Carrier ComfortPro PC6000 User Manual Download

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62--11175 Rev --

Operation & Service Manual

for

ComfortPro

™

Auxiliary

Power Unit

Auxiliary Power Unit

Models PC6000, PC6002, PC6003 & PC6006

Summary of Contents for ComfortPro PC6000

Page 1: ...R 62 11175 Rev Operation Service Manual for ComfortPro Auxiliary Power Unit Auxiliary Power Unit Models PC6000 PC6002 PC6003 PC6006...

Page 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...

Page 3: ...age 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 LOCA...

Page 4: ...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 a...

Page 5: ...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 br...

Page 6: ...nents of the Carrier ComfortPro system and Where They Should Best be Installed on the Truck DRIVER CONTROL PANEL DCP CLIMATE CONTROL UNIT CCU VEHICLE FUEL TANK CONDENSER AUXILIARY POWER UNIT APU BATTE...

Page 7: ...62 11175 COMFORTPRO SERVICE MANUAL c vi GENERAL ARRANGEMENT 18 5 16 0 24 9 2 6 28 5 2 75 3 875 10 5 3 0 TOP VIEW REAR LEFT SIDE APU Dimensions Measurements in inches FRONT VIEW RIGHT SIDE...

Page 8: ...2 3 3 3 1 3 0 1 3 3 4 3 0 6 9 3 0 3 0 6 9 12 6 12 9 125 24 4 23 4 7 9 12 FRONT VIEW BOTTOM VIEW CCU Dimensions Measurements in inches 26 5 24 25 8 3 5 2 0 5 62 5 62 13 93 16 25 16 90 FRONT RIGHT SIDE...

Page 9: ...62 11175 COMFORTPRO SERVICE MANUAL c viii...

Page 10: ...ximum 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...

Page 11: ...en 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 t...

Page 12: ...set the function See page 1 5 HOURS 00000 APU PLEASE WAIT APU STARTING OFF OFF WARNING Do not start the APU when the enclosure cover is removed Operating with the cover off may result in injury and or...

Page 13: ...ng 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 heate...

Page 14: ...otect 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...

Page 15: ...sword again then press to exit this function PROTECT FUNCTIONS with a PASSWORD 1 Press HOURS 00000 APU OFF PASSWORD PROTECT OFF 2 Press or until PASSWORD PROTECT is displayed then press If this menu i...

Page 16: ...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 temperat...

Page 17: ...T1 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...

Page 18: ...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 ca...

Page 19: ...ress 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 speci...

Page 20: ...ied 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...

Page 21: ...ayed 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 displa...

Page 22: ...er 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 syst...

Page 23: ...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...

Page 24: ...e 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 t...

Page 25: ...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 6 C...

Page 26: ...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 rep...

Page 27: ...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 Repai...

Page 28: ...ked 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 Kubot...

Page 29: ...place 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 Repai...

Page 30: ...e 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 Driv...

Page 31: ...oblem 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 re...

Page 32: ...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 Dete...

Page 33: ...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 senso...

Page 34: ...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...

Page 35: ...r 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 rep...

Page 36: ...radually 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...

Page 37: ...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...

Page 38: ...e 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...

Page 39: ...cial 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 m...

Page 40: ...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 connect...

Page 41: ...62 11175 COMFORTPRO SERVICE MANUAL 3 16...

Page 42: ...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 CHA...

Page 43: ...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...

Page 44: ...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...

Page 45: ...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...

Page 46: ...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...

Page 47: ...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 i...

Page 48: ...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...

Page 49: ...he 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 OPEN TO BLEED THE...

Page 50: ...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 valv...

Page 51: ...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 restr...

Page 52: ...9 3 k 24 75 104 5 k 25 77 100 0 k 26 79 95 7 k 27 81 91 6 k 28 82 87 7 k 29 84 84 0 k 30 86 80 5 k 31 88 77 1 k 32 90 73 9 k 33 91 70 9 k 34 93 68 0 k 35 95 65 2 k 36 97 62 5 k 37 99 60 0 k 38 100 57...

Page 53: ...ow Side Switching NOTE 1 Relay is supplied by end user 2 Ground connections MUST be common with APU controller LS1 RELAY SPDT 3 5 4 1 2 Wired to engage when truck ignition on APU Controller Pin 9 LS2...

Page 54: ...62 11175 COMFORTPRO SERVICE MANUAL A 13 APU WIRING DIAGRAM Serial No s KZX98002290 to Date CLIMATE CONTROL UNIT CCU VEHICLE SLEEPER AUXILLARY POWER UNIT APU...

Page 55: ...ier Transicold 700 Olympic Drive Athens GA 30601 USA Tel 1 706 546 6469 Fax 1 706 546 5207 Mexico and Central America Ejercito Nacional No 418 Piso 9 Torre Yumal Col Chapultepec Morales 11570 Mexico D...

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Carrier ComfortPro PC6000, Operation & Service Manual

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