Peterbilt ComfortClass Operator's Manual
Quick Table of Contents
Introduction ..................................................................................................... 1
Electric Power System.................................................................................... 7
Heating and Air Conditioning System......................................................... 25
Troubleshooting............................................................................................ 41
PART 1: INTRODUCTION Safety Signals
Figure -1
PART 1: INTRODUCTION
Safety Signals
A number of alerting messages are in this manual. Please
read and follow them. They are there for your protection
and information. These messages can help you avoid
injury to yourself and your passengers, and help prevent
costly damage to the vehicle.
Key symbols and “signal words” are used to indicate what
kind of message is going to follow. Pay special attention to
instructions prefaced by symbols and signal words
“WARNING,” “CAUTION,” or “NOTE.” Please do not ignore
any of these alerts.
Figure -2
When you see this symbol and word, the message that follows is especially vital. This signals something that can
cause injury or even death. This message will tell you what
the hazard is, what can happen if you don’t heed the warning, and how to avoid it. For example:
Figure -3
Figure -4
WARNING:
WARNING! Do not carry additional fuel containers in your vehicle. Fuel containers, either
full or empty, may leak, explode, and cause or
feed a fire. Do not carry extra fuel containers.
Even empty ones are dangerous.
Figure -5
Figure -6
CAUTION:
This symbol and word signals something that could damage your vehicle. For example:
Figure -7
CAUTION: Continuing to operate your vehicle
with insufficient oil pressure will cause serious
Figure -8
engine damage.
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Safety Signals PART 1: INTRODUCTION
NOTE:
Figure -9
Gives you information we feel you would like to
have. It could have to do with care of your vehi-
i
cle or with driving more efficiently. For example:
Figure -10
NOTE: Pumping the accelerator will not assist in
starting the engine.
i
Figure -11
Please take the time to read these messages when
WARNING!
Something that could cause an injury or even death.
CAUTION:
Something that could cause damage to your vehicle.
NOTE:
Useful information.
you see them, and remember:
– 2 – Y53-6017 R(09/07)
PART 1: INTRODUCTION The Peterbilt ComfortClass™ System
The Peterbilt ComfortClass™ System
This system utilizes a sleeper air conditioning system and
diesel fuel-powered sleeper heater that are compliant with
anti-idling requirements. The sleeper air conditioning system provides up to 10 hours of engine-off cooling in typical
conditions
vehicle is driven or by shore power and requires approximately 4-6 hours of recharging depending upon outside
conditions. The cold air for the air conditioning system
comes from a Storage Cooler that is located behind the
sleeper. It stores the system’s cooling capacity by freezing
water. As the system is used, the ice melts back into water
and needs to be recharged (frozen) again by the Air Conditioning Charge Unit.
The system is powered by an energy-efficient ComfortClass System Battery Box that includes four deep-cycle
AGM batteries and is outfitted with 2000 watt, 12 VDC/120
VAC inverter. The system includes a 20 amp shore power
capability with a 25-foot shore power cable and includes
ComfortClass System battery charging capability while on
shore power.
The system has an enhanced charge/start capability that
includes two 1000 CCA dedicated Starter Batteries in the
*
. The air conditioning system recharges as the
starter battery box, a starter battery charger and a 185A
alternator with remote voltage regulator located in the
ComfortClass System Battery Box. The voltage regulator is
optimized and pre-programmed with a specific charge profile for optimal charging of the deep-cycle batteries that
increases the deep-cycle battery life.
An enhanced insulation package includes upgraded
sleeper in-wall insulation. Interior features include the following:
• Floor insulation,
• A cab dash-mounted A/C charge enable switch,
• Two 120 VAC, GFCI (ground fault circuit interruption)
duplex outlets in passenger side closet and under
driver side bunk,
• A dedicated sleeper control panel with diagnostic feedback, via “blink” codes (status of HVAC modes,
inverter modes, alerts, etc.),
• Sleeper fresh or recirculated air intake, and
• A premium-grade dust and pollen filter readily accessible under sleeper bunk.
*
Overall performance may vary depending on conditions described on page 33.
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The Peterbilt ComfortClass™ System PART 1: INTRODUCTION
System features include:
• Engine-off sleeper heating, cooling, and 120-Volt AC
power.
• No engine noise or vibration.
• Decrease in overall fuel consumption.
Figure -12
NOTE: This system is NOT designed to cool a
hot sleeper. Use the vehicle’s air conditioner to
i
pre-cool the sleeper to at least 75°F prior to turning on the ComfortClass System air conditioner.
The system can then be used to maintain that
temperature.
Figure -13
NOTE: The system is designed to maintain the
interior sleeper temperature around 75°F for a
i
period of up to 10 hours
outside temperature of 95°F, a relative humidity
of 50%, and with the sleeper not in direct sunlight. The sleeper environment must be
pre-cooled to 75°F by the air conditioner prior to
use of the system. The system is NOT designed
to maintain sleeper temperatures under
extremes of heat or direct sunlight. You may
need to supplement the ComfortClass System by
operating the vehicle’s air conditioner if the ComfortClass System is unable to maintain the
desired temperature level.
* Overall performance may vary depending on conditions
described on page 33.
This Operator’s Manual contains useful information for the
safe and efficient operation of your ComfortClass System.
All information contained in this manual is based on the latest production information available at the time of publication. Peterbilt Motors reserves the right to make changes at
any time without notice.
*
, based on maximum
– 4 – Y53-6017 R(09/07)
PART 1: INTRODUCTION The Peterbilt ComfortClass™ System
Location of Components
Figure 1
Air Handler
(Under Lower Bunk)
uel-Fired Heater
F
(in passenger’s side
toolbox)
Enhanced Insulation
High Output Alternator
Air Conditioning
Starter Batteries
Disconnect Switch
ComfortClass System
Battery Disconnect Switch
Charge Unit
Shore Power Connector
ComfortClass System
Battery Box
Starter Batteries
Figure 2
Circuit Breaker Box
(located in driver’s side toolbox)
Storage Cooler
(Behind Sleeper)
ComfortClass System Batteries
PB00001
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The Peterbilt ComfortClass™ System PART 1: INTRODUCTION
g
Location of Components
Figure 3
Sleeper Control Panel
(located in Sleeper)
Fan Control Dial
(Page 26)
Temperature Control Dial
CHARGE
(Pages 29 & 32)
Air Conditioner Pump
ON Lamp (Green)
(Page 26)
OFF
Charge/Enable Switch
(located on cab dash)
Inverter/Charger Lamp
(Page 37)
(Page 19)
Shore Power Lamp
NORMAL
(120-Volt AC)
(Page 19)
Air Conditioning/Heating
Switch
(Pages 29 & 32)
Inverter/Charger Switch
(Page 18)
Figure -14
OFF/RESET
Sleeper Fresh/Recirculation Air
Switch
(Pa
e 27)
PB00002
– 6 – Y53-6017 R(09/07)
PART 2: ELECTRIC POWER SYSTEM Charging/Jump-Starting Instructions
Figure -15
PART 2: ELECTRIC POWER SYSTEM
Charging/Jump-Starting Instructions
Figure -16
Figure -17
Figure -18
WARNING! The electrical charging system
used for the ComfortClass System is different
from normal charging systems. Failure to
adhere to the proper charging or jump-starting
procedures could lead to death or serious
injury, damage to the Inverter/Charger or vehicle damage. Follow the Charging/Jump-Starting Instructions on page 10.
NOTE: The charging/jump-starting instructions
can also be found on the top of the ComfortClass
i
System Battery Box cover.
Figure -19
Starter Batteries
Figure -20
ComfortClass System
Batteries
PB00006A
Vehicles equipped with the ComfortClass System have
battery configurations that are different from traditional
vehicles. These vehicles have a dedicated set of batteries
in addition to the Starter Batteries. These batteries are
referred to as the “ComfortClass System Batteries.” These
batteries provide power to the vehicles’ electrical demands
including on-board computers and the starting batteries.
The starter is the only electrical device that does not
depend on the ComfortClass System Batteries. The schematic on page 9 is provided to help illustrate the system.
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Charging/Jump-Starting Instructions PART 2: ELECTRIC POWER SYSTEM
Figure -21
NOTE: Do not attempt to jump-start the vehicle
without first reading the instructions on top of the
i
ComfortClass System Battery Box cover. If you
have a battery problem, it is best to contact an
authorized repair facility or a reputable towing
service. When you do, inform them of the charging instructions on page 10 and the wiring schematic on page 9. These instructions can also be
found on the top of the ComfortClass System
Battery Box cover.
– 8 – Y53-6017 R(09/07)
PART 2: ELECTRIC POWER SYSTEM Charging/Jump-Starting Instructions
Figure 4
Wiring Schematic
Figure 5
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Charging/Jump-Starting Instructions PART 2: ELECTRIC POWER SYSTEM
The ComfortClass System Batteries are located in the
ComfortClass System Battery Box behind the sleeper, on
the driver’s side. They power all electrical systems on the
vehicle EXCEPT the starter motor.
Figure -22
NOTE: Because the ComfortClass System Batteries power the engine controls and starter
i
relay, you may experience a no-crank condition if
the ComfortClass System Battery voltage is
below 9.5-Volt, even though the Starter Batteries
are fully charged.
Figure -23
NOTE: A DC/DC charger, also located below
the cab on the driver’s side, serves to isolate the
i
starting batteries from the ComfortClass System
Batteries and provides charge to the starting batteries to maintain them at a minimum of 12-Volt.
Figure -24
NOTE: The DC/DC charger will only be activated when either the truck is running or the
i
truck is attached to a shore power electrical supply and the key is in the IGN or ON position.
Charging/Jump-Starting Instructions
There may be occasions where the vehicle will crank but it
will not start, even after charging the starting batteries
and/or attempting to jump-start the vehicle using normal
procedures found in the Operator’s Manual. You may also
notice that the voltage meter on your dash is below 11
volts, interior lights are dimmed or not on, and the DC outlets have no power.
Figure -25
NOTE: The voltmeter only monitors the ComfortClass System Batteries, not the Starter Batteries.
i
In such situations, the ComfortClass System System Battery voltage has dropped below 9.5 volts. It is necessary to
charge the ComfortClass System System Batteries to
above 11 volts (and ensure that the Starter Batteries are at
12 volts) in order to start the vehicle.
– 10 – Y53-6017 R(09/07)
PART 2: ELECTRIC POWER SYSTEM Charging/Jump-Starting Instructions
Figure -26
Charging Terminals
Shore Power
Connector
Figure -27
PB00032
The ComfortClass System Batteries are located in the
driver’s side frame-mounted box located behind the
sleeper. The batteries can be accessed by removing the
cover plate and connecting a charger to the charging terminals. Turn the battery disconnect switch, on the side of the
ComfortClass System Battery Box, to the “ON” position if
you want to charge the batteries using the charging terminals. Charging these batteries can also be performed by
using the shore power connection on the side of this box.
Please have your ComfortClass System inspected by an
authorized dealer if your ComfortClass System Batteries
continue to drop below 11 volts or if you are unable to start
the vehicle after charging both the starter and the ComfortClass System Batteries.
Refer to “Battery Charging” and “Jump-Starting Vehi-
cles” in the Peterbilt Operator’s Manual for additional bat-
tery charging and jump-starting procedures. Also, refer to
the Troubleshooting Section on page 41 for more
details.
Figure -28
CAUTION: Do not connect any accessories
directly to the starting batteries. This could
Figure -29
drain the batteries to a point where they can no
longer start the engine.
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Charging/Jump-Starting Instructions PART 2: ELECTRIC POWER SYSTEM
Disconnect Instructions
Figure -30
ComfortClass System
Batteries Disconnect
Switch (shown in the
off position)
Shore Power
Connector
ComfortClass System
Battery Box
PB00004
Figure -31
Prior to servicing the vehicle, disconnect the electrical system as follows:
1. Turn air heater off and wait three minutes prior to
turning the disconnect switches to the OFF position
(steps 3 and 4 below). This gives three minutes for
the heater to purge any fuel still in the heater and
allows the unit to cool off.
2. Unplug shore power connection.
3. Turn Starter Battery disconnect to OFF position.
4. Turn ComfortClass System Battery disconnect
located on ComfortClass System Battery Box
(located on driver’s side, rear of sleeper) to OFF
position.
Charging ComfortClass System Batteries using Shore Power
Figure -32
Figure -33
Figure -34
WARNING! Electric Shock Hazard. 120-Volt AC
ComfortClass System
Batteries Disconnect
Switch
Shore Power
Connector
PB00005
power present. This can cause electrical shock
Figure -35
or fire resulting in death, personal injury or
property damage. Only a trained technician
should work on the shore power system. Turn
all battery disconnect switches to the OFF
position and unplug the shore power electrical
supply before servicing any part of the vehicle’s electrical system.
– 12 – Y53-6017 R(09/07)
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