NHTSA ID Number: 10130981
Manufacturer Communication Number: IK1900207
TSB/Document Date: 2018-04-02
Summary
HVAC Diagnostic Information
IK1900207 2010 and Later ProStar and LoneStar HVAC Diagnostic Information
Page 1 of 10
Countries:
CANADA, COLOMBIA,
UNITED STATES, PUERTO
RICO
Document
ID:
IK1900207
Availability:
ISIS, FleetISIS, Body Builder
Revision:
6
Major System: ACCESSORIES
Created:
5/2/2013
Current
Language:
English
Last
Modified:
10/30/2014
Other
Languages:
NONE
Author:
Matthew
Boyer
Viewed:
16552
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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:
7/8/2014 - Updated troubleshooting information for DTC 2058
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_A3
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
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
2
3981
2
3984
2
HVAC Control
Head Air Inlet
DM1
HVAC Air Inlet Door
Stuck, Defective
Door Actuator, or
Open/Shorted
Circuit 1200_B1 to
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IK1900207 2010 and Later ProStar and LoneStar HVAC Diagnostic Information
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4202_A, or 1200_B2
to 4202_F
J1939BB_Rcv_61217_058_033_Timer
N/A
2058
9/14
Rear HVAC Data
Link
Communication
Failure
Body Builder J1939
Datalink: Loss of
Communication
between the Body
Controller and Rear
HVAC Controller.
Likely causes of
failure:
• Rear HVAC
Controls not
powered up or
defective.
• Body
Controller
Datalink
interface is
defective.
• Open J1939
Body Datalink.
• Datalink
shorted to
ground or
shorted
together.
• Datalink leads
miss pinned or
terminal pin
backed out.
Note: Ignition key
must be ON for
datalink voltage
tests.
1. Load test power
and ground
connections to
the Rear HVAC
Controller. At
connector 5210
perform a
continuity test
between Pin 4
and a known
good ground.
Pin 4 should be
grounded with
less than 1 ohm
resistance.
2. Turn ignition
switch to the ON
position (do not
start engine) at
connector 5210
check pin 3
which should be
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IK1900207 2010 and Later ProStar and LoneStar HVAC Diagnostic Information
Page 5 of 10
equal to current
battery voltage
(approx. 12
volts). If voltage
is missing
troubleshoot
loss of HVAC
power source
(supplied by
sleeper relay
5001).
3. Check J1939
body datalink
voltage at the
Rear HVAC
controller
harness
connector 5210
pins 15 and 16.
Ignition switch
must be ON.
Mesaure DC
voltage at pin 15
(J1939+)
voltage should
be approx. 2.6
volts. Measure
DC voltage at
pin 16 (J1939-)
voltage should
be approx. 2.3
volts. Each
voltage may
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TSB/Document ID: IK1900207
Replacement Service Bulletin Number:
MFR Communication Date: 2014-10-30
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:APPLIANCE:AIR CONDITIONER
MFR Component System:
MFR Component Subsystem:
Previous TSB | Next TSB |
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