IK1900228

IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
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IK1900228
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Title : 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
Applies To : Post 2010 NGV
CHANGE LOG
Please refer to the change log text box below for recent changes to this article:
06/01/2016 ‐ Corrected diagnostic table layout
09/01/2015 ‐ Repaired iKNow link in step 7
06/30/2015 ‐ Changed formatting of tables in Diagnostic section to fit on one page when printed.
08/31/2015 ‐ Fixed hyperlink.
06/24/2015 ‐ Changed all occurences of reference to IK1900198 to reference IK1900235 instead.
05/26/2015 ‐ Fixed link on step 6 to properly route viewer to IK1900226


DESCRIPTION
This document addresses Air Conditioning issues on the following 2010 to 2014 vehicles with a BCM.
The following procedures will guide the user through : Common Air Conditioning failure areas, diagnostic tools,
SRTs, and warranty filing.
Note: For anything Pre-2010, reference the Pre-2010 A/C HVAC Resource Center located IK1900156.
SYMPTOM
Diagnostic Trouble Code(s) & Dashboard Indicator Light(s):
SPN
FMI Description
2609
16
A/C High Pressure Protection
2609
15
Low Charge Protection
1079
1
5 volt sensor supply below normal
3985
9
A/C Control Head Circuit Failed To Communicate With Body Controller
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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
1552
2
A/C Control Head Temperature Mix DM1
3981
2
A/C Control Head Mode Fault DM1
3984
2
A/C Control Head Air Inlet DM1
2058
9
Rear A/C Data Link Communication Failure
2058
14
Rear A/C Data Link Communication Failure
3982
2
A/C Rear Blower Speed Control Switch Error
3983
2
Rear A/C Temperature Control Switch Error
520465 2
Page 2 of 7
A/C Control Head Multiple Motor Faults
Customer Observations or Concerns:
•
•
•
•
•
•
Malfunction Indicator Light (MIL)
No cab air conditioning
"Warm" A/C
No air flow through vents
No rear A/C
Inoperative MaxxPro no-idle A/C system
SPECIAL TOOLS / SOFTWARE
Tool Description
Tool
Number
Comments
Robinair Air Conditioning Machine
or equivalent
34988
A/C recovery, vac, and
performance test
Instructions
SERVICE PARTS INFORMATION
Due to variety of configurations, reference the parts catalog for vehicle being repaired.
Parts Catalog
PROCEDURE OVERVIEW
Do not start engine until steps 2-4 have been completed. If the engine has been run
recently, allow the vehicle to sit for one hour so system pressures can stabilize.
Consider the following before beginning:
• Are any Air Conditioning related AFC’s open?
• Was the vehicle recently in for an Air Conditioning repair, in which the system was not properly filled or
serviced?
• Were A/C repairs made recently, and fault codes not cleared properly?
If the A/C issue is known (blown off hose, visible dye, inoperative blower motor) go directly to the respective
steps or iKNow articles listed below. Otherwise, go to step 1.
•
•
•
•
•
IK1900226 A/C Control Head Issues
IK1900225 A/C Mechanical Pressures diagnostics
IK1900223 A/C Sensor/ Electronic Issues
IK1900235 No-Idle HVAC Operational Check - STARTING POINT
IK1900227 Rear A/C Electrical and Mechanical Diagnostics
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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
Page 3 of 7
DIAGNOSTIC STEPS
Step Action
Decision
Customer Interview:
Review the Repair Order to determine the following:
1
• What is the Air Conditioning System doing specifically? (No cold
air, not cold enough, no air flow at vent, or no defrost?
• When does the concern occur? Vehicle stationary, when idling
overnight, or going down the road?
• Is the problem intermittent, or happen consistently?
• Have you had the vehicle serviced recently? When and where?
Was there an A/C related service performed during that
service?
• Does issue concern the passenger compartment, the sleeper, or
both?
• If equipped with a No-Idle system does the issue only happen
when utilizing the No-Idle System?
Yes: Cab A/C works correctly
but rear A/C does not: Go to
step 7.
Yes: Concern is with MaxxPro
No-Idle HVAC unit: Go to
IK1900235
Is the problem confined to the rear A/C system while the Cab A/C
works correctly?
Is the problem confined to the operation or performance of the
MaxxPro No Idle system?
Step Action
2
No: Go to step 2.
Decision
Preliminary checks:
Yes: Repair as necessary.
Restore system to operational
Note: Do not start engine until steps 2-4 have been completed. If the condition and operate the A/C
engine has been run recently, allow the vehicle to sit for one hour to system to determine if the
allow system pressures to stabilize.
complaint was corrected.
Perform a visual check of the A/C system to verify that no obvious
problems are present. With the engine off, inspect the following
items:
No: Go to step 3.
•
•
•
•
•
•
•
•
•
•
•
•
Compressor and clutch mounting
Compressor clutch coil wiring and connection
Compressor drive belt and belt tensioner
A/C hoses and connections
Condenser mounting
Condenser fins (blockage by debris)
Receiver-drier mounting
Expansion valve mounting
Filter element
Fresh air module drains
Fresh air module mounting and overall condition
Electrical connections to pressure transducer and low pressure
switch
• Electrical connections to actuators for airflow doors (recirculate,
temperature, and mode doors)
• Fan speeds and mode door operation
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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
Page 4 of 7
Were any issues found?
Step Action
Decision
Diagnostic Trouble Codes:
3
Yes: Go to FAULT CODES in
IK1900207
Check for A/C related DTC’s:
Are any A/C related DTC’s found?
No: Go to step 4.
Step Action
4
Decision
Static Pressure:
NOTE: Have the engine OFF and A/C system at ambient
temperature when measuring static pressure.If the engine has been
run recently, allow the vehicle to sit for a minimum of one hour to
allow system pressures and temperatures to stabilize.
Yes: Go to step 5.
No: Go to Air Conditioning
Mechanical Pressures
Diagnostics IK1900225
1. Inspect high and low side Schrader valves for presence of dye
and pooling of oil in valve.
2. Connect gauges to the A/C system and record static pressure
readings.
3. Use a temperature probe to determine the ambient temperature
within 1 or 2 degrees. Record the measured temperature.
4. Locate the ambient temperature on the chart below and
compare the vehicle’s static pressure to the chart pressure.
Temp °F Temp °C R134A PSIG
40 °F
4.4 °C
35
45 °F
7.2 °C
40
50 °F
10.0 °C
45
55 °F
12.8 °C
51
60 °F
15.6 °C
57
65 °F
70 °F
18.3 °C
21.1 °C
64
71
75 °F
23.9 °C
78
80 °F
26.6 °C
86
85 °F
29.4 °C
95
90 °F
32.2 °C
104
95 °F
35.0 °C
113
100 °F
37.7 °C
124
105 °F
40.5 °C
134
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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
110 °F
43.3 °C
Page 5 of 7
146
Are the A/C pressures in spec?
Step Action
Decision
Yes: Go to step 6.
Compressor Engagement:
5
Start engine. Turn the A/C on. Verify compressor engagement.
No: Go to Air Conditioning
Electrical Diagnostics
IK1900223
Does the compressor engage?
Step Action
6
Decision
Performance Test:
Check the System Performance by performing the following steps:
A. Park the vehicle so there is no solar loading and no wind.
B. Position a thermometer approximately 30 to 60 cm (12-24
inches) in front of the vehicle grille.
C. Engage the engine cooling fan (unless viscous fan drive).
D. Close the hood, being careful not to damage the equipment.
E. Insert a thermometer into the passenger side, left instrument
panel vent. Do not allow the thermometer to touch the sides of
the duct. Insert a second thermometer into the lower passenger
bunk vent.
Yes: System is operating
correctly. Discuss concern with
customer.
No: Gauge readings are out of
specification: Go to Air
Conditioning Mechanical
Pressures Diagnostics
IK1900225
No: Gauge readings are
correct but cab vent
temperature is out of
specification: Go to Air
Conditioning Control Head
Diagnostics IK1900226
F. Start the engine and raise the idle speed to 1500 rpm.
G. Open windows and close both cab doors.
H. Set the mode control to: NORM A/C; Highest blower speed;
Coldest cooling temperature.
I. Operate the system for five minutes, or until gauge readings
settle.
J. Record the following data:
Test Point
Value
Ambient Air Temperature
Relative Humidity
Cab Air duct Temp
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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
Page 6 of 7
Low-Side psi @ 1500 RPM
Compressor on (cut-in PSI)
Compressor off (cut-out PSI)
High-Side psi @ 1500 RPM
Compressor on (cut-in PSI)
Compressor off (cut-out PSI)
Lower Passenger bunk vent
temp
K. Compare gauge readings, vent temperature, ambient
temperature, and humidity to the appropriate HVAC System
Pressure Test Chart.
Does the Cab and rear HVAC operate correctly?
Step Action
Rear A/C Test:
A. Start engine and raise engine speed to 1500 RPM.
B. Turn cab A/C switch to NORM
C. Turn cab blower switch to highest speed.
D. Turn cab temperature switch to coldest position.
Decision
Yes: Rear HVAC system
operates correctly
No: Rear A/C does not
function: Go to Rear Air
Conditioning Electrical and
Mechanical Diagnostics
IK1900227
E. Shut both cab doors and open both windows.
7
F. Use the dash SLPR-FAN switch to vary rear blower speed from No: Rear control panel TEMP
and FAN switches are
lowest to highest speed.
inoperative while SLPR-TEMP
G. Use the dash SLPR-TEMP switch to vary sleeper temperature and SLPR­FAN switches
function: Go to Rear A/C
from warmest setting to the coldest setting.
Control Panel Inoperative
IK1900231
H. Use the Rear HVAC Control panel blower switch to raise and
lower rear blower speed.
I. Use the Rear HVAC Control panel TEMP switch to raise and
lower the duct air Temperature.
J. Review rear duct temperature recorded in step-6
Do the dash SLPR-FAN and SLPR-TEMP switches control the rear
A/C?
No: One or both SLPR TEMP
and SLPR FAN switches are
inoperative but rear control
panel TEMP and FAN switches
functions correctly: Go to
Sleeper Fan and Sleeper TEMP
Switch Inoperative IK1900232
Do the rear control panel blower speed and temperature switches
control the rear A/C?
Does the stabilized rear duct temperature from step-6 meet
specifications (See appropriate 2010 HVAC SYSTEM PRESSURE
TEST CHART)?
No: Front and rear controls
function correctly, but rear A/C
blows warm air: Go to Rear A/C
Blows Warm Air IK1900231
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IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
Page 7 of 7
WARRANTY INFORMATION
Standard Repair Times: Due to the variety of vehicle confirgurations and number of components affected,
reference the SRT Manual (quick links below) for repair times.
Description
A/C SYSTEM PRELIMINARY DIAGNOSIS (EXCEPT 5000, 9000 SERIES), PERFORM
A/C MECHANICAL PRESSURES DIAGNOSIS (EXCEPT 5000, 9000 SERIES), PERFORM
A/C ELECTRICAL DIAGNOSIS ( EXCEPT 5000, 9000 SERIES) , PERFORM
A/C CONTROL HEAD DIAGNOSIS
A/C REAR UNIT ELECTRICAL AND MECHANICAL DIAGNOSIS (EXCEPT 5000,9000 SERIES),
PERFORM
SRT Manual
OTHER RESOURCES
Document
Number
Description
S16046
HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010 ­ 3200 Bus, DuraStar®,
TerraStar™, TranStar®, WorkStar® Models
0000002221
HEAT VENTILATION AIR CONDITIONING (HVAC) FOR 2010 ProStar and LoneStar
Models (Formerly S16047)
IK1900207
2010 and Later ProStar and LoneStar HVAC Information
IK1900022
A/C Refrigerant and Oil Capacities
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