FEELPURE DPF SYSTEM FEELPURE™ Platinum system ......REV7.2_12.12.2010 Pirelli & C. Eco Technology...

RE

V7.2

_12.1

2.2

010

Pirelli & C. Eco Technology Spa viale Luraghi snc, 20020 Arese (Mi) Italia

Tel +39 02 93874600 - Fax +39 02 93874664www.pirelliecotechnology.com

FEELPURETM DPF SYSTEM

FEELPURE™ Platinum

system installation, operation & maintenance book

[email protected]

UNITED [email protected]

[email protected]

BELGIUM, NETHERLANDS, [email protected]

[email protected]

[email protected]

[email protected]

[email protected]

SPAIN, [email protected]

[email protected]

ENGLISH

PLATINUM CATALYST VERSION

Date: 16.03.2011

FEELPURE™ PLATINUMSYSTEM

INSTALLATION, OPERATIONAND MAINTENANCE BOOK Revision: 1.0 - EN

March’11 – Rev. 1 – ENG

CONTENTS

Important notes page 2

Pirelli Eco Technology Warranty page 4

1) How the Feelpure™ Platinum system works + vehicle maintenance status page 61.1 List of the supplied components page 7

2) Basic selection/dimensioning guidelines for the Feelpure™ system page 15

3) Replacing the original muffler page 183.1 Mounting the Pirelli Muffler page 18

3.2 Installation of temperature sensor page 22

4) Assembling the back pressure measurement kit page 23

5) Making electrical connections page 26

6) Installing the software for managing the electronic control unit (ECU) page 28

7) Operations to be carried out at the end of the installation page 317.1 Functioning tests of the electrical wiring page 31

7.2 Functioning tests of the system by means of the ECU management software page 317.3 Setting of generic working parameters of the system on ECU 3.0 page 347.4 Checking the operational status of the system by means of the ECU 3.0 software page 36

7.5 Verifying the filtering efficiency of the Feelpure™ Platinum system page 37

7.6 “Feelpure™ Platinum Installation&Warranty form” filling-in rules page 378) Operation and maintenance page 42

8.1 Feelpure™ Platinum system operational status page 428.2 Scheduled maintenance page 448.3 How to carry out system diagnoses – filling in the Vehicle Inspection Form page 468.4 Replacing the filtering cartridge for Feelpure™ Platinum systems page 488.5 Replacing the catalyst for Feelpure™ Platinum systems page 49

Annex 1 – Feelpure™ Platinum system Installation & Warranty Form page 50

Annex 2 – Feelpure™ Platinum system Vehicle Inspection Form page 51


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March’11 – Rev. 1 – ENG 2

IMPORTANT NOTESDocumentation information

The information, instructions and recommendations contained in this manual (which is always suppliedwith the product) are essential for the correct installation, operation and maintenance of the Feelpure™filter system, and are updated to the date shown on the manual. Any updates or changes to this manualare available on the internet website: www.pirelliecotechnology.com.This manual is for the product installer and should be carefully kept on board the vehicle together withthe attached installation and maintenance manual.Before proceeding with the installation of the product, it is essential to read the entire manualcarefully and understand it completely, and also check if any updates are available on theinternet website or by contacting Pirelli Eco Technology S.p.A. Customer Assistance by email [email protected] you are unsure of anything at all about the installation procedure and/or the operation and/ormaintenance of the product, you should contact Pirelli Eco Technology S.p.A. Customer Assistance atthe email address above.Installation and maintenance of the product, as well as any operation carried out on it, must be done onlyand exclusively by qualified personnel with the necessary skills for performing these operations, usingthe correct tools and fully observing the instructions and recommendations in this manual, in addition toall safety regulations and precautions.The installation, operation and maintenance of the product, as well as any intervention on it, are the soleresponsibility of the person carrying them out, and Pirelli Eco Technology S.p.A. is expressly excludedfrom any responsibility.In some countries the product has been homologated to work with the original components of theproduct, therefore, Pirelli Eco Technology S.p.A. recommends you use original parts or parts withtechnical and functional specifications that conform completely to the originals and especially, but notonly, in terms of composition, physical dimensions, type, resistance and materials.Failure to observe these information notices and the recommendations contained in this document maylead to malfunction, breakdown, breakage etc. and also the danger of damage to objects and/or personalinjury, as well as voiding the Pirelli Eco Technology S.p.A. warranty specified on the following page.This manual is available in other languages on the CD-ROM delivered with the system.


Date: 16.03.2011



March’11 – Rev. 1 – ENG3

SafetyThe majority of accidents deriving from the operation, maintenance and repair of the product are causedby failure to observe basic safety rules or precautions. Accidents can often be avoided by anticipatingpotentially dangerous situations before the accident happens. You should always be alert to potentialdangers. You must also have the proper training, skills and tools required to carry out these operationscorrectly.

Do not begin installation of this product until you have read and understood all the informationgiven in this document.

Pirelli Eco Technology cannot predict all possible circumstances that could involve potentialdangers. For this reason the warning notices in this document and on the product do not coverall eventualities. If during the various operations you adopt procedures, tools or methods that arenot explicitly recommended by Pirelli Eco Technology, it is essential to make sure that the workis performed in full observance of your own personal safety and that of others. You must alsomake absolutely sure that the engine/vehicle on which you are working does not becomedamaged and is not made dangerous as a result of procedures you choose to follow.


Date: 16.03.2011




Pirelli Eco Technology WarrantyConditions

Pirelli Eco Technology S.p.A. guarantees the quality of the materials used in this product and theirworkmanship, and also guarantees the product's conformity to the technical specifications contained inthis manual.The existence of any defects must be verified by Pirelli Eco Technology S.p.A.'s technicians in all cases.If the product is defective, Pirelli Eco Technology S.p.A. undertakes exclusively to repair or replace, at itsfinal and unquestionable discretion, the product or part of the product that is recognised to be defective.If Pirelli Eco Technology S.p.A. or one of its network of assistance centres listed on the internet websitewww.pirelliecotechnology.com is requested to carry out a repair or replacement under warranty, theproduct said to be defective must be sent, post free, to Pirelli Eco Technology S.p.A. or to one of itsnetwork of assistance centres, which will return it post free.If Pirelli Eco Technology is requested for a repair or replacement under warranty outside of its workshopor the workshop of one of its authorised centres and Pirelli Eco Technology S.p.A. agrees to the request,all labour costs and shipping costs will be the exclusive responsibility of the party making the request.

The warranty does not cover: All those parts that, by their nature or use, are subject to wear or consumption and especially

those parts that are subject to periodic replacement Normal maintenance operations and/or adjustment of products Components that are not original Pirelli Eco Technology S.p.A. parts

The warranty expires at the moment in which one of the following three events occurs: Twenty four months have elapsed from the date of installation of the product as shown in the

installation sheet The product is used for 400,000 km The product is operated for 4,000 hours

In addition, the warranty becomes void and is withdrawn in each of the following situations: If Pirelli Eco Technology S.p.A., within five working days after the installation of the products

and/or after the carrying out of the periodic checks specified in this manual, has not received acopy of the sheets as specified in this manual, duly completed and signed as expressly specifiedin this manual

If the defects and faults have not been reported according to legislation If the request for repair or replacement under warranty is not accompanied by copies of the

sheets as per letter a) and/or the serial number of the products has been rendered illegible orremoved or altered

If the product has been modified or in any way interfered with or if equipment, parts or otheraccessories that are not original Pirelli Eco Technology S.p.A. or not of corresponding qualityhave been mounted, as per the information notices above

If the product has not been stored, installed, operated or subjected to maintenance inconformance with the specifications contained in this manual


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If fuels and/or lubricants have been used that are different from those specified by thevehicle/engine Manufacturer on which the products are installed, or additives have been usedother than those specified in this manual

If the operation and maintenance recommendations required by the vehicle/engine Manufacturer,on which the products are used, have not been followed

The carrying out of repairs or replacements or provision of spare parts does not extend or renew theoriginal date of expiry of the warranty.The duration of the warranty for spare parts and accessories is 6 months from the delivery.Repair or replacement of the defective product terminates the warranty provided by Pirelli EcoTechnology S.p.A. The company provides no further warranty, nor does it assume any otherundertakings, and, except where specified by law, expressly excludes any responsibility on the part ofPirelli Eco Technology S.p.A. for damages of any kind or nature, direct or indirect, for any accident topersons or objects, indemnities, compensation, including relating to failure to use the product and/orvehicle or engine on which the product is used and, in any case, any and all responsibility originatingfrom the product.

Feelpure™ Platinum system installation & warranty formThe Feelpure™ Platinum installation form (enclosed with this manual) must be filled in, stamped andcountersigned by the workshop that installed the system and by the owner of the vehicle.

This manual must be kept on board the vehicle with the vehicle's other identification documents and withthe Installation and Maintenance manual. It contains the information on the filtering system’s installationand (periodical and/or extraordinary) maintenance.A copy of the document (hardcopy or in electronic format) must be sent to Pirelli Eco Technology by faxto +39.02.938.74.664 or by e-mail to [email protected] and must subsequently be sentby post within 5 working days of the date of installation.

A copy of the document must also be kept by the installer.

This is essential for the warranty to be recognised by the Pirelli Eco Technology organisation,based on the regulations that govern it (see the above section).

Following the maintenance programme specified by the vehicle/engine Manufacturer it isessential for the product to be used correctly and in conformance with Pirelli recommendations.This is therefore an essential precondition in order to be able to avail of the warranty under theterms of the conditions of sale and use.


Date: 16.03.2011




1) How the Feelpure™ Platinum system works + vehicle maintenance statusThe Feelpure™ Platinum system reduces particulate emissions from diesel engines by over 95%, andcan be used on commercial vehicles, transport vehicles and construction site machines on all engineclasses.The Feelpure™ Platinum system uses CRT (Continuous Regeneration Trap) technology that allows theparticulate reduction without any additive usage: this is possible thanks to a special platinum-coated unitplaced upstream of the silicon carbide filtering cartridge.The following pages contain a detailed description of the principal features of the system.The Feelpure™ Platinum system is mainly comprised of (see the table in the following section):

A. A silencer (also referred to in this manual as a muffler), which in turn is comprised of:o A filter (particulate trap) enclosed in a special stainless steel canningo Inlet and outlet endcans for exhaust gaseso Gasket seals placed between the filter, the catalyst and the endcanso Locking V-clampso A catalyst, characterized by a platinum coated honeycomb that increases the oxidation

power of exhaust gases.B. Electronic Control Unit kit (including the electronic control unit, or ECU) and all the necessary

electrical connections.C. Backpressure control kit.D. Installation kitE. Thermal insulation kit for the pipe connecting the engine/turbocharger to the muffler

Also supplied with the system are 2 copies of this manual (Italian and English for the vehicle owner), anda CD containing the necessary software for installing the Feelpure™ system (and also the COMconnection cable)The filter (or filtering cartridge) is made of a honeycomb structure in silicon carbide (SiC) through whichthe exhaust gases are filtered. The particulate, made up mainly of particles of carbon of varyingdimensions, is held back, right down to particles of the smallest dimensions.The electronic control unit (ECU) monitors the level of backpressure and the temperature of theexhaust gases at the outlet endcan and stores the operational parameters of the system. In addition theunit signals the need, if necessary, to have a check carried out at a specialised workshop.Information on the working status of the system is notified to the vehicle driver by means of a warningLED installed on the dashboard (or on the operator panel in the case of stationary engines) together witha specific adhesive label containing the meanings of the different lighting codes (see section 8.1).

To avoid catalyst poisoning, fuel with a Sulphur content of less than 50 ppm has to beused.

All Diesel fuels supplied in the United Kingdom can be used with Feelpure™ Platinum system.

The maintenance intervals specified by the engine/vehicle manufacturer for the other auxiliarysystems of the Diesel engine (Diesel injection, air intake, lubrication, etc) remain unchanged andshould be strictly followed.Specifically, it must be guaranteed that: The smoke opacity of the exhaust gases, measured upstream of the filter, is lower than the

engine's opacity limit specified by the vehicle manufacturer and has to be always lower than1.5 K [m-1]


Date: 16.03.2011




The lube-oil consumption is lower than 800g/1000 km (0.25% of the fuel consumption) The temperature of the exhaust gases at the inlet side of the muffler must be kept at over

250°C for at least 30% and over 300°C for at least 15% of the running time of the engine.

1.1 List of the supplied components

The following table lists the components of the Feelpure™ Platinum system.Any non-compliance in relation to the following list of components (see the adhesive label on thepackaging of Feelpure™ systems for the packing list) can be notified to Pirelli Eco Technology via fax+39.02.398.74.664 or via mail to [email protected].


Date: 16.03.2011




Feelpure Platinum™ system components Quantity

A Muffler 1A.1 Inlet Endcan 1A.2 Outlet Endcan 1A.3 Filtering cartridge 1A.4 Catalytic Unit 1A.5 V-Clamp 3A.6 Gasket 3A.7 Endcan bracket 2A.8 Exhaust "heavy-bolt" - "U" clamps 4 - 6A.9 Exhaust pipe adapter 2 - 4

B Electronic Control Unit kit 3.0 1B.1 ECU 3.0 1B.2 ECU 3.0 PC connection cable 1B.3 LED 1B.4 Vehicle battery - ECU 3.0 electrical connector 1B.5 ECU 3.0 Electrical connection set 1B.6 CD-ROM (with software and documents) 1

C Backpressure kit 1C.1 ECU protection filter with condensation collector 1C.2 1/4" - 4mm Pipe tong 1C.3 1/8" - 4mm Pipe tong 2C.4 Ant vibration hose clamp 10mm + bolts/screws 2C.5 Pressure flexible pipe 1

D Installation kit 1D.1 Blue poliurethane pipe 1D.2 10 mm corrugated sheath 1D.3 10 mm cable gland 1D.4 Electric protecting box 1D.5 Thermistor 1D.6 20 mm corrugated sheath 1D.7 2 wires electrical cable 1D.8 7 wires electrical cable 1

E Thermal Insulation kit 2E.1 Self Bonding Tape 1E.2 Insulation Tape 1E.3 High Temperature Silicon 1


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For explanatory purposes the following table shows the main components (identified by the relevantprogressive number) in relation to the aforementioned list:

Photo of component Name Progressiveidentification number Quantity

Muffler / Silencer

Inlet endcan A.1 1

Outlet endcan A.2 1

Filtering cartridge A.3 1


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Catalyst A.4 1

V-clamp A.5 3

Filter gasket A.6 3

Endcan brackets A.7 2

Exhaust “Heavy-bolt” / “U-bolt”clamp A.8 4 – 6


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Exhaust pipe adapter A.9 2 – 4

Electronic Control Unit kit 3.0

ECU 3.0 B.1 1

ECU 3.0 PC connection cable B.2 1

LED B.3 1


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Vehicle battery - ECU 3.0 electricalconnector B.4 1

ECU 3.0 Electrical connection set B.5 1

Backpressure control KIT

ECU protection filter with condensationcollector C.1 1

1/4" - 4mm Pipe tong C.2 1

1/8" - 4mm Pipe tong C.3 2


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10mm Ant vibration clamp + bolts/screws C.4 2

Pressure flexible pipe C.5 1

Installation KIT

Blue polyurethane pipe D.1 1

10mm Corrugated sheath(for two wires electrical cable andbackpressure polyurethane pipe)

D.2 1

10mm Cable gland D.3 1


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Electric protecting box D.4 1

Thermistor with electrical connector D.5 1

20mm Corrugated sheath(for seven wires electrical cable)

D.6 1

Picture not available 2-wires electric cable / 7-wires electric cable D.7 / D.8 1 / 1

Thermal Insulation KIT

Self Bonding Tape E.1 1

Insulation Tape E.2 1

High Temperature Silicon E.3 1


Date: 16.03.2011




2) Basic selection/dimensioning guidelines for the Feelpure™ Platinum system

We strongly recommend checking on our website (www.pirelliecotechnology.com) themost updated guidelines for the choosing of the filtering system technology

(FEELPURE™ / FEELPURE™ AR / FEELPURE™ PLATINUM) that best fits your vehicletype/mission.

Muffler

For any vehicle/application, STANDARD systems are offered which are then adapted, via adjustmentoperations, to replace the original muffler. The components supplied by Pirelli are based on pastexperience: specific installations may require specific components that are not included in the installationkits.

Every Feelpure™ Platinum system has a “SAP code” (e.g. 2000083901) which is used forlogistical/administrative purposes, and a “MUFFLER code” (e.g. MST12111NC1) which is necessary forits recognition for homologation/road circulation purposes. This second code is found on the inlet endcanfor exhaust gases (which is part of the muffler) and it is also essential for identifying the system formaintenance purposes and for coverage by the warranty.

Filtering CartridgeIn the same way, the filter is identified by a “SAP code” (e.g. 6400000101) which is used forlogistical/administrative purposes, and by a “FILTER code” (e.g. F121515N71) which is necessary for itsrecognition for homologation/road circulation purposes. This second code is found on the metal platewelded to the filtering cartridge’s canning and it is also essential for identifying it for maintenancepurposes and for coverage by the warranty.

Catalyst

Catalyst is identified by a “SAP code” (e.g.6900002401) which is used for logistical/administrativepurposes, and by a “CATALYST code” (e.g. C3008) which is necessary for its recognition forhomologation/road circulation purposes. This second code is found on the metal plate welded to theCatalyst’s and it is also essential for identifying it for maintenance purposes and for coverage by thewarranty.In all cases the filter (particulate trap) is dimensioned on the basis of the engine characteristics(displacement, power, emissions level). Please refer to the table shown below (the engine power valuesare indicative).

Filterdiameter

Filterlength

Filtervolume

ENGINEDISPLACEMENT POWERSISTEM

DESIGNATIONFILTERING

CARTRIDGEDESIGNATION [inches] [inches] [liters] [liters] Up to [kW]

P1010 F1010 10 10 12.9 3 - 6.5 175P1012 F1012 10 12 15.5 6.5 - 8 215P1112 F1112 11.25 12 19.6 8-10 255P1114 F1114 11.25 14 22.8 10-13 270P1215 F1215 12 15 27.8 13 - 17 380


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As an example, an IVECO CURSOR 7.8 litre engine needs an F101215N71 cartridge with a useful filteringvolume of 15.5 litres.Buses equipped with MAN D2866 or Mercedes OM447 engines (both 11.9 litre) need F111415N71 cartridgeswith a filtering volume of 22.8 litres.A medium vehicle equipped with a 5.9 litre IVECO 8060 engine needs an F101215N71 cartridge with afiltering volume of 15.5 litres.

In some countries, matching the engine/vehicle with the respectivefiltering cartridge must take into account legislative restrictions and

the related specifications.

The homologation tables for Italy are shown below as an example, and from these we can identify thecorrect Feelpure™ system to install in order to obtain the update to the vehicle’s Registration Certificate.Note that the table shown is subject to continual updates.The most recent version is available for consultation at the following internet address:http://www.it.pirelliecotechnology.com/web/products/downloads/default.pageThe correct designation of the category to which the vehicle belongs is in the vehicle registrationdocument on line J, and the environmental homologation class (based on the EC directive) is indicatedon line V.9.

In detail, for the table of homologations valid for engines used in Heavy Duty vehicles:

- EURO 0: previous to the entry into force of the 91/542/EEC directive

- EURO 1: 91/542/EEC directive, line A

- EURO 2: 91/542/EEC directive, line B, i.e. 96/1/EEC

- EURO 3: 1999/96/EC directive to 2001/27/EC directive, line A


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Displacement

Min(cc)

Max(cc)

n°cylinders Feeding Engine born

homologation Pirelli system Homologation code Updatedhomologation

EURO 0 NADA061EST002EURO 1 NADA061EST003EURO 2 NADA061EST004EURO 3

FeelpurePlatinumP1215

NADA061EST005EURO 0 NADB064EURO 1 NADB064EST001EURO 2 NADB064EST002

13736 17176 8 TURBO

EURO 3


NADB064EST003

EURO 5

EURO 2 NAD/A06111.040 13.800 6 TURBOEURO 3

FeelpureP1215 NAD/A061EST001

EURO 5

EURO 0 NADA061EST006EURO 1 NADA061EST007EURO 2 NADA061EST008EURO 3


NADA061EST009EURO 0 NADB064EST004EURO 1 NADB064EST005EURO 2 NADB064EST006

8814 11022 6 TURBO

EURO 3


NADB064EST007

EURO 5


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3) Replacing the original muffler

3.1 Mounting the Pirelli muffler

Assembly of the Feelpure™ Platinum system involves replacing the original muffler and mounting anumber of additional components, including the back pressure line and the electronic control unit (seetable and descriptive list in section 1.1).The description of the operations to be carried out is divided into sections for each main component andalso for the mechanical and/or electrical connections between them.

Before beginning to assemble the system, read ALL of the followinginstructions. If the muffler is installed without following these instructions,

the product will not be covered by the warranty.

In every threaded connection to be made in the assembly described,The male-threading must be sealed with an adequate quantity of Teflon® tape.

Catalyst has to be placed between the inlet endcan and the filtering cartridge.Wrong catalyst positioning causes system failure and possible damages to

the engine.

The procedure for removing/installing the muffler described below is obviously generalised. There maybe small differences between the different systems. For notes on safety, see the Important Notessection at the beginning of this manual.

1) Fill out the Installation Warranty Form (following the instructions given in section 7.6), and inparticular fill in the ECU, inlet endcan, catalyst and filter codes, shown on the metal plates weldedto the items.

2) Test the smoke opacity of the exhaust gases. The value has to be lower than the engine's opacitylimit decided by the vehicle builder and has to be always lower than 1.5 K [m-1].

3) Remove the original muffler and check the reliability of the existing supports and mountings, andif they are not adequate rectify them via adjustment, observing good technical standards andnormal workshop practices. As well as the muffler supports, you also need to check theoperational and maintenance conditions of the components connected to the muffler itself (orwhich are installed in the immediate vicinity). In particular, check the pipes and hoses connectingthe turbocharger to the muffler, the hose clamps affixing them, the screws, nuts and bolts, theprotective panels in the muffler bay, the electrical/pneumatic cables etc. If these components arein a poor state of maintenance (bleeding, breakages, damaged or broken welds,cables/hoses/components fitted in a rough-and-ready manner etc) then they must bereplaced/repaired to proper technical standards and according to normal workshop practice. In noway can Pirelli be held responsible for damage to the aforementioned components or to thevehicle in relation to the sole application of the filtering system.

4) Position the Feelpure™ Platinum replacement muffler on the support brackets, taking care toinstall it on new, anti-vibration supports, even if these were not required for the originalmuffler. Pay attention to the exhaust gases direction indicating arrow, reported on thefilter cartridge plate. It must always be correctly directed toward the outlet end-can.Referring to this, catalyst has to be placed upstream of the filtering cartridge. There are notechnical issues related to the application of the above mentioned brackets directly onto thefiltering cartridge or onto the catalyst. All that is needed is to budget for extra time when replacingThe filtering cartridge (A.3) or catalyst (A.4).


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5) Connect the inlet and outlet pipes to the intake and outflow sides of the replacement mufflertaking care to position the identification plates (welded on the inlet end can, on the filterand on the catalyst) in a position where they can be easily read for anyscheduled/homologation/road worthiness checks. If the dimensions of the original pipes aredifferent from those of the Feelpure™ muffler, apply the necessary reductions (A.9).

6) Fix the endcan brackets supplied with the replacement muffler to the original supports andmountings on the vehicle, using the Pirelli components or via suitable adjustments. Duringinstallation take account of the fact that the height of the new muffler from the ground may vary; ifthis height is very low then make any necessary adjustments to restore the correct distance fromthe road surface.

7) When carrying out the installation, observe the vehicle/engine Manufacturer's standardrequirements and/or specifications (e.g. ensure the minimum distance from existing electricalwires, from fuel/oil/coolant pipes, from moving parts etc.). Also, adequate thermal insulation mustbe used at all points which could come into direct contact with the instruments on board and withelectric wires/cables (special kits and components are available on request).

Inflow

Outflow

Inlet endcanOutlet

endcan CatalystFiltering cartridge

V – clamps


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All adjustment/welding operations that may be necessary during the installation must beexecuted in accordance with good technical standards and normal workshop practice.Parts outside the system (brackets, supports etc.) must not be welded to thebody/canning of the filtering cartridge or catalyst.The correct functioning of the Feelpure™ Platinum system is linked to the temperatures at the inlet of themuffler. The use of catalytic unit permits the regeneration/combustion of the particulate collected in thefilter at temperatures of about 280 - 300 °C. It is therefore essential that these temperatures be available.In order to ensure the highest possible temperatures at the inlet to the filtering cartridge, it is necessaryto use the special thermal insulation kits (E) for the pipe between the engine/turbocharger and themuffler.Bear in mind that the longer the pipe, the greater the loss of heat/temperature. It is good practice to wrapthis pipe with the available insulating material, taking care to attach it using the special high temperaturesilicon supplied (for detailed information please refer to the thermal Insulation kit instructions you can findin the package). Each insulation kit supplied is sufficient to properly insulate an exhaust pipe of 1-1.3metres in length (depending on the diameter of the pipe itself).If the material supplied is not sufficient to entirely cover the pipe, then it is necessary to purchase one ormore additional insulation kits, available on request.

Note on SAFETY for A.D.R. VEHICLES:

If a Feelpure™ Platinum system is installed on a vehicle for transporting explosives or substances thatare inflammable, toxic, radioactive, corrosive or carcinogenic, special attention must be paid to thepositioning of the replacement muffler, taking into account the minimum distance required between apotential heat source and the load being transported by the vehicle. Take account of the fact that thereplacement muffler can reach, during the regeneration phase, an outside temperature of approximately300 - 400°C.All the components Pirelli Eco Technology provides with the systems are compliant with the Europeanregulations referring to A.D.R. vehicles.The electrical connections necessary to perform the installation do not modify the vehicle originalelectrical schemeThe responsibility of the filtering system Manufacturer is limited to the supplied materials. In fact theFeelpure™ systems are recognised as an auxiliary device that does not affect the vehicle ADRhomologation.The responsibility according the installation of the system is in charge of the installer, who has torespect:

- All the ADR regulations “in force” (he is also responsible for checking news and updates aboutthem).

- All the recommendations coming from the auxiliary device Manufacturer related to theinstallation.

Pirelli Eco Technology recommends for the following ADR categories:AT – OX – FL – EX

That the system installation is carried out by an approved/authorised workshop in assembling/working on


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ADR vehicles.

In the following pictures are reported the Feelpure™ Platinum standard system configurations(please visit the web site for sizes availability):

Inlet endcan A - outlet endcan A Inlet endcan A - outlet endcan C

Inlet endcan C - outlet endcan A Inlet endcan C - outlet endcan C


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Inlet endcan A - outlet endcan D Inlet endcan C - outlet endcan D

D-type endcans cannot be used as an inlet endcan. Mounting D-typeendcans as an inlet endcan, will void the warranty.

3.2) Installation of temperature sensor

For Feelpure™ Platinum systems, before placing the muffler in its housing, it is necessary to tighten thesupplied thermistor (D.5) in the sleeve welded on the exhaust gas inlet endcan (A.2) of the muffler:

Make sure the thermistor wire and electrical connector do not touch hot surfaces(such as inlet endcan and high temperature pipes).


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4) Assembling the back pressure measurement kit

Numbers given in brackets after components refer to the positions indicated in the following diagram(and to the components list in section 1.1).

1) Connect the flexible pipe [(1) in the following diagram, (C.5) in the components list], afterverifying with a burst of compressed air that it is not clogged, to the sleeve positioned on the exhaustgas inlet endcan (A.1) of the replacement muffler.

2) On the opposite side of the flexible pipe, connect the pipe tong connection to the quick fit ¼”-4mm (2)(C.2).

3) Prepare the condensation separator filter (5) (C.1) by installing the quick fit 1/8”-4mm (4) (C.3)connectors on its inlet and outlet ends.

Make sure to respect the direction of throughput (arrow)indicated on the filter body.

4) Connect the blue polyurethane pipe (3) (D.1) (protected by the corrugated sheath D.2) to the reducer(4) (C.3) and to the filter entry.

5) Connect, by means of the blue polyurethane pipe (protected by the corrugated sheath D.2), theelectronic control unit (PS1 connector) to the outlet point of the separator filter (5) (C.1).

6) Affix the flexible pipe (1) (C.5) to the vehicle chassis by means of the supplied anti-vibration clamps(6) (C.4) and the separator filter (5) (C.1) in a protected but accessible position (at least 1.5m fromthe muffler) by means of the supplied special supports.

Blue polyurethane pipe has to be protected by the apposite corrugatedsheath. Please avoid direct contact with hot surfaces.


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N°Q

.TY

SAP

CO

DE7

190

0000

406

268

0004

715

190

0000

654

290

0000

453

8m

9000

0009

21

9000

0049

11

6800

0429

4mm

POLI

URE

THAN

EPI

PEQ

UIC

KFI

T1/

4"F

-4m

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Date: 16.03.2011




The filter (5) (C.1) can be installed in the engine compartment at a suitable distance from heat sourcesby means of its support brackets (see photo below).

Condensation separator filter for Heavy Dutyvehicles installation Condensation separator filter

To verify the integrity and functionality of the condensation separator filter (during installation orscheduled maintenance interventions – section 8.2) refer to the following photo, which shows all thecomponents of the filter itself.

Connection to the electronic control unit Condensation separator filter for Heavy Dutyvehicles - components

When connecting the filter outlet (5) (C.1) to the quick-fit connector on the body of the electronic controlunit, of the two connectors, make sure to use the one closer to the electrical connector port, marked asPS1 (see the above reported photo). Also, you should insert the end of the blue pipe all the way into thequick-fit connector, as far as it will go, and then verify that the connection is solid by checking that theblue pipe does not detach from the quick-fit connector.


Date: 16.03.2011




5) Making electrical connections

Using the components supplied with the Installation kit (D.2 – D.3 – D.4 – D.6 – D.7 – D.8), ElectronicControl Unit kit 3.0 (B.1 – B.3 – B.4 – B.5) and the thermistor (D.5) make the electrical connectionsdescribed below, taking care to follow the usual good technical regulations and normal workshoppractice.

For all components described in this section, refer to the diagrams/drawings of the electrical connectionsand components of the systems, shown below.

1) Install the electronic control unit (ECU) (B.1) and the connection set (B.5) in a protected positionthat cannot be reached easily by the driver or by other persons using the vehicle (e.g. spaceunder the dashboard, glove compartment, Central electric panels or in some other position,preferably protected by the casing supplied with the Installation kit (D.4)). It is highly preferableNOT to install the control unit in passenger compartments.

2) Install the driver’s LED (B.3) on the dashboard in a shady place where the driver can easily see itand attach the adhesive label (supplied with the kit) with the LED codes that show the operationalstate of the system.

3) Install the vehicle battery ECU 3.0 connector (B.4)*, connecting the 2 cables to the poles of thebattery, and make the connection to the D+ signal (+24V rotating engine) of the alternator,according to the attached diagrams and drawings, using the appropriate connectors.

4) Make the electrical connections, according to the following diagrams, between the control unitconnection set (B.5) and: Vehicle battery - ECU 3.0 connector (B.4)* - (wires A1, B1 of the connector set) Driver’s LED (B.3) - (wires A4, A5 of the connector set) Inlet endcan thermistor (D.5) (wires B6, B7 of the connector set) Engine-on signal (wire C1 of the connector set)

*ECU power supply has to be connected directly to thevehicle batteries; different ECU connections will void the

warranty.

Please check the alternator signal stability and, ifnecessary, apply corrective operations: discontinuousengine-on signal may cause ECU malfunction/failure.


Date: 16.03.2011





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6) Installing the software for managing the electronic control unit (ECU)

To conclude the installation of the Feelpure™ Platinum system, it is necessary to verify functioningparameters of the installed system. This can be done thanks to the specific software included in thesupplied CD.

Feelpure™ Managing Software permits to view real time data and download ECU registers and logfiles.

The procedure to follow for installing this software is described below:

Browse the contents of the CD.

Open the “CD:\FEELPURE PLATINUM\PROGRAMS\SOFTWARE” folder and execute the filenamed “FeelPure Managing Software 2.3.exe”

(Please note: software version may vary – visit the web site to get the latest version).

The following setup language selection screen will be displayed:

Select the language from the drop-down menu and click on OK, then the following Copyrightacceptance window will be displayed:


Date: 16.03.2011




After accepting the conditions described in the Copyright text, the following window for choosingthe program installation folder opens:

Make the choice by means of the “Browse” button and then click on “Install”: the installationprocedure begins and at the end of it the following window opens:


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Click on “Close” to end the operation.

To run the program, choose the icon named “FeelPure Managing Software” from the Start menu -> All programs on the PC.


Date: 16.03.2011




7) Operations to be carried out at the end of the installation

7.1 Functioning tests of the electrical wiring Check that when the engine is turned on, the driver's LED indicator shows a steady green light.

When the engine is switched off, the LED must not be illuminated. Otherwise a check of theelectrical connections between the ECU (B.5) and the LED must be carried out (see section 5)

7.2 Functioning tests of the system by means of the ECU management softwareEvery time you make the connection between the PC and the ECU, follow exactly this procedure:

1) run the software2) connect the serial cable3) perform the desired operations4) disconnect the serial cable5) close the software

Launch the program named FeelPure Managing Software.exe Select the serial port for the connection to the control unit. The box in the bottom left corner of the

screen must become red:

While the box in the bottom right corner must show the availability of the selected port:

Connect the laptop PC to the control unit with the supplied serial cable (B.2). The “Connectionstatus” box must become green, indicating that there is communication activity between the PCand the control unit.

Click on VIEW and then on REAL TIME DATA. The following screen will be displayed:


Date: 16.03.2011




By clicking on START it is possible to verify:

1. “Digital inputs/outputs” field: Engine running: ON = engine turned on

OFF = engine turned offThe other fields are only for Feelpure™ and Feelpure™ AR systems, which operate withadditive. They are negligible for Feelpure™ Platinum systems.

2. “Pressure” field: Pressure: shows the instantaneous reading of the pressure before the filter in mbar. Average Pressure: shows the average pressure value, calculated on the set number of

samples (200 samples in 2000 seconds). Missing samples: shows the number of pressure samples which are still lacking for

calculating the average pressure. Upper Instantaneous Press. Condition

GREEN= instantaneous high pressure alarm condition not reached.RED= instantaneous high pressure alarm condition reached.

Upper Avg. Press. ConditionGREEN=average high pressure alarm condition not reached.


Date: 16.03.2011




RED = average high pressure alarm condition reached.

Lower Avg. Press. ConditionGREEN = average low pressure alarm condition not reached.RED = average low pressure alarm condition reached.

3. “Date/time” field: Date: shows the current date. Time: shows the current time.Both values can be updated in the Upload window, with the command “Update Date/Time”.

4. “Engine shut-down Date/Time” field: Date: shows the date of the last engine shutdown. Time: shows the time of the last engine shutdown.

5. “C.P.U” field: Frame/Second: display of the functioning parameter of the control unit processor. Power supply: display of the value of the control unit supply Voltage (12/24V).

6. “Regeneration” field Temperature: show the instantaneous temperature upstream of the filtering cartridge in °C.The other fields are only for Feelpure™ and Feelpure™ AR systems, which operate withadditive. They are negligible for Feelpure™ Platinum systems.

7. “Fuel level” fieldYou can ignore this field.

8. “Other Data” field (visible by selecting the “Show all data” check box): Pressure (ADC): Displays the internal signal read by the pressure sensor. Thermoses. (ADC): Displays the internal signal read by the temperature sensor. Thermoses. (Ohm): Displays the instantaneous value of the electrical resistance of thetemperature sensor.

The other fields are only for Feelpure™ and Feelpure™ AR systems, which operate withadditive. They are negligible for Feelpure™ Platinum systems.

9. “Service” field Service Engine Signal: GREEN = ECU correctly receives alternator signal.

RED = ECU cannot receive alternator signal – check theconnections and reset service.

Service Pressure: GREEN = No problem reported.RED = High back pressure – it is necessary to check the system.

The other services are only for Feelpure™ and Feelpure™ AR systems, which operate withadditive. They are negligible for Feelpure™ Platinum systems.

By starting the engine, you can now verify:

That the control unit is correctly powered. That the control unit correctly receives the “engine running” signal – (ON).


Date: 16.03.2011




That the current date and time is correct. The date and time when the engine was turned off the last time. The back pressure of the system at engine idle speed. (When accelerating fully) the back pressure at W.O.T. The average back pressure value or the number of missing samples to calculate it. The instantaneous pressure condition for the high pressure alarm and the average pressure

conditions for the high pressure alarm and for the low pressure alarm. The temperature of the exhaust gases coming out of the engine.

Typically the back pressure values that can be measured will be respectively approx. 10mbar (Pmin)and 50mbar (Pmax) at the end of the installation. These will gradually increase with use, until thefiltering cartridge is replaced for cleaning (see section 8.2).

The measured values must be logged on the “Feelpure™ Platinum Installation & WarrantyForm” (see annex 1 and the instructions in section 7.6).

If it is not possible to get a reading of the back pressure, check that there are noblockages/obstructions along the line (pressure flexible pipe and blue polyurethane pipe) or leaks(check that all threaded joints have been sealed with Teflon® and properly tightened). Also check thecorrect installation of the ECU protection filter (or condensation separation filter), checking that thedirection of throughput indicated on the filter body is correct (as specified in section 4).If, after performing these checks, you read the back pressure as constant 0 mbar, you will have toverify it with a manual pressure gauge. After doing this:

If the reading from the pressure check shows a value that is different from 0 mbar, contactthe supplier of the system to have the control unit replaced.

If the pressure gauge confirms the value of 0mbar, contact the supplier of the system tohave the filter checked to verify it is operating correctly.

If a back pressure level greater than 80mbar is read at engine idle speed, contact the supplier of thesystem to have a filter check in order to verify it is operating correctly.

7.3 Setting of generic working parameters of the system on ECU 3.0

Feelpure™ Platinum ECU 3.0 is ready to use: pre-loaded DCR setting file isFeelpure_Platinum_Tres.dcr.

Just verify the actual correspondence of all the parameters with the corresponding valuesshown on the following pages for the “Standard Setup” and “Regen. Setup”, attaining to theprocedure reported below:

1. Run the program named “FeelPure Managing Software.exe” following the instructionsdescribed in the first two steps of section 7.2.

2. Click on OPERATIONS and then on UPLOAD.

3. Click on the Download Registers icon: a screen of the ECU pre-loaded parameters will be


Date: 16.03.2011




displayed. (DCR settings file is named Feelpure_Platinum_Tres.dcr, a copy of it can be found onthe supplied CD).


Date: 16.03.2011




If all the “Standard Setup” and “Regen. Setup” fields match the above reported settings; you canclose the upload screen. If any field differs from the above reported settings, insert the correct valuesand then click on the Upload Registers icon. Remember to update the internal ECU clock by clicking“update date/time” icon.

Any unauthorised operation on the operatingparameters/settings of the electronic control unit will void the

warranty.

7.4 Checking the operational status of the system by means of the ECU 3.0 software

If the data in the electronic control unit is downloaded (in the OPERATIONS menu, selectDOWNLOAD) you can display and save 4 files that describe the operation of the Feelpure™Platinum system: REGISTERS, PRESSURE LOGS, TEMPERATURE LOGS, EVENTS LOGS.

These files can be converted/exported in Excel format (.xls) and if required they can be sent byemail to [email protected] (in the VIEW menu, select DATABASE and thenselect the file required and click on the EXPORT button).

During the display of the REGISTERS (or in the corresponding exported file), the following elementswill be displayed: Version and revision of the Firmware installed in the same control unit The ADDITIVE TOTALIZER (in terms of executed IMPULSES). ** The number of events, and the pressure and temperature logs stored in memory. Number of stored pulses which will be dosed at the following engine ignition. ** Counter of Emergency Regenerations which did not succeed. **

** These fields are only for Feelpure™ and Feelpure™ AR systems, which operate with additive.They are negligible for Feelpure™ Platinum systems

During the display of the PRESSURE data (or in the corresponding exported file), the last 50000stored values of instantaneous pressure will be displayed, in mbar (corresponding to the last 150engine operation hours).

During the display of the TEMPERATURE data (or in the corresponding exported file), the last 50000stored temperature values will be displayed, in °C (corresponding to the last 150 engine operationhours).

During the display of the EVENTS data (or in the corresponding exported file), the last 32000 storedoperation events will be displayed, according to the following summary table:


Date: 16.03.2011




EVENTCODE LOGGED EVENT DESCRIPTION

0 POWER_SUPPLY_ON Beginning of power supply2 ENGINE_ON Engine turned on3 ENGINE_OFF Engine turned off

4 CONTINUOUS_DOSING injection of additive in continuous mode (meaningless forPLATINUM systems, but still present in ECU logs)

9 SERVICE_PRESSURE_BEGIN Beginning of a high pressure service*10 SERVICE_PRESSURE_END End of a high pressure service24 LO_PRESS_AL_BEGIN Beginning of a low pressure alarm**

25 LO_PRESS_AL_END End of a low pressure alarm30 THERMOR_UNWIRED Unwired thermo resistance

31 THERMOR_WIRED Re-wired thermo resistance (following an unwired thermoresitance event)

41 REGISTERS_MODIFIED Execution of a change in the ECU registers (Upload registers)42 SERVICE_ENGINE_SIGN_BEGIN Beginning of a service request for engine-on fault*43 SERVICE_ENGINE_SIGN_END End of a service request for engine-on fault54 UPDATE_DATE/TIME ECU internal clock updated

*Beginning of a service leads to the LED status change (SOLID RED LIGHT). LED status has to be reset by aspecialised workshop after a system control.

**Beginning of an alarm leads to LED status change (BLINKING RED LIGHT). The system has to be controlled by aspecialised workshop (if the light does not permanently change back to green by its own).

7.5 Verifying the filtering efficiency of the Feelpure™ Platinum system1. With a smoke meter, perform the smoke opacity test of the exhaust gases output from the

replacement muffler installed.2. Compared to the value taken before installation (which has to be lower than the engine's opacity

limit decided by the vehicle Manufacturer and has to be always lower than 1.5 K [m-1]), asubstantial reduction can be measured (up to 95%). Bear in mind, however, that the readingtaken at the end of installation is not definitive. This is due to the filtering cartridge andcatalyst being "run in" and, because of this, the maximum filtering efficiency is reached only afteraround 2-300 km of running.

If you were not able to perform the smoke opacity test before the installation, you can still doit by removing the 1”1/4 threaded sleeve installed on the exhaust gas inlet end plate of theFeelpure™ muffler.

7.6 Feelpure™ Platinum Installation & Warranty form filling-in rulesAll the readings taken (smoke opacity before and after the installation of the system, back pressureat idle speed and full throttle, kilometres on the clock at installation time etc.) are necessary for fillingin the Installation & Warranty Form (see annex 1), together with the vehicle information containedon the registration certificate and the codes on the plates of the following:

Filter (filtering cartridge) Muffler inlet end-can Electronic control unit


Date: 16.03.2011




Catalyst

It is essential to fill in all the mandatory parts of the Installation Form (the optional fields are markedwith an asterisk). In particular the data about the vehicle on which the Feelpure™ filtering system isinstalled are absolutely essential in order to correctly issue the declaration of conformance (issued bythe manufacturer) for the homologation of the installed device. The cited data can easily be found byconsulting the vehicle registration document.

It is essential to fill in all the mandatory parts of the Installation Form (the optional fields are markedwith an asterisk). In particular the data about the vehicle on which the Feelpure™ filtering system isinstalled are absolutely essential in order to correctly issue the declaration of conformance (issued bythe maker) for the homologation of the installed device. The cited data can easily be found byconsulting the vehicle registration document.

Regarding the category of legislation, it is mandatory to transcribe the contents of the correspondingfield of the Vehicle Registration Certificate onto the form, and not just the Euro class, because forsome categories of vehicle the correct issuing of the declaration of conformance is subject to theexact legislation. If line of the certificate does not contain any information, the vehicle might be aEURO 0 class emission vehicle.

The readings before installation, as well as the date of installation, are essential in order to activateand benefit from the maker’s Warranty, based on the warranty conditions specified in this manual.

The data for the muffler, the filtering cartridge and the catalyst can be taken directly from the metalplates welded to the entry endcan, on the filtering cartridge and on the catalyst of the installedsystem (as shown below).

Pirelli recommends filling in the Installation & Warranty Form beforebeginning to assemble the system. During the mounting take care to place the

identification plates (welded on the inlet endcan, on the filter and on thecatalyst) in a position where they can be easily read for any

scheduled/homologation/roadworthiness checks.


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March’11 – Rev. 1 – ENG39*not mandatory

INLET OUTLET


Date: 16.03.2011




8) Operation and maintenanceUsing the Feelpure™ Platinum system generally does not involve changes to the way the vehicle onwhich it is installed has to be used, from the “operational and maintenance” points of view. Themaintenance intervals specified by the vehicle/engine Manufacturer for the other auxiliarysystems (diesel injection, air intake, lubrication, etc) remain unchanged and should be strictlyfollowed.

Specifically, the Feelpure™ Platinum system requires only that the driver (or operator, in the case ofstationary engines) pay attention to the LED installed on the dashboard. The recommendations in thesection 8.2 must also be strictly observed.

8.1 Feelpure™ Platinum system operational statusThe operational status of the system is shown by the LED installed on the vehicle dashboard, in aposition where it can be seen by the driver. The following is the sticker to be placed on thedashboard (or in a clearly visible position):


Date: 16.03.2011




The remaining data, concerning the electronic control unit and the readings made after installationare important to favour a rapid verification of the installation and any necessary recall/modifications.The stamp and signature of installer and customer must be clear and legible.

The Feelpure™ Platinum installation form must be filled in, stamped and countersigned bythe workshop that installed the system and by the owner of the vehicle.

This manual must be kept on board the vehicle, together with the other identificationdocuments.A copy of the document (hardcopy or in electronic format) must be sent to Pirelli Eco Technology byfax +39.02.938.74.664 or by e-mail [email protected] and must subsequently besent by post within 5 working days of the date of installation.

A copy of the document must also be kept by the installer.

This is essential for the Warranty to be recognised by the Pirelli Eco Technologyorganisation, based on the regulations that govern it.

To follow the maintenance programme specified by the vehicle/engine Manufacturer isessential for the product to be used correctly and in conformance with Pirellirecommendations. This is therefore an essential precondition in order to be able to benefitfrom the warranty under the conditions of sale and use.

Failure to complete the installation form in all its mandatory partswill void the maker's warranty.


Date: 16.03.2011




Below is an example of a warranty form with all sections correctly completed

FEELPURE™ PLATINUM INSTALLATION & WARRANTY FORM

MAKE A COPY and FAX TO : +39 02 938 74 664 OR E-MAIL: [email protected]

CUSTOMER/VEHICLE OWNER VEHICLE DATA:

CORPORATE NAME: PIRELLI ECO TECHNOLOGY PLATE: AA100AA VEHICLE N°: 2

______________________________________________________ CHASSIS: WDB1123AAA11111A1Q11

ADDRESS: VIA LURAGHI SNC VEHICLE MANUFACTURER: IVECO

CITY / CAP / COUNTRY: ARESE (MI) VEHICLE MODEL: 35 E 10

CONTACT Mr: _________________________________________ ENGINE MODEL: SOFIM 8140.23

TEL/FAX: 00390293874664 POWER: 76 [KW] DISPLACEMENT: 2800 [cc]

MAIL: _________________________________________________ EMISSION LEVEL: 96/69 CE -- EURO 2

STATEMENT BEFORE INSTALLATION

SMOKE OPACITY (m-1): 0.3 MILEAGE / RUNNING HOURS: 243977 *NOISE [dB]: ____________

FEELPURE™ SYSTEM DATA

MUFFLER (See the plate on the inlet endcan): FILTERING CARTRIDGE (See the welded plate):

TYPE: MST12111NC1 TYPE: F121515N71

SERIAL NUMBER: CR0003135 SERIAL NUMBER: B00000001

PRODUCTION DATE: 02/2011 PRODUCTION DATE: 02/2011

CATALYST (See the plate on the catalyst):

VERSION: CPT16405/31 TYPE: C2708

SERIAL NUMBER: 4600001 SERIAL NUMBER: XE1234567

PRODUCTION DATE: 02/2011 PRODUCTION DATE: 02/2011

Version / ECU Setting NOTES:

X_________________________________________________________

_________________________________________________________6 CYLINDERS - TURBOCHARGER

SMOKE OPACITY (m-1

): 0.05 NOISE [dB]: ___________________________________________________________________

BACKPRESSURES:

IDLE SPEED: 2 [mbar] WOT: 25 [mbar] _________________________________________________________

Measured by:

PRESSURE GAUGE X ECU SOFTWARE _________________________________________________________

_________________________________________________________

_________________________________________________________

INSTALLATION DATE: 11/03/2011

INSTALLER SIGNATURE & STAMP: VEHICLE OWNER SIGNATURE & STAMP:

*not mandatory

SEND BY POST WITHIN 5 WORKING DAYS OF THE INSTALLATION DATE TO START THE WARRANTY PERIOD (SEE THE MANUAL BACKSIDE COVER)

ELECTRONIC CONTROL UNIT (See the ECU labels):

I declare that I have received the Feelpure(TM) installation

manual and the CD with the ECU managing software. I have

read, understood and accepted their contents.

I have checked the pre-loaded DCR settings: they

match the ones reported on the Installation Book.

(Feelpure_Platinum_Tres.dcr)


Date: 16.03.2011








Date: 16.03.2011







SOLID GREEN LIGHT System ok.

DOUBLE RED BLINKINGLow backpressure.Service required.

SOLID RED LIGHTService required.Go to a specialist service centre as soon as possible.

EN


Date: 16.03.2011




NOTE:For the Feelpure™ Platinum version, the first time “high back pressure” alarm (SOLID RED LIGHT) isreported, you can perform the following procedure, exclusively to favour/allow regeneration:

Bring the engine to full running load (at full power/driving under load on a straight stretch of road at aconstant speed, observing the speed limit, or on a section of road going uphill). This is to ensure thehighest operating temperatures in the engine and exhaust system.

For auxiliary engines or earth movement vehicles, increase the power demand from the hydraulicssystem to achieve full load on the engine.

This procedure must be carried out for not more than 10 minutes.

Regardless of the result of the above procedure, you are strongly recommended to visit thenearest specialised workshop for a system check/diagnosis of the system.


Date: 16.03.2011




8.2 Scheduled maintenance

A necessary condition for the Feelpure™ Platinum system to work is to systematically follow themaintenance plan specified by the vehicle/engine Manufacturer.It is necessary to guarantee that:

The smoke opacity of the exhaust gases, measured upstream of the filter, is lower than theengine's opacity limit decided by the vehicle builder and has to be always lower than 1.5 K[m-1]

The lube-oil consumption is lower than 800g/1000 km (0.25% of the fuel consumption) The temperature of the exhaust gases at the inlet side of the muffler must be kept at over

250°C for at least 30% and over 300°C for at least 15% of the running time of the engine.

The operations to be performed specifically for the Feelpure™ Platinum system are the following:

o Verify back pressure upstream of filter at least every 60,000 km / 6 months(Depending on the first condition reported)

o Verify the smoke opacity of the exhaust gases upstream of filterAt least every 60,000 km / 6 months(Depending on the first condition reported)

o Check / bleeding of “ECU protection” gas filter (installed on the socket where the back pressureis manually measured)

At least every 60,000 km / 6 months(Depending on the first condition reported)

o Cleaning/replacing the particulate filter: 200,000 km *(And in any case whenever alerted by the dashboardLED)

o Replacing the catalyst: 400,000 km

The spare parts that may be necessary are the following: SPARE-PART SAP CODE

Filter/catalyst/endcan gaskets (IN-OUT) 6800000401 (11” diameter)6800006301 (12” diameter)

ECU protection filter 9000012271 (cartridge only)9000006501 (whole filter)

Please check the catalogue for the complete list of spare parts

* Value referred to a Euro 3 vehicle mainly running an intercity/highway mission


Date: 16.03.2011




In addition to the above, should there be an engine problem (such as a failed turbocharger,fuel-pump or injector) which would generate a large amount of soot in a short time period, it will benecessary to:

Carry out a diagnosis of the Feelpure™ Platinum system Inspect the condition of the filtering cartridge and catalyst If required, clean and replace the cartridge and/or catalyst

In terms of importance, the Feelpure™ Platinum system could be considered on the same levelas all the other auxiliary systems (lubrication, air intake, Diesel injection, braking system etc.)and therefore we recommend you to add the list of operations and checks described above to themaintenance plan for your vehicle fleet (i.e. these checks should be done at the regular servicesplanned for every 30-60-90-120,000 km). You should budget approximately half an hour ofadditional labour and 1.5 hours for replacing the filtering cartridge (2 hours for unusual mufflerconfigurations).

The checks/repairs/replacements described above must be carried out in observance of the propertechnical regulations, taking the necessary safety precautions, and preferably they should be performedat specialised workshops and sending the details of the servicing carried out to Pirelli Eco Technologyusing the VEHICLE INSPECTION FORM enclosed (see Annex 2).

Failure to notify Pirelli Eco Technology of the operations carriedout will result in the termination of the warranty.


Date: 16.03.2011




8.3 How to carry out system diagnoses - filling in the Vehicle Inspection Form

When filling in the VEHICLE INSPECTION FORM you must include the information on theINSTALLATION & WARRANTY FORM about the vehicle, the distance travelled and the smokeopacity of the exhaust gases logged by the installer at the time of installation.

Recognition of any replacement of a component via the Maker’sWarranty will only be possible if the request is accompanied by

the Vehicle Inspection Form, duly completed and signed.

The back pressure check can be done using the Pirelli software supplied, as described in section7.2: Launch the program named “FeelPure Managing Software.exe” Select the serial port to connect to the ECU. The box in the bottom left must become red, and the

box in the bottom right must indicate the availability of the selected port for communication. Connect the laptop PC to the ECU using the supplied serial cable. The connection status box

must become green, to indicate that actual communication is taking place between the PC andthe ECU.

Click on VIEW and then on REAL TIME DATA.

By clicking on START you can check the instantaneous value of the pressure (note the analoguepressure gauge at the “pressure” field), read downstream of the filter.In the absence of the supplied software you can make the same check using a manual pressuregauge.The value must be read when the engine is at idle speed (Pmin) and then at WOT condition (Pmax).In this way it is also possible to verify the status of the driver’s LED (and to log the correspondingluminous code on the VEHICLE INSPECTION FORM).Each replacement of components must be reported (by checking the appropriate boxes) on the form.Any further annotations must be entered in the NOTES/COMMENTS field.

As for the download of the data from the ECU 3.0 with the supplied software, please refer to theinstructions given in sections 7.2 – 7.4.

The downloaded files can be converted/exported in Excel format (.xls) and if required they can besent by email to [email protected]. To export the data follow the instructionsgiven below:

Click on VIEW, select DATABASE and then the following screen will appear, containingthe list of files downloaded with the software.


Date: 16.03.2011




Select the file of interest (the selected file is shown in green)

Click on the EXPORT button

Select the destination folder and name the export file – it will be saved in.xls format in theselected folder

The smoke opacity of the exhaust gases must be measured both upstream (through the 1”1/4threaded sleeve) and downstream of the filtering system.


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8.4 Replacing the filtering cartridge for Feelpure™ Platinum systemsReplacing the filtering cartridge must be carried out in observance of the proper technical regulationsand taking the necessary safety precautions. The details must then be sent to Pirelli Eco Technology.

Recognition of any replacement of a component via the Maker’sWarranty will only be possible if the request is accompanied by

the Vehicle Inspection Form, duly completed and signed.

The detailed procedure to replace the filtering cartridge is: Perform a smoke opacity test (upstream of the filter) and log the result on the Vehicle

Inspection Form (see Annex 2), and also enter the serial number of the filtering cartridge onthe form.

Position a suitable lifting/support system under the filter (the weight of the Feelpure™cartridge varies from 10 to 30 kg depending on the size).

If you have fixed the system with brackets placed on the filtering cartridge, detach thewhole muffler (inlet endcan, catalyst, filtering cartridge, outlet endcan) and position it in acomfortable position for working. Before doing this operation, make sure to disconnectthe thermistor connector and the back pressure pipe.

Remove the locking V-clamps (via the threaded connections held with nut & locknut) between- Catalyst and filtering cartridge- Outlet endcan and filtering cartridge

Detach the filtering cartridge (and enter the serial number on the Vehicle Inspection Form) Replace the gaskets positioned between the cartridge and the inlet/outlet end plates Attach the replacement cartridge (and enter the serial number on the Vehicle Inspection

Form). Reattach the locking V-clamps (the tightening torque required is 15Nm).

Note: the removed filtering cartridge must be stored in the pack provided by Pirelli Eco Technologyinside the special protective cover (and, if applicable, sent to Pirelli for the cleaning operation inaccordance with the sales/maintenance conditions agreed). Before inserting anything into thepackaging, verify that the object temperature is close to the ambient temperature.

When the operation is finished, the back pressure must be verified using the Pirelli softwaresupplied or using a pressure gauge. See the instructions given in section 7.2.

When replacing the cartridge, it is also necessary to reset the filter’s hour meter (i.e. hour log), usingthe supplied software. From the Operations – Download screen, select the command “Reset filtercounter”.

Whenever the filtering cartridge is removed and refitted you must log the serial numbers (s/n) ofthe removed filter and of the replacement filter on the VEHICLE INSPECTION FORM (the serialnumber is on the metal plate welded to the cartridge).


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The form (contained in this manual) must be filled in, stamped and countersigned by theworkshop that performed the maintenance operation and by the owner of the vehicle and kepton board the vehicle with the vehicle's other identification documents.A copy of the document (hardcopy or in electronic format) must be sent to Pirelli Eco Technology byfax +39.02.938.74.664 or by e-mail [email protected] and must subsequently besent by post within 5 working days of the date of inspection.

A copy of the document must also be kept by the workshop that carried out the check/diagnosis.

For further information contact Pirelli Eco Technology Customer Assistance by email [email protected]

Failure to notify Pirelli Eco Technology of the operations carriedout will result in the termination of the warranty.

8.5 Replacing the catalyst for Feelpure™ Platinum systems

Follow the instruction reported in section 8.4. Fill in the inspection form with removed and replacementcatalyst serial numbers.


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Annex 1 – Feelpure™ Platinum system Installation Warranty form

FEELPURE™ PLATINUM INSTALLATION & WARRANTY FORMMAKE A COPY and FAX TO : +39 02 938 74 664 OR E-MAIL: [email protected]

CUSTOMER/VEHICLE OWNER VEHICLE DATA:

CORPORATE NAME: ___________________________________ PLATE: __________________ VEHICLE N°: _________________

______________________________________________________ CHASSIS: ______________________________________________

ADDRESS: ___________________________________________ VEHICLE MANUFACTURER: _____________________________

CITY / CAP / COUNTRY: _______________________________ VEHICLE MODEL: _______________________________________

CONTACT Mr: _________________________________________ ENGINE MODEL: _______________________________________

TEL/FAX: _____________________________________________ POWER: __________[KW] DISPLACEMENT: _________[cc]

MAIL: _________________________________________________ EMISSION LEVEL: ______________________________________

STATEMENT BEFORE INSTALLATION

SMOKE OPACITY (m-1): ____________ MILEAGE / RUNNING HOURS: __________________ *NOISE [dB]: ____________

FEELPURE™ SYSTEM DATAMUFFLER (See the plate on the inlet endcan): FILTERING CARTRIDGE (See the welded plate):

TYPE: ______________________________________________ TYPE: ______________________________________________

SERIAL NUMBER: __________________________________ SERIAL NUMBER: __________________________________

PRODUCTION DATE: ______________________________ PRODUCTION DATE: ______________________________

CATALYST (See the plate on the catalyst):

VERSION: _________________________________________ TYPE: ______________________________________________

SERIAL NUMBER: __________________________________ SERIAL NUMBER: __________________________________

PRODUCTION DATE: ______________________________ PRODUCTION DATE: ______________________________

Version / ECU Setting NOTES:

_________________________________________________________

_________________________________________________________

SMOKE OPACITY (m-1): ___________ *NOISE [dB]: ___________________________________________________________________

BACKPRESSURES:

IDLE SPEED: _________ [mbar] WOT: ________ [mbar] _________________________________________________________

Measured by:PRESSURE GAUGE ECU SOFTWARE _________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________

_________________________________________________________INSTALLATION DATE: ________________________________

INSTALLER SIGNATURE & STAMP: VEHICLE OWNER SIGNATURE & STAMP:

* not mandatory

SEND BY POST WITHIN 5 WORKING DAYS OF THE INSTALLATION DATE TO START THE WARRANTY PERIOD (SEE THE MANUAL BACKSIDE COVER)

ELECTRONIC CONTROL UNIT (See the ECU labels):

I declare that I have received the Feelpure(TM) installationmanual and the CD with the ECU managing software. I haveread, understood and accepted their contents.

I have checked the pre-loaded DCR settings: theymatch the ones reported on the Installation Book.(Feelpure_Platinum_Tres.dcr)


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Annex 2 – Feelpure™ Platinum system Vehicle Inspection Form

FEELPURE™ PLATINUM INSPECTION FORMMAKE A COPY and FAX TO : +39 02 938 74 664 OR E- MAIL: [email protected]

COMPLAINT DATE: _______________________________ INSPECTION DATE: _______________________________

CUSTOMER (REFER TO THE INSTALLATION FORM):_________________________________________________________

VEHICLE MAKE: _____________________________________ VEHICLE MODEL: ______________________________

PLATE: ___________________________________________ VEH. NUMBER: ____________________________________

MILEAGE/HOURS AT COMPLAINT: _____________________ MILEAGE/HOURS AT INSPECTION: ____________________

INSTALLATION DATE: ________________________________ MILEAGE/HOURS INSTALLATION: ___________________

SMOKE OPACITY BEFORE INSTALLATION:_______________________________________________

DPF system version: Feelpure™ Platinum

SYSTEM Pmin: __________ Pmax: ___________ (VERIFY AT IDLE SPEED AND WOT)BACKPRESSURECHECK: Pavg: _________ Samples left: _______ (on the REAL TIME DATA ECU software window)

Temperature:_________ (check if is an acceptable value) SAMPLE FROM FUEL TANK: YES NO

DASHBOARD LED STATUS:

FIX GREEN DOUBLE RED FIX REDLIGHT BLINKING LIGHT

SMOKE OPACITY: ___________ (BEFORE FILTER) __________ (AFTER FILTER)

ECU DOWNLOAD: SETTINGS PRESSURE LOG EVENTS LOG TEMPERATURE LOG

SPARE PARTS USED:

FILTER CARTRIDGE REMOVED S/N: _________________ INSTALLED S/N: _________________

Reset filter cartridge hour counter

ELECTRONIC CONTROL UNIT REMOVED S/N: _________________ INSTALLED S/N: _________________

CATALYST REMOVED S/N: _________________ INSTALLED S/N: _________________

FILTER GASKETS 2 3 FILTER V-CLAMPS "ECU PROTECTION" GAS FILTER

BATTERY FUSE (3A) DASHBOARD LED THERMISTOR

NOTES/COMMENTS: _______________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

____________________________________________________________________________________________________________

INSPECTOR SIGNATURE AND STAMP: VEHICLE OWNER SIGNATURE AND STAMP:

SEND BY POST WITHIN 5 WORKING DAYS (SEE THE MANUAL BACKSIDE) TO START THE WARRANTY PERIOD


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March’11 – Rev. 1 – ENG

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Pirelli & C. Eco Technology Spa viale Luraghi snc, 20020 Arese (Mi) Italia

Tel +39 02 93874600 - Fax +39 02 93874664www.pirelliecotechnology.com

FEELPURETM DPF SYSTEM

FEELPURE™ Platinum

system installation, operation & maintenance book

[email protected]

UNITED [email protected]

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BELGIUM, NETHERLANDS, [email protected]

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SPAIN, [email protected]

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FEELPURE DPF SYSTEM FEELPURE™ Platinum system ......REV7.2_12.12.2010 Pirelli & C. Eco Technology...

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