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SAFETY

Read these instructions carefully before operating the system.

Safety alerts labeled

DANGER

,

WARNING

and

CAUTION

alert you to special

instructions or precautions concerning procedures that would be hazardous

if performed incorrectly or carelessly.

The safety alerts alone cannot eliminate all hazards. Strict compliance with

these special instructions and common sense are major accident

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 hazard-related.

CAUTION

Hazards or unsafe practices that

could result in minor injury or

product or property damage.

1

CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL

Safety Considerations

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.

Summary of Contents for B46C74.0GB

Page 1: ...INSTALLATION MANUAL FOR CLEARSKY DIESEL PARTICULATE FILTER CARB VERIFIED DPF MODEL PG1050 MODEL PG1060 62 11478 REV B...

Page 2: ...lling DPF Bracket 7 Step 7 Installing Flex Pipe 8 Step 8 Installing Pressure Sensor and Tube 9 Step 9 Installing the DPF Controller Harness 10 Step 10 Installing DPF Controller 12 Step 11 Installing t...

Page 3: ...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 WARN...

Page 4: ...14 9 7 8 5 6 12 15 16 18 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 D...

Page 5: ...Torque Wrench 5 50 in lbs 9 16 Flex Head Ratchet Wrench 1 2 Flex Head Ratchet Wrench 7 16 Flex Head Ratchet Wrench 12 mm Ratchet Wrench 3 6 9 Ratchet Extension 1 8 Allen Key 13 mm Socket 12 mm Socket...

Page 6: ...t System Remove and discard header and flex pipes Keep all hardware figure 4 Remove and discard Tail Pipe Remove and discard Muffler Keep the 5 16 stainless hardware shown in figure 5 item 1 Figure 4...

Page 7: ...from bracket Remove the capacitor clamp for later use Cut 3 cable ties figure 6 and figure7 Remove Teck cable p clamp Remove capacitor bracket Disconnect Teck cable Neutral white and Ground copper wi...

Page 8: ...utral wire at the original location Install Capacitor figure 9 item 3 reusing the gear clamp Capacitor should be slid towards the oil pan and have 1 16 clearance to the bracket refer to figure 9 item...

Page 9: ...ket Remove lower radiator mount fasteners figure 10 item 1 Remove cover from DPF assembly Install DPF bracket onto the frame using the 4 holes from the muffler and radiator bracket figure 11 Snug all...

Page 10: ...F inlet refer to figure 12 Ensure the tube is fully inserted it must completely block the slots Push clamp up against stops refer to figure 13 item 1 and tighten to 8 9 ft lb Install the engine mount...

Page 11: ...ing to 22 28 ft lb Install Pressure Sensor assembly figure 18 item 3 to the top of the pressure tube and tighten to 22 28 ft lb Remove the plastic fastening connector clip figure 18 item 4 from APU fr...

Page 12: ...e Teck cable with 11 of harness measured from the Teck cable P clamp to the 12 pin connector refer to figure 20 Route the harness beside the Teck cable for 4 then route along the 12v APU power cables...

Page 13: ...ach to the main ground as shown in figure 24 Sandwich the terminal in the middle of the stack Tighten to 16 20 ft lb Add dielectric grease to the red terminal and then attach to the starter terminal i...

Page 14: ...nnect from breaker Remove the boot from the wire and trim the boot entry point as shown in figure 27 Add dielectric grease to the power wire from the controller and place both wires through the boot a...

Page 15: ...ller neutral terminals and attach to generator neutral Add dielectric grease to the Teck cable Neutral white and Ground copper figure 30 item 1 wires and add to the generator neutral bolt Tighten gene...

Page 16: ...Teck cable above top stud battery lines above lower stud fuel lines below lower stud Tighten the P clamp nuts 45 50 in lb Connect the Temperature sensor Connect the power connector to the DPF heater R...

Page 17: ...CLEARSKY DPF PG 1050 PG1060 INSTALLATION MANUAL 15 Tie wrap the neutral harness DPF controller harness and the DPF Controller Power as shown in figure 35 Figure 35 Wire ties...

Page 18: ...pe and ensure the header pipe is fully engaged into the flex pipe The slots must be fully blocked by the header pipe as shown in figure 37 item 1 Tighten circumferential clamp to 8 9 ft lb The clamp m...

Page 19: ...nto the main DPF harness item 1 figure 38 Tie wrap harness to the existing control and power harnesses Route CAN harness along the existing control harnesses to the CCU Once inside the CCU continue ro...

Page 20: ...9 item 2 Connect to the CAN harness to the CAN adapter harness figure 39 item 5 Install cable tie as shown in figure 39 item 4 Install DCP3 into the display box with the four screws Step 13 Figure 39...

Page 21: ...lly inserted into the DPF outlet the slots must be fully blocked Refer to figure 40 item 1 Adjust DPF outlet clamp position so that the slots are visible behind the clamp it should be as far out as po...

Page 22: ...ver by running ComfortPro Programmer Driver xxl exe Install the ComfortPro software by running ComfortPro Install Software xxl exe Click the Remove option and follow the prompts to remove the existing...

Page 23: ...ltaneously push the MENU and ESC RESET buttons to access the firmware REV screen as shown in figure 48 item 1 The last 3 digits of the ComfortPro DCP3 icon name ComfortPro DCP3 07 01C correspond to th...

Page 24: ...mB Exhaust T 70 130 C If values are not in these ranges then check connections to sensors Start a filter regeneration cycle Start at home screen where date and time are displayed press ESC RESET if ne...

Page 25: ...nstalled they can not be removed without being damaged The decals have the same serial number as the DPF system and new decals can not be issued NOTICE If a truck is operating an APU in California the...

Page 26: ...CLEARSKY DPF PG 1050 PG1060 INSTALLATION MANUAL 24...

Page 27: ...6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 BLK INPUT 120 VAC BLU OUTPUT H2 120 VAC RED OUTPUT H1 120 VAC POWER 120VAC GROUND NEUTRAL SOLENOID APU STARTER INTERNAL GRND BLK BLK WHT WHT 1 2 3 2 1 2 BL...

Page 28: ...CLEARSKY DPF PG 1050 PG1060 INSTALLATION MANUAL 26...

Page 29: ...linger Crescent Kitchener Ontario Canada N2K 2Z3 Tel 1 800 667 4275 www impcotechnologies com Printed in Canada 04 11 30 630 99B Designed and Manufactured in North America 2009 IMPCO Ecotrans Technolo...

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