Carrier PC6000 Operation & Service Manual

[Page 1] Carrier PC6000

R 62--11175 Rev -- Operation & Service Manual for ComfortPro ™ Auxiliary Power Unit Auxiliary Power Unit Models PC6000, PC6002, PC6003 & PC6006 ...

[Page 2] Carrier PC6000

62-11175 COMFORTPRO SERVICE MANUAL c-i CONTENTS INTRODUCTION SAFETY Safety Alerts ................................................................................. c-iii Component Layout.................................................................

[Page 3] Carrier PC6000

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 .......................................

[Page 4] Carrier PC6000

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 practi...

[Page 5] Carrier PC6000

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 hazardou...

[Page 6] Carrier PC6000

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 DRIVER CONTROL PANEL (DCP) CLIMATE CONTROL UNIT (CCU) VEHICLE FUEL TANK ...

[Page 7] Carrier PC6000

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] Carrier PC6000

62-11175 COMFORTPRO SERVICE MANUAL c-vii 16.2" 15.2" 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 VIE...

[Page 9] Carrier PC6000

62-11175 COMFORTPRO SERVICE MANUAL c-viii ...

[Page 10] Carrier PC6000

62-11175 COMFORTPRO SERVICE MANUAL 1-1 1.0 OPERATION OF MULTI-FUNCTION DRIVER CONTROL PANEL Figure 1-0: Multi-Function Driver Control Panel APU ON/OFF HVAC OFF ESC/ RESET MENU A/C FAN HEAT HOURS 00000 APU SP 1 2 3 4 5 6 7 8 9 10 11 T 2 T 1 1.1.1...

[Page 11] Carrier PC6000

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 ...

[Page 12] Carrier PC6000

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....

[Page 13] Carrier PC6000

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...

[Page 14] Carrier PC6000

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...

[Page 15] Carrier PC6000

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 aga...

[Page 16] Carrier PC6000

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 cann...

[Page 17] Carrier PC6000

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 ma...

[Page 18] Carrier PC6000

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 . TIMER 1 OFF SET START OFF HOURS 00000 APU T1 If "ENTER PASSWORD" is ...

[Page 19] Carrier PC6000

62-11175 COMFORTPRO SERVICE MANUAL 1-10 Setting the START TEMPERATURE 1 Press . 2 Press or until "TEMP START" is displayed, then press . TEMP START : SET TEMP OFF -10C 14F OFF HOURS 00000 APU NOTICE Factory Default Temperature Sett...

[Page 20] Carrier PC6000

62-11175 COMFORTPRO SERVICE MANUAL 1-11 Setting the DURATION 1 Press . 2 Press or until "TEMP START" is displayed, then press . TEMP START : DURATION OFF 1.0 hrs OFF HOURS 00000 APU TEMP START OFF SET DURATION OFF HOURS 00000 APU NO...

[Page 21] Carrier PC6000

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 . BATTERY MONITOR OFF ON OFF HOURS 00000 APU If "ENTER PASSWORD" is displa...

[Page 22] Carrier PC6000

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 nitroge...

[Page 23] Carrier PC6000

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, muffl...

[Page 24] Carrier PC6000

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. • Harn...

[Page 25] Carrier PC6000

62-11175 COMFORTPRO SERVICE MANUAL 2-4 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 ...

[Page 26] Carrier PC6000

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 D...

[Page 27] Carrier PC6000

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 ...

[Page 28] Carrier PC6000

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 • ...

[Page 29] Carrier PC6000

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 ...

[Page 30] Carrier PC6000

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 ...

[Page 31] Carrier PC6000

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 Lo...

[Page 32] Carrier PC6000

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" • ...

[Page 33] Carrier PC6000

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 • In...

[Page 34] Carrier PC6000

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 • ...

[Page 35] Carrier PC6000

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 : ...

[Page 36] Carrier PC6000

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/...

[Page 37] Carrier PC6000

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 ...

[Page 38] Carrier PC6000

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 ...

[Page 39] Carrier PC6000

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 adjustin...

[Page 40] Carrier PC6000

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 capacit...

[Page 41] Carrier PC6000

62-11175 COMFORTPRO SERVICE MANUAL 3-16 ...

[Page 42] Carrier PC6000

62-11175 COMFORTPRO SERVICE MANUAL A-1 APPENDICES CAPACITIES AND SPECIFICATIONS .................................................... A-2 FUSE LOCATIONS ............................................................................ A-4 CIRCUIT BREAKER...

[Page 43] Carrier PC6000

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 an...

[Page 44] Carrier PC6000

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...

[Page 45] Carrier PC6000

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] Carrier PC6000

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] Carrier PC6000

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 ...

[Page 48] Carrier PC6000

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 ...

[Page 49] Carrier PC6000

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 OPEN TO BLEE...

[Page 50] Carrier PC6000

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 R...

[Page 51] Carrier PC6000

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 unti...

[Page 52] Carrier PC6000

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 (k�...

[Page 53] Carrier PC6000

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. LS1 RELAY SPDT 3 5 4 1 2 Wired to engage when ...

[Page 54] Carrier PC6000

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) ...

[Page 55] Carrier PC6000

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: 1--706--546--6469 Fax: 1--7...