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Diesel Particulate
Filter (DPF)
Installation Manual for
Model PG1060
(CARB Verified DPF)
30-G63-99 Rev. A
CONTENTS
Warranty Information................................................................................ ii
Pre-Installation Compatibility Assessment................................................. III
SAFETY ................................................................................................ 1
Safety Considerations.............................................................................. 1
INSTALLATION ..................................................................................... 3
Check kit to ensure you have all the parts................................................. 3
Tools Required........................................................................................ 4
Step 1 Preparing APU .............................................................................. 4
Step 2 Removing Existing Exhaust System ................................................ 5
Step 3 Installing the Header Pipe ............................................................. 6
Step 4 Installing Flex Pipe ....................................................................... 7
Step 5 Installing Pressure Sensor and Tube ............................................. 8
Step 6 Installing DPF Bracket .................................................................. 9
Step 7 Change Breaker ......................................................................... 10
Step 8 Installing the DPF Controller Harness .......................................... 12
Step 9 Installing the CAN Harness ......................................................... 14
Step 10 Completing the Install .............................................................. 15
Step 11 Installing the DCP3 .................................................................. 16
Step 12 System Startup ....................................................................... 17
Step 13 Place the Truck and APU Decals ............................................... 18
Step 14 Replace Access Cover .............................................................. 18
APPENDIX ........................................................................................ 19
Wiring Diagram...................................................................................... 19
Refer to www.impco.ws/apu-pub-truck.asp to ensure that you are working
with the most recent Installation Manual version.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
i
Warranty Information
THE COMFORTPRO APU AND DPF MUST BE REGISTERED
SEPARATELY ON THE IMPCO APU DEALERLINK;
https://dealerlink.gficontrolsystems.com.
FAILURE TO REGISTER BOTH THE APU AND DPF MAY
VOID THE CUSTOMER’S WARRANTY.
• Claims Filing
All warranty claims for DPF models and APU units containing DPF must be filed
through IMPCO APU Dealerlink https://dealerlink.gficontrolsystems.com.
In order to file a warranty claim unit must be registered first (also through
IMPCO APU Dealerlink).
• Warranty Coverage
Basic APU Unit
24/4000 (Months/Hours)
DPF Unit and DCP3 36/1600 (Months/Hours)
• Warranty Policy and Labor Allowance
As per Warranty Policy, Procedures & Labor Allowance Manual (30-870-21),
published at IMPCO APU Dealerlink.
ii
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
Pre-Installation Compatibility Assessment
1. Confirm that the Engine Family name listed on the APU engine Emission
Control Label matches one of the following:
Model
Year
Engine
Family
Displacement
(L)
Model
Engine
2005
5KBXL.719KCB
0.479
Z482-ES
2006
6KBXL.719KCB
0.479
Z482-ES
6KBXL.719KCC
0.479
Z482-D2-ES
7KBXL.719KCB
0.479
Z482-D2-ES
7KBXL.719KCC
0.479
Z482-D2-ES
2008
8KBXL.719KCC
0.479
Z482-D2-ET
2009
9KBXL.719KCC
0.479
Z482-D2-ET
2010
AKBXL.719KCB
0.479
Z482-ET
AKBXL.719KCC
0.479
Z482-ET
AKBXL.719NCB
0.479
Z482-D2-ET
BKBXL.719KCB
0.479
Z482-ET
BKBXL.719KCC
0.479
Z482-ET
BKBXL.719NCB
0.479
Z482-D2-ET
CKBXL.719KCB
0.479
Z482-ET
CKBXL.719KCC
0.479
Z482-ET
CKBXL.719NCB
0.479
Z482-D2-ET
2013
DKBXL.719KCC
0.479
Z482-D2-EF
2014
EKBXL.719KCC
0.479
Z482-D2-EF
2015+
Refer to the most recent version of the Clearsky
Diesel Particulate Filter Installation Manual
(www.impco.ws/apu-pub-truck.asp)
2007
2011
2012
If the engine family name is not identified above, stop immediately.
The engine is disqualified for CLEARSKY DPF installation.
2. Confirm that APU oil consumption does not exceed 1 quart per 250 hours
of APU operation. If it is in excess of this amount, stop immediately.
The engine is disqualified for use with the CLEARSKY DPF.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
iii
iv
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
SAFETY
Read these instructions carefully before operating the system.
Safety alerts labeled DANGER, WARNING and CAUTION alert you to special
instructions or precautions concerning procedures that would be hazardous
if performed incorrectly or carelessly.
The safety alerts alone cannot eliminate all hazards. Strict compliance with
these special instructions and common sense are major accident
prevention measures.
DANGER
CAUTION
Immediate hazards that will result
in severe injury or death.
Hazards or unsafe practices that
could result in minor injury or
product or property damage.
WARNING
NOTICE
Hazards or unsafe practices that
could result in severe personal
injury or death.
Information that is important to
proper installation or maintenance,
but is not hazard-related.
Safety Considerations
WARNING
HOT EXHAUST (PIPE AND GAS).
During filter regeneration, the
exhaust gas coming out of the tailpipe can exceed 1100°F (600°C). They
should not be directed onto materials that can melt and should not be near
wiring, brake lines or other sensitive items.
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.
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.
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.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
1
2
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
INSTALLATION
Check kit to ensure you have all of the parts
NOTICE
The DPF requires the use of a DCP3
or later.
NOTICE
To maintain warranty coverage and
comply with CARB regulations the DPF
system must be installed by qualified
personnel.
10
1 DPF Assembly x 1
(includes system decal)
2 DPF Controller x 1
3 Pressure Tube x 1
4 Pressure Sensor Assy. x 1
5 Header 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 Operator's Manual x 1
11 Warranty Information Card x 1
12 Truck Decal x 1
Small Parts Kit x 1 containing:
13 5ml Package of Dielectric Grease x 1
14 Oil Change Tag x 1
15 Header Gasket x 1
16 DCP CAN Adapter 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 Cable Ties x 30
22 P Clamp, Double x 1
23 Breaker, 35A x 1
11
7
3
2
6
9
17
4
1
12
8
15
20
19
5
14
18
22
23
21
16
Figure 1. System components.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
13
PG1060 is retrofittable to PC series; PC6021, PC6021-SP, PC6022, PC6022-SP, PC6024,
and PC6028.
3
Tools Required
Step 1
Torque Wrench 5-30 ft-lb
1/8" Allen Key
Torque Wrench 5–50 in-lbs
13 mm Socket
9/16” Flex-Head Ratchet Wrench
12 mm Socket
1/2” Flex-Head Ratchet Wrench
1/2” Socket
7/16” Flex-Head Ratchet Wrench
7/16” Socket
12 mm Ratchet Wrench
9/16” Socket
3", 6", 9" Ratchet Extension
Cutter for cable ties
Preparing APU
• Disconnect APU positive and negative terminals at the batteries.
• Remove Top and Bottom Enclosures from APU (figure 2).
• Disconnect J1 and J2 connectors from APU Controller (figure 3).
Figure 2. APU.
Figure 3. APU controller.
4
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
Step 2
Remove Existing Exhaust System
• Remove and discard header and flex pipes. Keep all hardware (figure 4).
• Remove and discard Tail Pipe.
• Remove and discard Muffler (Keep the 5/16” stainless hardware shown
in figure 6, item 1).
Figure 4. APU header & flex pipes.
1
1
Figure 5.
Figure 6. APU muffler & stainless hardware.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
5
Step 3
Installing the Header Pipe
• Install new header gasket.
• Install circumferential clamp on flex-pipe.
• Install the header pipe.
• Tighten exhaust manifold nuts to 13–15 ft-lb.
CAUTION
Be careful to not damage the insulation on the pipe.
Figure 7. Header pipe.
1
Figure 8. Flex-pipe clamp.
6
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
Step 4
Installing Flex Pipe
• Install flex-pipe sliding it through the hole in the frame and then into the
header pipe (Refer to figure 9).
CAUTION
Be careful to not damage the
insulation on the pipe.
• Push up on the flex-pipe and ensure the header pipe is fully engaged into
the flex-pipe. The slots must be fully blocked by the header pipe as shown
in figure 8, item 1.
• Push clamp up against stops and tighten to 8–9 ft-lb.
• Install the engine mount exhaust clamp (figure 10, item 2) but DO NOT
tighten.
• Tighten circumferential clamp to 8–9 ft-lb. The clamp must be at the end of the
flex pipe, the slots must be visible below the clamp. (Refer to figure 8, item 1.)
Figure 9. Flex pipe, radiator removed for clarity. .
2
7
Figure 10. Engine mount exhaust clamp.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
7
Step 5
Installing the Pressure Sensor Tube
• Install pressure tube by fishing it in from the top. (Refer to figure 11, figure 12,
item 1 and figure 13, item 2.)
• Align tube so it does not rub on APU frame or other parts.
• Tighten lower fitting to 22–28 ft-lb.
• Install pressure sensor assembly (figure 14, item 3) to the top of the pressure
tube and tighten to 22–28 ft-lb.
• Install P-clamp (figure 14, item 4) to the pressure sensor assembly and secure.
TOP
(VERTICAL)
1
BOTTOM
(ANGLED)
Figure 11. Pressure tube orientation.
Figure 12. Pressure tube.
3
4
2
Figure 13. Pressure tube.
8
Figure 14. Pressure sensor & P-clamp.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
Step 6
Installing DPF Bracket
• Remove lower radiator mount fasteners (figure 15, item 1).
• Remove cover from DPF assembly.
• Install DPF bracket onto the frame using the (4) holes from the muffler and
radiator bracket (figure 16).
• Snug all (4) bolts before tightening to a final torque of 16–20 ft-lb.
1
1
Figure 15. Radiator mount fasteners.
Figure 16. DPF installed onto frame.
1
Figure 17. Clamp positioning.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
9
Step 7
Change Breaker
• Disconnect the 2 wires from the generator breaker noting the position of,
each wire. Wiring to CCU (figure 18, item 1). Wiring from generator (figure 18,
item 2).
• Remove the existing breaker and replace with the breaker included in the kit.
Tighten mounting screws 8 – 10 in-lbs.
• Reconnect the wires. Do not tighten at this point.
1
2
Figure 18. Beaker wiring.
Figure 19.
• Remove the 2 P-clamps holding the teck cable and fuel lines to the APU
frame. Figure 19.
• Remove the 2 bolts retaining the fuel filter bracket. Figure 20, items 1 and 2.
• Remove the 2 P-clamps holding the teck cable and fuel lines to the fuel
filter bracket.
• Install the DPF controller bracket to the fuel filter bracket.
• Reinstall the fuel line and teck cable P-clamps to the fuel filter bracket.
10
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
1
2
Figure 20. Remove fuel filter bracket.
• Reinstall the P-clamp holding the generator harness back to the rearward
filter bracket mounting bolt. Figure 21, item 1.
• Reinstall the fuel filter bracket to the APU frame.
• Reinstall the fuel line and teck cable P-clamps to the APU frame.
• Remove the generator capacitor P-clamp.
• Install a P-clamp that was removed from the teck cable (figure 22, item 2) to
retain the DPF controller harness using the bolt retaining the generator capcitor.
• Tie up DPF controller harness & 14 pin DPF controller harness together as
shown in figure 22, item 1.
1
1
2
Figure 21.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
Figure 22.
11
Step 8
Installing the DPF Controller Harness
• Locate the ground at the fuel filter bracket, remove the bolt. Apply dielectric
grease and install with the DPF harness ground (figure 23, item 1). Tighten
to 16–20 ft-lb.
2
1
Figure 23. Main PF Ground and Power Connections.
• Apply dielectric grease and connect the DPF Harness power (figure 23, item 2)
to the generator side of the generator breaker. Tighten the terminal nut to
14–16 in-lbs.
• Connect the 14 pin DPF controller harness to the DPF Controller
• Route the DPF heater harness (figure 24, item 1) and temperature sensor
harness (figure 24).
1
Figure 24. Heater harness.
12
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
1 – APU 12VDC Harness
1
2 – Teck Cable
2
3 – DPF Heater Harness
4 – Temperature Sensor Harness
6
5 – Fuel Lines
3
5
4
Figure 25.
• Connect the DPF heater harness (figure 25, item 3) and temperature sensor
harness (figure 25, item 4).
• P-clamp the harnesses as shown in figure 25. Use supplied double P-clamp
for DPF heater & Teck cables (figure 25, item 6).
• Route the controller harness across the backside of the engine to the APU starter.
• Connect the positive lead of the DPF controller harness (figure 26, item 1) to
the starter main terminal. Tie up as shown in figure 26.
1
2
Figure 26.
• Connect the DPF Controller harness ground (figure 26, item 2) to the main
engine ground near the starter.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
13
• Continue routing the DPF controller harness along the main engine harness.
• Note new position of relay (figure 27, item 3) that was removed from PEM
stud (figure 27, item 4).
2
2
4
2
2
3
1
2
2
2
2
Figure 27. Tie strap locations, Item 2.
Step 9
Installing the CAN Harness
• Route the CAN Harness (figure 27, item 1) into the APU and connect to the
DPF Controller Harness.
• Following the existing harness to route the other end of the harness into
the CCU.
• From the CCU, route the CAN harness along the CAT5 cable to the DCP.
14
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
Step 10
Completing the Install
• Install the DPF cover and tighten fasteners to 7–9 ft-lb (figure 29).
• Reconnect APU controller J1 and J2 connectors.
• Reinstall APU Enclosures.
• Tighten enclosure fasteners to 10–12 ft-lb.
• Install tail pipe to DPF outlet and exhaust bracket. Ensure tailpipe is fully
inserted into the DPF outlet, the slots must be fully blocked. Refer to
figure 28 item 1.
• Adjust DPF outlet clamp position so that the slots are visible behind the
clamp, it should be as far out as possible (on the end of the DPF outlet) as
shown in figure 30, item 2. Tighten tail pipe to DPF clamp to 8–10 ft-lb.
• Tighten tailpipe bracket clamp to 17–20 ft-lb.
• Reconnect positive and negative APU battery cable terminals.
1
Figure 28. Tail pipe fastening.
Figure 29. DPF cover.
2
Figure 30. Tail pipe fastening.
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
Figure 31. Tail pipe.
15
Step 11
Installing the DCP3
• Connect the DCP3 CAN adapter harness to the DCP3 panel (refer to
figure 32, item 1).
• Install the temperature sensor, figure 32, item 3.
• Connect the CAT5 cable to the DCP3. Figure 32, item 2.
• Connect to the CAN harness to the CAN adapter harness, figure 32, item 5.
• Install cable tie as shown in figure 32, item 4.
• Install DCP3 into the display box with the four screws.
4
1
2
3
5
Figure 32. Connecting the DCP3.
16
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
Step 12
System Startup
• When all cables are connected the DCP3 should show “DPF Detected”.
If not, see Troubleshooting section.
• Start APU and allow it to run without load for 5 minutes.
• Check DPF variables:
– Start at home screen (where date and time are displayed), press
ESC/RESET if needed
– Press MENU
– Use arrows to find “DPF Manager”
– Press MENU
– Use arrows to find “Variables”
– Press MENU
– Look for values
Exhaust P = 5–20mB,
Exhaust T = 70–130°C
– If values are not in these ranges then check connections to sensors.
• Start a filter regeneration cycle:
– Start at home screen (where date and time are displayed), press
ESC/RESET if needed
– Press MENU
– Use arrows to find “DPF Manager”
– Press MENU
– Use arrows to find “Start Regen”
– Press MENU
– APU will slow down as DPF system draws power from the generator for
the exhaust heater
– Check DPF variables as above, within 5 minutes the Exhaust T should
be more than 500°C and the Exhaust P should be higher than the
reading before starting the regen.
• Press APU ON/OFF, the APU will shut down after the regen is complete
(just a few minutes).
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
17
Step 13
NOTICE
The same regulations that require the
DPF also require that these decals
be placed on the outside of the truck
and the valve cover.
NOTICE
Once the decals are installed they
can not be removed without being
damaged. The decals have the same
serial number as the DPF system
and new decals can not be issued.
Place the Truck and APU Decals
• Location of Truck Decal:
The label must be placed on the driver side within one foot of the top and
front edges of the hood. If this is not practical, place the label as close to
this area as practical but it must be easily visible (figure 33).
• Installation of Truck Decal:
Make sure the area is clean and dry and greater than 50°F. Work from one
edge of the label. Peel the backer off 1–2 inches and position the label using
just the edge and light pressure. Align the label carefully and then gradually
peel the backer and press the label being careful to not trap air bubbles.
NOTICE
If a truck is operating an APU in
California, the APU must have a DPF
AND the truck must display these
decals. It is illegal for a truck to
display these decals with an APU
that is not so equipped.
Figure 33. Truck decal placement.
• Installation of Engine Decal:
Select a place on the valve cover that will be visible with only the APU access
cover removed (but with the top enclosure installed on the APU). The valve
cover should be between 50°F and 120°F. Clean the area with alcohol. After
the alcohol has dried, apply the label with firm pressure (figure 34).
• Installation of DPF Oil Type Tag:
Secure the DPF Oil Type Tag onto the engine fuel lines using the 3 wire ties
provided. Refer to figure 35 for visual location of the tag. DO NOT over tighten
the wire ties as this could damage the tag.
Figure 34. APU decal location.
Step 14
18
Figure 35. Position of Oil Type Tag.
Replace Access Cover
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
2
1
2
1
BLK - INPUT (120 VAC)
BLU - OUTPUT H2 (120 VAC)
Figure 36. Wiring Diagram.
30-648-01A
3
3
DPF CONTROLLER
4
4
RED - OUTPUT H1 (120 VAC)
GENERATOR
1
2
3
4
5
6
7
8
9
10
11
12
BREAKER
35 AMP
1
2
3
4
5
6
7
8
9
10
11
12
COMMON
H1 (RED)
4 OHM
1
BRN - RTD
BLK - GROUND (-)
PLUG
PLUG
YEL - INPUT BP SENSOR
PUR - OUTPUT (5 VDC+)
BLK
2
ORN - RTD
BLU - BP SENSOR GROUND (-)
BLK - CAN BUS (LOW)
WHT - CAN BUS (HI)
RED - INPUT (12 VDC+)
H2 (BLU)
8 OHM
EXHAUST HEATER
POWER (120VAC)
GROUND
NEUTRAL
APU
CONNECTOR VENT
2
A
C
BACK PRESSURE SENSOR
EXHAUST TEMP SENSOR
2
APU STARTER
INTERNAL GRND
SOLENOID
CAN CONNECTOR
1
1
RED
BLK
TEMP
SENSOR
WHT
BLK
1
WHT
123
DRIVER
CONTROL
PANEL
(DCP)
2
CAN
CONNECTOR
BLK
2
GROUND
COMM TO APU: GLOW RUN 2.5V / CRANKING 3 .5V
COMM FROM CCU
COMM TO CCU
COMM TO CCU
COMM FROM APU: GLOW RUN 5V / FAULT 1.5V
INPUT (12 VDC +)
GROUND
VEHICLE SLEEPER
APPENDIX
19
20
CLEARSKY DPF (PG1060) INSTALLATION MANUAL
100 Hollinger Crescent
Kitchener, Ontario
Canada N2K 2Z3
Tel: 1-800-667-4275
Fax: 1-519-742-0287
www.impcotechnologies.com
Designed and Manufactured
in North America
© 2014 IMPCO Technologies Canada Inc.
07-14
PID# 30-G63-99A