleadingtomoresootgeneration.
Turbocharger:Checkturbochargerforproperoperationandexcessivewear.Turbochargersthatdonotproducesufficientairorhaveleakingsealsleadtomoresootorthepresenceoflubeoilintheexhaust.
Fuel filter: Replaceatprescribedintervals.Lookforthepresenceoflubeoilinthefuelfilterduringregularlyscheduledmaintenance.Ablackeningofthefiltermayindicatethatoilfromthecrankcaseismixingwiththefuelduetoaleakyinjector.
Fuel:Periodicallyinspectfuelintheon-boardfueltankforsignsoflubeoilcontamination(blackincolor).Inspectionshouldbedonepriortorefueling.Ablackeningofthefuelmayindicatemixingofcrankcaseoilwiththefuel.
Coolant: Monitorcoolantconsumption.Keepalogofthecoolantaddedtotheengine.CoolantleakagecanpoisontheDPFcatalystand/orcausefilterplugging.
Lube oil:Changethelubeoilatmileageintervalsindicatedbytheenginemanufacturer.Trackusage.
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Monitor Lube Oil Consumption Closely
SomeofthecomponentsinlubeoilcancollectintheDPFandcausepluggingormakethecatalystmalfunction.Therefore,itisimportanttoensurethattheengineisnotconsuminglubeoilataratehigherthanrecommendedbytheenginemanufacturer.
• Ifthelubeoilconsumptionexceedsspecificationstheenginemustberepaired.
• Increasedlubeoilconsumptionleadstoincreasedashloadandfilterplugging.Theashcannotberemovedbyregeneration.TheresultisanincreaseinDPFcleaningfrequencywhichiscostlyandinvolvesdowntime.
• Tracklubeoilusagebykeepingalogofhowmuchoilisaddedtotheenginebetweenoilchanges.
• Lowash(CJ-4)lubeoilisrecommended.
• Neverputcleanorusedlubeoil,additives,oralternativedieselfuelsthatarenotauthorizedbytheDPFmanufacturerinthefueltank.
Maintain the Proper Engine Duty Cycle
Thedutycycleisthedailypatternofuseoftheengineandhowthataffectstheengineexhausttemperature.Thedutycycle,forexample,couldvarybetweenhighwaydrivinglongdistancestocitydrivingwithshorttripswithlightorheavyloads.BeforetheDPFisinstalled,theengineisdataloggedtodetermineiftheengineexhaustishotenoughtohavethefilterrunproperly.TheDPFisdesignedtoworkforthedutycycleatthetimeitwasdatalogged.Therefore,changingthedutycyclecouldadverselyaffecttheperformanceofthefilter.
• Maintainthedutycyclethatwasusedwhenthetruckwasdataloggedbytheinstaller.
• Beawarethatifthedutycycleofatruckischanged,itmayaffecthowthefilterworks,leadingtoplugging.
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DPFdatalogger
installedDPFdatalogger
sootparticulatematter
CO2
breakdownregeneration
capturefiltration
Understanding Your DPF’s Regeneration System
TheDPFcollectssootfromtheengineexhaust.Thismusteventuallyberemovedtokeepthefilterfromclogging.Theprocessofburningthesootinthefilteriscalledregeneration.HightemperaturesforaspecifiedamountoftimearerequiredfortheDPFtoberegeneratedproperly.Yourtruckisequippedwithapassiveoractiveregenerationsystem.
Passive regeneration–Inthissystem,theengineexhausttemperaturegetshotenoughtotriggerregenerationduringvehicleoperation.
Active regeneration–Thissystemrequiresanoutsidesourceofheatenergy,suchasdieselfuelorelectricity,toburn-offaccumulatedsoot.Thisprocessmayormaynotrequireactionbythedriver.SomeDPFs,forexample,automaticallydoseandignitedieselfuelinthefilterforregeneration.DPFsequippedwithelectricalplugsuseheatersthatarerequiredtobepluggedintoanelectricaloutletforaregenerationandthisistypicallydoneovernight.
• MakesurethatactivelyregeneratedDPFsaregiventherequiredregenerationtime,sothesootcanbecompletelyremovedfromthefilterbeforethevehicleisdrivenagain.
• ActivelyregeneratedDPFsshouldnotbeparkednearflammablematerialswhentheregenerationtakesplace.TheDPFgetsveryhotandcouldcausecombustiblestocatchonfire.
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©copyrightJohnsonMattheyPlc2011
Understanding the DPF Monitoring System
ThecabofthetruckfeaturesamonitoringsystemfortheDPFthatincludesseveralindicatorlightsthatshowthestatusofthefilter.TheoperatormustunderstandandobservetheDPFindicatorlightsonaregularbasisandrespondaccordingly.
• TheindicatorlightsforthemonitoringsystemvarysomewhatbetweenDPFmanufacturers.Understandthemeaningofallindicatorlightsbytalkingtotheinstallerormaintenancepersonnel.
• Donotdisconnect,tapeover,orblocktheviewofindicatorlights.
• Donotignoreindicatorlights.Continuingtooperateavehiclethatrequiresattentionmayseverelyde-ratetheengine,damagetheDPFand/orengine,andvoidtheDPFwarranty.
• ForactivelyregeneratedDPFs,performregenerationorreturntothegarageforregenerationassoonaspossiblewhenrequiredbytheindicatorlight(s).
• IftheinstallerprovidesaquickreferencecardfortheDPFindicatorlights,keepareadilyaccessiblecopyinthetruck.
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Solid green - system okFlashing green - system regenerating
Solid orange - service neededFlashing orange - regeneration needed
Flashing red - regenerate ASAPWarranty at risk
Handle the Filter with Care
• TheDPFappearsruggedbutiscommonlymadewithceramicmaterials.
• MakesuretheDPFishandledproperlyduringinstallation.
• Neverbangortaponthefilterbecausethiscouldcrackthefilterelement.
• ReplacingtheDPFfilterelementiscostly.Crackingthefilterelementmayvoidthewarrantyandrequiresreplacement.
• Whenworkingonyourvehicle,donotweldanyothercomponentsontheretrofitsystemorcutordisconnectanycontrollines.
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DPF Cleaning Basics
TheDPFisamaintenanceitem.Itmustberemovedandcleanedperiodicallytoremoveaccumulatednoncombustibleashfromthefilter.
Ashremovalisdifferentandseparatefromregeneration.Ingeneral,DPFcleaningrequiresheatingthefilter,usingcompressedaircombinedwithavacuumsystemtoblowtheash,andcapturingitinasealedcontainer.
• OnlyusefiltercleaningproceduresapprovedbytheDPFmanufacturer.
• UsinganimpropercleaningmethodmayruintheDPFand/orexposepersonneltohazardouswaste.
• Donotuseshopcompressorinopenareatocleanfilter.
• DonotsteamcleantheDPF.
• Donotraponthefilterelementtoremoveash.
• Unlessithasbeentestedandverifiedassafe,DPFashmustbehandledanddisposedasaCaliforniahazardouswaste.
• Makesurefiltercleaningcontractorsusetheproperprocedureandhandleashproperly.
• Makesurethatfilterelementsareinstalledcorrectlyaftertheyarecleaned.Donotreversethefilterelements.
• Neveroperatetheenginewithoutthefilterelements.
• Maintainservicerecords.
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DPFcleaningmachine
dirtyfilter:requiresashremovalcleanfilter:noactionnecessary
Resolving DPF Related Problems
TheDPFisamechanicaldeviceandoccasionalproblemsmayariseduetofactorsrelatedtomanufacturing,installation,orenginemaintenancepractices.UsethefollowingprotocoltoresolveDPFrelatedperformanceorreliabilityproblems.
For Trucks & Buses (Including Drayage/Port Trucks)
Step 1: Contactyourinstaller Most problems are resolved in this manner
Step 2: Contactthedevicemanufacturer If the installer cannot resolve your complaint
Step 3: [email protected] If the installer or manufacturer cannot resolve your complaint
For Transport Refrigeration Units (TRUs or Reefers)
ContactARBat1-888-878-2826ortru@arb.ca.govandcontactyourinstallerand/ormanufacturer.
For more information
web www.arb.ca.gov/truckstopemail [email protected] 866-6DIESEL(866-634-3735)
July2012