LongMile -S
Contents
1. and effective this 16 day of 2013 Annette Hebert Chief Mobile Source Control Division LongMile S Owners Manual ESWCT 2013 07 16 Page 35 This page intentionally left blank LongMile S Owners Manual ESWCT 2013 07 16 Page 36 ESW CleanTech ESW CleanTech Inc 6755 Mira Mesa Blvd Suite 123 122 San Diego CA 92121 1 800 398 6105 LongMile S_Owner s_Manual ESWCT 2013 07 16 Page 372. confirm that the LED itself is good LongMile S Owners Manual ESWCT 2013 07 16 Page 13 Conditions That May Damage the LongMile S The operator should be aware of conditions that could result in damage or of the PM filter assembly or other parts of the system If any of these events occur it is the owners responsibility to have the LongMile S inspected and if necessary repaired See the owner s legal requirements under the Clean Air Act and CARB regulations in the 5 Legal Obligations section on page 2 Mechanical damage can occur if any system component is mishandled or accidentally impacted Internal damage to the PM filter 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 PM filter assembly likely causing some damage Furthermore losing a turbo a failed injector or a major oil leak could result in excessively high temperatures in the PM filter assembly If the engine loses the turbo the operator should move the vehicle to a safe location as soon as possible and shut the engine off Excessive idle can cause a buildup of soot in the DPF which could lead to excessive temperatures in the DPF during higher load operations resulting in damage to the DPF If the engine has been idling for more than 5 minutes turn it off Extended idle may lead to damage of the LongMile S and may be
3. specifically designed for the LongMile S 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 assembly requires the following care and handling Do not drop or hammer 4 4 1 Attention Use appropriate equipment when lifting Handle with care Protect from water intrusion Protect from accidental impacts Do not weld G Se oS Protect flanges during transport use the foam shipping covers LongMile S Owners Manual ESWCT 2013 07 16 Page 7 LongMile S system configuration with respect to engine horsepower Depending on the engine horsepower the verified LongMile S system configuration is shown in the table below Verified LongMile S Configurations and Engine Horsepower DOC Part Number DPF Part Number HP Range CJD 27 10 or CJF CJDA 27 10 or CKE 175 300 CJD 35 10 oa A H 350 CJD 20 10 or CJDA 20 10 275 400 300 450 400 500 Note ESW S reserves ves the right to limit part use where the ranges overlap 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 LongMile S creates backpressure on the engine At times the backpressure from the LongMile S system may be higher than the backpressure caused by a muffler The actual amount of backpressure from the LongMile S varies instant
4. 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 includes speeds greater than or equal to 3 000 rom 1 600 hours ee engines At or above 25 hp and under 50 h Stationary 2 600 hours Marine Locomotives 5 years or TRU and At or above 50 hp 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 13 Sections 2700 to 2706 and 2710 within the warranty period as defined above ESW CleanTech will repair or replace the diesel emission control system including parts and labor In addition ESW CleanTech will replace or repair the engine components to the condition they were in prior to the failure including parts and labor for damage to the engine proximately caused by the verified diesel emission control strategy This also includes those relevant diagnostic expenses in the case in which a warranty claim is valid ESW CleanTech m
5. turn out stack is knocked off or somehow missing Oil consumption is more than the engine manufacturer s specification Engine has been idling for more than 5 minutes Review this manual and know the requirements for the LongMile S system Be sure that operators and maintenance staff understand each item in the Operations section Contact a ESW CleanTech authorized distributor or a properly trained technician to investigate the cause of the flashing amber light and clean the DPF if needed Contact a properly trained technician to service the LongMile S as soon as possible Do not allow the engine to exceed 8 hours of run time If the turbo fails park in a safe place ASAP and shut the engine off Contact a properly trained technician promptly System components may be damaged from foreign material Contact a properly trained technician promptly since system components may be damaged including hidden damage to internal components Ensure that the tubing or component is installed properly and that no debris could enter the exhaust stream Debris or foreign matter in the exhaust stream can damage the PM filter assembly or system components Also exhaust leaks may result in poor system performance and safety hazards Replace the rain cap or turn out stack as soon as practical If any water entered the exhaust pipe then contact a properly trained technician Monitor and keep accurate records of the engine s
6. 13 07 16 Page 22 SPECIFICATIONS LongMile S Owners Manual ESWCT 2013 07 16 Page 23 LongMile S System PAE AN PM Filter Assembly Weight 125 to 150 pounds Materials of Construction 304 stainless steel Diesel Fuel Type same as engine fuel Any diesel fuel allowed for in the LongMile S verification ESW CleanTech MLC A 2 2 _ z gt PE Voltage 12 V or 24V nominal Real time clock Battery backed adapter from harness required Outputs LongMile S Owners Manual ESWCT 2013 07 16 Page 24 OWNER S OBLIGATIONS The owners actions in the following table are mandatory for proper system AN operation Failure to do the required action s could be the basis for denying a warranty claim or a fine by CARB Furthermore failure to adhere to these instructions could result in damage or failure to the LongMile S system LongMile S Owners Manual ESWCT 2013 07 16 Page 25 Event or Symptom Owner s Action Item Manual Section Initial installation of LongMile S system Flashing amber light DPF may need cleaning Solid amber light bad sensor or system fault Engine malfunction such as turbo failure injector failure excess oil consumption or leaky head gasket Debris or other object impacts LongMile S system or components Tubing or exhaust component between the engine and the PM filter assembly is removed replaced or in poor condition For a vertical exhaust stack the rain cap or
7. 2013 07 16 Page 9 OPERATIONS LongMile S Owners Manual ESWCT 2013 07 16 Page 10 Pay Attention to the System Engine and Vehicle The owner or operator should observe the LongMile S engine and vehicle s operation on a regular basis See the Driver Notification Lights section below for a detailed description of each ligh s meaning and the appropriate response Use the Troubleshooting Table page 20 if you suspect the engine or LongMile S are not operating properly Contact an ESW CleanTech authorized distributor or a properly trained technician under the owner s control when needed 1 Do not idle for more than 5 minutes in a row If the engine has been idling for more than 5 minutes turn it off In some states it is illegal to idle for more than 5 minutes 2 The operator should observe the green and amber lights regularly while operating the vehicle and respond accordingly 3 During engine operation there should not be soot emissions from the LongMile S clamps or tailpipe Notify ESW CleanTech authorized distributor or the owner s technician if any unusual exhaust emissions are observed 4 Periodically inspect the exhaust system for integrity Note anything abnormal and make repairs as warranted For vertical exhaust stacks make sure the turn out stack or rain cap is in place and functioning properly Contact an ESW CleanTech authorized distributor as needed Driver Notification Lights The operator must obser
8. ESW CleanTech LongMile S Owner s Manual CALIFOAMIA REPUBLIC EE ASSEMBLED IN USA 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 ESW CleanTech Inc LongMile S Owner s Manual Table of Contents LongMile S Owners Manual ESWCT 2013 07 16 General NOrmal sario isa NO Sale dio aaa ii oia Owners Legal ODIOS ew li E As Gonlaicillormeio o ne oo e NIESTE LC hl siata kosa EE E EN OING REDOWO amics as ACrONY M O EEO N LongMile S System 2 2 sli l vu aaa a a Product Summa ee A ANO ASSSM DIV ena O 7 CONTOS id ad eo e 8 Lab Sc atole 9 Opera isis 10 Pay Attention to the System Engine and Vehicle cccccccoooccnnccnnnnccnconnccnnnnnononona
9. Page 1 Cautions Please study this manual and understand the reguirements for the ESW CleanTech LongMile S system before operating your vehicle Do not idle for more than 5 minutes in a row If the engine has been idling for more than 5 minutes turn it off In some states it is illegal to idle for more than 5 minutes Long idle times could lead to an excessive build up of soot which could later lead to damage of the system under certain operating conditions Damage to the system caused by excessive idle could be the basis for denying a warranty claim The pictures and descriptions in this manual are for a typical LongMile S system Some parts components and configurations for your particular system may vary from those shown here depending on the engine 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 an ESW CleanTech authorized distributor if you need further assistance Safety Warnings e The LongMile S stays hotter longer than a stock muffler will after operating under heavy load and after the engine is turned off All surfaces could be hot and may cause burns e After operating under heavy load be very careful about operating or idling near any combustible material such as dry grass or trash The LongMile
10. S retains heat longer than a muffler will which makes it possible for very hot exhaust gases to exit the tailpipe for several minutes and be a potential source of ignition for combustible material e Do not allow combustible material from the working environment to come in contact with the LongMile S for example paper trash sawdust Owner s Legal Obligations Use of any alternative diesel fuels and or fuel additives not specifically listed in the CARB verification Executive Order E O is illegal and strictly prohibited Operating with an unapproved alternative diesel fuel or fuel additive violates the E O negates the verification for that engine and removes compliance status for the vehicle The end user must meet other requirements in the E O for the LongMile S which is provided in this manual beginning on LongMile S Owners Manual ESWCT 2013 07 16 Page 2 page 30 The E O for the LongMile S may also be obtained from the CARB website ntip www arb ca gov diesel verdev vt cvt htm The installation of the LongMile S 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 LongMile S will not violate tampering provisions of the Act at the time of installation because of the testing performed under the verification process provided tha
11. allation 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 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 at 1 800 398 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 There 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 vehi
12. aneously depending on the engine speed and load and the soot and ash loading in the DPF Passive regeneration removes the carbonaceous part of the soot and thereby lowers the backpressure Control System The MLC and some electrical components are housed in the Controls Box The MLC monitors the LongMile S when the engine is operating he MLC also continually logs operating data and records instances of unusual conditions The MLC controls the driver notification lights sometimes called the LEDs The meaning of each light and the appropriate actions for the driver or operator to take are described in the Operations section of this manual starting on page 10 LongMile S Owners Manual ESWCT 2013 07 16 Page 8 CARB Verification Labels The LongMile S is provided with two CARB verification labels One is installed on the engine Figure 3 and the other one is attached to the wiring harness at the LongMile S s Controls Box Figure 4 If either one is missing order a replacement label from an ESW CleanTech authorized distributor and be sure to order the correct label for your application see the table below the pictures Figure 3 Example of CARB verification label Figure 4 CARB verification label attached to installed on engine wiring harness at Controls Box Product Application Verification Family Name Label Part Number LongMile S On road CA ECT 2012 PM3 NOO0O ON DPF01 CUH 2001 1K LongMile S Owners Manual ESWCT
13. ay at its option instead pay the fair market value of the engine prior to the time the failure occurs LongMile S_Owner s_Manual ESWCT 2013 07 16 Page 28 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 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 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 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 at 1 800 398 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 Installation Warranty YOUR WARRANTY RIGHTS AND OBLIGATIONS The installer must warrant that the inst
14. cle accidents ignoring the driver notification 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 recommends that the verified diesel emissions control strategy be installed and serviced by ESW CleanTech 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 LongMile S Owners Manual ESWCT 2013 07 16 Page 29 CARB EXECUTIVE ORDER FOR THE LONGMILE S LongMile S Owners Manual ESWCT 2013 07 16 Page 30 State of California AIR RESOURCES BOARD EXECUTIVE ORDER DE 12 007 01 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 Section
15. ction required in exhaust tube 9 Visible emissions Engine problem resulting in oil or Contact an ESW CleanTech white or black coolant loss authorized distributor for repair smoke during e DPF failure None required if only visible at normal operations Normal at first start up after first start up after cleaning cleaning 6 Engine surges or e Engine malfunction Repair the engine has power loss most likely cause If the engine passes alll its e Overloaded DPF green light will diagnostic tests then contact an have been flashing for some ESW CleanTech authorized time if this is the cause of engine distributor for service surging or low power DPF will likely need cleaning There is additional troubleshooting information in the LongMile S Service Manual This manual is for trained technicians LongMile S Owners Manual ESWCT 2013 07 16 Page 20 Repair and Maintenance Clarifications The warranty page 27 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 owners manual is performed In addition to the scheduled preventative maintenance the solid amber light is another indicator that maintenance or repair is required ATTENTION The solid amber light indicates that service is required Cleaning the DPF is a maintenance item and is not covered under warranty If a repair is required it may b
16. de 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 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 will repair or replace your diesel emission control system at no cost to you including diagnosis parts and labor Table 1 Warranty Period Light heavy duty 70 to 170 hp Gross Vehicle Weight Rating GVWR less than 19 500 Ibs 5 years Medium heavy duty 170 to 250 hp GVWR from 19 500 Ibs to 33 000 Ibs 150 000 miles Heavy heavy duty exceeds 250 hp GVWR exceeds 33 000 lbs Heavy heavy duty exceeds 250 hp GVWR exceeds 33 000 lbs and truck 15 2 years 1 Typically driven over 100 000 miles per year and unlimited miles 2 Has less
17. e S Owners Manual ESWCT 2013 07 16 Page 15 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 lf 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 claim for a failed component of a diesel emission control strategy The Importance of Properly Maintaining a Diesel Emission Control Strategy Proper maintenance is critical for the diesel emission control strategy to function as intended Failure to document proper diesel emission control strategy maintenance including cleaning and or ash removal of the system replacement of consumables and replacement of broken failed parts may be grounds for denial of a warranty claim for a failed component of a diesel emission control strategy Maintenance Schedule ESW CleanTech recommends that a ESW CleanTech authorized technician or a properly trained technician under the owners control perform the maintenance and repair of a LongMile S Preventative maint
18. e 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 onsibilit unplanned High backpressure from DPF Owner p overloaded with ash regularly planned High backpressure from DPF Owner Maintenance 9 y P overloaded with ash comprehensive Clean out ash from the DPF preventative Perform multi step complete system Owner maintenance check out System or component fails in normal ESW warrantable application CleanTech System or component failed because warrantable Installer Repair it was installed improperly System or component damaged through abuse neglect or misapplication Warranty period has lapsed non warrantable LongMile S_Owner s_Manual ESWCT 2013 07 16 Page 21 Engine Oil Consumption and Lube Ash DPFs are 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 accumu
19. el Engines Procedure ARB assigns each diesel emission control strategy a family name The designated family name for the verification as outlined above is CA ECT 2012 PM3 NOO ON DPF01 The designated family name CA ECT 2012 PM3 N00 ON DPF01 replaces the previous name CA CLE 2012 PM3 NOO ON DPFO01 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 Clean Tech may be grounds for denial of a warranty claim LongMile S_Owner s_Manual ESWCT 2013 07 16 Page 34 This Executive Order is valid provided that the diesel fuel used in conjunction with the system 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 e The biodiesel portion of the blend complies with the American Society for Testing and Materials specif
20. enance is required once a year every 2 000 operating hours or every 50 000 miles whichever comes first to ensure that the system is maintained 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 22 for more information The owner is legally required to keep the LongMile S in good operating condition in 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 Maintenance or repairs done by anyone other than an ESW CleanTech authorized technician is the responsibility of the person or organization performing the work LongMile S Owners Manual ESWCT 2013 07 16 Page 16 The cost of parts and labor for preventative maintenance are not included in the purchase price of the LongMile S system The parts and labor included in preventative maintenance are listed in the Preventative Maintenance Labor and Parts section below Preventative Maintenance Labor and Parts The preventative maintenance by an ESW CleanTech authorized technician includes Inspect the Controls Box and components Download data from the MLC and review the Instant Report Confirm the driver notification lights are funct
21. hours of operation until after the engine has been inspected and the LongMile S has been serviced by an ESW CleanTech authorized technician Operator should continue to monitor the status of the lights for instruction A flashing green light indicates that the LongMile S is approaching its backpressure threshold The driver should reduce the load on the engine if that is possible with the current driving conditions If the driver s actions successfully result in the backpressure dropping below its threshold for a period of time the green light will automatically stop flashing If the green light stops flashing the driver may resume normal operations LongMile S Owners Manual ESWCT 2013 07 16 Page 12 Also avoid continuous idle anytime the green or amber light is flashing If the engine has been idling for more than 1 minute ESW CleanTech recommends turning it off Continuing to idle while the green or amber light is flashing could allow an uncontrolled regeneration and or cause damage to the LongMile S Possible causes of the flashing green light are given in the list below Consult an ESW CleanTech authorized distributor as needed e DPF is capturing soot at a higher than expected soot loading possibly caused by o Improper or contaminated fuel o Engine malfunction such as leaky injectors or blown turbo o Extended idle time followed by appreciable high load operation e DPF is approaching its ash removal requirement c
22. ication D6751 applicable for 15 parts per million sulfur content e 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 The LongMile S system must not be located over any occupied space e g driver or passenger compartments or 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 and any other location deemed unacceptable by ESW CleanTech 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 12 007 dated December 7 2012 Executed at El Monte California
23. ioning properly Inspect the BP sensor and sensor breather Clean out BP tubing and ports Inspect all components of the PM filter assembly and clean the DPF Inspect exhaust tubing Reinstall the PM filter assembly and confirm it is properly mounted Inspect the sensors and wiring harness Upgrade the MLC program if necessary Check CARB verification labels Make repairs if any of the above inspections showed repairs are needed Perform comprehensive tests of the system s operations GOTO A 07 Or HL 30 AJ 1 AJ DPF Maintenance It may be necessary to periodically clean the DPF in addition to the cleaning during preventative maintenance depending on the engine s duty 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 DPF over time If ash in the DPF results in high backpressure then the green or amber lights 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 4 oil These products have been specifically designed for use with diesel particulate filters 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 22 ESW CleanTech recommends cleaning the DPF according t
24. ive 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 LongMile S 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 inlet cone one DOC one silicon carbide wall flow DPF and one outlet cone The LongMile S system also includes a backpressure monitor and warning system The major components of the LongMile S 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 LongMile S system is comprised of a single silicon carbide wall flow DPF designed to filter the exhaust from a single engine LongMile S 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 LongMile S 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 Lo
25. l 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 Driver Notification Lights section page 11 However not all conditions will be detected by the MLC for example a traffic accident that physically damages the PM filter assembly Therefore it is important that the owner and or operator routinely observe the engine and LongMile S operations in addition to watching the driver notification lights See the Operations section page 10 for routine observations that the operator and or owner should perform and the Owner s Obligations section on page 25 Upon any indication of a malfunction promptly contact an ESW CleanTech authorized distributor or the owners technician See the Contact Information section on page 3 Please be prepared with the following information LongMile S Owners Manual ESWCT 2013 07 16 Page 18 1 Fault information and descriptions In as much detail as possible 2 The Verification Tag number see Figure 3 and Figure 4 3 The data plate part numbers and serial numbers see Figure 6 and Figure 7 e 800 398 6105 gt ESW CleanTech www eswgroup com ESW CleanTech wiweswaroup om Part CJF 255 LM _ Serial 000000 Part 20 10 Serial 000000 8 A Figure 6 DPF part tag and flow arrow Figure 7 DOC part tag Parts List A complete parts list was
26. lates 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 accumulation in the filter Pre 2007 Cl 4 oil typically contains between 1 2 and 1 5 ash by weight The new 4 oils designed especially for diesel engines with diesel particulate filters contain approximately 1 0 ash and will therefore result in a lower filter loading for a given amount of oil consumption ESW CleanTech recommends cleaning the DPF according to the engine oil consumption table below Cleaning Interval Based on Engine Oil Consumption and DPF Part LM LM LM LM 16 quarts 18 quarts 21 quarts 26 quarts Factors like engine duty cycle soot composition ash composition and others can also have an impact on the filter cleaning interval Furthermore if there are long periods of operation where the engine does not meet the temperature requirements for regeneration or if there are excessive soot emissions from a failed injector for example the filter may need to be cleaned more often Customers can extend their filter cleaning interval by e Maintaining their engines to minimize oil consumption e Switching to low ash oils LongMile S Owners Manual ESWCT 20
27. leaning will be required Amber Light Flashing A flashing amber light indicates that the LongMile S is causing backpressure above its threshold The driver should reduce the load on the engine if that is possible with the current driving conditions Contact a ESW CleanTech authorized distributor for service The DPF may need cleaning Do not exceed 8 hours of engine run time without express approval from an ESW CleanTech authorized distributor lf the high backpressure condition is temporary the amber LED will automatically stop flashing once the backpressure drops below the threshold for a period of time Amber Light on Solid A solid amber light indicates a broken sensor disconnected sensor or system fault Contact a ESW CleanTech authorized distributor or a properly trained technician under the owner s control as soon as practical Do not exceed 8 hours of engine run time without express approval from an ESW CleanTech authorized distributor ATTENTION If the amber light is solid service is required 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 by connecting the service computer to the MLC and performing software operations with the MLinC program The amber light will turn on solid for a few seconds after the engine is started and put under load This allows the operator to
28. ngMile S 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 LongMile S system conforms to all applicable industrial safety requirements LongMile S Owners Manual ESWCT 2013 07 16 Page 33 Changes made to the design or operating conditions of the LongMile S 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 LongMile S system do not recommend tuning the vehicle to specifications different from those of the vehicle manufacturer Marketing of the LongMile S system using identification other than that shown in this Executive Order or for an application other than that listed in this Executive Order shall be prohibited unless prior written approval is obtained from ARB This Executive Order shall not apply to any LongMile S 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 Dies
29. nncnnnnnnonononnncnnnnnnnnnnannnennns 11 Briver ton Id iS a o aad fo 11 Conditions That May Damage the LongMile S occccnccccocccnnccnnnccccononccnnnnconononannnnnnnnononnnnnncnnnnononnnancnnnnnnnnnnss 14 Maintenance and Repair ninia ii ii ln 15 Your to Maintenance Informal sarral ica lia 16 The Importance of Engine Maintenance 16 The Importance of Properly Maintaining a Diesel Emission Control Strategy 16 Maimenance schedule ee a O 16 Preventative Maintenance Labor Parts cccssccccccssseececcceeseeeccceaeseceeeseeasueeeessuaeeeeessuaeeeeesseaeeeesssaaaes 17 VI OG es zla O N 18 nn once cis 19 TROUDISSMOOUNG TA es 20 Repair and Maintenance 21 Engine Oil Consumption and Lube Ol ASM iia ii a 22 O DECIA as 23 Owner SOD INC AU ONS site doo 25 Waranty ars id 27 Prog ct VV a Va A a len 28 istalsiltori Wa Tania O 29 ESW CleanTech Inc Warranty ClarificatiONS cccoconcncccconcnccooncnnonononnnonnnnnononnnnononnnnononnnnnnnnnnnnonanennnnaness 29 CARB Executive Order for the LongMile S 30 GENERAL INFORMATION LongMile S Owners Manual ESWCT 2013 07 16
30. o the engine oil consumption table below Cleaning Interval Based on Engine Oil Consumption and DPF Part Oil Type LM 1 LM CPF LM 16 guarts 18 guarts 21 guarts 26 guarts LongMile S Owners Manual ESWCT 2013 07 16 Page 17 A ESW CleanTech authorized distributor can clean the DPF 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 The DPF is unidirectional and it processes exhaust flow in only one direction If the DPF is removed for cleaning it may only be reinstalled in the proper flow direction because the inlet and outlet flanges are different sizes There is also a flow arrow on the part tag see Figure 6 on page 19 Exhaust Tubing and Components All tubing connections between the engine and the PM filter assembly should be gas tight and leak free Also all tubing between the engine and PM filter assembly must be 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 DOC or DPF may plug resulting in high backpressure and engine power loss ESW CleanTech recommends using stainless steel tubing between the turbo and the PM filter assembly It is the engine owner or operator s responsibility to ensure that all tubing in this critica
31. oil consumption rate If oil consumption exceeds the specification repair the engine so that oil consumption is within the manufacturer s specification Turn the engine off LongMile S_Owner s_Manual ESWCT 2013 07 16 This entire manual Operations page 10 Driver Notification Lights page 11 Driver Notification Lights page 11 Conditions That May Damage the LongMile S page 14 PM Filter Assembly page 6 and Conditions That May Damage the LongMile S page 14 Exhaust Tubing and Components page 18 PM Filter Assembly page 6 and Conditions That May Damage the LongMile S page 14 Conditions That May Damage the LongMile S page 14 and Engine Oil Consumption and Lube Oil Ash p 22 Cautions page 2 Operations page 10 and Conditions That May Damage the LongMile S page 14 Page 26 WARRANTY LongMile S Owners Manual ESWCT 2013 07 16 Page 27 Product Warranty YOUR WARRANTY RIGHTS AND OBLIGATIONS ESW CleanTech Inc ESW CleanTech 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 performance level it was verified to or to the requirements in the California Co
32. 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 LongMile S System Major Parts List Part Number LM Diesel Particulate Filter Assembly Unidirectional CJD 20 10 CJDA 20 10 CJD 27 10 CJDA 27 10 Diesel Oxidation Catalyst DOC CJD 35 10 or CJD 33 10 CMA 4 Sensor Thermocouple CMKC 5 0 CMKC 60 5 0 or CMKM 6 0 electronic control unit Spaces represent variables depending on specific configuration and application LongMile S Owners Manual ESWCT 2013 07 16 Page 19 Troubleshooting lable Use the table below to diagnose and resolve potential LongMile S operating problems See the Driver Notification Lights section on page 11 for additional information 1 Green light off e No power to the MLC e Check fuse wires and power while engine is on e Loss of MLC program source battery if amber on and green off e Contact an ESW CleanTech e Faulty light or wiring authorized distributor for repair 2 Unusual exhaust e Loose tubing connection s Tighten connection s noises e Loose clamp s e Replace damaged tube e Crack in exhaust tube e Contact an ESW CleanTech e Crack in the DPF authorized distributor for repair e Engine turbo problem 3 White smoke Normal condensation inside the action required during startup DPF 4 Light soot dusting Normal condition e No a
33. s 2700 to 2711 of Title 13 of the California Code of Regulations CCR ESW CleanTech Incorporated ESW CleanTech LongMile S Diesel Particulate Filter System LongMile S ARB has reviewed ESW CleanTech s request for verification of the LongMile S 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 LongMile S system reduces emissions of diesel particulate matter PM consistent with a Level 3 device greater than or equal to 85 percent reductions 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 LongMile S system as a Level 3 Plus system for heavy duty on road vehicles that use certain heavy duty engines Engines for which the LongMile S system is verified the verified parts list the verified labels swapping and re designation information and other product information can be found here htto www arb ca gov diesel verdev companies esw longmile s htm The aforementioned verification is subject to the following terms and conditions The engine must be originally manufactured from model year 1993 through 2010 The engine must be used by an on road motor vehicle with a manufacturer s Gross Vehicle Weight Rating of o
34. sel engine exhaust Level 3 plus Features include e Stainless steel construction e Rugged silicon carbide diesel particulate filter DPF e Modular design to facilitate installation service and maintenance e Passive regeneration e ESW CleanTech MLC the system controller e Sound attenuation eliminating the need for a muffler or silencer even if that muffler or silencer contains an oxidation catalyst The LongMile S Figure 1 consists of the PM filter assembly and the control system e The DPF captures over 85 of the particulate matter soot from the diesel engine exhaust while the engine is operating e The DOC enables regeneration of the DPF when the engine Is operating under load e The control system monitors the LongMile S and engine during operation The control system also alerts the operator if action or service is required ae Driver Notification Lights LEDs Backpressure sensor Exhaust In Exhaust Out Figure 1 LongMile S system schematic drawing LongMile S Owners Manual ESWCT 2013 07 16 Page 6 PM Filter Assembly The PM filter assembly Figure 2 is the core of the LongMile S system and it usually will replace the muffler The assembly has important features listed below Inlet x cone 0 Outlet cone ta ly Backbone gt gt Figure 2 PM filter assembly of typical LongMile S system dimensions in inches ESW CleanTech provides a mounting assembly
35. ssure threshold System is operating above its backpressure threshold LongMile S needs service Meaning Required Action or Response Check the state of the lights regularly Do not operate the vehicle Check the fuse in the MLC power wire or see if the wire is disconnected or cut Low battery voltage may also be a cause Check the battery voltage If the fuse or battery is not the problem contact ESW CleanTech distributor to arrange for service by an ESW CleanTech authorized technician Do not operate the vehicle Low battery voltage may be a cause Check the battery voltage If the battery is not the problem contact an ESW CleanTech distributor to arrange for service by an ESW CleanTech authorized technician Reduce the engine load if possible the light stops flashing resume normal operation If the system has been installed for less than one month contact an ESW CleanTech distributor See the Green Light Flashing discussion below for further information Reduce the engine load if possible If the lights stop flashing resume normal operation If the system has been installed for less than one month contact an ESW CleanTech distributor See the Amber Light Flashing discussion below for further information Service required Contact a ESW CleanTech distributor to arrange for service by an ESW CleanTech authorized technician Operator may drive the vehicle but do not exceed 8
36. t 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 e 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 fuel additive s LongMile S Owners Manual ESWCT 2013 07 16 Page 32 e system must not be used with any other systems or engine modifications without ARB and manufacturer approval system must be 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 eguipment is in use The other terms and conditions specified below IT IS ALSO ORDERED AND RESOLVED That installation of the LongMile S system manufactured by ESW CleanTech 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 LongMile S system is exempt from the prohibitions in Section 27156 of the Vehicle Code 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 Execut
37. t the owner adheres to all installation instructions and meets all operating and maintenance requirements for the LongMile S e Specific events that require action by the owner or operator are given in the Owner s Obligations section on page 25 e 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 an ESW CleanTech authorized distributor for any sales or service support for your LongMile S 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 call ESW CleanTech at 1 800 398 6105 or visit www eswgroup com Distributor Address Contact person Contact person s phone Contact person s fax Contact person s email ae 0 product support representative representative one representative s phone eeseniaivesenal 00 o representative s email LongMile S Owners Manual ESWCT 2013 07 16 Page 3 Installation ESW CleanTech recommends that an ESW CleanTech authorized technician installs the LongMile S system The complete installation procedures are described in the LongMile S Installation Manual Copies of the manual are available upon request from your distributor The installation warranty page 29 is the responsibility of the distributor that ins
38. talls the LongMile S system AN Attention A ESW CleanTech certified technician must commission the system otherwise that may be the basis for denying a warranty claim Warranty registration 15 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 e 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 in a visible location Acronyms BP Backpressure CARB California Air Resources Board CO Carbon monoxide DECS Diesel emissions control system DOC Diesel oxidation catalyst DPF Diesel particulate filter HC Hydrocarbons LED Light emitting diode driver notification light MLC The electronic controller in the LongMile S system MLinC The software program used to communicate with the MLC OEM Original equipment manufacturer PM Particulate matter diesel soot TG Thermocouple ULSD Ultra low sulfur diesel fuel VDC Volts direct current LongMile S Owners Manual ESWCT 2013 07 16 Page 4 LONGMILE S SYSTEM DESCRIPTION LongMile S Owners Manual ESWCT 2013 07 16 Page 5 Product Summary The LongMile S has been verified by the California Air Resources Board to capture over 85 of the particulate matter PM from die
39. the basis for denying a warranty claim Engine oil consumption has an impact on the operation and maintenance of the LongMile S If engine oil consumption exceeds the engine manufacturer s specification the engine should be repaired Failure to do so may damage the LongMile S and may be the basis for denying a warranty claim High oil consumption will increase the rate of ash accumulation in the DPF and will lead to more frequent maintenance The Engine Oil Consumption and Lube Oil Ash section on page 22 explains the impacts of oil consumption and ash content on the operations and maintenance of the system Power washing the vehicle should not be a problem for the PM filter assembly Avoid pointing the high power wash at any LongMile S system components or connectors However depending on the power washing technique it may be possible to loosen an electrical connector If a connector comes loose the amber light might turn on If the amber light comes on follow the procedures in the Troubleshooting Table page 20 Turn out stacks or rain caps are required on vertical stacks to avoid water intrusion Be sure the turn out or 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 PM filter assembly Avoid low hanging branches or other obstacles that could knock off the rain cap LongMile S Owners Manual ESWCT 2013 07 16 Page 14 MAINTENANCE AND REPAIR LongMil
40. ve the LongMile S driver notification lights on a regular basis and respond accordingly Failure to adhere to these instructions could result in damage or failure to the LongMile S system ESW CleanTech The label placed next to the LongMile S Exhaust Filter lights Figure 5 provides a Solid System on brief description of each ligh s meaning A Flashing near threshold O Solid Service required The light meanings are Summarized in the table below and are explained Consult the Owner s Manual for additional information fu rther after the table Wiwwieswaroupocem Newer idle for more than 5 minutes CUH 2004 Flashing Backpressure above threshold Figure 5 Label for driver notification lights LEDs Attention The amber light will turn on solid for a few seconds after the engine starts and is first put under load This confirms that the amber light is working LongMile S Owners Manual ESWCT 2013 07 16 Page 11 Light Status Green light On solid Amber light Off Green light Off Amber light Off Green light Off Amber light On solid Green light Flashing Amber light Off Green light On solid or Flashing Amber light Flashing Green light On solid or Flashing Amber light On solid Green Light Flashing MLC is on and the LongMile S is operational LongMile S needs service LongMile S needs service System is operating near its backpre
41. ver 14 000 pounds The engine must be certified for on road applications LongMile S_Owner s_Manual ESWCT 2013 07 16 Page 31 The application must have a duty cycle with an exhaust temperature profile that meets either of the two criteria below o Greater than 260 degrees Celsius for at least 25 percent of the time or o Greater than 260 degrees Celsius for at least 20 percent of the time and greater than 300 degrees Celsius for at least 5 percent of the time e The engine s displacement must not exceed 15 liters e The engine must have a power rating of at least 175 horsepower and at most 500 horsepower Only one filter may be installed per engine e The engine must be in its original certified configuration e For model years 1994 and newer the engine must have 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 may be certified to have exhaust gas recirculation e The engine may be certified to have a pre existing original equipment manufacturer OEM diesel oxidation catalyst DOC The DOC may be removed to facilitate installation of the LongMile S system e The engine must not be certified to have an OEM diesel particulate filter DPF The engine must have a four stroke combustion cycle e The engine must be turbocharged e The engine may be mechanically or electronically controlled e The engine must be well maintained and no
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