Power For The Long Haul

Service and Repair Manual

These recommended service procedures are intended to support
authorized Dynasys trained dealers and service personnel in the
maintenance and servicing of Dynasys units.
These recommended service instructions apply to all class 8 OTR
vehicles. Please note that any modifications to the truck could influence
the serviceability of the Dynasys unit and/or methods used to service it.
Depending on the version and vehicle equipment, changes in procedure
and diagnosis may be required that are outside the scope of this manual.
In any event, the directives in the service manual must be followed.
Acknowledged engineering standards must also be observed when
performing service and maintenance work.
 Service Manual

Table of Contents

1.0 Definitions and Abbreviations 4 5.2.12 Air Filter Element and Assembly 10

2.0 Technical Assistance 4 5.2.13 Oil Filter Service 10

3.0 Additional Documentation 4 5.3 Electric Cooling Fans 11

4.0 Technical Information 4 5.3.1 Lower Cabinet Fan Replacement 11

4.1 Dimensions 4 5.3.2 Radiator Fan Replacement 11

4.2 Fluid Capacities & Types 4 5.4 Speed Sensor Service or Replacement 12

4.3 Technical Specifications 4 5.4.1 Speed Sensor Service 12

4.4 Maintenance Schedule 4 5.4.2 Speed Sensor Replacement 12

5.0 Enclosure, Engine and APU Components 4 5.5 120 VAC Circuit Breaker Replacement 12

5.1 Enclosure 4 5.6 Cover Safety Switch 12

5.1.1 Enclosure Parts Breakdown 4 5.7 Relay Replacement 13

5.1.2 Engine Mounting 5 5.8 Exhaust Manifold Gasket Replacement 13

5.2 Engine Components 6 5.9 Exhaust Pipe Assembly Removal 13

5.2.1 Starter Motor 6 5.10 Frame Flange Replacement 14

5.2.2 Generator Drive Belt Service 6 5.11 Muffler Replacement 14

5.2.3 Alternator Drive Belt Service 6 5.12 Tailpipe Replacement 14

5.2.4 Alternator Assembly 7 6.0 Electrical Schematics 15

5.2.5 Generator Assembly 7 6.1 APU Engine Harness 15

5.2.6 Radiator Assembly 8 6.2 Interconnect Harness to ECM 15

5.2.7 Radiator Hose Replacement 8 7.0 HVAC System 16

5.2.8 Coolant Bottle Replacement 8 7.1 General Service 16

5.2.9 Water Separator Filter Service 7.2 Basic Functions 16

or Assembly Replacement 9
7.3 Troubleshooting 16
5.2.10 Fuel Filter Service or Assembly Replacement 9
7.4 Service Procedures 18
5.2.11 Fuel Pump Replacement 10
7.5 Troubleshooting Flow Charts 21

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1.0 Definitions and Abbreviations

• APU (Auxiliary Power Unit) SAE Viscosity Grade and
• Class 8 Truck (Heavy Duty Trucks over 33,000 pounds [15,000 kg]
Outdoor Temperature
as defined by FHWA in the US) 20W-50
• CCU (Cabin Control Unit)
15W-40
• ECM (Engine Control Module)
10W-30
• FHWA (Federal Highway Administration)

• HVAC (Heating, Ventilating, and Air Conditioning)

5W-30

• OTR (Over the Road) 0W-30

-30 -20 -10 -0 10 20 30 40 50 60 70 80 90 100

2.0 Technical Assistance

Before calling technical assistance please have ready: Cooling System 50/50 mixture of ethylene glycol & water
• Dynasys Serial Number Air Conditioning R134a; 2 lbs, 12 oz
• Unit Hours Fuel Type Diesel Fuel Only

• In Service Date
• 4.3 Technical Specifications
• Dynasys Service Manual
Engine Yanmar, 2-cylinder, liquid cooled
Technical support is available Mon-Fri 8:00 am – 5:00 pm CT by
calling 512-225-0165 or 1-800-289-8282 Output 12 hp / (8.8 kW) @2800 RPM
Alternator 55 Amps
Generator Markon
Output 6 kW; 120 Volts [AC] / 60 hz
3.0 Additional Documentation
HVAC Hermetic Compressor / Electric
Dynasys Owners Manual, 2009 Model G1D Heating
Dynasys Installation Manual, Model G1D Output 12,500 BTU / 2.5 kW
Yanmar; User’s Handbook
• 4.4 Maintenance Schedule
Markon; AC Generator Installation, Service & Maintenance Manual
See table on opposite page

4.0 Technical Information

5.0 Enclosure, Engine and APU Components
• 4.1 Dimensions • 5.1 Enclosure
The Dynasys APU has five stainless steel panels that are fastened
Main Unit Bunk Heater/AC Unit with ¼ -20 x ½” hex head bolts. The front access panel is attached
Width 18” Width 11.50” to unit with four Southco latches.
Height 27” Height 12.50”
Depth 25” Depth 22.25”
• 5.1.1 Enclosure Parts Breakdown
Weight 385 lb Air Flow 12,000 BTU

• 4.2 Fluid Capacities & Types

Engine Oil w/filter 2.7 l / 3 US qt.
Type API CJ-4
Viscosity (See Chart Top Right)

4
Enclosure Parts Breakdown
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• 4.4 Maintenance Schedule

Each Trip * At 50 Hrs Total At 500 Hrs Total Every 1,000 Hrs Every 2,000 Hrs Inspect/Service These Items
ENGINE
✔ ✔ ✔ ✔ Check engine oil level
✔ ✔ ✔ ✔ Inspect belts, hoses for condition/tension
✔ ✔ ✔ ✔ Check for unusual noise or vibration
✔ Change air cleaner
✔ ✔ ✔ Inspect water separator
✔ Change fuel filter
✔ Check adjust engine speed
✔ Change engine coolant
ENGINE OIL CHANGE INTERVALS
✔ ✔ Change oil (use CJ-4 oil) and filter
ELECTRICAL
✔ ✔ ✔ Check cover safety switch
✔ ✔ Inspect battery terminals
✔ ✔ Inspect unit for broken or loose wires
✔ ✔ Check for loose connections
MISC
✔ ✔ ✔ ✔ Visually inspect for fluid leaks
✔ ✔ ✔ ✔ Visually inspect for damaged/loose components
✔ ✔ ✔ ✔ Check mounting bolts and brackets
✔ Check/clean condenser coil and generator air inlet

• 5.1.2 Engine Mounting • Rear Bracket and Frame Isolators

1. Remove the front access cover, top, lower, and rear panels.
2. Support engine with hydraulic jack at oil sump area.
3. Loosen Allen head bolts at block assembly.
4. Loosen hex head bolts at bracket to frame through bolts.
5. Remove generator front lower bracket bolts and bracket
assembly; retain for reinstallation.
6. Loosen alternator top adjusting bolt, swing alternator towards
engine assembly for clearance of radiator, remove radiator
mounting stud nuts at rear of APU frame and pull radiator
module towards engine assembly.
7. Remove rear frame-to-bracket through bolts; retain for
reinstallation.
Engine Mounting Diagram
8. Remove bracket and frame isolator; then replace with new
• Front Bracket and Frame Isolators bracket or isolator.
1. Remove the front access cover and lower panels (the top cover 9. Reverse procedure to complete installation; apply anti-seize
can be removed also if the operator feels this would aid in compound to all stainless steel fasteners.
the procedure).
10. Prior to testing APU, verify that all connections and fasteners are
2. Support engine with hydraulic jack at oil sump area. secure.
3. Loosen Allen head bolts at block assembly.
4. Loosen hex head bolts at bracket to frame through bolts. • Required Tools
• Allen head bolts – 8 mm hex key
5. Remove bracket, remove frame isolator, and replace with new
bracket or isolator. • Bracket through bolts – 14 mm socket and wrench

6. Reverse procedure to complete installation; apply anti-seize • Front generator lower bracket – 14 mm socket and wrench
compound to all stainless steel fasteners.
• Frame isolator – 13 mm socket and wrench
7. Prior to testing APU, verify that all connections and fasteners
• Cover panels – 7/16 socket 5
are secure.
 Service Manual

• 5.2 Engine Components • 5.2.2 Generator Drive Belt Service

Each Dynasys unit is supplied with an authorized Yanmar Service 1. Remove front access, top, and left lower side panels.
Manual. Refer to manual and Yanmar tech support BEFORE 2. Insert 3/8 drive ratchet into tensioner arm.
performing any engine component repair, service or replacement. 3. Release belt tension and remove belt.

• 5.2.1 Starter Motor 4. Removal of belt from unit can be achieved by slipping belt
through frame and crank pulley face.
1. Disconnect 12 volt power from the APU by removing the 125 amp
fuse located at the truck’s main battery box. 5. Reinstall by reversing procedure.
2. Remove front and top panels. 6. Prior to testing APU, visually check belt alignment to insure
3. Disconnect positive cable at starter assembly. proper belt and pulley(s) mating.
4. Remove top starter mounting bolt and nut; retain for reinstallation.
5. Remove lower starter nut, leaving bolt in flywheel flex plate
assembly.
6. Remove starter by sliding to the right from lower bolt in flex plate.
7. Reverse procedure to complete installation.
8. Recheck all connections and re-install 125 amp fuse.

Required Tools
• Top panel – 7/16” wrench

• Positive connection at starter post - 13 mm socket or 13 mm wrench

• Upper and lower starter bolts and nuts - 17mm socket and
17 mm wrench

Generator Drive Belt

Required Tools
• Generator belt tensioner - 3/8 drive ratchet and extension

• 5.2.3 Alternator Drive Belt Service

1. Remove front access and top panels.
2. Loosen top alternator adjusting bolt.
3. Loosen lower pivot bolt.
4. Slide alternator assembly towards engine to relieve belt tension.
5. Remove alternator belt and replace with new belt.
6. Insert small pry bar between engine lift bracket and top area
of alternator assembly to gently slide alternator along
adjustment arm.

Starter Motor
7. Reverse procedure to complete installation.
8. Prior to testing APU, verify proper belt tension and alignment and
all connections.

Required Tools
• Top alternator adjusting bolt - 12mm socket or 12 mm wrench

• Lower alternator pivot bolt - 14mm socket or 14 mm wrench

• Alternator adjustment - small pry bar

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6. Should belt replacement be necessary, removal of belt from

unit can be achieved by slipping belt through frame and crank
pulley face.
7. Support generator with hydraulic jack.
8. Loosen and remove nuts at rear of generator assembly;
retain nuts for reinstallation.
9. Remove front generator bracket; retain bracket, bolts, and
nuts for reinstallation.
10. Disconnect generator lead eyelet at circuit breaker.

11. Disconnect generator from 120 VAC Sure Seal connection.

12. Lower generator from APU; retain generator/frame spacers

located at the rear of the generator for reinstallation.
Alternator Drive Belt
13. Loosen Allen head set screw at QD bushing shaft key area

• 5.2.4 Alternator Assembly prior to attempting removal of QD bushing from generator

shaft. (see lower left picture on page 15).
1. Disconnect APU ground cable and 120 VAC ground cable. They
are on the same eyelet located on the exterior at the back of the 14. Removal of the pulley from the old generator is performed

APU Engine Cabinet. (see picture at 5.2.1) in the following manner: swap the 3 bolts from the threaded
holes in the pulley to the threaded holes in QD bushing. As
2. Remove front and top access panels.
bolts are tightened, place a large flat head screwdriver
3. Disconnect positive post terminal and field connector on between the front face of the pulley and the rear of the QD
alternator. bushing. This allows the taper lock to be released from the
4. Loosen top alternator adjusting bolt. pulley (see lower right picture below).
5. Relieve belt tension by sliding assembly towards engine; remove 15. Reinstall generator pulley and QD bushing, using Dynasys
belt. tool #55-1010. This ensures proper generator belt alignment.
6. Remove lower alternator pivot bolt. 16. Reverse procedure to complete installation.

7. Remove top alternator adjusting bolt. 17. Prior to testing APU, verify that all connections are secure
and belts are properly aligned.
8. Remove alternator assembly.
9. Reverse procedure to complete installation.
10. Prior to testing unit, verify that all connections are secure and
alternator belt tension is correct.

Required Tools
• Ground cable connection at frame stud - 7/16 socket

• APU access panels - 7/16 socket

• Top alternator adjusting bolt - 12 mm socket

• Lower alternator pivot bolt - 14 mm socket or 14 mm wrench

• Alternator positive stud - 10 mm socket or 10 mm wrench

• 5.2.5 Generator Assembly

1. Disconnect APU ground cable and 120 VAC ground cable. They
are on the same eyelet located on the exterior at the back of the
APU Engine Cabinet. (see picture at 5.2.1)
Generator Assembly
2. Remove front access, top, rear, and left lower side panels.
Required Tools
3. Loosen rear panel and let hang from rear of APU. (see top
• Ground cable connection at frame stud - 7/16 socket
picture on right)
• APU access panels - 7/16 socket
4. Insert 3/8 drive ratchet into tensioner manual
adjustment point. • Circuit Breaker retaining nut - grip pliers

5. Release belt tension and remove belt. • Generator belt tensioner - 3/8 drive ratchet or 3/8 drive
breaker bar 7
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• Generator front bracket - 14 mm socket and 14 mm wrench

• 5.2.7 Radiator Hose Replacement
• Circuit breaker terminal connection - flat head screwdriver 1. Remove front and top access panels.
• Generator rear bracket - 14 mm wrench (x2)
2. Attach coolant recovery system to coolant filler neck; drain
• Generator QD bushing set screw - 5/32 hex key coolant and retain.
• Generator QD bushing mounting bolts - 7/16 socket, large flathead 3. Remove radiator hose; retain clamps and radiator header
screwdriver. 28mm collar for reinstallation.
• Generator belt alignment - Dynasys tool #55-1010 4. Reverse procedure for reinstallation.

• 5.2.6 Radiator Assembly 5. Prior to testing APU, verify that all connections are secure
and coolant is at proper level.
1. Remove front and top access panels.
2. Disconnect ground at rear of APU.
3. Loosen top alternator adjusting bolt.
4. Loosen lower alternator pivot bolt.
5. Relieve belt tension by sliding alternator assembly towards engine.
This allows clearance for removal of radiator module assembly.
6. Drain coolant from cooling system by attaching coolant recovery
system inlet at filler neck. Remove and retain all coolant.
7. Disconnect radiator fan pigtail, located at right side center area of
APU frame.
Radiator Hose Replacement
8. Remove inlet and outlet radiator hoses at radiator header; move to
the side for ease of radiator module removal from frame. Required Tools
9. Remove radiator mounting stud nuts (3) located at rear of APU; • APU access panels - 7/16 socket
retain for reinstallation. • Coolant recovery system
10. Remove module from frame, avoiding rear frame insulation and
• Radiator hose clamps - 5/16 nut driver or 5/16 socket
module studs.
11. Drain any remaining coolant from radiator. • 5.2.8 Coolant Bottle Replacement
12. Remove shroud assembly bolts (4) from radiator; retain bolts for (For S/N: G1D-10037 and lower)
reinstallation. 1. Remove front access cover.
13. Reverse procedure for reinstallation 2. Loosen lower bottle clamp to allow bottle to slide upwards.
14. Prior to testing APU, verify that all connections and fasteners are
3. Loosen upper bottle clamp; open clamp to allow bottle to be
secure and that coolant is at proper level removed without removing clamp completely from panel.
4. Disconnect switch pigtail located at lower frame area below
bottle assembly.
5. Reverse procedure to complete reinstallation.
6. Prior to testing APU, verify that all connections and fasteners
are secure.

Required Tools
• Coolant bottle clamps - 5/16 nut driver or 5/16 socket

Radiator Assembly

Required Tools
• APU access panels - 7/16 socket

• Ground cable at frame stud - 7/16 socket or 7/16 wrench

• Top alternator adjusting bolt - 12 mm socket

• Lower alternator pivot bolt - 14 mm socket or 14 mm wrench

• Coolant recovery system

• Radiator frame mounting stud nuts - 7/16 socket or 7/16 wrench

• Radiator hose connections - 5/16 nut driver or 5/16 socket Coolant Bottle Replacement
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• 5.2.8a Coolant Bottle Replacement • 5.2.10 Fuel Filter Service or Assembly Replacement
(For S/N: G1D-10038 and higher)
Service Procedure
• Remove front access cover.
1. Remove front access panel and turn fuel level to ‘off’ at fuel
• Remove the two 5/16” nuts located on the side and top of
filter and water separator.
the bottle.
2. Remove fuel bowl collar to allow access to filter element;
• Slide the bottle off of the studs.
remove fuel bowl section. Retain collar and body gasket for
• Disconnect switch pigtail located at lower frame area below reinstallation.
bottle assembly. 3. Replace element.
• Reverse procedure to complete reinstallation.
4. Reverse procedure for reinstallation.
• Prior to testing APU, verify that all connections and fasteners 5. Prior to testing APU, verify that all connections are secure and
are secure. fuel levers are returned to the ‘on’ position.
Required Tools
Replacement Procedure
• Coolant bottle nuts - 7/16” nut driver or 7/16” socket
1. Remove front access panel and turn fuel level to ‘off’ at fuel
• 5.2.9 Water Separator Filter Service or filter and water separator.
Assembly Replacement 2. Disconnect fuel lines at fuel filter assembly.
Water Separator Service Procedure 3. Remove bracket assembly through bolt; retain bolt and nut for
reinstallation. Remove assembly.
1. Remove front access panel, remove top cover, and turn fuel level
to ‘off’ at fuel filter and water separator. 4. Reverse procedure for reinstallation.
2. Remove fuel bowl collar to allow for access of filter element; 5. Prior to testing APU, verify that all connections are secure and
remove fuel bowl section. Retain collar and body gasket fuel levers are returned to the ‘on’ position.
for reinstallation.
3. Clean or replace element.
4. Reverse procedure for reinstallation.
5. Prior to testing APU, verify that all connections are secure and
fuel levers are returned to the ‘on’ position.

Fuel Filter

Required Tools
Water Separator
• Fuel line clamps - grip pliers

Water Separator Replacement Procedure • Fuel filter through bolt - 12 mm socket

1. Remove front access panel, remove top cover, and turn fuel level • Fuel filter rear nut - 13 mm wrench
to ‘off’ at fuel filter and water separator.
2. Disconnect fuel lines at water separator assembly.
3. Remove bracket assembly through bolt; retain bolt and nut for
reinstallation.
4. Remove assembly.
5. Reverse procedure for reinstallation.
6. Prior to testing APU, verify that all connections are secure and
fuel levers are returned to the ‘on’ position.

Required Tools
• Fuel line clamps - grip pliers
9
• Water separator through bolt - 12 mm socket and 12 mm wrench
 Service Manual

• 5.2.11 Fuel Pump Replacement

1. Remove front access panel, remove top cover, and turn fuel level
to ‘off’ at fuel filter and water separator.
2. Disconnect fuel lines at fuel pump assembly and pigtail connector.
3. Remove fuel pump mounting bolts (2); remove assembly from bracket.
4. Reverse procedure for reinstallation.
5. Prior to testing APU verify that all connections are secure and fuel
levers are returned to the ‘on’ position.

Air Filter Element

Required Tools
• Lower Air Cleaner Bracket bolt - 13 mm socket and
13 mm wrench

• 5.2.13 Oil Filter Service

Fuel Pump Replacement 1. Remove front access panel.
Required Tools 2. Drain oil from engine using provided clear drain hose attached
• Fuel line clamps - grip pliers to ball valve located at lower right side of oil sump area.
• Fuel pump mounting bolts - 11 mm socket 3. Remove oil filter from block assembly; support filter with shop
towel to prevent excessive oil leakage.
• 5.2.12 Air Filter Element and Assembly 4. Apply thin coat of oil onto new oil filter sealing O-ring; hand
Service Procedure tighten oil filter to block assembly; remove all excess oil.

1. Remove front access panel. 5. Ensure ball valve is in the ‘closed’ position; refill oil to proper
level.
2. Detach assembly front cover by releasing snaps (2) to allow access
to filter element. 6. Prior to releasing unit back to customer, perform short run test,
and recheck oil level and proper filter sealing.
3. Remove element; replace with new filter.
4. Reverse procedure for reinstallation.
5. Special care should be used when realigning Air Cleaner front
cover with body assembly; housing may be damaged if misaligned.

Replacement Procedure
1. Remove front and left lower access panels.
2. Detach assembly front cover by releasing filter assembly snaps
(2), allowing removal of housing.
3. Remove air cleaner bracket lower bolt to allow release of cleaner
assembly from bracket.
4. Slide assembly towards the left for complete removal without Oil Filter

damaging bracket assembly.

Required Tools
5. Reverse procedure for reinstallation.
• Oil filter – end cap or pliers handle oil filter wrench
6. Special care should be used when realigning Air Cleaner front cover
with body assembly; housing may be damaged if misaligned. • Used oil – approved receptacle

7. Prior to testing APU, verify that all connections and fasteners are
secure.

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5.3 Electric Cooling Fans • 5.3.2 Radiator Fan Replacement

1. Remove front and upper access panels.
The Dynasys APU has two electric fans. The function of the lower
fan (pusher fan) is to evacuate the APU cabinet box. This fan is 2. Disconnect ground cable at rear of APU.
protected by an outside panel rock guard attached directly through 3. Disconnect fan harness pigtail located at lower area of APU
the bottom panel to the fan assembly. The function of the upper frame rail towards radiator assembly.
fan (puller fan) is to bring air into the APU cabinet and across 4. Loosen top alternator adjusting bolt and lower pivot bolt.
the radiator module. This fan is attached to the radiator shroud 5. Relieve belt tension by sliding alternator assembly towards
assembly. The air flow direction of these fans is critical for proper engine, allowing for removal of fan assembly.
APU function.
6. Remove fan assembly mounting nuts (4) from radiator shroud
studs; retain for reinstallation.
• 5.3.1 Lower Cabinet Fan Replacement
1. Remove front and right side lower access panels. 7. Removal of fan assembly is achieved by sliding unit off shroud
studs and lifting fan up between radiator hoses.
2. Disconnect fan harness pigtail located at lower area of APU
frame rail. 8. Reverse procedure for reinstallation.

3. Remove the attaching through bolts (4) located on the outside of 9. Prior to testing APU, verify that all connections and fasteners
lower panel, using a backup wrench at nuts on the fan assembly; are secure.
retain all hardware for reinstallation. Required Tools
4. Remove rock guard and fan assembly. • Upper access panel - 7/16 socket or 7/16 wrench
5. Reverse procedure for reinstallation. • Ground cable at frame stud - 7/16 socket
6. Prior to testing APU, verify that all connections and fasteners are • Top alternator adjusting bolt - 12 mm socket or 12 mm wrench
secure. • Lower alternator pivot bolt - 14 mm socket or 14 mm wrench

Required Tools • Alternator adjustment - small pry bar

Access panels - 7/16 socket or 7/16 wrench

Lower fan assembly through bolts - 7/16 socket and 7/16 wrench

Radiator Fan

Lower Cabinet Fan

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5.4 Speed Sensor Service or Replacement • 5.5 120 VAC Circuit Breaker Replacement
The Dynasys Speed Sensor is mounted through the Yanmar flex-plate 1. Disconnect ground at rear of APU.
and is located at the front of the APU. The sensor gap between the 2. Remove front and right lower side access panels.
sensor tip and ring gear is set at .050” or 1.27 mm. Should intermittent 3. Remove outside circuit breaker, retaining jam nut.
engine shut off be experienced with a ‘low-rpm’ error message, check 4. Removal of breaker assembly is achieved by pulling breaker
for debris buildup at sensor tip or excessive gap between the ring gear away from panel.
and sensor tip. Shut down engine to perform cleaning or adjustment. 5. Remove breaker protector boot.
6. Remove terminal screws from breaker.
• 5.4.1 Speed Sensor Service
7. Reverse procedure to complete reinstallation.
1. Remove front access panel.
8. Prior to testing APU, verify that all connections and fasteners
2. Check for debris at sensor tip and proper gap between sensor tip are secure.
and ring gear area. Factory setting is at .050” or 1.27 mm.
3. Remove any debris by using a controlled spray of shop air. Required Tools
• Right side access panel - 7/16 socket or 7/16 wrench
4. Adjustment is achieved by loosening retaining nut at rear of
flex-plate mounting and turning sensor closer to or farther • Ground cable at frame stud - 7/16 socket or 7/16 wrench

from ring gear. • Circuit breaker jam nut - grip pliers

5. Verify gap by using feeler gage (preferably non-magnetic) while • Circuit breaker terminal screws - med flat head screwdriver
tightening retainer nut.
6. Prior to testing APU, verify that all connections and fasteners
are secure.

• 5.4.2 Speed Sensor Replacement

1. Remove front access panel.
2. Disconnect cover switch pigtail located at APU lower frame area
near coolant bottle.
3. Loosen coolant bottle clamps to allow bottle to slide upwards.
VAC Circuit Breaker
(For S/N GD-10038 and higher this step is not required.)
4. Remove (2) cover switch mounting screws and nuts; retain • 5.6 Cover Safety Switch
for reinstallation. 1. Remove front access panel.
5. Reverse procedure to complete reinstallation. 2. Disconnect cover switch pigtail located at APU lower frame area
near coolant bottle.
6. Prior to testing APU, verify that all connections and fasteners
are secure. 3. Loosen coolant bottle clamps to allow bottle to slide upwards.
4. Remove (2) cover switch mounting screws and nuts; retain for
Required Tools reinstallation.
• Coolant bottle clamps - 5/16 nut driver or 5/16 socket 5. Reverse procedure to complete reinstallation.
• Safety switch - Phillips head screwdriver and 7/32 wrench or socket. 6. Prior to testing APU, verify that all connections and fasteners
are secure.

Required Tools
• Coolant bottle clamps - 5/16 nut driver or 5/16 socket

• Safety switch - Phillips head screwdriver and 7/32 wrench or

7/32 socket

Speed Sensor

12 Cover Safety Switch

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• 5.7 Relay Replacement • 5.9 Exhaust Pipe Assembly Removal

1. Remove front and upper access panels. 1. Remove front and upper access panels.
2. Disconnect molded pigtail at relay base. 2. Push exhaust temp sleeve in downward direction to allow access
3. Remove relay mounting tab nut from panel stud. Removal of to lower exhaust clamp.
coolant bottle is recommended for replacing relays #2 and #4. 3. Loosen lower exhaust clamp; let clamp slide down to clear
4. Reverse procedure to complete reinstallation. exhaust pipe.
5. Prior to testing APU, verify that all connections and fasteners 4. Remove exhaust manifold flange nuts and lock washers; retain
are secure. for reinstallation.

Required Tools 5. Pull upper exhaust flange away from manifold; lift exhaust pipe
assembly from frame.
• Relay mounting tab nut - 7/16 socket or 7/16 wrench
6. Reverse procedure to complete reinstallation.
• Coolant bottle clamps (optional) - 5/16 nut driver or 5/16 socket
7. Prior to testing APU, verify that all connections and fasteners
are secure.

Required Tools
• Upper access panel - 7/16 socket or 7/16 wrench

• Lower exhaust pipe clamp - ½ socket or ½ wrench

• Exhaust manifold nuts - 13 mm socket or 13 mm wrench

Relay Replacement

• 5.8 Exhaust Manifold Gasket Replacement

1. Remove front and upper access panels.
2. Remove flange nuts and lock washers; retain for reinstallation.
3. Pull exhaust pipe assembly away from manifold.
4. Remove old gasket; replace with new.
5. Reverse procedure to complete reinstallation.
6. Prior to testing APU, verify that all connections and fasteners
are secure. Exhaust Pipe Assembly

Required Tools
• Access panel - 7/16 socket or 7/16 wrench

• Exhaust manifold nuts - 13 mm socket or 13 mm wrench

Exhaust Manifold

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• 5.10 Frame Flange Replacement • 5.11 Muffler Replacement

1. Remove front and upper access panels. 1. Remove front access cover.
2. Push exhaust temp sleeve in downward direction to allow access 2. Loosen nuts at lower frame flange assembly; retain for
to lower exhaust clamp. reinstallation.
3. Loosen clamp and slide in an upwards direction to clear frame 3. Remove tailpipe hanger clamp assembly; retain for reinstallation.
flange inlet. 4. Slide tailpipe away from muffler outlet.
4. Remove muffler-to-flange bolts and nuts (4); retain for 5. Remove muffler assembly and flange gasket.
reinstallation. Let muffler hang, supported by tailpipe hanger.
6. Install new flange gasket and muffler assembly.
5. Remove flange-to-frame bolts and lock washers (2); retain for
7. Reverse procedure to complete reinstallation.
reinstallation.
8. Prior to testing APU, verify that all connections and fasteners
6. Remove frame flange assembly; replace with new flange and
are secure.
gasket.
7. Reverse procedure to complete reinstallation.
8. Prior to testing APU, verify that all connections and fasteners
are secure.

Muffler Replacement

Required Tools
• Frame muffler flange nut – ½ socket and ½ wrench

• Tail pipe hanger clamp – ½ socket or ½ wrench

• 5.12 Tailpipe Replacement

Frame Flange Replacement
1. Remove front access panel.
Required Tools 2. Remove tailpipe support clamp at right side of APU; retain for
• Upper access panel and rear frame flange – 7/16 socket or reinstallation.
7/16 wrench 3. Remove tailpipe hanger nuts; retain for reinstallation.
• Lower exhaust pipe clamp – ½ socket or ½ wrench
4. Remove tailpipe by sliding tailpipe inlet away from muffler outlet
connection.
5. Replace with new tailpipe assembly.
6. Reverse procedure to complete installation.
7. Prior to testing APU, verify that all connections and fasteners are
secure.

Tailpipe Replacement

Required Tools
1. Tailpipe support clamp nuts - ½ socket or ½ wrench
2. Tailpipe hanger clamp

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 Service Manual

• 6.0 Electrical Schematics

The following two diagrams (right) are provided to assist in electrical diagnosis. This information is current to the publish date of this
manual. Refer to the Dynasys web site for any revisions of electrical system.

BLACK
SAFETY SWITCH

FUEL SOLENOID HOLD

GRAY
RELAY GLOW
PLUG
ALTERNATOR
RED

FUEL PUMP
X
K W
J V
L B
H
M C A G U
N F T 30A
E
O D
S OIL PRESSURE RED/GREEN + -
P
Q
R FUEL 12V BATTERY
RELAY SOLENOID
PULL-IN
COOLANT TEMP
STARTER
RELAY SOLENOID
RPM SENSOR-
RED

RPM SENSOR+
30A
RELAY
RELAY 30A
RELAY

COOLANT LEVEL

red pin X
12VDC
red pin U
12VDC
ALTERNATOR
red pin W
12VDC
black pin J
GROUND
HVAC GROUND pin 9 black/purple
green pin F
FUEL SOLENOID PULL-IN COIL
green/white pin L
FUEL SOLENOID HOLD COIL
gray pin K
GLOW PLUG
tan pin B
ALTERNATOR
A/C Lt Grn/Purp pin 3

HEATER Dk Grn/Purp pin 2

orange pin Q
TACH +

WIRING HARNESS TO APU

PIGTAIL
TO HVAC orange/black pin P
TACH -
BLOWER HIGH Dk Blue/Purp pin 5 blue pin D
FUEL PUMP
Gray/Purp pin 1 white pin E
BLOWER LOW STARTER
purple pin H
BLOWER MED xxxxx/xxxx pin 6
(future) FAN
black pin N
GROUND
ECM red pin V
12VDC

SHORE POWER INPUT yellow/purple pin 8

RJ45
CONNECTOR

TRANSFER SWITCH red/purple

brown/white pin S COOLANT TEMP
blue/white pin T
OIL PRESSURE
pink pin M COVER INTERLOCK SWITCH
yellow pin O COOLANT LEVEL-OUTPUT
TO CABIN CONTROL UNIT
HVAC 12VDC POWER pin 4
red/purple pins C+G 12VDC

15
 Service Manual

7.0 HVAC System The FAN button cycles through the following fan options:
The Dynasys air conditioner is fully automatic. A constant FAN AUTO, FAN HIGH, FAN LOW and FAN OFF. Once the
comfort zone is maintained with the temperature set point. desired option is set, press SELECT to confirm. If the bunk
The Dynasys air conditioner is a 12,500 BTU Hermetic R134a temperature is different from the manual temperature set
system that is not integrated into the truck’s air conditioning point, the air conditioning/heating will run when the fan
system. When cooling mode is selected and the Dynasys is in speed is set and SELECT is confirmed. If the system was
operation, the compressor is activated (installed under the stopped by another method, the air conditioning/heating
bunk). The blower motor circulates internal cab air across will start immediately when the system is restarted. The
the evaporator coil, releasing cool air into the bunk area. This system will remember the last fan speed setting when the
system is designed to maximize bunk cooling efficiency. Dynasys is turned on.

WARNING: Only certified R134a air conditioning technicians

• 7.3 Troubleshooting
should service the Dynasys air conditioner system.
This is a guide to assist in the proper diagnosis of
The Dynasys heating system is fully automatic. A constant issues that can affect HVAC performance. The Dynasys
comfort zone is maintained with the temperature set point. The HVAC incorporates both 12VDC and 120VAC electrical
bunk heating system has a capacity of 8,536 BTUs (2.5kw). This systems. Only qualified individuals should perform these
is a complete stand-alone system that is not integrated into the procedures.
truck’s heating system. When heating mode is selected and the
Listed below are some simple checks that are designed
Dynasys is in operation, the electric heat element(s) are energized
to aid in the identification of a problem that may affect
(installed under the bunk). The blower motor circulates internal cab
the performance of the HVAC box. For a more detailed
air across the heating element(s), releasing warm air into the bunk
diagnosis, refer to the flowcharts and electrical diagrams
area. This system is designed to maximize bunk heating efficiency.
listed after this section.
• 7.1 General Service NO HVAC FUNCTION QUICK CHECK
Dynasys recommends a monthly inspection and/or cleaning
Does the control display Cool Mode?
of the HVAC inlet filter screen (part #55-8168). This will insure
odor free air delivery inside bunk and maximum evaporate core If not, check to ensure that the temperature set point
performance. The process for removal and replacement of the is below the ambient temperature in the bunk and the
screen is located on page 18 in the HVAC service section. fan is on high, low or auto. If the settings are correct and
the display still does not show “COOL MODE”, then the
Visual inspection of electrical connections, vents to HVAC control system needs to be reset. This is accomplished
ducting, and ducting tubing is recommended to verify that there by powering down the unit and unplugging the 8 pin (J101)
are no loose connections, tears or obstructions that can impede Molex connector from the ECM and leaving it disconnected
maximum air delivery and HVAC performance. for 15 seconds. After 15 seconds, plug the connector back in
and retry the cooling functions. If this does not correct the
• 7.2 Basic Functions display issue, refer to the troubleshooting guide for
The default temperature shown on the display is the bunk
NO AC on pp 22-23.
temperature. Press UP (red triangle) or DOWN (blue triangle)
arrow to adjust temperature set point on the display. When Does the control display Heat Mode?
editing the set point, the LCD display will show the set point If not, check to ensure that the temperature set point
instead of bunk temperature, and the display will read Temp is above the ambient temperature in the bunk and the
Edit. After adjusting the set point, press SELECT to save the fan is on high, low or auto. If the settings are correct and
new setting. The display will then revert back to the bunk the display still does not show “HEAT MODE”, then the
temperature. If the system is already running, temperature control system needs to be reset. This is accomplished
changes may take a few seconds after the last UP or DOWN by powering down the unit and unplugging the 8 pin (J101)
plus SELECT buttons are pressed. The system will remember Molex connector from the ECM and leaving it disconnected
the last temperature setting when the Dynasys unit is turned for 15 seconds. After 15 seconds, plug the connector back in
back on. and retry the cooling functions. If this does not correct the
display issue refer to the troubleshooting guide for
Press FAN button to enter the manual fan speed settings.
NO HEAT on pp 24-25.

16
 Service Manual

Is the HVAC blower operating? If there is 120 VAC at the connectors and the connectors
If the blower is not operating, check the breakers at the Power fit securely together, there may be a fault in the cable or
Distribution box and at the APU. Reset, if required. If this does connectors. Check the cables for damage.
not restore blower function, refer to the troubleshooting flow
Check the belt/drive system. With the APU operating, confirm
chart and HVAC electrical diagram to verify proper input and
that the main drive belt is driving the generator shaft. Remove
output signals.
the right lower side panel behind the tailpipe to provide access
Is the condenser fan operating? to the rear of the generator. Shaft motion can be detected by
If not, check the fuse (located at condenser fan assembly in observing the generator rotor through the plastic ventilation
harness) and replace, if required. Verify condenser fan motor cover on the rear of the generator.
spins freely and is not binding due to debris or internal motor
If the generator shaft is not turning, ensure that the main
failure. Refer to the troubleshooting flow chart and HVAC
drive belt is intact and engaged with all pulleys. Replace if
electrical diagram for additional checks.
necessary. (If the belt has been thrown from the pulleys,
Is there 120 VAC power at the convenience outlets? there may be a problem with either the belt tensioner or belt
Note: the convenience outlets have a built-in breaker (GFCI). alignment.)
Ensure that it is reset. Next check the breaker on the Power
Check for 120 VAC across the leads from the generator. This
Distribution Box and reset if required. If this is OK check the
can be done by attaching a volt meter across the 120VAC supply
main 60 AMP breaker located at the rear of the APU. Finally
side at the input terminal of the main breaker and the 120 VAC
check that the main connectors at the APU are properly
common lead at the power connector.
connected. If there still is no 120 VAC power, refer to the “No
120 VAC Power” troubleshooting guide. If the measured voltage does not fall within the range specified
above, replace the generator capacitor (found behind the
Is the refrigerant charge correct?
plastic ventilation cover). If replacing the capacitor does not
If the condenser fan and blower are on and the display is
solve the problem, replacement of the generator may be
showing COOL MODE, check the refrigerant charge with proper
required.
gauges. If the charge is low, check the system for leaks. If a leak
is found at the hoses, fittings or condenser, replace or repair. If Note: the convenience outlets have an additional breaker (GFCI)
a leak is found in the HVAC box at a threaded fitting or switch, located in the center of the outlets. Ensure that it is reset.
it can be tightened and/or the o-ring replaced and re-tightened. SHORE POWER Quick Check (Optionally installed item)
If a component is identified as leaking or needing replacement,
Most issues with unsatisfactory performance of the shore
refer to the service replacement section. Use an approved UL
power unit are a result of using too long of a power cord or too
leak detector to perform the leak check function.
small of a gauge wire. Hodyon recommends that a maximum
NO 120VAC POWER QUICK CHECK length of 50ft be used with a minimum wire gauge of 12 AWG.
Check that breakers at the Power Distribution box are not The shore power system must be operated on a dedicated 15
tripped. Reset, if necessary. amp circuit to prevent nuisance tripping of the breaker.
Check that cable connections at the Power Distribution box Intermittent starting of the APU, while connected to shore
are secure. power is usually a result of an improper setting of the Low
Check that the main breaker at the rear of the APU is not Battery Auto-Start feature.
tripped. NOTE: With the optional Shore Power Kit installed, only HVAC
Check that the cable connectors at the rear of the APU are operation is possible. Convenience outlets and Engine Block
secure. Heater power are disabled.

Check Voltage at APU. Disconnect the 120 VAC cables at the

rear of the APU. (Before disconnecting, make sure the APU
is not running.) Restart the APU and check for 120 VAC at the
connectors. The actual voltage measured may vary between
110-130 volts.

17
 Service Manual

7.4 HVAC Service Procedures • Compressor Assembly Service

1. Disconnect power sources to HVAC assembly.
• HVAC Inlet Filter Screen Service
2. Remove HVAC top covers.
Inlet screen is attached to the front of evaporative core with
4 white push pins located at each corner. Remove the pins and 3. Recover refrigerant using approved UL equipment.
carefully slide screen edges away from HVAC box assembly. 4. Remove #10 suction line at upper connection of expansion
Cleaning of the screen can be achieved by either shaking dust block.
and debris off or rinsing under low pressure, warm water. 5. Remove #8 discharge fitting at upper connection of
Reinstall screen after thoroughly drying, with attention being compressor assembly and hose support clamp.
given to the re-installation of the screen edges. The screen 6. Remove compressor top electrical cover.
should be inspected on a monthly basis.
7. Disconnect the 3 electrical wires at compressor top, noting
proper wire color location for reinstallation.
8. Remove the 3 compressor mounting nuts at lower
compressor flange.
9. Remove compressor assembly from HVAC.
1 10. Reverse procedure to complete reinstallation ensuring all
o-rings are in place and undamaged.
11. Perform leak check and performance check prior to
releasing unit to owner/operator.

1 – Filter Screen

• HVAC Evaporative Core / Expansion Valve Service

1. Disconnect power sources to HVAC assembly.
1
2. Remove HVAC top covers.
3. Recover refrigerant using approved UL equipment.
4. Remove Inlet Screen.
5. Remove #10 suction line at upper connection of expansion block.
6. Remove #6 bulkhead hose fitting at lower connection of
expansion block.
7. Remove expansion block through bolt.
8. Removal of core is achieved by sliding core assembly backwards
and lifting out of HVAC box. 1 – Compressor

9. Remove expansion block from core assembly. • HVAC PCB Service

10. Reverse procedure to complete reinstallation ensuring all o-rings 1. Disconnect power sources to HVAC assembly.
are in place and undamaged. 2. Remove HVAC top covers.
11. Perform leak check and performance check prior to releasing unit 3. Recover refrigerant using approved UL equipment.
to owner/operator.
4. Remove #10 suction line at upper connection of expansion
block.
2
5. Remove #8 discharge fitting at upper connection of
compressor assembly and hose support clamp.
6. Remove compressor top electrical cover.
1
7. Disconnect the 3 electrical wires at compressor top, noting
proper wire color location for reinstallation.
8. Remove the 3 compressor mounting nuts at lower
compressor flange.
9. Remove compressor assembly from HVAC.
1: Expansion Valve 2: Evaporator

18
 Service Manual

10. Remove electrical connections from PCB assembly, taking note • Blower Motor Service
of all connections for proper reinstallation.
1. Disconnect power sources to HVAC assembly.
11. Reverse procedure to complete reinstallation ensuring all o-rings
2. Remove HVAC top covers.
are in place and undamaged.
3. Recover refrigerant using approved UL equipment.
12. Perform leak and complete performance check prior to releasing
unit to owner / operator. 4. Remove #10 suction line at upper connection of expansion block.
5. Remove #8 discharge fitting at upper connection of compressor
assembly and hose support clamp.
6. Remove compressor top electrical cover.
7. Disconnect the 3 electrical wires at compressor top, noting
proper wire color location for reinstallation.
8. Remove the 3 compressor mounting nuts at lower compressor
flange.
9. Remove compressor assembly from HVAC.
10. Remove electrical connections at 1.0kw and 1.5kw heater
elements, noting wire color location for proper reinstallation.
HVAC Printed Circuit Board
11. Remove heater elements and retain all hardware for
• Heater Element Service reinstallation. NOTE- heater element location is critical for
1. Disconnect power sources to HVAC assembly. proper operation. The 1.5kw element is located closer to the
blower motor cavity of the HVAC box.
2. Remove HVAC top covers.
12. Remove blower motor cone, retain hardware for reinstallation.
3. Recover refrigerant using approved UL equipment.
13. Remove blower motor electrical connections at PCB assembly,
4. Remove #10 suction tube at upper connection of expansion block.
ground lug, and capacitor, noting proper wire location for
5. Remove #8 discharge fitting at upper connection of compressor reinstallation.
assembly and hose support clamp.
14. Remove the 4 blower motor assembly screws at outer face of
6. Remove compressor top electrical cover. HVAC box, retain for reinstallation.
7. Disconnect the 3 electrical wires at compressor top, noting 15. Remove blower motor and cone assembly from HVAC box.
proper wire color location for reinstallation.
16. Reverse procedure to complete reinstallation ensuring all o-rings
8. Remove the 3 compressor mounting nuts at lower compressor flange. are in place and undamaged.
9. Remove compressor assembly from HVAC. 17. Perform leak and complete performance check prior to releasing
10. Remove electrical connections at the1.0kw or 1.5kw heater unit to owner / operator.
element, noting wire color location for proper reinstallation.
11. Remove heater elements and retain all hardware for
reinstallation. NOTE- heater element location is critical for
proper operation. The 1.5kw element is located closer to the
blower motor cavity of HVAC box.
12. Reverse procedure to complete reinstallation ensuring all o-rings
are in place and undamaged.
1
13. Perform leak and complete performance check prior to releasing
unit to owner / operator.

1: Blower Assembly

1 – Heater Elements
19
 Service Manual

• Compressor Run / Start Capacitor Service • Condenser Assembly Service

1. Disconnect power sources to HVAC assembly. 1. Recover refrigerant using approved UL equipment.
2. Remove HVAC top covers. 2. Remove #6 and #8 hose fittings from assembly.
3. Recover refrigerant using approved UL equipment. 3. Remove the 6 (total) condenser shroud bolts located at the
4. Remove #10 suction line at upper connection of expansion block. flange areas of shroud. It is recommended to remove the
lower 3 first; Retain hardware for reinstallation.
5. Remove #8 discharge fitting at upper connection of compressor
assembly and hose support clamp. 4. Remove the condenser assembly from the shroud.

6. Remove compressor top electrical cover. 5. Reverse procedure to complete reinstallation ensuring all
o-rings are in place and undamaged.
7. Disconnect the 3 electrical wires at compressor top, noting
proper wire color location for reinstallation. 6. Perform leak and complete performance check prior to
releasing unit to owner / operator.
8. Remove the 3 compressor mounting nuts at lower compressor
flange.
9. Remove compressor assembly from HVAC.
10. Remove desired capacitor from holder located at left rear corner
of compressor assembly cavity of HVAC box, noting wire location
for proper operation.
1
11. Reverse procedure to complete reinstallation ensuring all o-rings
are in place and undamaged.
12. Perform leak and complete performance check prior to releasing
unit to owner / operator.

1 Condensor Assembly
1
• Receiver Drier Service
1. Recover refrigerant using approved UL equipment
2. Remove both #6 hose fittings from drier bottle assembly.
3. Loosen drier bottle clamps.
4. Remove drier from condenser shroud assembly.
5. Reverse procedure to complete reinstallation ensuring all
o-rings are in place and undamaged.
6. Perform leak and complete performance check prior to
1 Capacitors
releasing unit to owner / operator.

1 Receiver Drier

20
 Service Manual

7.5 Troubleshooting Flow Charts

• Engine Won’t Start

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21
 Service Manual

• No Air Conditioning

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22
 Service Manual

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23
 Service Manual

• Heater Not Working

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24
 Service Manual

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25
 Service Manual

• No Generator Output

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26
Service Manual

27
 Service Manual

28
Service Manual

29
 Service Manual

Service Performed Date

30
 Service Manual

Notes:

31
120 East Old Settlers Boulevard www.hodyon.com
Round Rock, TX 78664-2248 512.225.0165