Parks HP2000 XTREME Series Setup guide

Installation and Operator's Manual
HP2000 XTREME
www.hp2000apu.com
Keeps you cool, warm and powered up!

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Table of Contents:
In tr odu c t i on .......................................................................................................................... 6
W a rr an ty an d R e g i s tr a t i on (r e fe r t o ba c k pa g e w a r r an ty c a r d) ................................................ 6
M anua l Ove rv i e w .................................................................................................................. 7
S a fety ................................................................................................................................ .... 8
S y s tem C o mpo n e nts Po w e r Unit ............................................................................................ 8
Po w e r Un i t .................................................................................................................... 8
Ev apo r a to r A ss e mbly ................................................................................................ ..... 8
AP U C on tr o ll e r ( N e w an d Pr i o r Mo d e l s ) ................................................................ .......... 9
2 0 13 APU C o m man d e r ................................................................................................ ..... 10
G e tti n g S ta r ted ................................................................................................ ............ 10
S to p , B a c k, Mo r e an d S e tti n g s B u tto n s ................................................................ ......... 10
C l i mate C on t r o l ................................................................................................ ............ 14
B a tter y Mo n i to r ................................................................................................ ........... 14
C o l d s to r a g e ................................................................................................................. 14
10 - S tep I n s ta l l a ti o n .............................................................................................................. 15
S tep 1 : Mo un ti n g t h e A PU ................................................................................................ 17
S tep 2 : E vapo r a to r S y s tem i n s ta l l a ti on ............................................................................. 20
S tep 3 : A / C L i n e I n s ta l l a ti o n ............................................................................................. 23
S tep 4 : A / C S y s tem Va c uu m and C ha r g e ................................................................ ........... 25
S tep 5 : Fu e l Dr a w T ub e I n s ta ll a ti o n .................................................................................. 26
s tep 6 : C onn e c ti n g B a t tery C ab l e s .................................................................................... 28
S tep 7 : Wa ter C onn e c t i on s ............................................................................................... 29
S tep 8 : C on tr o l l e r an d air d u c t i n s ta l l a ti on ................................................................ ........ 34
S tep 9 : S y s te m Pr i me a nd S a fety C h e c k ................................................................ ............ 38
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C onn e c t th e c on tr o l c ab l e ............................................................................................ 38
Pr i mi n g t h e w a te r pu mp .............................................................................................. 39
S tep 10 : I n i ti a l S ta r t ................................................................................................ ......... 40
M a i n ten an c e ....................................................................................................................... 41
W a l k - Around I n s p e c ti o n ............................................................................................... 41
T yp ic a l I n s pe c ti o n ................................................................................................ ........ 41
M a i n ten an c e S c h e du l e ................................................................................................ ..... 42
A/ C S y s tem Ma i n ten an c e ................................................................................................ . 43
Owne r ’ s R e s pon s i b i li t y ................................................................................................ ......... 44
T r oub l e s hoo ti n g .................................................................................................................. 45
W a rr an ty P r o c e du r e ................................................................................................ ............ 46
S p e c i fi c a ti on s ....................................................................................................................... 47
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About Parks Industries LLC
Parks Industries L.L.C. has been in the business o f designing and manufacturing auxiliary power
units since 2004. We provide our APU technology to airports, military applications, emergency
vehicles, trucking companies , as well as construction equipment. Our goal is to provide a
quality and efficient auxi liary power unit for all of these industries.
Trademarks
HP2000
Exclusion for Documentation
Unless specifically agreed to in writing, Parks Industries L.L.C.
(A) Makes no warranty as to the accuracy, sufficiency or suitability of any technical
or other informa tion provided in its manuals or other documentation .
(B) Assumes no responsibility or liability for injury, losses, damages, costs or
expenses, whether special, direct, indirect, consequential or incidental, which
might arise out of the use of such information . The use of any such information
will be entirely at the user’s risk .
Revision information
Rev D, 09-01-16.
Manual Product Number
PCM002-02
Contact Information
15460 Crabtree School Rd.
Marion, IL 62959
Toll Free: 1-855-472-0002
Fax: [phone]
www . hp 2000 a pu . c o m
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the instructions: w w w .p e rk in s .com
h tt p ://w w w .k oh le r e n gine s .co m
WEB PA GE AND FOLL OW THE INSTR UCTI ONS: T
ENG INE W ARR ANT Y
I N T R O D U C T I O N
Congratulations on your purchase of your new HP2000 Xtreme Series Auxiliary Power Unit! Your fuel and
maintenance savings begin today! As you may already know, the HP2000 consists of a powerful yet lean
Kohler diesel engine along with a revolutionary HVAC system to keep you warm, cool and powered up.
With over a decade in development and on-road testing and usage, the HP2000 Auxiliary Power Unit is
designed specifically for the transportation industry. It is designed and built to handle the extreme
temperatures drivers’ battle every day. By eliminating the need for the truck’s engine to idle, fuel usage is
reduced significantly while allowing the driver to enjoy all of the comforts that are usually associated with
an idling engine.
W A RRA N T Y A N D RE G I ST R A T I O N ( RE F E R T O B A C K P A G E W A RRA N T Y C A RD )
EACH HP20 00 APU P UR CH ASED A FTE R A UGUS T, 201 6 COMES WI TH ONE O F
TWO WA RRAN TY CA TEGOR IES. DEPEND ING ON TH E H OUR S AN D TIME S IN CE P URCH ASED.
THE Y ARE AS FOLL OWS:
PERKINS ENGINE WARRANTY
PERKINS GI VES A TWO (2) YEAR / 2000 HOUR LIMI TED WARRANTY ( WHI CHEVER COMES F IR ST) ON
THE ENGINE AND ITS COMPONENTS. ANY I TEM RELATED TO THE ENGINE SUCH AS WATER PUMPS,
ALTERN A TOR S, INJECTION PUMP COM PONENTS, THERMOSTATS ETC. A RE ALL WARRANTED BY
PERKINS AND M UST GO THR OUGH A PERKINS AUTHORIZED DEALER FOR WAR RANTY RE PLA CE MENT.
TO FIND THE NEAREST PERKINS A UTHORIZED W AR RANTY REPA IR CENTER, GO TO THE FOLLOWING
H T P : // W WW . P E R K I N S . C O M /D IS T RI B U T OR
EVEN THOUGH PARKS INDUSTR IES OFFER S THESE ITEMS FOR S ALE, THEY CAN’T BE USED FOR
PERKIN S WA RR ANTY PURPO SES AND WILL NOT BE REIMBURSED BY PARKS INDUS TRI ES, LLC. THE
COMPONENTS THAT WE OFFER ARE FOR OUT OF WA RR ANTY R EPLACE MENT ONLY A ND ARE
STR IC TL Y CUS TO MER PA Y.
KO HLER ENGINE WARRANTY
KOHLE R E NGINES WILL CAR RY A THREE (3) YEA R/ 2000 HOUR LIMITE D WAR RANTY ( WHICHEVE R
COMES FI RS T) ON THE ENGINE AND INDIV IDUAL ENGINE COMPONENTS. IN A DDITIO N TO THE
WAR RANTY, E ACH OF OUR DEALERS HAS THE OPPORTUNITY TO BECOME A KOHLER WARRA NTY
REPAI R CENTE R. FOR M ORE INFOR MATI ON CONCERNING THIS PLEASE CONTACT US AT 618-997-
9608.
Even though Parks Industries offers engine components for sale, they can’t be used for Kohler and or
Perkins Warranty purposes and will not be reimbursed by Parks Industries, LLC. The components that we
offer are for out of warranty replacement only and are strictly customer pay. To find the nearest Kohler
Authorized Warranty repair center, go to the following web page and follow the instructions:
a
To find the nearest Perkins Authorized Warranty repair center, go to the following web page and follow
an d click on “Service and Dealer Locator”.
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IMPORTANT!
PAR KS IN DU STR I ES, L L C:
ST
20 16, P ARK S
E FFECTI VE FO R UNITS S OLD AF TER A UGUS T 1
INDUSTRIES LLC , PRO VIDE S ATW O YEAR, 2,00 0 HO UR WAR RAN TY (WHI CHEVE R COMES FIR ST )
ON THE FOLL OWIN G COM P ONENTS : A /C CO MPRE SSO R, CO N DENSER, CON DENSE R CHE CK
VALVE AS SEMB LY, E VAP OR ATOR CHECK V A LVE A SSE M BLY, AUTO CONTROLLE R, CONDENSE R
FAN, EVA POR A TOR, 12 V EV APOR A TOR BL O WER, RE VE RSIN G V ALV E ASSE MBL Y, H IGH P RESS URE
SWI TCH, LOW P RES SURE S WITCH . W AR RAN TY DOE S NOT CO VER: OIL, SH OP SUPPLIES,
MIS CELLANEO US MA TER I A LS, ETC. REFRI GER AN T IS O NLY COVE RED I F A COVE RE D CO MPONEN T
FAIL S AND THE REFR IG E RA NT IS LOS T. REF RI GE RAN T I S REIM BURSE D A S OUTL IN ED IN THE S R T
GUIDE. P AR KS IN DUSTRIES DOE S NO T P A Y MI SCEL LAN E OUS SUPPLIE S AND / OR H AZAR DO US
MA TERIA L CH AR GES. MA K E YO UR SELF A WA RE OF TH E MAIN TENANCE A ND CUS TO MER
RESPON SIB ILI TY POR TI ON OF THE MAN UA L, LA CK OF MAIN TENANCE AN D NE GLE CT ARE N O T
COVE RED UNDER THE W A R RAN TY. FO R M ORE INF OR MA TION PLE ASE SEE THE P OLICY AN D
PRO CED URES MAN UAL .
Without registration, your HP2000 is not covered under warranty. It is important
that you register your APU and have acopy of your registration card with the unit.
M A N U A L O V E R V I E W
This manual covers the topics of installation, operation, general maintenance and troubleshooting for the
HP2000 Xtreme Series APU by Parks Industries.
The patented design of the HP2000 makes it the leader in the auxiliary power unit industry. Its unique
features set it apart from any other unit currently available on the market today. It provides solutions to
many of the problems faced by the transportation industry on a daily basis, yet actually reduces overall
costs. You will immediately notice the fuel savings produced by the HP2000. In addition, the HP2000 saves
wear and tear on major truck components, cuts down on costly oil changes and increases battery life.
By following the proper installation, service and warranty procedures, your new HP2000 will provide years
of comfort and service.
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S A F E T Y
Tips and safety warnings are listed throughout this manual. These tips and safety
warnings alone cannot eliminate all hazards that can occur. Pay close attention
to instructions and use common knowledge during maintenance procedures to
prevent unnecessary accidents and injuries.
NOTICE:
Hazards or unsafe practices could result in injury or death.
Persistent inhalation of exhaust fumes may cause serious injury and/or death. Anyone suspected
of suffering from carbon monoxide inhalation should be removed from the hazardous area and
given immediate medical attention.
Exercise extreme caution when working near fuel.
Moving parts can cause severe injury and/or death. Before working on any unit, shut it off, and
make sure that the power supply is disconnected.
If the power is not disconnected the unit could automatically start up without warning. This
could cause serious injury.
Never use the APU to provide power for sensitive electrical or medical equipment.
SYS T E M C O M P O N E N T S P O W E R U N I T
P O W E R U N I T
The power unit consists of the diesel engine, A/C
components and electrical controls. This unit is typically mounted on the
frame rail of the truck. A/C lines, water lines, power and fuel must all be
routed to the APU in order to provide heating, cooling and battery
charging.
In the next section we will discuss the proper installation procedure for the power unit. Proper installation
is critical in guaranteeing proper operation of the APU system. Installation will vary slightly depending on
the make and model of the truck used.
E V A P O R A T O R A S S E M B L Y
The evaporator is mounted somewhere inside of your cab and provides hot or
cold air depending on your needs. Typically the evaporator is mounted
underneath the bunk. A/C lines and a power supply will need to be routed
from the evaporator to the APU to supply heating and cooling and evaporator
control.
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A P U C O N T R O L L E R ( N E W A N D P R I O R M O D E L S )
The APU controller is the brain of the APU. It is responsible for triggering the
relays which power and control the APU. The commander features automatic
climate control in which the user sets the temperature and the APU will heat
or cool to maintain it. It will also track and manage the charging cycle for
onboard truck batteries.
Please see the “Controllers” section for more detail and instruction for each
control system. Controller Operation
“APU CO MMAN DER”
The new, touch screen APU Commander* provides all previous APU features plus several new ones.
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Calendar start, storage mode, new error screens, error log, firmware updates, comprehensive fan speeds,
time and date and Telematics support are just a few of the new features.
2 0 1 3 A P U C O M M A N D E R
G E T T I N G S T A R T E D
The APU Commander has three basic functions, Climate Control, Battery Monitor Mode and Storage
Mode. To access these modes, press “Start” and select the desired mode. More details on each mode as
well as other settings can be found in this section.
S T O P , B A C K , M O R E A N D S E T T I N G S B U T T O N S
A button labeled “MORE” and “STOP” will be displayed at all times during APU operation. “SETTINGS”
however, will only be displayed when the APU is in the “OFF” mode.
STOP B UTTON
At any point during APU operation, press the “Stop” button in the bottom
left corner to stop the APU and return to the off screen.
BACK B UTTON
At any point during controller operation, press the “Back” button in the
bottom right corner to return to the previous screen.
MORE BUTTON
Press “MORE” at any time to access Fan Speed, Fan Mode, Calendar Start or APU Status.
By pressing the blower button, the blower fan
settings will rotate through Low, Medium, High,
Always Low, Always Medium and Always High.
“Always” indicates the evaporator fan will run
continuously during climate control mode, similar
to a “fan on” setting in your home thermostat.
Pressing “Calendar Start” will enter the calendar
start setup screens. See the “Calendar Start”
section for complete instructions.
Press “Status” to display APU status details and
access the error log. See the “Status” section for
complete instructions.
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CALEND AR S TAR T
Calendar start is designed to allow for the APU to start in a specific mode at a set time on any day of the
year. This is a useful feature if you plan to store your truck and return to it on a specific day. Using this
feature will preheat your engine, charge your batteries and, if you wish, cool or heat your cab in advance.
Access Calendar Start settings through the “MODE” button.
By pressing the “ON/OFF”” button, you can toggle this feature on and off. Once ON the button
will be green.
Press the “MODE” button to cycle through the mode you wish
to resume. Whenever activated, the setting that was last used
for this feature is what will be recalled. For example, if you
select “Climate Control” as the calendar start mode, and you
last had climate control set to hold at 70°F, when the calendar
start is initiated the temperature will again be at 70°F. This
holds true for settings in the battery monitor as well as the
storage modes.
To adjust the start time and date, press each value to advance it.
Once the calendar start operation has been performed, the calendar start feature will return to off.
This prevents any unintentional starting for the next calendar year.
STATUS
The status screen displays useful information about the current operating parameters of the APU.
Access the status screen through the “MORE” button.
“Engine Status” will display heating, cooling, running, or
charging depending on the current function.
“Mode” displays the function currently in use.
“APU hours” displays the total engine hours on the APU.
“Oil Hours” displays the number of hours since the timer has
been reset and the oil has been changed.
“Firmware Version” is displayed here. To update the firmware
version see the “Firmware Update” section.
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OIL TIMER RESE T
You can access the oil timer reset button through the “Status” screen.
To reset the oil timer, hold the “Hold to Reset Oil Timer” button until
“APU Oil Hours” goes to 0.
ERROR LO G
The error log keeps track of any error events as well as some of the
external conditions when the event occurred.
The error log can be exported to a USB drive in order
to have a diagnosis performed at a remote location.
To do so, insert a USB memory drive into the USB slot
on the right side of the controller and select “Export”.
The APU will read “Done” in the top right hand corner
once this is complete. Press page up and page down to
navigate through multiple entries.
SET TIN GS
The settings button is only available from the OFF mode screen. Use
this page to set the time and date, set temperature units and update
the firmware.
SET TIME AND DA TE
To adjust the time and date, depress each value to advance it. Once you
have reached the correct time and date, press “Back” to save your
settings and return to the previous screen.
SET TEMP
To select between Celsius and Fahrenheit, tap the symbol to
alternate it.
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UPD ATE FIR MWA RE
From time to time a firmware update may be available to add new features or offer solutions to software
issues. Performing this update is simple; however it is a very sensitive process. Failure to follow these
instructions carefully can cause permanent damage to the controller. Please refer to the notice supplied
with the firmware release for detailed instructions on how to update the firmware. The outline below is a
general outline and may not provide enough detail to complete the specific update.
Instructions to update the HP2000 Commander Firmware
1. From the Commander home screen, click on the "Settings" button in the bottom left hand corner.
2. This screen shows three buttons; click the far right button "Update Firmware".
3. It will instruct you to Insert the thumb drive and click the button on the screen to update. Insert the
thumb drive into the USB slot on the right side of the controller and click the update button on the screen.
Note: When saving the files to your thumb drive, make sure you have saved them to the root
directory of the thumb drive. DO NOT SAVE THEM TO A FOLDER ON THE THUMB DRIVE. If you
save them to a folder, it will not update.
4. There will be an "Update Display" button and an "Update Controller" button on the screen, you must
update the display first and THEN update the controller. Click the update display button.
5. Once the display has been updated, repeat this process and update the controller.
6. Once the controller has been updated, you will need to verify that the new version was properly
installed. To do this, go back to the home screen (the green start button should be in the middle of the
screen). From the home screen, click on the "More" button in the bottom right corner of the screen.
7. Click on the "Status" button. On the status screen, there will see a “Firmware Version” line. Contact
Parks Industries for the current version of the firmware.
If you have any additional questions or need help with updating your firmware, contact:
Parks Industries, LLC
618-997-9608
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C L I M A T E C O N T R O L
Climate Control mode is designed to provide heating or cooling as needed to maintain a certain set
temperature. During climate control the APU is constantly monitoring the battery bank charge. The APU
will run continuously to maintain a full battery charge.
Use the up and down arrows to select the desired
temperature.
The current temperature will be displayed at all times next
to “Currently” (2014 and older units only).
Press “Stop” at any time to stop the APU
Press “More” to access more settings. See the “More”
section for complete instructions.
B A T T E R Y M O N I T O R
Battery monitor mode is used in situations where battery charging is needed but A/C or heating is not.
Using this mode, the APU will maintain the battery voltage above a set point. If the voltage drops below
this point the APU will provide a charge for a period of 30 minutes. At the end of the cycle the APU will
begin monitoring again and provide additional charging
if necessary.
To specify the desired battery voltage, use
the up and down arrow to raise or lower the
voltage set point.
C O L D S T O R A G E
Cold Storage mode is designed to keep the batteries charged and
the main engine block and coolant from getting too cold in
times of truck storage. With this mode, the controller allows
you to set a voltage set point different from battery monitor
mode and a coolant temperature separate from climate control
that the APU will maintain. Both set values represent low limits
and the APU will run in order to keep the two parameters above
these set points.
To adjust the low temperature limit, set the “Keep
Coolant Temp Above” using the up and down arrows.
To set the low voltage limit, set the “Keep
Voltage Above” using the up and down arrows.
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10- S T EP I N S T A L L A T I O N
INSTALL ATI ON O VERV IEW :
To begin the installation, un-package your new system and all of its components. Inspect all of the
components to make sure they were not damaged during shipping. Locate the checklist that is included in
each of the installation kit boxes that accompany your HP2000 on the pallet. Verify that all parts on the
checklist are included within the installation kit boxes. Each box will have its own checklist. Each kit is
signed off by the builder of that kit as well as a verification person. If you believe you are missing a part,
please contact Parks Industries immediately with the initials of the builder.
Before you begin, perform an inspection of the truck and installation area. Be sure that all batteries are
fully charged and in good condition. We recommend that you load test each of your truck batteries
separately prior to installing your HP2000. Take your time to look over the area where you plan to install
the HP2000 and make necessary measurements to ensure proper installation. Make sure that you have at
least 21” of free frame rail space for the power unit installation. It is important to remember that the APU
location should not interfere with the driver’s access to other vital areas. Also, the location you choose
should not crowd any wires, air or fuel lines that may be nearby. Also, make sure you have the necessary
space available under the bunk for the evaporator unit and cable pass through.
Tools at truck side
Outside parts separate from inside parts
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REQUI RED TO OLS CHECKLI ST
IMPORTANT! IT IS IMPERATIVE THAT ALL TOOLS ARE AT THE TRUCK SIDE AND NOT IN YOUR TOOL BOX
ACROSS THE SHOP. TO KEEP YOUR INSTALL TIME TO 6-8 HOURS, YOU MUST HAVE TOOLS AT THE TRUCK.
Basic mechanics wrench and socket set to include:
½” drive ratchet 15/16” socket (1/2” drive)
18” –1/2” drive extension 15/16” wrench
7/16” wrench 7/8” wrench
¾” wrench ½” Impact driver (air or electric)
3/8” drive ratchet 7/16” socket (3/8” drive)
½” socket (3/8” drive) 5/16” nut driver
Hose cutter coolant hose crimping pliers (4)
Crescent wrench Channel Locks
3” hole saw 3 ½” hole saw
1 - 5/8” hole saw Torque wrench
Battery cable end crimper Teflon tape
Refrigerant leak lock Lift cart or fork truck
System to vacuum and charge the A/C unit Shop vac
Zip ties Cut-off wheel
Drill R134-A Refrigerant
Reduced Barrier A/C line Hand Crimping Tool Oetiker Crimping Pliers
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S T E P 1 : M O U N T I N G T H E A P U
You are now ready to install your HP2000. Begin by mounting the APU to the frame rail. On most
installations, the HP2000 does not require any drilling into the frame rail. However, some trucks (such as
certain models of Volvo trucks) do not feature a frame that allows for a simple locking device. For these
installations, some drilling may be required.
Remove the catwalk to access the frame rail.
Prepare the HP2000 to be installed on the frame. Remove the lid by releasing the two
rubber T-handles and set aside. Using a 7/16” wrench, remove the 4 bolts that hold the
top panel of the APU and set aside.
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Prepare and slide the patented low-pro mounting brackets onto the top frame rail. The
head of the bolt should be seated between the two bolt head locks.
Place the HP2000 on your lift cart or fork truck and move it into the mounting position.
Align the top mounting bolts with the top holes in the APU frame.
From inside the cabinet, apply the washer and self-locking nuts to the top bolts and
tighten until the APU is flush with the truck frame.
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The lift cart can now be removed and should no longer be needed.
Now install the bottom mounts. Slide the bolts through the mounting blocks with the
bolt head resting on the flat side of the mounting block as shown in the below
illustration.
After confirming that the APU is level, tighten the mounting bolts in an X pattern. Do not tighten one bolt
all the way and then go to the next. Tighten each bolt equally using the X pattern, until all bolts are tight
and the unit is level. Failure to tighten the APU properly will result in the unit being unlevel and potential
damage can occur to internal parts.
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S T E P 2 : E V A P O R A T O R S Y S T E M I N S T A L L A T I O N
The evaporator system is designed to be mounted under
the bunk in the storage area. The evaporator system
measures 19 inches in length by 8 inches in height by
8 inches in depth. For the A/C hoses and power supply cable,
you will need a 3-inch hole in the floor directly beneath the
hose connection side of the evaporator.
Once the install location has been determined, check
underneath the cab to be sure that there are no supports,
wires, hoses, cables or beams where the three inch hole
must be drilled. This hole will not only serve as a pass
through for cables and hoses, it will also act as the drain
for evaporator condensation.
The steps below represent our recommended evaporator installation. Additional parts are available to
facilitate an install which will not allow for the recommended procedure. Optional accessories such as air
towers and additional duct work vents are available.
Place the evaporator in the desired location.
Mark on the floor on the connection side of the evaporator box indicating where the
hole should be drilled.
Remove the evaporator and drill a pilot hole.
Using the pilot hole as center, trace a three inch circle and knife cut the circle in the
carpet and foam to prevent the material from getting caught in the hole saw.
Once the material is removed to expose the metal floor, use a hole saw to cut the 3”
hole.
Insert the provided pass through collar and secure it using the provided self-tapping
screws.
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