Carrier ComfortPro PC6000, ComfortPro PC6002, ComfortPro PC6006, ComfortPro PC6003 Operation & Service Manual

R

62--11175 Rev --

Operation & Service Manual

for

ComfortPro

™

Auxiliary

Power Unit

Auxiliary Power Unit

Models PC6000, PC6002, PC6003 & PC6006

62-11175 COMFORTPRO SERVICE MANUAL

c-i

CONTENTS

INTRODUCTION

SAFETY

Safety Alerts ................................................................................. c-iii

Component Layout.......................................................................... c-v

GENERAL ARRANGEMENT

APU Dimensions ............................................................................ c-vi

CCU Dimensions........................................................................... c-vii

Condenser Dimensions ................................................................. c-vii

1.0 OPERATION OF MULTI–FUNCTION D.C.P

1.1 PREPARATION

1.1.1 Multi–Function D.C.P Components....................................... 1-1

1.1.2 How the ComfortPro Operates ............................................. 1-2

1.2 MANUAL OPERATIONS

1.2.1 Starting the APU ................................................................ 1-3

1.2.2 Stopping the APU ............................................................... 1-3

1.2.3 Turning the Heater ON/OFF ................................................. 1-4

1.2.4 Heating: Setting the Temperature ........................................ 1-4

1.2.5 Turning the A/C ON/OFF ..................................................... 1-4

1.2.6 Setting the A/C Temperature .............................................. 1-4

1.2.7 Fan Operation .................................................................... 1-5

1.3 AUTOMATIC OPERATIONS

1.3.1 Password Protection........................................................... 1-5

1.3.2 Entering Password ............................................................. 1-6

1.3.3 Setting the Clock ............................................................... 1-7

1.3.4 Comfort Monitor................................................................. 1-7

1.3.5 Timer ................................................................................ 1-8

1.3.6 Cold Weather Watch ......................................................... 1-10

1.3.7 Maximum Run Time.......................................................... 1-11

1.3.8 Battery Monitoring............................................................ 1-12

2.0 CLIMATE CONTROL UNIT (CCU)

2.1 PREPARATION

2.1.1 Charging the CCU............................................................... 2-1

2.2 SERVICE

2.1.2 Maintenance Schedule ....................................................... 2-2

2.1.2 CCU Spring Tune–Up .......................................................... 2-3

3.0 TROUBLESHOOTING

3.0 MANUAL OPERATIONS

3.1 APU (Auxiliary Power Unit)............................................................... 3-2

3.2 GENERATOR .................................................................................. 3-6

3.3 DRIVER CONTROL PANEL ............................................................... 3-7

3.4 CCU AIR CONDITIONING ................................................................. 3-8

3.5 CCU Fan ..................................................................................... 3-11

3.6 CCU Heat.................................................................................... 3-11

3.7 RECEPTACLE PANEL..................................................................... 3-12

62-11175 COMFORTPRO SERVICE MANUAL

c-ii

3.0 TROUBLESHOOTING (Cont.)

3.8 TESTING PROCEDURES

3.8.1 Testing AMP draw for components ....................................... 3-13

3.8.2 Testing Voltage and Hz readings .......................................... 3-13

3.9 ADDITIONAL INFORMATION

3.9.1 Adjusting the 120 A/C Voltage............................................. 3-14

3.9.2 Capacitor Troubleshooting ................................................... 3-14

3.9.3 Capacitor Theory................................................................. 3-14

3.9.4 Potential Relay Theory......................................................... 3-15

3.9.5 Alternator Troubleshooting................................................... 3-15

APPENDICES

CAPACITIES AND SPECIFICATIONS ........................................................... A-2

FUSE LOCATIONS ................................................................................... A-4

CIRCUIT BREAKER LOCATIONS ................................................................ A-5

APU CONTROL UNIT................................................................................ A-6

CCU CONTROLLER.................................................................................. A-7

FUEL SYSTEM PURGE PROCEDURE ......................................................... A-8

COOLANT PURGE PROCEDURE ................................................................ A-9

DEFROST/HEAT & DCP SENSOR............................................................ A-11

ENGINE INTERLOCK.............................................................................. A-12

APU WIRING (Serial# KZX98002290 to Date) ......................................... A-13

62-11175 COMFORTPRO SERVICE MANUAL

c-iii

SAFETY

DANGER

Immediate hazards that will result
in severe personal injury or death.

WARNING

Hazards or unsafe practices that
could result in severe personal
injury or death.

CAUTION

Hazards or unsafe practices that
could result in minor injury or
product or property damage.

NOTICE

Information that is important to
proper installation or maintenance,
but is not hazard-related.

DANGER

A certified refrigeration technician
must charge and test the CCU.

For example:

Safety Alerts

Throughout this manual, you will see notes labeled "Warnings" or "Cautions"
to alert you to special instructions or precautions concerning a particular
procedure that would be hazardous if performed incorrectly or carelessly.

Observe them carefully!

These safety alerts alone cannot eliminate hazards that can occur. Strict
compliance with these special instructions when performing the installation and
maintenance, plus common sense, are major accident prevention measures.

62-11175 COMFORTPRO SERVICE MANUAL

c-iv

Safety Considerations

Inhalation of exhaust gas (containing carbon monoxide) may cause severe
personal injury and/or death. Anyone suspected of suffering from CO
inhalation should be removed from the hazardous area and given medical
assistance immediately.

Exercise extreme caution when working near fuel or fuel-filled equipment.
Do not operate equipment during fueling operations. Use eye protection
when working near batteries, which contain acid and can explode. Do not
smoke or use open flames near batteries.

Electric shock can cause severe personal injury, burns, and death. Before
working on any unit, disconnect the batteries. Use only approved materials
and methods when working on the electrical system, and follow local
electrical codes. Never work on the APU or the electrical circuitry when the
APU is running. Never work with electricity in wet conditions or when you
are tired.

Fuel, oil, coolant, and refrigerant are toxic and in some cases, carcinogenic.
Wear eye and hand protection at all times. Remove contaminated clothing
immediately and wash contaminated skin. Do not breathe in vapors.

Moving parts can cause severe injury and/or death. Before working on any
unit, shut it off and disconnect the battery. Do not start until protective
covers have been replaced. Also, loose parts falling into rotating machinery
can cause severe accidents. Always ensure bolts and clamps are correctly
torqued and secured. Inspect mechanical components periodically for
damage, corrosion, and proper torque.

The APU is designed to provide electrical power for heating and cooling
vehicles in normal on-road conditions. Never use the APU to power critical
medical equipment or sensitive electronic equipment without the
manufacturer's express written approval.

Exhaust

Fuel/Batteries

Electrical

Intoxicants

Hot or Moving Parts

Misuse

WARNING

California Proposition 65 Warning: This product contains lead, a
chemical known to the State of California to cause cancer and birth
defects and other reproductive harm.

62-11175 COMFORTPRO SERVICE MANUAL

c-v

COMPONENT LAYOUT

Figure C1: Main Components of the Carrier ComfortPro system and Where They Should Best be Installed on the Truck

COOLANT SUPPLY

AND RETURN

PANEL (DCP)

DRIVER CONTROL

CONDENSER

120 VAC

RECEPTACLE PANEL

UNIT (CCU)

CLIMATE CONTROL

BATTERY

VEHICLE FUEL TANK

AND RETURN

FUEL SUPPLY

AUXILIARY POWER UNIT (APU)

62-11175 COMFORTPRO SERVICE MANUAL

c-vi

GENERAL ARRANGEMENT

TOP VIEW

REAR

LEFT SIDE

APU Dimensions (Measurements in inches)

FRONT VIEW

RIGHT SIDE

3.0

2.75 3.875

18.5

16.0

10.5

2.6

24.9

28.5

62-11175 COMFORTPRO SERVICE MANUAL

c-vii

FRONT VIEW

BOTTOM VIEW

CCU Dimensions (Measurements in inches)

FRONT RIGHT SIDE

DOWN

Condenser Dimensions (Measurements in inches)

12"

7.9"

23.4"

24.4"

16.2"

15.2"

3.3"

3.1"

3.0"

6.9"

3.0"

6.9"

3.0"

3.4"

3.0"

12.6"

.125"

1.3"

12.9"

5.62"

13.93"

16.25"

16.90"

5.62"

26.5"

24.25"

8"

3.5"

2.0"

62-11175 COMFORTPRO SERVICE MANUAL

c-viii

62-11175 COMFORTPRO SERVICE MANUAL

1-1

1.0

OPERATION OF MULTI-FUNCTION
DRIVER CONTROL PANEL

Figure 1-0: Multi-Function Driver Control Panel

1.1.1 Multi-Function Driver Control Panel Components

1 When visible, the heating system is heating.

2 When visible, the A/C is cooling.

3 Indicates the number of operating hours on the APU.

4 Indicates the state of the APU.

The APU engine is running.

The APU engine is off.

The APU engine is in the starting process (flashing).

5 Indicates that Battery Monitor mode is enabled.

6 Indicates that maximum run time is enabled.

7 Indicates that Cold Weather Watch mode is enabled.

8 Indicates that Comfort Monitor mode is enabled.

9 Indicates that Timer 1 or Timer 2 mode is enabled.

10 Indicates that the ComfortPro is connected to shore power.

The APU cannot be started in Shore Power mode.

11 Indicates the state of the 115V outlet and CCU auto-reset breakers.

115 VAC power is being supplied to the outlet.

No power is being supplied to the outlet.

CCU breaker has tripped.
High Heat/Outlet breaker has tripped.

The breaker that tripped has reset automatically and the DCP needs
to be reset.

NOTICE

The DCP (driver control panel), which
is mounted inside the truck bunk,
controls the APU and the CCU. The
central panel on the DCP provides
status information using words
and icons:

PREPARATION 1.1

4 5

3

APU

ON/OFF

2

MENU

HOURS
00000

6 7 8 9

APU

A/ C FAN HEAT

1

10 11

SP

T2T

1

HVAC

OFF

ESC/

RESET

APU

APU

APU

T2T

1

OFF

TRIP

TRIP

RE­SET

62-11175 COMFORTPRO SERVICE MANUAL

1-2

1.1.2 How the ComfortPro Operates

The ComfortPro has two modes of operation: manual and automatic.

Manual Mode

You start the APU from within the truck bunk using the On/Off button on
the driver control panel (DCP). Once the APU is running, you can start and
stop the fan, heater and air conditioning using the DCP. See page 1-3.

Once the heater or A/C is running, it will cycle (automatically turn on and
off) in order to keep the truck bunk at the temperature you specify. The
HVAC will continue to cycle until you turn it off. While the HVAC is cycling,
the APU remains on and will only turn off when you manually turn it off
using the button on the DCP.

Note that in manual mode, the APU remains on until you turn it off. But in
Comfort Monitor mode (described below), the APU automatically turns off
and on as required.

When the APU is running, power is supplied to the power outlet in the
truck bunk (except in high heat).

In manual mode, the APU will turn off automatically if the Maximum Run
Time is reached.

Automatic Mode

The ComfortPro has several functions that will start it in automatic mode.

Comfort Monitor

(page 1-7)

FEATURE DESCRIPTION

The APU and HVAC automatically turn on to
maintain a comfortable temperature in the truck
bunk. When the desired temperature is met, the
APU and HVAC automatically turn off. When the
temperature is again out of range, they will both
turn on again, and cycle heat and air conditioning
as needed.

Timer

(page 1-8)

At the specified time, the APU and HVAC
automatically turn on. During the specified
timer duration, the HVAC cycles on and off to
maintain the desired temperature. When the
timer duration expires, both the APU and HVAC
turn off automatically and remain off.

Cold Weather Watch

(page 1-10)

The APU and heater on the HVAC automatically
turn on in order to prevent the APU engine and
truck engine from getting too cold. (Turning on
the heater creates a “load” that makes the APU
work harder and therefore warm up faster).
Both the APU and HVAC turn off automatically
once the preset duration time expires.

The APU automatically turns on for 90 minutes
in order to recharge the batteries. The HVAC
does not turn on. After the 90 minute run time,
the system will sense voltage for 10 minutes,
before restarting if needed.

Battery Monitor

(page 1-12)

There are icons on the DCP that flash when the APU and HVAC are running.
See page 1-1. If you enter the truck bunk and APU or HVAC is on but you
did not start it, you can assume it has started in one of the automatic
modes, as described above. On the DCP, one icon will be flashing steadily:
this is the icon for the mode that is currently operating.

Whenever the ComfortPro is running in automatic mode, if you then press
the heat, A/C or fan buttons on the DCP, the ComfortPro will switch to
manual mode. The APU will not automatically turn off! This icon on the
DCP will also stop flashing.

62-11175 COMFORTPRO SERVICE MANUAL

1-3

Automatic Mode and Minimum Time Off

All these automatic functions work on a "minimum time off": the ComfortPro
must be off for at least 10 minutes before the automatic function will turn
it on again. For example, the Timer function may be set to turn on the
ComfortPro at 10:00 a.m. You have been running the ComfortPro in manual
mode. You turn off the ComfortPro at 9:55 a.m. The timer will only turn on
the ComfortPro again 10 minutes later, at 10:05 a.m.

Clock

In order to use the Timer correctly, you must set the DCP clock. See page 1-7.

Maximum Run Time

You can set the maximum time that the APU is allowed to continuously run
in manual mode. See page 1-11.

Password Protection

You can add a password to the DCP, then you can protect one or more
functions so that only a person who knows the password can set the
function. See page 1-5.

WARNING

Do not start the APU when the enclosure
cover is removed. Operating with the
cover off may result in injury and/or death.

Press and release once.

The display shows "PLEASE WAIT – APU
STARTING" and flashes.

When stops flashing, then the APU
has started successfully.

The APU startup sequence consists of
20 seconds of glowing (30 seconds when
the ambient temperature is below -5°C or
23°F) and up to 10 seconds of cranking.

If the sequence fails, "RESTARTING"
appears for six seconds. Then the
startup sequence automatically repeats
up to five times or until the APU starts.

If "CRANK LIMIT" appears, see
Troubleshooting section.

APU

APU

WARNING

When the APU is about to start, a buzzer
sounds. Make sure no one is standing
near the APU or touching it.

1.2.1 Starting the APU "One Touch Start"

Press

.

The APU will stop. The display
shows .

APU

1.2.2 Stopping the APU

1.2 MANUAL OPERATIONS

HOURS
00000

APU

PLEASE WAIT

APU STARTING

HOURS
00000

APU

RESTARTING

HOURS
00000

APU

CRANK LIMIT

HOURS
00000

APU

OFF

OFF

OFF

OFF

OFF

OFF

OFF

62-11175 COMFORTPRO SERVICE MANUAL

1-4

1 Press to activate the heater.

The display shows "HEAT LOW".

The heater will turn on only if the
temperature is too low (to adjust the
temperature, see below). When the
heater is on, appears.

2 Press again to switch between

high and low heat to heat the truck
bunk more or less quickly. In "HEAT
HIGH" mode, the power outlet is
disabled and the display indicates .

The heat or A/C will turn off when the
desired temperature is reached.

3 Press to deactivate heating.

NOTICE

The heat mode will not function if the
temperature is higher than 85°F.

1.2.3 Turning the Heater ON/OFF

1.2.4 Heating: Setting the Temperature

1.2.5 Turning the A/C ON or OFF

1.2.6 A/C Setting the Temperature

Press or when the heater is on ("HEAT LOW"or "HEAT
HIGH" shows).

The notch on the temperature bar moves. The heater will automatically
turn on and off to maintain this temperature.

1 Press to activate the A/C.

The display shows "A/C LOW".

The A/C will turn on only if the
temperature is too high (to adjust the
temperature, see below). When the
A/C is on, appears.

2 Press again to switch between

high and low A/C to cool the truck
bunk more or less quickly.

3 Press to deactivate the A/C.

NOTICE

The air conditioning function will not
operate if the temperature is lower
than 65°F.

Press or when the A/C is on ("A/C LOW" or "A/C HIGH" shows).

The notch on the temperature bar moves. The A/C will automatically turn
on and off to maintain this temperature.

HOURS
00000

APU

HEAT LOW

CH

HOURS
00000

APU

HEAT HIGH

OFF

CH

OFF

HOURS
00000

APU

A/C LOW

CH

HOURS
00000

APU

A/C HIGH

CH

62-11175 COMFORTPRO SERVICE MANUAL

1-5

Press to toggle between low,
high and off.

The speed of the fan may automatically
change when the heat or A/C comes on,
then automatically change back when
the heat or A/C goes off.

You can still have the fan working even when the temperature is not low or
high enough for the heat or A/C to come on.

The fan operation is independent of the air conditioning and heat modes.
When the fan speed is manually set to high or low, the fan will return to
that setting when the desired temperature has been reached as the air
conditioning or heat cycles off.

1.2.7 Fan Operation

1.3.1 Password Protection

1.3 AUTOMATIC OPERATIONS

You can add a password to the DCP, then you can protect one or more
functions so that only a person who knows the password can set the function.

On a newly installed DCP, the password is always 000, which means that
no password protection is in place.

To password-protect functions, first change the factory password; see
'Setting up for Password Protection'. All functions will now be password
protected. Then remove password protection from chosen functions, as
desired; see 'Protect Functions with a Password'.

If you know the password, you can change it at any time, if you need to.
Note that if you change the password to 000, you will remove password
protection from all functions.

If the password is ever lost, contact your dealer to have the password
reset to 000.

Setting up for PASSWORD PROTECTION

1 Press .

2 Press or until "SET/CHANGE PASSWORD" is displayed,

then press .

"ENTER PASSWORD" is displayed
with three blank squares, one for
each digit in the password. The
first digit flashes.

HOURS
00000

APU

CH

HOURS
00000

APU

CH

FAN

LOW

FAN

HIGH

HOURS
00000

ENTER PASSWORD

APU

000

OFF

OFF

62-11175 COMFORTPRO SERVICE MANUAL

1-6

When you try to set up a function, you may be prompted to enter the password.

1 Press or until the first number in the password

is displayed, then press .

2 Repeat for each digit in the password.

3 Press again after entering the last digit.

1.3.2 Entering the Password

3

Press or until the first number in the password is displayed

.

For example, if your password is "432" press until "4" shows,

then press .

4 Repeat for each digit in the password.

5 Press again after entering the last digit. "NEW PASSWORD"

is displayed.

6 Repeat the above steps to enter the new password. "CONFIRM"

is displayed.

7 Enter the new password again, then press to exit this function.

PROTECT FUNCTIONS with a PASSWORD

1 Press .

2 Press or until

"PASSWORD PROTECT"
is displayed, then press .

If this menu item does not appear,
then you have not yet changed the
factory password from 000. Change
the password and then try again.
"ENTER PASSWORD" is displayed with three blank squares, one for
each digit in the password. The first square flashes.

3 Press or until the first number in the password is

displayed, then press .

4 Repeat for each digit in the password.

5 Press again after entering the last digit.

The first feature that can be password protected is displayed with
"YES" or "NO" (indicating whether it is currently password protected).

6 Press or to change the "YES" or "NO".

7 Press to move to the next feature.

Or press or to skip to the next feature.

HOURS
00000

APU

PASSWORD

PROTECT

OFF

OFF

62-11175 COMFORTPRO SERVICE MANUAL

1-7

1.3.3 Setting the Clock

1 Press

.

2 Press or until "CLOCK"

is displayed, then press .

If "ENTER PASSWORD" is displayed,
enter your password. If you do not
know the password, then you cannot
set up this function (see page 1-5).

The clock function takes you through
several settings: 12/24-hour-clock,
hour set, minutes set, am/pm-set (for
12-hour clock only), and day of the week.

You can set the clock on the DCP. This clock is used by the Timer function
(page 1-8). If you use the Timer function, remember that as you move from
one time zone to another, you must adjust the clock. Otherwise the Timer
will start the APU at the wrong time.

The clock settings remain even when the APU is turned off.

3 Press or to change the setting.

4 Press to move to the next setting. Or press to cancel any

changes you have not yet accepted.

5 When done, press to exit.

1.3.4 Comfort Monitor

You can specify the temperature you want in the truck bunk. Whenever the
truck bunk temperature goes 2° above or below this temperature, the APU
starts and the HVAC turns on until that temperature is reached or for
fifteen minutes, whichever is longer.

Turning COMFORT Monitor ON and OFF

1 Press .

2 Press or until

"COMFORT MONITOR" is displayed,

then press .

If "ENTER PASSWORD" is displayed,
enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "ON" or "OFF".

4 Press to confirm this setting.

The current setting remains until you change it; turning off the APU or
manually starting the APU does not permanently cancel this setting.

NOTICE

The clock does not automatically
adjust for time zone changes; you
must adjust it.

HOURS
00000

APU

CLOCK

HOURS
00000

CLOCK: SET MODE

APU

12 HOUR

OFF

OFF

HOURS
00000

COMFORT MONITOR:

APU

ON

62-11175 COMFORTPRO SERVICE MANUAL

1-8

You can set up the ComfortPro so that the

APU and CCU run automatically for

a specified

time on specified days of the week. There are two timers, so you

can set up two schedules.

For example, one schedule may be to run every day at 6:00 p.m. for .5 hours
and the other schedule may be to run every Monday at 6.00 a.m. for .5 hours.

You must set up the timer as follows: Specify the day and time you want
the APU to run, specify the duration (the length of time you want the APU to
run for) and specify the temperature you want maintained in the truck bunk
while the APU is running.

Turning TIMER On or Off

1 Press .

2 Press or until

"TIMER 1" or "TIMER 2" is displayed,

then press .

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "ON" or "OFF".

4 Press to confirm this setting.

The current setting remains until you change it; turning off the APU or
manually starting the APU does not cancel the timer function.

1.3.5 Timer

Setting the TEMPERATURE

1 Press .

NOTICE

Factory Default Temperature Setting is
21°C / 70°F. Range is 18°C / 64°F to
30°C / 86°F.

2 Press or until

"COMFORT MONITOR" is displayed,
then press .

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "SET".

4

Press to confirm this setting. The current temperature is displayed.

5 Press or to scroll to the desired temperature.

6 Press to confirm this setting. Or press to cancel and

retain the current temperature.

7 Press to exit.

HOURS
00000

COMFORT MONITOR

APU

SET

HOURS
00000

TIMER 1

APU

ON

OFF

OFF

T

1

62-11175 COMFORTPRO SERVICE MANUAL

1-9

Setting the Start Time/Day

1 Press .

2 Press or until

"TIMER 1" or "TIMER 2" is displayed,

then press .

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "SET START".

4 Press to confirm this setting. The current start time is displayed.

5 Press or to set the hours, minutes and day.

6 Press to confirm each setting.

Setting the DURATION

1 Press .

2 Press or until

"TIMER 1" or "TIMER 2" is displayed,

then press .

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "SET DURATION".

4

Press to confirm this setting. The current duration time is displayed.

5 Press or to scroll to the length of time to run the APU.

6 Press to confirm this setting. Or press to cancel and

retain the current duration.

7 Press to exit.

NOTICE

Factory Default Duration Setting

is 1 hour.
Range is 0.5 hrs - 10 hrs (in 0.5 hr
increments).

Setting the TEMPERATURE for the Timer

1 Press .

2 Press or until

"TIMER 1 or TIMER 2" is displayed,

then press .

NOTICE

Factory Default Temperature

Setting is

21°C / 70°F. Range is

18°C / 64°F to

30°C / 86°F.

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "SET TEMP".

4

Press to confirm this setting. The current temperature is displayed.

5 Press or to scroll to the desired temperature.

6 Press to confirm this setting. Or press to cancel and

retain the current temperature.

7 Press to exit.

HOURS
00000

TIMER 1

APU

SET START

OFF

T

OFF

1

HOURS
00000

TIMER 1

APU

SET DURATION

OFF

T

OFF

1

HOURS
00000

TIMER 1

APU

SET TEMP

T

1

OFF

OFF

62-11175 COMFORTPRO SERVICE MANUAL

1-10

Setting the START TEMPERATURE

1 Press .

2 Press or until

"TEMP START" is displayed, then
press .

NOTICE

Factory Default Temperature

Setting

-10°C / 14°F. Range is -

20°C / -4°F to

5°C / 41°F.

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "SET TEMP".

4 Press to confirm this setting. The current start temperature

is displayed.

5 Press or to scroll to the desired start temperature.

6 Press to confirm this setting. Or press to cancel and

retain the current start temperature.

7 Press to exit.

1.3.6 Cold Weather Watch

Turning Cold weather watch On and Off

1 Press .

2 Press or until

"TEMP START" is displayed, then

press .

You can set up the APU so that it automatically runs for a specified time
whenever the ambient temperature goes below a specified value. This
feature ensures that the APU engine and truck engine do not get so cold
that they will not start.

This feature is not intended to maintain a comfortable truck bunk
temperature; instead, see “Comfort Monitor”.

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "ON" or "OFF".

4 Press to confirm this setting.

The current setting remains until you change it; turning off the APU or
manually starting the APU does not permanently cancel this setting.

HOURS
00000

TEMP START

APU

ON

HOURS

00000

TEMP START : SET TEMP

APU

-10C 14F

OFF

OFF

OFF

OFF

62-11175 COMFORTPRO SERVICE MANUAL

1-11

Setting the DURATION

1 Press .

2 Press or until

"TEMP START" is displayed, then
press .

NOTICE

Factory Default Duration Setting

is 2
hours. Range is 1 hr to 4 hrs.

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "SET DURATION".

4 Press to confirm this setting. The current duration is displayed

in hours.

5 Press or to scroll to the

amount of time you want the APU to
run before automatically shutting off.

6 Press to confirm this setting.

Or press to cancel and retain the current start temperature.

7 Press to exit.

You can set the maximum time that the APU is allowed to run continuously.
If the APU runs for longer than the specified time, it automatically shuts off.
You can then start it manually, if desired; the "run time" clock will start
counting again.

Turning MAXIMUM RUN TIME ON OR OFF

1 Press .

2 Press or until

"MAXIMUM RUN TIME" is displayed,
then press .

NOTICE

Factory Default Run Time Setting is 8
hours. Range is 2 to 24 hours.

1.3.7 Maximum Run Time

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "ON" or "OFF".

4 Press to confirm this setting.

Setting the DESIRED RUN TIME

1 Press .

2 Press or until

"MAXIMUM RUN TIME" is displayed,
then press .

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "SET".

4 Press to confirm this setting.The current duration is displayed.

5 Press or to scroll to the desired number of hours.

6 Press to confirm this setting. Or press to cancel and

retain the current duration.

7 Press to exit.

HOURS
00000

TEMP START

APU

SET DURATION

OFF

OFF

HOURS
00000

TEMP START : DURATION

APU

OFF

OFF

1.0 hrs

HOURS
00000

MAXIMUM RUN TIME

APU

ON

HOURS
00000

MAXIMUM RUN TIME

APU

SET

62-11175 COMFORTPRO SERVICE MANUAL

1-12

Turning BATTERY MONITORING ON and OFF

1 Press .

2 Press or until

"BATTERY MONITOR" is displayed,
then press .

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "ON" or "OFF".

4 Press to confirm this setting.

The current setting remains until you change it; turning off the APU or
manually starting the APU does not permanently cancel this setting.

The APU starts if the battery voltage goes below the level you specify here.

Setting the Voltage Level

1 Press .

2 Press or until

"BATTERY MONITOR" is displayed,
then press .

NOTICE

Factory Default Voltage Setting is

11.8V.

Range is 11.0V to 13.5V.

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to display "SET".

4 Press to confirm this setting. The current voltage level is

displayed and flashes.

5 Press or to scroll to the desired voltage.

6 Press to confirm this setting. Or press to cancel and

retain the current voltage.

7 Press to exit.

You can set up the APU so that it automatically runs for 90 minutes when
the truck batteries are low.

When you set up this feature, you must enter the current voltage of the
batteries (see “Set the Initial Voltage”). The ComfortPro can then calculate
how much the voltage drops, as the batteries are used.

Set the INITIAL VOLTAGE

1. Press .

2 Press or until

"CALIBRATE VOLTAGE" is displayed,
then press .

1.3.8 Battery Monitoring

If "ENTER PASSWORD" is displayed, enter your password. If you do not
know the password, then you cannot set up this function (see page 1-5).

3 Press or to set the current voltage of the batteries.

4 Press to confirm this setting.

HOURS
00000

APU

CALIBRATE

VOLTAGE

HOURS

00000

BATTERY MONITOR

APU

ON

OFF

OFF

OFF

OFF

HOURS
00000

BATTERY MONITOR : SET

APU

11.8 V

OFF

OFF

MENU

62-11175 COMFORTPRO SERVICE MANUAL

2-1

NOTICE

The air conditioning system has a 5
minute delay timer (minimum time
between cycles is 5 minutes).

CLIMATE CONTROL UNIT (CCU)

1 Pressure test the system for leaks with nitrogen.

2 Vacuum all the nitrogen for a minimum of 30 minutes to 500 microns.

3 With the high and the low side valves open, charge the system with

R-134A

vapor to break the vacuum. Once the scale stabilizes and the

high and the low side pressures match, close the high side valve.

4 With only the low side valve open, start the A/C compressor by

selecting High A/C (APU Running). If needed lower the temperature
set point to start the A/C compressor.

5 Continue charging the system with vapor, on the low side only, until a

total of 64–68 oz of R-134A refrigerant has
been added as measured by the scale.

Figure 2- 1: Connecting hoses to CCU to Condenser

RED

LOW

BLUE

SCALE 64–68 OZ

CCU

CONDENSER

CAUTION

Vapor charge CCU only.

2.0

WARNING

This procedure must be performed by
a certified air conditioning technician
who has experience with hermetic
systems and Refrigerant R-134A.

NOTICE

Total System Capacity is 64–68 oz.

A scale must be used to measure the

refrigerant weight. No other method
is acceptable. Failure to follow this
procedure exactly will result in
improper air conditioning function.

NOTICE

Refrigerant Recovery:

Venting of refrigerant is against
the law and subject to fines and
loss of certification.

EPA regulations require that all
CFC and HCFC refrigerants be
recovered before any system can
be opened for service.

Recovery of refrigerant is done
using a certified recovery unit.

• Before a refrigeration system
can be opened to make repairs.

• Before pressurizing the system
with nitrogen for leak testing.

•

Before disposing of any system or

component containing refrigerants.

• When it is necessary to remove
excess charge from an
overcharged system.

HIGH

2.1.1 Charging the CCU

PREPARATION

2.1

62-11175 COMFORTPRO SERVICE MANUAL

2-2

2.2.1 Maintenance Schedule

2.2 SERVICE

First Every

Interval between checks (in hours of operation) 50 1000 2000

Change oil and oil filter x x
Check fuel hoses, fuel pipes, and clamps x x
Check fasteners, muffler clamps and frame grippers x x
Check battery cable connections x x
Check coolant hoses and clamps x x
Check alternator fan belt tension x x
Check generator belt tension x x
Check APU air filter, clean or replace as necessary x
Change fuel filters x
Change fan belt regardless of condition x
Adjust valve lash x
Clean inside enclosure x
Clean radiator fins x
Clean condenser fins x
Check CCU air filter, clean or replace as necessary. To clean, remove the

filter and vacuum or wash (soap and water). Shake dry and reattach. x
Check injection nozzle opening pressure x
Check injection pump timing x
Check water pump performance x
Check alternator performance x
Check starter performance x
Check air conditioning performance (HVAC) x
Check heater performance (HVAC) x
Check generator line voltage x
Check coolant hoses and clamps (from APU to main engine) x
Check engine thermostat x
Check air intake hose and clamps on APU x
Check fuel hoses and clamps x

62-11175 COMFORTPRO SERVICE MANUAL

2-3

2.2.2 CCU Spring Tune-Up

Purpose:

Recommended service and maintenance:

• Condenser.

• Air ducting and outlets.

• Evaporator and temperature sensor.

• Refrigerant lines connections and routing.

• Harness Connections and wiring.

• A/C operating efficiency - charge level.

Frequency:

Annually – preferably in the spring for the coming A/C season.

Recommended 1. Check the condenser for:

Service Actions: Damage, leakage and/or contaminated fins that may restrict air flow.

2. Check air ducting and outlets for:

Damage and/or restrictions.

3. Check electrical harnesses for:

Tight connections and harness abrasions.

4. Check the evaporator for:

• Intake filter cleanliness, clean if required.

• Damaged and/or contaminated fins that may restrict air flow.

•

Refrigerant leaks indicated by wet spots or dark stains on the evaporator
fins and connections.

• Check evaporator temperature sensor for proper function (see chart).

COMFORTPRO CCU EVAPORATOR DEFROST SENSOR TEMPERATURE – RESISTANCE CHART

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

60 65 70 75 80 85 90 95 100 105 110 115 120

TEMPERATURE (°F)

kOhm

77°F, 100 kOhm

5. Check the Refrigerant lines and connections for:

• Abrasion and wear points.

• Connection wet spots that may indicate refrigerant leakage.

62-11175 COMFORTPRO SERVICE MANUAL

2-4

6. Check the refrigerant charge level:

• Install the A/C gauges as shown in the ComfortPro Installation
Manual. Operate the A/C on high.

• Refer to chart below for high and low reference pressure.

If level is not ok, recover and recharge the A/C system with the
correct amount of refrigerant as shown on page 2-1.

7. Check the CCU drain:

For damage and that it operates correctly.

COMFORTPRO AIR CONDITIONING OUTDOOR AMBIENT TEMPERATURE AND
PRESSURE CHART

OUTDOOR TEMPERATURE 70°F 95°F 110°F

SUCTION PRESSURE 20 PSI 35 PSI 45 PSI

DISCHARGE PRESSURE 110 PSI 175 PSI 225 PSI

OVERALL CURRENT 5-9 AMPS 9-12 AMP 12-15 AMP
Note: A/C - High
Measure at 120 volt teck cable

FAN ONLY AMP READING
FAN LOW 1.2-1.5 AMP
FAN HGH 1.8-2.2 AMP

If both suction and discharge pressure is lower than the chart,
the system is undercharged.

If both suction and discharge pressure is higher than the chart,
the system is overcharged.

62-11175 COMFORTPRO SERVICE MANUAL

3-1

3.0 TROUBLESHOOTING

3.1 APU (AUXILIARY POWER UNIT) .....................................................3-2

3.2 GENERATOR...............................................................................3-6

3.3 DRIVER CONTROL PANEL ............................................................3-7

3.4 CCU AIR CONDITIONING ..............................................................3-8

3.5 CCU FAN ..................................................................................3-11

3.6 CCU HEAT ................................................................................3-11

3.7 RECEPTACLE PANEL .................................................................3-12

3.8 ADDITIONAL INFORMATION........................................................3-13

WARNING

Before undertaking ANY repair to
the APU, CCU or component of the
ComfortPro system disconnect
the batteries from the APU.

62-11175 COMFORTPRO SERVICE MANUAL

3-2

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

Engine does not start • No fuel • Check fuel stand pipe length • A-8

(starter works)

• Air in the fuel system • Bleed air • A-8

• Water in fuel system • Drain fuel tank(s) and replace

fuel filters

• Fuel solenoid not pulling in • Check for rust in plunger/check

for voltage

• Check for bent solenoid linkage

• Fuel pipe/line clogged • Clean/replace

• Fuel filters clogged • Replace • A-8

• Excessively high viscosity of • Use the specified engine oil • A-2

engine oil at low temperature

• Fuel leak due to loose injection • Tighten nut •

Kubota Manual

*

pipe retaining nut

•

Injection nozzle clogged/defective

• Clean/replace •

Kubota Manual

*

• Injection pump defective • Replace •

Kubota Manual

*

• Fuel lift pump defective • Replace

• Low cylinder compression • Repair/replace engine •

Kubota Manual

*

• Valve spring broken, valve stuck • Repair/replace •

Kubota Manual

*

• Excessive valve clearance • Adjust •

Kubota Manual

*

• Glow plugs malfunctioning • Check/replace •

Kubota Manual

*

• Plugged air filter • Clean/replace •

Kubota Manual

*

3.1 APU (AUXILIARY POWER UNIT)

Each symptom is followed by a probable cause and suggested solution. To isolate the
possible cause, proceed in a systematic manner to determine the faulty component. This
guide does not cover all possible situations that may occur under all conditions of operation.

Before using this guide verify correct voltage and ground to components.

WARNING

Disconnect the batteries from the
APU before performing any
repairs.

*Kubota Workshop Manual 97897-02400

62-11175 COMFORTPRO SERVICE MANUAL

3-3

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

Engine does not start • Low battery voltage to the APU • Check battery cables/charge battery • A-13

(starter does not work)

• Starter/solenoid defective • Repair/replace •

Kubota Manual

*

• Poor positive cable connection • Check/repair

• Poor ground cable connection • Check/repair

Engine will not stop • Starter solenoid jammed • Replace start solenoid or starter •

Kubota Manual

*

• Fuel solenoid bolt missing • Check bolt

• Speed control linkage broken • Replace control linkage

Engine runs rough • Fuel filters clogged or dirty • Replace • A-8

• Air filter plugged or dirty • Clean/replace • A-3

• Fuel leak due to loose injection • Tighten nut •

Kubota Manual

*

pipe retaining nut

• Injection nozzle clogged/defective • Clean/replace •

Kubota Manual

*

• Injection pump defective • Replace •

Kubota Manual

*

• Uneven cylinder compression • Repair/replace engine •

Kubota Manual

*

• Incorrect valve clearance • Adjust •

Kubota Manual

*

• Fuel return line clogged/kinked • Clean/replace •

Kubota Manual

*

• Governor defective • Repair/replace

Smoking (white or • Excessive engine oil • Reduce to specified level • A-2

blue exhaust)

• Piston ring worn or stuck • Repair/replace engine •

Kubota Manual

*

• Incorrect injector timing • Repair •

Kubota Manual

*

• Low cylinder compression • Repair/replace engine •

Kubota Manual

*

• Coolant in combustion chamber • Repair/replace engine •

Kubota Manual

*

Smoking (black or • Overloaded power draw • Reduce power consumption
dark gray exhaust)

• Low fuel grade • Use specified fuel grade

• Fuel filters clogged • Replace • A-3

• Air cleaner clogged • Clean/replace • A-3

Unable to bleed coolant

• Air lock • Run Truck engine until 185°F • A-9

• No coolant flow •

Check for blockages using flow indicator

• Kinked coolant lines • Straighten

• Shut-off valves 'OFF' • Turn 'ON'

• Incorrect plumbing • Re-plumb

• Small fittings on truck engine • Change to larger fittings (3/4")

Excessive oil • Oil ring worn • Replace •

Kubota Manual

*

consumption

• Piston ring groove worn • Replace the piston •

Kubota Manual

*

• Valve stem and guide worn • Replace •

Kubota Manual

*

• Crankshaft bearing and crank • Replace •

Kubota Manual

*

pin bearing worn

• Air filter clogged • Replace filter • A-3

*Kubota Workshop Manual 97897-02400

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

Oil level increases • Diesel fuel getting to oil pan • Replace O-ring in lower portion •

Kubota Manual

*

through governor lever of governor lever

•

Fuel lift pump diaphragm defective

• Replace •

Kubota Manual

*

Low oil pressure • Engine oil insufficient • Replenish • A-2

• Oil strainer clogged • Clean •

Kubota Manual

*

• Oil filter clogged • Replace •

Kubota Manual

*

• Relief valve stuck with dirt • Clean

• Relief valve spring weakened • Replace

or broken

• Excessive oil clearance of • Replace •

Kubota Manual

*

crankshaft bearings

• Excessive oil clearance of rocker • Replace •

Kubota Manual

*

arm boss

• Oil passage clogged • Clean

• Different type of oil • Use the specified type • A-2

• Oil pump defective • Repair/replace •

Kubota Manual

*

High oil pressure • Different type of oil • Use the specified type • A-2

• Relief valve defective • Replace

Engine overheated • Engine oil insufficient • Replenish • A-2

• Fan belt broken or loose • Repair/replace • A-2

• Air lock • Check for air lock in Kubota engine • A-9

and ensure there is coolant, purge
if necessary

• Coolant level insufficient • Add coolant, purge if necessary • A-9

• Coolant flow is restricted • Repair Plumbing

• Thermostat stuck • Replace •

Kubota Manual

*

• Water pump defective • Replace •

Kubota Manual

*

Overcharging of • Alternator malfunctioning • Replace • A-13

batteries

• Poor positive/ground connections • Repair

• Batteries defective • Load test or replace batteries

Dead batteries or • Alternator malfunctioning • Replace • A-13
undercharge

• Poor alternator connection • Check alternator connection

• DC load too high • Reduce load

• Poor positive/ground connections • Check connections

• Alternator belt loose/worn • Replace or tighten •

Kubota Manual

*

APU suddenly stops • Low oil pressure • See "Low oil pressure" • A-6
("Check APU" message

• Overheat • See "Engine overheated" • A-6

on Driver Control Panel

• Alternator Feedback • See "Alternator Troubleshooting" • 3-15, A-13

62-11175 COMFORTPRO SERVICE MANUAL

3-4

Do not turn the Driver Control
Panel off. Go to the APU and
look at the APU Control Unit
lights for the correct code.

*Kubota Workshop Manual 97897-02400

62-11175 COMFORTPRO SERVICE MANUAL

3-5

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

APU suddenly stops • No fuel • Check fuel stand pipe length/fuel level

in tank • A-8

(no message on Driver

• Air in the fuel system • Bleed air • A-8

Control Panel display)

• Water in fuel system • Drain fuel tank(s) and replace • A-3, A-8

fuel filters

•

Faulty communication between the

• Check APU control cable, and

APU Control Unit, CCU Control

Driver Control Panel cable for shorts

Board and/or the Driver Control Panel

or opens/replace

• Fuel solenoid faulty • Check for rust in plunger/wiring • 3-13

• Alternator belt loose or broken • Tighten/replace •

Kubota Manual

*

• Alternator faulty • Repair/replace • 3-15

• Low battery voltage • Check battery cables/charge battery

APU stops 15 seconds • Low oil pressure • See "Low oil pressure" • 3- 4
after starting sequence

• Overheat • See "Engine overheated" • 3- 4

completes ("Check APU"

• Truck engine interlock (optional) • Stop truck engine and re-start APU • A-13

message on Driver Control
Panel display)

APU stops after start • Alternator belt loose or broken • Tighten/replace • A-2
sequence completes.

• Alternator Defective • Repair/replace • 3-15

APU will only run with

• Poor connection between alternator • Check connection / wire for breaks

start button depressed

and APU controller (brown wire)

(no message on Driver
Control Panel display)

No "GLOWING" message

•

Faulty communication between the

• Check APU control cable, and

on the Driver Control APU Control Unit, CCU Control

Driver Control Panel cable for shorts

Panel, but APU will start Board and/or the Driver Control Panel

or opens/replace

and run normally

No "GLOWING" message

•

Faulty communication between the

• Check APU control cable, and

on the Driver Control APU Control Unit, CCU Control

Driver Control Panel cable for shorts

Panel and APU will only Board and/or the Driver Control Panel

or opens/replace

run with ON button
depressed

APU only ‘clicks’ after • Faulty APU Controller • Replace APU Controller
glowing has finished
and is attempting to start

(ALT POWER light not on,
ALT F/B light does not
come on during glowing)

APU only ‘clicks’ after • Loose connection from APU controller
glowing has finished to alternator, either at the APU
and is attempting to start controller end or at the Alternator end

(ALT F/B light on,

• Faulty Alternator

APU controller does not

•

Faulty APU Harness • Troubleshoot the Alternator • 3-15

come on during glowing)

This will occur when the APU
Control Unit sees a problem
during or after startup

This will occur when the APU
Control Unit does not see the
Alternator feed back signal
during or after start up.

*Kubota Workshop Manual 97897-02400

62-11175 COMFORTPRO SERVICE MANUAL

3-6

3.2 GENERATOR

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

No voltage • 35 Amp Breaker tripped • Determine reason and reset • A-5

• Generator Belt loose/broken • Tighten/replace • A-2

Low voltage • Generator belt loose/broken • Tighten/replace • A-2

(below 100 Volts)

• Engine air filter dirty • Clean/replace filter • A-3

• Engine fuel system problem • Change fuel filters • A-3

• Engine exhaust system problem • Clean/replace

• Engine speed low • Adjust • 3- 13

Very low voltage • Wiring to capacitor • Repair/replace

(4-10 Volts AC)

• Capacitor defective • Test and replace • 3- 13, 3- 14

Each symptom is followed by a probable cause and suggested solution. To isolate the
possible cause, proceed in a systematic manner to determine the faulty component. This
guide does not cover all possible situations that may occur under all conditions of operation.

WARNING

Disconnect the batteries from the
APU before performing any repairs.

62-11175 COMFORTPRO SERVICE MANUAL

3-7

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

APU starts and runs, • No 120 Volt power to CCU Board • See "Generator" section • 3- 6
but no CCU functions

• Controls "locked up" • Re-boot by turning APU off and

work and "OUTLET

disconnecting battery power to

OFF" is displayed

APU for 30 seconds

A/C will not turn on • Temperature in sleeper is too cold • Temperature must be above 65°F • 1- 4, 1- 8
(no icon)

(turn heat on to raise the sleeper temp)

• Temperature is below Driver Control • Set temperature to lower setting • 1- 4, 1- 8

Panel set point

Heat will not turn on • Temperature in sleeper is too hot • Temperature must be below 85°F • 1- 4, 1- 8
(no icon)

(turn A/C on to lower the sleeper temp)

• Temperature is above Driver Control • Set temperature to higher point • 1- 4, 1- 8

Panel set point

"HVAC BREAKER • 20 Amp CCU breaker tripped • Determine reason and press reset on
RESET" is displayed the Driver Control Panel

• Generator belt loose • Tighten/replace • A-2

"TRIP W/LIGHTENING • 20 Amp outlet breaker tripped • Determine reason and press reset on
BOLT ICON" is displayed the Driver Control Panel

• Generator belt loose • Tighten/replace

"LOW VOLTAGE" • Generator 35 Amp breaker tripped • Determine reason and reset • 3-6, A-5
is displayed

• Generator belt loose/broken • Tighten/replace • 3-6

• Engine air filter dirty • Clean/replace filter • A-3

• Engine fuel system problem • Change fuel filters • A-3

• Engine exhaust system problem • Clean/replace

• Engine speed low • Adjust • A-2

3.3 DRIVER CONTROL PANEL

Each symptom is followed by a probable cause and suggested solution. To isolate the
possible cause, proceed in a systematic manner to determine the faulty component. This
guide does not cover all possible situations that may occur under all conditions of operation.

WARNING

Disconnect the batteries from the
APU before performing any repairs.

62-11175 COMFORTPRO SERVICE MANUAL

3-8

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

Does not produce • Refrigerant leaked out • Check for leaks and repair • 2-3
cold air

• Compressor not working • Check voltage at compressor

• Inlet filter clogged • Clean filter • A-3

Produces cold air and • Evaporator blocked with ice • Increase air flow, increase return air
gradually stops

• Low refrigerant charge • Check for leaks and repair • 2-1

• Air Duct blocked • Check and remove any blockage

Tripped high • Condenser fan not working • See "Condenser fan not working" • 3-9
pressure switch

• Condenser is dirty • Clean

• Poor air flow around condenser • Check condenser location, relocate

if necessary

• Refrigerant is over charged • Reduce charge to 64–68 oz • 2-1

Tripped on EVAP • Evaporator blocked with ice • Increase air flow, increase return air
temp sensor

• Low refrigerant charge • Check for leaks and repair • 2-1

• EVAP temp sensor faulty • Verify sensor operation by using
Temperature vs. Resistance Chart • 2-3

3.4 CCU AIR CONDITIONING

Each symptom is followed by a probable cause and suggested solution. To isolate the
possible cause, proceed in a systematic manner to determine the faulty component. This
guide does not cover all possible situations that may occur under all conditions of operation.

NOTE: The five minute timer is activated any time the compressor is turned off (by the
thermostat, EVAP temp sensor or high pressure switch. It is used to let the pressure
between the high and the low side equalize so that the compressor can start under a
"no load" condition.

WARNING

Disconnect the batteries from the
APU before performing any repairs.

62-11175 COMFORTPRO SERVICE MANUAL

3-9

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

Condenser fan not • A/C is not on • Set temperature to lower setting • 1- 4, 1- 8
working

• DC power fuse blown •

Determine reason and replace fuse

• A-4

• Wiring damaged • Repair/replace

• Fan defective (seized) • Replace

Compressor will not • High pressure switch open • See "Tripped high pressure switch" • 3- 8
start (no hum)

• Evaporator frozen • See "Produces cold air and • 3- 8

gradually stops"

• Five minute timer active • Wait five full minutes

• Overload protector tripped • Let unit cool down, check for • 2- 1

low refrigerant

•

Driver Control Panel not calling for A/C

• Set temperature to lower setting

• Compressor seized • Replace compressor

Compressor will not • Low A/C Voltage to CCU • See "Generator" section • 3- 6
start (hums)

• Starting capacitor defective • Determine reason and replace

• Potential relay is open • Determine reason and correct,

replace if necessary

• Compressor motor winding open • Replace compressor

or shorted

• Internal mechanical trouble • Replace compressor

in compressor

Compressor will not • Low A/C Voltage to unit • See "Generator" section • 3- 6
start (hums but trips

• Potential relay is failing to open • Determine reason and correct,

on overload protection)

replace if necessary

• Run capacitor is defective • Determine reason and replace

• Excessively high discharge pressure • Check high pressure switch, possible

overcharge or insufficient cooling on
condenser (fan)

• Compressor motor has a winding • Replace compressor

open or shorted

• Internal mechanical trouble in • Replace compressor

compressor (tight)

Compressor starts and • Low voltage to unit • See "Generator" section • 3- 6
runs, but short cycles

• Overload protector defective • Check current and replace protector

on overload protector

• Run capacitor is defective • Determine reason and replace

• Excessively high discharge pressure • Check condenser (fan) and for

restriction in refrigeration lines

• Compressor too hot – suction • Check refrigerant charge (check for • 2- 1

line hot leaks) and add if necessary

• Compressor motor has a • Replace compressor

winding shorted

Air conditioner runs • Overload protector • See "Compressor starts and runs, but • 3- 9
OK, but short cycles short cycles on overload protector"

• Driver Control Panel too close • Remount away from ducts • 1- 1

to ducts

62-11175 COMFORTPRO SERVICE MANUAL

3-10

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

Air conditioner runs • Driver Control Panel temp sensor • Replace Driver Control Panel
OK, but short cycles defective

(cont.)

•

High pressure cut out due to

: • Check:

a) Insufficient air flow

a) Air flow through condenser (fan)

b) Overcharge b) Reduce charge to 64–68 oz.
c) Air in system c) Purge air (vacuum system)
d) Defective switch d) Replace

• Low temp(de-ice) cut out due to: • Check: • 2-1

a) Insufficient air flow a) Air flow through evaporator

(fan, filter, vents closed)
b) Faulty expansion valve b) Replace valve
c) Faulty de-ice sensor c) Verify sensor operation by using

Temperature vs. Resistance Chart • A-11
d) Undercharge d) Fix leak and recharge (64–68 oz)

A/C operates long • Shortage of refrigerant • Fix leak and recharge (64–68 oz) • 2-1
or continuously

• Driver Control Panel temp sensor • Verify sensor operation by using

defective Temperature vs. Resistance Chart

• Sleeper has an excessive heat load • Cover windows, close sleeper curtains

• Sleeper has poor insulation • Insulate sleeper

• Evaporator coil iced •

Faulty EVAP temp sensor, Verify sensor
operation by using Temperature vs.
Resistance Chart • 2-1

• Restriction in refrigerant system • Determine location and repair

• Dirty condenser • Clean condenser

• CCU air filter dirty • Clean or replace CCU filter • A-3

Start capacitor open, • Potential relay is not operating • Replace
shorted, or blown properly

• Prolonged operation on start cycle • Check:

due to:
a) Low voltage to unit a) Determine reason and correct

(see "Low Voltage")
b) Starting load too high b) Check: pressure equalization

before compressor starts,

(5 minute timer faulty)

• Excessive short cycling • Determine reason for short cycling

and repair (see "Unit runs OK, but
short cycles")

Potential relay defective • Line voltage to low or to high • Determine reason and correct
or burned out

• Excessive short cycling • Determine reason for short cycling

and repair (see "Unit runs OK, but
short cycles")

• Relay being influenced by a loose • Remount rigidly

and vibrating mount

Suction line frosted • Evaporator fan not running • Determine reason and correct • 3-11
or sweating

• Overcharge of refrigerant • Reduce charge to 64–68 oz. • 2-1

Unit noisy • Loose parts or mounting • Find and tighten

• Tubing rattle • Move object that is touching the

tubing to be free of contact

• Bent fan blade causing vibration • Replace blade

• Fan motor bearings worn • Replace motor

62-11175 COMFORTPRO SERVICE MANUAL

3-11

3.5 CCU FAN

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

CCU fan not working • Fuse on CCU Board • Check/replace • A-4

• Wiring defective • Repair/replace

• Capacitor defective • Test/replace

CCU fan only works on • Low speed resistor defective • Check/replace heating element • A-2
high speed

• Resistor wiring defective • Repair/replace • A-2

• CCU Board defective • Test/replace

3.6 CCU HEAT

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

High Heat Mode does • Heat is not on (heat icon must be on) • Turn temperature setting up • 1- 4, 1- 8
not produce warm air

• Thermo fuse blown • Check/replace thermal fuse • A-2

• CCU Board defective • Replace

Low Heat Mode does • Heat is not on (heat icon must be on) • Turn temperature setting up • 1- 4, 1- 8
not produce warm air

• Thermo fuse blown • Check/replace thermal fuse • A-2

• CCU Board defective • Replace

Produces warm air and • Set point has been reached • Turn set point up • 1- 4, 1- 8
gradually stops

• High temperature cut out due to • Increase air flow/Increase return air

insufficient air flow

High temperature • High temperature cut out due to • Increase air flow, increase return air
sensor tripping insufficient air flow

• Temperature sensor wiring damaged • Repair/replace

• Temperature sensor defective • Verify sensor operation by using
Temperature vs. Resistance Chart • A-11

• Ducting blocked • Check and remove any blockage

Heat works OK, but • Driver Control Panel too close to duct • Remount away from ducts • 1- 1

short cycles

• Driver Control Panel temp sensor • Verify sensor operation by using

defective Temperature vs. Resistance Chart

Heat operates long or • Driver Control Panel temp sensor • Verify sensor operation by using
continuously defective Temperature vs. Resistance Chart • A-11

• Sleeper has an excessive heat loss • Cover windows, close sleeper curtains

• Sleeper has poor insulation • Insulate sleeper

• CCU air filter dirty • Clean/replace CCU filter • A-3

WARNING

Disconnect the batteries from the APU before
performing any repairs.

WARNING

Disconnect the batteries from the APU before
performing any repairs.

62-11175 COMFORTPRO SERVICE MANUAL

3-12

3.7 RECEPTACLE PANEL

SYMPTOM PROBABLE CAUSE SOLUTION REFERENCE

No 120 VAC power • High Heat Mode is selected • Switch to 'Low Heat' position • 1- 4, 1- 8

• APU not running • Start APU • 1- 4, 1- 8

• 35 Amp breaker tripped at • See "Generator" Section • 3-6

generator

Each symptom is followed by a probable cause and suggested solution. To isolate the
possible cause, proceed in a systematic manner to determine the faulty component. This
guide does not cover all possible situations that may occur under all conditions of operation.

WARNING

Disconnect the batteries from the
APU before performing any repairs.

62-11175 COMFORTPRO SERVICE MANUAL

3-13

3.8 TESTING PROCEDURES

3.8.1 Testing AMP draw for components

When checking functions of individual components, place amp clamp over black (power)
wire coming in from the generator to the CCU board. (As shown in below.)

When cross-referenced with the “AMP DRAW AND VOLTAGE CHART”, the components
should show the same amp readings.

3.8.2 Testing Voltage and Hz readings:

When checking for 120 VAC at the CCU board, the probes are placed at the black wire
terminal and the white wire terminal.

When APU is running there should always be between 110 – 130 VAC present.

When APU is running the Hz reading should always be 60 +/- 2.

62-11175 COMFORTPRO SERVICE MANUAL

3-14

3.9.1 Adjusting the 120 AC Voltage

This does not need to be adjusted under normal operation. If you find low
AC voltage, check the generator belt, air filter, fuel filters and exhaust
system before adjusting.

1 With the APU running turn all 120-volt components off.

2 Measuring the voltage at the outlet panel adjust the engine speed

until 120 (+/- 10) volts AC and 60 Hz +/- 2 Hz is read.

3.9.2 Capacitor Troubleshooting

1 Disconnect generator output from breaker.

2 With APU running, measure generator output voltage.

3 If voltage < 105 volts AC, try a known good capacitor and retest.

NOTE: Most multimeters will not test this capacitor reliably in either MF

(capacitance) or Ω (resistance) modes. The above methods are the ONLY
reliable means of testing the capacitor without a lab-grade capacitance meter.

3.9.3 Capacitor Theory

A single-phase motor can not be "fed" with just single-phase current
(120 Volt AC), there must be some way to create an artificial second
(or third) phase to smooth out the magnetic filed. Capacitors are electrical
components that help create and strengthen the artificial second phase in
single-phase electric motors. They work much like a battery, storing and
releasing a charge of electricity (AC Voltage) that is out of phase with the
oscillating (AC) current that is fed into the motor.

If single-phase induction motors do not have a second phase (created by
the capacitor) then it will not have an even magnetic field. This will cause
the rotor to hesitate at those spots that are uneven. This hesitation will
cause the rotor to spin slowly or even stop moving (compounding the
problem), draw more current (Amp's), become noisy, and overheat.

The CCU Fan and the Compressor use a Run Capacitor. Run Capacitors
are designed for continuous duty, and are energized the entire time the
motor is running.

The Compressor motor needs a Start Capacitor in addition to the Run
Capacitor. Start Capacitors are designed for momentary use. Start
capacitors stay energized long enough to bring the motor to75% of full
speed (RPM) and are then taken out of the circuit by means of a
Potential Relay.

3.9 ADDITIONAL INFORMATION

62-11175 COMFORTPRO SERVICE MANUAL

3-15

3.9.4 Potential Relay Theory

In a Capacitor Start, Capacitor Run compressor the start capacitor is only designed for
momentary use. The Potential Relay (NC) is used to connect and disconnect the start
capacitor from the compressors start windings. Induced Voltage is generated in the start
winding when of the compressor when it is running. The voltage induced in to the start
winding is a function of the speed of the rotor and the magnetic field that is generated.
When the compressor is first energized, the voltage in the start windings is less than the
line voltage (120 VAC). As the compressor speed (RPM) increases, the voltage in the
start windings increases significantly higher than the line voltage (up to 275 Volts) until
full compressor speed (RPM) is reached.

The Potential Relay's coil is connected across the start windings, and is designed to
respond to the increase of voltage as the compressor's speed increases. The normally
closed Potential relay contacts are designed to open at a 75% of the full compressor
speed (RPM). The Start Capacitor is connected to the relay contacts so when the relay
opens (75% of the full compressor speed RPM) the start capacitor is disconnected from
the system.

3.9.5 Alternator Troubleshooting

1 Unit switched OFF, harness connected

Check alternator feedback wire (brown) at the alternator for 5 volts.

If 5 volts are not found disconnect 'T' connector from alternator and retest. If 5 volts are
found the alternator is faulty.

If 0 volt is found check alternator feedback wire (brown) for open, and power (B+) and ground
(B-) to APU controller and repair as required. If no fault is found the APU controller is faulty.

2 Unit switched ON (glowing), harness connected

Check alternator field power wire (purple) for 12 volts. If 0 volt is found check alternator
field power wire (purple) for open and power (B+) and ground (B-) to APU controller and
repair as required. If no fault found the APU controller is faulty.

Check alternator feedback wire (brown) at alternator for 0 volt. If 5 volts are found the
alternator is faulty.

3 Unit running, harness connected

Check alternator feedback wire (brown) at alternator for 5 volt. If 0 volts are found the
alternator is faulty.

4 Unit running, then stops

Check alternator jumper harness (red) at alternator connection for 12.5-14.1 volts.

If 16-17 volts is found, check for alternator jumper (red) open and replace as required.

62-11175 COMFORTPRO SERVICE MANUAL

3-16

62-11175 COMFORTPRO SERVICE MANUAL

A-1

APPENDICES

CAPACITIES AND SPECIFICATIONS .................................................... A-2

FUSE LOCATIONS ............................................................................ A-4

CIRCUIT BREAKER LOCATIONS.......................................................... A-5

APU CONTROL UNIT ......................................................................... A-6

CCU CONTROLLER ........................................................................... A-7

FUEL SYSTEM PURGE PROCEDURE ................................................... A-8

COOLANT PURGE PROCEDURE.......................................................... A-9

DEFROST/HEAT AND DCP SENSOR CHARTS .................................... A-11

ENGINE INTERLOCK DIAGRAMS ...................................................... A-12

APU WIRING DIAGRAMS ................................................................. A-13

62-11175 COMFORTPRO SERVICE MANUAL

A-2

Engine . . . . . . . . . . . . . . 13.9 hp Kubota, 2 cyl, 479cc (model Z482-B)

Engine Oil . . . . . . . . . . . . 3.5 US Qts (3.3L) with filter.

You can use any API Service CF, CF-4, CG-4
or CH-4 oil and any ASE Viscosity (or weight) of
Oil according to the chart.

Belt Tension . . . . . . . . . . Alternator 45-55 ft-lb (61-75 N-m).

Generator 70-80 ft-lb (95-108 N-m).

Engine compression . . . . 327 PSI min. (2.26 MPa min).

Engine Speed . . . . . . . . . Approx. 2400 RPM.

Valve Clearance (Cold) . . . 0.145 to 0.185 mm (0.0057 to 0.0073 in).

Engine Drain Plug . . . . . . Torque 25 ± 2 ft/lb.

Intake & Exhaust Valves . 0.0057-0.0073" (0.145 – 0.185 mm) Cold.

Fast Burn Glow Plugs . . . . 0.9 Ohms each, 22 Amps then ramps down

to 12 Amps.

Starter . . . . . . . . . . . . . . 160 Cranking Amps (includes glow plugs and

fuel solenoid).

Alternator . . . . . . . . . . . . 60 Amps @ 14.2 Volts DC.

Generator . . . . . . . . . . . . 35 Amps @ 120 Volts AC.

Fuel Solenoid . . . . . . . . . Pull-in winding 29 Amps, Hold winding 1 Amp.

Oil pressure switch . . . . . Normally closed, opens at 7 psi.

Overheat switch . . . . . . . Normally open, closes at 245°F.

Thermostat . . . . . . . . . . . Starts to open at 160°F and fully opens at 185°F.

Air Conditioner . . . . . . . 10,000 BTU/ hr hermetic compressor.

System capacity . . . . 64–68 oz of R-134A.

System Oil capacity . . 14 oz of PVE (Polyvinylether).

Compressor . . . . . . . 6–10 Amps @ 120 Volts.

Condenser Fan . . . . . 9-12 Amps .

Binary Pressure Switch

. Normally closed between 26–335 psi.
Operating pressures . . Low side, 24–45 psi, High side, 110–250 psi.
Condenser Air inlet to outlet temperature difference should be no more

than 30°F. Evaporator Air inlet to outlet temperature difference 18° - 25°F.

Heat . . . . . . . . . . . . . . . 10,000 BTU/ hr (3,000 watts).

Blower Fan low

speed resister . . . . . . 25 Ohms.

Heating Coils . . . . . . . 10 Ohms each.

Thermo Fuse . . . . . . . Blows at 307.4°F (152°C).

CAPACITIES AND SPECIFICATIONS

APU

CCU

40

30

20

20W

10W

5W

5W20

5W30

10W30

15W40

20W50

243 253 263 273 283 293 303 313 323

-30 -20 -10 0 10 20 30 40 50

-22 -4 14 32 50 68 86 104 122

K

°C

°F

SINGLE

GRADE

MULTI

GRADE

AMBIENT

TEMP

62-11175 COMFORTPRO SERVICE MANUAL

A-3

Figure A-1: Maintenance Components

OIL FILTER

FUEL FILTER

AIR FILTER

OIL DIPSTICK

AIR INLET FILTER

FUEL FILTER INLINE FUEL OIL FILTER AIR FILTER GENERATOR ALTERNATOR

FILTER BELT BELT

CARRIER 96-101-24K 30-186-01K 96-101-23K 30-724-10K 40-304-01K 96-969-03K

Maintenance Parts Crossover List

INLINE FUEL FILTER

62-11175 COMFORTPRO SERVICE MANUAL

A-4

FUSE LOCATIONS

Figure A-2: Fuse Locations

CCU FAN FUSE
250V, 3 AMP

CCU

THERMAL FUSE x2

APU

DC POWER FUSE
12V, 20 AMP

62-11175 COMFORTPRO SERVICE MANUAL

A-5

CIRCUIT BREAKER LOCATIONS

Figure A-3: Circuit Breaker Locations

GENERATOR

35 AMP BREAKER
(MANUAL RESET)

OUTLET BREAKER
(AUTO RESET)

CCU BREAKER
(AUTO RESET)

CCU

62-11175 COMFORTPRO SERVICE MANUAL

A-6

APU CONTROL UNIT

Output Indicators

STARTER – This is the output (+) to the Starter solenoid.

GLOW PLUGS – This is the output (+) to the Glow Plugs.

SOL PULL – This is the output (+) to the Fuel Solenoid Pull windings

(Only on during cranking for the first .5 seconds).

SOL HOLD – This is the output (+) to the Fuel Solenoid Hold windings.

ALT POWER – This is the output (+) to the Alternator field windings.

Input Indicators

OIL – This is the input (-) from the Oil Pressure Switch (NC). You will see

this light illuminated when the oil pressure is below 7 psi. This will shut
the APU off when it is illuminated.

TEMP – This is the input (-) from the Overheat Switch (NO). You will see
this light illuminated when the coolant temperature is above 245°F. This
will shut the APU off when it is illuminated.

ALT F/B – This is the input (-) from the Alternator Charging light. When
the APU is not running this light will be on. When the APU is running and
the Alternator is charging this light will be out (or very dim). This will shut
the APU off when the light is illuminated.

APU

Figure A-4: APU Control Unit

CONTROL

UNIT

STARTER

GLOW PLUGS

SOL PULL

SOL HOLD

ALT POWER

COOLANT

TEMP

ALT F/B

OIL

62-11175 COMFORTPRO SERVICE MANUAL

A-7

Inputs

AC – This is the input from the Driver Control Panel only when it is calling

for Air conditioning. (Low or High A/C.)

HEAT – This is the input from the Driver Control Panel only when it is
calling for Heat. (Low or High Heat.)

FAN LOW – This is the input from the Driver Control Panel only when it is
calling for CCU Low Fan. (Used in Fan, A/C, and Heat modes.)

FAN HIGH – This is the input from the Driver Control Panel only when it is
calling for CCU High Fan. (Used in Fan, A/C, and Heat modes.)

*Outputs

OUTLET – This is the output signal to the Power Outlet relay. It is On any

time 120 VAC Power is available to the Outlet. If High Heat mode is selected
the Outlet will be turned off.

LOW HEAT – This is the output signal to the Low Heat relay. It is On any
time Low Heat is called for.

**COMPRESSOR – This is the output signal to the A/C Compressor relay.
It is On any Time the A/C is called for. (Low or High.)

**CONDENSER – This is the output signal to the Condenser Fan relay. It is
On any Time the A/C is called for. (Low or High.)

LOW FAN – This is the Output signal to the CCU Low Fan relay. It is On any
time the CCU Low Fan is called for. (Used in Fan, A/C, and Heat mode.)

HIGH FAN – This is the Output signal to the CCU High Fan relay. It is On any
time the CCU High Fan is called for. (Used in Fan, A/C, and Heat modes.)

HIGH HEAT – This is the output signal to the High Heat relay. It is On any
time High Heat is called for. High Heat and Outlet can not be on at the
same time.

Service Light

If yellow Service Light is illuminated, reprogram or replacement of CCU
board may be required.

*NOTE: Outputs only indicate the signal to turn the component relay on.
They do not indicate that the actual component itself is working.

**NOTE: Air Conditioning is a sequence start. CCU fan will come on first,

0.5 seconds later the Condenser Fan will come on, and 0.5 seconds after
the Condenser fan the A/C Compressor will come on.

CCU CONTROLLER

Figure A-5: CCU Controller

NOTICE

Yellow Service Light will flash when
CCU is OFF.

62-11175 COMFORTPRO SERVICE MANUAL

A-8

1. Start the APU with the APU Test Switch Module. If APU fails to start,
crank in 15 second bursts until fuel system is purged of air and APU
starts and runs smoothly.

FUEL SYSTEM PURGE
PROCEDURE

FUEL FILTER

Figure A-6: Fuel Filter

OPEN TO BLEED THE
FUEL SYSTEM

62-11175 COMFORTPRO SERVICE MANUAL

A-9

1 Ensure that the coolant supply valve to the APU (located at the truck

engine) and the coolant return valve to the APU (also located at the
truck engine) are open.

2 Release pressure from coolant system.

3 Remove the truck engine radiator cap.

4 Top up the coolant if necessary in the expansion tank.

5 Run the truck engine at fast idle until 185°F (85°C)is reached on truck

temperature gauge. This

should

purge most of the air out of the APU.

6 Purging Air From the Coolant.

• Place thermostat drain hose into bucket (see Figure A-7).

• Open the thermostat bleed valve, using a wrench, and let any trapped
air escape until a steady stream of coolant flows from the valve.

• Close thermostat bleeder fitting.

• Top up the coolant if necessary in the truck expansion tank.

• Run the truck engine at fast idle for another 10 minutes to continue
purging air.

COOLANT PURGE PROCEDURE

Figure A-7: Drain Hook-up

THERMOSTAT

DRAIN HOSE

1/2"

WRENCH

BLEEDER VALVE

OPEN 1/4–1/2 CCW

62-11175 COMFORTPRO SERVICE MANUAL

A-10

7 Start the APU by following the instructions on page 1- 3 (Multi-Function

Driver Control Panel).

8 With the APU and truck engines running, open the thermostat bleed

valve and let any trapped air escape until a steady stream of coolant
flows from the valve.

9 Shut the truck engine off.

10 Check the truck engine; ensure it is getting hot coolant from the APU.

If it is not, the APU is not purged of all its air. Stop APU by following
the instructions on page 1- 3 (Multi-Function Driver Control Panel).
Check for a restriction (i.e. valves/kinks etc.) and repeat steps 5 to 9.

11 Let APU run for at least 30 minutes. During this time keep checking

for signs of coolant leaks, fuel leaks and overheating.

12 Top up the coolant if necessary in the truck expansion tank and

replace the truck engine radiator cap.

13 Clean up any spilled coolant from inside APU and on the ground.

62-11175 COMFORTPRO SERVICE MANUAL

A-11

DEFROST/HEAT & DCP SENSOR

T(°C) T(°F)

RESISTANCE Ω

15 59 157.6

(kΩ)

16 61 150.4

(kΩ)

17 63 143.5

(kΩ)

18 64 137.1

(kΩ)

19 66 130.9

(kΩ)

20 68 125.1

(kΩ)

21 70 119.6

(kΩ)

22 72 114.3

(kΩ)

23 73 109.3

(kΩ)

24 75 104.5

(kΩ)

25 77 100.0

(kΩ)

26 79 95.7

(kΩ)

27 81 91.6

(kΩ)

28 82 87.7

(kΩ)

29 84 84.0

(kΩ)

30 86 80.5

(kΩ)

31 88 77.1

(kΩ)

32 90 73.9

(kΩ)

33 91 70.9

(kΩ)

34 93 68.0

(kΩ)

35 95 65.2

(kΩ)

36 97 62.5

(kΩ)

37 99 60.0

(kΩ)

38 100 57.6

(kΩ)

39 102 55.3

(k

Ω)

40 104 53.1

(kΩ)

41 106 51.0

(kΩ)

42 108 49.0

(kΩ)

43 109 47.1

(kΩ)

44 111 45.3

(kΩ)

45 113 43.5

(kΩ)

46 115 41.9

(kΩ)

47 117 40.3

(kΩ)

48 118 38.7

(kΩ)

49 120 37.3

(kΩ)

50 122 35.9

(kΩ)

Temperature vs.
Resistance Chart

62-11175 COMFORTPRO SERVICE MANUAL

A-12

ENGINE INTERLOCK (PG1011)

High Side Switching

Low Side Switching

NOTE:

1 Relay is supplied by end user.

2 Ground connections MUST be common with APU controller.

APU Controller Pin 9

Wired to engage when truck ignition on

LS1

5

3

4

1

2

RELAY SPDT

APU Controller Pin 9

Wired to engage when truck ignition on

12V

LS2

5

3

4
1
2

RELAY SPDT

62-11175 COMFORTPRO SERVICE MANUAL

A-13

APU WIRING DIAGRAM (Serial No.s KZX98002290 to Date)

CLIMATE CONTROL UNIT (CCU)VEHICLE SLEEPERAUXILLARY POWER UNIT (APU)

Carrier Transicold Division,
Carrier Corporation
Truck/Trailer Products Group
P.O. Box 4805
Syracuse, N.Y. 13221 U.S A

www.carrier.transicold.com

North America

Carrier Transicold
700 Olympic Drive
Athens, GA 30601 USA
Tel: [phone]
Fax: 1 --706--546--5207

Mexico and
Central America

Ejercito Nacional No. 418
Piso 9, Torre Yumal
Col. Chapultepec Morales
11570 Mexico, D.F.
Tel: [phone]
Fax: [phone]

A member of the United Technologies Corporation family. Stock symbol UTX
©2006 Carrier Corporation • PrintedinU.S.A.0706