Performance A/C International A N AV I S TA R C O M PA N Y Program IV: ProStar TM Study Guide TMT-160701 Series Study Guide Performance A/C Program IV: International ProStar Series TMT-160701
2007 International Truck and Engine Corporation 4201 Winfield Road, Warrenville, IL 60555 All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of International Truck and Engine Corporation.
Table of Contents Module 1: System Design & Components...5 Compressor... 6 Evaporator Core... 6 Condenser Core... 6 Pressure Transducer... 7 Cooling Fan... 7 Filter Drier... 7 Climate Control Assemblies... 8 Compressor Pressure Relief Valve... 9 Service Gauge Port Valves... 9 Air Distribution & Operational Modes... 10 Operational Modes... 10 Re-Circulate Air Mode... 10 Fresh Air Mode... 11 A/C Mode... 11 Heat Mode... 11 Refrigerant... 11 Module 2: Diagnostics...13 Shop Safety... 13 Preliminary Diagnostics... 14 DTCs... 15 Testing... 16 Module 3: Repair Procedures...17 Filter Drier Assembly Removal... 17 Filter Drier Assembly Installation... 18 Expansion Valve Removal... 19 Expansion Valve Installation... 19 Rear Heater Core Removal...20 Rear Heater Core Installation... 21 Rear Evaporator Core Removal...22 Rear Evaporator Core Installation...23 Rear HVAC Housing Removal...24 Rear HVAC Housing Installation...25
2 Performance A/C Program IV: International ProStar Series
Introduction 3 Introduction The innovative design of the International ProStar maximizes driver ergonomics, comfort and performance. Performance A/C Program IV: International ProStar Series is built on an understanding that premium comfort can only be achieved with a well-maintained HVAC system. This program covers International ProStar HVAC components, unique diagnostics and service procedures. Objectives: Upon completion you will be able to: Identify International ProStar HVAC system design Describe components on the International ProStar Describe system modes of operation and how they are accomplished These comprehensive Performance A/C DVDs, along with a proven certification program, provide technicians and dealers with all the expertise needed to effectively service and maintain HVAC systems. Performance A/C Program IV: International ProStar Series covers components and service procedures that are unique to the International ProStar vehicle. For in-depth training that covers air conditioning theory, refrigerant servicing, and flushing and purging procedures, please refer to the Performance A/C Program I DVD. To receive credit for completing this program, you are required to take a post-test on ISIS /Education/Service/ Online Testing.
4 Performance A/C Program IV: International ProStar Series NOTES
Module 1: System Design & Components 5 System Design & Components Module 1 Before we look at components, let s take a moment to discuss the unique design of the system. As with other vehicles, the base A/C system is divided between the cab and engine compartment. The cab module contains the blower motor, mode doors, temp door, door actuators and heater core. The remaining components are on the engine side, including the compressor, condenser and evaporator. What makes the system unique is the auxiliary HVAC sleeper module located under the lower bunk. Contained in the module is an additional heater core, evaporator core, blower assembly, temperature door and temperature door actuator. It also includes a constant discharge sensor, filter, thermal expansion valve, inlet grill, rear sleeper ducting and outlet registers. You can control both modules from the dash; also, separate controls for the sleeper module are located in the lower bunk. The control of the auxiliary HVAC is accomplished by a last-touch system between the instrument panel and the Note The front blower setting must be ON before the rear system can be operated from either the instrument panel or the sleeper control panel.
6 Performance A/C Program IV: International ProStar Series sleeper control panel. Both systems use a thermal expansion valve design. Let s start our review by looking at the common component technology, then we will move on to discuss unique subsystem components. Compressor The Sanden Model SD7 is configured with a proprietary International rearport or top-port head to accommodate block C-plate fittings, which are used on other models. Evaporator Core The evaporator core is located in the evaporator housing, mounted on the engine side of the cowl panel. The core is a heat exchanger made of plate and fin construction and block C-plate inlet and outlet fittings. Condenser Core The air conditioning condenser is located at the front of the vehicle between the engine radiator and grill. The condenser is a heat exchanger with the same plate and fin construction. It too, has C plate inlet and outlet fittings.
Module 1: System Design & Components 7 Pressure Transducer On the International ProStar the pressure transducer is a pressuresensing device located between the condenser and the filter drier. The transducer provides an electrical signal to the truck s computer system, which monitors and controls the operation of the A/C system, eliminating need for a high pressure switch and a fan override switch. Cooling Fan The cooling fan is located behind the radiator and is driven by the engine belt. It draws air through the radiator and condenser to remove heat. Engines equipped with the electronically controlled fan operate automatically but have a driver control option to manually turn the fan on and off. Filter Drier In the International ProStar the receiver/drier has been replaced with the filter drier. Its function is to remove any moisture or solid contaminants before they can cycle through the system and cause internal damage. In the International ProStar the receiver/drier has been replaced with the filter drier.
8 Performance A/C Program IV: International ProStar Series You should refer to TSI 06 16 07 on ISIS for conditions requiring the replacement of the filter drier. You should refer to TSI 06-16-07 on ISIS for conditions requiring the replacement of the filter drier. The filter drier assembly is not serviceable and must be replaced if it is found to be defective. Climate Control Assemblies The primary module and sleeper discharge temperatures and blower speeds are controlled independently of each other. The HVAC driver control panel is located at the bottom of the center console. The control panel has separate control knobs for blower speed, temperature and mode of operation. All mode and temperature doors are controlled by actuator motors. The instrument panel center console has two dedicated multiplexed rocker switches for the rear HVAC system; one controls the sleeper blower setting, while the other controls the sleeper temperature setting. These control settings are displayed to the operator in the gauge cluster in the form of a bar graph. In the sleeper area there are two controls; one for the blower and one for temperature control.
Module 1: System Design & Components 9 In all modes except Max A/C, the front HVAC module is operated on a 100% fresh air mode, while the rear auxiliary unit operates in recirculation mode 100% of the time. The rear HVAC module can be set to maintain a constant temperature in the cab. The blower motor on the rear module can run at up to 50% of full power when the engine is not running. The blower motor on the rear module can run at up to 50% of full power when the engine is not running. Compressor Pressure Relief Valve A pressure relief valve is located on the rear of the compressor housing. It prevents damage to the compressor and other system components. The relief valve also prevents total refrigerant loss by relieving unusually high refrigerant system discharge pressure. Service Gauge Port Valves The low-pressure service port valve is located on the evaporator outlet line. The high-pressure service port valve is located on the compressor-tocondenser line.
10 Performance A/C Program IV: International ProStar Series Air Distribution & Operational Modes Cab airflow is controlled by four doors. Actuator motors from the control assembly adjust the doors and divert the airflow. The four doors are: Re Circulate, Temperature and two Mode doors. One Mode door controls the airflow for the panel and floor vents, allowing air to flow from either one or both. The other controls the airflow for the panel and defrost vents, allowing air to flow through either one or both. The Re-Circulate door allows either re-circulated air or fresh air to enter the cab. The Temperature door allows either warm air, cold air or a combination of both to enter the cab. Operational Modes Re-Circulate Air Mode In the Re-Circulate Air Mode, the Re Circulate door closes off all ambient airflow to the system. Air is pulled from and re-circulated through the cab.
Module 1: System Design & Components 11 Fresh Air Mode In the Fresh Air Mode, the Re-Circulate door closes off all re-circulated airflow. Air is pulled into the system from outside the cab. A/C Mode In the A/C Mode, air flows through the evaporator, bypasses the heater core and enters the cab. Heat Mode In the Heat mode, air flows through the evaporator, then through the heater core and enters the cab through the panel, defrost or floor ducts, depending on the setting of the mode switch. Refrigerant The final system component is the refrigerant itself. International only recognizes R134a for the International ProStar. Refrigerant blends and alternative refrigerants are not recognized. International only recognizes R134a for the International ProStar.
12 Performance A/C Program IV: International ProStar Series NOTES
Module 2: Diagnostics 13 Diagnostics Module 2 Shop Safety When performing HVAC system diagnostics, repair or maintenance, keep in mind that proper service techniques, environmental concerns and safety are the most important parts of this process. When performing service work of any kind, always protect the interior of the vehicle by using a paper floor mat, a steering wheel cover and a seat cover. Be sure to follow each warning, caution, and note as they are presented throughout this training program. Warnings indicate procedures and safety measures that must be followed precisely to avoid the risk of death or personal injury to yourself or other shop personnel, and to avoid damage to the vehicle, equipment or components. Cautions indicate a procedure that you must follow exactly to avoid equipment or component damage. Notes indicate operations, procedures or instructions that are important for proper service.! Warning Before beginning diagnostic or service procedures, always shift the transmission to park or neutral, set the parking brake and block the wheels.
14 Performance A/C Program IV: International ProStar Series! Warning Always provide ventilation when operating an engine in an enclosed area. Inhalation of exhaust gas can be fatal.! Warning Whenever performing procedures that require the batteries to be disconnected, always disconnect the main negative battery cable first. When reconnecting, always connect the main negative battery cable last.! Warning When working with the HVAC system, always wear safety glasses with side shields and use hearing protection. Wear chemicalblocking nitrile gloves any time your hands could come in contact with refrigerant, refrigerant oil or flushing solvents. When working on the HVAC system, keep the work area and tools as clean as possible. Also, clean all connections before disconnecting or removing components. All A/C component and refrigerant line openings should be immediately plugged during removal and remain so until reinstallation to prevent the entry of dirt, moisture and other foreign material. Even the slightest particle can cause problems if carried to a vulnerable place within the system. Federal law mandates that refrigerants must never be released into the atmosphere. They must always be recycled. Be sure that you know the location of properly rated and charged fire extinguishers. Be sure you know the location of an emergency eyewash station. Preliminary Diagnostics Diagnostics should always start by verifying the HVAC concern documented within the service writer s notes. A solid understanding of what the driver is experiencing can help the diagnostic process significantly.
Module 2: Diagnostics 15 If the concern is not evident, do a simple walk-around inspection. Look for the most obvious problems: Does the compressor have a drive belt? Is there any damage to hose lines or fittings? Is there any oil residue at line fittings, which could be a sign of a leak? Is the condenser free of debris? Is it free of oil residue and signs of leaking? If the walk-around doesn t reveal anything, start the engine, turn on the air conditioning system, and check to see if the compressor is turning. Then check for trouble codes. DTCs The body controller monitors the refrigerant sensors, both the transducer and the thermistors, as well as other system parameters to determine if they are all within acceptable limits. If the parameters are acceptable, the body controller turns on the compressor when requested by the system. It cycles the compressor to keep the system within acceptable operating specifications. If the body controller detects readings outside of the acceptable range, it generates and logs a diagnostic trouble code, or DTC.! Warning To avoid property damage, personal injury or death, refer to the manufacturer s service information before working on any high voltage equipment. By definition, high voltage circuits and components contain voltage levels that may cause equipment damage, electrical shock and/ or electrocution if handled incorrectly. Only a trained technician may perform service inside high voltage components. If you will be working around or maintaining high voltage circuits, please seek high voltage training. For further information refer to TSI 06-08-05 on ISIS.
16 Performance A/C Program IV: International ProStar Series Testing After you complete your walk-around and have cleared all DTCs, but you still haven t been able to rectify the driver s concern, perform the standard A/C diagnostic tests. Refer to Performance A/C Programs I and II for detailed diagnostic instructions. Also, refer to ISIS for the most up-to-date specifications for the International ProStar system.
Module 3: Repair Procedures 17 Repair Procedures Filter Drier Assembly Removal The filter drier inlet and outlet lines are part of the filter drier assembly. Disconnect the condenser-toevaporator line from the filter drier inlet line. Discard the C-plate and O-ring. Cap both lines. Remove the screw securing the filter drier inlet line clamp to the evaporator housing. Remove the screw securing the filter drier outlet lock plate to the expansion valve. Remove the lock plate from the top of the expansion valve. While supporting the filter drier, remove the two mounting bolts securing it to the evaporator housing. Remove the filter drier. Discard the O-rings and cap all openings.! Module 3 Caution You must recover the refrigerant from the system prior to servicing any refrigerant system component. Note When removing and replacing multiple components for the air conditioning system, the filter drier should be the last component installed. This reduces the amount of time the desiccant is exposed to atmospheric moisture. Note Remove tie straps as necessary and be sure not to bend any lines when disconnecting them. Hold line fittings together when re connecting them to avoid twisting or bending.
18 Performance A/C Program IV: International ProStar Series Filter Drier Assembly Installation Remove the cap plug and install new, lubricated O-rings on the filter drier outlet tube. Remove the cap plug from the expansion valve. Insert the filter drier outlet tube into the expansion valve. Mount the filter drier to the evaporator housing and tighten the mounting bolts. Position the lock plate on top of the expansion valve and torque to the specification found on ISIS. Install a screw, securing the filter drier inlet tube clamp to the evaporator housing. Remove the cap plugs from the lines. Install a new, lubricated O-ring and C-plate. Connect the condenser-toevaporator line to the filter drier inlet line. Torque the block fitting to the specification found on ISIS.
Module 3: Repair Procedures 19 Expansion Valve Removal Remove the filter drier as shown earlier in this module. Remove the two cap screws from the expansion valve body. Lift the output thermistor line from the top of the expansion valve. Discard the O-ring and cap the line and opening. Remove the expansion valve. Discard the remaining O-rings and cap the lines and openings. Remove the bottom lock plate. Expansion Valve Installation Remove the cap plugs from the evaporator inlet and outlet lines. Install new, lubricated O-rings on both lines. Install the bottom lock plate to the evaporator inlet and outlet lines. Remove the cap plugs from the evaporator side of the expansion valve and position the expansion valve on top of the evaporator inlet and outlet lines.
20 Performance A/C Program IV: International ProStar Series Secure the expansion valve to the lock plate with two cap screws. Torque the cap screws to the specification found on ISIS. Remove the cap plug from the outlet thermistor line and install a new, lubricated O-ring. Insert the outlet thermistor line into the top of the expansion valve. Install the filter drier as shown previously in this module. Rear Heater Core Removal Note Be sure to use a suitable drain pan when working with components or opening lines with engine coolant. Disconnecting or removing components may cause coolant to be discharged from the system. Remove the right side, rear-most aerodynamic skirt from the vehicle. Install clamping pliers on the heater core inlet and outlet hoses. Remove the hose clamps and the hoses from the heater core. Cap the hoses. Remove the heater core retaining cover. Partially remove the heater core. Remove the lock plate fitting. Remove the tubes from the heater core.
Module 3: Repair Procedures 21 Discard the O-rings and cap all lines and openings. Remove the heater core and then the tubes. Rear Heater Core Installation Install the heater core tubes and then partially install the heater core. Remove the cap plugs. Install new O-rings and insert the tubes into the heater core. Install and tighten the lock plate. Push the heater core into position. Install the heater core retaining cover. Remove the cap plugs from the heater hoses. Install the heater hoses and clamps. Remove the clamping pliers from the heater core inlet and outlet hoses. Top off the cooling system.
22 Performance A/C Program IV: International ProStar Series Rear Evaporator Core Removal Remove the heater core as previously shown in this module. Remove the refrigerant lines from the expansion valve and discard the lock plate retaining nut. Discard the O-rings. Cap the lines and openings. Remove the two expansion valve cap screws and then remove the valve. Discard the remaining O-rings and cap the remaining openings. Open the right-side compartment door. Disconnect the linear power module harness and the blower motor harness. Remove the blower motor. Remove the air distribution duct. Remove the output temperature sensor. Remove the air filter. Remove the HVAC housing upper section.
Module 3: Repair Procedures 23 Remove the evaporator core retaining screw. Remove the evaporator core. Rear Evaporator Core Installation Install the evaporator core. Install the evaporator core retaining screw. Align the temperature door and install the upper HVAC housing. Install the air filter. Install the output temperature sensor. Install the air distribution duct. Install the blower motor. Reconnect the blower motor harness and the linear power module harness. Remove the cap plugs from the evaporator core and the expansion valve. Install new, lubricated O-rings. Install the expansion valve and torque the cap screws to the specification found on ISIS.
24 Performance A/C Program IV: International ProStar Series Remove the cap plugs from the refrigerant lines. Install new, lubricated O-rings. Connect the refrigerant lines to the expansion valve. Using a new locknut, install the lock plate and torque to specification found on ISIS. Reinstall the heater core as shown previously in this module. Top off the cooling system. Also, follow the proper procedures to evacuate and recharge the refrigerant system. Rear HVAC Housing Removal Remove the right side, rear-most aerodynamic skirt from the vehicle. Install clamping pliers on the heater core inlet and outlet hoses. Remove the heater hoses and refrigerant lines as previously shown in this module. Remove the inlet air grill. Remove the heater core cover. Remove the air distribution duct.
Module 3: Repair Procedures 25 Remove all vehicle harness electrical connections from the HVAC housing. Unbolt and remove the HVAC housing from the floor of the sleeper cab. Rear HVAC Housing Installation Install and bolt the HVAC housing to the floor of the sleeper cab. Install all vehicle harness electrical connections to the HVAC housing. Reinstall the air distribution duct. Install the heater core cover. Install the air inlet grill. Reconnect the refrigerant lines and heater hoses as previously shown in this module. Remove the clamping pliers from the heater core inlet and outlet hoses. Top off the cooling system. Also, follow the proper procedures to evacuate and recharge the refrigerant system.
26 Performance A/C Program IV: International ProStar Series Conclusion This concludes Performance A/C Program IV: International ProStar Series. Completion of this educational process is a key component towards International Technician Certification. You are now required to take a post-test via ISIS / Education/Service/Online Testing.
Module 3: Repair Procedures 27 NOTES
28 Performance A/C Program IV: International ProStar Series NOTES
Module 3: Repair Procedures 29 NOTES
30 Performance A/C Program IV: International ProStar Series NOTES