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1. U UNIT r a i ki pe Pan i i Ee 1 4 p Lay 5 A L i y AUXILIARY POWER User Manual amp Warranty Information For Green APU Auxiliary Power Unit Your comfort powered by GREEN APU AMER IC A Green APU Manual Page 1 Trademarks Green APU Exclusion for documentation Unless specifically agreed to in writing Green APU LLC makes no warranty as to accuracy sufficiency or suitability of any technical or other information provided in its manuals or other documentation assumes no responsibility or liability for injury losses damages costs or expenses whether special direct indirect consequential or incidental which might arise out of the use of such information The use of any such information will be entirely at the user s risk Revision information Contact information 411 W Factory Road Addison IL 60101 Toll Free 877 751 0686 www greenapu com Green APU Manual Page 2 Congratulations on your purchase of your new Green APU The Green APU consists of a powerful yet efficient Perkins Caterpillar diesel engine along with a revolutionary HVAC system to maintain comfort With over 15 years in the transportation industry we designed it especially to save you money keep you warm and keep you cool Fuel usage is reduced significantly while allowing the driver to enjoy all of the comforts that are usually associated with idling the engine by eliminating the need for the truc2. The only exception is a modification with the express written approval of Green APU LLC Il COMPONENTS LIMITATIONS A Warranty coverage on receiver driers is limited to leaking or desiccant breakdown only B No warranty is offered for compressor mounting brackets or related parts used to attach the compressor to the drive belts lack of proper maintenance The materials are used at the risk and option of the installer III WARRANTY REPAIRS A Warranty repairs must be done by an approved technician by Green APU LLC adhering to all applicable regulations IV WARRANTY CLAIMS A Warranty claims should be submitted through original installer B For full warranty consideration claims and parts parts returned transportation prepaid must be submitted within 60 days of date repaired C Warranty claims will be paid based on the most current settlement schedule released by Green APU LLC No allowance will be made for mileage travel time down time or related expenses This warranty becomes invalid when a unit or component has been discontinued and has been out of production for a period of 12 months Green APU Manual Page 5 This warranty supersedes all previous warranty policies expressed or implied and frees the manufacturer of any other obligations or liability including consequential incidental damages The manufacturer will not assume or allocate the assumption of any other liability in connection with the sale of units or
3. e Part tampered with on heat setting HEATER CORES e Broken or bent tubes e Damaged fins e Improper application installation HOSE Refrigerant Duct Tubing Sleeve e Damage due to battery acid e Damage due to excessive heat or low temperature e Improper hose routing allowing cutting of hose e Damaged by moving parts FITTINGS e Stripped threads e Part altered or modified RECEIVER DRIER ACCUMULATOR e Bent or broken lines stripped threads e System contamination e Improper application installation e Damage due to abuse e Part modified to fit application altered e Brackets cut off e Flushing through part e Stripped threads Owner s Responsibility As the engine owner you are responsible for the required maintenance listed in your User Manual We require that you retain the original purchase documents and all receipts covering maintenance of your engine Please be aware that we may deny warranty coverage if your engine or a part has failed due to neglect abuse improper maintenance improper installation and or unapproved modifications As the owner you are responsible for presenting your APU to an authorized service facility as soon as a problem occurs The warranty repairs should be completed in a reasonable amount of time Keep all maintenance records dates receipts and parts used for all warranty claims You may be asked to provide all maintenance records and parts used for the warranty to be effect
4. APU Engine Off Oil FP 7 Run Failure service 877 751 0686 www Ggreenapu com This is the most common error message to appear It can appear before engine start after the engine check process if the engine turns over and does not start and if the engine is running and shuts off DO NOT ASSUME LOW OIL LEVEL Do not overfill the crank case Doing so can damage the engine and void your warranty Time Probable Cause Solution Appears Automatically Problem With Oil Press Switch Or Wiring Engine Starts Shuts Off After Engine Check Low Oil Pressure Faulty Press Switch Check Wire Connections And Voltage Of Press Sensor in I O State Menu Check Oil Level Should Be Between Notches On Dipstick Check Wiring And Connections And Switch Voltage Engine Cranks No Start Problem With Fuel System Check Fuel Level Check Fuel Pump Operation Check Fuel Solenoid Operation Check Wiring For Fuel Pump Solenoid Engine Runs After Check Problem With Fuel System Check Fuel Level Shuts Off Engine Shuts Off After A C Turns On Faulty A C Compressor Idle Speed Low Check For Leaks Kinks In Fuel Lines Check For Air Or Water In Fuel Lines Check Wiring For Fuel Pump Solenoid Increase Idle Speed Check Clutch Operation Take To Authorized Dealer For Service Green APU Manual Page 18 GREEN APU AUXILIARY POWER UNIT APU Engine Off Qverheat Probable Cause Solution Air In Coo
5. Manual Page 13 Service Timer Reset GREEN APU AUXILIARY POWER UNIT vice Hours t Contrast e Oil Timer service 877 751 0686 GREEN APU AUXILIARY POWER UNIT r Pin service 877 751 0686 www greenapu com GREEN APU AUXILIARY POWER UNIT st Oil Timer service 877 751 0686 Green APU Manual To reset the oil timer select it from the Maintenance Menu Enter the 2 2 Digit pin number Green APU does not give individual drivers the reset pin Either the company or Green APU will have the pin This is to protect the APU from damage that may void the warranty Once the correct pin has been entered the oil timer can be reset Page 14 Diagnostics GREEN APU ta B GREEN APU AUXILIARY POWER UNIT Basic Hd ane AUXILIARY POWER UNIT Climate Control Battery Charger Maintenance gt D1la3nost ics Selecting the Diagnostic option from the menu will take you to the Basic Diagnostic Tools Menu The Advanced Menu will be locked and only used by APU dealer mechanics GREEN APU AUXILIARY POWER UNIT In the General menu you will find service 877 om the current battery voltage water temperature and cabin temperature AUXILIARY POWER UNIT batters 127 0 WLM 66 HAtmr Green APU Manual Page 15 I O State GREEN APU AUXILIARY POWER UNIT GREEN APU AUXILIARY POWER UNIT ACHLIH OTL OL TS SEL OLH ACHL L Refrigerant Pressure Norma
6. UTO service 877 751 0686 www greenapu com Page 11 Battery Charger GREEN APU AUXILIARY POWER UNIT GREEN APU AUXILIARY POWER UNIT service 877 751 0686 www greenapu com GREEN APU AUXILIARY POWER UNIT When selecting the Battery Charger option from the menu The APU will go into battery monitoring If the battery is full the APU will continue monitoring If the battery is low the APU will start and charge the battery The APU will run for two hours or until the battery reaches 14 6V The APU will then automatically shut off To turn off the battery monitoring mode simply press the rotary knob and select OFF Green APU Manual Page 12 Maintenance GREEN APU AUXILIARY POWER UNIT Selecting Maintenance from the main menu lets you access Service hours and lets you adjust the contrast service 877 751 0686 www greenapu com GREEN APU AUXILIARY POWER UNIT GREEN APU AUXILIARY POWER UNIT service 877 751 0686 www JGreenapu com service 877 751 0686 www greenapu com The service hours displays information such as total run hours hours on current oil hours run on heat and A C and hours until oil change When the hours to oil change CHG reaches O the APU will run for only 7 more hours Then an error will appear and APU WILL NOT start Selecting Adjust Contrast will allow you to change the contrast of the display according to preference Green APU
7. components ALLEGED DEFECTS NOT CONSIDERED AS WARRANTY BLOWER MOTORS RADIATOR FAN MOTOR e Bent or alter flange bent shaft brackets altered e Dismantled rusted weather beaten e Burned out due to electrical problems e Improper installation stripped threads e Wires cut off at motor housing COMPRESSORS e Stripped threads Bent or cracked fittings e Compressor contamination e Bent cracked shaft e Evidence of being dropped e Altered disassembled or missing parts e Seized due to improper service installation e Abuse or improper service install e Fittings ports not capped before returning e Wires cut off CONDENSER e Broken stripped threads or bent fittings e Damage to fins due to abuse e Screw hole in line due to improper installation e Leakage at seam joint due to bending fitting CONTROL VALVES e System contamination e Stripped threads ELECTRICAL COMPONENTS e Burned up due to electrical problems e Improper application installation e Altering or changing parts to fit application e Part broken due to abuse or force EVAPORATOR CORES e Broken stripped threads or bent fittings e Plugged orifice CCOT tubes e System contamination e Damage to fins Green APU Manual Page 6 e Screw hole in line due to improper installation e Bent fitting line causing leakage at seam joint EXPANSION VALVE e System contamination in part e Broken off capillary line or pinched line e Stripped threads
8. g the simple maintenance procedures outlined in this book you can rest easy knowing your unit is well taken care of so it can run at its best performance for you For any service related questions call us 24 hours a day at 877 751 0686 We Will Be Happy To Assist You As Best As We Can GREEN APU AUXILIARY POWER UNIT Dimensions Main Unit 578mm 19 125 486mm APU Controller hy Green APU Manual gF Sleeper Heater A C 10 5 Heating Cooling Diagram The Green APU uses the truck radiator as the radiator for the diesel engine in the APU This allows the truck engine to stay warm to help engine starting Heating Mode vecom Truck Radiator SH A C Unit Green APU Manual Page 25 Oil Dipstick Air Filter Fuel Filter Fuse Box Fuel Solenoid Reciever idle Drier Control Oil Filter Belt Tensioner Low Port High Port Blower Motor Air Filter Thermostat Expansion Valve Water Valve amp Actuator Green APU Manual
9. he following parts only carry a one year warranty e A C Compressor e Condenser e Expansion valve e Condenser Fan e Evaporator e Heater core e Water vale assembly e Blower motor e Engine Wiring Harness e Green APU Controller SRT time has been established on all replacement parts and will be paid accordingly This warranty only covers defective parts and labor Green APU LLC is not responsible for hoses wiring and etc that has been cut or has had holes rubbed in them due to lack of maintenance Green APU LLC will not be liable for state anti idle citations Web Address www greenapu com Green APU LLC 411 W Factory Rd Addison IL 60101 Toll Free 877 751 0686 Green APU Manual Page 8 Table of Contents 1 Welcome Screen A Startup Screen B Shut Off 2 Climate Control A Set Temperature B Set Fan Speed C Battery Charger 3 Maintenance A Service Hours B Adjust Contrast C Reset Oil Timer 4 Diagnostics A 1 0 State B Water Valve Test C Blower Motor Test 5 Troubleshooting 6 Service Intervals 7 Advanced Diagnostics 8 Dimensions 9 Heating Cooling Diagram 10 Parts Diagram For any service related questions call us 24 hours a day at 877 751 0686 Green APU Manual Page 9 Welcome Screen AUXILIARY POWER UNIT service 877 751 0686 GREEN APU AUXILIARY POWER UNIT GREEN APU AUXILIARY POWER UNIT This is the Welcome screen On here you will find the software version a
10. ive Green APU Manual Page 7 Inspecting your equipment daily will help keep your APU working for a long time Dirt and debris in the heat and air conditioning bunk blower unit or condenser oil will cause unsatisfactory heating and cooling Please keep these clean at all times Never block access to bunk unit filter or air ducts When filing a warranty claim or ordering parts you have to know e Serial number and hours on APU e Part number and part description Warranty procedure Obtain a work order number from Green APU LLC and report the unit serial number and hour meter reading to determine warranty coverage Report failed parts and obtain a RMA number return material authorization please email g tom greenapu com or contact Green APU LLC Any part subject to warranty must be returned to Green APU LLC at 411 W Factory Road Addison IL 60101 for warranty inspection Claim hours are as follows Monday Friday 8 00AM 4 00PM All returned parts must be accompanied with an RMA number unit serial number and total hours If the RMA number is not attached you will not be credited for any returned parts A credit card is required to be on file for all part orders to ensure failed parts are returned All warranty ID non transferable To maintain a positive relationship we will make sure all warranty claims are handled ina timely manner Engine APU parts and Labor are warranted for 2 years or 2 000 hours whichever comes first T
11. k s engine to idle You can avoid up to 25 000 in fines because of idling regulations in multiple States Warranty and registration All components of Green APU carry a 12 month warranty accompanied by a two year 2 000 hour warranty on the Caterpillar Perkins diesel engine At the time of purchase your dealer will have completed the warranty registration card A copy of that card has been submitted to us while the original is yours This is completed register you into our warranty system The warranty begins on the date of purchase Please retain a signed copy of your warranty registration card iin order to verify your warranty If you did not receive a copy or if your copy has been destroyed or misplaced you should contact your dealer to obtain a new one IMPORTANT Without registration your Green APU is not covered under warranty It is important that you have a copy of your registration card GREEN APU service warranty CARD ALIMVLIASY POWER UNI NO Owner s Name Manufacture Lereem APL LILA Toll Free 87775106086 Date of purchase Dealer s Name Buyer Singature Schier Signature Green APU Manual Page 3 Safety This safety tip alone cannot eliminate all hazards that can occur Pay close attention to instructions and use common knowledge during maintenance procedures to prevent unnecessary accidents and or injuries Warning Hazards or unsafe practices could result in injury and or death Exhaust It i
12. l ACHL H Refrigerant Pressure Out Of Range ALT 0 0V Main engine off APU will start ALT 8 44V Main engine on or alt sensing wire damaged disconnected APU will not start In the I O State Menu you can get more detailed readings such as oil pressure refrigerant levels and alternator voltages The readings are explained in greater detail below OIL 8 44V Normal operating voltage while running OIL 0 0V Oil Pressure Low APU will not run OVH 8 4V Normal operating voltage OVH 0 0V APU overheated or faulty sensor Green APU Manual Page 16 Water Valve Test Can be used to determine if water valve is opening to allow for heating GREEN APU AUXILIARY POWER UNIT Water Ualue Test Orenins Waluwe i4 Uri 74 s Uris Blower Test Can be used to determine operation of blower motor When the Water Valve Test is selected the water valve motor will open and close as displayed on the screen Check to see the motor is operating at this time GREEN APU AUXILIARY POWER UNIT Water Halve Test Closing Valve Wroied S service 877 751 0686 When selecting the Blower Motor Test a display will appear and you can control the blower speed with the rotary knob The values range from 0 to 225 As the value increases the speed will increase You should feel the air blow through the vents at this time Green APU Manual Page 17 Troubleshooting GREEN APU AUXILIARY POWER UNIT
13. ling System Make Sure All Air Is Evacuated From The System Broken Alt Water Pump Belt Inspect Belt And Replace If Necessary Leaking Or Kinked Lines Inspect All Coolant Hoses For Kinks Or Leaks Closed Valves If Equipped Make Sure All Valves Are Open Faulty Temp Sensor Check Water Temperature In I O State Menu If Temp is Under 230 F Sensor Is Faulty Radiator Cap Is Damaged Check Main Radiator Cap For Leaks And Replace If Necessary Coolant Is Contaminated Check Condition Of Coolant And Look For Debris Small Particles Can Clog Lines Flush And Refill If Needed Check Coolant Level And Fill If Needed Coolant Level Low GREEN APU AUXILIARY POWER UNIT AFU Engine OFF Main Engine Funning Probable Cause Solution Alternator Sensor Wire Damaged Check Wire Condition And Connection Main Engine On Turn Off Main Engine Green APU Manual Page 19 GREEN APU AUXILIARY POWER UNIT Service Past Due Perform Service _ Before APU Oreration Press to continue service 877 751 0686 e When this message appears the APU unit will run for an additional 5 A hours after which it will not start to GREEN APU O7 U AUXILIARY POWER UNIT prevent damage to the unit that could void your warranty Service due in 5hrs Press to continue service 877 751 0686 Green APU Manual Page 20 Service Intervals Initial Service At 100 Hours Oil Change Inspect For Loose Bolts Pass Blower And Wa
14. long with your Vin Code The Vin Code contains the following First Letter Chassis Version Second Letter Engine Type 4 Numbers After Green APU Unit 8 Characters After Engine Serial 4 Numbers After Week Of Year Built This is the Main Menu From here you can access the Climate Control Battery Charging Maintenance Records and Basic Diagnostic Tools To turn APU off scroll to the bottom of the main menu and select OFF The unit and display will turn off Green APU Manual Page 10 Climate Control GREEN APU AUXILIARY POWER UNIT GREEN APU AUXILIARY POWER UNIT Selecting Climate Control from the menu will start the APU After the APU starts the display will change to the one below GREEN APU AUXILIARY POWER UNIT service 877 751 0686 www greenapu com GREEN APU SY AUXILIARY POWER UNIT i ES wh EN 7 service 877 751 0686 GREEN APU AUXILIARY POWER UNIT Green APU Manual This display shows the current cabin temperature set temperature fan speed and current battery voltage Press the rotary knob to access the fan speed and temperature settings The temperature and fan speed can be increased and decreased by the rotary knob If H or Cis selected heating or cooling will stay on constantly Otherwise if anything in between is selected the APU will maintain the temperature selected The fan can be set to one constant fan speed or to A
15. ner or part to be free from defects in materials and workmanship under conditions of normal use and service for a period of 1 year from date originally put into service The manufacturers obligation under this warranty shall be limited to repairing or replacing at its option any part or parts of said unit found to the manufacturers satisfaction to be defective GENERAL CONDITIONS A No unit is guaranteed to maintain a specific temperature output or cab temperature since many variables in installation and geographical location affect this output B Many system failures are the result of poor installation practices e g lack of proper hose routing Failures resulting from installation are not covered C Green APU LLC reserves the right to make design improvements without any obligation to change units or parts previously manufactured D Green APU LLC retains the right to inspect faulty parts at its factory and determine whether such parts are defective No materials should be returned to Green APU LLC without prior written permission E In no event shall Green APU LLC be liable for consequential damage or contingent liabilities including without limitation such things as damage to vehicles contents or product cargo or expenses incurred arising from failure of any part of any unit or parts thereof to operate properly F Alterations or modifications in any form to a unit or parts thereof shall nullify and void this warranty
16. s responsibility of the user to make sure unit is turned completely off while parked in enclosed space garage car port etc Persistent inhalation of exhaust fumes may cause serious injury and or death Anyone suffering from carbon monoxide inhalation should be removed from the area and given immediate medical attention Fuel Batteries Exercise extreme caution when working near fuel or fuel filled equipment Do not operate equipment during fueling operations Always use eye protection at all times Remove contaminated clothing immediately and wash contaminated skin Do not inhale vapors Toxic substances Fuel oil coolant and refrigerant are toxic and in some cases carcinogenic Wear eye and hand protection at all times Remove contaminated clothing immediately and wash contaminated skin Do not inhale vapors Hot and moving parts Moving parts can cause severe injury and or death Before working on any unit shut it off and then ensure that the power is disconnected from the truck batteries Important If the power is not disconnected the unit could automatically start up This could cause serious injury The Green APU is designed to provide electricity and climate control for vehicles in normal on road conditions Never use the APU to provide power for sensitive electrical or medical equipment without written consent from Green APU Green APU Manual Page 4 The manufacturer warrants each new Green APU unit heater air conditio
17. ter Valve Tests Inspect For Any Leaks Adjust RPM If Needed Regular Service Every 600 Hours Change Oil And Oil Filter Clean K amp N Air Filter with K amp N Filter Cleaner and Oil Clean APU Unit From Any Debris And Dirt Inspect All Belts Clean A C Condenser Pass Blower and Water Valve Tests Green APU Manual Page 21 Advanced Diagnostics The Advanced Diagnostics menu cannot be accessed by individual drivers GREEN APU AUXILIARY POWER UNIT Control charger GREEN APU AUXILIARY POWER UNIT Calibrate Connect to Precision 12 00 Power Surely Press when reads GREEN APU AUXILIARY POWER UNIT Basic Advance tack GREEN APU AUXILIARY POWER UNIT uC 3 31 2472 _ S 00485 Calibration done service 877 751 0686 In order for the Advanced Diagnostics to work correctly the controller must be calibrated to exactly 12V GREEN APU AUXILIARY POWER UNIT Set Oil Password Set SN Calibration _ SOuteut Control GREEN APU AUXILIARY POWER UNIT AC Compressor Accessory Water Heater gt A11 Off In the Advanced Diagnostics menu the technician is able to access necessary information and outputs of all systems in the Green APU This makes it easy to diagnose and solve any problem that may arise with the Green APU unit Green APU Manual Page 22 This User Manual was made for you to better understand and help protect your investment in your brand new Green APU Followin
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