IK1900207 ­ 2010 and Later ProStar and LoneStar HVAC Diagnostic Information

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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

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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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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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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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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