NEFF B46C74.0GB User manual

INSTALLATION MANUAL FOR

CLEARSKY DIESEL PARTICULATE FILTER

(CARB VERIFIED DPF)

MODEL PG1050

MODEL PG1060

62-11478 REV. B

CONTENTS

SAFETY ......................................................................................... 1

Safety Consi erations ...................................................................... 1

INSTALLATION.............................................................................. 1

Check kit to ensure you have all the parts ......................................... 2

Tools Require ................................................................................ 3

Step 1 Changing Oil ......................................................................... 3

Step 2 Preparing APU ....................................................................... 3

Step 3 Removing Existing Exhaust System......................................... 4

Step 4 Removing Capacitor Bracket .................................................. 5

Step 5 Installing DPF Capacitor Bracket............................................. 6

Step 6 Installing DPF Bracket............................................................ 7

Step 7 Installing Flex Pipe ................................................................ 8

Step 8 Installing Pressure Sensor an Tube....................................... 9

Step 9 Installing the DPF Controller Harness.................................... 10

Step 10 Installing DPF Controller..................................................... 12

Step 11 Installing the Hea er Pipe .................................................. 16

Step 12 Installing the CAN Control Harness ..................................... 17

Step 13 Installing the DCP3 ........................................................... 18

Step 14 Completing the Install........................................................ 19

Step 15 Controller Software Up ate ................................................ 20

Step 16 System Startup ................................................................. 22

Step 17 Place the Truck an APU Decals ......................................... 23

Step 18 Replace Access Cover ....................................................... 23

APPENDIX ................................................................................. 25

Wiring Diagram .............................................................................. 27

SAFETY

Rea these instructions carefully before operating the system.

Safety alerts labele DANGER,WARNING an CAUTION alert you to special

instructions or precautions concerning proce ures that woul be hazar ous

if performe incorrectly or carelessly.

The safety alerts alone cannot eliminate all hazar s. Strict compliance with

these special instructions an common sense are major acci ent

prevention measures.

DANGER

Immediate hazards that will result

in severe injury or death.

WARNING

Hazards or unsafe practices that

could result in severe personal

injury or death.

NOTICE

Information that is important to

proper installation or maintenance,

but is not hazar -relate .

CAUTION

Hazards or unsafe practices that

could result in minor injury or

product or property damage.

CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL

Safety Consi erations

WARNING

HOT EXHAUST (PIPE AND GAS). During filter regeneration the

exhaust gas coming out of the tailpipe can exceed 700 F (370 C) and

should not be directed onto materials that can melt or burn. The tailpipe,

where it exits the DPF, can reach 1100 F (600 C) and should not be near

wiring, brake lines or other sensitive items.

WARNING

AC HIGH VOLTAGE. The DPF uses 120VAC from the APU's onboard

generator. This voltage is a shock hazard and wiring should be performed

only by trained personnel.

WARNING

HOT DPF. Just as with a standard muffler, the DPF enclosure can reach

400 F (200 C) during filter regeneration and can cause burns if touched.

NOTICE

DISCONNECT APU FROM BATTERY TO WORK ON IT.

The APU is equipped with a Multi-Function control panel which can start the

APU automatically. Also, the installation of the DPF requires making electrical

connections to the battery wiring in the APU enclosure – a misplaced wrench

can become welded and cause batteries to explode. To prevent both hazards,

disconnect the APU negative and positive battery terminals from the truck

batteries before installing the DPF or working on the APU. As there are often

several connections to the batteries, ensure that there is no battery power at

the APU by checking the voltage at the main starter or alternator terminals.

Check kit to ensure you have all of the parts

2CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL

Figure 1. System components.

INSTALLATION

NOTICE

To maintain warranty coverage and

comply with CARB regulations the DPF

system must be installed by trained

personnel.

1 DPF Assembly x 1

(inclu es system ecal)

2 DPF Controller x 1

3 Pressure Tube x 1

4 Pressure Sensor Assy. x 1

5 Hea er Pipe x 1

6 Flex Pipe x 1

7 Tail Pipe x 1

8 DPF Main Harness x 1

9 35ft CAN Harness x 1

10 Owner/User Manual

11 Warranty Car

12 Truck Decal

23 21

* DCP3 is only available with Model PG1050. All newer APUs are equipped with DCP3 already.

If the unit is equipped with a DCP3, Model PG1060 is needed.

To distinguish between the DCP and DCP3 controllers, look on the front face, top left corner,

of the controller. There will be a 'DCP3' logo on the DCP3 controller and there will be none on

the DCP controller.

Small Parts Kit x 1 containing:

13 5ml Package of Dielectric Grease x 1

14 Oil Change Tag x 1

15 Hea er Gasket x 1

16 DCP CAN A apter Harness x 1

17 Engine Label S/N x 1

18 1.5” Circumferential Exhaust Clamps x 2

1.5” Stainless Steel Exhaust Clamp x 1

20 1.5” Steel Exhaust Clamp x 1

21 Capacitor Bracket x 1

22 Cable Ties x 30

23 P Clamp x 1

24 Flat Washers x 2

25 DCP3* x 1

26 Nuts x 2

Tools Required

Preparing APU

• Disconnect APU positive an negative terminals at the batteries.

• Remove Top an Bottom Enclosures from APU (figure 2).

• Disconnect J1 an J2 connectors from APU Controller (figure 3).

Torque Wrench 5-30 ft-lb

Torque Wrench 5–50 in-lbs

9/16” Flex-Hea Ratchet Wrench

1/2” Flex-Hea Ratchet Wrench

7/16” Flex-Hea Ratchet Wrench

12 mm Ratchet Wrench

3", 6", 9" Ratchet Extension

1/8" Allen Key

13 mm Socket

12 mm Socket

1/2” Socket

7/16” Socket

9/16” Socket

Cutter for cable ties

Programmer for APU Controller

CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL

Figure 2. APU.

Figure 3. APU controller.

Step 2

Changing Oil

• Change oil to SAE CJ-4 type.

Step 1

4CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL

Remove Existing Exhaust System

• Remove an iscar hea er an flex pipes. Keep all har ware (figure 4).

• Remove an iscar Tail Pipe.

•Remove an iscar Muffler (Keep the 5/16” stainless har ware shown

in figure 5, item 1).

Figure . APU header & flex pipes.

Step 3

Figure 5. APU muffler & stainless hardware.

CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL

Removing Capacitor Bracket

• Remove Breaker from bracket.

• Remove the capacitor clamp for later use.

•Cut 3 cable ties (figure 6 an figure7).

• Remove Teck cable p-clamp.

• Remove capacitor bracket.

• Disconnect Teck cable Neutral (white) an Groun (copper) wires from

generator chassis.

Figure 6. Cable tie location.

Step 4

Figure 7. Cable tie locations.

6CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL

Installing DPF Capacitor Bracket

• Install the new capacitor bracket reusing the 5/16” har ware.

• Locate the groun strap wire (figure 8, item 1), it is the one which goes to

the engine block. Remove from present bolt, apply ielectric grease to the

terminal an move to new location near capacitor as shown in figure 8,

item 2. A flat washer to protect ring terminal. Leave the generator

Neutral wire at the original location.

• Install Capacitor (figure 9, item 3) reusing the gear clamp.

Capacitor shoul be sli towar s the oil pan an have 1/16” clearance to

the bracket (refer to figure 9, item 4).

Torque clamp to 18–22 in-lb.

• Install Teck cable as shown an torque fastener to 16–20 ft-lb.

• Route the white an copper groun wires (figure 9, item 5) through new

1/4” p-clamp (figure 9, item 6). DO NOT connect yet.

• Torque fasteners to 16–20 ft-lb, leave Neutral bolt loose.

• More work will be one at the generator later.

Figure 8. Capacitor ground strap.

Step 5

Figure 9. Capacitor.

NOTICE

Breaker installation detailed in Step 10.

Figure 10. Radiator mount fasteners.

CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL

Installing DPF Bracket

• Remove lower ra iator mount fasteners (figure 10, item 1).

• Remove cover from DPF assembly.

• Install DPF bracket onto the frame using the (4) holes from the muffler an

ra iator bracket (figure 11).

• Snug all (4) bolts before tightening to a final torque of 16–20 ft-lb.

Step 6

Figure 11. DPF installed onto frame.

8CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL

Figure 13. Clamp positioning.

Installing Flex Pipe

• Install flex-pipe sli ing it through the hole in the frame an then into the

DPF inlet (refer to figure 12).

• Ensure the tube is fully inserte , it must completely block the slots.

•

Push clamp up against stops (refer to figure 13, item 1) an tighten to 8–9

ft-lb

• Install the engine mount exhaust clamp (figure 14, item 2) but DO NOT tighten.

Step 7

Figure 1 . Engine mount exhaust clamp.

Figure 12. Flex pipe.

CAUTION

Be careful to not damage the insulation on the pipe.

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