Perkins Manual RegenMitsubishi 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 Ø Perkins ECM code: J3719-0 D-87 Particulate Trap #1 Soot Load Percent High – moderate severe Ø Perkins ECM code: J3719-16 Cause/Discussion: Perkins Manual Regen . using the Diesel Oxidation Catalyst (DOC) to reduce particulates and promote the production of NO2. soot accumulation will continue to rise. Cause/Discussion: Perkins Manual Regen . Passive Regeneration: The system is designed to passively regenerate during engine/truck operation. These chemical reactions will occur when the gas temperature into the DOC is greater than 482°F (250°C). This chemical process is known as ‘Passive Regeneration’. which is used for oxidization of Particulate Matter (PM) in the Diesel Particulate Filter (DPF).The system passively regenerates at different levels depending on truck load/duty cycle and DOC temperature. If the engine duty cycle does not allow sufficient exhaust temperature for passive regeneration. Connect the EST Software to the truck.Solution: 1. Perkins Manual Regen . Solution: 2. Perkins Manual Regen D-87 D-98 . Verify diagnostic fault codes. Navigate to Service > Service Procedures Perkins Manual Regen .Solution: 3. Manual DPF Regeneration Solution: 4. Navigate to the Manual DPF Regen screen Perkins Manual Regen . Perkins Manual Regen .Solution: 5. Note the current values and status on this screen. Confirm DPF Soot Loading value in grams. Confirm DPF Status and DPF Active Regeneration Status Solution: 6.7. Perkins Manual Regen . at the bottom of the screen.Solution: 8. note the requirements/instructions on the left. Before attempting to start the Regen process. Perkins Manual Regen . Perkins Manual Regen . There are two methods of initiating a Manual Regen.• EST Service Tool > Manual DPF Regen section • DPF Connector underneath dash compartment Solution: 9. at this time engine RPM will automatically rise to 2000. Perkins Manual Regen .Method #1 Solution: Click ‘Start’ button. Solution: Method #2 Perkins Manual Regen . Install a jumper wire for 4 seconds and remove.Close the DPF connector circuit. at this time engine RPMs will automatically rise to 2000. Solution: Note Engine RPMs when the Regen process initiates. Perkins Manual Regen . DOC and Intake Temperature will need to rise to approximately 1000°F during the manual regen process.Solution: In order to get the DPF#1 Soot Loading value to start dropping. At this time particulate soot matter will begin to oxidize/burn efficiently. Perkins Manual Regen . If anything abnormal is detected.Solution: During the Manual Regen process. the Manual Regen process can manually be stopped. Perkins Manual Regen . it is very important to monitor temperatures and engine RPM. 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 . The maximum time between oil changes is 500hrs. In derate mode.Solution: Important Note: Failure to perform a scheduled oil and filter service with an oil life service reset will trigger an engine derate mode. soot accumulation will rise quickly and cause an high soot load code. Perkins Manual Regen . the light engine duty cycle will not allow sufficient exhaust temperature for passive regeneration. Highest Level Perkins Manual Regen .Solution: DPF Status .Normal State • Regeneration Needed .Moderate Level • Regeneration Needed .Lowest Level • Regeneration Needed .Stages of DPF Soot loading: • Regeneration Not Needed . 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 .6.7g 8.53g 9.