| Machine | Hyundai 35DN-9V (diesel forklift) |
|---|---|
| ECU | Bosch EDC17C57 |
| Solution | DPF off* + EGR off* |
The situation
In an industrial yard a forklift is expected to run every shift without excuses. The 35DN-9V does that work in short cycles: lift, drive, set down, reverse, with long idle phases in between. That is the duty profile a DPF struggles with most, because the exhaust rarely gets hot enough for passive regeneration. The result on this truck was regular forced regenerations, DPF fault messages and an EGR system that fouled the intake and cost response under load. Each fault meant a stop, and each stop meant a workshop visit.
The operator wanted the forklift fit for continuous use: no unnecessary fault messages, full output when it is needed and fewer workshop days.
What we did
The EDC17C57 was read and the file developed for this software version. The fault-prone systems were handled in software; the power maps were not the issue and were left as they are.
- DPF: regeneration logic disabled, back-pressure model and sensors neutralised – no forced regenerations and no DPF-related fault messages in short-cycle use.
- EGR: valve closed in software – clean intake, no recirculated soot, stable combustion temperatures and no EGR-related codes.
Checksum corrected and the file written to the ECU.
The result
Less standstill, full power when it is needed and longer uninterrupted working time. The forklift is no longer held back by regeneration cycles or EGR faults, and the display stays quiet. For the operator this means fewer workshop visits and a truck that can be planned into continuous operation. Files for the EDC17C57 are developed from the original read of each machine, not from a generic base – the software version decides what the file looks like.
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* Emission-related solutions (DPF, EGR, AdBlue/SCR) are intended for off-road, agricultural, export and motorsport use only, where permitted by local law. The operator is responsible for legal use in their market.
