IK1900144 - ProStar™ and LoneStar™ HVAC system compressor and discharge hose fai... Page 1 of 6

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Title:
ProStar™ and LoneStar™ HVAC system compressor and discharge hose failure diagnostics and repair
procedures
Applies To:
2008 through pre-2010 emissions engine, equipped ProStar™ and LoneStar™ sleeper model vehicles
DESCRIPTION

This document covers two specific HVAC failures requiring special diagnostics and repair processes.
1. Ruptured and leaking A/C compressor discharge hoses, ("high side", compressor to condenser hose):
These ruptures and leaks have commonly occurred at the fitting closest to the compressor.
The rupture causes damage to the A/C compressor from the sudden loss of refrigerant and lubricant,
therefore replacement of the compressor and complete system flushing is necessary.

2. A/C Compressor Failures :
This can include, but is not limited to seizure, clutch failures (caused by internal siezure), audible metallic
noise and/or poor compressor performance.

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FAILURE DETAILS

The primary cause of these two failures is high head pressure, which can be caused by:
System overcharge, either refrigerant or oil
Plugged condenser / cooling package (limited air flow across condenser)
Improper flushing or purging from prior repair
Inoperative fan drive
Missing or damaged fan shroud
Running blower speeds on low speed for extended periods during high ambient temperatures.
Kinked, rubbing or misrouted hoses
Inadequate air flow through the evaporator (may be caused by dirty/plugged evaporator core or cabin
filters, both cab and sleeper-replace if necessary)
Thermister failures
REPAIR PROCEDURE:
UPDATE THE BODY CONTROLLER TO THE LATEST VERSION.
Changes were implemented to data version 137 and above.
NOTE:
Always follow proper flushing, purging and evacuation procedures.

Follow recommended service procedures found in Master Service Manual
S16039 -HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM - ProStar and LoneStar
.
Compressor Replacement Procedure:
1. Evacuate the HVAC system.
2. Remove compressor.
3. Remove receiver/dryer.
4. Flush and purge HVAC system. See IK1900145- "A/C Flushing Tools, Techniques, and Flushing Solvent"
NOTE: This procedure is necessary to remove metallic debris and residual oil from the system. Whether
the HVAC system has experienced metallic contamination or not, this procedure should be performed.
This will remove all residual oil from the system, so that an accurate oil level can be attained.
5. Do not flush the condenser, replace it. See TSI1900001 "Air Conditioning (A/C) condenser
replacement versus flushing" for additional details.
6. Install a HVAC Screen Kit 2607294C91 in the suction hose per IK1900170

7. Since the entire A/C system has been flushed and purged, the new Sanden compressor does not

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need to be drained (oil). It already contains 300cc of the proper PAG 100 oil. Do not add any
additional oil or dye to the the system. Compressor oil calculations are required whenever a system
has not been completely flushed.
8. Connect to the vehicle with Diamond Logic Builder. With the ignition key ON, enter "Diagnostic
Mode" by selecting the "Diagnostic" icon. Under the "Features" tab select the HVAC feature that is
checked and select "Make Session". Monitor the "AC_Evaporator_Inlet_Temp" and the
"AC_Evaporator_Outlet_Temp" If the temperatures do not read ambient temperature or are not within
5 degrees of each other replace both thermistors. Consider replacing thermisters if you are not
certain that they were shrink-tubing sealed when initially installed. A check of warranty history will
assist you.
9. Just before evacuating replace the receiver/dryer. Note: The new dryer contains a UV dye wafer
inside.
10. Evacuate and recharge the system as outlined in the HVAC Master Service manual (1000-2000
microns of vacuum must be achieved). See hose filter note below. While the system is evacuating and
charging complete the installation of all attaching hardware, component mounting, hose mounting, etc.
11. Run the unit for several minutes to stabilize the pressures, and test the HVAC performance.
12. If satisfactory perform a road test monitoring HVAC vent outlet temperature.
13. Compare the readings to the HVAC performance charts found in the Master Service manual. If
satisfactory, no further action is required.
14. Open a Tech Service case file indicating a failed compressor, or failed hose in the details.
Document all diagnostics and all repairs performed in the case file notes and request closure if no
further assistance is required.
NOTE: If any metallic debris or residue is noted, indicated by metal shavings or black oily residue, after
evacuation and disassembly, both TXVs (thermal expansion valves) and the condenser should be
replaced. If the compressor discharge hose was ruptured or leaking, replace it also. Install these
parts after the flushing and purging.
IF YOU RECOVER REFRIGERANT FROM A TRUCK AND THEN DETERMINE THAT THE A/C SYSTEM
NEEDS FLUSHING, THE 2 HOSE FILTERS ON THE INTERNATIONAL A/C MACHINE (RTI) NEED TO BE
CLEANED OR REPLACED AND BEFORE RECHARGING THE HVAC SYSTEM (Replacement filters listed
below)

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See- S16039 -HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM - ProStar and LoneStar

PARTS INFORMATION
Part numbers below are for reference only. All part numbers should be verified using the Parts Catalog
Part Number

Description

2607294C91

Suction hose screen kit (mandatory install)

3670134C1

Filter, drier

3660853C2

TXV Exp valve-Cab HVAC unit

3599589C1

TXV Exp valve-Sleeper HVAC unit

3612296C92

Compr. To cond. Hose-Cummins application

3626413C94

Compr. To cond. Hose- MaxxForce 11 and 13 IBB application

3808548C1

Compressor- MaxxForce 11 and 13 IBB Application

3628699C1

Compressor-Cummins Application

ZGGR725028

Oil, Castrol A/C, PAG 100 (8 oz.)

3543727C1

RING,O SEAL 10.78 X 2.62 (TAN)

3543728C1

RING,O SEAL 15.54 X 2.62

3543881C1

SEAL,C-PLATE 1/2"

3543882C1

SEAL,C-PLATE 3/4"

3622764C3
3660862C1
3660864C1

Thermistor
O-ring, Front TXV
O-ring, Front TXV

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3660865C1
1693968C1

O-ring, Rear TXV
O-ring, Rear TXV

1693970C1

O-ring, Rear TXV

3824715C1

O-ring, Rear TXV

3824716C1

O-ring, Front TXV

MaxxPower, "No-Idle" (Bergstrom) APU equipped vehicles
3688242C1 TXV Exp valve-Sleeper HVAC unit
3685792C1 O-ring, Rear TXV (one required)

Other Parts
ZGG15704
ZGGR725031
ZGGR725022
ZGGR725032
IRTI3608161800

Flush Solvent Based 1 Gallon (preferred)
Flush Solvent Based 1 Quart
Flush Solvent Based 1 Quart
Flush Non Flammable Solvent 1 Gallon
Flush Non Flammable Solvent 1 Quart
RTI Hose Filter Screens

ZGGR725030

Mineral oil for O-rings

ZGG16061

Customer A/C modified operating guide for balance A/C System operation
To prevent high head pressures that can cause hose and compressor failures instruct the operator to follow these
modified A/C operating guidelines. This will help to provide better balance in the HVAC system operation.
1. When running the Cab A/C set the Sleeper blower control to a a minimum of low speed.
2. When running the Sleeper A/C set the Cab blower control to a minimum of low speed
OTHER RESOURCES
S16039 -HEAT VENTILATION AIR CONDITIONING (HVAC) SYSTEM - ProStar and LoneStar
S16019- AIR CONDITIONING BASIC THEORY, SYSTEM DIAGNOSIS AND SERVICE (with R-134a Refrigerant
System)
SFN Number: 08-10RB 125401NAV Vehicle Air Conditioning Oil and Dye Injection Equipment
RTI RHS 980C-NAV A/C Recovery Recycling and Charging Machine Operators Manual
IK1900024 Repairing AC Thermistor Connectors and Terminals
IK1900014 AC System Refrigerant and Oil Capacity Quick Reference Chart
IK0900025 - MaxxForce 11 and 13 Fan Drive Diagnostics
IK1900123 Evaporator Temps are Normal, But the Vent Temp is High.
IK1900145 A/C Flushing Tools and Solvents
TSI 11-16-01
A/C Support (Tools & Equipment Page)
HVAC Resource Center

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TOWN HALL Q&A
Q- "If we dont' have nitrogen, what is the next best thing to use?"
A- CAUTION – When purging the system, or components of the system, use only dry nitrogen. The introduction
of compressed air into the A/C system may cause contamination of the system. (Taken from S16039 Master
Service manual)
Q- "Is denatured alcohol acceptable to flush the A/C system, or should we use only Navistar approved A/C flush?"
A- When flushing components, use only flushing agents approved for R-134a charged air conditioning systems
Q- "How much oil should we put back into a new compressor when we do not flush the system, because you do
not know history of past repairs? It could have too much or too little."
A- If a component only is replace, the oil level in the system will need to be adjusted accordingly. Refer to the Oil
Fill Guideline section of the HVAC Master Service manual found on ISIS. If the system oil quantity is in question,
or can not be accurately measured, it's recommended the entire system be flushed, the receiver/dryer be
replaced, and the compressor fill guidelines be followed. This will accurately install the required amount of oil into
the system.

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Number of Ratings: 51

Feedback Comments
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DYYRDM1

Rod Minor

DYYWAC1 William Cosby

Job
PA003, Parts
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Comments

Date

DODGE CITY INTL INC
(670133 - 000)

what is wrong when dash displays "HVAC High Temp"

3/24/2011
9:09:02 AM

SE003,
Service
Manager

RUSH TRUCK
CENTERS OF UT
(799064 - 000)

Is there any way you can identify by date what has been added
going forward? I reread the entire thing every time you make a
9/1/2010
change and I would really only like to read the parts that have 11:43:04 AM
been added. Thanks

DYYJKG9

Joseph
Goodwin

SE008,
Service
Technician

ATTERBERY TRK
SALES INC (625202 000)

DYYWEC7

Willis
Cunningham

SE008,
Service
Technician

GOODPASTURE
it is not clear about the flush an purge on comp. replacement, an
8/19/2010
MOTOR CO (696260 can be read either way an leads some to think you flush an
3:01:54 PM
000)
purge only if comp. is damaged.

DYYCXJ8

Clayton
Jenkins

SE008,
Service
Technician

RUSH TRUCK
CENTERS OF GA
(610030 - 002)

very helpful

8/16/2010
8:36:49 PM

SE003,
Service
Manager

MCCANDLESS INTL
TRUCKS (754010 000)

What about Sanden compressors sold over the counter to the
Penske's,Ryder's and used on the 4,7 and 9000 series trucks?

8/9/2010
6:10:43 PM

DYYMRB7 Mike Babbitt

thank you for adding the additional o-ring part#s on this iknow

8/20/2010
1:34:31 PM

Copyright © 2012 Navistar, Inc

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