manual - operationwillisapu.com/willisapu/files/67/67ce5f6c-c0e0-4c09-b5ab-cbff03da...most other...

Edited Oct. 29, 2008

MANUALfor

Operation,Routine Maintenance, and

Troubleshooting of the

Willis APU by

Email: [email protected]: www.willisapu.com

WILLISPOWER SYSTEMS, LLC

Willis Power Systems, LLC“Stop idling and start saving”

2950 N. Martin Ste B

800-825-4631

mailto:[email protected]

http://www.willsapu.com/

Willis APU Manual; Oct. 29, 2008; of 24

INTRODUCTION The Willis APU is the most capable APU available today. It requires less attention and maintenance than most other APUs and truck generators. Although service demands are not extensive, it is important to adhere to the service schedules defined in this manual. Service is generally quite simple to perform and all serviceable components are within easy reach. Our warranty provides good protection. To keep the warranty in force, follow the recommended maintenance procedures and schedules. Please call us at 1-775-825-4566 if you have any questions about procedures or requirements. TABLE OF CONTENTS PAGE 1. Safety Advisory 2 2. Warning Labels 3 3. Fluids 3 4. Parts for Routine Maintenance 3 5. Willis APU Warranty 4 6. Operating Instructions 5 7. Maintenance Schedule 7 8. Troubleshooting 8 9. Truck Interface Problems 9 10. Parts and Service 9 11. Periodic Maintenance Instructions 9 12. Long Term Storage 14 13. Pictures of Obsolete Drive Systems 14 14. System Troubleshooting Guide 15 15. Common Repairs and Suggested Repair Time Guide 17 16. System Diagrams 20 1. SAFETY ADVISORY GUIDELINES FOR SAFE OPERATION Before operating the Willis APU, be sure and read this manual and understand the features of the unit. Also read the separate manual for the diesel engine and other manuals that may have been included with your purchase. Do not remove or replace the APU’s cover while the APU engine is running. If the unit is running with the cover off, stay clear of the accessory drive belt. When the cover is removed, only qualified maintenance personnel should operate the Willis APU. Do not insert anything in the holes in the transmission case while the APU is running. Do not leave any foreign object in the transmission case. Do not work on any Willis APU components located on or near the truck engine when the truck engine is running. The unit is hot when running and for a time thereafter. Use protective clothing and gloves when working around hot components. The APU contains hot oil and coolant under pressure. Inspect hoses and connections frequently for signs of leakage or damage.


2. WARNING LABELS Observe all labeled warnings. Do not remove warning labels. 3. FLUIDS California Proposition 65 Warning: diesel engine exhaust and some of its constituents are known to cause cancer, birth defects and other reproductive harm. Follow the APU engine manufacturer’s instructions for handling and disposal of engine coolant and oil. Follow the instructions provided with the host truck manufacturer regarding handling and disposal of air conditioning refrigerant. 4. PARTS FOR ROUTINE MAINTENANCE All of the parts listed are available overnight from Willis. Call 1-775-825-4566. Air Intake/Silencer Filter: Willis Part Number 0770 Serpentine Belt: Willis Part Number 0977 for Willis APU; or 0957 for past production Willis APU without Air Compressor, past production Willis with Air Compressor 0330 Poly Insert for Engine-to-Drive Coupler: Willis Part Number 0333 Fan Drive Belt: Willis Part Number Varies by Tractor Model (Consult Service at Willis APU) Oil Filter for Engine: Willis Part Number 0373 Fuel Filter for Engine: Willis Part Number 0234 Engine Water Pump Belt: Willis Part Number 0171 Engine Oil: SAE 15W-40, all temperatures. Oil should meet API classification CC/CD/CE. Nominally 500 hours, or when truck’s oil is changed, whichever is earlier. Do not run the APU more than 750 hours without changing the oil. The first oil change must be performed at 50 hours per Kubota Engine Co. Notes:

1. Engine Coolant: No separate maintenance is needed. The APU uses the truck’s coolant. Nominally this is low-silicate 40% permanent antifreeze by volume for temperatures down to -12o F and 50% by volume below -12o F.


5. The Willis APU Warranty Program Auxiliary Power Dynamics (APD) warrants to the original buyer that the Willis APU installation hardware will be free from defects in material and workmanship for two years or 2000 hours of operation, whichever comes first, from the date of original truck installation by an Auxiliary Power Dynamics “Authorized Installation Center”. Kubota Engine The Kubota engine is warranted separately by Kubota Engine America Corporation for two years or 2000 hours which ever comes first, from the date of original truck installation by an Auxiliary Power Dynamics “Authorized Installation Center”. Major components The following major components are covered by the Original Equipment Manufacturer warranty. ( Alternator-one year, Air Conditioning Compressor-one year, Pneumatic Compressor – one year, and Cooling Fan, Radiator, Air Conditioning Remote Condenser Unit – one year ). APD will repair or replace any part covered by this warranty that becomes defective, malfunctions or otherwise fails to conform to this warranty under normal use and during the term of this warranty, at no charge for parts or labor. Repair and replacement of components under this warranty shall not extend the warranty period for the Willis APU, or for any component of the Willis APU, except as may be provided in manufacturers’ warranties for individual components at their option. In order to obtain warranty repairs, you should deliver the product, together with proof of purchase, to an Auxiliary Power Dynamics Authorized Installation and Service Center at your expense. If it is not practical to deliver the product, you should communicate the nature of the problem to APD. APD will work with you to arrive at a mutually acceptable solution, within reason. The names and addresses of Authorized Willis APU Installation and Service Centers are listed at www.willisapu.com or you may write or telephone us to obtain them. Warranty Disclaimer

1. Defects, malfunctions, or failures resulting from accidents, abuse, modifications, alteration, improper servicing, improper installation, or failure to perform required service

2. Normal maintenance services or parts associated with such services, including but not limited to filters, filter elements, oils, lubricants, coolant, belts, and glow plugs

3. Non-approved parts 4. Used parts 5. Any damage caused by overheating the Willis APU that is not a direct result of a defect in APU materials

or workmanship 6. Damage caused to the host truck due to improper maintenance or utilization of such truck, whether or not

such damage is related in any way to the presence of the Willis APU on the truck

http://www.willisapu.com/


We neither assume nor authorize anyone to assume for us any other express warranty. The Distributor/Dealer has no authority to make any representation or promise on behalf of Auxiliary Power Dynamics or to modify this warranty. All other expressed or implied warranties arising under law of equity, and including without limitation, the implied warranties of merchantability and fitness for a particular purpose are hereby expressly excluded from the sale and purchase of the Willis APU and related apparatus sold hereunder, regardless of whether a claim arises under contract tort principles. The buyer’s sole remedy hereunder shall be limited to the repair or replacement of any nonconforming equipment or parts, but only if returned to the company’s factory or an Auxiliary Power Dynamics “Authorized Installation Center” within the warranty period defined above, or with the express approval of APD management. Auxiliary Power Dynamics’ liability on any and all claims for damage or loss related to the delivery, installation and use of the Willis APU shall not exceed the original installed price of the Willis APU. IN NO EVENT WILL WE BE LIABLE FOR LOSS OF USE, LOSS OF PROFITS, LOSS OF, OR DAMAGE TO, SHIPPED GOODS, INCONVENIENCE, COMMERCIAL LOSS, OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES.

Maintenance Proper use of the Willis APU requires that it be maintained according to the schedule defined in the Willis APU Instruction Manual. As a condition of this warranty, Auxiliary Power Dynamics may require written substantiation that scheduled service performed on the Willis APU has been carried out.

Transfer of Warranty This warranty shall be for the benefit of the initial purchaser. If a truck upon which the Willis APU is installed is sold, the new owner may request in writing that Auxiliary Power Dynamics transfer the remainder of the original warranty. Such a request shall note the hours accumulated by the Willis APU at the time of ownership transfer, as well as the initial date of installation. No warranty transfer will be granted for a Willis APU unit that has been removed from one truck and installed on another, unless such installation is done at a Willis APU Authorized Installation and Service Center, and the transfer is requested in writing as described previously. Auxiliary Power Dynamics reserves the right to deny transfer of warranty if these conditions are not met. Auxiliary Power Dynamics also reserves the right to deny warranty extension if the transfer and reinstallation of the Willis APU is not done to the satisfaction of a company-authorized inspector. This warranty is extended under the laws of the State of Nevada. Enforcement of this warranty shall be conducted according to the laws of the State of Nevada. By acceptance of this warranty, the owner of the Willis APU agrees that any litigation and the resolution of any dispute between Auxiliary Power Dynamics shall be conducted exclusively in courts of the State of Nevada. 6. OPERATING INSTRUCTIONS OPERATING MODES


The Willis APU Cab Controller is mounted on the truck’s instrument panel. The Cab Controller’s menu screen shows all selected actions. When the APU has power, it will display a menu saying “Select Mode” or “Shutdown.” Navigate through Controller menus by pressing either the “Up” arrow or the “Down” arrow on the Controller menu. Select a menu item by pressing the center “Select” button. If the Controller is not being used it will cycle between being blank and being on at half brightness. This is normal. The sequence of screens (pressing the “Up” arrow) is 1) Select Mode, Shutdown 2) Manual 3) Auto 4) Monitor 5) Utility, back to Select Mode Shutdown. There are five modes to select from: Shutdown, Manual, Auto, Monitor, and Utility. Shutdown The APU is shut down in this mode. To shut down the APU, scroll to “Shut Down” on the Main Menu. Press the select button. This will give the operator a choice to shutdown or not. Pressing the “Up” arrow, will shutdown the APU. Pressing the “Down” arrow will return to the Main Menu. Select one of these positions on the Cab Controller. Nothing more is required to operate the APU.

Manual This is the APU “Start” position when the truck has not been running long enough for the APU engine to be warm. This mode starts and operates the APU whether the truck engine is running or not. In the case where the Truck has not been running and is cold, the APU must be started in “Manual” mode in order activate the APU engine’s glow plugs. Upon switching to “Manual” there will be a 90-second delay while the glow plugs heat before the APU engine begins to crank. Once the engine is running the glow plugs will shut off automatically. Also, once the APU engine is running, it can be switched to “Auto” mode; this is the normal procedure. “Manual” mode will not allow the pneumatic air compressor to operate if the truck engine is off, but the air conditioner and heater will operate (if the A/C or heater is “On” in the cab). To operate the APU engine at low RPM when air pressure is not needed, one might choose to operate the APU in Manual. Noise will be minimized since the APU will not cycle between low RPM and high RPM. The truck’s heater can be turned on and will operate normally truck’s “Start” switch is in the “Accessory” or “On” position. Auto This mode starts the APU when the truck engine has been operating and the driver stops and sets the truck’s parking brake. The truck engine will shut down if it has been programmed to do so. Turn the key off. Turn the “Start” key to the “On” position if air conditioner or heater operation is desired. The APU shuts down automatically when the truck engine is restarted and the parking brake is released (once the air pressure is at an acceptable level in the truck’s air tank). The A/C compressor and the pneumatic air compressor will operate as needed in this mode. Sensors control them automatically. Monitor “Monitor” mode is used when the truck is to be inactive for one to several days. In this mode the APU is started automatically when battery voltage is below 12.2 v or engine temperature drops below 55oF. Once the APU is started, it runs until voltage and engine temperature reach acceptable levels, and then it shuts down again automatically. Leave the truck “Start” key in the “Off” position, and shutdown the APU when in “Monitor” mode. Note that the APU may start at any time when in this mode. Utility This mode allows the operator to set the clock, check and change the service hours, change the display, set the APU idle, and activate the timed run. Set time


The “Set Time” function sets the internal clock’s time. To set the clock time scroll through the Utility mode until “Set Time” is displayed. Press “Select” and the screen will display Hours. Use the up/down arrows to set the clock to the current hour (0 to 23). Press the Select button. The display will move to Minutes. Then press the up/down arrows again to set the current minute. The Controller will now return by itself to the main menu. Engine Service Engine Service keeps track of APU engine run time and it also enables the operator to set a service-hour threshold. Scroll and select “Eng Service.” You will see “Engine Hours” displayed. Press the down arrow to see “Service Hours.” To enter the hours at which the next service will be due, use up/down arrows to change the hours to service as follows. Notice that one digit is highlighted. Use the up/down arrow to change the digit to the desired value then press select. That digit will be locked in and the next digit will flash. Repeat the process until all digits have been selected. Once the last digit is selected, the screen will return to the main menu. Change Display This mode allows the operator to change the display from 15 sec. on / 45 sec. off (normal), to off all the time until there is a system change (night). Select “Normal” or “Night” depending on light conditions in the cab. Set Throttle Use this mode to raise RPM to “High” when the outside temperature may drop below 25°F and more heat will be necessary to keep the cab/sleeper warm. Use “High” idle when either the inverter or a high amperage draw device is in use. Timed run This mode is to be used when the operator wants the APU to start automatically at a preprogrammed time in the future. Shut down the APU. Set programmed time and activate. CAB CONTROLLER WARNING LIGHTS Four horizontal lights on the Electronic Controller indicate the APU’s operating mode. Four vertical warning lights are service or trouble indicators. These warning lights indicate when the APU is ready for service, or when there is a danger alert, as follows:

• “ON” glows green when the APU is operating, otherwise it is off. If any of the following conditions occurs the “ON” light will blink: Low RPM, Low Oil Pressure, or High APU Temperature. Any of these conditions will immediately cause APU engine shutdown.

• “ENG” glows red when there is an over-temperature condition or low oil pressure indication; otherwise, it is off.

• “BAT” glows red when there is a low voltage condition; otherwise, it is off.

• “SRV” glows amber when it is time for an oil change; otherwise, it is off.

• “COM” is off when the electrical connection between the cab and the APU is operating correctly, and it is red if there is an electrical disconnect between the dash controller and the ECM. A disconnect means no signal will pass between the controller and the APU. The screen will read “Com Failure!” If communication is not re-established quickly, the APU will shut down.

7. MAINTENANCE SCHEDULE


The Willis APU requires a minimum of maintenance, but it is important to perform maintenance actions specified here on schedule. Always check that the APU control is set to OFF before removing the cover and working on the unit. The following list identifies required maintenance actions. Instructions to perform the required maintenance follow in the next section of this manual. APU run time may be checked by reading the Electronic Controller’s hour recorder. Every 50 hours of APU run time:

• Check APU engine oil level on dipstick. Add oil if necessary. Every 500 hours of APU run time:

• Replace the APU’s engine oil and filter, and air filter. • Replace the fuel filter on the APU engine. • Check belts and hoses.

Every 2000 hours of APU run time:

• Check the fuel hoses on the APU. • Check the five water hoses on the APU. • Replace the APU engine’s water pump belt.

Every 8000 hours of APU run time: • Check or replace the serpentine belt.

Other components in the system should be replaced only when there is evidence of wear or pending failure. 8. TROUBLESHOOTING Auxiliary Power Dynamics provides a Hot Line to call for diagnostic help. The number is 1-775-825-4566 ext. 12. Review the text below to get an idea of what the problem may be before calling. FAILURE TO START 1. If there is no response at all to setting the Electronic Controller to “Manual” operating position, there may a problem with the Electronic Controller, the connection between the Controller and the ECM is open, the truck battery is dead, or if equipped, the battery “SWITCH” may be ‘OFF’. 2. The APU engine may fail to start if: a) it lacks fuel, b) there is a problem with the electronic controller, c) the battery or starter has a problem, d) it lacks intake air, e) the starter control relay is bad, f) there is blockage in the exhaust system, or g) the engine speed sensor is defective, h) the oil pressure switch may be defective. A fuel shortage may be due to air in the fuel line or a blocked fuel filter. Too little intake air may be from a restriction in the air supply system. THE APU ENGINE WILL NOT GO TO HIGH RPM Engine output may be low if: a) the throttle-advance solenoid is not working, b) the throttle linkage has a problem, or c) the Electronic Controller isn’t sending proper output. THE APU ENGINE STOPS SUDDENLY


Sudden stopping may be due to: a) the Electronic Controller senses overheating or low oil pressure (warning light comes on), b) fuel pump failure, c) “shutdown solenoid” relay failure, d) fuel shutoff solenoid failure, e) engine speed sensor failure, or f) the truck’s fuel tank is empty. THE APU ENGINE OVERHEATS If the engine overheats it will shut down (warning light will come on). Look for a coolant hose leak or blockage, or water pump or water pump belt failure. Check coolant level in the main engine. Check to make sure the coolant control valve at the truck radiator is open. OIL LEAKS Oil accumulating in the bottom of the enclosure case is not normal. Check for leaks. Check hoses from the oil pump to truck engine. Make sure the breather hose (if so equipped) extends through bottom of case. SERPENTINE DRIVE BELT FAILURE Failure of the APU’s internal drive belt causes all accessories except the oil pump to stop functioning. There will be no alternator function, no A/C compressor, and no pneumatic compressor. Failure symptom: the unit will not go to “low idle” and there will be a slight increase in APU engine RPM over the normal “high idle” RPM. ALTERNATOR FAILURE The battery will discharge when the APU is running. The APU may experience an overly high temperature reading in the enclosure as the alternator approaches failure. PNEUMATIC COMPRESSOR FAILURE The truck’s air tank won’t pressurize when running the APU. ENGINE SPEED SENSOR FAILURE If the speed sensor fails it causes the APU starter to make repeated attempts to engage even though the APU engine is already running. If this occurs, shut down the APU engine immediately. AIR CONDITIONER COMPRESSOR FAILURE If there is no air conditioning when running the APU it may be due to A/C compressor failure, a refrigerant leak, failure of the A/C pressure switch, or failure of the fan drive system on the truck. If the fan drive motor on the truck isn’t working the APU’s Air Conditioner compressor will cycle on and off every few seconds. Do not operate the air conditioner if this is happening. 9. TRUCK INTERFACE PROBLEMS REMOTE CONDENSER/RADIATOR FAN SYSTEM Failure of the fan system may be due to fan motor failure, timer failure, or failure of the fan solenoid. As noted above, the APU’s air conditioner compressor will cycle in short intervals if the fan is not coming on. Do not operate the air conditioner if this is happening. A high water temperature shut down AIR GOVERNOR Air pressure will either be too high or too low.


AIR INTAKE SYSTEM TO APU The APU won’t run if the air intake hose becomes blocked. EXHAUST SYSTEM The APU won’t start if too much restriction of the exhaust system occurs. 10. PARTS AND SERVICE

All parts for the Willis APU are available from the factory and many are also available from authorized installation centers. During the Warranty period, repairs and service must be performed by authorized service centers unless prior authorization has been obtained from the factory. 11. PERIODIC MAINTENANCE INSTRUCTIONS The services below require removal of the APU cover. Be sure the cab control is in the OFF position (APU not running) before removing the cover. FUEL SYSTEM Changing the Fuel Filter on the APU The fuel filter cartridge is replaced at every 500/700-hour service. Simply remove the old filter (quarter turn of the retaining ring), fill a new one with fuel, and install it. After replacing the filter, pump the primer button on top of the filter housing several times to restore fuel to the system. Pump the primer until resistance is felt.

ACCESSIBLE SIDE OF ENGINE Changing the Fuel Hoses There are two fuel hoses attached to the fuel filter housing, and one betwemanifold block that is attached to the end plate. Check the hoses and clam

DIPSTICK

OIL FILLER CAP

PRIMER BUTTON

en the fuel pump and the ps every 4000 hours. After

OIL FILTER

FUEL FILTER


replacing the hoses use the primer button to pump new fuel through the lines. Pump until resistance is felt. Checking the Oil Level and Adding Oil Never pull out or reinsert the dipstick into the engine when the engine is running. The dipstick is readily located on the accessible side of the engine. Check the oil level at least every 150 hours. Use only recommended oil. Oil is added through the oil filler openings on the engine. Never overfill - overfilling could cause damage to the bottom of the pneumatic compressor, causing an oil leak. The running oil level will be between the numbers on the dipstick and the full line. The recommended oil level is ¾ US quart above the add line. This will not fill the crankcase to the full line. Draining the Engine Oil and Replacing the Fuel Filter Opening the petcock on the bottom of the crankcase drains engine oil. Allow sufficient time for the oil to drain thoroughly. At the same time remove the oil filter. Fill a new oil filter with oil. Coat the filter’s rubber seal with oil and replace. The engine will not run if the oil filter is not pre-filled. Close the petcock. Add new oil through the filler on the valve cover. The capacity is approximately 3.5 quarts. Use oil approved by the engine manufacturer (API classification CC/CD/CE). Do not fill past the full line on the dipstick. If overfilling accidentally occurs, drain enough oil to bring the oil level back to the full mark. This is very important. Be sure to close the petcock before adding oil. Engine cooling system The cooling system circulates coolant to and from the truck engine. Therefore no coolant is added to the APU engine, nor does it require any attention, other than to check for leaks. Checking and Replacing the Hoses There are five hoses. All are ¾” hoses attached to the engine or the heat exchanger. After replacing the hoses, and before starting the APU, start the truck engine to bleed the system (run for about ten minutes). Water Pump Belt When the belt needs replacement, simply relieve the tension on the belt tensioner to remove and replace the belt. Serpentine Drive Belt Replace the Belt as Follows: 1. Remove the fiberglass fairing covering the APU (if present). 2. Remove the APU cover after making sure the cab control is in Shutdown position. 3. Remove the bottom cover of the enclosure. 4. Remove the left end cover plate. 5. Remove the air compressor’s air intake bolts. 6. Pull back the air intake from the compressor to allow more working room (caution: do not misplace

the compressor intake gasket).

S E
AIR INTAKE BOLT
AIR INTAKE TUB


7. Slide the tie wraps off the bracket, and then loosen the clamp on the 90-degree intake rubber hose.

Tie the intake pipe up and out of the way. It is not necessary to disconnect the intake pipe on its other end behind the engine on the right side.

8. Remove the seven Allen head bolts holding the transmission case together. 9. Remove the two case-securing bolts on the underside of the “U” channel beneath the transmission

case. Remove the five nuts from the studs on the flywheel. Access through the hole in the rear of the transmission housing.

10. Slide the rear half of the transmission case back along the “U” channel (angle outward for extra

space).

TWO OF SEVEN BOLTS

Tie-wrap

Clamp on Hose INTAKE PIPE

TIE WRAP

CLAMP ON HOSE


11. Release belt tension by prying down on the tensioner using a breaker bar or long-handled socket

wrench. With tension relaxed, slip belt out of case.

CURRENT PRODUCTION BELT CONFIGURATION 12. Clean and reassemble, routing the belt as shown in the picture above. Make sure the ring mass is in

place on the flywheel studs. Sliding the rear transmission case steadily along the support rail will assure easy re-assembly. Align the studs with the holes in the pulley. Push the transmission assembly onto the studs. Install the nuts and washers on the studs through the hole in the back/bottom of case. Tighten nuts every other stud until all 5 nuts are tightened to 25 ft-lbs. The engine can be rotated using a 22mm wrench on the nut on the crankshaft front of the engine. Complete the assembly process.

12. LONG TERM STORAGE Before storing the Willis APU for more than a few months, perform the following:

PLACE BREAKER BAR HERE

APU TRANSMISSION HOUSING

“U” CHANNEL

NOTE: A screwdriver may be used to hold the case spread open.

Flywheel studs (five)

Ring mass


1. Remove dirty engine oil. Fill the engine with new oil and run for five minutes to let the oil circulate. Do not overfill. 2. When the engine is not used for a long period of time run it under “no load” condition for about five minutes every three months to keep it free of rust. 13. PICTURES OF OBSOLETE APU DRIVE SYSTEMS OLD DRIVE SYSTEM: NO LONGER USED IN PRODUCTION ON THE WILLIS APU


OLD DRIVE SYSTEM: NO LONGER USED IN PRODUCTION ON THE WILLIS APU


14. SYSTEM TROUBLESHOOTING GUIDE

Symptom Probable Cause Solution Reference

Battery Problem Check Batteries and Cables Check Fuse F1, Relay R1,

Power at Starter

1 APU does not

start Starter Problem Check starter

Lacks Fuel Air In Fuel, Blocked Fuel Filter

Cold Engine Glow Plugs No Power, or Faulty Fuse F7, Relay R4

Lacks Air Change Air Filter Exhaust Blockage Check Exhaust System Return Fuel Line

Blockage Clear Blockage From Fuel

Line

Check Fuses F3,F5,Relays,R2,R3

2 APU Turns over

but does not start

Shutdown Solenoid Check shutdown solenoid

Check Dash Control For Faults See Fault

Symptom Shutdown Solenoid Check fuse F3,Relay R2

Lacks Fuel Air in fuel, Blocked fuel filter Lacks air Change air filter

Check exhaust system Exhaust blockage Check for smoke from exhaust

3 APU starts but does not run

Return fuel line blockage Clear blockage from fuel line

4 APU Runs but nothing works Check serpentine belt Replace belt See Repair

Manual Throttle solenoid Check fuse F9, relay R5 5 APU won't go to

high idle ECM Check throttle solenoid Check serpentine belt 6 APU alternator

not charging Alternator

Check alternator output

Check serpentine belt Replace belt See Repair Manual

A/C clutch Check for power at clutch wire 7 APU A/C

compressor not working

A/C charge Check for leaks/ does truck system work?

See Repair Manual

A/C charge Check for leaks See Repair Manual

DC motor Check operation Fan clutch not

releasing Check fan solenoid Y

A/C high pressure switch

Check for power going through if over 300psi

Oil pressure switch Check for power going through if truck engine off

Timer Fan runs for 3 minutes

8 APU A/C on not cooling

Solenoid Check that solenoid is switching


Check serpentine belt Replace belt See Repair Manual

Clutch Check for power at clutch wire Check reed valve Small amount of air, at

air comp. Check “check valve” (plugged) Set governor

9 APU pneumatic compressor not

working Governor Replace governor

Power to motor Check clutch for power, Replace motor

10 DC motor not working No power to motor Check solenoid, timer, and air

pressure

Check timer 11

DC motor not running for 3

minutes Timer

Replace timer

Com failure Check connection from controller to ECM

Oil pressure bad Check oil level Alternator overload, switch

to utility high idle RPM low

Not switching to high idle See symptom 4

Check coolant in main engine Check for leaks or blockage Check that all control valves

are open

12 Cab controller

APU temperature bad

Check water pump and belt for failure

Willis APU Manual; June, 2009 ; of 24

15. COMMON REPAIRS AND SUGGESTED REPAIR TIME GUIDE

PROCEDURES

Remove APU cover. Remove 6mm bolts from unit holding left hand aluminum end plate. Remove stainless hose from air compressor (if equipped). Remove air cleaner assembly and intake tube/hose assy. Remove seven (7) bolts that hold the transmission assembly to flywheel housing. Remove the rear two (2) bolts that hold the transmission housing to the rear motor mount assembly. Using the lower access hole in the transmission housing, remove the five (5) nuts and washers from the drive pulley studs. Carefully slide the drive pulley off the studs. Slide the transmission to the rear about 6” and rotate the housing 45°. This will give access to the inside of the transmission. Check the torque spec. chart for proper torque on nuts. NOTE: The belt can be removed by turning engine with a 7/8” (22mm) wrench and rolling belt from pulley. The pulley can then be removed after the case is split.

Warranty time allowed for this procedure is 2.0 hours.

2) Throttle Rod Adjustment Start APU, raise RPM to high idle using the “utility” function on the dash control. Loosen jamb nut on the throttle stop screw and back the screw out 2 turns. Adjust rod by loosening the jamb nut on the solenoid end and turning the boot assembly onto the rod. Tighten the jamb nut. Turn the throttle stop screw in until it touches, and then back it out ½ turn. Tighten the jamb nut.

Warranty time allowed for this procedure is .5 hours.

3) Alternator Replacement Perform Procedure 1. Remove the drive belt from the transmission. Remove power and ground cables from the rear of the alternator. Remove mounting bolts on the alternator. One removes from inside the case, the other from outside the case. Be careful not to drop the alternator; it is heavy and could cause bodily harm. Reverse this procedure to assemble the unit. Check the torque spec. chart for proper torque values.

Warranty time allowed to complete this procedure is 2.5 hours.

4) Auto-Adjust Pulley Assembly Replacement

Perform Procedure 1. Remove the drive belt from transmission. Remove nut from the bolt that holds the pulley assembly in the case. Remove the bolt from the case. Remove the auto-adjust pulley assembly. Install new pulley assembly, and torque bolt to 35 ft.-lbs. Install nut, tighten, and make sure the ground cable is in place. Reverse the procedure to assemble the unit. Check the torque spec. chart for proper torque values.


; of 24

5) Idler Pulley Replacement Procedure will be used only on units with idler pulleys. Perform Procedure 1. Remove the drive belt from the transmission. Remove the bolt, washer, and lock washer from the idler pulley bearing. Remove the idler pulley. Check the housing for damage. If the housing is not damaged, install a new idler pulley assy. Install the bolt, lock washer, and washer. Torque the bolt to 45 ft.-lbs. inspect the belt for wear; if it is OK, reinstall the belt. Reverse the procedure to assemble the unit. Check the torque spec. chart for proper torque values.


6) Pneumatic Compressor Replacement

Perform Procedure 1. Remove belt from transmission. Clamp off all five (5) coolant hoses to prevent coolant loss. Remove coolant hoses from compressor head. Remove stainless steel hose from compressor head. Remove the bolt from the clutch assy. Use a 5/8” USS bolt to remove clutch from compressor. Remove the two (2) bolts and two (2) nuts that hold the compressor to transmission housing. Use a pan to catch oil that will spill out of compressor. Remove the compressor. Inspect the gasket between the compressor and the housing; if it is not damaged, install the new compressor. If the gasket is damaged in any way, replace the gasket. Re-install the bolts and nuts that hold the compressor. Install the clutch on the compressor shaft. Install the bolt in the clutch and tighten. Inspect the belt; if it is OK, then re-install. If the belt shows any wear, install a new belt. Reverse the procedure to assemble the unit. Make sure all hoses are tight. Remove the five (5) clamps that were used to clamp the coolant hose. Check the torque spec. chart for the proper torque values.


7) A/C Compressor Replacement

Recover R134a refrigerant. Take note of amount recovered. Perform Procedure 1. Remove drive belt from housing. Remove both hoses attached to rear of A/C compressor. Remove clutch wire from plug (use a Weather-Pack removal tool). Remove 4 nylock nuts and washers from studs in transmission housing. Remove compressor/clutch assembly from transmission housing. Install new compressor/clutch assembly. Install and torque the nylock nuts to 40 ft.-lbs. Install the drive belt.Inspect the belt before installing; if it is worn or hard, replace belt with a new belt. Reverse procedure 1 to assemble the unit. Install both hoses on rear of the A/C compressor. Pump system down with a vacuum pump. Check A/C system R134a capacity, and add 10 oz. Add 2.5 lbs for remote condenser system. Charge system with proper weight of R134a, and perform a complete system check for leaks and proper operation. Check the torque spec. chart for the proper torque values.


8) Shutdown Solenoid Replacement

Unplug the wiring harness to the solenoid. Remove the two (2) 6mm bolts holding the solenoid to the Kubota engine. Remove the solenoid assembly. Install new solenoid assembly, making sure the solenoid pin is in the proper position on the shutdown arm. Install the two (2) 6mm bolts that hold the solenoid to the Kubota engine. Connect the wiring harness. Perform a system test.

Warranty time allowed to complete this repair is 0.5 hours.

Willis APU Manual; June, 2009

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9) Throttle Solenoid Replacement

Unplug the wiring harness, or remove the screws that hold wires on the solenoid. Remove the nut and lock washer from the stud on the throttle arm. Remove the four (4) 6mm bolts that hold the throttle solenoid to the bracket. Remove the throttle solenoid assembly from the bracket. Measure the length of the rod when it is in the solenoid. Loosen the jamb nut on the throttle rod, and remove the rod from the solenoid. Install the rod in the new solenoid to the same length as it was in the old solenoid. Install the throttle rod stud on the Kubota throttle arm. Using the four (4) 6mm bolts install the throttle solenoid assembly on the bracket. Check the throttle assembly for proper adjustment. Refer to Procedure 2.


10) Remove and replace the Kubota Engine

Warranty time allowed for this procedure is 6.0 hours

17) Troubleshooting for electrical problems will be limited to 1/2 (ONE HALF) hour. If the problem is not found, then a phone call to Willis Warranty must be

8:00 am to 5:00

pm Monday through Friday Pacific time. Failure to make the call to Wills WILL result in Warranty claim denial.

18) TORQUE SPEC. CHART

A/C Compressor Clutch Bolt 35 ft.-lb. A/C Compressor Nut 40 ft.-lb. Auto Tensioner to Transmission Housing 35 ft.-lb.

.bl-.tf 04 rotanretlA .bl-.tf 04 rosserpmoC riA .bl-.tf 42 yelluP evirD .bl-.tf 42 gnisuoH leehwylF

Kubota Engine Flywheel bolts 54 ft.-lb. .bl-.tf 54 yelluP reldI

Outside Engine Mounts 40 ft.-lb. Transmission Assembly 35 ft.-lb.

11) Remove & Replace (R:R) Serpantive Belt 2.0 hours

12) R:R Water Pump Belt 0.5 hours

13) R:R Water Pump 1.0 hours

14) R:R Fan Timer 1.0 hours

15) R:R Electric Fan 0.5 hours

16) R:R ECU 0.5 hours

made at 800-825-4631

Willis APU Manual; June, 2009


Pin N


DASH CONTROL COMM. LINE WIRING DIAGRAM


APU CONNECTOR PIN-OUT DIAGRAM


APU ENGINE HARNESS SCHEMATIC

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