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Blackrock User Manual

1. Ratchet Handle Ratchet Extension Strap Wrench for Ratchet 17mm Wrench Alternative 2 13mm wrenches and Strap Wrench 11 1 Black Rock recommends using a strap wrench that is attached to a ratchet handle with an extension when removing the oil filter 11 2 Ifa strap wrench is unavailable use 2 13mm wrenches as alternative e Yale Turn off the BLACKROCK APU before working on the unit If draining hot oil use appropriate protection for hands and face 11 3 Remove the lower APU Splash Shield from the bottom of the APU This is the bottom cover 11 4 Remove the Drain Plug on the bottom of the APU s Oil Pan using a 17mm wrench to unscrew it 11 5 Drain all of the oil from the APU s Oil Pan into an appropriate container and recycle appropriately 11 6 Replace the Oil Drain Plug in the bottom of the Oil Pan after all the oil has been drained from the Pan en aile 14 17 During the removal of the Kubota filter do not touch the terminals of the Starter or Alternator 11 7 Wait for the engine to cool before replacing the Oil Filter Rev 05 12 03 108 0001 B W USER MANUAL 20 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 11 8 Remove the old Oil Filter using a strap wrench that can be used with a ratchet and an extension APU O
2. year or from 2 001 to 4 000 hours of operation only major components are covered under warranty Black Rock will repair or replace at its discretion any part covered by this warranty that becomes defective malfunctions or otherwise fails to conform to this warranty under normal use and during the term of this warranty at no charge for parts or labor Repair or replacement will be performed at any Dealer upon presentation of proof of purchase and determination by Black Rock and its Dealer that a component is defective or has failed under normal service and use Repair and replacement of components under this warranty shall not extend the warranty period for the APU or for any component of the APU 8 3 Disclaimer of Other Warranties 8 3 1 Black Rock INCLUDING ITS AGENTS AND DEALERS MAKES NO OTHER WARRANTIES AND EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING ALL WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE No person firm or representative is authorized to assume any obligation or make any warranty on behalf of Black Rock other than the limited warranty as stated herein 8 3 2 This warranty is extended under the laws of the State of Nevada Enforcement of this warranty shall be conducted according to the laws of the State of Nevada By acceptance of this warranty the owner of the APU agrees that any litigation and the resolution of any dispute between Black Rock and the owner of
3. 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 13 APU AIR FILTER CHANGE PARTS REQUIRED Air Filter Black Rock P N 109 0006 13 1 Unlatch the APU Air Filter and remove the Cover APU AIR FILTER COVER AIR FILTER LATCH DIAGRAM 4 APU AIR FILTER COVER WITH LATCH 13 2 Pull out the Air Filter 13 3 Replace the Air Filter with Black Rock P N 109 0006 Manufacturer s P N Enginaire P N 2S E1 APU AIR FILTER DI AGRAM 5 REMOVING AIR FILTER Rev 05 12 03 108 0001 B W USER MANUAL 24 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 14 APU FUEL FILTER CHANGE PARTS REQUIRED YANMAR Black Rock P N 109 0007 Fuel Filter YANMAR P N 119810 55650 Kubota Black Rock P N 109 0008 Fuel Filter Kubota P N 15231 43560 TOOLS REQUIRED Channel Lock Pliers 14 1 Close the valve on the APU Fuel Filter 14 2 Unscrew the Fuel Filter Collar 14 3 Remove the Fuel Filter Element 14 4 Replace the Fuel Filter Element with 14 4 1 P N 119810 55650 or Black Rock P N 109 0007 14 4 2 P N 15231 43560 or Black Rock P N 109 0008 FUEL FILTER COLLAR FUEL FILTER ELEMENT INSIDE HOUSING A APU FUEL
4. 18 3 Remove Coolant Pressure Cap from the APU Coolant Tank 18 4 Add coolant 50 anti freeze and 50 water mix until the level of the coolant just reaches the bottom of the tube that extends into the tank 18 5 Replace Pressure Cap 18 6 Bleed air from the system at the outlet of the engine thermostat if necessary COOLANT COOLANT PRESSURE CAP DIAGRAM 12 APU COOLANT TANK Rev 05 12 03 108 0001 B W USER MANUAL 30 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 19 BLACKROCK APU CONTROL CONSOLE Warning Lights amp Start Button Icons Temperature Control Knob any NS 7 ee iy e A Te As ety p r Stop Button 2 Heat Cool Switch Air Fan Speed Cool to 0 Right Main Power Switch Power Light Load Management Control Knob Coolant Temperature Gauge Optional Indicator Light DIAGRAM 13 AUXILIARY POWER UNIT CONTROL CONSOLE The following section details the function and meaning of the various controls on the module Low oil High Coolant Over Speed Charge Alt Fail To Auxiliary Pressure Temperature Shutdown Speed Failure Start Input 1 Input 2 Shutdown Shutdown Shutdown VW art Shutdown Active Active Wanmnimg Warnin
5. 32 32 32 32 33 34 34 35 35 36 36 36 37 37 37 37 37 USER MANUAL 4 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com Phone DI AGRAMS 1 BLACKROCK APU INTERNAL VIEW MODEL Y360 USING A YANMAR ENGINE rev 2 8 2 REMOVING OIL FILTER 21 3 AIR FILTER BRACKET 21 4 APU AIR FILTER COVER WITH LATCH 24 5 REMOVING AIR FILTER 24 6 APU FUEL FILTER 25 7 WATER SEPARATOR 26 8 TENSIONER 27 9 REMOVING DRIVE BELT 28 10 BELT PATH 28 11 TIGHTENING ALTERNATOR BELT WITH LEVER 29 12 APU COOLANT TANK 30 13 AUXILIARY POWER UNIT CONTROL CONSOLE 31 14 CONTROL CONSOLE ICONS 31 15 CIRCUIT BREAKER PANEL 33 Rev 05 12 03 108 0001 B W USER MANUAL 5 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 1 THE BLACKROCK APU 1 1 The BLACKROCK APU is the highest performing most reliable APU on the market today with one of the best warranties available To keep the warranty in force follow the recommended maintenance procedures and schedules 1 2 We try to create manuals for our customers and dealers that are easy to read complete and accurate If you have any changes or corrections to suggest we want to hear from you
6. 5897 FAX 775 246 5989 E mail apusupport blackrockapu com US SALES amp MARKETING Steve Rovarino Vice President Sales amp Marketing Black Rock Systems LLC 18124 Wedge Parkway Suite 436 Reno NV 89511 8134 800 731 5791 775 246 5897 FAX 775 246 5989 E mail rovarino blackrockapu com European Union SALES amp MARKETING Willie Burke Vice President Sales amp Marketing Black Rock Systems LLC Hibernian House Portumna CO GALWAY IRELAND 353 9097 41163 E mail europesales blackrockapu com Rev 05 12 03 108 0001 B W USER MANUAL 9 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 4 SAFETY INFORMATION California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to cause cancer birth defects and other reproductive harm Black Rock Systems LLC encourages all individuals who work with the BLACKROCK Auxiliary Power Unit APU to 4 1 Read the BLACKROCK APU User Manual carefully and completely before using the APU If you have questions on any of the items explained in the manual please contact us at 800 731 5791 before attempting to use the BLACKROCK APU 4 2 Follow the stated procedures set forth in this Manual 4 3 Wear protective safety equipment and clothing when working with the BLACKROC
7. FILTER HOUSING DIAGRAM 6 APU FUEL FILTER Rev 05 12 03 108 0001 B W USER MANUAL 25 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 15 FUEL WATER SEPARATOR PARTS REQUIRED ANMAR ONLY P N 109 0009 Water Separator Screen TOOLS REQUI RED Channel Lock Pliers 15 1 Close the valve on the APU Water Separator 15 2 Unscrew the Water Separator Collar 15 3 Remove the Water Separator Screen 15 4 Wash the Water Separator Screen under running water and reinstall 15 5 If the Water Separator Screen needs to be replaced use YANMAR P N 17108 55910 or Black Rock P N 109 0009 Valves x Fos p 4 Water Separator gd EZ k ls J Collar APU Fuel Filter E mes Collar IL E 28 5 Water Separator Screen Inside APU Fuel Filter Element Housing APU Fuel Filter Water Separator E 7 Housing DIAGRAM 7 YANMAR WATER SEPARATOR Rev 05 12 03 108 0001 B W USER MANUAL 26 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 16 CHANGING THE APU DRIVE BELT PARTS REQUIRED ENGI NE TYPE BLACK ROCK BELT NAPA Belt P N 2TNV or 3TNV 104 0016 25 080570
8. Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 8 9 Black Rock management Black Rock s liability on any and all claims for damage or loss related to the delivery installation and use of the APU shall not exceed the original installed price of the APU IN NO EVENT WILL BLACK ROCK BE LIABLE FOR LOSS OF USE LOSS OF PROFITS LOSS OF OR DAMAGE TO SHIPPED GOODS INCONVENIENCE COMMERCIAL LOSS OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES Transfer of Warranty 8 9 1 8 9 2 8 9 2 This warranty shall be for the benefit of the initial purchaser If a truck upon which the APU is installed is sold and the unit is not removed the new owner may request in writing that Black Rock transfer the remainder of the original warranty Such a request shall note the hours accumulated by the APU at the time of ownership transfer as well as the initial date of installation If the APU is being removed and installed onto a different truck then a Dealer must perform the installation and the warranty transfer must be requested in writing as described above Upon approval by Black Rock the new owner will be covered for the remaining warranty left on the APU Black Rock reserves the right to deny transfer of warranty if these conditions are not met Rev 05 12 03 108 0001 B W USER MANUAL 17 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 775 246 5791
9. Kubota 7482 104 0022 25 080550 D722 104 0021 25 080537 TOOLS REQUI RED 1 2 Ratchet Square Depression Drive Belt Tensioner in Fa 3 DIAGRAM 8 TENSI ONER 16 1 Turn off the APU 16 2 Turn off the Main Power Switch 16 3 Change Drive Belt when 16 3 1 Excessive cracking 1 per 1 2 has occurred 16 3 2 Wear is evident 16 3 3 Tensioner is less than 1 2 inch from the full travel position 16 4 Insert 1 2 ratchet into the square depression in the Belt Tensioner 16 5 Pull upward on the ratchet handle to loosen the belt Rev 05 12 03 108 0001 B W USER MANUAL 27 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 16 6 Remove the belt from the Pulleys DRIVE BELT 1 PULLEYS US E _ d A Ze a Km LJ SQUARE DEPRESSION 7 n aes 1 1 d Pur DIAGRAM 9 REMOVING DRIVE BELT 16 7 Replace the new Drive Belt by wrapping it around the pulleys as shown below using the ratchet to pull the Tensioner up so Drive Belt is installed around it DIAGRAM 10 BELT PATH Rev 05 12 03 108 0001 B W USER MANUAL 28 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 2
10. Please contact us by phone at 800 731 5791 or e mail apusupport blackrockapu com You have just purchased the best APU on the market with the following Superior features o Choice of 2 cylinder or 3 cylinder diesel engine o Choice of generator size o Best A C and heating output in the industry o Best in class oil change interval o Stand alone design with no interface to main engine which eliminates truck OEM warranty concerns o Truck engine failure won t disable APU o APU failure won t disable the truck o Smart Power Management APU load balancing between HVAC and electricity generation that directs the power where you need it most o HVAC temperature control and blower speeds Full Instrumentation guards against damage due to High coolant temperature Engine over under speed Overload Alternator fail to charge Generator and belt failure detection Coolant temperature gauge optional Rev 05 12 03 108 0001 B W USER MANUAL 6 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 2 SPECIFICATIONS 2 Cylinder 3 Cylinder US EPA Tier 11 Compliant Diesel Engines 29 5 in 75 cm 28 5 in 72 cm 30 in 76 cm Customer Option 2 cylinder or 3 cylinder engine 2 Cylinder 425 105 193 kg plus 35 Ib 16kg HVAC unit 3 Cylinder 480 105 218 kg plus
11. Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com Phone 9 SERVICE INTERVALS FOR YANMAR ENGI NES Every Every Every System Daily 50 Hours Hours Hours Replace Fuel Filter Check Engine Oil Leve a SE Engine Oil Replacement EMEN SE Engine Oil Filter after Replacement Check for functionality EIL fins fans Check amp Addition of Coolant Coolant Water Path Contact Flushing and Maintenance Dealer Rubber Fuel and Water Hose 4 or 2 Hoses Replacement years Air Cleaner Element Intake amp Cleaning ed QN Replacement Adjust I ntake Exhaust Contact Cylinder Valve Clearance Dealer Head Lapping Intake Exhaust Contact Valve Seats Dealer Check Fuel Injection Contact Valve Pressure and Adjust Dealer Check amp Adjust Fuel Contact The specific emissions related parts for EPA ARB regulations Oil Change First oil change after 50 hours No synthetic oil may be used during the first 50 hours of operation CF CF 4 and CG 4 class oils may be used Oil Filter Change First filter change after 50 hours change oil and filter every 1 000 hours thereafter Rev 05 12 03 108 0001 B W USER MANUAL 18 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com
12. standard service rate which must be a published and verifiable rate multiplied by no more than Black Rock authorized number of labor hours 8 8 2 Parts reimbursement is based on the Dealer s cost plus 20 All warranty reimbursement claims by Dealers must be Submitted within one month of performance of the warranty work 8 8 3 Parts replaced under this warranty must be retained for 90 days for inspection and be sent to Black Rock if so requested Return Material Authorization RMA numbers are required for all returned parts Replaced warranty parts are covered for three 3 months or the remainder of the original warranty period whichever is longer 8 8 4 All other express or implied warranties including without limitation those arising under the laws of equity and the implied warranties of merchantability and fitness for a particular purpose are hereby expressly excluded from the sale and purchase of the APU and related apparatus sold hereunder regardless of whether a claim arises under contract or tort principles or on any other basis 8 8 5 The buyer s sole remedy hereunder shall be limited to the repair or replacement of any nonconforming equipment or parts but only if returned to a Dealer within the warranty period defined above or with the express written approval of Rev 05 12 03 108 0001 B W USER MANUAL 16 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll
13. www blackrockapu com 10 SERVICE INTERVALS FOR ENGINES Svety Every Every Every Every System Check Item Daily 100 200 400 1000 SC rs Hours Hours Hours Hours Drain Water Separator LL E Fuel Clean Water Em e I Check Engine onte X Engine Oil Replacement Engine Oil Filter Replacement Check Drive Belt X Tightness Sones x FE Boa egener Coolant ear Coolant Water Path Flushing and or gt Maintenance years Rubber Fuel and Water Hose or 2 Hoses Replacement mE Air Cleaner Element Intake amp Cleaning Exhaust Air Cleaner Element Replacement Adjust Intake Exhaust Or e Valve Clearance Cylinder ears KEE Lapping Intake Exhaust or i Valve Seats years Check Fuel Injection Valve Pressure and or e Adjust ears Check amp Adjust Fuel or E Injection Pump years The specific emissions related parts for EPA ARB regulations Oil Change First Oil and Filter Change after 50 hours Change oil and filter every 100 hours thereafter No synthetic oil may be used during the first 50 hours of operation CF CF 4 and CG 4 class oils may be used Rev 05 12 03 108 0001 B W USER MANUAL 19 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 11 APU OIL AND OIL FILTER CHANGE TOOLS REQUIRED
14. 35 Ib 16kg HVAC unit Fuel Consumption 2 Cylinder 0 2 gal hr 0 76 l hr 3 Cylinder 0 3 gal hr 1 14 br AC Power Output Customer Option 3 7 to 6kW generator Range Meets National Park Standard 36 CFR2 12 60 DB at the A WEI GHTED scale 50 Feet Oil Change Interval 1000 hours itr Cold Weather Package fa ee ee eee Dimensions W H X D 17in 43 cm 10 in 25 4 cm 18 in 46 cm 30 Ibs 13 6kg Air Conditioning 26 000 BTU hr 26 000 BTU hr 405 cfm 11 5cmm Refrigerant R 134A 2 years or 4 000 hours Rev 05 12 03 108 0001 B W USER MANUAL 7 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com ALTERNATOR AIR FILTER A C COMPRESSOR EXHAUST GENERATOR BELT TENSIONER DIAGRAM 1 BLACKROCK APU INTERNAL VIEW MODEL Y360 USING A YANMAR ENGINE rev 2 Rev 05 12 03 108 0001 B W USER MANUAL 8 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 3 CUSTOMER SERVICE and SALES amp MARKETING INFORMATION CUSTOMER SERVICE Maria Mueller Vice President Operations Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 800 731 5791 775 246
15. 46 5989 E mail apusupport blackrockapu com www blackrockapu com 17 ADJUSTING APU ALTERNATOR BELT PARTS REQUIRED MANUFACTURER BLACK ROCK PART NUMBER BELT PART NUMBER YANMAR P N YANMAR EE 109 0010 Kubota P N TOOLS REQUIRED 12mm Wrench 13mm Wrench 17 1 TURN OFF the APU and TURN OFF the Main Power Switch 17 2 APPLY MODERATE THUMB PRESSURE to the Alternator Belt at the midpoint below the Alternator The Belt should deflect approximately 5 16 7mm to 9mm If Belt tension is incorrect proceed with the below steps 17 3 LOOSEN the Alternator Mounting Bolts 17 4 Using a lever between the Alternator and the Engine Block push the Alternator Belt out until Belt deflection is within acceptable limits DIAGRAM 11 TIGHTENING ALTERNATOR BELT WITH LEVER 17 5 REPLACE Belt if damaged Rev 05 12 03 108 0001 B W USER MANUAL 29 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 18 ADDING COOLANT TO APU PARTS REQUIRED Coolant e Yael Removing Coolant Pressure Cap while engine is hot can result in personal injury 18 1 With the Main Power Switch of the APU in the ON position turn the Temperature Control Knob on the Control Console clockwise until it stops 18 2 Turn APU s Main Power Switch to OFF and let the APU cool
16. ABELS 11 6 FLUIDS 12 7 ENGINE COOLANT 13 8 WARRANTY PROGRAM 14 8 3 Disclaimer of Other Warranties 14 8 4 Maintenance 15 8 5 Installation 15 8 6 Warranty Expectations 15 8 Warranty Claims 16 8 8 Claim Reimbursement 16 8 9 Transfer of Warranty 17 9 SERVICE INTERVALS FOR ENGINES 18 10 SERVICE INTERVALS FOR ENGI NES 19 11 APU OIL AND OIL FILTER CHANGE 20 12 and ENGINE OIL CAPACITIES 23 13 APU AIR FILTER CHANGE 24 14 APU FUEL FILTER CHANGE 25 15 FUEL WATER SEPARATOR 26 16 CHANGING THE APU DRIVE BELT 27 17 ADJ USTING APU ALTERNATOR BELT 29 18 ADDING COOLANT TO APU 30 19 BLACKROCK APU CONTROL CONSOLE 31 Rev 05 12 03 108 0001 B W USER MANUAL 3 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com TABLE OF CONTENTS CONT 20 OPERATING THE BLACKROCK APU 20 1 20 2 20 3 20 4 20 5 20 6 Starting the APU Using the Control Console Operating the Air Conditioning Operating the Heater Using the Electrical Outlets Using the Engine Block Heater Shutting Off the APU Unit 24 CONTROL CONSOLE FAILURE INDICATOR ICONS LIGHTS 21 1 21 2 21 3 21 4 21 5 21 6 21 7 21 8 21 9 Failure Indicator icons Warnings Battery Charge Failure Shutdowns Fail to Start Low Oil Pressure High Engine Temperature Over Speed Under Speed Lights Rev 05 12 03 108 0001 B W
17. BLACKROCK THE APU WITH POWER PERFORMANCE AND RELIABILITY BLACKROCK AUXILIARY POWER UNIT APU User Manual Version 5 0 YOUR BLACKROCK APU SERIAL NUMBER IS We attempt to make all of our manuals as clear complete and accurate as possible If you have any suggestions or corrections we would welcome them Please contact us either by phone at 775 246 5897 or by e mail to apusupport blackrockapu com Thank you the BLACKROCK APU Team Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 Fax 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com BLACK ROCK SYSTEMS LLC COPYRIGHT AND DISCLAIMER This manual is intended to assist the owner of a BLACKROCK APU in using and enjoying his her purchase It is not intended to be a service or installation manual Service and installation should only be done by an authorized BLACKROCK APU dealer Copyright 2005 Black Rock Systems LLC Rev 05 12 03 108 0001 B W USER MANUAL 2 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com TABLE OF CONTENTS COPYRIGHT amp DISCLAIMER 2 l THE BLACKROCK APU 6 2 SPECIFI CATI ONS 7 ES CUSTOMER SERVICE and SALES amp MARKETING INFORMATION 9 4 SAFETY INFORMATION 10 WARNING L
18. IL FILTER STRAP WRENCH DIAGRAM 2 REMOVING OIL FILTER ATTENTION If a strap wrench is unavailable remove the Air Filter Bracket using 2 13mm wrenches and socket so that an oil filter wrench can be fitted onto the Oil Filter AIR FILTER BRACKET DI AGRAM 3 AIR FILTER BRACKET Rev 05 12 03 108 0001 B W USER MANUAL 21 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 11 9 Replace the Oil Filter with Black Rock Oil Filter YANMAR Black Rock P N109 0002 both 2 and 3 cylinder YANMAR P N 119305 35150 IKUBOTA Black Rock P N109 0001 both 2 and 3 cylinder Kubota P N 70000 15241 11 10 If removed reattach the Air Filter Bracket 11 10 Refill the Engine with 15W 40 oil Rev 05 12 03 108 0001 B W USER MANUAL 22 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 12 YANMAR AND KUBOTA ENGINE OIL CAPACITIES ENN OIL CAPACITY YANMAR 2TNV 70 ASA 2 cylinder engine 0 42 gal 1 58L YANMAR 3TNV 70 KBR 3 cylinder engine 0 74 gal 2 8L Kubota Z482 2 cylinder engine 0 66 gal 2 49L Kubota D722 3 cylinder engine 1 0 gal 3 78L Rev 05 12 03 108 0001 B W USER MANUAL 23 Black Rock Systems LLC
19. Input 2 shutdown Shutdown shutdown Waming Shutdown Active Active Warning Warning shutdown shutdown Stop Mode Manual Automatic Tamperproof LCD Hours Counter Mode Mode And Displaying Hours and Tenths Of Indicator LED Hours when fuel solenoid is energised 21 1 Failure Indicator I cons Warnings 21 1 1 Warnings are used to alert the operator of an impending fault They are either an audible alarm or a highlighted button as shown above Rev 05 12 03 108 0001 B W USER MANUAL 35 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 21 2 Battery Charge Failure 21 1 2 If the Control Console does not detect adequate voltage from the truck s batteries the light under the BATTERY ICON will illuminate This means that the APU alternator is not charging the main engine s batteries adequately and either the condition needs to be corrected or the APU turned off 21 1 3 Running the APU without the alternator functioning properly could result in a discharged main truck battery This fault could indicate that too many 12 volt 24 volt in the EU devices are turned on at one time 21 3 Shutdowns 21 3 1 If the Control Console senses a condition that could cause damage to the APU the electronic control unit will shut down the APU and a failure warning light will illumin
20. K APU 4 4 Do not operate the APU with its cover off or with any obstructions 4 5 Always disconnect the main battery cables on the truck before connecting the APU to the truck s interface 4 6 Allow only qualified and trained personnel to work on the BLACKROCK APU 4 7 Take appropriate precautions when handling fuel coolant and oil 4 8 Do not ingest any such fluids and avoid contact with skin and eyes 4 9 Dispose of materials in accordance with all applicable laws 4 10 Inspect hoses and connections frequently for signs of leakage or damage since the BLACKROCK APU contains hot oil and coolant under pressure 4 11 Do not leave children and animals unattended in a truck even with the APU running Rev 05 12 03 108 0001 B W USER MANUAL 10 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone E mail apusupport blackrockapu com www blackrockapu com 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 9 WARNING LABELS 5 1 Observe all labeled warnings Do not remove warning labels Rev 05 12 03 108 0001 B W USER MANUAL 11 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 6 FLUIDS 6 1 Follow the APU engine manufacturer s instructions for handling and disposing of the engine s coolant and oil 6 2 Follow the i
21. ate on the control console 21 3 2 To reset the system the alarm must be turned off Push the yellow STOP BUTTON on the Control Console to reset the module After a shutdown the fault must be cleared by pushing the STOP BUTTON before the unit be re started The first detected condition that caused the shutdown will appear on the Control Panel as a steady light above the appropriate warning icon Any additional faults that were detected after the first one will flash 21 4 Fail to Start 21 4 1 When the APU s engine does not fire after the pre set 3 attempts at starting a shutdown will be initiated and the SHUTDOWN ICON F will illuminate Rev 05 12 03 108 0001 B W USER MANUAL 36 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 21 5 Low Oil Pressure 20 5 1 If the Control Console detects that the APU s engine oil pressure has fallen below the allowed minimum a shutdown sand teow OTT GEN Lar CEET 21 6 High Engine Temperature 21 6 1 If the Control Console detects that the engine coolant temperature has exceeded the allowed maximum a shutdown w s will occur and the HIGH TEMPERATURE ICON gt will illuminate 21 7 Over Speed 21 7 1 When the pre set engine speed is exceeded a shutdown will be
22. erant belts fuses and glow plugs 8 6 3 Non approved parts 8 6 4 Used parts 8 6 5 Any damage caused by overheating the APU that is not a direct result of a defect in APU materials or workmanship 8 6 6 Damage caused to the host truck whether or not such damage is related in any way to the presence of the BLACKROCK APU on the truck Rev 05 12 03 108 0001 B W USER MANUAL 15 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 8 Warranty Claims 8 7 1 In order to obtain warranty repairs the owner will need to provide verification of proof of purchase with the APU serial number to a Dealer The names and addresses of Dealers are listed at www blackrockapu com or the owner may contact Black Rock directly to obtain the information 8 7 2 The Dealer handling the warranty claim must call Black Rock for authorization of all warranty work and may rely on Black Rock s written authorization which must include the authorized number of labor hours for the warranty repair Black Rock will deal with all component vendors so the Dealer does not have to do so though Black Rock may request that defective parts under warranty be shipped from the Dealer to the original manufacturer on behalf of Black Rock 8 8 Claim Reimbursement 8 8 1 Labor rate recovery is based on the Dealer s
23. g Shutdown Shutdown Stop Mode Manual Automatic Tamperproof LCD Hours Counter Mode Mode And Displaying Hours and Tenths Of Indicator LED Hours when fuel solenoid is energised DIAGRAM 14 CLOSEUP OF CONTROL CONSOLE ICONS Rev 05 12 03 108 0001 B W USER MANUAL 31 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 20 OPERATING THE BLACKROCK APU 20 1 Starting the APU Using the Control Console 20 1 1 Turn the APU MAIN POWER SWITCH to the ON position by flipping the switch 20 1 2 Push and release the yellow START BUTTON The APU will crank after a 10 second pre heat time If the APU fails to start it will automatically try to restart two more times 20 2 Operating the Air Conditioning 20 2 1 Flip the HEAT COOL SWITCH on the Control Console to the COOL position 20 2 2 Turn the TEMPERATURE CONTROL KNOB to the desired cool temperature For maximum cooling turn the knob counterclockwise until it stops 20 2 3 Turn the AIR FAN SPEED CONTROL KNOB clockwise to the desired speed low medium or high 20 3 Operating the Heater 20 3 1 Flip the HEAT COOL SWITCH to the HEAT position 20 3 2 Turn the TEMPERATURE CONTROL KNOB clockwise to the desired heat temperature For maximum heating turn the knob clockwise until it stops 20 3 3 Turn t
24. he AIR FAN SPEED CONTROL KNOB clockwise to the desired speed low medium or high Rev 05 12 03 108 0001 B W USER MANUAL 32 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 20 4 Using the Electrical Outlets 20 4 1 Use the APU electrical outlets like any common household outlet 20 4 2 If too much power is demanded from an outlet a circuit breaker will trip inside the APU box 20 4 3 If a circuit breaker trips turn the APU OFF by flipping the MAIN POWER SWITCH to the OFF position 20 4 4 Remove the APU s cover 20 4 5 Locate the CIRCUIT BREAKER PANEL on the upper right hand side of the APU The tripped circuit breaker will be a white button extending out from the breaker panel 20 4 6 To reset the circuit breaker push the white button in APU CIRCUIT BREAKER PANEL TRIPPED CIRCUIT BREAKER DIAGRAM 15 CIRCUIT BREAKER PANEL fthe electrical demand places a strain on the APU s engine without tripping a circuit breaker it is possible that the BLACKROCK APU Smart Power Management System will engage The APU will monitor the load and return to normal once the load is reduced NOTE During this time air conditioning output will be reduced in order to supply the required electrical output Rev 05 12 03 108 0001 B W USER MANUAL 33 Black Rock Sys
25. initiated and the OVER SPEED ICON Ag will illuminate 21 8 Under Speed 21 8 1 When the engine speed falls below the pre set level a shutdown is initiated and the UNDER SPEED ICON 2 Will illuminate 21 9 Lights 21 8 1 Lights 1 and 2 CURRENTLY NOT BEING USED Rev 05 12 03 108 0001 B W USER MANUAL 37 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com
26. nstructions provided by the truck manufacturer regarding handling and disposing of air conditioning refrigerant Rev 05 12 03 108 0001 B W USER MANUAL 12 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 7 ENGINE COOLANT 7 1 The APU uses the same coolant type as the truck Normally this is low Silicate permanent antifreeze 50 by volume for temperatures down to 32 F 35 6C Rev 05 12 03 108 0001 B W USER MANUAL 13 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 8 WARRANTY PROGRAM 8 1 Subject to all terms and conditions contained herein Black Rock Systems LLC Black Rock warrants to the original buyer that under normal service and use the BLACKROCK APU will be free from defects in material and workmanship for two 2 years or four thousand 4 000 hours of operation whichever comes first from the date of original installation on a truck by a Black Rock authorized dealer Dealer 8 2 The YANMAR engine has a limited warranty three 3 years or four thousand 4 000 hours The first two 2 years or 2 000 hours of operation whichever comes first are warranted on all YANMAR engine components During the 3
27. tems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 20 5 Using an Engine Block Heater 20 5 1 To utilize the block heater Plug the correct end of the block heater extension cord into the main engine s block heater receptacle and the other end into one of the APU s electrical outlets to turn the block heater on 20 6 Shutting Off the APU Unit 20 6 1 Press the YELLOW STOP BUTTON The APU engine will shut down 20 6 2 Turn the AIR FAN SPEED CONTROL KNOB counterclockwise to the OFF position ATTENTION Not turning off the fan will cause the battery to discharge 20 6 3 Flip the HEAT COOL SWITCH to the HEAT position ATTENTION Not following the above step will cause the battery to discharge 20 6 4 Flip the APU MAIN POWER SWTICH to the OFF position Rev 05 12 03 108 0001 B W USER MANUAL 34 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 21 CONTROL CONSOLE FAILURE INDICATOR ICONS LIGHTS The following section details the function and meaning of the various controls on the module Low Dil High Coolant Over Speed Under Charge Alt Fail To Auxiliary Auxiliary Pressure Temperature Shutdown speed Failure Start Input 1
28. the APU shall be conducted exclusively in courts of the State of Nevada Rev 05 12 03 108 0001 B W USER MANUAL 14 Black Rock Systems LLC 4 Carry Way Suite 101 Carson City NV 89706 7777 Phone 775 246 5791 Toll Free 800 731 5791 FAX 775 246 5989 E mail apusupport blackrockapu com www blackrockapu com 8 4 Maintenance 8 4 1 The BLACKROCK APU Owner s Manual lists all maintenance functions required to validate this limited warranty PLEASE NOTE THAT COMPONENTS WHICH FAIL DUE TO POOR OR IMPROPER MAINTENANCE WILL NOT BE COVERED BY THIS LIMITED WARRANTY As a condition of this warranty Black Rock reserves the right to request proof in the form of receipts for maintenance and any other records that service on the APU has been carried out as per the maintenance set forth in this User Manual 8 5 Installation 8 5 1 In order to validate the BLACKROCK APU warranty a Black Rock Dealer must install the unit Black Rock is not responsible for components that fail as a result of improper installation 8 6 Warranty Expectations This limited warranty does not apply to 8 6 1 Defects malfunctions or failures resulting from accidents abuse modifications alteration improper servicing contamination road hazards or failure to perform required service 8 6 2 Normal maintenance services or parts associated with such services including but not limited to filters filter elements oils lubricants coolant refrig

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