Regen problem

Today is my third time at the volvo service shop in one month. I have '09 volvo d13 with 660000 miles. It hasn't been done regen while driving since february. Every time I had to stop and do parked regen. Just a month ago it didn't allow me parked regen anymore. It entered in 4th level,soot level critically high and derate is active and I got red stop light on. I towed my truck to the volvo service shop and they just cleaned the soot,did regen twice and said everything is fine. After that I had clean my DPF at certified shop in MO. Just after 1,400 miles I got same messages,level 4th,derate active and stop light on. But I kept driving for about 200 miles to the volvo service shop in Orlando. They said 7th injector failed. They replaced it,did regen twice and said everything is fine. I didn't see regen for about 3,500 miles. After that same issue. No regen while driving,red stop light on,derate active,no parked regen and it shot down my engine. I towed my truck once again to the volvo service shop in KS and waiting to see what they will say. Already spent more that $3,000 in just one month.
I will appreciate any advice. Thanks

 

If you are in shop ask them to pull out and print report for last ten regeneration. Report will reflect temperatures reached during regeneration and differential pressure sensor readings. Faulty codes history report will help too.
Post it here I will look this evening.

 

I've noticed that most Volvo-certified shops are concerned with following the approved official troubleshooting and resolution steps from Volvo instead of actually fixing the problem, ESPECIALLY when it comes to regen systems. This truck (OP) has had tens of thousands of dollars spent chasing regen issues. It honestly just boggles my mind that so many people can have so many problems and the shops can't !@#$ fix them even in five or six !@#$ tries. When you go to the fourth or tenth repair place and say "here is what is going on, here is what has been done so far by the previous three/nine places, please just fix it so I can drive more than 2500 miles without a problem" and they... can't...

What the hell is wrong with your service process, Volvo?

 

They said the temperature is ok,and no codes. It only shoves the soot level is 200%.
I asked them to upgrade my software and force the regen so I can go.
This is something very confusing for them. And for us,no truck running,no job no living. May God bless !

 

Like it is stated above, Volvo is more concerned with following steps than actually fixing problem I have seen more than one customer come in with these kind of issues and spents thousands for simple repair. I would need to see what snailexpress asked about the regen reports to give you an idea of what it is or i would need to see the truck while it's doing a regen monitor values and all either this truck is dumping something in the exhaust like coolant or oil, or it is not a proper regen either way for one reason or another doesn't make sense it would take this long and this much money to figure out, I actually had a guy today spent a day in peterbilt and i don't know how much and still didn't bother to look that when they installed def injector the ####ing hole was plugged and no def was going in it blows my mind sometimes

 

Why they can't print out report? we need to look at exact numbers. What is the DPF differential pressure was during regeneration? Did they reset soot level after filter was cleaned? What a DPF differential pressure readings was after filter cleaning?
Now is what you can do to take control over this situation. For start driving regeneration ECM need:
1. DPF differential pressure sensor readings exceed some level and during some time defined in ECM software.
If sensor doesn't accurate regeneration will not be initiated.
Take a side fairinf off and check is the sensor tubes connected, no leaks around rubber connectors and clamps are tight. Check sensor electrical plug and wires. Disconnect plug and check is no rust or dirt inside the plug. Check wire harness along the frame should be no any damage.It good practice to replace sensor $120 - 160
2. Check exhaust system is any leaks. Even small leak can cause regeneration to fail
3.Is EGR cooler has no leaks. Do you have coolant loss and wetness on the end of exhaust stack? If so you have to fix it first.
4. How is engine running at idle? Shacking, rough? Find a small but computer equipped shop and ask mechanic to run cylinder performance test and cylinder cut out test to make sure all cylinders are working equally.
Sometime weak cylinder produces a lot of soot and filter is full even before ECM can recognize it.
Good luck and keep us informed.

 

all the holes are to small everywhere...the manufacturer needed to do that so they would pass epa and blow clean...trucks only good till 300k now

My last company gave up on all the EGR/DEF DPF and sensor issues...all the tractors have a check engine light on, and none of them make it up hills
All 2012 2013 prostars

 

ha ha.. you must be one of Volvo's or freightliner's servicemans..)))) no regen ? doser block, injector or controls are guilty ! there is one factor that can stop/abandon regen process and nobody from dealers ase certified staff pay attention on it. before to suggest to change the part ask them to do basic things that written in books. the book says check the fuel pressure between fuel pump and doser block at certain rpm's..i know what is the problem with these trucks and 90% its not your mentioned parts fault.

 

I had to leave last night with no problem solved.
The tech told me when he hooked up his comp that temperature is OK. It was before regen.He said that soot level is overhigh,more than 200%,and doesn't allow him to force regen. He asked me to reset soot level and then try to regen. I told him to do so,and when he reseted soot level the regen started. He lovered a soot to 7%.
He didn't find anything also. Said that they should take off DPF filter and test the smoke in muffler and test turbo as well.
"Snailexpress" I don't know where is that DPF differential sensor located !?
I noticed a leak,like an ash, on the top of my EGR,from one side of turbo. Not in cab direction,but in front direction. It is coming from turbo !?
When I cleaned my DPF filter three weeks ago they told me it's cracked. I can use it but it will fill up faster. Can it be an issue to prevent regening ?!
"Mhyn" thanks for that suggestion. I need to drop a load tomorrow morning and will go to another service. Been there already many times and will ask them to check that fuel pressure.

 

victorio usually low or high fuel pressure does not allow diagnostic software to do force regen . you may have broken spring in fuel pressure regulator/check valve or inside of fuel pump. your engine's fuel system is similar to dd s60 fuel system. read this thread. its same issue.

http://www.thetruckersreport.com/tr...ries-regen-problem.286171/page-3#post-4726007