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Kenworth Clean Power™ System Operator’s Manual

Y53-1024 12/06

English Page 5

French Page x

Spanish Page x

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NORMAL

OFF/RESET

OFF

Inverter/Charger Lamp

Shore Power Lamp (120-Volt AC)

Air Conditioning/Heating Switch

Inverter/Charger Switch

Air Conditioner Pump Lamp

Fan Control Dial

Sleeper Fresh/Recirculation Air Switch

CHARGE

Charge/Enable Switch (located on dash)

Protection Unit (Circuit Breaker/GFCI) (located in driver’s side tool box)

Sleeper Control Panel

Temperature Control Dial

Green Snowflake

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NORMAL

OFF/RESET

OFF

Page 19

Page 26

Page 24

Page 19

Page 28

Page 25 & 27

Page 28

CHARGE2

Page 22

Page 27

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contents

Jump-Start Procedure ................................................. 9Diagram ...................................................................................10Charging using Shore Power ...................................................12Charging using Battery Charger ..............................................13

12-Volt DC System ..................................................... 14Main Batteries ..........................................................................15Starter Batteries ......................................................................16Interior Lighting ........................................................................16Electrical System Monitoring ...................................................17Low Voltage Disconnect ...........................................................17

120-Volt AC System ................................................... 18Shore Power and Inverter ........................................................18Inverter/Charger Switch ...........................................................19Inverter/Charger & Shore Power Lamps ..................................19Inverter/Charger Indicator Chart ..............................................20

Protection Unit .........................................................................22120-Volt AC Outlets .................................................................23

Introduction

The Kenworth Clean Power System .......................... 5Location of Components ............................................................6Safety Signals ............................................................................7

Electric Power System

Troubleshooting

Troubleshooting ......................................................... 34

Heating and Air Conditioning SystemUsing the Heater ........................................................ 24

Air Conditioning/Heating Switch ..............................................24Temperature Control Dial .........................................................25Fuel-Fired Heater ....................................................................25

Using the Air Conditioner ......................................... 26Air Conditioning/Heating Switch ..............................................26Temperature Control Dial .........................................................27Air Conditioning Pump ON Lamp ............................................27Fan Control Dial .......................................................................28Fresh/Recirculation Air Switch .................................................28Cooling Vents ..........................................................................29Storage Cooler ........................................................................30Air Conditioning Charge Unit ...................................................31Charge Enable Switch .............................................................32System Operation to Ensure Maximum Cooling Efficiency ....................................................................33

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Introduction

InTrODUCTIOn

The Kenworth Clean Power System

The Kenworth Clean Power System is a battery-powered sleeper climate control system with the capability to provide engine-off heating and cool-ing, plus 120-Volt AC accessory power to drivers for up to 10 hours. To recharge the cooling and electrical capacity, the truck must be driven or connected to shore power.

The Kenworth Clean Power System sleeper heating and air conditioning system is an independent system from the cab heating and air conditioning system. Both the controls and the heat and cooling sources are different.

Kenworth Clean Power System features include:

Compliance with all state and federal anti-idling regulations.

Engine-off sleeper heating, cooling, and 120-Volt AC power.

No engine noise or vibration.

Improved fuel economy.

•

•

•

•

This Operator’s Manual contains useful information for the safe and ef-ficient operation of your Kenworth Clean Power System.

All information contained in this manual is based on the latest production information available at the time of publication. Kenworth Truck Company reserves the right to make changes at any time without notice.

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Introduction

High Output Alternator

Starter BatteriesStorage Cooler (under lower bunk)

Main Batteries

Air Conditioning Charge Unit

Enhanced Insulation

Fuel-Fired Heater(in passenger’s side tool box)

LED Lighting

Protection Unit(in driver’s side tool box)

location of Components

Starter Battery Disconnect Switch (cab fl oor)

Shore Power (120-Volt AC)Connector

Main BatteryDisconnect Switch

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Introduction

Safety Signals

A number of alerting messages are in this manual. Please read and follow them. They are there for your protection and information. These messages can help you avoid injury to yourself and your passengers, and help prevent costly damage to the vehicle.

Key symbols and “signal words” are used to indicate what kind of message is going to follow. Pay special attention to instructions prefaced by symbols and signal words “WARNING,” “CAUTION,” or “NOTE.” Please do not ignore any of these alerts.

WArnInG

When you see this symbol and word, the message that follows is especially vital. This signals something that can cause injury or even death. This message will tell you what the hazard is, what can happen if you don’t heed the warning, and how to avoid it.

Example:

WARNING! Do not carry additional fuel contain-ers in your vehicle. Fuel containers, either full or empty, may leak, explode, and cause or feed a fire. Do not carry extra fuel containers, even empty ones are dangerous.

CAUTIOn

This symbol and word signals something that could damage your vehicle.

Example:

CAUTION: Continuing to operate your vehicle with insufficient oil pressure will cause serious engine damage.

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Introduction

nOTE

Gives you information we feel you would like to have. It could have to do with care of your vehicle or with driving more efficiently.

Example:

NOTE: Pumping the accelerator will not assist instartingtheengine.

Please take the time to read these messages when you see them, and remember:

WARNING!

Something that could cause an injury or even death.

CAUTION:

Something that could cause damage to your vehicle.

NOTE:

Useful information.

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Charging instructions for the Kenworth Clean Power System is as follows:

ElECTrIC POWEr SySTEMWARNING! Do not attempt to jumpstart the ve-hicle. The electrical charging system used for the Kenworth Clean Power System is different than normal charging systems. Failure to adhere to the proper charging procedure could lead to seri-ous injury or vehicle damage. Refer to the charg-ing instructions located on the top of the main battery box cover or in the Kenworth Clean Power operator’s manual supplement/service manual.

Do not attempt to jumpstart the vehicle. If you have a battery problem, it is best to contact an authorized Kenworth repair facility or a reputable towing service. When you do, inform them of the charging instructions and the wiring schematic on page 10.

Vehicles equipped with the Kenworth Clean Power System have battery configurations that are different than traditional vehicles. These vehicles have two different sets of batteries; the Main Batteries and the Starter Bat-teries.

Starter Batteries Charging Terminals Main Batteries

Charging Instructions

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CHARGING

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The Main Batteries are located behind the sleeper, on the driver’s side. They power all electrical systems on the vehicle EXCEPT the starter mo-tor.

The Starter Batteries are located below the cab, on the driver’s side, where the vehicle’s batteries have traditionally been located. They power the starter motor.

NOTE: Thestarter relayandotherenginecontrolsrelyon theMainBatteries forpower; therefore, theStarterBatteriescanbefullychargedandtheStart-erMotorwillnotcrankif theMainBatteriesarenotcharged.DonotjumpstarttheStarterBatterieswith-outcheckingtheMainBatteryvoltagefirst.

A DC/DC charger, also located below the cab on the driver’s side, serves to isolate the starting batteries from the main batteries and provides charge to the starting batteries to maintain them at a minimum of 12-Volt.

NOTE: The DC/DC charger will only be activatedwhen either the truck is running or the truck is at-tachedtoa120-VoltACelectricalsupplyandthekeyisintheIGNposition.

1. Check battery voltmeter gauge on dash to ensure main battery voltage is at least 9.5-Volt.

2. If not, plug into 120-Volt AC electrical supply to charge main batteries or attach battery charger to charging terminals located in back of sleeper.

3. Once main battery voltage is at least 9.5-Volt, attempt to start the truck. If truck does not start, ensure that starter battery voltage is at least 12-Volt (check at starter using voltmeter.)

4. If not, charge the starter batteries with an external battery charger.

5. Once starter battery voltage is at least 12-Volt, attempt to start the truck. If truck does not start, the truck should be towed to the nearest authorized Kenworth dealer.

Refer to the Troubleshooting Section on page 33 for more details.

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Disconnect Instructions

Prior to servicing the vehicle, disconnect the electrical system as follows:

1. Unplug connection to 120-Volt AC electrical supply.

2. Turn disconnect located at cab floor to OFF position.

3. Turn disconnect located on main battery box (located driver’s side, rear of sleeper) to OFF position.

NOTE: Donotconnectanyaccessoriesdirectly tothe starting batteries. Accessory loads should beconnectedtothemainbatteriesonly.

Refer to Kenworth Clean Power operator’s manualsupplement/servicemanualforfurtherdetails.Ifyouare uncomfortable with performing the proceduresabove, contact the nearest authorized Kenworthdealer.

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WARNING! Electric Shock Hazard. 120-Volt AC power present. Only a trained technician should work on the 120-Volt AC system. Turn all dis-connects (both at the cab floor and on the main battery box located on the driver’s side, back of sleeper) to the OFF position and unplug the 120-Volt AC electrical supply before servicing any part of the vehicle’s electrical system.

WARNING! An improperly maintained 120-Volt AC electrical system can cause fires and electrical shocks that may lead to personal injury or prop-erty damage. Regularly inspect 120-Volt AC

Charging using Shore Power (120-Volt AC Electrical Supply)

Shore Power Connection

electrical wiring connectors for damage. Always use a properly grounded 20 Amp AC extension cord that is no longer than 25 ft. and a 20 Amp AC protected power source with a grounding con-ductor when connecting to a 120-Volt AC electri-cal supply.

WARNING! The Shore Power electrical system can cause fires resulting in personal injury and/or property damage if not properly maintained. Regularly inspect the Volt AC truck wiring, AC ex-tension cord, plugs, and connectors for damaged or frayed wiring. Do not use the Shore Power system if there are any signs of problems. Con-tact your authorized Kenworth Dealer if you are in need of repairs or information.

Attach the 120-Volt AC extension cord to a 20 amp protected circuit un-til system voltage is restored. The Shore Power electrical connection is located on the rear of the Main Battery Box. Make sure that the Inverter/Charger Switch is in the ON position and that the circuit breaker on the Protection Unit box has not been tripped. The Shore Power Lamp on the Sleeper Control Panel will illuminate green and the Inverter/Charger Lamp will illuminate orange.

Normal system voltage is 13.5 to 14.6 -Volts. Typically the Main Batteries must reach at least a 9.5-Volt charge to power the engine controls neces-sary to start the engine.

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Charging using Battery Charger

Attach a battery charger to the charging terminals and charge batteries until system voltage is restored. Refer to “Battery Charging” in the KenworthOperator’sManual for proper battery charging procedures.

Caution: Do not attempt to jumpstart the vehicle. Terminals are for use with external battery char-ger only. For charging instructions, see top of main battery box cover or the kenworth Clean Power operator’s manual supplement/service manual.

Positive (+) and negative (-) charging terminals for are located above the frame rail, behind the sleeper, on the driver’s side of the vehicle.

Negative (-) Charging Terminal

Positive (+) Charging Terminal

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12-Volt DC System

Starter Batteries Main Batteries

The 12-Volt Direct Current (DC) System consists of Main Batteries, Starter Batteries, a Low Voltage Disconnect system, gauges for Electrical Moni-toring, and special Interior Lighting. Vehicles equipped with the Kenworth Clean Power System have a unique 12-Volt electrical system. The system uses a high output alternator and two sets of batteries; the Main Batteries and the Starter Batteries.

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The Main Batteries are located on the driver’s side of the vehicle behind the sleeper compartment. The four Deep Cycle AGM (Gel-Cell) batteries power all electrical system components on the vehicle EXCEPT the starter motor.

Caution: Do not replace the Deep Cycle AGM (Gel-Cell) batteries with common lead acid batteries. The Kenworth Clean Power System is designed to draw to very low voltages which will signifi-cantly reduce the life of a lead acid battery. Use only PACCAR recommended Main Batteries. See your Kenworth dealer for additional information.

NOTE: Because theMainBatteriespower theen-ginecontrols,youmayexperienceano-crankcondi-tionifthemainbatteryvoltageisbelow�.5-Volt,eventhoughtheStarterBatteriesarefullycharged.

Main Batteries

WARNING! Do not cover the batteries with ad-ditional insulation or covers or store any items around the batteries. Additional insulation or items around the batteries will lead to poor vent-ing which could result in a fire and/or explosion that may lead to personal injury or equipment damage.

Main Batteries Deep-Cycle AGM (Gel Cell) Batteries

Shore Power Connector

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Starter Batteries

The Starter Batteries (two 1000 Cold Cranking Amp 12-Volt batteries) are located below the cab on the driver’s side of the vehicle. These batteries are used only to power the starter motor.

A DC/DC charger is located below the cab on the driver’s side of the ve-hicle. It serves to isolate the starting batteries from the main batteries and provides charge to the starting batteries to maintain them at a minimum of 12-Volts.

NOTE: The DC/DC charger will only be activatedwhen either the truck is running or the truck is at-tachedtoa120-VoltACelectricalsupplyandthekeyisintheIGNposition.

low Voltage Disconnect

The electrical system is equipped with a low voltage disconnect feature that will shut-down all non-essential electrical components if Main Battery voltage drops below 11.0 -Volt. Three minutes prior to system disconnect an audible warning in the Sleeper Control Panel will sound to give the operator time to switch to an alternative power source or reduce loads. To reset the system the Main Batteries must be charged until a system voltage of 13.2-Volts or greater is reached. This can be accomplished by attaching to shore power, starting the engine, or attaching a battery charger to the charging terminals. Turning the ignition key to the ON position will not disable the Low Voltage Disconnect.

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Electrical System Monitoring

Normal system voltage on vehicles equipped with the Kenworth Clean Power System is between 13.5 and 14.6 -Volts. This is slightly higher than vehicles without the Kenworth Clean Power System.

All vehicles come equipped with a dash-mounted voltmeter. Some vehicles may be equipped with an optional ammeter as well.

-150-75

0

+150+75

AMPSA- +

VOLTS

18

1512

9- +

300

250200

150

100WATER

10080

60200

OIL

NOTE: These gauges monitor the Main Batteries,nottheStarterBatteries.

An indicator lamp on the face of the voltmeter will illuminate if system volt-age reaches 15.0 -Volts. This is considered an over voltage condition. If this occurs, contact the nearest authorized Kenworth repair facility.

Ammeter (Optional)

Voltmeter

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Interior lighting

Your vehicle may be equipped with Light Emitting Diode (LED) interior lamps. These lamps are more efficient and have a greater life expectancy than incandescent lamps.

LED light fixtures do not have replaceable bulbs as do incandescent light fixtures. If an LED light fails the entire fixture may need to be replaced.

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Shore Power (120-Volt AC System)

WARNING! Electric Shock Hazard. 120-Volt AC power present. Only a trained technician should work on the 120-Volt AC system. Turn all dis-connects (both at the cab floor and on the main battery box located on the driver’s side, back of sleeper) to the OFF position and unplug the 120-Volt AC electrical supply before servicing any part of the vehicle’s electrical system.

The 120-Volt Alternating Current (AC) system consists of a 120-Volt AC Electrical System connection, Inverter/Charger, Protection Unit, and 120-Volt AC outlets in the sleeper.

Shore Power and Inverter

Shore Power Hook Up

WARNING! An improperly maintained 120-Volt AC electrical system can cause fires and elec-trical shocks that may lead to personal injury or property damage. Regularly inspect 120-Volt AC electrical wiring connectors for damage. Always use a properly grounded 20 Amp AC extension cord that is no longer than 25 ft. and a 20 Amp AC protected power source with a grounding con-ductor when connecting to a 120-Volt AC electri-cal supply.

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WARNING! The Shore Power electrical system can cause fires resulting in personal injury and/or property damage if not properly maintained. Regularly inspect the Shore Power truck wiring, AC extension cord, plugs, and connectors for damaged or frayed wiring. Do not use the Shore Power system if there are any signs of problems. Contact your authorized Kenworth Dealer if you are in need of repairs or information.

The Kenworth Clean Power System enables you to access 120-Volt AC power from two different sources. A Shore Power connection allows access to an outside power source and an electrical inverter system can produce 120-Volt AC from the Main Batteries.

Inverter/Charger Switch

The 120-Volt AC system function is controlled by the Inverter/Charger Switch located on the Sleeper Control Panel.

When the top of the switch is pressed, (NORMAL position) the inverter/charger is on and the green electrical outlet symbol on the switch will turn on. This is the normal operating position for the invert-er/charger.

When the bottom of the switch is pressed (OFF/RE-SET position), the inverter/charger will be off and the green electrical outlet symbol on the switch will turn off. Refer to the Inverter/Charger Indicator chart on the next two pages for Reset information.

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LED Status System Status

Inverter/Charger LED 120VAC LampInverter/Charge

Switch 120VAC Inverter Charger

Solid Green OFF ON OFF ON OFF

Blinking Green (0.5 sec ON, 4.5 sec OFF) OFF ON OFF Input Low Voltage OFF

Blinking Green (0.2 sec ON/OFF, 4.5 sec OFF) OFF ON OFF Input Low Volatge Warning OFF

Blinking Green (0.5 sec ON, 4.5 sec OFF) OFF ON OFF Input Over Voltage Protection OFF

Solid Red OFF ON OFFOverload; Short Circuit

Protection; Output Over Voltage Protection

OFF

Blank OFF ON OFF Over Temp OFF

Solid Orange Solid Green ON ON OFF ON

Solid Orange Solid Green ON ON OFF Thermally Derated ChargeSolid Orange Solid Green ON ON OFF Overload; SCP

Blinking Orange/Red (4 sec Orange, 1 sec Red) Solid Green ON ON OFF Low Voltage Charging

Blinking Orange/Red (0.5 sec Orange, 0.5 sec Red) Solid Green ON ON OFF Low Voltage Timed Charge

Blank OFF ON Battery Disconnect

Blank OFF OFF OFF

Inverter/Charger Indicator Chart

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LED Status

Inverter/Charger LED 120VAC Remedy

Solid Green Blank Normal inverter/charger operation, no action required.

Blinking Green (0.5 sec ON, 4.5 sec OFF) Blank

- Inverter/charger will auto-restart if voltage reaches an acceptable level.- Cycle inverter/charger on/off switch to off/reset and then back on to reset inverter.1

Blinking GreenBlank

- Inverter/charger will auto-restart if voltage reaches an acceptable level.

(0.2 sec ON/OFF, 4.5 sec OFF) - Cycle inverter/charger on/off switch to off/reset and then back on to reset inverter.1

Blinking Green (0.5 sec ON, 0.5 sec OFF) Blank

- Inverter/charger will auto-restart if voltage reaches an acceptable level.- Cycle inverter/charger on/off switch to off/reset and then back on to reset inverter.1

Solid Red Blank - Cycle inverter/charger on/off switch to off/reset and then back on to reset inverter.1

Blank Blank - Inverter/charger will auto-restart if temperature reaches an acceptable level.- Cycle inverter/charger on/off switch to off/reset and then back on to reset inverter.1

Solid Orange Solid Green Normal inverter/charger operation, no action required.

Solid Orange Solid Green Charging will derate at high temperatures, no action required.

Solid Orange Solid Green- Inverter/charger will auto-restart if conditions reach an acceptable level.- Cycle inverter/charger on/off switch to off/reset and then back on to reset inverter.1

Blinking Orange/Red (4 sec Orange, 1 sec Red) Solid Green

Low voltage charging operation, allows for charging of batteries as low as 5V, no action required.

Blinking Orange/Red (0.5 sec Orange, 0.5 sec Red) Solid Green

If batteries at a low voltage are not successfully accepting a charge, inverter/charger will turn off. Cycle inverter/charger on/off switch to off/reset and then back on to reset inverter/charger.1,2

Blank BlankTurn inverter/charger on/off switch to off/reset. Reconnect batteries to inverter/charger. Turn inverter/charger on/off switch to on.

Blank Blank For inverter/charger function, turn inverter/charger on/off switch to on.1 If after restarting the inverter/charger the blink code persists, please see your local Kenworth service dealer.2 Continuous charging of low voltage batteries is not recommended. If low voltage charging is unsuccessful after restarting inverter/charger, replace main batteries.

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Inverter/Charger & Shore Power lamps

Inverter/Charger Lamp

Shore Power Lamp

The Inverter/Charger and Shore Power Lamps located in the center of the Sleeper Control Panel will illuminate in an array of colors and configurations to designate system status. Refer to the Inverter/Charger Indicator chart on the next page for more information.

Protection Unit

20 Amp Circuit Breaker

Protection Unit (GFCI)

Protection Unit

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The Protection Unit houses a 20 Amp circuit breaker and a Ground Fault Circuit Interrupter (GFCI) that provides circuit protection for the 120-Volt AC system. The Protection Unit is located in the front of the tool box on the driver’s side of the sleeper.

The circuit breaker is located on the right side of the Protection Unit box. If the breaker is tripped (circuit open) it can be reset by pressing the top of the rocker switch to the ON position.

The GFCI is located on the left side of the Protection Unit box. The GFCI will open (disconnecting the power) if a ground fault is detected on the cir-cuit. The unit can be reset by pressing the RESET button on the top of the GFCI.

NOTE:ReplaceGFCIiflightonGFCIflashes.Ifthisisnotdone,outletswillnotbepowered.

WARNING! Electrical shock hazard. Use of a ground-fault circuit-interrupter other than that supplied with the Protection Unit may fail to op-erate properly and may lead to personal injury or equipment damage. Use only the ground-fault circuit interrupter that is supplied with the Pro-tection Unit.

120-Volt AC Outlets

120-Volt AC Outlets

Two 120-Volt AC duplex style outlets are located in the sleeper compart-ment, one under the driver’s side lower bunk, the second in the passenger side closet. They are powered by either a 120-Volt AC electrical supply or by the Main Batteries through the Inverter.

NOTE:TheInverterhasitsownlowvoltagediscon-nectsystemthatwillshutoffpowertothetwoduplexoutletswhentheMainBatteryvoltagegetsbelow11-Volts.

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Heating and Air Conditioning System

HEATInG AnD AIr COnDITIOnInG SySTEM

The Air Conditioning/Heating Switch is the leftmost switch in the Sleeper Con-trol Panel. The middle is the OFF position of the switch. Pressing on the top of the switch will turn on the sleeper air conditioning system. Pressing on the bottom of the switch will turn on the sleeper heating system.

The Temperature Control Dial is located on the left side of the Sleeper Con-trol Panel. Turning the dial clockwise from the 12 o’clock position to the red bands controls the sleeper heater. Turning the dial counterclockwise from the 12 o’clock position to the blue bands controls the sleeper air conditioning.

Air Conditioning ON Position

Heat ON Position

OFF

Heating Mode Red Bands

Air Conditioning Mode Blue Bands

Controls and Switches

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cab or sleeper. Entry of carbon monoxide into the cab or sleeper is also possible from other ve-hicles nearby. Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab/sleeper and cause serious illness.

Using the Heater

WARNING! Do not operate the sleeper heating system or ventilating system around hazardous fumes or exhaust gases. Hazardous fumes and exhaust fumes may be vented into the sleeper compartment causing serious illness that may lead to death. Do not park your vehicle near other vehicles that are idling or where other hazardous fumes may be present.

WARNING! Do not operate the heater portion of Kenworth Clean Power system in an enclosed, unventilated area. Exhaust fumes from the air heater contain carbon monoxide, a colorless and odorless gas which if inhaled, can cause serious illness. Never park in an enclosed area when op-erating the heater.

WARNING! Exhaust fumes from the engine con-tain carbon monoxide, a colorless and odorless gas. Do not breathe the engine exhaust gas. A poorly maintained, damaged, or corroded exhaust system can allow carbon monoxide to enter the

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Rotate the Temperature Control Dial clockwise to the Heating Mode. Rotat-ing the dial in a clockwise direction (reds band on dial) increases both the temperature and the Fuel-Fired Heater fan speed simultaneously.

NOTE:ThesleeperheaterhasitsownventandfanwhichareseparatefromtheSleeperVentsandFanControlDial.EventhoughtheheaterfaniscontrolledbytheTemperatureControlDial,theFanControlDialcanalsobeusedtomoveheatedairthroughoutthesleeperbysettingtheFresh\RecirculationAirSwitchtotheRecirculationposition.

Turn the Air Conditioning/Heating Switch to the On position.

NOTE:AflashingREDlampindicatesasystemfault.Contact the nearest authorized Kenworth repairfacility.

Air Conditioning/Heating Switch Temperature Control Dial

Heat ON Position

Heating Mode

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Fuel-Fired Heater

The Fuel-Fired Heater is a stand-alone unit that is controlled only by the Sleeper Control Panel. It is located in front of the toolbox on the passenger’s side of the vehicle. It’s design and function is similar to units used on other Kenworth vehicles. The heater uses diesel fuel drawn from the vehicle’s fuel tank(s) to create heat.

Using the Air Conditioner

WARNING! Do not operate the sleeper air con-ditioning system or ventilating system around hazardous fumes or exhaust gases. Hazardous fumes and exhaust fumes may be vented into the sleeper compartment causing serious illness that may lead to death. Do not park your vehicle near other vehicles that are idling or where other hazardous fumes may be present.

WARNING! Exhaust fumes from the engine con-tain carbon monoxide, a colorless and odorless gas. Do not breathe the engine exhaust gas. A poorly maintained, damaged, or corroded exhaust system can allow carbon monoxide to enter the cab or sleeper. Entry of carbon monoxide into the cab or sleeper is also possible from other ve-hicles nearby. Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab/sleeper and cause serious illness.

Fuel-Fired Heater

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Air Conditioning ON Position

Rotate the Temperature Control Dial counterclockwise to the Air Condi-tioning Mode. Rotating the dial in a counterclockwise direction from the 12 O’clock position (blue band on dial) adjusts air conditioning output tem-perature. Setting the dial within the green band should give 8 to 10 hours of cooling (depending upon the outside heat conditions). Adjusting the dial further to the left (yellow band on dial) will lower the output temperature but will deplete the cold storage capacity quicker.

Air Conditioning/Heating Switch Temperature Control Dial

Turn the Air Conditioning/Heating Switch to the air conditioning ON posi-tion.

Blue Band – Air Conditioning Mode

Green Band – 8 to 10 Hours Cooling

Yellow Band – Reduced Cooling Time

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Air Conditioning Pump On lamp

OFF

Fan Control Dial

The Air Conditioning Pump ON Lamp is located on the left side of the Tem-perature Control Dial between the blue band and the green snowflake. The lamp will illuminate green when the Temperature Control Dial is turned to a temperature range which requires the air conditioning pump to turn ON (i.e. colder temperature).

NOTE:RunningtheACPumpwilldepletethecoldstoragecapacityquicker.

Fan Control Dial

The Fan Control Dial is located on the right side of the Sleeper Control Panel. The dial controls fan speed for the air conditioning system only. In the full counterclockwise position the dial is in the OFF position. Turning the dial clockwise gradually increases fan speed. With the Fan Control Dial in the OFF position, the air conditioning system will be deactivated.

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Fresh/recirculation Air Switch

The Fresh/Recirculation Air Switch is the rightmost switch on the Sleeper Control Panel. The two-position switch controls the source of the incoming air to the air conditioning and ventilation system. With the switch in the FRESH position (Top position pressed) outside air is introduced to the air conditioning or ventilation system. In the RECIRCULATION position (Bottom position pressed) sleeper air is recirculated through the system.

The system can be operated in a ventilation only mode by placing the Air Conditioning/Heating Switch in the OFF position and moving the Fan Con-trol Dial from the OFF position. With the Fresh/Recirculation Switch in the FRESH position, outside air is vented to the sleeper compartment.

NOTE:TheFresh/RecirculationSwitchisonlyopera-tionalwhentheFanControlDialisintheONposition.WhentheFanControlDialisintheOFFposition,theFresh/Recirculationdoorandcontrolwill bedeacti-vated.TheFresh/Recirculationdoorwillremainintheposition(openorclosed)selectedpriortoturningtheblowerOFF.

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Cooling Vents

Output Vents

Return Vents

Up to four cooling vents are located in the sleeper compartment (depend-ing on the sleeper configuration). One or two output vents is/are located on the driver’s side of the compartment. One or two return vents is/are located on the passenger side compartment.

NOTE:Donotcloseorotherwiseobstructthereturnvent(s).Doingsowillnotallowthesystemtofunctionnormally.

This system is completely separate of the Fuel-Fired Heater and the cab air conditioning system. Cooling vents are used only to cool and ventilate the cab sleeper.

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Storage Cooler

Storage Cooler

Air Filter Air Handler

Storage Cooler

The Storage Cooler is located in the sleeper under the lower bunk. It stores the system’s cooling capacity by freezing water. As the system is used, the ice melts back into water and needs to be recharged (frozen) again by the Air Conditioning Charge Unit in order to cool the sleeper. A fully charged (frozen) Storage Cooler can cool the sleeper up to 10 hours (depending upon the outside heat conditions). The approximate time required to fully charge the Storage Cooler, without the sleeper Air Conditioning ON, is 4 to 8 hours. The sleeper cooling system can be used while the Storage Cooler is being charged by the Air Conditioning Charge Unit; however, this will increase the time required to fully charge the Storage Cooler.

This Storage Cooler is independent of the cooling system of the truck, and other than the air filter, there are no serviceable components inside or out-side of the container.

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The Air Conditioning Charge Unit is an electric refrigeration unit that op-erates automatically to cool the Storage Cooler, and is located on the passenger’s side of the vehicle, behind the sleeper compartment. The dash mounted Charge Enable Switch must be in the CHARGE posi-tion to enable the Charge Unit to operate. The unit will operate when the engine is running or connected to a 120-Volt AC electrical supply. It will not operate using only battery power as this will deplete the batteries too quickly.

WARNING! Electrical shock hazard. 120-Volts AC is present inside the charging unit. Disconnect power source to inverter before servicing equip-ment.

WARNING! Immediately get away from vehicle if you hear sounds or arching (sizzling, sputting or popping) inside the charging unit. Hot gas may vent from compressor terminals causing burns or ignition. Improper servicing can lead to fire, electrocution or explosion. Never service, repair or troubleshoot a system unless you are a trained service person.



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WARNING! The charging unit contains high pres-sure gas. Unauthorized access is prohibited. Tam-pering or improper service may result in sudden release of high pressure gas causing serious in-jury or damage to product. Only authorized deal-ers may perform maintenance or service of this product. All recommended service procedures and safety precautions must be followed to pre-vent the possibility of serious injury or damage to service equipment, or damage to product.

System is factory-filled with 23 lbs (1.0kg) of ultraviolet R134a refrigerant and POE oil. No additional oil needs to be added to the system when com-pleting recovery and recharging of refrigerant. After refrigerant recovery, a vacuum should be pulled on the system for approximately 0.5 hours to ensure that the system is properly sealed and leak-free.

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The Charge Enable Switch is located on the cab dash and enables the Air Conditioning Charge Unit to cool the Storage Cooler. The switch should normally be left in the CHARGE position (top of switch is pressed). Switch-ing to the OFF position (bottom of switch is pressed) will disable the Air Conditioning Charge Unit. When the Air Conditioning Charge Unit is on, a green lamp will be displayed on the Charge Enable Switch. When the Green lamp turns off, the charging cycle is complete.

NOTE:TheGreenlampcancycleonandoffasthesystemmaintainsthecoolingcapacity.

NOTE:TheChargeEnableSwitchdoesnotturnontheSleeperAirConditioningSystem.ItonlyenablestheAirConditioningChargeUnittocooltheStorageCooler.

SET

RESUME

SPARECHARGE

Charge Enable Switch

Charge Enable Switch

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System Operation to Ensure Maximum Cooling Efficiency

In order to achieve 8 to 10 hours of engine-off cooling many factors must be considered that will affect the systems cooling ability:

Vehicle Color

Ambient Temperature

Initial Compartment Temperature

Intake Air Mix

Sleeper Curtain Position

Window Coverings

The cooling system is meant to be a temperature maintained system, not a temperature pull-down system. That is, it should be used to maintain an already cooled sleeper compartment, not to lower the temperature of a warm sleeper.

For maximum cooling ability:

The sleeper compartment should already be at a comfortable tem-perature using the cab A/C system.

The window covers and sleeper curtain should be in place and closed.

The recirculation vents on the passenger’s side must be fully opened.

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The Fresh/Recirculation Switch should be in the RECIRC position.

The Temperature Control Dial of the sleeper should be in the green band.

The filter must be clean and clear of dust and pollen.

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Troubleshooting

Preventative Maintenance

Air Handling Filter

Check and replace dirty dust and pollen filter once every twelve months, or earlier if operating in highly dusty environments.

Other factors can also affect cooling. The air handler located under the bunk, houses the air filter for the air conditioning system. The air filter should be checked and cleaned periodically. You should also refrain from storing items under the bunk near the air handler and electrical components.

Air Handler

Fuel Filter

The fuel filter should be inspected every month during the heating season. Check the filter for debris, sediment or water. Replace if any is found.Replace the filter annually, preferrably before the start of the heating season.

Dust and Pollen Filter

NOTE: Do not substitute the Webasto supplied fuelfilter with a non-Webasto replacement filter. Irregularheater operation may result if a non-Webasto filter isused.

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Troubleshooting

TrOUBlESHOOTInGConcern Possible Cause Remedy

Parked truck will not get cool.

Storage core not charged.

1) Make sure chargeable dash switch is enabled.2) Make sure the inverter switch is in the ON position.3) Make sure the Protection Unit circuit breaker is not tripped, if necessary, reset.4) Air conditioning component service/refrigerant level check.(Please note if outside temperature is below 55°F, compressor will not turn on.)

Parked truck will not get cool.

Lack of cool air out of vents.

1) Make sure air conditioning mode is selected.2) Make sure blower is in the ON position.3) Make sure temperature control is set in the blue zone.4) If in recirc mode, make sure recirc vents are open.5) Service fresh air/recirc filter.6) Check coolant level.7) Component service.

Parked truck will not stay cool for 8-10 hours.

Storage core is depleting too quickly.

1) Make sure temperature control is set in the green zone.2) Make sure sleeper pass-through curtain is closed and all window coverings are installed.

Parked truck will not get warm.

Lack of hot air out of lower heater vent.

1) Make sure heating mode is selected.2) Make sure temperature control is set in the red zone.3) Check for heater diagnostic blink codes at the heater mode selection LED.4) Make sure heater inlet in tool compartment is not blocked.5) Make sure fuel and exhaust lines are not blocked.6) Component service

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Troubleshooting

Concern Possible Cause Remedy

Sleeper AC electrical outlets not working.

No power to sleeper AC electrical outlets.

1) Make sure inverter switch is in the ON position.2) Make sure the Protection Unit circuit breaker is not tripped, reset if necessary.3) Make sure Protection Unit GFCI is not tripped, reset if necessary.4) Component service.

Cannot run cab/sleeper DC loads.

Not enough power available for cab/sleep-er DC loads.

1) Make sure battery disconnects are not tripped, reset if necessary.2) Make sure LVD is not tripped (to reset, main battery voltage must be brought up to 13.2-Volts by starting the truck or using 120-Volt AC electrical supply).3) Check main battery voltage, if voltage is below 11.0-Volts, start truck to charge batteries, hook up 120-Volt AC electrical supply to charge batteries, or attach battery charger to charging terminals.

Cannot start truck. Voltage at main batter-ies is too low (below 9.5-Volt).

1) Make sure battery disconnects are not tripped, reset if necessary. 2) Hook up to 120-Volt AC electrical supply to charge main batteries or attach battery charger to charging terminals.

Cannot start truck. Not enough cranking power from starting batteries.

1) Check starting battery voltage, if voltage is below 12-Volt (check at starter using voltmeter), charge starting batteries with external battery charger.2) If starting battery voltage continues to discharge, replace starting batteries and/or service DC/DC charger.

Troubleshooting

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Notes

notes

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