Installation and Commissioning of Auxiliary Power Unit

Models PC6012 PC6013 PC6014 PC6015 PC6022 PC6023 PC6024 Installation and Commissioning of Auxiliary Power Unit 30-871-21 Rev. E

Warning & Cautions Vehicles with longer wheel bases should have the APU mounted closer to the sleeper unit to avoid obstacles such as railway crossings, speed bumps, curbs, etc. Before beginning installation of the ComfortPro system, disconnect the vehicle's batteries. If truck is equipped with a coolant valve, valve must be fully opened before starting APU. The APU is heavy. Do not drop it! Use a lifting device. Do not mount the APU to bottom pan. Unit is designed to hang from frame rails. Plumbing through the dash or sleeper heater will void your warranty. Take care not to spill antifreeze. Exercise safety precautions when working near flammable fuel. Keep fuel lines away from exhaust pipes and hot or moving parts. Protect fuel lines from wear points. Ensure fuel line routing is away from heat source and sharp corners/edges. The standpipe must enter the tank from the top. If you are mounting the condenser to the back wall of the sleeper, use large fender washers or a backing plate for extra support. To avoid serious injury, allow the engine to cool before opening the radiator cap. 30-871-21 i

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1 ComfortPro Installation Guide DRIVER CONTROL PANEL Read Before Starting Installation CONDENSER CCU Each truck is unique and will require a different approach. Plan the placement of ALL components before beginning the installation. BATTERY FUEL SUPPLY AND RETURN 120 VAC OUTLET PANEL AUXILIARY POWER UNIT (APU) VEHICLE FUEL TANK COOLANT SUPPLY AND RETURN NOTICE The APU requires periodic maintenance. Ensure you have access to internal components (i.e., oil filter, air filter, fuel filter and the oil filler). The ComfortPro comes filled with long life coolant. Consult the truck owner prior to altering the vehicle in any way. Vehicles with longer wheel bases should have the APU mounted closer to the sleeper unit to avoid obstacles such as railway crossings, speed bumps, curbs, etc. Before beginning installation of the ComfortPro system, disconnect the vehicle's batteries. If truck is equipped with a coolant valve, valve must be fully opened before starting APU. APU Components ITEM QTY APU (Kubota Engine/........... 1 120 VAC Generator) APU Mounting Kit............. 1 Frame grippers.............. 4 3/4" x 6 1/2" Bolts.......... 4 3/4" Washers............... 8 3/4" Nyloc nuts............. 4 Frame washers.............. 2 Fuel Pick-up Kit............... 1 Pick-up.................... 1 Clamps.................... 2 Exhaust Extension Kit.......... 1 90 Degree exhaust pipe........ 1 Support bracket............. 1 Exhaust clamps.............. 2 5/16" NC bolt............... 1 5/16" Washers.............. 2 5/16" Lock nuts............. 2 Parts and Tools Required Coolant hose - 3/4" Coolant shut off valves Coolant hose clamps Assorted nuts, bolts and washers as required Assorted electrical connectors, and protective loom as required Heat shrink, pipe sealant, never seize, electrical tape, expanding foam Torque wrench (100 ft/lb) Hole saw kit (1", 1 1/4", 3", 3 1/2", 4 1/2") Portable lighting ITEM....................QTY Battery Terminal Kit............ 1 Red heat shrink.............. 1 Black heat shrink............. 1 Ring terminals............... 2 Cable Ties................. 75 Condenser................... 1 Hoses..................... 2 Mounting hardware........... 1 Harness................... 1 CCU........................ 1 Driver Control Panel........... 1 Power Outlet................ 1 Hand forklift/lifting device Step drill Angle drill Reciprocating saw Nutsert installation tool Scale (refrigerant) accurate to ounces Gauges (refrigerant) 134A compatible ComfortPro Test Switch Module PG1008 Flow Meter TK9002 200A fusible link 200A fusible link holder 30-871-21 1

2 Mounting the APU USE OF SPACERS (viewed from above) Note: All Bolts required come with kit. OBSTACLES 1" SPACER (OPTIONAL) FRAME RAIL 2" OFFSET SPACER (OPTIONAL) FRAME GRIPPER BACK PLATE OF APU ENCLOSURE TORQUE 100 ft/lb 3/4" 3/4" FRAME GRIPPER BOLTS WASHER ALTERNATE LOCATION 2 5/8" MINIMUM SIDE CLEARANCE 2 5/8" MINIMUM SIDE CLEARANCE The APU is heavy. Do not drop it! Use a lifting device. PREFERRED LOCATION 11" MINIMUNM GROUND CLEARANCE Do not mount the APU to bottom pan. Unit is designed to hang from frame rails. Mounting 1. Use existing holes at back of APU. DO NOT DRILL NEW HOLES IN THE APU. 2. Torque mounting bolts to 100 ft/lbs. 3. Install exhaust pipe extension to APU; direct exhaust away from vehicle. Consider the following: NOTICE Consult OEM frame drilling requirements if bolting APU directly to the trucks frame rail. Clearance around existing fairings. Brackets for attaching fairings, dryers, fuel tanks, fasteners, existing plumbing for air, fuel and water lines. Battery boxes. Any hardware located in the mounting location: move or modify if necessary. 2 30-871-21

3 Mounting the Condenser NUTSERTS CONDENSER (SLEEPER MOUNTED) CONDENSER 12 VOLT POWER HARNESS 3/8" NC BOLTS (3) PER SIDE BLUE MARKING MIN 5" CLEARANCE TO ALLOW FOR HOSE CONNECTION REFRIGERANT HOSES - CLAMP SECURELY CCU CONDENSER CCU 4" MIN REFRIGERANT HOSES 8 FEET MAX 4" MIN HEAT SOURCE 4" MIN 4" MIN NOTICE Condenser unit must be securely fastened to the back wall of the sleeper. For specific questions regarding proper condenser installation please call 1-877-750-8906 for technical assistance. NOTICE All hoses, cables, and electrical wiring should be protected and secured using split loom and cable ties to prevent abrasion. Stay clear of exhaust pipe and muffler. NOTICE For 'Expediter' trucks and trucks with headache racks, the condenser will have to be mounted vertically onto the frame rail or suspended vertically from the sleeper body. Additional protection for the condenser will be needed. Condenser Mounting 1. Select the location for the condenser on the rear of the vehicle sleeper. 2. Hold condenser in the desired location and mark the holes clearly. 3. Drill holes 17/32" for Nutserts. 4. Install the condenser assembly. 5. Refrigerant hoses are attached with 25-30 ft-lb of torque. Mounting Considerations The condenser must be mounted on the back wall of the sleeper (outside). Airflow around the condenser must not be obstructed by headache racks, for example. Mount condenser within 8' of the CCU. The condenser must be mounted vertically with the blue-marked side on the bottom right (where the liquid refrigerant collects). Hose connection side of the condenser requires 5" clearance to the nearest obstruction to allow for hose connection. Keep the condenser out of the direct line of road spray. Refrigerant hoses must be clamped securely. The condenser, wiring harness and refrigerent MUST be located a minimum of 4" away from any part of the main truck exhaust system. Do not allow Refrigerant hoses to touch each other, heat transfer will occur and affect the performance of the CCU. Insulate or keep the hoses apart. The instructions for connecting the condenser to the CCU are covered in Installing the CCU Guide. 30-871-21 3

4 Cooling System Installation APU to Main Engine 3/4" FITTING RETURN FROM APU APU BACK VIEW 3/4" ID HOSE LOOM ALL HOSES NO SHARP BENDS HIGH PRESSURE PORT PREFERRED METHOD OF INSTALLATION TRUCK ENGINE CHOOSE PORTS THAT ARE FAR APART FOR MAX CROSSFLOW 1/2" OR LARGER NPT FITTINGS 3/4" FITTING SUPPLY TO APU LOW PRESSURE PORT (SUCTION) USE A FLOW INDICATOR TO CONFIRM FLOW DIRECTION AND SPEED INSTALL SHUTOFF VALVES (OPTIONAL) Cooling System Connections The preferred method of connecting the coolant lines involves drawing coolant from the main engine below the thermostat and returning near the water pump. As many current engines have limited capability for connections into the cooling system, it is not always possible to connect the APU to the main engine in the preferred manor. On some applications it may be necessary to connect into the truck heater lines using coolant Tees or Ys. If a connection to the engine is not possible, consideration must be given to maintaining proper coolant flow with a sufficient flow rate to cool the APU engine. The entire cooling system must be evaluated to ensure that coolant flow will be maintained under all conditions. The installer must verify that coolant flow to the APU will not be interrupted should any OEM heater control be moved to any position. Coolant connections should be located as far apart as possible to ensure proper heat dissipation to the main engine cooling system. Where possible, coolant Ys should be used and positioned to attempt to maximize the coolant flow in the preferred direction. Ensure that the coolant connections are sufficiently spread to ensure sufficient heat transfer to the main engine cooling system. Failure to ensure sufficient heat transfer may result in the APU engine shutting down due to an overheat condition. Operation must be verified by the installer prior to releasing the vehicle. 4 30-871-21

4 Cooling System Installation Cont. Cooling System Ensure coolant lines are routed away from heat source and sharp corners/edges. Proper strain relief (14 from connection). No kinks in coolant lines. Split loom (or equivalent) in place to prevent abrasion. Check to make sure there are no coolant leaks. Verify air is purged from APU cooling system. Verify proper coolant flow direction and speed using flow meter (TK9002). To avoid serious injury, allow the engine to cool before opening the radiator cap. Take care not to spill antifreeze. Cooling System Installation Procedure 1. Remove the truck radiator cap to release pressure from coolant system. Do not open when hot. 2. Drain the truck coolant system (if necessary). 3. The APU is shipped with extended life anti-freeze. Ensure this is compatible with truck coolant. 4. Ensure that the coolant will flow in the right direction (same direction whether ComfortPro or main engine is running). The flow indicator can be used to verify the flow (TK9002). 5. Coolant connections must be made in such a way to ensure that there is proper coolant flow through the APU regardless of any OEM heater control position. 6. Refill the engine coolant in the system according to the specific engine manufacturer's recommendations (additional coolant will be required). Questions for installing technician: 1. Verify air is purged from APU cooling system. 2. Verify proper coolant flow. Was a flow meter (TK9002) used to verify? 30-871-21 5

5 Installing Fuel Lines INSTALLING STAND PIPE NUT TIGHTEN UNTIL SECURE WASHER GASKET DRILL 1 HOLE USING UNIBIT OR HOLE SAW CUT TUBE BOTTOM 45 FLANGE TANK SUPPLY 5/16" ID RETURN 3/16" ID 12" MIN BETWEEN SUPPLY AND RETURN ALLOW 1" TO 2" MIN SPACE TO BOTTOM OF FUEL TANK NO KINKS OR ABRASION POINTS Exercise safety precautions when working near flammable fuel. Protect fuel lines from wear points. Ensure fuel line routing is away from heat source and sharp corners/edges. Keep fuel lines away from exhaust pipes and hot or moving parts. The standpipe must enter the tank from the top. Fuel Tank & Fuel Line Installation Ensure fuel line routing is away from heat source and sharp corners/edges. Fuel lines must run away from 120V and 12V cables and wire. Make sure adequate tie-wraps are in place and they do not restrict fuel flow. Split loom (or equivalent) in place to prevent abrasion. Check to confirm there are no fuel leaks. Ensure the pickup tube is 2 away from bottom of the tank, with supply and return lines spread apart and cut at a 45 angle. Installation Procedure 1. Locate hole in an area where the fuel pickup is protected (the center of the tank is recommended). 2. Tighten clamps. 3. Secure the fuel lines to minimize movement. Question for installing technician: 1. Was the pickup tube properly installed with the pick-up and return lines 2 off bottom of the tank, lines spread apart & cut at a 45 angle? 6 30-871-21

6 Prepare Battery Cables Crimping Tool Ensure a proper crimping tool is used when preparing battery cables. We recommend the use of approved Hex Crimping Tool: Quick Cable 4255-001 Quick Cable 4255-001M Quick Cable 4255-001MR Quick Cable 4255-001R Or equivalent RED OR BLACK HEAT SHRINK TUBING STRIP 3/8 POSITIVE OR NEGATIVE BATTERY CABLE APPLY HEAT TO SHRINK COPPER LUG USING THE CORRECT CRIMPING TOOL CRIMP AND SOLDER COPPER LUG TO BATTERY CABLES Connecting to the truck s battery Do not attach the APU battery connections until the installation is complete and the APU is ready to test-start. Ensure that the battery terminals are clean and free of corrosion. If not, remove and clean them. Apply dielectric grease to prevent corrosion. Apply anti-corrosion paint over cable ends. Ensure the 120 VAC Teck cable is connected to the installed CCU (if applicable). Terminate cable ends if no CCU is installed. APU - CCU CONTROL HARNESS Ensure that the polarity is correct before attaching battery leads. (The APU connects to 12VDC systems only). 12 VDC POWER SUPPLY HARNESS POSITIVE (+ Red) 12 VDC BATTERY CABLE FUSIBLE LINK NEGATIVE ( Black) GROUND CABLE TRUCK BATTERIES TECK CABLE Note: As shown in the inset above, a 200A fusible link must be installed in-line with the positive cable. The installer must install the fusible link as close to the positive battery terminal as possible to a maximum of 36 inches. The fusible link must be located inside the truck s battery box. 30-871-21 7

7 Commissioning the APU Important: Perform these steps only after the CCU and all other components have been installed. THERMOSTAT DRAIN HOSE BLEEDER VALVE OPEN 1/4-1/2 CCW 1/2" WRENCH COMFORTPRO TEST SWITCH MODULE (PG1008) ON Glow/ Run OFF START System Check Oil level in the APU engine, add if necessary. Electrical and plumbing connections are secure. Coolant valves (if any) fully open. Do not start or run the APU prior to purging the entire cooling system of air. Failure to do so will result in APU engine failure. Do not operate the engine without the enclosure cover in place. Failure to do so may result in injury. System Air Bleed Run the truck engine at fast idle until 170 F (76.6 C) is reached on the truck temperature gauge. Open the thermostat bleed valve, as shown, and let trapped air escape until a steady stream of coolant flows from the valve. If necessary, top up the coolant in the truck expansion tank. Close the thermostat bleeder fitting. APU First Time Start Up Use ComfortPro test switch module PG1008 to start APU first time, if available. Multi Function Control Panel: Pressing and holding the APU on/off button will override the auto program. The unit will enter a 5 second glow period and start to crank the engine for as long as you hold the button (no longer than 15 seconds at once). With the APU and truck engine running, open the thermostat bleed valve and let trapped air escape until a steady stream of coolant flows from the valve. Shut the truck engine off. Let the APU run for at least 30 minutes. During this time check for signs of coolant leaks, fuel leaks, and APU overheating. Top up the coolant if necessary in the truck overflow tank and replace the truck engine radiator cap. Clean up any spilled coolant from inside APU and on the ground. 8 30-871-21

8 Finishing the Installation Test all functions of the APU and CCU Replace vehicle access panels, fairings, interior components and hardware that was removed to facilitate the installation. Seal all holes made through the floor or walls of the truck with a suitable sealant such as expanding foam. For Models PC6022, PC6023, and PC6024 new installations only: 1. Disconnect the 12 pin connector from the APU Control Module 2. Cut the butt splice from each lead of the generator excitation leads (red smaller gauge wires), strip back 3/8" of insulation 3. Connect the jumper leads to the generator excitation leads 4. Reconnect the 12 pin connector to the APU control module 5. Start the APU. With the engine running, connect the jumpers to a 12 volt power source for 2 seconds 6. Stop the APU and disconnect the 12 pin connector to the APU control module 7. Using the provided butt splice connectors, connect the capacitor to the excitation windings 8. Restart the APU and verify the generator output. Perform engine break-in procedure - With all enclosures and covers in place: - Start the APU and select high heat from the DCP - Set the temperature to the highest point - Leave doors and other ventilation open. If necessary, set up a fan to circulate heat out of the sleeper to keep the system operating under a full load - If ambient temperature is above 90 degrees F (32 degrees C) disconnect the temperature sensor at the DCP to keep the heat on - Run the APU under these conditions for 5 hours to properly break in the engine - After 5 hours, turn off the heat and allow the engine to run with no load for 10 minutes to allow the engine to cool before shutting down - Check the APU for any leaks - Check the oil level and top up as required Check all belts for proper tension Vacuum the interior of the cab/sleeper 30-871-21 9

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