The air filter is a key component for any fossil fuel driven engine, and this is particularly true in regard to diesel engines. Air filters help to remove dirt and contaminants before the air reaches the engine, thus preventing catastrophic issues. However, over time, air filters become clogged with debris and this reduces their effectiveness. Here is some information on what you need to know about diesel air filter cleaning.
During the Inspection Process, the Air Filter will be Checked for Tears and Pinholes.
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The first phase of air filter cleaning is the inspection process. During this process, the filter media will be evaluated to ensure that the filter itself is suitable for cleaning. In most cases, a high-powered light is used to check for imperfections, such as tears and pinholes. Using a light also helps to keep the filter from being damaged during the inspection.
Air Filter Testing
The Testing Phase is Used to Determine the Viability of the Filter.
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Once the filter has been inspected, it will move on to the testing phase. The testing phase requires the use of a manometer, which will measure pressure fluctuations as air is passed through the filter. These measurements can then be compared to standard operating criteria in order to determine the quality of the filtration media. Testing will also indicate whether the filter is fit for service.
The final stage of air filter cleaning involves the use of a dry-cleaning machine. Dry-cleaning machines utilize several vacuum nozzles to pull debris from the filter, while the filter remains sealed in a cleaning chamber. This helps to ensure that the entire filter has been properly cleaned and is ready for use, and this includes both the inside and the outside of the filter.
Always Consider Air Filter Cleaning
Changing air filters can be an expensive undertaking and one that can be avoided by having the filter cleaned. In turn, your truck will increase its fuel mileage rate and run more smoothly. And although there are a few steps in the cleaning process, each is vital in ensuring that the air filter will function properly. The filter will first need to be inspected for tears and other imperfections. From there, it will be tested for unwanted drops in pressure. After the filter has been inspected and tested, it will be cleaned in a vacuum chamber, thus removing dirt and grime from both sides of the filter. If the air filter in your diesel truck is not functioning at full capacity, then you will surely want to consider having it professionally cleaned.
There is no doubt that on-road trucks take their fair share of abuse by racking up miles very quickly and as these miles accrue, it brings about the necessity for replacement parts. This is especially true when it comes to diesel oxidation catalysts (DOCs) and diesel particulate filters (DPFs). DOCs and DPFs are used together as a means of ensuring that diesel engine emissions are free of pollutants. And while these components can be purchased brand-new when the units need replacing, aftermarket parts are well worth the consideration. Here are the benefits of using aftermarket DOC and DPF replacement parts.
Aftermarket Replacement Parts are Actually Newly Manufactured.
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It may come as a surprise, but aftermarket replacement DOCs and DPFs, such as those by Roadwarrior, are actually newly manufactured products. This means that the primary components have been replaced with new parts and not those that have been re-manufactured or re-conditioned. In fact, these parts are typically made from high-quality materials, such as 409 stainless steel, and this helps to ensure that the unit functions as if it were new out of the box.
The Perfect Fit
If you are familiar with semi-trucks, then you are probably aware that there are many different manufacturers and many of these require unique DOCs and DPFs. Thankfully, these aftermarket parts are manufactured to fit nearly any model of truck, including popular brands like Caterpillar, Detroit Diesel, Cummins, Kenworth, and much more. To ensure that the part will fit your truck properly the unit can be cross-referenced with OEM part numbers.
Backed by a Warranty
With a Warranty, there is No Needed to Worry About the Part Malfunctioning.
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Not only are aftermarket DOCs and DPFs designed to fit the vehicle perfectly, but they are often backed by a warranty. When you purchase a part that has a warranty there is no need to worry that the unit will malfunction, as it will be replaced with no cost to the operator. Of course, with such rigid manufacturing standards, issues with aftermarket DOCs and DPFs are kept to a minimum.
Always Consider Aftermarket Replacement Parts
Diesel oxidation catalysts and diesel particulate filters are a necessity in reducing the emission of harmful chemicals into the atmosphere, and, as with most parts, they require replacing before becoming faulty. When it comes time for maintenance, you will want to consider aftermarket parts. Both aftermarket DOCs and DPFs are newly manufactured and never remanufactured, and this means that they will function as if they were new. In addition, aftermarket replacement parts come in an array of sizes that will fit nearly any model of truck. Furthermore, most replacement components come backed by a warranty, so there is no need to worry about the parts operating properly. When the diesel oxidation catalyst or the diesel particulate filter on your truck becomes faulty, always consider these benefits of aftermarket DOC and DPF replacement parts.
It is no secret that Diesel Particulate Filters (DPF) and Diesel Oxidation Catalysts (DOC) are vital in reducing the amount of harmful chemicals that are emitted into the atmosphere by diesel engines. But did you know that both DPFs and DOCs can be recycled, rather than being pitched in the trash? Here are some reasons why DPF and DOC recycling is important.
Platinum Group Metals Have Monetary Value.
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One of the most overlooked aspects of DPF and DOC recycling is the monetary value of the components. This value comes from the platinum metals that are used as a means of ensuring that the chemicals in the exhaust stream are being mixed correctly. When properly recycled, these platinum-group metals can be extracted from DPFs and DOCs that are no longer functioning adequately. In fact, a spent DPF or DOC system can be worth over $500, and this is substantially more than the amount of money that would be received if the parts were to be scrapped. Not to mention, recycling is a far better option than having the part hauled away to the garbage dump.
Helps Lower New Part Prices
Recycling Parts Helps to Keep Supply and Demand in Balance.
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Recycled DPF and DOC systems also help to keep new part prices down by because they make for a more sustainable supply chain. Since the spent parts can be reused, it costs manufacturers less money, as they will not have to continually invest in all new components. Not only this, but recycling also goes a long way in keeping the supply and demand curves at equilibrium, because there is less likelihood of a drop in supply. Therefore, so long as demand does not skyrocket, then prices will remain stable. In addition, this ability to reuse the certain parts means that there will be a decrease in waste materials and, in the end, these savings can really add up. These savings can then be passed on to customers through various discounts and refunds, and this bodes well for both businesses and consumers.
Always Consider Recycling DPFs and DOCs
Diesel particulate filters and diesel oxidation catalysts are very effective in keeping the environment a much cleaner place, and when they are recycled, rather than thrown in the garbage, it only increases the positive nature of the components. By recycling DPFs and DOCs, businesses can save money by extracting the valuable metals used in the system and that value can be passed on to customers in the form of savings or refunds. In addition, recycling parts help keep the supply in check, so that the overall prices do not rise unexpectedly. Keep these reasons in mind when recycling your DPF or DOC components.
There is no doubt that a diesel particulate filter or DPF is very important in keeping harmful chemicals from being emitted into the atmosphere. After all, keeping the environment clean is something that everyone should be concerned with. And while having a clean DPF will help the environment, it can also go a long way in ensuring that your truck is running properly. Here are some external factors that can affect the performance of the DPF.
Air Filter Cleanliness
Ensuring that the Vehicles Air Filter is Clean is a Must for a Proper Functioning DPF.
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Having a clean air filter is just as important as having a clean DPF, as an unclean air filter can actually lead to build-up within the DPF. If your truck’s air filter is dirty, then chances are it is not allowing for adequate airflow to the engine and this can cause changes to the air/fuel ratio. When the air to fuel ratio is not correct this means that the cylinders will not be able to process the fuel properly. In the end, this could lead to an increase in the potential of the DPF becoming clogged.
It is always recommended that you continually monitor your vehicles turbocharger to ensure that it is functioning properly. If a turbocharger has a leaky seal or it is not allowing for adequate amounts of air to enter, then this can lead to a buildup of oil and soot in the exhaust system of the truck. Down the line, this soot buildup could cause the DPF to become plugged, and thus, malfunction.
Make Sure that You Use Certified Oil to Reduce Ash Emissions.
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One of the most overlooked aspects in helping to keep the DPF clean is the type of oil that is being used in the vehicle. When you are considering oil for your truck, make sure that you go with one that is CJ-4 rated, as this type has minimal ash generating properties, and this can help increase the longevity of the DPF system and reduce harmful chemical emissions. Furthermore, if you notice that the vehicle is using excessive amounts of oil, you will want to have it inspected immediately to prevent further damage to the DPF.
There are many facets of vehicle maintenance that can have an effect on the DPF, and therefore it is important to have your vehicle regularly inspected. For instance, a dirty air filter may be all that it takes to increase the amount of fuel being burned in the cylinders and this could eventually lead to DPF clogging. In addition, if there is a turbocharger installed on your vehicle, you will want to make sure that it is properly sealed so that it does not promote the buildup of soot. Lastly, it is vital that you use an approved oil that has low ash generating properties. By keeping these things in mind, you will help to ensure that the DPF functions correctly.
One of the most important steps that over-the-road truck drivers need to take before hitting the highway is to ensure that their DPF system is properly cleaned. And although bake cleaning is necessary to clean the ash from this inside of the unit, there are external components that need to be replaced with every cleaning, such as the clamps and gaskets. Here are the reasons that you need to use new clamps with each DPF cleaning.
Clamps Are Often Over Tightened
If you are not used to replacing the clamps on a DPF device, then there is a chance that you will inadvertently over tighten the clamps. When the clamps are tightened too much it can make them difficult to remove, especially when they have been put through 150,000 miles of varying weather elements. In addition, when clamps are over tightened it can ruin the threading, which could cause a failure of the clamp altogether.
Clamps May Strip During Removal
Threads Can Become Stripped When They Corrode.
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A common problem during the removal of the V-clamps that are used to hold the DPF unit in place is thread stripping. The primary reason that clamps strip during the removal process is because they have been over tightened and this causes the threading to become compromised. In addition, there is a certain level of corrosion that occurs with V-clamps when the have been subjected to wet conditions for extended periods of time and this can increase the chances of the clamp stripping during removal.
The V-Clamps are Meant for One-Time Use
V-Clamps on a DPF System are Only Meant to be Used One Time.
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The foremost reason that you need to use new clamps after DPF cleaning is the simple fact that they are only meant to be used one time. This means they are not meant to be removed and then re-tightened after the cleaning process has been completed. As mentioned, there are various factors that will deteriorate the V-clamps, such as weather conditions and moisture, and in the end, this could cause the clamp to fail. While you are having the DPF bake cleaned and the gaskets replaced, you will want to ensure that new clamps are used as well.
There is no doubt that having the DPF cleaned is a great way to increase fuel mileage and ensure that the there is no ash built up within the unit. However, when you are considering a DPF cleaning, it is important to replace the V-clamps that hold the system in place, and also the gaskets. Always consider these reasons that you should replace the V-clamps with each DPF cleaning.
Fuel consumption is the second largest expense for any truck fleet and affects revenue more than anything besides labor. The long haul trucking industry has a thin profit margin, to begin with, and with the average truck drives thousands of kilometers each year fuel costs per unit to eat into the bottom line. When it comes to saving money; there are many things that you can do to stretch your company dollar.
Slowing Speed can Reduce Fuel Consumption by 27%.
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Deadlines and delivery dates affect your bottom dollar but slowing down can have the same impact. Reducing your speed by just 15km per hour from 120km to 105 can reduce fuel consumption by 27%. With fuel prices rising and oil prices dropping, this is one of the quickest and easiest ways to lower your fleet’s fuel consumption and lessening the wear and tear on your engine as well.
Idling is a huge gas guzzler and during the Canadian winters, trying to eliminate idling is almost impossible. With many products and technologies on the market such as automatic engine shut down systems and truck stop electrification that will help reduce unnecessary idling, you can cut down on fuel consumption. The average long hauler can idle between 6-8 hours per day costing the fleet operator around $6000 per year per vehicle.
Maintaining a properly running engine and its components can save thousands of dollars per year. From tire pressure to regular cleaning of DOC and DPF Filters, every bit of maintenance will cut down on wear and tear as well as fuel consumption. DOC filters should be cleaned every six months to 1 year.The process only has a 24-hour turnaround for regular cleaning and can save up to 5% in your overall fuel economy. Using low viscosity lubricants reduces friction and energy losses and on axle and transmission parts can save up to 2% fuel consumption during our cold winter months.
When your drivers undergo drivers training and monitoring, the cost savings on fuel consumption are noteworthy. Studies have shown that drivers training can save over 1200 dollars per year which is about a 20% fuel consumption savings. Using cruise control, braking and accelerating smoothly, and block shifting are all skills that help in the amount of fuel your fleet consumes yearly.
Every fleet operator wants to maximize profit while minimizing costs. When you take into account the amount of money you could save by looking at your fleets habits and fuel consumption, the numbers are staggering. Start with regular maintenance of your long haulers, taking filter cleaning into account, then go down the checklist to see what other choices you can make to add extra profit to the bank and longevity within your fleet.