Peterbilt Model 579 HVAC

Section HVAC
Number KM811250/PM820009
Date 08/14/2012
2012 HVAC Service Manual

©2012 PACCAR Corporation
Confidentiality Notice: This document and the information contained herein is proprietary. It shall not be
reproduced, copied or disclosed, in whole or in part, or used for manufacture without the written permission
of PACCAR. You are hereby notified that any dissemination of this information is strictly prohibited.
ii KM811250/PM820009 (08/14/2012)
HVAC
Table of Contents
Safety............................................... 1
Applies To ....................................... 2
Exploded View ................................ 3
What's New ..................................... 4
General Information ....................... 5
Special Tools .................................. 6
Specifications ................................. 7
How It Works................................... 8
Maintenance.................................... 9
Disassembly / Assembly ............... 10
Inspection........................................ 11
Troubleshooting ............................. 12
Glossary .......................................... 13
Index ................................................ 14
KM811250/PM820009 (08/14/2012) iii

iv KM811250/PM820009 (09/30/2011)
HVAC 1
1 Safety
General Safety Instructions....................... 1 - 2
Warnings, Cautions and Notes ................. 1 - 3
Important Safety Notices ........................... 1 - 5
KM811250/PM820009 (08/14/2012) 1-1

1 HVAC
General Safety Instructions

A number of alerting messages are in this
manual. Please read and follow them. They are
there for your protection and information. These
messages can help you avoid injury to yourself or
others and help prevent costly damage to the
vehicle.
1-2 KM811250/PM820009 (08/14/2012)

HVAC 1
Warnings, Cautions and Notes Precautions For Working With

HFC134a (R134a) Refrigerant And
Key symbols and “signal words” are used to
indicate what kind of message is going to follow.
Polyalkleneglycol (PAG) Refrigerant Oil
Pay special attention to instructions prefaced by
symbols and signal words “WARNING”, WARNING!
“CAUTION”, or “NOTE”. Please do not ignore any
• DO NOT breathe A/C refrigerant and oil va-
of these alerts.
por or mist. Exposure may irritate eyes, nose
and throat.
WARNING!
• Additional health and safety information may
When you see this symbol and word, the mes- be obtained from refrigerant and oil manufac-
sage that follows is especially vital. This sig- turers.
nals something that can cause injury or even
• If accidental system discharge occurs, venti-
death. This message will tell you what the haz-
late work area before resuming service.
ard is, what can happen if you don’t heed the
warning, and/or how to avoid it.
CAUTION
CAUTION • The air conditioning system uses HFC134a
(R134a) refrigerant and polyalkleneglycol
This symbol and word signals something that
(PAG) refrigerant oil, which are not compati-
could damage your vehicle.
ble with CFC-12 (R12) refrigerant and miner-
al oil. If the refrigerants are mixed the com-
NOTE pressor may fail.
This symbol gives you information we believe • Do not attempt to use R-12 servicing equip-
to be helpful. The information can be a service ment; damage to the air condition system or
hint or something to assist with the repairing of your servicing equipment will result.
the vehicle. • Use only service equipment that is U.L. listed
and is certified to meet the requirements of
SAE J2210 to remove HFC134a (R134a)
from the air conditioning system.
• Verify the HFC134a (R134a) refrigerant in
the vehicle system and the recycling equip-
ment/recovery tank are contaminant free by
using a refrigerant identifier.
NOTE
The Air Conditioning system is designed for

use only with the specified polyalkleneglycol
(PAG) refrigerant oil for HFC134a (R134a) A/C
systems and HFC134a (R134a) components.
Sanden SP15 PAG oil is the ONLY recommen-
ded oil. The PAG oil is very Hygroscopic. Hy-
groscopic means that it absorbs water. Without
proper sealing, oil will become moisture satura-
ted and should not be used.
KM811250/PM820009 (08/14/2012) 1-3

1 HVAC
NOTE
Take care to follow the handling procedures be-

low:
• Only use the specified SP15 PAG 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 not allow PAG oil to come in contact with
styrofoam parts. Damage may occur.
• Do not allow PAG oil to come in contact with
vehicle paint. Damage may occur.
• If any connection in the refrigerant loop is
opened it should be closed as soon as possi-
ble in order to minimize the amount of mois-
ture that enters the system.
• Any components that are replaced should
have dust caps left in place until the compo-
nent is ready to be installed in the refrigerant
loop.
• Any component removed from the refrigerant
loop should have dust caps in place as soon
as possible in order to minimize moisture in-
trusion.
NOTE
R134a service equipment or vehicle air condi-

tioning systems should not be pressure tested
or leak tested with compressed air.
1-4 KM811250/PM820009 (08/14/2012)

HVAC 1
Important Safety Notices • Corrosion inhibitors and lubricating oils may

contain alkali. Do not get the substance in eyes
WARNING! and avoid prolonged or repeated contact with
skin. Do not swallow. In case of contact,
Improper practices, carelessness, or ignoring immediately wash skin with soap and water. In
any warnings may cause death, personal in- case of harmful contact, immediately contact a
jury, equipment or property damage. physician. Always keep any chemicals OUT
OF REACH OF CHILDREN.
Read and understand all of the safety precautions
• Naptha and Methyl Ethyl Ketone (MEK) are
and warnings before performing any repair. This
flammable materials and must be used with
list contains the general safety precautions that
caution. Follow the manufacturer's instructions
must be followed to provide personal safety.
to ensure safety when using these materials.
Special safety precautions are included in the
Always keep any chemicals OUT OF REACH
procedures when they apply.
OF CHILDREN.
• Work areas should be dry, well lit, ventilated,
and be free from clutter, loose tools, parts, • When working on the vehicle, be alert for hot
ignition sources and hazardous substances. Be parts on systems that have just been turned off,
aware of hazardous conditions that can exist. exhaust gas flow, and hot fluids in lines, tubes,
and compartments. Contact with any hot
• Wear protective glasses and protective shoes surface may cause burns.
when working.
• Always use tools that are in good condition.
• Rotating parts can cause cuts, mutilation or Make sure you have the proper understanding
strangulation. of how to use the tools before performing any
• Do not wear loose-fitting or torn clothing. service work. Use ONLY genuine replacement
Remove all jewelry before working. parts from PACCAR.
• Before beginning any repair, disconnect the • Always use the same fastener part number (or
battery (negative [-] cable) and discharge any equivalent) when replacing items. Do not use a
capacitors. fastener of lesser quality if replacements are
• Disconnect the air starting motor, if equipped, to necessary.
prevent accidental engine starting. • Do not perform any repair when impaired, tired,
• Put a "DO NOT OPERATE" tag in the fatigued or after consuming alcohol or drugs
operator's compartment or on the controls. that can impair your functioning.
• Allow the engine to cool before beginning any • Some state and federal agencies in the United
repair. States of America have determined that used
• Always use blocks or proper stands to support engine oil can be carcinogenic and can cause
the vehicle or vehicle components before reproductive toxicity. Avoid inhalation of vapors,
performing any service work. Do not work on ingestion, and prolonged contact with used
anything that is supported only by lifting jacks or engine oil.
a hoist. • Liquefied petroleum gas is heavier than air and
• To reduce the possibility of personal injury, use can accumulate near the floor, in sumps, and low-
a hoist or get assistance when lifting lying areas.
components that weigh 23 kg [50 lb] or more. • Close the manual fuel valves prior to performing
Ensure all lifting devices such as chains, hooks, maintenance and repairs, and when storing the
or slings are in good condition and are of the vehicle inside.
correct load capacity. Make sure any lifting
devices are positioned correctly. Always use a • California Proposition 65 Warning - Diesel
spreader bar when necessary. The lifting hooks engine exhaust and some of its constituents are
must not be side-loaded. known to the State of California to cause
KM811250/PM820009 (08/14/2012) 1-5

1 HVAC
cancer, birth defects, and other reproductive

harm.
• DO NOT breathe A/C refrigerant and oil vapor
or mist. Exposure may irritate eyes, nose and
throat.
• Additional health and safety information may be
obtained from refrigerant and oil manufacturers.
• If accidental system discharge occurs, ventilate
work area before resuming service.
1-6 KM811250/PM820009 (08/14/2012)

HVAC 2
2 Applies To
Applicability ................................................ 2 - 2
KM811250/PM820009 (08/14/2012) 2-1

2 HVAC
Applicability
The information here applies to:
Table 1
Peterbilt Model Cab Sleeper*
579 Yes Yes
386, 384, 365, 388,

No Yes
389
587 No No
Kenworth Model Cab Sleeper*
T660, T680, T800 Yes Yes
W900 No No
T700 No No
*refers to the HVAC blower unit, does not refer to the sleeper
HVAC control head.
2-2 KM811250/PM820009 (08/14/2012)

HVAC 3
3 Exploded View
HVAC System Overview ............................ 3 - 2
Cab Air Handling Unit Overview ............... 3 - 3
Sleeper HVAC Unit ..................................... 3 - 4
KM811250/PM820009 (08/14/2012) 3-1

3 HVAC
HVAC System Overview

HVAC Refrigerant System Component Overview
1. Refrigerant Compressor 3. Receiver Dryer 5. Cab Air Handler
2. Suction Line 4. Cab Thermal Expansion Valve (TXV) 6. Discharge Line
3-2 KM811250/PM820009 (08/14/2012)

HVAC 3
Cab Air Handling Unit Overview

Cab Air Handling Unit Overview
1. Blower Motor 4. Temperature Actuator 7. Panel Actuator
2. Evaporator Core 5. Floor Actuator 8. Intake Actuator
3. Heater Core 6. Defrost Actuator
KM811250/PM820009 (08/14/2012) 3-3

3 HVAC
Sleeper HVAC Unit

Sleeper HVAC Unit
3-4 KM811250/PM820009 (08/14/2012)

HVAC 5
5 General Information
A/C System Recovery, Evacuation
and Charging........................................... 5 - 2
KM811250/PM820009 (08/14/2012) 5-1

5 HVAC
A/C System Recovery, Evacuation and A/C System Refrigerant Recovery

Charging
NOTE
Refrigerant Identification When repairing a vehicles A/C system be sure
to wear safety equipment including goggles
Prior to recovery of refrigerant with an R134a
and appropriate clothing. Refrigerant vaporizes
refrigerant recovery machine the refrigerant in the
at -13°F (-25°C) and will freeze skin. Never al-
vehicle must be verified or contamination of the
low large quantities of refrigerant to escape in
machine may occur. Stored containers of
a closed space as it displaces oxygen and can
refrigerant should also be verified as R134a with
lead to death. An ignition source should never
a refrigerant identifier.
be near R134a gas.
1. Follow the instructions on the refrigerant
identifier. Prior to recovery of refrigerant an A/C refrigerant
2. Take the sample and review the findings. analyzer should be utilized to verify the vehicle
refrigerant purity. Failure to check the refrigerant
3. If contaminated refrigerant is identified repeat purity may risk contaminating the R134a
the test to verify that the material is refrigerant recovery machine and your refrigerant
contaminated. source. If the refrigerant is contaminated refer the
If the refrigerant is contaminated DO NOT customer to the last location of A/C service or
recover the refrigerant into an R134a utilize a dedicated recovery cart to recover the
refrigerant recovery machine it may damage refrigerant. All contaminated refrigerant must be
the machine and will contaminate the supply recovered and disposed of as hazardous waste.
of refrigerant. Refrigerant that is contaminated
may not be recycled. The mixed refrigerants 1. Before recovery begins verify the purity of the
should be reclaimed or destroyed by a refrigerant in the vehicle.
properly licensed facility. The EPA maintains 2. Connect the R134a refrigerant recovery
a list of reclaimers. The website is machine to the low and high pressure service
www.epa.gov/ozone/title6/608/ reclamation/ ports. Follow recovery machine operating
reclist.html. instructions.
4. Recover the contaminated refrigerant using a 3. Recover the refrigerant per the recovery
dedicated recovery cart or other appropriate machine operating instructions provided by
equipment that is used for contaminated the manufacturer. Identify and record the
refrigerant only. amount of oil that is recovered during the
recovery.
NOTE
4. Shut off the recovery machine.
If this is not available contact a location that 5. Leave the service hoses connected to the
has the appropriate facilities. DO NOT vent the system and allow the system to sit for 5
refrigerant to atmosphere. minutes. If the vacuum in the system holds for
5 minutes disconnect the service hoses.
5. Continue service of the vehicle based on the
concern of the customer. 6. If the system does lose vacuum repeat steps
3 – 5 until the vacuum level is not lost over a
6. Replace the receiver drier and flush the A/C 5 minute period.
system.
7. Complete the necessary repairs to the A/C
system.
5-2 KM811250/PM820009 (08/14/2012)

HVAC 5
A/C System Evacuation (Using a R134a A/C System Evacuation (Using a R134a
Refrigerant Recovery Machine) Manifold Gauge Set and Vacuum Pump)
1. Connect the R134a refrigerant recovery 1. Connect the R134a manifold gauge set to the
machine to the low and high pressure service low and high pressure service ports.
ports. Follow recovery machine operating
2. Connect the center hose from the gauge set
instructions.
to the vacuum pump suction port.
2. Evacuation of the system should continue
3. All valves on the gauge set and at the high
until the low pressure gauge is at least 29 in-
and low service ports should be open.
Hg (98.2 kPa) - (30in-Hg is preferred). If the
low pressure gauge does not reach at least 4. Turn on the vacuum pump. Evacuation of the
27 in-Hg (91 kPa) in 15 minutes then there is system should continue until the low pressure
a leak in the system. Partially charge the gauge is at least 29 in-Hg (98.2 kPa) - (30in-
system and leak check using refrigerant Hg is preferred). If the low pressure gauge
sniffer leak detector. Evacuation should does not reach at least 27 in-Hg (91 kPa) in
continue for at least 45 min. to allow for any 15 minutes then there is a leak in the system.
moisture to be removed from the system. Partially charge the system and leak check
using refrigerant sniffer leak detector.
3. Turn off the recovery machine and observe
Evacuation should continue for at least 45
the low pressure gauge for 5 minutes to verify
min. to allow for any moisture to be removed
that the vacuum is held. If the vacuum does
from the system.
not hold for 5 minutes, leak test the system,
repair the leak, and evacuate again. 5. Turn off the vacuum pump and observe the
low pressure gauge to verify that the vacuum
is held for 5 minutes. If the vacuum does not
hold for 5 minutes, leak test the system, repair
the leak, and evacuate again.
KM811250/PM820009 (08/14/2012) 5-3

5 HVAC
Charging the A/C system (Using a A/C System Flushing

R134a Refrigerant Recovery Machine)
NOTE
1. Add the appropriate amount of PAG SP15 oil
(and dye if necessary) that is to be injected to When repairing a vehicles A/C system be sure
the system (see A/C Refrigerant Oil to wear safety equipment including goggles
Replacement on page 5-5) to the oil charge and appropriate clothing. Refrigerant vaporizes
reservoir. at -13°F (-25°C) and will freeze skin. The A/C
2. Connect the low and high side service valves refrigerant should be analyzed for purity and re-
to the service ports and follow the machine moved from the vehicle. Before flushing the re-
specific instruction manual to charge the ceiver drier and TXVs should be removed from
system. the vehicle and replaced with connectors to
loop the system.
3. Set the refrigerant amount and oil charge
amount and follow the instructions.
NOTE
4. Replace service valve caps to prevent leaks.
A full oil charge is standard in replacement com-
pressors 10.1 oz (300 cc) and must be utilized
if a system is completely flushed clean.
Flushing or replacement of all A/C system

components is required if a compressor fails
internally. The failed compressor will have
distributed debris throughout the A/C system. The
receiver drier, condenser, front and sleeper
thermal expansion valves (TXVs) and complete
oil charge (new compressor comes with full oil
charge) must all be replaced.
The condenser tubes have a small cross section

and removal of this debris is not possible. The
condenser should be replaced following a
compressor internal failure. The receiver drier has
a fine mesh filter that is not serviceable and will
require replacement following a compressor
failure. TXVs have a small orifice where debris
can lodge and impair correct operation. The
TXV(s) should be replaced following a
compressor internal failure.
All A/C lines, evaporator(s) should be flushed

prior to installing new components and
evacuating the system. The evaporators should
be flushed in the reverse flow direction in order to
dislodge any debris.
Connect the A/C flush machine to each

component individually. Flushing of the
component should be continued for a minimum of
20 minutes. After flushing a component be sure to
replace dust caps to keep the fittings clean and
moisture out.
5-4 KM811250/PM820009 (08/14/2012)

HVAC 5
After all components are flushed completely the A/C Refrigerant Oil Replacement – Oil
refrigerant system should be closed and Balancing
evacuation should be completed for one hour to
eliminate any of the flushing solvent. If a new Under normal operating conditions oil is
compressor is installed the complete oil charge circulated through the A/C system with the
(service compressors are shipped with the 10.1 refrigerant. When the system is not operating, the
oz / 300 cc oil charge) is installed with the oil settles to the lowest points in the system.
compressor. These low points are typically the suction lines
and evaporator. Oil will typically settle out in the
If a new compressor is not being installed follow cooler parts of the system.
the oil balancing process.
When a component is serviced the small amount
of oil that is retained in each of the components
requires replacement. It is necessary to balance
the oil charge in the vehicle when servicing
components and/or the refrigerant charge. The
chart below identifies the component, the amount
of PAG oil to be added to the system, and the
method of adding the oil that is recommended.
Component Amount of SP15 Method to add

oil to add
Front Evaporator 2 oz (60 ml) Add to evaporator inlet

tube or inject to low side
port during A/C charge
Rear Evaporator 1 oz (30) ml Add to evaporator inlet

Condenser 2 oz (60 ml) Add to condenser inlet

Receiver Drier 1.5oz (45ml) Add to receiver drier in-

let or inject to low side
Large leak (cut AC 3.0 oz (88ml) Inject to low side port

line) during A/C charge
Small leak (loose fit- 1 oz (30) ml Inject to low side port

ting) during A/C charge
Suction line to rear 2.5 oz (74ml) Inject to low side port

evaporator during A/C charge
Other line or hose 1 oz (30) ml Inject to low side port

during A/C charge
KM811250/PM820009 (08/14/2012) 5-5

5 HVAC
Component Amount of SP15 Method to add Oil Balancing Procedure – EXAMPLE 1

oil to add
A truck that requires new compressor, new
Compressor Balancing proce- Add to compressor -
condenser, and refrigerant charge. System has
dure see compres- see balancing procedure
been flushed
sor replacement
section
Drain oil from old compressor 2.0 oz
When replacing a component in the A/C system it
Oil remaining in old compressor (0.5 oz will re- 0.5 oz
is important to replace the PAG SP15 oil that is
main in compressors as film coating)
lost with the component and any oil lost that may
have escaped from the system. The total amount Condenser replacement oil (from oil charge 2.0 oz
of oil in the system is listed on the sticker of the chart)
compressor and is 10.1 oz (300 cc). It is Oil in recovery machine 1.0 oz
important for proper compressor lubrication that
Amount of oil to be replaced 5.5 oz total
this amount be maintained as close as possible to
the design intent.
New compressor shipped with (system oil 10.1 oz
amount per design intent)
Amount of oil to be replaced Subtract this from - 5.5 oz

the new compressor oil amount
Amount of oil that needs to be drained from 4.6 oz

new compressor
5-6 KM811250/PM820009 (08/14/2012)

HVAC 5
Oil Balancing Procedure – EXAMPLE 2

Truck that requires new condenser and
refrigerant charge.
Condenser replacement oil 2.0 oz

(from oil charge chart)
Oil in recovery machine 1.0 oz
Amount of oil to be replaced 3.0 oz total
KM811250/PM820009 (08/14/2012) 5-7

5-8 KM811250/PM820009 (08/14/2012)
HVAC 6
6 Special Tools
Hand Tools .................................................. 6 - 2
KM811250/PM820009 (08/14/2012) 6-1

6 HVAC
Hand Tools
Torx T20
Fluke Digital Multimeter or equivalent
Test light
ESA tool
Shop ambient thermometer
6-2 KM811250/PM820009 (08/14/2012)

HVAC 7
7 Specifications
A/C Refrigerant Oil ..................................... 7 - 2
Electrical System - Block Diagram ........... 7 - 3
Pinout Information...................................... 7 - 5
KM811250/PM820009 (08/14/2012) 7-1

7 HVAC
A/C Refrigerant Oil
System requirements: Oil capacity
Oil Type Capacity
Sanden SP-15 PAG 10.1 oz (300 cc)
7-2 KM811250/PM820009 (08/14/2012)

HVAC 7
Electrical System - Block Diagram
Cab HVAC
KM811250/PM820009 (08/14/2012) 7-3

7 HVAC
Sleeper HVAC
7-4 KM811250/PM820009 (08/14/2012)

HVAC 7
Pinout Information
Engine Harness
KM811250/PM820009 (08/14/2012) 7-5

7 HVAC
Instrument Panel Harness
7-6 KM811250/PM820009 (08/14/2012)

HVAC 7
Sleeper Control Harness
KM811250/PM820009 (08/14/2012) 7-7

7 HVAC
Sleeper Harness
HVAC Control Wire Harness Connector
7-8 KM811250/PM820009 (08/14/2012)

HVAC 7
KM811250/PM820009 (08/14/2012) 7-9

7 - 10 KM811250/PM820009 (08/14/2012)
HVAC 8
8 How It Works
Functional Description............................... 8 - 2
A/C Line Layout ......................................... 8 - 8
Fitting Features – Slim Line Seals ............ 8 - 9
A/C Line Diagram...................................... 8 - 10
System Components................................ 8 - 11
KM811250/PM820009 (08/14/2012) 8-1

8 HVAC
Functional Description The Heating Cycle

The cab and sleeper have “blend air” units. Heating is the act of adding heat to the air. This is
Airflow path through the heater and evaporator accomplished by bringing air into contact with a
cores is controlled by air deflection doors to hot surface — in this case, a heater core located
control both air temperature and mode. in the blower unit. The vehicle’s engine supplies
the heat for the heating cycle. Hot engine coolant
The air that circulates inside the vehicle can is constantly routed to the heater core. For
come from outside the vehicle (fresh air mode) or vehicles with a sleeper, heated coolant will be
can be recirculated air from inside the vehicle diverted in parallel for independent temperature
(recirc mode). control by the water pump and heater hoses. As
coolant flows through it, the air absorbs heat from
The cab HVAC air handling unit is capable of
the coolant by flowing across the tubes of the
circulating fresh air or recric air in the cabin. A
heater core. The cycle is completed when the
vehicle that is equipped with a sleeper HVAC air
coolant absorbs heat from the engine and is
handling unit is capable of circulating recirc air only.
again pumped into a heater core.
Fresh air that is circulated by the cab HVAC is
Unheated air is drawn into the system by the
filtered by a fine particulate filter mounted in the
blower. Air is directed through a heater core by a
air intake housing, outside the cab, in the engine
blend air door, where it absorbs heat from the
compartment.
core. Air is distributed to the cab via ducting and
Cab recirculated air is filtered via a coarse filter air deflection doors. The amount of heat added to
that is located inside the cab, between the blower the air is controlled by the rate of airflow (i.e., the
motor and the front wall. speed of the blower and the position of the air
deflection door).
Sleeper recirculated air is filtered by a fine
particulate filter (similar to the fresh air filter
mounted in the engine compartment) that is
housed in the HVAC air handling unit under the
sleeper bunk.
Proper troubleshooting, diagnosis or repair of this

heating and air conditioning system requires an
understanding of heating and refrigeration cycles
as well as the operation of the basic system. A
review of the principles of heating and air
conditioning will help relate the function of the
major parts.
8-2 KM811250/PM820009 (08/14/2012)

HVAC 8
The Refrigeration Cycle The Control System

Refrigeration removes heat from the air. Heat is The air conditioning system has a traditional
removed from the air by drawing the air over tube- manually controlled heating and cooling system.
fin-type evaporators filled with liquefied R134a. The operator can adjust the airflow, fan speed
The boiling action of the R134a removes heat and temperature as they want. The air
from the air passing through the evaporator, conditioning system is enhanced with two new
producing refrigerated air. The refrigerant moves features that are for automatic climate control and
from the evaporator to the compressor where it is maximum defrost performance.
compressed into a high pressure liquid form. The
heat from this process is then dissipated as the The two new features of the cab control system
liquid passes through the condenser. The incorporates a temperature sensor in the control
refrigerant then travels to the expansion valve to head, a sunload sensor on the dashboard and a
be changed into a low pressure gas that can computer integrated into the control head to
accept heat as it passes through the evaporator enable automatic climate control and MAX defrost
in the cab. control. Logic in the computer will alter air flow
and fan speed to meet the user’s temperature
setting (via the temperature knob on the control
head).
In addition to the traditional manual controls, the

sleeper will have an optional automatic
temperature control that controls the relative
temperature in the air supply. This sleeper
temperature control system is not the same as
the cab automatic climate control. The cab
climate control will control the inside air
temperature relative to the amount of sunlight
exposure and the current outside air temperature.
The new cab climate control for these models
adjusts the settings to control the actual air
temperature in the cab.
The HVAC control system also protects the

compressor by limiting the compressor cycling to
4 cycles per minute.
KM811250/PM820009 (08/14/2012) 8-3

8 HVAC
HVAC Functional Diagram
8-4 KM811250/PM820009 (08/14/2012)

HVAC 8
Air Distribution System Kenworth Instrument Panel
Air is distributed throughout the cabin of the truck

by the Heating, Ventilation, and Air Conditioning
(HVAC) unit, ducts and control. The HVAC unit
directs air to the appropriate location via ducts
based on how the operator sets the control. For
example, if the AUTO button is pushed, the
system will change the air flow distribution, air
source and the fan speed setting to attain the
desired temperature setting.
Air is routed through the HVAC unit by doors that

are driven by direct drive electric actuators to the
appropriate duct(s). 1. Demist outlet
2. Defrost outlet
The air distribution actuators are calibrated 3. Panel outlet
whenever power is removed and restored. 4. Floor outlet
Peterbilt Instrument Panel
1. Demist outlet
2. Defrost outlet
3. Panel outlet
4. Floor outlet
KM811250/PM820009 (08/14/2012) 8-5

8 HVAC
The R134a Refrigeration System HVAC System Diagram
The main component in the refrigeration system

is the refrigerant R134a. It is circulated, under
pressure, through other components including the
compressor, condenser, A/C lines and receiver
drier, Thermal Expansion Valve (TXV), and
evaporator(s).
The refrigeration (air conditioning) system has a

high pressure (discharge or head) side and a low
pressure (suction) side. These high and low sides
are split at the expansion devices and at the
compressor: The function of the receiver drier is to dry the
refrigerant and provide pure liquid to the
The high side extends from the compressor expansion valve(s). Inside the receiver drier is a in-
through the condenser and to the expansion line drier designed specifically to dry and filter the
device. refrigerant before it reaches the thermal
expansion valve(s). An ultraviolet dye wafer is
The low side extends from the outlet of the also inserted into the receiver drier and will
expansion devices through the evaporators, the dissolve into the oil inside the system for easier
accumulator, and then back into the compressor. leak detection during service. It is located
between the condenser and the expansion valve.
The compressor pumps R134a refrigerant
through the air conditioning system. The The receiver-drier should be replaced anytime the
compressor is an engine-mounted assembly. It is refrigerant system is opened for repair or routine
engaged and driven by the engine belt through its maintenance.
clutch pulley. The expansion device meters the amount of
refrigerant entering the evaporator. Refrigerant
The compressor takes in R134a as a low-
changes from a high-temperature, high-pressure
temperature, low-pressure gas, pressurizes it by
liquid to a low-temperature, low-pressure liquid as
means of pistons inside the compressor, and
it passes through the expansion device.
forces it into the condenser as a high-
temperature, high-pressure gas. The output The function of the TXV is to meter the amount of
capacity of the compressor is determined by the refrigerant that flows into the evaporator. The
engine speed: the higher the speed, the greater TXV also replaces the old style accumulator by
the output of the compressor; the lower the accurately metering refrigerant to avoid ‘slugging’
speed, the less the output. of the compressor. This is controlled by the
temperature and pressure of the R134a as it
The function of the condenser is to condense the flows out of that evaporator.
refrigerant gas from the compressor before
entering the expansion device. The refrigerant The evaporator receives low-pressure, low-
enters the condenser at the top through the inlet temperature liquid from the expansion device.
tube as a high-temperature, high-pressure gas. The blower pulls air through for the cab unit and
As it flows through the core, it gives up heat then pushes warm air across the evaporator core.
energy to the ambient air passing over the As the refrigerant flows through the evaporator,
condenser core. The refrigerant becomes a high- heat moves from the warm air to the cooler
temperature, high-pressure liquid; this normally refrigerant. The refrigerant absorbs heat energy
happens in the bottom third of the condenser. during the phase change from liquid to gas. The
This liquid flows out of the bottom of the fins on the evaporator core are colder than the
condenser through the outlet tube and a dewpoint of the air moving across them, causing
refrigerant line to the receiver drier. condensate to form on the fins. The result will be
8-6 KM811250/PM820009 (08/14/2012)

HVAC 8
cool air in the cab or sleeper, with the condensate

from the fins falling to the bottom of the assembly
case and through the drain tube. The now-
gaseous refrigerant (and possibly some liquid)
flows from the evaporator(s) back to the
compressor.
The system is protected on the low side using the

pressure transducer as well as the evaporator
freeze sensor. The transducer uses the high side
pressure along with the ambient air temperature
to define the saturation point of the refrigerant.
The low side pressure is determined from the
high side using look up tables created through
cell testing. If the low side pressure is found to be
near or below the saturation point the compressor
is disengaged. The pressure transducer has 3
connections; ground, power (5V), and output
signal. The only variable is the output signal. A
breakdown of voltage to pressure can be found
with this equation…% VOUT=0.18802 * PSIA +
2.28
KM811250/PM820009 (08/14/2012) 8-7

8 HVAC
A/C Line Layout ISX engine
MX engine
8-8 KM811250/PM820009 (08/14/2012)

HVAC 8
Fitting Features – Slim Line Seals installation unlike previous o-ring connections.
The system utilizes several different sizes of the
The refrigerant connections throughout the A/C slim line washer. This washer may be lubricated
system utilize “peanut” fittings and slim line seals. using Sanden SP-15 oil if the connection is too
The slim line seal helps the vehicle maintain strict dry to assemble. Do not use any other oil or
EPA requirements with respect to Global lubricant other than Sanden SP-15 PAG oil or
Warming Potential refrigerant containment. The damage to the A/C system may result.
slim line seal resists “rolling” or cutting during
Slim Line Seal
KM811250/PM820009 (08/14/2012) 8-9

8 HVAC
A/C Line Diagram

The pictures below identify the size and part
number of the slim line washer that should be
utilized at each joint location.
Engine compartment Slim Line Seals (Day Cab)
Before servicing any refrigerant joint be sure to

recover all refrigerant utilizing the A/C system
recovery cart. The A/C system should have a
negative pressure prior to opening any
connection to service it. Refer to A/C service
precautions.
After opening any refrigerant connection be sure

to plug all open connections to prevent moisture
intrusion and collection of dirt and debris.
Engine compartment Slim Line Seals (sleeper) Do not remove dust caps from replacement
components until the it is ready for assembly.
Utilize new slim line seals at all suspected leak

connections. Be careful not to damage the slim
line seal when installing the seal over the male
peanut fitting.
After joints are assembled be sure to tighten the

line to the proper torque and always use a torque
wrench to verify connection torque.
All A/C connection joints require a torque of 15.5

lb-ft ± 2.2 (21 Nm ± 3).
8 - 10 KM811250/PM820009 (08/14/2012)
HVAC 8
System Components Ducts

Mode doors are located in the system to direct
Motor/Blower Assembly the air to the appropriate outlets. These doors are
positioned by electric actuators that are controlled
Mounted on the air conditioning unit case, a
by the HVAC control unit on the control panel.
blower motor and wheel assembly is used to
move air across the heater and evaporator cores
and distribute the air through the air duct system.
The blower draws air from either the outside
(fresh air) or cab (recirculated air). All the air
passes through the evaporator cores in both
systems (cab and sleeper) regardless of what
mode the system is in.
The cab blower motor is a brushless type

therefore there are no resistors on the unit. The
blower unit in the optional sleeper, however, is
not brushless and does have a resistor mounted
on the air unit in the sleeper.
Motor/Blower Assembly
KM811250/PM820009 (08/14/2012) 8 - 11
8 HVAC
Hoses and Fittings Heater Core

Heater hoses are 5/8-inch (16 mm) ID rubber or This system uses an aluminum heater core to
silicone hoses. They are attached to other achieve reduced weight and improved efficiency.
components with spring clamps. The heater core is designed to work in concert
with a by-pass valve that reduces flow and
Refrigeration system hoses are constructed with pressure in the heater core and increases
single braid polyester hose and reinforced with durability.
chlorobutyl rubber covers.
The heater core by-pass valve allows flow to the
Refrigeration system switch ports have metric heater core up to a defined pressure/flow point
instead of standard threads. (6.5 gpm). When that point is reached, the valve
will divert coolant back to the coolant pump. It is
NOTE designed to protect the heater core from high
pressure/flow and failures from pressure and
Mineral oil is NOT recommended over PAG oil erosion. The bypass valve is mechanical using a
for slim line washer seal lubrication prior to in- spring to open a seal on a bypass loop. Pressure
stallation. However PAG oil has a greater affini- of the supply coolant is the applying force that
ty for water and care should be taken to keep causes the spring to compress and allow coolant
oil canisters tightly capped. to bypass the heater core.
Refrigeration system fittings that require O-rings Heater Core

will use HNBR R134a slim line washer style seals
not O-rings.
8 - 12 KM811250/PM820009 (08/14/2012)
HVAC 8
R134a Refrigerant (Tetrafluoroethane) Compressor

R134a/R134aUV operates at higher pressures The Sanden SHD compressor is standard with
than R12. R134a HVAC systems. Sanden has designed this
compressor specifically for use with R134a and
The boiling point of R134a/R134aUV is -14.9°F has incorporated new seal materials and a
(-26°C) and will be reached instantly when sturdier design to handle higher operating
exposed to the atmosphere. pressures that can occur with R134a systems. A
diode in this system suppresses any compressor/
WARNING! clutch voltage spike when the compressor clutch
disengages.
Always take measures to avoid frostbite or eye
damage when working with R134a or Lubrication is very important to the compressor in
R134aUV. Wear protective clothing and eye pro- that it reduces friction and component wear. PAG
tection. Failure to comply may result in death, oil will lubricate the compressor while the system
personal injury or equipment damage. is running.
Liquids are virtually incompressible; therefore,

any liquid refrigerant entering the compressor will
damage the reed valves and the pistons.
KM811250/PM820009 (08/14/2012) 8 - 13
8 HVAC
Compressor Clutch Pressure Transducer

The compressor clutch drives the compressor. It
is powered by the accessory drive belt and
operated by a relay.
An electromagnet is mounted inside the pulley of

the compressor clutch and is bolted to the
compressor, setting up a magnetic field between
the pulley and drive plate. This magnetic field
allows the pulley to lock up to the drive plate, thus
engaging the clutch and allowing the pulley to
turn the compressor shaft.
A diode in this system suppresses any compressor/

clutch voltage spike when the compressor clutch
The refrigerant system is protected against
disengages.
pressures that are outside normal operating
When the clutch is disengaged, the pulley will conditions (high or low) by a refrigerant pressure
spin free without turning the compressor shaft. transducer located on the discharge line. The
control head inside the vehicle reads the signal
The compressor clutch includes a thermal fuse. from the transducer and will disable the
The fuse protects the unit from overheating, thus compressor when the pressure reading is outside
preventing truck down conditions. of normal operating conditions – approximately
424 psi (29.3 bar). The fan clutch is locked on at
Compressor and Clutch Assembly approximately 330 psi (22.8 bar) and allowed off
at 235 psi (16.4 bar).
8 - 14 KM811250/PM820009 (08/14/2012)
HVAC 8
Evaporator Thermistor Compressor Pressure Relief Valve

(PRV)
A thermistor that is mounted in the HVAC unit
monitors the temperature of the air that has The compressor is protected by a high pressure
passed through the evaporator. If the air relief valve located on the body of the
temperature is low enough to cause the compressor. The PRV will open automatically if
condensed water to freeze then compressor the pressure in the compressor reaches an
clutch will be disengaged. abnormally high level of approximately 508-595
psig.
KM811250/PM820009 (08/14/2012) 8 - 15
8 HVAC
Control Algorithms Sensors

The control head is programmed with specific The pressure transducer is located on the
control algorithms that monitor the pressure discharge AC line from the compressor to the
transducer, system voltage, component status, condenser. It monitors the AC system pressure
evaporator core temperature, outside air and cab and works with the control head to determine
temperatures, and light sunload on the vehicle. clutch engagement.
These parameters are all utilized to adjust
comfort for the operator and protect the system if The evaporator temperature sensor is located on
a component in the system fails. Refer to the the cab evaporator module. This sensor does not
troubleshooting section in this manual for the exist on the sleeper HVAC unit.
DTC codes and input parameters.
The ambient air temperature (outside air
temperature [OAT]) sensor is located on the
bottom of the drivers mirror. For more information
regarding the ambient air temperature sensor,
see the Electrical Manual.
The cabin air temperature sensor is located on

the control head.
8 - 16 KM811250/PM820009 (08/14/2012)
HVAC 8
Filter/Receiver Drier Expansion Devices

Where applicable, the filter/receiver-dryer This system utilizes a Thermal Expansion Valve
receives high-pressure, high-temperature liquid (TXV). The TXV controls refrigerant flow through
refrigerant from the condenser. It is an in-line a spring loaded valve.
dryer designed to dry and filter the refrigerant
before it reaches the expansion devices. The thermal expansion valve uses inputs from the
pressure signal from the temperature sensing
The receiver drier also contains a UV dye wafer bulb and the pressure of the evaporator outlet.
that dissolves in the PAG oil and helps in The resulting net pressure value is what is used
detecting leaks. by the top potion of the TXV valve. These two
pressures countering against one another will
Filter-Drier equalize the pressure against the top of the valve
diaphragm. A large net pressure value will signal
the TXV valve to allow more refrigerant through.
Whereas a low net pressure value would indicate
a potential slugging situation, therefore the TXV
valve would reduce the amount of refrigerant
supplied to the evaporator core.
Whether the TXV opens or closes depends on

the need for R134a at the evaporator inlet port.
The gas in the TXV power head contracts and
expands from the heat in the suction side of the
valve and pushes against the top of the
diaphragm. This pushing action will open the valve.
Expansion Devices (TXV)
KM811250/PM820009 (08/14/2012) 8 - 17
8 HVAC
Evaporator Cab Evaporator
An aluminum tube and tank evaporator core is

used with the R134a system.
Aluminum cores offer reduced weight and

improved efficiency. The fins on the core are
colder than the air moving across them causing
condensate to form on the fins. The result will be
cool air in the cab and the condensate from the
fins will fall to the bottom of the assembly case
and out the drain tube.
The evaporator receives low pressure, low

temperature liquid from the expansion device. As
the refrigerant flows through the evaporator coil,
heat moves from the warm air to the cooler
refrigerant. The refrigerant absorbs energy during
the phase change from liquid to a gas.
In normal operation, the expansion valve will

meter the proper amount of refrigerant into the
evaporator to ensure that all of the liquid R134a
changes to vapor before it reaches the
compressor. However, there are certain
conditions that may exist in the system that
prevent the evaporator from performing to its
capacity.
Evaporator has too little refrigerant:
The expansion valve will not be able to meter the

correct amount of refrigerant into the evaporator
coil. The R134a will vaporize too quickly before
passing through the evaporator and poor cooling
will result.
Evaporator has too much refrigerant:
If too much refrigerant is allowed to enter the

evaporator poor cooling will result due to the high
pressure of the R134a. The R134a will not
vaporize quickly enough and liquid refrigerant will
be allowed to leave the evaporator. Too much
condensate may accumulate on the evaporator
coil and the refrigerant temperature becomes too
low. The moisture will freeze on the fins and
restrict airflow across the core. This will inhibit
performance. A good example of when this
problem may occur is if the humidity is high and
the Fresh Air mode is selected.
8 - 18 KM811250/PM820009 (08/14/2012)
HVAC 8
Control Panels Peterbilt Cab Control With Bunk Override
The control panel in the cab is the only control

panel for cab air conditioning. If the vehicle has a
sleeper, a separate and independent control
panel will operate the air conditioner for the
optional sleeper. This manual does not cover the
control panel in the optional sleeper. Vehicles
with sleepers will have an additional button on the
control head that will allow the sleeper controls to
work. This button is in the center of the right most
knob (air flow mode).
Kenworth Cab Control With Bunk Override 1. Fan Control Dial
2. AUTO Mode
3. Temperature Control Dial
4. MAX Defrost
5. Dash & Floor
6. Dash
7. Floor & Defrost
8. Defrost
9. Sleeper Override (if equipped)
10. Floor
11. Air Conditioner Enable
12. Fresh Air / Recirculate
1. Fan Control Dial Sleeper Control Panel
2. AUTO Mode
The conventional sleeper control panel will have
3. Temperature Control Dial
three controls (two for vehicles without air
4. MAX Defrost
conditioning).
5. Dash & Floor
6. Dash 1. A rotary knob (A) in the left portion controlling
7. Floor & Defrost the blower speed with four settings.
8. Defrost
2. A rotary knob (B) in the right portion
9. Sleeper Override (if equipped)
controlling the air temperature.
10. Floor
11. Air Conditioner Enable 3. A rocker switch/push button (C) in the center
12. Fresh Air / Recirculate portion to engage the air conditioner
compressor (only vehicles with air
conditioning).
KM811250/PM820009 (08/14/2012) 8 - 19
8 HVAC
Pressure Switches Relays, Fuses, And Resistors

1. The R134a system has one pressure Relays, fuses, and resistors are an integral part of
transducer. this system. They are electrical controls that are
2. Freeze switch (for vehicles built after July not normally affected by temperature and pressure.
2008).
Relays
A relay is an electrical device in the wiring circuit

used to distribute power. It is used when the need
for power exceeds the ability of the control switch.
All of the wiring harnesses coming from the
control panels are wired through relays. The
relays are used as logic controls.
The compressor is controlled directly by a relay.

A diode in this system suppresses any compressor/
clutch voltage spike when the compressor clutch
disengages.
For location of fuses and relays on the vehicle,

not on the HVAC unit itself, please refer to the
electrical service manual.
Resistor
For the sleeper HVAC unit only, A 4-level resistor

is used to control blower speed by varying the
voltage to the blower motor. The resistor has a
thermal limiter for upper temperature protection;
this limiter is set at 363°F (184°C) for this system.
If the temperature reaches this value at the
resistor due to malfunction or debris jammed in
the blower wheel that prevents it from turning, the
thermal limiter opens up the circuit and shuts off
power to the blower motor. This resistor is located
in the sleeper HVAC unit.
Air Filters
For the applicable models as shown in Table 1 on

page 2-2, air filters are designed into the system
for fresh air cab filtering and also a recirculation
cab air filter.
The sleeper HVAC also has an independent air

filter. Both the cab and the sleeper air filters have
the same specifications and size.
8 - 20 KM811250/PM820009 (08/14/2012)
HVAC 9
9 Maintenance
General Information ................................... 9 - 2
Cab HVAC Fresh Air Filter

Replacement ........................................... 9 - 3
Cab HVAC Recirculation Air Filter

Replacement ........................................... 9 - 4
Sleeper HVAC Air Filter Replacement ...... 9 - 5
KM811250/PM820009 (08/14/2012) 9-1

9 HVAC
General Information
Replacement of the filters is recommended at
regular intervals based on driving habits and
conditions.
HVAC AIR FILTER MAINTENANCE SCHEDULE
Filter Inspect Replace
Cab HVAC Fresh Air Weekly As necessary
Cab HVAC Recirc Air Annually As necessary
Sleeper HVAC Air Weekly As necessary
9-2 KM811250/PM820009 (08/14/2012)

HVAC 9
Cab HVAC Fresh Air Filter Replacement 6. Replace the filter cover on the air intake
housing and slide the cover forward in
The fresh air filter for the cab HVAC is located in vehicle. An audible snap sound can be heard
the air intake housing that is located in the when the cover is correctly in place. If the
passenger rear corner of the engine snap feature is damaged there are two screw
compartment. The filter can be replaced without features that may be utilized to retain the
using any tools. cover in place.
1. Tilt the hood open. 7. Close and secure hood of vehicle.
2. Locate air intake housing at passenger rear
corner of vehicle under the rain tray.
3. Locate filter cover labeled “OPEN” with an

arrow pointing rearward in vehicle. Slide filter
cover rearward in vehicle until you are able to
remove the cover.
4. Remove and inspect filter referring to
maintenance interval schedule.
5. Replace filter in housing taking care to align
the airflow direction that is indicated on the
side of the side of the filter element with the
airflow direction that is clearly marked on the
air intake housing.
KM811250/PM820009 (08/14/2012) 9-3

9 HVAC
Cab HVAC Recirculation Air Filter

Replacement
The recirculation filter is located on the front side
the HVAC assembly against the inside of the
bulkhead on the passenger side of the vehicle.
Access to this area requires the removal of the

lower trim panel and glove box assembly.
1. Park the vehicle on a level surface, set the
parking brake, and turn the engine off. Block
the tires.
2. Access to the unit is from behind the
glovebox. The sequence of panels that
precede removing the glovebox is covered in
the Dash Service Manual. All kick panels
must be removed in order to remove the
glovebox.
For Peterbilt only, the glovebox and its
surround must be removed to access the
equipment.
3. Reach through the glove box access and
remove the white filter media from the left side
of the recirculation housing.
4. Slide new filter media (or cleaned media) into

position making sure that the media seats into
slots at top and bottom. If the filter is installed
correctly there should be white media
showing at either side of the blower scroll.
5. Re-assemble the glove box assembly to the
instrument panel substrate.
6. Re-assemble the passenger side kick panel
to the instrument panel substrate.
9-4 KM811250/PM820009 (08/14/2012)

HVAC 9
Sleeper HVAC Air Filter Replacement

The recirculation filter is located under the
sleeper bunk, on the passenger side of the vehicle.
Access to this area requires lifting the bunk.
The filter can be replaced without using any tools.

the tires.
2. Lift the sleeper bunk to expose the sleeper
HVAC module.
4. The filter element can be pulled straight up to

be removed.
NOTE
Note there is a retention tab at the side of the

filter element that should be gently moved to re-
lease the filter.
3. Press on the small tab that holds the filter in 5. Replace filter in housing taking care to align
the slot. the airflow direction that is indicated on the
side of the filter element such that it points
into the HVAC housing.
6. Close the bunk.
KM811250/PM820009 (08/14/2012) 9-5

9-6 KM811250/PM820009 (08/14/2012)
HVAC 10
10 Disassembly/Assembly
Cab Evaporator Replacement ................. 10 - 3
Cab HVAC Module Blower Motor

Replacement ......................................... 10 - 4
Cab HVAC Module Defrost Door

Actuator Replacement.......................... 10 - 5
Cab HVAC Module Evaporator

Temperature Sensor Replacement ..... 10 - 6
Cab HVAC Module Floor Door

Actuator Replacement.......................... 10 - 7
Cab HVAC Module Fresh/Recirc Air

Door Actuator Replacement ................ 10 - 8
Cab HVAC Module Heater Core

Replacement ......................................... 10 - 9
Cab HVAC Module Panel Door

Actuator Replacement........................ 10 - 11
Cab HVAC Module Temperature

Door Actuator Replacement .............. 10 - 12
Compressor Replacement ..................... 10 - 13
Control Head Replacement.................... 10 - 14
HVAC Air Intake Replacement .............. 10 - 15
KM811250/PM820009 (08/14/2012) 10 - 1
10 HVAC
Receiver Drier Replacement.................. 10 - 16
Sleeper HVAC Module Blower Motor

Replacement ....................................... 10 - 17

Speed Control Resistor
Replacement ....................................... 10 - 18
Sleeper HVAC Module Heater Core

Replacement ....................................... 10 - 19
Sleeper HVAC Module Temperature

Door Actuator Replacement .............. 10 - 20
Sleeper HVAC Unit Replacement .......... 10 - 21
Sleeper TXV Replacement ..................... 10 - 22
Sunload Sensor Replacement............... 10 - 23
10 - 2 KM811250/PM820009 (08/14/2012)
HVAC 10
Cab Evaporator Replacement For Peterbilt only, the glovebox and its
Before replacing any component in the A/C equipment.
system be sure to utilize a refrigerant identifier to
verify refrigerant purity. Connect a refrigerant 4. The evaporator core sits behind a service
recovery machine to the service ports and cover. Remove the six T-20 torx screws to
evacuate the refrigerant from the system. Identify access the evaporator core. The evaporator
and record the amount of oil recovered from the core may be removed from the HVAC module.
system for oil balancing. Keep all dust caps in
place on components until installation.
NOTE
It is recommended that the TXV be replaced

with the evaporator.
1. Remove the suction and liquid lines from the
TXV.
Evaporator Service Cover

5. The replacement evaporator core may be
reinstalled using the reverse order.
Thermal Expansion Valve (TXV)

NOTE
2. Remove the two T-27 torx bolts that hold the
TXV to the evaporator core. Screws in the plastic should be hand tight-
3. Access to the unit is from behind the ened…not torqued.
precede removing the glovebox is covered in Install new slim line seals at all four connections
the Dash Service Manual. All kick panels to the TXV to ensure a leak free system.
glovebox. Tighten the expansion valve to evaporator bolt
torque is 3.3 lb-ft ± 0.3 (4.5 Nm ± 0.5).
NOTE
Tighten the suction/liquid line to expansion valve
For Kenworth applications there is a connect- torque is 15.5 lb-ft ± 2.2 (21 Nm ± 3).
ing bar at the bottom of the instrument panel
that must be removed to access the heater core. Check the system for leaks prior to evacuation
and re-charge.
KM811250/PM820009 (08/14/2012) 10 - 3
10 HVAC
Cab HVAC Module Blower Motor 5. Rotate the blower motor 90 degrees
Replacement clockwise and pull blower motor out of the
HVAC unit.
The blower motor in the cab HVAC is a Brush
Less Direct Current (BLDC) blower motor that
provides long life durability.
The blower wheel is not serviceable separately.

The motor and wheel must be replaced as a
complete unit.
The blower motor is located behind the glove box

in the vehicle.
the tires.
6. Install the new blower motor into the HVAC in
the reverse order.
the Dash Service Manual. All kick panels NOTE
Screws in the plastic should be hand tight-
glovebox.
ened…not torqued.
surround must be removed to access the 7. Replace the glovebox.
equipment.
3. Remove the wire harness connector from the
blower motor.
4. Remove the three T-20 torx screws to release
the blower motor.
1. Blower motor electrical connector

2. Blower motor T-20 torx retaining
screws
10 - 4 KM811250/PM820009 (08/14/2012)
HVAC 10
Cab HVAC Module Defrost Door

Actuator Replacement
The defrost door actuator interfaces with the
control head and defrost door to direct air to the
defrost duct.
the tires.
2. Turn battery disconnect to the off position or
remove the ground cable to the batteries that
provides power to the vehicle.
3. Remove the B-panel surround from around
Defrost Door Actuator
the control head from the dash. It is retained
to the instrument panel by spring clips. 5. Remove the B-panel substrate screws and
pull aside the gauge cluster.
NOTE 6. Remove the wire harness connector from the
blower motor.
Remove the B-panel frame along with the ac-
cessories mounted to them. This will provide 7. Remove the two T-20 torx screws to release
better access to the actuator for removal. the actuator.
8. Install the replacement actuator using the
reverse order.
NOTE

ened…not torqued.
4. The defrost door actuator is located behind

the left gauge cluster/navigation screen.
KM811250/PM820009 (08/14/2012) 10 - 5
10 HVAC
Cab HVAC Module Evaporator

Temperature Sensor Replacement
The temperature sensor located downstream of
the evaporator.
The sensor measures the temperature of the

airflow through the evaporator core which is used
to cycle the compressor off and keep water
condensate from freezing on the evaporator core.
the tires.
glovebox.
Accessing the sensor in a Peterbilt vehicle
may not require removal of the glovebox
surround.
temperature sensor.
Temperature Sensor
4. Remove the temperature sensor from the
HVAC case.
5. Replacement sensor is installed using the
reverse order.
10 - 6 KM811250/PM820009 (08/14/2012)
HVAC 10
Cab HVAC Module Floor Door Actuator

Replacement
The floor door actuator interfaces with the control
head and floor door to direct air to the floor duct.
the tires.
3. For Kenworth: Remove the B-panel surround
Floor Door Actuator
from around the control head from the dash. It
is retained to the instrument panel by spring 6. Remove the B-panel substrate screws and
clips. pull aside the gauge cluster.
NOTE

cessories mounted to them. This will provide
better access to the actuator for removal.

blower motor.
8. Remove the two T-20 torx screws to release
the actuator.
reverse order.
NOTE
4. For Peterbilt: Remove the C-panel surround Screws in the plastic should be hand tight-
from around the control head from the dash. It ened…not torqued.
is retained to the instrument panel by spring
clips.
5. The floor door actuator is located behind the
right gauge cluster.
KM811250/PM820009 (08/14/2012) 10 - 7
10 HVAC
Cab HVAC Module Fresh/Recirc Air NOTE

Door Actuator Replacement
The fresh/recirc air door actuator interfaces with ened…not torqued.
the control head and air inlet door to allow air
from the outside of the vehicle or recirculated air
to used by the cab HVAC module.
the tires.
3. The fresh/recirc air actuator is located behind
the glovebox.
glovebox.
equipment.
fresh/recirc air actuator.
Fresh/Recirc Air Door Actuator

6. To remove the actuator a 1/4" drive 90 degree
ratchet must be used. Remove the two T-20
torx screws to release the actuator.
reverse order.
10 - 8 KM811250/PM820009 (08/14/2012)
HVAC 10
Cab HVAC Module Heater Core

Replacement
The heater core is accessible from the inside of
the cab. Access is gained by removing the
passenger dash panels and accessories.
the tires.
2. Tilt the hood open.
WARNING!
The area that is being worked on is in close Bypass Valve Direction

proximity to the engine turbo. Injury may occur
if the engine is still hot and the coolant is not WARNING!
drained or shut off correctly. Failure to comply
may result in death or personal injury. Injury may occur if the engine is still hot and
the coolant is not drained or shut off correctly.
3. Locate heater core pass through points at the Failure to comply may result in death or person-
passenger side of the bulkhead in the engine al injury.
compartment.
5. When the engine is not HOT, drain coolant
4. The heater core inlet and outlet tubes have a
from engine or shut off coolant lines at shut
by-pass valve attached to them with standard
off valves.
hose clamps. The by-pass valve controls the
flow thorough the heater core. 6. Label and disconnect the inlet and outlet
hoses from the heater core.
CAUTION
The heater bypass valve should not be re-

moved from the system unless it is being re-
placed. Do not operate the system without the
heater core bypass valve installed. Operating
the system without the bypass valve may result
in equipment damage.
NOTE
The heater core bypass valve must be installed

in the proper orientation for proper operation
and should NOT be removed from the system
or heater core damage may occur. The inlet con-
nection from the engine is a 3/4" hose fitting
while the outlet is 5/8" diameter hose fitting.
KM811250/PM820009 (08/14/2012) 10 - 9
10 HVAC
7. Access to the heater core is from behind the NOTE

precede removing the glovebox is covered in Screws in the plastic should be hand tight-
the Dash Service Manual. All kick panels ened…not torqued. Do not reverse the inlet
must be removed in order to remove the and outlet hoses of the by-pass valve attach-
glovebox. ment to the core. Verify that there is no leak at
the heater core connections.
NOTE
11. Replace lost coolant per coolant replacement
For Kenworth applications there is a connect- guidelines.
ing bar at the bottom of the instrument panel
12. Close and secure hood of vehicle.
that must be removed to access the heater
core. Peterbilt applications do not have this bar.

equipment.
8. The heater core sits behind a service cover.
Remove the four T-20 torx screws to access
the heater core.
Heater Core Service Cover

9. The heater core may now be removed from
the HVAC module. The core will be full of
coolant, take care not to spill coolant from the
core.
10. The replacement heater core may be installed
using the reverse order.
10 - 10 KM811250/PM820009 (08/14/2012)
HVAC 10
Cab HVAC Module Panel Door

The panel door actuator interfaces with the
control head and panel door to direct air to the
panel duct.
the tires.
Panel Door Actuator
3. For Kenworth: Remove the B-panel surround
from around the control head from the dash. It 6. Remove the wire harness connector from the
is retained to the instrument panel by spring actuator.
clips. 7. Remove the two T-20 torx screws to release
Remove the B-panel frame and its accessories. the actuator.
NOTE
reverse order.
cessories mounted to them. This will provide NOTE
better access to the actuator for removal.
ened…not torqued.
4. For Peterbilt: Remove the C-panel surround

from around the control head from the dash. It
is retained to the instrument panel by spring
clips.
5. The panel door actuator will located about
half way down the B-panel vertically and to
the right side of the panel horizontally.
KM811250/PM820009 (08/14/2012) 10 - 11
10 HVAC
Cab HVAC Module Temperature Door NOTE

The temperature door actuator interfaces with the ened…not torqued.
control head and temperature door to direct air
through the evaporator or heater core to control
the airflow temperature.
the tires.
3. The temperature actuator is located behind
the glovebox.
glovebox.
equipment.
5. The temperature actuator is located to the left
of the blower motor.
Temperature Door Actuator

temperature door actuator.
the actuator.
reverse order.
10 - 12 KM811250/PM820009 (08/14/2012)
HVAC 10
Compressor Replacement
Before replacing any component in the A/C
verify refrigerant purity. Connect a refrigerant
recovery machine to the service ports and
evacuate the refrigerant from the system. Be sure
to record the amount of oil that is recovered
during this process in order to balance the oil in
the system during recharge. Drain the oil from old
compressor into a graduated cylinder and record
it for oil balancing. Follow oil balancing procedure
for the replacement compressor. Keep all dust
caps in place on components until installation.
Suction and discharge line torque to the

compressor is 15.5 lb-ft ± 2.2 (21 Nm ± 3).
Torque the for the four nuts that retain the

compressor to the engine block is 25 lb-ft ± 2.2
(34 Nm ± 3).
KM811250/PM820009 (08/14/2012) 10 - 13
10 HVAC
Control Head Replacement

The HVAC system control head is serviceable as
a complete unit. The knobs are not individually
serviceable. For control head replacement, see
the Dash and Instrumentation Manual.
10 - 14 KM811250/PM820009 (08/14/2012)
HVAC 10
HVAC Air Intake Replacement

The air intake module that is located in the engine
compartment of the vehicle provides a path for
fresh air from the base of the windshield to be
routed into the vehicle.
The air intake separates water from the air and

drains it under the vehicle. The air intake also
provides a location for the fresh air filter and an
optional fine filtration element or ember filter
element.
By taking air from the base of the windshield

heated, dirty air from the engine compartment is
not introduced into the passenger compartment.
The seal between the hood and raintray of the

vehicle should be inspected for damage to keep
“clean” air entering the air intake module.
the tires.
WARNING!
The area that is being worked on is in close

proximity to the engine turbo. Injury may occur
if the engine is still hot. Do not work in this area
until the vehicle engine is cool. Failure to com-
ply may result in death or personal injury.
3. Locate air intake housing at passenger rear

corner of vehicle under the rain tray.
4. Six fasteners must be removed to replace the
air intake. One fastener holds the refrigerant
line in place, another two secure the housing
to the cowl and then three more fasteners
secure the housing to the front wall.
5. Remove the air intake module.
6. Install the intake module taking care not to
damage seal to rain tray and bulkhead.
Tighten to 3.7 - 5.1 ft·lbs (5 - 7 Nm).
KM811250/PM820009 (08/14/2012) 10 - 15
10 HVAC
Receiver Drier Replacement

evacuate the refrigerant from the system. Identify
and record the amount of oil recovered from the
1. Remove the liquid lines from the TXV.

2. Remove the two bolts that retain the receiver
drier to the front wall.
3. Install the replacement receiver drier using
new slim line seals, in the reverse order.
Tighten the suction/liquid line to replacement
receiver drier to 15.5 lb-ft ± 2.2 (21 Nm ± 3).
NOTE
⅜” = Parker PN 730392 & ½” = Parker PN

730393
10 - 16 KM811250/PM820009 (08/14/2012)
HVAC 10

Replacement
The blower motor in the sleeper HVAC module is
a brush blower motor that provides long life
durability.
The blower wheel is not serviceable separately

from the blower motor and must be replaced as a
complete unit.
The blower motor is located in the sleeper HVAC

module under the bunk of the sleeper.
the tires.
2. Lift the bunk mattress.
3. Remove the wire harness connectors from the
HVAC module.
4. The blower motor is behind the sleeper HVAC
module service cover.
5. Remove six T-20 torx screws and 2 clips on
the cover then remove the cover. 7. The blower motor is retained in the blower
scroll with 3 screws. The blower motor is
attached to the scroll and comes out by
pulling straight up.
6. The blower motor is located under the service

cover and removes by pulling directly up. 8. Install the replacement blower using the
reverse order.
NOTE

ened…not torqued.
KM811250/PM820009 (08/14/2012) 10 - 17
10 HVAC
Sleeper HVAC Module Blower Motor NOTE

Speed Control Resistor Replacement
The blower motor resistor in the Sleeper HVAC ened…not torqued.
module controls the blower speed and therefore
the amount of air that the HVAC module provides.
The blower motor resistor is located in the

sleeper HVAC module under the bunk of the
sleeper.
CAUTION
The speed control can be hot for some time af-

ter usage. Take appropriate measures when
handling the resistor.

the tires.
blower motor resistor.
the blower motor resistor.
Sleeper Blower Motor Resistor

5. Install the replacement blower motor resistor
10 - 18 KM811250/PM820009 (08/14/2012)
HVAC 10
Sleeper HVAC Module Heater Core NOTE

Replacement
There are two O-rings and the tubes that can
The heater core in the Sleeper HVAC module is be replaced. (if the heater tubes are leak free
an aluminum heater core system, meaning that they do not need to be removed from the
the coolant system including the coolant lines, the HVAC unit).
restrictor attached to the heater lines, and the
coolant have all been tuned for durability and
performance.
the tires.
4. Remove the wire harness connectors from the
HVAC module.
5. Remove six T-20 torx screws and 2 clips on
the cover, then remove the cover. Heater Core Bolt
6. Remove the two T-20 torx screws that retain 10. The heater core inlet tube has an inline flow
the heater core service piece. restrictor under the sleeper floor. Mark the
inlet and outlet lines to ensure proper
installation. If the lines are not attached
correctly during re-assembly performance
degradation will occur.
11. The core may now be removed from the
HVAC module by pulling up.
CAUTION
The core will be full of coolant, take care not to

spill coolant from the core.
12. The inlet and outlet tubes may be transferred

to the new core.
13. Install the replacement blower using the
reverse order.
Sleeper Heater Core NOTE

7. Locate heater core pass through points under Screws in the plastic should be hand tight-
the passenger side of the sleeper ened…not torqued.
compartment.
8. The coolant lines are held in place on the
aluminum tubes by constant tension spring
clamps. Pinch off the coolant lines and
remove to drain the core.
9. Remove the single T-25 torx bolt that retains
the tubes to the heater core.
KM811250/PM820009 (08/14/2012) 10 - 19
10 HVAC
Sleeper HVAC Module Temperature

Door Actuator Replacement
The temperature door actuator interfaces with the
control head and temperature door to direct air
through the evaporator or heater core to control
the airflow temperature.
the tires.
blower motor.
the actuator.
Sleeper Temperature Door Actuator

reverse order.
NOTE

ened…not torqued..
10 - 20 KM811250/PM820009 (08/14/2012)
HVAC 10
Sleeper HVAC Unit Replacement

the tires.
4. Disconnect the electrical connectors from the
sleeper HVAC unit.
5. Label and disconnect the coolant and
refrigerant lines.
6. Remove the three fasteners holding the
sleeper HVAC unit to the floor.
Sleeper HVAC Unit Fasteners

7. Remove the sleeper HVAC unit from the
vehicle.
8. Install the replacement sleeper HVAC unit
KM811250/PM820009 (08/14/2012) 10 - 21
10 HVAC
Sleeper TXV Replacement d. Check the system for leaks prior to

evacuation and re-charge.
1. Remove the suction and liquid lines from the
TXV.
2. Remove the two T-27 torx bolts that hold the

TXV to the evaporator core.
3. Remove the TXV from the evaporator.

4. Install the replacement TXV in the reverse and:
a. Install new slim line seals at all 4
connections to the TXV to ensure a leak
free system.
b. Tighten the expansion valve to evaporator
bolts to 3.3 lb-ft ± 0.3 (4.5 Nm ± 0.5).
c. Tighten the suction/liquid line to
expansion valve to 15.5 lb-ft ± 2.2 (21 Nm
± 3).
10 - 22 KM811250/PM820009 (08/14/2012)
HVAC 10
Sunload Sensor Replacement

The sunload sensor is located on the driver's side
of the dash, where the windshield meets the dash
board. The sensor is mounted beneath the
defrost vents.
This sensor should not be blocked by any debris

as it reads the intensity of the sun and influences
temperature control of the HVAC system.

the tires.
2. Remove the defrost panel (there are 9 spring
clips that retain the pad to the instrument
panel substrate).
3. Twist the sensor 90 degrees to remove from
the substrate.
sensor.
5. Install the new sunload sensor in the
instrument panel in the reverse order.
KM811250/PM820009 (08/14/2012) 10 - 23
10 - 24 KM811250/PM820009 (08/14/2012)
HVAC 12
12 Troubleshooting
General Troubleshooting Guide.............. 12 - 2
Checking the A/C System

Performance .......................................... 12 - 3
Refrigerant and Leak Detection .............. 12 - 5
Checking the A/C System for

Refrigerant Leaks ................................. 12 - 6
Troubleshooting the Electrical

Controls of the HVAC System ............. 12 - 8
Symptom Based Diagnostics ................ 12 - 13
KM811250/PM820009 (08/14/2012) 12 - 1
12 HVAC
General Troubleshooting Guide

Perform a visual inspection of the A/C system
prior to troubleshooting any problem.
1. Confirm the ignition is turned off and inspect
the A/C components for any visual damage,
leaks etc. Look particularly for oil at joints, at
the compressor, and at TXVs.
2. Check and/or replace the fresh air filter as
necessary.
3. Make sure that nothing is blocking the
condenser airflow. Be sure to review the
space between the heat exchangers.
4. Carefully clean the condenser with a mild
detergent and water. Dry with shop air being
careful not to damage the fins of the condenser.
5. With the engine now running let the A/C run
for a few minutes. Verify that the compressor
engages with the pulley and clutch plate
rotating at the same speed (not slipping).
6. Verify that the engine fan engages after
approximately 5 minutes of A/C operation.
7. The sunload sensor should not be blocked by
any debris as it reads the intensity of the sun
and influences temperature control of the
HVAC system.
8. The A/C clutch will lock out when over/under
pressure. To unlock the clutch, cycle ignition
key twice or reset it using ESA tool.
9. If the compressor is cycling 4 times per
minute and the ambient temperature is hot,
then check refrigerant levels in the system.
12 - 2 KM811250/PM820009 (08/14/2012)
HVAC 12
Checking the A/C System Performance 3. Set the controls of the vehicle to Hi blower,
full cold, panel mode, fresh air with the A/C
Checking the refrigerant pressure in vehicles with on. Verify that the compressor clutch is
automatic climate control and NAMUX 4 engaging. If the vehicle has a sleeper module
instrumentation can be viewed by using ESA. it should be set to Hi blower in full cold.
Use the procedures below as a backup to what
ESA displays as the refrigerant pressure. 4. The vehicle should operate until the low side
and high side gauge pressures are stable or
Use this procedure for testing the A/C system fluctuate in a repeatable range.
performance in ambient (shop) temperatures 5. Use the shop temperature along with the high
100°F (38°C) and lower. side pressure to determine if the system is
1. Run the vehicle until it reaches the normal operating in the normal range utilizing the
operating temperature. discharge pressure chart (see High Side Port
Pressure Charts on page 12-4).
2. Connect the R134a refrigerant recovery
To use the pressure table graphs, utilize the
machine or R134a manifold gauge set to the
high side pressure (across the horizontal
vehicles A/C system.
lines) and the ambient (shop) temperature
3. Set the controls of the vehicle to Hi blower, (vertical lines) in the graph and they should
full cold, panel mode, fresh air with the A/C intersect in the shaded area. Any
on. Verify that the compressor clutch is measurements that are outside this region
engaging. If the vehicle has a sleeper module may warrant additional diagnosis.
it should be set to Hi blower in full cold.
6. Use the shop temperature along with the low
4. The vehicle should operate until the low side side pressure to determine if the system is
and high side gauge pressures are stable or operating in the normal range utilizing the
fluctuate in a repeatable range. suction pressure chart.
5. Use the shop temperature along with the high
side pressure to determine if the system is
operating in the normal range utilizing the
discharge pressure chart (see High Side Port
Pressure Charts on page 12-4).
To use the pressure table graphs, utilize the
high side pressure (across the horizontal
lines) and the ambient (shop) temperature
(vertical lines) in the graph and they should
intersect in the shaded area. Any
measurements that are outside this region
may warrant additional diagnosis.
6. Use the shop temperature along with the low
side pressure to determine if the system is
operating in the normal range utilizing the
suction pressure chart
Use this procedure for testing the A/C system

performance in ambient (shop) temperatures
100°F (38°C) and higher.
1. Run the vehicle until it reaches the normal
operating temperature.
2. Connect the R134a refrigerant recovery
machine or R134a manifold gauge set to the
vehicles A/C system.
KM811250/PM820009 (08/14/2012) 12 - 3
12 HVAC
To use the graphs below, utilize the high side

pressure (across the horizontal lines) and the
ambient (shop) temperature (vertical lines) in the
graph and they should intersect in the shaded
area. Any measurements that are outside this
region may warrant additional diagnosis.
High Side Port Pressure (Day Cab)
High Side Port Pressure (Sleeper)
12 - 4 KM811250/PM820009 (08/14/2012)
HVAC 12
Refrigerant and Leak Detection Refrigerant

The information here applies to: For the models shown in the table have a UV
wafer in the receiver/dryer so that leak detection
is available regardless of the type of refrigerant
Peterbilt Model Cab Sleeper*
used.
386, 384, 365 Yes Yes
The model 388/389 and 587 will be using
388, 389 No Yes
R134aUV, which contains a leak dye that
587 No No fluoresces under ultraviolet (UV) light. R134aUV
*refers to the HVAC blower unit, does not refer to the sleeper is completely interchangeable with R134a during
HVAC control head. servicing of any Peterbilt HVAC system, so either
product may be involved wherever the word
"R134a" appears in these maintenance
instructions.
KM811250/PM820009 (08/14/2012) 12 - 5
12 HVAC
Checking the A/C System for Refrigerant dye and UV light source
Refrigerant Leaks
The refrigerant system as manufactured from the
Checking the system for leaks can be done in factory contains an ultraviolet (UV) fluorescent
several different ways, however a thorough visual leak detection dye. An ultraviolet light source is
inspection can usually give clues or help identify required to make the dye fluoresce. ALWAYS
a leak site. wear UV enhancing safety glasses when using a
UV light source. A thorough visual inspection will
help identify potential leak sites at refrigerant
connections that the UV light will likely confirm as
a leak point. Once the leak site is confirmed and
repaired remove the dye from the leak site to
avoid misdiagnosis at a later date. Verify the
repair by reviewing the leak site after running the
vehicle for approximately 10 min. Replacement
receiver driers are manufactured with a dye wafer
that will dissolve after approximately 30 minutes
of operating the A/C system. Even if a significant
amount of oil is lost due to a leak there should be
enough dye in the system to identify a leak.
12 - 6 KM811250/PM820009 (08/14/2012)
HVAC 12
Soap bubble solution Refrigerant sniffer leak detector

An alternative method that is utilized across the An alternernative to the UV light and soap
industry is utilizing a soapy water solution and solution would be the sniffer leak detection
looking for bubbles at leak sites. Verify the device. Follow the operating instructions of the
refrigerant purity with a refrigerant identifier and refrigerant sniffer leak detector. The leak detector
recover appropriately if contaminated. Recover should be utilized in a well ventilated area. A
the refrigerant from the vehicle using the partial charge of R134a should be in the A/C
refrigerant recovery machine. Nitrogen should be system (approximately 60 psi at 75°F) prior to
used to charge the A/C system when using soap using the leak detector and the engine should be
solution to look for leaks. Shop air should NEVER turned off. Other fluids such as diesel, gasoline,
be used to check for leaks. Compressed air and coolant, and brake fluid may cause the leak
R134a can cause serious damage to the A/C detector to indicate a leak. A clean work area and
system and possible bodily injury. After charging a fan will clear the air around the test location.
the system with approximately 60-70 psi of The fan should be off during testing. R134a gas is
nitrogen, apply the soap bubble solution to all heavier than air, therefore the detector wand
connections between A/C lines and compressor should be moved completely around a connection
to A/C line joints. Bubbles will be generated at joints and possible leak sites.
any leak site(s).
All connections between A/C lines, compressor to
A/C line joints, the compressor front shaft seal,
evaporators and condenser should be checked
for leaks.
The evaporators may be checked by using the

leak detector at the condensate drain for each of
the HVAC modules.
KM811250/PM820009 (08/14/2012) 12 - 7
12 HVAC
Troubleshooting the Electrical DTC 3509 - Cab Pressure Sensor

Controls of the HVAC System Supply Voltage
Visually verify that there is no leak at any of the A/
DTC 871 - Low Refrigerant Charge C joints, cut hoses etc (look for oil or dirt that is
sticking to A/C joint). See Checking the A/C
Visually verify that there is no leak at any of the A/
system for leaks on page 12-6.
C joints, cut hoses etc (look for oil or dirt that is
sticking to A/C joint). See Checking the A/C Verify that the discharge pressure transducer has
system for leaks on page 12-6. not failed.
Specifically look for oil and dirt accumulation at 1. Locate the pressure transducer on the
ALL A/C joint connections. Utilize appropriate discharge line from compressor to condenser
leak detection tools (soapy water and or line.
refrigerant sniffers) to complete this task. Repair/
replace components as necessary. 2. Verify condition of the sensor…ie look for
wear of the connection and condition of wires,
Repair/replace components as necessary. damage, etc. Replace as necessary.
Charge the A/C system with the appropriate
amount of refrigerant as indicated on the sticker WARNING!
of the vehicle. See Checking the A/C system for
leaks on page 12-6 When repairing a vehicles A/C system be sure
NOTE and appropriate clothing. Refrigerant vaporizes
at -13°F (-25°C) and will freeze skin. Never al-
When DTC 871 is set the code must be reset. low large quantities of refrigerant to escape in
This can be accomplished by using the ESA a closed space as it displaces oxygen and can
tool or by completing two ignition on/off cycles lead to death. An ignition source should never
after the system has been charged with the ap- be near R134a gas.
propriate amount of refrigerant.
NOTE
The sensor may be removed from the A/C line

without having to discharge the A/C system.
The pressure tap location has a Schrader
valve that retains the vehicle refrigerant charge.
3. Complete a resistance test across the pins of

the sensor using the Pinout Information on
page 7-5.
4. If the sensor does not fall within the
specifications, replace the sensor.
5. If required, verify transducer wiring continuity
from sensor connector to HVAC control head
connector. See Cab HVAC System – Block
Diagram on page 7-3.
6. Verify that the transducer is receiving 5 V
power.
7. Verify that the transducer is sending a 0V to
5V signal to the control unit.
12 - 8 KM811250/PM820009 (08/14/2012)
HVAC 12
DTC 876 - Compressor Clutch Relay DTC for HVAC Actuators

Circuit
1. Locate and visually verify that the connector DTC Cab HVAC Actuator
at compressor clutch is not damaged. ie look DTC 3981 Panel Mode Actuator
for wear of the connection and condition of
wires, damage, etc. Rework as necessary. DTC 3986 Temperature Actuator
DTC 3984 Fresh/Recirculation Actuator

2. Locate and visually verify that the connector
at compressor clutch relay is not damaged. ie DTC PropB 52019 Defrost Mode Actuator
look for wear of the connection and condition DTC PropB 520197 Floor Mode Actuator
of wires, damage, etc. Rework as necessary.
1. Access the actuator related to the DTC code.
WARNING! 2. Verify condition of the actuator and wire
harness…ie look for wear of the connection
When repairing a vehicles A/C system be sure
and condition of wires, damage, etc. Repair
as necessary.
and appropriate clothing. Refrigerant vaporizes
at -13°F (-25°C) and will freeze skin. Never al- 3. Complete a resistance test across the pins of
low large quantities of refrigerant to escape in the actuator per the drawing.
a closed space as it displaces oxygen and can The resistance between pin 1 and pin 6: ~28
lead to death. An ignition source should never – 45 Ω
be near R134a gas. Refer to A/C Refrigerant
Service
3. Complete a resistance test across the pins of

the compressor clutch.
4. With the vehicle off and the connector
removed from the clutch measure the
resistance of the clutch with a multimeter. The
resistance should be between 2.8 and 4.4
Ohms. If the clutch resistance does not fall 4. If required, verify actuator wiring continuity
within the specifications, replace the from HVAC wire harness actuator connector
compressor. to HVAC C1 connector. See Cab HVAC
5. With the engine running and the clutch System – Block Diagram on page 7-3, repair
engaged measure the voltage with a as necessary.
multimeter. The minimum voltage should be 5. If required, verify connector wiring continuity
11.5 V. from C1 body harness connector to HVAC
6. If required, verify compressor relay wiring control head connector. See Cab HVAC
continuity from relay connector to HVAC System – Block Diagram on page 7-3, repair
control head connector. See Cab HVAC as necessary.
System – Block Diagram on page 7-3. 6. Verify that the control unit is sending a +/- 6V
to +/- 12 V signal to the actuator.
KM811250/PM820009 (08/14/2012) 12 - 9
12 HVAC
DTC 1553 - Cab HVAC Blower Motor DTC 168 - Battery Potential Power Input
Speed Adjustment 1. Locate the cab HVAC control head fuse for
1. Locate the cab HVAC blower motor behind both battery and switch power. This fuse is
the glove box in the vehicle. (see HVAC behind the driver side kick panel where the
Module Overview on page 3-3) diagnostic connector is. The label on the back
of the fuse panel access door will illustrate the
2. Verify condition of the blower motor and wire location of these fuses.
harness…ie look for wear of the connection
and condition of wires, damage, etc. Repair 2. Turn vehicle key to accessory position.
as necessary. 3. Using a digital volt meter measure the voltage
3. Complete a resistance test across the pins of between the battery feed and ground. The
the motor per the Pinout Information on page value should be between 9 and 16 volts.
7-5 4. Using a digital volt meter measure the voltage
4. If required, verify blower motor wiring between the switched battery feed and
continuity from HVAC wire harness blower ground. The value should be between 9 and
motor connector to HVAC C1 and C2 16 volts.
connector. See Cab HVAC System – Block
Diagram on page 7-3, repair as necessary.
5. If required, verify connector wiring continuity
from C1 body harness connector to HVAC
control head connector. See Cab HVAC
System – Block Diagram on page 7-3, repair
as necessary.
12 - 10 KM811250/PM820009 (08/14/2012)
HVAC 12
DTC 639 - J1939 DTC 919 - Sunload Sensor

1. Locate the cab HVAC control head in the 1. Locate the sunload sensor that is on the top
instrument panel in the vehicle. of the instrument panel and remove for
inspection.
2. Verify condition of the control head and wire
harness…ie look for wear of the connection 2. Verify condition of the sensor and wire
and condition of wires, damage, etc. Repair harness…ie look for wear of the connection
as necessary. and condition of wires, damage, etc. Repair
as necessary.
3. The control uses the following inputs that are
broadcast across the J1939 BUS. Verify the 3. Test the actuator resistance across pin A and
availability of these inputs across the BUS pin B: ~150K – 190K Ω with no direct sunlight.
using the USB Link Service Tool.
4. If the sensor does not fall within the
Troubleshoot any signals that are not
specifications, replace the sensor.
broadcasting.
5. If required, verify transducer wiring continuity
from sensor connector to HVAC control head
Signal Name SPN PGN SA DA Message Description connector. See Cab HVAC System – Block
Engine Speed 190 61444 0 25 EEC1 Actual Engine Diagram on page 7-3, repair as necessary.
Speed
6. Verify that the control unit is recieving a 0 to 5
Engine Cool- 110 65262 0 25 Engine Coolant Tem- V signal from the sensor.
ant Tempera- perature
ture
Wheel-Based 84 65265 0 25 CCVS (Cruise Control

Vehicle Speed Vehicle Speed)
Ambient Air 171 65269 49 25 AMB (Ambient Condi-

Temperature tions) Temperature sur-
rounding vehicle
Dash Illumina- 1487 53248 49 255 CL (Cab Illumination

tion Message)
NOTE
The ambient air temperature signal is pro-

cessed though the door control module and the
Cab ECU. Be sure to verify the operation of the
sensor and its control units.
KM811250/PM820009 (08/14/2012) 12 - 11
12 HVAC
DTC 1547 - A/C Evaporator Temperature 4. If required, verify sensor wiring continuity from
HVAC wire harness sensor connector to
1. Locate the evaporator temperature sensor
HVAC C1 connector. See Cab HVAC System
behind the glove box in the vehicle.
– Block Diagram on page 7-3, repair as
2. Verify condition of the sensor…ie look for necessary.
wear of the connection and condition of wires,
damage, etc. Replace as necessary. 5. If required, verify sensor wiring continuity from
C1 body harness connector to HVAC control
3. Complete a resistance test across the pins of head connector. See Cab HVAC System –
the sensor. Resistance should be between Block Diagram on page 7-3, repair as
1400 and 10000Ω. If the resistance is outside necessary.
these values replace the sensor.
6. Verify that the control unit is receiving a 0 to 5
V signal from the sensor.
12 - 12 KM811250/PM820009 (08/14/2012)
HVAC 12
Symptom Based Diagnostics

Symptom Diagnostic procedure Next check
Blower, Control head and A/C does not Check: Control head power and ground circuit, blown fuses and the condi-
turn on (no lights, no function) tions of related HVAC harness, sensor and controller terminals.
The Condenser fan does not turn on A/C condenser fan circuit troubleshooting. (PACCAR circuit diagram) DM1 messages ( 871, 876,
Check pressure transducer circuit. 1547, 3509, 639)
Check condition of all terminals.
The Compressor does not engage Compressor clutch circuit troubleshooting. (PACCAR circuit diagram) DM1 messages ( 871, 876,
Check the connection between evaporator sensor and control head. 1547, 3509, 639)
Ensure ambient air temperature (outside air temperature [OAT]) sensor is
reading above 32°F (0°C).
Check condition of all terminals at back of control head, relay, and com-
pressor clutch.
The A/C clutch will lock out when over/under pressure. To unlock the
clutch, cycle ignition key twice or reset it using ESA tool
The blower motor runs slower than expec- For "AUTO" mode It is normal for the blower to run slowly until the engine DM1 message (1553, 639)
ted coolant temperature begins to rise. If the blower continues to run slowly for
an abnormal length of time, continue to troubleshoot the problem.
Check condition of all of related HVAC harness, control head and blower
motor terminals.
Insufficient heating Check the condition of the HVAC air filter(s). Diagnose the coolant sys-
Check the blower motor for obstructions. tem, refer to appropriate
Check for air leaks around the ducts and vents. service manual.
Check the inlet hose temperature. DM1 message (3986,

1553)
1. If cold, check for restrictions in the hose, a damaged or leaking ther-
mostat, and a damaged or leaking water pump, a blocked heater
core or a defective heater core by-pass valve.
2. If it is hot, check heater core outlet hose if this is cold check heater
core for blockage or check for defective heater core by-pass valve.
Insufficient Cooling Check the condition of the HVAC air filter(s). DM1 messages ( 871, 876,
Check if compressor clutch and condenser fan are turning on. 1547, 3509, 3986, 639,
Check refrigerant circuit for leaks (see leak check procedure). 1553)
Check the operation of the temperature mix actuator door.

Check blower motor for obstructions.
Check for air leaks around the ducts and vents.
Check condition of all terminals at back of control head, actuator connec-
tions.
Air flow coming out of the wrong ducts Check the operation of the mode actuator doors (Floor, Defrost, Panel, re- DM1 messages (3981,
circ). 520196, 520197)
Change airflow location using control using "manual" operation from Pan-
el, to floor, to defrost and verify airflow is coming from correct location.
Change air temp using control in "manual" from hot to cold check for tem-
perature and quantity of airflow change (less in hot temp).
Put HVAC into recirc mode listening for higher air rush noise and more air-
flow Check condition of all terminals at back of control head and at actuator.
KM811250/PM820009 (08/14/2012) 12 - 13
12 - 14 KM811250/PM820009 (08/14/2012)
Index
A Sleeper HVAC Air Filters...................... 8-20
Applicability ....................... 2-2 Module Blower Compressor ................. 8-13
Motor Compressor Clutch ...... 8-14
Replacement .......... 10-17 Control Panels ............. 8-19
C Sleeper HVAC Ducts............................ 8-11
Cautions ............................ 1-3 Module Blower Evaporator ................... 8-18
Motor Speed Expansion Devices ...... 8-17
D Control Resistor Filter/Receiver Drier ..... 8-17
Disassembly/Assembly Replacement .......... 10-18 Heater Core ................. 8-12
Cab HVAC Module Sleeper HVAC Hoses and Fittings ....... 8-12
Blower Motor Module Heater Kenworth Control
Replacement ............ 10-4 Core Panel ........................ 8-19
Cab HVAC Module Replacement .......... 10-19 Motor/Blower
Defrost Door Sleeper HVAC Assembly.................. 8-11
Actuator Module Peterbilt Control
Replacement ............ 10-5 Temperature Panel ........................ 8-19
Cab HVAC Module Door Actuator Pressure Switches ....... 8-20
Evaporator Replacement .......... 10-20 R134a Refrigerant ....... 8-13
Temperature Sleeper HVAC Unit Relays, Fuses, And
Sensor Replacement .......... 10-21 Resistors .................. 8-20
Replacement ............ 10-6 Sleeper TXV Resistor........................ 8-20
Cab HVAC Module Replacement .......... 10-22 Sensors........................ 8-16
Floor Door Sunload Sensor Sleeper Control
Actuator Replacement .......... 10-23 Panel ........................ 8-19
Replacement ............ 10-7 How It Works
Cab HVAC Module F Functional descriptions ........
Fresh/Recirc Air Functional Description
Door Actuator Air Distribution I
Replacement ............ 10-8 System ....................... 8-5 Important Safety Notices ... 1-5
Cab HVAC Module Control System .............. 8-3
Heater Core Heating Cycle ................ 8-2
Replacement ............ 10-9 L
Refrigeration Cycle ........ 8-3 Leak Detection
Cab HVAC Module Refrigeration System ..... 8-6
Panel Door Troubleshooting ........... 12-5
Actuator
Replacement .......... 10-11 H M
Cab HVAC Module HVAC System Maintenance
Temperature Functional description .... 8-2 Cab HVAC fresh air
Door Actuator HVAC Module filter replacement........ 9-3
Replacement .......... 10-12 Component Cab HVAC
Compressor Overview .................... 3-3 recirculation air
Replacement HVAC Refrigerant filter replacement........ 9-4
Procedure............... 10-13 System HVAC Air Filter
Control Head Component Maintenance
Replacement .......... 10-14 Overview .................... 3-2 Schedule .................... 9-2
HVAC Air Intake Sleeper HVAC Unit ........ 3-4 Sleeper HVAC air
Replacement .......... 10-15 HVAC System Components filter replacement........ 9-5
..................................... 8-11
(08/14/2012) Index - 1
R
Refrigerant
Troubleshooting ........... 12-5
S
Safety
General safety
instructions ................. 1-2
Important safety
notices ........................ 1-5
Warnings, cautions
and notes ................... 1-3
Special Tools ..................... 6-2
T
Troubleshooting
Refrigerant ................... 12-5
W
Warnings ........................... 1-3
What's new
Leak Detection ............. 12-5
Index - 2 KM811250/PM820009 (08/14/2012)

Peterbilt Model 579 HVAC

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Peterbilt Model 579 HVAC

Uploaded by

Copyright:

Available Formats

Section HVAC

2012 HVAC Service Manual

KM811250/PM820009 (08/14/2012) iii

Warnings, Cautions and Notes ................. 1 - 3

Important Safety Notices ........................... 1 - 5

KM811250/PM820009 (08/14/2012) 1-1

General Safety Instructions

1-2 KM811250/PM820009 (08/14/2012)

Warnings, Cautions and Notes Precautions For Working With

The Air Conditioning system is designed for

KM811250/PM820009 (08/14/2012) 1-3

Take care to follow the handling procedures be-

R134a service equipment or vehicle air condi-

1-4 KM811250/PM820009 (08/14/2012)

Important Safety Notices • Corrosion inhibitors and lubricating oils may

KM811250/PM820009 (08/14/2012) 1-5

cancer, birth defects, and other reproductive

1-6 KM811250/PM820009 (08/14/2012)

KM811250/PM820009 (08/14/2012) 2-1

Peterbilt Model Cab Sleeper*

579 Yes Yes

386, 384, 365, 388,

Kenworth Model Cab Sleeper*

T660, T680, T800 Yes Yes

2-2 KM811250/PM820009 (08/14/2012)

Cab Air Handling Unit Overview ............... 3 - 3

Sleeper HVAC Unit ..................................... 3 - 4

KM811250/PM820009 (08/14/2012) 3-1

HVAC System Overview

1. Refrigerant Compressor 3. Receiver Dryer 5. Cab Air Handler

2. Suction Line 4. Cab Thermal Expansion Valve (TXV) 6. Discharge Line

3-2 KM811250/PM820009 (08/14/2012)

Cab Air Handling Unit Overview

1. Blower Motor 4. Temperature Actuator 7. Panel Actuator

2. Evaporator Core 5. Floor Actuator 8. Intake Actuator

3. Heater Core 6. Defrost Actuator

KM811250/PM820009 (08/14/2012) 3-3

Sleeper HVAC Unit

3-4 KM811250/PM820009 (08/14/2012)

KM811250/PM820009 (08/14/2012) 5-1

A/C System Recovery, Evacuation and A/C System Refrigerant Recovery

5-2 KM811250/PM820009 (08/14/2012)

KM811250/PM820009 (08/14/2012) 5-3

Charging the A/C system (Using a A/C System Flushing

Flushing or replacement of all A/C system

The condenser tubes have a small cross section

All A/C lines, evaporator(s) should be flushed

Connect the A/C flush machine to each

5-4 KM811250/PM820009 (08/14/2012)

Component Amount of SP15 Method to add

Front Evaporator 2 oz (60 ml) Add to evaporator inlet

Rear Evaporator 1 oz (30) ml Add to evaporator inlet

Condenser 2 oz (60 ml) Add to condenser inlet

Receiver Drier 1.5oz (45ml) Add to receiver drier in-

Large leak (cut AC 3.0 oz (88ml) Inject to low side port

Small leak (loose fit- 1 oz (30) ml Inject to low side port

Suction line to rear 2.5 oz (74ml) Inject to low side port

Other line or hose 1 oz (30) ml Inject to low side port

KM811250/PM820009 (08/14/2012) 5-5

Component Amount of SP15 Method to add Oil Balancing Procedure – EXAMPLE 1

Amount of oil to be replaced Subtract this from - 5.5 oz

Amount of oil that needs to be drained from 4.6 oz

5-6 KM811250/PM820009 (08/14/2012)

Oil Balancing Procedure – EXAMPLE 2