Thermo King TriPac DPF Operator's Manual

Diesel particulate filter

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Operator's Manual

TriPac™

Diesel Particulate Filter

(DPF)

Revision 2

TK-53925-19-OP

September 2011

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Summary of Contents for Thermo King TriPac DPF

Page 1 Operator’s Manual TriPac™ Diesel Particulate Filter (DPF) Revision 2 TK-53925-19-OP September 2011...
Page 4 Thermo King dealer. The procedures described herein should be undertaken only by qualified personnel. Failure to implement these procedures correctly may cause damage to the Thermo King unit or other property or personal injury. Thermo King Corporation and its affiliates shall have no liability in contract or tort (including negligence...
Page 5: Table Of Contents
Table of Contents Introduction ....... . . 3 Fault Codes ....... .27 Clearing Fault Codes .
Page 6 Table of Contents...
Page 7: Introduction
If more information is required, consult your All service requirements, major and minor, should be handled Thermo King Service Directory for the location and by a Thermo King dealer for four very important reasons: telephone number of the local dealer. •...
Page 8 Introduction...
Page 9: Safety Precautions
Fuel vapors could ignite if they Additional safety warnings and precautions regarding the come in contact with hot TriPac Diesel Particulate operation of the Thermo King TriPac unit can be found in the Filter (DPF). TriPac Operator’s manual TK-53035-19-OP.
Page 10: Burn Hazard
Safety Precautions Burn Hazard WARNING: The Diesel Particulate Filter (DPF) canister, exhaust system components and exhaust discharge at the tail pipe can get extremely hot and could cause serious burns to the skin. Fire Hazard WARNING: The Diesel Particulate Filter (DPF) canister, exhaust system components and exhaust discharge at the tail pipe can get extremely hot and could ignite a fire if placed in close proximity with...
Page 11: Dpf Description
Due to the large current draw required by the DPF, the regeneration The Thermo King Diesel Particulate Filter (DPF) is designed process should only be initiated during daytime hours while to reduce the particulate matter output from the TriPac APU’s the truck is expected to be operating at highway speeds diesel engine.
Page 12: Design Features & Components
DPF Description Design Features & Components DPF Canister The DPF canister is typically mounted to the rear of the APU • Stainless Steel DPF canister and exhaust components in place of the standard exhaust and muffler system. The • Exhaust Monitor exhaust particulate matter that is captured and retained in the •...
Page 13 DPF Description DPF Exhaust Monitor The DPF Exhaust Monitor is typically mounted in the bunk area of the tractor. Two indicator lights are displayed on the monitor to alert the driver when to initiate a regeneration, when a regeneration is in process, or when a fault has been detected by the on-board diagnostic system.
Page 14 DPF Description Regeneration Switch Control Module Assembly The DPF Regeneration Switch is typically mounted in the The Control Module Assembly is typically mounted on top or truck’s instrument panel. The switch allows the driver to near the existing TriPac control box and is connected to the initiate a regeneration or to cancel the regeneration if TriPac’s control system.
Page 15 DPF Description Valve Box The Valve Box is mounted on the exterior of the truck and contains an electrical contactor, air solenoid and blower motor. These components are used to operate the DPF system. Valve Box Valve Box...
Page 16: Protection Devices
DPF Description Protection Devices Fuses Three fuses are used to protect the DPF components: Battery Voltage Monitoring Main Fuse: A 150 amp fuse protects the DPF canister from shorts. The fuse is located on the positive battery The DPF control system monitors the truck’s battery voltage cable, near the truck’s battery.
Page 17 DPF Description Relays Four relays are used to operate the components of the DPF system. The relays are located on the Control Module Assembly panel inside the truck. Control Module Assembly and Relays...
Page 18 DPF Description...
Page 19: Manual Pretrip Inspection
Manual Pretrip Inspection Complete TriPac pretrip inspections are an important part of a TriPac and DPF Electrical: Check all electrical preventative maintenance program designed to minimize connections to make sure they are securely fastened. Wires and operating problems and breakdowns. Perform this pretrip terminals should be free of corrosion, cracks, and moisture.
Page 20 Manual Pretrip Inspection...
Page 21: Dpf Operation
DPF Operation Turning the Switches ON Engine On/Off Switch The Engine On/Off Switch is located inside the TriPac APU WARNING: The unit may start automatically without housing on the right side of the frame. This switch must be in warning if the Engine On/Off Switch is in the On the ON position for the TriPac engine and the DPF system to position.
Page 22 DPF Operation HMI Controller Main Power Key HMI Controller APU Power Key Press the Main Power Key. The green LED indicator will Press the HMI Controller APU On/Off Key to enable the be illuminated when the HMI Controller is turned on. diesel power unit and also enable sleeper compartment air conditioning, air circulation, truck battery voltage sensing and engine coolant temperature sensing.
Page 23 DPF Operation Standby Switch DPF Regeneration Switch The dash mounted Standby Switch must be in the NORMAL The dash mounted DPF Regeneration Switch switch must be in position to allow the TriPac and the DPF systems to operate. the ON position for the TriPac and the DPF systems to operate. The switch has two positions: The switch has three positions: •...
Page 24: Indicator Light System
DPF Operation Indicator Light System Two indicator lights are displayed on the DPF Monitor to alert the driver when to initiate a regeneration, when a regeneration is in process, or when a fault has been detected by the on-board diagnostic system. The red DPF Fault and amber DPF Status indicator lights are displayed on the Exhaust Monitor, while only the amber DPF Status indicator light is displayed on the Regeneration Switch.
Page 25: Amber Indicator Lights
DPF Operation Amber Indicator Lights Red Indicator Light Two amber DPF STATUS indicator lights are used to display A flashing red DPF Fault indicator light illuminated on the the operating status of the DPF system. One light is located on exhaust monitor indicates an abnormal condition has been the Exhaust Monitor and another is located on the DPF detected and a fault code, either WARNING or SHUTDOWN,...
Page 26: No Indicator Lights
DPF Operation No Indicator Lights When no indicator light is displayed, the DPF system has not detected any need to initiate a regeneration and the TriPac APU can be operated as usual. The DPF control system determines when a regeneration is needed by displaying a steady amber DPF STATUS indicator light.
Page 27: Indicator Light Quick Reference Chart
Action - Initiate Regeneration - only when the truck is operating during the daytime hours at (DPF STATUS) highway speeds (above 1150 rpm) for a minimum of one hour. See IMPORTANT note below. Push and hold the top of the TriPac DPF REGEN switch for 5 seconds (until the amber light starts flashing). FLASHING...
Page 28: Initiating A Regeneration
DPF Operation Initiating a Regeneration IMPORTANT: The DPF system operates using electrical voltage supplied by the truck’s alternator system. Due to the large current draw required by the DPF, the regeneration process should only be initiated during daytime hours while the truck is expected to be operating at highway speeds Steady Amber (above 1150 rpm) for a minimum of one hour.
Page 29 DPF Operation To initiate a regeneration: • Push and hold the top (REGEN) of the DPF Regeneration switch for 5 seconds. • The steady amber light will now begin flashing on both the Regeneration Switch and the Exhaust Monitor indicating the system is in the regeneration mode.
Page 30: Cancelling A Regeneration
DPF Operation Cancelling a Regeneration To cancel the regeneration process: • Press the bottom (OFF) of the Regeneration switch. • The flashing amber DPF STATUS light will go out, the regeneration process will stop and the HMI will display [Eng] code. •...
Page 31: Fault Codes
Fault Codes A fault code is generated when the DPF on-board diagnostic WARNING CODE - The red DPF FAULT indicator light system detects an abnormal condition. These codes direct an located on the Exhaust Monitor will illuminate indicating a operator or service technician to the source of a problem. Warning Code has been detected by the DPF on-board diagnostic system.
Page 32 Fault Codes CODE CODE TYPE CODE DESCRIPTION NUMBER SHUTDOWN Air Control Relay Input SHUTDOWN Air Control Relay Closed WARNING Air Control Relay Open WARNING Heater Contactor Input SHUTDOWN Heater Contactor Closed WARNING Heater Contactor Open WARNING Excessive High Ambient Air Temperature WARNING Excessive Low Ambient Air Temperature WARNING...
Page 33 Fault Codes CODE CODE TYPE CODE DESCRIPTION NUMBER WARNING High Zero Back Pressure WARNING Low Zero Back Pressure WARNING Low Back Pressure WARNING Consecutive Rapid Filter Loading SHUTDOWN Maximum Time Reached Since Last Regeneration WARNING Maximum Low Voltage Aborted Regeneration SHUTDOWN Maximum Regenerations Reached with Pressure Fault WARNING...
Page 34: Clearing Fault Codes
If APU shuts down due to [Eng] code, turn off the HMI main power to clear the code. Turn the HMI back on and restart the APU. If the APU fails to start, contact the nearest Thermo King Dealer for assistance.
Page 35: Specifications
Specifications Electrical Control System DPF System Voltage 12.5 Vdc Alternator (vehicle) 160 Amp minimum required 150 Amp Main Fuse Fuses 1 Amp Ignition Switch Fuse 10 Amp Control Module Relays Four 12 Vdc relays are located on the DPF Controller Assembly. Blower Motor 12 Vdc Air Solenoid...
Page 36: Engine Operation
DPF. The lube oil in the fuel will result in premature clogging of the DPF. DPF Canister If the DPF canister is ever suspected to be in need of cleaning, contact the nearest authorized Thermo King dealer.
Page 37: Maintenance Inspection Schedule
Inspect air cleaner. Change as needed, or annually. • • Inspect fuel pre-filter. Change as required or annually. • Change fuel filter. Thermo King replacement fuel filter is required. • Drain water from fuel tank and check vent. • •...
Page 38 Maintenance Inspection Schedule Pre-Trip Annual 2,000 Inspect/Service These Items APU ENGINE OIL CHANGE INTERVALS (Change oil and filters hot) Note: Oil change interval is every 1,000 hours of operation when using a Thermo King brand oil filter and CJ-4 or better oil. Oil change interval is every 500 hours of operation when using any other brand oil •...
Page 39 Maintenance Inspection Schedule Pre-Trip Annual 2,000 Inspect/Service These Items DPF ELECTRICAL • • Inspect electrical connections at battery posts to assure they are clean and tight. • • Inspect electrical connections at 150 amp fuse to assure they are clean and tight. •...
Page 40 Maintenance Inspection Schedule Pre-Trip Annual 2,000 Inspect/Service These Items DPF STRUCTURAL • • • Visually inspect DPF canister and exhaust system components for leaks, damaged, loose or broken parts. • • Drain air inlet hose condensation trap. • • • Inspect air inlet and air outlet hoses for kinks or damage.
Page 41: Warranty
Your (Customer) Warranty Rights and Warranty Coverage: Obligations: For the TK270M engine used in a Thermo King APU Thermo King warrants the diesel emission control system, in application, the warranty period for damage caused by the the application for which it is sold or leased, to be free from...
Page 42 King may have grounds to deny warranty coverage. Owner is responsible for presenting the APU and diesel emission control system to a Thermo King dealership as soon as a problem is detected. The warranty repair or replacement should be completed in a reasonable amount of time, not to exceed 30-days.
Page 43 Warranty The following is to be furnished to the Owner’s Warranty Responsibility owner: As the APU owner, you are responsible for presenting your APU to (Enter Installer’s Name Here) as soon as a problem Your Warranty Rights and Obligations with the installation is detected. (Enter Installer’s Name Here) must warrant that the installation If you have questions regarding your warranty rights and of a diesel emission control system is free from defects in...
Page 44 Warranty...
Page 45: Dpf Serial Plate Locations
DPF Serial Plate Locations Matching serial plate located inside the APU on the front engine mount below the oil filter. Serial plate located on the DPF canister Serial Plate Locations...
Page 46 DPF Serial Plate Locations...
Page 47: Emergency Cold Line
If you can’t get your rig rolling, and you have tried the Thermo King North American Service Directory (available from any Thermo King dealer) to reach a dealer without success, then call the Toll Free Emergency Cold Line Number (888) 887-2202.
Page 48: California Proposition 65 Warning
CALIFORNIA Proposition 65 Warning Diesel exhaust is a chemical known to the State of California to cause cancer.
Page 50 1938. For more information, visit www.thermoking.com or www.tranetechnologies.com Thermo King has a policy of coninuous product and data improvements and reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices.

Thermo King TriPac DPF Operator's Manual

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Summary of Contents for Thermo King TriPac DPF

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