Paccar SM001-300, Service Manual

Page 1: ...liar with the working components of the Kenworth Idle Management System and the proper steps and procedures to completely diagnose the Kenworth Idle Management System unit 2016 PACCAR Corporation Confidentiality Notice This document and the information contained herein is proprietary It shall not be reproduced copied or disclosed in whole or in part or used for manufacture without the written perm...

Page 2: ...emperature Sensor Freeze Switch 10 G Evaporator Blower 10 H Condenser Fan 10 I Battery Management System BMS 10 J Battery Separator 10 INTERNAL COMPONENTS 12 A High Pressure Switch 12 B Compressor 12 C Thermal Limit Switch on Compressor 12 D Evaporator Inlet Filter 12 A C System Diagnostic 13 ESPAR Heating System Diagnostic Table 16 Appendix 18 A Battery Condition and Performance 18 B Fan and Temp...

Page 3: ...sting 20 K Compressor Rubber Mounts 20 L Testing the Battery Management System BMS 21 M Can Bus 22 N Testing the Espar Heater Connected to the EHVAC Digital Controller 22 O Connecting the System 23 P Evacuating the System 24 Q Charging the Kenworth EHVAC System 25 Service Instructions for Ring Terminal Controller and Compressor 33 Operation 37 ...

Page 4: ...sconnect Solenoid located in the battery box 11 Figure 11 High Pressure Switch 12 Figure 12 Compressor 12 Figure 13 Thermal Limit Switch on Compressor 12 Figure 14 Evaporator Inlet Filter 12 Figure 15 Relay Testing 18 Figure 16 Service Equipment 23 Figure 17 Service Recovery Connections 24 Figure 18 Internal Wiring Diagram Before 8 1 2016 28 Figure 19 External Wiring Diagram 29 Figure 20 Wiring Di...

Page 5: ...and oil manufacturers If accidental system discharge occurs ventilate work area before resuming service CAUTION The air conditioning system uses HFC134a R134a refrigerant and polyvinyl ether PVE refrigerant oil which are not compatible with CFC 12 R12 refrigerant mineral oil or PAG oil If the refrigerants or oils are mixed the com pressor may fail Do not attempt to use R 12 servicing equipment dam...

Page 6: ...battery negative cable from both battery boxes and dis charge any capacitors Disconnect the air starting motor if equipped to pre vent accidental engine starting Put a DO NOT OPERATE tag in the operator s compartment or on the controls Allow the engine to cool before beginning any repair Always use blocks or proper stands to support the vehicle or vehicle components before performing any service w...

Page 7: ...s heavier than air and can accumulate near the floor in sumps and low lying areas Close the manual fuel valves prior to performing maintenance and repairs and when storing the vehi cle inside California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm DO NOT breathe A C refrigera...

Page 8: ...es and Relays Units built 8 1 2016 to Present F1 Fuse 10 Amp Mini This fuse provides short circuit protection for the System control NOTE Removing fuse F1 for 10 15 seconds will reset the sys tem controller to factory default settings Location on the control center F2 Fuse 10 Amp Mini This fuse provides short circuit protection for the con denser fan ...

Page 9: ...tage to the compressor controller C Fan and Temperature Control Display LED Display Allows for temperature and Blower speed adjustment of the EHVAC Electrical Heating and Ventilation Air Condi tioning unit when operating in Auto cool or heat mode A C Unit stops when unit is shut off or batteries are depleted Figure 3 Fan and Temperature Control Display Auxiliary heater will shut down when batterie...

Page 10: ...em Figure 7 Evaporator Blower and Condenser Fan I Battery Management System BMS This device monitors the auxiliary batteries for state of charge communicates with the EHVAC system and con trols the battery separator solenoid LED light on this device indicates power to the device and does not pro vide diagnostics Power inputs to this device are fuse protected If one of the BMS fuses blows the solen...

Page 11: ...agement System Automated Battery Disconnect Option This device disconnects the EHVAC batteries from the EHVAC unit when the cab disconnect switch is set to OFF The cab disconnect switch must be set to ON for the EHVAC unit to operate Figure 10 Automated Battery Disconnect Solenoid located in the battery box ...

Page 12: ...12 Compressor C Thermal Limit Switch on Compressor This is a normally closed auto reset switch to protect the compressor from high temperature Figure 13 Thermal Limit Switch on Compressor D Evaporator Inlet Filter This filter protects the evaporator coil from dust and debris It is washable and should be serviced periodically during routine maintenance Figure 14 Evaporator Inlet Filter When necessa...

Page 13: ...oid Unit has a low volt age disconnect of 11 2 volts 3 Check all fuses See Figure 18 Internal Wiring Diagram Before 8 1 2016 on page 28 and Figure 19 External Wiring Diagram on page 29 4 Check for 12 volt through the 100 amp main fuse and F1 10 amp control fuse to controller pin C1 Also see H Main Controller Compressor Controller on page 19 5 Check control See B Fan and Temperature Control Display...

Page 14: ...m pressor Thermal Limit Switch on page 19 7 Check evaporator blower and linear power module See J Evaporator Blower Motor and Linear Power Module Testing on page 20 8 If all tests check OK a loss of refrigerant charge may have occurred Unit cycles On and Off and doesn t cool 1 Poor electrical con nection 2 Condenser fan inop erative 3 Air flow blockage causing high pres sure or freeze condi tion 1...

Page 15: ...uld signal compressor or internal com ponent issue Amperage ranges 40 to 75 depending on settings and conditions 4 Check battery management device harness and sep arator 5 Same as 4 Unit is noisy or vibrates 1 Evaporator Blower motor 2 Condenser fan motor 3 Compressor mount ing 4 Compressor internal 1 Check evaporator blower See J Evaporator Blower Motor and Linear Power Module Testing on page 20 ...

Page 16: ... wires and battery cables 2 Check Aux batteries for Voltage Check for heater enable signal from EHVAC unit Heater unit has a low voltage disconnect of 10 6 volts See N Testing the Espar Heater Connected to the EHVAC Digital Con troller on page 22 3 Check 20 amp main fuse and 5 amp control fuse See Espar manual 4 Check harness 5 Check control See N Testing the Espar Heater Con nected to the EHVAC D...

Page 17: ...le Management System Heater blows cold air but no heat 1 Fuel 2 Fuel pump 3 Connections 4 Glow pin screen 5 Sensors See Espar Manual Table 2 ESPAR Heating System Diagnostic Table PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Appendix on page 18 ...

Page 18: ...u turn the EHVAC unit on if all safety switches are okay such as the high pressure switch temperature sensor freeze switch and the compressor thermal limit switch the Main Compressor controller will connect the compressor relay condenser fan relay and the evapora tor blower relay terminals 86 to ground at their respective terminals D10 D11 and D12 at the controller This will close the contacts 30 ...

Page 19: ...mation on Service Instructions for Ring Terminal Controller and Compressor on page 33 You must remove the cover Do not attempt to test the controller or compressor until you have completely eliminated all other possibilities Overview When you turn the Kenworth EHVAC unit on if all safe ties are okay such as the high pressure switch tempera ture sensor freeze switch and the compressor thermal limit...

Page 20: ...oltage will vary depending on requested speed approximately 1 6 for low 2 6 for high If all voltages are correct and the fan does not run it is defective and needs to be replaced Using a DC ammeter you can check the amperage draw of the blower Normal amps approximately 5 10 depend ing on speed requests CAUTION If attempting to connect blower to an outside power source internal electronic component...

Page 21: ...e wiring harness With aux voltage okay LED flashing and 12 volts across pins 8 and 1 start the truck or connect the start batteries to a battery charger and bring the voltage above 13 2 for at least 15 seconds You should hear a click when the solenoid pulls in This would indicate that the BMS has sent the engage signal from pin 5 orange wire of the BMS to pin 2 on the Terra Power separator pin 1 i...

Page 22: ...ness still connected to control and unit back probe harness You should measure 120 ohms Reconnect the harness to the BMS With all harnesses connected you should measure 60 ohms N Testing the Espar Heater Connected to the EHVAC Digital Controller The Espar heater control harness connects to the EHVAC unit using a 6 pin connector Pin 1 is heater option This is a 12 volt input from the Espar heater t...

Page 23: ... replace unit 3 recover holding charge 4 evacuate leak test 5 recharge proper refrigerant level WARNING Before doing any of the work below be aware of the dangers involved Working with refrigerant could lead to serious personal injury CAUTION The Kenworth EHVAC uses PVE lubricant in the refrig erant system PVE oils absorb atmospheric moisture very quickly Never leave PVE oil exposed to air for a p...

Page 24: ...lly counterclockwise CCW 2 Connect the electronic vacuum gauge to the recov ery station at the vacuum manifold using a valve and T fittings 3 Connect the recovery stations blue hose to the ser vice port located on the Kenworth EHVAC system 4 On the blue hose open the valves on the quick dis connect fittings turn the knobs fully CW 5 On the recovery station set both hand valves to the RECOVERY VACU...

Page 25: ... may enter the system and cause compressor damage NOTE Although your service equipment may appear physi cally different from the equipment shown here the function of the equipment used to perform each service procedure is basically the same If you are performing these service procedures using service equipment dif ferent from that shown refer to the manufacturer s instructions supplied with that e...

Page 26: ...th the specified amount of refrigerant 2 On the recovery station set the high side valve to CLOSED and the low side valve to CHARGE 3 Press the CHARGE button to start the charge proce dure When the system is fully charged the recovery station will turn off 4 Complete the charging procedure by setting both hand valves on the recovery station to the CLOSED position 5 Close valve on hose at condenser...

Page 27: ...Table 4 Discharge Sensor Freeze Switch Testing Chart Page 27 of 39 Number SM001 300 HVAC Idle Management System ...

Page 28: ...I T E GND BLACK COND SIG WHI T E HEATER CONDENSER FAN 12 VOLTS RED CANH YELLOW CANL GREEN HEATER_OPTION RED VEHICLE ACCESSORY INPUT WHI T E IGNITION INPUT WHI T E 12_VOLTS_COMP RED ACCESSORY INPUT WHI T E IGNITION INPUT WHI T E HEATER_OPTION RED R3 100A 12V W RESISTOR RELAY 30 87 85 86 DELPHI 12052623 A B C D F2 10 AMP MINI CONDENSER 6 35 MM BLADE t EVAP SENSOR YAZAKI 7283 6458 40 1 2 AMP 929505 2...

Page 29: ... HOLE WIRE GAUGE 2AWG WIRE GAUGE 2AWG WEBASTO FUEL OPERATED HEATER GROUND BROWN WHITE ESPAR FUEL OPERATED GROUND HEATER GROUND WHITE HEATER_OPTION RED ESPAR OPTION HEATER_EN BLACK HEATER_LVL BLUE HEATER_EN YELLOW HEATER_LVL GRAY RED STRIPE WEBASTO OPTION TRUCK BATTERY FUSE A B FUSE AUX BATTERY 1 2 3 4 5 6 AMP 929504 2 1 2 3 4 5 6 5A FUSE 100A FUSE DEUTSCH DT06 4S 1 2 3 4 1 2 3 4 5 6 7 8 DEUTSCH SR...

Page 30: ... SPLICE_SENSOR GND BLWR FUSED BLWR RLY SIG BLWR RLY SIG 12 VOLTS 12 VOLTS 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 A A B B C C D D E E F F THE INFORMATION HEREON IS CONFIDENTIAL AND PROPRIETARY PROPERTY OF BERGSTROM INC AND OR ITS SUBSIDIARIES ANY USE EXCEPT THAT FOR WHICH IT MAY BE LOANED IS PROHIBITED REDDY SUDHAKAR REDDY SUDHAKAR 19AUG2015 19AUG2015 N A N A N A N A IN WORK US A2 1 1001120451 1 1 SCH PHO...

Page 31: ...te PWM ground switched output to control condenser fan speed 0V fan off 1 6 2 6V cooling mode Condenser fan 3 way connector C8 C9 C10 C11 C12 C13 BLWR_CTL Blue PWM ground switched output to control blower speed 5 6V speed 1 4 9V speed 2 3 1V speed 3 Linear Power Module C14 C15 HEATER_EN Yellow 12V output to enable FOH operation 11 14V in heat mode and parking brake engaged Fuel Operated Heater C16...

Page 32: ...e 11 14V Relay in electrical center D11 COND_RLY _SIG White Switch to Ground output to relay 1 Condenser fan power from AUX Batteries 0 5V if on otherwise 11 14V Relay in electrical center D12 BLWR_RLY _SIG White Switch to Ground output to relay 2 Evap blower power from AUX Batteries 0 5V if on otherwise 11 14V Relay in electrical center D13 D14 PROGRAM _EN White Ground input to go into reprogramm...

Page 33: ...he connector pins identified in FIGURE 1 After the controller with phase harness has been removed from the unit follow the below instructions to replace the phase harness W 1 Remove and retain cover 4 cover screws 2 wiring grommets Phase harness routes thru this position in cover using grommet Power wires route thru this position in cover using grommet 2 Remove 3 nuts holding the ring terminals to...

Page 34: ...ls of new harness over threaded posts of PCB and route wires as shown Align each colored wire to specific threaded post identified only 5 Secure wire terminals with 3 nuts Torque to 12 to 14 in lbs Use the torque value specified Blue Wire A Orange Wire B Yellow Wire C 6 Plug 2 Pin connector of new harness into PCB 7 Orient ring terminals and route wiring harness out of cover as shown 8 Replace 2 w...

Page 35: ...o avoid potential property damage or personal injury Read Important Safety Warnings and ALL instructions before attempting to install or service product Page 35 of 39 Number SM001 300 HVAC Idle Management System ...

Page 36: ...o avoid potential property damage or personal injury Read Important Safety Warnings and ALL instructions before attempting to install or service product Page 36 of 39 Number SM001 300 HVAC Idle Management System ...

Page 37: ...R SPEED press ENTER until display shows FAN and SPEED Press up or down arrows to select 1 2 3 speed After 5 seconds selection will be set See Figure 23 Figure 23 Changing Blower Speeds ENTER Changing TEMPERATURE set point Anytime the tem perature set point is displayed on the screen push the up or down arrows to change Temperature range is from 60 F coolest to 85 F warmest See Figure 24 NOTE Contr...

Page 38: ...o the temperature set point screen Figure 26 Change from F to C ENTER To enter SERVICE MODE Push both the ON OFF and ENTER button simultaneously at any time See Figure 27 Display will show service indicator and code 00 unless a fault has occurred If there is an active fault the display will show it as 01 02 or 03 Use up and down arrows to scroll through the Fault Codes 1 Evaporator sensor open or ...

Page 39: ...nit Amperage draw Pressing ENTER arrow after viewing service screen will return you to the fault code screen Pressing the ON OFF button will return you to the Tem perature Display screen Figure 28 Service Screens When necessary Check Filter light will notify you that the EHVAC filter must be cleaned or changed To reset filter at screen 1 press and hold enter button for 3 seconds See Figure 29 Figu...