Diamond Power Products DPS6500 Oxygen Equipment User Manual
Contents
1. DIAMONDPOWER ces A Se AE inn DIAMONDPOWER s y S t e ms READ BEFORE STARTING INSTALLATION Each truck chassis is built differently and will require a different installation method Review the placement of ALL parts and components before beginning the installation process __ 3 DCP Driver Control Panel A Eu HVAC CONDENSER Driver Control Panel Condenser 120 VAC Receptacle Panel HVAC APU Parts and Components Battery Terminal Kit 5 16 Washers 5 16 Lock Nuts Parts List Red heat shrink APU 1 Black heat shrink APU Installation Kit 1 Ring terminals Frame locks 4 Cable ties x O Bolts 4 Condenser _ Split Lock Washers 8 Hoses lock nuts 4 Mounting hardware Frame Washers 2 Harness Fuel Pick up Kit 1 Pick up 1 HVAC Clamps Driver Control Panel Power Outlet Exhaust Extension Kit 1 90 Degree exhaust pipe 1 Support bracket 1 Exhaust clamps 2 5 16 NC bolt 1 2 2 APU Fuel Supply And Return Vehicle Fuel Tank Parts and Tools Required e Radiator hose 3 4 e Radiator shut off valves e Radiator hose clamps e An assortment of nuts bolts and washers as required e An assortment of electrical connectors and protective conduit as required e Heat shrink pipe sealant never seize electrical tape expanding foam e Torque wrench 100ft Ib e Hole saw kit 17 1 _ 3 3_ 4_ e Portable lighti2. Do not allow Refrigerant hoses to touch each other heat transfer will occur and change the performance of the HVAC Insulate or keep the hoses together Allow For Hose Connection Hoses Clamp securely Condenser 12V Power Harness WARNING If you are installing the A NOTE All hoses cables and condenser to the back wall of the sleeper use electrical wiring should be kept safe and large fender washers or a backing plate for extra secured using split loom and cable ties Support to prevent abrasion Stay clear of exhaust pipe and muffler Pages DIAMONDPOWER otep Four s y S t e ms PLUMB THE APU TO THE MAIN ENGINE A Note This APU Systems comes with a built in radiator The connection below is optional Plumbing Procedure 1 Remove the truck radiator cap to free pressure from coolant system Do not open when hot 2 Deplete the truck coolant system if necessary 3 The APU is shipped with extensive life anti freeze Ensure this is compatible with truck coolant 4 Ensure that the coolant will flow in the right direction same direction whether the Diamond or main engine is running The Diamond flow indicator can be used to verify the flow 5 Replenish the engine coolant in the system according to the specific engine manufacturer s recommendations additional coolant will be required Plumbing Considerations e Silicon hose is satisfactory to use as coolant hose but requires the use of silicon
3. d plumbing connections are secure e Radiator coolant valves if any fully open APU First Time Start Up Before first time starting use the priming pump to clear the air in the fuel line Priming Pump WARNING Do not start or run the APU prior to purging the entire cooling system of air Failure to do so will result in APU engine failure WARNING Do not operate the engine without the enclosure cover in place Failure to do so may result in injury Completing the Installation e Test all the functions of the APU and the HVAC e Replace vehicle access panels fairings interior components and hardware that was removed to facilitate the installation e Seal all holes made through the floor or walls of the truck bunk with suitable sealant such as expanding foam e Vacuum the interior of the cab sleeper e Review the installation with the owner and instruct them on the proper operation of the Diamond Power Systems Give the owner the Operator s Manual e Complete all warranty cards and return to Diamond Power Systems
4. e Frame Gripper Torque 100 ft lb Frame Rail 2 5 8 Minimum Side Clearance 2 5 8 Minimum Side Clearance 11 Minimum Ground Clearance WARNING The APU is weighty Do not drop it Use a lifting device A CAUTION Do not mount the Diamond APU to bottom pan Unit is designed to hang from chassis rails A NOTE Consult OEM frame drilling requirements if you are bolting APU directly to the trucks frame rail Page2 DIAMONDPOWER otep Three s y S te ms MOUNTING THE CONDENSER Condenser Installation 9 Nutserts 1 Select the site for the condenser on the rear or the vehicle sleeper 2 Hold condenser in the preferred location and mark the holes clearly 3 Drill holes 17 32 for Nutserts 4 Install the condenser assembly in the preferred location Blue Marking Mounting Considerations e The condenser must be installed on the back wall of the sleeper outside Airflow around the condenser must not be blocked by headache racks for example e Install condenser within 8 of the HVAC e The condenser must be installed vertically with the blue marked side on the bottom right where the liquid refrigerant collects e Hose connection side of the condenser requires 5 free space to the nearest obstruction to allow for hose connection 3 8 NC Bolts 3 Per Side e Keep the condenser out of the path of road spray e Refrigerant hoses must be clamped firmly Min 5 Clearance To e
5. hose clamps e Ensure radiator coolant can always flow between truck engine and APU 3 4 Fitting Return From APU 1 2 Or Larger No Sharp Bends NPT Fittings High Pressure Port 3 4 ID Hose f Loom All j Choose Ports That Are Far Apart For Max Crossflow Hoses 7 5 E ul 3 4 Fitting Low Pressure Supply To APU Port Suction Back View Of APU Truck Engine Install ShutOff Valves Use A Flow Indicator To Comfirm Flow Direction And Speed WARNING To avoid serious injury permit the engine to cool before opening the radiator cap A CAUTION Plumbing through the dash or sleeper heater will null and void your warranty A CAUTION Take care not to spill coolant Page4 DIAMONDPOWER otep Five s y S te ms INSTALLING THE FUEL LINES Installing The Stand Pipe 1 Locate hole in an area where the fuel pickup is kept safe the center of the tank is recommended 2 Tighten hose clamps 3 Secure the fuel lines to reduce movement Nut Washer Gasket Tank Tighten Until Secure Cut Tube Drill 1 Hole Using Unibit or Hole Saw Bottom 45 Supply 5 16 ID q No Kinks Or Abrasion Points 12 Min Between Supply And Return Fuel Line Gas Tank Allow 1 To 2 Min Space To Bottom Of Tank WARNING Exercise safety measures when working A CAUTION Keep fuel lines away from exhaust pipes and heated moving parts near flammable fuel A CAUTION The
6. ng e Hand forklift lifting device e Step drill e Angle drill e Reciprocating saw e Nutsert installation tool e Scale refrigerant accurate to ounces e Gauges refrigerant 134A compatible e Diamond Test Switch Module PG1008 e Flow Meter TK 9002 A NOTE The APU requires periodic maintenance Ensure you have access to internal components i e oil filter air filter fuel filter and oil filter The Diamond comes filled with long life coolant Consult the truck owner prior to altering the vehicle in any way A CAUTION Trucks with longer chassis should have the APU mounted closer to the sleeper unit to avoid obstacles such as railway crossings speed bumps curbs etc Before beginning installation of the Diamond system disconnect the vehicle s batteries If truck is equipped with a coolant valve valve must be fully opened before starting APU DIAMONDPOWER mM S s y st MOUNTING THE APU Installing 1 Use existing holes at back of APU Do not drill new holes in the APU 2 Torque mounting bolts to 100 ft Ibs 3 Install exhaust pipe extension to APU direct exhaust away from vehicle Consider the Following e Free space around existing covers e Brackets for attaching covers dryers fuel tanks fasteners existing plumbing for air fuel and water lines e Battery tray e Any hardware found in the mounting location move or modify if necessary Step Two Back Plate OF APU Enclosur
7. standpipe must enter the tank from the top and not the side A CAUTION Keep fuel lines safe from wear points Page DIAMONDPOWER otep Six s y S t e ms ARRANGE BATTERY CABLES Connecting To The Truck s Battery Strip 3 8 Apply Heat To Shrink 12 VDC Power Red Or Black Heat Positive Or Negative Supply Harness Shrink Tubing se Battery Cable APU HVAC Control Harness Back View Of APU Copper Lug Using The Correct Crimping Tool Crimp And Solder Copper Lug To Battery Cables Negative Black Ground Cable Ensure That the battery terminals are clean and free of corrosion If not remove and clean them Apply an dielectric grease to prevent corrosion Apply anti corrosion paint over cable ends Teck Cable Positive Red 12 VDC Battery Cable Truck Batteries WARNING Do not join the APU battery connections until the installation is complete and the APU is ready to test start WARNING Make sure the 120 VAC cable is connected to the installed CCU if applicable Terminate cable ends if no CCU is installed WARNING Make sure that the polarity is correct before attaching battery leads The APU connects to 12VDC systems only Pageb DIAMONDPOWER otep Seven s y S te ms SYSTEM CHECK Important Perform these steps only after the HVAC and all other components have been installed System Check e Qil level in the APU engine add oil if necessary e Electrical an
Download Pdf Manuals
Related Search