RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF/ULETRU Carrier TRU. Manual Operation, Installation and Maintenance

Transcription

1 RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF/ULETRU Carrier TRU Manual Operation, Installation and Maintenance Page 1

2 YOUR RIGHT TO MAINTENANCE INFORMATION The Air Resources Board requires that Rypos Inc. provide detailed maintenance information for the diesel emission 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 Rypos at THE IMPORTANCE OF ENGINE MAINTENANCE Proper engine maintenance is critical for the proper functioning of your diesel emission 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. CAUTION Before beginning this installation, take a few minutes to read the entire instructions. Check that all necessary materials, units, and kits that are listed in the application guide are on hand. Check the website frequently for Rypos product updates and information This manual is the sole property of RYPOS, Inc. (RYPOS) Copying, faxing, ing, altering or in any way reproducing this manual in whole or in part is forbidden without the express written consent of RYPOS. RYPOS reserves the right to change or alter any and all specifications at anytime without prior notification and without incurring any obligation to such changes. The information included in this publication is believed to be accurate at the time of publication; however, no responsibility is taken by RYPOS unless expressly given Page 2

3 TABLE OF CONTENTS Installation Information New CARB Dealer/Installer Requirements 4 Pre-installation requirements and documentation 5 Safety precautions and required tool list 7 Initial checks. 8 Removal of existing parts and installation of new parts... 9 Electrical connections.16 Start up and final checks Maintenance Information Maintenance requirements.. 20 Ash clean out procedure 21 Rypos system checklist...22 Troubleshooting Light bar codes Troubleshooting procedure...24 Wiring diagram..28 Service Parts Service parts list.. 27 Component identification photos..29 Compatible Engine Models.30 Warranty Statements and CARB Registration information Page 3

4 New CARB Dealer/Installer Requirements: Pre-installation compatibility assessment procedures The following checks need to be made PRIOR to installing a DPF/ULETRU filter onto a TRU unit: 1) Inspect the engine for signs of poor maintenance, (oil leaks, oil filter over 1 year old, oil with more than recommended hours on it, dirty air filter, worn belts, etc) 2) Inspect the tailpipe for signs of oil contamination (is the soot oily? Does it look like grease?) 3) The CARB Executive Order requires a check for oil consumption and the condition of the injectors. An easy, functional way to do this is to inspect the exhaust plume for signs of high PM emissions and oil burning. There should be no visible color to the exhaust during steady speed operation. The DPF/ULETRU will not work on an engine that is producing excessive smoke, which is a sign that the engine may have a stuck injection pump plunger, broken injection pump nozzle, or have excessive oil consumption. All repairs to the engine must be made prior to filter installation. In order to prevent excessive PM emissions rates, engine emissions-related maintenance, such as injector replacements, air filter replacements and valve adjustments, should be performed in accordance with OEM required maintenance schedules. Such maintenance is necessary to prevent RYPOS DPF/ULETRU system failure and inefficient fuel consumption. The DPF/ULETRU filter will plug up if the engine is producing visible smoke on a continuous basis. The puffs seen during start up and speed changes are normal. Written statement of Compatibility If the candidate engine is found to be compatible with the Diesel Emission Control Strategy (DECS), the party conducting the pre-installation compatibility assessment must provide the end user with a written statement stating its compatibility based upon the CARB Executive Order (EO) and the DECS manufacturers pre-installation instructions no later than the date of installation. We have created a form on the next page to allow the dealer/installer to document the Pre-installation compatibility assessment. This form must be: 1) Signed and a copy given to the customer/end user of the DPF/ULETRU system 2) Signed copy must be sent to Rypos for warranty registration and filing. Any warranty claims submitted for a system that is not registered with Rypos will be the responsibility of the dealer/installer. The pre-installation compatibility/warranty registration must be on file at Rypos in order to have Rypos warranty coverage. 3) The dealer/installer must keep a copy of the Pre-installation compatibility assessment on file and be able to produce it to CARB upon request. Page 4

5 Pre-Installation Compatibility Assessment and Warranty Registration Form 1) Verify that the engine year and family is listed in the Compatible Engine Models Table 2) Inspect the TRU unit for oil leaks, general maintenance, signs of oil in exhaust, hrs on the oil and oil filter, condition of air filter, color of smoke during steady state operation at both high and low speed) 3) Fill out ALL information below, sign statement, give one copy to the customer and send one copy to Rypos (Warranty coverage for incomplete information will be the responsibility of the installer!) TRU owner s company name and address: Contact name phone: Installer s name: phone: Installation date: TRU readings: Switch on hours Engine hours TRU model name: (Ultra, Ultima, etc.): (CANNOT BE INSTALLED ON MULTI-TEMP) TRU serial number: Date in Service: TRU engine serial number (stamped on block in front of injection pump): Rypos DPF/ULETRU serial number: U Date of Manufacture Current ARB # Valeo Alternator Serial number: Statement of Compatibility: I have inspected the engine for signs of poor maintenance (oil leaks, oil filter over 1 year old, oil with more than recommended hrs on it, dirty air filter, worn belts, etc). I have looked at the exhaust soot for oil content, and I have observed the color of the exhaust both in high and low speed (No color should be visible in steady state operation) and I hereby affirm that the TRU listed above has met ALL of the above compatibility criteria for installation of DPF/ULETRU YES, ALL CRITERIA ACCEPTABLE NO, THERE ARE ISSUES WITH THE UNIT THAT MUST BE ADDRESSED BEFORE A DPF/ULETRU MAY BE INSTALLED (LIST ISSUES ) Statement of Warranty: I hereby warrant that the installation of the Rypos DPF/ULETRU is free from defects in workmanship or materials which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to The warranty period and the extent of the warranty coverage provided by me must be the same as the warranty provided by me are the same as the warranty provided by Rypos, Inc., and the same exclusions must apply SIGNED DATE Page 5

6 Rypos Family Name for Verification: CA/RYP/2011/PM3+/N00/TR/DPF01 Customer Copy OWNERS WARRANTY RESPONSIBILITY As the engine owner, you are responsible for performing the required maintenance described in your owner s manual. Rypos, Inc. recommends that you retain all maintenance records and receipts for maintenance expenses for your vehicle, engine, or equipment, and diesel emission control system. If you do not keep your receipts or fail to perform all scheduled maintenance, Rypos, Inc. may have grounds to deny warranty coverage. You are responsible for presenting your vehicle, equipment, or engine, and diesel emission control system to a Rypos, Inc. dealer as soon as a problem is detected. The warranty repair or replacement should be completed in a reasonable amount of time, not to exceed 30 days. If a replacement is needed, this may be extended to 90 days should a replacement not be available, but must be performed as soon as a replacement becomes available. If you have questions regarding your warranty rights and responsibilities, you should contact Rypos, Inc. at or the California Air Resources Board at 9528 Telstar Avenue, El Monte, California 91731, or (800) , or electronic mail: helpline@arb.ca.gov. Page 6

7 Safety First Safety is paramount for all involved in the installation of the RYPOS DPF/ULETRU. Only work on a TRU that is not hot. If hot or it is running, turn off and allow ample time for it to cool down. Please make sure you have A secure platform and/or method to reach to the top of the TRU. Proper hand, eye, and foot protection at all times. Disconnect both terminals of the battery. Insulate and protect the terminals. RECOMMENDED STANDARD TORQUE VALUES FOR STANDARD FASTENERS Torque Values for clean dry threads Bolt size Thread pitch Torque (ft-lbs) ¼ / HAND TOOLS REQUIRED Electrical/Cordless Drill ~1/8 bit (for pilot holes) Cutting Pliers 3/8 Drill Bit Center Punch Terminal Crimper 5/32, 5/16 Allen wrench Phillips head screwdriver Knife or wire stripper Digital multi-meter 9/16 swivel socket Standard 3/8 drive shallow and deep socket set with 3 and 6 extensions Hammer Air tool w/cutting disk Standard open end/boxed wrench set (ex. ¼ - ¾ ) Offset head Phillips screwdriver (helpful) 9/16 short handle wrench Installation The installation is broken down into the following sections. 1. Initial checks and pre-installation compatibility statement 2. Removal of existing parts and installation of new parts 3. Electrical connections 4. Start up and testing of DPF/ULETRU Page 7

8 Initial Checks Unless otherwise specified, all instructions are given from the front view of the TRU. 1. Complete the pre-installation compatibility checks and fill out the forms above, sign and give copy to customer and send one to Rypos. 2. If the unit has a datalink box mounted on it, it must be removed and either discarded or moved to a different location on the unit before it will be possible to install the Rypos DPF/ULETRU. (The datalink box mounting bracket can be modified and the datalink box can be installed just above the battery on most units) Datalink box must be removed from this position before installing the DPF/ULETRU 3. Compatible Carrier TRU models are: Ultra XT, Ultra XTC, Extra XT, Ultima XTC MULTI-TEMP UNITS ARE NOT COMPATIBLE WITH DPF/ULETRU 4. Carrier units that are NOT supported by this product include: Optima, Phoenix Advantage, Thunderbird, TM900, TM1000, Genesis, and anything else not specifically mentioned above. 5. For the RYPOS DPF/ULETRU to operate properly, the proper alternator, alternator pulley, and wiring must be installed in the TRU. The wiring will be supplied in the installation kit. Part Numbers for Required TRU Charging System Uprade: Rypos Part Number Description Alternator, 105 amp (Carrier PN ) Pulley, 2.62" OD, (Carrier PN ) Alternator hardware kit, (Carrier PN ) The TRU charging system must be upgraded using Rypos-specified parts to ensure that the Rypos DPF/ULETRU system will work properly. Page 8

9 Removal of Existing Parts and Installation of New Parts For safety, disconnect both the positive and negative terminals from the battery(s) and protect the terminals from accidental contact or falling parts. Remove the doors from the unit to allow easier access to all areas of the unit while performing the installation. 1. Remove muffler: Spraying some penetrating oil (WD40 or similar) onto the exhaust joints before starting will help loosen them up and make disassembly much easier. Unbolt the upper and lower muffler clamps and remove the muffler. It may be easier to get at the lower muffler clamp by removing the front grille of the unit 2. Loosen the air inlet hose clamp on the engine and unbolt the entire air filter assembly from the unit. This will make it easier to change the alternator and to add the new mounting bracket with the idler attached. Hose clamps New Old 3. Remove the old alternator and install the new 105 amp alternator along with the new 2 5/8 alternator pulley At the same time, remove the old alternator tension bracket and install the new supplied tension bracket with the integral back side idler (see photo above right). Install the new alternator tensioning bracket using the same 2 mounting bolts that were removed from the old one. Page 9

10 4. On the 2.2L DI engine, the crank pulley will need to be changed to a 6 pulley. The 1.9L engine (Extra XT unit) already has a 6 crank pulley on it, so you do not have to change it. You will need a 46mm, or 1 13/16 wrench or deep socket in order to remove the crank pulley nut. You will also need to use a large screwdriver or crow bar used through the timing hole in the bell housing and wedged into the ring gear in order to keep the crankshaft from rotating when you loosen the crank nut. You will need to remove the mounting hardware for the Carrier micro and slide it back out of the way in order to remove the crank pulley. You may also need to use a pulley puller in order to remove the existing crankshaft pulley (see photo below). After the new 6 pulley is installed, lock the flywheel into position with a large screwdriver or crow bar and tighten the crank pulley nut to at least 100-ft lbs of torque. The micro box will need to be moved back out of the way in order to get at the crankshaft pulley. Note: A pulley puller may be required to remove the existing crankshaft pulley as shown above. Page 10

11 5. Install the alternator along with both the Rypos alternator cable and the Carrier cables onto the back of the alternator and install the supplied belt as shown in the photos below. B+ B- Install the Rypos alternator wires along with the Carrier unit wires onto the back of the 105 amp alternator. You will need a pair of pliers to remove one of the plastic tabs so the wires may be installed onto the posts as shown D+ The belt is wrapped around the alternator pulley and then the back side of the belt goes around the idler pulley as shown. Re-attach the coolant inlet hose with the same Adel clamp that was used on the old alternator tension bracket. NOTE: for units with the Advance Micro - The D+ connector is not used on units that have the Advance Micro, and therefore it is not necessary to install the D+ wire on the alternator. The D+ is still used for units with the Summit (older style) micro. Page 11

12 6. Reinstall Air cleaner assembly with original hardware. 7. Route the alternator cables down to the front of the unit frame and run along with the rest of the wiring to the battery as shown below. Route cable along with other unit wires and secure in place with cable ties. Route cable up toward the battery and power solenoid and leave loose for the moment.. 8. Go to the top of the TRU. Several holes need to be marked and drilled before positioning parts into place. Use the supplied template to mark the holes on the TRU s frame. Lay the template into the bracket all the way to the right as shown. Tape the template into place with masking tape. Center-punch the holes through the template. Drill a small pilot hole first and then finish with a 3/8 drill bit. Debur all holes. Remove the upper cross member as well. Note: place template so that first set of holes is about 6 from corner. Remove the cross member bolts and the cross member itself Page 12

13 9. Mount ECU: The ECU will mount in the left hand corner Remove the upper corner shroud bolt. Position ECU as shown, and reinstall existing bolt to hold the ECU bracket in place. Installation of ECU using existing and new hardware. Removal of existing fan shroud bolt. This is the plastic rib material that must be removed in order to install the ECU mounting bracket If necessary, you will either need to trim the ECU bracket as shown above (preferred), or trim the plastic rib on the shroud so that the ECU bracket can be installed in the correct position. 10. Route wires: Route 4 gauge wires down toward the battery. Using the supplied hardware, install 1 loop-strap type clamp (Adel clamp) to hold wires secure at the top. ECU mounting bolt w/flat and lock washers. Wire routing and additional loop strap. ECU w/external pressure transducer. Page 13

14 11. Install new heat shield: Route the long ECU wire harness and the connector pack along the back of heat shield, and then attach the large connector with 2 of the bolts. Check to see that the solenoid connector is sticking out about 8 from the end of the heat shield. Adjust the wire in the harness to get it to about 6-8 before installing 2 of the ¼ -20 bolts through the Adel clamps to hold the harness to the back of the heat shield. Attached the large plug with 2, screws supplied. Check for approx 6-8 of length beyond the heat shield. After the solenoid plug is attached, install P clip around the harness and tighten the ¼ -20 bolts. 12. Position the heat shield and attach with the center bolt on the upper rail. Make sure holes in the heat shield line up with the new holes in the frame. Adjust the holes with a drill if necessary. 13. Loosely attach the mounting straps and filter mounting brackets to the filter and set into place on the unit as shown below. Start all of the ¼-20 bolts (with flat and lock washers) first, then tighten the brackets into place. Slide the heat shield underneath the frame and hold into position with the center bolt (with flat and lock washer) Long mounting bracket is to the left, and the short one is to the right, near the exhaust inlet. Long mounting bracket Set the filter into place and attach mounting brackets using ¼-20 bolts with flat and lock washers Page 14

15 14. Connect upper wiring: Connect both sets of solenoid wires by attaching the small WeatherPack connectors on each end of the DPF. Connect both sets of larger connector packs on each end of the DPF (large red and black plugs). Make sure all connectors snap into place properly. 15. Install the pressure tubing: Connect the flexible hose from the external pressure transducer to the stainless tube with a cable tie. Route tube under ECU and into the compression fitting on the left side of the DPF. Use the stub handle 9/16 open end wrench to tighten the compression fitting. It may be helpful to reuse the old clamp to better hold the 2 pipes together 16. Install upper exhaust pipe w/doc: Slide the bottom of the exhaust pipe onto the existing TRU flex pipe and position the 2 bolt flange to the DPF flange. Mount the pipe to the DPF with the supplied hardware and gasket. A 9/16 swivel socket with a long extension is very helpful for starting the lower flange bolt. Reinstall the upper U-bolt clamp, leave loose. Use the new U-bolt clamp provided for the pipe to pipe interface. Install finger tight. If the TRU pipe is distorted, it may be helpful to slit the bottom 1/4 or so of the new pipe to help get it started over the TRU pipe. Make sure all connections are finger tight and lined up with no gaps. Adjust position of pipes and DPF if necessary. Tighten all exhaust clamps and the flange. It is a good idea to reuse the old clamp as a secondary clamp on the joint as shown. 17. Tighten the band clamp bolts to secure the DPF to the filter mounting brackets. 18. Install extension pipes with clamps and rain caps. When closed the rain caps should be slightly below the top of the trailer. Cut extensions to accomplish this, if needed. The rain caps should be installed counter weights facing toward the front of the unit. 19. Insure that the position of the flex exhaust pipe is in the same place previous to removal of the original upper pipe (the flex section of the OEM exhaust should be horizontal, not tilted). Tighten U-bolt clamp at the interface of the flex pipe and the new exhaust pipe. Page 15

16 Electrical Connections: Most of the wiring for the DPF/ULETRU is done at the factory. Some simple wiring and connections need to be made here. 1. Run signal: The run harness has a single WeatherPack connection on one end and an intercept MetriPack on the other end. On the front of the engine identify the fuel shut off solenoid. The intercept MetriPack will go in series with the MetriPack on the solenoid. Route the harness toward the battery for now. The WeatherPack connector will plug into the pigtail on the ECU. 2. Indicator lights: The light panel is an indicator of system operation. It should be installed on the outside of the unit in the approximate position of a TRU light bar Mount with self drilling screws. Then route the wire along with the Carrier wires up to the ECU. Cable tie to secure the wire along the way. Plug into ECU connection and loop remaining wire out of the way. TRU unit Proper position of light bar installed next to the TRU unit and mounted to the trailer Trailer Page 16

17 3. Power Solenoid: a. Position the new solenoid bracket assembly to the frame in the location above the battery as shown in the photo below b. Mount the bracket to the TRU frame using the supplied standoff spacers and self drilling screws supplied. Make sure to get the resistor and solenoid ground wires are under the heads of the long self drilling screws supplied (see photo). This is important to insure a good ground. Future brackets may have offset bends in them and will not require the spacers, but the ground wires will still need to be under the screw heads as shown. c. Locate the Rypos run solenoid wire (routed up toward the ECU) and determine the length in order to have enough wire to go over to the power solenoid. This wire is what will activate the Rypos power solenoid when the engine run solenoid is engaged. d. Cut the wire and the protective covering and crimp the small ring terminals on the wire connected to the run solenoid. Install the larger ring terminal on the other end of the wire going up to the ECU. Using the heat shrink tool, heat shrink the connectors to the wires. e. Attach the wire from the run solenoid to the open small post on the power solenoid.(see photo). f. Attach the run solenoid wire with the larger ring terminal to the output side of the power solenoid (see photo). This wire then goes up to the ECU g. Connect the positive Rypos cable from the alternator to the open side of the power solenoid h. Connect the short cable containing the 100 amp fuse to the other side of the solenoid (this should already be connected on the bracket assembly) i. Connect the positive wire from the ECU to the other side of the fuse. Make sure the nuts are tight, and snap the cover back in place. j. Recheck all solenoid nuts to be sure they are tight. Connect the positive wire going to the ECU to the open end of the fuse. Make sure that the nuts are tight. Snap the fuse cover in place. Ground cable attached from terminal to solenoid mounting bolt (ground connection to frame). Short power cable with 100 amp fuse. Should already be attached as shown Rypos run solenoid wire, cut with small ring terminal installed, connected to center post on solenoid. Ground cable attached from resistor (ground connection to frame). Rypos run solenoid wire going to ECU, cut with larger ring terminal installed, connected to output post on solenoid. Positive Rypos alternator cable attached to open post on the solenoid. Page 17

18 THIS PHOTO IS FOR REFERENCE. MAKE SURE TO REINSTALL THE FUSE COVER AND TO SECURE ALL WIRES WITH CABLE TIES. USE THE WIRING DIAGRAM AS A REFERENCE IF NEEDED. Using the supplied cable ties secure all harnesses at this time. Loop any extra wires and secure to the main wires under the large P clip in the upper left hand corner of the unit, making sure they are out of the way of everything else. 4. Use a digital multi-meter to check for any shorts between the positive and negative battery harnesses (ohm out). If a short is found, double check wiring. Do not proceed until all shorts have been fixed. 5. Connect the Carrier harness wire(s) to the positive (+) terminal on the battery 6. Connect the following wires to the negative (-) wires to the battery at this time. a. 4 gauge black wire from the ECU harness b. Negative wire from the alternator harness c. Original wires from TRU harness Wire Routing example for units with compressor discharge line as shown ECU wires fit snugly through the hole in the plate. Wrap one of the extra insulated clips around both wires and hold in place with a cable tie in order to protect the wires from chaffing. Compressor discharge lines: They get very hot! Make sure to keep wires clear of any contact with them. Continue to connect the ECU cable, alternator cable and Carrier unit cable to the negative terminal to help insure a good ground connection. Use extra insulated wire clip to keep wires clear of compressor discharge line and secured from unnecessary motion. Positive cable from Carrier unit is the only cable attached to the positive battery post. Page 18

19 Start-up and Operation of DPF: 1. Disconnect the speed solenoid on the TRU unit so that the initial testing of the unit is conducted at low speed. This will make it easier to hear the solenoid actuate and to be able to hear the engine speed change with the load applied by the alternator during regeneration. 2. Turn on the unit switch to start the TRU engine and verify operation of DPF. The green light on the indicator panel should light up once the engine is running. Green light verified 3. Approximately 40 seconds after start up the DPF will actuate one flow control solenoid and regenerate one filter element. You will be able to hear the solenoid engage, which will shut off exhaust flow to one of the 2 outlet pipes. The filter will then regenerate for the next 3.5 minutes. While the unit is regenerating, check the low speed rpm, it should be at least 1350 rpm during the regeneration, adjust up if necessary. Write in new low speed during regen 4. The engine will pick up a few rpm in speed after the regeneration is completed. Approximately 10 seconds after the speed increases, the solenoid will open and exhaust will flow through both pipes again. Shut the unit off, wait for a few seconds and turn on again. The unit will go through the same sequence as above, only this time with the other solenoid, and the flow will be shut off to the other outlet pipe. This check will make sure both solenoids are working properly. Both solenoids working properly and the system is regenerating as it should 5. If you have any problems, check out the troubleshooting section for assistance. Final Checks: 1. Double check all connections to make sure they are tight, and make sure all wires are safely supported and cable tied to prevent excessive motion during unit operation. 2. Reinstall unit doors, re-connect the speed solenoid, and re-tighten the alternator belt. 3. Once everything is complete, place the labels as shown below. Clean the surface with a damp cloth to remove any dirt and wipe dry. Remove tape covering and place the label into position. Press firmly across the entire label to insure good contact. It is suggested to also rivet or use self drilling screws to secure the RYPOS label firmly onto the unit. RYPOS Serial Number Label 105 Amp Alternator Label 4. Set the automatic defrost timer to 1.5 or 3 hrs as this helps maintain good filter health. Write in new defrost time set during filter installation Page 19

20 5. INSTALLER MUST FILL OUT AND SEND RYPOS THE WARRANTY REGISTRATION FORM OR THE INSTALLER IS RESPONSIBLE FOR ALL COSTS OF ANY CLAIMS FILED AGAINST THE UNIT! MAINTENANCE REQUIREMENTS: Daily or every use: 1) Check the alternator belt tension along with doing all other OEM recommended pre-trip checks a. Re-tension belt if loose, or replace if belt is worn 2) Check indicator light panel to make sure the green light is on and the yellow is off when the TRU is running Quarterly or every 500 hours: 1) Inspect alternator belt, re-tighten if belt is in good condition, replace if belt is showing signs of wear/checking/cracking 2) Conduct complete system checkout per the RYPOS SYSTEM CHECKLIST to insure that your system is operating properly and save a copy for the maintenance records. Annual Maintenance: 1) Inspect alternator belt, re-tighten if belt is in good condition, replace if belt is showing signs of wear/checking/cracking 2) Remove the blue hose from the external pressure transducer and blow air back through it into the filter to make sure the line is clear 3) Conduct complete system checkout per the RYPOS SYSTEM CHECKLIST to insure that your system is operating properly and save a copy for the maintenance records. 4) Check low speed during regeneration and adjust to 1350 rpm or greater 5) Inspect for ash accumulation and follow procedure below if required Non-Rypos Maintenance and Replacement parts suggestions: Belts - Gates belt AX42 will require re-tensioning at 500 hours and replacement at 1000 hours - Goodyear will not require re-tensioning (if tight when installed) but will require replacement at 1000 hours. If this belt becomes loose, replace immediately, do not re-tension - Goodyear AX42 did not last beyond 400 hours use not recommended - Rypos is continuing to test other belts in order to make recommendations to our customers Alternator - Only use the Valeo 105 amp alternator, which can be purchased from Rypos or Carrier. Other alternators have demonstrated shorter operational life and are not recommended. Page 20

21 Ash Cleanout Procedure During the annual maintenance inspection the unit should be checked for ash accumulation. The ash inspection port is located on the right side of the unit (the side near the exhaust inlet pipe). Ash is considered a hazardous waste material and must be collected using a vacuum with a HEPA filter. Follow the ash handling guidelines as prescribed by CARB at 1. The engine should be off before proceeding. 2. Disconnect the positive terminal from the battery to ensure the unit is not operational. 3. Open the ½ NPT port and connect a suitable vacuum cleaner hose. 4. Remove the rain caps from the two exhaust pipes. 5. Close off one of the exhaust ports with a 2 cap or tape. 6. Attach a 2 blower hose to the open exhaust port. 7. Manually open the solenoid valve by moving the plunger away from the body of the unit. 8. Turn on the vacuum and the blower and run for 5 minutes. 9. Repeat the same operation on the other side. 10. Remove all hoses and reattach the rain caps to the exhaust pipes. 11. Put anti-seize on the threads of the NPT port plug and reattach. 12. Reattach the positive terminal of the battery. Page 21

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23 TROUBLESHOOTING LIGHT BAR CODES Lamp Mode System Status Trouble Shooting If Problem Persists Green Solid System ON, Functioning Normally Not Required No action required Green Flashing System ON but low voltage condition. Ensure battery charger or alternator is connected and charging. See troubleshooting chart below Green Off System is inoperable. Check battery and charging system connections and fuses. See troubleshooting chart below. Yellow On Solid System is in overpressure condition. Shut down TRU as soon as possible, and no longer than 4 hours after observing a SOLID YELLLOW light. Check alternator voltage, current and belt tension If lamp remains on call for service. See troubleshooting chart below Yellow Flashing Low pressure condition. Check entire TRU exhaust system for leaks and repair/seal as necessary. See troubleshooting chart below Yellow Off System Operating Normally. No action required. No action required. SERVICE UPDATES Check our website at for maintenance updates and service bulletins. Page 23

24 PROCESS FOR TROUBLESHOOTING RYPOS DPF FIELD ISSUES Start Here Is the engine running? Yes Run the Start up and operation of DPF test in this installation manual Are both solenoids working and is the unit regenerating properly? No No Check battery voltage, over 11V? Yes Check starter circuit and refer to the TRU manual for troubleshooting Yes Go to page 3 and continue troubleshooting No Go to page 2 and check the DPF system lights Charge Battery Check battery voltage, over 11V? Yes Start engine and check alternator output voltage. Is the voltage above 13V? No Change Battery No Check alternator belt tension. Retighten and check voltage again. Yes Replace the Alternator. (Return to Rypos if supplied by Rypos and is still under warranty) No Is the voltage above 13V? Yes System OK FLOWCHART PAGE 1 Page 24

25 PROCESS FOR TROUBLESHOOTING RYPOS DPF FIELD ISSUES FROM PAGE 1 Check the DPF system lights Green LED Solid, flashing, or off? Solid Yellow LED Off Flashing No Power to ECU: check connection at engine run solenoid and connection coming out of ECU System Voltage is low, check alternator output voltage Solid, flashing, or off? Solid Off System back pressure is high: perform off-line regeneration as outlined in Rypos Installation manual Flashing Off System is running fine No Alternator output voltage over 13V? System back pressure is low: check back pressure measurement pipe and hose going to ECU. Also check exhaust system for leaks from engine to DPF Check alternator belt tension, retighten and check voltage again Yes Call Rypos for Service Change Alternator, return to Rypos if it is still under warranty (Only if alternator was supplied by Rypos) No Alternator output voltage over 13V? Yes System should be ok FLOWCHART PAGE 2 Page 25

26 PROCESS FOR TROUBLESHOOTING RYPOS DPF FIELD ISSUES Continuation of troubleshooting from page 1 after completing the start-up test Are both solenoids working properly? No Yes Check all wiring connections and connectors at the solenoid and harness. Loose wires found? No Call Rypos for Service Yes Repair loose connections and run the start-up test again FLOWCHART PAGE 3 Page 26

27 TRU DPF/ULETRU SERVICE PARTS LIST Page 27

28 ULETRU DPF WIRING DIAGRAM External Pressure Transducer Status Panel DPF/ULETRU Installation Manual - Carrier Power Solenoid Attach ground cable to solenoid mounting screw Engine On Sense (+12V) (From Fuel Cutoff Solenoid) +12V Commons Controller Assembly Green LED Amber LED Resistor Blk 100 Amp Fuse (+) (-) 12VDC Battery Inline Disconnect Red Blk (+) (-) 3A Fuse Blk/Red Inline Disconnect Red Blk Blk Blk Blk Inline Disconnect Red Inline Disconnect Inline Disconnect Negative Output Positive Output Filter Assembly Common [Blk]> (+12V) <Hold [Red] (-) <Energize [Wht] (-) 105 Amp Alternator Solenoid Solenoid Chamber 2 Chamber 1 (Exhaust Inlet Side) Page 28

29 Component Identification DPF/ULETRU Hardware Tail Pipe Extensions Rain Caps DPF/ULETRU FILTER Heat shield Exhaust flange gasket ECU assembly with wires and external pressure transducer Exhaust inlet Pipe Band Clamps Operator s Manual Alternator idler assembly Power cut out solenoid Mounting Hardware kit 2 Exhaust Clamps Alternator Harness Run Signal Harness Alternator Belt 6 Crank Pulley Fuse Harness Drill Pattern Template Status Panel and Harness Mounting brackets Page 29

30 Compatible Engine Models Engine Manufacturer Engine Manufacturer's Model Name Engine Model Year Engine Family Kubota 2003 V1903-E 3KBXL01.9FCD Kubota 2003 V2203-DI-E 3KBXL02.2ECD Kubota 2003 V2203-E 3KBXL02.2FCD Kubota 2004 V1903-ES 4KBXL01.9FCD Kubota 2004 V2203-DI-ES 4KBXL02.2ECD Kubota 2004 V2203-ES 4KBXL02.2FCD Kubota 2005 V1903-ES 5KBXL01.9FCD Kubota 2005 V2203-DI-ES 5KBXL02.2ECD Kubota 2005 V2203-M-DI-ES 5KBXL02.2ECD Kubota 2005 V2203-ES 5KBXL02.2FCD Kubota 2006 V1903-ES 6KBXL01.9FCD Kubota 2006 V2203-DI-ES 6KBXL02.2ECD Kubota 2006 V2203-M-DI-ES 6KBXL02.2ECD Kubota 2006 V2203-ES 6KBXL02.2FCD Kubota 2007 V1903-ES 7KBXL01.9FCD Kubota 2007 V2203-DI-ES 7KBXL02.2ECD Kubota 2007 V2203-M-DI-ES 7KBXL02.2ECD Kubota 2007 V2203-ES 7KBXL02.2FCD Kubota 2008 V1903-M-ET 8KBXL01.9FCD Kubota 2008 V2203L-DI-ET 8KBXL02.2RCD Kubota 2009 V1903-M-ET 9KBXL01.9FCD Kubota 2009 V2203L-DI-ET 9KBXL02.2RCD Kubota 2010 V1903-M-ET AKBXL01.9FCD Kubota 2010 V2203L-DI-ET AKBXL02.2RCD Kubota 2011 V1903-M-ET BKBXL01.9FCD Kubota 2011 V2203L-DI-ET BKBXL02.2RCD Page 30

31 Warranty Statement YOUR WARRANTY RIGHTS AND OBLIGATIONS Rypos, Inc. must warrant the diesel emission control system in the application for which it is sold or leased to be free from defects in design, materials, workmanship, or operation of the diesel emission control system which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your diesel emission control system, vehicle or equipment, as specified in the owner s manuals. Where a warrantable condition exists, this warranty also covers the engine from damage caused by the diesel emission control system, subject to the same exclusions for abuse, neglect or improper maintenance of your vehicle or equipment. Please review your owner s manual for other warranty information. Your diesel emission control system may include a core part (e.g., particulate filter, diesel oxidation catalyst, selective catalytic reduction converter) as well as hoses, connectors, a back pressure monitor (if applicable), and other emissionrelated assemblies. Where a warrantable condition exists, Rypos, Inc. will repair or replace your diesel emission control system at no cost to you including diagnosis, parts, and labor. WARRANTY COVERAGE: For a 25 to 50 horsepower engine used in a single temperature Thermo King or Carrier transport refrigeration unit application, the warranty period will be 4 years or 2600 hours, whichever occurs first. If any emission-related part of your diesel emission control system is defective in design, materials, workmanship, or operation of the diesel emission control system thus causing the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to 2706, and 2710, within the warranty period, as defined above, Rypos, Inc. will repair or replace the diesel emission control system, including parts and labor. In addition, Rypos, Inc. will replace or repair the engine components to the condition they were in prior to the failure, including parts and labor, for damage to the engine proximately caused by the verified diesel emission control strategy. This also includes those relevant diagnostic expenses in the case in which a warranty claim is valid. Rypos, Inc. may, at its option, instead pay the fair market value of the engine prior to the time the failure occurs. OWNER S WARRANTY RESPONSIBILITY As the engine owner, you are responsible for performing the required maintenance described in your owner s manual. Rypos, Inc. recommends that you retain all maintenance records and receipts for maintenance expenses for your vehicle, engine, or equipment, and diesel emission control system. If you do not keep your receipts or fail to perform all scheduled maintenance, Rypos, Inc. may have Page 31

32 grounds to deny warranty coverage. You are responsible for presenting your vehicle, equipment, or engine, and diesel emission control system to a Rypos, Inc. dealer as soon as a problem is detected. The warranty repair or replacement should be completed in a reasonable amount of time, not to exceed 30 days. If a replacement is needed, this may be extended to 90 days should a replacement not be available, but must be performed as soon as a replacement becomes available. If you have questions regarding your warranty rights and responsibilities, you should contact Rypos, Inc. at or the California Air Resources Board at 9528 Telstar Avenue, El Monte, California 91731, or (800) , or electronic mail: helpline@arb.ca.gov. THIS WARRANTY IS THE ONLY WARRANTY APPLICABLE TO RYPOS ULETRU SYSTEMS. RYPOS MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. RYPOS SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES EXCEPT AS OTHERWISE PROVIDED HEREIN. DENIAL OF WARRANTY COVERAGE 1. Repairs due to accident, misuse, alteration, misapplication, storage damage, negligence or modification not authorized by Rypos, Inc. are not covered by this warranty. 2. The warranty does not cover repairs under the following conditions, without limitation: a) Failure of the engine owner or operator to heed the Rypos system s warning lamps and take timely action according to the Troubleshooting section of this Manual. b) Failure of the engine owner or operator to maintain the Rypos system according to the maintenance requirements stated in this Manual. c) Failure of the engine owner or operator to maintain the engine according to the engine manufacturer recommended requirements. 3. Except as otherwise provided above paragraph titled WARRANTY COVERAGE, Rypos, Inc. is not responsible for repair of components and/or assemblies which are manufactured or supplied by another manufacturer. Such items may be covered by the manufacturer or supplier. LIMITATION OF DAMAGES The performance of repair or replacement of the Rypos ULETRU system or of TRU engine components is the Owner s exclusive remedy under this warranty. Rypos does not authorize any person to assume or create for it any other obligation or liability in connection with the Rypos ULETRU. Except as expressly warranted in the above paragraph titled WARRANTY COVERAGE, Rypos is not responsible for incidental or consequential costs or expenses which the owner may incur as a result of a malfunction or failure covered by this warranty, including but not limited to loss of profits, loss of time, inconvenience, and other costs and expenses. CARB Identification Number (IDN) Registration After installing the RYPOS DPF/ULETRU system, the TRU owner may apply for a CARB IDN at: Page 32

33 Pre-Installation Compatibility Assessment and Warranty Registration Form 1) Verify that the engine year and family is listed in the Compatible Engine Models Table 2) Inspect the TRU unit for oil leaks, general maintenance, signs of oil in exhaust, hrs on the oil and oil filter, condition of air filter, color of smoke during steady state operation at both high and low speed) 3) Fill out ALL information below, sign statement, give one copy to the customer and send one copy to Rypos (Warranty coverage for incomplete information will be the responsibility of the installer!) TRU owner s company name and address: Contact name phone: Installer s name: phone: Installation date: TRU readings: Switch on hours Engine hours TRU model name: (Ultra, Ultima, etc.): (CANNOT BE INSTALLED ON MULTI-TEMP) TRU serial number: Date in Service: TRU engine serial number (stamped on block in front of injection pump): Rypos DPF/ULETRU serial number: U Date of Manufacture Current ARB # Valeo Alternator Serial number: Statement of Compatibility: I have inspected the engine for signs of poor maintenance (oil leaks, oil filter over 1 year old, oil with more than recommended hrs on it, dirty air filter, worn belts, etc). I have looked at the exhaust soot for oil content, and I have observed the color of the exhaust both in high and low speed (No color should be visible in steady state operation) and I hereby affirm that the TRU listed above has met ALL of the above compatibility criteria for installation of DPF/ULETRU YES, ALL CRITERIA ACCEPTABLE NO, THERE ARE ISSUES WITH THE UNIT THAT MUST BE ADDRESSED BEFORE A DPF/ULETRU MAY BE INSTALLED (LIST ISSUES ) Statement of Warranty: I hereby warrant that the installation of the Rypos DPF/ULETRU is free from defects in workmanship or materials which cause the diesel emission control system to fail to conform to the emission control performance level it was verified to, or to the requirements in the California Code of Regulations, Title 13, Sections 2700 to The warranty period and the extent of the warranty coverage provided by me must be the same as the warranty provided by the product manufacturer, and the same exclusions must apply SIGNED DATE Rypos Family Name for Verification: CA/RYP/2011/PM3+/N00/TR/DPF01 Scan/ to: Registration@rypos.com, or fax to Rypos Copy Page 33