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RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00...

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DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com Tel: 508-429-4552, Fax: 508-429-4553 Page 1 RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF/LETRU Manual Operation, Installation and Maintenance
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Page 1: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  1 

RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF/LETRU

Manual Operation, Installation and Maintenance

Page 2: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  2 

 

CAUTION

Read this entire manual and any other publications relevant to this project prior to installing, modifying or operating the equipment described here within. Follow safe practice standards, observe all local, state and federal codes, and use this manual for safe, effective operation. Improper installation, operation or other use of this product could result in any combination of poor performance, equipment damage, human injury or possible death. This manual is the sole property of RYPOS, Inc. (RYPOS) Copying, faxing, e-mailing, altering or in anyway reproducing this manual in whole or in part is forbidden without the express written consent of RYPOS. RYPOS reserves the right to change or alter any and all specifications at anytime without prior notification and without incurring any obligation to such changes. The information included in this publication is believed to be accurate at the time of publication; however, no responsibility is taken by RYPOS unless expressly given.

Page 3: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  3 

CAUTION Before beginning this installation, take a few minutes to read the entire instructions.

Check that all necessary materials, units, and kits that are listed in the application guide are on hand.

Safety First Safety is paramount for all involved in the installation of the RYPOS DPF/LETRU. Only work on a TRU that is not hot. If hot or it is running, turn off and allow ample time for it to cool down.

Please make sure you have

A secure platform and/or method to reach to the top of the TRU.

Proper hand, eye, and foot protection at all times.

Disconnect the battery, insulate and protect the terminals.

RECOMMENDED STANDARD TORQUE VALUES FOR STANDARD FASTENERS

Torque Values for clean dry threads Bolt size – Thread pitch Torque (ft-lbs) 10-32 3-4 ¼ - 20 9 – 11 5/16 – 18 21 – 23

Unless otherwise specified, all instructions are given from the front view of the TRU.

HAND TOOLS REQUIRED

• Electrical/Cordless Drill • Marking Pen/Scribe • Cutting Pliers

• 5/16” Drill Bit • Center Punch • Hammer

• 5/32, 5/16 Allen wrench

• Phillips head screwdriver

• Digital multi-meter

• Standard 3/8” drive shallow and deep socket set with 3” and 6” extensions

• Standard open end/boxed wrench set (ex. ¼” - ¾”)

• Offset head Phillips screwdriver (helpful)

Page 4: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  4 

Installation

The installation is broken down into the following sections.

1. Initial checks

2. Removal of existing parts

3. Installation of new parts

4. Electrical connections

Initial Checks

On compatible TRU’s, several factors need to be identified to insure the proper mounting kit and components come with the RYPOS DPF/LETRU.

1) Check Appendix C to verify engine year and model compatibility. 2) Compatible Carrier TRU models came through with 2 different frame styles.

a. Welded frame i. Ultra, UltraXL, TM900, TM1000, Genesis, Extra

b. Bolted frame i. Ultima, Ultima53

The frame style can be easily determined by looking at the central cross member where the muffler is attached. In the following picture, notice the bolts holding in the cross member. This is a “bolted” frame style. If the cross member is welded in and has no bolts it would be a “welded” frame style. The “welded” frame central cross member is rectangular, where the “bolted” cross member is flared out.

Welded Style Rectangular member 

Bolted Style Flared member 

Page 5: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  5 

3) For the RYPOS LETRU to operate properly, the proper alternator, alternator pulley, and wiring must be installed in the TRU. The wiring will be supplied in the installation kit. Part Numbers for RYPOS Alternator Kit (950-0003-00-00):

Rypos Part Number  Description 

175‐0003‐00‐00  Alternator, 105 amp 775‐0001‐00‐00  Pulley, Single Groove 2.62" OD 780-0001-00-00 Belt, TRU Alternator

No mounting changes or fabrication are needed. Some Carrier TRU’s are set to meet these specifications. Some may have alternators that meet the specification and simply need to have the pulley changed. All will need additional wiring supplied in the kit. As with any alternator service checking belt condition and tension is recommended. Belt replacement at this time is suggested.

Removal of Existing Parts

For safety, disconnect both the positive and negative terminals from the battery(s) and protect the terminals from accidental contact or falling parts. Remove the doors from the unit to allow easier access to all areas of the unit while performing the installation.

Some parts removed will be discarded and others will be reinstalled. Reserve all parts and hardware removed from TRU until the end of the installation. Working from the top of the TRU down to the bottom, follow the outlined steps below.

1. Remove muffler: Unbolt the 4 muffler bracket bolts and the muffler clamp and slide muffler out to the left. If the TRU frame is the bolted type, remove the central cross member bolts and the cross member as well. The muffler bolts to this central cross member.

2. Remove Aluminum heat shielding below muffler: Unbolt the 4 bolts holding it in place and take out.

3. Remove Air Cleaner Assembly: Unbolt the 4 bolts holding its mounting plate to the frame. Loosen hose clamp to remove assembly from intake tube. Cover the intake so nothing is allowed to enter the intake during installation.

Page 6: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  6 

4. Remove upper exhaust pipe: Mark or record

the position of the lower pipe. (See photo at right) Unbolt the upper and lower exhaust pipe clamp and remove pipe and clamps. Clean mating pipe, in preparation for installation of new upper pipe. When remounting the new upper pipe, insure lower pipe is in the same place.

5. If the alternator needs to be removed or if

the pulley needs to be changed, it should be done now (see pre-purchase literature). Remove Alternator/Pulley: Double check the positive terminal of the battery is disconnected.

 

Mark or record this distance, or use a spacer to maintain this clearance

Remove 4 bolts

Loosen hose clamp

Page 7: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  7 

Loosen the 3 adjustment bolts on the alternator and slide alternator back to remove belt. If just alternator pulley needs to be changed do it now. If alternator needs to be changed continue and remove the 3 adjustment bolts. Label and disconnect the wiring from the alternator.

Loosen three adjustment bolts

Page 8: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  8 

Install new alternator wiring harness and original wiring on the new alternator. Route new harness toward the battery. Do not connect to battery at this time. Install alternator and tighten belt as specified in the unit manual. Secure new alternator harness with cable ties. Be sure to route harness for maximum clearance around the exhaust system as shown below.

Cable tie alternator harness to underside of right angle drive 

Cable tie alternator harness to frame behind the compressor 

Page 9: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  9 

Installation Appendix A has the installation kit laid out with descriptions.

1. Several holes need to be marked and drilled before positioning parts into place. Use the supplied template to mark the holes on the TRU’s frame. Lay the template into the bracket

all the way to the right as shown. Tape into place with masking tape. Center punch the holes, drill with 5/16” drill bit (making a small pilot hole first is suggested), and debur all holes. (If you are an installer, you may want to create a template from masonite or sheetmetal with ~1/8” dia holes to use as a guide for center punching. It will save time and improve accuracy)

2. Mount ECU: The ECU will mount in the left hand corner (previously where muffler outlet was located). Remove specified bolt. Position ECU as shown, and reinstall existing bolt and additional bolt, flat washer, locking nut.

Removal of existing fan shroud bolt

Installation of ECU using existing and new hardware

Page 10: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  10 

3. Route wires: Route 4 gauge battery wires down toward the battery. Using the supplied hardware, install 1 loop-strap type clamp to hold wires secure at the top.

Do not connect to the battery at this time.

4. Install new heat shield: Attach long ECU wire harness and the connector pack to back of heat

shield using 2 of the ¼”-20 bolts. Then attach the large connector with 2 of the 10-32 bolts

     

Wire routing and additional loop strap. 

Page 11: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  11 

Position the heat shield and attach with the center bolt on the upper rail and the 2 self tapping bolts (supplied) on the bottom rail. Make sure holes in the heat shield line up with the new holes in the frame. It may be a good idea to loosely install the bolts from the muffler brackets into the holes before installing the 2 self tapping screws.

5. Set LETRU DPF up on top of the unit. On units that have the welded frame, loosen the solenoid cover screws as shown and slide the cover off. This is necessary in order to get the DPF into position.

Page 12: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  12 

6. Position LETRU DPF: Point the DPF down to the right (air cleaner side), slide the unit in place, and lower the opposing end. Twisting the DPF and lower it at the same time may be necessary. Reinstall the solenoid cover and tighten the cover screws. It may be helpful to have an offset Phillips head tool as shown to make this easier.

Slide the band clamps around each end of the DPF as shown below. Attach the band clamp to the bracket and finger start the nuts to hold in place

Page 13: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  13 

Drop DPF in position as shown for a bolted frame

7. Mounting Brackets: Install mounting brackets as shown. Utilize bolts from muffler removal. Using supplied hardware start the hex nuts on the T-bolts. REPLACE THIS PHOTO

8. Connect upper wiring: Connect both sets of solenoid wires by attaching the small

WeatherPack connectors on each end of the DPF. Connect both sets of larger connector packs on each end of the DPF.

9. Install the pressure tubing: Install the supplied pressure port tubing (stainless steel) in the open port on the left side of the DPF. Next connect the tube flexible hose from the end of the tubing to the barbed port on the ECU. Use a cable tie to clamp the hose on both ends.

Page 14: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  14 

10. Install upper exhaust pipe: The new pipe has an oval, two bolt, flange on it. This mates to

the LETRU DPF. Install the pipe with the supplied hardware and gasket. Reinstall the upper U- bolt clamp, leave loose. Use the new U-bolt clamp provided for the pipe to pipe interface. Install finger tight. (NOTE: you may need to trim some of the length off of the exhaust pipe in order for it to fit up properly, particularly on the welded frame unit.

11. Tighten the T-bolts to secure the DPF. 12. Install extension pipes with clamps and rain caps. When closed the rain caps should be

slightly below the top of the trailer. Cut extensions to accomplish this, if needed. The rain caps should be installed counter weights facing toward the left and right edges of the trailer not facing each other.

13. Insure lower exhaust pipe is in the same place previous to removal of the original upper pipe. A spacer can be used to help keep this clearance space. Tighten U-bolt clamp at interface.

14. Reinstall Air cleaner assembly with original hardware. 15. Double check all wiring and physical connections and clearances from moving parts and hot

exhaust. Electrical Connections: Most of the wiring for the LETRU DPF is done at the factory. Some simple wiring and connections need to be made here.

1. Run signal: The run harness has a single WeatherPack connection on one end and an intercept MetriPack on the other end. On the front of the engine identify the fuel shut off solenoid. The intercept MetriPack will go in series with the MetriPack on the solenoid. Route the harness toward the battery and up with the 4 gauge cables from the ECU. The single WeatherPack connector will plug into the pigtail on the ECU.

Page 15: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  15 

2. Remote light panel: The remote light panel is an indicator of system operation. It should be

installed on or near the TRU’s control panel and no further than edge of the trailer. 3. Short battery harness: The short battery harness connects the red 4 gauge wire from the ECU

to the B+ Terminal of the battery. This harness holds a 125A fuse in a protective holder. Remove the fuse cover and attached the red wire to the fuse. Mount above the battery on the frame (see picture). Using the existing hole by the frame mount, insert one of the provided ¼-20 bolts through the hole and the fuse holder and tighten with a lock nut as shown.

4. Using the supplied cable ties secure all harnesses at this time. 5. Use a digital multi-meter to check for any shorts between the positive and negative battery

harnesses (ohm out). If a short is found, double check wiring. Do not proceed until all shorts have been fixed.

6. Connect the following wires to the positive (+) position on the battery at this time. a. 4 gauge red wire from the short battery harness b. Positive wire from the alternator harness c. Original wire(s) on the terminal

Page 16: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  16 

7. Connect the following wires to the negative (-) wires to the battery at this time. a. 4 gauge black wire from the ECU harness b. Negative wire from the alternator harness c. Original wire(s) on the terminal

8. Start up TRU engine and verify operation of DPF. The green light on the indicator panel

should light up and the yellow lamp should flash. Initially the yellow lamp will flash until the DPF builds up more than 3 inches of water (3inH20) of back pressure. Approximately 1 minute after start up the DPF will actuate one flow control solenoid and heat a filter. You will be able to hear the solenoid engage. The filter will then regenerate for the next 2-3 minutes. After running for ~5 minutes, shut unit off, wait for a few seconds and turn on again. The unit will go through the same sequence as above, only with the other solenoid. This check will make sure both solenoids are working properly.

9. Double check all connections to avoid looseness and make sure all wires are safely supported and cable tied to prevent excessive motion during unit operation.

10. Reinstall unit doors 11. Once everything is complete, place the label as shown below.

 Positive:

 Alternator Harness 

 Short Battery Harness 

Negative: 

Alternator Harness 

ECU Harness 

Page 17: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  17 

Ash Cleanout Procedure During the annual maintenance inspection the unit should be checked for ash accumulation. The ash inspection port is located on the right side of the unit ( the side near the exhaust inlet pipe). Ash is considered a hazardous waste material and mult be collected using a vacuum with a HEPA filter. Follow the ash handling guidelines as prescribed by CARB at www.arb.ca.gov/diesel/tru/documents/ashguide.pdf.

1. The engine should be off before proceeding. 2. Disconnect the positive terminal from the battery to ensure the unit is not operational. 3. Remove the air cleaner to provide better access to the right side of the unit. 4. Open the ½” NPT port and connect a suitable vacuum cleaner hose. 5. Remove the rain caps from the two exhaust pipes. 6. Close off one of the exhaust ports with a 2” cap or tape. 7. Attach a 2” blower hose to the open exhaust port. 8. Manually open the solenoid valve by moving the plunger away from the body of the unit. 9. Turn on the vacuum and the blower and run for 5 minutes. 10. Repeat the same operation on the other side. 11. Remove all hoses and reattach the rain caps to the exhaust pipes. 12. Put anti-sieze on the threads of the NPT port plug and reattach. 13. Reattach the air cleaner. 14. Reattach the positive terminal of the battery.

Page 18: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  18 

Offline Regeneration (engine not running) At times an offline regeneration of the DPF may be necessary. Examples of when include but are not limited to failures of batteries, alternators, drive belts, or wire connections Offline regeneration can be accomplished with a simple jumper wire and battery charger/booster. The following steps should be followed to accomplish a complete, offline regeneration.

1. Disconnect the run signal harness connector completely from the fuel run solenoid on the engine, as shown in the photo on the left below.

2. Attach the battery booster to the battery. Set for 50-75 Amps. 3. Jumper the red wire form the disconnected run signal harness to the B+ terminal of the

battery. (The post on the starter can be used.) It is best to use a Rypos service harness for this task, as shown in the right photo below

4. Wait 20 minutes. During this time four regenerations will occur. Four solenoid closures

will be heard confirming the beginning of each regeneration. 5. Disconnect the jumper wire (or service harness) 6. Disconnect the battery booster. 7. Reconnect the engine run signal harness connectors to the fuel run solenoid.

Plug Rypos service harness into system harness.  Clamp alligator clip to starter positive  as shown 

Disconnect both ends of the run solenoid harness connection 

Page 19: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  19 

Lamp Mode  System Status  Trouble Shooting If Problem Persists 

Green Solid  System ON, Functioning Normally

Not Required No action required 

Green Flashing 

System ON but low voltage condition.   

Ensure battery charger or alternator is connected and charging. 

Call for service. 

Green Off  System is inoperable.  Check battery and charging system connections and fuses. 

Call for service. 

Yellow On Solid

System is in overpressure condition. 

Shut down TRU and inspect filter for damage.  Perform a manual regeneration procedure.  Restart TRU.  Run 5 minutes.  If lamp remains on perform ash removal procedure.  Restart TRU.  Run for 15 minutes.  If lamp remains on call for service.  

Call for service 

Yellow Flashing 

Low pressure condition.  Check entire TRU exhaust system for leaks and repair/seal as necessary.   

Call for service. 

Yellow Off  System Operating Normally.

No action required. No action required. 

Page 20: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  20 

Page 21: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  21 

Appendix A: Component Identification

Rain Caps  Inlet Pipe Gasket 

1.75”  Clamps 

ECU assembly with wires

Tail Pipe Extensions 

Band Clamps 

2” Extension Clamps 

Operator’s Manual 

Flexible Pressure tubing 

Stainless Steel Pressure tubing 

Alternator Harness

Short Battery Harness

Status Panel and Harness

Drill Pattern Template

Run Signal Harness

LETRU DPF 

Mounting Hardware

Page 22: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  22 

Appendix A: Component Identification: Carrier TRU Frame style specific parts

Bolted Frame Heat Shield and mounting brackets 

Welded Frame Heat Shield and mounting brackets 

Page 23: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  23 

Appendix B: Warranty Registration and Installer’s checklist

First, verify that the engine year and model family is listed in Appendix C

TRU owner’s name:___________________________________________________________________ 

TRU owner’s contact phone number:_____________________________________________________ 

TRU owner’s  E‐mail__________________________________________________________________ 

Installer’s name:_____________________________________________________________________ 

Installer’s contact phone number:_______________________________________________ ________ 

Installer’s E‐mail_____________________________________________________________________ 

Installation date:_____________________________________________________________________ 

TRU hour readings on installation date:    Switch on hours____________Engine hours_____________ 

TRU model name: (Ultra, Ultima, etc.):___________________________________________________ 

TRU serial number:___________________________________________________________________ 

TRU unit model year:_________________________________________________________________ 

Date in Service:______________________________________________________________________ 

TRU engine model (V1903, V2203, etc.):_____________________________________________ _____ 

TRU engine serial number (stamped on block in front of injection pump):_______________________ 

Rypos  DPF serial number:___________________________________________________________ 

Size of alternator on unit:_____________ If less than 105 amps, need to install 105 amp alternator. 

Page 24: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  24 

Appendix C: Compatible Engine Models

  Engine Engine Mfr  

Engine  Model Model Name Engine Family 

Manufacturer  Year  

Kubota  Pre‐1999 V1903‐EB‐CARRIER‐1 Pre‐Tier 1 

Kubota  Pre‐1999 V2203‐DI‐EB‐CTD‐4 Pre‐Tier 1 

Kubota  Pre‐1999 V2203‐B‐CARRIER‐1 Pre‐Tier 1 

Kubota  Pre‐1999 V2203‐B‐CARRIER‐2 Pre‐Tier 1 

Kubota  Pre‐1999  V2203‐DIB‐CARRIER‐3  Pre‐Tier 1 

   

Kubota  1999 V1903‐EB‐CARRIER‐1 XKBXL01.9FCD 

Kubota  1999 V2203‐DI‐EB‐CTD‐6 XKBXL02.2ECC 

Kubota  1999 V2203‐DI‐EB‐CTD‐4 XKBXL02.2ECD 

Kubota  1999 V2203‐EB‐CARRIER‐1 XKBXL02.2FCD 

Kubota  1999 V2203‐EB‐CARRIER‐2 XKBXL02.2FCD 

   

Kubota  2000 V1903‐EB‐CARRIER‐1 YKBXL01.9FCD 

Kubota  2000 V2203‐DI‐EB‐CTD‐6 YKBXL02.2ECC 

Kubota  2000 V2203‐DI‐EB‐CTD‐4 YKBXL02.2ECD 

Kubota  2000 V2203‐EB‐CARRIER‐1 YKBXL02.2FCD 

Kubota  2000 V2203‐EB‐CARRIER‐2 YKBXL02.2FCD 

   

Kubota  2001 V1903‐EB‐CARRIER‐1 1KBXL01.9FCD 

Kubota  2001 V2203‐DI‐EB‐CTD‐6 1KBXL02.2ECC 

Kubota  2001 V2203‐DI‐EB‐CTD‐4 1KBXL02.2ECD 

Page 25: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  25 

  Engine Engine Mfr  

Engine  Model Model Name Engine Family 

Manufacturer  Year  

Kubota  2001 V2203‐EB‐CARRIER‐1 1KBXL02.2FCD 

Kubota  2001 V2203‐EB‐CARRIER‐2 1KBXL02.2FCD 

   

Kubota  2002 V1903‐EB‐CARRIER‐1 2KBXL01.9FCD 

Kubota  2002 V2203‐DI‐EB‐CTD‐6 2KBXL02.2ECC 

Kubota  2002 V2203‐DI‐EB‐CTD‐4 2KBXL02.2ECD 

Kubota  2002 V2203‐EB‐CARRIER‐1 2KBXL02.2FCD 

Kubota  2002 V2203‐EB‐CARRIER‐2 2KBXL02.2FCD 

   

Isuzu   Pre‐1999 D201  Pre‐Tier 1 

Yanmar   Pre‐1999 4TNE82‐TK  Pre‐Tier 1 

Yanmar   Pre‐1999 4TNE86‐TK  Pre‐Tier 1 

   

Isuzu   1999 D201  XSZXL02.2DNA  

Yanmar   1999 4TNE82‐ETK  XYDXL1.90D4N  

Yanmar   1999 4TNE86‐ETK  XYDXL2.09D4N  

   

Isuzu   2000 D201  XSZXL02.2DNA  

Yanmar   2000 4TNE82‐ETK  XYDXL1.90D4N  

Yanmar   2000 4TNE86‐ETK  XYDXL2.09D4N  

   

Isuzu   2001 D201  XSZXL02.2DNA  

Page 26: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  26 

  Engine Engine Mfr  

Engine  Model Model Name Engine Family 

Manufacturer  Year  

Yanmar   2001 4TNE82‐ETK  XYDXL1.90D4N  

Yanmar   2001 4TNE86‐ETK  XYDXL2.09D4N  

   

Isuzu   2002 D201  XSZXL02.2DNA  

Yanmar   2002 4TNE82‐ETK  XYDXL1.90D4N  

Yanmar   2002 4TNE86‐ETK  XYDXL2.09D4N  

Page 27: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  27 

Appendix D: Warranty Statement

WARRANTY RIGHTS AND OBLIGATIONS

RYPOS, Inc. must warrant 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 causes 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, for the periods of time listed, provided there has been no abuse, neglect, or improper maintenance of your diesel emission control system or equipment, as specified in the owner’s manuals . Where a warrantable condition exists, this warranty also covers other equipment parts 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 includes particulate filter(s), hoses, connectors, a backpressure monitor, and other emission-related assemblies. Where a warrantable condition exists, RYPOS, Inc. will repair or replace your diesel emission control system at no cost to you including diagnosis, parts, and labor.

WARRANTY COVERAGE:

For 25 to 50 horsepower Tier 1 or older with a certified PM emission rate no greater than 0.8 g/bhp-hr used in the transport refrigeration application, the warranty period will be 4 years or 2600 hours, 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, Title13, Sections 2700 to 2706, and 2710, within the warranty period, as defined above, RYPOS, Inc. will repair or replace the diesel emission control system, including parts and labor. In addition, RYPOS will replace or repair the equipment, or engine components to the condition they were in prior to the failure, including parts and labor, for damage to the engine or other vehicle components proximately caused by the verified diesel emission control strategy. This also includes those relevant diagnostic expenses in the case a warranty claim is valid. RYPOS, Inc. may, at its option, instead pay the fair market value of the vehicle, equipment, or engine prior to the time the failure occurs.

INSTALLER WARRANTY RESPONSIBILITY

(Installer’s name) __________________________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’s name) must be the same as the warranty provided by the product manufacturer, and the same exclusions must apply.

OWNER’S WARRANTY RESPONSIBILITY

As the engine owner, you are responsible for performing the required maintenance described in your owner’s manual. RYPOS, 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

Page 28: RYPOS DIESEL EXHAUST PARTICULATE FILTER DPF… · DPF/TRU Manual Rev. C Part Number 820-0002-00-00 Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 Tel: 508-429-4552, Fax:

DPF/TRU Manual Rev. C Part Number 820-0002-00-00    

 

Rypos, Inc., 260 Hopping Brook Road, Holliston, MA 01746 www.rypos.com

Tel: 508-429-4552, Fax: 508-429-4553               Page  28 

not keep your receipts or fail to perform all scheduled maintenance, RYPOS, Inc. may have grounds to deny warranty coverage. You are responsible for presenting your engine, and diesel emission control system to a RYPOS dealer 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 RYPOS, Inc. at 1-508-429-4552 or the California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731,or (800) 363-7664, or electronic mail: [email protected].

CARB Identification Number (IDN) Registration After installing the RYPOS DPF/LETRU system, the TRU owner may apply for a CARB IDN at: www.arb.ca.gov/diesel/tru.htm For complete details refer to pages 9-11 of the following CARB document: www.arb.ca.gov/diesel/tru/documents/comply07-07.pdf


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