Page 68 - 2018 Alliance Parts Catalog USA Edition

SERVICE TIPS

DIESEL ENGINE OPERATION AND EMISSIONS

Concrete pumps rely on their truck engines to provide seamless and uninterrupted service and operation in order to get the job done. As each year
comes and goes, newer and tighter emission regulations are affecting the way our engines must be operated, especially when pumping in PTO mode
operation. There are two aspects of the emission components that we might consider that our pumping habits can and do have a direct influence on. The
DPF (Diesel Particulate Filter) is a unique “Muffler Trap” that captures and holds any soot or by product particles from polluting the environment. As the DPF
fills with particles it plugs up and develops back pressure. When the cab and dash warning systems provide you with a message that the system is plugging
or will require cleaning up (called a “Regeneration” or regen for short) then a count down towards reduced performance has started that if left unchecked will
interrupt driving, or pumping. We will discuss how to deal with those messages when they show up, below. As well, there is another cleanup circuit called
the SCR (Selective Catalytic Reduction) that requires a fluid known as DEF (Diesel Exhaust Fluid) to be added into a tank near the fuel tank. This “Urea” fluid
catalyzes further cleaning up of the exhaust.
When you drive your Alliance Concrete Pump down the road, there are circuits and controls in place to allow the engine exhaust system to remain
clean, and to allow it to perform cleanup operations. These are referred to as “Passive Regeneration” and “SCR Dosing”. The dash display might show that
there are high exhaust temperatures at these times.
When you pump with your Alliance Concrete Pump, the same regeneration and dosing may take place but there are important operational
requirements to allow them to occur. If the requirements are not taking place then the pumping of concrete while in PTO (power take off) mode may need to
come to a stop, all circuits on the pump turned off and the drive mode selected to perform what is called the “Parked Regen”.
Below we will consider how to get the best emission system behaviour in these different situations, and how to allow these
important functions of engine operation to take place:
DRIVING & CLEAN EMISSION NOTIFICATION AND DESCRIPTION DRIVER ACTION
SYSTEM FUNCTION Check Engine Lamp or Amber Warning Light (CEL or AWL) Vehicle can be driven to end of shift. Call for service.
The best way to keep your Alliance Pump CHECK • Engine controls, aftertreatment control system and/or
ENGINE
component issues exist.
Engine and Emission System clean, is by High Exhaust System Temperature Lamp (HEST) No change in driving style is required. When parked, keep vehicle at a safe
avoiding prolonged idle periods, allowing • Solid: Exhaust is at high temperature and vehicle is at low speed or parked. distance from people and flammable materials or vapors.
• Flashing: Parked regeneration in process. System is not up to temperature.
the engine to work hard, and keeping DEF Malfunction Indicator Lamp (MIL) /Check Engine Lamp Vehicle can be driven to end of the shift. If the MIL remains on after 3 drive
fluids topped up and systems maintained. The • There is a potential problem with the emission control system or component. cycles, call for service.
• May illuminate at the same time as the Check Engine Lamp.
DEF fluid can freeze but the truck plumbing CHECK • Driving for a prolonged period with the MIL on can cause damage to the engine
ENGINE
and/or aftertreatment system as well as degrade mileage and drivability.
circuits have heaters and flow pumps that DPF Regeneration Lamp Perform a parked regeneration OR bring vehicle to highway speeds to enable
allow normal operation even in very cold • Solid: Parked regeneration may be needed. Automatic Regeneration of the filter.
• Flashing Parked regeneration is required as soon as possible.
climates. If warnings are noted on the dash • Diesel Particulate Filter reaching system limits.
like plugging, or engine warnings then it Flashing DPF Regeneration Lamp / Check Engine Lamp A parked regeneration must be performed. If the parked regeneration exits
and the lamps remain on, repeat the parked regeneration. If the second
ENGINE DERATED
is best to seek the assistance of your local • Diesel Particulate Filter has reached system limits. attempt fails, call for service.
dealer, or you may call ACP to gain help. CHECK
ENGINE
Flashing Stop Engine Lamp A parked regeneration must be performed. If the parked regeneration exits
PUMPING & CLEAN EMISSION ENGINE SHUTDOWN and the lamps remain on, repeat the parked regeneration. If the second
attempt fails, call for service.
• Diesel Particulate Filter has exceeded system limits.
SYSTEM FUNCTION CHECK Note: Engine can be restarted, but a parked regeneration must be initiated
ENGINE
When pumping with your Alliance, it is ENGINE within 30 seconds or the engine will shutdown.
STOP
important to observe the same advice as Fuel Filter Restriction Sensor Lamp (FFRS) Driver has one to three days to seek service or the engine may derate.
above, but ensure you operate with the • Fuel Filter is restricted.
following: a) pump rpms elevated above Water In Fuel Lamp (WIF) Engine water separator must be drained or an engine derate will occur.
• Water level is too high and must be drained from the fuel system.
the minimums (we recommend between
1200-1300rpm’s), b) pumping loads above (Some notifications may be reported by Virtual Technician TM .)
25% capacity, this may be difficult to achieve if small jobs are being done but you can operate at lowest engine rpm’s while dialing up the delivery volume),
and c) exhaust temperature above 575°f (this is hard to gauge but if in doubt, work her harder). These constraints when followed will ensure the exhaust
system remains clean during pumping, allowing the dosing, and regen function.
PARKED REGENERATIONS
When the cab dash shows you that the emission systems are either getting plugged, or a regen is required, you can do the following:
a) have engine running at an idle, warmed up and not just started from sitting cold,
b) park brake applied,
c) not in pto mode,
d) not in gear,
e) locate the manual regen request switch on the dash (some trucks have a dash menu that you can scroll through to get to the “request” button,
f) press lightly on the service brake pedal, cycle the cruise switch up and down, (this lets the computers know you are there and wanting to do something),
g) press the “Regen Request” button or switch down and hold (perhaps for 5-10 secs) until you notice a change in the sound of the engine idle. It may speed
up slightly, the exhaust sound will enrichen, and a dash warning will come on that a regen is in process and high exhaust temps may be encountered.
h) never interrupt a regen session, allow it to complete on its own which may require a period of time from 20minutes to 40minutes depending on
“plugging” and particular machine. When the regeneration is complete the engine will safely return to idle and can be shut off. If you interrupt a regen
cycle, the engine will not clean up and may risk going into a further state of urgency, perhaps a deration of power or engine shut down ultimately.
1.888.870.0908 www.allianceconcretepumps.com 1.888.584.7231
Alliance Concrete Pumps Inc. will not be held liable for any loss, damage, or injury relating to these procedures.