IK1900198 Service Bulletin/Repair Instructions

IK1900198 - MaxxPower No Idle Battery-Powered A/C System Diagnostic Guide
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ID:
IK1900198
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Revision:
17
Major System:
ACCESSORIES
Created:
7/23/2012
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Modified:
7/31/2017
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Author:
Charles

Schroeder
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Title : MaxxPower No Idle Battery-Powered A/C System Diagnostic Guide

Applies To : Feature code 16UZL
Change Log

Please refer to the change log text box below for recent changes to this article:

07/31/2017 ‐ Made notes in Service Parts Information that the Cold Loop part number applies to ProStar and LoneStar only.

07/31/2017 ‐ Changed menu based on dealer feedback.

12/19/2016 ‐ Updated Diagnostic information section.

10/19/2015 ‐ Author updated for feedback purposes.

10/13/2015 ‐ Added the prerequisite of replacing the complete system replacement is Not Warrantable

10/01/2015 ‐ Updated formatting of SRT table.


Description

Safety Recall 14516 has been issued for units built prior to June 23, 2014.

•

•

•

•
To properly diagnose the system you must ensure the recall has been performed.

Only the "Cold Loop" sealed refrigerant core PN # 2614669C1 is to be replaced when the refrigerant circuit fails.

DO NOT REPLACE THE COMPLETE UNIT IF THE A/C IS NOT FUNCTIONING. Complete unit is not Warrantable

Refer to the BASIC TROUBLESHOOTING below prior to replacing any components. This will help you identify which component is at fault

or any electrical issues.

• Refer to PARTS INFORMATION to properly identify the parts that may require replacement

• The A/C portion of the system is listed below in the parts section.

• The 16UZL No‐Idle HVAC system is designed to disengage when the engine is started, and can be turned on with the key in any position.

This battery‐powered no idle HVAC system provides heating and cooling of the sleeper area without use of the vehicle engine.

• The system is comprised of the no idle HVAC components located in the sleeper HVAC module, a separate fuel operated coolant heater

mounted under the sleeper, and four additional batteries housed in a second battery box.

• The no idle HVAC system shares the air handling assembly and several major components with the truck's standard HVAC system.

• Most importantly, the shared evaporator core contains refrigerant circuits for both the no idle system and the truck's standard A/C

system.

• With this configuration, some procedures required to service the no idle A/C system will require opening the refrigerant circuit of the

truck's standard A/C system.

Trucks equipped with 16UZL No‐Idle HVAC system have two separate HVAC systems (Standard Truck A/C and the MaxxPower unit), it is

important to identify each clearly, so you are troubleshooting the correct system.
Per the Operators Manual page 10: Run the heater at least once a month during the year (for a minimum of 15 minutes).

TABLE OF CONTENTS
Use the menu bar at the top of the screen to navigate through the topics listed.

• Basic Troubleshooting

• Component Identification and Location
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IK1900198 - MaxxPower No Idle Battery-Powered A/C System Diagnostic Guide
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A: Compressor Fuse 60 Amp (Maxi)

B: System Controller Fuse 10 amp (Mini)

C: Blower Fuse 20 amp (Mini

D: Condenser Fan Fuse 20 amp (Mini)

E: Relays (Compressor, Condenser Fan, Blower)

F: Fan and Temperature Control Display

G: System Controller

H: Compressor Controller

I: Linear Power Module

J: Blend Door Actuator

K: Inlet Temperature Air Sensor

L: Discharge Temperature Sensor

M: Evaporator Blower

N: Condenser Fan

O: High Pressure Switch

P: Compressor

Q: Thermal Limit Switch – Compressor

R: Evaporator Inlet Filter

• Diagnostic Information ‐ Link to ProStar Technician Manual

• Circuit Diagrams

• Photos with Call Outs

• Parts Information ‐ with Cold Loop Identification

• Additional Resources

• SRT Information
Basic Troubleshooting

Prior to replacing any components, these basic electrical checks should be performed.

• System will not turn on.

• System starts and cools, but then stops cooling or shuts off.

• Verify proper power and ground is present at the system controller. (Load test the circuits with a headlamp). If the complaint is the

system stops cooling, verify you still have power and ground at 31 and 32 when the issue occurs (Figure 1)

• Verify 12 volt input to pin 6 from the Cool Switch (Figure 1)

• Verify ground control output from pin 3 to the 150A Relay and Condenser Fan Relay

If you have ground control from pin 3 to the relays and the system is still not operating properly, the system controller is not at fault. Continue

with further diagnostics.

Figure 1
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• Verify proper voltage at pin 30 (Figure 2) of the 150A Relay. (Load test the circuit with a headlamp).

◦ If you do not have proper voltage at this point, you need to check the truck wiring from the fuses in the battery box to the relay

terminal.

• Verify power on pin 1 and ground on pin 2 of the Relay Control. (Load test both circuits with a headlamp).

• Verify the relay engages and power is present on the output pin 87 of the 150A Relay to the Compressor Controller Circuit Board. (Figure

2)

Figure 2
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• The 150A fuse feeds power to the compressor controller circuit board (Figure 2)
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• Check the 4 pin connector between the fuse and the compressor controller circuit board, ensuring the terminals are fully seated and

locked. (Figure 4)

• Verify proper power terminal C1 of the compressor controller connector. (Load test the circuit with a headlamp). (Figure 3)

Figure 3
• Depending on the type of compressor controller, you will have one of the 2 style connectors on the compressor (Flag or Cluster Block).

• Check for 6 volts cycling on each of the three wires.

Figure 4
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( Return to Table of Contents )
Component Identification and Location

Navistar main system fuses in battery box:
Navistar main system fuses

• Location: Inside battery box

• These fuses are identified on the wiring diagram as F6 and F7
150A Relay for Units built June 23, 2014 or later

• This relay also applies to units that have had the power

harness upgrade ‐ Safety Recall 14516
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A: Compressor Fuse ‐ (No longer used)

• Removed with Safety Recall 14516.

B: System Controller Fuse 10 Amp (Mini)

A‐E: Fuses and Relays

• This fuse provides short circuit protection for the unit

controls.

• Location: On the control center

C: Blower Fuse 20 Amp (Mini)

• This fuse provides short circuit protection for the evaporator

blower.

• Location: On the control center

D: Condenser Fan Fuse 20 Amp (Mini)

• This fuse provides short circuit protection for the condenser

fan.

• Location: On the control center

E: Relays

• Location: On the control center

• Compressor Relay ‐ (No longer used)

◦ Removed with Safety Recall 14516.

• Condenser Fan Relay

◦ This relay controls the voltage to the condenser fan.

◦ (ENGINE OFF MODE)

• Blower Motor Relay

◦ This relay controls the voltage to the evaporator blower

◦ (ENGINE OFF and ENGINE ON MODE)
F: Switches / Fan and Temperature Control Display
F: Switches / Fan and Temperature Control Display:
• COOL / No Idle switch:

◦ Lights up and starts the MaxxPower A/C unit at default

settings in the parked mode.

• HEAT / No Idle switch:

◦ Lights up and starts the MaxxPower unit and auxiliary

coolant heater at default settings in the parked mode.

• LED Display:

◦ Allows for temperature and Blower speed adjustment of

the MaxxPower unit when operating in A/C or heat

mode.
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◦ Operates like standard Auxiliary HVAC when the engine

is running.

◦ MaxxPower A/C Unit and Auxiliary Coolant Heater ‐ stop

when, engine is started, unit is shut off or batteries are

depleted.
G: System Controller:
G: System Controller

• This device stores the operating program and controls the

MaxxPower unit.

• Location: Under the bunk, next to blend door motor, under

the grey 32 pin connector.
H: Compressor Controller:
H: Compressor Controller:

• This device controls the output voltage to the variable speed

compressor.

• Location: On the top / rear area under the plastic access

cover.
I: Linear Power Module:

I: Linear Power Module (LPM):

• This module controls the amount of voltage delivered to the

evaporator blower creating variable blower speeds.

• Location: On the blower wheel housing.
J: Blend Door Actuator:
J: Blend Door Actuator:
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• This actuator operates the blend door, changing air flow path

through the MaxxPower evaporator coil and heater core.

• Location: Under the bunk, near the blower motor.
K‐L: Inlet and Discharge Temperature Sensor:

K: Inlet Temperature Sensor:

• This sensor monitors the return air temperature in front of the

evaporator coil.

L: Discharge Temperature Sensor ‐ Freeze Switch:

• This sensor monitors the evaporator outlet temperature as it

enters the vehicle duct system.
M: Evaporator Blower:

M: Evaporator Blower:

• This blower pulls air through the evaporator coil or heater

core and blows conditioned air into the interior of the sleeper.

This blower operates with parked (no‐idle) and engine driven

systems.
N: Condenser Fan:
N: Condenser Fan:

• This blower draws air from outside the truck, through a

section of the louvered door on the passenger side and pushes

it through the condenser coil to cool the refrigerant flowing

through the system. The hot air is exhausted out the same

louver panel on the passenger side of the truck.
O:High Pressure Switch:
O: High Pressure Switch:
• This brazed pressure switch will open and prevent the

operation of the compressor due to high internal pressure. It

is NOT serviceable.
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P: Compressor:
P: Compressor

• This unit is part of the hermetically sealed refrigeration

system.
Q: Thermal Limit Switch on Compressor:
Q: Thermal Limit Switch on Compressor:

• This is a normally closed (auto reset) switch to protect the

compressor from high temperature.
R: Evaporator Inlet Filter:

• This filter protects the evaporator coil from dust and debris.

• It needs to be inspected and serviced periodically during

routine maintenance.
( Return to Table of Contents )
Diagnostic Information

Please refer to the 2010‐2016 ProStar Technician Manual (0000863170) for step based diagnostics:

( Return to Table of Contents )
Circuit Diagrams
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The Bergstrom No‐Idle HVAC System uses a Bergstrom harness that connects to the OEM harness.

• The wiring schematic books will only show the OEM wiring.

• The PDFs below will outline the OEM wiring and show all the Bergstrom wiring.

• The wiring shown as "A/C UNIT" is where the OEM and Bergstrom harnesses meet.

Also note the OEM wiring has standard sleeper HVAC wiring and all other sleeper wiring configurations. Take time to ensure you're looking at

the correct schematic for this system. In the most current schematic book "0000002122" the No‐Idle system wiring starts on Ch 12 Pg 15.

• Discharge Sensor / Air inlet sensor temp chart CLICK HERE

• Service Portal Master Service Information CLICK HERE

Circuit Diagrams vary based on the build date of the unit

◦ For units that have had Safety Recall 14516 performed, refer to the schematic "06/23/2014 and newer"

MaxxPower No‐Idle System Circuit Diagram (PDF)

Prior to 11/11/2013

CLICK HERE

MaxxPower No‐Idle System Circuit Diagram (PDF)

11/11/2013 to 06/23/2014 CLICK HERE

MaxxPower No‐Idle System Circuit Diagram (PDF)

06/23/2014 and newer

CLICK HERE

( Return to Table of Contents )
Photos with Call Outs

Figure 5
Figure 6
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( Return to Table of Contents )
Service Part(s) Information

Part #
Description
Qty.
2614669C1
Sealed Ref System 12V, Cold Loop *See Note Below* This Cold Loop will only work for ProStar and LoneStar
1
3685807C1
Condenser Fan
1
3695241C1
Temp Sensor
2
4060729C1
System Controller (Under the Grey 32 Pin Connector)
1
2517316C1
Compressor Controller (Circuit Board) with Cluster Block Connector (Blue 32 Pin Connector) *See Figure 7 Below*
1
2602024C92
Compressor Controller (Circuit Board) with Flag Connectors (Blue 32 Pin Connector) *See Figure 7 Below*
1
2602548C91
Blend Door (The physical door)
1
3685800C1
Blend Door Actuator
1
3693481C1
LPM
1
2602545C91
Kit, Bunk Blower Motor with Scroll Assembly
1
3685805C1
Evaporator Inlet Filter (Blue)
1
REPLACMENT OF NEW REFRIGERANT LOOP 2614669C1 MAY ALSO REQUIRE THE REPLACMENT OF THE NEW COMPRESSOR CONTROLLER WITH

CLUSTER BLOCK CONNECTOR 4047671C91 AS WELL.
Replacing the Cold Loop
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The Bergstrom Maxx‐Power air conditioning system has a cold loop replacement housing used to replace the non‐serviceable air conditioning

components. If the system has lost its refrigerant, if there is a compressor failure, or damage to the evaporator, condenser, or refrigerant lines,

the cold loop will need to be replaced.

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