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Carrier TRANSICOLD AspenINT Operation And Service Manual

Auxiliary power unit
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Operation and Service Manual
AspenINT, AspenSTA,
AspenPWR, AspenSKY
Auxiliary Power Unit (APU)
62-12174 Rev E

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  • Page 1 Operation and Service Manual AspenINT, AspenSTA, AspenPWR, AspenSKY Auxiliary Power Unit (APU) 62-12174 Rev E...

  • Page 3: Auxiliary Power Unit (Apu)

    Operation and Service Manual AspenINT, AspenSTA, AspenPWR, AspenSKY Auxiliary Power Unit (APU) © Carrier Corporation, 2024 Printed in U. S. A. June 2024...
  • Page 4 12/13/2023 Section 7: Added Alarm 5100 (AC Check) 2/8/2024 Corrected manual title (AspenINT not Aspen 200 INT) per BM Section 2 - Updated figure 2.6 (Fuse Locations); Section 5 – Updated image page 5- 4/9/2024 3; Section 7 - Added alarm 00013, Updated Corrective Action alarms 00014, 05105,...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS PARAGRAPH NUMBER Page SAFETY ................1–1 SAFETY PRECAUTIONS .
  • Page 6 2.10 COMPRESSOR DATA ............2–10 2.11 REFRIGERATION SYSTEM DATA .
  • Page 7 AUTOMATIC RESTART ............4–2 TEMPERATURE CONTROL .
  • Page 8 Stand Alone ............. 8–12 ENCT .
  • Page 9 8.8.10 Heater Replacement ........... . . 8–59 8.8.11 Evaporator Fan Replacement .
  • Page 10 62-12174...

  • Page 11: Safety

    Safety Safety Precautions Your Carrier Transicold Aspen Auxiliary Power Unit (APU) has been designed with the safety of the operator in mind. During normal operation, all moving parts are fully enclosed to help prevent injury. During all pre-trip inspections, daily inspections, and problem troubleshooting, you may be exposed to moving parts. Please stay clear of all moving parts when the unit is in operation and when the Main Power switch is not in the OFF position.Warnings,...

  • Page 12: Specific Warnings, Cautions And Notice Statements

    Specific Warnings, Cautions and Notice Statements Throughout this manual, we have included notes with special labels calling special instructions or precautions con- cerning a particular procedure that would be hazardous if performed incorrectly or carelessly. WARNING • Unit may start automatically at any time even if the Aspen Interface (AI) is Off. Before performing any work, turn OFF the AI, disconnect the battery cable ends, lockout both battery ends, and remove shore power if equipped.
  • Page 13 WARNING • Once automatic functions are set the system could start at any time. Before servicing the unit be sure to disable the unit to prevent injury should the unit attempt to start while servicing. All pre- sets will remain once battery cable is reconnected. •...
  • Page 14 CAUTION • CAUTION must be used as there are both 12 VDC and 120 VAC circuits within the CCU. Prior to performing any repairs on the CCU, disable the APU to prevent any possibility of the APU acci-dentally starting. Ensure the shore power or other external power source is disconnected.
  • Page 15 • It is the responsibility of the servicing technician to comply with the local and federal law when handling refrigerants. • Only properly trained technicians shall perform repairs on the Aspen APU system. • The large diameter of the compression limiter must be installed so that it faces the frame insert. If installed incorrectly damage to the cover and frame insert may result.

  • Page 16: Safety Decals

    Safety Decals 62-12174 1–6...

  • Page 17: Lockout-Tagout

    Lockout-Tagout 1.5.1 Equipment The following equipment is required to perform lockout-tagout (LOTO) on the Aspen APU. • Battery cable lockout is used on the APU battery cables and disables the 12 VDC power source for the APU. • In some applications there may be potential ground path through the APU and truck frames so BOTH the B+ and B- cables must be disconnected and...

  • Page 18: Aspen Apu Lockout-Tagout Locations

    • Secures vehicle keys 1.5.2 Aspen APU Lockout-Tagout Locations • Disconnect the APU B+ and B- battery cables from the truck batteries. • Apply battery cable lockout to each of the battery cable ends • Refer to truck OEM and local regula- tions for additional battery cable lockout requirements •...
  • Page 19 • The starter solenoid disconnect (SSD) is located at the front of the engine near the front engine mount and below the fuel pump • Depress the locking tab to separate the connector • Insert the larger end of the SSD into opening at the end of the lockout, •...
  • Page 20 62-12174 1–10...

  • Page 21: Unit Description

    • Units equipped with the shore power option feature a Shore Power module (SPM) that contains high voltage relays and a breaker. Temperature control is provided by the Carrier Transicold APX control system (Refer to Section 2.6). Once the system is set at the desired temperature, the unit will operate automatically to maintain the desired temperature.

  • Page 22: Aspen Models

    Provides air conditioning and heating to the truck cab. The 120 VAC outlet is available to power most 120 VAC appliances and electronics. Cooling Integrated (AspenINT) system is integrated into the truck cooling system, allowing the APU to warm the truck engine.

  • Page 23: Stand-Alone Cooling System

    Figure 2.3 Integrated Cooling System 2.3.1.2 Stand-Alone Cooling System The Stand-Alone APU cooling system is self-contained and does not plumb into the truck’s cooling system. Coolant level can be checked through the sight glass on the surge tank. The surge tank is mounted remotely away from and above the APU, where the sight-glass is easily visible.

  • Page 24: Generator

    2.3.5 Generator The generator is attached to the engine and driven by a serpentine drive belt. The generator supplies 120V 60hz power to the Climate Control Module (CCM). Condenser Figure 2.4 Condenser Table 2–3 Condenser Components The AAT is a thermistor type sensor that provides the control system with the temperature of the air at the condenser.

  • Page 25: Climate Control Unit (Ccu)

    Climate Control Unit (CCU) Figure 2.5 Climate Control Unit 2.5.1 Compressor Discharge Pressure Transducer (CDP) The CDP provides a signal to the control system equivalent to pressure leaving the compressor. The read- ing is displayed, recorded in the data recorder and used to control the refrigeration system. It is located in the discharge line leaving the compressor.

  • Page 26: Binary Pressure Switch (Bps)

    2.5.5 Binary Pressure Switch (BPS) The BPS is normally closed and opens on pressure rise to signal the control system to shutdown the com- pressor if the discharge pressure rises above the switch setting. It will also open to signal the control sys- tem to shutdown the compressor when the discharge pressure drops below the switch setting.

  • Page 27: Evaporator Surface Temperature Sensor (Est)

    2.5.15 Evaporator Surface Temperature Sensor (EST) The EST is a thermistor type sensor located in the evaporator coil. It provides the control system with evaporator temperature information to be displayed, recorded in the data recorder and used to determine when defrost is required. 2.5.16 Climate Control Module (CCM) The CCM functions as the main control for the APX system.

  • Page 28: Fuse Locations

    System Operating Controls and Components 2.8.1 Fuse Locations The APU fuses are located under the right-side cover of the power unit. Top, bottom, and right-side covers must be removed to access the fuses. CAUTION Do not inspect or change fuses while the system is running. Replacement fuses must have the appropriate rating.
  • Page 29 Figure 2.7 Fuse Locations - Truck Body Table 2–6 Fuse Locations - Truck Body Fuse Description Location Truck Interlock Truck Cab Air Heater Air Heater FBAT Truck Battery Battery Box 2–9 62-12174...

  • Page 30: Engine Data

    Engine Data Table 2–7 Engine Data Engine Kubota, 2-cylinder (Z482) 3.5 US quarts (3.3L), any API service CK-4 oil. Reference Table 2–8 for oil Engine Oil viscosity grade. Engine Coolant 5.0 US quarts (4.7L) Organic Acid Technology (OAT), Nitrite Free (NF), (Aspen STA) ASTM D3306, ASTM D6210 Table 2–8 Engine Oil Grade Temperature Ranges...

  • Page 31: Electrical Data

    2.12 Electrical Data Table 2–11 Electrical Data Unit Specification Detail Locked Rotor Amps 54 +/- 10% Capacitor 60µf Compressor Motor Voltage 120 VAC 60Hz Winding Resistance 0.76 +/- 5% ohms (main) 2.06 +/- 5% (aux) Open: 320°F ± 9 (160°C ±5) Thermal Switch Reset: 194°F ±18 (90°C ±12) Voltage...

  • Page 32: Safety Devices

    2.13 Safety Devices Table 2–12 Safety Devices Unsafe Condition Safety Device Device Setting Buzzer energized prior to APU engine APU engine starting Buzzer start Buzzer energized on/off when starter APU starter output fault Buzzer output circuit fault detected Arc/ground fault on block Opens circuit when arc or ground fault heater circuit AFCI/GFCI device...

  • Page 33: Refrigeration Circuit

    Opens at 135F, reset at 120F, fuse High heater temperature 1 Thermal switch/fuse opens at 225F Opens at 135F, reset at 120F, fuse High heater temperature 2 Thermal switch/fuse opens at 225F Low compressor discharge pressure Binary Pressure Switch Low 20-33 psig (123-227 kPa) Low engine oil pressure Engine oil pressure switch Opens below 7 psi...

  • Page 34: Heating Circuit

    2.15 Heating Circuit 62-12174 2–14...

  • Page 35: Operation

    The Carrier Transicold APX Control System incorporates the following features: • Control cab air temperature to tight limits by providing cooling or cooling to maintain operator comfort •...

  • Page 36: Home Screen

    3.3.1.1 Starting the APU 1. Press the ON/OFF button. 2. The Carrier Transicold logo will be displayed and then switch to the Home screen. 3. Next, the system will begin the start sequence by turning on the buzzer and then starting the engine.

  • Page 37: Enabling Heating, Air Conditioning Or Fans (Run Mode)

    Enabling Heating, Air Conditioning or Fans (Run Mode) The user must select a Run Mode before the heating, air conditioning, or fans will operate. • HVAC OFF – Power Unit and HVAC system is turned OFF • MANUAL HEAT – The electric and/or air heater runs depending on configuration. Operator can select desired temperature and fan speed.

  • Page 38: Adjust Setpoint

    3.4.2 Adjust Setpoint From the Home screen push in the dial button. The current setpoint will be shown on screen along with the word ‘SET.’ Adjust the setpoint by rotating the dial left to lower temperature or right to increase temperature. Note that the CAB signifies the current cabin tem- perature.

  • Page 39: Setup

    Setup Display options can be adjusted from the setup menu to suit the user preference. The items that can be adjusted from the setup menu include: • Time and Date • Units • Brightness • Auto Dim • Language To access the setup menu: Press the menu button from the home screen.
  • Page 40 3.5.2 Units The displayed temperature units can be switched between Celsius and Fahrenheit. Press the menu button from the Home screen. Rotate the dial to select Setup and press the dial. Rotate the dial to select Units and press the dial. Rotate the dial to switch between C and F.

  • Page 41: Auto Dim

    The current brightness value will be displayed. Rotating dial to the left will decrease brightness and rotating to the right will increase brightness. Press Menu to return to the home screen. 3.5.4 Auto Dim The auto dim feature automatically reduces the display brightness when the Aspen Interface is not in use by the operator.

  • Page 42: Language

    3.5.5 Language The displayed language can be changed between English, Spanish, and French. From the home screen press the menu button. Rotate the dial and select setup. Press the dial. Rotate the dial to select LANG. Press the dial. Rotate the dial to switch between ENG (English), SPAN (Spanish), and FREN (French).

  • Page 43: Unit Information

    3.6.1 Unit Information The unit information sub-menu displays the APU serial number and current software version. From the home screen press the menu button. Rotate the dial and select Service. Press the dial. Rotate the dial to select Unit Informa- tion.
  • Page 44 The active alarms will be displayed, a maximum of six alarms will be dis- played. Rotate the dial to the right to scroll through the alarm list, if additional a l a r m s a r e p r e s e n t , t h e y c a n b e viewed by continuing to rotate the dial to the right.

  • Page 45: Clearing Alarms

    3.6.3 Clearing Alarms Active alarms can be reset from the alarm menu. From the Alarm menu, rotate the dial to select the alarm code to clear. Rotate the dial to "RESET" at the end of the alarm list. Press the dial to clear the alarms.

  • Page 46: Dpf Regen

    3.6.5 DPF Regen For units equipped with the ClearSky emission control system, the Diesel Particulate Filter (DPF) regen menu will be available. The DPF regen feature allows the user to monitor the status of a current regenera- tion or initiate a manual regeneration. From the home screen press the menu button.

  • Page 47: Run Mode

    Run Mode WARNING Once automatic functions are set the system could start at any time. Before servicing the unit be sure to disable the unit to prevent injury should the unit attempt to start while servicing. All presets will remain once battery cable is reconnected. Automatic run mode functions can be turned on and off from the run mode menu.

  • Page 48: Configurations

    Configurations 3.8.1 Alarm Settings Parameter Default Description Coolant Sensor Alarm Shutdown APU engine shutdown if coolant temp sensor is detected open/short Engine Oil Pressure Shutdown APU engine shutdown if low oil pressure is detected High Engine Temp Shutdown APU engine shutdown if coolant temperature is high Compressor Alarm Shutdown APU/CCU shutdown if compressor alarm is detected.

  • Page 49: Other Settings

    Functional Settings 3.9.1 View Preferences Parameter Options Default Description Temperature C or F Temperature units displayed on AI Pressure PSIG or BAR PSIG Pressure units displayed on AI Date/Time MM/DD/YYYY or MM/DD/YYYY Date and time format displayed on the AI DD/MM/YYYY Language English, Spanish, or...
  • Page 50 Timer 2 Everyday, Everyday Day(s) timer will operate Monday, Tuesday, Wednesday, Thursday, Friday, Saturday, Sunday Auto Timer 2 0-23 Hours 8 Hours Timer 2 activation time Activate Time 0-60 Minutes 0 Minutes Auto Timer 2 Start 0-9 Hours 1 Hour Run duration for Timer 2 Duration 0-60 Minutes...

  • Page 51: Engine And Temperature Control

    SECTION 4 Engine and Temperature Control Introduction Sequence of Operation With the battery connected, power is available from the battery to the: • F8 fuse • Starter motor • Alternator B+ • B+ bus bar • APU Module: F1 fuse to J2-4 and F2 fuse to J1-1 •...

  • Page 52: Engine Shutdown Sequence

    4.4.2 Engine Shutdown Sequence The APU engine shutdown sequence is initiated by pressing the ON/OFF button on the Aspen Interface. When the ON/OFF button is pressed a CAN message is sent to the APU module to stop the engine. After the message is received the APU module de-energizes the hold circuit for the fuel solenoid.

  • Page 53: Heat (Electric)

    4.9.2 Heat (Electric) Choose MAN_HEAT in RUN MODE and then adjust evaporator fan speed. • Evaporator fan must be on before turning on heat • When CAT is below setpoint by more than 1.1°C (2°F), turn on both HTR1 and HTR2. When on shore power only HTR1 is powered.

  • Page 54: Defrost

    4.11 Defrost When the evaporator surface temperature is lower than -2.8°C (27F), defrost is initiated by turning off the compressor. • Compressor Minimum ON time must be met before defrost can start. • Minimum Defrost Time is set to 3.5 minutes. •...

  • Page 55: Control System Interface

    SECTION 5 Control System Interface Interface Methods There are three methods for interfacing with the APX Control System: Activities such as Start, Stop, Pretrip, reading alarms, reading data and Aspen Interface enabling/disabling automatic modes Activities using the USB memory device include, downloading data files, USB Memory Device installing software, and uploading configuration files CabinTech...
  • Page 56 The tools listed are required to interface with the Aspen APU Connect harness (D) to CAN BUS Interface (C). Connect CAN BUS Interface (C) to USB A port on PC (A). Connect harness (D) to CAN SERVICE con- nector located on 12 VDC/CAN harness near the CCM When CabinTech is launched, it will open to the Home menu.
  • Page 57 • Clicking on the hamburger icon (1) expands the menu bar on the left side of the screen. • Clicking on any of the menu bar items (2) or tiles (3) will open the corresponding menu. • The menu bar is present within each menu The system status menu is made up of four parts 1.
  • Page 58 Connection status to the APU is indicated by the connection light (1) at the top right of the screen. Green: Connected Red: Disconnected The connection light is present in the status, val- ues, setup, configuration and download menus. 62-12174 5–4...
  • Page 59 The Systems Value menu allows the user to monitor temperatures, pressures and component status in real time. A data recorder function is present and captures unit data for later review as a CSV file. System values can be viewed within preset tabs/groups as well as user defined cus- tom views.
  • Page 60 When connected to a unit and a tab is selected, the value for each parameter will be displayed on the left half of the screen. To graph a parameter, the check box next to the graph color must be selected. The graph color for each parameter can be changed from the color select drop- down.
  • Page 61 The System Setup menu has three sections: 1. Set Controller: Set APU model, APU and tractor serial number 2. Set Date/Time: Adjust system time/date 3. Software Upgrade: Updates APU/CCU software Set the following controller data: Unit Model Number - Select from drop-down: A-INT - Integrated with CCU A-STA - Stand-Alone with CCU...
  • Page 62 Check the APU date and time. If it is not correct it needs to be updated. Select PC Date Time or User Date Time and then press SET to update the date and time setting. Check for software update. Download the latest Aspen APU software from the Carrier Solu- tionCenter.
  • Page 63 The system configuration menu is used to set parameters that define how the system will operate. There are two sections within the system configuration menu. Configuration: 1. Alarm: Enables and disables alarm shutdown parameters 2. Installation: Configure installed options 3. Setpoint/Range Lock: Sets minimum and maximum setpoint temperature 4.
  • Page 64 Functional: 1. View Preferences: Aspen Interface display setting (C/F, Date Format, Brightness) 2. Other Settings: Automatic mode (Battery Monitor, timers, Temp Start), operational settings, enable/disable power outlet. 62-12174 5–10...
  • Page 65 Configuration files can be saved and opened for future use. To save a configuration file click the Save button (1) at the top right part of the screen. Name the configuration file and click Save. To open existing configuration files, click the Open (2) button at the top right part of the screen. High- light the desire file and click Open.
  • Page 66 The data download menu allows data to be downloaded from the unit for usage and troubleshooting analysis. The time period that the data is downloaded can be defined by the user. To perform a data download, click the Download button (1). The progress bar will indicate the status of the download.
  • Page 67 Reports can be viewed in multiple formats: • Text View: Displays sensor and event data in text format. Displayed data can be filtered by Sen- sors and Events, Events and Sensors. Sensor and event data can also be presented in tabular format.
  • Page 68 Sync view combines the features of Text view (1) and Graph view (2) into a single view The USB Operations menu allows the user to load, manage and view configurations, downloads and soft- ware when a Carrier USB is detected. The USB device information that is show can be changed fro the type (1) drop-down.

  • Page 69: Usb Operation

    USB Setup Only Carrier Transicold APX USB Flash Drives may be used for this procedure. The USB can only be used for one function at a time and must be modified to switch between functions. The name of the folder under the CARRIER directory will determine the USB operation.

  • Page 70: Performing Usb Operations (Configuration, Download And Software Update)

    In this example the CONFIG, DATAEXT, and PROGRAM folders are all located in the CARRIER folder and will not function when inserted into the CCM USB slot. In the second example the PROGRAM folder is located in the CARRIER folder and will function as a PROGRAM device. The CONFIG and DATAEXT folders have been moved to the ARCHIVE folder.

  • Page 71: Apx Control System Module Replacement And Setup

    APX Control System Module Replacement and Setup Under no circumstances should a technician electrically probe the modules at any point, other-than the connector terminals where the harness attaches. Module components operate at different voltage levels and at extremely low current levels. Improper use of voltmeters, jumper wires, continuity testers, etc. could permanently damage the module.

  • Page 72: Pre-Replacement Steps

    5.2.1 Pre-replacement Steps Before the unit can be started using the replacement module certain unit specific and time sensitive data must be known. • Unit Serial Number • Unit Model Number • Tractor Serial Number • Date and Time • Engine Hours 1.

  • Page 73: Message Center

    SECTION 6 Message Center Message Center Messages The following table lists common messages that do not appear in other lists in this manual and a description of their meaning. Refer to Section 9 for a list of Alarm messages. Table 6–1 Message Center Messages Message Description LOSS OF...
  • Page 74 62-12174 6–2...

  • Page 75: Alarm Troubleshooting

    SECTION 7 Alarm Troubleshooting 00011 – Check Engine Oil Pressure NOTE This alarm may be activated if too high a viscosity oil is used in cold ambient Not for Shore Power mode. If the system is in Diesel Engine mode AND if Alarm 41 (Engine Stalled) is NOT active and the oil pressure switch = Activation pressure low (open) for five seconds and engine running and not cranking the...
  • Page 76 00012 – High Coolant Temperature Not for Shore Power mode. If the system is in Diesel Engine Mode AND the coolant temperature sensor alarm is NOT active AND engine is running AND any of the following conditions occur when the engine is running and NO oil Activation pressure failures present: •...
  • Page 77 5. Check Water Pump Belt - Check belt condition. Verify no Glazing, no Cracking, no Slipping. Replace belt if required. Refer to Section 8.6.15. 6. Check Engine Coolant Temperature Sensor Wiring a. Inspect harness and APU Module connector pins and termi- nals.
  • Page 78 00013 – High Discharge Pressure Compressor discharge pressure switch is open and discharge pressure is >200 psi. Pressure must be High for three seconds consecutively. Activation Compressor only: • If activated while compressor is off, Alarm Condition only. Unit Control •...
  • Page 79 4. Check HPS Power and Wiring a. Inspect switch, connector pins and terminals. Verify that there is no physical damage to the switch. Check the con- nections for damage and corrosion. b. Check continuity from the CCM J1-6 to HPS-B and J1-12 to HPS-A.
  • Page 80 00014 – Low Discharge Pressure Compressor discharge pressure switch is open and discharge pressure is <200 psi and AAT >45°. Pressure must be low for three seconds Activation consecutively. Compressor only: If activated while compressor is off, Alarm Condition only. Unit Control Compressor high discharge pressure switch closed and Power Switch is ON Alarm Reset...
  • Page 81 4. Check Refrigerant Charge - Refer to Section 8.7.2. Charge must be correct. 5. Check HPS Power And Wiring a. Inspect switch, connector pins and terminals. Verify that there is no physical damage to the switch. Check the con- nections for damage and corrosion. b.
  • Page 82 00015 – High Battery Voltage Activation Battery voltage at the main microprocessor is greater than 17VDC Unit Control Shutdown and alarm Battery voltage between 11 and 14VDC Reset Condition Alarm Reset Check Battery Voltage a. Test voltage at battery with unit off. Must be between 11-16 VDC. b.
  • Page 83 00016 – Battery Voltage too Low Activation Battery voltage at the main microprocessor is less than 10VDC (except when the engine starter is engaged) Unit Control • Required Shutdown • If activated while starting, Alarm Condition only and do not crank the engine if battery voltage is still low.
  • Page 84 00020 – Maximum Compressor Alarms • Alarms 00013 (High Discharge Pressure) or 00014 (Low Discharge Pressure) occur three times within the last two hours when power is Activation • This alarm cannot be cleared from the active queue. If this alarm is activated, both this alarm and the alarm that caused it will remain in the active alarm queue after power cycle.
  • Page 85 00021 – Technician Test Required • Alarms 11 (Low Oil Pressure) or 12 (High Coolant Temp) or 126 (Coolant Temp Sensor) or 2006 (Starter Output Fault) individually occur three times within the last two hours of engine running time. This alarm is enabled by configuring Coolant Sensor Alarm Shut- down or High Engine Temp Shutdown or Engine Oil Press Shut- down to YES.
  • Page 86 00030 – Minimum Run Time Fail When the number of required or unconditional alarm shutdowns >=3 Activation Required Shutdown • Clear the start attempts counter and shutdown counter at the start or Pretrip Unit Control • Clear the shutdown counter when engine running for 15 minutes OR when normal shutoff Alarm Reset Reset Condition...
  • Page 87 00031 – Failed to Start – Auto Mode Not for Shore Power mode Activation If the system is in Diesel Engine mode AND the engine fails to start on three consecutive attempts. Required Shutdown • Clear the start attempts counter and shutdown counter at the start of Pretrip Unit Control •...
  • Page 88 00034 – Engine Failed to Stop Not for Shore Power mode If the system is in Diesel Engine mode AND High Pressure alarm is not Activation Active AND attempt to shut engine off after Starting or Attempting to Start and the alternator feedback input is active for 20 seconds OR the oil pressure switch = pressure good after 20 seconds.
  • Page 89 4. Check for correct engine oil - Check viscosity is correct for ambient conditions. Refer to Section 2.7. 5. Check Engine Exhaust System - Inspect the exhaust system. Must be clear and unobstructed. Corrective Actions 6. Check Generator - Check for proper preventative maintenance and operating precautions.
  • Page 90 00035 – Engine Failed to Crank Not for Shore Power mode If the system is in Diesel Engine mode AND engine fails to crank after two Activation attempts. Alternator feedback input presence shall be checked. • If the system is in Diesel Engine mode, REQUIRED SHUTDOWN •...
  • Page 91 4. Check Starter a. Inspect starter and wiring. Verify there is no damage or corrosion. Wiring and battery cable must be clean and tight. b. Check voltage to starter motor. Must be above 10 VDC while cranking. c. Check resistance of starter motor. d.
  • Page 92 00041 – Engine Stalled Not for Shore Power mode If the system is in Diesel Engine mode AND if the engine is running and the alternator feedback signal is not present and oil pressure switch is open Activation NOTE Alarm will not activate is 00013 High Pressure Discharge alarm is pending or active.
  • Page 93 Check Fuel System Check for fuel level. Fill tank as needed. Check fuel flow. Unrestricted fuel flow through system. Fuel filter clean. Fuel not gelled. Check fuel system prime. No air in fuel system. Check APU Module and Fuel Solenoid (FS) Inspect fuel solenoid (FS) and APU Module connector pins and terminals.
  • Page 94 00051 – Data Recorder Memory Fail Activation No data is being recorded by the data recorder Alarm only Unit Control Alarm may be manually reset from the Aspen Interface or CabinTech Reset Condition NOTE Follow the steps below until a problem is found. Once a repair or correction has been made, the active alarm should clear itself (refer to reset condition above).
  • Page 95 00052 – Real Time Clock Fail Activation The Real Time clock in the data recorder does not contain a valid date. Alarm only Unit Control Set RTC Reset Condition Cycle Power 1. Check Real Time Clock: Check Real Time clock in the Unit Data or using CabinTech must show correct date and time.
  • Page 96 00073 – Check Prestart (Glow Plug) Trigger On: Prestart relay output is ON and FET Feedback Voltage is below minimum ON threshold Prestart relay output is OFF and FET Feedback voltage is above maximum ON threshold Trigger Off: If alarm was active when Prestart Output was ON, trigger OFF if Output is ON and FET Feedback Voltage is sensed in Active range Activation If alarm was active when Prestart Output was OFF, trigger OFF if Output is...
  • Page 97 00075 – Check Condenser Motor Relay Trigger On Condenser Motor Relay is ON and Relay Feedback Voltage is below Minimum ON Threshold Condenser Motor Relay is OFF and Relay Feedback Voltage is above Maximum OFF Threshold. Trigger Off If alarm was active when Condenser Motor Relay was ON, trigger OFF if Output is ON and FET Feedback Voltage is sensed in Active range Activation If alarm was active when Condenser Motor Relay was OFF, trigger OFF if...
  • Page 98 00076 – Check Radiator Fan Circuit Trigger On Radiator Fan relay Output is ON and FET Feedback Voltage is below Minimum ON Threshold Radiator fan relay Output is OFF and FET Feedback Voltage is above Maximum OFF Threshold. Trigger Off If alarm was active when Radiator Fan Relay was ON, trigger OFF if Output is ON and FET Feedback Voltage is sensed in Active range Activation...
  • Page 99 1. Open CabinTech system values and verify if 00076 occurs when the radiator fan output is ON or OFF. If ON go to step 2. If Off go to step 2. Measure resistance between SAR-1 and SAR-3 (radiator fan side of connector).
  • Page 100 00121 – Discharge Temperature Sensor Check Ambient Air Temperature Sensor (AAT) is not within range of -53 to +158°F (- Activation 47° to +70° C). Engine and Shore Power Operation: A value of 122°F (50°C) will be used for Unit Control any calculations.
  • Page 101 1. Check Sensor a. Inspect sensor and connectors. Verify there is no damage to sensor, and no damage, moisture, or corrosion in connectors. b. Check sensor resistance 90,000 Ohms @ 77°F (25°C). Refer to Table 8–3 for chart of resistances for different sensors. 2.
  • Page 102 00125 – Check Suction Temperature Sensor Compressor Suction Temperature Sensor (CST) is not within the range of -53 to Activation +158°F (-47 to +70° C.) Unit Control Engine and Shore Power Operation (Alarm only) Auto reset when sensor is in range or, alarm may be manually reset from the AI, Reset Condition Cabin Tech, or by turning the unit off and then back on again.
  • Page 103 00127 – Check Evaporator Temperature Sensor Evaporator Surface Temperature Sensor (EST) is not withing range of -53° Activation +158°F (-47° to + 70°C). Unit Control Engine Operation Shore Power Operation (Alarm only) Auto reset when sensor is in range or alarm may be manually reset from the AI, Reset Condition Cabin Tech, or by turning the unit off and then back on again.
  • Page 104 00231 – Setpoint Error There is an error in the setpoint that is stored in the main microprocessor Activation memory. Unit Control Shutdown and alarm Auto reset when a valid setpoint is entered, or alarm may be manually reset by Reset Condition turning the unit off, then back on again.
  • Page 105 Select the correct model number in the Unit Model Number setting in System Setup menu in CabinTech, if correct model number is not found, install (or have Carrier Transicold dealer install) latest software revision. 2. Reset Microprocessor a. Turn APU OFF from the Aspen Interface. Disconnect negative battery Corrective Action cable, wait 20 seconds and reinstall.
  • Page 106 00233 – Functional Parameter Error There is an error in one or more of the Functional Parameters that are stored in Activation the Climate Control Module memory. Unit Control Incorrect Functional Parameter(s) will be automatically set for default value. Auto reset when valid Functional Parameters are entered, or alarm may be Reset Condition manually reset by turning the unit off, then back on again.
  • Page 107 00234 – Configurations Error There is an error in the Configurations settings stored in the control systems Activation memory. Unit Control Incorrect Configuration(s) will be automatically set for default value. Auto reset when valid Configurations are entered, or alarm may be manually Reset Condition reset by turning the unit off, then back on again.
  • Page 108 00235 – Cannot Save Setting There is an error in sending and saving new settings in the main microprocessor Activation memory. Unit Control Alarm only Alarm may be manually reset from the alarm menu in the Aspen Interface or by Reset Condition turning the unit off, then back on again.
  • Page 109 02000 – Software Incompatibility The software version in one or more of the modules is not compatible with Activation the remainder of the control system Unit Control If the invalid software versions are only reported by display modules: ALARM ONLY, otherwise: REQUIRED SHUTDOWN Cycle Power on Reset Condition NOTE...
  • Page 110 1. Disconnect (Starter Solenoid Disconnect) SSD located near APU flywheel. If the starter motor continues to run, disconnect both the positive and negative battery cables. 2. Check for voltage between APU module side of SSD and starter ground. If voltage is present, go to step 4. 3.
  • Page 111 05001 – Check Engine Preheat Enable Circuit Trigger On Glow Plug Relay is ON and Relay Feedback Voltage is below Minimum ON Threshold Glow Plug Relay is OFF and Relay Feedback Voltage is above Maximum OFF Threshold. Trigger Off If alarm was active when Glow Plug Output was ON, trigger OFF if Output is Activation ON and FET Feedback Voltage is sensed in Active range If alarm was active when Glow Plug Output was OFF, trigger OFF if Output is...
  • Page 112 05002 – Check Alt Enable Circuit Trigger On Alt Enable FET is ON and FET Feedback Voltage is below Minimum ON Threshold ALT Enable FET is OFF and FET Feedback Voltage is above Maximum OFF Threshold. Trigger Off If alarm was active when ALT Enable Output was ON, trigger OFF if Output is ON and FET Feedback Voltage is sensed in Active range Activation If alarm was active when ALT Enable Output was OFF, trigger OFF if Output...
  • Page 113 05003 – Check Solenoid Pull Circuit Trigger On Solenoid Pull FET is ON and FET Feedback Voltage is below Minimum ON Threshold Solenoid Pull FET is OFF and FET Feedback Voltage is above Maximum OFF Threshold. Trigger Off If alarm was active when Solenoid Pull was ON, trigger OFF if Output is ON Activation and FET Feedback Voltage is sensed in Active range If alarm was active when Solenoid Pull was OFF, trigger OFF if Output is OFF...
  • Page 114 5. Replace APU module. 6. Remove APU J2-6 terminal from connector and reinstall connector into module. a. Check for voltage between J2-6 and starter ground. Corrective Actions b. If voltage is present, check APU harness for short to power between APU module and fuel solenoid. c.
  • Page 115 05004 – Check Solenoid Hold Circuit Trigger On Solenoid Hold FET is ON and FET Feedback Voltage is below Minimum ON Threshold Solenoid Hold FET is OFF and FET Feedback Voltage is above Maximum OFF Threshold. Trigger Off If alarm was active when Solenoid Hold was ON, trigger OFF if Output is ON and FET Feedback Voltage is sensed in Active range Activation If alarm was active when Solenoid Hold was OFF, trigger OFF if Output is...
  • Page 116 1. Verify if condition occurs when solenoid hold output is ON or OFF a. Check solenoid pull output status in System Values menu in Cabin Tech. b. If status is ON go to step 2. c. If status in OFF go to step 6. 2.
  • Page 117 05009 – Check FFH Enable Circuit Trigger On Alt Enable FET is ON and FFET Feedback Voltage is below Minimum ON Threshold ALT Enable FET is OFF and FET Feedback Voltage is above Maximum OFF Threshold. Trigger Off If alarm was active when ALT Enable Output was ON, trigger OFF if Output is ON and FET Feedback Voltage is sensed in Active range Activation If alarm was active when ALT Enable Output was OFF, trigger OFF if Output...
  • Page 118 05010 – Check FFH Setpoint Circuit Trigger On Alt Setpoint FET is ON and FFET Feedback Voltage is below Minimum ON Threshold ALT Setpoint FET is OFF and FET Feedback Voltage is above Maximum OFF Threshold. Trigger Off If alarm was active when ALT Setpoint Output was ON, trigger OFF if Output Activation is ON and FET Feedback Voltage is sensed in Active range If alarm was active when ALT Setpoint Output was OFF, trigger OFF if Output...
  • Page 119 05100 – AC Check The unit is operating in Diesel or Shore Power and AC voltage at TB1 is Activation less than 50VAC Unit Control Alarm Only • Auto Reset when AC power is restored (TB1 voltage is greater than 50VAC •...
  • Page 120 Diesel 1. Alarm history and engine/generator condition a. Check for engine related alarms. This alarm can be gener- ated by low engine speed or a condition that caused the engine to shut down. b. Verify the engine and generator are operating properly. Check for restricted air intake, fuel filters and drive belt condi- tion.
  • Page 121 05101 – AC CB1 The unit is operating in Diesel or shore power and AC voltage is present at Activation TB1 but no voltage is present at CB1. Unit Control Alarm Only. CB1 outputs will not be powered when active ·...
  • Page 122 05102 – AC CB2 The unit is operating in Diesel or Shore Power and AC voltage is present at Activation TB1, but no voltage is present at CB2. Unit Control Alarm Only. CB2 outputs will not be powered when active •...
  • Page 123 05104 – AC Compressor VAC reading from compressor does not match ordered compressor state. Activation A05100 or A5102 not active or pending Alarm Only Unit Control VAC reading from compressor matches ordered state Reset Condition 1. Inspect compressor. a. Check terminal connections at the compressor. 2.
  • Page 124 05105 – AC Outlet VAC reading from outlet does not match ordered compressor state. A05100 Activation or A5103 not active or pending • If outlet is ordered ON but VAC is not present, Alarm Only Unit Control • If outlet is ordered OFF but VAC is present, REQUIRED SHUTDOWN VAC reading from compressor matches ordered state Reset Condition 1.
  • Page 125 05106 – AC Heater 1 VAC reading from Heater 1 does not match ordered heater state. A05100 or Activation A5101 not active or pending Alarm Only Unit Control VAC reading from compressor matches ordered state Reset Condition 1. Check Heater 1 status in the System Values menu in CabinTech. a.
  • Page 126 05107 – AC Heater 2 VAC reading from Heater 2 does not match ordered heater state. A05100 or Activation A5101 not active or pending Alarm Only Unit Control VAC reading from compressor matches ordered state Reset Condition 1. Check Heater 2 status in the System Values menu in CabinTech. a.
  • Page 127 05108 – AC Block Heater VAC reading from block heater does not match ordered block heater state. Activation A05100 or A5101 not active or pending. • If Block Heater is ordered ON but VAC is not present, Alarm Only Unit Control •...
  • Page 128 05109 – AC Evap Fan Fuse VAC reading from evaporator fan fuse does not match ordered state. Activation A05100 or A5103 not active or pending. Alarm Only Unit Control VAC reading from evaporator fan matches ordered state Reset Condition 1. Check evaporator fan fuse a.
  • Page 129 05110 – AC Evap Fan VAC reading from evaporator fan does not match ordered fan state. Activation A05100, A5102, or A5109 not active or pending. Alarm Only Unit Control VAC reading from evaporator fan matches ordered state Reset Condition 1. Check evaporator fan status in the System Values menu in CabinTech. a.
  • Page 130 07000 – Check Cab Temp Sensor Cab Air Temperature Sensor (CAT) is not within the range of -53° to Activation +158°F (-47° to +70°C). Engine and Shore Power Operation (Alarm only). Return Air Unit Control Temperature (RAT) will be used for temperature control. Auto reset when Cabin Air Temperature is in range or alarm may be Reset Condition manually reset from the alarm menu in the Aspen Interface, or by turning...
  • Page 131 07006 – Suction Pressure Sensor Check Suction pressure sensor is out of range. Suction pressure is >14.7 psig or <100 Activation psig with the compressor running. Unit Control Engine and Shore Power Operation (Alarm only) Auto reset when Suction Pressure Sensor is in range or, alarm may be reset manually from the Aspen Interface alarm menu, CabinTech or by turning the unit Reset Condition off and then back on again.
  • Page 132 07013 – Discharge Pressure Sensor Check Discharge pressure sensor is out of range. Suction pressure is > 0.0 psig or Activation <500 psig with the compressor running. Unit Control Engine and Shore Power Operation (Alarm only) Auto reset when Discharge Pressure Sensor is in range or, alarm may be reset manually from the Aspen Interface alarm menu, CabinTech or by turning the unit Reset Condition off and then back on again.
  • Page 133 20002 – CCU IO CAN Fail Activation No communication from Climate Control Module Shutdown all modules except the Aspen Interface and alarm. (The alarm will Unit Control only display if the AI is communicating.) Climate Control Module status LED will illuminate steady green (not pulsing).
  • Page 134 20005 – CCU IO Lost Configuration Activation Climate Control Module loses configuration 10 times System Response APU will shut down and reboot will occur. Display will remain powered. Auto reset when valid configuration is restored. Manual reset by turning unit Reset Condition OFF and the back ON.
  • Page 135 20009 – APU IO Lost Config APU Module has lost configuration 10 times (determined by invalid APU_IO Activation checksum). System Response APU will shut down and reboot will occur. Display will remain powered. 1. Inspect APU Module indicator LED. ü Is light solid red –...
  • Page 136 62-12174 7–62...

  • Page 137: Service

    SECTION 8 Service WARNING Once automatic functions are set the system could start at any time. Before servicing the unit be sure to disable the unit to prevent injury should the unit attempt to start while servicing. All presets will remain once battery cable is reconnected.

  • Page 138: Pretrip Inspection

    Table 8–3 Maintenance Schedule - Adjust Adjust test Torque Every 1,000 Hours Every 2,000 hours APU mounting bolts Injection nozzle Injection pump timing Valve lash Water pump Engine thermostat Alternator AFCI/GFCI device High voltage grounding Air conditioning Heater Table 8–4 Maintenance Schedule - Change Change Every 1,000 Hours Every 2,000 hours...

  • Page 139: Afci/Gfci Devices And Shore Power

    AFCI/GFCI Devices and Shore Power WARNING Do not connect shore power cord to any electrical outlet or shore power receptacle without checking that it meets the 120/1/60 and 15 Amp electrical requirements. Ensure the power plug is clean and dry before connecting to any electrical outlet / receptacle.
  • Page 140 AFCI trip – press RESET, if Tripped – Button out device continues to trip there is a problem with the load connected to the outlet. Determine OFF and flashes RED 2X every five seconds GFCI trip – Press RESET, Tripped – Button out if Device will not reset there is no power on the circuit Refer to 62-12173 Section 14 for AFCI/GFCI device/outlet installation instructions...

  • Page 141: Block Heater / Shore Power Connector/Receptacle Inspection

    8.3.2 Block Heater / Shore Power Connector/Receptacle Inspection Inspect the block heater connector/harness for damage Verify the connector is free of corrosion/mois- ture. Apply dielectric grease (02-00311-02/03) to the connector. Stow the connector when not in use. Inspect the block heater/shore power cable and receptacle body for damage and loose connec- tion Verify that the harness connector is locked into...

  • Page 142: Apu

    WARNING Inhalation of exhaust gas (containing carbon monoxide) may cause severe personal injury and/ or death. Anyone suspected of suffering from CO2 inhalation should be removed from the hazardous area and given medical assistance immediately. The APU contains parts which may become very hot and can cause burns. Always ensure proper personal protective equipment is used when working around hot components.
  • Page 143 Release spring clips (1) to remove air filter housing cover (2) Remove filter element. Clean filter housing before installing replace- ment filter element. Install filter element, ensuring it is fully seated in the housing. Install air filter housing cover (1) with drain (2) oriented down.

  • Page 144: Air Filter Housing

    8.4.1.3 Air Filter Housing Remove APU left/top cover and step plate Reposition constant tension clamp (1) on air intake hose. Remove nuts/washers (2) from air filter housing clamp to air filter bracket Before reinstalling air filter clamp/housing ensure clamp is centered on the air filter housing and the vertical slot end of the clamp is positioned on the upper air filter bracket stud.

  • Page 145: Air Filter Bracket

    8.4.1.4 Air Filter Bracket 8.4.2 Cooling System WARNING HOT PARTS - Refer to Table 1 COOLANT - Refer to Table 1 Do not start or run the APU prior to purging the entire cooling system of air. Failure to do so will result in APU engine failure.

  • Page 146: Integrated Cooling System

    Secure engine wire harness to air filter bracket using harness tape markers as guide. Secure harness with clamp to engine plate. Install air filter housing. Before starting the APU, the cooling system must have the air bleed from the system. Failure to completely remove air from the system may cause damage to the APU engine.
  • Page 147 8.4.2.1.2 Coolant System Bleed Fill tractor cooling system Start the tractor engine and run until the tractor thermostat opens. Open the APU engine bleeder valve ½ turn until coolant starts to flow Remove the interlock fuse or temporarily disable interlock configuration setting Start APU engine and run both engines simultaneously until all air is purged from the cooling sys- tem.

  • Page 148: Stand Alone

    8.4.2.2 Stand Alone Park truck on level surface and turn APU OFF. Observe coolant level in the coolant tank sight glass. The coolant level is OK when coolant fills the bottom half of the sight glass. If coolant level is low, allow APU engine to completely cool before removing the coolant tank cap.

  • Page 149: Enct

    8.4.2.3 ENCT Disconnect the ENCT connector (1) located below the air intake hose. Drain the coolant level below the height of he ENCT Remove the ENCT (2) Apply thread sealant to the external threads on the ENCT Install the ENCT 6ft-lb Refill and bleed air from the cooling system.

  • Page 150: Engine

    Engine WARNING Moving parts can cause severe injury and/or death. Before working on any unit, shut it off and disconnect the battery. Do not start the unit 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.
  • Page 151 Measure the belt tension halfway between the fan and alternator pulley If the belt tension is out of specification, loosen the alternator mounting hardware and adjust the belt tension to specification. 8–15 62-12174...

  • Page 152: Alternator Removal And Installation

    8.5.2 Alternator Removal and Installation 8.5.2.1 Alternator Removal Remove B+, B-, D+, and IG terminals from back of alternator Remove upper (1) and lower (2) pivot bolts. Remove belt from alternator pulley. Remove alternator 62-12174 8–16...

  • Page 153: Alternator Installation

    8.5.2.2 Alternator Installation Inspect and clean the following 1. Engine front housing/lower alternator mount 2. Alternator bushing (both sides) 3. Alternator lower pivot Surfaces must be flat and free of corrosion/paint. Alternator bushing must not extend past alternator pivot 8–17 62-12174...
  • Page 154 Insert the bushing into the front housing side of the non-threaded alternator mounting hole. Position the alternator on the engine as shown in Insert the long bolt with flat washer into the lower hole and through the engine support. Place a flat washer and locking nut on the other end of bolt.

  • Page 155: Breather

    8.5.3 Breather Remove the screws securing the breather to the valve cover. Clean and inspect the breather valve. Verify that the breather tube between the valve cover and intake is free of obstructions. 8.5.4 Engine Coolant Temperature Sensor ENCT Disconnect the ENCT connector (1) located below the air intake hose.
  • Page 156 Remove the ENCT (2) Apply thread sealant to the external threads on the ENCT Install the ENCT 6ft-lb Refill and bleed air from the cooling system. 62-12174 8–20...

  • Page 157: Engine Oil Level Check

    8.5.5 Engine Oil Level Check Turn the APU OFF and wait at least five minutes to allow he engine oil to return to the oil pan. Remove the dipstick from the engine Wipe the dipstick with a clean cloth Reinsert the dipstick and remove the dipstick again Do not overfill engine oil or operate APU if oil level is below lower mark.

  • Page 158: Engine Oil Filter And Filter Change

    8.5.6 Engine Oil Filter and Filter Change Start the APU and allow it to run for several minutes to warm-up the engine oil Turn OFF the APU. Disconnect the Starter Solenoid Disconnect (SSD) and LOTO the SSD. Remove the drain plug from the engine oil pan and allow the oil to drain into a suitable container.

  • Page 159: Engine Fan Ring

    Refill engine oil through the filler cap on the side of the block. Add oil until level is at the full/upper mark. DO NOT remove the cap from the valve cover Reconnect the SSD Run the APU engine and check for leaks 8.5.7 Engine Fan Ring Remove the two bolts (1) and nut (2) secur-...

  • Page 160: Engine Fan Ring Seal

    8.5.8 Engine Fan Ring Seal NOTE The fan ring seal is required for proper air flow into the APU enclosure and through the radiator. Inspect the foam seal on the fan ring for damage. When replacing the seal, align the edge of the seal with the engine side of the fan ring.

  • Page 161: Fuel Filter - Spin-On

    8.5.10 Fuel Filter - Spin-on Turn OFF the APU. Disconnect the Starter Solenoid Disconnect (SSD) and LOTO the SSD connector. Place a pan under the fuel filter Remove the fuel filter. Fill replacement filter with clean diesel fuel Apply clean diesel fuel to the gasket on the replacement filter with clean engine oil. Install the replacement filter tightening ¾...

  • Page 162: Glow Plugs

    8.5.11 Glow Plugs Refer to Engine Workshop manual 62-11161 Electrical WARNING 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 electri- cal system, and follow local electrical codes.

  • Page 163: Generator Drive Belt Replacement

    8.6.2.2 Generator Drive Belt Replacement Use a 3/8” breaker bar to pull up on the ten- sioner and let belt slip under tensioner. Remove belt from around the large engine pul- ley. To release the belt tensioner, it must be pulled UP toward the APU frame.
  • Page 164 Use a 3/8” breaker bar to pull up on ten- sioner and let belt slip under tensioner pul- ley. To release the belt tensioner, it must be pulled UP toward the APU frame. DO NOT push down on the tensioner as damage to the tensioner may result.

  • Page 165: Generator Removall

    8.6.2.3 Generator Removal Remove skid plate. Remove lower legs. Disconnect the generator power wire from the generator breaker Disconnect the generator neutral wire from the ground stud at the breaker bracket __________________________________ 1. Generator power wire 2. Generator neutral wire Remove the cable ties securing the generator leads to the breaker bracket __________________________________...
  • Page 166 Remove the bolt securing the generator ground wires to the generator housing. Note: It may be necessary to remove the breaker bracket to access the generator ground wire hardware. __________________________________ 1. Generator ground wires Support the generator with a suitable lifting device.
  • Page 167 Connect the APU engine harness/generator ground wire to the generator __________________________________ Connect the generator power wire to the breaker Connect the APU engine harness/generator ground wire to the generator. __________________________________ 1. Generator power wire 2. Generator neutral wire 18 in-lb 20 ft-lb Install lower legs.

  • Page 168: Belt Tensioner Bracket/Belt Installation

    8.6.2.4 Belt Tensioner Bracket/Belt Installation Position the belt tensioner bracket on the generator. Apply Loctite 243 to the screw threads and torque. __________________________________ 8ft-lb Place the tensioner on the belt tensioner bracket. Install lock washer and flat washer on the tensioner mounting bolt. Apply Loc- tite 243 to mounting bolt threads and torque.

  • Page 169: Generator Alignment

    8.6.2.5 Generator Alignment CAUTION The generator weighs 80 lbs. (36.4 kg). Lift replacement generator into position A suitable lifting device MUST be used to raise and lower the generator for removal and installation. Failure to Hand tighten the bolts/nuts properly support the generator could result in injury or damage to the gener- ator.
  • Page 170 Place the target on the generator pulley so that it faces the laser. The alignment ribs must rest so that there is one pulley groove on either side of the target. Adjust the generator alignment by loosening the mounting bolts and sliding the generator until the laser and target are in alignment.

  • Page 171: Generator Capacitor Replacement/Testing

    8.6.2.6 Generator Capacitor Replacement/Testing Remove the cable ties securing the capacitor / generator leads to the breaker bracket. 1. Cable tie location One at a time cut the capacitor leads at the capacitor/generator splice points. Strip 1/4” of insulation from the capacitor leads. Do not allow leads to contact each other. CAUTION The generator capacitor contains high voltage and may remain energized when the system is turned OFF.
  • Page 172 Remove the nuts/washers securing the capacitor/clamps to the breaker bracket. _______________________________ Position heat shrink tubing over the ends of both of the generator excitation leads Strip ¼” of insulation from the generator exci- tation and replacement capacitor leads Crimp the butt splice to the excitation leads and then the other end to the capacitor leads.

  • Page 173: Generator Flashing

    Secure capacitor/excitation wires to breaker bracket with cable ties using cable tie base. 1. Cable tie locations 8.6.2.7 Generator Flashing NOTE Under normal operation and with replacement generators, this flash procedure is not typi- cally required. Generator field flashing may be required if the generator does not produce voltage.
  • Page 174 Reconnect battery cables and start APU Connect one of the insulated jumper wires to the B+ bus bar and the other to the ground bus for two seconds. Remove the jumper wires Stop the APU Disconnect the battery cables and perform LOTO Reconnect the generator excitation leads to the generator capacitor.

  • Page 175: Frame Cover Removal

    8.6.3 Frame Cover Removal WARNING Unit may start automatically at any time even if the Aspen Interface (AI) is Off. Before performing any work, turn OFF the AI, disconnect the battery cable ends, lockout both battery ends and remove shore power if equipped. Proper lockout/tagout procedures must be followed.
  • Page 176 Slide the side covers along the frame, ensuring the tabs (1) are inside the frame and fully seated. Insert the bolts (2) through the bushing/sleeve verifying the gap between the frame and busing is less than 0.10”(2.5 mm). If the gap is greater than 0.10” (2.5mm) remove the cover and adjust 89 ±...
  • Page 177 Grab the sides of the top cover and insert the back edge between the flange bracket and APU frame. Push the cover toward the back of the APU until the posts extend past the cover on both sides. Insert the knob through the hole in the flange bracket and cover.

  • Page 178: Top Bracket

    8.6.4.1 Top Bracket The top cover of the APU is not intended to be a step. The top bracket provides support to the top cover and reduces the likelihood of injury or damage to the cover in the event that weight is acciden- tally placed on the cover.

  • Page 179: Flange Bracket

    8.6.4.2 Flange Bracket Remove the tether/knob if installed Remove the bolts securing the flange bracket to the frame Inspect the condition of the tether and knob Inspect the condition of the spring clips on the underside of the flange bracket Replace the bracket if the clips are damaged or missing Install the flange bracket on the frame also...

  • Page 180: Lower Legs/Skid Plate

    8.6.4.3 Lower Legs/Skid Plate Remove the three bolts on each side of the frame securing the lower leg/skid plate assembly. __________________________________ Remove the five bolts securing the skid plate to the lower legs Remove the countersunk bolts from the side of the legs __________________________________ Install the lower leg assembly...

  • Page 181: Latch And Keeper Replacement

    8.6.4.4 Latch and Keeper Replacement Remove the screw securing the latch and keeper to the upper and lower covers. When reinstalling the keeper orient it so that the post aligns with the top hole and the screw on the bottom. Position the latch so that the angled handle will face outward when installed.

  • Page 182: Step Plate

    8.6.4.5 Step Plate 8.6.4.6 APU Frame and Hardware Mounting Inspection Inspect the APU frame and all attached brackets/hardware for cracks, damage, and/or loose/missing hardware. Repair as required. Verify position the frame grippers on the truck frame rail. Mounting bolts/washers pass through the frame grippers and then into the back of the APU frame through the mounting holes.

  • Page 183: Power Unit Lifting (Refer To Installation Manual)

    Verify the torque the APU mounting bolts using 1-4 stepped torque sequence. NOTE Thick-walled impact sockets may not allow socket to properly engage hard- ware inside frame. Use appropriately sized deep well socket. Improper torquing of the mounting bolts may result in APU frame damage. Torque bolts 1-2-3-4 to 30 ft-lbs Torque bolts 1-2-3-4- to 70 ft-lbs Torque bolts 1-2-3-4 to 100 ft-lbs...

  • Page 184: Aspen Interface

    Aspen Interface 8.7.1 Aspen Interface Remove the battery cables and perform Lockout/Tagout. WARNING Unit may start automatically at any time even if the Aspen Interface (AI) is in APU OFF status. Before performing any work, ensure the AI is in the APU OFF status, both bat- tery cables disconnected and any external shore power removed.
  • Page 185 8.7.2 Aspen Interface (AI) Installation Insert AI into the opening. DO NOT force the AI into the panel open- ing as damage may occur. If the AI does not easily snap into place, the opening is too small. Remove the AI and trim the panel to fit.

  • Page 186: Ccu Service

    CCU Service CAUTION CAUTION must be used as there are both 12 VDC and 120 VAC circuits within the CCM/CCU. Prior to performing any repairs on the CCU, Perform LOTO to prevent any possibility of the APU accidentally starting. Ensure the shore power or other external power source is discon- nected.
  • Page 187 Disconnect CCM board connections J1 - J13. Disconnect TB1 connections. Loosen generator cable strain relief nut and remove generator wire leads from CCM opening. 3.5 x 0.6mm Remove the eight screws securing the CCM board to the CCM housing. Electronic modules MUST be handled with care to prevent accidental damage or degradation from electrical static dis- charge (ESD), contamination or abuse.
  • Page 188 Insert generator wires/strain relief through CCM opening. Position nut over wires. Insert ferrules into TB1 connector. Tighten set screws. Tighten strain relief jam nut. WARNING When tightening the TB1 screws, the appro- priate slotted bit size (3.5x0.6mm) and torque screwdriver must be used. Incorrect bit size may damage the connector/screws and prevent proper toquing.
  • Page 189 Install HV harness cover over studs Secure CCM harnesses to CCN. Refer to 62-12173, Section??? Tighten HV harness cover hardware. Reconnect battery cables and leave starter solenoid disconnected. Update software. Upload/program unit configuration. 8–53 62-12174...

  • Page 190: Filter Replacement

    8.8.2 Filter Replacement Grasp the top center of the filter and pull out- ward. Clean/replace the filter if required. Clean filter by running warm water over the filter in the reverse direction of normal flow Shake/blow-out excess water. Reinstall filter by centering filter over evaporator opening and tucking filter behind flange.

  • Page 191: Compressor Cover

    8.8.4 Compressor Cover Remove the bolts (A) securing the compressor cover. Remove the compressor cover. Install the compressor cover. Tighten bolts. 4 ft-lb 8.8.5 High Voltage (HCV) Harness Cover Remove nuts securing HV harness cover to CCU. Separate wiring harnesses from HV harness cover studs.

  • Page 192: Evaporator Cover

    8.8.6 Evaporator Cover Remove HV harness cover. Remove cable ties securing CCM harnesses as needed. Remove bolts (A) securing cover to CCU. Lift the CCU cover off and hinge to the right side of CCU as viewed from the filter face. NOTE If the CCM harnesses have been installed pro perly, the CCM and harnesses can...

  • Page 193: Heater/Evaporator Fan Assembly Removal

    8.8.8 Heater/Evaporator Fan Assembly Removal Remove CCU evaporator cover (see Section 8.8.6) Disconnect HTR_CCU (A) and BMR_CCU (B) connectors. Disconnect EVM (C) connector. Remove evaporator motor capacitor cover. Discharge capacitor. Remove spade terminals from capacitor. Remove SAT from evaporator fan support. Lift Evaporator fan/heater assembly out of CCU.

  • Page 194: Heater/Evaporator Fan Assembly Installation

    8.8.9 Heater/Evaporator Fan Assembly Installation Install heater/evaporator assembly into CCU. Ensure the flanges of the evaporator fan sup- port align with the channels in the CCU housing. Verify evaporator fan spins freely. Reconnect HTR_CCU, BMR_CCU, and EVM connectors. Secure connectors with cable ties to wire tie base.
  • Page 195 8.8.10 Heater Replacement Remove the outer nuts on the fan side of the evaporator/heater assembly. Remove the heater assembly from the evaporator fan motor bracket Install the replacement heater assembly. Install star washer and nuts on the heater assembly studs. Tighten nuts.
  • Page 196 8.8.11 Evaporator Fan Replacement Remove cable ties (A) securing evaporator fan motor harness to evaporator motor frame. Remove grommet (B) and feed EVM_CCU through opening. Remove nuts (A) securing evaporator motor frame to evaporator/heater assembly. Remove bolts (A) securing evaporator motor to evaporator motor frame.
  • Page 197 Install evaporator motor on the evaporator motor frame. NOTE Position the motor so that the wire harness is on the same side as the fir tree holes in the evaporator motor frame. Tighten the bolts. 8-10 ft-lb Secure the evaporator motor harness to the evaporator motor frame at the tape locations using cable ties.
  • Page 198 8.8.12 EST Removal Remove CCU evaporator cover. Disconnect EST connector (A) and pull EST sensor (B) straight out of evaporator core. CAUTION The evaporator core fins are sharp. Use appropriate hand and arm protection when servicing the evaporator core. Insert EST Sensor between the evaporator core tubes and fins.
  • Page 199 8.8.13 Evaporator Removal Remove CCU evaporator and compressor covers Recover refrigerant charge. Remove EST from evaporator core Remove suction line (A) from TXV. Remove sight glass/strainer assembly (B) from TXV. Remove bolt (A) securing TXV support to CCU housing. Lift evaporator assembly out of the CCU hous- ing.
  • Page 200 8.8.14 TXV Replacement Remove hardware securing TXV support to TXV body. Loosen evaporator inlet and outlet fittings. Cap evaporator fittings if TXV will not be replaced immediately. Install new O-rings on evaporator inlet and outlet fittings. Lubricate O-rings with oil. Install TXV on the inlet/outlet fittings.
  • Page 201 8.8.15 Evaporator Core Install TXV support bracket hardware hand tight. Install evaporator assembly in the CCU housing. CAUTION The evaporator core fins are sharp. Use appropriate hand and arm protection when servicing the evaporator core. Tighten the TXV support bracket to the CCU housing.
  • Page 202 Install new O-ring on the sight glass/strainer. Lubricate O-ring with oil. Install sight glass/strainer assembly to TXV. DO NOT remove caps until ready to make connections. DO NOT over-tighten connections. DO NOT twist or stress tubes when tighten- ing hoses. DO NOT bend tubes to adjust alignment/fit.
  • Page 203 8.8.16 Compressor Removal Remove CCU compressor cover Recover refrigerant charge Remove compressor access cap. Remove nut securing compressor wire cover/ ground Disconnect compressor wires. Disconnect CDT, CST, CDP, CSP and BPS electrical connectors. If replacing the compressor, remove the sensors and pressure switch. Disconnect discharge hose (1).
  • Page 204 Remove hardware (1) securing compressor to CCU. Lift compressor assembly out of CCU. 62-12174 8–68...
  • Page 205 8.8.17 Compressor Discharge/Suction Pressure Sensor (CDP/CSP) and Binary Pressure Switch (BPS) ReplacementRefrigerant Recovery Remove the electrical connector from the sen- sor/switch. 1. CDP 2. BPS 3. CSP NOTE Schrader valves are installed between the sensor/switch and the port on the compres- sor line.
  • Page 206 8.8.18 Refrigerant Recovery WARNING Never use air or gases containing oxygen for leak testing or operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to explosion. Do not use a nitrogen cylinder without a pressure regulator. Cylinder pressure is approximately 2350 psig (159.9 bar).
  • Page 207 8.8.19 Evacuation and Charge Connect manifold gauge set, micron gauge, and vacuum pump. Vacuum system to 500 microns and verify sys- tem holds for minimum 15 minutes. NOTE If system did not hold pressure, perform leak check. Scan code to access leak check pro- cedure (98-50398).
  • Page 208 Connect R-134a cylinder to manifold gauge set Zero refrigerant scale. Open low and high side valves and vapor charge with R-134a to break vacuum. Close high side valve when scale stabilizes and low/high side pressures match. Continue adding refrigerant until scale reads 40- 45oz.
  • Page 209 Condenser 8.9.1 Condenser Assembly Removal Disconnect the condenser fan connector (1) Remove AAT bracket/sensor assembly (2) Recover refrigerant from the system. Disconnect the refrigerant lines from the con- denser inlet/outlet and filter/drier. Use backing wrench. 8–73 62-12174...
  • Page 210 Remove the six bolts securing the condenser assembly and filter drier to the cab. 62-12174 8–74...
  • Page 211 8.9.2 Filter Drier Loosen band clamps from filter drier bracket assembly. Remove filter drier. Install replacement filter drier with inlet/outlet ports parallel to inlet/outlet ports on the con- denser core. Tighten band clamps. Keep filter drier and refrigerant lines capped until lines are being installed.
  • Page 212 8.9.4 Condenser Core Replacement Remove the four bolts securing the condenser core to the housing Position replacement condenser in the housing Secure condenser core to housing with bolts 1. Condenser core mounting bolts 26-35 in-lb 8.9.5 Condenser Assembly Installation Leave caps on the inlet/outlet ports and refrigerant lines until refrigerant lines are being installed.
  • Page 213 Connect the refrigerant lines using new O-rings. Apply POE oil to O-rings. Tighten fittings with the use of backing wrench. Leave the caps on the inlet/outlet ports and refrigerant lines until refrigerant lines are installed. Only use POE oil from sealed pipette. 10-15 ft lb Vacuum system for 500 microns.
  • Page 214 8.9.6 Condenser Inspection and Cleaning Inspect the condenser core cleanliness and condition. 90% or more of the condenser core must be undamaged. Inspect condenser and fittings for dark spots/oil that may indicate leaks. Verify hardware is in good condition and tight. Remove all foreign material from the condenser using compressed air or low pressure water.
  • Page 215 8.9.9 Battery WARNING Never use air or gases containing oxygen for leak testing or operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to explosion. Do not attach battery connections until repair is complete and unit is ready to run. Fuse/fuse holder must be installed.
  • Page 216 Install replacement fuse. WARNING Tighten fuse holder nuts. Apply insulating varnish or dielectric grease Do not attach battery connections nil repair to battery cable connections. is complete and unit is ready to run. Install fuse holder cover. Fuse/fuse holder must be installed. Attach battery cable ends after repairs are complete and unit is ready to run.
  • Page 217 8.10 Diagnostic Testing 8.10.1 No/Low AC Voltage Diagnostic Test Directions: Complete each of the applicable diagnostic steps to determine the cause of no / low voltage. Record measured values in the appropriate boxes on the form. Refer to reverse side of form and 62-12174 for additional detail for each diagnostic test.
  • Page 218 62-12174 8–82...
  • Page 219 Value Preliminary Diagnostics a) Is generator belt broken, missing, or Replace belt Go to 1b worn? b) Check generator frequency from Hz Go to 1c Determine cause CabinTech system values. Is generator of incorrect frequency between 60 Hz ± 2 generator speed (low heat ON and no other loads)? (page 2).
  • Page 220 Reset Breaker/Check Breaker Output (Engine Running/No Load) Is voltage greater than 100VAC between VAC Go to step 10 Replace breaker generator breaker output and ground? Check Current Draw (Generator Output/Engine Running/No Load) Is there greater than 0.5A flowing in the A Locate/repair load on Go to step 11 circuit with engine running?
  • Page 224 Central America and Mexico Carrier Transicold Carrier Transicold 700 Olympic Drive Ejercito Nacional 253-A Piso 5 Athens, GA 30601 USA Colonia Anahuac 11320 Mexico D.F. ©2024 Carrier Corporation. Printed in USA 06/24. Carrier, Carrier Transicold is a registered trademark of Carrier Corporation.

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