Running a fleet of heavy-duty vehicles means facing the challenges of keeping your rigs compliant with emissions regulations and performing at their peak. Aftertreatment systems are designed to control emissions, keeping pollutants in check while maximizing engine performance. However, without proper attention to aftertreatment systems, even the best equipment can suffer from performance issues and expensive downtime. Here at 205 Diesel Repair, we want to help you navigate these potential pitfalls and keep your fleet running smoothly. Let’s dive into the seven common aftertreatment issues and how to avoid them.
1. Neglecting Diesel Particulate Filter (DPF) Maintenance
The Diesel Particulate Filter (DPF) traps particulate matter—essentially soot—from the exhaust. The system is required in all vehicles like heavy equipment to meet strict environmental regulations. Over time, soot builds up and must be burned off in a process called regeneration. Many overlook this step or wait too long, which can clog the filter and lead to reduced engine power, lower fuel efficiency, and eventually costly repairs. A regular DPF cleaning schedule, including forced regeneration when necessary, keeps your filter functioning effectively and avoids unnecessary breakdowns.
Common Symptoms Of DPF Damage
Reduced Engine Performance: A clogged DPF restricts exhaust flow, causing the engine to lose power, accelerate sluggishly, and struggle with heavy loads.
Increased Fuel Consumption: A blocked DPF forces the engine to work harder to expel exhaust gases, leading to higher fuel consumption.
Frequent Regeneration Cycles: Neglected maintenance may cause the DPF to fill up faster, triggering more frequent or prolonged regeneration cycles, which consume extra fuel and wear out components.
Excessive Exhaust Smoke: A malfunctioning DPF may fail to filter soot properly, leading to noticeable black smoke from the exhaust, especially during acceleration.
2. Ignoring Diesel Exhaust Fluid (DEF) Quality
The Selective Catalytic Reduction (SCR) system uses Diesel Exhaust Fluid (DEF) to neutralize nitrogen oxides (NOx) in the exhaust. The quality of DEF is crucial for this system to function correctly. If your heavy equipment uses contaminated or expired DEF, it can damage the SCR system, causing performance issues and possibly violating emissions standards. Ensure DEF quality by purchasing from reputable suppliers and storing it in a clean, temperature-controlled environment.
3. Skipping Regular Exhaust Gas Recirculation (EGR) Valve Cleaning
An Exhaust Gas Recirculation (EGR) system recirculates exhaust gases back into the combustion chamber to lower NOx emissions. When the EGR valve gets dirty, it can cause carbon buildup and clog the system. This impacts both performance and emissions compliance. Schedule regular EGR cleanings to prevent carbon buildup, ensuring your heavy equipment operates smoothly and maintains fuel efficiency. Neglecting the EGR valve can lead to erratic idling, engine stalling, or increased emissions, as the clogged system disrupts the delicate air-fuel mixture required for efficient combustion. Over time, excessive carbon buildup in the EGR system can strain other components like the turbocharger and intake manifold, resulting in costly repairs if not addressed promptly.
4. Overlooking Temperature Control in Aftertreatment Systems
Aftertreatment systems operate within specific temperature ranges to function correctly. For example, the DPF regeneration process requires high temperatures to burn off soot. Temperature issues, such as a faulty thermostat or coolant system, can prevent systems from reaching these optimal levels, impacting regeneration and SCR performance. To avoid this, keep your cooling systems in check and monitor engine temperatures closely.
5. Failing to Address Warning Lights and Alerts
Dashboard alerts, such as the check engine light or DPF warning, are the vehicle’s way of saying something needs attention. Many operators ignore these alerts, which can lead to worsening issues and costly repairs. Responding to warning lights promptly can catch small issues before they escalate. If you’re unsure of the cause, consult a diesel repair professional for a thorough diagnostic.
6. Improper DEF Usage and Storage
DEF is sensitive to temperature extremes and contaminants. Storing DEF in an area prone to freezing temperatures or direct sunlight can compromise its effectiveness. Moreover, avoid using makeshift funnels or containers, as even small contaminants can damage the SCR system. Proper storage, along with quality equipment for filling DEF, ensures that you maintain the integrity of your aftertreatment system.
7. Using Unapproved Aftermarket Parts
While aftermarket parts may save money upfront, they’re often not designed to the same specifications as original components, especially for emissions-critical systems. Using unapproved aftermarket parts can lead to non-compliance issues, reduced efficiency, and system malfunctions. Always use certified parts for your engine and aftertreatment systems to ensure compatibility and maintain emissions standards.
Summary of Key Steps for Better Aftertreatment Performance:
- Regularly clean and regenerate DPF filters to prevent clogs.
- Use only high-quality, unexpired DEF and store it properly.
- Maintain EGR valves to prevent carbon buildup.
- Keep aftertreatment systems within optimal temperature ranges.
- Address all warning lights promptly to prevent escalation.
- Store and handle DEF carefully to avoid contamination.
- Opt for approved parts only, especially for emissions systems.
Master Aftertreatment for Peak Performance!
With 205 Diesel Repair, maintaining your aftertreatment systems is an essential service for optimizing the performance of your heavy equipment. Avoiding these seven pitfalls can help keep your engines running smoothly, reduce emissions-related issues, and extend the life of your equipment. For more advice on keeping your aftertreatment systems in top condition, consult with a professional diesel repair service in Rockwall, TX. Their expertise can ensure that your heavy-duty equipment meets standards and performs at its peak. To learn about tips for your heavy-duty truck or equipment, give our article on preventive maintenance a read.
What are the common signs of a failing aftertreatment system?
Common signs include increased fuel consumption, reduced engine power, excessive exhaust smoke, and warning lights on the dashboard. If you notice any of these symptoms, it’s crucial to have your vehicle inspected immediately to prevent further damage.
How often should I perform DPF regeneration?
DPF regeneration frequency depends on your driving conditions and vehicle usage. Typically, passive regeneration occurs during normal driving conditions, but active regeneration might be needed every 300-500 miles. Regular diagnostics can help determine the best interval for your specific fleet.
