4.1 Maintenance Requirements
The following are maintenance requirements to follow for servicing theDPF. Due to large variations on operating conditions, the maintenance schedulemay change slightly depending on the specifics of the application. Below in Table 4.1, are requirements to followfor servicing the DPF.
Table 4.1 – Maintenance Schedule
Frequency | Action | Description |
Every 50 hours of operation | Manual Backpressure Check | Operate the engine at high idle. At exhaust port upstream of DPF install manual backpressure gauge. Record results in a log sheet. |
Every 200 hours of operation | Check for leaks | Make visual check of piping, fittings, clamps and gaskets in the exhaust system for exhaust leaks. Look specifically for evidence such as soot present near connection. Repair if necessary. |
Every 200 hours of operation | Check Pressure Transducer | Remove pressure transducer and apply pressure to the line. Check line for leaks. Indicator lights must illuminate at a specified backpressure. |
Every 1000 hours of operation | Filter Cleaning | Conduct Level 2 Cleaning (See section 4.4 below for details) |
Filter Cleaning | Conduct Level 1 Cleaning or Level 2 Cleaning according to guidelines in Table 4.2 below. |
4.2 Manual Backpressure Checks
When taking manual backpressure measurements, operate the engine athigh idle. At an exhaust port upstream of the DPF install a manual backpressuregauge. Record results in a log sheet.
Table 4.2 – Manual Backpressure Check
Reading | Filter Condition | Actions |
<5"wc (<1.25kPa) | DPF is damaged | Remove DPF and contact Foley Engines for further assistance |
5-25"wc (2.5-6.25kPa) | DPF is clean | No action |
25-40"wc (6.25-10kPa) | DPF is moderately loaded with soot and/or ash | Level 1 Cleaning or Level 2 Cleaning is required within the next 50 hours of operation |
>40"wc (>10kPa) | DPF is highly loaded with soot and/or ash | Remove DPF immediately and conduct Level 2 Cleaning |
4.3 Level 1 Cleaning
4.3.1 Standard Design
1. Remove the DPF center-body using thequick-release clamps. Be sure to properly support the DPF upon removal as thefilters are fragile and can break if dropped. Depending on the size of the DPF,this may take two people.
2. Attach to the filter inlet (sooted end of DPF),a vacuum which feeds into a high-efficiency particle arrestance (HEPA) filtermaking sure that all connections are airtight to prevent soot/ash from escapingbefore being forced through the HEPA filter.
3. Using compressed air (~80psi) blow theparticulates/ash from the outlet end of the DPF towards the inlet of the DPF,through the vacuum and through the HEPA filter. The air gun should be held aminimum of 2 inches from the surface of the DPF to prevent damage to the filteritself.
4. Move the air gun around to ensure that all ofthe DPF channels on the outlet have been exposed to the compressed air. Compressedair cleaning should be performed for an approximate duration of 10 minutes.
5. Remove the HEPA filter and store away for re-useor dispose of if saturated with soot/ash.
6. Reinstall DPF center-body on given applicationand fasten securely using all applicable mounting hardware.
7. Perform a manual backpressure check at no loadand high idle conditions to ensure that the Level 1 Cleaning reduced thebackpressure build-up due to soot/ash removal. Backpressure should be less thaninitial backpressure reading before cleaning procedure.
4.3.2 Custom Design
The majority of custom DPF designs are developed to replace theoriginal equipment muffler. The two most popular designs allowing access to theDPF for cleaning are shown in Figure 4.1and Figure 4.2 below.
Figure 4.1 – Flanged Center-bodyDPF Muffler Figure 4.2 –Bolted End-disc DPF Muffler
4.3.2.1 Custom Design 1 (See Figure 4.1)
- Remove DPF muffler from application in the same manner as if removing original muffler. Be sure to properly support the DPF upon removal as the DPFs are fragile and can break if dropped. Depending on the size of the DPF muffler, this may take two people.
- Remove DPF from muffler center-body by undoing the quick-release clamps or removing the bolts from the flanges in the center of the muffler.
- Perform Level 1 Cleaning steps 2-5 inclusive of Standard Design cleaning instructions above.
- Reinstall the DPF into the center-body of the muffler and secure it in place by either tightening the clamps or bolting the flanges.
- Reinstall muffler into application in the same manner as installing the original muffler.
- Perform a manual backpressure check to ensure that the Level 1 Cleaning reduced the backpressure build-up due to soot/ash removal. Backpressure should be less than initial backpressure reading before cleaning procedure.
4.3.2.2 Custom Design 2 (See Figure 4.2)
1. Remove DPF muffler from application in the samemanner as if removing original muffler. Be sure to properly support the DPFupon removal as the DPFs are fragile and can break if dropped. Depending on thesize of the DPF muffler, this may take two people.
2. Remove bolts on muffler body end-disc and removedisc from muffler exposing DPF inside.
3. Attach to the muffler exhaust flow inlet, avacuum which feeds into a HEPA filter and secure around the muffler inlet pipeto prevent soot/ash from escaping before being forced through the HEPA filter.
4. Perform Level1 Cleaning steps 3-5 inclusive of Standard Design cleaning instructionsabove.
5. Replace muffler end-disc onto muffler and boltto secure.
6. Reinstall muffler into application as installingthe original muffler.
For other custom designs, please contact Foley Engines for propercleaning procedures.
4.4 Level 2 Cleaning
1. Remove the DPF from the application. If it is astandard design, simply remove the quick-release clamps. If it a custom designDPF muffler such as Figure 4.1 or Figure 4.2 above, remove the DPFmuffler in the same manner as the original equipment muffler. For removal ofother custom designed filters, contact Foley Engines as necessary.
2. Place the DPF center-body, inside an oven orkiln ensuring that the inlet and outlet of the DPF are exposed (i.e. DO NOT sitthe DPF vertically in the oven so that the DPF inlet or outlet filter faces areagainst the surface on which the DPF is resting).
3. Increase the temperature of the oven to 500*Cover a period of 1.5-2 hours.
4. Retain an oven temperature of 500*C for a continuous period of 4 hours to allow complete combustion of accumulated sootin the DPF.
5. Decrease the temperature back down to a temperature that will allow for safe removal of the DPF by hand.
6. Remove the DPF from the oven and perform a Level 1 Cleaning to remove thenoncombustible ash content.
7. For standard DPF designs, reinstall DPFcenter-body into position on the application. For custom designs, eitherreassemble muffler by placing the DPF center-body into a muffler and clampingor bolting it into place, or reinstall the muffler end-disc by bolting it to themuffler.
8. For custom design muffler replacements,reinstall the DPF muffler back into the application in the same manner asinstalling the original equipment muffler.
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