Introduction
To limit the amount of particulate emitted into the atmosphere, the industrial vehicles of the Japanese manufacturer are supplied with a particulate filter system called DPR (Diesel Particulate Reduction).
During normal use of the vehicle, the particulates released by the engine are retained by this filter.
NOTE: the name DPR (Diesel Particulate Reduction) is the acronym chosen by the Japanese manufacturer for its particulate filtering technology. The operating logic is proprietary, but it can be compared to a standard DPF with a built-in oxidation catalyst.
When the amount of particulates accumulated in the filter exceeds a certain threshold (preset in the engine control unit), the driver will be warned by a specific warning light in the instrument panel to start a procedure to clean the DPR filter, called regeneration.
Determination of the filter clogging status
You can determine the DPR filter's clogging status directly from the instrument panel.
NOTE: based on the model, the equipment and the year of production, the display [BJ may not be installed.
When the DPR particulate filter warning light [A] starts to flash, this means that the particulate filter must be cleaned through a manual regeneration (see following section).
ATTENTION: When the DPR filter warning light starts to flash, you must stop and carry out a manual regeneration within 150 km (the distance may vary based on the driving style and on the traffic conditions).
If the vehicle is equipped with a small display in the instrument panel [BJ, then you can determine the degree of clogging of the DPR filter. A diagram that can reach up to 10 notches is displayed.
The first two notches indicate a low level of clogging and no operation is required.
The third and the fourth notch indicate that the filter is starting to be clogged. In this zone the engine control unit automatically activates a filter regeneration procedure called "automatic". No action is required for this level either.
From the fifth notch to the ninth the filter is more and more clogged and you must proceed with a manual regeneration (see following section).
If the amount of clogging reaches the tenth notch, the DPR particulate filter can no longer be regenerated manually and you must carry out a regeneration using the diagnostic tool.
NOTE: reaching the tenth notch also makes the engine warning light turn on and the vehicle enters a Recovery mode which limits the speed and the torque delivered.
ATTENTION: If you continue driving even with the tenth notch active, the DPR filter may clog up to a level at which no regeneration can be carried out, but it must be replaced!
DPR filter regeneration strategies
There are three DPR particulate filter regeneration modes:
1. Automatic Regeneration
2. Manual regeneration
3. Forced regeneration with the Self-diagnosis
The first does not require any action by the operator or driver; the second must be carried out directly by the driver, while the third mode requires using the diagnostic tool.
Automatic Regeneration
When the vehicle is operating normally, the DPR filter is continuously regenerated thanks to the action of the built-in oxidation filter built and to specific engine mappings that the diesel injection control unit activates automatically.
These different mappings create exhaust gas that are hotter, thus able to burn the particulate accumulated in the filter.
During this phase, you will hear a "different engine noise" and the idle speed will increase.
Manual regeneration
If the vehicle's operating conditions do not allow keeping the DPR filter clean only with the automatic regeneration (ex. constant service at low speeds, frequent stop & goes, engine does not reach the operating temperatures, ... ), you must use the manual regeneration.
ATTENTION: The regeneration procedure involves an engine operating mode that produces extremely hot exhaust gases. Proceed with caution and position the vehicle away from flammable materials, following all the safety regulations regarding property and people.
Perform the following procedure:
1. Position the vehicle in a safe place, with its exhaust away from people and inflammable materials.
2. Apply the parking brake.
3. Select the neutral position.
4. Turn on the engine.
5. Disable, if present, any power take-off (PTO).
6. Warm up the engine to its appropriate running temperature.
7. Make sure the DPR warning light is flashing (manual regeneration request).
8. Press the manual regeneration button on the dashboard (see figure 1 ).
9. The engine will automatically be brought to a preset speed and the DPR warning light will remain on without flashing.
10. Wait up to 15 + 20 minutes.
11. The procedure is complete when the DPR filter warning light turns off and the engine returns to idle speed.
NOTE: We recommend reading all the regulations and warnings in the user and maintenance manual provided with the vehicle.
Forced regeneration with the Self-diagnosis
If you ignore the manual regeneration request and continue driving the vehicle with the DPR warning light flashing (o if you reach the tenth notch in the vehicle equipped with the display in the instrument panel) the clogging status may be at a point that no longer allows a manual regeneration.
In these cases you must use the diagnostic tool and proceed with a forced regeneration.
Perform the following procedure:
1. Position the vehicle in a safe place, with its exhaust away from people and inflammable materials.
2. Apply the parking brake.
3. Select the neutral position.
4. Check that the engine is switched off.
5. Connect the diagnostic tool and, from the Adjustments page, run the function "Reset all DPR status".
6. Turn on the engine.
7. Disable, if present, any power take-off (PTO).
8. Perform the adjustment "Forced regeneration" and follow the on-screen instructions.
NOTE: We recommend reading all the regulations and warnings in the user and maintenance manual provided with the vehicle.
WARNING: The makes and distinguishing signs of the vehicle manufacturers included in this document are only provided to inform the reader about the potential suitability of the said TEXA products to be used for the vehicles of the above-mentioned manufacturers. References to makes and models contained in this document are to be considered only as a rough guide.
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