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Installation, Service, and Operator’s Manual

For HP2000 Auxiliary Power Unit

Quality Without Compromise!

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Содержание HP2000 XTREME Series

Страница 1: ......

Страница 2: ...2 Page ...

Страница 3: ...ired Tools Checklist 18 Step 1 Mounting the APU 19 Step 2 Evaporator System and Duct Hoses 20 Step 3 A C Line Installation 2 2 Step 4 A C System Vacuum and Charge 2 3 Step 5 Fuel Draw Tube Installation 24 S tep 6 Connecting Battery Cables 26 Step 7 Water Connections 27 Step 8 Controller And Ductwork Installation 3 0 Step 9 System Prime and Safety Check 33 Step 10 Initial Start 34 System Components...

Страница 4: ...esponsibility 53 Specification s 55 Warranty Registration Card 56 Installation Service and Operator s Manual Form 57 Other Provisions 58 Warranty Coverage Table 59 Perkins Engine Coverage 60 HP2000 APU Scale 61 2 Cyl Perkins Cross References 62 A C Components Diagram 63 Maintenance Components Diagram 64 Component Notes 65 Contact Information 66 4 Page ...

Страница 5: ...ency or suitability of any technical or other information provided in its manuals or other documentation B Assumes no responsibility or liability for injury losses damages costs or expenses whether special direct indirect consequential or incidental which might arise out of the use of such information The use of any such information will be entirely at the user s risk 5 Page ...

Страница 6: ...on information Rev G February 2021 Manual Product Number PCM002 01 Contact Information 15460 CRABTREE SCHOOL RD MARION IL 62959 OFFICE PHONE 618 997 9608 OFFICE FAX 618 997 9608 https www hp2000apu com 6 Page ...

Страница 7: ...ies Auxiliary Power Unit Your fuel and maintenance savings begin today As you may already know the HP2000 consists of a powerful yet lean 2 Cyl Perkins Tier 4 Final California Compliant Diesel Engine along with our patented heat pump system to keep you warm cool and powered up 7 Page ...

Страница 8: ...se invoice Extended warranties are available and can be acquired by contacting the Parks Industries LLC office at 618 997 9608 To find the nearest Authorized Warranty Repair Center for your engine please visit the Perkins website at www perkins com and follow the provided instructions Even though Parks Industries offers parts and items for sale they can t be used for PERKINS warranty purposes and ...

Страница 9: ... only covered if a covered component fails and the refrigerant is lost at which point they are reimbursed as outlined in the SRT Guide Parks Industries LLC does not pay miscellaneous supplies and or Hazardous Material Charges Freon however is covered at 0 78 per ounce a complete fill is 29 6 ounces or 1 85lbs only if the leak was caused by manufacturing defect not by normal wear and tear Make your...

Страница 10: ...ion 3 You must promptly notify Parks Industries LLC of all Warranty Claims 4 You must perform the Scheduled Maintenance on your APU and the Perkins Engine as listed in this Manual 5 You must bring the APU to Parks Industries LLC or to one of their Authorized Service Centers for Warranty Work 6 Parks will not pay for down time or any consequential damages 7 APU s must be Installed by an Authorized ...

Страница 11: ...egistration Form and the Installation Service and Operator s Manual Form your HP2000 is not covered under warranty It is important that you register your APU within fifteen 15 days of having your unit purchased and installed and have a copy of your registration card with the unit 11 Page ...

Страница 12: ... the HP2000 Xtreme Series APU by Parks Industries The patented design of the HP2000 and the HP2000 Xtreme s unique features set it apart from any other unit currently available on the market today It provides solutions to many of the problems faced by the transportation industry on a daily basis yet reduces the overall costs 12 Page ...

Страница 13: ...r Pay close attention to instructions and use common knowledge during maintenance procedures to prevent unnecessary accidents and injuries 13 Page THIS SYMBOL IS USED TO CALL YOUR ATTENTION TO SAFETY PRECAUTIONS THAT SHOULD BE FOLLOWED BY THE OPERATOR AND MAINTENANCE PERSONNEL TO AVOID CARELESS ACCIDENTS WHEN YOU SEE THIS SYMBOL BE SURE TO OBSERVE AND FOLLOW THESE PRECAUTIONS BE CERTAIN THAT ANYON...

Страница 14: ...b you are performing with the machine Such equipment may include hard hats safety shoes ear protectors reflective clothing safety goggles heavy gloves etc as well as safe work clothing Do not wear rings watches jewelry or other loose or hanging apparel that can catch on moving parts while servicing the machine The APU should only be operated or serviced by those who are qualified responsible and d...

Страница 15: ... being near the battery Additionally do not lay tools or other conductive materials on the battery where they may cause short circuits and sparks Use extreme caution when removing the radiator cap Stop the engine and let it cool off before removing the cap When removing the cap loosen it very slowly and avoid pressurized steam that might be in the radiator Coolant may be added ONLY when the engine...

Страница 16: ... immediate medical attention Exercise extreme caution when working near fuel or flammable substances Moving parts can cause severe injury and or death Before working on any unit shut it off and make sure that the power supply is disconnected If the power supply is not disconnected the unit could automatically start up without warning This could cause serious injury It is not recommended for the AP...

Страница 17: ... more than one inch Also make sure you have the necessary space available under the bunk for the evaporator unit and cable pass through Before you get started un package your new system and all components Inspect all components to make sure they were not damaged during shipping Examine your truck thoroughly both inside and out to locate the best place to mount the APU The diesel engine A C compone...

Страница 18: ...drive ratchet with 15 16 socket Tubing cutter 5 16 Nut Driver 15 16 wrench 3 hole saw 3 8 Drive Ratchet Hose cutter 3 hole saw Wire Ties 4 hose clamps Battery cable end crimper Drill 7 16 wrench Teflon tape Shop Vac 9 16 wrench 1 5 8 Hole Saw Cut Off Wheel Crescent wrench Lift cart or fork truck R134 A Refrigerant Channel locks Torque Wrench nut driver A C Machine ADDITIONAL TOOLS MAY BE REQUIRED ...

Страница 19: ...frame rail Check the back of the APU to ensure the bolt holes align with the top and bottom of the frame rail Slide the patented low pro mounting blocks onto the top frame rail the two blocks will mount to the bottom of the frame MAKE SURE THAT THE MOUNTING BLOCKS DO NOT INTERFERE WITH AIR LINES OR WIRING INSIDE THE FRAME RAIL After confirming that the APU is level tighten the mounting bolts to 80...

Страница 20: ... the A C hoses and power supply cable you will need a 3 inch hole in the floor directly beneath the hose connection side of the evaporator Once the install location has been determined check underneath the cab to be sure that there are no supports wires hoses cables or beams where the three inch hole must be cut This hole will serve as a pass through for cables and hoses for the evaporator system ...

Страница 21: ...cure it using the self tapping screws Reposition the evaporator so that the drain tube is inserted into its own hole as to allow the passing of condensation to the outside of your truck Secure the evaporator to the floor using four self tapping screws Some trucks may not have a return air supply If this is the case return air holes will need to be cut to allow air back to the evaporator Most truck...

Страница 22: ...the bottom fitting on the evaporator and connect the 5 16 line supply to the check valve Connect the 13 32 return hose to the other valve Once connected tighten the fittings Be sure not to over tighten fittings as this will damage the O Rings Cable tie all hoses and wires to the frame up and out of the way IMPORTANT DO NOT OVER TIGHTEN THE A C LINES AS DAMAGE TO O RINGS MAY OCCUR IMPORTANT BE CARE...

Страница 23: ...MPORTANT IT IS IMPORTANT TO PULL THE VACUUM AT THIS POINT IN THE INSTALLATION AS IT ALLOWS YOU TO CONTINUE WITH THE INSTALL WHILE THE SYSTEM CHECKS FOR LEAKS THIS IS IMPERATIVE IN KEEPING TO YOUR 4 6 HOUR INSTALL TIME Once the system has passed the leak test it is time to charge the A C system Be sure to use R 134a refrigerant Charge the system by adding 1 85 lbs of R 134a to start then adjust bas...

Страница 24: ...order to provide fuel supply return and tank venting to the APU It is important that you DO NOT tie into existing truck fuel lines Locate the existing truck s fuel tank vent cap Remove the cap from the tank Use Teflon thread tape install and screw in the fuel block assembly 24 Page ...

Страница 25: ...ses onto the barbs of the fuel draw tube using the worm gear clamps or oetiker clamp supplied Connect the fuel supply and return to the correct barbs on the APU The top fitting is the return and the bottom fitting is the supply Reversing the two fuel lines will not allow fuel to reach the APU Tighten all hose connections using a worm gear clamp or oetiker clamp IMPORTANT When installing the fuel b...

Страница 26: ...ble to the truck s battery bank Cable tie all slack during this process Be extra careful to not let the cables rest on or come in contact with any moving parts This could cause a short in the future Prior to connecting the cables to the batteries to the APU install the included MRBF fuse onto one of the positive posts on the battery This will be the APU power supply and truck charge supply This fu...

Страница 27: ...tures can exceed 150 F so be cautious when working with coolant lines to avoid burns Lift the truck hood take note of the current truck coolant level In connecting this APU you will need to add approximately two gallons of coolant to make up for the additional coolant line volume Locate the coolant supply and coolant return lines at the main truck engine If unsure check the temperature The return ...

Страница 28: ...uld cause the APU to overheat Connect the supply water line to the bottom fitting on the APU and tighten it to the water barb using the included worm gear hose clamps Remember which line you selected for supply and which line for return Connect the return water line to the top fitting on the APU and tighten it to the water barb using the included worm gear hose clamps Route the hoses to the front ...

Страница 29: ...with a hose clamp on each side o Tighten the two hose clamps o Install a worm gear hose clamp and connect the APU coolant hose to the clamp o Tighten the worm gear hose clamp Once this has been completed for both Y s check that the hoses and clamps are tight and then remove the hose crimpers 29 Page ...

Страница 30: ...flow Failure to do so will lead to inaccurate temperature readings and poor performance Make sure that the location selected for the controller 1 Has a clear path to route the control cable 2 Provides a flat surface for mounting 3 Has decent air flow Secure the APU controller to the flat surface using the short self tapping screws Be careful not to drill into any other wires or obstacles 30 Page ...

Страница 31: ...ight if possible Track the cable back to the evaporator box Push the round APU end of the controller through the floor collar From the outside of the truck pull enough slack to reach the APU Cable tie the control cable up and out of the way being sure to leave enough length to reach the APU without leaving too much additional slack Connect the power supply to the evaporator as shown in the figure ...

Страница 32: ...ed 1 Use the 3 hole saw to cut the holes where the vents will be located Do not cut this hole larger than 3 the vents will not fit correctly 2 Use a 3 hole saw to cut the holes that the ducting will pass through Holes must be 3 3 is not large enough for duct hose to pass through 3 Connect each of the duct hoses to the evaporator and tighten all the hose connections using the included 3 worm gear c...

Страница 33: ...IMING THE WATER PUMP It is necessary to run the truck engine for a period of at least five minutes in order to prime the APU water pump Not doing so could cause the APU to overheat causing serious and permanent damage I MPORTANT TO SPEED THE PRIMING PROCESS YOU MAY REMOVE THE SUPPLY LINE BOTTOM HOSE FROM THE APU UNTIL YOU SEE ENGINE COOLANT START TO FLOW FROM IT IF YOU USE THIS METHOD TO PRIME THE...

Страница 34: ...r in the fuel lines If this is the case unplug the controller and bleed any air out of the fuel filter by unscrewing the top screw and allowing air to escape Allow the APU to run for 30 minutes to guarantee that the system is working properly Check thoroughly for any water leaks or cable wear If any other issues are encountered during the initial startup check the troubleshooting guide for a solut...

Страница 35: ...ts and the Electrical Controls This unit is typically mounted on the Frame Rail of the truck or on the Catwalk located directly behind the Cab A C lines water lines fuel lines and power supply lines must all be routed to the APU in order to provide its heating cooling and battery charging capabilities 35 Page ...

Страница 36: ...where inside of your cab and provides hot or cold air depending on your needs Typically the evaporator is mounted underneath the bunk A C lines and a power supply will need to be routed from the evaporator to the APU to supply heating and cooling 36 Page ...

Страница 37: ...l which will allow the APU to heat or cool as necessary without any additional user input There s no computer required and in the event of a problem your APU Commander will alert you with an easy to read problem report and description as well as remind you when it needs to be serviced All errors are saved in an easy to access log giving the APU total transparency and history when taking it to a re...

Страница 38: ...e modes press Start and select the desired mode More details on each mode as well as other settings can be found in this section S TOP B ACK M ORE AND S ETTINGS B UTTONS A button labeled MORE and STOP will be displayed at all times during APU operation SETTINGS however will only be displayed when the APU is in the OFF mode 38 Page ...

Страница 39: ...Always High Always indicates the evaporator fan will run continuously during climate control mode similar to a fan on setting in your home thermostat Pressing Calendar Start will enter the calendar start setup screens See the Calendar Start section for complete instructions Press Status to display APU status details and access the error log See the Status section for complete instructions 39 Page ...

Страница 40: ...utton will be green Press the MODE button to cycle through the mode you wish to resume Whenever activated the setting that was last used for this feature is what will be recalled For example if you select Climate Control as the calendar start mode and you last had climate control set to hold at 70 F when the calendar start is initiated the temperature will again be at 70 F This holds true for sett...

Страница 41: ...play heating cooling running or charging depending on the current function Mode displays the function currently in use APU hours displays the total engine hours on the APU Oil Hours displays the number of hours since the timer has been reset and the oil has been changed Firmware Version is displayed here To update the firmware version see the Firmware Update section 41 Page ...

Страница 42: ...events as well as some of the external conditions when the event occurred The error log can be exported to a USB drive in order to have a diagnosis performed at a remote location To do so insert a USB memory drive into the USB slot on the right side of the controller and select Export The APU will read Done in the top right hand corner once this is complete Press page up and page down to navigate ...

Страница 43: ...rature units and update the firmware S ET T IME AND DATE To adjust the time and date depress each value to advance it Once you have reached the correct time and date press Back to save your settings and return to the previous screen S ET T EMP To select between Celsius and Fahrenheit tap the symbol to alternate it 43 Page ...

Страница 44: ...to stop the APU Press More to access more settings B ATTERY M ONITOR Battery monitor mode is used in situations where battery charging is needed but A C or heating is not Using this mode the APU will maintain the battery voltage above a set point If the voltage drops below this point the APU will provide a charge for a period of 30 minutes At the end of the cycle the APU will begin monitoring agai...

Страница 45: ...t All these error messages come with a short troubleshooting guide built directly into the controller The errors that can be displayed are as follows Low Oil Pressure High Engine Temperature Low Battery AC Low Pressure Failure AC High Pressure Failure Starting Failure Standby Engine Stalled Low Engine RPM No RPM 45 Page ...

Страница 46: ...will not start Error displays on screen Low Oil Pressure Fuel Supply clogged Fuel filter dirty Blown Fuse Oil Level Low Check that the fuel lines are clear and that the filter is not clogged Check the fuse panel for any blown fuses Make sure the engine has the proper amount of oil APU engine shut down Error displays on screen High Engine Temp The engine is overheated Check the truck s coolant line...

Страница 47: ...h A C Pressure Fault High head pressure Fan is turning in the wrong direction or not working Check condenser and evaporator for air restriction Make sure the condenser fan is running If not check or replace the fuse If the fan is not functioning contact a service center near you Make sure the operating pressures are correct A C System Maintenance Error displays on screen Low A C Pressure Fault Low...

Страница 48: ...y leaks loose bolts and or worn belts and service your APU accordingly as these are not covered under warranty T YPICAL I NSPECTION After the initial break in period it is important to check all A C connections Although the unit is leak tested at the factory heat and vibration can loosen certain components over time Most A C leaks are the result of loosened components In addition all fluid levels ...

Страница 49: ...r loose fittings loose connections or signs of fuel coolant or A C system leaks X X Check power cable connections at the battery bank APU starter and alternator Look for excessive corrosion or loose connections X X Check the muffler clamps and the frame mounts for tight fit X X Check tighten the isolator compressor and cabinet bolts X Check the alternator and the compressor belt tensions adjust or...

Страница 50: ...aintenance on these items will void warranty 50 Page Interval Between Maintenance Break In Period 50 hrs after initial start Every 600hrs Check the air filter and clean or replace it as needed X Check and or Replace the fuel filter X X Using a low pressure water hose clean debris from APU cabinet X Clean condenser fins from both directions Use only low pressure water X ...

Страница 51: ...oil Only use a maximum of 6oz of pag 46 oil when servicing this unit Evaporator and condenser coils must be inspected and cleaned regularly Recommended operating pressures Note Readings will be affected by ambient temperatures A C Mode Low side 12 15psi High side Ambient Temperature multiplied by 2 and then add 50 Doors and windows need to be closed and readings should be taken 20 minutes after th...

Страница 52: ...uses use your fingers to press the release latches on both sides of the box and slowly pull out The inside of the fuse box should have a list of all the fuses in order from left to right If the readout is illegible please consult the table below FUSE BOX LAYOUT 52 Page Heat Relay Cool Relay Heat Fan Rev Valve 40A Cool Fan Only 40A Evap 40A Comp 40 Fuel Alt 40 Glow 40 Starter 40 Cont GND 2 Cont Pow...

Страница 53: ...pproved modifications 4 As the owner you are responsible for presenting your APU to an authorized service facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time and following the SRT Guide Suggested Repair Time 5 Keep all maintenance records dates receipts and parts used for all warranty claims You may be asked to provide all maintenance record...

Страница 54: ...TO CONTROLLER SERIAL NUMBER All of the information above is required to be on the warranty invoice before it will be submitted for payment Warranty claims can only be manufactured defects and do not cover the cost of shipping In order for any warranty claim to be honored the attached Warranty sheet must be filled out completely and sent to Parks Industries LLC at 15460 Crabtree School Road Marion ...

Страница 55: ...Page APU Engine 402F 05 9 9 HP Engine Oil 2 8 US Quarts 15W 40 Non Synthetic Alternator 60 Amp Weight 310 lbs Dimensions 20 5 x 22 8 x 24 4 BTU s 20 000 from Compressor Refrigerant 1 85 lbs 29 6 oz of R 134A AC System oil capacity 6 oz of PAG 46 ...

Страница 56: ...___________________________ CITY ____________________________________ STATE __________ ZIP ________________ PHONE NUMBER ______________________________________________________________ EMAIL ADDRESS ______________________________________________________________ PURCHASER S INFORMATION PURCHASING COMPANY ___________________________________________________________ COMPANY REPRESENTATIVE _____________...

Страница 57: ...and information contained in this manual and you agree to be bound by the terms conditions warranty and information herein OWNER PURCHASER OR DULY AUTHORIZED REPRESENTATIVE ______________________________________________________________ PRINT NAME ______________________________________________________________ SIGNATURE _____________________________ TITLE _____________________________ DATE 57 Page ...

Страница 58: ...anual sets forth the entire agreement between Parks Industries LLC and the Owner Purchaser and supersedes any other agreement by the parties whether written or oral This Agreement may not be modified except in writing signed by Parks Industries LLC and the Owner Purchaser 58 Page ...

Страница 59: ...R LABOR 12 V EVAP BLOWER 1 HOUR LABOR REVERSING VALVE ASSY 1 HOUR LABOR EVAPORATOR CORE 1 HOUR LABOR A C ADJ REPLACEMENT 1 HOUR LABOR HOSE MANUFACTURER S DEFECT 1 HOUR LABOR TUBE MANUFACTURING DEFECT 1 HOUR LABOR DIAGNOSTIC LABOR 1 HOUR LABOR FREON IS COVERED AT 0 78 PER OUNCE A COMPLETE FILL IS 29 6 OZ OR 1 85 LBS ONLY IF THE LEAK WAS CAUSED BY MANUFACTURING DEFECT NOT NORMAL WEAR AND TEAR ...

Страница 60: ...AGE TABLE IT IS NOT COVERED WEAR TEAR IS NOT A COVERED EXPENSE AT ANY TIME 60 Page For Perkins Engine Warranty Coverage you must contact a Perkins Dealer www perkins com ALL WARRANTY WORK MUST BE DONE AT PARKS INDUSTRIES OR AT A CERTIFIED PARKS INDUSTRIES SERVICE CENTER ...

Страница 61: ...d by Parks Industries LLC The current version of the H2000 and components were weighed on 01 01 2020 The weight of the unit and the material needed for connection to the truck is listed below for each model engine These units were weighed without fluids The scales are certified annually ...

Страница 62: ...ELT COMPRESSOR BELT PARKS INDUSTRIES PCC081 00 PCA037 F1 PCF082 00 PCC049 00 KCC041 01 PERKINS 140517030 130366040 NAPA 7145 6449 3262 25 7300 25 050316 WIX 57145 46449 33262 BALDWIN B37 RS3715 PF937 FRAM PH4386 CA9248 C7516 MITSUBOSHI RECMF 1305 5PK805 DAYCO 15305 5050316 GATES 7300 K050316 ...

Страница 63: ...A C Components Diagram 63 Page ...

Страница 64: ...Maintenance Components Diagram 64 Page ...

Страница 65: ...sure Hose and the Low Pressure Switch is connected to the charging port on the Low Pressure Hose Wiring Harness Notes The Fuse Box located on the Wiring Harness contains all of your APU s fuses and relays including 7 40 AMP Mini Fuses 1 2 AMP Mini Fuse 1 5 AMP Mini Fuse 2 5 Pin Relays and 5 4 Pin Relays PE Valve Notes The Diagram to the right displays which A C components are connected to each of ...

Страница 66: ...P ARKS I NDUSTRIES LLC 15460 Crabtree School Road Marion IL 62959 618 997 9608 www hp2000apu com 66 Page ...

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