IK1900207 ­ 2010 and Later ProStar and LoneStar HVAC Diagnostic Information

Page 1 of 9

Countries:

CANADA, COLOMBIA, UNITED Document
STATES, PUERTO RICO
ID:

Availability:

ISIS, FleetISIS, Body Builder

IK1900207

Revision:

4

Major System: ACCESSORIES

Created:

5/2/2013

Current
Language:

English

Last
Modified:

6/25/2014

Other
Languages:

NONE

Author:

Matthew
Boyer

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12534
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23

Title : 2010 and Later ProStar and LoneStar HVAC Diagnostic Information
Applies To : 2010 and Later ProStar and LoneStar Trucks

Change Log
Dealers: Please refer to the change log text box below for recent changes to this article:
6/25/2014 - Updated troubleshooting information for DTC 2058

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Description
This iKNow describes the unique service procedures and signals that apply to the post 2010
Bergstrom air conditioning system installed in ProStar and LoneStar vehicles.

HVAC Door Motor
If any of the following components are serviced, the HVAC door system needs to be calibrated:
•
•
•
•

Blend air control, mode air control, or temperature air control door actuators or doors
Any wiring that runs from the above listed HVAC door actuators to the HVAC control head
Any wiring to the HVAC control head
The HVAC control head

For resetting the system, the connector to the HVAC control head needs to be removed for a
minimum of 15 seconds with the key in the on position. Alternatively, the battery power from the
truck can be removed to accomplish the same thing, although this may interfere with driver
programmable settings. For more information refer to IK1900203 ­ Troubleshooting and Resetting
HVAC Doors

HVAC Control Head

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IK1900207 ­ 2010 and Later ProStar and LoneStar HVAC Diagnostic Information

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The HVAC control head performs 3 tasks. It provides the A/C request to the body controller from
the user, controls the operation of all the door actuators in the HVAC system based on knob
position, and sends a signal to the body controller for the status of the HVAC door actuators. The
body controller does not control any of the HVAC door positions. If the HVAC control head is
replaced with an incompatible part number, any of the following situations can result:
•
•
•
•

Door actuators working opposite of driver selected positions
Air conditioning inoperative
HVAC door actuators inoperative
Door actuator fault codes in the Body Controller

As a result, the correct part number should be verified using the parts catalog, and cross checked
to the old HVAC control head.

A/C Refrigerant and Oil
The HVAC system contains 40 OZ (2.5 LBS) for daycab models, and 48 OZ(3.0 LBS) for sleeper
cab models of R-134a refrigerant. The refrigerant should be purchased from Navistar parts to
ensure that a quality brand name refrigerant is used. Please see IK1900165 - R134a refrigerant
quality and concerns with some imported refrigerants for more details.
300 cc(10.14 OZ) of PAG 100 oil (PN ZGGR725028) is the lubricating oil installed in all post 2010
ProStar and LoneStar trucks A/C compressors.
Mineral oil (PN ZGGR6912) should be used as lubricating oil for assembly on all o-rings and
fittings.

Air Conditioning Compressor Operation
The following interlocks must be meet for the A/C compressor to transition states from off to on:
•
•
•
•
•
•

Ignition and Accessory voltage at body controller (Checkmarks at A1 and A16 at 1602 of B/C)
Air conditioning request from HVAC control head to B/C (Checkmark at 1600_A2)
Engine running signal (Engine_Running)
Engine speed above 300 RPM (Engine_Speed)
Low pressure input is grounded (Checkmark at 1600_B5)
Freeze Probe Thermistor input is ≥ 38° F ( HVAC_Freeze_Protect_Raw above 2.4976 volts
1600_B13)
• A/C high side pressure is greater that 35 psi, but less then 218 psi (AC_High_Side_PSI) Pressures may change due to programmable parameters. See table below.
• No HVAC fault codes active

HVAC Filter Maintenance
Remove the fresh air filter(s) once each season and check for dirt, lint, etc. Replace if necessary.
Vehicles operating in unusually dusty conditions may require inspecting and replacing the air filter
(s) more often. ProStar and LoneStar models have 3 air filters. 2 are recirculation filters that are
located on the inside of the cab. Those filters may be carefully power­washed with a soap solution
and reused. Be sure to wash and rinse both sides and be sure to keep the spray head at least six
inches away from the filter to prevent damage. The fresh air filter is located on the outside of the
cab.

HVAC Flushing Procedure

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IK1900207 ­ 2010 and Later ProStar and LoneStar HVAC Diagnostic Information

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A new air conditioning service tool has been developed to flush the air conditioning system after a
catastrophic A/C compressor failure. The tool is an essential dealer tool for all medium duty and
heavy duty dealers.
Tool Information
Flushing Instructions

DLB Session
Please download and import the attached DLB session for diagnosing electrical issues
ProStar_LoneStar_AC

Fault Codes
Signal

B/C
Pin

SPN

FMI

Description

Action

BC_RCD_Pressure_Raw_Signal

1600
-B12

2609

16

HVAC High
Pressure
Protection

HVAC Pressure Sensor
Reading Above 480 PSI

Switched_5V_Sense_Raw_Signal

1602
-E6

1079

1

5 volt sensor
supply below
normal

Short Circuit From
1602_E6 to 6201_C

9

HVAC Control
Head Circuit
Failed To
Communicate
With BC

Open Circuit From
1200_A9 to 1600_A2

HVAC Control
Head
Temperature
Mix DM1

HVAC Temperature
Door Stuck, Defective
Door Actuator, or Open/
Shorted Circuit
1200_B11 to Temp
Actuator Pin A, or
1200_B12 to Temp
Actuator Pin F

HVAC Control
Head Mode
Fault DM1

HVAC Mode Door
Stuck, Defective Door
Actuator, or
Open/Shorted Circuit
1200_B9 to Mode
Actuator A, or
1200_B10 to Mode
Actuator Pin F

HVAC Control
Head Air Inlet
DM1

HVAC Air Inlet Door
Stuck, Defective Door
Actuator, or
Open/Shorted Circuit
1200_B1 to 4202_A, or
1200_B2 to 4202_F

RCD_HVAC_Ctrl_Head_Diag_Signal

RCD_HVAC_Ctrl_Head_Diag_Signal

RCD_HVAC_Ctrl_Head_Diag_Signal

RCD_HVAC_Ctrl_Head_Diag_Signal

1600
-A3

1600
-A3

1600
-A3

1600
-A3

3985

1552

3981

3984

2

2

2

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IK1900207 ­ 2010 and Later ProStar and LoneStar HVAC Diagnostic Information

J1939BB_Rcv_61217_058_033_Timer

N/A

2058

9

Rear HVAC
Data Link
Communication
Failure

Page 4 of 9

Body Builder Datalink
Connecting Body
Controller circuit
failure, Rear HVAC
Controller Not Powered
Up or Defective.
1. Load Test Power
and Ground to Rear
HVAC Controller. At
Rear HVAC
Controller 5210
Connector Test Pin
3 to known good
ground should be
12V and test pin 3
to pin 4 should be
12V.
2. Check datalink
voltage and
resistance at the
Body Controller
connector 1602 with
a break out box on
pins F5 and F6.
3. You should have
approximately 5V
total when you add
the voltages from
each wire together.
If out of spec
unplug the rear
HVAC controller
and retest - If back
in spec replace the
rear HVAC
controller.
4. The CAN High
(Yellow) should
have a higher
voltage than the
CAN Low (Green).
5. The voltage on the
wires should not
match. If they do
you might have the
2 wires shorted
together.
6. Check the
resistance between
the 2 wires with key
off (it may be
necessary to
disconnect the
batteries to ensure
there is no voltage
on the datalink. You
should have
approximately 60
ohms with there

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IK1900207 ­ 2010 and Later ProStar and LoneStar HVAC Diagnostic Information

Page 5 of 9

being 2 120 ohm
resistors wired in
parallel on the
datalink. If you have
0 ohms indicating
low resistance you
have a short
between the 2
wires. If you get 120
ohms you have a
open somewhere in
the datalink or you
are missing one of
the resistors.
7. Check resistance
from pin F5 and F6
to Ground.
Resistance should
be greater than
1,000 ohms. If
resistance is less
than 1,000 ohms