When to Clean Your DPFs
Regular maintenance of the DPF is crucial to prevent costly repairs and keep your fleet operating at peak efficiency. Most truck manufacturers recommend cleaning the filter every 150,000 to 300,000 miles. These numbers are generally overly optimistic and presume ideal operating conditions. The actual cleaning interval of DPFs can vary greatly depending on the driving conditions and the type of diesel fuel used.
Based on years of cleaning thousands of DPFs in our own shops, Filtertherm recommends servicing your DPFs at least once a year or 1,000 engine hours for high idle applications. Removing the ash regularly will help extend the life and performance of your fleet’s aftertreatment systems and engines. If hardened ash builds up in the DPF, it restricts the flow and often causes unnecessary engine issues or even filter failure.
Ultimately, the real-world driving conditions of each vehicle are the crucial factor when determining DPF cleaning for fleet maintenance schedules. Expect that trucks operating in stop-and-go traffic or high idling situations will need DPF cleanings at closer intervals.
Here are some indications that your trucks’ DPF may require cleaning:
- Increased Frequency of Regeneration: If your trucks are going through regeneration cycles more frequently than usual, it could indicate that the DPF is becoming clogged with soot and needs cleaning.
- Failed Regeneration Cycles: If your trucks’ DPF fails to complete regeneration cycles successfully, it could be an indication of damage or excessive clogging.
- Reduced Fuel Efficiency: A clogged DPF can lead to decreased fuel efficiency, resulting in higher operational costs for your fleet.
- Warning Lights: When the DPF warning light illuminates on your dashboard, it is a clear indication that the DPF needs immediate attention and may require cleaning.
- Engine Performance Issues: A damaged DPF can lead to reduced engine performance, including decreased power output, rough idling, and increased/black exhaust smoke.
Data-Driven Decisions
Leveraging your fleet’s data is vital given the competitive nature of the industry. At this scale, every advantage and incremental efficiency improvement pays you back exponentially. DPF Cleaning is no different. Waiting too long between cleanings, not being aware of upstream issues, or that a DPF is having issues can have an adverse effect on fuel efficiency, repair costs, and down time. Tracking your DPF cleaning data can help you spot trends or flag problematic filters and remove them from operation.
We have developed a software tool for that. It’s called FilterTrak, and every Filtertherm DPF Cleaning System comes with a free 1-year standard FilterTrak subscription (a $1,200 value).
Diagnosing a Damaged DPF
Early detection of DPF damage is vital to avoid expensive repairs or replacements. Here are some signs that often indicate a damaged DPF:
- Excessive Soot or Ash Accumulation: During regular inspections, look for excessive soot or ash accumulation in the DPF. A severely clogged filter may be damaged and require replacement.
- Aftertreatment Codes: Train your drivers to not ignore dash light warnings.
- Engine Performance Issues: A damaged DPF can lead to reduced engine performance, including decreased power output, rough idling, and increased exhaust smoke.
- Failed Regeneration Cycles: If your trucks’ DPF fails to complete regeneration cycles successfully, it could be an indication of damage or excessive clogging.
- Unusual Noises: Uncommon rattling or knocking sounds from the DPF area could signal internal damage or loose components.
If you suspect a damaged DPF, it’s crucial to inspect the filter promptly.
How to Inspect a DPF for Damage
Have your technicians follow these inspection procedures whenever a DPF comes off a truck for cleaning or otherwise.
- Visual Inspection: Look for cracks, holes, or other damage to the filter brick.
- Wire/Pin Test: Perform a wire/pin test before and after cleaning. If the DPF has hardened areas after cleaning, it may need additional cleanings or replacement if the ash is too compacted.
- Heat Damage? Check the DPF for signs of extreme heat damage such as scorching or melting. If the DPF has experienced an extreme heat event, it is likely damaged beyond repair.
- Dirty Outlet? Check the outlet side of the DPF for soot. This indicates DPF is compromised and should be replaced.
- Fluids Present? See if there are any engine fluids such as oil, fuel, or coolant on the filter.
Use the Right Tool for the Job
The Filtertherm Inspection Table is designed specifically for this stage of the process.
You can weigh and flow test your DPFs for benchmarking before and after cleanings. It even has a built-in high-intensity light that shines up through the filter for crack detection and a convenient built-in holder for pin test wires.
Proper Disposal of Damaged DPFs
When a DPF reaches the end of its service life or is irreparably damaged, proper disposal is critical to ensure environmental responsibility. DPFs contain hazardous materials, so they should not be thrown away in the trash/regular recycling. Follow these steps to dispose of damaged DPFs responsibly:
- Compliance with Local Regulations: Ensure that you comply with all local, state, and federal regulations regarding the disposal of hazardous waste. DPFs are considered hazardous due to the presence of heavy metals.
- Engage Authorized Recyclers: Contact authorized DPF recycling facilities that can safely handle and process damaged filters. These facilities can extract valuable metals and dispose of the remaining components responsibly.
- Document Disposal: Keep detailed records of the disposal process, including the date, disposal facility information, and any relevant paperwork, as part of your fleet’s environmental compliance efforts.
“Who you gonna call?”
We recommend contacting Red Fox Resources and asking about a Fox Box or their other flexible recycling options. They will even pay you for your accumulated, unusable DPFs, and DOCs.
Red Fox Resources handles all the logistics of shipping parts from your location to their facility. They arrange for truckload, LTL, or express shipments. They even pay shipping costs for collection partners.
Contact Red Fox Resources for more information.
Frequently Asked Questions About DPF Maintenance
Q: When should I clean my fleet’s DPFs?
A: While manufacturers often suggest cleaning every 150,000 to 300,000 miles, this is usually based on ideal conditions. A better approach, recommended by Filtertherm, is to service your DPFs at least once a year or every 1,000 engine hours for high-idle applications. Trucks operating in stop-and-go traffic will also likely need more frequent cleanings.
Q: What are the signs that a DPF needs cleaning?
A: You should check your DPF if you notice:
- Increased Regeneration: The truck’s regeneration cycles are more frequent than usual.
- Failed Regeneration: The DPF fails to complete its regeneration cycles.
- Reduced Fuel Efficiency: A clogged DPF can hurt your fuel economy and raise operational costs.
- Warning Lights: A DPF warning light on the dashboard is a clear sign that it needs immediate attention.
- Poor Engine Performance: This can include reduced power, rough idling, or increased black exhaust smoke.
Q: How can I tell if a DPF is damaged?
A: Signs of a damaged DPF can be similar to a dirty one, but may also include:
- Excessive soot or ash accumulation found during inspection.
- Aftertreatment warning codes on the dashboard.
- Unusual rattling or knocking noises coming from the DPF area.
Q: What’s the proper way to inspect a DPF for damage?
A: When a DPF is off the truck, your technicians should:
- Perform a Visual Inspection: Look for any cracks, holes, scorching, or melting.
- Do a Wire/Pin Test: Check for hardened, compacted ash that may require extra cleaning or replacement.
- Check the Outlet: Soot on the outlet side of the filter indicates it is compromised and needs to be replaced.
- Look for Fluids: See if any oil, fuel, or coolant is on the filter, which points to other engine issues.
Q: How do I get rid of an old or damaged DPF?
A: You cannot throw DPFs in the regular trash or recycling because they contain hazardous materials and heavy metals. You must follow all local, state, and federal regulations for hazardous waste disposal. The best method is to contact an authorized DPF recycling facility, which can safely process the filters, extract valuable metals, and dispose of the rest responsibly.
Q: Why is tracking DPF cleaning data important for my fleet?
A: Tracking your DPF data helps you spot trends and identify problematic filters before they cause major issues. Failing to clean DPFs on time or missing an upstream issue can negatively impact your fleet’s fuel efficiency, increase repair costs, and lead to more vehicle downtime.
Check out FILTERtrak, our software tool for tracking DPF Cleaning data and pictures.
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