Cleaire Vista User Manual
™
Vista
Owner’s Manual
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.
The Cleaire logo, Cleaire Advanced Emission Controls, Allmetal, Horizon, Lonestar, LongMile, Longview,
MLC and Phoenix are registered trademarks of Cleaire Advanced Emission Controls, LLC.
Keep a copy of this Owner’s Manual in the vehicle.
ATTENTION:
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Cleaire Vista™ Owner’s Manual
Table of Contents
General Information.................................................................................................................. 1
Cautions............................................................................................................................................................. 2
Safety Warnings ................................................................................................................................................ 2
Owner’s Legal Obligations................................................................................................................................. 3
Contact Information ........................................................................................................................................... 3
Installation.......................................................................................................................................................... 4
DPF Swapping ................................................................................................................................................... 4
System Re-Designation ..................................................................................................................................... 5
Engine Repower ................................................................................................................................................ 6
Acronyms ........................................................................................................................................................... 6
Vista System Description ......................................................................................................... 7
Product Summary .............................................................................................................................................. 8
PM Filter Assembly ............................................................................................................................................ 9
Control System ................................................................................................................................................ 10
Regeneration System ...................................................................................................................................... 11
Low-Voltage Switch (Optional) ........................................................................................................................ 13
CARB-Verification Labels ................................................................................................................................ 13
Operations ............................................................................................................................... 14
Pay Attention to the System, Engine and Vehicle ........................................................................................... 15
Regenerating the Vista .................................................................................................................................... 15
Operator Interface Module............................................................................................................................... 16
Conditions That May Damage the Vista .......................................................................................................... 19
Maintenance and Repair ........................................................................................................ 20
Your Right to Maintenance Information ........................................................................................................... 21
The Importance of Engine Maintenance ......................................................................................................... 21
The Importance of Properly Maintaining a Diesel Emission Control Strategy ................................................ 21
Maintenance Schedule .................................................................................................................................... 21
Preventative Maintenance Labor and Parts .................................................................................................... 22
Service Calls .................................................................................................................................................... 23
Parts List .......................................................................................................................................................... 24
Troubleshooting ............................................................................................................................................... 25
Repair and Maintenance Clarifications ............................................................................................................ 27
Engine Oil Consumption and Lube Oil Ash ..................................................................................................... 28
Specifications ......................................................................................................................... 30
Owner’s Obligations ............................................................................................................... 33
Warranty .................................................................................................................................. 35
Product Warranty ............................................................................................................................................. 36
Installation Warranty ........................................................................................................................................ 37
Cleaire Warranty Clarifications ........................................................................................................................ 37
CARB Executive Order for the Vista ..................................................................................... 38
Vista_Owner's_Manual-2011-06
G
ENERAL INFORMATION
Vista_Owner's_Manual-2011-06 Page 1
Cautions
Please study this manual and understand the requirements for the Cleaire Vista system
before operating your vehicle.
The pictures and descriptions in this manual are for a typical Vista system. Some parts,
components and configurations for your particular system may vary from those shown here
depending on the vehicle 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 dealer for further assistance.
Safety Warnings
• Before starting regeneration, park the vehicle on level ground 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:
o Caution: The Vista emits hot exhaust gases during regeneration.
o During regeneration, the engine will be off, but the Vista (including the
downstream pipes) will be very hot.
o 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.
• 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.
• After operating under heavy load, be very careful about operating or idling near
any combustible material such as dry grass or trash. 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 (after the high-load operation) and be a
potential source of ignition for any combustible material.
• Do not allow combustible material from the working environment to come in
contact with the Vista (for example, paper, trash, sawdust).
• Inspect regularly for any fuel leaks. If any are found, contact your dealer
immediately for further assistance.
• Be sure the Vista heat shield panels are in place. If any are missing, contact a
Cleaire-authorized dealer as soon as possible for service.
Vista_Owner's_Manual-2011-06 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 vehicle, and removes compliance status for the vehicle. The end-user must meet other
requirements in the E.O. for the Vista which is provided in this manual beginning on page 38.
The E.O. for the Vista may also be obtained from the CARB website at
http://www.arb.ca.gov/diesel/verdev/level3/level3.htm.
The installation of the Vista 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
Vista 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 Vista.
• Specific events that require action by the owner or operator are given in the
“Owner’s Obligations” section on page 33.
• 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 Vista 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
Vista_Owner's_Manual-2011-06 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 installs the Vista system. The
complete installation procedures are described in the Vista Installation Manual. Copies of the
manual are available upon request from your dealer. The installation warranty (page 37) is the
responsibility of the dealer that installs the Vista 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
Vista_Owner's_Manual-2011-06 Page 4
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.
• 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
Vista_Owner's_Manual-2011-06 Page 5
(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.
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
EFC exhaust flow conditioner
HC hydrocarbons
LED light emitting diode (system indicator light)
MLC® the electronic controller in the Vista system
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
VDC volts direct current
Vista_Owner's_Manual-2011-06 Page 6
V
ISTA SYSTEM DESCRIPTION
Vista_Owner's_Manual-2011-06 Page 7
Product Summary
The Vista 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
• Rugged silicon carbide diesel particulate matter filter (PM filter)
• Modular design to facilitate installation, service and maintenance
• Filter regeneration when the vehicle is parked and the engine is off
(a complete regeneration cycle takes approximately 2 hours)
• Cleaire MLC® (the system controller)
• Sound attenuation eliminating the need for a muffler or silencer
The Vista (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 vehicle is operating.
• The control system monitors the Vista and engine during operation and controls the
regeneration cycle, which cleans out the PM filter.
• The regeneration system operates while the vehicle is parked, engine is off, and the
operator has started regeneration in response to the flashing amber light. The complete
regeneration cycle takes approximately 2 hours.
Figure 1: Vista system schematic drawing.
Vista_Owner's_Manual-2011-06 Page 8
PM Filter Assembly
Attention:
The PM filter assembly (Figure 2) is the core of the Vista system and it usually will replace the
muffler. The assembly has important features listed below:
Figure 2: PM Filter Assembly.
Cleaire provides a mounting assembly specifically designed for the Vista. 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 Vista
system as a whole) may be higher than the backpressure caused by a muffler. The actual
amount of backpressure from the Vista 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.
Handle with care!
Vista_Owner's_Manual-2011-06 Page 9
Control System
The MLC and some electrical components are housed in the Controls Box. The MLC monitors
engine conditions and the Vista when the engine is operating. The MLC also continually logs
operating data and records instances of unusual conditions. The MLC controls the
regeneration cycle and it controls the system indicator lights (see Figure 3, also referred to as
the LED’s). The MLC turns on the flashing amber light to alert the operator when regeneration
is required.
Figure 3: Operator Interface Module.
The installing dealer will have installed the Operator Interface Module in a clearly visible and
accessible location. The operator should look at the lights daily and respond accordingly: the
meaning of each light and the appropriate actions for the operator to take are described in the
“Operations” section of this manual starting on page 14.
If the operator neglects to regenerate the Vista, 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 PM filter is well past due for regeneration. Further prolonged operation could
damage the emission control system and engine exhaust components. The driver or operator
should respond to a flashing red light according to the detailed explanation given in the “Red
Light – Flashing” section on page 18.
Vista_Owner's_Manual-2011-06 Page 10
Regeneration System
The regeneration system cleans out the PM filter. It consists of a fuel burner module and an
air blower. Over a controlled cycle, heat and air are provided to the PM filter to oxidize the
collected soot. The burner module (Figure 4) provides heat and the Blower Box (Figure 5)
provides air. The regeneration process is controlled by the MLC.
Figure 4: Burner module
Figure 5: Blower Box.
Before starting a regeneration
Before starting regeneration, the vehicle must be parked on level ground in a well ventilated
area far away from any combustible material and the engine must be off. Battery chargers
must not be connected during regeneration. If parked underneath an overhead structure, there
must be good air circulation and at least 18 inches of vertical clearance above the stack
(Figure 6). Also, in cold weather, Cleaire recommends starting regeneration soon after the
engine is turned off so the fuel is still warm. After the operator pushes the start button (see
Figure 7), the MLC powers the blower and ignites the burner to start the regeneration process.
Have at least 18 inches of clearance
Figure 6: If parked under an overhead
structure, have at least 18-inch clearance.
Figure 7: When the amber LED starts
flashing, push the button to regenerate.
Vista_Owner's_Manual-2011-06 Page 11
Typical regeneration cycle
During regeneration, the blower moves the hot air from the burner through the PM filter
causing the collected soot to oxidize. The burner turns off after approximately 75 minutes.
The blower continues to run several minutes to cool down the burner. The PM filter will remain
hot for several hours. A complete regeneration cycle takes approximately 2 hours.
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.
Regeneration-on-demand option
With the regeneration-on-demand option activated in the MLC, the operator may regenerate
the system any time they want by pushing the start button; in this case, the amber LED does
not have to be flashing in order to initiate regeneration. Operators use this feature when they
want to ensure they have a soot-free filter, such as before starting a mission-critical trip.
Whether or not to activate the regeneration-on-demand feature is the customer’s preference.
The option is not activated in the factory setting for the MLC. A trained technician using the
MLinC program can activate the regeneration-on-demand option in the MLC.
Do not start engine during regeneration; if engine is needed, do a controlled shutdown
Starting the engine before the full two hours have elapsed may damage the PM filter. If the
engine needs to be started before the regeneration has finished, then push and hold the
regeneration start button for 5 seconds. This will stop the regeneration and allow the system
to safely go through a controlled shutdown. After the system has finished the controlled
shutdown (the blower will be off), the engine may be started without damaging the PM filter.
Attention:
Damage to the PM filter caused by starting the engine during the regeneration
cycle may be the basis for denying a warranty claim.
Fuel pump may turn on and off at the start of regeneration
During the first 7 minutes of burner operation, there may be periods when the fuel pump shuts
off for a few seconds, then comes back on for a short time, then turns off again, and so on. Do
not be alarmed if you hear the fuel pump turn off for short periods of time. Similarly, you may
hear the glow plug relay click on and off repeatedly at the very start of regeneration.
If burner fails to light
If the burner fails to light, the red LED will turn on solid after a few minutes alerting the operator
to push the button again. If the burner fails to light after repeated attempts, the amber LED will
turn on solid indicating that service is required.
Vista_Owner's_Manual-2011-06 Page 12
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