Related Manuals for NEFF B46C74.0GB
Summary of Contents for NEFF B46C74.0GB
- Page 1 ® INSTALLATION MANUAL FOR CLEARSKY DIESEL PARTICULATE FILTER (CARB VERIFIED DPF) MODEL PG1050 MODEL PG1060 62-11478 REV. B...
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Page 2: Table Of Contents
CONTENTS SAFETY ..................1 Safety Considerations ..............1 INSTALLATION ................1 Check kit to ensure you have all the parts ......... 2 Tools Required ................3 Step 1 Changing Oil ................. 3 Step 2 Preparing APU ............... 3 Step 3 Removing Existing Exhaust System......... 4 Step 4 Removing Capacitor Bracket .......... -
Page 3: Safety
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. -
Page 4: Installation
INSTALLATION Check kit to ensure you have all of the parts NOTICE Small Parts Kit x 1 containing: 1 DPF Assembly x 1 (includes system decal) 13 5ml Package of Dielectric Grease x 1 To maintain warranty coverage and 2 DPF Controller x 1 comply with CARB regulations the DPF 14 Oil Change Tag x 1 system must be installed by trained... -
Page 5: Tools Required
Tools Required Torque Wrench 5-30 ft-lb 13 mm Socket Torque Wrench 5–50 in-lbs 12 mm Socket 9/16” Flex-Head Ratchet Wrench 1/2” Socket 1/2” Flex-Head Ratchet Wrench 7/16” Socket 7/16” Flex-Head Ratchet Wrench 9/16” Socket 12 mm Ratchet Wrench Cutter for cable ties 3", 6", 9"... -
Page 6: Step 3 Removing Existing Exhaust System
Step 3 Remove Existing Exhaust 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: Step 4 Removing Capacitor Bracket
Step 4 Removing Capacitor Bracket • Remove Breaker 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) wires from generator chassis. -
Page 8: Step 5 Installing Dpf Capacitor Bracket
Step 5 Installing DPF Capacitor Bracket • Install the new capacitor bracket reusing the 5/16” hardware. • Locate the ground strap wire (figure 8, item 1), it is the one which goes to the engine block. Remove from present bolt, apply dielectric grease to the terminal and move to new location near capacitor as shown in figure 8, item 2. -
Page 9: Step 6 Installing Dpf Bracket
Step 6 Installing DPF Bracket • 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). •... -
Page 10: Step 7 Installing Flex Pipe
Step 7 Installing Flex Pipe • Install flex-pipe sliding it through the hole in the frame and then into the DPF 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. •... -
Page 11: Step 8 Installing Pressure Sensor And Tube
Step 8 Installing Pressure Sensor and Tube • Install pressure tube by fishing it in from the top. (Refer to figure 16, item 1 and figure 17, item 2.) • Align tube so it does not rub on APU frame or other parts. •... -
Page 12: Step 9 Installing The Dpf Controller Harness
Step 9 Installing the DPF Controller Harness • Tie wrap the harness to the 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 until you reach the red and black DPF Controller power wires. - Page 13 • Add dielectric grease to the black terminal (item 1) and attach 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 in between the main battery power and alternator terminals.
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Page 14: Step 10 Installing Dpf Controller
Step 10 Installing DPF Controller • Get a box to prop the controller up (figure 31). • Remove the generator power wire from the breaker wire (generator to breaker). - Locate the wire which goes from the generator to the breaker. Disconnect from breaker. - Page 15 • Route controller neutral wires behind the capacitor towards the generator neutral. • Add dielectric grease to the DPF controller 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.
- Page 16 • Remove the fuel filter nuts (figure 32, item 1) and Wire P-clamp nuts (item 2), remove P-clamps from studs • Install the DPF controller on the P-clamp studs and fuel filter bolts • Replace the fuel filter nuts and tighten to 25–30 ft-lb •...
- Page 17 • Tie wrap the neutral harness, DPF controller harness, and the DPF Controller Power as shown in figure 35. Figure 35. Wire ties. CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL...
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Page 18: Step 11 Installing The Header Pipe
Step 11 Installing the Header Pipe • Install new header gasket. • Install circumferential clamp on flex-pipe. CAUTION • Install the header pipe. Be careful to not damage the insulation on the pipe. • Tighten exhaust manifold nuts to 13–15 ft-lb. •... -
Page 19: Step 12 Installing The Can Control Harness
Step 12 Installing the CAN Control Harness • Plug the CAN harness into 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. •... -
Page 20: Step 13 Installing The Dcp3
Step 13 Installing the DCP3 • Remove the existing DCP and discard. This only applies to units that have a D P installed. Units equipped with a D P2 or D P3 DO NOT require a replacement D P. • Connect the DCP3 CAN adapter harness to the DCP3 panel (refer to figure 39, item 1). -
Page 21: Step 14 Completing The Install
Step 14 Completing the Install • Install the DPF cover and tighten fasteners to 7–9 ft-lb (figure 14). • Reconnect APU controller J1 and J2 connectors. • Reinstall APU Enclosures. • Tighten enclosure fasteners to 10–12 ft-lb. • Install tail pipe to DPF outlet and exhaust bracket. Ensure tailpipe is fully inserted into the DPF outlet, the slots must be fully blocked. -
Page 22: Step 15 Controller Software Update
Step 15 Controller Software Update • Check software updates for the APU and DCP3 controllers. • If a software update is required, update using the PG1027 programmer kit. Getting the Latest Software • Download the installation wizards listed below, by visiting the Special ™... - Page 23 Checking the APU Controller Revision • The APU Controller has a REV label on the top of the device as shown in figure 47, item 1. • The last 3 digits of the APU icon name “APU 04.03B” correspond to the REV label on APU Controller.
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Page 24: Step 16 System Startup
Step 16 System Startup • When all cables are connected the DCP3 should show “DPF Detected”. If not, see Troubleshooting section. • Start APU and allow it to run without load for 5 minutes. • Check DPF variables: – Start at home screen (where date and time are displayed), press ESC/RESET if needed –... -
Page 25: Step 17 Place The Truck And Apu Decals
Step 17 Place the Truck and APU Decals NOTICE • Location of Truck Decal: The label must be placed on the driver side within one foot of the top and The same regulations that require the front edges of the hood. If this is not practical, place the label as close to DPF also require that these decals this area as practical but it must be easily visible (figure 50). - Page 26 CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL...
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Page 27: Appendix
APPENDIX CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL... - Page 28 CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL...
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Page 29: Wiring Diagram
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