NEFF B46C74.0GB User manual

INSTALLATION MANUAL FOR
CLEARSKY DIESEL PARTICULATE FILTER
(CARB VERIFIED DPF)
MODEL PG1050
MODEL PG1060
®
®
62-11478 REV. B
®

CONTENTS
SAFETY ......................................................................................... 1
Safety Consi erations ...................................................................... 1
INSTALLATION.............................................................................. 1
Check kit to ensure you have all the parts ......................................... 2
Tools Require ................................................................................ 3
Step 1 Changing Oil ......................................................................... 3
Step 2 Preparing APU ....................................................................... 3
Step 3 Removing Existing Exhaust System......................................... 4
Step 4 Removing Capacitor Bracket .................................................. 5
Step 5 Installing DPF Capacitor Bracket............................................. 6
Step 6 Installing DPF Bracket............................................................ 7
Step 7 Installing Flex Pipe ................................................................ 8
Step 8 Installing Pressure Sensor an Tube....................................... 9
Step 9 Installing the DPF Controller Harness.................................... 10
Step 10 Installing DPF Controller..................................................... 12
Step 11 Installing the Hea er Pipe .................................................. 16
Step 12 Installing the CAN Control Harness ..................................... 17
Step 13 Installing the DCP3 ........................................................... 18
Step 14 Completing the Install........................................................ 19
Step 15 Controller Software Up ate ................................................ 20
Step 16 System Startup ................................................................. 22
Step 17 Place the Truck an APU Decals ......................................... 23
Step 18 Replace Access Cover ....................................................... 23
APPENDIX ................................................................................. 25
Wiring Diagram .............................................................................. 27

SAFETY
Rea these instructions carefully before operating the system.
Safety alerts labele DANGER,WARNING an CAUTION alert you to special
instructions or precautions concerning proce ures that woul be hazar ous
if performe incorrectly or carelessly.
The safety alerts alone cannot eliminate all hazar s. Strict compliance with
these special instructions an common sense are major acci ent
prevention measures.
DANGER
Immediate hazards that will result
in severe injury or death.
WARNING
Hazards or unsafe practices that
could result in severe personal
injury or death.
NOTICE
Information that is important to
proper installation or maintenance,
but is not hazar -relate .
CAUTION
Hazards or unsafe practices that
could result in minor injury or
product or property damage.
1
CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Safety Consi erations
WARNING
HOT EXHAUST (PIPE AND GAS). During filter regeneration the
exhaust gas coming out of the tailpipe can exceed 700 F (370 C) and
should not be directed onto materials that can melt or burn. The tailpipe,
where it exits the DPF, can reach 1100 F (600 C) and should not be near
wiring, brake lines or other sensitive items.
WARNING
AC HIGH VOLTAGE. The DPF uses 120VAC from the APU's onboard
generator. This voltage is a shock hazard and wiring should be performed
only by trained personnel.
WARNING
HOT DPF. Just as with a standard muffler, the DPF enclosure can reach
400 F (200 C) during filter regeneration and can cause burns if touched.
NOTICE
DISCONNECT APU FROM BATTERY TO WORK ON IT.
The APU is equipped with a Multi-Function control panel which can start the
APU automatically. Also, the installation of the DPF requires making electrical
connections to the battery wiring in the APU enclosure – a misplaced wrench
can become welded and cause batteries to explode. To prevent both hazards,
disconnect the APU negative and positive battery terminals from the truck
batteries before installing the DPF or working on the APU. As there are often
several connections to the batteries, ensure that there is no battery power at
the APU by checking the voltage at the main starter or alternator terminals.

Check kit to ensure you have all of the parts
2CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Figure 1. System components.
INSTALLATION
NOTICE
To maintain warranty coverage and
comply with CARB regulations the DPF
system must be installed by trained
personnel.
1 DPF Assembly x 1
(inclu es system ecal)
2 DPF Controller x 1
3 Pressure Tube x 1
4 Pressure Sensor Assy. x 1
5 Hea er Pipe x 1
6 Flex Pipe x 1
7 Tail Pipe x 1
8 DPF Main Harness x 1
9 35ft CAN Harness x 1
10 Owner/User Manual
11 Warranty Car
12 Truck Decal
3
4
10
11
2
1
20
25
19
13
22
26
24
23 21
17
14
9
7
85
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 DCP and DCP3 controllers, look on the front face, top left corner,
of the controller. There will be a 'DCP3' logo on the DCP3 controller and there will be none on
the DCP controller.
Small Parts Kit x 1 containing:
13 5ml Package of Dielectric Grease x 1
14 Oil Change Tag x 1
15 Hea er Gasket x 1
16 DCP CAN A apter Harness x 1
17 Engine Label S/N x 1
18 1.5” Circumferential Exhaust Clamps x 2
19 1.5” Stainless Steel Exhaust Clamp x 1
20 1.5” Steel Exhaust Clamp x 1
21 Capacitor Bracket x 1
22 Cable Ties x 30
23 P Clamp x 1
24 Flat Washers x 2
25 DCP3* x 1
26 Nuts x 2

Tools Required
Preparing APU
• Disconnect APU positive an negative terminals at the batteries.
• Remove Top an Bottom Enclosures from APU (figure 2).
• Disconnect J1 an J2 connectors from APU Controller (figure 3).
Torque Wrench 5-30 ft-lb
Torque Wrench 5–50 in-lbs
9/16” Flex-Hea Ratchet Wrench
1/2” Flex-Hea Ratchet Wrench
7/16” Flex-Hea Ratchet Wrench
12 mm Ratchet Wrench
3", 6", 9" Ratchet Extension
1/8" Allen Key
13 mm Socket
12 mm Socket
1/2” Socket
7/16” Socket
9/16” Socket
Cutter for cable ties
Programmer for APU Controller
3
CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Figure 2. APU.
Figure 3. APU controller.
Step 2
Changing Oil
• Change oil to SAE CJ-4 type.
Step 1

4CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Remove Existing Exhaust System
• Remove an iscar hea er an flex pipes. Keep all har ware (figure 4).
• Remove an iscar Tail Pipe.
•Remove an iscar Muffler (Keep the 5/16” stainless har ware shown
in figure 5, item 1).
Figure . APU header & flex pipes.
Step 3
Figure 5. APU muffler & stainless hardware.
11

5
CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Removing Capacitor Bracket
• Remove Breaker from bracket.
• Remove the capacitor clamp for later use.
•Cut 3 cable ties (figure 6 an figure7).
• Remove Teck cable p-clamp.
• Remove capacitor bracket.
• Disconnect Teck cable Neutral (white) an Groun (copper) wires from
generator chassis.
Figure 6. Cable tie location.
Step 4
Figure 7. Cable tie locations.

6CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Installing DPF Capacitor Bracket
• Install the new capacitor bracket reusing the 5/16” har ware.
• Locate the groun strap wire (figure 8, item 1), it is the one which goes to
the engine block. Remove from present bolt, apply ielectric grease to the
terminal an move to new location near capacitor as shown in figure 8,
item 2. A flat washer to protect ring terminal. Leave the generator
Neutral wire at the original location.
• Install Capacitor (figure 9, item 3) reusing the gear clamp.
Capacitor shoul be sli towar s the oil pan an have 1/16” clearance to
the bracket (refer to figure 9, item 4).
Torque clamp to 18–22 in-lb.
• Install Teck cable as shown an torque fastener to 16–20 ft-lb.
• Route the white an copper groun wires (figure 9, item 5) through new
1/4” p-clamp (figure 9, item 6). DO NOT connect yet.
• Torque fasteners to 16–20 ft-lb, leave Neutral bolt loose.
• More work will be one at the generator later.
Figure 8. Capacitor ground strap.
Step 5
Figure 9. Capacitor.
23
4
5
1
6
NOTICE
Breaker installation detailed in Step 10.

Figure 10. Radiator mount fasteners.
7
CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Installing DPF Bracket
• Remove lower ra iator mount fasteners (figure 10, item 1).
• Remove cover from DPF assembly.
• Install DPF bracket onto the frame using the (4) holes from the muffler an
ra iator bracket (figure 11).
• Snug all (4) bolts before tightening to a final torque of 16–20 ft-lb.
Step 6
1
Figure 11. DPF installed onto frame.
1

8CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Figure 13. Clamp positioning.
Installing Flex Pipe
• Install flex-pipe sli ing it through the hole in the frame an then into the
DPF inlet (refer to figure 12).
• Ensure the tube is fully inserte , it must completely block the slots.
• Push clamp up against stops (refer to figure 13, item 1) an tighten to 8–9 ft-lb .
• Install the engine mount exhaust clamp (figure 14, item 2) but DO NOT tighten.
Step 7
1
Figure 1 . Engine mount exhaust clamp.
Figure 12. Flex pipe.
2
CAUTION
Be careful to not damage the insulation on the pipe.

9
CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Installing Pressure Sensor and Tube
• Install pressure tube by fishing it in from the top. (Refer to figure 16, item 1
an figure 17, item 2.)
• Align tube so it oes not rub on APU frame or other parts.
•Tighten lower fitting to 22–28 ft-lb.
• Install Pressure Sensor assembly (figure 18, item 3) to the top of the
pressure tube an tighten to 22–28 ft-lb.
• Remove the plastic fastening connector clip (figure 18, item 4) from APU
frame an bolt the p-clamp into this hole as shown in figure 19. Tighten
to 8–10 ft-lb.
Step 8
Figure 16. Pressure tube.
Figure 15. Pressure tube orientation.
Figure 18. Pressure sensor. Figure 19. Pressure sensor.
1
TOP
(VERTICAL)
BOTTOM
(ANGLED)
Figure 17. Pressure tube.
2
4
3

10 CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Figure 21. Wire ties. Figure 22. Wire ties.
Installing the DPF Controller Harness
• Tie wrap the harness to the Teck cable with 11” of harness measure from
the Teck cable P-clamp to the 12 pin connector (refer to figure 20).
• Route the harness besi e the Teck cable for 4” then route along the 12v
APU power cables until you reach the re an black DPF Controller power
wires. Tie up as shown in figure 21, 22 an 23
.
Step 9
Figure 23. Wire ties.
Figure 20. DPF harness length.

11
CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Figure 2 . Main ground connection.
Figure 26. Wire ties.
Figure 25. Starter terminal.
• A ielectric grease to the black terminal (item 1) an attach to the main
groun as shown in figure 24. San wich the terminal in the mi le of the
stack. Tighten to 16–20 ft-lb.
• A ielectric grease to the re terminal an then attach to the starter
terminal in between the main battery power an alternator terminals. (Refer
to figure 25.) Tighten to 6-8 ft-lb.
• Continue routing harness along existing harnesses using cable ties as
shown in figure 26.
1

12 CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
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.
- Remove the boot from the wire an trim the boot entry point as shown in
figure 27.
- A ielectric grease to the power wire from the controller an place both
wires through the boot an onto the breaker terminal as per figure 28.
- Tighten terminal nut to 14–16 in-lb.
- Install breaker onto bracket as shown in figure 29 an tighten mounting
screws to 8–10 in-lb.
Step 10
Figure 29. Breaker installed on bracket.
Figure 27. Boot. Figure 28. Breaker terminal.

13
CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
Figure 30. Generator connection.
Figure 31. DPF controller.
• Route controller neutral wires behin the capacitor towar s the generator
neutral.
• A ielectric grease to the DPF controller neutral terminals an attach to
generator neutral.
• A ielectric grease to the Teck cable Neutral (white) an Groun (copper)
(figure 30, item 1) wires an a to the generator neutral bolt.
• Tighten generator neutral bolt to 16–20 ft-lb.
• Tie wrap the neutrals as shown in figure 27, item 2.
• Plug 12 pin connector of harness into DPF controller. It can be helpful to
put the DPF controller on a box or other prop. (Refer to figure 31.)
1
2

14 CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
• Remove the fuel filter nuts (figure 32, item 1) an Wire P-clamp nuts (item 2),
remove P-clamps from stu s
• Install the DPF controller on the P-clamp stu s an fuel filter bolts
• Replace the fuel filter nuts an tighten to 25–30 ft-lb
• Rearrange fuel an electric lines as shown in figure 34: Teck cable above
top stu , battery lines above lower stu , fuel lines below lower stu .
Tighten the P-clamp nuts 45–50 in-lb
• Connect the Temperature sensor. Connect the power connector to the DPF
heater. Route both cables between Teck an battery lines an tie as shown
in figure 34, item 3.
• Tie wrap main harness to controller clip as shown in figure 33, item 4.
Figure 32. Fuel filter and p-clamp attachments, original routing of cables and fuel lines.
Figure 3 . Final routing of cables and fuel lines.
Figure 33. Controller tie wrap clip.
1
4
2
3

CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL 15
• Tie wrap the neutral harness, DPF controller harness, an the DPF Controller
Power as shown in figure 35.
Figure 35. Wire ties.

CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
16
Figure 36. Header pipe.
Installing the Header Pipe
• Install new hea er gasket.
• Install circumferential clamp on flex-pipe.
• Install the hea er pipe.
• Tighten exhaust manifol nuts to 13–15 ft-lb.
• Push up on the flex-pipe an ensure the hea er pipe is fully engage into
the flex-pipe. The slots must be fully blocke by the hea er pipe as shown
in figure 37, item 1.
• Tighten circumferential clamp to 8–9 ft-lb. The clamp must be at the en of
the flex pipe, the slots must be visible below the clamp. (Refer to figure 37,
item 1.)
• Tighten the u-clamp to secure the exhaust to the engine mount.
Step 11
Figure 37. Flex-pipe clamp.
CAUTION
Be careful to not damage the
insulation on the pipe.
1

CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL 17
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 an power harnesses
• Route CAN harness along the existing control harnesses to the CCU.
• Once insi e the CCU continue routing the harness along the DCP wiring
to the DCP mounting location.
Step 12
Figure 38. CAN control harness.
1

CLEARSKY DPF (PG 1050 & PG1060) INSTALLATION MANUAL
18
Installing the DCP3
• Remove the existing DCP an iscar .
This only applies to units that have a DCP installed. Units equipped with
a DCP2 or DCP3 DO NOT require a replacement DCP.
• Connect the DCP3 CAN a apter harness to the DCP3 panel (refer to
figure 39, item 1).
• Install the temperature sensor, figure 39, item 3.
• Connect the CAT5 cable to the DCP3. Figure 39, item 2.
• Connect to the CAN harness to the CAN a apter harness, figure 39, item 5.
• Install cable tie as shown in figure 39, item 4.
• Install DCP3 into the isplay box with the four screws.
Step 13
Figure 39. Connecting the DCP3.
1
4
5
3
2
NOTICE
A DCP3 controller is only available with model PG1050. All newer APUs are
equipped with DCP2 or DCP3 already. If the unit is equipped with a DCP2 or
later, model PG1060 is needed.
To distinguish between DCP and DCP3 controllers, look on the front face, top
left corner of the controller. There will be a ‘DCP2’ or later logo on the controller
but none on the original DCP.