Operation And Service Manual

MODEL No. DPS6500

 DP Contents

TABLE OF CONTENTS

INTRODUCTION
SAFETY
Safety Alerts 2
Component Diagram and Specifications 3
Multi- Function DCP Components 4
OPERATION
How the Diamond Power APU Operates 5
Feature & Description 5
MANUAL OPERATIONS
Starting the APU 6
Stopping the APU 7
Turning the Heater ON/OFF 7
Heater Setting the Temperature 8
Fan Operation 8
AUTO OPERATIONS
Reset the password 9
Set Password 9
Entering the Password 10
Setting the Clock 11
Turning the Comfort Monitor ON/OFF 12
Timer 13
Turning Timer ON/OFF 13
Turning the Low Temperature Monitor On/OFF 14
Turning On the Start Temperature 15
Setting the Run Timer for Low Temperature Monitor 16
Setting the Maximum Run Time 17
Battery Monitoring 18
Setting the Voltage Level for Battery Monitor 19

MAINTENANCE
Maintenance Schedule 20
TROUBLESHOOTING
APU (Auxiliary Power Unit) 21
Generator 24
HVAC (AC, HEAT and FAN) 25
Air Conditioning 25
Fan 27
Heat 27
WARRANTY
Warranty Policy 28

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 DP Safety

SAFETY ALERTS
Throughout this manual, you will see notes labeled “Warnings” or “Cautions” to alert you to special instructions or precautions
concerning a particular procedure that would be hazardous if performed incorrectly or carelessly.

Observe them carefully!

These safety alerts alone cannot eliminate hazards that can occur. Strict compliance with these special instructions when performing the
installation and maintenance, plus common sense, are major accident prevention measures.

DANGER: Immediate hazards that will result in severe personal injury or death

WARNING: Hazards or unsafe practices that could result in severe personal injury or death

CAUTION: Hazards or unsafe practices that could result in minor injury or product or property damage.

NOTE: Information that is important to proper installation or maintenance, but is not hazard-related.

For example:

DANGER: A certified refrigeration technician must charge and test the HVAC.

EXHAUST – Inhalation of exhaust gas (containing carbon monoxide) may cause severe personal injury and/or death. Anyone suspected
of suffering from CO inhalation should be removed from the hazardous area and be given medical assistance immediately.

WARNING – California Proposition 65 Warning: This product contains lead, a chemical known to the state of California to cause
cancer and birth defects and other reproductive harm.

FUEL/BATTERIES: Extreme caution is needed when working near fuel or fuel-filled equipment. Do not operate equipment during fueling
operations. Use eye protection when working near batteries, which contain acid and can explode. Do not smoke or use near open flames.

ELECTRICAL: Electric Shock can cause severe personal injury, burns, and even death. Before working on any unit, disconnect the batteries.
Use only approved materials and methods when working on the electrical system, and follow local electrical codes. Never work on the
APU or the electrical circuitry when the APU is running. Never work with electricity in wet conditions or when you are tired.

INTOXICANTS: 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 breathe in vapors.

HOT OR MOVING PARTS: Moving part can cause severe injury and/or death. Before working on any unit, shut it off and disconnect the
battery. Do not start until protective covers have been replaced. Also, loose parts falling into rotating machinery can cause severe
accidents. Always ensure bolts and clamps are correctly torque and secured. Inspect mechanical components periodically for damage,
corrosion, and proper torque.

MISUSE: The APU is designed to provide electrical power for heating and cooling vehicles in normal on-road conditions. Never use the
APU to power critical medical equipment or sensitive electronic equipment without the manufacturer’s written approval.

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 DP Safety

Component Diagram and Specifications

Condenser
Part of the air
conditioning system,
connected to the
evaporator and located
outside the truck.

Driver’s Control Panel

APU
ON/OFF
HVAC
OFF
Located inside the cab or HVAC Part of the
MENU

ESC/RESET sleeper, displays all settings HVAC system, includes

A/C FAN HEAT
and makes it easy to set fan blower, compressor
automatic controls. and heater, located inside
APU Contains the two-cylinder the truck, typically under
diesel engine and AC & DC electrical the sleeper in the storage
power generation compartment

APU Specifications HVAC Specifications

Engine 14 Hp, 2 Cylinder , Water cooled, Diesel Air Conditioning 15000 BTU/hr
Bore X Stroke 2.64" X 2.68" System capacity 64~68 oz of R-134A
Rated Power 6.5 KW @ 2600RPM System oil capacity 14 oz of PVE (Polyvinylether)
Fuel Consumption .157 to .26 G/Hr based on load Compressor 6~10 Amp @ 120V
Electrical Draw AC: 4 kW DC: 0.8 kW Condenser Fan 9~12 Amp @ 13.5 VDC
Exhaust Temp 860°F Binary Pressure Switch Normally closed between 26~335 psi
Engine Oil 0.793G/3.0L (Use any API Service CF, Operating Pressures Low side 24~45 psi, High side 110~250 psi
CF-4, CG-4 or CH-4 oil) Heat 7500/15000 BTU'hr (Low/High)
Valve Clearance 0.2~0.3mm Heater Draw 5K BTU - 1.3 kW, 10K BTU - 3.9 kW
Engine Compression 300 PSI (2.0 MPa) Speed Resister 25 Ohms
Starter 160 Cranking Amps Heating Coils 10 Ohms each - dual
Noise Level (dB) 70 dB Thermo Fuse Blows at 307.4°F (152°C)
Alternator 70 Amp @ 14 V DC Weight 100lb
Generator 35 Amp @ 120V AC Dimensions (HVAC) 24.25" W X 16.88"D X 12.80"H
Oil Pressure Switch 7.1 ~ 142.2 psi (0.5 ~ 10 kgf/cm2)
Overheat Switch Close at 203°F SAE Viscosity Grades
Intake & Ex. Valves intake:_26mm__Ex.:_22.5mm 40
Belt Tension Alternator: 45~55 ft-lb (61~75 N-M) 30
20
Generator: 70~80 ft-lb (95~108 N-M)
20W
Thermostat Starts to open at 160°F and fully open 10W Single
at 185°F 5W
Grade
Weight Total system 460 lbs
5W20
APU Dimensions 21.5" W X 29.5" H X 28.5" D 5W30

10W30
Condenser Dimensions 32.5"x 17.75" x 9" (w/dryer) Multi
15W40
Control Dimensions 6.3" x 3.94" x 1.18" 20W50
Grade

243 253 263 273 283 293 303 313 323 K

Ambient
-30 -20 -10 0 10 20 30 40 50 °C
Temp
-22 -4 -14 32 50 68 86 104 122 °F

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 DP DCP

OPERATION OF MULTI-FUNCTION DRIVER CONTROL PANEL

1.1 STATUS CODES AND SIGNS

1.1.1 Multi-function Driver Control Panel Components
• HEAT/SUN (2) sign - When heat is visible, the heating system is heating on high power mode.
• HEAT/SUN (1) sign - When heat is visible, the heating system is heating on low power mode.
• SNOW FLAKE sign - When cool is visible, the A/C is cooling.
• FINGER/TEMP sign – Temperature set-up indicator.
• THERMOMETER = Indicates cab temperature.
• RPM sign – Indicates running APU engine RPM’s (revolutions per minute).
• “FanH” sign – Indicates the fan speed is on high speed mode.
• “WIND” sign – Indicates the fan speed is on medium speed mode.
• “FanL” sign – Indicates the fan speed is on low power mode.
• “WT” sign – Indicates the water temperature.

LCD Screen APU On/Off Switch

Menu Select STATUS CODES AND SIGNS

AC FanL Fan Speed/Low

HVAC Off Button

APU HVAC
1 Heat/Low Cab Temp.
ON/OFF OFF

MENU ESC/Reset Button

ESC/RESET
2 Heat/High WT Water Temp.

Heater Control
A/C FAN HEAT
18ºC Temp/Set Up rpm Engine RPM

FanH Fan Speed/High

Driver Control Panel (DCP)
Fan Control Fan Speed/Medium
A/C Control
Menu Set Up

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 DP Operation

HOW THE DIAMOND POWER OPERATES

The Diamond Power has two adjustments for operation: Manual and Automatic.

Manual Mode
You start the APU from within the truck bunk using the APU button on the driver control oanel (DCP). Once the APU is running, you
can start and stop the fan, heater air conditioning using the DCP.

Once the heater or A/C is running, It will cycle (automatically turn on and off) in order to keep the truck bunk at the temperature you specify.
The HVAC will continue to cycle until you turn it off. While the HVAC is cycling, the APU remains on and will only turn off when you
manually turn it off using the button on the DCP. (Described Below), The APU automatically turns OFF and ON as required. When the APU
is running, power is supplied to the power outlet in the truck bunk (except in high heat). In manual mode, the APU will turn off
automatically if the Maximum Run Time is reached.

Automatic Mode
The Diamond Power has several functions that will start It in automatic mode.

FEATURE & DESCRIPTION

Comfort Monitor: The APU and HVAC automatically turn on to maintain a comfortable temperature in the truck bunk. When the desired
temperature is met, the APU and HVAC automatically turn off. When the temperature is again out of range , they will both turn on again,
and cycle heat air conditioning as needed.

Timer: At the specified time, the APU and HVAC automatically turn on. During the specified timer duration, the HVAC cycles on and off to
maintain the desired temperature is again out of range, they will both turn on again, and cycle heat and air conditioning as needed. Cold

Temperature Operation: The APU and heater on the HVAC automatically turn on in order to prevent the APU engine and truck engine from
getting too cold. (Turning on the heater creates a “load” that makes the APU work harder and therefore warm up faster). Both the APU and
HVAC turn off automatically one the preset duration time expires.

Battery Monitor: The APU automatically turns on for 90 minutes in order to recharge the batteries. The HVAC does not turn on. After the
90 minute run time, the system will sense voltage for 10 minutes, before restarting if needed.

There are indicators on the DCP that flash when the APU and HVAC are running. If you enter the truck bunk and APU or HVAC is on but
you did not start it, you can assume it has started in one of the automatic modes, as described above. On the DCP, one icon will be
flashing steadily: this is the icon for the mode that is currently operating.

Whenever the Diamond Power is running in automatic mode, if you then press the heat, A/C or fan buttons on the DCP, the Diamond
Power will switch to manual mode. The APU will not automatically turn off! This icon on the DCP will also stop flashing.

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 DP Operation

Automatic Operation and Minimum Time Off

All these automatic functions work on a “minimum time off”: the Diamond Power must be off for at least 10 minutes before the automatic
function will turn it on again. For example, the Timer function may be set to turn on the Diamond Power at 10:00 a.m. You have been
running the Diamond Power in manual mode. You turn off the Diamond Power at 9:55 a.m. The Timer will only turn on the Diamond
Power again 10 minutes later, at 10:05 a.m.

Clock
In order to use the timer correctly, you must set the DCP clock.
Maximum Run Time
You can set the maximum time that the APU is allowed to continuously run in manual mode.
Password
You can reset a password to the DCP, the you can protect one or more functions so that only a person who knows the password can set
the function.

MANUAL OPERATIONS
Starting the APU:

Press and hold then release the switch once.

The display shows “APU STA” (PIC 1). When the display shows engine RPM and water temperature, then the APU has started successfully
(PIC 2).

The APU startup sequence consists of 15 seconds of glowing and up to 10 seconds of cranking.

If the sequence fails, “restarting’ appears for six seconds. Then the startup sequence automatically repeats up to five times. Or until the
APU starts (PIC 3).

If “crank limit” appears, see troubleshooting section appears.

(PIC 1) (PIC 2) (PIC 3)

APU:STA 2600rpm 6.0V APU:2600rpm WT:77°F APU:Restart......10

77.9°F 77.9°F 77.9°F

77°F 77°F 77°F

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 DP Operation

Stopping the APU:

Press the APU will stop. The display shows “APU OFF”. Make sure the HVAC is off before you shut the APU off.

APU:OFF

77.9°F

77°F

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Turning the Heater ON/OFF:

Press to activate the heater, the display shows 1 (PIC 1). If the temperature is over 85ºF, the heater will be disabled.

The heater will turn on only if the temperature is too low (to adjust the temperature, see below). When the heater is on, 1 appears.

Press again to switch between high and low heat the truck bunk more or less quickly. In 2 (high heat) mode, the power
outlet is disabled (PIC 2).

The heater or A/C will turn off when the specified temperature is reached.

Press to deactivate heating.

(PIC 1) (PIC 2)

APU: 2600rpm WT: 77°F APU: 2600rpm WT: 77°F

77.9°F 77.9°F
1 2

77°F Fan L 77°F Fan L

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 DP Operation

Heater setting the temperature:

Press or to adjust the temperature you need for the cab. The heater will automatically turn on and off to maintain this temperature.

Turning the A/C ON/OFF:

Press A/C
to activate the A/C, the display will show . If the temperature is lower than 65 ºF, the A/C will be disabled.

Press A/C
to deactivate the A/C, or press HVAC
OFF
to turn the HVAC off.

APU: 2484rpm WT:84.2°F

47.5°F

64.4°F Fan L

2008-03-01 12:00 Tus

The temperature setting is same as heater temperature setting.

Fan Operation:

You can still have fan working even the temperature is not low or high enough for the heat or A/C to come on (PIC 1).

The fan operation is independent of the air conditioning and heat modes. When the fan speed is manually set to high or low, the fan will
return to that setting when the desired temperature has been reached as the air conditioning or heat cycles off.

Press FAN
to toggle between low, high and off (PIC 2).

The speed of the fan may automatically change when the heat or A/C comes on, them automatically change back when the heat or A/C
goes off.

(PIC 1) (PIC 2)

APU:2489rpm WT:132.8°F APU:2475rpm WT:91.4°F

48.6°F 47.5°F

64.4°F Fan L 64.4°F Fan H

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 DP Operation

Auto Operation
Reset the PASSWORD:
You can set a password to the DCP, and then you can protect one or more functions so that only a person who knows the password can
set the function.

On a newly installed DCP, the password is always 9999, which means that no password protection is in place.

To password-protect function, first change the factory password; see “Set Password”.

If you lost the password then you can follow the following steps to reset it:

1. Unplug the DCP from the HVAC.

2. Press and hold and at the same time for 2 seconds and plug the DCP back to the HVAC.

3. The display will show “clear parameters” until it shows “OK” the password will be back to factory setting which is 9999.

4. After all these steps you have to reset all the settings.

“WARNING” ONCE THE PASSWORD IS RESET ALL OF THE SETTINGS DEFAULT TO THEIR NORMAL FACTORY SETTINGS.
(REMEMBER TO RESET TO YOUR SPECIFICATION)

Set password:

Press once.
MENU

MENU
Press or until “System Setup” is displayed, then press (PIC 1).

Press or then choose “Set Password” (PIC 2).

The display will show 0000, you can press or until the number you desired is displayed (PIC 3).

For example, if your password is 4321 press or until 4 shows. Then press MENU
to confirm.

After you enter the last digit then press the display will show new password (PIC 4).
MENU

Repeat the steps until the display shows “confirm password”, enter the new password again then press to confirm (PIC 5).
MENU

When the display shows “OK” that means the new password is already set up (PIC 6).

After doing all the steps press MENU

to exit.

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 DP Operation

(PIC 1) (PIC 2)

APU:OFF APU:OFF

APU setup
Set Clock
HVAC setup
Set Password
Auto run setup
Exit
System setup
Diagnose

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(PIC 3) (PIC 4)

APU:OFF APU:OFF

Password: New Password:

0000 0000

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(PIC 5) (PIC 6)

APU:OFF APU:OFF

Confirm Password: OK

8888

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Entering the Password:

When you try to set up a function, you may be prompted to enter the password.

MENU
Press or until the first number in the password in the password is displayed, then press .

Repeat for each digit in the password.

MENU
Press again after entering the last digit.

APU:OFF

Password:

0000

2008-03-01 12:00 Tus

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 DP Operation

Setting the clock:

You can set the clock on the DCP. This clock is used by the timer function. If you use the timer function, remember that as you move from
one time zone to another, you must adjust the clock. Otherwise the timer will start the APU at the wrong time.

The clock settings remain even when the APU is turned off.

Press .
MENU

MENU
Press or until “System Setup” is displayed, then press .

Press or until “Set Clock” displayed, then press (PIC 1).

MENU

If “enter password” is displayed enter your password. If you do not know the password, then you cannot setup the function.

Press or to change the setting.

Press to remove to the next setting. Or press to cancel any changes you have not yet accepted (PIC 2).
MENU

ESC/RESET

When done, press to exit.

MENU

(PIC 1) (PIC 2)

APU:OFF APU:OFF

Set Clock 2008-01-11

Set Password 12:00
Exit

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 DP Operation

Turning the Comfort Monitor ON/OFF:

You can specify the temperature you want in the cab. When the cab temperature goes to 2 degrees above or below than this temperature,
the APU starts and the HVAC turns on until the temperature is reached or for fifteen (15) minutes, whichever is longer.

Turning Comfort Monitor ON/OFF:

Press MENU
.

MENU
Press or until display “Auto run setup” then press (PIC 1).

MENU
Press or until “Comfort monitor” is displayed then press (PIC 2).

If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.

MENU
Press or until the “Set on/off” displayed then press (PIC 3).

Press or to display “ON or OFF” MENU

(PIC 4).

Press to confirm this setting.

MENU

(PIC 1) (PIC 2)

APU:OFF APU:OFF

APU setup Auto run status

HVAC setup Comfort monitor
Auto run setup Low Temp monitor
System setup Battery monitor
Diagnose Exit

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(PIC 3) (PIC 4)

APU:OFF APU:OFF

Set on/off Comfort monitor

Time table 1
Time table 1 off
Time table 1
Exit

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 DP Operation

Timer:
You can set up the DCP so that the APU and HVAC run automatically for a specified time on specified days of the week. There are 3 timers,
so you can set up three schedules.

For example, one schedule may be to run every day at 18:00 for .5 hours and the other schedule may be run every Monday at 6:00 for
.5 hours.

You may set up the timer as follows: Specify the day and time you want to run the APU, specify the duration (the length of the time you
want the APU to run for) and specify the temperature you want maintained the cab while the APU is running.

Turning timer ON/OFF:

Press .
MENU

Press or until display “Auto run setup” then press .

MENU

Press or until “Comfort monitor” displayed then press .

MENU

If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.

Press or until “Time Table” is displayed, then press MENU

. (There are 3 time tables you can setup) (PIC 1)

Press or to set the hours, minutes and day (PIC 2). Press MENU
to confirm the setting (PIC 3).

(PIC 1) (PIC 2)

APU:OFF APU:OFF

Set on/off Time table 1

Time table 1 Type: Disable
Time table 1
Time table 1
Exit

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(PIC 3)

APU:OFF

Time table 1

Type: mon-fri
Start: 06:00
End: 20:00

2008-03-01 12:00 Tus

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 DP Operation

Turning the Low Temperature monitor ON/OFF:

You can set up the APU so that it automatically runs for a specified time whenever the ambient temperature goes below a specified value.
This feature ensures that the APU engine and truck engine do not get so cold that they will not start.

This feature is not intended to maintain a comfortable truck cab temperature.

Press MENU
.

Press or until “Auto run setup” displayed, then press (PIC 1).
MENU

MENU
Press or until “Low Temp Monitor” displayed then press (PIC 2).

If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.

Press or until “set ON/OFF” displayed, press (PIC 3).

MENU

Press or to display ON or OFF (PIC 4).

Press to confirm this setting.

MENU

The current setting remains until you change it; turning the APU off or manually starting the APU does not permanently cancel this setting.

(PIC 1) (PIC 2)

APU:OFF APU:OFF

APU setup Auto run Status

HVAC setup Comfort monitor
Auto run setup Low Temp monitor
System setup Battery monitor
Diagnose Exit

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(PIC 3) (PIC 4)

APU:OFF APU:OFF

Set on/off Lowtemp Monitor

Set temp
Run time off
Exit

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 DP Operation

Turning on the Start Temperature:

Press .
MENU

Press or until “Auto run setup” displayed, then press MENU

.

Press or until “Low Temp Monitor” displayed then press MENU

.

If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.

Press or until “Set Temp” displayed (PIC 1).

MENU
Press to confirm this setting. The current start temperature is displayed (PIC 2).

Press or to set up the desired temperature (PIC 3).

Press to confirm this setting or press to cancel and retain the current start temperature.
MENU

ESC/RESET

Press to exit.
MENU

(PIC 1) (PIC 2)

APU:OFF APU:OFF

Set on/off Low Temp monitor

Set temp Set temp
Run time
Exit 41°F

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(PIC 3)

APU:OFF

Low Temp monitor

Set temp

46.4°F

2008-03-01 12:00 Tus

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 DP Operation

Setting the Run Time for Low Tem Monitor:

Press .
MENU

Press or until “Auto run setup” displayed, then press MENU

.

Press or until “Low Temp Monitor” displayed then press MENU

.

If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.

Press or until “Run Time” is displayed (PIC 1).

MENU
Press to confirm this setting. The current start temperature is displayed (PIC 2).

Press or to set up the desired run time (PIC 3).

Press to confirm this setting or press to cancel and retain the current run time.
MENU

ESC/RESET

Press to exit.
MENU

(PIC 1) (PIC 2)

APU:OFF APU:OFF

Set on/off Low Temp monitor

Set temp APU Run time
Run time
Exit 60min

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(PIC 3)

APU:OFF

Low Temp monitor

APU Run time

120min

2008-03-01 12:00 Tus

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 DP Operation

Setting the Maximum Run Time:

You can set the maximum run time that APU is allowed to run continuously. If the APU runs for longer than the specified time, it
automatically shuts off. You can then start it manually, if desired; the “Run Time” clock will start counting again.

Press .
MENU

Press or until “APU setup” displayed, then press MENU

(PIC 1).

If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.

Press or until “Max run time” is displayed (PIC 2).

Press MENU
to confirm this setting. The current max run time is displayed (PIC 3).

Press or to scroll to the desired max run time (PIC 4).

Press MENU
to confirm this setting or press ESC/RESET
to cancel and retain the current run setting.

Press MENU
to exit.

(PIC 1) (PIC 2)

APU:OFF APU:OFF

APU setup Min stop time

HVAC setup Max run time
Auto run setup Warm up time
System setup Startup time
Diagnose Restart Interval

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(PIC 3) (PIC 4)

APU:OFF APU:OFF

APU APU
Max run time Max run time
600min 300min

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 DP Operation

Battery Monitoring:

You can set the APU so that it will automatically runs for 90 minutes when the truck batteries are low.
When you set up this feature, you must enter the current voltage of the battery. The Diamond Power APU can then calculate how much
the voltage drops, as the batteries are used.

Press MENU
.

Press or until “Auto run setup” displayed, then press (PIC 1).
MENU

Press or until “Battery monitor” displayed, then press (PIC 2).

MENU

If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.

MENU
Press or until “Set ON/OFF” displayed, then press (PIC 3).

Press or to display ON or OFF (PIC 4).

MENU
Press to confirm this setting. The current setting remains until you change it; turning the APU off or manually starting the APU
does not permanently cancel this setting.

(PIC 1) (PIC 2)

APU:OFF APU:OFF

APU setup Auto run Status

HVAC setup Comfort monitor
Auto run setup Low Temp monitor
System setup Battery monitor
Diagnose Exit

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(PIC 3) (PIC 4)

APU:OFF APU:OFF

Set on/off Battery Monitor

Set voltage
Run Time off
Exit

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 DP Operation

Setting the Voltage Level for the Battery Monitor: The Factory setup is 11.8V.

Press .
MENU

MENU
Press or until “Auto run setup” displayed, then press .

Press or until “Battery Monitor” displayed, then press .

MENU

If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.

Press or until “Set Voltage” displayed (PIC 1).

MENU
Press to confirm this setting. The current voltage is displayed (PIC 2).

Press or to scroll to the desired voltage (PIC 3).

Press MENU
to confirm this setting or press to cancel and retain the current setting.
ESC/RESET

MENU
Press to exit.

(PIC 1) (PIC 2)

APU:OFF APU:OFF

Set on/off Battery Monitor

Set voltage Set voltage
Run Time
Exit 11.8V

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(PIC 3)

APU:OFF

Battery Monitor
Set voltage

11.5V

2008-03-01 12:00 Tus

Page19
 DP Maintenance

Maintenance Schedule
First 50 Every 1,000 Every 2,000

Change oil and filter x x

Check fuel hoses, fuel pipes, and clamps x x

Check fasteners, muffler clamps and frame grippers x x

Check battery cable connections x x

Check coolant hoses and clamps x x

Check alternator fan belt tension x x

Check generator belt tension x x

Check APU air filter, clean or replace as necessary x

Change fuel filters x

Change fan belt regardless of condition x

Adjust valve lash x

Clean inside enclosure x

Clean radiator fins x

Clean condenser fins x

Check CCU air filter. Clean or replace as necessary. To clean, remove the filter

and vacuum or wash (soap and water). Shake dry and reattach. x

Check injection nozzle opening pressure x

Check injection pump timing x

Check water pump performance x

Check alternator performance x

Check starter performance x

Check air conditioning performance (HVAC) x

Check heater performance (HVAC) x

Check generator line voltage x

Check coolant hoses and clamps (from APU to main engine) x

Check engine thermostat x

Check air intake hose and clamps on APU x

Check fuel hoses and clamps x

Page20
 DP
Troubleshooting
WARNING Disconnect the batteries from the APU before performing any repairs.
Each condition is followed by a probable cause and suggested solution. To isolate the probable cause, proceed in a systematic manner to
determine the faulty component. This guide does not cover all possible situations that may occur under all conditions of operation.
Before using this guide verify correct voltage and ground components.
APU (AUXILIARY POWER UNIT)
Issue Probable Cause
Engine does not start
(starter works) • No fuel
• Air in the fuel system
• Water in the fuel system
• Fuel solenoid not pulling in
• Fuel pipe clogged
• Fuel filters clogged
• Excessively high viscosity of engine
oil at low temperature
• Glow plugs malfunctioning
• Injection nozzle clogged or defective
• Injection pump defective
• Fuel lift pump defective
• Low cylinder compression
• Valve spring broken or valve stuck
• Excessive valve clearance
• Plugged air filter
• Low battery voltage to the APU
• Starter or solenoid defective
Engine will not stop • Starter solenoid jammed
• Speed control linkage broken
Engine runs rough • Fuel filter clogged or dirty
• Air filter plugged or dirty
Page21
Troubleshooting
Solution
• Check fuel stand pipe length
• Bleed air
• Drain fuel tank(s) and replace fuel filter
• Check for rust in plunger/ check for voltage
• Check for bent solenoid linkage
• Clean or replace if necessary
• Replace
• Use the specified engine oil
• Check or replace is necessary
• Clean or replace if necessary
• Replace
• Replace
• Repair
• Replace
• Adjust
• Clean or replace if necessary
• Check battery cables or charge battery
• Repair or replace if necessary
• Replace start solenoid or starter
• Replace control linkage
• Replace
• Clean or replace if necessary
 DP
Troubleshooting
Issue
Engine runs rough
Smoking
(white or dark gray exhaust)
Unable to bleed coolant
Excessive oil consumption
Oil level increases
Low oil pressure
Page22
Troubleshooting
Probable Cause Solution
• Fuel leak due to loose injection pipe
retaining nut • Tighten nut
• Uneven cylinder compression • Repair
• Incorrect valve clearance • Adjust
• Fuel return line clogged • Clean or replace if necessary
• Governor defective • Repair or replace if necessary
• Overload power draw • Reduce power consumption
• Low fuel grade • Use specified fuel grade
• Fuel filter clogged • Replace
• Air clean clogged • Clean or replace if necessary
• Air lock • Run truck engine until 185ºF
• No coolant flow • Check for blockage for using flow indicator
• Kinked coolant lines • Straighten
• Shut-off valves “OFF” • Turn “ON”
• Incorrect plumbing • Re-plumb
• Small fitting on truck engine • Change to large fittings
• Oil ring worn • Replace the oil ring
• Piston ring groove worn • Replace the piston
• Valve stem and guide worn • Replace
• Crankshaft bearing and crank pin bearing
worn • Replace
• Air filter clogged • Replace the filter
• Diesel fuel getting to oil pan through
governor lever • Replace O-ring in lower portion of governor lever
• Fuel lift pump diaphragm defective • Replace
• Engine oil insufficient • Replenish
• Oil strainer • Clean
• Oil filter clogged • Replace
• Relief valve stuck with dirt • Clean
 DP
Troubleshooting
Issue
Low oil pressure
High oil pressure
Engine overheated
Overcharging of batteries
Dead batteries or undercharge
APU suddenly stops
(Check the APU control unit
lights for the correct code)
Page23
Troubleshooting
Probable Cause Solution
• Relief valve spring weakened or broken • Replace
• Excessive oil clearance of crankshaft bearing • Replace
• Excessive oil clearance of rocker arm boss • Replace
• Oil passage clogged • Clean
• Different type of oil • Use the specified type
• Oil pump defective • Repair or replace if necessary
• Different type of oil • Use the specified type
• Relief valve defective • Replace
• Engine oil insufficient • Replenish
• Fan belt broken or loose • Repair or replace if necessary
• Air lock • Check for air lock in Diamond Power engine and ensure
there is coolant, purge if necessary
• Coolant level insufficient • Add coolant, purge if necessary
• Coolant flow is restricted • Repair plumbing
• Thermostat stuck • Replace
• Water pump defective • Replace
• Alternator malfunctioning • Replace
• Poor connection • Repair
• Batteries defective • Load test or place batteries
• Alternator malfunctioning • Replace
• Poor connection • Check connection
• DC load too high • Reduce load
• Alternator belt loose or worn • Tighten or replace if necessary
• Low oil pressure • See Low oil pressure
• Overheat • See Engine overheated
• Alternator Feedback • See Alternator troubleshooting
• No fuel • Check fuel pipe or valve
 DP
Troubleshooting
Issue Probable Cause
APU suddenly stops
(Check the APU control unit
lights for the correct code) • Air in the fuel system
• Water in the fuel system
• Faulty communication between the
component
• Fuel solenoid faulty
• Alternator belt loose or broken
• Alternator faulty
• Low battery voltage
Troubleshooting (Generator)
Issue Probable Cause
No voltage
• Circuit breaker tripped
• Generator belt loose or broken
Low voltage
(below 100 volts) • Generator belt loose or broken
• Engine air filter dirty
• Engine fuel system problem
• Engine exhaust system problem
• Engine speed low
Very low voltage
(4~10 Volts AC) • Wiring to capacitor
• Capacitor defective
Page24
Troubleshooting
Solution
• Bleed air
• Drain fuel tank and replace fuel filter
• Check APU control cable and DCP cable
• Check for rust in plunger
• Tighten or replace if necessary
• Repair or replace if necessary
• Check battery cables or charge the battery
Solution
• Determine reset and reset
• Tighten or replace if necessary
• Tighten or replace if necessary
• Clean or replace the filter if necessary
• Change fuel filter
• Clean or replace if necessary
• Adjust
• Repair or replace if necessary
• Test and replace
 DP Troubleshooting

Troubleshooting
HVAC (AC, HEAT, and FAN)

WARNING:Disconnect the batteries from the APU before performing any repairs.

Each condition is followed by a probable cause and suggested solution. To isolate the probable cause, proceed in a systematic manner to
determine the faulty component. This guide does not cover all possible scenarios that may occur under all conditions of operation.

NOTE: The five minute timer is activated any time the compressor is turned off (by the thermostat, temp sensor or high pressure
switch). It is used to let the pressure between the high and the low side equalize so that the compressor can start under a “no load” condition.

Troubleshooting (Air Conditioning)

Issue Probable Cause Solution

Does not produce cold air
Produces cold air and gradually
stops
Tripped high pressure switch
Condenser fan not working
Compressor will not start (no hum)
• Refrigerant leaked out
• Compressor not working
• Inlet filter clogged
• Evaporator blocked with ice
• Low refrigerant charge
• Air duct blocked
• Condenser fan not working
• Condenser is dirty
• Poor air flow around condenser
• Refrigerant is over charged
• A/C is not on
• DC power fuse blown
• Wiring damaged
• Fan defective (seized)
• High pressure switch open
• Evaporator frozen
• Five minute timer active
• Check for leaks and repair
• Check voltage at compressor
• Clean filter
• Increase air flow, increase return air
• Check for leaks and repair
• Check and remove any blockage
• See “condenser fan not working”
• Clean
• Check condenser location, relocate if necessary
• Reduce charge to 64-68 oz.
• Set temperature to lower setting
• Determine reason and replace fuse
• Repair or replace id necessary
• Replace
• See “tripped high pressure switch”
• See “produces cold air and gradually stops”
• Wait five minutes

Page25
 DP
Troubleshooting
Issue
Compressor will not start (no hum)
Compressor will not start (hums)
Compressor will not start
(hums but trips on overload
protection)
Compressor starts and runs,
but short cycles on overload
protector
Suction line frosted or sweating
Page26
Probable Cause
• Overload protector tripped
• Driver control panel not calling for A/C
• Compressor seized
• Low A/C voltage to CCU
• Starting capacitor defective
• Potential relay is open
• Compressor motor winding open or shorted • Replace compressor
• Internal mechanical trouble in compressor
• Low A/C voltage to unit
• Potential relay is failing to open
• Run capacitor is defective
• Excessively high discharge pressure
• Compressor motor has a winding open
or shorted
• Low voltage to unit
• Overload protector defective
• Run capacitor is defective
• Excessively high discharge pressure
• Compressor too hot – suction line hot
• Compressor motor has a winding shorted
• Evaporator fan not running
• Overcharge of refrigerant
Troubleshooting
Solution
• Let cool down, check for low refrigerant
• Set temperature to lower setting
• Replace compressor
• See “generator” section
• Determine reason and replace
• Determine reason and correct, replace if necessary
• Replace compressor
• See “generator” section
• Determine reason and replace
• Determine reason and correct, replace if
• Check high pressure switch, possible overcharge or
insufficient cooling on condenser (fan)
• Replace compressor
• See “generator” section
• Check current and replace protector
• Determine reason and replace
• Check condenser fan and for restriction in refrigerant
lines
• Check refrigerant charge (check for leaks) and add if
necessary
• Replace compressor
• Determine reason and correct
• Reduce charge to 64-68 oz.
 DP Troubleshooting

Troubleshooting (Fan)

Issue Probable Cause Solution

Fan not working
• Wiring defective
• Capacitor defective
Fan only works on high speed
• Low speed resistor defective
• Resistor wiring defective
• Repair or replace if necessary
• Test or replace if necessary
• Check or replace heating element if necessary
• Repair/replace

Troubleshooting (Heat)

Issue Probable Cause Solution

High heat mode does not
produce warm air
Low heat mode does not
produce warm air
Produces warm air and
gradually stops
• Heat is not on (heat icon must be on)
• Thermo fuse blown
• Circuit board defective
• Heat is not on (heat icon must be on)
• Thermo fuse blown
• Circuit board defective
• Set point has been reached
• High temperature cut out due to
insufficient air flow
• Turn temperature setting up
• Check or replace thermal fuse is necessary
• Replace
• Turn temperature setting up
• Check or replace thermal fuse is necessary
• Replace
• Turn set point up
• Increase air flow/return air

High temperature sensor tripping

• High temperature cut out due to
insufficient air flow • Increase air flow/return air
• Temperature sensor wiring damaged • Repair or replace if necessary
• Ducting blocked • Check and remove any blockages

Page27
 DP Warranty

Page28