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
Page1
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.
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.
Page2
DP Safety
Condenser
Part of the air
conditioning system,
connected to the
evaporator and located
outside the truck.
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
Page3
DP DCP
Heater Control
A/C FAN HEAT
18ºC Temp/Set Up rpm Engine RPM
Page4
DP Operation
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.
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.
Page5
DP Operation
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:
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).
Page6
DP Operation
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
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.
(PIC 1) (PIC 2)
77.9°F 77.9°F
1 2
Page7
DP Operation
Press or to adjust the temperature you need for the cab. The heater will automatically turn on and off to maintain this temperature.
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.
47.5°F
64.4°F Fan L
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)
48.6°F 47.5°F
Page8
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:
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).
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).
Page9
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
(PIC 3) (PIC 4)
APU:OFF APU:OFF
0000 0000
(PIC 5) (PIC 6)
APU:OFF APU:OFF
Confirm Password: OK
8888
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 .
MENU
Press again after entering the last digit.
APU:OFF
Password:
0000
Page10
DP Operation
The clock settings remain even when the APU is turned off.
Press .
MENU
MENU
Press or until “System Setup” is displayed, then press .
If “enter password” is displayed enter your password. If you do not know the password, then you cannot setup the function.
Press to remove to the next setting. Or press to cancel any changes you have not yet accepted (PIC 2).
MENU
ESC/RESET
(PIC 1) (PIC 2)
APU:OFF APU:OFF
Page11
DP Operation
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).
(PIC 1) (PIC 2)
APU:OFF APU:OFF
(PIC 3) (PIC 4)
APU:OFF APU:OFF
Page12
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.
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 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
(PIC 3)
APU:OFF
Time table 1
Type: mon-fri
Start: 06:00
End: 20:00
Page13
DP Operation
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.
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.
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
(PIC 3) (PIC 4)
APU:OFF APU:OFF
Page14
DP Operation
Press .
MENU
If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.
MENU
Press to confirm this setting. The current start temperature is displayed (PIC 2).
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
(PIC 3)
APU:OFF
46.4°F
Page15
DP Operation
Press .
MENU
If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.
MENU
Press to confirm this setting. The current start temperature is displayed (PIC 2).
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
(PIC 3)
APU:OFF
120min
Page16
DP Operation
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
If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.
Press MENU
to confirm this setting. The current max run time is displayed (PIC 3).
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
(PIC 3) (PIC 4)
APU:OFF APU:OFF
APU APU
Max run time Max run time
600min 300min
Page17
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
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).
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
(PIC 3) (PIC 4)
APU:OFF APU:OFF
Page18
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 .
If “enter password” is displayed, enter your password. If you do not know the password, then you cannot setup this function.
MENU
Press to confirm this setting. The current voltage is displayed (PIC 2).
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
(PIC 3)
APU:OFF
Battery Monitor
Set voltage
11.5V
Page19
DP Maintenance
Maintenance Schedule
First 50 Every 1,000 Every 2,000
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
Page20
DP Troubleshooting
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.
Page21
DP Troubleshooting
Troubleshooting
Page22
DP Troubleshooting
Troubleshooting
Page23
DP Troubleshooting
Troubleshooting
Troubleshooting (Generator)
Page24
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.
Page25
DP Troubleshooting
Troubleshooting
Page26
DP Troubleshooting
Troubleshooting (Fan)
Troubleshooting (Heat)
Page27
DP Warranty
Page28