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Longview Owner`s Manual

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1. 28 2 30 Dci T 32 Product M alTanty dae rtt e dived Wad Ree shes EE ERR R RETO 33 Installatiori W artabity ir iecit ctp A E pie ae bora rece eet 34 ESW CleanTech Inc Warranty 34 CARB Executive Orders for the 35 ESW Longview Owner s Manual 2013 Rev0820 GENERAL INFORMATION ESW Longview Owner s Manual 2013 Rev0820 Page 1 Cautions Please study this manual and understand the requirements for the ESW CleanTech Inc Longview system before operating your vehicle The pictures and descriptions in this manual are for a typical Longview 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 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 15 and all CARB Level 3 verified systems The Longview system is designed to operate automatically This manual describes routine observations periodic maintenance requirements and the owner s obligations Contact your distributor or an ESW CleanTech authorized technician if you need further assistance Safety Warnings D
2. ESW CleanTech Longview Owner s Manual MADE IN CALIFORNIA The instructions specifications and recommendations in this manual are based on current information when this manual was released ESW CleanTech Inc 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 ESW CleanTech distributor or call ESW CleanTech at 1 800 398 6105 Allmetal Horizon Lonestar LongMile Longview MLC Phoenix and Vista are registered trademarks of ESW CleanTech Inc The ESW CleanTech logo and ESW CleanTech Inc are trademarks of ESW CleanTech Inc This page intentionally left blank Longview Owner s Manual Table of Contents General Information waciki ywa 1 MED 2 Safety WZ el bathe OLA AO xc ONO cc d od pe a 2 Owner s Legal 2 Contact Intormatiorizs AB C EEN RSL 3 MNS tEAM IO Mees cess OWE PGL 4 Engine REPOWE i rudi niin ndi dE 4 ACTONYMS sees E 4 System Description D M M 5 giro Wie eet ura 6 ric mers LEES 7 Gontrol System o ade ee da ate Ne en Ra tat eue RN ME d 7 EuelInjectior Systeme ite tea estu tart iustos tero n ledere te pie E Seeds 8 Major Component Pictures eee 9 GARB Verlfication Lbels 5 55 2 este teer etu
3. As specified in Section 2706 Title 13 CCR of the Verification Procedure Warranty and In Use Compliance Requirements for In Use Strategies to Control Emissions from Diesel Engines Procedure ARB assigns each diesel emission control strategy a family name The designated family name for the verification as outlined above is e CA ECT 2008 PM3 N25 ON LNFO1 The designated family name CA ECT 2008 PM3 N25 ON LNFO1 replaces the previous name CA CLE 2008 PM3 N25 ON LNF01 As stated in the Procedure ESW CleanTech is responsible for recordkeeping requirements Section 2702 honoring the required warranty Section 2707 and conducting in use compliance testing Section 2709 Proper engine maintenance is critical for the proper functioning of the diesel emission control strategy The owner of the vehicle on which the diesel emission control strategy is installed is strongly advised to adhere to all good engine maintenance practices Failure to document proper engine maintenance including keeping records of the engine s oil consumption may be grounds for denial of a warranty claim Use of system parts or replacement parts not authorized by ESW CleanTech may be grounds for denial of a warranty claim This Executive Order is valid provided that the diesel fuel used in conjunction with the device complies with Title 13 CCR Sections 2281 and 2282 and if biodiesel is used the biodiesel blend shall be 20 percen
4. The engine must be turbocharged The engine must be well maintained and not consume lubricating oil at a rate greater than that specified by the engine manufacturer e Lube oil or other oil must not be mixed with the fuel The engine must be operated on fuel that has a sulfur content of no more than 15 parts million by weight The system must not be operated with fuel additives as defined in Section 2701 of Title 13 of the CCR unless explicitly verified for use with the fuel additive s The system must not be used with any other systems or engine modifications without approval from ARB and the manufacturer The system must be installed with backpressure monitor to notify the operator when the backpressure limit is reached The notification must occur and be clearly visible to the operator while the vehicle or equipment is in use The other terms and conditions specified below IT IS ALSO ORDERED AND RESOLVED That installation of the Longview system manufactured by ESW CleanTech Incorporated 6755 Mira Mesa Boulevard Suite 123 122 San Diego California 92121 has been found not to reduce the effectiveness of the applicable vehicle pollution control system and therefore the Longview system is exempt from the prohibitions in Section 27156 of the Vehicle Code ESW Longview Owner s Manual 2013 Rev0820 Page 38 for installation on heavy duty on road vehicles This exemption is only
5. Longview will not violate tampering provisions of the Act at the time of ESW Longview Owner s Manual 2013 Rev0820 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 Longview Events that require action by the owner or operator are given in the Owner s Obligations section beginning on page 30 f 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 an ESW CleanTech authorized distributor for any sales or service support for your Longview system The tables below for contact information are provided for the customer to complete at their convenience For more information contact your local ESW CleanTech product support representative ESW CleanTech at 800 398 6105 visit www eswgroup com Distributor Address Contact person Contact person s phone Contact person s fax Contact person s email Name of local ESW CleanTech product support representative Local ESW CleanTech representative s phone Local ESW CleanTech representative s email ESW Longview Owner s Manual 2013 Rev0820 Page 3 Installation ESW CleanTech recommends that an ESW CleanTech authorized technician instal
6. Rev0820 Page 45 ESW CleanTech and must not be installed in a way which would result in noncompliance with any applicable safety standards including but not limited to Federal Motor Carrier Safety Administration Subpart G Miscellaneous Parts and Accessories Section 393 83 Exhaust Systems Systems verified under this Executive Order shall conform to all applicable California emissions regulations The terms and conditions of this Executive Order must be satisfied regardless of where the system is sold in order for the system to be considered verified Systems sold as verified or which carry the ARB approved label must satisfy all the terms and conditions of this Executive Order This Executive Order does not release ESW CleanTech from complying with all other applicable regulations Violation of any of the above conditions shall be grounds for revocation of this Executive Order This Executive Order hereby supersedes Executive Order DE 08 007 04 dated June 16 2011 Executive Order DE 08 007 03 dated January 18 2011 Executive Order DE 08 007 02 dated January 14 2010 Executive Order DE 08 007 01 dated February 27 2009 and Executive Order DE 08 007 dated December 9 2008 Executed at El Monte California and effective this 13th day of June 2013 Annette Hebert Chief ile Source Control Division ESW Longview Owner s Manual 2013 Rev0820 Page 46 This page intentionally left blank ESW Longview Owner s Manual
7. all applications Factors like engine duty cycle soot composition ash composition and others can also have an impact on the filter cleaning interval Furthermore the guide applies only to ash accumulation in the filter if the engine does not meet the temperature requirements for regeneration or if there are excessive soot emissions e g from a failed injector more frequent filter cleaning may be required to remove the soot ESW CleanTech as an industry leader in filter cleaning techniques continues its efforts to improve its cost effective filter cleaning solutions As these techniques improve we expect to be able to clean filters with ash loadings greater than 200 grams thereby extending the cleaning interval beyond the values described above In summary to ensure that the DPF is fully cleanable ESW CleanTech recommends that the customer monitor their oil consumption rate and schedule filter cleaning before the filter has accumulated 200 grams of ash Customers can extend their filter cleaning interval by Maintaining their engines to minimize oil consumption Switching to low ash oils ESW Longview Owner s Manual 2013 Rev0820 Page 28 SPECIFICATIONS ESW Longview Owner s Manual 2013 Rev0820 Page 29 Longview System J Size System Total Weight 123 pounds Catalyst Assembly Weight 98 pounds Construction 304 Stainless Steel Fuel Type same as engine fuel ULSD or CARB diesel Fuel C
8. be sure to order the correct label for your application see the table below the pictures Figure 11 Example of CARB verification Figure 12 CARB verification label installed label for Longview installed on engine on Longview wiring harness at Controls Box Product Application Verification Family Name Label Part Number Longview On road CA ECT 2008 PM3 N25 ON LNF01 CUH 2201 1K Longview On road CA ECT 2008 PM3 N25 ON LNF02 CUH 2201 2K ESW Longview Owner s_Manual 2013 Rev0820 Page 11 ESW Longview Owner s Manual 2013 Rev0820 Page 12 OPERATIONS ESW Longview Owner s Manual 2013 Rev0820 Page 13 Pay Attention to the System Engine and Vehicle The green light on indicates that the system is operational During normal operation the amber light will be off If the amber light turns on or blinks contact an ESW CleanTech authorized technician or a properly trained technician under the owner s control as soon as practical The indicator lights are described below Refer to the Troubleshooting Table page 22 if you suspect the system is not operating properly 1 The operator should observe the green and amber lights regularly during normal operation and respond accordingly 2 During engine operation note any indications of unusual exhaust emissions or odor Notify an ESW CleanTech authorized technician or the owner s technician if any unusual odors or emissions are observed 3 Periodically inspect
9. electronic control unit 8 1 CUE 45 Sensor backpressure 9 1 CU ME _ Static mixer assembly 10 1 CUE 55 Diesel fuel pump filter 11 1 CUP 7 Fuel pressure regulator 12 1 CUE 1 Injector assembly 13 1 CUE 41 Sensor manifold absolute pressure 14 1 Su Kit label Verification Longview Underlined spaces represent variables depending on specific configuration and application Parts that may be required for preventative maintenance are not covered by the product warranty as discussed in the Maintenance Schedule section on page 18 and are listed in the table below Longview Maintenance Parts List Part Number Description CUP 49 Fuel pump filter small CUP 50 Fuel pump filter large ESW Longview Owner s Manual 2013 Rev0820 Page 22 Troubleshooting Table Use the table below to diagnose and resolve potential Longview operating problems Most abnormal conditions will require service or repair by an ESW CleanTech authorized technician or a properly trained technician Condition Probable Cause Remedy 1 Green LED On e MLC has power e No action required desired condition e Operate amp monitor normally 2 Green LED Off No power or open fuse e Check fuse wires and power to Loss of MLC program the MLC if amber on and green off e Contact a properly trained Faulty LED or wiring technician for repair 3 Amber LED blinks High backpressure e Follow the Amber Lig
10. installed with a backpressure monitor to notify the operator when the backpressure limit is reached The notification must occur and be clearly visible to the operator while the vehicle or equipment is in use The other terms and conditions specified below IT IS ALSO ORDERED AND RESOLVED That installation of the Longview system manufactured by ESW CleanTech Incorporated 6755 Mira Mesa Boulevard Suite 123 122 San Diego California 92121 has been found not to reduce the effectiveness of the applicable vehicle pollution control system and therefore the Longview system is exempt from the prohibitions in Section 27156 of the Vehicle Code ESW Longview Owner s Manual 2013 Rev0820 Page 43 for installation on heavy duty on road vehicles This exemption is only valid provided the engines meet the aforementioned conditions ARB reserves the right in the future to review this Executive Order and the exemption and verification provided herein to assure that the exempted and verified add on or modified part continues to meet the standards and procedures of CCR Title 13 Section 2222 et seq and CCR Title 13 Sections 2700 through 2711 The Longview system consists of the following major system components listed in order from exhaust inlet to outlet as they are arranged within the exhaust system of the vehicle one fuel injector one static mixer one inlet cone two lean NOx catalyst modules one catalyzed wall flow DPF and one outlet cone
11. service 3 Amber LED flashing High backpressure 4 Amber LED on solid Longview needs service o Green Light On The green light indicates that the system power is on o Green Light Off Attention If the green light is off while the engine is operating service is required See the Troubleshooting Table page 22 for possible causes and remedies o Amber Light Flashing A flashing amber light indicates high backpressure Maintenance is required A number of factors can cause this situation such as excessive idling or the engine producing excessive soot These primary causes produce an overloaded DPF or soot accumulation on the NRC which in turn cause high backpressure See the Troubleshooting Table page 22 for possible causes and remedies If the amber light is still flashing after following the recommended procedures then contact an ESW CleanTech authorized technician for maintenance o Amber Light On Solid A solid amber light indicates a broken or disconnected sensor or a system fault Verify that all the wiring harness connections are properly attached If the amber light stays on have the system serviced as soon as possible For some faults the solid amber light can only be turned off through the service computer connection to the MLC The amber light will turn on solid for a few seconds after the engine starts This allows the operator to confirm that the LED itself is operational ATT
12. the exhaust system for integrity Note anything abnormal and make repairs as warranted For vertical exhaust stacks make sure the rain cap is in place and functioning properly Contact an ESW CleanTech authorized technician as needed 4 Periodically inspect the Longview fuel system for integrity Note anything abnormal and make repairs as needed Contact an ESW CleanTech authorized technician as needed System Indicator Lights The operator must observe the Longview system indicator lights on a regular basis and respond accordingly The label placed next to the lights Figure 13 provides a brief description of each lights meaning The light meanings are explained in greater detail after the label below ESW CleanTech LONGVIEW NOx Exhaust Filter www eswgroup com Solid System On 2 Flashing Maintenance Required Solid Service Required Consult the Owner s Manual for additional information CAREB Verification Labels are located the engine and at the Controls Box Figure 13 Label for Longview system indicator lights ESW Longview Owner s Manual 2013 Rev0820 Page 14 Meaning Action 1 Green LED is off Contact an ESW CleanTech while engine is on authorized distributor for service No action required unless 2 Green LED is on solid MLC is on indicated AE 2 light Follow the Amber Light Flashing guide p 23 Contact an ESW CleanTech authorized distributor for
13. valid provided the engines meet the aforementioned conditions ARB reserves the right in the future to review this Executive Order and the exemption and verification provided herein to assure that the exempted and verified add on or modified part continues to meet the standards and procedures of CCR Title 13 Section 2222 et seq and CCR Title 13 Sections 2700 through 2711 The Longview system consists of the following major system components listed in order from exhaust inlet to outlet as they are arranged within the exhaust system of the vehicle one fuel injector one static mixer one inlet cone two lean NOx catalyst modules one catalyzed wall flow DPF and one outlet cone The Longview system also includes a backpressure monitor and warning system The major components of the Longview system are identified in the parts list The parts list and schematics of the approved product and engine labels are available on the website shown above The Longview system is comprised of two lean NOx catalyst modules and a single catalyzed wall flow DPF designed to filter the exhaust from a single engine Longview systems with multiple DPFs including designs with two or more filter components canned together or multiple individually canned filter components in parallel or in series or any combination thereof are not valid under this Executive Order Channeling exhaust from a single engine through multiple Longview systems deployed in parallel or in
14. 013 Rev0820 Page 42 The engine must have a power rating of at most 450 horsepower The application must have a duty cycle with a temperature profile greater than 260 degrees Celsius for at least 25 percent of the time The engine must be in its original certified configuration The engine must not be certified to a pre existing original equipment manufacturer OEM DPF The engine must be certified to have a pre existing OEM diesel oxidation catalyst DOC The DOC may be removed to facilitate installation of the Longview system e For model years 1994 and newer the engine must a PM certification level of at most 0 1 grams per brake horsepower hour g bhp hr and greater than 0 01 g bhp hr e The engine must have a four stroke combustion cycle The engine must be turbocharged e The engine must be well maintained and not consume lubricating oil at a rate greater than that specified by the engine manufacturer e Lube oil or other oil must not be mixed with the fuel e The engine must be operated on fuel that has a sulfur content of no more than 15 parts per million by weight The system must not be operated with fuel additives as defined in Section 2701 of Title 13 of the CCR unless explicitly verified for use with the fuel additive s The system must not be used with any other systems or engine modifications without approval from ARB and the manufacturer The system must be
15. 2013 Rev0820 Page 47 E W CleanTech ESW CleanTech Inc 6755 Mira Mesa Blvd Suite 123 122 San Diego CA 92121 1 800 398 6105 ESW Longview Owner s Manual 2013 Rev0820 Page 48
16. ENTION A solid or flashing amber light indicates that service or maintenance is required ESW Longview Owner s Manual 2013 Rev0820 Page 15 Monitoring the Fuel System The operator should observe both the engine and Longview system for the following o Fuel Leaks Clearly any fuel leak presents a safety concern warranting immediate action The first step is to investigate and see if the problem can be resolved immediately and locally In the event that special parts that is Longview components are at fault then contact your distributor immediately for further assistance o Fuel Consumption Fuel consumption varies with the specific application driving habits and other factors Generally the Longview system s fuel consumption will be in the range of 3 to 5 or less of the engine s fuel consumption If you experience excessive fuel consumption please contact the distributor o Fuel Supply The Longview system s operation depends on a clean fuel supply An integrated fuel pump and filter is part of the Longview fuel system The fuel filter should be inspected and replaced if necessary during the Longview system s preventative maintenance Ultra low sulfur diesel fuel ULSD is required for CARB Level 3 verified Longview applications ESW Longview Owner s Manual 2013 Rev0820 Page 16 Conditions That May Damage the Lonqview The operator should be aware of conditions that could result in damage to or failure of the catalyst as
17. The Longview system also includes a backpressure monitor and warning system The major components of the Longview system are identified in the parts list The parts list and schematics of the approved product and engine labels are available on the website shown above The Longview system is comprised of two lean NOx catalyst modules and a single catalyzed wall flow DPF designed to filter the exhaust from a single engine Longview systems with multiple DPFs including designs with two or more filter components canned together or multiple individually canned filter components in parallel or in series or any combination thereof are not valid under this Executive Order Channeling exhaust from a single engine through multiple Longview systems deployed in parallel or in series or any combination thereof is also not valid under this Executive Order No changes are permitted to the system ARB must be notified in writing of any changes to any part of the Longview system Any changes to the system must be evaluated and approved in writing by ARB Failure to do so shall invalidate this Executive Order ESW CleanTech must ensure that the installation of the Longview system conforms to all applicable industrial safety requirements Changes made to the design or operating conditions of the Longview system as exempted by ARB which adversely affect the performance of the vehicle s pollution control system shall invalidate this Executive Order This E
18. There is additional troubleshooting information in the Longview and Lonestar Service Manual a manual intended for trained technicians ESW Longview Owner s Manual 2013 Rev0820 Page 23 Amber Light Flashing A flashing amber light indicates high backpressure High backpressure is usually the result of an overloaded DPF or soot accumulation on the front of the NRC The causes and remedies for an overloaded DPF or soot accumulation on the NRC are provided after the chart below Follow Figure 15 to respond to a flashing amber light condition The Drive Hard Procedure is explained after the chart Begin Amber light flashin Perform Drive Hard Procedure Yes Customer s option Check amber light Amber light ON Monitor and drive vehicle normally 4 No Solid Y Call for service or take the vehicle in Not necessary to abort the vehicle s mission May repeat Drive Hard at owner s option First time to Drive Hard No Y Schedule vehicle for maintenance Soon Operate as usual until then Vehicle is maintained by a properly trained technician gt End Figure 15 Flashing Amber Light Troubleshooting Process o Drive Hard Procedure The customer may perform this procedure at their option If they do not want to do it then they should schedule the Longview for maintenance by
19. a properly trained technician as soon as practicable The vehicle may be operated normally until the maintenance appointment ESW Longview Owner s Manual 2013 Rev0820 Page 24 Run the engine hard under as much load as possible for at least 30 to 45 minutes at sustained intervals This operation may regenerate the DPF and the light will reset itself Check the light again at the end of the day If the amber light goes out then operate normally from that time onward If the light stays on the customer may repeat this process at their option If the amber light is still flashing after more than one Drive Hard then schedule the system for maintenance by a properly trained technician as soon as practicable The operator may use the vehicle normally until the maintenance appointment ATTENTION If the amber light turns on solid at anytime then the Longview will require maintenance by a properly trained technician o DPF overloaded with soot or ash In some cases driving the vehicle under load Drive Hard Procedure can regenerate a DPF overloaded with soot Sometimes though the high backpressure from the DPF is the result of ash loading in the DPF which requires cleaning the DPF off of the vehicle If high backpressure from an overloaded DPF becomes repetitive it might be that the engine is producing high levels of soot or the vehicle s duty cycle is relatively light A light duty cycle causes the engine s average exhaust temperature t
20. anging the fuel filter at that time and anytime the engine fuel filter is changed Catalyst Assembly and DPF Maintenance It may be necessary to periodically clean the DPF module in addition to the annual cleaning depending on the vehicle s driving cycle and the ash content of the diesel fuel and lube oil The collection of inorganic ash results in an increase in backpressure from the catalyst assembly over time If ash in the DPF results in high backpressure then the amber light will flash Note higher than normal oil consumption will increase the rate of ash accumulation in the DPF and thus may require more frequent maintenance ESW CleanTech recommends the use of low ash engine oils CJ 4 oil These products have been specifically designed for use with a DPF and can significantly reduce the buildup of ash in the DPF and extend the filter cleaning interval See the Engine Oil Consumption and Lube Oil Ash section on page 26 An ESW CleanTech authorized distributor can clean the DPF module They also will ensure that the collected material ash and soot is properly disposed in accordance with all applicable Federal State and local laws governing waste disposal ESW Longview Owner s Manual 2013 Rev0820 Page 20 The catalyst assembly is designed to process exhaust flow in only one direction The order of the individual modules within the catalyst assembly is also critical for the proper operation of the Longview system If any sec
21. ashing the vehicle should not be a problem for the catalyst assembly Longview system Avoid pointing the high power wash at any Longview system connectors However depending on the power washing technique it may be possible to loosen an electrical connector If a connector comes loose the amber LED might light If the amber light comes on follow the procedures in the Troubleshooting Table page 22 For vertical stacks be sure the rain cap is in place and functioning properly It is important that water does not enter the exhaust pipe where it could migrate to the catalysts or DPF Avoid low hanging branches or other obstacles that could knock off the rain cap ESW Longview Owner s Manual 2013 Rev0820 Page 17 MAINTENANCE AND REPAIR ESW Longview Owner s Manual 2013 Rev0820 Page 18 Your Right to Maintenance Information The Air Resources Board requires that ESW CleanTech 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 ESW CleanTech at 1 800 398 6105 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 clai
22. ceeds 250 hp GVWR exceeds 33 000 Ibs and the truck is 2 years 1 Typically driven over 100 000 miles per year and unlimited miles 2 Has less than 300 000 miles on the odometer at the time of installation Off Road Under 25 hp and for constant speed engines rated under 50 hp with rated 3 years or ara speeds greater than or equal to 3 000 rpm 1 600 hours portable engines At or above 25 hp and under 50 h SU AD Stationary P P 2 600 hours Marine Locomotives 5 years TRU and 4 200 hours APU WARRANTY COVERAGE For an engine used in an application listed in Table 1 the warranty period will be the years or hours or miles of operation shown in Table 1 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 18 Sections 2700 to 2706 and 2710 within the warranty period as defined above ESW CleanTech Inc will repair or replace the diesel emission control system including parts and labor In addition ESW CleanTech 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 b
23. easet tan Pese ae e rese Eee eR 11 ODOFdtlOKIS nuca dae xol cand tad nae Eod bla d da ii c Xo eva YE aaa acceda 12 Pay Attention to the System Engine and 4 1 1 1 enne enne 13 System Indicator Lights ice t ten duce x EE dde E PEE de E Banda 13 Monitoring the Fuel 15 Conditions That May Damage the 16 Maintenance and Repair 17 Your Right to Maintenance 18 The Importance of Engine 18 The Importance of Properly Maintaining a Diesel Emission Control Strategy 18 Maintenance Schedules o Ip p ee rU vr 18 Preventative Maintenance Labor and Parts 19 Service Calls ah hp it tad eb beh i n feda 20 Parts List E 21 Troubleshooting Table cocer ere ep Ree ect ve ea ud ende ve Edu E dope 22 Amber Light Flashing ouod eee eve ae v pee e dece t ee 23 Repair and Maintenance 25 Engine Consumption and Lube 4 440 0 000 aaa aaa aaa aaa 26 Specifications qme
24. ed 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 Fuel Injector Assembly Fuel shut off 6 hose 28 inch maximum elevation above BZ gt 9 To Engine bottom of fuel tank Engine s fuel filter and filter Figure 3 Fuel system flow diagram ESW Longview Owner s Manual 2013 Rev0820 Page 8 Major Component Pictures The major components of the Longview system not previously shown are given in this section the catalyst assembly is shown in Figure 2 on page 7 and the fuel injection system components are shown in Figure 3 on page 8 Parts Shown Individually Backbone Figure 5 Inspection port Figure 7 Thermocouples ESW Longview Owner s Manual 2013 Rev0820 Page 9 Figure 8 Figure 9 Engine RPM sensor Manifold pressure sensor Figure 10 Controls box ESW Longview Owner s Manual 2013 Rev0820 Page 10 CARB Verification Labels The system is provided with two CARB verification labels One is installed on the engine Figure 11 and the other one is attached to the wiring harness at the Controls Box Figure 12 If either one is missing order a replacement label from an ESW CleanTech authorized distributor and
25. eplaces the stock muffler ESW CleanTech provides a mounting assembly specifically designed for the Longview Exhaust from Engine z Port not visibie DPF Module Figure 2 Catalyst Assembly cone configurations vary depending on vehicle Care and handling requirements for the catalyst assembly are as follows Do not drop or hammer Use appropriate equipment when lifting Attention Protect from water intrusion Protect from accidental impacts Do not weld Protect the flanges during transport use the foam shipping covers D um me Although the catalyst assembly replaces the OEM muffler be aware that the catalyst assembly is approximately twice the weight of a typical muffler E The catalyst assembly creates backpressure on the engine The DPF provides high filtration efficiency which results in backpressure on the engine The backpressure from the Longview varies instantaneously depending on the engine speed and load and the soot and ash loading in the DPF At times the backpressure from the Longview 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 Longview system is not nearly high enough to lead to excessive exhaust manifold temperatures or significant loss of performance Typical average backpres
26. ew operations in addition to watching the indicator lights See the Operations section beginning on page 12 for routine observations that the driver and or owner should perform Also see the Owners Obligations section on page 30 Upon any indication of a malfunction promptly contact an ESW CleanTech authorized distributor or the owner s technician See the Contact Information section on page 3 Please be prepared with the following information 1 Fault information and descriptions in as much detail as possible 2 The part number and serial number of each catalyst and DPF module see Figure 14 em ESW CleanTech 800 398 6105 www eswgroup com Part CJC 02 Serial 000000 Figure 14 Example of NRC Module Data Plate ESW Longview Owner s Manual 2013 Rev0820 Page 21 Parts List A complete parts list was provided with the system Contact your ESW CleanTech authorized distributor if you need a replacement list The major parts are listed in the table below with underlined spaces representing variables that depend on specific configuration and application Longview System Major Parts List ltem Qty Part Number Description 1 1 C_F _ Diesel Particulate Filter Assembly Unidirectional 2 2 C_C 02 NOx reduction catalyst 3 1 D AP Cone inlet 4 1 C Cone outlet 5 1 CMA Sensor RPM 6 2 4 Sensor thermocouple 7 1 CMK 5 0 or CMK 6 0 MLC MLC
27. fied the verified parts list the verified labels swapping and re designation information and other product information can be found here http www arb ca gov diesel verdev companies esw longview htm The aforementioned verification is subject to the following terms and conditions The engine must be originally manufactured from model year 1993 through 2006 e The engine must be used by an on road motor vehicle with a manufacturer s Gross Vehicle Weight Rating of over 14 000 pounds The engine must be certified for on road applications The engine must not employ exhaust gas recirculation e The engine s displacement must not exceed 14 liters ESW Longview Owner s Manual 2013 Rev0820 Page 37 The engine must have a power rating of at most 450 horsepower The application must have a duty cycle with a temperature profile greater than 260 degrees Celsius for at least 25 percent of the time The engine must be its original certified configuration The engine must not be certified to have a pre existing original equipment manufacturer OEM diese particulate filter DPF The engine must not be certified to have a pre existing OEM diesel oxidation catalyst For model years 1994 and newer the engine must have PM certification level of at most 0 1 grams per brake horsepower hour g bhp hr and greater than 0 01 g bhp hr e The engine must have a four stroke combustion cycle
28. here are no other warranties expressed or implied of merchantability or fitness for a particular purpose For the purpose of the product warranty and installation warranty abuse or neglect includes vehicle accidents ignoring the System indicator lights blending lubricating oil with fuel or any engine failure or condition that are not proximately caused by the diesel emission control system that allows excess lubricating oil coolant contaminants or debris to enter the exhaust system The owner shall not use any fuel additive or lube oil additive that is not approved by EPA or CARB for use in diesel engines equipped with catalytic mufflers ESW CleanTech Inc recommends that the verified diesel emissions control strategy be installed and serviced by ESW CleanTech Inc authorized personnel Improper installation or service by unauthorized or untrained personnel may result in a denial of coverage under the product warranty or installation warranty ESW Longview Owner s Manual 2013 Rev0820 Page 35 CARB EXECUTIVE ORDERS FOR THE LONGVIEW Note that the first EO is for engines without an original equipment DOC muffler the second EO is for engines which have an original DOC muffler ESW Longview Owner s Manual 2013 Rev0820 Page 36 State of California AIR RESOURCES BOARD EXECUTIVE ORDER DE 08 006 05 The diesel emission control strategy described herein qualifies as a potential compliance option for the Air Resources Board s ARB i
29. ht overloaded DPF or Flashing guide p 23 soot accumulation on NRC e Contact a properly trained technician for maintenance Sensor connection loose Check wiring connections Faulty sensor Contact a properly trained System malfunction technician promptly Loss of MLC program system needs maintenance as if amber on and green off soon as practical Loose connection s Tighten connection s Defective hose Replace faulty parts Fatigued or damaged O ring e Contact a properly trained Faulty injector technician for repair Loose tubing connection s Tighten connection s Loose clamp s Replace damaged tube Crack in exhaust tube Contact a properly trained Crack in catalyst assembly technician for repair Loose injector mount e Repair the engine Engine injector or turbo problem 7 White smoke e action required during startup catalyst assembly in exhaust tube 4 Amber LED on solid 5 Fuel drips or leaks 6 Unusual odor or exhaust noises 9 Visible emissions MLC power or signal loss e Contact a properly trained white or black e Fuel injector malfunction technician for repair smoke during e Sensor failure normal operations DPF failure 10 Engine surges or e Engine malfunction e Repair the engine has power loss e Loose connection fuel system Contact a properly trained e Soot accumulation on NRC or technician for service overloaded DPF Amber light should have been flashing
30. iance testing Section 2709 Proper engine maintenance is critical for the proper functioning of the diese emission contro strategy The owner of the vehicle on which the diesel emission control strategy is installed is strongly advised to adhere to all good engine maintenance practices Failure to document proper engine maintenance including keeping records of the engine s oil consumption may be grounds for denial of a warranty claim grounds for denial of a warranty claim This Executive Order is valid provided that the diesel fuel used in conjunction with the device complies with Title 13 CCR Sections 2281 and 2282 and if biodiesel is used the biodiesel blend shall be 20 percent or less subject to the following conditions The biodiesel portion of the blend complies with the American Society for Testing and Materials Specification D6751 applicable for 15 parts per million sulfur content and Use of system parts or replacement parts not authorized by ESW CleanTech may be The diesel fuel portion of the blend complies with Title 13 CCR Sections 2281 and 2282 Other alternative diesel fuels such as but not limited to ethanol diesel blends and water emulsified diesel fuel are excluded from this Executive Order Longview system must not be located over any occupied space e g driver or passenger compartments or any other location deemed unacceptable by ESW Longview Owner s Manual 2013
31. ions Violation of any of the above conditions shall be grounds for revocation of this Executive Order This Executive Order hereby supersedes Executive Order DE 08 006 04 dated June 16 2011 Executive Order DE 08 006 03 dated January 18 2011 Executive Order DE 08 006 02 dated January 14 2010 Executive Order DE 08 006 01 dated February 27 2009 and Executive Order DE 08 006 dated December 9 2008 Executed at El Monte California and effective this 13 day of June 2013 ESW Longview Owner s Manual 2013 Rev0820 Page 41 State of California AIR RESOURCES BOARD EXECUTIVE ORDER DE 08 007 05 The diesel emission control strategy described herein qualifies as a potential compliance option for the Air Resources Board s ARB in use diesel fleet rules Pursuant to the authority vested in ARB by the Health and Safety Code Division 26 Part 5 Chapter 2 and pursuant to the authority vested in the undersigned by Health and Safety Code Sections 39515 and 39516 and Executive Order G 02 003 Relating to Exemptions under Section 27156 of the Vehicle Code and Verification under Sections 2700 to 2711 of Title 13 of the California Code of Regulations CCR ESW CleanTech Incorporated ESW CleanTech Longview Diesel Particulate Filter DPF System Longview ARB has reviewed ESW CleanTech s request for verification of the Longview system Based on an evaluation of the data provided and pursuant to the terms and conditions s
32. l the Longview system complete installation procedures are described in the Longview Installation Manual Copies of the manual are available upon request from your distributor or ESW CleanTech The installation warranty page 34 is the responsibility of the distributor that installs the Longview system Attention An ESW CleanTech certified technician must commission the system otherwise that may be the basis for denying a warranty claim Warranty registration is submitted by the ESW CleanTech authorized distributor Engine Repower A DECS installed on a vehicle that is repowered may remain installed provided e 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 e The appropriate DECS engine label is affixed to the replacement engine 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 NO Nitrogen oxides NRC NO reduction catalyst OEM Original equipment manufacturer PM Particulate matter diesel soot TC Thermocouple ULSD Ultra low sulfur diesel fuel VDC Volts direct cur
33. ly and that no debris could enter the exhaust stream Debris or foreign matter in the exhaust stream can damage the catalysts or system components Also exhaust leaks may result in poor system performance and safety hazards Exhaust Tubing and Components page 20 For a vertical exhaust stack the rain cap is knocked off or somehow missing Replace the rain cap immediately If any water entered the exhaust pipe then contact the distributor immediately Catalyst Assembly page 7 and Conditions That May Damage the Longview page 16 Oil consumption is more than the engine manufacturer s specification Monitor and keep accurate records of the engine s oil consumption rate If oil consumption exceeds the specification repair the engine so that oil consumption is within the manufacturer s specification Conditions That May Damage the Longview page 16 and Engine Consumption and Lube Oil Ash page 26 ESW Longview Owner s Manual 2013 Rev0820 Page 32 WARRANTY ESW Longview Owner s Manual 2013 Rev0820 Page 33 Product Warranty YOUR WARRANTY RIGHTS AND OBLIGATIONS ESW CleanTech Inc warrants 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 pe
34. m 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 Maintenance Schedule ESW CleanTech recommends that an ESW CleanTech authorized technician or a properly trained technician under the owner s control perform the maintenance and repair of a Longview Preventative maintenance is required once a year unlimited operating hours or every 50 000 miles whichever comes first to ensure the system is in good operating condition however the DPF may require cleaning more often than that depending on the engine s oil consumption rate See the Engine Oil Consumption and Lube Oil Ash section on page 26 for more information The owner is legally required to keep the Longview in good operating condition in Ay order to comply with the Clean Air Act and CARB regulations for systems operating in California See the Owner s Legal Obligations section on page 2 Failure to have the preventative maintenance performed may be the basis for denying a warranty claim Mai
35. n use diesel fleet rules Pursuant to the authority vested in ARB by the Health and Safety Code Division 26 Part 5 Chapter 2 and pursuant to the authority vested in the undersigned by Health and Safety Code Sections 39515 and 39516 and Executive Order G 02 003 Relating to Exemptions under Section 27156 of the Vehicle Code and Verification under Sections 2700 to 2711 of Title 13 of the California Code of Regulations CCR ESW CleanTech Incorporated ESW CleanTech Longview Diesel Particulate Filter System Longview ARB has reviewed ESW CleanTech s request for verification of the Longview system Based on an evaluation of the data provided and pursuant to the terms and conditions specified below the Executive Officer of ARB hereby finds that the Longview system reduces emissions of diesel particulate matter PM consistent with a Level 3 device greater than or equal to an 85 percent reduction reduces emissions of oxides of nitrogen NOx consistent with a Mark 1 device greater than or equal to a 25 percent reduction Title 13 CCR Sections 2702 f and 2708 and is compliant with the 2009 nitrogen dioxide emissions limit Accordingly the Executive Officer determines that the system merits verification and subject to the terms and conditions specified below classifies the Longview system as a Level 3 Plus Mark 1 system for heavy duty on road vehicles that use certain heavy duty engines Engines for which the Longview system is veri
36. ntenance or repairs done by anyone other than an ESW CleanTech authorized technician is the responsibility of the person or organization performing the work The cost of parts and labor for preventative maintenance are not included in the purchase price of the Longview system The parts and labor included in preventative maintenance are listed in the Preventative Maintenance Labor and Parts section below ESW Longview Owner s Manual 2013 Rev0820 Page 19 Preventative Maintenance Labor and Parts Preventative maintenance by an ESW CleanTech authorized technician includes Download data from the MLC and review the Instant Report Confirm the system indicator lights are functioning properly Inspect the fuel injector assembly Replace the fuel filter and inspect the fuel pump Inspect the Controls Box and components Inspect and clean the backpressure sensor tubing and breather filter Inspect the sensors and wiring harness Inspect and clean the DPF Inspect the NRC modules and clean if necessary Inspect exhaust tubing Reinstall the DPF and confirm the system is securely mounted Upgrade the MLC program if necessary Make repairs if any of the above inspections showed repairs are needed Perform comprehensive tests of the system s operations O O O O O O O O O O O O Fuel Pump and Filter Maintenance The integrated fuel pump and filter should be inspected during the scheduled annual maintenance ESW CleanTech recommends ch
37. o be too cold to regenerate the DPF consistently Long idle times could also be the cause Rotating the vehicle to a tougher duty cycle application or reducing idle time to a minimum may be sufficient to avoid repeat amber light events caused by a DPF overloaded with soot Another cause of a frequently overloaded DPF may be engine problems such as excessive oil consumption that result in a high rate of ash into the DPF An ESW CleanTech authorized distributor can provide the DPF cleaning service to remove the ash Since engine problems may be the cause of the Longview amber light coming on ESW CleanTech recommends that the engine receive a thorough evaluation if the amber light does not turn off after performing the Drive Hard Procedure o Sootaccumulation on the NRC Soot accumulation on the NRC face occurs on a small percentage of vehicles due to a variety of factors including engine age and condition bad fuel injectors driver habits driving cycle and engine load If NRC soot accumulation has occurred a properly trained technician will be able to diagnose the condition and clean the NRC when the vehicle is brought in for maintenance according to Figure 15 The ESW CleanTech authorized distributor will be able to assist the customer in minimizing the impact of NRC soot accumulation on the vehicle s use and availability ESW Longview Owner s Manual 2013 Rev0820 Page 25 Since engine problems may be the cause of the excessive soot and thu
38. o not touch the Longview 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 e 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 Longview which is provided in this manual beginning on page 35 for the Longview may also be obtained from the CARB website at http www arb ca gov diesel verdev level3 level3 htm The installation of the Longview 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
39. onsumption maximum 2 2 gallons hour ESW CleanTech MLC Model ESW CleanTech MLC Rev 5 or Rev 6 Voltage Rev 5 9 to 15 VDC 12 V nominal Rev 6 9 to 28 VDC 12 or 24 V nominal Real time clock Battery backed Diagnostic and Programming I O 9 pin serial RS 232 or USB serial adapter adapter from harness required Inputs Catalyst Assembly Inlet Temperature Type K thermocouple ungrounded Catalyst Assembly Outlet Temperature Type K thermocouple ungrounded Engine RPM Sensor Frequency 0 5 12 kHz Catalyst Assembly Backpressure 0 5 VDC Engine Manifold Absolute Pressure 0 5 VDC Fuel Pressure Switch 0 5 VDC Outputs Fuel Pump Relay 12 VDC Two Power Output Lines for Sensors 5 VDC System Power On Indicator Green LED on System Service Indicator Amber LED on or flashing Pulse Width Modulation Channel One ESW Longview Owner s Manual 2013 Rev0820 Page 30 OWNER S OBLIGATIONS ESW Longview Owner s Manual 2013 Rev0820 Page 31 It is the owner or operator s obligation to take the appropriate action if any of these events symptoms occurs These actions are mandatory for proper system operation Failure to follow the required action s could be the basis for denying a warranty claim or a fine by CARB Event or Symptom Owner s Action Item Manual Section Initial installation of Longview sys
40. pecified below the Executive Officer of ARB hereby finds that the Longview system reduces emissions of diesel particulate matter PM consistent with a Level 3 device greater than or equal to an 85 percent reduction reduces emissions of oxides of nitrogen NOx consistent with a Mark 1 device greater than or equal to a 25 percent reduction Title 13 CCR Sections 2702 f and 2708 and is compliant with the 2009 nitrogen dioxide emissions limit Accordingly the Executive Officer determines that the system merits verification and subject to the terms and conditions specified below classifies the Longview system as a Level 3 Plus Mark 1 system for heavy duty on road vehicles that use certain heavy duty engines Engines for which the Longview system is verified the verified parts list the verified labels swapping and re designation information and other product information can be found here http www arb ca gov diesel verdev companies esw longview htm The aforementioned verification is subject to the following terms and conditions e The engine must be originally manufactured from model year 1993 through 2006 e The engine must be used by an on road motor vehicle with a manufacturer s Gross Vehicle Weight Rating of over 14 000 pounds The engine must be certified for on road applications The engine must not employ exhaust gas recirculation e The engine s displacement must not exceed 14 liters ESW Longview Owner s Manual 2
41. rent ESW Longview Owner s Manual 2013 Rev0820 Page 4 SYSTEM DESCRIPTION ESW Longview Owner s Manual 2013 Rev0820 Page 5 Product Summary The Longview system reduces oxides of nitrogen NO particulate matter PM carbon monoxide CO and unburned hydrocarbons HC from diesel engine exhaust Features include reduction catalyst NRC e Diesel particulate filter DPF ESW CleanTech MLC the electronic controller in the system e Stainless steel construction e Modular design to facilitate installation service and maintenance e Sound attenuation eliminating the need for a muffler or silencer The Longview system shown in Figure 1 consists of three main subsystems the catalyst assembly fuel delivery system and the control system Fuel Return Vehicle Fuel 1 Engine sensors 1 1 Tank d Monitoring Regulation Figure 1 ESW CleanTech Longview system The MLC monitors engine conditions Longview 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 NO emissions to the atmosphere The catalyzed DPF reduces the PM HC and CO emissions ESW Longview Owner s Manual 2013 Rev0820 Page 6 Catalyst Assembly The catalyst assembly Figure 2 is the core of the system and it r
42. rformance 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 in Table 1 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 emission related assemblies Where a warrantable condition exists ESW CleanTech Inc will repair or replace your diesel emission control system at no cost to you including diagnosis parts and labor Table 1 Warranty Period Engine Type Engine Size Warranty Period Light heavy duty 70 to 170 hp Gross Vehicle Weight Rating GVWR less than 19 500 Ibs 5 years or Medium heavy duty 170 to 250 hp GVWR from 19 500 Ibs to 33 000 Ibs 150 000 miles On Road Heavy heavy duty exceeds 250 hp GVWR exceeds 33 000 Ibs Heavy heavy duty ex
43. s installed Installer Repair improperly System or component damaged through abuse neglect or misapplication Warranty period has lapsed warrantable ESW CleanTech non warrantable Owner ESW Longview Owner s Manual 2013 Rev0820 Page 26 Engine Oil Consumption and Lube Oil Ash ESW CleanTech recommends that owners monitor the oil consumption of their engines and know the ash content of the engine oil to ensure that the DPF is scheduled for cleaning before it becomes overloaded with ash This section of the manual provides information to extend the filer cleaning interval of the DPF The DPF is designed to capture all solid particles coming from the tailpipe While most of the captured material can be readily regenerated oxidized inside the filter the DPF will accumulate incombustible materials collectively called ash which cannot be regenerated and must be removed through offline cleaning The majority of the ash comes directly from oil consumed during engine operation though small amounts of ash also come from the fuel and engine wear Most of the ash that accumulates in the DPF is part of the lube oil additive package and since the DPF will capture all solid materials coming from the engine exhaust all the ash from oil consumption will ultimately end up in the DPF Thus the ash content of the lube oil and the oil consumption rate become critical factors in determining the rate of ash acc
44. s the amber light flashing ESW CleanTech recommends that the engine receive a thorough evaluation if soot accumulation is frequent Repair and Maintenance Clarifications The warranty page 32 includes a section titled Owners Warranty Responsibility which clarifies that the owner or operator is responsible for making sure that the maintenance described in this owner s manual is performed In addition to the annual maintenance the amber light is another indicator that maintenance is required ATTENTION The amber light indicates that service is required Maintenance items such as cleaning an overloaded DPF or soot accumulation on an NRC that are caused by engine or vehicle operating conditions are warrantable items If a repair is required it may be covered under the installation or product warranty depending on the cause The table below provides a summary of service types maintenance or repair and what organization is responsible for the cost of the service Service Type and subtype Definition Example Cost Responsibility High backpressure from NRC unplanned soot accumulation or Owner overloaded DPF High backpressure from NRC Maintenance regularly planned soot accumulation or Owner overloaded DPF De ash filter change fuel pump annual filter perform multi step Owner complete system check out System or component fails in normal application System or component failed warrantable because it wa
45. sembly or Longview system any of these events occur it is the owner s responsibility to have the Longview inspected and if necessary repaired See the owner s legal requirements under the Clean Air Act and CARB regulations in the Owner s Legal Obligations section on page 2 Mechanical damage can occur if any system component is mishandled or accidentally impacted Internal damage to the catalyst assembly can occur from various forms of engine failure such as losing a turbo or head gasket These events would cause foreign debris to enter the exhaust gas and then impact the catalyst assembly likely causing some damage Furthermore losing a turbo or other major oil leaks could result in excessively high temperatures in the catalyst and DPF If the engine loses the turbo the driver should pull off the road as soon as possible and shut the engine off Engine oil consumption has an impact on the operation and maintenance of the Longview If engine oil consumption exceeds the manufacturers specification the engine should be repaired Failure to do so may damage the Longview and may be the basis for denying a warranty claim High oil consumption will increase the rate of ash accumulation in the diesel particulate filter and will lead to more frequent maintenance The Engine Oil Consumption and Lube Oil Ash section on page 26 explains the impacts of oil consumption and ash content on the operations and maintenance of the system Power w
46. series or any combination thereof is also not valid under this Executive Order No changes are permitted to the system ARB must be notified in writing of any changes to any part of the Longview system Any changes to the system must be evaluated and approved in writing by ARB Failure to do so shall invalidate this Executive Order ESW CleanTech must ensure that the installation of the Longview system conforms to all applicable industrial safety requirements Changes made to the design or operating conditions of the Longview system as exempted by ARB which adversely affect the performance of the vehicle s pollution control system shall invalidate this Executive Order This Executive Order is valid provided that installation instructions for the Longview system do not recommend tuning the vehicle to specifications different from those of the vehicle manufacturer Marketing of the Longview system using identification other than that shown in this Executive Order or for an application other than that listed in this Executive Order is prohibited unless prior written approval is obtained from ARB ESW Longview Owner s Manual 2013 Rev0820 Page 39 This Executive Order does not apply to any Longview system advertised offered for sale sold with or installed on a motor vehicle prior to or concurrent with transfer to an ultimate purchaser copy of this Executive Order must be provided to the ultimate purchaser at the time of sale
47. sure values from the Longview are well within acceptable levels for the engine The control system continuously monitors backpressure and alerts the operator if necessary Control System The control system consists of the and various sensors 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 ESW Longview Owner s Manual 2013 Rev0820 Page 7 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 Longview fuel pump does not turn on until a few seconds after the engine starts The fuel injector is mount
48. t or less subject to the following conditions e The biodiesel portion of the blend complies with the American Society for Testing and Materials specification 06751 applicable for 15 parts per million sulfur content and The diesel fuel portion of the blend complies with Title 13 CCR Sections 2281 and 2282 Other alternative diesel fuels such as but not limited to ethanol diesel blends and water emulsified diesel fuel are excluded from this Executive Order Longview system must not be located over any occupied space e g driver or passenger compartments or any other location deemed unacceptable by ESW Longview Owner s Manual 2013 Rev0820 Page 40 ESW CleanTech and must not be installed in a way which would result in noncompliance with any applicable safety standards including but not limited to Federal Motor Carrier Safety Administration Subpart G Miscellaneous Parts and Accessories Section 393 83 Exhaust Systems Systems verified under this Executive Order shall conform to all applicable California emissions regulations The terms and conditions of this Executive Order must be satisfied regardless of where the system is sold in order for the system to be considered verified Systems sold as verified or which carry the ARB approved label must satisfy all the terms and conditions of this Executive Order This Executive Order does not release ESW CleanTech from complying with all other applicable regulat
49. te California 91731 or 800 363 7664 electronic mail helpline arb ca gov Installation Warranty YOUR WARRANTY RIGHTS AND OBLIGATIONS The installer must warrant that the installation of a diesel emission control system 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 2706 The warranty period and the extent of the warranty coverage provided by the installer must be the same as the warranty provided by ESW CleanTech Inc and the same exclusions apply OWNER S WARRANTY RESPONSIBILITY As the vehicle engine or equipment owner you are responsible for presenting your vehicle engine or equipment and diesel emission control system to the installer as soon as a problem with the installation is detected If you have questions regarding your warranty rights and responsibilities you should contact the installer or ESW CleanTech Inc at 800 398 6105 or the California Air Resources Board at 9528 Telstar Avenue El Monte California 91731 or 800 363 7664 or electronic mail helpline arb ca gov ESW CleanTech Inc Warranty Clarifications Which do not limit or modify the provisions of the Product Warranty or Installation Warranty in any way The product warranty above is the sole warranty made by ESW CleanTech Inc T
50. tem Review this manual and pay close attention to each item in the Operations section Operations page 12 Flashing amber light high backpressure May perform the Drive Hard Procedure at the operator s option Contact a properly trained technician as needed System Indicator Lights page 13 and Troubleshooting Table page 22 Solid amber light bad sensor or system fault Contact a properly trained technician as soon as possible System Indicator Lights page 13 and Troubleshooting Table page 22 Engine failure such as turbo failure injector failure excess oil consumption or leaky head gasket If the turbo fails get off the road safely ASAP and shut the engine off Contact a properly trained technician immediately Longview catalysts or system components may be damaged from foreign material Conditions That May Damage the Longview page 16 Road debris or other object impacts Longview system or components Contact a properly trained technician immediately since system components may be damaged including hidden damage to internal catalyst components Catalyst Assembly page 7 and Conditions That May Damage the Longview page 16 Tubing or exhaust component turbo or exhaust brake for example between the engine and the catalyst assembly is removed replaced or in poor condition Ensure that the tubing or component is installed proper
51. tions are disassembled for maintenance or any other reason be sure that they are reinstalled in their proper position Also be aware that the DPF module has a flow direction arrow on it and must be installed accordingly The NRC modules can be installed in either direction as long as they are installed in their proper sequence within the catalyst assembly Exhaust Tubing and Components All tubing connections between the engine and the catalyst assembly should be maintained in a gas tight and leak free manner Also all tubing between the engine and catalyst assembly must be maintained in good condition This requirement includes any other components such as exhaust brakes Aluminized mild steel tubing or rusty tubing could flake off into the exhaust stream If flaking occurs the catalyst or DPF may plug resulting in high backpressure and engine power loss ESW CleanTech recommends using stainless steel tubing between the turbo and the catalyst assembly It is the engine owner or operator s responsibility to ensure that all tubing in this critical area be maintained in good condition Service Calls The MLC controls the green and amber indicator lights to provide system status as described in the System Indicator Lights section page 13 Not all conditions will be detected by the MLC for example an accident that physically damages the catalyst assembly Therefore it is important for the owner and or operator to observe the engine and Longvi
52. umulation in the filter It is important to note that once the DPF captures approximately 200 grams about 7 ounces of ash it will no longer be possible to remove all the ash from the filter using existing cleaning techniques Therefore it is important to proactively clean your DPF based on 1 oil consumption rate and 2 lube oil ash content Pre 2007 4 oil typically contains between 1 2 and 1 596 ash by weight The new CJ 4 oils designed especially for diesel engines with a DPF contain approximately 1 096 ash and will therefore result in a lower filter loading for a given amount of oil consumption Given the ash content the filter must be cleaned once the engine has consumed the following amount of oil Every 24 Quarts with CJ 4 Every 16 Quarts with 4 Using the ash content of these oils the service intervals shown in Figure 16 are recommended to ensure optimum performance and cleanability of the DPF ESW Longview Owner s Manual 2013 Rev0820 Page 27 DPF Cleaning Interval for 4 and CJ 4 Oils 80 000 70 000 60 000 50 000 40 000 CJ 4 Interval 30 000 Miles to DPF Cleaning 10 000 20 000 5 0 500 1 000 1 500 2 000 2 500 3 000 3 500 Oil Consumption Rate Miles Quart Figure 16 DPF cleaning interval as a function of oil consumption rate for a typical well maintained engine The values presented above are provided as estimations and may not apply to all filters in
53. xecutive Order is valid provided that installation instructions for the Longview system do not recommend tuning the vehicle to specifications different from those of the vehicle manufacturer Marketing of the Longview system using identification other than that shown in this Executive Order or for an application other than that listed in this Executive Order is prohibited unless prior written approval is obtained from ARB ESW Longview Owner s Manual 2013 Rev0820 Page 44 This Executive Order does not apply to any Longview system advertised offered for sale sold with or installed on a motor vehicle prior to or concurrent with transfer to an ultimate purchaser A copy of this Executive Order must be provided to the ultimate purchaser at the time of sale As specified in Section 2706 j Title 13 CCR of the Verification Procedure Warranty and In Use Compliance Requirements for in Use Strategies to Control Emissions from 4 Diesel Engines Procedure ARB assigns each diesel emission control strategy family name The designated family name for the verification as outlined above is CA ECTI2008 PM3 N25 ONILNF02 The designated family name CA ECT 2008 PM3 N25 ON LNFO2 the previous name CA CLE 2008 PM3 N25 ON LNFO2 As stated in the Procedure ESW CleanTech is responsible for recordkeeping requirements Section 2702 honoring the required warranty Section 2707 and conducting in use compl
54. y the verified diesel emission control strategy This also includes those relevant diagnostic expenses in the case in which a warranty claim is valid ESW CleanTech Inc may at its option instead pay the fair market value of the engine prior to the time the failure occurs ESW Longview Owner s Manual 2013 Rev0820 Page 34 OWNER S WARRANTY RESPONSIBILITY As the vehicle engine or equipment owner you are responsible for performing the required maintenance described in your owner s manual ESW CleanTech 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 ESW CleanTech Inc may have grounds to deny warranty coverage You are responsible for presenting your vehicle equipment or engine and diesel emission control system to an ESW CleanTech Inc distributor 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 ESW CleanTech Inc at 1 800 398 6105 or the California Air Resources Board at 9528 Telstar Avenue El Mon

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