3Aftertreatment System Passive RegenerationPassive regeneration occurs when the exhaust temperature during normal operation is adequate to trigger regeneration (600ºF - 750ºF)During normal driving mode the soot is regenerated without driver interventionIntake throttle valve may be used to increase passive regeneration without the aid of dosing
4Aftertreatment System Active RegenerationActive regeneration takes place when normal operation does not allow for passive regeneration to take placeDDEC VI uses the doser and intake throttle valve to elevate exhaust temperatures allowing for complete regenerationActive regeneration just like passive regeneration does not require driver interventionRegeneration is suspended when the vehicle drops below a minimum threshold (~5 mph) for S60/MB MB900 Engines will regenerate down to 0 mph.If vehicle slows below a minimum threshold during an active regeneration a “high exhaust temp” lamp will illuminate until exhaust temperature drops below 750ºF
5Stationary or “Parked” Regeneration Aftertreatment SystemStationary or “Parked” RegenerationIn a small number of select engine duty cycles completion of an active/passive regeneration may not be possible. In these cases, a stationary regeneration will need to occurThe DPF lamp has been added to inform the driver that a stationary regeneration needs to take placeThe operator will be alerted hours before a stationary regeneration MUST take place.The operator should perform the stationary regeneration as soon as possible after the light is illuminated.To complete a stationary regeneration the following conditions must be metVehicle must be in parkClutch is depressed and releasedTransmission must be in neutral/parkOnce initiated by the driver, active regeneration takes roughly 20 minutes to completeDDC expects stationary regeneration will be required in less than 5% of customer applications
6Regeneration Strategy Vocational Applications Aftertreatment SystemRegeneration Strategy Vocational ApplicationsVocational Applications may require stationary or “Parked” regenerationsunder light-load conditionsSTATIONARY “PARKED”Active Regens take approx. 40 minutes to complete – stationary regens approx minutesACTIVENo Driver Effort RequiredPASSIVE
7The DPF Regeneration Cycle NO DRIVER INTERACTION REQUIRED, FILTER CLEANING (also called regeneration) IS FULLY AUTOMATIC.You will only see warning lights if the filter cannot perform an automatic cleaning.The DPF is in ‘self cleaning’ mode.No driver interaction is required.Driver cannot tell if system is ‘Passively’ or ‘Actively’ regenerating.When the regeneration process is complete the timers are all reset to zero and the process starts again.Driver will only see warning lamps if the filter cannot perform an automatic cleaning (regeneration).
8The DPF Regeneration Cycle Bring vehicle to highway speeds to allow for an Automatic RegenerationOR Perform a Parked Regeneration. FILTER REGENERATION RECOMMENDED.SOLIDA parked regeneration can be performed at any time when the DPF lamp is on.The engine will continue to try and complete an active regeneration during this time.Lamp will begin flashing after approximately 1 hour of driving time if an over-the-road regeneration cannot be completed.If regeneration is completed, lamp will go out and all timers will be reset to zero.
9The DPF Regeneration Cycle Bring vehicle to highway speeds to allow for an Automatic RegenerationOR Perform a Parked Regeneration as soon as possible. FILTER REGENERATION NECESSARY.FLASHINGA parked regeneration should now be performed as soon as possible.The engine will continue to try and complete an active regeneration during this time.Check Engine Lamp will come on after approximately 1/2 hour of driving time if an over-the-road regeneration cannot be completed.If regeneration is completed, lamp will go out and all timers will be reset to zero.
10The DPF Regeneration Cycle Vehicle must be parked and a Parked Regeneration OR Service Regeneration must be performed.PARKED REGENERATION REQUIRED – ENGINE DERATE.+FLASHINGA parked regeneration MUST now be performed.The engine will NOT try and complete an active regeneration during this time.Engine is derated by 25%.Stop Engine Lamp will come on after approximately:1 hour of driving time for MBE 900.
11The DPF Regeneration Cycle Vehicle must be parked and a Parked Regeneration OR Service Regeneration must be performed.PARKED REGENERATION REQUIRED – ENGINE SHUTDOWN.++FLASHINGA parked regeneration MUST now be performed.The engine shutdown over ride switch functions normally.(the number of over-rides is recorded)
12High Idle Regeneration Procedures Aftertreatment SystemHigh Idle Regeneration ProceduresFrom Time to Time The Yellow DPF Regeneration Lamp May Come OnThis Indicates that Soot Level is ElevatedDriving on the Highway or Having the Engine Under Load will Allow the Filter to “Self-Clean”If the Light Starts to Flash you Will need to Pull the Truck Over and Initiate a High Idle RegenerationDPF RegenerationLampLight On Solid
13High Idle Regeneration Procedures Aftertreatment SystemHigh Idle Regeneration ProceduresThe Engine Needs to be Warm (Approximately 180F)It is Best to do This Immediately After StoppingWith the Truck Running,Set Park BrakePut Transmission in NeutralDepress & Release Clutch PedalVerify No Other Codes in System (No Check Engine Light)DPF RegenerationLampLight Flashing
14High Idle Regeneration Procedures Aftertreatment SystemHigh Idle Regeneration ProceduresDepress Switch for 4 SecondsRPM will Increase to about 1200Engine will bring up the Temperatures & Initiate Regenerating the FilterApproximately Minutes Later the Engine will Complete the Regeneration & the Engine will Return to 600 RPMHot Exhaust Temp Indicator Lamp May Remain OnHot Exhaust Lamp is Information Only “No Driver Action Required”DPF Regeneration SwitchHigh ExhaustTemperature Lamp
15Exhaust Diluter Testing 415°F Reduction in Max 6” Away from PipeStock PipeMax Temp = 806°F / 430°CWith Diluter PipeMax Temp = 388°F / 198°C
18Trigger Significance – All Engines FLASHINGFLASHING+FLASHING+SOLIDZone 1 Trigger(Auto Regen)Zone 2 TriggerZone 3 TriggerZone 4 Trigger(Parked Regen)Zone 5 TriggerSeries 60 & HDEP Customer Demo6 Hrs250 Miles157 kg fuel13.5 Hrs460 Miles289 kg fuel14.5 Hrs520 Miles327 kg fuel15 Hrs550 Miles345 kg fuel19 Hrs800 Miles502 kg fuelMBE 40008 Hrs300 MilesNo fuel trig16 Hrs450 Miles17 Hrs500Miles17.5 Hrs525 Miles28 HrsMBE 900 – 9.0”Low HP Units124 Miles30 kg fuel7.5 Hrs174 Miles55 kg fuel8.5 Hrs217 Miles65 kg fuel9 Hrs239 Miles75 kg fuel10 Hrs283 Miles85 kg fuelMBE 900 – 10.5”High HP Units280 Miles60 kg fuel9.5 Hrs357 Miles90 kg fuel10.5 Hrs388 Miles105 kg fuel11 Hrs419 Miles115 kg fuel12 Hrs466 Miles140 kg fuelSpeaker Notes:Passive Regeneration happens naturally; the heat of the exhaust burns off the soot. No driver interaction is needed. No lights will come on.Automatic Active Regeneration is necessary when the temperature is too low to completely burn off the soot. It is initiated by injecting fuel into the exhaust. No driver interaction is needed. No driver interaction is needed.If an Active Regeneration can not be initiated automatically, the DPF regeneration light will light up 1.5 hours (solid) and 0.5 hours (flashing) before the engine is going to derate and a regeneration must be initiated.Parked Regeneration is initiated by operating the regeneration switch on the dash; all safety conditions have to be met.Explaining the above slide: If the truck hasn’t been able to passively or actively regenerate the DPF Regeneration lamp will go on at 13.5 hours. An hour later, the lamp will start to blink and alert the driver that he or she has to initiate a regeneration. He or she then has 30 minutes until the Check Engine Lamp goes on and the torque will derate by 25%.Once a regeneration has taken place, the timer resets to zero.
19Idle Time Strategy – MBE 900 (9”) Idle Scenario (Overnight):If the truck idles overnight, just before any of the regeneration indicator lamps light up, you have at least the amount of time – indicated by the dotted lines below – remaining, until the Aftertreatment System has to regenerate.Idle RPM>15 hrs800361063661>22 hrsSpeaker Notes:The above colors match the colors on the previous page.The values circled in black refer to the overall amount of time.As the values and graphs above indicate, the higher the engine speed the less idle time you have until the next regeneration is required.Example: After 42 hours of 800 RPM the engine can still be idled for another 8 hours until the Aftertreatment Device requires a regeneration and another 6 hours of idle after that before the engine shuts down.The idle time is based on driving hours (see previous slide) by the following factors:700 RPM = Driving Hours x 6.67800 RPM = Driving Hours x 5.567005514949911020304050607080100Idle Time/Hours
20Parked Regeneration Procedure (FAQ) - Parked Regen Engine Speeds:MBE900 = 1200 rpmS60/HDEP Customer Demo = 1600 rpmMBE4000 = 1300 rpm (potential to vary)- To Cancel a Parked Regeneration hold the DPF Switch to the ON position for five (5) seconds and release.- A Parked Regeneration will stop if the key is turned to the off position, the truck is put into gear or the parking brake is released.- If a Parked Regeneration is canceled; the driver has 15 minutes to restart the process to have it pick up where it was interrupted. If the 15 minute timer has expired then the Parked Regeneration will start over from the beginning.- The High Exhaust System Temperature (HEST) Lamp will remain on until the exhaust temperature falls below 975F or the vehicle speed exceeds 5 mph.- Idle Shutdown Timer (if enabled) starts when Parked Regeneration is completed.
22DDEC Reports – Trip Activity Explanation 2/2 1Parked Regen Count: Count of Parked Regeneration attempts.Driving Regen Count: Count of Over-the-road Regenerations.Parked Regen Fuel: Dosing Fuel + Fuel to run the engineDriving Regen Fuel: Dosing Fuel used during Over-the-road Regenerations.Idle Fuel: The amount of fuel used while the engine was in Idle Mode.Trip Fuel: Driving Fuel + Idle Fuel + Total Regen Fuel Total Regen Fuel = Parked Regen Fuel + Driving Regen FuelIdle Time: Trip Time spent in Idle Mode.Trip Time: Driving Time + Idle Time + Parked Regeneration TimeParked Regen Time: Total time required for Parked Regeneration.2
23DPF Maintenance Frequency Engine ModelCleaning interval (Miles)Series 60550,000 milesMBE 4000300,000 milesMBE 900150,000 milesAsh Cleaning Intervals are fixed in the engine calibrationDependent on engine onlyCJ- 4 oilrequired on the MBE 900optional on MBE 4000 & Series 60When mileage is reached the Check Engine lamp comes on.
24DPF Maintenance DDC Exchange Program Aftertreatment SystemDPF MaintenanceDDC Exchange ProgramUtilizes a liquid cleaning solution to flush out ash from the filter cells95% EffectiveShorter Service time than air cleaningNo Parked Regen Required!Blowing ash out is around 30-40% effective. We have been cleaning filters for several years and thru testing determined liquid cleaning is the only effective method for cleaning and at this time don’t recommend air cleaningand comes with 1yr 100k mile warranty (same as any other reman part)Ash accumulation
25Aftertreatment System Liquid CleaningFilter is cleaned with a proprietary liquid solution only available with DDC filtersMost efficient method, % efficientProcess will be performed at DDC Remanufacturing CentersExchange program will be available45 minutes of labor time$500 - $750 expected list priceA process only available with DDC filters
26The DPF Regeneration Cycle Indicator Lamp Progression ++SOLIDFLASHINGFLASHINGFLASHINGNO DRIVER INTERACTION REQUIRED, FILTER CLEANING (also called regeneration) IS FULLY AUTOMATIC.About1 hourLess than1 hourHeavy-DutyAbout 4 hrsYou will only see warning lights if the filter cannot perform an automatic cleaning.Medium-DutyAbout 1 hourBring vehicle to highway speeds to allow for an Automatic RegenerationOR Perform a Parked Regeneration. FILTER REGENERATION RECOMMENDED.SOLIDBring vehicle to highway speeds to allow for an Automatic RegenerationOR Perform a Parked Regeneration as soon as possible. FILTER REGENERATION NECESSARY.FLASHINGVehicle must be parked and a Parked Regeneration OR Service Regeneration must be performed.PARKED REGENERATION REQUIRED – ENGINE DERATE.+FLASHINGVehicle must be parked and a Parked Regeneration OR Service Regeneration must be performed.PARKED REGENERATION REQUIRED – ENGINE SHUTDOWN.++FLASHING