DPF Check Point

A. Back Pressure line was not tightened. B. Leakage between filter and heater C. Heater terminal was damaged D. Filter was missassmbled (opposite).
Defective Cause

The back pressure pipe must be tighten
to avoid accumulation of water in the
pipe.
If you find longer, after cutting the
pipe must be used.
Countermeasure
Make sure that the contact between In case of putting the counterweight, There is one sense to mount the filter, the
heater and filter is good (test without pay much attention not to give any damage to flange shown must be fitted on the heater
gasket), If the heater flange is bent, mount heater terminal. side.
2 filters temporally to avoid any leakage.

There are 3 white marks that have to be

Before putting the counterweight, roughly aligned.
start up the engine and check with your hand
a possible leakage between heater and filter.
 E. Back Pressure line was not tightened. F. Back Pressure line was too snapped. G. Inlinefilter was mis-located, direction. H. DPF valve was mis-direction (opposite).
Defective Cause

Always use Toyota genuine clamp (45552-

The back pressure pipe must be tighten to Inlinefilter must be located not near the sensor The arrow on the valve must point to the
30510-71) to hold the pipe,
avoid accumulation of water in the pipe. part but muffler side. front of the forklift as shown below.
Never use adjustable clamps that can
If you find longer, after cutting the pipe And the "DENSO" mark on the filter must
snap the pipe and gives wrong back
must be used. point to the front of the forklift as shown.
pressure value.
Countermeasure
 I. Sensing pipe was clogged. J. Heater lelay connector is easy to fall out. K. AC200V supply cover was difficult to open. L. DPF sensor harness was melted.
Defective Cause

Before assembling, make sure that the new
sensing pipe is not clogged.
Countermeasure
Before covering CPU part, make sure that
the connecting of heater terminal is OK.
Some operators never re-generate By using adjustable clamps, the harness
because of this. must be located as far as possible from
We found that this is one of the cause 5- heat influence.
1(Over collecting) error.
So, cut the cover in order that the operator is
easy to open as shown below.
 M. AC200V supply was below.
Defective Cause
During re-generation AC200 supply must
be over 210V. Otherwise, the filter does
not get enough heat.
Listen to the operator where is usual supply
for re-generation. Near the supply, there is
a big equipment as shown above. Pay
much attention.
Check the voltage during re-generation and
also the equipment turning on.
Countermeasure
N. DPF valve maintenance was bad.
This is one of cause 4-2 error.
DPF valve must be inspected and cleaned
every 12 months or 2000hrs (please refer to
the P&S news EN-3001).
O. Air flow sensor was clogged.
As a result of bad DPF valve maintenance,
the airflow sensor is sometimes contaminated
as shown above.
In that case, it must be changed.
P. The operator didn't know how to use DPF.
1. Interrupt the DPF regeneration
process incorrectly.
2. The re-generation can not be started
by full led.
1. Never interrupt the DPF regeneration
process incorrectly.
It is important to tell to the customer that
each time the regeneration is interrupted,
the DPF system is damaged (error code 7-2
is shown).
In order to interrupt correctly, please refer
to the operator manual.
<From operator manual>
If the regeneration interruption is
unavoidable, press the maintenance switch
until the buzzer sounds, Then the left green
lamp and maintenance lamp will turn on,
After all the lamp turns off, the engine can
be started again.
2.The latest DPF version allows the
regeneration process regardless any
leds.
At the end of the day,if the DPF display
shows 1-5 leds, the customer can start the
regeneration. This will ensure a full day
using.