IK1900198 - MaxxPower No Idle Battery-Powered A/C System Diagnostic Guide.

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Countries:

UNITED STATES

Availability:

ISIS, Bus ISIS, FleetISIS Revision :

Document ID: IK1900198

Major System:

ACCESSORIES

5

Created:

7/23/2012

Current Language: English

Last Modified: 3/6/2013

Other Languages: NONE

Author:

Viewed:

Will (Mark) Wiley

1899
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Title: MaxxPower No Idle Battery-Powered A/C System Diagnostic Guide.
Applies To: Feature code 16UZL

DESCRIPTION
Diagnostic guide for the MaxxPower A/C system.




For the A/C side, only a few electrical components can be replaced.
 DO NOT REPLACE THE COMPLETE UNIT IF THE A/C IS NOT FUNTIONING.
 The A/C portion of the system is listed below in the parts section. .
The 16 UZL system is designed to disengage when the engine is started, and can be turned on with the key on in any position.

Per the Operators Manual page 10: Run the heater at least once a month during the year (for a minimum of 15 minutes).

PARTS INFORMATION
Part #
2614669C1

Description

Qty.

Sealed Ref System 12V (See Note below.)

1

3685807C1
3695241C1
3685810C1
2614670C1
3685818C1
3693481C1
3688223C1

Condenser Fan
Temp Sensor
System Controller
Compressor Controller (Circuit Board)
Blend Door
LPM
Bunk Blower Motor

1
2
1
1
1
1
1

REPLACMENT OF NEW REFRIGERANT LOOP 2614669C1 WILL ALSO REQUIRE THE REPLACMENT OF THE NEW CLUSTER BLOCK 2614670C1 AS WELL.

Table of Contents

Appendix

Component Identification and Location
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

A: Batteries
B: LED Control Display Testing
C: Relay Testing
D: Pressure Switch Testing
E: Fuses
F: Discharge Temperature Sensor/Freeze Switch Testing
G: Inlet Temperature Sensor
H: Blend Door Actuator
I: Compressor Thermal Limit Switch
J: System Controller
K: Compressor Controller
L: Condenser Fan Testing
M: Evaporator Blower/Linear Power Module Testing
N: Compressor Rubber Mount
O: Discharge Sensor and Air Inlet Sensor Chart
P: Navistar Fault Codes Chart
Q: Pin out Chart
R: MaxxPower Unit Wiring Diagrams

Diagnostics Table

Component Identification and Location
Navistar main system fuses in battery box:

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Navistar main system fuses




Location: Inside battery
box
These fuses are identified on the wiring diagram as F6 and F7

A: Compressor Fuse 60 Amp (Maxi)



This fuse provides short circuit protection for the compressor.
Location: On the control center
A-E: Fuses and Relays:

B: System Controller Fuse 10 Amp (Mini)



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
 This relay controls the voltage to the compressor controller.
 (ENGINE OFF MODE)
Condenser Fan Relay
 This relay controls the voltage to the condenser fan.
 (ENGINE OFF MODE)
Blower Relay
 This relay controls the voltage to the evaporator blower.
 (ENGINE OFF and ENGINE ON MODE)

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:




F: Switches / Fan and Temperature Control Display:

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.
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

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shut off or batteries are depleted.

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.

G: System 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.

H: Compressor Controller:

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:




I: Linear Power Module:

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.

J: Blend Door Actuator:
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.

K-L: Inlet and Discharge Temperature Sensor:

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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 (noidle) and engine driven systems.

M: Evaporator Blower:
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.

N: Condenser Fan:

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.

O: High Pressure Switch:
P: Compressor


This unit is part of the hermetically sealed refrigeration system.

P: 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 should be inspected and serviced periodically during routine maintenance.

Q: Thermal Limit Switch on Compressor:

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Diagnostics Table
Problem

Possible Cause
1.
2.
3.
4.

Test with Engine OFF

5.

Unit Will Not Run or Turn ON

6.
7.
8.
9.

Loose Connection
No power is available at
the unit
Blown fuse or fuses
Check Voltage path to
controller and switches
Defective Switch on
Control panel
System Controller
Defective
Park brake switch
defective or wrong logics
Broken wire or defective
wire harness
Check for Fault code

Corrective Action / See Appendix
1.
2.
3.
4.

5.
6.
7.
8.
9.

1.
1.
2.
3.

Unit Runs- But Does Not
Blow Cold Air

4.
5.
6.

7.
8.
9.
10.

Unit Cycles On and Off

Unit Blows Cold Air, But Low
Airflow

Unit Runs Correctly, But
Less Than Expected Run
Time

Unit is Noisy or Vibrates

Airflow blockage
Compressor Fuse or Relay
Compressor Controller