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    Perkings Manual Regeneration

    Uploaded by

    Erik Martinez
    This document provides instructions for performing a manual regeneration on Perkins 854 tier 4 engines when the diesel particulate filter (DPF) reaches a high soot loading level. It describes the cause for high soot loading as light engine usage not allowing for sufficient exhaust temperatures for passive regeneration. The solution outlined is to use an EST service tool or jumper wire method to initiate the manual regeneration process, monitoring temperatures and engine RPM until the regeneration is complete and the DPF soot loading value drops sufficiently. It stresses the importance of properly performing scheduled oil changes to prevent engine derate mode which can cause high soot loading.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Perkings Manual Regeneration

    Uploaded by

    Erik Martinez
    6K views26 pages
    This document provides instructions for performing a manual regeneration on Perkins 854 tier 4 engines when the diesel particulate filter (DPF) reaches a high soot loading level. It describes the cause for high soot loading as light engine usage not allowing for sufficient exhaust temperatures for passive regeneration. The solution outlined is to use an EST service tool or jumper wire method to initiate the manual regeneration process, monitoring temperatures and engine RPM until the regeneration is complete and the DPF soot loading value drops sufficiently. It stresses the importance of properly performing scheduled oil changes to prevent engine derate mode which can cause high soot loading.

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    This document provides instructions for performing a manual regeneration on Perkins 854 tier 4 engines when the diesel particulate filter (DPF) reaches a high soot loading level. It describes the cause for high soot loading as light engine usage not allowing for sufficient exhaust temperatures for passive regeneration. The solution outlined is to use an EST service tool or jumper wire method to initiate the manual regeneration process, monitoring temperatures and engine RPM until the regeneration is complete and the DPF soot loading value drops sufficiently. It stresses the importance of properly performing scheduled oil changes to prevent engine derate mode which can cause high soot loading.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    6K views26 pages

    Perkings Manual Regeneration

    Uploaded by

    Erik Martinez
    This document provides instructions for performing a manual regeneration on Perkins 854 tier 4 engines when the diesel particulate filter (DPF) reaches a high soot loading level. It describes the cause for high soot loading as light engine usage not allowing for sufficient exhaust temperatures for passive regeneration. The solution outlined is to use an EST service tool or jumper wire method to initiate the manual regeneration process, monitoring temperatures and engine RPM until the regeneration is complete and the DPF soot loading value drops sufficiently. It stresses the importance of properly performing scheduled oil changes to prevent engine derate mode which can cause high soot loading.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    The document discusses the manual regeneration process for Perkins 854 tier 4 engines, including causes for needing regeneration, steps to perform regeneration using EST software or the DPF connector, and stages of the regeneration process.

    Signs that a manual regeneration is needed include the engine lacking power, inability to drive up ramps, diagnostic codes D-87 or D-98, inability to reach full RPM, and derate mode being activated due to high soot loading in the DPF.

    The steps to perform a manual regeneration using EST software are to connect the software, verify diagnostic codes, navigate to the service procedures and manual DPF regeneration screens, note current values, confirm soot loading and status, review requirements, and start regeneration by clicking start or jumping the DPF connector.

    Perkins Manual Regen

    Mitsubishi Forklift Trucks:


    FD40N1, FD45N1, FD50CN1, FD50N1, FD55N1
    AF12C-00011 and up, AF19E-50001 and up, AF19E-80001 and up,
    AF28D-50001 and up, AF28D-80001 and up

    Cat Lift Trucks:


    DP40N1, DP45N1, DP50CN1, DP50N1, DP55N1
    AT12C-00011 and up, AT19E-50001 and up, AT19E-80001 and up,
    AT28D-50001 and up, AT28D-80001 and up

    Models:

    Perkins Manual Regen

    Cause/Discussion:
    Engine is lacking power
    Truck will not drive up a ramp
    Code D-87 or D-98 is being displayed on the meter panel
    Engine will not accelerate full RPM
    Engine is in derate mode
    DPF has high soot load level
    DPF needs a manual regeneration
    Light usage or light truck duty cycle
    Fuel quality
    Oil life reset

    Topic:
    Perkins 854 tier4 engine - manual regeneration process

    Perkins Manual Regen

    D-98 Particulate Trap #1 Soot Load Percent High most severe


    Perkins ECM code: J3719-0

    D-87 Particulate Trap #1 Soot Load Percent High moderate severe


    Perkins ECM code: J3719-16

    Cause/Discussion:

    Perkins Manual Regen

    The system passively regenerates at different levels depending on


    truck load/duty cycle and DOC temperature. These chemical
    reactions will occur when the gas temperature into the DOC is greater
    than 482F (250C). This chemical process is known as Passive
    Regeneration. If the engine duty cycle does not allow sufficient exhaust
    temperature for passive regeneration, soot accumulation will continue
    to rise.

    Passive Regeneration:
    The system is designed to passively regenerate during engine/truck
    operation, using the Diesel Oxidation Catalyst (DOC) to reduce
    particulates and promote the production of NO2, which is used for
    oxidization of Particulate Matter (PM) in the Diesel Particulate Filter
    (DPF).

    Cause/Discussion:

    Perkins Manual Regen

    Solution:
    1. Connect the EST Software to the truck.

    Perkins Manual Regen

    Solution:
    2. Verify diagnostic fault codes.

    Perkins Manual Regen

    D-87

    D-98

    Solution:
    3. Navigate to Service > Service Procedures

    Perkins Manual Regen

    Manual DPF Regeneration

    Solution:
    4. Navigate to the Manual DPF Regen screen

    Perkins Manual Regen

    Solution:
    5. Note the current values and status on this screen.

    Perkins Manual Regen

    7. Confirm DPF Status and DPF Active Regeneration Status

    Solution:
    6. Confirm DPF Soot Loading value in grams.

    Perkins Manual Regen

    Solution:
    8. Before attempting to start the Regen process, note the
    requirements/instructions on the left, at the bottom of the screen.

    Perkins Manual Regen

    EST Service Tool > Manual DPF Regen section


    DPF Connector underneath dash compartment

    Solution:
    9. There are two methods of initiating a Manual Regen.

    Perkins Manual Regen

    Method #1

    Solution:

    Click Start button, at this time


    engine RPM will automatically
    rise to 2000.

    Perkins Manual Regen

    Close the DPF connector circuit.


    Install a jumper wire for 4 seconds
    and remove, at this time engine
    RPMs will automatically rise to
    2000.

    Solution:

    Method #2

    Perkins Manual Regen

    Solution:
    Note Engine RPMs when the Regen process initiates.

    Perkins Manual Regen

    Solution:
    In order to get the DPF#1 Soot Loading value to start dropping, DOC
    and Intake Temperature will need to rise to approximately 1000F
    during the manual regen process. At this time particulate soot matter
    will begin to oxidize/burn efficiently.

    Perkins Manual Regen

    Solution:
    During the Manual Regen process, it is very important to monitor
    temperatures and engine RPM. If anything abnormal is detected, the
    Manual Regen process can manually be stopped.

    Perkins Manual Regen

    If the manual regen was initiated per DPF Connector underneath


    dash compartment
    Depress the accelerator pedal once
    Shut the key off and wait 25 sec

    If the manual regen was initiated per the EST Service Tool
    Click on the Stop button on the bottom the Manual DPF
    Regeneration page
    Depress the accelerator pedal once
    Shut the key off and wait 25 sec

    Solution:
    Methods of stopping a Manual Regeneration that is in progress.

    Perkins Manual Regen

    Solution:
    First stage during a Manual Regen

    Perkins Manual Regen

    Solution:
    Second stage during a Manual Regen

    Perkins Manual Regen

    Solution:
    Third stage during a Manual Regen

    Perkins Manual Regen

    Solution:
    Fourth and final stage of a Manual Regen - Complete:
    RPMs will automatically drop to 800
    DPF Soot Loading value will be between 1g ~ 3g

    Perkins Manual Regen

    Solution:
    Important Note:
    Failure to perform a scheduled oil and filter service with an oil life
    service reset will trigger an engine derate mode. The maximum time
    between oil changes is 500hrs. In derate mode, the light engine duty
    cycle will not allow sufficient exhaust temperature for passive
    regeneration, soot accumulation will rise quickly and cause an high
    soot load code.

    Perkins Manual Regen

    Solution:
    DPF Status - Stages of DPF Soot loading:
    Regeneration Not Needed - Normal State
    Regeneration Needed - Lowest Level
    Regeneration Needed - Moderate Level
    Regeneration Needed - Highest Level

    Perkins Manual Regen

    6.7g

    8.53g

    9.65g

    25g

    Regen not needed

    Regen needed Lowest level

    (Derate Mode)

    Regen needed Moderate Level

    (Derate Mode)

    Regen needed Highest Level

    Perkins Manual Regen

    Passive regeneration

    Manual regeneration
    Needed

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