DIESEL PARTICULATE FILTER HANDLING. Manual - part 2

 

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DIESEL PARTICULATE FILTER HANDLING. Manual - part 2

 

 

INFORMATION

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

I-2

OPERATE SAFELY

• Do not use the machine after you consume alcohol

or medication or when you are tired.

• Put on applicable clothing and safety equipment.
• Use applicable tools only. Do not use alternative

tools or parts.

• When 2 or more persons do servicing, make sure

that you do it safely.

• Do not touch the hot parts or parts that turn when the

engine operates.

• Do not remove the radiator cap when the engine

operates, or immediately after it stops. If not, hot
water can spout out from the radiator. Only remove
the radiator cap when it is at a sufficiently low
temperature to touch with bare hands. Slowly loosen
the cap to release the pressure before you remove it
fully.

• Released fluid (fuel or hydraulic oil) under pressure

can cause damage to the skin and cause serious
injury. Release the pressure before you disconnect
hydraulic or fuel lines. Tighten all connections before
you apply the pressure.

• Do not open a fuel system under high pressure.

The fluid under high pressure that stays in fuel lines
can cause serious injury. Do not disconnect or repair
the fuel lines, sensors, or any other components
between the fuel pump and injectors on engines with
a common rail fuel system under high pressure.

• Put on an applicable ear protective device (earmuffs

or earplugs) to prevent injury against loud noises.

• Be careful about electric shock. The engine

generates a high voltage of more than DC100 V in
the ECU and is applied to the injector.

PREVENT A FIRE

• Fuel is very flammable and explosive under some

conditions. Do not smoke or let flames or sparks in
your work area.

• To prevent sparks from an accidental short circuit,

always disconnect the battery negative cable first
and connect it last.

• The battery gas can cause an explosion. Keep the

sparks and open flame away from the top of battery,
especially when you charge the battery.

• Make sure that you do not spill fuel on the engine.

INFORMATION

DIESEL PARTICULATE FILTER HANDLING MANUAL, WSM

I-3

KEEP A GOOD AIRFLOW IN THE WORK AREA

• If the engine is in operation, make sure that the area

has good airflow. Do not operate the engine in a
closed area. The exhaust gas contains poisonous
carbon monoxide.

DISCARD FLUIDS CORRECTLY

• Do not discard fluids on the ground, down the drain,

into a stream, pond, or lake. Obey related
environmental protection regulations when you
discard oil, fuel, coolant, electrolyte and other
dangerous waste.

PREVENT ACID BURNS

• Keep electrolyte away from your eyes, hands and

clothing. Sulfuric acid in battery electrolyte is
poisonous and it can burn your skin and clothing and
cause blindness. If you spill electrolyte on yourself,
clean yourself with water, and get medical aid
immediately.

PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher ready at all

times.

• Keep the emergency contact telephone numbers

near your telephone at all times.

ENGINE

CONTENTS

1. FUNCTION OF DIESEL PARTICULATE FILTER (DPF).............................................................1-S1
2. DPF REGENERATION AND DPF CLEANING............................................................................1-S2
3. DPF MAINTENANCE FLOW .......................................................................................................1-S3

[1] CLEANING & RETURN FLOW .............................................................................................1-S4
[2] DPF EXCHANGE FLOW.......................................................................................................1-S5

4. DPF CLEANING PROCEDURE ..................................................................................................1-S6

[1] TO ENSURE SAFETY AND GOOD PERFORMANCE IN DPF CLEANING PROCEDURE .1-S6
[2] SEPARATION OF DPF MUFFLER FULL ASSY...................................................................1-S7

(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ....................................1-S8
(2) V2607-CR-E4 ..................................................................................................................1-S9
(3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S10
(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S11

[3] DISASSEMBLY OF DPF MUFFLER FULL ASSEMBLY.....................................................1-S12

(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ..................................1-S12
(2) V2607-CR-E4 ................................................................................................................1-S13
(3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S13
(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S14

[4] JUDGMENT OF REUSE OF DPF FILTER COMPLETE BEFORE CLEANING..................1-S15
[5] PREPARATION OF "AFTER-TREATMENT DEVICE EXCHANGE REPORT FORM" .......1-S15
[6] PREPARATION OF "DPF CLEANING ORDER FORM" .....................................................1-S16
[7] PACKING, DELIVERING, AND HANDLING STANDARD OF DPF FILTER COMPLETE

.............................................................................................................................................1-S17

[8] DPF CLEANING METHOD, RESPONSIBLE FOR CLEANING CONTRACTOR (REFERENCE)

.............................................................................................................................................1-S18

[9] JUDGMENT OF REUSE OF DPF FILTER COMPLETE AFTER CLEANING, RESPONSIBLE 

FOR CLEANING CONTRACTOR .......................................................................................1-S19

[10]ASSEMBLY OF DPF MUFFLER FULL ASSEMBLY...........................................................1-S22

(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ..................................1-S22
(2) V2607-CR-E4 ................................................................................................................1-S24
(3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S26
(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S28

[11]MOUNTING OF DPF MUFFLER FULL ASSEMBLY...........................................................1-S30

(1) D1803-CR-E4, D1803-CR-TE4, V2403-CR-E4, V2403-CR-TE4 ..................................1-S30
(2) V2607-CR-E4 ................................................................................................................1-S31
(3) V2607-CR-TE4, V3307-CR-TE4 ...................................................................................1-S32
(4) V3800-CR-TE4, V3800-CR-TIE4, V3800-CR-TE4C, V3800-CR-TIE4C .......................1-S33

[12]RESETTING BY USING DIAGNOSIS TOOL ......................................................................1-S34

(1) In Case of Scheduled Maintenance for Every 3,000 Hours of Operation, or In 

Case of Heavy Soot Accumulation (P-Code:P3008, J1939:3701-0) .............................1-S34

(2) In Case of Excessive Regeneration Frequency (P-Code:P3024, J1939:523602-0) .....1-S36

[13]EXECUTION CONDITION FOR MANUAL REGENERATION ............................................1-S38
[14]ATTACHED FORM..............................................................................................................1-S39

(1) After-Treatment Device Exchange Report Form ...........................................................1-S39
(2) DPF Cleaning Order Form.............................................................................................1-S40

SERVICING

 

 

 

 

 

 

 

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