Diesel particulate filters play key role in ensuring ultra-low emissions.
Ultra-low emission diesel engines that power earthmoving equipment are fast becoming industry standard.
Despite not being mandated under environmental standards in Australia, government departments, major contractors and project managers keen to reduce their impact on the environment are increasingly giving preference to earthmoving equipment suppliers who can offer machines that comply with Tier 4 Final emission requirements.
Tier 4 Final engines reduce both Diesel Particulate Matter (PM) and nitrous oxide (NOx) levels by 90% when compared with previous generation Tier 3 engines.
Komatsu engines achieve this through a combination of Closed Crankcase Ventilation (CCV), optimised combustion systems, advanced electronic controls and heavy duty exhaust gas after-treatment.
These include cooled Exhaust Gas Recirculation (EGR) systems, Variable Geometry Turbochargers (VGTs) and Diesel Particulate Filters (DPFs).
A critical element of ensuring Tier 4 engines achieve such significant reductions in PM and NOx level, is the Diesel Particulate Filter (DPF), a regenerating filter that captures soot and ash.
Typically, it has a life expectancy of 4500 hours or more (depending on application, operating conditions and operator practices) before requiring replacement or a major overhaul, says Steve Bowling, Komatsu’s National Operations Manager – Manufacturing Support.
As a way of ensuring quality and supply reliability for customers, Komatsu has recently set up a remanufacturing facility for DPFs at its Fairfield head office in Sydney.
Komatsu’s DPF Reman process involves a series of quality assurance inspections and tests at all stages of the process to ensure they continue to meet emission and reliability standards, says Bowling.
This includes high-pressure air cleaning and/or baking of the Diesel Oxidation Catalyst (DOC) and the Catalysed Soot Filter (CSF), the primary elements that make up the DPF core.
In addition, the DPF Reman process covers 100% replacement of all gaskets, hardware –essential due to the high operating temperatures in these units – along with pressure and temperature sensors to ensure reliability.
Komatsu’s DPF Reman facility caters for the 9 inch, 10.5 inch, 12 inch and 14 inch diameter core sizes currently used on Komatsu T4 engines.
“Changing over a DPF is a very straightforward process for our customers,” says Bowling.
“We offer a fixed price, depending on the machine model, and it’s simply a matter of giving us the old DPF when we swap it out.
“Komatsu Reman DPFs are available through our service and parts departments throughout Australia, New Zealand and New Caledonia, and cost approximately one-quarter to one-third the price of a new unit.
“And as with all our Reman products, Komatsu Reman DPFs are backed by our full factory warranty,” says Bowling.