Maintenance & Trouble Shooting
Although the regeneration process burns the collected soot, it leaves behind traces of residual ash. Ash is a term used to describe the inorganic compounds that do not combust. Ash is derived from lube oil and other wear metals of the engine. Ash deposits accumulate within the filter center body and need to be removed periodically to reduce the risks of increased backpressure and fully utilize the catalyst function. The DPF is supplied as a modular unit to allow full access to the filter center body for periodic inspection, cleaning and removal of the residual ash. To ensure the DPF and engine performance are maintained, the filter must be cleaned every 1000-1500 hours for on-road and off-road 500 hours depending upon duty cycle and engine age. This interval typically represents 32,000miles or 50,000km. Performing ash removal will extend product lifetime and insure fuel economy. Please set standard PM schedule for cleaning intervals for various vehicle types. Engines older than 5 years should be cleaned more frequently, at the lower indicated engine hour or mile intervals.
If the engine fault resulted in oil being emitted into the DPF, it MUST be submitted to an authorized EGS dealer.
- DO NOT reinstall oil laden DPF.
- NEVER reinstall a DPF backward, ALWAYS operate in the correct flow direction as indicated on the filter center body
- NEVER wash a DPF with water, high pressure water, steam, diesel fuel, gasoline, or other solvents.
- NEVER use compressed air on a HOT filter.
- ALWAYS ensure that the entire filter is at ambient temperature.
- ALWAYS use a NIOSH approved dust mask or respirator when cleaning with compressed air in a WELL ventilated area.
If the filter becomes plugged due to engine fault or the Backpressure Monitor indicates increased backpressure before the scheduled maintenance, the DPF can be cleaned with compressed air in this emergency situation.
Instructions for Cleaning the DPF in an Emergency
- The filter center body is marked with an arrow showing the direction of exhaust flow. Re-draw if necessary.
- Properly support the filter center body prior to the removal of the center body clamps. Remove the center body clamps. Care must be taken to ensure the heavy filter center body does not fall when these clamps are removed.
- Remove the filter center body from the assembly. The use of appropriate heavy lifting equipment is advised.
- Inspect the exhaust system upstream of the DPF for the presence of engine oil. If signs of engine oil are found, refer to the Troubleshooting section (If engine oil has entered the DPF, it should be sent to an EGS approved dealer for further inspection and proper cleaning.
- Inspect the outlet face of the filter center body for signs of cracks, other damage, passage of soot, or discoloration. The outlet of the filter center body should be clean. Record observations on page 6 of the manual.
- Inspect the inside of the outlet section for indications of soot. Record observations on page 6.
- Take the filter center body to well-ventilated areas and follow appropriate personal safety steps for soot removal (treat soot as similar to vehicle brake dust). Fit a regular shop vacuum paper bag on the DPF filter center body inlet face. Lay the filter center body on its side on a workbench or other suitable surface and properly secure from movement. Blow the filter center body outlet face thoroughly with compressed air not greater than 100 psi, keeping the tip of the nozzle at least 2 inches away from the filter face, for approximately 5 minutes. Take the bag off to see if air blown through comes out clean. If not, replace bag and continue to blow the filer until the air comes out clean.
- Once cleaning is complete, replace the filter center body between the inlet and outlet sections. Ensure the direction of the exhaust flow is correct. Inspect sealing gaskets between the filter center body and inlet/outlet sections, replace gaskets if necessary.
- Re-position and tighten center-body clamps to ensure joints are central and flush.
- Check the Backpressure Monitor components are still in working order (see page 21 for instructions).
- Inspect DPF mounting and exhaust connections. Repair any defects.
Monitoring DPF Performance
DPF records should be maintained to monitor performance. Records should always be updated at each service interval and with every test. Record keeping will also foreshadow unit failure.
Records should be kept of the below listed occurrences. Along with these records should be vehicle identity, vehicle mileage, and dates. Space is provided for recording this information below.
Some regulatory agencies require proper record keeping of the emission control device performance and maintenance. These records will help the operator provide such data when requested and also use it as a unit failure tool.
- Backpressure test figures.
- Smoke opacity test figures.
- Filter observations from inspection.
- Change or replacements of any exhaust components.
- Change in vehicle duty cycle.
DPF testing should be considered preventative maintenance and as such, scheduled with regular vehicle preventative maintenance procedures.
Although an exhaust Backpressure Monitor is supplied with the DPF, EGS requires a routine measurement of backpressure to be recorded. This should be recorded at two engine conditions, rated speed and idle. A port is located at the inlet side of the DPF for this purpose. This information should be recorded immediately before the servicing of the DPF and midway between DPF servicing. Testing frequency will vary between 16,000miles, 25,000km, every 6 months, or if the Backpressure Monitor is triggered frequently.
DPF testing intervals can be completed along with regular vehicle maintenance. EGS supplies optional gauges and fittings for this purpose. Please call EGS for further information. Also, regular smoke opacity tests should be conducted using a Ministry approved opacity test meter. EGS recommends that the above tests are carried out.