IK1900228

IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
Countries:
Page 1 of 7
AUSTRALIA, BAHAMAS, BOLIVIA, BRAZIL,
BELIZE, CANADA, CHILE, COLOMBIA,
COSTA RICA, DOMINICAN REPUBLIC,
ECUADOR, EL SALVADOR, TRINIDAD AND
Document
TOBAGO, UNITED STATES, URUGUAY,
IK1900228
ID:
VENEZUELA, MEXICO, ARUBA, NICARAGUA,
PERU, PUERTO RICO, Curaçao,
GUATEMALA, GUYANA, HAITI, HONDURAS,
JAMAICA, NEW ZEALAND, PANAMA
Availability: ISIS, FleetISIS
Revision: 10
Major
System:
ACCESSORIES
Created:
English
Last
6/30/2015
Modified:
Current
Language:
Other
Français, Español,
Languages:
Viewed:
Author:
8/18/2014
Kevin
Kochanek
7176
Less Info
Coding Information
Hide Details
Copy Link
Copy Relative Link
Bookmark
Add to Favorites
Print
Provide Feedback
Helpful
Not Helpful
26
4
View My Bookmarks
Title : 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
Applies To : Post 2010 NGV
CHANGE LOG
6/30/2015 - Changed formatting of tables in Diagnostic section to fit on one page when printed.
6/24/2015 - 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
5/15/2105 - Fixed link to S16046 Manual and added link to PDF for the HVAC System Pressure Test Chart.
4/9/2015 - Added SPN 2609 to symptom table


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
1552
2
A/C Control Head Circuit Failed To
Communicate With Body Controller
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
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2015
IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
2058
9
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
A/C Control Head Multiple Motor Faults
Page 2 of 7
Rear A/C Data Link Communication
Failure
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
34988
or equivalent
Instructions
A/C recovery, vac, and performance test
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
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2015
IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
•
•
Page 3 of 7
IK1900235 No-Idle HVAC Operational Check - STARTING POINT
IK1900227 Rear A/C Electrical and Mechanical Diagnostics
DIAGNOSTIC STEPS
Step Action
Decision
Customer Interview:
Review the Repair Order to determine the following:
•
•
•
•
1
•
•
Yes: cab A/C works correctly but
What is the Air Conditioning System doing specifically? (No cold air, not rear A/C does not: Go to step 7.
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?
YES: concern is with MaxxPro
If equipped with a No-Idle system does the issue only happen when
No-Idle HVAC unit: Go to
utilizing the No­Idle System?
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
No: to step 2.
Action
Decision
Preliminary checks:
Yes: Repair as necessary.
Restore system to
operational condition and
operate the A/C system to
determine if the complaint
was corrected..
2
Note: 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 to allow system pressures to
stabilize.
No: Go to step 3.
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:
•
•
•
•
•
•
•
•
•
•
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
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2015
IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
•
•
•
•
Page 4 of 7
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
Were any issues found?
Step Action
Decision
Diagnostic Trouble Codes:
Yes: Go to FAULT CODES in IK1900207
3
Check for A/C related DTC’s:
No: Go to step 4.
Are any A/C related DTC’s found?
Step Action
Decision
Yes: Go to step 5.
4
Static Pressure:
No: Go to Air Conditioning
Mechanical Pressures
Diagnostics IK1900225
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.
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
40 °F
45 °F
50 °F
55 °F
60 °F
65 °F
70 °F
75 °F
80 °F
85 °F
90 °F
95 °F
100 °F
Temp °C
4.4 °C
7.2 °C
10.0 °C
12.8 °C
15.6 °C
18.3 °C
21.1 °C
23.9 °C
26.6 °C
29.4 °C
32.2 °C
35.0 °C
37.7 °C
R134A PSIG
35
40
45
51
57
64
71
78
86
95
104
113
124
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2015
IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
105 °F
110 °F
40.5 °C
43.3 °C
Page 5 of 7
134
146
Are the A/C pressures in spec?
Step Action
Decision
Compressor Engagement:
Yes: Go to step 6.
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:
Yes: System is operating correctly.
Discuss concern with customer.
A. Park the vehicle so there is no solar loading and no wind.
No: gauge readings are out of specification:
B. Position a thermometer approximately 30 to 60 cm (12-24 inches)
Go to Air Conditioning Mechanical Pressures
in front of the vehicle grille.
Diagnostics IK1900225
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
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
Ambient Air Temperature
Relative Humidity
Cab Air duct Temp
Low-Side psi @ 1500 RPM
Compressor on (cut-in PSI)
Value
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.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2015
IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
Page 6 of 7
Does the Cab and rear HVAC operate correctly?
Step
Action
Decision
Rear A/C Test:
A. Start engine and raise engine speed to 1500 RPM.
Yes: rear HVAC system operates correctly
B. Turn cab A/C switch to NORM
C. Turn cab blower switch to highest speed.
D. Turn cab temperature switch to coldest position.
E. Shut both cab doors and open both windows.
No: Rear A/C does not function: Go to Rear Air
Conditioning Electrical and Mechanical
Diagnostics IK1900227
F. Use the dash SLPR-FAN switch to vary rear blower
speed from lowest to highest
speed.
G. Use the dash SLPR­TEMP switch to vary sleeper
temperature from warmest setting to the coldest
setting.
7
No:
rear control panel TEMP and FAN switches are
H. Use the Rear HVAC Control panel blower switch to inoperative while SLPR­TEMP and SLPR­FAN
raise and lower rear blower
switches function: Go to Rear A/C Control Panel
speed.
Inoperative IK1900231
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?
No: Front and rear controls function correctly, but
Does the stabilized rear duct temperature from step-6 rear A/C blows warm air: Go to Rear A/C Blows
meet specifications (See appropriate 2010 HVAC
Warm Air IK1900231
SYSTEM PRESSURE TEST CHART)?
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
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2015
IK1900228 - 2010 and Newer Vehicle Air Conditioning Diagnostics (Start Here)
Page 7 of 7
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
air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air
conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning air conditioning
Hide Details
Feedback Information
Viewed:
7175
Helpful:
26
Not Helpful: 4
No Feedback Found
Copyright © 2015 Navistar, Inc.
https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/1/2015