DP20~35N3
DPF System
Copyright © MITSUBISHI LOGISNEXT CO., LTD. All Rights Reserved
Particulate matter (PM)
Diesel and engine oil burned in combustion produce particulate matter that
is captured in the DPF.
ＰＭ ＝ Soot ＋ Ash
Soot is a carbon-based byproduct of incomplete combustion.
It collects in the channels of the DPF until it is oxidized to carbon dioxide
and water during regeneration.
Ash is a noncombustible residue that comes from a variety of engine oil
additives and diesel.
The filter must be removed and replaced with a clean exchange filter,
according to applicable service intervals.
2
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Regeneration
To maintain the filtering efficiency of the DPF, as well as engine operating
efficiency, soot that collects in the filter must be periodically removed using a
process called regeneration.
During regeneration, the internal
temperature of a Diesel Particulate
Filter (DPF) is high enough to facilitate
a chemical reaction that converts the
carbon-based soot trapped in the filter
into carbon dioxide and water.
Depending on the engine, this process
is accomplished using either active
regeneration or passive regeneration.
3
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF System
DPF Assy. consists of DOC, DPF, exhaust
temperature sensors and differential pressure
sensors. And capture and purify Soot and
Ash.
The ECU estimates the amount of PM collected from
exhaust gas temperature, pressure, operating conditions,
Etc., and performs regeneration control, alarm display, etc.
4
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF assembly
DPF inlet temp.
DPF ASSY : sensor
DPF differential pressure
DOC + DPF sensor
with catalyst loading DPF output temp. sensor
D PF
DOC inlet temp.
DPF type : sensor
Wall flow type DOC
１． DOC (Diesel Oxidation Catalyst) function
① Oxidation of CO & HC to CO2 & H2O
② Convert NO to NO2.
２． DPF (Diesel Particulate Filter) function
① Collect PM in exhaust gas.
② Promote combustion of PM by using NO2 generated by DOC as an oxidant.
Combustion of PM by NO2 in DPF proceeds at a much lower temperature than when oxygen is used as an
oxidant. 5
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Wall flow type DPF
Partition wall
(thickness about 1 mm) Plug
Gas flow
Cross section PM collection Pore
point (several tens of
microns)
Base Material ： Silicon carbide
The structure is like a staggering of honeycombs, and exhaust gas passes
through fine holes in the wall to collect PM. By coating a catalyst on the
surface, the soot in the device is burned off and removed.
6
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF
regeneration
Passive
regeneration
DPF regeneration Automatic regeneration
Active
regeneration
Manual regeneration
Regeneration Start condition Regeneration condition
Under operating conditions where the exhaust temperature is high
Passive ECU control
enough, the soot collected by the DPF burns.
When the amount of soot accumulated in the DPF exceeds a certain
Automatic ECU control value, the ECU controls the fuel injection pattern, the exhaust throttle
valve, raises the exhaust temperature, and burns the PM.
Service tool
If the amount of reproducible soot accumulation is exceeded during
or
Manual operation, the indicator on the meter panel is activated to facilitate
regeneration
manual regeneration.
SW
7
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Automatic regeneration
Regeneration condition
Time Approx. 15 – 40 minutes
Exhaust temp. Approx. 600 ～ 750℃ (DPF outlet)
Start conditions Warming up of the engine is complete
The soot load amount is judged to be less than the
Exit conditions specified value, and a fixed time has elapsed from the start
of regeneration.
Truck operation Possible
Low idle speed Approx. 1000 min-1
When regeneration time is over.
Interruption
condition When regeneration does not work during certain time.
In case of system failure
8
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Automatic regeneration
Operation schematic
Engine DPF Assy
High gas
HC temp.
burn Soot burn
DOC DPF
Post Injection
Early ： increase gas
temp. ETV ： close (variable)
Late ： HC supply
Increase gas temp.
9
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Automatic regeneration
normal DOC warm Soot burn Cool down
up
610
DPF outlet
temp.
400
DOC inlet
Gas temp （℃）
temp. DPF inlet
temp.
1 ～ 10min 15 ～ 25min
time
Exhaust gas temp on regeneration
The regeneration time and the DPF outlet temperature during regeneration changes
depending on PM deposition in the DPF and the engine operating condition.
10
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Multistage fuel injection
Main inj.
Early post inj. Late post inj.
Pilot inj.
Oil dilution period
(Injection during soot burn period)
Pilot injection
PM reduction by pre-mixed combustion prior to main injection
Post injection
( early post, late post )
The fuel is injected again after the main injection to actuate the diffusion combustion and reduce the PM
Exhaust temperature is raised for the after treatment.
11
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Manual regeneration
Regeneration condition
Time Approx. 15 – 40 minutes
Exhaust temp. Approx. 600 ～ 750℃ (DPF outlet)
With the Engine Scoop or manual
Start conditions regeneration switch on dashboard
during low idle with truck parked
The soot load amount is judged to be less
than the specified value, and a fixed time
Exit conditions
has elapsed from the start of
regeneration.
Truck operation Impossible
Engine speed Approx. 1700 min-1 constant
Interruption When the accelerator is operated
condition When the ECU detects a failure
12
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Caution of manual regeneration
Notes on manual regeneration
１． Do not leave the truck (keep an eye on the truck).
２． Engine speed is high during regeneration,
Need to consider truck noise.
3. Make sure that there is nothing flammable around
the exhaust outlet, at bottom and around of truck,
because the exhaust temperature is high.
(exhaust gas temperature: 600 ° C or more).
13
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Regeneration Mode
Soot load
Regeneration mode is controlled by the soot load and
(ECU calculate) the accumulated time after previous regeneration.
Level 7 ： Disable regen. Needed DPF change
Level 6 ： Enable manual regen. with service tool
9.0g/l
8.0g/l Level 5 ： Enable manual regen.
Level 4 ： Enable manual regen.
10h
Level 3 ： Enable manual regen.
7.0g/l
5.6
6.5g/l Level 2 ： Enable automatic or manual regen.
h
5.5g/l
50
2.0g/l Level 0,1 ： Disable activate
regen.
h
Elapsed Cumulative time
within same range from
last regeneration
14
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Soot meter
High exhaust system temperature lamp(HEST) Oil change ( Diesel) indicator
Flashes during activate regeneration & Error code
DPF soot meter (normal operate)
DPF indicator
DPF warning when DPF soot meter (manual regenerate)
soot meter is full.
15
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Indicator for normal operation
Soot manual
Soot DPF Error Limited Regeneration
load regeneration
meter indicator code output mode
level switch
７ DPF change
Flash ⇔ D-98
50% Disable
Alternate Engine
６ Scope
manual
D-87
５ ⇔ 50%
Alternate Enable Manual
４
- -
３
Automatic
２ - - Enable
or Manual
１
- - Disable Passive
０
16
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Soot meter for manual regeneration
The amount of soot monitor displayed on the meter panel during manual regeneration
Soot load
Stage No. soot meter DPF indicator
level
７～６ 15 ～ 14 20dot
５～ 3 13 ～ 11
２ 10 18dot
9 16dot
１
8 14dot
7 12dot
6 10dot
5 8dot
0 4 6dot
3 4dot
2 2dot
1～0 Manual regeneration ends in stage 2
The operator can confirm the progress of manual regeneration 17
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Engine Scope
Select “DPF maintenance” from the main menu
After ash-cleaning need
to re-enter DPF number
for resetting
18
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF maintenance
Item Function
This mode can be executed even when the soot
Manual regeneration accumulation amount is small.
by service engineer For example, to use at the time of delivery to the
customer
DPF recovery Use for soot over deposition (level 6)
Before DPF replacement
DPF replacement Implement manual service regeneration before
Ash maintenance.
DPF initial inspection Conduct before shipping from the factory
19
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
Manual regeneration by service engineer
Even when the amount of soot accumulation in DPF is small,
"manual regeneration" is optionally performed.
For example, used when delivering truck
(If the stage No. is 1 or less, manual regeneration is not possible.)
Procedure
① Start the engine
② Others do not operate
1. Click on “Manual regeneration
By service engineer” of service
tool
20
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF recovery
Used when the accumulation amount of soot level 6 of DPF is excessive.
It is slower than normal manual regeneration and takes about 45 minutes.
Normal manual regeneration is not possible
Procedure
① Start the engine
② Others do not operate
1. Click on “DPF recovery” of
service tool
Operate according to the instructions
on the PC
21
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF replacement
Used when necessary to replace the DPF.
Used before DPF removal during Ash cleaning every 3000 hours
maintenance.
Procedure
1. Click on “DPF replacement” of
service tool
Notes:
1) When removing the DPF, wait for the
temperature of the DPF to decrease.
22
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF replacement
If there is no problem, click OK
23
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF replacement
Start the engine and click Next
24
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF replacement
Follow the instructions and if there is no problem click NEXT
25
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF replacement
Follow the instructions and if there is no problem click Record
26
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF replacement
Stop the engine after the revolutions go back to idle. Click next
27
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF replacement
After ash-cleaning need
to re-enter DPF number
for resetting
+ Enter the data printed on the DPF unit.
+ Click Input complete
28
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF replacement
DPF printed information
DPF ASSY Lot number
Note: DOC is printed in the same place
29
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
DPF replacement
Work according to the instructions.
Click “DPF body installation complete”
A DPF Lot file recording DPF information is created on the PC.
File storage folder : C:/ Engine Scope Data / Be Uploaded /
Upload the file to the "MHI Service Web".
30
© MITSUBISHI LOGISNEXT CO.,LTD. All rights reserved.
