Diesel Particulate Filter
Contents
1. Metering pump Additive tank with additive filter Additive tank ventilation discharge Diagnostic connector HJS ECU N 9 on A w AGR connection as per wiring diagram o CAN and terminal 30 connected in accordance with wiring diagram Differential pressure sensor Diesel Particle Filter Pressure measurement point before filter Temperature gauge Pressure measurement point after filter Heating power supply Exhaust outlet pipe Earth strap Connection as per wiring diagram term 30 31 100 amp fuse up gt Functional description The filter system consists of a diesel particle filter using sintered metal technology and a fully automatic regeneration unit The latter is able to burn off the soot trapped by the filter without intervention by the driver and to do so under any engine operating conditions Once an adequate quantity of soot has built up in the filter the electronic control unit automatically triggers regeneration To ensure combustion of the soot is complete with as good as no residue and conducted in very short time an additive that lowers the ignition temperature and increases the burn off speed of the soot is added to the diesel by the automatic dosing system When the truck starts up after fuelling the system automatically detects the amount of fuel added and meters the correspondi2. system must only be operated on by the manufacturer s specialist service engineers Start phase Both indicator lamps lit constantly approx 10 sec oo 06 gt gt of 00 gt O Filter system check If neither of the indicator lamps lights up during this test there is a fault in the system Contact expert personnel of the manufacturer Yellow indicator lamp flashing Conduct regeneration cycle If the truck is permanently used for short journeys the filter system may not fully regenerate In this case regeneration must be con ducted as follows leave the stationary industrial truck running at governed maximum no load speed for 10 minutes so that the system performs regeneration If the indicator lamp does not go out after repeating regeneration once contact expert personnel of the manufacturer Yellow indicator lamp lit constantly Automatic regeneration during operation When automatic regeneration is being performed the vehicle must not be switched off Normal vehicle operation should be continued until the yellow indicator lamp goes out Regeneration must be conducted outdoors Red indicator lamp flashing Serious fault gt The system may be damaged Contact expert personnel of the manufacturer A serious fault has arisen or the system has become damaged Red indicator lamp lit constantly Fault Contact expert personnel of the manufacturer An error has occurred or the filter system has brok
3. DFG 316 320 DFG 316s 320s DFG 425 435 DFG 425s 435s 12 07 NGHEINRICH Machines Ideas Solutions Du Diesel Particulate Filter Operating Instructions 51098680 08 10 0810 GB oe Up 8 Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck The information is provided clearly and concisely The chapters are arranged by letter Each chapter starts with page 1 The page identification consists of a chapter letter and a page number For example Page B 2 is the second page in chapter B The operating instructions detail different truck models When operating and servicing the truck make sure that the instructions apply to your truck model Safety instructions and important explanations are indicated by the following graphics Used before safety instructions which must be observed to avoid danger to personnel Used before notices which must be observed to avoid material damage Used before notices and explanations Used to indicate standard equipment Used to indicate optional equipment Our trucks are subject to ongoing development Jungheinrich reserves the right to alter the design equipment and technical features of the truck No guarantee of particular features of the truck should therefore be inferred from the present operating instructions Copyright Copyright of these operating instructions
4. en down Con tact expert personnel of the manufacturer o O 00068 Safety instructions To ensure safe operation the filter system must only be operated in accordance with the operator manual The legal and safety regulations of relevance to operation must be observed at all times when using the system The same applies to the use of accessories The filter system must only be serviced or assembled by the manufacturer s spe cialist service engineers The filter housing of the filter system is heated during operation and can burn if touched The hot filter housing poses a fire or ignition hazard The vehicle must al ways be parked in a location that ensures the diesel particulate filter does not come into contact with easily inflammable materials e g dry grass The additive used is detrimental to human health and is subject to special directions that are listed in detail in the next section entitled Consumables Operating the diesel particle filter in conjunction with the Jungheinrich ISM or other access systems If an access system is used which causes the truck to shut down automatically when the driver leaves the truck note the following Set the automatic shutdown delay interval to at least 10 minutes to avoid cancelling a regeneration operation that has already started continual yellow indicator lamp If the interval is set shorter the driver must remain on the truck while regeneration con tinues unti
5. l the yellow indicator lamp goes out 0810 GB 0810 GB 6 1 Consumables Follow special instructions consult safety data sheet Identification R 40 Irreversible damage possible R 51 Poisonous for water organisms R 53 May have long term harmful effect in water R65 Harmful to health can cause lung damage if swallowed R 66 Repeated contact can cause brittle cracked skin R 67 Vapours can cause drowsiness and numbness S 36 Wear safety clothing during work S 37 Wear appropriate safety gloves S 60 This substance and or its container must be disposed of as hazardous material S 61 Do not release into the environment Seek medical advice immediately and show packaging or label Identification S 62 Do not induce vomiting if swallowed 10 Maintenance Care Repair Any work performed on the filter system service and repairs must only be carried out by the manufacturer s specialist service engineers Use only spare parts and materials approved by the manufacturer To ensure the long useful life of the filter system always follow the hints and actions listed for error messages 0810 GB
6. ng the amount of additive into the fuel return line A slightly clicking noise can be heard from the metering pump The following points must be observed As a self test the two indicator lamps are illuminated for approx 10 seconds when the ignition is switched on If one or both of these indicator lamps does not light up during this test there is a fault in the system Contact expert personnel of the manu facturer If one indicator lamp is defective the other lamp flashes continuously The meaning of these indicator lamps is described in detail on the following page Regeneration must be conducted outdoors However if the truck is located indoors warehouse etc at the time of the automatic regeneration there is a regeneration suppression option Regeneration suppression Approx 5 minutes before automatic regeneration starts the button pic ture begins to flash During this time the operator can leave the indoor gt area in the truck If this proves impossible the operator can press the button this activates a 20 minute regeneration suppression which gives the operator more time to vacate the truck from the indoor area This process can only be repeated once The third time the flashing light cannot be suppressed by pressing the button After approx 5 minutes the system regenerates fully automatically to protect itself 0810 GB 0810 GB 5 2 Meaning of the indicator lamps and relevant actions The filter
7. ram Differential pressure sensor Diesel Particle Filter Pressure measurement point before filter Temperature gauge Pressure measurement point after filter Heating power supply Exhaust outlet pipe Earth strap Connection as per wiring diagram term 30 31 100 amp fuse Overview DFG 425 435 Wire harness Hose line Metal line Indicators and switches for regeneration suppression Reservoir indicator connection as per wiring diagram Diesel return line to fuel tank Metering pump Additive tank with additive filter Additive tank ventilation discharge Diagnostic connector HJS ECU Air mass sensor Connection as per wiring diagram term 15 31 Differential pressure sensor Diesel Particle Filter Pressure measurement point before filter Temperature gauge Pressure measurement point after filter Heating power supply Exhaust outlet pipe Earth strap 100 amp fuse 0810 GB 0810 GB Overview DFG 425s 435s Wire harness mm Hose line Metal line Indicators and switches for regeneration suppression N Reservoir indicator connection as per wiring diagram Diesel return line to fuel tank
8. remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg GERMANY Telephone 49 0 40 6948 0 www jungheinrich com 9 0180 0810 GB Table of contents OnankhRwn N ce _ Overview DFG 316 320 2 220unssunnnnnsnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnn 2 Overview DFG 3168 3208 u22204240nnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnen 3 Overview DFG 425 435 22uusneensnenssnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnen namen 4 Overview DFG 4258 4358 unnssensnensnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnn 5 Functional description unse sense tieren 6 Regeneration suppression uusssssssnssssnennnennnnnnnnnnannnnnnnnnnnnnnnnnnn 6 Meaning of the indicator lamps and relevant actions 7 Safety iNStruCtions citadas 8 Consumabl s x ci Aki ah es EM nein 9 Maintenance Care Repair eceeecceeeceeeeeeeeeeceeeeeneeseeeeeeeeseeeeseeeeae 10 89 0180 12 0810 GB Diesel Particle Filter Diesel Particle Filter The filter system must only be used for the exhaust gas filtering of diesel engines The manufacturer shall accept no liability if the product is not used in the manner in tended The User s Manual of the vehicle the general accident prevention regulations and all other generally recognised rules pertaining to safety and industrial health are to be complied with at all times All maintenance and repair
9. work must be performed by expert personnel of the man ufacturer Overview DFG 316 320 Wire harness gems Hose line Metal line Indicators and switches for regeneration suppression Reservoir indicator connection as per wiring diagram Diesel return line to fuel tank Metering pump l Additive tank with additive filter Additive tank ventilation discharge Diagnostic connector HJS ECU Air mass sensor Connection as per wiring diagram term 15 30 Differential pressure sensor Diesel Particle Filter Pressure measurement point before filter Temperature gauge Pressure measurement point after filter Heating power supply Exhaust outlet pipe Earth strap 100 amp fuse Connection as per wiring diagram term 31 0810 GB 0810 GB Overview DFG 316s 320s Wire harness mm Hose line Metal line Indicators and switches for regeneration suppression N Reservoir indicator connection as per wiring diagram Diesel return line to fuel tank Metering pump Additive tank with additive filter Additive tank ventilation discharge Diagnostic connector HJS ECU N 9 on A w Air mass sensor o CAN and terminal 15 connected in accordance with wiring diag
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