Freightliner HVAC Diagnostics Training

HVAC Diagnostics
Course Contents i
Course Information.............................................................................................ii-1
Heating System................................................................................................. 1-1
A/C System Fundamentals................................................................................ 2-1
A/C System Service .......................................................................................... 3-1
A/C System Diagnostics.................................................................................... 4-1
HVAC System Controls..................................................................................... 5-1
Troubleshooting................................................................................................. 6-1
Appendix ...........................................................................................................A-1
i-2
Course Learning Objectives ii
Chapter 1—Heating System

Chapter 2—A/C System Fundamentals
Chapter 3—A/C System Service
Chapter 4—A/C System Diagnostics
Chapter 5—HVAC System Controls
Chapter 6—Troubleshooting
Parked HVAC System (CVH05)
ii-6, ii-7
Chapter 1 – Heating System
4
Heating System 1
Chapter 1 Objectives
A. Locate and identify heating system components
B. Identify the three types of water control valves
C. Diagnose air flow and blower motor problems
1-1
Worksheet 1.1 Heating System 1
Instructions: During class discussion, fill-in answers and enter notes below.
1-2
1. What role does the engine play in the Heating System?

source of heat for the system and coolant flow
______________________________________________
1-2
2. List some potential problems encountered in the heating system?
Plumbing:
• direction of flow,
• Shut off valves, Heater core
• thermostat seals and thermostats.
Internal plugging:
• subject to all the same conditions
of radiator
1-2
3. What is the function of the heater core?

Heat exchanger, similar to a mini radiator
_________________________________________________
4. What is the heater core's most likely potential problem?
Leaks, internal plugging same as a radiator, SB 83-110, 115
_________________________________________________
Link-Material\sb83110.pdf
Link-Material\sb83115.pdf 1-3
Cable Operated Water Valves 1
5. What is the function of the water valves?
Control coolant flow into the heater core to control temperature
6. Identify this type of water valve?
Cable controlled
Identify some problems you might see
with this valve?
• Leaks internally
• Leaks externally
• Control cable out of adjustment
• Sticks open or closed
How is this valve tested?

• Feel temperature inlet/outlet
1-4
Air Operated Water Valves 1

Electric over air (WST, FLD sleepers)
Identify some problems you might see with this valve?
Leaks internally
Leaks externally
Air cylinder bypassing, allowing air
into engine cooling system.
installation (direction of flow)
Sticks open or closed
Solenoid circuit power and ground

Remove air line from valve
Feel temperature inlet/outlet
Air bubbles in cooling system
Voltage on power and ground circuit
1-4
Electronic Water Valves 1

Solenoid operated (Pre2002 Century Class)
Identify some problems you might see with this valve?
• Leaks internally
• Leaks externally
• Installation (direction of flow)
• Sticks open or closed
• Solenoid circuit power and ground
• CTC/ATC board
Solenoid Water Valve
• Feel temperature inlet/outlet

• Voltage on power and ground circuit
• Turn CTC/ATC knob full hot and full
cold check solenoid operation
Thermistor ATC Board

1-4
ATC water valve control 1
FLD ATC Troubleshooting / Specification

83.05300-1 and 83.05 400-2
1-4
9. What is the function of the blower motor?

Provides air flow for a more effective heat exchange. Blows
____________________________________________________________
air into the cab.
__________________________________________________________
10. What are two types of HVAC ventilation blower motors?
__________________________________________________
Brush type motors, and DC Brushless (ECM type motors)
Brush type motor DC Brushless type motor
1-5
Worksheet 1.1 – Heating System, Blower Motor 1
11. List some potential problems of a brushed-type blower motors?

• power supply
• ground
• open, shorted or excessive resistance in the motor windings.
11. How are blower motors tested?
• voltage on power and ground circuits
• amperage to test motor (after circuit has been determined good)
• excessive amperage and slow blower = shorted windings
• low amperage and slow blower = resistance in windings/brushes
• low amperage and fast blower = blocked or restricted air passage
1-5, 1-6
Worksheet 1.1– Heating System, Blower Motor 1
13. How does the blower motor resister function?

By providing various current paths, with different resistances in
___________________________________________________
___________________________________________________
series with the motor (the resistors use up part of the voltage)
14.List some potential problems with blower motor resistors?
___________________________________________________
Thermal fuse goes open due to excessive heat caused from lack of air flow.
___________________________________________________
Excessive current due to shorted motor
1-6
Blower Motor Circuit in Appendix page A-2 11
FLD HVAC Wiring
Operation:
• Key off
• blower switch off
Page A-2
FLD HVAC Wiring
Operation:
• Key on
• blower switch off
Page A-2
FLD HVAC Wiring
Operation:
• Key on
• blower switch on
• low
Page A-2
FLD HVAC Wiring
Operation:
• Key on
• med
Page A-2
FLD HVAC Wiring
Operation:
• Key on
• med high
Page A-2
FLD HVAC Wiring
Operation:
• Key on
• high
Page A-2
Worksheet 1.1– Heating System, Blower Motor 1
15. How is the speed of a brushless motor controlled?

___________________________________________________
With a variable-voltage signal (Century Class) or
PWM signal (Cascadia & M2) to the motor controller
___________________________________________________
16. What are some potential problems with brushless type motors?
___________________________________________________
Power and ground circuits open or having excessive resistance
___________________________________________________
Corrosion in the controller and between the electromagnet connectors
___________________________________________________
Stator bearings worn out/seized.
DC Brushless type motor
1-7
Worksheet 1.1 – Heating System, Blower Motor 1
17. How are brushless type motors tested?

___________________________________________________
Check power & ground circuits
Apply/Verify a PWM signal to the motor.
___________________________________________________
Amperage test once circuit integrity is confirmed
___________________________________________________
18.What are the advantages of brushless motors?
More efficient at lower speeds. Ability to have numerous speeds
___________________________________________________
No need for resistors that fail.
___________________________________________________
___________________________________________________
No brushes to wear out.
DC Brushless type motor

1-7
Valeo and Behr Blower Motor
Brushless Motor – Permanent Magnets (6)
Cage
Brushless Motor - Coils
Brushless Motors - Control
Hall Sensor to Monitor Speed & Direction

Instruction for Exercise 1.1, 1.2 and 1.3 1
The following exercises will be done in a groups rotation upon completing the
shop test section the class will return to classroom to look and related information
Exercise 1.1 Blower Motor Control – Brushed Motor Page 1-8
1. Test the voltage and amperage of a brush-type motor on all speeds and use
the information to fill-in the table below.
Exercise 1.2 Blower Motor Control – Behr Brushless Motor Page 1-9
1. Test the voltage and amperage of a Behr brushless motor on all speeds and
use the information to fill-in the table below.
2. Attach your DVM lead to the signal wire of the blower motor, and record the
parameters measured at each blower speed.
3. Prevent the motor from rotating and then energize it. What happen and why?

Exercise 1.3 Blower Motor Control – Valeo Brushless Motor Page 1-10, 1-11
1. Test the voltage and amperage of a Valeo brushless motor on all speeds and
use the information to fill-in the table below.
2. Attach your DVM lead to the signal wire of the blower motor and record the
parameters measured at each blower speed
Questions 3, 4, 5 are on page 1-11.
1-8 to 1-11
Exercise 1.1 Blower Motor Control – Brushed Motor 1
1. Test the voltage and amperage of a brush-type motor on all speeds and use
the information to fill-in the table below.
Knob 1 Speed 1 Speed 2 Speed 3 Speed 4

Position
.
Voltage 4.5 V 7.4 V 9.3 V Source
Current 4A 8A 11 A 15 A
Slow Med Med-High
1 2 3
4
High or Direct
1-8
Exercise 1.2 Blower Motor Control–Behr Brushless Motor 1
Instructions: Perform the following tests on the truck assigned to you by the instructor.
1. Test the voltage and amperage of a Behr brushless motor on all speeds and use the
information to fill-in the table below.

Knob Low Medium High
Off
Position 1 2 4
Voltage Source Source Source Source
Current 0 1.6 A 5.5 A 19A
(May be Orange)
Link-Material\WRG-HVAC_Main_24U.pdf
1-9
Exercise 1.2 Blower Motor Control–Behr Brushless Motor 1
2. Attach your DVM lead to the signal wire of the blower motor, and record the

Knob Low Medium High
Off
Position 1 2 4
Voltage ~0 2.0 V 3.2 V 6.3 V
Frequency 0.0 0.0 0.0 0.0

Duty Cycle % OL OL OL OL
3. Prevent the blower motor from rotating and then energize it. What happens,
and why?
Motor attempts to start 5-6 times before shutting down for protection.
1-9
Exercise 1.3 Blower Motor Control–Valeo Brushless Motor 1
DC Brushless type motor pin locations
Cascadia Troubleshooting Manual, March 2011 C02.01/21
1-10
Exercise 1.3 Blower Motor Control–Valeo Brushless Motor 1
Instructions: Perform the following tests on the truck assigned to you by the instructor
.
1.Test the voltage and amperage of a Valeo brushless motor on all speeds and use the
information to fill-in the table below
Knob Cascadia- 2 Cascadia- 4 Cascadia- 8

Off
Position M2- 1 M2- 2 M2- 4
Voltage Source Source Source Source
Current 0 1.5 A 5.9 A 19 A
1-10
Exercise 1.3 Blower Motor Control –Valeo Brushless Motor 1
2. Attach your DMM positive lead to the signal wire of the blower motor, and record the

Knob Cascadia- 2 Cascadia- 4 Cascadia- 8

Off
Position M2- 1 M2- 2 M2- 4
Voltage 12.5 V 9.8 V 5.8 V 0.9 V
Frequency 0 2000 Hz 2000 Hz 0
Duty Cycle % OL (100%) 65% 40% OL (0%)
1-10
Exercise 1.3 Blower Motor Control –Valeo Brushless Motor 1
3. Prevent the blower motor from rotating and then energize it. What happens,
and why?
The motor attempts to start 5-6 times, then goes into protection mode

4. With the fan turned off, jump the ground wire at the blower motor to the PWM signal
wire at the blower motor. What does the motor do? Why?
Motor goes to high speed because PWM is ground input and it works off
of duty cycle (direct jump = 100% duty cycle)
5. What is the maximum allowable current for this motor per the workshop manual?
(Blower motor at high speed)
The Cascadia manual lists 23.5 A as the maximum allowable motor current

Cascadia Troubleshooting Manual, March 2011 C02.01/29
800 — Specifications C02.01/40
1-11
Behr PicoScope Demo 1
Behr unit control; set at “4” (medium) speed
A-21
Behr PicoScope Demo 1
Behr unit control; set at “8” (high) speed
A-21
Behr Feedback Signal (Low Speed)
Behr feedback signal (Low Speed)
A-22
Behr Feedback Signal (High Speed)
A-22
Valeo PicoScope Demo 1
A-23
Worksheet – Heating System, Blower Motor
Voltage
Valeo, Front Control Reading @
Pos. #2 Signal Wire:
Duty Cycle 9.72V
Approx. 69%
A-23
A-23
Valeo, Control Pos. # 4

Voltage @ Signal
Wire: 6.85 V.
Duty Cycle:
Approx. 49%
A-24
1
Valeo PicoScope Demo
A-25
Worksheet – Heating Systems, Blower Motor
Valeo Control Pos. #7

Voltage @
Signal Wire:
Duty Cycle: Approx. 23% 3.258 V.
A-25
A-26
Valeo Cont. Pos. #8

Voltage @
Signal
Wire
Average Voltage:
980.2 mv
A-26
Chapter 1 Review questions 1
1. Which heater control valve will not work if direction of water flow is not correct?
a. cable operated valve
b. electric solenoid operated valve
c. air operated valve
2. Which type of signal does a Valeo brushless blower motor use as an input for
blower motor speed?
a. a variable 5 volt signal b. a PWM signal
3. What will happen if a Behr brushless blower is jammed and will not turn?
The motor will try to start 5-6 times, then sets a code.
4. What is another reason for the blower resistor thermal fuse to be open besides
a shorted blower motor?
Low airflow due to plugged inlet, filter, or evaporator.
5.What is the feedback signal cavity position on a Behr brushless motor?
Position #1

1-13
Chapter 2 – A/C System
Fundamentals
50
A/C System Fundamentals 2
A. Explain the basic thermal laws that relate to HVAC system operation
B. Identify, locate, and explain the functions of A/C system components
C. Identify where and how thermal properties and processes affect
operation of an A/C system
D. Determine condenser and evaporator operating ranges from the
temperature-pressure relationship table
E. Explain the refrigerant flow cycle
2-1
Safety Precaution Discussion 2
Safety Precautions R-134a

• In a good system, refrigerant lines are under pressure
• Only disconnect lines after the refrigerant charge has been recovered at the service valves.
• Always wear safety goggles and cotton-lined barrier gloves while recovering, evacuating,
charging, and leak-testing the system.
• Refrigerant quickly evaporates and will freeze skin and eye tissue.
Serious injury or blindness could result if you come into contact with liquid refrigerant.
• R-134a air conditioning systems should not be pressure-tested or leak-tested with
compressed air.
Combustible mixtures of air and R-134a may form, resulting in fire or explosion.
• Work area must be well ventilated, when the system is recovered, evacuated, charged,
and leak-tested.
• Service equipment must meet certification requirements of SAE J2210
(R-134a recycling equipment.)
• Never expose refrigerant containers to temperatures higher than 125°F (52°C), or they may
explode.
•Use care when handling around painted surfaces, plastic parts, and other components.
(Drive belts could be damaged if PAG oil is spilled on them.)
2-2
Worksheet 2.1 Basic Thermal Properties 2
During class discussion, fill-in answers and enter notes below.

1. In what direction does heat flow?
From hot to Cold
_____________________________
Heat Transfer Equalizes Temperature
2-3
2. When would a hot coffee and a cold soda reach “thermal equilibrium”
When heat from the coffee has moved to the cooler ambient air,
and when the ambient air’s warmth has moved into the cold soda
so that the two drinks reach and remain the same temperature
. 150°F 40°F
2-3
3. What is meant when we say something is “cold”?

Absence of heat. Having or being a temperature that is
uncomfortably low for humans
-459°F
4. At what temperature does an object lose its ability to get colder?___________
5. What happened at that temperature to prevent the ice cube from getting
At -459°F No further heat loss is measurable.
colder? ______________________________________________________
2-3
6. What is a British Thermal Unit (BTU)?

A unit used to measure the quantity of heat. One BTU will raise the
_______________________________________________________________
temperature of one pound of water one degree Fahrenheit.
__________________________________________________________
Raise water
temperature
1 degree
1 LB of
Water

Amount of
heat = 1 BTU
2-3
7.Condensation (latent heat) When refrigerant changes from a Vapor (gas) to
liquid
a_______,it releases a relatively large amount of heat with out a change in
temperature.
liquid
Vaporization (latent heat) When refrigerant changes from a___________ to
a_______________,
Vapor (gas) it absorbs a relatively large amount of heat without a
change in temperature
2-4
8. A. Why is this concept important to our A/C discussion?
The objective of the A/C system is to move heat from inside the cab to
the outside of the cab
970 BTUs/lb
9. What is the Latent Heat of Vaporization for Water__________
2-4
Pressure– A change of pressure will affect either a vapor or a liquid
212 F and
10. What is the boiling point of water at sea level__________
206 F
above 5000ft sea level___________.
A. Why is this concept important to our A/C discussion?
By controlling the pressure of the refrigerant we can influence the point in
the system that the heat will transfer

2-5
Example Of Boiling Point In Sealed System 2
Pressure cap for every 1 pound increases boiling point increases by 3 degrees
10 pound cap increase boiling point to 242 degrees
2-5
Chart for Refrigerant R134a

11. What is the Latent Heat of Vaporization for Refrigerant R134a? 78 BTUs/lb
__________
12. What is the boiling temperature for R134a at standard atmospheric pressure
-15.0 F
2-6
Compression:
13. When vapor is compressed , what happens to the vapor?
Temperature of the vapor increases without adding heat
14.How does this work in an A/C System ?

The low pressure vapor is drawn into the compressor, Temperature
increases during compression, the high pressure vapor is forced to the
condenser to remove the heat.

2-7
Temperature/Pressure Table of Refrigerant R134a 2

125
100
Vapor
75
50
25 Liquid
-25
0 25 50 75 100 125 150 175
2-8
Worksheet 2.2 A/C System Cycle & Components 2
During class discussion, enter notes and answer questions about the location and
function of each component listed below.
1. Compressor:
Manufacturer: CCI
______________________________________ Climate Control ( CCI)
Reciprocating Type
Type: Fixed displacement
______________________________________
Oil: PAG since 2002

______________________________________
Oiling System: Mostly in crankcase,

______________________________________
Oil circulates through the system

______________________________________
2-9
1. Compressor:
Manufacturer: sanden Sanden
______________________________________
Type: Swash Plate Type

______________________________________
Oil: PAG
______________________________________
Oiling System: Oil circulates throughout

______________________________________
the system
______________________________________
Warranty Evaluation Guide - Class Demo on next slide
www.accessfreightliner.com, WarrantyLit, Supplier Component

Warranty Evaluation Guides
2-9
Sanden – Warranty Evaluation Guide
2-9
1. Compressor: Denso
Manufacturer: Denso
______________________________________
Type: Swash Plate Type

______________________________________
Oil: ND8
______________________________________
Oiling System: Oil circulates throughout

______________________________________
the system
______________________________________
2-9
2. Condenser:
_________________________________________________________________
Condenses high pressure, high temperature gas into high pressure,
_________________________________________________________________
high temperature liquid
2-10
Serpentine (tube) and Parallel flow (25% more efficient)

Types of Condensers: ______________________________________
Serpentine Flow Parallel Flow
2-10
a. What is a drawback of a “parallel flow” condenser?

Impossible to fully flush debris in case of compressor failure
_________________________________________________________________
2-10
b. What are factors that might hinder performance?

Anything that would restrict air flow or refrigerant flow
2-10
3. Receiver/Drier: _________________________________________________
Filters and dries refrigerant, ensures that only liquid
refrigerant is allowed through.
________________________________________________________________
What is Freightliner's replacement policy for receiver/driers?
SB83-119, do not replace with every A/C repair, see bulletin for details
________________________________________________________________
And Warranty letter 02-43X.
Cut away of Receiver/ Drier Refrigerant flow inside Receiver/Drier

Link-Material\sb83119.pdf Link-Material\02-043R.pdf
Link-Material\11-011.pdf 2-11
4. Expansion valve:
Restriction in the system; separates the high side from the low side.
_______________________________________________________________
Valve meters the amount of refrigerant entering the evaporator at a rate that
________________________________________________________________
matches the amount of refrigerant being boiled off in the evaporator
________________________________________________________________
a. What happens if TXV is plugged?

__________________________
Low side pressure, lower
than normal (possibly creates vacuum)
__________________________
High side pressure ranges
__________________________
from lower to higher than normal
__________________________
b. What happens is TXV is stuck

open (uncommon)?
Low side pressure, higher
__________________________
than normal
__________________________
High side pressure, normal to
__________________________
lower than normal
__________________________ Thermo Expansion Valve (TXV) - H block
2-12
Thermostatic Expansion Valve 2
Charge of
Refrigerant
Evaporator Compressor
Evaporator
High psi liquid
From Receiver-Drier
Spring
Closed
2-12
Charge of
Refrigerant
Low psi gas Low psi gas
From Evaporator To Compressor
Low psi liquid
Evaporator
High psi liquid
From Receiver-Drier
Spring
Open
2-12
Charge of
Refrigerant
Low psi gas Low psi gas
From Evaporator To Compressor
Low psi liquid
Evaporator
High psi liquid
From Receiver-Drier
Spring
Open
2-12
Absorbs heat from the cab (latent heat of evaporation)
5. Evaporator: ___________________________________________________
This is where liquid changes to a gas. Dries cab air.
_______________________________________________________________
a. What are some environmental concerns that might hinder performance?

Anything that might restrict airflow (dirt, leaves, etc)
____________________________________________________________
b. What might happen if air flow across evaporator is restricted?
______________________________________________________________
Evaporator freeze up, possible excessive cycling of the A/C clutch,
______________________________________________________________
Premature clutch and/or compressor failure.
2-13
Worksheet 2.3 Basic Thermal Processes and the A/C System 2
Cold
_____ Temperature Hot
_____ Temperature
4 Low
_____ Pressure
S u c t io n S i d e D is c h a r g e S id e
1 _____ Pressure
High
Gas
_____ Refrigerant State Gas
_____ Refrigerant State
8 6 ºF (3 0 ºC )
1 5 8 ºF (7 0 ºC )
H o t C a b A ir
Compressor
Plate And Fin Evaporator
1 4 0 ºF (6 0 ºC )
8 6 ºF (3 0 ºC )
Expansion Valve
A m b ie n t R a m A i r
4 1 ºF (5 ºC )
a n d F a n A ir
C o ld C a b A i r
Cold
_____ Temperature Warm
_____ Temperature
Low
3Liquid
_____ Pressure 2 High
_____ Pressure
_____ Refrigerant State Liquid
2-14
Exercise 2.1 System Orientation 2
Place tags at each location and leave on truck for future exercises. Perform a walk
around of a running A/C system with your instructor and fill-out the chart below using
hand temperature measurements. Note the temperature at each location, and mark
whether the refrigerant is a liquid or a gas, and whether it is at high or low pressure.

x x x
x x x
x x x
x x x
2-15
Worksheet 2.4 Refrigerant Flow in a Fixed Orifice System 2
Cold
_____ Temperature Hot Temperature
_____
Low High
4 _____ Pressure 1 _____ Pressure
Gas
S u c t io n S i d e D is c h a r g e S id e
Gas
8 6 ºF (3 0 ºC )
1 5 8 ºF (7 0 ºC )
H o t C a b A ir
1. Fixed Orifice Tube: Compressor

_____________________
Restriction, separates
_____________________
high side from low side
_____________________ Plate And Fin Evaporator
2. Accumulator:
Ensures only gas
_____________________
is drawn into
_____________________
1 4 0 ºF (6 0 ºC )
8 6 ºF (3 0 ºC )
compressor,
_____________________ A m b ie n t R a m A ir
supplies oil to
_____________________ 4 1 ºF (5 ºC )
C o l d C a b A ir
a n d F a n A ir
compressor,
_____________________
Dries refrigerant
Fixed Orifice Tube
_____________________
Cold
_____ Temperature Warm
_____ Temperature
3 _____ Pressure
Low 2 _____ Pressure
High
Liquid
_____ Refrigerant State Liquid
2-16
A/C Components – Fixed Orifice Tube 2
Orifice Tube Removal Tool

Damaged Orifice Tube Removal Tool
Repair Line and Orifice Tube
2-17
A/C Components – Fixed Orifice Tube 2
2-17
A/C Components – Accumulator 2
Pressure
Inlet from Switch Outlet to
Evaporator Schrader Compressor
Valve
O-ring seal
Accumulator
Dome
. Anti-siphon
vent
Vapor
Return
Line
Desiccant bag
Oil Return Orifice Filter

2-18
Worksheet 2.5 Auxiliary A/C Systems 2
Cold
_____ Temperature
D is c h a r g e S id e
4 Low S u c tio n S id e
During class discussion, enter _____ Pressure
Gas
High
1 _____ Pressure
Gas
notes and answer questions
about the location and function 8 6 ºF (3 0 ºC )
1 5 8 ºF (7 0 ºC )
of each component listed below. H o t C a b A ir
Compressor
1. Compressor, condenser,
receiver/drier:
__________________________
Common to both units, both Plate And Fin Evaporator
__________________________
units will show problem
__________________________
symptoms
1 4 0 ºF (6 0 ºC )
2. Heater cores:
8 6 ºF (3 0 ºC )
Expansion Valve
__________________________
Independent, check control 4 1 ºF (5 ºC )
C o ld C a b A ir
A m b i e n t R a m A ir
a n d F a n A ir
__________________________
valves or blend door operation
3. Blower motors:
__________________________
Independent, check circuit, Warm
_____ Temperature
High
2 _____ Pressure
__________________________
airflow restriction Cold
_____ Temperature
Low
Liquid
3 _____ Pressure Plate And Fin Evaporator
Liquid
2-20,2-21
Worksheet 2.5 Auxiliary A/C Systems 2
Cold
_____ Temperature
D is c h a r g e S id e
4 Low
S u c tio n S id e
High
4. Evaporator/expansion valves _____ Pressure
Gas
1 _____ Pressure
Gas
(or evaporator/ fixed orifices):
Independent, check line temps
__________________________ 8 6 ºF (3 0 ºC )
1 5 8 ºF (7 0 ºC )
and evaporator temps

__________________________ H o t C a b A ir
Will likely not show up on

__________________________ Compressor
gauge readings
__________________________
5. Controls: Plate And Fin Evaporator
Independent, check CTC/ATC

__________________________
controls and valves
__________________________
1 4 0 ºF (6 0 ºC )
6. Evaporator temp switch:
8 6 ºF (3 0 ºC )
Expansion Valve
__________________________
Main unit only; may cause 4 1 ºF (5 ºC )
C o ld C a b A ir
A m b i e n t R a m A ir
a n d F a n A ir
__________________________
freeze up or excessive clutch
__________________________
cycling or no clutch cycling
Warm
_____ Temperature
High
Cold
_____ Temperature
2 _____ Pressure
Liquid
Low
3 _____ Pressure Plate And Fin Evaporator
Liquid
86F 2-21
Ambient temp
Chapter 2 Review Questions 2
1. In an A/C system, where does heat transfer occur?

In the condenser and in the evaporator (from hot to cold)
2. Where is Latent Heat of Vaporization is applied to the refrigerant?
In the evaporator
3. Where is Latent Heat of Condensation is removed from the refrigerant?
In the condenser
4. Changing the pressure applied to refrigerant will change:
a. Its boiling point b. Its condensation point
c. Its temperature d. All of the above

5. What component prevent liquid refrigerate from entering the compressor in a
fixed orifice tube system?
The accumulator
2-22
Service
87
A/C System Service 3
A. Create a checklist for A/C system recovery

B. Find DTNA HVAC online service information
C. Verify correct A/C compressor oil level
D. Safely recover, evacuate, and charge air conditioning systems
3-1
Worksheet 3.1 A/C Systems Worksheet 3
Instructions: During class discussion, fill in the answers below.

1. Do technicians need to be certified to service A/C systems?
Yes- to handle refrigerant and required to purchase containers over 25 lbs
2. If certification is needed, where can It be obtained?
www.macsw.org or www.asecert.org
3. Are there any equipment requirements for a shop?
Minimum of machine capable of recovering refrigerant, preferably unit that can
recover and recycle.
4. Is there a fine for EPA violations regarding refrigerant handling?
Yes-Fines of up to $25,000 per day.

3-2
Worksheet 3.2 A/C Machine Worksheet 3
Instructions: Find evacuation and charging procedures in ServiceLit for your
assigned vehicle.
.Where did you find Daimler Trucks North America evacuation and charging
procedures for your assigned model?
Manual ________________
Section ________________
Subject ________________

1. According to the Robinair manual for model 34788 how often should the
vacuum pump oil be changed?
Every 10 hours of pump operation
2. How often should the filter/dryer be replaced on the A/C machine?
After filtering 100—150 lbs of refrigerant.
3. How often should the rest of the components be checked for leaks & how are
they checked?
Every three months, using an electronic Leak Detector
4. Why is it critical to vacuum down an A/C system?
To remove air & moisture and check for leaks
3-3
Preliminary Check Discussion 3

Before testing the operation of the air conditioning system, what
things would you check?
REPAIR ORDER
Complaint: Poor A/C System Performance____________________________
Locate:
Pre-inspection
Results:________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
______________________________________________________________
3-4, 3-5
Worksheet 3.3 - Clutch Gap 3
1. What are three potential problems that excessive clutch gap can cause?
Clutch failure
Leaking front seal from excessive heat due to slippage.
open fuse(s) from over current condition (Starting in 07 )
2. In which manuals can we find information on proper clutch gap checking and
adjusting?
Workshop manual
Maintenance manual
Vendor websites
3-6
Worksheet 3.3 - Clutch Gap (continued) 3
3-5
Using a feeler gauge, check the clutch

clearance at location shown as “A” in
the diagram above. For Sanden
compressors, the gap should be 0.016
to 0.031 inch (0.4 to 0.8 mm). For
Denso compressors, the gap should
be 0.014 to 0.024 inch (0.35 to
0.60mm). If the gap is not even around
the clutch, gently tap down at the high
areas. If the overall gap is out of spec,
remove the drive plate assembly and
change the shims as necessary.
3-7
Worksheet 3.3 - Clutch Gap (continued) 3
Magnetic Clutch Inspection
Part Name Check Point and Expected Action

Damage
Dislocation or peeling of rubber. Replace or

Repair
Hub
Roughness, burn, rust, slip, or
extreme wear on mating surface.
Play, unusual sound, rust,

insufficient grease, or seized
bearing.
Rotor
Roughness, burn, rust, slip, or
extreme wear on mating surface. Replace
Burn, wire breakage or layer short
circuit of stator coil. Resistance of
stator coil at 68°F (20°C) (2.8 to
3.2 Ohms)
Stator
Damage or deformation of rotor

(pulley) groove's).
3-7
Worksheet 3.4 - Leak Detection 3
1. List the service bulletins providing information regarding approved leak

detection tools and practices
83-109
83-114 83-11 (Sterling)
83-55 83-8 (Sterling)
2. What is the only recommended tool to test for a refrigerant leak at the front
compressor seal?
Robinair 22791 or Kent Moore J-39400. (found under Dealer Operation in
Essential Tool list)
3. How would a technician know if dye was already in the system to check for
leaks ?
1. Check service bulletins for information regarding dye wafer in drier.
2. Look at drier label.
Link-Material\sb8355.pdf Link-Material\sb83114.pdf
3-8
4. Is there an acceptable amount of refrigerant leakage? If so how much and Is it

the same for all vehicles?
Yes - 0.25 oz/year or 0.50oz. per year depending on the component.
From Coronado
SD Manual
3-8
Blow out front of compressor and charge port cap areas with shop air. This clears
any refrigerant that may be in the area that may cause false readings when it
is time to check
0.25 oz/year or
0.50oz. per year
depending on Infrared Leak Detector
the component. Kent Moore J-39400
Robinair 22791
3-9
Worksheet 3.5 Check A/C Compressor Oil Level 3
Your instructor will assign a truck model and serial number.
Fill in the model and serial number.

Model ______________________ Serial ___________________________
Instructions: Answer questions below for your truck and type of compressor.
Login to http://www.AccessFreightliner.com Use ServiceLit to answer questions 1-11.
83
1. What group number contains air conditioning service information?______________
1-3 oz
2. How much oil (approximately) is removed during recovery?___________________
Drain it
3. Before recovery, what should you do to the oil container?_____________________
Measure it and record level
4. After recovery, what should you do to the oil container?_____________________
3-10
Exercise 3.5 Check A/C Compressor Oil Level 3
Note: Numbers 5 and 6 apply to CCI compressor only.
By using a protractor
5. How is the compressor mounting angle measured? ________________________
Level on the dipstick
6. What is determined by the compressor's mounting angle?___________________
Varies by truck
7. What type of compressor is listed on your assigned truck?___________________
Varies by brand of compressor
8.What type of oil should you use?________________________________________
Varies by compressor on truck
9.What is the correct oil level for your truck?________________________________
The RO
10.Where should a technician document this information during service?__________
3-10
Exercise 3.5 Check A/C Compressor Oil Level 3
11. What type of oil is used in a Sanden Compressor:

PAG SP-15 or 20
Sanden
12 a. On a system with a Sanden compressor. If you are changing the compressor
along with a condenser and receiver dryer, how much oil would we have to remove
from the new compressor assuming we drained 2 oz out of the old compressor?
10 - (2 + 3 + 1) = 4 The worksheet for oil balancing the Sanden

compressor shows that for a result of 4, you remove 4 oz of oil
from the compressor and then install it.
12 b. What if you were changing the components in question 12a and also changing
both evaporators and a low pressure aux. A/C line?
10 - ( 2 + 3 + 1 + 3 + 2 + 3) = -4 The worksheet for oil balancing the
Sanden compressor shows that for a negative number, you remove
2 oz of oil from the compressor and then install it.

3-11
Exercise 3.5 Check A/C Compressor Oil Level (cont) 3
13.What type of oil is used in a Denso compressor?
ND8 Oil only
Denso
14a. After flushing the A/C system on the following vehicles how much oil would
you add back in to the systems?
AX9415: 4.4 oz in compressor + 3 additional oz = 7.4 oz total per PartsPro
AX9359: 4.4 oz in compressor + 8 additional oz = 12.4 oz total per PartsPro

14b. On a system with a Denso compressor, if you are changing the compressor
along with the main A/C evaporator. If you recovered 3 ounces of oil from the old
compressor, how would you refill the system with the appropriate amount of oil?
Dump out all oil from the new compressor, add 3 oz back in to replace the oil
in the old compressor. Install the compressor. When charging the system,
replace any oil recovered during evacuation, as well as an additional 3 oz for
replacing the main A/C evaporator.

3-11
Exercise 3.1 A/C System Preliminary Checks 3
3-12
Exercise 3.2 A/C Recovery Checklist 3
Instructions: Use ServicePro and equipment manufacturers information to
develop an A/C system recovery checklist.
1. What is our logical first step?
Identify the refrigerant
______________________________________
2. Step two
______________________________________
Empty the machines oil recovery bottle
3. Step three
______________________________________
Hook up hoses
4. Step four
______________________________________
Open couplers
5. Step five
Press “RECOVER”
______________________________________
6. Step six Hint: Run the blower fan in the
cab to speed up the recovery process.
______________________________________________________________________________
Wait for machine to display “COMPLETE”,
Monitor for 5 minutes ensure the system pressure does not rise above 0
______________________________________________________________________________
7. Step seven
Measure, record, and empty the recovered oil
______________________________________________________________________________
8. Step eight
http://www.robinair.com/opmans/manual_34700Z.pdf
Perform required system service; cap any open connections during service operation
______________________________________________________________________________
3-13
Safety Precautions R-134a 3
Safety Precautions R-134a

In a good system, refrigerant lines are under pressure
Only disconnect lines after the refrigerant charge has been recovered at the service valves.
Always wear safety goggles and cotton-lined barrier gloves while recovering, evacuating,
charging, and leak-testing the system.
Refrigerant quickly evaporates and will freeze skin and eye tissue.
Serious injury or blindness could result if you come into contact with liquid refrigerant.
R-134a air conditioning systems should not be pressure-tested or leak-tested with
compressed air.
Combustible mixtures of air and R-134a may form, resulting in fire or explosion.
Work area must be well ventilated, when the system is recovered, evacuated, charged,
and leak-tested.
Service equipment must meet certification requirements of SAE J2210
(R-134a recycling equipment.)
Never expose refrigerant containers to temperatures higher than 125°F (52°C), or they may
explode.
Use care when handling around painted surfaces, plastic parts, and other components.
(Drive belts could be damaged if PAG oil is spilled on them.)
3-14
Exercise 3.3 A/C Evacuation and Charge 3
Your instructor will assign a truck to use during this exercise. Fill in the model and
serial number.
Model __________________________ Serial __________________________
Instructions: Find evacuation and charging procedures in ServiceLit for your
assigned vehicle. Then perform evacuation and charging procedures on your
assigned vehicle.
The following activities involve work in or near vehicles. Be sure to follow all
safety precautions and be alert to prevent accidents.
3-15
Exercise 3.3 A/C Evacuation and Charge 3
Check box when each procedure has been verified by your instructor
1. Purge system if needed.
2. Vacuum system.
3. Add proper amount of oil to high side only (close low side valve).
4. Add refrigerant to system, high side only (liquid charge).
5. Close both gauge valves with engine stopped. Start truck and run engine
at 1500 rpm if possible. (50 state clean idle engines may be limited to 900
rpm). Observe temperature/pressure readings, check hose temperatures.
6. Clear the manifold gauge hoses by closing high side valve at the coupler
Then open both high and low side valves on machine until gauge
pressures stabilize (truck needs to running and system operating during
this procedure), close low side valve. Disconnect hoses.
7. Remaining refrigerant in hoses can be removed by selecting "RECOVER"
on the machine. Coupler valves closed, machine valves open.
3-15
Chapter 3 Review 3

1. If a compressor shaft seal shows signs of oil leakage, you should:
Clean the area and check for leaks with a calibrated electronic leak detector
2. When servicing a system with a Sanden compressor what type of refrigerant oil should be
used?
PAG
3. When servicing a system with a Denso compressor what type of refrigerant oil should be
used?
Denso ND8 Oil
4. What is the allowable clutch gap range for the Denso compressor?
0.014 to 0.024 inch.
5. When using an electronic leak detector, what is the maximum allowable leak rate for the
front seal of a compressor?
0.50oz per year

3-16
Diagnostics
108
Safety Precautions While in our Shop 3
Some of our course activities require you to turn on the vehicle ignition. Remember
that safety precautions must always be performed before you turn trucks on in the
shop.
To start a vehicle, the technician must be properly seated in the driver’s seat.
Vehicles are not started from the floor.
Park the vehicle on level surface, shut down the engine, set the parking brake and
chock the tire before working under the vehicle. Releasing air from the system can
cause the vehicle to roll.
nIn some cases the whole class may be working on a single vehicle. If you are in the
cab, do not:
Start the engine
Honk the horn
Turn on the windshield wipers
Release the parking brakes
Depress the clutch pedal (manual linkage)
Operate anything that may cause harm to another student
Observe normal shop safety procedures and be alert to prevent accidents
Page i-4
Shop Rules: 3
1. If you take it apart, please put it back together properly. Leave the trucks in “as
good as” or better shape than you found them.
2. If you get a tool out please put it back where you found it. Don’t leave it out for
the next group.
3. If anything breaks or you find something broken, let the instructor know.
4. Once you find a “bug” ask your instructor whether you should remove it or
leave it.
5. Work safety. If you don’t have the proper equipment, ask for it.
Page i-5
A/C System Diagnostics 4
A. Diagnose refrigerant-related problems

B. Isolate refrigerant-related problems in dual-evaporator systems
C. Establish a baseline for performance testing
D. Find performance test conditions in ServiceLit
E. Locate A/C system leaks using the 7 Steps detection method
4-1
Worksheet 4.1 Baseline Performance Testing 4
Instructions: During class discussion, fill in answers and enter notes below.
1. Why is a baseline performance test necessary?
_________________________________________________________________
To establish what are normal system values in order to compare them with
values of a similar vehicle that is not functioning properly.
_________________________________________________________________
2. Locate the Performance Test Criteria in the Workshop Manuals for these models:
83.00 300/1
M2 _________________________________________________
83.06 320/1
Century Class (Blend Air)________________________________
83.02 400 below temperature pressure tables
Western Star__________________________________________
Cascadia_____________________________________________
TM C02.01-800
Sterling, A/L Line_______________________________________
83.05 400 under table
Coronado SD _________________________________________
83.00 320/1
3. Complete the table on page 4-3 using the service documentation you found in
question #2 above. Complete the row of the table for your assigned model,
then fill-in the answers obtained by other students during the discussion
4-2
Worksheet 4.1 Baseline Performance Testing 4
Generic Test Condition for HVAC Base Line Century Cascadia WST M2 Sterling
Performance Test. Family
1. No solar load, engine off, tires chocked X X X X X

2. Open hood, keep open for test X X X X X
Both doors open, keep open for test X X X X X
3.
Start engine, attain operating temperature X 0 0 X 0
4.
Set engine RPM at 1500 (if possible) X X 1200 X X
5. Engage engine fan X X X X X
6. Cab climate controls panel settings:
•Air selector switch to “Face” mode X 0 0 0 0
7.•Air Conditioning on full-cold X 0 0 0 0
•Blower speed switch set on “high” X X 0 X X
•Recirculation switch set to “off”
If equipped with sleeper set controls to: X X X X X
•Air Conditioning on full-cold
X 0 0 NA NA
• Blower speed switch set on high
X 0 0 NA NA
Run-Time: Run system for at least 5 minutes or
until the dash and sleeper duct temperatures X X 0 X 0
8.have reach a minimum, then record the values.
4-3
Instruction for Exercise 4.1 a, b and c 4
The following exercises will be done in a groups on assign trucks, upon completing
the shop test section the class will return to classroom to review the information
Run test for 10 minute before recording values.

Record gauge reading after A/C clutch has engages and the pressure stabilizes
a count of 3 to 4 seconds, but before A/C clutch disengages.
The Instructor will provide a Relative Humidity % and temperature reading.
Exercise 4.1a, Group A assigned truck ___________________________
Exercise 4.1b, Group B assigned truck ___________________________
Exercise 4.1c, Group C assigned truck ____________________________
4-4
Exercise 4.1a, b and c Baseline Performance Testing 4
Model __________________________ Serial __________________________
A/C Performance Test

Test Criteria Reading Workshop Manual Specs
Ambient Air Temperature °F °F
Relative Humidity %RH %RH
Center Dash Outlet
°F °F
Temp
Sleeper Lower Outlet
°F °F
Temp
High Side Pressure psi psi
Low Side Pressure psi psi
Compressor cycling? Y / N Y / N
4-4 / 4-6
Exercise 4.1a, b and c Baseline Performance Testing 4
During Performance test, indicate your ”touch test” temperature finding for
each of the ” Tagged” locations 1- 4. Then put a check Ok or Not Ok for
location.
Temperature Table
Cool/
Tagged Location Hot Warm OK Not OK
Cold
Location 1 (comp out)

Location 2 (cond out) .

Location 3 (evap in) .
Location 4 (evap out)
4-4 / 4-6
Exercise 4.1a,b,c Baseline Performance Testing Results 4
High Low Cab

Sleeper Temp Temp Temp Temp Not
Side Side Center
Truck Gauge Gauge Duct
Duct Location Location Location Location OK
Temp One Two Three Four OK
Reading Reading Temp
Coronado
Cascadia
Western
Star
M2
A-28
Worksheet 4.2– Refrigerant Pressure 4
Model: Business Class M2 Serial: AX9364

Base Model Business Class M2 106” BBC
EPA Compliant 2010
Locate the correct temperature/pressure specification table in the M2 WSM.
Table number 7 on page 83.00 400/7
The values given in this chart are representative of a normally functioning HVAC
system on this particular vehicle.
Compare these numbers to the values given in the following problems to
determine the most probable root cause of the complaint.
1.Use System Diagnosis Using Refrigerant Pressure Readings table in
troubleshooting section and the observation noted on each problem.
2.Make a list of possible causes
3.Use the list of observations to arrive at a most probable cause, and list your
next actions.
4-7
Worksheet 4.2– Problem 1 4
Complaint: Poor A/C Performance, driver complains engine fan on more than
usual.
Observation noted: Location 2 (condenser outlet) warm to hotter-than-
normal.
A/C Performance Test Data
Test Data Item Published Readings Actual Readings
Ambient Temperature 80 °F (°C)
Relative Humidity (RH) For: 80 °F, 70% RH
70 % RH
Center Dash Outlet Temp 52 °F (°C) to 52 °F (°C) 65 °F (°C)
High-side Pressure 143 psi (kPa) 143 psi (kPa) 175 psi (kPa)
Low-side Pressure 18 psi (kPa) 18 psi (kPa) 30 psi (kPa)

Compressor Cycling YES / ON YES / ON
Compressor On/Off Time On steady sec On steady sec
(If cycling) Off 0 sec Off 0 sec
4-8
4
Actual Readings
4-8
4
Published Readings
4-8
Comparison between published and actual readings:

Dash outlet temperature higher than normal, high & low-side gauges
higher than normal
List of possible causes:
Restricted condenser airflow, air or moisture in the refrigerant, system
overcharge, blockage downstream of condenser
Most likely cause: Restricted condenser airflow

Next Step: Check airflow across condenser
4-8
Worksheet 4.2–Problem 2 4
Complaint: Poor A/C Performance

Observation noted :Location 4 (Evaporator Outlet) frosty- colder than normal,
driver complains system works only for a short time when first started

70 % RH

Compressor On/Off Time On steady sec On 7 sec
4-9

Dash outlet temperature lower than normal, high & low-side gauges lower
than normal
Frozen evaporator, blockage in system, faulty TXV, faulty evap sensor,
low refrigerant charge.
Most likely cause: Frozen evaporator

Next Step: Check Evaporator probe, and airflow across
evaporator
4-9

Observation noted: Location 4 (Evaporator Outlet) warmer than normal

70 % RH

4-10

Dash outlet temperature warmer than normal, high & low-side gauges
lower than normal
Low refrigerant charge, blockage downstream of evaporator, faulty
evaporator sensor
Most likely cause: Low refrigerant charge

Next Step: Check for leaks– dye and inspect w/black
light and electronic leak detector
4-10

Observation noted : Location 1 (Compressor Outlet) cooler than normal, location
4 (Evaporator Outlet) warmer than normal

70 % RH

Compressor On/Off Time On steady sec On Steady sec
4-11

Dash outlet temperature warmer than normal, high-side gauges lower
than normal, low-side gauges higher than normal
Worn compressor
Most likely cause: Worn compressor

Next Step: Recover refrigerant, check for contamination
in system due to wear/failure.
4-11

Observation noted : Location 2(Condenser Outlet) warmer than normal, location 4
(Evaporator Outlet) warmer than normal

70 % RH

4-12

Dash outlet temperature warmer than normal, high and low-side gauges
reading higher than normal
Restricted condenser air flow, air/moisture in the refrigerant, refrigerant
overcharge blockage downstream
Most likely cause: Air or moisture in refrigerant

Next Step: Use refrigerant identifier to check for contamination.
4-12
Worksheet 4.2– Problem 6 and 7 Optional 4
Complaint: ________________________________________
Observation noted : ____________________________________

Ambient Temperature °F (°C)
Relative Humidity (RH) % RH
Center Dash Outlet Temp °F (°C) to °F (°C) °F (°C)
High-side Pressure psi (kPa) psi (kPa) psi (kPa)
Low-side Presure psi (kPa) psi (kPa) psi (kPa)

Compressor On/Off Time On sec On sec
(If cycling) Off sec Off sec
4-13,14
Exercise 4.2a,b,c Refrigerant System Performance Testing 4
Model __________________________ Serial __________________________
A/C Performance Test

Test Criteria Reading Workshop Manual Specs
Ambient Air Temperature °F °F
Relative Humidity %RH %RH
Center Dash Outlet
°F °F
Temp
Sleeper Lower Outlet
°F °F
Temp .
High Side Pressure . psi psi

Low Side Pressure psi psi
Compressor cycling? Y / N Y / N
4-15
Exercise 4.2a,b,c Refrigerant System Performance Testing 4
During Performance test, indicate your ”touch test” temperature finding for
each of the ” tagged” locations 1- 4. Then put a check Ok or Not Ok for
location.
Temperature Table
Cool/
Tagged Location Hot Warm OK Not OK
Cold
Location 1 (comp out)

Location 2 (cond out) .

Location 3 (evap in) .
Location 4 (evap out)
4-15
Exercise 4.3 Refrigerant Level Exercise 4
There is a refrigerant weight conversion table in the appendix on page A-27.
4-18
Exercise 4.3 Refrigerant Level Exercise 4

Charge Static Low Side Static High Side Running Low Running High Duct Compress Condenser Compress Inlet
(lbm) Press Press Side Press Side Press Temperature Discharge Outlet Temp Temp
Temp
0.13
0.25
0.38
0.50
0.63
0.75
1.00
1.25
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00 4-18
Comparing: 4
Exercise 4.1a,b,c Baseline Performance Testing Results
Exercise 4.2a,b,c Refrigerant System Performance Testing Results
High Low Cab

Sleeper Temp Temp Temp Temp Not
Side Side Center
Truck Gauge Gauge Duct
Duct Location Location Location Location OK
Temp One Two Three Four OK
Reading Reading Temp
Coronado
Cascadia
Western
Star
M2
A-29
Refrigerant System Troubleshooting Flow Chart 4
4-19
Chapter 4 Review 4

1. What two basic systems make up the A/C system?
Refrigerant system
Electrical/Electronic control system

2. Why is a baseline performance test necessary?

To establish what are normal system values in order to compare them with
values of a similar vehicle that is not functioning properly.

3. If your truck had a low refrigerant charge, what would you expect for the following
parameters?
Dash Outlet Temperature colder / hotter than normal
High-Side Pressure Gauge lower / higher than normal
Low-Side Pressure Gauge lower / higher than normal

4-20
Chapter 4 Review 4
4. What are the important keys to performing successful A/C system leak
detection?
Quality tools, UV light and glasses, electronic leak detector
Blow away any residual refrigerant from the compressor front seal with shop
air. Operate the system for 10 minutes and shut down before checking the
front seal Compare leak rate to the table in the Workshop Manual
5. For a properly running system, what would you expect to discover for
location 4 (evap outlet) during a touch-test?

Temperature Pressure State
Cool/
Hot Warm High Low Liquid Gas
Cold
Location 4 (evap out) x x x
4-20
Chapter 5 – A/C Control
System
140
A/C Control System 5
A. Determine if an A/C problem lies with the refrigerant system or the control
system
B. Use PartsPro and EZWiring to locate schematics and wiring diagrams
C. Use schematics and wiring diagrams to isolate electrical problems
D. Use ServiceLink templates to observe A/C controls information
E. Use ServiceLit to find sensor specifications and information on control
operation
5-1
Worksheet 5-1a Rules of Engagement—Century Class 5
Worksheet 5-1a Rules of Engagement—Century Class

Instructions: Your instructor will break you into groups - look up rules of clutch
engagement for the Century Class unit located in Section 83.06-310/1 & 83.06-
330/3&4.
Ignition on, engine speed above 450_ RPM for at least 5 seconds.
Air system pressure above 60 psi, evaporator temperature above 44°F.
Refrigerant high-side pressure must be above 20 psi High side refrigerant
pressure below ________________
450 psi
Must see feedback from the main blower motor with appropriate RPM.

5-2
Worksheet 5-1b Rules of Engagement—M2 5

Instructions: Your instructor will break you into groups - look up rules of clutch
engagement for the M2 unit located in Section 83.00-300/15,16 & 17.
Air selection switch in one of the A/C or defrost settings, or recirc mode is on.
Fan switch is on any setting other than off.
40.1 F.
Evaporator sensor temperature is above ______
Engine has been running for more than seconds._____5______
9.25 V
Battery voltage greater than ______________.
Low air pressure Warning_ not active on the ICU.
The A/C clutch has not been engaged in the previous 15 seconds.

5-2
Worksheet 5-1c Rules of Engagement—Cascadia 5
Instructions: your instructor will break you into groups- look up rules of clutch engagement
for the Cascadia located in Section C02.01/8 and fill in the boxes.
60 psi
> 34psi
> 12.5 V
> 38.5 F
5-3
Worksheet 5-1d Rules of Engagement-Western Star with ATC 5
Anything other than off
7 psi 25 psi
350 psi 275psi
40 psi 50 psi
11
5-3
Worksheet 5-1e Rules of Engagement—Coronado (EPA2010) 5
Default to 450 RPM

Default to 60 PSI
>44 F
No active faults from the blower feedback signal
5-4
Notes: Rules of Engagement - Sterling 5
5-4
Worksheet 5.2 A/C Troubleshooting Flow Chart
5-6
Worksheet 5.2 A/C Troubleshooting Flow Chart 5
Review Refrigerant System Troubleshooting: The A/C Troubleshooting Flow

Chart instructions indicate that the key is in the on position with A/C controls
set to high and with at least 75 psi of air in the system in order to determine
whether the A/C clutch en-gages.
Step Two: Our example A/C system clutch does not engage, but the
temperature/pressure relationship is okay, i.e. system has enough refrigerant
to close the binary switch.
1. What test can be performed to quickly determine direction of the problem?
Voltage available to and through the binary switch (if applicable)
Voltage available to the A/C clutch (power and ground)
2. If there is no power to the binary switch what would be the next step?
Check fuses and relays, obtain wiring diagram and WM info
3. If there is power on both sides of the binary switch what would be the next
step?
Check the A/C clutch power and ground, obtain wiring diagram if a
necessary
5-7
Worksheet 5.3 A/C System Schematic Analysis 5
1. Draw a simple A/C electrical circuit. (Follow instructor demonstration)
Ign Blower A/C SW T-Stat SW Binary SW Clutch
Defrost
Ign Blower A/C SW T-Stat SW Binary SW Clutch
Defrost
ECU
5-8
Worksheet 5.4 Electrical System Electronic Diagnostics 5
During class discussion, fill in answers and enter notes.

About Common A/C Electrical components:
1. Control panel micro switch

Closed A/C or Defrost position
Open in all other position
2. Horton low air switch

Closes above 65
Used with air engaged engine fan clutch
5-9
3. Thermostatic Switch
Normally closed, opens below 32 F, closes above 38 F

4. Old Binary Switch

Normally closed (installed on system under pressure)
Opens low below 26-31 psi, opens high above 356-413 psi

5. New Binary Switch

Normally closed (installed on system under pressure)
Opens low below 25.6-31.2 psi
Opens high above 313-426 psi

5-9
6. Fan cycling switch

Not part of clutch circuit, normally closed. For vehicles built
With electronic engines, fan on at 300± psi and rising, and
turns off when pressure drops below 250±10.

5-9
Worksheet 5.5 FLD 54.00/400 page 3 drawing 24-00441 5
Link-Material\HVAC Diag
5-10
CVH02 PrintPack.pdf
Worksheet 5.5 FLD Electrical Schematic 5
To find wiring diagrams for FLD models, go to Group 54, Section 00, Subject 400
of the Workshop Manual. Now using the FLD electrical system schematic
(Drawing 24-00441) answer the following questions:
1. What circuit number supplies source voltage to the HVAC fan switch? 98
2. According to schematic, wire 98 is connected to a relay. The relay is shown

open to wire 98. What would you have to do to have the relay close the circuit
to wire 98.
Need power on circuit 71 (Ign)
3. The circuit number for the A/C clutch coil is? 98A
4. What components are in the control circuit between the HVAC fan switch and
the low pressure switch?
The thermostatic switch and A/C clutch relay
5. Circuit 98T is for the Blower motor. Explain in detail what has to happen in order
for wire 98T to receive source voltage
When the fan switch is on high, power is sent out on wire 98L which
energizes the heater blower relay. Source voltage comes from a 30A CB on
wire 98 to relay terminal 87 and out the relay on terminal 30 to wire 98T.
5-10
Worksheet 5.6 Inputs, Controls, and Outputs- APADS 5
Hi Pressure SW Eng Fan
Low Pressure SW
A/C Clutch
A/C SW T-Stat SW
Service Information on APADS can be found in Heavy-Duty WSM (FLD 83.04/300)

SB83-74 for replacement parts
5-11
Worksheet 5.7 Inputs, Controls, and Outputs- Sterling 5
Visteon
Switch Not Potentiometer Not
Electronic electronic
Actuators
Face
Floor
Defrost
Recirc
Blower Motor
Hi Pressure Switch
A/C Clutch Relay
Temp Actuator
Lo Pressure Switch
A/C Clutch
5-12
CVH02 PrintPack.pdf
23 psi. 40-47
450- 490.
310 – 340 255 -295
240 210
5-13
Using drawing G06-60844 from your print pack to answer the follow questions
5. What specific part of the circuit is the blower switch operating?
Ground (blower motor and circuit).
6. If wire 210G in the AC4 connector was inadvertently relocated to the F cavity,
would that affect the operation of the blower motor?
Yes, power would be removed from the HVAC controller.
7.The A/C compressor clutch receives its power supply from the a/c compressor
clutch relay. What specific part of the relay is circuit 220 controlling?
Power to relay coil.
8. If we now have correctly figured out what circuit 220 does, what part of the
circuit does wire 97 operate?
Relay coil ground.
9. According to drawing G06-60844 what are the two circuits that go to the A/C
low pressure switch?
97F and 97E.
CVH02 PrintPack.pdf 5-13
Worksheet 5.8 Inputs, Controls, and Outputs- M2 5
Valeo
Evap Temp
Actuators
Mode
Temp
Recirc
BHM
Binary SW A/C Clutch
Blower signal
5-14
Worksheet 5.8 Inputs, Controls, and Outputs- M2 (cont) 5
Instructions: Use the lines provided to write down the sensors operation and
switches pressure values given to you by your instructor.
1. Binary Switch: Low side opens at psi, closes at 25-31 psi. 26-34
High side opens at 426- 483 psi, closes at 313- 426 psi.
2. Fan Cycling Switch turns on at 300 ± 10 psi, turns off at 250 ± 10 psi.
3. Evaporator Probe opens at 38 °F, closes at 40 °F.

Monitored by HVAC ECU to prevent evaporator freeze.
5-15
Worksheet 5.8 Inputs, Controls, and Outputs- M2 (cont) 5
Use the Print Pack to answer the following questions.

4. What specific function does circuit 338 perform?
5 volt reference to all actuators
5. Is the power supply to the blower motor switch controlled?

No.
6. According to the drawing, what size fuse is in circuit 98F?

30A (see foot note #3)
CVH02 PrintPack.pdf
5-15
Worksheet 5.8 Inputs, Controls, and Outputs- M2 5
7. The HVAC control head continually monitors the position of the actuator
motors during operation. What circuit number performs this function for the
"mode" actuator?
338F1
8. According to the switch positions of the binary switch, would the air
conditioning system be full of refrigerant?
No. Unless it was very cold.
9. Using ServiceLit, go into the group 83.00 of the M2 workshop manual. In the
troubleshooting section & find which tables (there are two of them) list the
evaporator probe resistances.
Table 7 (pre Jan 7/07) and table 8 (post Jan 8/07)
10. What is the resistance value of the evaporator probe if the ambient
temperature is 32 F and the truck was manufactured on January 8, 2007
9000 ohms
5-15
Worksheet 5.9 Inputs, Controls, & Outputs- Century Class 5
BEHR Constant Temperature Control (CDTC)
Bunk override SW
Temp actuator
Duct temp
Mode actuator
Evap temp
Recirc actuator
Blower signal/feedback Blower motor

J1587
A/C clutch relay Binary SW
A/C Clutch
CDTC temp
Temp actuator
Blower motor
Blower signal/feedback
Worksheet 5.9 Inputs, Controls, & Outputs-Century Class 5
26-31 26-34
427-484 313- 426
300 ± 10 250 ± 10
44
37
ECU monitored. Controls temp by blending air (see table 23 in WM 83.06)
5-17
Worksheet 5.9 Inputs, Controls, & Outputs-Century Class 5
Use the Print Pack to locate the HVAC wiring diagram and answer the
following questions.
5. What is the circuit description for wire 98?
VBATT (battery voltage)
6. What does circuit 98 do?
Power to the Blower Motor
5. What size fuse protects the front HVAC controller?
5A
6. Wire 97T from the front HVAC controller is sending what type of signal to the
a/c clutch relay?
Power
5. What specific part of the relay is wire 97T operating?
A/C clutch relay coil
CVH02 PrintPack.pdf
5-17
Worksheet 5.10 Inputs, Controls, and Outputs- Cascadia 5
Actuators
Temperature
Duct Outlet Temp Defrost

Floor
Evap Temp Recirc
CPC MCM Fan

Blower Signal/Feedback
Blower motor
J1939 CGW
Outlet Temp
Cabin
CAN
Temp Ambient Temp

actuator Refrig Pressure
Air Pressure
Blower motor Blower
Signal/Feedback
A/C Clutch
5
1. 38.5 F or higher - FCU

Evaporator temperature: ______________________________
2. above 34 psi and below 450 psi - SAM Cab

Refrigerant pressure: ________________________________
3. above 60 psi – SAM Cab

Vehicle air pressure: _________________________________
4. 450 rpm for 5 seconds- Engine ECU

Engine RPM: _______________________________________
5-19
5
Use the Print Pack to locate and answer the following questions.
5. What are the circuit numbers and pin outs for the evaporator temp sensor?
Circuit # 338K—Pin 9 , Circuit 338G2—Pin 11
6. What diagram would you use to locate the A/C pressure transducer?
D22-60648 found in module 703
5. What are the circuit numbers and pin-outs for the ambient air temp sensor?
Circuit #299A—Pin 16 at Sam Cab, Circuit GND—Pin 18 at Sam Cab
6. Where does the a/c clutch receive its ground?
Ground stud on the starter. (G06-53571)

5. What are the circuit numbers and pin-outs for the air pressure sensor?
Circuit #303S—pin 11 at Sam Cab, Circuit #303R—pin 10 at Sam Cab
CVH02 PrintPack.pdf
5-19
Blend Air – Calibration 1
Century Class Cascadia

1. Turn the ignition key to the “on” position, 1. Turn the ignition ON (engine OFF)
do not start the engine.
2. Set the blower speed control to OFF (full
2. Turn the fan switch to the “off” position. counterclockwise position)
3. Turn the air selector switch to the “full 3. Set the temperature control knob to the full
defrost” mode. clockwise position (HOT)
4. Turn the temperature control switch to the 4. Set the mode control knob to the full
“full hot” position. counterclockwise position (FACE)
5. Press and hold the recirculation and air 5. Press the A/C and RECIRC buttons
conditioning buttons for five seconds. simultaneously until the A/C and RECIRC
indicators begin flashing simultaneously.
6. The recirculation and air conditioning
indicators will blink, the fan will turn to the The calibration process will begin and will
highest speed, the air selector switch will continue until the A/C and the RECIRC
cycle through the modes and the LEDs stop flashing.
recirculation door will open and shut. The
entire cycle takes approximately 20-30
sec.
5-20
Blend Air – Components - Cascadia 1
5-20
Blend Air – Flow in DEF/Floor on Medium Heat - Cascadia 1
Temp sensor
(Blend air) Evaporator
Temp sensor
5-21
Blend Air – Flow in FACE Full COLD - Cascadia 1
Temp sensor
(Blend air) Evaporator
Temp sensor
5-21
HVAC Filters - Cascadia 1
Fresh Air
Sleeper
Recirculation
Aux or ParkSmart
5-22
HVAC Filter Intervals – Cascadia, M2, WST 1
Cascadia - Maintenance Manual, 83-02
M2 - Maintenance Manual, 83-02

Filter located in cab
Interval miles; 8,000, 32,000, or 40,000 (or every 6 months)
WST - Maintenance Manual, 83-02

Filter(s) located in cab
Interval miles; 1,000 or 12,500 (or every 3 months)
5-23
Worksheet 5.11 Inputs, Controls,& Outputs-Western Star 5
Red Dot Automatic Temperature Control (ATC)

Hi pressure transducer
Lo pressure transducer
ECU
Evap Temp
Cabin Temp
Duct Temp
Data Bus
Duct Temp Water Valve
A/C Clutch Relay
Engine Fan Relay
Blower Motor
Mode Actuator
Recirc Actuator
Temp Actuator
CVH02 PrintPack.pdf Blower Motor
5-24
Worksheet 5.11 Inputs, Controls,& Outputs- Western Star 5
1. Cab air thermistor

Monitored by HVAC ECU to control fan speed and adjust temperature
2. Outlet air thermistor
Monitored by HVAC ECU to adjust temperature
3. Evaporator sensor
Monitored by HVAC ECU to prevent evaporator freeze.
Clutch out less than 31 F, clutch on greater than 37 F
4. Low pressure transducer
Monitored by HVAC ECU for low pressure protection
Low cut out less than 7 psi on 25 psi
5. High pressure transducer
Monitored by HVAC ECU for high pressure protection and engine fan
request
High cut out 350 psi, clutch on less than 275
6. Engine fan
Signal to engine ECU from HVAC ECU
Fan on 275 psi—fan off 225 psi—fan on min 30 sec. on time.
5-25
Worksheet 5.11 Inputs, Controls, & Outputs- Western Star 5
Use drawing 603B13415 from your print pack to answer the following questions.
7. The blower motor speed control knob is on the control panel. The power for
the blower motor comes from the ATC module. What color wire controls the
blower motor speed?
Orange
8. The inverter relay operates what specific a/c component?

A/C clutch relay coil
9. Circuit number HT52C18 at the TXV is for what function?

5V reference to low pressure transducer
10. What specific function does wire HT49B18 at the TXV serve?
Hi pressure input (hi pressure transducer return signal to control module
11.What circuit number from the ATC module controls the water control valve?
BRN-HT43B-HT43C
12.The red wire at pin 5 of the Fresh/Recirc Servo Actuator is:

12 VDC power
Exercise 5.1 ServiceLink Operations - M2 5
5-26
5-26
2. Use A/C clutch function to test Bulk Head Module (BHM): (circle answer)
Go To Test Mode
a. A/C clutch test mode; does clutch engage? (Clutch On) Y / N
3.95 A (may vary)
b. Write in Amps reading when clutch engaged (Clutch On) ________________
c. Pull connector at binary switch, enter the Amps reading. _____________
0
d. Input to BHM: Is A/C request box displaying ON? Y / N
e. Output from BHM: Is A/C Clutch box displaying ON? Y / N
Reconnect binary switch
f. A/C clutch test mode; does clutch disengage? (Clutch Off) Y / N

5-27
Exercise 5.1 ServiceLink Operations - M2
3. Normal operation of A/C system with out ServiceLink connected:

· Turn on key (do not start the engine)
· Turn on A/C and blower
a. Did the A/C clutch engage (Circle one) Y / N
b. If the A/C clutch did not engage, list reason(s) here:
The bulkhead module software requires engine to be running to activate A/C clutch
without ServiceLink hooked-up.

5-27
Exercise 5.2 ServiceLink Operations Century Class Day Cab 5
The following activities involve work in or near vehicles.
Be sure to follow all safety precautions and be alert to prevent accidents.
Instructions: Your instructor will assign a vehicle serial number.

Indicate correct answers and readings in space provided.
• Open ServiceLink, connect to the truck, turn key to on position (Do not start the truck)
• In ServiceLink locate HVAC Front Control Unit Icon and open tab for Template
• Open the template for Front Control Unit for a Day Cab.
1. For each setting of the HVAC Control Unit record the following:
a. Front Temp control knob setting at Cold-20% Write in the Step Counts for
the Front Temp Mix Door (programmed) Position. ____________
b. Front Temp control knob setting at middle Warm-40% Write in the Step Counts
for the Front Temp Mix Door (programmed) Position. ____________
c. Front Temp control knob setting at far right Hot-60 % Write in the Step Counts
forthe Front Temp Mix Door (programmed) Position. ____________
5-29
Exercise 5.2 ServiceLink Operations Century Class (Day Cab) 5
d. Did the Front Temp Mix Door follow the setting of the Temp control knob in all
position? (Circle one) Y / N
e. If No, why did the Front Temp Mix Door (programmed) position not follow the
Front Temp control knob in all positions?
position varies, depends upon front CDTC discharge temp.
_______________________________________________________________
f. Record the temperature from the Front CDTC Discharge Temp. varies
g. Compare Front CDTC Discharge Temp to temperature of the day do they

match? (Circle one) Y / N answers varies, depends on how
recently truck was running
5-29
Exercise 5.2 ServiceLink Operations Century Class Day Cab (cont) 5
• In ServiceLink locate HVAC Front Control Unit and open tab for Faults
2.Record any Active or Historic faults listed in the space below. (Do not Clear faults)
Answer varies if codes have been cleared
____________________________________________________________
3.Find the following components and unplug the electrical connectors one at time and
record result. (J1587 fault was set write in the information)
a. Front Temp Mix Door Actuator Fault Set No Fault Set
▸ operate temperature control
b. Front CDTC Discharge Temp Thermistor Fault Set No Fault Set
c. Front Evaporator Temp Thermistor: Fault Set No Fault Set
5-30
Exercise 5.3 ServiceLink Operations Century Class Sleeper 5
5-32
Exercise 5.3 ServiceLink Operations Century Class Sleeper (cont) 5
• Open ServiceLink, connect to the truck, turn key to on position (Do not start the truck)
• In ServiceLink locate HVAC Sleeper Icon and open tab for Template
• Open the template for Sleeper.
1. Write in the RPMs of the Front Blower motor at the each setting.
Note :Answer vary with voltage
2000
1500 2400
1100 2700
700 3250
0 3500
5-33
Exercise 5.3 ServiceLink Operations Century Class (Sleeper Cab) 5
2. Bunk Override Control (with ServiceLink connected)

• Press the upper part of the Bunk Override switch in the truck.
a. Did the switch indicator light come on? (Circle one) Y / N
b. Change of the speed of the Front Blower, did the Aux Blower change to match
the Front Blower speed? (Circle one) Y / N
5-33
Front Temp Control Settings:
• Change the Front Temp Control Setting to the positions indicated below (c through e).
For each setting and position, circle yes or no. Does the Aux Temp Control Setting and
Aux Temp Mix Door (programmed) position change to match the Front Temp Control
Setting and Temp Mix Door (programmed) position?
c. Cold Far left position (Circle one) Y / N
d. Hot Far right position (Circle one) Y / N
e. Warm Center position (Circle one) Y / N
f. If No was the answer in any of the above, why did the Aux Temp Mix Door
(programmed) position not follow the Temp control knob in all positions?
The unit controls differ from the way the units operate.
The control reads duct temperature to determine position
5-34
3. With Bunk Override switch in truck in off position. In ServiceLink click on the Bunk
Override Test. What, if any, change did you observe?
Bunk setting should change to match

the front control settings
4. In ServiceLink, test Rear Override (with key on, engine off)
• Set control on the Front Controls to the following: Blower speed to Off.
• Set the Aux Controls to the following: Blower to Low speed. Temp control to
full cold.
• In ServiceLink HVAC template locate Rear Override Test icon. Click, On Test
a. What, if any change did you observe?

Front blower setting from off to low speed,
AC mode light on and FCU light on
Exit Test Mode, disconnect, and exit ServiceLink. Leave computer On for next group
5-34
Exercise 5.3 ServiceLink Operations Century Class Sleeper (cont) 5
5. Normal Operation of the Bunk Override Switch
• Use the Bunk Override Switch to change the Control Setting in the Bunk.
How are the operations of the Bunk Override different when not using ServiceLink?
Normal (no ServiceLink) settings change only when bunk override is depressed.
With ServiceLink connected Settings change with each control position
change.
• Turn key off.
5-35
Exercise 5.4 HVAC Template Cascadia 5
5-36
Instructions: Go to a truck/simulator and connect ServiceLink. Open the

appropriate HVAC template.
1. What do you have to do on this template to see all of the data?
Press the “ON” button
2. Turn on the front blower motor and observe the indicators. What do you think
the Protect button represents?
The blower is not in protected mode
• Move the temperature knob to half way and observe the indicators. Now push
the bunk override button.
3. Did you see the bunk indicators respond? Y / N
• Push the override button again and turn off the front blower. With the park
brake set, turn the bunk blower switch to half way.
4. Did the front unit indicators respond? Y / N
• Move the bunk temperature knob from one extreme to the other.
5-37
5. Did the front unit indicators respond? Y / N

• Turn on the front blower switch and push the recirc button.
6. Did you see the recirc indicators respond? Y / N
• Turn the front mode switch to various positions.
7. Did the AC mode ever become active? Y / N
If no, why not?
No engine RPM.
8. Are the door indicators indicating real door position? Y / N
9. Record the following: Answer will vary with condition
Eng Temp ____ Ambient Temp ____ HS Press ____% HS Press ____PSI
• Disconnect ServiceLink, turn ignition off, turn load cut-off switch to Off.
5-37
Exercise 5.5 ATC Operation & Error Codes - Western Star 5
The following activities involve work in or near vehicles. Be sure to follow

all safety precautions and be alert to prevent accidents.
Instructions: Your instructor will assign a vehicle serial number. Use ATC
controls and print pack schematics to answer the questions below. Indicate the
correct answers and readings in space provided.
1. Test operation of heater valve solenoid:
 Turn key to on position
Do not start the truck. Truck air system must have pressure.

5-38
Turn blower switch to low speed position.

• Push right side (Hot) Temperature Up/Down switch to increase
temperature to 80 degree setting.
a. Does the air solenoid click? (Circle one) Y / N
b. Does the air solenoid puff air out of the valve exhaust vent? Y / N
c. What is the water valve position? (Circle one) Open / Shut
Push left side (Cold) Temperature Up/Down switch to decrease
temperature to lowest setting.
d. Does the air solenoid click? (Circle one) Y / N
e. Does the air solenoid puff air out of the valve exhaust vent? Y / N
f. What is the valve position? (Circle one) Open / Shut
5-38
2. Checking power to the water valve:

a. Unplug the inline fuse for the water valve solenoid use Print Pack to help
locate fuse) What do you hear happening at the water valve solenoid?
Audible valve clicks and air puffs from exhaust
b. What is the valve position? (Circle one) Open / Shut
· Plug in the inline fuse

5-39
3. Checking error codes

• Turn blower to OFF position
To check for codes press and hold right side (Hot) Temperature "Up/Down
switch" to increase temperature to highest setting until codes are displayed.
All codes start with a capital “E” followed by a number.
a. What is the first code displayed? E0
• Find the following components and unplug electrical connectors one at
time. Check for codes and record results after each connector is
unplugged.
The following are located on the expansion valve:
b. Low pressure transducer E7 c. High pressure transducer E8
The following are mounted to the lower lip of dash under relay panel:
d. Cab temperature Sensor E2,E7,E8
5-39
The following are located behind the glove box. (Remove screws to aid in glove
box removal.)
e. Evaporator sensor E4,E2,E7,E8
f. Power lead to ATC module (6 pin round Deutsch connector) E17,E4,E2,E8,E10
• Reinstall all electrical connectors that were unplugged.
g. What code is displayed after restoring connectors? E0
h. Explain the meaning of code “E0” No fault detected
i. Swap high and low pressure sensors leads E9
5-39
Chapter 5 Review 5
1. In the Century Class A/C clutch rules of engagement, what engine speed must be
attained for the clutch to energize?
450 RPM
2. On a Cascadia, A/C compressor clutch operation is an output of which ECU?
a. SAM Chassis
b. HVAC Front Control Unit
c. SAM Cab
d. HVAC Rear Control Unit
3. In the Cascadia A/C clutch rules of engagement, what battery voltage must be
attained for the clutch to energize?
12.5 volts or higher
4. When using the ServiceLink M2 A/C Clutch Function template, what must be done
to control the A/C clutch output using the “Clutch On” or Clutch Off” buttons?
You must be in “Test Mode”.

5. True or False The Behr CDTC Blend Air HVAC System Day Cab template
displays A/C clutch current on a graph.
False- current draw is only on the M2 template
5-40
Chapter 6– Troubleshooting
A/C Problems
Troubleshooting A/C Problems 6
A. Use diagnostic routines in conjunction with applicable service documentation to

troubleshoot HVAC systems on a vehicle.

6-1
Troubleshooting HVAC Worksheet. 6
Model _________________________ Serial __________________________
Complaint:
List symptoms:
A. Does the compressor clutch activate? Circle: Yes / No

Yes = Performance test; No = Check pressure and continue to leak testing or electrical.
B. Performance Test (if necessary)
Actual Performance Results: Baseline Test Result H L N

Ambient Temperature __________ºF __________ ºF _______
Ambient Humidity __________%RH __________%RH _______
Center Dash Temp __________ºF __________ ºF _______
Sleeper Lower Temp __________ºF __________ ºF _______
High Side Pressure __________ psi __________ psi _______
Low Side Pressure __________ psi __________ psi _______
Compressor Cycling Yes / No
6-2
C. Compare the Actual result against the Typical Baseline Performance

List three possible causes for the A/C complaint. Circle the most likely cause

D. What is the correction for this problem?

· Be sure that you understand the system/circuit, research if necessary.
E. Check open circuit source voltage, record results.
F. Check closed circuit source voltage, record results
G. Check closed circuit voltage at power and ground side of complaint component,
record results.
Power Side ______________ Ground Side
H. Compare readings to chart on troubleshooting tips page, determine direction of
problem
Upstream Downstream Component

6-2
I. Determine next test point, it may be necessary at this point to obtain a wiring
diagram and determine all possible test points.
Drawings Used ________________________ Module _________
J. Check voltage available at next best test point to determine direction of problem.
Test Point Expected Value Actual Value
____________ ____________ ____________
____________ ____________ ____________
____________ ____________ ____________
____________ ____________ ____________
K. Perform steps 7 and 8 until you have isolated the problem between two test
points.
Location of Problem ________________________________________
L. Repair or replace as necessary.
M. Confirm correct operation after repair

6-3

Freightliner HVAC Diagnostics Training

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HVAC Diagnostics

Chapter 1—Heating System

A. Locate and identify heating system components

B. Identify the three types of water control valves

C. Diagnose air flow and blower motor problems

1. What role does the engine play in the Heating System?

2. List some potential problems encountered in the heating system?

3. What is the function of the heater core?

6. Identify this type of water valve?

How is this valve tested?

7. Identify this type of water valve?

How is this valve tested?

8. Identify this type of water valve?

• Feel temperature inlet/outlet

Thermistor ATC Board

FLD ATC Troubleshooting / Specification

9. What is the function of the blower motor?

Brush type motor DC Brushless type motor

11. List some potential problems of a brushed-type blower motors?

13. How does the blower motor resister function?

FLD HVAC Wiring

FLD HVAC Wiring

FLD HVAC Wiring

FLD HVAC Wiring

FLD HVAC Wiring

FLD HVAC Wiring

15. How is the speed of a brushless motor controlled?

DC Brushless type motor

17. How are brushless type motors tested?

DC Brushless type motor

Hall Sensor to Monitor Speed & Direction

Knob 1 Speed 1 Speed 2 Speed 3 Speed 4

Voltage 4.5 V 7.4 V 9.3 V Source

Slow Med Med-High

Voltage Source Source Source Source

Current 0 1.6 A 5.5 A 19A

Voltage ~0 2.0 V 3.2 V 6.3 V

Frequency 0.0 0.0 0.0 0.0

DC Brushless type motor pin locations

Cascadia Troubleshooting Manual, March 2011 C02.01/21

Knob Cascadia- 2 Cascadia- 4 Cascadia- 8

Voltage Source Source Source Source

Current 0 1.5 A 5.9 A 19 A

Knob Cascadia- 2 Cascadia- 4 Cascadia- 8

Voltage 12.5 V 9.8 V 5.8 V 0.9 V

Frequency 0 2000 Hz 2000 Hz 0

Duty Cycle % OL (100%) 65% 40% OL (0%)

800 — Specifications C02.01/40

Behr unit control; set at “4” (medium) speed

Behr unit control; set at “8” (high) speed

Behr feedback signal (Low Speed)

Valeo, Control Pos. # 4

Valeo Control Pos. #7

Valeo Cont. Pos. #8

Safety Precautions R-134a

During class discussion, fill-in answers and enter notes below.

Heat Transfer Equalizes Temperature

3. What is meant when we say something is “cold”?

6. What is a British Thermal Unit (BTU)?

8. A. Why is this concept important to our A/C discussion?

Pressure– A change of pressure will affect either a vapor or a liquid

Oil: PAG since 2002

Oiling System: Mostly in crankcase,

Model Serial