For Service Training SECTION 2 SYSTEM Exhaust Filter 1

Group 3 ECM System

Exhaust Filter
Outline
Exhaust filter removes particulate matter (PM) and other Exhaust filter is equipped with three sensors:
exhaust substances from the diesel engine exhausts. DOC exhaust temperature sensor (3), DPF exhaust
Exhaust filter consists of diesel oxidation catalyst (DOC) temperature sensor (4), and differential pressure sensor
(1), diesel particulate filter (DPF) (2), and silencer (6). (7).
DOC (1) oxidizes unburned fuel and raises exhaust DOC exhaust temperature sensor (3) and DPF exhaust
temperature. temperature sensor (4) measure the temperature before
DPF (2) traps PM in form of soot, then burns and removes and after DPF (2). The signals from these sensors are used
the PM by using high-temperature exhaust gas with DOC to effectively control the catalytic functions of both DOC
(1). DPF (2) and DOC (1) operate at the same time and this (1) and DPF (2).
burns the soot from DPF (2), resulting in a light oil-free Differential pressure sensor (7) measures the differential
ash remaining. pressure among DOC (1), DPF (2), and atmosphere and
After many self-cleaning cycles on the machine, the DPF determines when DPF (2) is becoming clogged and will
will need to be removed and professionally cleaned. If it need to be cleaned.
is damaged, or cannot be cleaned, it must be replaced.
Careful handling is required since the DPF internal
material is ceramic and subject to cracking or breakage.

Machine Front

95TNED-02-03-05DPF

A- Exhaust Gas

1- Diesel Oxidation Catalyst 3- Diesel Oxidation Catalyst 4- Diesel Particulate Filter (DPF) 6- Silencer
(DOC) (DOC) Exhaust Temperature Exhaust Temperature Sensor 7- Differential Pressure Sensor
2- Diesel Particulate Filter (DPF) Sensor 5- Differential Pressure Check
Port

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For Service Training SECTION 2 SYSTEM Exhaust Filter 2

Group 3 ECM System

Operation
1. Exhaust gas from the engine goes to diesel
particulate filter (DPF) (2) through diesel oxidation
NOTE: Diesel oxidation catalyst (DOC) (1) is used during
the required service level cleaning (regeneration) of the
catalyst (DOC) (1). exhaust filter.
2. Diesel Particulate Matter (PM) is filtered out of the
exhaust gas by DPF (2) as the exhaust gas flows
through it.
3. The filtered exhaust gas is exhausted through the
end of the filter.
4. This process traps the PM (soot) in DPF (2).
5. The PM (soot) must be burned up through the
DPF cleaning process (known as regeneration) and
discharged as CO2. (Refer to Exhaust Filter Cleaning
Control.)

Exhaust Filter Assembly

1 2

TDAA-02-03-012

2 2 Cleaning (Also known as 2

Filtration Soot deposits "regeneration")

CO2

PM PM

TDAA-02-03-006

1- Diesel Oxidation Catalyst 2- Diesel Particulate Filter (DPF)

(DOC)

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For Service Training SECTION 2 SYSTEM Exhaust Filter 3

Group 3 ECM System

Exhaust Filter Regeneration Control Auto Regeneration (Automatic Cleaning):

x Required Auto-regeneration is automatically
The exhaust filter regeneration control burns off the done 8 hours from the last regeneration. (Timed
Particulate Matter (PM or also known as "soot") which has Regeneration)
deposited in Diesel Particulate Filter (DPF) (5) by using hot xA required Auto-regeneration is done when the
exhaust gas. This process is referred to as "regeneration" pressure differential sensor (4) indicates that the
("cleaning"). pressure difference between the front and back of
The regeneration of the exhaust filter consists of "Passive the DPF (5) has exceeded acceptable limits prior
Regeneration" and "Active Regeneration". "Active to this 8 hour time frame. (Pressure Differential
Regeneration" is a form of required regeneration that Regeneration)
starts automatically (auto regeneration) or initiated either
by the operator (manual regeneration). (Refer to SYSTEM / Manual Regeneration:
Control System.) When the Exhaust Filter Regeneration Request is
displayed on the monitor, the regeneration is manually
y Passive Regeneration (Self cleaning while in operation) done as follows:
1. Passive regeneration (self cleaning) works by using x Leave the accelerator pedal up (do not use throttle
normal high exhaust temperatures that come with pedal),
medium to heavy workloads. x Activate the control lever lock switch,
x Place the forward/reverse lever in neutral,
2. A catalyst is more activated in case the exhaust
x Place the forward/reverse switch in neutral,
temperature at the inlet of DPF (5) is higher,
x Apply the parking brake,
increasing regeneration amount.
x Press the exhaust filter regeneration switch

y Active Regeneration (Required cleaning) Follow the prompts on the monitor panel screen. It will
1. Fuel is injected (post injection (11)) into the hot indicate when this process is over.
exhaust gas by diesel engine cylinder (7) and the
exhaust gas mixed with unburned fuel is supplied
to DOC (6).
2. DOC (6) oxidizes unburned fuel and raises DPF (5)
temperature.
3. The exhaust temperature at the inlet side of DPF (5)
increases to about 580 to 600 °C (1,075 to 1,100 °F)
and DPF (5) is cleaned.

NOTE: When the exhaust temperature before DPF (5)

is above 250 °C (480 °F) post injection (11) is used. When
the exhaust temperature before DPF (5) is 250 °C (480 °F)
or less, after-injection of the engine cylinder diesel fuel
injectors (10) is used and raises the exhaust temperature.
After-injection (10) can be used only when the engine
coolant temperature is 70 °C (160 °F) or more.

T2-3-16
For Service Training SECTION 2 SYSTEM Exhaust Filter 4

Group 3 ECM System

2 3

6 5
TDAA-02-03-13KC

TDAA-02-03-022KC
8 9 10 11

1- Engine Control Module (ECM) 3- Diesel Particulate Filter (DPF) 6- Diesel Oxidation Catalyst 10- After-Injection
2- Diesel Oxidation Catalyst Exhaust Temperature Sensor (DOC) 11- Post Injection
(DOC) Exhaust Temperature 4- Pressure Differential Sensor 7- Cylinder
Sensor 5- Diesel Particulate Filter (DPF) 8- Pilot Injection
9- Main Injection

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For Service Training Exhaust Filter 5

OPERATOR'S STATION

Exhaust Filter
The exhaust filter removes particulate matter (PM) from the
exhaust gas. The exhaust filter traps PM, and it is automatically
regenerated by burning PM when a set amount of PM is
accumulated in the filter. Follow the instructions below to
prevent the exhaust filter from being damaged.

IMPORTANT:
Refer to 1-32 for further information.

Exhaust gas from the exhaust filter, and exhaust

piping becomes hotter during and right after engine
running and filter regeneration (burning PM). Be
careful not to let your skin contact any part of
exhaust system or hot gas from the exhaust piping.
It may cause severe burns.

If flammable objects such as dried leaves or paper

scraps are around the muffler, they may cause a fire.

Before maintaining the machine, stop the engine

and make sure the engine has cooled down
sufficiently to prevent burns.

Be sure to use fuel that complies with JIS K-2204,

EN-590 and ASTM D-975 which contents 15 ppm or
lower sulfur. If the fuel described above is not used,
exhaust gas that exceeds the regulation values may
be discharged and serious problems may arise on the
engine.

Use only recommended engine oil. Using engine

oil other than the recommended may shorten the
exhaust filter cleaning interval and increase the fuel
consumption rate.

Contaminated fuel, incorrect fuel additives,

gasoline, kerosene or other incorrect fluids will
damage the fuel injection system and will lead
to engine malfunction, which is not covered by
warranty. Incorrect fuels will also damage the Diesel
Particulate Filter (DPF).
Use only clean Ultra Low Sulfur Diesel (ULSD) fuel
without additives that contain metal elements, oil
distillates or alcohol. These items will permanently
damage the Exhaust Filter and are not covered by
warranty.

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For Service Training Exhaust Filter 6

OPERATOR'S STATION

It is important that the exhaust system filter

components, Engine Control Module (ECM), fuel
system components and all hoses, and piping be
worked on only by qualified service technicians.
NEVER swap out components between machines!
This is known as "tampering".
Repairs or replacement of components by untrained
personnel can cause emissions compliance problems
due to changes to exhaust and fuel system fictions.
It is unlawful to tamper with or bypass emissions
system parts.
Varied and severe penalties may be charged to
technicians and/or owners.
Refer to "OPERATING THE MACHINE" for more
details.

Diesel Particulate Filter (DPF, or Exhaust Filter)

Do not modify the machine without authorization.
Never attempt to modify the air inlet and exhaust
parts such as the air duct, exhaust filter and the
exhaust outlet. Also never attempt to disassemble
the exhaust filter.
Cleaning the exhaust filter may generate white
smoke. Do not attempt to perform exhaust filter
manual regeneration indoors in an area that is not
well ventilated or free from flammables.

Description of DPF functions

The exhaust filter traps Particulate Matter (PM), and disposes
of it by burning it when enough has been accumulated to do
this. This process is called regeneration since it regenerates the
exhaust filter for use again to trap more PM.

fNOTE: It is normal to see white smoke appear during

regeneration. It is not caused by a malfunction.

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For Service Training Exhaust Filter 7

OPERATOR'S STATION

Automatic regeneration
An automatic regeneration (Auto-regeneration) mode is
designed to automatically clean this filter when the filter
needs to be cleaned. (Auto-regeneration can start typically
8 hours after the previous regeneration.) Auto-regeneration
is performed at random times depending on the machine
condition. Auto-regeneration may start during normal
machine operation, and the machine can be operated as
normal (refer to 1-32).

Auto-regeneration may be "terminated" early (inhibited) when

in the presence of flammable materials, such as flammable
airborne debris, wood dust, grain dust, dried leaf debris, or
other flammable risks.

However, when "early termination" (inhibiting regeneration)

happens often, the system will sense this and eventually call
for a manual regeneration, as needed by the exhaust filtration
system. The regeneration request symbol will show, indicating
that manual regeneration is required. Refer to the procedure
on page 1-34.

During auto-regeneration, if the operator does not move the

machine controls, engine rpm's (min-1) may increase to build
heat for the regeneration process. This is not a malfunction.

Do not stop the engine during regeneration unless it is

absolutely necessary to do so.

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For Service Training Exhaust Filter 8

OPERATOR'S STATION

Repeated inhibiting of exhaust filter cleaning

If auto-regeneration is interrupted and inhibited often
enough, the exhaust filter cleaning (regeneration) request
becomes more insistent and continues to request that the
Diesel Particulate Filter (DPF) be cleaned, showing the DPF
cleaning request symbol.
When the cleaning has been inhibited for 10 hours
and 30 minutes from the last attempted exhaust filter
regeneration, the filter cleaning request will show on the
monitor panel.
At 12 hours from the latest exhaust filter regeneration,
the filter regeneration request alarm will sound, and the
request symbol will flash on the monitor panel (refer to
1-34). At this point, the engine power will derate and the
buzzer will continue to sound intermittently. It is required to
perform manual regeneration (refer to 1-34).

When requests for manual regeneration have been

ignored, after 13 hours, the exhaust filter alarm and engine
monitor alarm will be displayed on the monitor panel, and
the buzzer will sound (refer to 1-34).
At this point, call your local authorized dealer to repair the
exhaust filtration system.

IMPORTANT: When the machine is operated without

performing manual regeneration, the exhaust filter
may be damaged. Immediately move the machine to a
safe area and perform manual regeneration.

Both auto and manual regenerations restore exhaust filter

function. It is not a malfunction.

If auto-regeneration interval becomes shorter, consult your

authorized dealer.

White smoke may occur for several minutes after the

engine start, this is not a malfunction.

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For Service Training Exhaust Filter 9

OPERATOR'S STATION

Exhaust Filter Regeneration 2

The machine is equipped with an exhaust filter (this is also
referred as a diesel particulate filter or "DPF"), in order to meet
governmental emissions regulations.

The exhaust filter captures soot from the exhaust system.

To keep the system working correctly, periodically, the

collected soot is turned to ash by burning it at a high
temperature. This process is known as "regeneration". 95MNEC-01-100EN
1

DPF regeneration is done in three ways; automatic

regeneration (abbreviated as auto-regeneration), manual
regeneration, and service regeneration.

Exhaust Filter Status Display

Exhaust Filter Display (1) displays the regeneration level of
the exhaust filter.

This symbol indicates that the exhaust temperature

is higher than normal during the exhaust filter
regeneration. It lights while auto-regeneration or
manual regeneration is in process.)

Automatic regeneration (Auto-regeneration)

When the accumulated soot (PM) reaches to the specified
quantity, the machine automatically increases the exhaust
temperature during normal operation to convert soot to ash.

fNOTE: The PM accumulation condition is viewed using the

Monitoring menu. Refer to page 1-78.

There are no actions on the part of the operator when auto-

regeneration is performed.

There is no set hourly interval or time for auto-regeneration

to occur.
Auto-regeneration may start while operating the machine,
and there is no need to stop the machine when this
happens.
Engine speed may change and white smoke may occur.
This is not abnormal.
Auto-regeneration is a normal maintenance process, and is
not a malfunction.
Do not stop the engine or regeneration once auto-
regeneration has started, unless it is absolutely necessary.

1-32
For Service Training Exhaust Filter 10

OPERATOR'S STATION
If manual regeneration switch (3) is pressed while auto-
regeneration is in progress, the message "You don't have
to press the Regeneration Switch." will be displayed on
monitor (2).

Auto-regeneration may not be completed due to system

limitations while operating the machine. If this occurs, 3
the exhaust filter regeneration request will appear on
the monitor panel. Refer to page 5-11 to perform manual
regeneration.

This symbol indicates that the exhaust filter

regeneration is set to the "inhibited" position.
Regeneration can not be performed while this
indicator is shown. MNEC-01-041

IMPORTANT: Set the exhaust filter regeneration

to "inhibited" while operating in a flammable
environment. (Refer to page 1-55)

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For Service Training Exhaust Filter 11

OPERATOR'S STATION
Manual Regeneration
When the soot level increases to a level that is more than 1
an exhaust filter auto-regeneration can remove, a manual
regeneration is required.
The yellow regeneration symbol (shown below)(1) and
2
service indicator (2) are provided to make the operator
aware that this is required.
This symbol indicates that the exhaust filter
manual regeneration is required. Perform
manual regeneration (Refer to page 5-11 for Basic Screen 95MNEC-01-280EN
the procedure.)
(Lighting,
Yellow) 1

This symbol indicates that immediate exhaust

filter manual regeneration is required. Perform
manual regeneration (Refer to page 5-11 for 2 (Rear View Camera Sight)
the procedure.)
(Blinking,
Yellow)

The manual regeneration must be performed as soon as Basic Screen 95MNEC-01-281EN

possible, and it will take the loader out of service for about (Operating Rear View Monitor)
10~20 minutes.
Refer to page 5-11 for the manual regeneration procedure.

fNOTE: When the manual regeneration is attempted but

not needed, the message "You don't have to press the
Regeneration Switch." is displayed on the monitor panel.

Service Regeneration
When the soot level increases to a level that is more than
an exhaust filter manual regeneration can remove, a service
regeneration is required. This must be performed by an
authorized service dealer.
The red regeneration symbol (shown below) is provided to
make the operator aware that this is required.
It may be necessary to remove the exhaust filter and clean
or replace it, depending on its condition. Contact your local
authorized dealer.

This symbol indicates that the exhaust filter

service regeneration is required. Immediately
stop operation, park the machine in a safe
location. Then, contact your nearest authorized
(Blinking,
dealer.
Red)
This symbol indicates that the exhaust filter
regeneration is inhibited. It is displayed when
the manual regeneration is requested while
filter regeneration "inhibited" feature has been
applied. Move the machine to a safe place.
(Lighting, Perform manual regeneration following the
Yellow) below procedure. Refer to page 1-55 for more
information.

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For Service Training Exhaust Filter 12

OPERATING THE MACHINE

Exhaust Filter Manual Regeneration

1
When manual regeneration is needed, symbol (1) and
service indicator (2) as shown to the right will be displayed.
Perform manual regeneration as shown in the following
2
procedure.

IMPORTANT:
Park the machine in a safe area where exhaust
temperatures will not damage property or other Basic Screen 95MNEC-01-280EN
potential flammable sources.
Be sure that there are no flammable materials in the
engine area, including, but not limited to:
Coal dust.
Wood chip particles, saw dust.
Animal feed products (straw, hay, grain dust, etc.)
Inorganic man made debris; plastics, paper, refuse, etc.
Any other loose flammable debris.
Manual Regeneration Request Screen
Manual Regeneration Procedure 95MNEC-01-282EN
1. Park the machine in a safe and open place. Place the
1
transmission in neutral. Apply parking brake. Lower the
front attachment level to the ground.
2. Verify that items are set as shown below. Rear View Camera Display
2
Forward/Reverse Lever : N (Neutral)
Forward/Reverse Switch (opt) : N (Neutral)
Accelerator Pedal : UP (OFF)
Parking Brake Switch : ON Basic Screen
(When Rear View Camera ON) 95MNEC-01-281EN
Loading Control Lock Switch : LOCK ( )
(4)
Exhaust Filter Regeneration : OFF 4
Inhibited Setting
Hydraulic oil temperature : 5~70 °C
(41~158 °F) 3
Coolant temperature : 70 °C (158 °F) or
higher
Remaining fuel alarm does not light.
3. Press the exhaust filter regeneration switch (3).

fNOTE:
When "Exhaust Filter Regeneration Inhibited" is preset to
MNEC-01-041
ON, manual regeneration cannot be started. Refer to page
1-53.
Refer to pages 1-5 and 1-32 for Automatic Regeneration
and more information.

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For Service Training Exhaust Filter 13

OPERATING THE MACHINE

4. When exhaust filter switch has been pressed, screen (5) 5
appears as shown to the right and manual regeneration
starts. The bar graph on the screen (6) indicates
regeneration progress.

fNOTE: The manual regeneration cannot start unless the

following items are as indicated.
Item Condition 6

Accelerator pedal UP (OFF)

95MNEC-01-283EN
Forward/reverse lever Neutral
Forward/reverse switch (opt) Neutral
Parking switch ON
Control lever lock switch (4) ON
If any of the listed items are changed, or the key is turned
to the "OFF" position, the regeneration process will be
aborted. If the manual regeneration has been aborted, start
the process over again.

5. Manual Regeneration Completed (Successful) 95MNEC-01-284EN

When manual regeneration is completed, "Regeneration
Completed." message will be displayed and the
regeneration symbol disappears.
6. Manual Regeneration Failed (Unsuccessful)
If the message "Regeneration Failed." appears on the
monitor panel, start the regeneration process over again.
Failure to regenerate manually may be caused by a
problem not in the above list, such as malfunction of
a sensor that affects regeneration at a low ambient
temperature. 95MNEC-01-285EN

fNOTE: Exhaust filter regeneration cannot be started when

the hydraulic oil temperature is too high. Run the engine
at low idle to lower the oil temperature, and restart the
procedure.

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For Service Training Exhaust Filter 14

OPERATOR'S STATION

Exhaust Filter Regeneration Inhibited 1

IMPORTANT: The exhaust filter regeneration can be

inhibited at this screen to prevent auto regeneration
while operating the machine in a flammable area or
indoors.

Setting Procedure 95MNEC-01-103EN

1. Press selector knob (2) while displaying Basic Screen (1)
to display Main Menu screen (3).

MNEC-01-006

2. Rotate selector knob (2) to highlight Setting Menu (4). 3

95MNEC-01-140EN

3. Press selector knob (2) to display Setting Menu screen 5

(5).

95MNEC-01-141EN

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For Service Training Exhaust Filter 15

OPERATOR'S STATION
4. Rotate selector knob (2) to highlight Exhaust Filter
Regeneration Inhibited (6).
2

MNEC-01-006

5. Press selector knob (2) to display Exhaust Filter

Regeneration Inhibited screen (7).

6. Rotate selector knob (2) to highlight (8), and press 95MNEC-01-170EN

selector knob (2) to display Exhaust Filter Regeneration 7
Inhibited screen (9).

7. Rotate selector knob (2) to highlight ON (10).

8
Confirmation screen is added.
Press selector knob (2) to turn Exhaust Filter
Regeneration Inhibited ON. Press selector knob (2) again
to turn Exhaust Filter Regeneration Inhibited OFF.
95NEC-01-171EN
When ON is selected, regeneration inhibited icon (11)
will be displayed on the monitor. 9

fNOTE: When the function is ON, the mark " " is displayed in
green. When the function is OFF, the mark " " is displayed in 10
gray.

IMPORTANT: This procedure will inhibit both automatic

and manual exhaust filter regeneration.
When the machine is operated with the exhaust filter
95MNEC-01-172EN
regeneration inhibited, the exhaust filter becomes 11
clogged more quickly than expected.
When the exhaust filter regeneration request is
displayed, move the machine to a safe place. Perform
the manual regeneration following the specified
procedure. Failure to do so may damage the exhaust
filter. Refer to page 5-11 for the manual regeneration.

1-54