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Longstar
User Manual
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Cleaire Longstar User Manual

Lonestar
Owner’s Manual
The Cleaire logo, Cleaire Advanced Emission Controls, Allmetal, Horizon, Lonestar, LongMile, Longview,
MLC and Phoenix are registered trademarks of Cleaire Advanced Emission Controls, LLC.
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Lonestar

Owner’s Manual
Table of Contents
General Information.................................................................................................................. 1
Cautions............................................................................................................................................................. 2
Safety Warnings ................................................................................................................................................ 2
Owner’s Legal Obligations................................................................................................................................. 2
Contact Information ........................................................................................................................................... 3
Installation.......................................................................................................................................................... 4
DPF Swapping ................................................................................................................................................... 4
System Re-Designation ..................................................................................................................................... 5
Engine Repower ................................................................................................................................................ 6
Acronyms ........................................................................................................................................................... 6
System Description .................................................................................................................. 7
Product Summary .............................................................................................................................................. 8
Catalyst Assembly ............................................................................................................................................. 9
Control System ................................................................................................................................................ 10
Fuel Injection System ...................................................................................................................................... 10
Major Component Pictures .............................................................................................................................. 11
CARB-Verification Labels ................................................................................................................................ 13
Operations ............................................................................................................................... 14
Pay Attention to the System, Engine and Equipment ..................................................................................... 15
System Indicator Lights ................................................................................................................................... 15
Monitoring the Fuel System ............................................................................................................................. 17
Conditions That May Damage the Lonestar .................................................................................................... 18
Maintenance and Repair ........................................................................................................ 19
Your Right to Maintenance Information ........................................................................................................... 20
The Importance of Engine Maintenance ......................................................................................................... 20
The Importance of Properly Maintaining a Diesel Emission Control Strategy ................................................ 20
Maintenance Schedule .................................................................................................................................... 20
Preventative Maintenance Labor and Parts .................................................................................................... 21
Service Calls .................................................................................................................................................... 22
Parts List .......................................................................................................................................................... 23
Troubleshooting Table ..................................................................................................................................... 24
Amber Light Flashing ....................................................................................................................................... 25
Repair and Maintenance Clarifications ............................................................................................................ 27
Engine Oil Consumption and Lube Oil Ash ..................................................................................................... 28
Specifications ......................................................................................................................... 30
Owner’s Obligations ............................................................................................................... 32
Warranty .................................................................................................................................. 34
Product Warranty ............................................................................................................................................. 35
Installation Warranty ........................................................................................................................................ 36
Cleaire Warranty Clarifications ........................................................................................................................ 36
CARB Executive Order for the Lonestar ............................................................................... 37
Lonestar_Owner's_Manual-2011-06
G
ENERAL INFORMATION
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Cautions
Please study this manual and understand the requirements for the Cleaire Lonestar system before operating your equipment.
The pictures and descriptions in this manual are for a typical Lonestar system. Some parts, components and configurations for your particular system may vary from those shown here depending on the equipment and application.
The use of parts that are materially different than the verified retrofit parts or system may void the verification and the warranty. Ultra-low sulfur diesel fuel (ULSD) is required for your system (see p. 17) and all CARB Level 3 verified systems.
The Lonestar system is designed to operate automatically. This manual describes routine observations, periodic maintenance requirements, and the owner’s obligations. Contact your dealer or a Cleaire-authorized technician if you need further assistance.
Safety Warnings
• Do not touch the Lonestar catalyst assembly or tubing during or after operation.
All surfaces can become hot and may cause burns. At times, the catalyst assembly (and especially the end cones) may be at a higher temperature than a muffler would be under the same engine conditions.
• The catalyst assembly stays hotter much longer than a stock muffler will after the
engine is turned off.
• If it is necessary to move a hot catalyst module, use gloves and other appropriate precautions (as previously mentioned, it is much heavier than a muffler).
Owner’s Legal Obligations
Use of any alternative diesel fuels and or fuel additives not specifically listed in the CARB verification Executive Order (E.O.) is illegal and strictly prohibited. Operating with an unapproved alternative diesel fuel or fuel additive violates the E.O., negates the verification for that vehicle, and removes compliance status for the vehicle. The end-user must meet other requirements in the E.O. for the Lonestar which is provided in this manual beginning on page
37. The E.O. for the Lonestar may also be obtained from the CARB website at http://www.arb.ca.gov/diesel/verdev/level3/level3.htm.
The installation of the Lonestar system is based on the owner’s understanding that adding a new part to or altering an original part of a certified configuration could be considered a violation of the tampering prohibition of the Clean Air Act. The owner understands that the installation of the Lonestar will not violate tampering provisions of the Act, at the time of
Lonestar_Owner's_Manual-2011-06 Page 2
installation, because of the testing performed under the verification process and provided the owner adheres to all installation instructions and meets all operating and maintenance requirements for the Lonestar.
• Events that require action by the owner or operator are given in the “Owner’s Obligations” section beginning on page 32.
• If any of these events occur, it is the owner’s obligation to take the appropriate action. Failure to do so may be the basis for denying a warranty claim.
Contact Information
Contact a Cleaire-authorized dealer for any sales or service support for your Lonestar system. The tables below for contact information are provided for the customer to complete at their convenience. For more information, contact your local Cleaire product support representative, call Cleaire at 800-308-2111, or visit www.cleaire.com.
Dealer
Address
Contact person
Contact person’s phone
Contact person’s fax
Contact person’s email
Name of local Cleaire product support representative
Local Cleaire representative’s phone
Local Cleaire representative’s email
Lonestar_Owner's_Manual-2011-06 Page 3
Installation
Cleaire recommends that a Cleaire-authorized technician install the Lonestar system. The complete installation procedures are described in the Lonestar Installation Manual. Copies of the manual are available upon request from your dealer or Cleaire. The installation warranty (page 36) is the responsibility of the dealer that installs the Lonestar system.
Attention:
A Cleaire-certified technician must commission the system;
otherwise, that may be the basis for denying a warranty claim.
Warranty registration is submitted by the Cleaire-authorized dealer.
DPF Swapping
CARB defines component swapping as the movement of designated parts between different vehicles/applications utilizing the same Diesel Emissions Control System (DECS). In this case, Cleaire is limiting this process only to swapping of the diesel particulate filter (DPF) module. Cleaire has a specified process for DPF swapping that has been approved by ARB. Failure to follow the ARB-approved process completely could be the basis for enforcement action against the end-user by ARB.
Attention:
Failure to follow the Cleaire swapping process may be grounds for enforcement action by ARB against whoever performed or allowed the swapping to occur without following the Cleaire-approved process.
Cleaire recommends that only a properly trained service technician perform DPF swapping. This service is available from a Cleaire dealer. The end-user may attend Cleaire training classes in order to become a properly trained technician. Please note: damage to the DPF caused by improper handling or damage to other components of the system caused by improper service techniques could be the basis for Cleaire to deny a warranty claim (in this case, the person causing the damage will bear the warranty responsibility).
For end users who choose not to use a Cleaire-authorized technician, the detailed process for DPF swapping is provided in the “Cleaire DPF Swapping Process” document. The Cleaire DPF Swapping Manual is also available and it provides step-by-step instructions. Both of these documents are available from a Cleaire dealer, Cleaire or at www.cleaire.com/swapping/. In summary, the process involves:
• Technician confirms that there is not a solid amber LED; otherwise the cause of the solid amber LED must be fixed before swapping can be done. Items requiring repair as specified in the “Operations” section (page 14) should also be done before swapping.
• Technician removes DPF from a vehicle.
Lonestar_Owner's_Manual-2011-06 Page 4
• Technician inspects the DPF:
o If DPF requires cleaning, technician will either perform the cleaning or have it
done.
o If the DPF fails the inspection, the technician will either acquire a new DPF from
a Cleaire dealer or a spare DPF from the end-user’s inventory.
• Technician will inspect the engine to confirm it is in good working condition, including:
o Oil consumption is within the engine manufacturer’s recommendation o Injectors and turbo are in good condition and do not cause excessive soot in the
engine’s exhaust (at the inlet to the DPF).
o The fuel and tank are reasonably clean
• Technician installs the DPF on the recipient vehicle following all the specified service procedures.
• Technician or administrative staff input the following data into Cleaire’s web-based portal at www.cleaire.com/swapping/: (Note: If you do not have Internet access, contact your Cleaire dealer or contact Cleaire at 1-800-308-2111 or 14333 Wicks Blvd., San Leandro, CA 94577-6719.) Donor vehicle/DPF
o CARB-verification label serial number for the DECS o DPF part number o DPF serial number o Customer name (end user) o Engine Serial Number o Vehicle mileage or hours o Date of DPF removal
Recipient vehicle/DPF (if known, or upon re-installation)
o CARB-verification label serial number for the DECS o DPF part number o DPF serial number o Customer name (end user) o Engine Serial Number o Vehicle mileage or hours o Date of DPF installation
• Warranty is maintained for the DPF by properly following this process in its entirety
System Re-Designation
CARB defines re-designation as the movement of a used verified Diesel Emissions Control System (DECS) from an appropriate engine/application (donor) and installation on another engine/application (recipient) meeting the terms and conditions of the DECS Executive Order (E.O.) within the same common ownership fleet. At some point in the future, the customer may want to remove the Cleaire DECS from the current vehicle and have it installed on a different vehicle. There could be a variety of reasons such as retiring the current vehicle from service. To avoid violation of the governing ARB Executive Order, violation of anti-tampering laws, not complying with a fleet rule, and putting warranty coverage in jeopardy, the customer should get approval from Cleaire for re-designation prior to movement.
Lonestar_Owner's_Manual-2011-06 Page 5
Cleaire only allows the dealer to implement a re-designation; the customer must work through the dealer if they want a DECS re-designated. Cleaire has a detailed process approved by CARB for re-designating a DECS. In summary, the process involves:
• Pre-authorization (dealer collects information and submits it to Cleaire)
• Review (Cleaire confirms the recipient vehicle is compatible with the DECS)
• Notification (Cleaire notifies the dealer that the re-designation has been approved)
• DECS removed by the dealer from the donor application
• DECS installed by the dealer on the new approved application (and is fully
commissioned)
• Warranty (Cleaire activates the warranty on the new application with the remaining warranty life)
Engine Repower
A DECS installed on a vehicle that is repowered may remain installed provided:
• The replacement engine meets all the terms and conditions of the governing Executive Order or conditional verification letter,
• The DECS is not more than ten years old (based on the date of manufacture), and
• The appropriate DECS engine label is affixed to the replacement engine in a visible
location.
Acronyms
BP backpressure CARB California Air Resources Board CO carbon monoxide DECS Diesel Emissions Control System DPF diesel particulate filter HC hydrocarbons LED light emitting diode (system indicator light) MLC® the electronic controller in the system MLinC the software program used to communicate with the MLC NOx nitrogen oxides NRC NOx reduction catalyst OEM original equipment manufacturer PM particulate matter (diesel soot) TC thermocouple ULSD ultra-low sulfur diesel fuel VDC volts direct current
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S
YSTEM DESCRIPTION
Lonestar_Owner's_Manual-2011-06 Page 7
Product Summary
The Lonestar system reduces oxides of nitrogen (NOx), particulate matter (PM), carbon monoxide (CO) and unburned hydrocarbons (HC) from diesel engine exhaust. Features include:
• NOx reduction catalyst (NRC)
• Diesel particulate filter (DPF)
• Cleaire MLC® (the electronic controller in the system)
• Stainless steel construction
• Modular design to facilitate installation, service and maintenance
• Sound attenuation eliminating the need for a muffler or silencer
The Lonestar system shown in Figure 1 consists of three main subsystems: the catalyst assembly, fuel delivery system, and the control system.
Figure 1: Cleaire Lonestar system.
The MLC® monitors engine conditions, Lonestar system operation and controls the fuel addition. The injector adds fuel at the rate dictated by the MLC in order to provide a reducing agent for the NRC. With the addition of diesel fuel to the engine exhaust by the fuel injector, the NRC reduces the NOx emissions to the atmosphere. The catalyzed DPF reduces the PM, HC and CO emissions.
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Catalyst Assembly
Attention:
The catalyst assembly (Figure 2) is the core of the system and it replaces the stock muffler. Cleaire provides a mounting assembly specifically designed for the Lonestar.
Figure 2: Catalyst Assembly (cone configurations vary depending on the equipment).
Care and handling requirements for the catalyst assembly are as follows:
1. Do not drop or hammer.
2. Use appropriate equipment when lifting.
3. Protect from water intrusion.
4. Protect from accidental impacts.
5. Do not weld.
6. Protect the flanges during transport (use the foam shipping covers).
Although the catalyst assembly replaces the OEM muffler, be aware that the catalyst assembly is approximately twice the weight of a typical muffler.
The catalyst assembly creates backpressure on the engine
Handle with care!
The DPF provides high filtration efficiency, which results in backpressure on the engine. The backpressure from the Lonestar varies instantaneously depending on the engine speed and load and the soot and ash loading in the DPF. At times, the backpressure from the Lonestar system may be higher than the backpressure caused by a muffler. However, other devices such as exhaust brakes put much higher backpressure loads on the engine for short time periods, and are approved by engine manufacturers. The backpressure caused by the Lonestar system is not nearly high enough to lead to excessive exhaust manifold temperatures or significant loss of performance. Typical average backpressure values from the Lonestar are well within acceptable levels for the engine. The control system continuously monitors backpressure and alerts the operator if necessary.
Lonestar_Owner's_Manual-2011-06 Page 9
Control System
The control system consists of the MLC® and various sensors. The MLC reads the backpressure sensor and uses the data to calculate the backpressure profile over a certain period of operation. If the pre-programmed thresholds are exceeded, the MLC causes the amber LED to blink, thus alerting the operator or other personnel that the system is experiencing unusually high backpressure. The MLC also logs the time and conditions of the occurrence. The constant monitoring of the backpressure sensor by the MLC ensures that the backpressure is within safe limits and alerts the owner in time to take corrective action if necessary.
The MLC not only monitors the system and alerts the operator if service is required, but also continually logs operating data and records instances of unusual conditions. The MLC also controls the fuel injection system.
Fuel Injection System
The Fuel Injection System is shown in Figure 3. Fuel is drawn directly from the engine fuel supply system to ensure that it will not interfere with engine operation. A combination pump and filter pressurizes the fuel to the injector. (Note: the Lonestar fuel pump does not turn on until a few seconds after the engine starts.) The fuel injector is mounted in a fuel-cooled assembly attached to the exhaust tube upstream of the catalyst assembly. The fuel flow is monitored by the pressure switch and controlled by the pressure regulator and shut-off valve.
Figure 3: Fuel system flow diagram.
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Major Component Pictures
The major components of the Lonestar system not previously shown are given in this section (the catalyst assembly is shown in Figure 2 on page 9 and the fuel injection system components are shown in Figure 3 on page 10).
Figure 4: Mounting Assembly: backbone, saddles and straps.
Figure 5: Inspection port.
Figure 6: Mixer
Figure 7: Thermocouples.
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Figure 8:
Engine RPM sensor.
Manifold pressure sensor.
Figure 9:
Figure 10: Controls box.
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