Donaldson SEF User manual

SEF Muffler
DPF
Regeneration
Station
Emissions Device
Monitor
Thermal Wrap
Junction Box
This manual is property of the owner. Leave with the unit when installation and start-up are complete.
Donaldson Company reserves the right to change design and specifications without prior notice.
Do not make any system modifications or adjustments that would alter the original retrofit installation.
Modifications may not meet California Air Resources Board (CARB) Executive Order requirements, be
considered illegal devices and may result in denial of warranty coverage.
Consult your Donaldson certified emissions dealer if you have questions regarding the installation, operation,
maintenance or warranty.
Illustrations are for reference only as actual product may vary.
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
OWNER’S MANUAL
Installation, Operation and Maintenance Information
SEMI-ACTIVE ELECTRIC FILTER (SEF)
MUFFLER SYSTEM
Manual Number P232575 Rev 2

2 Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2
Donaldson Retrofit Emissions System
SEF Muffler System ..................................................... 3
Abbreviation Key ......................................................... 4
ARB Disclaimer............................................................ 4
Introduction .................................................................. 5
SEF Muffler ......................................................................... 5
Pre-Installation Requirements............................................ 5
Junction Box ....................................................................... 7
EDM .................................................................................... 7
DPF Regeneration Station .................................................. 8
Lock-Out/Tag-Out............................................................ 8
Installation ................................................................... 8
Vertical Muffler Installation................................................ 9
Remove the Existing Muffler.......................................... 9
Install the SEF Muffler.................................................... 9
Device Identification..................................................... 10
Horizontal Muffler Installation ......................................... 10
Remove the Existing Muffler........................................ 10
Install the SEF Muffler.................................................. 10
Junction Box Installation.................................................. 11
EDM Installation............................................................... 12
DPF Regeneration Station Installation ............................. 12
Installation Checklist ........................................................ 13
Semi-Active Electric Filter (SEF)............................ 14
Installer and Data...................................................... 15
Theory of Operation.......................................................... 15
Basic Regeneration Station Logic .................................... 16
Operation of the DPF Regeneration Station..................... 16
DPF Regeneration Station Controls.................................. 17
Contents
Maintenance and Service ....................................... 18
Filter Maintenance ........................................................... 18
Conditions That May Plug A DPF Muffler Prematurely ... 18
How to Regenerate a Dirty DPF........................................ 18
Reset the EDM.................................................................. 19
Time Between SEF System Regenerations ...................... 19
Filter Ash Cleaning Interval .............................................. 19
DPF Section Cleaning Method & Process ........................ 19
Filter Cleaning Instructions............................................... 20
Record Filter Service ........................................................ 20
Routine Inspection ........................................................... 21
Disposal Information ........................................................ 21
Spare Parts ....................................................................... 21
DPF Regeneration Station & Spare Parts..................... 21
SEF Diesel Particulate Filter*....................................... 21
SEF Muffler Service Parts............................................. 21
SEF Troubleshooting Guide............................................... 22
DPF Swapping and Re-Designation....................... 24
SEF Limited Warranty ............................................... 27
Warranty Coverage........................................................... 27
Owners Warranty Responsibility...................................... 27
Installation Warranty Responsibility................................ 27
Maintenance that May Void Warranty............................. 28

Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2 3
Donaldson Retrofit Emissions System
SEF Muffler System
Major components of the Donaldson SEF Muffler System
Regeneration Station Control Panel
• Operator interface for monitoring the status of
automated DPF regeneration cycles
Emissions Device Monitor (EDM)
• Monitors status of SEF Muffler
• Indicates when DPF regeneration is required
Junction Box
• Houses connections for DPF regeneration (power
and thermocouple)
• Install on vehicle in accessible location
DPF Regeneration Station
• Provides automated control
of SEF Muffler regeneration
cycle
• Controls up to two DPF
regeneration cycles
simultaneously
• Requires electrical power
and compressed air supplies Regeneration Cable-25 ft.
• Provides power, thermocouple and air
connections to SEF Muffler for DPF
regeneration cycle
SEF Muffler
• Eliminates PM and gaseous emissions from diesel exhaust
• Requires heat regeneration cycle to burn PM in the DPF
• Up to 4 times heavier than OEM muffler

4 Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2
Donaldson Retrofit Emissions System
ARB Disclaimer
Your Right to Maintenance Information
The Air Resources Board requires that Donaldson Company,
Inc. provide detailed maintenance information for the diesel
emissions control system upon delivery to the end-user
pursuant to section 2706(h)(2), Title 13, California Code of
Regulations, at no additional cost to the owner. If you do not
already have this information, contact Donaldson Emission
Retrofit Technical Support at 1 [phone].
The Importance of Engine Maintenance
Proper engine maintenance is critical for the proper functioning
of your diesel emissions control strategy. Failure to document
proper engine maintenance, including oil consumption records,
may be grounds for denial of a warranty claim for a failed
component of a diesel emission control strategy.
The Importance of Properly Maintaining a Diesel Emission
Control Strategy
Proper maintenance is critical for the diesel emission control
strategy to function as intended. Failure to document proper
diesel emission control strategy maintenance, including
cleaning and/or ash removal of the system, replacement of
consumables, and replacement of broken/failed parts, may be
grounds for denial of a warranty claim for a failed component
of a diesel emission control strategy. See page 27-28 for
warranty information.
Abbreviation Key
ASTM = American Society for Testing and Materials
CARB = California Air Resources Board
CJ-4 = Engine oils made for high-performance diesel engines and
designed to meet 2007 on-highway exhaust emission standards.
API (American Petroleum Institute) CJ-4 oils exceed previous
performance requirements and are specifically designed to protect
emission control systems when used with ULSD fuel
COMS = Communication port for diagnostics (EDM)
DCI = Donaldson Company, Inc.
DECS = Diesel Emissions Control System
DOC = Diesel Oxidation Catalyst
DPF = Diesel Particulate Filter
EDM = Emissions Device Monitor
EFN = Engine Family Number
EPA = Environmental Protection Agency
HP = Horsepower
Hrs = Hours
IOM = Installation and Owner’s Manual
LNF = Low NO2Filter
LXF = Low NOxFilter
mV = Millivolts
MY = Model Year
NEMA = National Electrical Manufacturers Association
OEM = Original Equipment Manufacturer
PM = Particulate Matter
RPM = Revolutions per Minute
RTV SILICONE = Room temperature vulcanization silicone used as a
sealant
sec = Seconds
SECM = Small Electronic Control Module
SEF = Semi-Active Electric Filter
SUBSTRATES = Internal filtration components of the SEF system
Temp = Temperature
ULSD = Ultra Low Sulfur Diesel
V = Volts
VAC = Volts Alternating Current
VIN = Vehicle Identification Number
WAT = Weighted Average Temperature

Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2 5
Donaldson Retrofit Emissions System
Pre-Installation Requirements
This section includes pre-installation requirements and
considerations for the four major system components:
• SEF Muffler
• Junction Box
• EDM
• DPF Regeneration Station
The content of this section draws attention to topics
and information that should be considered BEFORE you
start installing. The information includes mounting tips
and considerations, procedures and techniques that may
be required and may impact how and where you install
components of the system.
In order to maximize the diesel emission control system
performance, the installation must meet the requirements in
the following sections. Failure to follow these instructions may
void the warranty and may lead to device failure.
Introduction
The Donaldson Semi-Active Electric Filter (SEF) Muffler System
is designed to reduce emissions from in-use diesel engines.
Besides reducing diesel particulate matter (PM) emissions
by over 90%, the SEF Muffler is also effective at reducing
hydrocarbon and carbon monoxide emissions.
The SEF Muffler System is made up of the following
assemblies:
SEF Muffler Kit
• SEF Muffler
• Junction Box
• Emissions Device Monitor (EDM)
• Serialized Muffler and Engine Tags
DPF Regeneration Station
• Automated Control Panel
• Regeneration Cables
The SEF Muffler System is an active DPF system designed
to capture diesel PM and eliminate gaseous emissions. The
system uses an electric heater to periodically burn the PM
captured in the DPF. An off-board DPF Regeneration Station
controls the regeneration process once connected to the
vehicle-mounted junction box. The Regeneration Station
provides the control and monitoring needed to ensure complete
DPF regeneration in a safe and timely manner. An EDM is
included to inform the operator when DPF regeneration is
required.
Installation and operating instructions for each of these
assemblies is included in this manual, except for the EDM,
which comes with its own Installation and Owner’s Manual
(P484891).
CAUTION!
Follow Donaldson Installation
Guidelines
Installations must follow Donaldson installation guidelines
to ensure full warranty coverage. For optimum performance,
follow all the installation, operation and maintenance
recommendations covered in this manual.
SEF Muffler
Donaldson’s pre-installation requirements are provided below.
In order to maximize performance and enhance warranty
coverage, the installation must meet these requirements.
Outlet Section
(component 5)
V-Band Clamps
(4 places)
DPF Section
(component 4)
Heater Section
(component 3)
DOC Section
(component 2)
Inlet Section
(component 1)
Thermal Wrap
Stays on during
vehicle operation
Exploded view of the SEF Muffler Assembly
Engine Exhaust Flow
Engine Tag
(Serialized)
Muffler Tag
(Serialized)
Muffler Tag
(Serialized)

6 Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2
Donaldson Retrofit Emissions System
Application Pre-Assessment
Verify that the application PASSED the Donaldson Application
Pre-assessment conducted by a Certified Emissions Dealer. The
pre-assessment worksheet and opacity test results need to be
forwarded to Donaldson upon warranty registration.
The application pre-assessment confirms the following:
• The engine family
number (EFN) for the
vehicle is included in
the California ARB-
Approved Engine Family
listing of Executive
Order
• Vehicle and engine
has been properly
maintained
• Vehicle passed the
pre-assessment visual
system inspection
• Opacity test results
collected meet Donaldson requirements (based on SAE
J1667 test specification)
• Vehicle engine duty cycle meets the application
temperature criteria. The temperature profile should not
exceed the passive system criteria.
NOTE
The engine must be inspected by a qualified technician
to verify the engine is operating within the engine OEM’s
specifications. If the engine does not meet specifications,
necessary repairs must be made prior to installation. The
technician must document compliance on the warranty
registration form. Failure to comply may void the warranty.
Poor engine performance will reduce the operating interval
between DPF regeneration cycles.
Proper SEF Muffler Application
Be sure the engine meets the SEF Muffler flow limits for your
application. SEF Mufflers have a maximum flow limit of 2700
CFM. SEF Muffler assemblies will be applied according to:
• Engine flow at 2700 CFM or below
• Approved CARB engine list
• Muffler assemblies rated for engines below 275 hp.
• Muffler assemblies rated for engines above 275 hp.
Application of the device on engines outside of these
parameters will result in shorter intervals between
regenerations, affect exhaust system performance and may
result in poor engine performance. Improper application may
also result in regulatory fines and/or other enforcement action.
Fuel Requirement
The SFF Muffler System requires the use of ULSD Fuel (15
ppm or less sulfur content) that meets ASTM D975. BioULSD
(20% biodiesel/80% ULSD) per ASTM D6751 diesel fuel
specifications may also be used. Fuel additives are not
permitted and may void your warranty.
Engine Lube Oil Requirement
The SEF Muffler requires the use of engine lube oil that
meets CJ-4 specifications (low ash). The engine must NOT be
consuming oil higher than a rate of one quart per 500 miles.
Fuel Penalty
The effect of a SEF System on fuel consumption is negligible.
SAE Paper 810858 – ‘Fuel Efficient Exhaust Systems’ outlines
fuel consumption of a turbocharged diesel engine with respect
to backpressure. It states that fuel consumption will increase
0.5% for every 1" Hg backpressure over the manufacturer’s
specification. The SEF System will increase backpressure on
the engine compared to a stock muffler. However, the expected
increase will be less than 1" Hg on average. Thus, the expected
fuel consumption increase will be ~0.5%. Given the vast
differences in duty cycles for on-road vehicles, this would not
be a measurable difference.
Backpressure Increase
The SEF system could increase the nominal engine
backpressure by 20" H2O (1.46" Hg) compared to stock exhaust
system. When the SEF Muffler is plugged from engine
inspection or yearly cleaning, the engine backpressure can
increase to 100" H2O (7.36" Hg) or 127" H2O (9.34" Hg).
Noise Level Control
Expected noise level of the SEF system will be equal to or less than
the stock exhaust system.
Vehicle Clearance & Access for DPF Regeneration
For installation flexibility, the heater and inlet assemblies can
be rotated easily by loosening
the v-band clamp to determine
the best position for fit on the
vehicle and for easy access
during DPF regeneration. On
horizontal installations, refer to
the diagram at right to
properly orient the
heater assembly. Rotate electrical heater tube
from shaded areas
OK
OK
OK
OK

Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2 7
Donaldson Retrofit Emissions System
Junction Box
Please consider the following as you think about where to
mount the junction box:
• for access and convenience when it’s time to regenerate the DPF,
consider the position of your DPF regeneration station prior to mounting
the Junction Box
• should be accessible from the ground
• should be protected from damage or abuse during vehicle use
• access cover requires clearance to open door completely for cable
connection
• should be closed securely when not in use
• dimensions are 5"D x 8"H x 8"W (127 mm D x 203mm H x 203mm W)
• comes attached to SEF Muffler with 10 ft. (3.0m) long cable
Quick Connect Air Supply
208-240V
Electrical
Connection
(attached to
control station)
Junction Box
Thermocouple
Connection
Allow clearance
for junction box
door to open and
ensure that it
does not
obstruct other
components.
CAUTION!
Orient Junction Box
Mounting Location
Make sure that your junction box mounting location allows for cable
disconnect in the event of a drive away without disconnecting.
CAUTION!
Do not ADD or DISCONNECT cables from
the Junction Box after Starting Regen
DO NOT ADD OR DISCONNECT a second cable to the junction
box after pressing the START button, doing so will interrupt the
regeneration cycle and damage the DPF component.
EDM
The EDM has a separate installation, operation and maintenance
manual (P484891) and will be packaged separately from the SEF
Muffler.
CAUTION!
Do Not Drill Pressure Tap or Temperature
Probe Ports for EDM
The pressure tap and temperature probe ports are already welded
on to the inlet assembly of the SEF Muffler. Skip Section A in the
Installation section of the EDM Manual (P484891).
Inspection Mounting Hardware
An SEF Muffler weighs considerably more than a traditional
OEM truck muffler (120 lbs. vs. 30 lbs. [55 kg vs. 13.6 kg]).
Inspect any mounting system hardware intended for reuse
to ensure it is in good condition and can adequately support
the added weight. Look for signs of rust, corrosion or fatigue.
Do not re-use suspect components. Use new heavy-duty
components specially designed for retrofit applications.
NOTE
An SEF Muffler is nearly four times heavier than
a traditional OEM truck muffler. The mounting
system should be inspected to ensure it is in good
condition and can adequately support the added
weight. Inspect all hardware intended for re-use for
rust, corrosion or fatigue. Replace all questionable
components with heavy-duty components.
Vertical Tailpipe Support
Vertical tailpipes over 4 ft. (1.2 m) require additional support.
Tailpipes at this length, over time, will start to vibrate and
cause unwanted stress on the outlet section. To prevent this
failure, support the outlet stack appropriately.
Avoid Vibration
The SEF Muffler must be isolated from engine vibration. Do
not hard-mount the muffler assembly directly to the engine
or install where the device can be subject to vehicle or
equipment vibration.
Inspect Tubing
To maximize effectiveness, exhaust tubing and flex should be
structurally sound and leak-free. Inspect the exhaust tubing
for leaks due to damage or corrosion, and replace defective
components. Also look for flaking due to corrosion and/or
soot build-up. Loose contaminants can cause DPF plugging,
increased backpressure and degraded engine performance.
NOTE
If you see any evidence of rust or corrosion on
existing tubing between the turbocharger and SEF
Muffler inlet, replace with new aluminized steel
tubing. If reusing existing exhaust tubing, banging
and tapping on the tubing may dislodge soot. Be
sure to clean out any pipes prior to installing new
components. Operate engine at high idle to blow
out exhaust pipes prior to installation of the SEF
Muffler. Protect yourself and others from loud
noise and flying debris.

8 Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2
Donaldson Retrofit Emissions System
DPF Regeneration Station
Items to Consider:
• Unit weight: 117 lbs. / 53 Kg (with cables)
• Mounting Space Requirement: 24"W x 21"H x 9"D
• Clearance: (1) Allow 20" clearance for door to open; (2) minimum 12"
clearance on three remaining sides
• The control station display panel should be mounted at eye level
• Locate the DPF Regen Station so that two vehicles can park within 25
feet of the station for the DPF regeneration process as the cables are
25 ft. long.
• If installed outside or for exterior access, a cover or awning is required
to protect the control panel.
• If installing indoors, make sure to use an exhaust removal system that
will vent the exhaust outdoors.
• The DPF Regeneration Station requires a clean, dry compressed air
source: 100 PSI @ 4.5 SCFM
• Minimum air supply requirements for a stand alone SEF Regeneration
Station: 3 HP, 60 gallon, single stage air compressor
• Only a certified electrician should make connections. Follow all local
electrical codes.
• DPF Regeneration Station comes with NEMA 6-30R (3-prong) power
cord for standard 220V power outlets. If your existing receptacle
doesn’t match the 6-30R plug style, discuss your options with your
electrician (i.e., hardwire to a single phase 208
or 240 VAC/30A branch circuit, or changing the
plug style to match your existing 208 or 240
VAC 30-50 branch receptacle).
• When not in use, Donaldson recommends the
install and use of cable storage hangers for the
power cables. Keep in a safe place when not in
use to prevent damage.
CAUTION!
High Temperature Alert!
Tailpipe / Stack Pipe Position
During DPF regeneration, the exhaust flow exiting the muffler outlet
tube can reach 600ºC. To avoid personal or property damage, make
sure your tailpipe and/or stack pipe connected to the DPF Muffler
is NOT exiting the exhaust flow near flammable objects. Shorter
tailpipes and stack pipes are more problematic. Longer tailpipes
or stack pipes by design, should provide adequate length to cool
the exhaust flow.
Lock-Out/Tag-Out Instructions During DPF
Regeneration
The following lock-out/tag-out instructions should be followed
just prior to starting an SEF DPF Regeneration.
Pre Lock-Out / Tag-Out
1. Lock-out/tag-out should only be performed by an individual
authorized to tag out the specific piece of equipment or vehicle.
2. Be sure the vehicle is parked within close proximity to the DPF
Regeneration Station so that the cables can reach the Junction
Box on the vehicle.
NEMA 3-Prong
Plug Style 6-30R
3. Verify that there are no nearby hazards located close to the
vehicle (i.e. electrical cords, heavy foot or vehicle traffic, etc.).
4. Verify that the muffler stack is not close to any objects that may
be damaged from the high heat of the regeneration exhaust
gases.
5. Be sure to verify that the vehicle is in park with the parking brake
applied and the wheels chocked.
6. Verify that all stored or residual energy (such as hydraulic
systems, air pressure or water pressure, etc.) is dissipated or
restrained by blocking, bleeding down, etc.
7. Notify any maintenance or operations individuals that the vehicle
is locked-out.
Lock- Out / Tag-Out
8. If there is a main power shut off to the vehicle, shut off the power
(also known as the “dead man out switch”)
9. Place a lock with marking tag on the
vehicle steering wheel (the tag should
include the name of the individual locking
out the vehicle).
10.If the vehicle is equipped with a dead man
out switch, the lock should be placed on
this switch. The tag may be placed on the
vehicle steering wheel or the dead man
out switch.
11.The lock-out/tag-out procedure shall
conform to all company standard
procedures.
Installation
This section includes separate installation procedures for the
SEF Muffler (vertical and horizontal installations), the Junction
Box, EDM and the DPF Regeneration Station. Please use
the muffler installation procedure that matches your current
muffler orientation.
The installation procedures for the EDM are in a separate
manual that ships with the EDM.
Install
Tip
Save Install Time if Disposing of the Old
Muffler and Components
It's not a good idea to reuse old exhaust components on new
retrofit emission installations. So, if your installation plan is to
discard the old components, reduce install time by using a Sawzall
to cut the muffler and old clamps out of the exhaust system.

Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2 9
Donaldson Retrofit Emissions System
Vertical Muffler Installation
Remove the Existing Muffler
1. Loosen stack clamp at muffler outlet (top). Remove stack and
clamp.
2. Loosen tubing clamp at muffler inlet (bottom).
3. Loosen clamps on flex tubing. Remove clamps, flex and inlet
elbow.
4. Loosen muffler and heat shield mounting bands. Remove and
discard muffler and heat shield.
5. Operate engine to blow scale or rust contaminants from exhaust
tubing.
Install the SEF Muffler
1. Prepare the muffler mounting area. Ensure the mounting stanchion
or mast is robust enough to support the weight of an SEF Muffler.
A mast extension is typically required to accommodate the added
length of the SEF Muffler (+6 in. / +15cm). Be sure to allow
enough clearance for the thermal wrap to fit between the mast
and the muffler body.
Replace any existing mounting parts that appear rusted, damaged
or of questionable strength with heavy-duty parts. Mounting
components must be strong enough to adequately support the
120 lbs. (55 kg) muffler weight. Use new heavy-duty mounting
brackets, bands, supports and/or stanchion. Donaldson offers
many components designed specifically to handle the added
weight of emissions retrofit devices.
2. Ensure the SEF Muffler is installed so that flow arrows match
the exhaust flow direction. Position the SEF Muffler on mast in
position of original muffler and secure with heavy-duty mounting
bands. Rotate SEF Muffler so CARB emissions device tag is
visible.
5431
2
NOTE Mounting System Space Allowance
Allow 2" (50 mm) space for the thermal wrap to fit between the
SEF Muffler and corresponding stanchion/mast, frame rails,
cross members, etc.
3. Position the mounting bands on the inlet/outlet sections only.
Do not position mounting bands over DOC Assembly, Heater
Assembly, or DPF Sections (components 2, 3 and 4 in above
illustration), as that may result in damage to those components
and interfere with thermal wrap installation. Ensure exhaust
tubing lines up properly with SEF Muffler inlet/outlet sections to
avoid damage to muffler.
CAUTION!
Avoid Excessive Force on Inlet
and Outlet Piping!
Excessive force on the inlet and outlet piping caused by tubing
misalignment in conjunction with vehicle vibration can result
in stress cracking at the emissions device inlet/outlet. Failures
caused by misalignment are a result of improper installation
and are not covered under the warranty.
4. Position flex tubing and clamps onto exhaust tube. Replace the
existing flex tubing if it is not flexible. Do not tighten clamps until
all tubing is assembled.
NOTE Flex is not approved in some locations. Check
local ordinances to confirm if the use of flex
tubing is permitted.
5. Position inlet elbow and muffler inlet clamp. Locate flex tube so
that there are equal lengths of rigid tubing (within the flex) on
both ends. Tighten clamps to secure flex tubing and inlet elbow.
6. Reconnect exhaust stack onto muffler outlet tube. The SEF Muffler
is longer than the OEM muffler. The height (or length) of the existing
stack pipe may need to be reduced to avoid clearance problems.
7. Position clamp over SEF Muffler outlet tube. Insert the stack into
the muffler outlet and tighten securely. If using a straight stack,
install a rain cap.
NOTE Water from Rain or Truck Washing Can
Damage Internal DPF Components
Rain and truck wash water can damage the DPF retention materials.
Vertical tailpipes must be fitted with rain caps or curved outlets.
8. Verify that all bolts and fasteners have been sufficiently tightened.
9. Operate engine and check for exhaust leaks. Repair any leaks.
10.Turn off the engine.
11.Install thermal wrap.
12. Permanently attach the DECS label (supplied in documentation
package) onto the engine. CARB regulations require the DECS label
be installed in a clearly visible location for Enforcement Staff.
13.Install Emissions Device Monitor (EDM). Installation instructions
will be included with the monitor (Manual P484891).
NOTE Permanently affix DECS
label onto engine
California ARB regulations require a DECS label be permanently
installed on the engine in a clear, visible location. Use high-temp
RTV or a screw.

10 Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2
Donaldson Retrofit Emissions System
CAUTION!
Additional Support is Required on
Vertical Tailpipes over 4 ft. (1.2m)!
Vertical tailpipes over 4 ft.(1.2 m) require additional support.
Tailpipes at this length, over time, will start to vibrate and
cause unwanted stress on the outlet section. To prevent this
failure, support the outlet stack appropriately.
Device Identification
Donaldson Retrofit Devices have two identification tags/
numbers. The first, center body identification, can be found
near the inlet side of the DPF Section.
DPF Section P/N Manufacturing Code
Lot Code Date Code "WW-YY"
The second, the device tag, can be found welded on the
DPF Section, Thermal Wrap or the engine tag. This contains
information for the complete SEF Muffler. The information on
this tag is described below:
DECS
Device S/N
Device Date Code
SEF MUFFLER
SEF
1
Horizontal Muffler Installation
Remove the Existing Muffler
1. Loosen clamp at muffler outlet. Remove clamp and tailpipe.
2. Remove clamp at muffler inlet.
3. Loosen muffler mounting bands. Remove and discard muffler.
4. Operate engine to blow scale or rust contaminants from exhaust
tubing.
Install the SEF Muffler
1. Prepare the muffler mounting area. Ensure the mounting
arrangement or hangers are robust enough to support the weight
of an SEF Muffler. The added length of an SEF Muffler compared
to an OEM muffler will require additional room (+6 in./+15 cm). Be
sure to allow enough clearance for the thermal wrap to fit between
the frame rail/mounting base and the muffler body. Ensure there is
adequate clearance between the road and SEF Muffler bottom to
avoid damage. The SEF Muffler bottom should rest higher than the
vehicle differential or lowest component on the vehicle.
NOTE Mounting System Space Allowance
Allow 2" (50 mm) space for the thermal wrap to fit between the
SEF Muffler and corresponding stanchion/mast, frame rails, cross
members, etc.
NOTE Check Road Clearance
Ensure there is adequate space from the road to the bottom of
the SEF Muffler to avoid damage.
Replace any existing mounting parts that appear rusted, damaged
or of questionable strength with heavy-duty parts. Mounting
components must be strong enough to adequately support the
120 lbs. (55 kg) muffler weight. Use new heavy-duty mounting
brackets, bands, supports and/or stanchion. Donaldson offers
many components designed specifically to handle the added
weight of emissions retrofit devices.
2. On vehicles with a vertical tailpipe, drill a 1/4" (6mm) drain hole 6"
(152 mm) from the outlet end of the SEF Muffler.
NOTE Drain Hole Required on Horizontal Mount
with Vertical Tailpipe
Horizontally-mounted, vertical tailpipe systems must have a 0.25"
(6mm) diameter drain hole drilled through the lowest point of the
body 6" (152mm) from the outlet end of the DPF Muffler. Rain and
truck wash water can damage the DPF retention material. Vertical
tailpipes must be fitted with rain caps or curved outlets.

Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2 11
Donaldson Retrofit Emissions System
3. Position and secure the SEF Muffler with heavy-duty brackets and
mounting bands. Ensure the SEF Muffler is installed so that flow
arrows match the exhaust flow direction. Rotate the muffler so the
drain hole is oriented downward. Ensure the mounting bands do
not cover the drain hole.
Position the mounting bands on the muffler inlet and outlet
sections only. Do not position mounting bands over DOC or DPF
sections as that can result in damage to those components and
interfere with thermal wrap installation.
See ‘Vehicle Clearance and Access for DPF Regeneration’ section
for a detailed explanation of the heater assembly orientation in a
horizontal installation.
Ensure exhaust tubing lines up properly with muffler inlet and
outlet joints to avoid damage to muffler. Be sure to allow enough
clearance for the thermal wrap to fit between the frame and the
SEF Muffler body.
CAUTION!
Avoid Excessive Force on Inlet
and Outlet Piping!
Excessive force on the inlet and outlet piping caused by tubing
misalignment in conjunction with vehicle vibration can result
in stress cracking at the emissions device inlet/outlet. Failures
caused by misalignment are a result of improper installation
and are not covered under the warranty.
4. Position inlet tubing and clamp on muffler inlet tube and tighten
clamp.
5. Install tailpipe and secure clamp on muffler outlet/tailpipe joint.
6. Verify that all bolts and fasteners have been sufficiently tightened.
7. Operate the engine and check for exhaust leaks. Repair any leaks.
8. Turn off the engine.
9. Install thermal wrap.
10.Permanently attach the DECS label (supplied in documentation
package) onto the engine. CARB regulations require the DECS
engine tag be installed in a location clearly visible to Enforcement
staff.
11.Install Emissions Device Monitor (EDM). Installation instructions
will be included with monitor (Manual P484891).
NOTE Permanently affix DECS
label onto engine
California ARB regulations require a DECS label be permanently
installed on the engine in a clear, visible location. Use high-temp
RTV or a screw.
Junction Box Installation
The Junction Box houses
the power and
thermocouple connections
for the SEF Muffler
regeneration cycle. This box
must be permanently
mounted to the vehicle in a
location that will be
convenient to access and
yet out of the way from
damage or abuse. The junction box comes attached to the SEF
Muffler via a 10 ft. (3 m) cable. A compressed air line is also
included in the cable bundle and will need to be connected.
Quick Connect Air Supply
208-240V
Electrical
Connection
(attached to
control station)
Junction Box
Thermocouple
Connection
Allow clearance for
junction box door
to open and ensure
that it does not
obstruct other
components.
1. Select a location on the vehicle to mount the junction box,
being sure to accommodate the 10 ft. (3 m) long cables that are
attached to the DPF body.
2. Select hangers and/or mounting brackets that are strong enough
to support the weight of the junction box (approximately 20 lbs. [9
kg]). Custom brackets may be required.
3. Mount the junction box.
4. Attach the unfinished end of the air hose to the combustion air
inlet tube located in the SEF Muffler inlet assembly. Orient the
air hose near the junction box. Take precautions to prevent road
debris from accumulating in the air hose connector.
5. Secure cable assembly and air hose firmly and prevent contact
with SEF Muffler assembly or exhaust pipes to prevent heat
damage.
CAUTION!
Prevent Air Hose From Touching
SEF Muffler Assembly
High heat can damage the power cable / air hose. Make sure to
secure the hose away from the SEF Muffler to avoid damage.

12 Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2
Donaldson Retrofit Emissions System
EDM Installation
The EDM In-Cab Display should be installed in a visible area
inside the cab. The Donaldson
EDM is a required key component
of Donaldson DPF systems as it
records and analyzes DPF
operating conditions.
Temperature and backpressure
readings are continuously recorded to aid in analyzing vehicle
operating trends and to support troubleshooting. A date and
time module (DTM) adds dates and time to the log file
download. An EDM kit is included with all Donaldson SEF
Muffler kits.
To enhance DTM capabilities, a replacement battery is
incorporated to maintain settings during periods when the
vehicle is in storage or the battery is disconnected.
COMS Connection Access - Position for Easy Access
• A technician will need to access the connector labeled “COMS” when
the DPF is serviced or cleaned. Make sure the COMS connector is easy
to access.
• If retrofitting several vehicles in a fleet, consider positioning the COMS
connector in the same general area so the technicians can locate it
easier.
Mounting Location - SECM
• If installing the EDM on a rear engine vehicle, you will need to order
the 50 foot sensor harness (P231739) separately to reach the sensors.
Light Actions and Descriptions
Display Lights
Action
Description
Start-up
(Current
Systems)
All LEDs
Illuminate
Steady
A self-test is performed at start-up and
all lights illuminate steady for three
seconds. When done, the In-Cab
Display will reveal any fault condition
activated prior to shutdown.
Service
Soon
HOURS HOURS
Steady
Yellow
Filter requires service within 8 hours.
This light will stay on for the duration of
the key cycle.
This light will turn off after key cycle.
Service
Now
HOURS HOURS
Steady Red Service the filter within 2 hours of
operation or before the next work shift.
Reset Service Now light after Filter
service.
Temp
Alarm
Flashing
Red
Safely stop engine immediately. An
engine situation has caused elevated
exhaust temperatures. Visually inspect
the filter for physical damage. If okay,
service filter and reinstall. If not, filter
will need to be replaced.
Reset Temp Alarm light after the filter
service.
Service
Soon &
Service
Now
Alternate
Flashing
This action indicates a problem
with, filter missing, the wiring and/or
connections. To diagnose, connect the
EDM to a laptop using the computer
link-up cable or use the Diagnostic
Reset Tool to retrieve specific fault
codes for troubleshooting.
A separate installation instruction, operation and maintenance
manual (P484891) is included with the EDM documentation
package. Follow those instructions for proper installation.
DPF Regeneration Station Installation
The DPF Regeneration Station is designed to regenerate two
DPFs (filters) on two separate vehicles simultaneously. The
automated cycle takes each SEF Muffler through a predefined
warm-up, combustion and cool-down cycle to regenerate the
DPF.

Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2 13
Donaldson Retrofit Emissions System
Installation of DPF Regeneration Station
CAUTION!
Install only with Certified Electrician
Installation of the Thermal Regeneration Control System must
be completed by a Certified Electrician. Failure to use a certified
electrician may result in personal injury, damage to the unit or
to property.
1. To allow owner to easily see and operate the control station
display panel, mount control panel at eye level.
2. Install a hood or awning, if mounted outdoors.
3. Connect panel to an electrical power source. Installation of the
control station should only be completed by a trained, certified
electrician. A control circuit electrical schematic is included in
this manual. Follow all local electric and building codes. See ‘DPF
Regeneration Station’ Section for additional information.
4. Connect to compressed air supply. Install air dryer/filter to avoid
damage. Air supply must be a constant 100 psi.
Installation Checklist
SEF Muffler
SEF Muffler mounted in proper exhaust flow
direction. As shown by the flow arrows on the
muffler segments.
SEF Muffler isolated from engine/frame rail
vibration by use of flex pipe, bellows, or mounting
clamp isolators
Thermal wrap in position (over the DPF and
heater assembly) and secure.
Vertical tailpipes over 4 ft. (1.2m) require
additional support
Thermal wrap clear of other parts, and does not
interfere with other vehicle or engine parts when
vehicle is in operation
New hardware and clamps installed per this
manual
All SEF Muffler mounting hardware and clamps
are tightened
No visible exhaust leaks in the system
Rain cap installed on vertical installations.
Labels clearly visible on device
Junction Box
Junction Box mounted in location that can be
easily accessed during service
Junction Box door has clearance for opening and
closing
Mounting bolts or brackets tightened
Air quick connection properly mounted near
Junction Box
Air hose mounted and connected to the SEF
Muffler inlet section
No loose compressed air, thermocouple, or
electrical lines
All compressed air, thermocouple, and electrical
power lines mounted safely, securely, and away
from hot or moving parts
Emissions Device Monitor (EDM)
Refer to EDM installation and operation manual
(P484891)
The EDM will include a date and time module
(DTM) allowing backpressure and temperature
data to be aligned with time of occurrence
Vehicle operators trained on new In-Cab Display
and alerts
Complete Vehicle Setup: Connect laptop with
COMS port and enter information into SECM
“Vehicle Setup” (VIN, Diesel Emission Control
Strategy [DECS], Serial No., install date,
etc.)
See the EDM manual (P484891) for instructions
Program Compliance
Warranty card filled out completely and filed
electronically
ARB engine tag permanently affixed to the engine
with RTV silicone in a visible location
End user has warranty document, preliminary
temperature data log, Donaldson recommendation
letter, copy of ARB Executive Order and this
manual for their records
Pre-assessment complete

14 Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2
Donaldson Retrofit Emissions System
Activate the Warranty
For regulatory reporting and warranty registration purposes,
Donaldson Company requires the installer/dealer to complete
and submit the warranty for the vehicle or equipment owner on
our Warranty Registration web site.
A Warranty Registration Worksheet is included in the
documentation packet Register the new installation within
30 days using our on-line warranty registration site at:
http://pwww.donaldson.com
Emissions Retrofit Documentation
Retain all emissions retrofit documentation on each vehicle,
including:
• Vehicle temperature data / profile form
• Donaldson response letter that approved the retrofit
application
• Date of installation
• Mileage / hours at install
• Installation and owner information
• Part number
• Serial number
• DPF service and cleaning records
SEMI-ACTIVE ELECTRIC FILTER (SEF)
Connecting control station to SEF Muffler
Connection between the SEF control station and the SEF
Muffler assembly will be through a 25 ft. cable assembly (2X) at
the control station with three (3) connections:
a. Power – Large blue electric plug
b. Air – Black hose with quick coupler
c. Temperature – Yellow with two (2) prong plug
2. A Junction box (located on vehicle) is a 6"x 6" NEMA4 gray
enclosure mounted in an area close to the SEF Muffler. There
are receptacles in the enclosure for power and thermocouple
termination. The air connection is made with mating quick
couplers.
Regeneration control station pre-startup checks
Prior to energizing the control station enclosure:
1. Ensure the power plug is disconnected or the knife switch
providing power to the enclosure is OFF.
2. Check the internal circuit breakers inside the enclosure. To do this:
a. The main enclosure disconnect, located in the center of
the door must in the OFF position.
b. Open the door latch located on the center right by
inserting a straight blade screwdriver or a coin into the
slot and rotate 90 degrees counter clockwise.
c. Cycle circuit breaker CB 109 located left center and circuit
breaker CB 103 located lower left to ensure that they are
in the ON position.
CB103
CB109
*IMPORTANT*--CB 103 is the Main/heating circuit breaker. Make
sure that this breaker is secure on the baseplate. Push on the face of
this breaker to ensure that it is seated properly. The connection can
be jarred loose during shipment.
3. After checking breakers, close the door, secure the latch, plug
the power cord in or engage the ON switch of the facility power
disconnect for the enclosure.
Regeneration control station pre-startup checks
1. Turn the main enclosure disconnect to the ON position. If power is
on, the display panel of the control station should be lit up.
2. E-stop should be in the UP or ON position.
a. Push the E-stop down to the OFF position. This will
kill power. To release, rotate the mushroom switch as
instructed on the top surface of the button and let the
head rise to the ON position.
3. Take note of the temperature value displayed on the temperature
controller display.
a. If the connection is correct between the 25 foot cable and
the SEF heater junction box, a positive temperature will be
visible on the display. Either the ambient temperature (if

Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2 15
Donaldson Retrofit Emissions System
the muffler is cold) or the temperature of a cooling muffler
after engine shutdown will be shown.
b. The green number is the SEF heater set point. It will
always be visible when the display has power
c. The red number above the green value is the actual
temperature measured at the SEF heater. The controller
will display a temperature within the SEF Muffler whether
the heater is activated or not.
d. Depending on whether Side A or Side B is chosen to
be connected to the SEF Muffler, the connected side
and corresponding controller will display a positive
temperature.
i. If a negative number is displayed, the
thermocouple lead wires have been switched in
polarity. The correct polarity is (+) Yellow, (-) Red.
e. On the side NOT chosen for connection to the muffler the
temperature controller display will show a solid or flashing
“Er.il” warning. This is normal.
i. If the “Er.il” warning is flashing on the side
chosen for connection, either the thermocouple
connection at the junction box has not been made
OR the thermocouple has been damaged in some
way.
f. The examples below show the desired set point in green
and heater temperature in red. The right image shows a
complete regeneration. The green complete light is on
and the temperature controller display shows the ambient
temperature of the muffler.
Green# = Set Point
Red# = Heater Temp
Example: Complete
Generation
Restoring the Equipment to Service
1. Remove ALL of the DPF Regeneration Station cables and any other
items that may be attached to the vehicle.
2. Check the work area to ensure that all employees have been
safely positioned or removed from the area.
3. Verify that the vehicle is still in park and wheel chocks in place.
4. Remove the lock-out device and the tag-out label.
5. Notify affected employees and update service records to reflect
that the vehicle has completed maintenance and is ready for use.
Installer and Data
Theory of Operation
The SEF Muffler System consists of an SEF Muffler assembly,
an Emissions Device Monitor (EDM) and a DPF Regeneration
Station. The SEF Muffler Assembly collects soot (PM) and ash
from the diesel exhaust via a robust silicon carbide DPF. As
the DPF loads, the system backpressure increases. The EDM
monitors exhaust system backpressure, and tells the vehicle
operator when a regeneration cycle is needed via an in-cab
display. When the backpressure exceeds preset limits, the
vehicle must be removed from service and connected to the
DPF Regeneration Station to complete a regeneration cycle.
This is typically done over the night shift to minimize impact on
fleet operations.
NOTE
See EDM Manual (P484891)
for details on the In-Cab
Display Alerts & Actions
The DPF Regeneration Station controls the regeneration cycle.
It switches on and off the muffler-mounted electric heater and
compressed air flow through the muffler to obtain safe and
efficient soot oxidation. The DPF Regeneration Station can
control two cycles simultaneously. Each cycle includes preheat,
burn and cool-down phases. The regeneration cycle time is 4.5
hrs for one unit or 7.0 hrs for two. When two are regenerated
simultaneously, the cycle time is reduced by overlapping the
cool-down phase of the first cycle with the pre-heating and
burn phases of the second cycle.

16 Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2
Donaldson Retrofit Emissions System
Basic Regeneration Station Logic
• Correct Power to all components is assumed.
• Is the main power disconnect on the front of the enclosure ON and the
E-stop ON?
• Are the internal breakers/fuses on or OK?
• After five minutes, if the heater controller is not sensing temperature
above 500°F the cycle is aborted and the flashing light is illuminated.
Refer to the Troubleshooting Guide for solutions.
• If at anytime the temperature exceeds 1400°F, the cycle is aborted and
the red flashing light is illuminated.
• After 15 minutes of core warm-up (heater temperature is greater than
500° F and less than 1400° F) the compressed air solenoid is energized
and pulses 1 second ON and 2 seconds OFF.
• If air pressure drops below 60 PSI for 3 seconds, the regeneration
cycle is aborted (yellow flashing light). See the Troubleshooting Guide.
• After 2 hours and 30 minutes the SEF heater power relay is de-
energized for the A or B filter being heated and the air pulse will
continue at the same 1 second ON and 2 second OFF rate with a
continuous yellow cool down light illuminated.
• If both A and B filters are selected for regeneration, the filter B
energizes at this point if filter A has been de-energized.
• After 4.5 hours the compressed air solenoid for filter A or B is de-
energized and the cleaning cycle is complete for that filter. If filter A
and B are selected for regeneration, the compressed air solenoid for
filter B will stay on for another 2.5 hours (.5 hours of heating cycle
with air pulses and 2 hours of air “cool down” pulses).
• When regeneration cycles are complete the green light flashes.
• In the event the regeneration needs to be interrupted, push the
emergency stop button. This action will abort the regeneration
cycles. This should be done only in cases of emergency. Shutting
down the system is not recommended unless absolutely necessary.
Structural damage can occur to the systems substrates.
To ensure proper functioning of these products, Donaldson
preventive maintenance and service procedures must be
incorporated into your regular vehicle maintenance routines.
Operation of the DPF Regeneration Station
The DPF Regeneration Station is designed to clean a single
DPF on a truck or two DPFs on two separate trucks at the same
time. The length of the cleaning cycle duration is dependant on
the number of trucks connected (at the same time).
Trucks Filters Regen Time
1 Truck System A 4.5 hours
1 Truck System B 4.5 hours
2 Trucks System A & B 7 hours
CAUTION!
Do not ADD or DISCONNECT cables from
the Junction Box after Starting Regen
DO NOT ADD OR DISCONNECT a second cable to the junction
box after pressing the START button, doing so will interrupt the
regeneration cycle and damage the DPF component.
CAUTION!
DO NOT Change the Selector Switch Once
Regen Cycle Has Started!
DO NOT change the selector switch once cycle is started–doing
so will interrupt the regeneration cycle and damage the DPF
component.
CAUTION!
DO NOT Stop the Regen Process for truck
to connect a second truck to the station!
Stopping the regen cleaning procedure at any time during the entire
cycle may damage the DPF component. The DPF can easily be
damaged if the heating cycle is shut off . Please note that the DPF
is a very expensive component within the system and would have
to be replaced if damaged occurred due stopping the programmed
regeneration cycle.
CAUTION!
Well ventilated area required for regeneration
Do not regenerate the SEF system in a closed area without dedicated
power ventilation for the exhaust
CAUTION!
High Temperature Alert
Make sure thermal wrap is installed on DPF
Muffler BEFORE regen cycle starts.
The body of the DPF muffler becomes very hot during DPF
Regeneration. The thermal wrap included with the SEF Muffler kit
must remain in place to avoid injury and protect nearby components
from heat.

Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2 17
Donaldson Retrofit Emissions System
DPF Regeneration Station Controls
During the regeneration cycle, the DPF goes through a 15
minute preheating stage, and a 2.5 hour combustion cycle,
followed by a 1.5 hour cool down cycle to safely reduce
the temperature of the core and eliminate the possibility of
damage from thermal shock.
While the DPF is being regenerated the operator can monitor
which part of the cycle the control station is in by the lights on
the instrument cluster. Refer to the chart on the right.
Solid red or yellow lights indicate a normal heating or cooling
cycle. If problems occur, red or yellow flashing lights will
indicate the following:
• Insufficient combustion air supply
• Insufficient electrical supply current
• Heater does not reach regeneration temperature
• There is poor or no feedback from thermocouple
A flashing green light will indicate a successful regeneration
cycle.
Action on
Panel Button shape/color and Description
Start Green push button – Starts
regeneration cycle.
Stop Red push button – Stops
regeneration cycle. Clears
flashing alarm lights or cycle
complete light.
E-Stop Red maintained push button –
Stops regeneration cycle. Shuts
off power to PLC outputs. Clears
flashing alarm lights or cycle
complete light.
To restore the SEF from an
emergency stop, twist the E-stop
button in the direction shown on
the head of the button.
Heating
System A & B
Lights
Red buttons will be solid during
heating mode
Red flash indicates temperature
fault (the temperature was <500°F
or >1400°F during heating.
Cool Down Solid Yellow: System A or System
B is in the Cool Down Mode.
Flashing Yellow: Low air pressure
alarm. Air pressure dropped
below 60PSI for at least 3
seconds. Cycle is aborted
Cycle Flashing green: Regeneration
cycle has completed. Press Stop
button to acknowledge
System
Selection
One of the three
positions must be
selected before
pressing the Start
Button
The position of this
switch is checked
when pressing the
Start push button.
If the System
selection needs
to change during
a regeneration
cycle, press the
Stop button to
exit the cycle
and move the
selector switch to
the appropriate
position and press
Start again.
Systems A & B Cycle & Timing
00:00 Heating starts on
System A
00:15 Pulsing begins on
System A
02:30 Heating complete for
System A cool down
begins; heating starts
on System B
02:45 Pulsing begins on
System B
04:30 System A cool down
complete, System B
pulse stops
05:00 System B cool down
starts
07:00 System B cool down
complete, Cycle
Complete light flashes
System A Cycle & Timing
00:00 Heating starts
00:15 Pulsing begins
02:30 Heating Complete Cool
Down Begins
04:30 Cycle Complete
System B Cycle & Timing
00:00 Heating starts
00:15 Pulsing begins
02:30 Heating Complete Cool
Down Begins
04:30 Cycle Complete
System A & B
Temperature
Temperature controller -
separate displays for System A
& B
Upper Display (Red Text):
Displays current temperature
of System A or System B
thermocouple
Lower Display (Green Text):
Displays temperature set point
(1350°F)

18 Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2
Donaldson Retrofit Emissions System
Maintenance and Service
Filter Maintenance
The DPF Section of the SEF Muffler captures soot and ash
from diesel exhaust. Over time the DPF will load and will
need to be regenerated by using the SEF Muffler regeneration
station. While the electric heater burns off the soot, the ash
slowly builds up. Eventually, the DPF must be removed to be
ash-cleaned. This should occur annually or every 50,000 miles,
whichever comes first. See Filter Cleaning instructions for more
information.
The DPF does not require maintenance other than routine
cleaning by means of the DPF Regeneration Station and ash
cleaning or PM.
Preventive maintenance recommendations during normally
scheduled vehicle maintenance.
1. Inspect the emissions device, exhaust piping and mounting
brackets.
2. Look for leaks, structural failures (cracks), and loose or missing
fasteners.
3. Repair or replace defective parts as appropriate.
NOTE Do Not Use Fuels Blended
with Lube Oil
Engine oil must not be blended with the engine's fuel since the oil
may cause reduced emissions performance and deposits in the filter
that may cause higher backpressure, plugging and reduced engine
performance and may result in the denial of warranty.
NOTE For Electronically Controlled Engines
Electronically controlled engines are certified with a specific fuel
and electronic program based on engine configuration and model
year. Use only the fuel and electronic program specified for your
engine. Using the incorrect fuel and/or electronic program may
cause excessive soot generation and filter plugging, and may void
the warranty.
CAUTION! Lube Oil
To protect against DPF failure and/or plugging, ensure that the
engine is not consuming oil at a rate higher than specified by the
engine manufacturer. Use low ash oils, when possible. Do not use
fuel blended with lube oil. Check with your local Donaldson dealer
to review additives before use.
Conditions That May Plug a DPF Muffler
Prematurely
• The conditions below, if not corrected, may result in denial
of the SEF warranty
• Improper engine maintenance
• Engine operation at low load or idling for extended periods
of time
• Engine failures that increase PM emissions including,
leaking or failed injectors, leaking turbocharger seals and/
or intake manifold leaks
• Engine failures that emit contaminants that may foul the
pre-filter or DPF
• Improper engine calibration for the specific fuel type being
used
• The above conditions may face plug the pre-filter. To clean
the pre-filter, use a shop vacuum with a bristle attachment
to gently clean the face. The pre-filter does NOT require
regular service during its life under normal operating
conditions. The DPF section in the SEF Muffler will need
routine service.
How to Regenerate a Dirty DPF
CAUTION!
High Temperature Alert!
Tailpipe / Stack Pipe Position
During DPF regeneration, the exhaust flow existing the muffler outlet
tube can reach 600ºC. To avoid personal or property damage, make
sure your tailpipe and/or stack pipe connected to the DPF Muffler
is NOT exiting the exhaust flow near flammable objects. Shorter
tailpipes and stack pipes are more problematic. Longer tailpipes or
stack pipes by design, should provide adequate length to cool the
exhaust flow.
NOTE Do Not Start Vehicle During Regeneration
Never attempt to start the vehicle while the DPF filter is being
regenerated. Damage to the filter and other components may occur.
NOTE Do Not Stop the Regeneration Cycle Unless
of Emergency
Do not use the emergency stop button as a means to pre-maturely
end the regeneration cycle. Damage to the filter may occur due to
thermal shock. The emergency stop button should only be used in
emergency situations.

Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2 19
Donaldson Retrofit Emissions System
Once a vehicle has been docked at the control station, use the
following steps to complete a regeneration:
1. Three items will need to be plugged in: the power cable, the
thermocouple cable, and the combustion air hose. System A or B,
or both may be used.
2. The engine of the vehicle must be shut off and remain off for the
entire duration of the regeneration cycle.
3. Look at the instrument cluster and verify that there is a
temperature reading on the System A Temperature or System
B Temperature read-out (depending on which is plugged in). If
temperature reading is “Er. il”, an error code, the thermocouple is
missing or broken. Restore or repair part.
4. Verify that the emergency stop button is not depressed.
NOTE Two Vehicles Can be Regenerated at the
Same Time!
The DPF Regeneration Station is designed to regenerate two
filters on two separate vehicles simultaneously.
5. Turn the Selector switch to the System A or System B. The
System A switch is connected to the cables on the bottom left of
the regen station, the System B switch is connected to the cables
on the bottom right of the box.
6. Press the start button.
7. A single regen cycle is complete after 4.5 hours, two regens
(System A & B ) take about 7 hours. The green complete button
will illuminate and flash when regen cycle is complete.
Reset the EDM
Once the DPF filter has been
regenerated the light on the
EDM will need to be reset. If
your backpressure monitor is
equipped with a push button
reset P231740 Diagnostic
Reset Tool (DRT), depress the
button (6 seconds) before operating the vehicle. If you do not
have a push button reset, refer to installation, operation, and
maintenance manual for your monitor. (EDM document no.
P484891).
The DRT will also allow reading diagnostic codes stored
in the EDM. Refer to the EDM manual for information on
code reading and refer to the chart in the EDM manual for
interpretation of the diagnostic codes.
Time Between SEF System Regenerations
SEF equipment vehicles can expect acceptable times between
regenerations. Factors affecting the length of time include:
• Engine soot output
• Duty cycle
• Engine size and exhaust flow
After system installation, a consistent regeneration pattern
will be established as operators become accustomed to EDM
warning lights that signal when regeneration is necessary.
Filter Ash Cleaning Interval
Over time, after many regenerations, there will be ash left
behind in the DPF core. This ash can cause the filter to plug.
In order to clean this ash out of the filter, the filter will need to
be removed and pulse cleaned by using the Donaldson Pulse
Cleaner, the compressed air method, or by having the core
cleaned by a Donaldson service dealer. Donaldson recommends
that the DPF filter be ash cleaned every 12 months or every
50,000 miles, whichever occurs first. For information on using
the pulse cleaner refer to Donaldson Document no. P480801.
The supplied service monitor provides illuminated alerts to
guide your filter cleaning interval. Alerts include:
• Service Soon - Steady Yellow (this is the ideal stage to clean)
• Service Now - Steady Red
Executing the following ash removal (filter cleaning)
guidelines will maintain filter performance, proper operation
and durability. Failure to follow the procedure may void the
warranty.
CAUTION!
Failure to follow the ash removal
(filter cleaning) guidelines may
void the warranty.
DPF Section Cleaning Method & Process
The DPF Section of the SEF Muffler must be cleaned using
the Donaldson Pulse Cleaner and Thermal Regenerator or
a Donaldson approved DPF cleaning system. The approved
cleaning method is the “pulse-bake-pulse” process and the
procedures are outlined in the Donaldson DPF Pulse Cleaner
(Doc. No. P480801) and Donaldson Thermal Regenerator (Doc.
No. P480802) Failure to use Donaldson or Donaldson-approved
methods may result in denial of SEF Muffler Kit warranty
coverage.

20 Semi-Active Electric Filter (SEF) Muffler Systems Owner’s Manual - P232575 Rev 2
Donaldson Retrofit Emissions System
Do not use any wet or liquid type cleaning system to clean the
DPF.
CAUTION!
Do not use STEAM or LIQUID DETERGENTS
to clean the DPF Section.
Donaldson does not recommend cleaning the DPF Section with
steam and/or other detergents. Use of these products may damage
and/or deactivate the DPF and may result in denial of warranty
coverage.
CAUTION!
DO NOT Pulse Clean a HOT DPF Section
The DPF inlet/outlet surface must be below 200ºF (93ºC) before
placing into the unit. Pulse cleaning a HOT DPF may result in fire
leading to personal injury or property damage.
CAUTION!
DO NOT Pulse Clean a DPF Section with
Compressed Air > 70 psi!
Do not clean the DPF section with compressed air greater than
70 psi. Doing so may damage the DPF section and result in denial
of warranty coverage.
The recommended method and process to clean the DPF
Section includes these steps:
Before Cleaning
• Measure and record weight of DPF Section
• Test and record backpressure of DPF Section in Donaldson Pulse
Cleaner
DPF Section Cleaning
• Pulse clean in Donaldson Pulse Cleaner (removes ash and soot)
• Bake (thermally regenerate)
• Pulse clean DPF Section when cool (removes additional ash created
during the regeneration cycle)
After Cleaning
• Test and record backpressure of DPF Section in Donaldson Pulse
Cleaner
• Measure and record weight of DPF Section
Filter Cleaning Instructions - DPF Remove and
Replace
CAUTION!
Wear Protective Gear During Cleaning
A dust mask, gloves and safety glasses should be worn while performing
the cleaning process.
The preferred method of cleaning a filter would be using the
Donaldson Pulse Cleaner and Thermal Regenerator. Inquire
with Donaldson for more information on our Pulse Cleaner or
our two stage cleaning systems. If you do not have access
to our cleaning system, the instructions below can be used.
Please know what your local codes regarding cleaning ash
with an air nozzle.
1. Remove the exterior of the thermal wrap by disconnecting the
eight springs.
2. Before removing the DPF filter (marked by number 4) note the
sequentially numbered flow directional arrows on the SEF Muffler
outer body of each component. You will be installing the DPF
filter in the same position.
3. Loosen the two v-band clamps on the inlet and outlet side of the
DPF filter and remove the filter.
4. Clean the filter using the appropriate filter cleaning equipment.
(Donaldson DPF Pulse Cleaner is the preferred method).
5. Reinstall the filter in the same direction/position it was removed
using the sequential flow direction arrows as a guide.
6. Place the filter between the heater and outlet assembly.
7. Reset the backpressure monitor light using directions supplied in
backpressure monitor (EDM) document no. P484891.
Record Filter Service
Regulatory agencies require that you maintain the following
filter service and cleaning records:
• Date of installation
• Vehicle mileage at the time of installation
• SEF Kit Number
• DECS Serial number
• Date of filter cleaning
• Mileage at each filter cleaning
• Weight of DPF Section before and after cleaning. Use a precision
scale that detects small weight changes.
• Backpressure (restriction) test readings of DPF Section from pulse
cleaner before and after cleaning