CCS Lightning Cab Comfort System Workshop Manual
Below you will find brief information for Cab Comfort System Lightning. This manual provides information on the description, service and maintenance of the CCS Lightning system. The CCS Lightning system is designed to provide comfort and convenience for truck drivers, with features such as an auxiliary power unit (APU), climate control, and power distribution.
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CCS Lightning
Workshop Manual
P/N 1061837 REV B
TABLE OF CONTENTS
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CCS Lightning Workshop Manual
Table of contents
CCS Lightning Workshop Manual
3
INTRODUCTION
This Workshop Manual has been prepared to provide servicing personnel with information on the description, service and maintenance of CCS Lightning system.
All information, illustrations and specifications contained in this manual are based on the latest production information available at the time of publication.
The right is reserved to make changes in all information at any time without notice.
This manual is to be used in conjunction with Kubota Engine Workshop Manual (WSM, 02400), CCS
Lightning Flat Rate Schedule and any/all pertaining CCS Lightning Service Bulletin(s).
Figure 0-1: Service Bulletin example
Documents included in this manual: 1061837-A
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CCS Lightning Workshop Manual
LIST OF ABBREVIATIONS
A
A ampere
APU auxiliary power unit
AWG American wire gauge
B
B Fan bay fan
BTU British thermal units
C
C Celsius
CF condenser / fan (unit)
CFM cubic feet per minute
C Fan condenser fan
CH channel
CHEB compressor / heater / evaporator / blower
CLNT coolant cm centimetre cond condenser
D
dBa decibel
DSPL display
E
ECU electronic control unit
F
F Fahrenheit
FNPT female national pipe thread ft feet
G
GFCI ground fault circuit integrator
G L1 generator line 1
G L2 generator line 2
H
Hz Hertz
I
ID identification in inch
K
K thousand kg kilogram kW kilowatt
L
lbs pounds
LED light emitting diode l/hr litre per hour
M
m meter
MFD microfarads mm millimetre
MNPT male national pipe thread
N
Nm Newton-meter
P
psi pounds per square inch
R
R Fan radiator fan
RPM revolutions per minute
RTV room temperature vulcanizer
S
S L1 shore power line 1
SW switch
V
V volt
VAC volts alternating current
VDC volts direct current
W
W watt
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1. CCS LIGHTNING SYSTEM IDENTIFICATION
The CCS Lightning system consists of several components:
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Figure 1-1: CCS Lightning component locations
CCS Lightning Workshop Manual
System identification
1.1. Auxiliary Power Unit - APU
The APU is a two cylinder, diesel engine driven generator capable of producing 6000W of 120VAC power.
This unit is typically bolted to the chassis of the truck behind the fuel tank on the passenger side of the vehicle.
Type:
Power rating:
Weight:
Dimensions (WxHxD):
Battery charging:
Operating temperature:
Fuel consumption:
Noise:
Figure 1-2: Auxiliary power unit
Liquid-cooled diesel engine driven AC generator
Kubota Z482 engine
Direct drive generator, not belt-driven
6kW, 120VAC, and 60Hz
360 lbs (163kg)
21” x 28.8” x 28.8”
(53.4cm x 73.2cm x 73.2cm)
30A (optional 40A)
-40ºF to 122ºF
(-40ºC to +50ºC)
0.21 US Gallons per hour
0.8l/hr typical
65dBa @10’ (3m)
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System identification
1.2. Remote Radiator – Sleeper Mounted
The remote radiator allows the APU to be independent from the truck cooling system. It is designed to prevent the possibility of disabling both systems in the event of a coolant system failure.
1.3. Remote Radiator – Frame Mounted
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CCS Lightning Workshop Manual
System identification
1.4. Heat Exchanger – Sleeper Mounted
The heat exchanger allows the truck and APU to share cooling systems. It is designed to prevent the cold starting of the truck engine and APU in cold climates.
1.5. Heat Exchanger – Frame Mounted
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1.6. Climate Control System
The climate control system is a split system consisting of two separate components:
a) The CHEB unit
(compressor/heater/evaporator/blower) is a combined air conditioning and heating unit complete with a ventilation blower fan. This unit is installed in the truck’s sleeper, beneath the sleeper bed.
The system is supplied pre-charged with refrigerant. It will not require charging if installed properly.
System identification
Heating Capacity:
Cooling Capacity:
Figure 1-3: CHEB unit (10K)
Standard: 10,000 BTU/hr (High) / 3,330 BTU/hr (Low)
Optional: 13,500 BTU/hr (High) / 4,530 BTU/hr (Low)
Standard: 10,000 BTU/hr
Optional: 14,000 BTU/hr
(condenser/fan) is a combined condenser system complete with an electric driven cooling fan. This unit is installed outside of the truck, typically underneath the sleeper, between the frame rails.
10
Figure 1-4: Condenser / fan unit
CCS Lightning Workshop Manual
1.7. Power Distribution Box
The power distribution box is the central electrical distribution/connection system to which all power is supplied and then distributed. This unit is installed in the truck’s sleeper, beneath the bed.
System identification
Figure 1-5: Power distribution box
The battery charger is a 12VDC output unit.
The input voltage is 120VAC (fed from the power distribution box), which allows the unit to operate while the APU is running or while the system is connected to the optional shore power system.
Battery charger safety features include:
• Over-current shutdown
• Reverse polarity protection
• Ignition protection
An optional 40A version is available.
Figure 1-6: Battery charger
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System identification
1.9. Control Panel
The control panel is the main interface, controlling all CCS functions, complete with control knobs and an LCD display. This unit is installed in the sleeper, in an easy to access location.
1.10. Indoor And Outdoor Receptacles
The indoor and outdoor receptacles are supplied pre-assembled. The receptacle end is supplied with a circular connector, which plugs into the power distribution box.
Figure 1-7: Control panel
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CCS Lightning Workshop Manual
System identification
1.11. Shore Power - Optional
The shore power option allows the user to connect the CCS Lightning system to a 120V external source and power a portion of the equipment without running the APU.
When connected to a live source and the APU is not running, the system automatically:
• transfers incoming power to the shore power source
• disables the external receptacle
• disables “high” heat stage
The disabling of features allows the system to function on a basic 15A household electrical circuit. If the indoor receptacle is highly loaded while heat or cooling is being supplied, an overload condition could exist on the source feed, that might cause a shore power source breaker to trip.
1.12. Keyless Remote Starter - Optional
The keyless remote start option allows the user to remotely start and stop the APU at a range of up to 1000 feet.
The keyless remote start option kit includes:
•
1 keychain transmitter
•
1 receiver module c/w input harness and antennae harness
•
1 extended range antenna
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2. SAFETY PRECAUTIONS
1. Exhaust gases produced by the APU can be fatal. It is imperative that the exhaust gases are discharged in a direction that does not allow them to enter the sleeper of the truck. If the instructions are followed correctly, there will not be any problems.
2. Fuels used for this APU are highly explosive. Care must be taken to ensure that the fuel lines are properly installed and that there is no leaking fuel at any time. No open flames or cigarettes are to be near the APU while maintenance is being performed or when the APU is being refuelled. During refuelling be sure to maintain metal-to-metal contact between the filler nozzle and fuel tank opening to reduce chances of static charge dissipation. A fatal fire or explosion could result if an ignition source comes in contact with fuel or fuel fumes.
3. Fuels used in this APU can be toxic to the eyes, skin, and respiratory tract. When dealing with diesel fuel always wear proper eye/skin protection. Avoid prolonged contact between diesel fuel and skin.
Good ventilation is required in order to ensure that diesel fumes are not a hazard.
4. High voltage is produced when the APU is in operation. Improper operation or installation of components could cause fatal injury. When the APU is in operation, be sure to remain a safe distance from all electrical connections. During installation it is mandatory to properly ground the APU to the frame of the truck.
5. Remove all jewellery and tie back loose clothing / hair while performing work on the APU. Failure to do so can lead to serious bodily harm or even fatal injury.
CALIFORNIA PROPOSITION 65
The engine exhaust from this product contains chemicals known to the State of
California to cause cancer, birth defects or other reproductive harm.
These symbols are used throughout this manual to warn of the possibility of personal injury and to give helpful information:
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury
Gives helpful information
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CCS Lightning Workshop Manual
3. TROUBLESHOOTING
3.1. Engine
Engine will not crank when attempting to start a) Battery discharged or faulty – Check that the cable ends are clean and tight on the battery posts and engine. b) Broken or disconnected wire – Check that the wire #12 (signal wire) is secure and clean on the starter solenoid and the engine to chassis ground strap is secure and clean. c) Faulty starter relay – Check relay #1 for proper operation. d) Faulty starter - see Kubota WSM. e) Engine seized- see Kubota WSM.
Engine cranks but will not start a) Lack of fuel – Inspect the fuel bowl to ensure it is full of fuel. b) Faulty low-pressure fuel pump – see Kubota WSM. c) Water in fuel system – Remove fuel bowl, drain and replace fuel filter. d) Blown glow plug fuse – Replace 30A fuse e) Faulty glow plug(s) – see Kubota WSM. f) Faulty glow plug relay – Check relay #2 for proper operation. g) Faulty fuel run solenoid relay – Check relay # 3 for proper operation. h) Blown fuel run solenoid fuse – Check 30A fuse marked SOLENOID. i) Faulty fuel run solenoid – Check that the harness connection is clean and properly connected and that the solenoid is adjusted properly. j) Clogged / dirty air cleaner – Replace air filter, reset maintenance counter. k) Clogged / dirty fuel filter – Replace fuel filter. l) Air in fuel system – Bleed fuel system, inspect complete fuel system for leaks. m) Wrong engine oil (for ambient temperature) – Change oil and filter, reset maintenance counter. n) Broken valve spring, stuck valve, improper valve timing – see Kubota WSM. o) Worn fuel camshaft, incorrect injection timing – see Kubota WSM. p) Faulty injection pump, clogged injectors – see Kubota WSM. q) Compression leak, worn piston ring – see Kubota WSM.
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Troubleshooting
Engine does not run smoothly a) Air in fuel system – Bleed fuel system, and inspect complete fuel system for leaks (ensure fuel in tanks is sufficient). b) Clogged / dirty air cleaner – Replace engine air filter, reset maintenance counter. c) Clogged / dirty fuel filter – Replace fuel filter. d) Faulty fuel run solenoid – Replace run solenoid – see Kubota WSM. e) Clogged injector nozzle – see Kubota WSM. f) Governor defective / worn – see Kubota WSM.
Black or dark grey exhaust gas from engine a) Excessive engine oil – Reduce to specified level. b) Clogged / dirty air cleaner – Replace engine air filter, reset maintenance counter. c) Clogged / dirty fuel filter – Replace fuel filter. d) Worn or stuck piston ring – see Kubota WSM. e) Incorrect injection timing – see Kubota WSM. f) Poor engine compression – see Kubota WSM.
Excessive fuel consumption a) Worn or stuck oil ring – see Kubota WSM. b) Worn piston ring groove – see Kubota WSM. c) Worn valve stem and guide – see Kubota WSM. d) Worn crankshaft bearing and crank pin – see Kubota WSM.
Fuel mixed into oil a) Worn injection pump plunger – see Kubota WSM.
Engine starts and quits a) Clogged / dirty fuel filter – Replace fuel filter. b) Clogged / dirty air filter – Replace air filter, reset maintenance counter. c) Low oil pressure / oil pressure switch – Test / replace.
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CCS Lightning Workshop Manual
Troubleshooting
Engine overheating a) Insufficient coolant in system – Replenish coolant. b) Water pump belt defective or not adjusted properly – Adjust / replace; reset maintenance counter. c) Faulty engine thermostat – see Kubota WSM. d) Blown radiator fan fuse – Inspect harness, check fan if it spins freely, replace 15A fuse. e) Faulty remote cooling fan – Check that the correct harness has been plugged in and it is clean and properly connected. Check if fan spins freely. f) Faulty radiator fan driver – Replace fan driver. g) Blown enclosure fan fuse – Replace 15A fuse. h) Faulty enclosure fan – Test & replace. i) Faulty radiator cap – Test & replace. j) Defective water pump – see Kubota WSM. k) Defective temperature switch – see Kubota WSM. l) Contaminated engine coolant – Remove and replenish. m) Obstructed or pinched coolant lines – Check / reroute / replace. n) Air lock – Bleed cooling system.
Engine overcooling a) Faulty engine thermostat – see Kubota WSM.
Water and oil mixed a) Defective head gasket – see Kubota WSM. b) Faulty crankcase / cylinder head – see Kubota WSM.
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Troubleshooting
3.3. Generator
No / low voltage output (16 to 24VAC) a) Low engine RPM – Increase engine speed to 3750 RPM (no load). b) Circuit breaker is tripped / failed – Reset / replace breaker. c) Faulty capacitor – Test and replace capacitor. d) Defective receptacle – Replace with 20A GFCI. e) Failed stator – Test / replace. f) Failed rotor – Test / replace. g) Failed diode(s) – Test / replace rotor.
No / minimum power output (8 to 12VAC) a) No load (correct RPM), failed diode or exciter winding - Test & replace. b) Slightly low engine RPM – Increase engine speed to 3750 RPM (no load). c) Rotor wire off at diode solder joint – Test / replace rotor. d) Rotor slipping from engine – Replace rotor & PTO shaft. e) Partially shorted rotor – Replace rotor. f) No voltage output – Flash the generator (see Chapter 7.5.).
High voltage output a) High engine RPM – Reduce engine speed to 3750 RPM (no load). b) Wrong capacitor – Order correct capacitor from CCS distributor.
Voltage output drops a) Diode failure (diodes will test fine but they have a partial loss) – Replace rotor. b) Low engine HP – see Kubota WSM. c) Electrical load has a power factor below 0.7 – Remove inappropriate electrical load.
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Troubleshooting
3.4. Chassis
Vibration a) Loose / damaged vibration mount – Remove and replace. b) Loose engine foot bolts – Remove thread locking compound, re-install and torque. c) Loose / damaged drive pulley – Remove and replace pulley (install new key). d) Loose / damaged generator – Replace generator. e) Incorrect exhaust tail pipe position – Re-position to center of extraction point. f) Internal engine damage – (Kubota WSM). g) Uneven generator mounting feet – Loosen generator bearing housing and re-align mounting feet.
Rattling, noise a) Loose body panel / missing bolts – Replace / tighten. b) Loose engine bolts / damaged part(s) – see Kubota WSM. c) Loose / damaged generator – Inspect for damage replace and tighten.
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Troubleshooting
3.5. Climate control system
If a compressor fails due to an internal electrical short, it is recommended
that the entire A/C system be replaced due to oil contamination.
No operation at all (power at controller) a) No function selected on control panel – Select HEAT or COOL function on control panel. b) Selected temperature is insufficient – Adjust temperature. c) No power – Tripped circuit breaker(s) / no power source (generator / shore power)
No or little cold air a) Cool function not activated – Select COOL function on control panel. b) Selected temperature too high – Adjust temperature. c) Clogged / dirty evaporator filter – Clean / replace. d) Faulty evaporator blower – Test & replace. e) Blown condenser fan fuse – Replace. f) Faulty condenser fan – Test & replace. g) Clogged / dirty condenser coil – Clean. h) Faulty condenser fan driver – Replace. i) Blocked or insufficient return air – Unblock / increase return air. j) Evaporator coil frozen up – Defrost. k) Excessive heat transfer through cab windows – Close curtains. l) Insufficient or leaking ducting – Increase or repair ducting. m) Outlet temperature sensor failure – Test & replace.
20 o) Insufficient refrigerant – Test & replace.
No or little hot air a) Heat function not activated – Select HEAT function on control panel. b) Selected temperature too low – Adjust temperature. c) Clogged / dirty evaporator filter – Clean / Replace. d) Faulty evaporator blower – Test replace. e) Blocked or insufficient return air – Unblock / increase return air. f) Tripped HVAC 2 breaker – Reset breaker. g) Faulty heater coil – Test & replace. h) Insufficient or leaking ducting – Increase / repair ducting. i) Faulty thermal breaker(s) – Test & replace. j) Outlet temperature sensor failure – Test & replace.
CCS Lightning Workshop Manual
Troubleshooting
No 120V power at receptacles a) 20A GFCI breaker tripped – Reset breaker. b) 20A power distribution box breaker tripped – Reset breaker. c) 30A main breaker tripped – Reset breaker.
No or poor battery charging a) Blown 50A charger fuse – Replace fuse. b) Excessive 12v load – Reduce load. c) Tripped interior outlet 20A breaker – Reset breaker.
No power at controller a) Blown 150A main fuse – Replace fuse. b) Blown 7.5A ECU battery fuse – Replace fuse. c) Unplugged / damaged controller cable – Replace cable.
No / loss of shore power a) Tripped HVAC 1 breaker – Reset breaker. b) Continuous tripping of HVAC 1 breaker – Reduce load / Check for correct source voltage. c) Continuous tripping of shore power source breaker – Check for correct plug (20A) / cable length on extension cord. d) Discharged batteries – Recharge.
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3.7. Electrical protection locations
Troubleshooting
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Figure 2-1: Circuit breakers on APU
CCS Lightning Workshop Manual
Figure 2-2: Circuit breakers on power distribution box
PDB Circuit breaker
HVAC 1
HVAC 2
Outlet interior
Outlet exterior
Rating
20A
30A
20A
20A
Equipment powered
First stage heating element
Blower circulation fan
Air conditioning compressor
Second stage heating element
Indoor receptacle
Battery charger
Outdoor receptacle
Troubleshooting
Figure 2-3: Indoor / outdoor receptacle – ground fault circuit interrupter
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Troubleshooting
Figure 2-4: 150A fuse
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Figure 2-5: 50A fuse
CCS Lightning Workshop Manual
Troubleshooting
3.8. Self-diagnostic flash codes
The APU and power distribution box (PDB) are both equipped with a diagnostic LED to indicate system faults and shutdown conditions. When a fault is present, the LEDs will flash the relevant sequence to help the user/repair technician diagnose and repair the fault.
Each code will flash and will be separated by approximately 1 second long pause(s) between present codes. When the list of present fault codes has been displayed, the sequence will repeat itself until cleared.
Example: If the engine over temperature and generator AC over voltage faults occurred, the flash sequence would produce 3 quick flashes, a long pause, 5 quick flashes, long pause, 3 quick flashes, a long pause and so on.
Once the fault has been repaired, pressing the START/STOP button on the CCS Lightning control panel will clear the fault message(s) on the screen. The LED will continue to flash until the system has gone through 3 consecutive start/stop cycles without any faults.
Figure 2-6: Diagnostic LED on APU
Figure 2-7: Diagnostic LED on power distribution box
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Troubleshooting
Flash code
APU PDB
Possible causes
1 1 For CCS use only
Unplugged / faulty coolant return temperature sensor
2 2
Unplugged / faulty enclosure temperature sensor
Unplugged / faulty refrigerant temperature sensor
- 2
Unplugged / faulty CHEB vent temperature sensor
Generator AC output over 138V
Generator AC output under 100V
- 3
Shore power AC output over 138V
Shore power AC output under 100V
Batteries depleted (below 8VDC)
Poor connection to batteries
4 4
Faulty battery charger
APU circuit board failure
Insufficient engine oil
Poor fan belt tension
Low coolant level
Coolant air lock
Contamination in coolant
Faulty radiator fan / blown fuse
Faulty engine thermostat
Faulty enclosure fan
Debris in engine compartment (air inlet/outlet)
Circuit board overheated
CHEB vent overheated
- 5
Refrigerant overheated
CCS Lightning Workshop Manual
Flash code
APU PDB
Possible causes
Faulty speed sensor
Faulty engine harness
Starter relay / fuse blown
Starter solenoid wire unplugged
Faulty starter
Blown ECU drive fuse
Wrong speed setting
6 6
Governor failure
Clogged air filter
Clogged fuel filter
Faulty fuel solenoid
Blown glow plug fuse
Blown glow plug(s)
Blown glow plug relay
7 7
Lack of fuel / clogged filter
Faulty fuel solenoid
Faulty fuel relay / fuse
Faulty fuel pump
Faulty glow fuse / relay
Overcrank
Glow plugs
Low oil
Low oil pressure / clogged filter
Faulty oil pressure switch
Plugged oil gallery / component in engine
Unplugged / faulty condenser fan or driver
Excessive debris on condenser
Defective refrigerant pressure sensor
Internal blockage of refrigerant paths
Troubleshooting
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Troubleshooting
Fig. 2-8: Cab controller
28
Battery voltage / hour meter display flashes
Blank screen
Set temperature flashes
Unplugged / broken controller cable
APU circuit board failure
APU circuit board failure
Control panel circuit board failure
HVAC circuit board failure
Communication fault
CCS Lightning Workshop Manual
Troubleshooting
To perform the test, proceed as follows:
1. Unplug the controller.
2. Press and hold the ENTER button while plugging the cable back into the controller.
3. Release the ENTER button, then push each button once to light up from left to right (starting with the HEAT button).
4. After all buttons are pressed in the correct sequence, the controller will perform a self-check and beep (if working).
5. Wait about 30s for the display to appear and adjust contrast if necessary (press and hold the ENTER button while turning the SCROLL DIAL counter clockwise).
6. The controller will now operate the condenser fan, enclosure fan and the radiator/heat exchanger fan for 30s (verify operation).
7. Press and hold the FAN button while turning the SCROLL DIAL to scroll through the operating parameters (displayed directly below the temperature setting).
8. Unplug controller cable from the controller and plug back in to exit diagnostic mode.
Refer to Figure 2-8 on the previous page.
Line Display Parameter
1
2
3
4
G L1
Generator power to cab
G L2
Generator power to outdoor receptacle
S L1
RPM
Shore power to cab
Engine speed
V
V
V
RP
M
5
6
7
8
9
CLNT
Engine coolant temp.
R FAN
Radiator / heat exchanger fan speed
COND
High side refrigerant line temp.
%
ºC
C FAN
Condenser fan speed
BAY
Engine bay temperature
ºC
%
ºC
10
B FAN
Engine bay fan speed
11
DSPL
Sleeper temp. at display
12
VENT
Sleeper vent temp.
%
ºC
ºC
A faulty sensor is identified by a (????).
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4. MAINTNTENANCE
• Before disassembling or servicing live wires, make sure to always disconnect the battery first.
• During disassembly, carefully arrange removed parts in a clean area to prevent confusion later.
Screws, bolts and nuts should be replaced in their original position to prevent reassembly errors.
• Gaskets and O-rings must be replaced during reassembly. Apply grease to new O-rings or oil seals before reassembling
Maintenance Item 50 Hours 500 Hours 1000 Hours
Check oil and coolant level
Check fuel / coolant lines and clamps
Check / adjust water pump belt tension
Change engine oil and filter
Check air filter (replace as necessary)
Change fuel filter element / drain sediment bowl
Check / replace water pump belt
Clean CHEB filter
Adjust valve lash
Clean remote radiator / heat exchanger fins
Clean condenser fins
Check injector nozzle opening pressure
Change coolant, fuel hoses and clamps daily
9
9 after first 50 hrs
9
9
9
9
9
800 hours Authorized dealer
9
9 every 2 years Authorized dealer every 2 years Authorized dealer
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CCS Lightning Workshop Manual
Maintenance
4.3. Engine oil specifications
Engine oil should be MIL-L-2104C or have properties of API classification CD grades or higher. Minimum recommendation is CD, CE or CF engine oil for Kubota diesel engine.
API classification
CD
CE
CF
Application
Oil suitable for the diesel engines operated under severe conditions, which will resist high temperature piston deposits, ring sticking and thermal breakdown
Oil suitable for the diesel engine which is operated under the most severe conditions, having the property to restrain oil consumption, oil deposit, and oil viscosity increase, in addition to the properties of CD
Oil suitable for the diesel engine to be mounted on the off-road vehicles, of which fuel is a high-sulphur (0.2%) fuel
With the emission regulations now in effect, the CF-4 and CG-4 lubricating oils have been developed for use with low-sulphur fuel on on-road vehicle engines. When an off-road vehicle engine runs on a high-sulphur fuel, it is advisable to employ the CF, CD or CE lubricating oil with a high total base number.
{
- recommended
±
- not recommended
Lubricating oil class
CF
CF-4
CG-4
Low sulphur
{
{
{
Fuel
High sulphur
{
±
±
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Fig. 3-1: Suitable oil viscosity chart
Maintenance
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CCS Lightning Workshop Manual
4.4. Checking level and adding engine oil
Maintenance
Figure 3-2: Checking/adding engine oil
1. Check engine oil level before starting or more than 5 minutes after stopping engine.
2. Remove engine oil dipstick, wipe it clean and re-install it.
3. Remove dipstick and check oil level – see illustration.
4. If oil level is low, remove the oil filler plug and add new oil to the appropriate level.
5. After adding oil, wait more than 5 minutes to verify oil level. It takes some time for oil to fall into the oil pan.
Be sure to stop the engine before checking and changing the engine oil and oil filter.
Do not touch the muffler or exhaust pipe.
These could be hot and cause severe burns.
Contact with engine oil can damage your skin. Use gloves when working with engine oil. If you come into contact with oil, wash it off immediately.
Be sure to check engine oil with engine on a horizontal surface. Placing the engine on gradients could result in inaccurate engine oil level readings.
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4.5. Checking and adding coolant – remote radiator
Maintenance
Figure 3-3: Checking/adding coolant – remote radiator
1. Check to see that the coolant level lies between FULL (A) and LOW (B).
2. Remove radiator cap, fill radiator, replace cap.
3. Run until thermostat opens.
4. Allow engine to cool and repeat step 2.
Do not remove the radiator cap until coolant temperature is cool. Then loosen the cap slightly to relieve any excess pressure before removing the cap completely.
While filling the coolant, air must be vented from the engine coolant passages using bleed plug on thermostat housing (refer to
Figure 4-4, bleed air).
Be sure to close the radiator cap securely. If the cap is loose or improperly closed, coolant may leak out and the engine could overheat.
Do not use an antifreeze and scale inhibitor at the same time.
Never mix the different types or brands of
L.L.C.
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CCS Lightning Workshop Manual
4.6. Checking and adding coolant – heat exchanger
Maintenance
Figure 3-4: Checking/adding coolant – heat exchanger
2. Bleed air from heat exchanger.
3. Bleed air from APU engine.
4. Start truck and run for 5 minutes.
5. Start APU and run for 5 minutes.
7. Start APU and run for 30 minutes.
8. Check coolant level and top up if necessary.
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4.7. Checking / adjusting water pump belt tension
To check water pump belt tension, proceed as follows:
1. Measure the deflection, depressing the belt halfway between the fan drive pulley and the belt tensioner pulley at 98N (10kgf, 22lbs) of force.
2. If the measurement is not the specified value, loosen the bolts and the nuts and relocate the belt tensioner to adjust.
Maintenance
Figure 3-5: Checking / adjusting water pump belt tension
To adjust water pump belt tension, proceed as follows:
1. Loosen tensioner nut using a 14mm wrench.
2. Tap the outside of the tensioner pulley using a rubber mallet to ensure proper spring tension.
3. Tighten tensioner nut using 14mm wrench.
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CCS Lightning Workshop Manual
4.8. Replacing water pump belt
Maintenance
Figure 3-6: Replacing water pump belt
To replace water pump belt, proceed as follows:
1. Loosen tensioner nut using a 14mm wrench.
2. Remove 4 water pump pulley bolts using
10mm wrench.
4. Tighten 4 water pump pulley bolts using
10mm torque wrench.
5. Tighten tensioner nut using a 14mm wrench.
Figure 3-7: Belt wear determination
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4.9. Replacing air filter
Maintenance
Figure 3-8: Replacing air filter
1. Replace engine air filter as per routine maintenance schedule or as necessary.
2. Release the two retaining clips on the side of the air cleaner housing cap.
3. Remove the old air filter element by pulling it straight out of housing.
4. Insert the new air filter.
5. Re-install air cleaner housing cap ensuring evacuator valve is pointing to the ground.
Be careful not to knock dust from the dirty filter.
Evacuator valve must point to the ground.
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4.10. Draining water from sediment bowl / changing fuel filter
Maintenance
Figure 3-9: Draining water from sediment bowl/changing fuel filter
The fuel filter has been designed to trap water in the see-through fuel bowl. Periodically check bowl for presence of water.
To remove water/change fuel filter, proceed as follows:
1. Turn fuel valve on filter body to the horizontal “OFF” position.
2. Unscrew the fuel bowl retaining ring and remove the fuel bowl being careful not to spill any fuel.
3. Dispose of water in fuel bowl.
6. If fuel filter element is dirty or the running hours have reached the level in the routine maintenance schedule, remove the fuel filter element.
4. Install a new filter element if necessary.
Make sure O-rings are properly re-installed.
5. Fill fuel bowl to approximately 2/3 before reinstalling.
6. Install fuel bowl and tighten retaining ring.
7. Turn fuel valve to vertical “ON” position.
8. Run engine to check for fuel leaks. Repair if necessary.
or fuel system.
Do not mix gasoline or alcohol with diesel fuel.
Do not spill fuel during refuelling or fuel system maintenance. If fuel should spill, wipe it off at once.
Always shut engine off before refuelling.
Do not smoke while working around battery
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4.11. Bleeding the fuel system
Maintenance
Figure 3-10: Bleeding the fuel system
To bleed the fuel system, proceed as follows:
1. Loosen injection line nuts (using 17mm wrench).
2. Attempt to start the unit. Once fuel is observed, tighten both injector line nuts one at a time.
The system will automatically attempt 3 start cycles. If it fails to start after 3 cycles, it will stop and display an “Over crank” message on the control panel display. Simply reset the system by pressing the START/STOP button.
Press the START/STOP button again to reinitiate the start cycle.
The system may start when performing this procedure. Keep away from rotating and moving engine parts.
Safety glasses are required when performing this procedure.
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Maintenance
4.12. Cleaning evaporator filter
Figure 3-11: Cleaning evaporator filter
1. Pull out white filter retaining clips.
3. Soak filter in soapy water.
4. Blow dry with compressed air.
Safety glasses are required when performing this procedure.
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4.13. Cleaning condenser, heat exchanger and remote radiator
Maintenance
Figure 3-12: Cleaning condenser, heat exchanger and remote radiator
1. Spray coil cleaner on condenser / exchanger
/ radiator coils.
2. Follow directions on coil cleaner for soaking duration.
3. Hose off using garden hose and tap pressure.
Safety glasses are required when performing this procedure.
Be sure that selected coil cleaner will not damage truck finish.
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Testing
5. TESTING
5.1. APU
Engine
3750RPM (no load)
Speed sensor
Generator main windings*
0 to 8.4VDC between signal (26) and ground (30)
0.343
Ω to 0.348Ω between black wires #1 & #2 and between black wires #3 & #4
- no continuity to ground
Generator capacitor windings*
1.227
Ω to 1.232Ω
- no continuity to ground
Rotor windings*
0.735
Ω to 0.755Ω
- no continuity to ground
Diodes
Capacitor
Oil pressure switch
* These resistance values are very small and testing requires a good quality low resistance reading meter.
- continuity in one direction, no continuity in other direction
50MFD at 370V
- no continuity to ground
Below 7psi – switch is closed to ground
Above 7psi – switch is open
Overheat switch
Below 110ºC (230ºF) – switch is closed to ground
Above 110ºC (230ºF) – switch is open
Engine bay temperature sensor
“Self-test”, use diagnostic mode
Coolant temperature sensor
“Self-test”, use diagnostic mode
0 to 4.5VDC (no contact-contact)
Door switch
Engine bay fan
Shutdown solenoid
5.6A, 75W, average 290cfm
V BATT / 46A (pull), 1.1A (hold)
Rated: 20lbs pull / 40lbs hold
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Testing
5.2. HVAC
Condenser fan
Evaporator fan
Thermal heater breakers
Thermal compressor breaker
Heat elements
10K: 8 to 10A, 110W, 12VDC, average 600CFM
14K: 11 to 14.5A, 225W, 12VDC, average 1000CFM
1.6A, 185W, 115VAC, average 400CFM
Normally “closed”, open at 180, reset at 140
°F
Normally “closed”
10K: 14.4
Ω, 1000W on low heat; 7.2Ω, 2000W on high heat
14K: 10.8
Ω, 1333W on low heat, 5.4Ω, 2660W on high heat
Vent temp. sensor
“Self-test”, use diagnostic mode
Compressor line temp. sensor
“Self-test”, use diagnostic mode
Compressor
Check for continuity between the three windings and be sure there is no continuity from the winding to case.
Refrigerant pressure
Refrigerant pressure switch
If a compressor fails due to an internal electrical short, it is recommended that the entire A/C system be replaced due to oil contamination.
There is no way to give a specification for refrigerant pressures.
Generally if there is a refrigerant leak, the system will empty quickly and a low or no pressure will show on gauges.
Normally “closed”, opens at 425psig, closes at 325psig
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6. TABLES
6.1. General torque specification
Size
1/4-20
5/16-18
3/8-16
1/2-13
5/8-18
Grade 5 Grade 7 Grade 8
Lube Dry Lube Dry Lube Dry
6.25 ft-lbs
13 ft-lbs
8 ft-lbs
17 ft-lbs
8 ft-lbs
16 ft-lbs
10 ft-lbs
21 ft-lbs
9 ft-lbs
18 ft-lbs
12 ft-lbs
25 ft-lbs
23 ft-lbs
55 ft-lbs
130 ft-lbs
30 ft-lbs
75 ft-lbs
170 ft-lbs
30 ft-lbs
70 ft-lbs
160 ft-lbs
40 ft-lbs
95 ft-lbs
210 ft-lbs
35 ft-lbs
80 ft-lbs
180 ft-lbs
45 ft-lbs
110 ft-lbs
240 ft-lbs
6.2. CCS Lightning torque specification
Assembly Thread
Flywheel bolts M10 x 1.25
Setting
39.8 to 43.4 ft-lbs; 54.0 to 58.8 Nm
Stub shaft to flywheel bolts
Rotor to stub shaft bolt
M8 x 1.25
5/16” - 24
13.0 to 14.5 ft-lbs; 17.6 to 19.7 Nm
15 ft-lbs; 20.3 Nm
Flywheel housing bolts
Engine feet bolts
Stator bolts
Engine cradle bolts
M8 x 1.25
1/4” - 20
5/16” x 18
13.0 to 15.2 ft-lbs; 17.7 to 20.6 Nm
M10 x 1.25 28.9 to 33.3 ft-lbs; 39.1 to 45.1 Nm
8 ft-lbs; 10.8 Nm
18 ft-lbs; 24.4 Nm
Through frame bolts
Frame gripper bolts
Refrigerant lines
Battery charger screws
5/8” - 18
5/8” - 18
N/A
N/A
100 ft-lbs; 135.6 Nm
30 ft-lbs; 47.5 Nm
10-12 ft-lbs
16 in-lbs
Consult Kubota engine manual for torque specifications of all engine components.
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6.3. Temperature conversion
Celsius Fahrenheit
-40 -40
-30 -22
-25 -13
-20 -4.0
-15 5.0
-10 14.0
-5 23.0
0 32.0
5 41.0
10 50.0
15 59.0
20 68.8
25 77.0
30 86.0
32 89.6
35 95.0
40 104.0
45 113.0
50 122.0
55 131.0
60 140.0
70 158
80 176
90 194
100 212
110 230
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7. DISASSEMBLING
Figure 6-1: Engine and generator
1. Pull out 150A main fuse at batteries.
2. Remove generator cover – eight bolts.
3. Remove alternator air intake shroud – four screws.
4. Disconnect capacitor plug.
5. Remove back plate – four stator nuts.
6. Re-install four stator nuts on to bearing housing assembly.
7. Disconnect stator wires from APU conduit wires by cutting apart the butt-splice insulated connectors. Be careful to mark the wires so that reconnections are correct.
8. Remove generator vibration mount bolts.
9. Remove negative cables from starter housing and re-install starter bolt. solenoid.
11. Unplug starter solenoid signal wire #12.
12. Unplug coolant temperature sensor and cut wire tie.
13. Remove #17 wire from oil pressure switch.
14. Remove #15 wire from coolant temperature switch.
15. Unplug run solenoid (3-wire connector) and cut wire ties.
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Disassembling
Figure 6-2: Removing engine and generator from chassis
16. Unplug speed sensor (3 wires) and cut wire ties.
17. Pull main wire harness away from the engine and allow to hang from right side. necessary). Tape over engine intake to avoid debris from entering into the engine.
19. Undo spring clip and remove fuel inlet hose from low-pressure fuel pump. Cut wire ties.
20. Undo spring clip from fuel return hose from the tee closest to the truck frame.
21. Remove exhaust clamp from muffler and pry exhaust pipe from muffler.
22. Remove engine vibration mount bolts.
23. Drain APU/engine coolant.
24. Remove coolant inlet and outlet hoses from engine.
25. Remove engine/generator assembly from chassis using either an engine hoist and chains or a jack under the oil pan. (Be sure to secure engine/generator so that it cannot fall off jack).
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7.2. Removing generator from engine
Disassembling
Figure 6-3: Removing generator from engine
1. Disconnect stator wires from conduit wires by cutting apart the butt-splice insulated connectors. Be careful to mark the wires so that reconnections are correct.
2. Remove all four stator through studs. Use two of the stator nuts to tighten one against the other and remove stud.
3. Support the stator with blocks of wood and remove the bearing housing. It is a tight fit on the stator so a puller may be required.
The stator is heavy and contact between the stator and rotor could damage the windings.
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Disassembling
Figure 6-4: Removing generator from engine
4. Remove the stator. Pry the stator assembly away from the adapter plate using two small pry bars. Once the stator is free, remove the blocks and carefully pull the stator over the rotor and free it from the engine.
5. Remove the rotor nut.
6. Separate the tight fit of rotor shaft male taper and PTO shaft female taper using a dead blow plastic hammer. Give the rotor one or two sharp blows, and then alternate to the other side of the rotor with equal sharp blows. Repeat (switching sides) until the taper breaks free and the rotor can be removed.
7. If the rotor will not break free due to rust or corrosion between tapers, position the engine/rotor assembly straight up and spray penetrating oil straight down the hollow rotor shaft (it may be necessary to remove stud).
Let sit overnight and proceed to repeat step 6.
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7.3. Radiator / heat exchanger
Disassembling
Figure 6-5: Disassembling cab mounted remote radiator
Figure 6-6: Disassembling cab mounted heat exchanger
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Figure 6-7: Disassembling frame mounted heat exchanger
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Figure 6-8: Disassembling frame mounted remote radiator
CCS Lightning Workshop Manual
Disassembling
Disassembling
Figure 6-9: Disassembling CHEB unit
1. Remove cover 1 - four screws and one bolt.
2. Remove cover 2 – four screws.
3. Remove cover 3 – four screws.
High voltage wires!
Do not attempt to do this procedure with APU running or shore power plugged in.
Remove start-up relays to ensure safety.
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Figure 6-10: Disassembling CHEB unit
4. Unplug blower black #2 and brown #10 wires. Pull through grommets so that fan harness is free.
5. Remove panel 4 – five screws (see Fig.6-9).
6. Remove panel 5 – six screws.
7. Remove four nuts for blower motor and remove motor.
8. Remove two bolts and remove vent temperature sensor.
9. Remove white wires #16 and #12 and heavy black wires from thermal breakers and pull out heat element assembly.
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Disassembling
Disassembling
Figure 6-11: Disassembling CHEB unit
compressor cap, remove cap. Unplug wires on thermal breakers and remove.
11. Remove nuts and remove compressor line temperature sensor. breakers.
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7.5. Condenser / fan unit
Disassembling
Figure 6-12: Disassembling condenser / fan unit
1. Unplug fan driver.
2. Remove four #10 screws using Philips screwdriver.
3. Remove #10 screw from fan driver using
Philips screwdriver.
Do not misplace spacer behind driver when disassembling.
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8. REPAIR PROCEDURES
8.1. Reclaiming /recovering refrigerant NU-22 (R417a)
Figure 7-1: Reclaiming / recovering the refrigerant (Condenser and refrigerant end lines not shown)
1. Connect manifold / gauges to CHEB (high side to 1, low side to 2).
2. Connect the hose 3 to the low side of your reclaimer.
3. Connect the hose 4 to the high side of the reclaimer and the liquid valve on tank.
4. If your reclaimer and tank are equipped with a fill sensor, connect the cable to the tank (if not, it is recommended that you weigh your reclaiming tank to prevent damage to your reclaimer).
5. Set reclaimer valves to recover and liquid.
6. Open liquid valve on manifold gauges.
7. Recover liquid until low pressure gauge on reclaimer has 0psi.
8. Set reclaimer valves to recover and gas.
9. Recover gas until low pressure manifold gauge reads 10lbs of vacuum.
The following procedure may ONLY be performed by a person holding proper Ozone
Depleting Products Certification. Practices and safety should be in accordance with laws governing Ozone Depleting Substances.
Use reclaiming tank certified for NU-22
(R417a). Do no mix refrigerants.
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8.2. Vacuuming / leak testing refrigerant NU-22 (R417a)
Repair procedures
Figure 7-2: Vacuuming / leak testing the refrigerant (Condenser and refrigerant end lines not shown)
1. Connect manifold / gauges to CHEB (high side to 1, low side to 2).
2. Connect the hose 3 to vacuum tee fitting.
3. Connect the Micron meter probe 6 to vacuum tee fitting.
4. Connect the hose 4 with the shut-off valve to the vacuum tee fitting and the vacuum pump.
5. Start pump, open gas ballets on pump and open both manifold gauges. Wait 30 seconds and close gas ballets on pump.
6. Pull 400 microns and stop pump. Shut valve
5 and observe gauge for leaks (you should not see more than 100 microns increase per
20 seconds).
The following procedure may ONLY be performed by a person holding proper Ozone
Depleting Products Certification. Practices and safety should be in accordance with laws governing Ozone Depleting Substances.
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Repair procedures
Figure 7-3: Charging / recharging the refrigerant (Condenser and refrigerant end lines not shown)
1. Connect manifold / gauges to CHEB (high side to 1, low side to 2).
2. Connect the hose 3 to the NU-22 (R417a) fill tank on the liquid valve.
3. Place the NU-22 (R417a) fill tank on the scale and open the tank valve.
4. Purge line by opening service hose on manifold to purge freon.
5. Open the high side manifold valve and charge the system (low side of manifold valve is closed):
3lbs for 10 000BTU system
4lbs for 14 000BTU system
6. If refrigerant stops flowing prior to desired weight, close high side manifold valve and leave system sit for 15 minutes or more.
7. Operate the system in air-conditioning.
Slowly measure the amount of liquid refrigerant by opening the high side manifold valve until you reach the desired weight.
High pressure gauge should not read more than 15psi higher than low pressure gauge.
NU-22 (R417a) may not be re-used or topped up. Reclaim / vacuum complete system prior to re-charging.
Do not allow liquid freon to enter the compressor or permanent damage can occur.
NU-22 (R417a) is a blended refrigerant and
MUST be charged in the liquid phase.
The system must be vacuumed to between
400 and 1000 microns before attempting this procedure.
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Repair procedures
Figure 7-4: Capacitor
If this capacitor is open or shorted, near to no generator output voltage will result.
1. With the engine stopped, unplug connector and remove the protective rubber cover.
Check the capacitor “charge to discharge” readings using the ohmmeter. With the ohmmeter leads placed on the capacitor, a meter deflection should be observed
(charged) followed by a slow return to infinity
(discharged).
2. Reverse the ohmmeter leads and repeat the process for the same results.
No meter deflection or continuity indicates an open or shorted capacitor. All capacitors have an internal built-in circuit breaker. When the breaker trips it causes the entire top portion to be extremely convexed or pushed outwards. If this happens, replace the capacitor.
Figure 7-5: Diagnosing capacitor
Extremely high voltage is present even when engine is stopped. Use extreme caution when handling.
When re-installing the capacitor, make sure that rubber boot is installed and drain hole is pointing down.
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Repair procedures
8.5. Flashing the generator
Figure 7-6: Flashing the generator
1. Install wires, do not connect battery yet. Cap must remain connected to the alternator.
2. Connect voltmeter to observe alternator output.
4. Briefly touch wires to battery and release
(polarity is not important).
5. Repeat until alternator is producing output voltage.
6. Stop APU and remove flashing wires.
7. Reassemble.
If flashing the field has restored voltage output; but when the generator set is stopped and restarted, a no voltage output occurs - check that the engine speed is not too low.
A potential shock hazard exists when handling battery jumper leads. Never wear jewellery, or use tools, or metal items that may make the contact across battery terminals.
When alternator is producing output voltage, an extremely high voltage appears on the capacitor!
If battery is held across cap for more than a brief second, the battery will heat up and can explode.
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Repair procedures
8.6. Diagnosing the stator
Figure 7-7: Diagnosing the stator
The stator windings consist of two main poles and an exciter winding. There are four large black wires labelled 1-4 for the main poles and the exciter winding is connected to the capacitor via a short harness.
To test the stator, use an ohmmeter:
1. Place one meter lead on the main pole wire
1 and the other meter lead on the main pole wire 2 and compare the meter reading to the value found in the tests section of this manual.
2. Repeat this process using the main wires 3 and 4.
3. Repeat this process for the exciter winding using the pigtail harness that plugs into the capacitor.
4. Test for continuity between main pole wires and exciter winding.
5. Test for continuity between the two main poles.
6. Test all wires for continuity to case (ground).
Disconnect power so that unit will not start.
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Repair procedures
8.7. Diagnosing the rotor
Figure 7-8: Diagnosing the rotor
1. Visually inspect windings for dark streaks.
2. Place an ohmmeter across the solder connection of each diode. If the resistance does not compare with resistance values in test section of this manual, replace rotor.
3. Check bearing spin by hand. If it is rough, noisy or dry, replace bearing.
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9. WIRING DIAGRAMS
The wiring diagrams provided with this document are for reference purposes only.
Before proceeding to diagnose or repair ANY wiring, call CCS for approval.
Wiring diagnosis and repair should only be performed by a qualified technician or electrician.
The CCS wiring has extremely high voltage!
Disconnect power so the unit will not start.
If the unit requires DC power for testing purposes, remove the relays to prevent unit from starting.
This section contains following wiring diagrams:
AUXILIARY POWER UNIT WIRING DIAGRAM
POWER DISTRIBUTION WIRE DIAGRAM
CCS_WM_085
CCS_WM_087
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Key features
- Auxiliary power unit (APU)
- Climate control system
- Power distribution box
- Battery charger
- Control panel
- Indoor and outdoor receptacles
- Shore power
- Keyless remote starter