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INSTALLATION MANUAL FOR

CLEARSKY DIESEL PARTICULATE FILTER

(CARB VERIFIED DPF)

MODEL PG1050
MODEL PG1060

62-11478 REV. B

Содержание B46C74.0GB

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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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