IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Page 1 of 11

Countries:

AUSTRALIA, CANADA, UNITED
STATES, MEXICO, NEW ZEALAND

Document
ID:

IK1600210

Availability:

ISIS, FleetISIS

Revision:

4

Major System: CAB / SLEEPER / HOOD

Created:

9/15/2014

Current
Language:

English

Last
Modified:

10/16/2014

Other
Languages:

NONE

Author:

Kevin
Kochanek

Viewed:

341
Less Info

Coding Information

Hide Details

Copy Link

Copy Relative Link

Bookmark

Add to Favorites

Print

Provide Feedback

Helpful

Not Helpful

2

0

View My Bookmarks

Title : MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade
Applies To : ProStar+ Sleeper Cabs LoneStar

CHANGE LOG
Dealers: Please refer to the change log text box below for recent changes to this article:
9/19/2014 - Initial Article Release
10/10/2014 - Parts Available External Release
10/15/2014 - Added SRT number
10/16/2014 - Added SRT for LoneStar and ProStar




DESCRIPTION
This document will guide the user through updating the No Idle HVAC Wiring, on certain ProStar® vehicles, Feature Code
16UZL built before 23 June 2014. Vehicles with this feature code may experience an inoperable HVAC or a continuous failure of
the main fuse. In addition, inspection may reveal failed wiring.

SYMPTOM(s)
Inoperable HVAC, continuous failure of main fuse, or failed wiring.

DTC/Light
Not Applicable

Description

SPECIAL TOOL(s) / SOFTWARE
Tool Description
Tool, Pin Removal

Tool Number
12094430

Comments
Part of ZTSE 4443

Instructions

Tools Resource Center

SERVICE PARTS INFORMATION

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Kit Description

Part Number

Cable, Battery

See Battery Cable Matrix Below

Strap, Tie

Obtain Locally

Kit, Relay Assembly
Field

2513547C91

Page 2 of 11

Quantity Required Notes
1
As Required
1

See Table Below

Kit 2513547C91 contents:
Description

Part Number

Quantity Required

Decal

1

Screw, #10 x 1/2 Self
Tapping

2

Relay, High Current
(150A Relay)

1

Bracket, Relay

1

Gasket, Bracket Relay

1

Strap, Tie with Fir Tree

8

Screw

2

Nut, M6

2

Harness, Power

1

Harness, Relay Control

1

Notes

Battery Cable Matrix

Description

Part Number

OEM Part
Number

Battery Box and Fuel
Quantity
Tank Feature Code
Required
Without SCR

Cable, Battery,
Bergstrom No Idle Short 4047811C91 3838192C91
Sleeper

1

Cable, Battery,
Bergstrom No Idle Long 4047810C91 3838206C92
Sleeper

1

Harness, Bergstrom No
4051667C91 3712820C91
Idle Long Slpr, Vert Exh

1

Cable, Battery,
Bergstrom No Idle,
6470MM
Cable, Battery,
Bergstrom No Idle,
5710MM

4051668C91 3878461C91

1

4051669C91 3847380C92

1

0008WRN, 0508062, or
0008TSN with 0016AUM or
0016AUS without 0015DPY
0008WRN, 0508062,
0008TSN, or 0008WRV
with 0016AUN or 0016AUP
without 0015DPY
0008WRN, 0508062,
0008TSN, or 000WRV with
0016AUN or 0016AUP with
0015DPL
0008WJN or 0008WZV with
0016AUM or 0016AUS with
F­Dual­BOC­Tank
0008WJN or 0008WZV with
0016AUN or 0016AUP with
F­Dual­BOC­Tank

4051670C91 3712850C91

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Harness, Bergstrom No
Idle Long Slpr, Vert Exh
Cable, Battery,
Bergstrom No Idle

4051671C91 3838548C91

1

0008WRN, 050862, or
0008TSN with 0016AUN or
0016AUP with 0015DPY

1

0008WRN with LF51700

Page 3 of 11

Battery Box and Fuel
Tank Feature Code With
SCR
Cable, Battery,
Bergstrom No Idle

4051671C91 3838548C91

1

0008XGG or 0008XGS with
0015DVX or 0015DVZ

DIAGNOSTIC STEP(s)
Not Applicable

REPAIR STEP(s)

To prevent property damage, personal injury, and / or death, read all safety instructions in
the “Safety Information” section of the Service Manual or Diagnostic Manual.

To prevent property damage, personal injury, and / or death, park vehicle on a hard, flat
surface, turn engine off, set parking brake, and install wheel chocks to prevent vehicle
from moving in either direction.

To prevent personal injury and /or death, make sure the engine has cooled before
removing components

To prevent property damage, personal injury, and /or death, remove ground cable from
negative terminal of main battery before disconnecting or connecting electrical
components. Always connect ground cable last.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Page 4 of 11

To prevent personal injury and /or death, always wear safe eye protection when
performing vehicle maintenance.

REMOVAL PROCEDURE:

Before starting upgrade, verify system operation. Vehicle must be temperature acclimated to above 60°F (15.5°C) for
A/C system check.
1. Bring vehicle into shop and park on flat surface.
2. Shift transmission to Park or Neutral, set parking brake, and install wheel chocks.
3. Open battery box and disconnect negative battery cables, MaxxPower harness, and 50 amp power fuse from batteries.
4. Cut and remove tie straps from MaxxPower harness. Discard tie straps.
5. Open sleeper compartment.

Figure 1: Control Center Harness.
Item 1: Control center
Item 2: Control center harness 4-pin connector
6. Disconnect battery cable 4-pin connector (Figure 1, Item 2) from harness connector near control center (Figure 1, Item 1).
7. Remove battery cable from vehicle. Discard battery cable.

Figure 2: Top Support Bracket.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Page 5 of 11

Item 1: Screw (4)
Item 2: Top support bracket
8. Remove four screws (Figure 2, Item 1) and top support bracket (Figure 2, Item 2) from vehicle.

Figure 3: Power Center Cover.
Item 1: Power center cover
Item 2: Power center
Item 3: Screw
9. Remove screw (Figure 3, Item 3) and cover (Figure 3, Item 1) from power center (Figure 3, Item 2).

Figure 4: 70 Amp Relay and 60 Amp Compressor Fuse.
Item 1: 70 amp relay
Item 2: 60 amp compressor fuse
Item 3: Control center
10. Remove 70 amp relay (Figure 4, Item 1) and 60 amp compressor fuse (Figure 4, Item 2) from control center (Figure 4, Item
3). Discard relay and fuse.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Page 6 of 11

Figure 5: Control Center and End Section.
Item 1: End section
Item 2: Screw
Item 3: Support bracket
Item 4: Control center
11. Remove screw (Figure 5, Item 2) from control center (Figure 5, Item 4) and slide control center off support bracket (Figure 5,
Item 3).
12. Remove red locking clip and release end section (Figure 5, Item 1) from control center (Figure 5, Item 4).

The yellow tabs will unlock the two control wires.
13. Using pin removal tool, push Yellow pins down in removed end section.
14. Using pin removal tool, unpin and release two control terminals from removed end section.

There are two small locking tabs on Green wires.
15. Pull two green wires out of relay control circuit of removed end section.
16. Inspect terminals and verify locking tabs are not damaged.

Figure 6: Control Center Assembly Harness.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Page 7 of 11

Item 1: Wire (3) (two not shown)
Item 2: Control center assembly harness

Do not cut previously removed Green wires.
17. Cut and discard remaining 3 wires (Figure 6, Item 1) from control center assembly harness (Figure 6, Item 2).
18. Cut and discard control center assembly harness 4­pin connector at breakaway.

Figure 7: Control Center Assembly Harness 4-Pin Connector.
Item 1: Compressor controller harness 4­pin connector
Item 2: Control center assembly harness 4­pin connector
19. Disconnect control center assembly harness 4-pin connector (Figure 7, Item 2) from compressor controller harness 4-pin
connector (Figure 7, Item 1).
20. Cut and discard control center assembly harness 4-pin connector (Figure 7, Item 2) at breakaway.

Figure 8: Control Center Assembly Harness 32-Pin Connector.
Item 1: Control center assembly harness 32-pin connector
Item 2: Compressor controller
21. Disconnect control center assembly harness 32-pin connector (Figure 8, Item 1) from compressor controller (Figure 8, Item
2).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Page 8 of 11

Figure 9: Wire Removal Control Center Assembly Harness 32Pin Connector.
22. Cut and remove approximately 1 in of wire as shown in Figure 9.
23. Connect control center assembly harness 32-pin connector (Figure 8, Item 1) to compressor controller (Figure 8, Item 2).
24. Remove Blue terminal lock from new 2­pin connector.
25. Install two Green wire terminals into 2-pin connector until they click into place.
26. Install Blue terminal lock into 2-pin connector.
27. Install control center (Figure 5, Item 4) on support bracket (Figure 5, Item 3) with screw (Figure 5, Item 2).
28. Install new fuse decal onto control center cover.
29. Install cover (Figure 3, Item 1) on power center (Figure 3, Item 2) with screw (Figure 3, Item 3).

Figure 10: Relay Control Harness 2-Pin Connector.
Item 1: Relay control harness 2­pin connector
Item 2: Control center assembly harness 2-pin connector
30. Connect new relay control harness 2-pin connector (Figure 10, Item 1) to control center assembly harness 2-pin connector
(Figure 10, Item 2).
31. Route relay control harness through center of MaxxPower unit to HEATER COIL.
32. Install top support bracket (Figure 2, Item 2) in vehicle with four screws (Figure 2, Item 1).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Page 9 of 11

Figure 11: Relay Assembly.
Item 1: Relay assembly
Item 2: HEATER COIL area
Item 3: Screw (2)
33. Install new relay assembly (Figure 11, Item 1) behind area marked HEATER COIL (Figure 11, Item 2) with two new screws
(Figure 11, Item 3).
34. Using torque wrench, tighten two screws (Figure 11, Item 3) to 20 lb-in (2 N•m).

Figure 12: Battery Cable 4-Pin Connector.
Item 1: Battery cable 4­pin connector
Item 2: Compressor controller harness 4-pin connector
35. Connect new battery cable 4-pin connector (Figure 12, Item 1) to compressor controller harness 4-pin connector (Figure 12,
Item 2).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Page 10 of 11

Figure 13: Relay Assembly Harness Connections.
Item 1: Nut (2)
Item 2: Black wire ring terminal
Item 3: Red wire ring terminal
Item 4: Relay control harness connector
Item 5: Relay assembly
Item 6: Ground side of power harness
Item 7. Ground cable connector and fir tree
36. Install Black wire ring terminal of power harness (Figure 13, Item 2) on left post of relay assembly (Figure 13, Item 5) with
new nut (Figure 13, Item 1).
37. Using torque wrench, tighten nut (Figure 13, Item 1) to 41 lb-in (5 N•m).
38. Route ground cable connector (Figure 13, Item 7) around relay assembly (Figure 13, Item 5), secure into relay assembly,
and push fir tree into relay assembly.
39. Route new battery cable through hole in floor to battery box.
40. Install Red wire ring terminal of power harness (Figure 13, Item 3) onto middle post of relay assembly (Figure 13, Item 5)
with new nut (Figure 13, Item 1).
41. Using torque wrench, tighten nut (Figure 13, Item 1) to 41 lb-in (5 N•m).
42. Connect ground side of power harness (Figure 13, Item 6) to ground cable connector (Figure 13, Item 7).
43. Connect relay control harness connector (Figure 13, Item 4) to relay assembly (Figure 13, Item 5).
44. Install 50 amp power fuse, Navistar unit harness, and negative battery cables to batteries.
45. Install tie straps as required.
46. Close battery box.
47. Close sleeper compartment.
FUNCTIONAL CHECK:

Checking compressor amperage will be the best test to prove status depending on ambient temperature.

If unit or compressor does not start, check at fuse for power and verify connection.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014

IK1600210 ­ MaxxPower (0016UZL) Compressor Relay and Power Harness Upgrade

Page 11 of 11

1. Start engine and allow vehicle temperature to acclimate to 60°F (16°C) for A/C system check.
2. Remove wheel chocks.

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 19030- Aux No Idle HVAC
Noun:

638- Electric HVAC Module

Standard Repair Time(s):
Step Description

Chassis

Engine

SRT

Hours

All
All

ProStar
LoneStar

11 and 13L
11 and 13L

S20­1002A
S19­1002A

1.0 hr
1.0 hr

Upgrade MaxxPower Harness
Upgrade MaxxPower Harness

Claim SRT Example:
Not Applicable
Claim Comment Suggestion:
Not Applicable
Special Requirement(s):
Not Applicable

OTHER RESOURCES
Master Service Information Site

Hide Details

Feedback Information
Viewed:

340

Helpful:

2

Not Helpful: 0
No Feedback Found

Copyright © 2014 Navistar, Inc.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlI...

11/3/2014