Auxiliary Power Unit (APU) Owner s manual D

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1 Auxiliary Pwer Unit (APU) Owner s manual D

2 The Dynasys TM APU has been designed fr ease f peratin and maintenance. Review f this manual and the pre-trip inspectins will reduce any ver-the-rad perating issues. A regular maintenance prgram (enclsed) will help t ensure that Dynasys APU prvides lng-term and maintenance-free superir perfrmance. Shuld there be any questins r cncerns, please cntact Dynasys Technical Services at: r refer t fr a list authrized Dynasys dealers, their lcatins, and their cntact infrmatin.. APU Serial Number: Nte yur serial number fr quick and easy reference. Please have yur serial number ready befre cntacting Technical Services r Custmer Supprt.

3 2 Table f Cntents 1.0 Overview Dynasys Safety Systems Safety Cver Switch Aut-Start (Autmatic Start/Stp) Feature Starting Aids Warning Label Starting with the Cver Off Cautin: Ht Surfaces Inspectin f the Safety Systems Cntact Us Pre-Trip Inspectin Dynasys Cabin Cntrller Unit (CCU) Descriptin Operatin f the Heater, Air Cnditiner and Generatr Heater Air Cnditiner Generatr Technical Infrmatin... 8

4 6.1 Dimensins and Weight Fluid Capacities and Type Maintenance Schedule Limited Warranty Warranty Cverage Warranty Obligatin Maintenance in Relatin t Warranty Installatin in Relatin t Warranty Mdificatins in Relatin t Warranty Exclusins t Warranty Limitatins f Remedies Indemnity Warranty Claims Transfer f Warranty Warranty Claims Califrnia Prpsitin 65 Warning Dynasys APU Service Recrd Owner s Ntes

5 4 1.0 Overview The Dynasys APU system is a ttally self-cntained, stand-alne AC (6kW) generatr, air cnditiner and heater (HVAC) system. The nly supply surces that are shared with the truck systems are the fuel and battery supply. The APU als recharges the truck batteries while in peratin. Superir design and perfrmance have been incrprated int this prduct t prvide truble-free and ecnmical APU system peratin. We are cnfident yu will be satisfied with yur new Dynasys auxiliary pwer unit. The fllwing pages cntain descriptins f design features, principles f peratin and preventive maintenance prcedures. Please review it carefully prir t starting and perating yur Dynasys unit. All safety warnings and advisries fund within this wner s manual must be bserved. 2.0 Dynasys Safety Systems Prir t perfrming any service, maintenance r repairs, the APU must be discnnected frm its battery surce r the intercnnect harness must be discnnected frm the back f the unit. In the recmmended installatin cnfiguratin, the Dynasys APU system shares the battery supply with the truck s main battery bank. After discnnecting the battery cables frm the battery r discnnecting the intercnnect harness, verify the battery psts inside the engine cabinet t cnfirm there is n vltage present at the APU. 2.1 Safety Cver Switch It is critical the safety cver switch n the APU main engine is never deactivated r bypassed. Failure t cmply may result in serius injury. The safety cver switch is designed t prevent the Dynasys APU frm starting when the frnt engine access panel is lse r has been remved. When the switch is pen, the panel has been remved r is lse. When the switch is clsed, the frnt access panel is attached. The switch is lcated at the frnt f the engine enclsure near the clant verflw bttle, in the lwer right hand crner f the APU cabinet assembly.

6 2.2 Aut-Start (Autmatic Start/Stp) Feature The Aut-Start feature allws the APU t be started autmatically in a variety f situatins. Battery level, vltage, temperature f the cabin bunk, APU clant temperature, and time f day can be prgrammed t prmpt the APU engine t start. Review the cabin cntrller unit (CCU) perating instructins fr further infrmatin regarding the Aut-Start feature. Further, this feature must be deactivated befre refilling the truck s diesel fuel tanks. 2.3 Starting Aids D nt use aersl starting aids such as ether. Use f any starting aids can result in an explsin and/r persnal injury, and will render the warranty null and vid due t internal engine damage. 2.4 Warning Label Please nte, fr safety reasns, it is best t discnnect the APU intercnnect harness at the back f the unit prir t perfrming maintenance activities. 2.5 Starting with the Cver Off Sme installatin r repair/diagnsis prcedures may require the APU t be started with the frnt access panel remved. Never deactivate r bypass the safety cver switch. If perating the unit with the cver ff is abslutely necessary, have anther individual assist by manually hlding the safety cver switch dwn in the clsed psitin fr the duratin f the prcedure. 5

7 6 2.6 Cautin: Ht Surfaces Exercise cautin when perfrming repair and maintenance activities, as the APU s surfaces can reach extremely high temperatures. 2.7 Inspectin f the Safety Systems The safety systems n the Dynasys APU shuld be examined and/r tested whenever maintenance is perfrmed n the APU, t ensure that the systems are in gd cnditin and in prper wrking rder. 2.8 Cntact Us Dynasys Technical Services can be cntacted tll free at (800) Pre-Trip Inspectin Prir t perfrming the start-up prcedure, the fllwing steps must be perfrmed: Remve the frnt access panel Verify all belts are in gd cnditin and are prperly tensined Verify all electrical cnnectins are nt lse r crrded Verify the unit is free f leaks, has n lse r brken parts, and has n ther damage t cmpnents Verify all engine fluid levels are adequate Replace and secure the frnt access panel 4.0 Dynasys Cabin Cntrller Unit (CCU) Descriptin Refer t the Dynasys User s Manual fr peratin f the tuch screen cntrller.

8 5.0 Operatin f the Heater, Air Cnditiner and Generatr 5.1 Heater The heating system is fully autmatic. A cnstant cmfrt zne is maintained with the CCU temperature settings. The bunk heating system has a capacity f 2.5kW. This is a cmplete stand-alne system that is nt integrated int the truck s heating system. When heat mde is selected and the Dynasys APU is in peratin, the electric heating elements are energized (installed under the bunk). The blwer mtr circulates the internal cab air acrss the heating element, releasing warm air int the bunk area. This system is designed t maximize the bunk heating efficiency. 5.2 Air Cnditiner The air cnditiner is als fully autmatic. A cnstant cmfrt zne is maintained with the CCU temperature settings. The air cnditiner is a 12,000 BTU Hermetic R134a system that is nt integrated int the truck s air cnditining system. When cl mde is selected and the APU is in peratin, the cmpressr is activated (installed under the bunk). The blwer mtr circulates the internal cab air acrss the evapratr cil, releasing cl air int the bunk area. This system is designed t maximize the bunk cling efficiency. WARNING: Only certified R134a air cnditining technicians shuld service the Dynasys air cnditiner system. 5.3 Generatr The 6kW 120vac heavy-duty generatr is lcated at the rear f the Dynasys unit and is belt-driven. The generatr supplies a lad center with three breakers. First, there is ne blck heater receptacle n a 15 amp circuit, which allws the truck s blck heater t be plugged int the generatr. It is recmmended that the blck heater be plugged in nly during the winter. Keep the heater unplugged during the spring, summer, and fall. Next, there is ne 120vac dual utlet receptacle fr the driver s cnvenience; this utlet is n a 15 amp circuit. This receptacle can be installed anywhere in the truck s bunk area t prvide pwer fr 120vac devices. Finally, the third breaker is a 25 amp circuit fr the Dynasys HVAC unit under the bunk. 7

9 WARNING: Only a certified electrician shuld service the generatr and 120vac distributin system. 6.0 Technical Infrmatin Fr technical specificatins (dimensins, weight, fluid capacity and type) f the Dynasys APU cmpnents, see the fllwing sectins. 6.1 Dimensins and Weight Main Unit (Figure 1) Bunk Heater/AC Unit (Figure 2) Width: 18 Width: Height: 27 Height: Depth: 25 Depth: Weight: 397 lbs. Air Flw: 400 CFM Figure 1 Figure 2 8

10 6.2 Fluid Capacities and Type Engine Oil with Filter: 2.5 US qt. (70z) Type: API CJ-4 Viscsity: (See Figure 3) Cling System: 50/50 mixture f ethylene glycl & water (72 z. capacity) Fuel Type: Diesel Fuel Only Air Cnditining (R134a): 1lb, 14 z. (min) t 2lb. (max) Integrated Cndenser Figure 3 9

11 7.0 Maintenance Schedule Each Trip* After first 50 Hrs. At 250 Hr. Intervals At 500 Hr. Intervals At 1,000 Hr. Intervals At 2,000 Hr. Intervals Service Cmpnents r Prcedures ENGINE Check engine il level Inspect belts, hses fr cnditin/tensin Check fr unusual nise r vibratin Replace air filter element (as needed) Inspect/clean water separatr (as needed) Change fuel filter (as needed) Adjust valve clearance Change engine clant Check and/r adjust engine speed (as needed) ENGINE OIL CHANGE INTERVALS Oil (CJ-4 il) and filter ELECTRICAL Check cver safety switch Inspect battery terminals Inspect unit fr brken r lse wires Check fr lse cnnectins MISC. Visually inspect fr fluid leaks Visually inspect fr damaged/lse cmpnents Check munting blts and brackets Check/clean cndenser cil and generatr air inlet Check/clean HVAC air inlet filter (as needed) *A Trip is the perid f time befre an APU is used 10

12 Nte: Maintenance schedules listed are fr nrmal rad cnditins, and the specific hur intervals must als be fllwed. Fr severe cnditins, perfrm the scheduled maintenance earlier. 8.0 Limited Warranty The limited warranty nly applies t the Dynasys auxiliary pwer unit (APU), and des nt extend t items made by ther manufacturers. 8.1 Warranty Cverage Hdyn, Inc. (Hdyn) warrants that, under nrmal service and use, the Dynasys APU will be free frm defects in material and wrkmanship until the earlier f twenty-fur (24) mnths frm the date f installatin r 4,000 hurs f use. This warranty is subject t all terms, cnditins, limitatins, and prvisins f this limited warranty and the applicable terms f sale frm the respective Dynasys APU dealer. This limited warranty is gverned by the laws f the State f Texas, and any claims r disputes arising ut f this limited warranty shall be gverned by the laws f the State f Texas. The express warranty set frth abve is exclusive, and n ther warranties f any kind, whether statutry, ral, written, expressed r implied, including any implied warranties f merchantability r fitness fr a particular purpse, shall apply. There are n warranties that extend beynd the descriptin n the face heref. The cnsumer s exclusive remedies fr breach f warranty, and Fallbrk s nly bligatin arising ut f r in cnnectin with breach f warranty shall be thse stated herein. Fallbrk expressly disclaims liability fr incidental and cnsequential damages caused by the Dynasys APU sld. 8.2 Warranty Obligatin Fallbrk will repair r replace, at its ptin, the Dynasys APU cmpnents that are cvered under the terms f this warranty. Repair r replacement will be cmpleted at an authrized dealer r cmpany-wned facility, at n charge t the wner f the Dynasys APU, within a reasnable time after presentatin f prf f purchase and determinatin by 11

13 Fallbrk r its authrized dealer that a cmpnent is defective r has failed under nrmal service and use within the 24- mnth/4000-hur warranty perid. Please nte that replacement parts culd be new r remanufactured. 8.3 Maintenance in Relatin t Warranty The Dynasys APU wner s manual lists all maintenance functins required t validate and cntinue this limited warranty. Please nte that cmpnents that failed due t pr r imprper maintenance will nt be cvered by this limited warranty and culd cause the entire APU warranty t be vid. Where a dispute arises regarding prper maintenance, the manufacturer reserves the right t request prf in the frm f receipts fr maintenance, and any ther recrds f service, t establish that prper maintenance has been perfrmed, as per the maintenance manual and/r dealer cmmunicatins frm the manufacturer. 8.4 Installatin in Relatin t Warranty It is the respnsibility f the installer and the wner t ensure that all Dynasys APU cmpnents are in prper wrking rder at the time f installatin. The manufacturer is nt respnsible fr cmpnents that fail as a result f imprper installatin. In rder t validate yur Dynasys APU warranty, the unit installatin must be 1) perfrmed by an authrized Dynasys dealer r 2) verified by an apprved Dynasys dealer. A Dynasys Installatin Checklist and Warranty Registratin Frm must be cmpleted and registered at Fallbrk t certify the installatin. 8.5 Mdificatins in Relatin t Warranty Any mdificatin t the Dynasys APU withut a written authrizatin frm the manufacturer will vid this limited warranty. Repair, replacement, r maintenance, using ther than apprved parts, will be cause t terminate this limited warranty, as will use f starting aids such as ether. 12

14 8.6 Exclusins t Warranty This warranty des nt cver the cst f nrmal maintenance, such as (but nt limited t): Tune-ups, adjustments, r inspectins The tightening f clamps, fasteners, r hses The replacement f belts, fuel, air filters r il filters 8.7 Limitatins f Remedies The remedy f repair r replacement as set frth herein is the sle exclusive remedy available t the purchaser r user f the Dynasys APU. Fallbrk disclaims and shall nt be liable r respnsible t the wner r user f the Dynasys APU r any ther persn fr incidental, cnsequential, direct, indirect, special r general damages f any kind arising ut f r in any way related t the use f the Dynasys APU, including but nt limited t twing charges, accident repairs, rad calls, traveling expenses, lss f revenue prfits, lss f truck use, r damage t persns r prperty. N claim f any kind asserted against Dynasys APU, whether asserted under legal theries f negligence, strict liability, warranty, r any ther cmmn law r statutry basis, shall be greater in amunt than the purchase price f the Dynasys APU, with respect t which damages are claimed. 8.8 Indemnity The user and wner f the Dynasys APU agree t indemnify and hld Fallbrk harmless frm any and all claims, expenses, suits r liability f any nature whatsever asserted against Fallbrk arising ut f r in any way related t negligence n the part f the user r wner f the Dynasys APU. 13

15 8.9 Warranty Claims Failed r defective parts must be inspected and their replacement installed by an authrized Dynasys APU dealer. The manufacturer reserves the right t inspect failed r defective parts prir t a decisin n any claim under this limited warranty. It is the wner s respnsibility t act prmptly in submitting any such claim Transfer f Warranty Where the truck with the Dynasys APU has been sld by the first wner t a secnd wner and the Dynasys APU has nt been remved, this limited warranty is transferable frm the riginal wner t a secnd wner with whatever prtin f the limited warranty that remains frm the date f sale t the first wner. Where the Dynasys APU has been remved frm the vehicle in which it was riginally installed, and sld by the first wner t a secnd, re-installatin is required t be cmpleted r inspected by an authrized dealer in rder t validate the remaining prtin f this limited warranty. Where the riginal wner transfers the Dynasys APU t a new vehicle, the installatin must be cmpleted r inspected by an authrized dealer t validate the remaining prtin f this limited warranty. 14

16 9.0 Warranty Claims T btain warrantied repairs, yu must request the needed repairs within the warranty perid frm an authrized Dynasys dealer. A reasnable time must be allwed t perfrm the warranty repair after taking the unit t a dealer lcatin. Repairs will be perfrmed during nrmal business hurs. T ensure a timely repair prcess, the fllwing steps must be fllwed: Cntact the nearest Dynasys dealer t schedule a warranty service appintment. Prir t cntact, have the fllwing infrmatin available: - Unit serial number - Hur meter reading - In-service and purchase dates - Nature f prblem Deliver unit t dealer fr service. Upn cmpletin f repairs, review and sign the dealer wrk rder (keeping a cpy fr persnal reference). If yu still have questins, please cntact the Dynasys Warranty Administratin by phne at (800) r at apusupprt@dynasysapu.cm. 15

17 10.0 Califrnia Prpsitin 65 Warning Prpsitin 65 requires businesses t ntify Califrnians abut significant amunts f chemicals in the prducts they purchase, in their hmes r wrkplaces, r that are released int the envirnment. By prviding this infrmatin, Prpsitin 65 enables Califrnians t make infrmed decisins abut prtecting themselves frm expsure t these chemicals. Fr mre infrmatin regarding Prpsitin 65, reference 16

18 11.0 Dynasys APU Service Recrd Owner s Name: APU Serial Number: Date f Service: Lcatin: Perfrmed By: Signature: Service Type APU Hurs: ,000 1,500 2,000 First il change Inspect & clean water separatr Replace fuel filter Replace air filter element Change il Clant replacement Adjust valve clearance Other service Other service Other service 17

19 12.0 Owner s Ntes 18

20 2620 Brushy Creek Lp Cedar Park, TX dynasysapu.cm

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