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Paccar SM001-300 Service Manual

Manual is about: Kenworth Idle Management System

Summary of SM001-300

  • Page 1

    S ervice m anual section hvac title idle management system service manual number sm001-300 date rev. 9 © 9/2016 model all w/ idle management system page 1 of 39 kenworth idle management system technical information and diagnostic guide hvac pm820010 rev. 9 © 9/2016 this guide will assist you in beco...

  • Page 2

    Page 2 of 39 number sm001-300 hvac: idle management system contents general safey instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 warnings, cautions, and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 precautions for working wit...

  • Page 3

    Page 3 of 39 number sm001-300 hvac: idle management system i. Condenser fan motor testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 j. Evaporator blower motor and linear power module testing . . . . . . . . . . 20 k. Compressor rubber mounts . . . . . . . . . . . . . . ....

  • Page 4

    Page 4 of 39 number sm001-300 hvac: idle management system list of figures figure 1. Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 figure 2. Fuses and relays (units built 8/1/2016 to present). . . . ...

  • Page 5

    Page 5 of 39 number sm001-300 hvac: idle management system general safey instructions a number of alerting messages are in this manual. Please read and follow them. They are there for your pro- tection and information. These messages can help you avoid injury to yourself or others and help prevent c...

  • Page 6

    Note take care to follow the handling procedures below: • only use the specified fvc68d pve oil from a sealed container. • immediately reseal containers of oil. • to avoid contamination, do not return oil to original container once it is dispensed, and never mix it with other refrigerant oils. • do ...

  • Page 7

    Page 7 of 39 number sm001-300 hvac: idle management system • do not perform any repair when impaired, tired, fatigued or after consuming alcohol or drugs that can impair your functioning. • some state and federal agencies in the united states of america have determined that used engine oil can be ca...

  • Page 8

    Page 8 of 39 number sm001-300 hvac: idle management system external component identification and location a. Fuses figure 1. Fuses and relays figure 2. Fuses 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 re...

  • Page 9

    Page 9 of 39 number sm001-300 hvac: idle management system location: on the control center. F3 fuse 20 amp (mini) this fuse provides short circuit protection for the evapo- rator blower. Location: on the control center. F4 fuse 60 amp (maxi) this fuse provides short circuit protection for the com- p...

  • Page 10

    Page 10 of 39 number sm001-300 hvac: idle management system e. Linear power module this module controls the amount of voltage delivered to the evaporator blower creating variable blower speeds. It is located in the return air in front of the evaporator coil. Figure 5. Linear power module f. Discharg...

  • Page 11

    Figure 9. Battery separator solenoid, located in the battery box. Page 11 of 39 number sm001-300 hvac: idle management 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 ...

  • Page 12

    Page 12 of 39 number sm001-300 hvac: idle management system internal components a. High pressure switch this normally closed brazed pressure switch will open and prevent the operation of the compressor due to high internal pressure. It is not serviceable. Figure 11. High pressure switch b. Compresso...

  • Page 13

    Page 13 of 39 number sm001-300 hvac: idle management system a/c system diagnostic check service screens before troubleshooting, see “ operation ” on page 37. Note removing fuse f1 for 10-15 seconds will reset the sys- tem controller to factory default settings. Table 1. A/c system diagnostic problem...

  • Page 14

    Page 14 of 39 number sm001-300 hvac: idle management system unit runs—but does not blow cold air. 1. Airflow blockage. 2. Compressor. 3. Fuse or relay. 4. System and com- pressor controller connections/ defec- tive compressor. 5. Condenser fan and high pressure switch. 6. Evaporator dis- charge temp...

  • Page 15

    Page 15 of 39 number sm001-300 hvac: idle management system unit runs correctly, but less than expected run time. 1. Ground terminal(s). 2. Batteries weak or not charged correctly. 3. High amperage draw. 4. Check battery man- agement system. 5. Check battery sep- arator. 1. Inspect and tighten all c...

  • Page 16

    Page 16 of 39 number sm001-300 hvac: idle management system espar heating system diagnostic table check service screens before troubleshooting, see “ operation ” on page 37. Monthly running and periodic maintenance are required for proper heater operation and performance. Table 2. Espar heating syst...

  • Page 17

    Page 17 of 39 number sm001-300 hvac: idle 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

    Page 18 of 39 number sm001-300 hvac: idle management system appendix a. Battery condition and performance battery voltage is critical for system operation. Special attention should be given to both sets of batteries. Note poor quality batteries or a weak alternator will have a negative impact on uni...

  • Page 19

    Page 19 of 39 number sm001-300 hvac: idle management system connection, high pressure situation or defective switch. If the pressure, harness and connections are okay, the ehvac unit will have to be replaced. E. Check continuity across fuse body fuse does not look blown. Remove fuse from fuse holder...

  • Page 20

    Page 20 of 39 number sm001-300 hvac: idle management system e. If all signals are correct and the safety controls thermal limit on compressor, high pressure switch and temp sensor /freeze switch are okay, the control is calling for cold and the sleeper tem- perature is above 60 degrees, you should h...

  • Page 21

    Page 21 of 39 number sm001-300 hvac: idle management system l. Testing the battery management system (bms) overview the bms monitors the auxiliary batteries for state of charge, communicates with the ehvac system and con- trols the battery separator solenoid. Led light on the bms indicates power to ...

  • Page 22

    Page 22 of 39 number sm001-300 hvac: idle management system if the separator switch tests okay, reconnect the separa- tor wires, unplug the bms for at least 15 seconds, recon- nect bms and repeat bms test. If the bms will not operate the separator, replace the bms. M. Can bus note before checking ca...

  • Page 23

    Page 23 of 39 number sm001-300 hvac: idle management system does not operate, the problem is internal in the heater. See espar’s airtronic installation, troubleshooting, and parts manual for complete heater diagnostics. If the resistance level is not present or correct, check across pins 5 and 7 on ...

  • Page 24

    Page 24 of 39 number sm001-300 hvac: idle management system on the recovery station and hose fittings, verify that all valves are closed. The valves at the recovery sta- tion must be set to the closed position. The valves at the quick-disconnect fittings must be set fully counterclockwise (ccw). 2. ...

  • Page 25

    Page 25 of 39 number sm001-300 hvac: idle management system c. Continue to operate the recovery station vacuum pump until the system has pulled a vacuum of 750 – 1000 microns as measured by the elec- tronic vacuum gauge (15 minutes minimum). D. Close both hand valves on the recovery station, and the...

  • Page 26

    Page 26 of 39 number sm001-300 hvac: idle management system 1. Determine the model of truck to charge the a/c sys- tem. Table 3. Charge capacity model size t680, w/ 76 inch sleeper 21.00 oz. (1.31 lbs.) above shows tested charge level for current ken- worth models. Following the instructions provide...

  • Page 27

    Table 4. Discharge sensor / freeze switch testing chart page 27 of 39 number sm001-300 hvac: idle management system.

  • Page 28

    Fi g u re 1 8 . In te rn al wi ring dia gram (be fo re 8 /1 /2 016) heater_en ( yellow) heater_lvl (g ray/red) blwr ctl ( blue) freeze (g reen) heater_en ( yellow) 12_volts_comp (red) canl (gre en) contro l sensor gnd (black) comp_gnd_2 (black) canh (yel low) power a nd battery monito ring system pr...

  • Page 29

    Fi g u re 1 9 . Extern al wi ri ng dia gram power harness wire gauge: 2/0 ground (brown/white) wire gauge: 2/0 battery monitoring system common (white) truck- (black) wire gauge: 2awg can h (yellow) wire gauge: 2awg ignition input to unit heater_en (yellow) engage (orange) deutsch dtm06-6s 12 volts ...

  • Page 30

    Fi g u re 2 0 . Wiri ng diag ram (8 /1/20 16 to pre s e n t) hvac: idle management system page 30 of 39 number sm001-300 dwg no part number sheet rev created by noun, description bergstrom inc. Property of lifecycle state project no pcn number customer cust ref no created on last modified by last mo...

  • Page 31

    Page 31 of 39 number sm001-300 hvac: idle management system table 5. Control module pinout with functional information pin circuit id wire color function typical voltage other end of circuit c1 control_f used red/white 12v power from f1 - 10amp fuse 12-14v control fuse f1 and control pin 1 c2 gnd bl...

  • Page 32

    Page 32 of 39 number sm001-300 hvac: idle management system d6 wakeup blue switch to ground input from acu - turns on parked unit 9-14v with control off, blue wire (pin 6) in connector on back of control d7 iso 9141 brown reprogramming used for software upgrades - no normal function d8 d9 d10 comp_r...

  • Page 33

    Page 33 of 39 number sm001-300 hvac: idle management system service instructions for ring terminal / controller and compressor warning: to avoid potential property damage or personal injury, read important safety warnings and all instructions before attempting to install or service product. Caution:...

  • Page 34

    Warning: to avoid potential property damage or personal injury, read important safety warnings and all instructions before attempting to install or service product. Caution: care must always be taken to install the control cover without bending the connector pins identified in figure 1. 4. Slide (3)...

  • Page 35

    Warning: to 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

    Warning: to 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

    Page 37 of 39 number sm001-300 hvac: idle management system operation to start the system push on/off button. Display will show current mode/ temperature setting / battery level. See figure 21. Initial default setting is blower speed 1/ auto- mode /60 °f. Figure 21. On/off button on/off changing mod...

  • Page 38

    Figure 25. View system runtime/hours enter page 38 of 39 number sm001-300 hvac: idle management system to change from °f to °c press enter until temperature symbol only shows – push the up or down arrow to change. After 5 seconds selection will be locked. See figure 26. Anytime the control is idle f...

  • Page 39

    Page 39 of 39 number sm001-300 hvac: idle management system press the enter button to proceed through the avail- able service screens. See figure 28. 1. Sv = starting batteries voltage 2. Av = auxiliary batteries voltage 3. Aa = unit amperage draw pressing enter arrow after viewing service screen wi...