Cleaire Skyline User Manual

,

™

Skyline

Owner’s Manual

ATTENTION:

Keep a copy of this Owner’s Manual in the equipment cab.

The instructions, specifications, and recommendations in this manual are based on current information when this
manual was released. Cleaire Advanced Emission Controls, LLC reserves the right to make changes at any time
without obligation. If you find differences between your system and the information in this manual, contact your
Cleaire dealer or call Cleaire at 1-800-308-2111.

MLC® and Cleaire Advanced Emission Controls® are registered trademarks

of Cleaire Advanced Emission Controls

LLC

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Cleaire Skyline™ Owner’s Manual

Table of Contents

General Information..................................................................................................................................................1

Cautions.............................................................................................................................................................2

Safety Warnings................................................................................................................................................2

Owner’s Legal Obligations.................................................................................................................................3

Contact Information...........................................................................................................................................3

Installation .........................................................................................................................................................4

Acronyms...........................................................................................................................................................4

Skyline System Description ....................................................................................................................................5

Product Summary..............................................................................................................................................6

PM Filter Assembly............................................................................................................................................7

Control System..................................................................................................................................................8

Low-Voltage Switch (Optional)..........................................................................................................................9

Regeneration System........................................................................................................................................9

CARB-Verification Labels................................................................................................................................10

Operations...............................................................................................................................................................11

System Indicator Lights...................................................................................................................................12

Regenerating the Skyline ................................................................................................................................15

Pay Attention to Skyline, Engine and Equipment............................................................................................15

Conditions That May Damage the System......................................................................................................16

Maintenance and Repair ........................................................................................................................................17

Maintenance Schedule....................................................................................................................................18

Preventative Maintenance...............................................................................................................................18

Service Calls....................................................................................................................................................21

Parts List..........................................................................................................................................................21

Troubleshooting Table.....................................................................................................................................22

Repair and Maintenance Clarifications............................................................................................................23

Engine Oil Consumption and Lube Oil Ash.....................................................................................................24

Specifications .........................................................................................................................................................26

Owner’s Obligations...............................................................................................................................................28

Warranty..................................................................................................................................................................30

Product Warranty.............................................................................................................................................31

Installation Warranty........................................................................................................................................32

Cleaire Warranty Clarifications........................................................................................................................32

CARB Executive Order for the Skyline.................................................................................................................33

Skyline_Owner's_Manual-2010-01

GENERAL INFORMATION

Skyline_Owner's_Manual-2010-01 Page 1

Cautions

Please study this manual and understand the requirements for the Cleaire Skyline
system before operating your equipment.

The pictures and descriptions in this manual are for a typical Skyline 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 which are materially different than the verified retrofit parts or systems may
void the verification and the warranty.

The owner’s obligations, routine observations and periodic maintenance requirements are
described in this manual. Contact a Cleaire-authorized dealer if you need further assistance.

Safety Warnings

• Before starting regeneration, park the equipment in a well ventilated location far

away from any combustible material. Turn the engine off. Do not regenerate
indoors.

• The system may be hot when not normally expected: During regeneration, the

engine will be off, but the Skyline (including the downstream pipes) will be very
hot.

• Do not touch any of the PM filter assembly components or exhaust tubing during

regeneration or after engine operation. All surfaces can become hot and may
cause burns.

• The PM filter stays hotter much longer than a stock muffler will after operating

under heavy load, after the engine is turned off, and after a completed
regeneration cycle.

• After operating under heavy load (for example, driving up to a mountain pass),

the driver should be very careful if they need to pull off to the side of the road and
leave the engine idling. The PM filter retains heat much longer than a muffler
which makes it possible for very hot exhaust gases to exit the tailpipe for several
minutes and be a potential source of ignition for combustible material (such as
dry grass).

• Do not allow combustible material from the working environment to come in

contact with the Skyline (for example, paper, trash, sawdust).

• The Skyline’s regeneration system uses high voltage (see the “Specifications” on

page 26). Only a technician qualified for high-voltage work should install or
repair any of the high-voltage electrical components.

Skyline_Owner's_Manual-2010-01 Page 2

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 engine, and removes compliance status for the equipment. The E.O. for the Skyline is
provided in this manual beginning on page 33. It also may be obtained from the CARB
website at http://www.arb.ca.gov/diesel/verdev/level3/level3.htm.

The installation of the Skyline 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
Skyline will not violate tampering provisions of the Act, at the time of installation, because of
the testing performed under the verification process—provided that the owner adheres to all
installation instructions and meets all operating and maintenance requirements for the Skyline.

• Specific events that require action by the owner or operator are given in the

“Owner’s Obligations” section on page 28.

• 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 Skyline 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

Skyline_Owner's_Manual-2010-01 Page 3

Name of local Cleaire product
support representative

Local Cleaire representative’s phone
Local Cleaire representative’s email

Installation

Cleaire recommends that a Cleaire-authorized technician install the Skyline system. The
complete installation procedures are described in the Skyline Installation Manual. Copies of
the manual are available upon request from your dealer or Cleaire. The installation warranty
(page 32) is the responsibility of the dealer that installs the Skyline system.

Note: the power-supply station installation is the responsibility of the customer and their
electrical contractor. Copies of the Power-Supply Station Installation and Maintenance Guide
are available upon request from your dealer or Cleaire.

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.

Acronyms

AC alternating current
BP backpressure
CARB California Air Resources Board
CO carbon monoxide
DPF diesel particulate filter
HC hydrocarbons
LED light emitting diode (system indicator light)

®

MLC
MLinC the software program used to communicate with the MLC
OEM original equipment manufacturer
PM particulate matter (diesel soot)
TC thermocouple
ULSD ultra-low sulfur diesel fuel
VAC volts alternating current
VDC volts direct current

the electronic controller in the Skyline system

Skyline_Owner's_Manual-2010-01 Page 4

SKYLINE SYSTEM DESCRIPTION

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Product Summary

The Skyline has been verified by the California Air Resources Board to capture over 85% of
the particulate matter (PM) from diesel engine exhaust (“Level 3 plus”). Features include:

• Stainless steel construction

• Particulate matter filter (PM filter)

• Modular design to facilitate installation, service and maintenance

• Filter regeneration when the equipment is parked (5-hour regeneration cycle)

• Cleaire MLC® (the system controller)

• Sound attenuation eliminating the need for a muffler or silencer

The Skyline (Figure 1) consists of three main subsystems: the PM filter assembly, the control
system, and the regeneration system:

• The PM filter captures over 85% of the particulate matter (soot) from the diesel engine
exhaust while the equipment is operating.

• The control system monitors the Skyline and engine during operation and controls the
regeneration cycle, which cleans out the PM filter.

• The regeneration system operates while the equipment is parked and plugged into AC
power.

Figure 1: Skyline system schematic drawing.

Skyline_Owner's_Manual-2010-01 Page 6

PM Filter Assembly

The PM filter assembly (Figure 2) is the core of the Skyline system and it usually will replace
the muffler. The assembly has important features highlighted below:

Figure 2: PM Filter Assembly.

Cleaire provides a mounting assembly specifically designed for the Skyline. Although the PM
filter assembly replaces the stock muffler, it is important to note that the PM filter
assembly is heavier than a typical muffler.

The PM filter includes ceramic materials; its care and handling require the following:

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 flanges during transport (use the foam shipping covers).

The PM filter assembly creates backpressure on the engine

In the process of removing over 85% of the soot and ash from the exhaust, the PM filter
creates backpressure on the engine. At times, the backpressure from the PM filter (and
Skyline system as a whole) may be higher than the backpressure caused by a muffler. The
actual amount of backpressure from the Skyline varies instantaneously depending on the
engine speed and load and the soot and ash loading in the PM filter. The regeneration
process removes the carbonaceous part of the soot and thereby lowers the backpressure.

Attention:

Handle with care!

Skyline_Owner's_Manual-2010-01 Page 7

Control System

The MLC controls the regeneration cycle and the system indicator lights (also referred to as
the LED’s). The meaning of each light and the appropriate actions for the operator to take in
response to the lights are described in the “Operations” section of this manual (page 11).

The MLC also monitors engine conditions and the Skyline when the equipment is operating.
The MLC turns on the flashing amber light to alert the operator when regeneration is required.
In addition, the MLC continually logs operating data and records instances of unusual
conditions.

If the operator neglects to regenerate the Skyline, the MLC will turn on a flashing red light. At
this point, the operator may experience a loss of power from the engine. The flashing red light
indicates that the Skyline is well past due for regeneration and that service is required
immediately. Further prolonged operation could damage the emission control system and
engine exhaust components.

The MLC and some electrical components of the Skyline system are housed in the Controls
Box (Figure 3). The Air Pump Box (Figure 4) houses the regeneration air pump and the
backpressure sensor. Note that both boxes can be connected to high voltage. Only trained
technicians should open the boxes.

Figure 3: Controls Box.

Figure 4: Air Pump Box.

Skyline_Owner's_Manual-2010-01 Page 8

Low-Voltage Switch (Optional)

A low-voltage switch is an option for the Skyline for equipment that is operated intermittently. It
is designed to disconnect power to the MLC in the event voltage drops to a set point. Once
the engine is started, the low-voltage switch automatically resets and restores power to the
MLC and Skyline system.

Regeneration System

The regeneration system cleans out the PM filter while the equipment is parked outdoors in a
well ventilated location away from any combustible material. The primary components of the
regeneration system are heating elements and an air pump. Over a controlled cycle, heat and
air are provided to the PM filter to oxidize the collected soot. The regeneration process is
controlled by the MLC. The operator must connect the power-supply receptacle (Figure 5) to
the plug on the Skyline (Figure 6) whenever regeneration is needed. The engine starter is
automatically locked out during the regeneration cycle so that the equipment cannot be
accidentally driven off while plugged in.

Figure 5: Receptacle and power supply.

Typical regeneration cycle

After the operator plugs in the Skyline in response to the flashing amber light, the MLC detects
the AC power and initiates the regeneration cycle by turning on the electric heater and air
pump. The pump blows air past the heaters to the PM filter causing the collected soot to
oxidize. The heater turns off after four hours. The air pump continues to run another hour to
cool down the PM filter. A complete cycle takes approximately five hours. If the equipment
needs to be used before the regeneration cycle has completed, follow the guidance in the
“Impact on Regeneration If Parked Less Than Five Hours” section on page 10.

Skyline_Owner's_Manual-2010-01 Page 9

Figure 6: Power plug (on equipment).

Elapsed time between regenerations

Typically, the vehicle or equipment will operate approximately 8 to 32 hours between
regeneration requests. The actual elapsed engine-on time between regenerations will depend
on many factors including engine model, maintenance condition, engine load pattern, and
operator behavior.

Immediate Regeneration Option

The MLC can be configured so that the Skyline is regenerated anytime it is plugged into AC
power, whether or not the amber light is flashing. This setting is made through the MLinC
program by a trained technician.

Impact on Regeneration If Parked Less Than Five Hours

If the equipment must be operated before the 5-hour cycle has been completed, then turn off
the circuit breaker for the power supply and unplug the receptacle from the Skyline’s plug
before starting the engine. When the equipment returns from service, plug it in again (if the
amber light is flashing) so the Skyline can go through a complete regeneration cycle. (Be sure
the circuit breaker was turned back on.)

Attention: the PM filter assembly and exhaust may be very hot under these
conditions. See the “Safety Warnings” section on page 2.

CARB-Verification Labels

The Skyline is provided with two CARB-verification labels. One is installed on the engine
(Figure 7) and the other one is attached to the wiring harness at the Skyline’s Controls Box
(Figure 8). If either one is missing, order a replacement label from a Cleaire-authorized dealer
and be sure to order the correct label for your application (see the table below the pictures).

Figure 7: Example (from Horizon) of CARB-

verification label installed on engine.

Figure 8: CARB-verification label attached

to wiring harness at the Controls Box.

Product Application Verification Family Name Label Part Number

Skyline Off-road CA/CLE/2007/PM3+/N00/OFF/DPF01 CUH-738-2

Skyline_Owner's_Manual-2010-01 Page 10