STANDARD OWNER S MANUAL

Transcription

1 WILLIE 1.0 STANDARD OWNER S MANUAL OPERATION, MAINTENANCE, & TROUBLESHOOTING STANDARD INSTRUCTIONS FOR ALL SYSTEMS DSE /28/2011 Willis Power Systems 2950 N Martin Springfield, MO service@willisapu.com

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3 Table of Contents Willie 1.0 Standard Owner s Manual... 1 Controller Quick Start Guide... 5 Starting Your APU... 5 Set Your Temperature... 5 Introduction to the Willie Parts and Service... 6 Guidelines... 6 Maintenance Requirements... 7 Controller Quick Start Guide... 8 Starting Your APU... 8 Thermostat Quick Start... 8 DSE3000 Operating Guide... 9 Dimensions and Mounting... 9 DC Supply, Fuel, and Start Outputs Operational Instructions DSE 3100 Quickstart Starting the Engine Stopping the Engine Controls ENGINE RUNNING STOPPING SEQUENCE MANUAL OPERATION WAITING IN MANUAL MODE STARTING SEQUENCE ENGINE RUNNING Protections Warnings Shutdowns Module Display RUNNING ICON USB ICON MEMORY CORRUPTION BACKLIGHT DSE 3100 Troubleshoot Fault Finding APU Troubleshooting Guide Failure to Start Page 3 of 36

4 Engine Will Not Go to High RPM APU Engine Stops Suddenly APU Engine Overheats Oil Leaks Serpentine Drive Belt Failure (For Premium Unit Only) Alternator Failure Pneumatic Compressor Failure (For Premium Unit Only) Engine Speed Sensor Failure Air Condition Compressor Failure TRUCK INTERFACE PROBLEMS Fan Drive System Air Governor Air Intake System to APU Exhaust System Thermostat Operating Guide Fan Operating Mode Displaying the Temperature Setting the Temperature Backlight Thermostat Control Mode Manual/Permanent Hold Mode Programmable Mode Temporary Bypass Battery Replacement Indicator Configuration Menu Programming Setting the Time & Day Setting the Date Energy Saving Schedule Modifying Your Schedule Page 4 of 36

5 CONTROLLER QUICK START GUIDE Warning: Always check your thermostat batteries. Dead batteries will prevent your AC from working. STARTING YOUR APU Caution: Some trucks currently operate with the coolant temperature at 230⁰F. This temperature can cause an excessive heat load on your APU at startup, signaling your APU to shutdown. In order to run your APU properly, leave your truck engine fan running for 30 minutes while the APU is running to reduce the heat. 1. While the truck is running, press the stop button on your DSE to initiate the manual mode. 2. Press the Start button to crank the APU engine. 3. After engine starts running, do not shut down your truck and allow the truck engine fan to run for 30 minutes with the APU to reduce excessive heat load. 4. To shutdown the APU, press the Stop/Reset button. SET YOUR TEMPERATURE 1. Use the selector switch to set the fan to AUTO or ON. 2. Press one of the arrow buttons until the temperature you want is displayed. Page 5 of 36

6 INTRODUCTION TO THE WILLIE 1.0 The Willie APU offers up to 50% more engine power than competitive products and its compact and lightweight design allows for easy installation. Willie provides the power and quality while priced competitively to meet the needs of the average driver and trucking company. Willie gives built-in redundancy to a big rig s critical systems. It is designed to be serviceable and is backed by parts availability. The company provides products that achieve maximum APU-related savings in fuel and maintenance designed to offset the costs of installing emissions control equipment mandated by state idling and federal emissions laws. PARTS AND SERVICE All parts for the Willis APU are available from the factory and authorized installation centers. Warranty repairs and service must be performed by authorized service centers unless prior authorization has been obtained. Willis Power Systems Have your contact information and engine serial number ready when calling. Please leave a message with the information if the line is busy. GUIDELINES Before operating the Willis APU, be sure and read all manuals included with your purchase to understand the features of the unit. Do not remove or replace the APU s cover while the engine running. If the unit is running with the cover off, stay clear of the accessory drive belt. The APU contains hot oil and coolant under pressure. Inspect hoses and connections frequently when the engine is NOT running for signs of leakage or damage. Do not insert anything in the holes in the transmission case while the APU is running. Do not leave any foreign object in the transmission case. Do not work on any Willis APU components located on or near the truck engine when the truck engine is running. Only qualified maintenance personnel should operate the Willis APU. Page 6 of 36

7 MAINTENANCE REQUIREMENTS The Willis APU requires a minimum of maintenance, but it is important to perform maintenance actions specified here on schedule. APU run time may be checked by reading the Electronic controller s hour recorder. Refer to the DSE operation or troubleshooting section for more information. WARNING: If your APU has not been running, do not immediately shut down your truck. Allow the truck engine fan to run for 15 minutes in order to reduce the excessive heat going into your APU. Always check that the APU control is set to off before removing the cover and working on the unit. It is recommended that you take your unit to one of our service locations for routine maintenance checks. Every 50 Hours of APU Runtime Check the APU engine oil level on dipstick Every 500 Hours of Runtime Check and/or change thermostat batteries Replace the APU s engine oil and filter Replace the APU engine fuel filter Disconnect/clean ALL grounds and power connections & reseal with Plasti-coat or equivalent. Check the engine air filter Check belts and hoses for wear Check wires, harnesses, clamps, & tie wraps for wear Every 2000 Hours of APU Runtime Engine Oil Check the fuel hoses on the APU Check the five water hoses on the APU Replace the APU engine s water pump belt Use SAE 15W-40 engine oil for all temperatures. Oil should meet API classification CC/CD/CE and be replaced every 500 hours of APU runtime or when truck s oil is changed, whichever comes first. Engine Coolant No separate maintenance is needed. The APU uses the truck s coolant. Nominally, this is low-silicate 40% permanent anti-freeze by volume for temperatures down to -12⁰F and 50% by volume below -12⁰F. Page 7 of 36

8 CONTROLLER QUICK START GUIDE You have two main controllers: DSE & Thermostat. STARTING YOUR APU Caution: Some trucks currently operate with the coolant temperature at 230⁰F. This temperature can cause an excessive heat load on your APU at startup, signaling your APU to shutdown. In order to run your APU properly, leave your truck engine fan running for 30 minutes while the APU is running to reduce the heat. 1. While the truck is running, press the stop button on your DSE to initiate the manual mode. 2. Press the Start button to crank the APU engine. 3. After engine starts running, do not shut down your truck and allow the truck engine fan to run for 30 minutes with the APU to reduce excessive heat load. 4. To shutdown the APU, press the Stop/Reset button. THERMOSTAT QUICK START 1. Use the selector switch to set the fan to AUTO or ON. 2. Press one of the arrow buttons until the temperature you want is displayed. Page 8 of 36

9 DSE3000 OPERATING GUIDE Dimensions and Mounting Dimension 99mm x 79 mm x 40mm (3.9 x 3.1 x 1.6 ) Panel Cut-out 80mm x 68mm (3.2 x 2.7 ) Weight 89g (0.089kg) DC SUPPLY, FUEL, AND START OUTPUTS PIN Description CABLE NOTES No SIZE 1 DC Plant Supply Input (Negative) 2.5mm² AWG 13 2 DC Plant Supply Input (Positive) 2.5 mm² AWG 13 (Recommended Maximum Fuse 15A anti-surge) Supplies the module (2A anti-surge requirement) and all output relays 3 Output A (FUEL) 4 Output B (START) 5 Output C 6 Output D 7 Charge fail / excite 1.0mm² AWG mm² AWG mm² AWG mm² AWG mm² AWG 13 Page 9 of 36 Plant Supply Positive from terminal 2. 3 Amp rated. Plant Supply Positive from terminal 2. 3 Amp rated. Plant Supply Positive from terminal 2. 3 Amp rated. Plant Supply Positive from terminal 2. 3 Amp rated. Do not connect to ground (battery negative). If charge alternator is not fitted, leave this terminal disconnected.

10 3100 OPERATIONAL INSTRUCTIONS The following section details the function and meaning of the various controls on the module and the module s operations. Page 10 of 36

11 DSE 3100 QUICKSTART This section provides a quick start guide to the module s operation. Starting the Engine Stopping the Engine Page 11 of 36

12 3100 CONTROLS Stop / Reset This button places the module into its Stop/Reset mode. This will clear any alarm conditions for which the triggering criteria have been removed. If the engine is running and the module is in Stop mode, the module will automatically instruct the changeover device to unload the generator ( Close Generator becomes inactive (if used)). The fuel supply de-energizes and the engine comes to a stand-still. Should a remote start signal be present while operating in this mode, a remote start will not occur. Auto This button places the module into its Automatic mode. This mode allows the module to control the function of the generator automatically. The module will monitor the remote start input and once a start request is made, the set will be automatically started and placed on load. Upon removal of the starting signal, the module will automatically transfer the load from the generator and shut the set down observing the stop delay timer and cooling timer as necessary. The module will then await the next start event. For further details, please see the more detailed description of Auto operation elsewhere in this manual. Start Pressing this button in auto mode will start the engine and run off load. Pressing this button in STOP/RESET mode will turn on the CAN engine ECU (when correctly configured and fitted to a compatible engine ECU). Page Pressing this button scrolls the display to show the various instruments. Page 12 of 36

13 ENGINE RUNNING Once the engine is running and all starting timers have expired, the animated icon is displayed. DSE3110 -The generator will be placed on load if configured to do so. NOTE:-THE LOAD TRANSFER SIGNAL REMAINS INACTIVE UNTIL THE OIL PRESSURE HAS RISEN. THIS PREVENTS EXCESSIVE WEAR ON THE ENGINE. If all start requests are removed, the stopping sequence will begin. STOPPING SEQUENCE The return delay timer operates to ensure that the starting request has been permanently removed and isn t just a short term removal. Should another start request be made during the cooling down period, the set will return on load. If there are no starting requests at the end of the return delay timer, the load is removed from the generator to the mains supply and the cooling timer is initiated. The cooling timer allows the set to run off load and cool sufficiently before being stopped. This is particularly important where turbo chargers are fitted to the engine. After the cooling timer has expired, the set is stopped. MANUAL OPERATION NOTE: IF A DIGITAL INPUT CONFIGURED TO PANEL LOCK IS ACTIVE, CHANGING MODULE MODES WILL NOT BE POSSIBLE. VIEWING THE INSTRUMENTS AND EVENT LOGS IS NOT AFFECTED BY PANEL LOCK. Manual mode allows the operator to start and stop the set manually, and if required change the state of the load switching devices. Module mode is active when the button is pressed. WAITING IN MANUAL MODE 1. To begin the starting sequence, press the button. 2. If protected start is disabled, the start sequence begins immediately. 3. If Protected Start is enabled, the icon is displayed to indicate manual mode and the manual LED flashes. 4. The button must be pressed once more to begin the start sequence. Page 13 of 36

14 STARTING SEQUENCE NOTE:-THERE IS NO START DELAY IN THIS MODE OF OPERATION. The fuel relay is energized and the engine is cranked. NOTE:-IF THE UNIT HAS BEEN CONFIGURED FOR CAN, COMPATIBLE ECU S WILL RECEIVE THE START COMMAND VIA CAN. If the engine fails to fire during this cranking attempt then the starter motor is disengaged for the crank rest duration after which the next start attempt is made. Should this sequence continue beyond the set number of attempts, the start sequence will be terminated and the display shows Fail to Start. The starter motor is disengaged when the engine fires. Speed detection is factory configured to be derived from the main alternator output frequency but can additionally be measured from a Magnetic Pickup mounted on the flywheel (Selected by PC using the 3000 series configuration software). Additionally, rising oil pressure can be used disconnect the starter motor (but cannot detect under-speed or over-speed). NOTE: IF THE UNIT HAS BEEN CONFIGURED FOR CAN, SPEED SENSING IS VIA CAN. After the starter motor has disengaged, the Safety On timer activates, allowing Oil Pressure, High Engine Temperature, Under-speed, Charge Fail and any delayed Auxiliary fault inputs to stabilize without triggering the fault. ENGINE RUNNING In manual mode, the load is not transferred to the generator unless a loading request is made. A loading request can come from a number of sources. Activation of an auxiliary input that has been configured to remote start on load. Activation of the inbuilt exercise scheduler if configured for on load runs. NOTE: THE LOAD TRANSFER SIGNAL REMAINS INACTIVE UNTIL THE OIL PRESSURE HAS RISEN. THIS PREVENTS EXCESSIVE WEAR ON THE ENGINE. Once the load has been transferred to the generator, it will not be automatically removed. To manually transfer the load back to the mains either: Page 14 of 36

15 1. Press the auto mode button to return to automatic mode. The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence. 2. Press the stop button De-activation of an auxiliary input that has been configured to remote start on load. STOPPING SEQUENCE In manual mode the set will continue to run until either: a) The stop button is pressed The set will immediately stop b) The auto button is pressed. The set will observe all auto mode start requests and stopping timers before beginning the Auto mode stopping sequence. PROTECTIONS When an alarm is present, the common alarm LED if configured will illuminate. The LCD display will show an icon to indicate the failure. WARNINGS Warnings are non-critical alarm conditions and do not affect the operation of the generator system, they serve to draw the operators attention to an undesirable condition. Warning alarms are self-resetting when the fault condition is removed. The icon will appear steady in the display. SHUTDOWNS 1. Shutdowns are critical alarm conditions that stop the engine and draw the operator s attention to an undesirable condition. 2. When shutdown alarms are latching, the fault must be removed and the button pressed to reset the module. The icon will appear flashing in the display. Page 15 of 36

16 8 MODULE DISPLAY TIMER ICON When the module is controlling the engine (starting and stopping) an animated timer icon will be displayed in the icon area to indicate that a timer is active, for example cranking time, crank rest etc. STOPPED ICON When there are no alarms present, an icon will be displayed to indicate the engine is stopped and what mode the unit is in. Stop Auto Manual The hand is only displayed when the arming options is enabled; otherwise the engine starts when entering the manual mode. RUNNING ICON When there are no alarms present, an animated icon is displayed to indicate the engine is running. USB ICON When a USB connection is made to the module the USB icon is displayed. MEMORY CORRUPTION If either the configuration file or engine file becomes corrupted the unit will display the icon. BACKLIGHT The backlight will be on if the unit has sufficient voltage on the power connection while the unit is turned on, unless the unit is cranking for which the backlight will be turned off. Page 16 of 36

17 DSE 3100 TROUBLESHOOT ICON DESCRIPTION AUXILIARY INPUTS FAIL START TO Auxiliary inputs can be user configured and will display the message as written by the user. The engine has not fired after the preset number of start attempts FAIL TO STOP LOW OIL PRESSURE ENGINE HIGH TEMPERATUR E UNDERSPEED OVERSPEED CHARGE FAILURE The module has detected a condition that indicates that the engine is running when it has been instructed to stop. NOTE: Fail to Stop could indicate a faulty oil pressure sensor -If engine is at rest check oil sensor wiring and configuration. The module detects that the engine oil pressure has fallen below the low oil pressure pre-alarm setting level after the Safety On timer has expired. The module detects that the engine coolant temperature has exceeded the high engine temperature pre-alarm setting level after the Safety On timer has expired. The engine speed has fallen below the under speed pre alarm setting The engine speed has risen above the over speed pre alarm setting The auxiliary charge alternator voltage is low as measured from the W/L terminal. LOW LEVEL FUEL The level detected by the fuel level sensor is below the low fuel level setting. BATTERY UNDER/ OVER VOLTAGE GENERATOR UNDER VOLTAGE The DC supply has fallen below or risen above the low/high volts setting level. The generator output voltage has fallen below the pre-set pre-alarm setting after the Safety On timer has expired. Page 17 of 36

18 GENERATOR OVER VOLTAGE GENERATOR UNDER FREQUENCY GENERATOR OVER FREQUENCY CAN ECU WARNING CAN ECU SHUTDOWN The generator output voltage has risen above the pre-set pre-alarm setting. The generator output frequency has fallen below the pre-set pre-alarm setting after the Safety On timer has expired. The generator output frequency has risen above the pre-set pre-alarm setting. The engine ECU has detected an alarm CHECK ENGINE LIGHT Contact Engine Manufacturer for support. CAN FAIL DATA The module is configured for CAN operation and does not detect data on the engine Can data link. EMERGENCY STOP MAGNETIC PICKUP FAILURE INTERNAL MEMORY ERROR The emergency stop button has been depressed. This is a fail-safe (normally closed to battery positive) input, and will immediately stop the set should the signal be removed. Removal of the battery positive supply from the emergency stop input will also remove DC supply from the Fuel and Start outputs of the controller. NOTE: The Emergency Stop Positive signal must be present otherwise the unit will shutdown. Pulses are no longer being detected from the magnetic pickup probe (3110-xxx-01 magnetic pickup version only) Either the configuration file or engine file memory is corrupted. Contact your supplier for assistance. Page 18 of 36

19 3100 FAULT FINDING SYMPTOM Unit is inoperative Read/Write configuration does not operate Unit shuts down Unit locks out on Emergency Stop Intermittent Magnetic Pick-up sensor fault Low oil Pressure fault operates after engine has fired High engine temperature fault operates after engine has fired. POSSIBLE REMEDY Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse. Check DC supply voltage is not above 35 Volts or below 9 Volts Check the operating temperature is not above 70 C. Check the DC fuse. If no Emergency Stop Switch is fitted, ensure that a DC positive signal is connected to the Emergency Stop input. Check emergency stop switch is functioning correctly. Check Wiring is not open circuit. Ensure that Magnetic pick-up screen only connects to earth at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages. Check pickup is correct distance from the flywheel teeth. Check engine oil pressure. Check oil pressure switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the 3310 Module and is correctly configured. Check engine temperature. Check switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the 3000 series module. Shutdown operates fault Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input. Page 19 of 36

20 Warning operates fault Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input. Fail to Start is activated after preset number of attempts to start Continuous starting of generator when in AUTO Generator fails to start on receipt of Remote Start signal. Pre-heat inoperative Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module. Check the speed-sensing signal is present on the 3000 series module inputs. Refer to engine manual. Check that there is no signal present on the Remote Start input. Check configured polarity is correct. Check Start Delay timer has timed out. Check signal is on Remote Start input. Confirm correct configuration of input is configured to be used as Remote Start. Check that the oil pressure switch or sensor is indicating low oil pressure to the controller. Depending upon configuration, the set will not start if oil pressure is not low. Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check preheat configuration is correct. Starter inoperative motor Check wiring to starter solenoid. Check battery supply. Check battery supply is present on the Starter output of module. Ensure that the Emergency Stop input is at Positive. Ensure oil pressure switch or sensor is indicating the low oil pressure state to the 3000 series controller. Engine runs but generator will not take load Check Warm up timer has timed out. Ensure generator load inhibit signal is not present on the module inputs. Check connections to the switching device. Note that the set will not take load in manual mode unless there is an active remote start on load signal. Page 20 of 36

21 Incorrect reading on Engine gauges Fail to stop alarm when engine is at rest Module appears to revert to an earlier configuration Set will not take load Inaccurate generator measurements on controller display Check engine is operating correctly. Check sensor and wiring. When editing a configuration using the PC software it is vital that the configuration is first read from the controller before editing it. This edited configuration must then be written back to the controller for the changes to take effect. When editing a configuration using the Front Panel Editor, be sure to press the Save button to save the change before moving to another item or exiting the Front Panel Editor. Ensure the generator is available. Check that the output configuration is correct to drive the load switch device and that all connections are correct. Remember that the set will not take load in manual mode unless a remote start on load input is present. The 3000 series controller is true RMS measuring so gives more accurate display when compared with an average meter such as an analogue panel meter or some lower specified digital multimeters. Accuracy of the controller is better than 1% of full scale. IE Gen volts full scale is 333V ph-n so accuracy is ±3.33V (1% of 333V). NOTE: THE ABOVE FAULT FINDING IS PROVIDED AS A GUIDE CHECK-LIST ONLY. AS THE MODULE CAN BE CONFIGURED TO PROVIDE A WIDE RANGE OF DIFFERENT FEATURES, ALWAYS REFER TO THE SOURCE OF YOUR MODULE CONFIGURATION IF IN DOUBT. Page 21 of 36

22 APU TROUBLESHOOTING GUIDE FAILURE TO START If there is no response at all to setting the Electronic Controller to Manual operating position, there may a problem with the Electronic Controller, the connection between the Controller and the ECM is open, the truck battery is dead, or if equipped, the battery SWITCH may be OFF. The APU engine may fail to start if: a) It lacks fuel; a fuel shortage may be due to air in the fuel line or a blocked fuel filter. b) There is a problem with the electronic controller, c) The battery or starter has a problem, d) It lacks intake air; too little intake air may be from a restriction in the air supply system. e) The starter control relay is bad, f) There is blockage in the exhaust system g) The engine speed sensor is defective. ENGINE WILL NOT GO TO HIGH RPM Engine output may be low if a) the throttle-advance solenoid is not working, b) the throttle linkage has a problem, or c) the Electronic Controller isn t sending proper output. APU ENGINE STOPS SUDDENLY Sudden stopping may be due to a) the Electronic Controller senses overheating or low oil pressure (warning light comes on), b) fuel pump failure, c) shutdown solenoid relay failure, d) fuel shutoff solenoid failure, e) engine speed sensor failure, or f) the truck s fuel tank is empty. APU ENGINE OVERHEATS If the engine overheats it will shut down (warning light will come on). Look for a coolant hose leak or blockage, or water pump or water pump belt failure. Check coolant level in the main engine. Check to make sure the coolant control valve at the truck radiator is open. Page 22 of 36

23 OIL LEAKS Oil accumulating in the bottom of the enclosure case is not normal. Check hoses from the oil pump to truck engine. Make sure the breather hose (if so equipped) extends through bottom of case. SERPENTINE DRIVE BELT FAILURE (FOR PREMIUM UNIT ONLY) Failure of the APU s internal drive belt causes all accessories, except the oil pump, to stop functioning. There will be no alternator function, no A/C compressor, and no pneumatic compressor. Failure symptom: the unit will not go to low idle and there will be a slight increase in APU engine RPM over the normal high idle RPM. ALTERNATOR FAILURE The battery will discharge when the APU is running. The APU may experience an overly high temperature reading in the enclosure as the alternator approaches failure. PNEUMATIC COMPRESSOR FAILURE (FOR PREMIUM UNIT ONLY) The truck s air tank won t pressurize when running the APU. ENGINE SPEED SENSOR FAILURE If the speed sensor fails the APU will start about 5 seconds, and attempt to run the self test. Without a speed signal the test will fail and the APU will shutdown. No fault will be recorded on the dash control. AIR CONDITION COMPRESSOR FAILURE If there is no air conditioning when running the APU it may be due to A/C compressor failure Refrigerant leak Failure of the A/C pressure switch Failures of the fan drive system on the truck. If the fan drive motor on the truck isn t working the APU s Air Conditioner compressor will cycle on and off every few seconds. Do not operate the air conditioner if this is happening. Page 23 of 36

24 TRUCK INTERFACE PROBLEMS Fan Drive System Failure of the fan drive system may be due to DC drive motor failure, clutch failure, belt failure, timer failure, or failure of the fan solenoid. As noted above, the APU s air conditioner compressor will cycle in short intervals if the fan is not being driven. Do not operate the air conditioner if this is happening. Air Governor Air pressure will either be too high or too low. Air Intake System to APU The APU won t run if the air intake hose becomes blocked. Exhaust System The APU won t start if too much restriction of the exhaust system occurs. Symptom APU does not start Check #1 Display does not have power Additional Checks Check fuses and mega fuse block Verify correct voltage at (+) post on APU Probable Cause Fuse / Relay link broken Bad battery or loose connection Actions Replace fuse and relay if necessary. Look for loose connections or corrosion in wire 12 volts minimum required Are connections clean Road dirt / tar Clean connections Display has power Check supply power at ECU This is pin(2) at the 12 pin male connector If voltage checks OK Check F1 fuse and R1 relay (Power at Starter) Bad ECU Before installing new ECU Fuse / Relay link broken System voltage Replace ECU Verify new ECU has new battery Replace fuse and relay if necessary. Look for loose connections or Page 24 of 36

25 corrosion in wire If OK, check voltage at starter wire when activated If voltage is not system voltage then Potential Bad Starter Potential Bad ECU Break in wiring harness or connection If voltage is system voltage then replace Starter Check output voltage at ECU Pin #4 at the 12 pin male connector If no voltage replace ECU Find and or replace wiring harness APU cranks but will not start Starter Glow Plugs Shut down Solenoid Check Fuse F- 1, Relay R1 Check Fuse F- 7, Relay R4 Check Fuses F- 3, F-5, Relay R2, R3 If OK then put in start mode and check voltage at glow plugs Verify shut down solenoid is working Check oil pressure switch Check temp sender Check resistance Bad Switch Bad Temp Sender Bad RPM sensor Replace fuse and relay if necessary. Look for loose connections or corrosion in wire Replace fuse and relay if necessary. Look for loose connections or corrosion in wire Replace fuse and relay if necessary. Look for loose connections or corrosion in wire If not system voltage; then broken wire. Find and replace Visual inspection Replace Oil pressure switch Replace Temp Sender With no power 135 ohms resistance Page 25 of 36

26 Exhaust Lacks Fuel Lacks Air Check resistance and proper set of speed sensor Check for blockage Check for fuel supply Check fuel filter supply Check air filter Dirt / Oil causing incorrect RPM reading Air blockage in line from fuel pump Bad or blocked filter Blockage in air delivery Remove RPM sensor and clean. Install to finger tight against the flywheel teeth and back off 1/4 turn. Tighten secure nut. Visual Pull pump supply line and observe fuel flow Replace fuel filter Repair and or replace Low engine power or bogs down Check air filter for improper cleaning and replacement Check fuel supply Check fuel filter Replace air filter Find blockage and remove Replace fuel filter Engine starts but will not run to operating RPM Throttle Solenoid Review controller icon list for fault indication Check fuse F-9 and relay R-5 Check power at throttle solenoid and test solenoid with VOM Check throttle solenoid travel by resistance ohms check Replace fuse and relay if necessary. Look for loose connections or corrosion in wire System voltage Open should be low ohms 2 or less Closed will be ohms Page 26 of 36

27 APU starts but major components are inoperable Check drive belts visually Replace AC inoperable Check in-line fuses Check belt on AC compressor Check power at AC clutch connection Check R134 level Check for evidence of R134 leakage at all AC fittings this is the most common cause of AC failure Replace fuse and relay if necessary. Look for loose connections or corrosion in wire Replace System voltage Add additional if necessary Yellowish color at fitting crimp or threads APU will not go to high idle Throttle Solenoid WPS "Willie" APU Check fuse F- 9 and relay R- 5 In Cab A/C switch connect ion Check power at throttle solenoid and test solenoid with VOM Check throttle solenoid travel by resistance ohms check Replace fuse and relay if necessary. Look for loose connections or corrosion in wire System voltage Open should be low ohms 2 or less Closed will be ohms Fix connection or replace switch Page 27 of 36

28 APU alternator not charging APU A/C compress or not working APU A/C on not cooling A/C charge A/C fan inopera ble A/C high pressur e switch Oil pressur e switch Solenoi d Check drive belt Check alternator output to system voltage 14 volts+ Check drive belt Check for system voltage at clutch wire Check for freon leakage Check for leaks Check in-line fuse / breaker and relay Check for power going through if over 300psi Check for power going through if truck engine off Check that solenoid is switching Broken belt Bad Alternator Broken belt A/C clutch Road vibration causing leak at fitting or hoses Road vibration causing leak at fitting or hoses Loose connection s Replace alternator belt Replace alternator Replace belt Replace A/C compressor and clutch Replace fittings / hoses and pull vacuum to verify proper seal. Replace fittings / hoses and pull vacuum to verify proper seal. Replace fuse and relay if necessary. Look for loose connections or corrosion in wire Replace if no system voltage Replace if no system voltage Replace if not switching Page 28 of 36

29 Bunk Controller Unit shuts down Intermittent Magnetic Pick-up sensor fault Low oil Pressure fault operates after engine has fired High engine temperature fault operates after engine has fired. Fail to Start is activated after preset number of attempts to start Pre-heat inoperative Starter motor inoperative Check DC supply voltage is not above 35 Volts or below 9 Volts Check the operating temperature is not above 160 F. Check the DC fuse. Ensure that Magnetic pick-up screen only connects to earth at one end, if connected at both ends, this enables the screen to act as an aerial and will pick up random voltages. Check pickup is correct distance from the flywheel teeth. Check engine oil pressure. Check oil pressure switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) Check engine temperature. Check switch/sensor and wiring. Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module. Check wiring to engine heater plugs. Check battery supply. Check battery supply is present on the Pre-heat output of module. Check pre-heat configuration is correct. Check wiring to starter solenoid. Check battery supply. Check battery supply is present on the Starter output of module. Replace fuse and relay if necessary. Look for loose connections or corrosion in wire Reset speed sensor to proper depth Replace oil sensor switch Replace temp sensor System voltage: Replace wire to component or component System voltage: Replace wire to component or component System voltage: Replace wire to component or component Page 29 of 36

30 THERMOSTAT OPERATING GUIDE The following information reflects the standard instructions for operating common thermostat settings. Making adjustments to the settings of your controller is not recommended without reviewing the provided information, and verifying with your Willis representative that the changes will not affect the performance of your unit. For detailed information, view the instruction guide that accompanies your thermostat. NOTE: YOU MUST HAVE A CLOSED LOOP (CIRCUIT) PROGRAM TO EFFECTIVELY USE THE THERMOSTAT CONTROLS. IF YOU HAVE A CLOSED LOOP AC SYSTEM ONLY, THE HEATING SYSTEM IS NOT AFFECTED BY THE THERMOSTAT. IF YOU HAVE A CLOSED LOOP HEAT AND AC SYSTEM THEN BOTH HEAT AND AC CONTROLS ARE AFFECTED BY THE THERMOSTAT. FAN OPERATING MODE Page 30 of 36

31 DISPLAYING THE TEMPERATURE Setting the Temperature BACKLIGHT THERMOSTAT CONTROL MODE Manual/Permanent Hold Mode Programmable Mode Temporary Bypass Page 31 of 36

32 BATTERY REPLACEMENT INDICATOR CONFIGURATION MENU Page 32 of 36

33 PROGRAMMING Setting the Time & Day Setting the Date Page 33 of 36

34 ENERGY SAVING SCHEDULE Modifying Your Schedule Page 34 of 36

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