DPD Feature and Operation

DPD Feature and Operation

This training program will explain the DPD Feature and its Operation.

This is a new features for the CX_C excavators and will be used on the CX250C,
CX300C, and CX350C models to meet the current Tier 4a EPA requirements.

Terms used in this training program:

EPA – Environment Protection Agency

IT4 - Interim Tier 4
ECM – Engine Control Module
EGR – Exhaust Gas Recirculation
DPD - Diesel Particulate Diffuser
DOC - Diesel Oxidation Catalyst
DPF - Diesel Particulate Filter
VGT - Variable Geometry Turbo Charger
MAF – Mass Air Flow

NO – Nitrous Oxides
PM - Particulate Matter
HC – Hydro Carbons

2011-03-08 DPD Feature and Operation 1

Notes

DPD Feature and Operation 2

 Table of Contents

What is DPD and How does it work 4

Machine Models used on 5
DPD: Diesel Particulate Diffuser 7
DOC (Diesel Oxidation Catalyst) 9
DPF (Diesel Particulate Filter) 10
DPD (Diesel Particulate Diffuser)
DPD Regenerating Operation 12
Fuel Injection Control 16
DPD Operation System Overview 19
DPD Regenerating Operation (Monitor display) 20
Normal DPD Regenerating Operation 21
DPD Regenerating Operation (Optional) 22
DPD Regenerating Operation (Manual) 23
DPD Regeneration Control at Low Water Temperature 24
DPD Regeneration Control at High Water Temperature 25
DPD Hydraulic Load Assist Control 26
Regeneration Control In Case Of Problems 28
DPD Regenerating Operation (Compulsory) 29
DPF Overhaul 30
Tier 4a Required Fuel and Engine Oil Types 31
DPD Mechanical Failure (Filter Plugged) 32
Overhaul of DPD Filter Cartridge 35

DPD Feature and Operation 3

 What is DPD and How does it work?

What is DPD (Diesel Particulate Diffuser

DPD is a regenerating after-treatment device that collects particulate matter emitted
from the engine by means of a ceramic filter and efficiently burns PM using the
precise fuel injection of the electronic control common-rail system and emission
temperature controls.

DPD – How it works

The Diesel Particulate Diffuser minimizes the amount of PM a engine emits via the
exhaust.

The DPD, which is located on the rear of the engine assembly, combines an
oxidation catalyst to clean carbon monoxide and hydrocarbons, and a ceramic filter
that traps PM.

Pressure differential sensors within the ceramic filter are used to monitor the
accumulation of trapped PM. Once a certain amount of PM is detected, the ceramic
filter regenerates; this is done via post-injection which elevates the exhaust gas
temperature to burn off the accumulated PM

DPD Feature and Operation 4

 Machine Models used on

DPD for 4HK1X Isuzu Engine

g

DPD: Diesel Particulate Diffuser

The DPD is used on the 4HK1X engine for the following model: CX250C

DPD Feature and Operation 5

 Machine Models used on

DPD for 6HK1X Isuzu Engine

DPD: Diesel Particulate Diffuser

The DPD is used on the 6HK1X engine for the following models: CX300C and CX350C

DPD Feature and Operation 6

 DPD: Diesel Particulate Diffuser

Temperature Sensors

Differential Pressure
Monitoring Port

Differential Pressure Monitoring Port

Several new components are required to monitor and control the DPD and the
associated regeneration of the DPD.

These new components include:

Pressure Monitoring Ports – 2
These ports are used to monitor the internal DPD pressure on each side of the DPF
(Diesel Particulate Filter).

Temperature Sensors - 2
These temperature sensor sensors monitor the front DOC ( Diesel Oxidation
Catalyst) temperature and the front DPD temperature.

DPD Feature and Operation 7

 DPD: Diesel Particulate Diffuser

Differential Pressure Sensor

DPD for 4HK1X Isuzu Engine

Additional new components that are required to monitor and control the DPD and the
associated regeneration of the DPD.

DPS : Differential Pressure Sensor

This sensor is used to monitor the internal DPD pressure on each side of the DPF
(Diesel Particulate Filter).

DPD Feature and Operation 8

 DOC (Diesel Oxidation Catalyst)

Shown is the DOC removed from the excavator and separated from the DPF (Diesel
Particulate Filter).

The DOC (Diesel Oxidation Catalyst), converts NO (Nitrous Oxides) in the exhaust to
NO2 (Nitrogen Oxides) at the upstream side of DPF (Diesel Particulate Filter) .

DPD Feature and Operation 9

 DPF (Diesel Particulate Filter)

Shown is the DPF (Diesel Particulate Filter) removed from the excavator and
separated from the DOC (Diesel Oxidation Catalyst).

The DPF is a wall flow type that is capable of removing up to 90% or more of the
diesel particulate matter (PM) or soot. The trapped/removed PM is handled through
DPD regeneration process.
process

PM diffused at the ceramic filter will be burnt by the extreme heat of exhaust gas.

DPD Feature and Operation 10

 DPD (Diesel Particulate Diffuser)

PM diffused inside DPF will be burnt by the heat of engine exhaust gas.

PM is not properly burn in cases of low engine temperatures of exhaust gas because
of low engine load such as long idling time.

High sulfur fuel & engine oil will also stay with the DPF as well as other contaminated
materials.

Even if engine temperatures increase for PM burning, those materials will stay in the
filter and finally damage the catalyst and filter.

DPD Feature and Operation 11

 DPD Regenerating Operation

DPF
Cleaning Machine Diesel Particulate Monitor Engine
Cleaning
Condition operation Filter Cleaning Start Display Revolution
Time

Variable -
Self Nothing Full
Continuous Accessible - -
Regeneration Displayed Operator
Control
Every 8 Hours Variable -
Auto or Elevated Regeneration Minimum of Full
Accessible Automatic
Regeneration DPD Pressure Icon : Green 8 minutes Operator
Detected Control
1) Engage Gate
Incomplete Regeneration Minimum of
Manual Non- Lever Lock Fixed at
Auto Icon : Orange 20 - 25
Regeneration Operational 2) Push DPD Switch 1000 rpm
Regeneration & flashing minutes
ON once
1) Engage Gate
Lever Lock
Manual Stopping Regeneration Minimum of
Non- 2) Push DPD Switch Fixed at
Regeneration Auto Icon : Orange 20 - 25
Operational ON for 3 seconds 1000 rpm
(Optional) Regeneration & flashing minutes
3) Push DPD Switch
ON once again
Warning with Service Technician
Slow Non- Minimum of Fixed at
engine error accesses
Regeneration Operational 100 minutes 1000 rpm
code diagnostic menu

To get slow PM burning, exhaust

High temperature of
temperature of 482°F, engine is
exhaust gas produced
fixed at 1000 rpm and main pump
by normal machine
is put under light load.
operation will
contribute to shorter
DPD operation time.

The above chart details the four types of DPD regeneration:

Self Regeneration
Auto Regeneration
Manual Regeneration
Optional Manual Regeneration
Slow Regeneration

DPD Feature and Operation 12

 DPD Regenerating Operation

DPF
Cleaning Machine Diesel Particulate Monitor Engine
Cleaning
Condition operation Filter Cleaning Start Display Revolution
Time

Variable -
Self Nothing Full
Continuous Accessible - -
Regeneration Displayed Operator
Control
Every 8 Hours Variable -
Auto or Elevated Regeneration Minimum of Full
Accessible Automatic
Regeneration DPD Pressure Icon : Green 8 minutes Operator
Detected Control
1) Engage Gate
Incomplete Regeneration Minimum of
Manual Non- Lever Lock Fixed at
Auto Icon : Orange 20 - 25
Regeneration Operational 2) Push DPD Switch 1000 rpm
Regeneration & flashing minutes
ON once
1) Engage Gate
Lever Lock
Manual Stopping Regeneration Minimum of
Non- 2) Push DPD Switch Fixed at
Regeneration Auto Icon : Orange 20 - 25
Operational ON for 3 seconds 1000 rpm
(Optional) Regeneration & flashing minutes
3) Push DPD Switch
ON once again
Warning with Service Technician
Slow Non- Minimum of Fixed at
engine error accesses
Regeneration Operational 100 minutes 1000 rpm
code diagnostic menu

The above chart details the four types of DPD regeneration:

Auto regeneration

In order to stop Auto Regeneration

Move the gate lock lever from release position

Or - Push DPD Regeneration Switch once again

In order to restart DPD regeneration

R l
Release the
th gate
t lock
l k lever
l from
f locked
l k d position.
iti
Push the regeneration switch again.
Restarts regeneration procedure from the beginning.

DPD Feature and Operation 13

 DPD Regenerating Operation

Diesel Particulate DPF

Cleaning Machine Monitor Engine
Filter Cleaning Cleaning
Condition operation Display Revolution
Start Time

Variable -
Self Nothing Full
Continuous Accessible - -
Regeneration Displayed Operator
Control
Every 8
Hours or Variable -
Auto Elevated Regeneration Minimum of Full
Accessible Automatic
Regeneration DPD Icon : Green 8 minutes Operator
Pressure Control
Detected
Incomplete 1) Engage Gate
Regeneration Minimum of
Manual Auto Non- Lever Lock Fixed at
Icon : Orange 20 - 25
Regeneration Regeneratio Operational 2) Push DPD 1000 rpm
& flashing minutes
n Switch ON once
1) Engage Gate
Lever Lock
Stopping 2) Push DPD
Manual Regeneration Minimum of
Auto Non- Switch ON for 3 Fixed at
Regeneration Icon : Orange 20 - 25
Regeneratio Operational seconds 1000 rpm
(Optional) & flashing minutes
n 3) Push DPD
Switch ON once
again
Warning with Service Technician
Slow Non- Minimum of Fixed at
engine error accesses
Regeneration Operational 100 minutes 1000 rpm
code diagnostic menu

The above chart details the four types of DPD regeneration:

Manual regeneration / Optional Manual regeneration

I order
In d tot stop
t Manual
M l Regeneration
R ti / Optional
O ti l Regeneration
R ti

Release the gate lock lever from locked position

Or - Change Engine RPM by throttle volume use
Or - Push DPD Regeneration Switch once again

In order to restart DPD regeneration

g
Push the regeneration switch again.
Restarts regeneration procedure from the beginning.

DPD Feature and Operation 14

 DPD Regenerating Operation

Diesel Particulate DPF

Cleaning Machine Monitor Engine
Filter Cleaning Cleaning
Condition operation Display Revolution
Start Time

Variable -
Self Nothing Full
Continuous Accessible - -
Regeneration Displayed Operator
Control
Every 8
Hours or Variable -
Auto Elevated Regeneration Minimum of Full
Accessible Automatic
Regeneration DPD Icon : Green 8 minutes Operator
Pressure Control
Detected
Incomplete 1) Engage Gate
Regeneration Minimum of
Manual Auto Non- Lever Lock Fixed at
Icon : Orange 20 - 25
Regeneration Regeneratio Operational 2) Push DPD 1000 rpm
& flashing minutes
n Switch ON once
1) Engage Gate
Lever Lock
Stopping 2) Push DPD
Manual Regeneration Minimum of
Auto Non- Switch ON for 3 Fixed at
Regeneration Icon : Orange 20 - 25
Regeneratio Operational seconds 1000 rpm
(Optional) & flashing minutes
n 3) Push DPD
Switch ON once
again
Warning with Service Technician
Slow Non- Minimum of Fixed at
engine error accesses
Regeneration Operational 100 minutes 1000 rpm
code diagnostic menu

The above chart details the four types of DPD regeneration:

Slow regeneration
In order to stop Slow Regeneration

Release the gate lock lever from

f locked position
Or - Change Engine RPM by throttle volume use
Or - Push DPD Regeneration Switch once again

In order to restart DPD regeneration

Push the regeneration switch again.
Restarts regeneration procedure from the beginning.

Slow Regeneration can be started by Service technician.

Refer to “Engine Service Monitor” program regarding the procedure.

DPD Feature and Operation 15

 Fuel Injection Control

Main Injection

Tier 2

Electric Governor

Pilot Injection Main Injection

Tier 3

Common Rail

Pre-Injection Initial Control

(Noise Reduction) (NOx Reduction) Main Injection
((PM Reduction))

Pilot Injection
(Noise Reduction)

Interim Tier 4

Under normal operating conditions, there are 3 fuel injections during the
compression phase of the combustion process for IT4:

Pilot Injection for noise reduction

Pre-Injection for noise reduction
Main Injection for NOx control and particulate matter reduction

Injection timing and volume are fully controlled by the new style ECM

DPD Feature and Operation 16

 Fuel Injection Control

Main Injection
(PM Reduction)

Initial Control
(NOx Reduction) Late Injection
Pre-Injection (PM Reduction and DPD Control)
(Noise Reduction)

Pilot Injection Post Injection

(Noise Reduction) (DPD Control)

Injection During Manual DPD Clean-Out

During “Auto” and “Manual” regeneration, there is a 4th injection when the temperature is
below 250C/482F at the DOC and DPF.

This increases exhaust gas temperature to assist in “burning off” particulate matter.

When temperature is above 250C/482F at the DOC and DPF, there is a 5th injection to
h l create
help t hhotter
tt exhaust
h t gas ttemps.

Intent is to gradually build-up heat to burn off PM; as opposed to an initial burst of
extreme heat which could damage the DPF.

During DPD Manual Cleaning, when the machine has been parked, the hydraulics (Gate
Lock) must be in neutral. The controller then sends a signal to the P1 proportional
solenoid and Boom 2 proportional solenoid putting a slight load on the engine. This also
helps generate higher engine temperatures.

DPD Feature and Operation 17

 Fuel Injection Control

Main Injection
(PM Reduction)

Initial Control
(NOx Reduction) Late Injection
Pre-Injection (PM Reduction and DPD Control)
(Noise Reduction)

Pilot Injection Post Injection

(Noise Reduction) (DPD Control)

Injection During Manual DPD Clean-Out

Fuel Injection Control – DPD – Additional Details

DPD regenerating operation condition details:
1) Less than 250C/482F at DOC and DPF
- Multi injection start (Late injection)
- EGR Valve Is Fully Closed
- Intake Throttle Fully Open
2) More than 250C/482F at DOC and DPF
- Post Injection Start
- EGR Valve Fully Closed
- Intake Throttle Adjusted by the Load
(low load => close, high load => open)

DPD Feature and Operation 18

 DPD Operation System Overview

Capturing PM Self Regeneration

■Every 8hrs operation

■ DPD pressure sensor detected

DPD s/w push for 3 seconds.

Auto Regeneration Manual Regeneration
(Optional)
■DPD sensor detected high pressure
diff
difference in
i DPD (IN/OUT)
■ Incomplete Auto regeneration for some
reason

Manual Regeneration （Flashing Slow）

20 to 25 min. ■ Did not practice DPD manual regeneration

(did not push DPD s/w)
Cannot operate
p excavator
■ Failure to complete DPD manual regeneration

Manual Regeneration （Flashing Fast）

■ Not practice DPD manual regeneration

20 to 25 min. (did not push DPD s/w)
■ Failure to complete DPD manual regeneration
Cannot operate excavator

Warning with engine error code Slow Regeneration

1. Auto Regeneration
Every 8hrs operation
DPD pressure sensor detects high pressure

2. Manual Regeneration （Icon Flashing Slow)

DPD sensor detects high pressure difference in DPD (IN/OUT)
Incomplete Auto regeneration for some reason

3. Manual Regeneration （Icon Flashing Fast）

3
Did not practice DPD manual regeneration procedure (did not push DPD switch)
Failure to complete DPD manual regeneration

4. Slow Regeneration
Warning with engine error code

DPD Feature and Operation 19

 DPD Regenerating Operation (Monitor display)

DPD Icon DPD Status Gauge

Normal: Normal :
No Icon Displayed “DPD” message displayed Gauge
shows PM accumulation
Auto Regeneration:
Green icon “ ”
DPD Working :
“ ”
“Regeneration” message
Manual Regeneration: Flashing
Gauge shows remaining time
Orange icon

In line with ISO standard

DPD Regenerating Operation (Monitor display)

DPD Icon
Normal: No Icon Displayed
Auto Regeneration: Green icon
Manual Regeneration: Orange icon

In line with ISO standard

DPD Status Gauge

Normal : “DPD” message displayed
Gauge shows PM accumulation
DPD Working : “Regeneration” message
Gauge shows remaining time

DPD Feature and Operation 20

 Normal DPD Regenerating Operation
Cooled high density air to engine

Interccooler
Radiator Burning PM by the
Engine normal heat of
exhaust gas through
machine operation.
Suction
Exhaust
Compressed Turbocharger
And
Heated air Capturing PM Self Regeneration

Every 8hrs of operation (Machine Hr Meter Checked by ECM)

DPD pressure sensor detects (Pressure Difference between IN/OUT to see if it is high

Auto Regeneration

DPD regenerating Time : 8min. Monitor : DPD icon Green

minimum Specific action by operator :
Regenerating time is subject to None
the condition of exhaust gas Machine operation : Possible
temperature Engine revolution : Variable

Every 8hrs of operation (Machine Hr Meter Checked by ECM)

DPD pressure sensor detects (Pressure Difference between IN/OUT to see if it is high

DPD Regenerating Time : 8 minutes minimum

R
Regenerating
ti TiTime iis S
Subject
bj t tto th
the C
Condition
diti off E
Engine
i E Exhaust
h tGGas T
Temperature
t

Monitor : DPD icon Green

Specific action by operator : None
Machine operation : Possible
Engine revolution : Variable

DPD Feature and Operation 21

 DPD Regenerating Operation (Optional)

Capturing
p g PM Self regeneration

DPD Auto regeneration

Switch
pushing
(3
seconds)

DPD icon : Orange and flashing slow DPD Regenerating

Time : 20-25min.

DPD Regenerating Time : 20-25min.

DPD Regenerating Operation (Optional)

Monitor : DPD icon Orange

S
Specific
ifi action
ti tto be
b ttaken
k byb operator
t :Y
Yes
Machine operation : No – Lever Lock Engaged
Engine revolution : 1000 rpm fixed

1) Stop Auto regeneration

2)) Move the excavator to safe p

place

3) Lock excavator out by Lever Lock Engagement

4) Push the DPD regenerating switch for 3 seconds

5) Icon lights for 3 seconds, and flashing for 10 seconds afterwards

6) Push the DPD regenerating switch once again during 10 seconds while icon is flashing

7) Wait for regeneration to complete

DPD Feature and Operation 22

 DPD Regenerating Operation (Manual)

Capturing PM Self regeneration

DPD sensor Auto regeneration

detected
abnormal
pressure
Incomplete Auto DPD regenerating time : 20-25min.
difference in
regeneration for some
DPD (IN/OUT) Monitor : DPD icon Orange
reason
Specific action by operator :
DPD icon : Orange and flashing slow Yes
Machine operation :
Impossible
■ Did Not Push Manual Regeneration Switch Engine revolution : 1000rpm
■ Fail for DPD manual regeneration to be completed fi d
fixed
1) Move the machine in safety place
DPD icon : Orange and flashing fast 2) Lock position the gate lever
3) Push the DPD regenerating s/w
4) Wait for regenerating completed

DPD Regenerating Operation (Manual)

Incomplete Auto regeneration for some unknown reason

DPD sensor detects abnormal pressure difference in DPD (IN/OUT)
DPD icon : Orange and flashing slow
Reason: Did Not push manual regeneration switch when required
R
Reason: F il
Failure for
f DPD manuall regeneration
ti tto b
be completed
l t d
DPD icon : Orange and now flashing fast
Monitor : DPD icon Orange
Specific action by operator : Yes
Machine operation : No – Lever Lock Engaged
Engine revolution : 1000 rpm fixed
1)) Move the excavator to safe pplace
2) Lock excavator out by Lever Lock Engagement
3) Push the DPD regenerating switch for 3 seconds
4) Wait for regeneration to complete

DPD regenerating time : 20-25min.

DPD Feature and Operation 23

 DPD Regeneration Control at Low Water Temperature

￭ DPD Auto Regeneration control does not work if the water temperature is 70ºC
(158ºF) or less because the combustion temperature (exhaust temperature) is low
and DPD regeneration is not carried out at low water temperatures
temperatures.

<Automatic regeneration>
Engine side: The green lamp does not go on at low water temperatures when
automatic DPD regeneration request is issued.
Main body side: No control is executed, in particular.
Æ The followingg patterns
p are executed after the water temperature
p rises.
￭ Gate lever locked – Dead
Regeneration does not start even if the water temperature rises, since automatic
regeneration has not started.
￭ Gate lever unlocked (Engine is running by not being operated)
This pattern assumes that an operator exists. Automatic regeneration starts as the
g
water temperature rises. Auto regeneration maybe
y extended beyond
y 8 minutes,
depending on the exhaust temperature.
￭ Gate lever unlocked (Engine is running and being operated)
Automatic regeneration starts as the water temperature rises.

If machine is operated with continued low temperature that manual DPD icon will
flash Manual regeneration. Operation will be required.

Automatic regeneration will not start until the water temperature rises due to
automatic warming or machine operations.

<Manual regeneration>
Engine side: The amber lamp begins to blink even at low water temperatures when
manual DPD regeneration request is issued.
Main body side: The amber lamp goes on when the DPD switch is pressed.
Æ The auxiliary hydraulic load is turned on.

The water temperature rises and manual regeneration starts, since the auxiliary
hydraulic load is turned on.

DPD Feature and Operation 24

 DPD Regeneration Control at High Water Temperature

￭ DPD regeneration control does not work at the water temperatures over 100ºC
(212ºF) , because the combustion temperature (exhaust temperature) is to high
when the water temperature is to high
high. The DPD is in danger of melting.
melting

<Automatic Regeneration>
Engine side: The green lamp does not go on at high water temperatures when an
automatic DPD regeneration request is issued.
Main body side: It is necessary to inform the operator that regeneration cannot be
executed since the water temperature
p is high.
g
Thus, if automatic regeneration stops or does not start due to high water
temperature, the operator is prompted to cool down engine by the following:
￭ The green DPD lamp displayed and blinking.
￭ The “Automatic DPD regeneration” is displayed.
￭ The DPD indicator is displayed and blinking.

<Manual Regeneration>
Engine side: The amber lamp begins to blink even at high water temperatures
when a manual DPD regeneration request is issued.
Main body side: The amber lamp goes on when the DPD switch is pressed and the
engine revolution changes to 1000 rpm for 4HK1X and 6HK1X engines
Æ The water temperature lowers since the machine is left in the idling condition.
DPD regeneration control starts as the water temperature lowers.

The water temperature lowers since the machine is left in the idling
condition.

DPD Feature and Operation 25

DPD Hydraulic Load Assist Control

DPD Feature and Operation 26

DPD Hydraulic Load Assist Control

DPD Feature and Operation 27

 Regeneration Control In Case Of Problems
Regeneration Control In Case Of Problems
(Main Body Side: Manual Regeneration Only)

￭ If the solenoid valves used for the auxiliary hydraulic load fails than manual
regeneration load assist does not work.
<Applicable solenoid valves>
- P1/ Flow proportional solenoid valve
- Boom 2 proportional solenoid valve (for auxiliary regeneration)

<Countermeasures for problem>

Under normal condition manual regeneration will not occur with gate lever lock – Live.
But due to failed solenoids, system will override and allow manual machine operation to
raise engine temperatures.

The normal gate lock lever condition for manual regeneration is cancelled if wire
breakage or a short circuit of either proportional solenoid valve is detected.

It still will be possible to turn on the load, since the auxiliary hydraulic load cannot be
automatically be controlled.

Engine revolution is fixed to 1000 rpm for 4HK1X and 6HK1X engines

DPD Feature and Operation 28

 DPD Regenerating Operation (Compulsory)

Capturing PM Self regeneration

Auto regeneration

DPD icon : Orange and flashing

slow

DPD icon : Orange and flashing fast Service Technician

accesses diagnostic
menu or uses engine
■ Did Not Push Manual Regeneration Switch service tool
■ Fail for DPD manual regeneration to be completed

Slow regeneration
Warning with engine error code (100 Minutes)

DPD Regenerating Operation (Compulsory)

DPD icon : Red and flashing fast

Reason: Did Not push manual regeneration switch when required
Reason: Failure of DPD manual regeneration to be completed

Warning
W i with
ith engine
i error code
d
Compulsory Regeneration (Slow Regeneration)
Service Technician accesses diagnostic menu or uses engine service tool

-Slow regeneration is required if any of the following problem codes are issued.
◆P242F: Excessive PM collection by the DPD (judging from the differential pressure).
◆P1455: Excessive PM collection 2 byy the DPD (j (judging
g g from the time))
◆P2458: Too frequent DPD regeneration timeouts
◆P1471: DPD purification judgment error

- Engine oil should be changed after conducting slow regeneration. (Oil is

deteriorated by long-term regeneration.)

DPD Feature and Operation 29

 DPF Overhaul

■ Overhaul of DPD (Necessary for Ash Removal of DPF)

Although you are using allowed fuel and engine oil, there still contains a certain level of ash in
the DPF.
DPF will need to be overhauled.

DPF pressure
(IN/OUT)
Start of auto DPD regenerating

If In
frequency HR meter
case of of auto DPDof
increasing regeneration
frequency increases it may
of auto DPD indicate that overhaul of
regenerating,
DPF is required
it is the time to overhaul of DPD (elimination of ash)

DPF Overhaul

Overhaul of DPF (Necessary for Ash Removal of DPF)

Although you are using allowed fuel, and engine oil there still contains a certain level of
ash.

DPF will need to be overhauled.

If frequency of auto DPD regeneration increases it may indicate that overhaul of DPD is
required.

DPD Feature and Operation 30

 Tier 4a Required Fuel and Engine Oil Types

High sulfur fuel will plug DPD device as well as decrease emission capability.

Allowable sulfur content level:

EU/Japan Less than 10 ppm
NA (EPA) Less than 15 ppm

Engine oil use for Interim Tier IV engine

Engine Oil Standard

JASO ： DH-2
API ： CJ-4
ACEA ： E6

Tier 4a Required Fuel and Engine Oil Types

Hi h sulfur
High lf ffuell will
ill plug
l DPD d device
i as wellll as d
decrease emission
i i capability.
bilit
Allowable sulfur content level:
EU/Japan Less than 10 ppm
NA (EPA) Less than 15 ppm
Engine oil use for Interim Tier IV engine
Engine Oil Quality Requirement
1) Oil change interval,
interval same as current
current, 500hrs
2) Lower impurities and lower alkalinity to decrease ash
3) Lower viscosity and soot diffusing capability
4) Lubrication capability against dilution
Engine Oil Standard
JASO ： DH-2
API ： CJ-4
ACEA ： E6

DPD Feature and Operation 31

 DPD Mechanical Failure (Filter Plugged)
■DPD Filter Plugged
*In case of low quality of fuel and high sulfur fuel, ash reacts chemically from
sulfide in the fuel and will plug up the filter.
=> prohibition
hibiti to
t use any fuel
f l nott complied
li d with
ith the
th regulation
l ti
=> no warranty when confirmed use of low quality or high sulfur fuel usage.
=> no machine shipments to T2/T3 regulation countries, only for IT4/T4 regions
*In case of low quality of engine oil, ash reacts chemically from additive in
engine oil will plug up the filter.
=> prohibition to use any engine oil not complied with the
regulation

DPD Mechanical Failure (Filter Plugged)

DPD Filter Plugged

*In case of low quality of fuel and high sulfur fuel, ash reacts chemically from sulfide in
the fuel and will plug up the filter.

=> Isuzu prohibits use of any fuel not complied with regulation
=> No warranty when confirmed use of low quality or high sulfur fuel usage.
=> no machine shipments to T2/T3 regulation countries
countries, only for IT4/T4 region

*In case of low quality of engine oil, ash reacts chemically from additive in engine oil and
will plug up the filter.
=> prohibition to use any engine oil not complied with the regulation

DPD Feature and Operation 32

 DPD Mechanical Failure (Filter Plugged)

(Filter Damage by High Temperatures)

Caused by too much PM accumulation in DPD. PM reacts with the heat and too much
burning will cause the filter to be damaged.
=> Monitoring DPD pressure (IN/OUT) and exhaust temperature, DPD regenerating
operation needs to be monitored by operator. In case pressure or temperature are to
high, DTC code is displayed and ECM reduces fuel injection amount. This allows
ECM to protect DPD and engine.
<Factors of PM Accumulation>
Long engine idling time without machine operation.
Restricted or plugged air cleaner
cleaner.
Use of low quality of fuel, high sulfur fuel, or wrong specification of
engine oil

DPD Mechanical Failure (Filter Plugged)

(Filter Damage by High Temperatures)

Caused by too much PM accumulation in DPD. PM reacts with the heat and too much
PM burning will cause the filter to be damaged.

=> DPD pressure (IN/OUT) and exhaust temperature, DPD regenerating operation needs
to be monitored by operator.

In case pressure or temperature are to high, DTC code is displayed and ECM reduces
f l injection
fuel i j ti amount. t Thi
This protects
t t DPD and d engine.
i

<Factors of PM Accumulation>

Long engine idling time without machine operation.

Restricted or plugged air cleaner
Use of low q
quality
y fuel,, high
g sulfur fuel,, or wrong
g specification
p engine
g oil.

DPD Feature and Operation 33

 DPD Mechanical Failure (Filter Plugged)

Serial Number

DPD Mechanical Failure (Filter Plugged)

Isuzu recommends that the DPF be (cleaned) serviced at 4500 hours. For extended life
of DPF Case recommends that the filter be cleaned at 3500 ~ 4000 hours.

Any servicing or warranty of DPF will require S/N identification

(S/N of DPF cartridge is also necessary to track and report to EPA).

The part number and serial number of the DPF and DOC can be found on the housing
face.

DPD Feature and Operation 34

 Overhaul of DPD Filter Cartridge

Distinctive Device for DPD Filter Cleaning is Required.

Overhaul of DPD Filter Cartridge

There are two primary categories of particulate that will plug a DPF:

Ash is the primary component that will gradually plug the filter. Under normal
operating conditions ash will gradually build up in the filter at a rate based on hours of
operation. The build-up can be increased by the types of lubricants used, condition of
the engine, quality and type of diesel fuel and engine oil.

Soot is the plugging component that comes from unfavorable operating conditions.
Low filter temperature, a bad injector, poor fuel, or worn cylinder walls and rings can
quickly cause soot build-up in the filter. Filters that are in good condition can plug in
one day due to an unfavorable operating condition. A soot filled DPF is now the
diagnostic tool mechanics use to indicate certain engine or fuel problems.

The DPF has eliminated the ability to look at the exhaust stack as an indicator where
to look for an operating problem.

DPD Feature and Operation 35