Perkins Manual Regen

Mitsubishi 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

Perkins ECM code: J3719-0

D-87 Particulate Trap #1 Soot Load Percent High moderate severe

Perkins ECM code: J3719-16

Cause/Discussion:

Perkins Manual Regen

The system passively regenerates at different levels depending on

truck load/duty cycle and DOC temperature. These chemical
reactions will occur when the gas temperature into the DOC is greater
than 482F (250C). This chemical process is known as Passive
Regeneration. If the engine duty cycle does not allow sufficient exhaust
temperature for passive regeneration, soot accumulation will continue
to rise.

Passive Regeneration:
The system is designed to passively regenerate during engine/truck
operation, using the Diesel Oxidation Catalyst (DOC) to reduce
particulates and promote the production of NO2, which is used for
oxidization of Particulate Matter (PM) in the Diesel Particulate Filter
(DPF).

Cause/Discussion:

Perkins Manual Regen

Solution:
1. Connect the EST Software to the truck.

Perkins Manual Regen

Solution:
2. Verify diagnostic fault codes.

Perkins Manual Regen

D-87

D-98

Solution:
3. Navigate to Service > Service Procedures

Perkins Manual Regen

Manual DPF Regeneration

Solution:
4. Navigate to the Manual DPF Regen screen

Perkins Manual Regen

Solution:
5. Note the current values and status on this screen.

Perkins Manual Regen

7. Confirm DPF Status and DPF Active Regeneration Status

Solution:
6. Confirm DPF Soot Loading value in grams.

Perkins Manual Regen

Solution:
8. Before attempting to start the Regen process, note the
requirements/instructions on the left, at the bottom of the screen.

Perkins Manual Regen

 EST Service Tool > Manual DPF Regen section

DPF Connector underneath dash compartment

Solution:
9. There are two methods of initiating a Manual Regen.

Perkins Manual Regen

Method #1

Solution:

Click Start button, at this time

engine RPM will automatically
rise to 2000.

Perkins Manual Regen

Close the DPF connector circuit.

Install a jumper wire for 4 seconds
and remove, at this time engine
RPMs will automatically rise to
2000.

Solution:

Method #2

Perkins Manual Regen

Solution:
Note Engine RPMs when the Regen process initiates.

Perkins Manual Regen

Solution:
In order to get the DPF#1 Soot Loading value to start dropping, DOC
and Intake Temperature will need to rise to approximately 1000F
during the manual regen process. At this time particulate soot matter
will begin to oxidize/burn efficiently.

Perkins Manual Regen

Solution:
During the Manual Regen process, it is very important to monitor
temperatures and engine RPM. If anything abnormal is detected, the
Manual Regen process can manually be stopped.

Perkins Manual Regen

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

Solution:
Important Note:
Failure to perform a scheduled oil and filter service with an oil life
service reset will trigger an engine derate mode. The maximum time
between oil changes is 500hrs. In derate mode, the light engine duty
cycle will not allow sufficient exhaust temperature for passive
regeneration, soot accumulation will rise quickly and cause an high
soot load code.

Perkins Manual Regen

Solution:
DPF Status - Stages of DPF Soot loading:
Regeneration Not Needed - Normal State
Regeneration Needed - Lowest Level
Regeneration Needed - Moderate Level
Regeneration Needed - Highest Level

Perkins Manual Regen

6.7g

8.53g

9.65g

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