Troubleshooting Active Regeneration Issues in New Holland L216 Skid Steer Loaders

[MikePhua]

The New Holland L216 skid steer loader, introduced as part of the 200 Series, is equipped with a Tier 4 Final emissions-compliant engine featuring a Diesel Particulate Filter (DPF) system. This system is designed to reduce particulate emissions by capturing soot in the DPF and periodically burning it off through a process known as regeneration. Regeneration can occur in three modes: passive, active, and forced. However, some operators have reported issues with the active regeneration process, leading to concerns about the machine's performance and emissions compliance.
Understanding the Regeneration Process

• Passive Regeneration: This occurs automatically during normal operation when exhaust temperatures are high enough to burn off soot in the DPF without operator intervention.
  
• Active Regeneration: Initiated by the Engine Control Unit (ECU) when passive regeneration is insufficient. The ECU increases exhaust temperatures by injecting extra fuel into the exhaust stream, prompting the operator to notice increased engine noise and a burning smell.
  
• Forced Regeneration: A manual process performed by a technician using diagnostic tools when active regeneration fails to clear the DPF.
  

Reported Issues with Active Regeneration
Operators have reported that despite the machine indicating "Active Regen" on the display and emitting a beeping sound, the regeneration process does not seem to occur effectively. Symptoms include:

• No noticeable increase in exhaust temperature or engine noise during the regeneration process.
  
• Absence of the characteristic burning smell associated with soot burn-off.
  
• The need for multiple forced regenerations, each taking several hours, to clear the DPF.
  

These issues suggest that while the ECU attempts to initiate active regeneration, the process is not completing as intended, potentially due to underlying mechanical or electronic faults.
Potential Causes of Active Regeneration Failures

1. Faulty Sensors: The DPF system relies on various sensors, including temperature and pressure sensors, to monitor soot levels and determine when to initiate regeneration. Malfunctioning sensors can provide incorrect data to the ECU, preventing proper regeneration cycles.
   
2. Clogged DPF: Over time, the DPF can accumulate ash and soot that may not be fully burned off during regeneration cycles. If the DPF becomes excessively clogged, it can hinder the regeneration process.
   
3. Burner System Malfunctions: The burner system, which includes components like the burner glow plug and air pump, is crucial for increasing exhaust temperatures during active regeneration. Failures in these components can prevent the necessary temperature rise for effective regeneration.
   
4. ECU Software Issues: Software glitches or outdated firmware in the ECU can lead to improper management of the regeneration process, causing it to fail or not initiate at the appropriate times.
   

Diagnostic and Repair Recommendations
To address active regeneration issues in the New Holland L216, consider the following steps:

• Diagnostic Scanning: Use diagnostic tools to retrieve fault codes from the ECU. Codes related to the DPF system, such as those indicating high soot levels or sensor malfunctions, can provide insight into the underlying issues.
  
• Sensor Inspection: Check the functionality of temperature and pressure sensors associated with the DPF system. Replace any faulty sensors to ensure accurate data transmission to the ECU.
  
• DPF Cleaning or Replacement: If the DPF is found to be clogged, attempt to clean it using appropriate methods. If cleaning is ineffective, replacement may be necessary to restore proper function.
  
• Burner System Check: Inspect the burner glow plug and air pump for proper operation. Replace any faulty components to ensure the burner system can achieve the required exhaust temperatures.
  
• ECU Software Update: Verify that the ECU is running the latest software version. Update the software if necessary to correct any potential bugs affecting the regeneration process.
  

Conclusion
Active regeneration issues in the New Holland L216 skid steer loader can stem from various sources, including sensor malfunctions, DPF clogging, burner system failures, and ECU software problems. By systematically diagnosing and addressing these components, operators can restore the proper functioning of the regeneration process, ensuring compliance with emissions standards and maintaining the machine's performance. Regular maintenance and timely repairs are essential to prevent recurrence of these issues and extend the lifespan of the equipment.