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DPF Repairs & Cleaning

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- DPF SERVICES, LLC -


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DPF SERVICES, LLC

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DPF SERVICES, LLC

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DPF REPAIRS & CLEANING

DPFs that arrive with defects or repairs needed to save an individual unit will be evaluated on a case-by-case basis.  Repairs, such as straightening of flanges, welding cracked flanges or repairing bungs, are offered by DPF Services, LLC and will be estimated per unit.  Please contact DPF Services, LLC prior to shipping a defective unit in order to expedite estimates.  After a DPF cleaning cycle is complete, each filter runs through another series of testing to determine whether the cleaning cycle has restored the filter to its optimum filtration capabilities.  Once testing results have concluded and the filter has successfully been cleaned, the unit will then be secured, packaged, shipped and/or delivered to your facility within 24 hours* in fully restored condition.  A work order of all services conducted including filters specifications can be emailed, faxed, or delivered with the filter(s).

Stage 1: Pneumatic Cleaning


STAGE 1 DPFs are initially cleaned using a pneumatic system that blasts air at 100 psi through both ends of the filter and through each individual cell.  This process of bilateral, high-pressure air movement through the filter ensures that each cell is targeted and diagnosed individually.  This will effectively remove all cell and micro-pore inhibitors and will restore the filter to its optimum filtration capabilities. The filter will be continuously cleaned until ash is completely removed and ash is no longer visible. This process may take up to 60 minutes.



 

Stage 2: Thermal Cleaning


STAGE 2 DPFs are kiln-baked at temperatures reaching 1100°F.  During the bake cycle, the high temperatures will burn off any excess soot and will create a fracture between ash deposits in the cells and the ceramic cell walls.  The “stage 1” process is the repeated to remove additional soot/ash resulting from the baking cycle.  Depending on the condition of the filter upon arrival, thermal cycle times can take anywhere from 9 to 24 to 48 hours.  **Filters that are “oil soaked or dripping wet” upon arrival will increase the cleaning and thermal baked cycle times a minimum of 2 days.



 

Diesel Particulate Filter(DPF) Cleaning

Diesel Particulate Filter(DPF) Repairs


Bungs


BUNGS

Gaskets


GASKETS

Clamps


CLAMPS


 

DPF BUNG REPAIR (SOP)


 

Repairing and replacing of sensor fittings (bungs).

 

The purpose of this Standard Operating Procedure (SOP) is to clarify the parameters used in evaluating sensor bungs for repair or replacement.

 

Initially, when a filter comes in with a request for bung repair / replacement, the following procedure is followed.

 

  1. The bung is visually examined for cracks, breakage, and thread damage.
  2. If cracked or broken, the bung is replaced.
  3. If thread damage is evident, the bung is examined to see if sensor threads have galled in the bung. If so, then the galled metal is removed if possible and the bung is rethreaded with the appropriate tap.
  4. If threads are damaged and no galling is present, the bung is checked for usability by attempting to screw in a new sensor. If the new sensor will not turn in, the bung is rethreaded with the appropriate tap.

 

All bungs are checked for functionality using a new sensor to see if the threads need to be retapped before any work is done to ensure that the work being done is necessary.

 

All bungs that are repaired will be designated with the letter R next to the bung.

 

All bungs that are replaced will be designated with the letter W next to the bung.

 

All efforts are made to repair the bung before a full replacement is performed. The focus of this shop is always to do the best work and do only what is necessary to return the filter to full functioning status.

 

All bungs that are replaced are done so with new bungs that we have manufactured exclusively for our shop. They are all designed to be more robust than industry standard and also more durable.

 

All parts that are removed from filter units are bagged, labeled with the customer identification, and returned to the customer with the filter unit.

 

Matthew Pixley

Shop Manager


 

DPF SENSOR REMOVAL (SOP)


 

 Removing sensors from the filters before cleaning.

 

The purpose of this Standard Operating Procedure (SOP) is to clarify the parameters used in removing sensors that are left in filters so that they can be properly cleaned.

 

Initially, when a filter comes in with a request for sensor removal, the following procedure is followed.

 

  1. The sensor fitting is sprayed with PB Blaster penetrating oil by the employee picking it up so the oil has a chance to properly penetrate the threads.
  2. Every attempt is made to remove the sensor manually with minimal or no additional damage.
  3. If the sensor cannot be removed manually with the proprietary tooling that we use, then the wire is cut so that a pneumatic tool can be brought to bear on the sensor.
  4. If the sensor is successfully removed, the bung is checked with a new sensor to ensure that no thread damage is present.
  5. If the new sensor does not turn in, then the bung is rethreaded with the appropriate tap.
  6. If the sensor cannot be removed or the sensor breaks off in the bung, then the bung is removed and replaced with a new one.

 

All bungs that are replaced are done so with new bungs that we have manufactured exclusively for our shop. They are all designed to be more robust than industry standard and also more durable.

 

All efforts are made to repair the bung before a full replacement is performed. The focus of this shop is always to do the best work and do only what is necessary to return the filter to full functioning status.

 

All parts that are removed from filter units are bagged, labeled with the customer identification, and returned to the customer with the filter unit.

 

Matthew Pixley

Shop Manager


 



2017 SHOP PRICING/SERVICE FEES

DPF SERVICES, LLC



Pneumatic DPF or DOC Cleaning------------------------ $200.00


Pneumatic COMBO (both DPF & DOC) --------------- $300.00


Thermal DPF Cleaning---------------------------$430.00


Thermal DOC Cleaning---------------------------$200.00


Thermal DPF & DOC Combo----------------$500.00


Bad Filter Fee--------------------------------------------------$100.00

 (Waived if Customer buys NEW DPF or DOC otherwise RECYCLE)


De-Grease DPF or DOC (prior to Thermal) ----------- $  25.00


OIL SOAKED DPF/DOC Cleaning ----------------------$800.00


Cut & Weld DPF/DOC (each) -----------------------------$  70.00


Thermal Patch ------------------------------------------------$  70.00


Bung Replacement (each) ----------------------------------$  75.00


Bung Repair (each) ------------------------------------------$  40.00


Disassemble DPF/DOC -------------------------------------$  45.00


Bent Flange Repair ------------------------------------------$  25.00


Sensor/Probe Removal (each) -----------------------------$  10.00


**  Saturday Delivery Surcharge-------------------------$ 150.00

** No Weekend Pick-Up Service








                       

AFTER MARKET FILTERS

We offer a wide variety of Aftermarket Diesel Particulate Filters.  These filters are made to the same specifications as an OEM part.  Our Aftermarket filters come with a 1 year or 150,000 mile warranty.


We also do not have a core charge.  Most dealers have a core charge for their filters.


The aftermarket filters will be shipped, so please expect 1-3 days for delivery.


Use our convenient search tools to find the exact filter you need.


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