Paccar SM001-300 User manual

SERVICE
MANUAL
Section HVAC
Title Idle Management System Service Manual
Number SM001-300
Date Rev. 9 © 9/2016
Model All w/ Idle Management System
Page 1 of 39
Kenworth Idle Management System
Technical Information and Diagnostic Guide
HVAC
PM820010 Rev. 9 © 9/2016
This guide will assist you in becoming more familiar with the working components
of the Kenworth Idle Management System and the proper steps and procedures to
completely diagnose the Kenworth Idle Management System unit.
©2016 PACCAR Corporation
Confidentiality Notice: This document and the information contained herein is proprietary. It shall not be reproduced, copied or disclosed,
in whole or in part, or used for manufacture without the written permission of PACCAR. You are hereby notified that any dissemination of
this information is strictly prohibited.

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Number SM001-300
HVAC: Idle Management System
Contents
GENERAL SAFEY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings, Cautions, and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Precautions for Working with HFC134a (R134a) Refrigerant and Polyvinyl Ether
(PVE) Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
• Important Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EXTERNAL COMPONENT IDENTIFICATION AND LOCATION . . . . . . . . . . . . . . . 8
A. Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
B. Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
C. Fan and Temperature Control Display LED Display . . . . . . . . . . . . . . . . . 9
D. System and Compressor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
E. Linear Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
F. Discharge Temperature Sensor – Freeze Switch . . . . . . . . . . . . . . . . . . 10
G. Evaporator Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
H. Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
I. Battery Management System (BMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
J. Battery Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INTERNAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A. High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
C. Thermal Limit Switch on Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
D. Evaporator Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A/C System Diagnostic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ESPAR Heating System Diagnostic Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A. Battery Condition and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B. Fan and Temperature Control Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C. Relay Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
D. Pressure Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
E. Check Continuity Across Fuse Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
F. Discharge Temperature Sensor/Freeze Switch Testing . . . . . . . . . . . . . 19
G. Compressor Thermal Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
H. Main Controller/Compressor Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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HVAC: Idle Management System
I. Condenser Fan Motor Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
J. Evaporator Blower Motor and Linear Power Module Testing . . . . . . . . . .20
K. Compressor Rubber Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
L. Testing the Battery Management System (BMS) . . . . . . . . . . . . . . . . . . .21
M. Can Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
N. Testing the Espar Heater Connected to the EHVAC Digital Controller . . .22
O. Connecting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
P. Evacuating the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Q. Charging the Kenworth EHVAC System . . . . . . . . . . . . . . . . . . . . . . . . . .25
Service Instructions for Ring Terminal / Controller and Compressor . . . . . . . . . . . .33
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

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HVAC: Idle Management System
List of Figures
Figure 1. Fuses and Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 2. Fuses and Relays (Units built 8/1/2016 to Present). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 3. Fan and Temperature Control Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 4. System and Compressor Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5. Linear Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 6. Discharge Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 7. Evaporator Blower and Condenser Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 8. Battery Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9. Battery Separator Solenoid, located in the battery box.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 10. Automated Battery Disconnect Solenoid, located in the battery box. . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 11. High Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 12. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 13. Thermal Limit Switch on Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 14. Evaporator Inlet Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 15. Relay Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 16. Service Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 17. Service Recovery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 18. Internal Wiring Diagram (Before 8/1/2016) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 19. External Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 20. Wiring Diagram (8/1/2016 to Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Figure 21. On/Off Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 22. Changing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 23. Changing Blower Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 24. Changing Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 25. View System Runtime/Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 26. Change from °F to °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 27. Enter Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 28. Service Screens. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 29. EHVAC Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Number SM001-300
HVAC: Idle Management System
GENERAL SAFEY INSTRUCTIONS
A number of alerting messages are in this manual.
Please read and follow them. They are there for your pro-
tection and information. These messages can help you
avoid injury to yourself or others and help prevent costly
damage to the vehicle.
Warnings, Cautions, and Notes
Key symbols and “signal words” are used to indicate
what kind of message is going to follow. Pay special
attention to instructions prefaced by symbols and signal
words “WARNING”, “CAUTION”, or “NOTE”. Please do
not ignore any of these alerts.
WARNING!
When you see this symbol and word, the message that
follows is especially vital. This signals something that
can cause injury or even death. This message will tell
you what the hazard is, what can happen if you don’t
heed the warning, and/or how to avoid it.
CAUTION
This symbol and word signals something that could
damage your vehicle.
NOTE
This symbol gives you information we believe to be
helpful. The information can be a service hint or some-
thing to assist with the repairing of the vehicle.
Precautions for Working with HFC134a
(R134a) Refrigerant and Polyvinyl Ether
(PVE) Refrigerant Oil
WARNING!
• 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.
CAUTION
• The air conditioning system uses HFC134a
(R134a) refrigerant and polyvinyl ether (PVE)
refrigerant oil, which are not compatible with
CFC-12 (R12) refrigerant, mineral oil, or PAG
oil. If the refrigerants or oils are mixed the com-
pressor may fail.
• Do not attempt to use R-12 servicing equipment;
damage to the air condition system or your servic-
ing equipment will result.
• 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 condi-
tioning system.
• Verify the HFC134a (R134a) refrigerant in the vehi-
cle system and the recycling equipment/recovery
tank are contaminant free by using a refrigerant
identifier.
NOTE
THIS SYSTEM MUST BE SERVICED BY QUALIFIED
PERSONNEL ONLY.
R134a service equipment or vehicle air conditioning
systems should not be pressure tested or leak tested
with compressed air.
• This air conditioning system may contain R134a
fluorescent dye for leak detection. Inspect with a
high intensity ultraviolet light system.
• A label on the unit will identify systems with fluores-
cent dye.
NOTE
The Air Conditioning system is designed for use only
with the specified polyvinyl ether (PVE) refrigerant oil
for HFC134a (R134a) A/C systems and HFC134a
(R134a) components. Idemitsu FVC68D PVE oil is the
ONLY recommended oil. The PVE oil is very Hygro-
scopic. Hygroscopic means that it absorbs water. With-
out proper sealing, oil will become moisture saturated
and should not be used.

NOTE
Take care to follow the handling procedures below:
• Only use the specified FVC68D PVE oil from a
sealed container.
• Immediately reseal containers of oil.
• To avoid contamination, do not return oil to original
container once it is dispensed, and never mix it
with other refrigerant oils.
• Do not allow PVE oil to come in contact with Styro-
foam parts. Damage may occur.
• Do not allow PVE oil to come in contact with vehi-
cle paint. Damage may occur.
• If any connection in the refrigerant loop is opened it
should be closed as soon as possible in order to
minimize the amount of moisture that enters the
system.
• Any components that are replaced should have
dust caps left in place until the component 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 intrusion.
Page 6 of 39
Number SM001-300
HVAC: Idle Management System
Important Safety Notices
WARNING!
Improper practices, carelessness, or ignoring any
warnings may cause death, personal injury, equipment
or property damage.
Read and understand all of the safety precautions and
warnings before performing any repair. This list contains
the general safety precautions that must be followed to
provide personal safety. Special safety precautions are
included in the procedures when they apply.
Work areas should be dry, well lit, ventilated, and be free
from clutter, loose tools, parts, ignition sources and haz-
ardous substances. Be aware of hazardous conditions
that can exist.
• Wear protective glasses and protective shoes when
working.
• Rotating parts can cause cuts, mutilation or strangu-
lation.
• Do not wear loose-fitting or torn clothing. Remove all
jewelry before working.
• Before beginning any repair, disconnect the battery
(negative [-] cable) from both battery boxes and dis-
charge any capacitors.
• Disconnect the air starting motor, if equipped, to pre-
vent accidental engine starting.
•Puta“DO NOT OPERATE” tag in the operator's
compartment or on the controls.
• Allow the engine to cool before beginning any repair.
• Always use blocks or proper stands to support the
vehicle or vehicle components before performing any
service work. Do not work on anything that is sup-
ported only by lifting jacks or a hoist.
• To reduce the possibility of personal injury, use a
hoist or get assistance when lifting components that
weigh 23 kg [50 lb] or more. Ensure all lifting devices
such as chains, hooks, or slings are in good condi-
tion and are of the correct load capacity. Make sure
any lifting devices are positioned correctly. Always
use a spreader bar when necessary. The lifting
hooks must not be side-loaded.
• Corrosion inhibitors and lubricating oils may contain
alkali. Do not get the substance in eyes and avoid
prolonged or repeated contact with skin. Do not swal-
low. In case of contact, immediately wash skin with
soap and water. In case of harmful contact, immedi-
ately contact a physician. Always keep any chemi-
cals OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flamma-
ble materials and must be used with caution. Follow
the manufacturer's instructions to ensure safety
when using these materials. Always keep any
chemicals OUT OF REACH OF CHILDREN.
• When working on the vehicle, be alert for hot parts on
systems that have just been turned off, exhaust gas
flow, and hot fluids in lines, tubes, and compart-
ments. Contact with any hot surface may cause
burns.
• Always use tools that are in good condition. Make
sure you have the proper understanding of how to
use the tools before performing any service work.
Use ONLY genuine replacement parts from PAC-
CAR.
• Always use the same fastener part number (or equiv-
alent) when replacing items. Do not use a fastener of
lesser quality if replacements are necessary.

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Number SM001-300
HVAC: Idle Management System
• Do not perform any repair when impaired, tired,
fatigued or after consuming alcohol or drugs that can
impair your functioning.
• Some state and federal agencies in the United States
of America have determined that used engine oil can
be carcinogenic and can cause reproductive toxicity.
Avoid inhalation of vapors, ingestion, and prolonged
contact with used engine oil.
• Liquefied petroleum gas is heavier than air and can
accumulate near the floor, in sumps, and low-lying
areas.
• Close the manual fuel valves prior to performing
maintenance and repairs, and when storing the vehi-
cle inside.
• California Proposition 65 Warning – Diesel engine
exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects,
and other reproductive harm.
•DO NOT breathe A/C 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.

Page 8 of 39
Number SM001-300
HVAC: Idle Management System
EXTERNAL COMPONENT
IDENTIFICATION AND LOCATION
A. Fuses
Figure 1. Fuses and Relays
Figure 2. Fuses and Relays (Units built 8/1/2016 to
Present)
F1 Fuse 10 Amp (Mini)
This fuse provides short circuit protection for the System
control.
NOTE
Removing fuse F1 for 10-15 seconds will reset the sys-
tem controller to factory default settings.
Location: on the control center.
F2 Fuse 10 Amp (Mini)
This fuse provides short circuit protection for the con-
denser fan.

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Number SM001-300
HVAC: Idle Management System
Location: on the control center.
F3 Fuse 20 Amp (Mini)
This fuse provides short circuit protection for the evapo-
rator blower.
Location: on the control center.
F4 Fuse 60 Amp (Maxi)
This fuse provides short circuit protection for the com-
pressor.
Location: on the control center.
B. Relays
Location: on the control center.
R1. This relay controls the voltage to the condenser fan.
R2. This relay controls the voltage to the linear power
module and evaporator blower.
R3. This relay controls the voltage to the compressor
controller.
C. Fan and Temperature Control Display
LED Display
Allows for temperature and Blower speed adjustment of
the EHVAC (Electrical Heating and Ventilation Air Condi-
tioning) unit when operating in Auto, cool or heat mode.
A/C Unit – stops when unit is shut off or batteries are
depleted.
Figure 3. Fan and Temperature Control Display
Auxiliary heater will shut down when batteries are
depleted but will continue to run through the cool down
cycle. Also displays hours of service, battery health and
service items.
D. System and Compressor Controller
This device controls the unit and the output voltage to the
variable speed compressor. It is located under the large
access cover.
Figure 4. System and Compressor Controller

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Number SM001-300
HVAC: Idle Management System
E. Linear Power Module
This module controls the amount of voltage delivered to
the evaporator blower creating variable blower speeds. It
is located in the return air in front of the evaporator coil.
Figure 5. Linear Power Module
F. Discharge Temperature Sensor – Freeze
Switch
This sensor monitors the evaporator outlet temperature
as it enters the vehicle duct system.
Figure 6. Discharge Temperature Sensor
G. Evaporator Blower
This blower pulls air through the evaporator coil and
blows conditioned air into the interior of the sleeper.
H. Condenser Fan
This blower draws air through the condenser coil to cool
the refrigerant flowing through the system.
Figure 7. Evaporator Blower and Condenser Fan
I. Battery Management System (BMS)
This device monitors the auxiliary batteries for state of
charge, communicates with the EHVAC system and con-
trols the battery separator solenoid. LED light on this
device indicates power to the device and does not pro-
vide diagnostics. Power inputs to this device are fuse
protected.
If one of the BMS fuses blows, the solenoid will disen-
gage.
Figure 8. Battery Management System
J. Battery Separator
This device connects the truck batteries to the EHVAC
batteries. When the starting batteries are at or above
13.2 volts, the battery management device will engage
the solenoid to allow the alternator to charge the auxiliary
batteries. When the voltage drops to or below 12.5 volts
the battery management system will disengage the sole-
noid to prevent the truck starting batteries from being dis-
charged below the engine start level.

Figure 9. Battery Separator Solenoid, located in the
battery box.
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Number SM001-300
HVAC: Idle Management System
Automated Battery Disconnect (Option)
This device disconnects the EHVAC batteries from the
EHVAC unit when the cab disconnect switch is set to
OFF. The cab disconnect switch must be set to ON for
the EHVAC unit to operate.
Figure 10. Automated Battery Disconnect Solenoid,
located in the battery box.

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Number SM001-300
HVAC: Idle Management System
INTERNAL COMPONENTS
A. High Pressure Switch
This normally closed brazed pressure switch will open
and prevent the operation of the compressor due to high
internal pressure. It is NOT serviceable.
Figure 11. High Pressure Switch
B. Compressor
This unit is part of the hermetically sealed refrigeration
system.
Figure 12. Compressor
C. Thermal Limit Switch on Compressor
This is a normally closed (auto reset) switch to protect
the compressor from high temperature.
Figure 13. Thermal Limit Switch on Compressor
D. Evaporator Inlet Filter
This filter protects the evaporator coil from dust and
debris. It is washable and should be serviced periodically
during routine maintenance.
Figure 14. Evaporator Inlet Filter
When necessary, the Check Filter indicator will notify you
that the EHVAC filter must be cleaned or changed. To
reset “Check Filter” – at screen 1 press and hold enter
button for 3 seconds.

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Number SM001-300
HVAC: Idle Management System
A/C System Diagnostic
Check service screens before troubleshooting, see
“Operation” on page 37.NOTE
Removing fuse F1 for 10-15 seconds will reset the sys-
tem controller to factory default settings.
Table 1. A/C System Diagnostic
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION / “Appendix” on page 18.
Unit will not run or turn on
Display comes on for 5 sec-
onds, shows service screen
for 3 seconds and then pow-
ers off (see #9)
1. Loose connection.
2. No power is available
at the unit.
3. Blown fuse or fuses.
4. Check Voltagepathto
unit and control
5. Defective control
panel.
6. A/C system controller
defective.
7. Broken wire or defec-
tive wire harness.
8. Check for Fault code.
9. Can Buss connection.
10. Ignition switch
1. Confirm all connections are tight, including ground lugs,
and terminals crimped on wires and battery cables.
2. Check All batteries for Voltage. Check battery manage-
ment system and separator solenoid. Unit has a low volt-
age disconnect of 11.2 volts.
3. Check all fuses. See “Figure 18. Internal Wiring Diagram
(Before 8/1/2016)” on page 28 and “Figure 19. External
Wiring Diagram” on page 29.
4. Check for 12 volt through the 100 amp main fuse and F1
10 amp control fuse to controller pin C1. Also see “H.
Main Controller/Compressor Controller” on page 19.
5. Check control. See “B. Fan and Temperature Control
Display” on page 18.
6. Test system controller. See “H. Main Controller/Com-
pressor Controller” on page 19.
7. Inspect wiring harness and all ground wires.
8. View faults on the controller. See “ Operation” on
page 37.
9. Check can bus harness, resisters and connections.
Reset controller. See “M. Can Bus” on page 22, “Figure
18. Internal Wiring Diagram (Before 8/1/2016)” on
page 28 and “Figure 19. External Wiring Diagram” on
page 29.
10. See “Control Module Pinout with Functional Information”
on page 31 (pin D2)
Auxiliary batteries will not
recharge 1. Check battery Man-
agement System.
2. Check Battery Sep-
arator.
1. Check battery management device, harness and sep-
arator. See “L. Testing the Battery Management System
(BMS)” on page 21.
2. See “H. Main Controller/Compressor Controller” on
page 19.

Page 14 of 39
Number SM001-300
HVAC: Idle Management System
Unit runs—but does not
blow cold air. 1. Airflow blockage.
2. Compressor.
3. Fuse or Relay.
4. System and Com-
pressor controller
connections/ defec-
tive compressor.
5. Condenser fan and
high pressure switch.
6. Evaporator dis-
charge temp sen-
sor/Freeze switch
defective.
7. Compressor thermal
switch.
8. Evaporator blower/
Linear Power Module.
9. Loss of charge (refrig-
erant system is ser-
viceable).
1. Clear any blockage from recirculation grill or louvers.
Also check condenser inlet and outlet for restriction (out-
side truck).
2. Check F4 compressor fuse and R3 compressor relay.
See “C. Relay Testing” on page 18 and “E. Check Conti-
nuity Across Fuse Body” on page 19.
3. Confirm all wire harness plugs are connected. Test sys-
tem and compressor controller. See “H. Main Control-
ler/Compressor Controller” on page 19.
4. Check high pressure switch and condenser fan. “D.
Pressure Switch Testing” on page 18 and “I. Condenser
Fan Motor Testing” on page 20.
5. Check sensor. See “F. Discharge Temperature Sen-
sor/Freeze Switch Testing” on page 19.
6. Check normally closed thermal switch. See “G. Com-
pressor Thermal Limit Switch” on page 19.
7. Check evaporator blower and linear power module. See
“J. Evaporator Blower Motor and Linear Power Module
Testing” on page 20.
8. If all tests check OK, a loss of refrigerant charge may
have occurred.
Unit cycles On and Off and
doesn’t cool 1. Poor electrical con-
nection.
2. Condenser fan inop-
erative.
3. Air flow blockage
causing high pres-
sure or freeze condi-
tion.
1. Check all electrical connections.
2. Check condenser fan. See “I. Condenser Fan Motor
Testing” on page 20.
3. Check for restricted airflow outside truck at condenser
inlet and outlet and at louvers and recirculation grill.
Check pressure switch, thermal limit and/or discharge
temperature sensor. See “D. Pressure Switch Testing”
on page 18, “F. Discharge Temperature Sensor/Freeze
Switch Testing” on page 19, and “G. Compressor Ther-
mal Limit Switch” on page 19.
Unit blows cold air—but
low airflow 1. Check all duct work
connections.
2. Air flow restricted.
3. Evaporator Blower
motor inoperative.
1. Make sure all ducts are connected, sealed and secure.
2. Check for airflow at louvers and recirculation grill.
3. Check evaporator blower motor and linear power mod-
ule. See “J. Evaporator Blower Motor and Linear Power
Module Testing” on page 20.
Table 1. A/C System Diagnostic
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION / “Appendix” on page 18.

Page 15 of 39
Number SM001-300
HVAC: Idle Management System
Unit runs correctly, but
less than expected run
time.
1. Ground terminal(s).
2. Batteries weak or not
charged correctly.
3. High amperage draw.
4. Check battery Man-
agement System.
5. Check Battery Sep-
arator.
1. Inspect and tighten ALL connections.
2. Check batteries for condition and state of charge. Check
service screens in EHVAC control. See “A. Battery Con-
dition and Performance” on page 18.
3. Check amp draw in EHVAC control service screen or
use DC ammeter to check amps when running. Exces-
sive amperage could signal compressor or internal com-
ponent issue. Amperage ranges 40 to 75 depending
on settings and conditions.
4. Check battery management device, harness and sep-
arator.
5. Same as 4.
Unit is noisy or vibrates. 1. Evaporator Blower
motor.
2. Condenser fan motor.
3. Compressor mount-
ing.
4. Compressor internal.
1. Check evaporator blower. See “J. Evaporator Blower
Motor and Linear Power Module Testing” on page 20.
2. Check condenser fan. See “I. Condenser Fan Motor
Testing” on page 20.
3. Check rubber compressor mounts. See “K. Compressor
Rubber Mounts” on page 20.
4. If rubber compressor mounts check out acceptable, and
compressor vibrates excessively, call your local dealer
for support.
Table 1. A/C System Diagnostic
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION / “Appendix” on page 18.

Page 16 of 39
Number SM001-300
HVAC: Idle Management System
ESPAR Heating System Diagnostic
Table
Check service screens before troubleshooting, see
“Operation” on page 37.
Monthly running and periodic maintenance are required
for proper heater operation and performance.
Table 2. ESPAR Heating System Diagnostic Table
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION / “Appendix” on page 18.
Heater is connected to the
EHVAC unit and will not oper-
ate.
1. Loose connection.
2. No power is avail-
able at the unit.
3. Blown fuse or fuses.
4. Check Voltage path
to unit and control.
5. Defective EHVAC
Control.
6. System controller
defective.
7. Broken wire or
defective wire har-
ness.
8. Check for Fault
code.
1. Confirm all connections are tight, including ground
lugs, and terminals crimped on wires and battery
cables.
2. Check Aux. batteries for Voltage. Check for heater
enable signal from EHVAC unit. Heater unit has a low
voltage disconnect of 10.6 volts. See “N. Testing the
Espar Heater Connected to the EHVAC Digital Con-
troller” on page 22.
3. Check 20 amp main fuse and 5 amp control fuse. See
Espar manual.
4. Check harness.
5. Check control. See “N. Testing the Espar Heater Con-
nected to the EHVAC Digital Controller” on page 22
and Espar manual.
• Test System Controller.
6. Inspect wiring harness and all ground wires.
7. View faults in the heater controller with Espar’s Edith
PC diagnostics or hand held diagnostics tool. See
Espars guide.
Heater is not connected to the
EHVAC unit and will not oper-
ate.
1. Loose connection.
2. No power is avail-
able at the unit.
3. Blown fuse or fuses.
4. Check Voltage path
to unit and control.
5. Defective Heater
Control.
6. System controller
defective.
7. Broken wire or
defective wire har-
ness.
8. Check for Fault
code.
See Espar Manual.

Page 17 of 39
Number SM001-300
HVAC: Idle Management System
Heater blows cold air but no
heat. 1. Fuel.
2. Fuel pump.
3. Connections.
4. Glow pin / screen.
5. Sensors.
See Espar Manual.
Table 2. ESPAR Heating System Diagnostic Table
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION / “Appendix” on page 18.

Page 18 of 39
Number SM001-300
HVAC: Idle Management System
Appendix
A. Battery Condition and Performance
Battery Voltage is critical for system operation. Special
attention should be given to both sets of batteries.
NOTE
Poor quality batteries or a weak alternator will have a
negative impact on unit run time. Always maintain the
best possible batteries and charging system.
Load test and maintain batteries as required by the man-
ufacturer.
Battery symbol in diagnostics screen indicates battery
health. This is created after many cycles. If batteries
have been disconnected recently this symbol will reset.
Several cycles will be needed to get accurate battery
health.
B. Fan and Temperature Control Display
With the control off: check for 12 VOLT at and from F1 10
amp fuse to the connector on rear of control, terminal 1.
Terminal 7 is negative. Check for 12 volts at control termi-
nal 6 (wake up) coming from the main/ compressor con-
troller terminal D6. Pushing the control (on) will switch
this input from the main controller to ground at the control
panel. This signals the main control to start the system.
When control is on the wake up signal should be less
than 1 volt.
C. Relay Testing
With relay unplugged, confirm there is 12 VOLT on the
sockets where 85 and 30 relay terminals are connected.
If you do not have 12 VOLT here check fuses, wiring and
battery connections.
Figure 15. Relay Testing
87
86
85
30
Now, with relay unplugged, check across terminals 85
and 86 of the relay, using an OHM meter. You should
have approximately 90 ohms + or - 10% at 68°F (20°C).
This is measuring the resistance through the relay coil. If
you do not, replace relay.
Overview
When you turn the EHVAC unit on, if all safety switches
are okay, such as the high pressure switch, temperature
sensor / freeze switch and the compressor thermal limit
switch, the Main / Compressor controller will connect the
compressor relay, condenser fan relay and the evapora-
tor blower relay terminals 86 to ground at their respective
terminals D10, D11 and D12 at the controller. This will
close the contacts 30 and 87 of all 3 relays and allow
power to each component.
You should now have 12 VOLT passing through the
relays on spade terminals 87. This provides power to
fuses F2, F3 and F4, continuing to the Linear Power
Module, evaporator blower, condenser fan and the com-
pressor controlling section of the Compressor Controller
Assembly.
With relay plugged in: turn the unit on. If you do not have
12 VOLT on terminal 87, check across terminals 85 (+)
an 86 (-). You should have 12 VOLT. If you do not, you
may have a defective harness or system controller. If you
have 12 VOLT here and do not have 12 VOLT on termi-
nal 87 your relay is defective. The internal coil of the relay
is energized but the contacts are not closing. Replace the
relay.
If you have 12 VOLT on terminal 87 and the compressor,
condenser fan or evaporator blower does not run you
could have a defective component such as evaporator
blower, condenser fan or compressor controller.
See testing “J. Evaporator Blower Motor and Linear
Power Module Testing” on page 20, “I. Condenser Fan
Motor Testing” on page 20, and “H. Main Controller/Com-
pressor Controller” on page 19.
D. Pressure Switch Testing
You must remove top covers to access the switch.
The brazed “A. High Pressure Switch” on page 12 is not
removable. This switch is normally closed. When the unit
is off for a few minutes, unplug the System Controller and
check between pins D2 and D5, you should always have
continuity. If you do not, you may have a broken wire, bad

Page 19 of 39
Number SM001-300
HVAC: Idle Management System
connection, high pressure situation or defective switch. If
the pressure, harness and connections are okay, the
EHVAC unit will have to be replaced.
E. Check Continuity Across Fuse Body
Fuse does not look blown.
Remove fuse from fuse holder. Using a meter, check for
continuity across the fuse. You can check for voltage at
and through the fuse using a DC volt meter, with the fuse
installed.
F. Discharge Temperature Sensor/Freeze
Switch Testing
Location: Between evaporator coil and intake side of
blower.
The freeze switch is a temperature sensor. To verify the
condition you will need a Volt/OHM meter.
If a freeze condition occurs, the unit will stop the com-
pressor. If the freeze condition leaves, the compressor
will restart and the unit will continue to run.
Check resistance (ohms) value at the system controller
with the 32 pin connector disconnected. You should read
a resistance across terminals D3 (pos) and D5 (neg)
within the range listed on the “Table 4. Discharge Sensor
/ Freeze Switch Testing Chart” on page 27. If you cannot
read the resistance, check at the sensor connection. If
you read the resistance here, and it's within the range
allowed, you have a defective harness.
If you cannot read the resistance or it is not within the
given range, your sensor is defective.
G. Compressor Thermal Limit Switch
You must remove the top cover and the plastic shield on
top of the compressor, to access the switch.
This device is a normally closed switch. If the compressor
gets too hot, the thermal limit switch will open and the
compressor will stop. Checking with a meter you should
always have continuity between the two terminals when it
is cool.
H. Main Controller/Compressor Controller
See updated information on “Service Instructions for Ring
Terminal / Controller and Compressor” on page 33
You must remove the cover.
Do not attempt to test the controller or compressor until
you have completely eliminated all other possibilities.
Overview
When you turn the Kenworth EHVAC unit on, if all safe-
ties are okay, such as the high pressure switch, tempera-
ture sensor / freeze switch and the compressor thermal
limit switch, the Main / Compressor controller will connect
the compressor relay, condenser fan relay and the evap-
orator blower relay terminals 86 to ground at their respec-
tive terminals D10, D11 and D12 at the controller. This
will close the contacts 30 and 87 of all 3 relays and allow
power to each component. The compressor and evapo-
rator blower will begin to operate at a speed determined
by the manual control panel. The condenser fan will run
at normal operational speed.
Initial start up, the system defaults to Auto Mode, Blower
speed 1 and 60°F set point. After the settings are
changed for the first time, they will always default to the
last setting.
Use the following steps to check the controller:
a. With the control switch off – check for 12 VOLT
from F1 10 amp fuse to the back of the control.
b. Now check for 12 volts at switch terminal 6 (wake
up) coming from the main/ compressor controller
terminal D6. Turning the unit on will switch this
12 volt input from the main controller to ground at
the control panel. This signals the main control to
start the system.
c. With a correct 12 volt signals to and from the
control, now check for (ground) signals to relays
on D10, 11 and 12. All relays should be closed
and all terminals # 87 should have 12 volts. If you
lose any signals from the controller it must be
replaced.
d. With relays closed, the main controller will now
signal each component to start. The evaporator
blower receives its power from the linear power
module. Safety controls must be in a normal
state for the above signal to operate the unit.

Page 20 of 39
Number SM001-300
HVAC: Idle Management System
e. If all signals are correct and the safety controls
thermal limit on compressor, high pressure
switch and temp sensor /freeze switch are okay,
the control is calling for cold and the sleeper tem-
perature is above 60 degrees, you should have
voltage out on the three wires connected to the
compressor terminals: A – Blue, B – Orange and
C – Yellow. (ABC – BOY), and the compressor
should run.
f. If the compressor does not operate, disconnect
the three wires from the compressor. You will
have to remove plastic cap from the top of com-
pressor.
• Using a volt meter check each wire, positive
on (blue, orange or yellow) negative to bat-
tery ground. If you do not have a 6 volt pulse
voltage out on each wire, replace the control-
ler. Pulse voltage means the controller will
cycle to each colored wire. You should see
the voltage appear and disappear continu-
ously.
• If you do have a 6 volt pulse voltage out and
the compressor does not run you have a
defective compressor. Contact the Kenworth
Service line.
I. Condenser Fan Motor Testing
First do a visual inspection of all fan parts.
NOTE
This fan cycles on and off with the compressor! Before
testing fan, start the unit, make sure the control is set
for full cold and the temperature in the truck will allow
the control to attempt to start the compressor and fan.
Turn the unit on, you should have 12 volts across termi-
nals 1 and 2 at the condenser fan connector. If you do not
have 12 volt at the fan, check fuse F2 And relay R1. If
condenser fan 12 volt power is okay, check condenser
speed signal from C7 on main controller. This voltage will
vary depending on requested speed: approximately 1.6
for low, 2.6 for high. If all voltages are correct, and the fan
does not run, it is defective, and needs to be replaced.
Using a DC ammeter you can check the amperage draw
of the blower. Normal amps approximately 5–10 depend-
ing on speed requests.
CAUTION
If attempting to connect blower to an outside power
source, internal electronic components are sensitive to
arcing or reverse polarity! Damage will occur.
J. Evaporator Blower Motor and Linear
Power Module Testing
First do a visual inspection of all blower parts. The evapo-
rator blower speed is controlled by the LPM. See “E. Lin-
ear Power Module” on page 10.
Turn the unit on, you should have 12 volt at the LPM pins
6 (pos) and pin 5 (neg), if you do not, check fuse F3 and
relay R2. If you have 12 VOLT main power, check for the
speed signal voltage on the LPM at pin 3 coming from the
system controller pin C13. You should have approxi-
mately 5.6V for speed 1, 4.9V for speed 2 and 3.1V for
speed 3. If all of these voltages are correct, check the
output voltage from the LPM pins 1 and 2 going to the
blower. You should have approximately 6.6V out for
speed 1, 8.1V out for speed 2 and 10V out for speed 3 to
the blower.
If fan does not run, it is defective, and needs to be
replaced.
Using a DC ammeter you can check the amperage draw
of the blower. Normal amps will range from 4 to 10 amps.
CAUTION
If attempting to connect blower to an outside power
source, internal electronic components are sensitive to
arcing or reverse polarity! Damage will occur!
K. Compressor Rubber Mounts
Visual inspection of the compressor rubber mounts may
be necessary if excessive vibration is present. Check for
loose mounting nuts. If mounting nuts and captive studs
are okay, vibration could be from the internal part of the
compressor.