Kenworth Clean Power System - Webasto Technical Support Website
Contents
1. Compressor electrical problems a Compressor motor has a winding open or shorted b Start capacitor or PTCR not working properly c Relay does not close Internal mechanical troubles in compressor Compressor starts but does not switch off of start winding wired Compressor electrical problems a Compressor motor has a winding open or shorted b Relay failing to open c Run ia not working properly Discharge pressure too high pressure too high Internal mechanical trouble in compressor Compressor starts and runs but short cycles on thermal protector Too much current passing through thermal protector a Extra sources of current draw b Compressor motor has winding shorted Low voltage to compressor Compressor electrical problems such as thermal protector or run capacitor not working properly Discharge pressure too high Suction pressure too high Return gas too warm Workbook No 2 2007 Volume 0 Remedy Thermal protector not working properly See Identifying Compressor Electrical Problems Check against wiring diagram and wire properly See Identifying Compressor Electrical Problems Improperly wired Check against wiring diagram and wire properly Low voltage to compressor Turn off system until proper voltage is restored See Identifying Compressor Electrical Problems See Checking for Adequate Compressor Pu2. N Service port High pressure liquid side Hermetic compressor for R134a refrigerant system Run capacitor Cover for electrical connections and thermal overload protector Condenser Condenser outlet connection Ambient temperature limiter 12 Volt wiring harness and connector Service port low pressure gas side WO AON Oo um P H N Magnetic equalization bypass valve Workbook No 2 2007 e Volume 80 3 Components Storage Cooler Unit The Storage Cooler Unit is a sealed system with no internal serviceable items A vacuum sealed water saturated graphite matrix interlaced with a refrigeration evaporator core and coolant circulation core make up the freeze medium 1 Cold storage core assembly 8 Coolant return line from air handler 2 Storage Cooler Control Unit SCCU 9 Coolant supply line to air handler 3 Lifting bolt 3 total 10 Coolant circulating pump AC pump 4 Refrigerant supply line from charging unit 11 Coolant reservoir with filler cap 5 Refrigerant return line to charging unit 12 Large pallet base 6 Temperature control thermostat 13 Control and power harness with connectors 7 Thermal eXpansion Valve TXV SCCU 1 and SCCU 2 4 Workbook No 2 2007 e Volume 80 Components Air Handler Assembly The air handler assembly is in the central compartment of the storage cooler It consists of e A liquid to air heat exchan
3. Table 2 Charge Unit Troubleshooting Possible Cause Core temperature control thermostat S4 OPEN Opens at 3 3 C 26 1 F Closes at 13 6 C 56 5 F Open sensor pressure switch circuits Ambient temperature limiter S6 OPEN Opens at 7 2 C 45 F Closes at 12 8 C Tolerance of 3 3 C 55 F Tolerance of 6 F Low refrigerant pressure switch S2 OPEN Opens at gt 1 03 bar Tolerance of 0 24 bar gt 15 psig Tolerance of 3 psig Closes at 2 13 bar 31 psig High refrigerant pressure switch S7 OPEN High refrigerant pressure switch S7 OPEN Opens at lt 20 68 bar Tolerance of 0 69 bar lt 300 psig Tolerance of 10 psig Closes at 12 4 bar 180 psig Core temperature control thermostat S4 OPENS prematurely Confirm charge state of cold storage assembly If fully charged it is normal for the thermostat S4 to be open If partly or fully discharged and thermostat remains open replace thermostat Disconnect 8 pin connector at the charge unit Check for continuity across pins A 8 and C 8 of the charge unit side of connector No continuity indicates one or more sensors S2 S6 or S7 are open Check sensors individually for open circuit Replace limiter if open at temperatures above 16 C 61 F Confirm refrigerant pressures with A C gauge set If pressure above 1 27 bar 18 psig replace sensor If pressure below 0 8 bar 12 psig check system for leaks and repair Perform
4. A dirty condenser A malfunctioning relay A restriction in the refrigeration circuit All of the above 10 The driver cannot control sleeper cooling temperature and the cold storage unit depletes quickly A defective or unplugged cabin temperature sensor is definitely not the problem a b True False Workbook No 2 2007 Volume 80 Answer sheet Faster Easier Testing ONLINE Take your Professional Service test and get your score instantly ONLINE Here s how 1 Go to the Kenworth Training page and access the training website in one of two ways a From the Internet type www kenworth training com into the browser address box Click Go to display the Kenworth training page OR b From the Kenworth DealerNet Home Page 1 Click on the Training tab at the top of the page 2 Select Service from the menu on the left 3 Select Kenworth Service Training 2 Verify that the displayed log in information is correct then click the Submit button 3 Select the box titled Workbooks and Update Tests 4 Moving the cursor reveals workbook or Update tests you may want to take It s fast and easy and you ll see your score instantly Good luck If you re faxing or mailing your test please print your name and dealership information below Name PRINT ONE LETTER IN EACH BOX LEAVE A BLANK BETWEEN NAMES AND INITIALS Deal
5. and needs to be adequate compressor pumping replaced Possible reasons that a run capacitor is not working properly include e Use of incorrect run capacitor Replace with proper run capacitor e Line voltage is too high greater than 110 of rated voltage e Rust through of capacitor housing or severe corrosion of terminals Replace with new capacitor PSC Compressor Motor with External Thermal Current Protector Run Capacitor and PTCR I Overheat Overload Protector p Start Winding X1 120 VAC RECEPTACLE R n Locking Tab Main Motor Winding Black Hot White Neutral Green Ground PSC Compressor with run capacitor external thermal protector Compressor Casing PTC resistor wired Ground 1 8 Workbook No 2 2007 e Volume 80 Troubleshooting Refrigerant Compressor Never troubleshoot service or repair a refrigerant compressor unless you are a certified professional air conditioning refrigeration technician Improper procedures can lead to serious injury or death from fire electric shock or explosion Follow the troubleshooting procedures in Table 4 Table 4 Refrigerant Compressor Troubleshooting Possible Causes Compressor will not start no audible hum Wiring improper or 0000000000 improper or loose Compressor motor has a ground fault also known as a short Circuit to ground Compressor will not start hums but trips on thermal protector
6. complete refrigerant system service Pressure switch defective replace Air flow over condenser blocked Clear obstruction Open circuit to condenser fan Check circuits and repair Condenser fan defective Replace fan Refrigerant circuit blocked Confirm refrigerant pressures with A C gauge set Clear obstruction Confirm open state with digital onm meter Replace thermostat TIP The quickest way to determine the charge state of the Storage Cooler Unit is to simply switch the system on in cooling mode After a couple of minutes on maximum output feel the air exiting the sleeper vents If the air is cold allow the unit to continue to discharge until the compressor engages The engine must be running or the power supply plugged into shore power for the compressor to operate If the air is warm and the charge unit is not responding there is a system malfunction For this test ensure that the Charge Enable Disable switch located on the dashboard is functional and in the enabled up position Note that the LED light will not illuminate unless the compressor is running 14 Workbook No 2 2007 Volume 0 Troubleshooting Discharging Mode For Discharge Mode troubleshooting first set the operator s control panel for cooling e Place the AC Heat switch to A C mode e Rotate the temperature control dial counter clockwise to A C modet e Rotate the fan control dial clockwise to turn on fan Follow the troubleshootin
7. for the night all without running the engine Troubleshooting Cooling Troubleshooting Heating Flow Charts Test Your Knowledge 2007 Kenworth Truck Co a division of PACCAR Produced by Burgio Cooney amp Associates Independence MO This publication may not be reproduced without the written permission of Kenworth Truck Company Phone 816 353 3672 Fax 816 353 4206 e mail dave bcakc com e With the engine off there s no noise or vibration while the driver sleeps e By eliminating all night idling fuel economy is improved and costs are reduced Sleeper Cooling Components Clean Power is a complete system with all components designed to function together for efficient and effective battery powered cooling and heating to keep the sleeper comfortable during the driver s off hours Enhanced insulation makes temperature control more effective a high output alternator keeps both banks of batteries charged while driving and LED lighting provides more illumination with less power draw Starter Batteries are isolated and charged by the Main Batteries via a DC DC charger which operates only when the ignition key is ON The Starter Batteries are charged while driving ensuring a full state of charge for the next startup Storage Cooler The Clean Power System s Storage Cooler stores the system s cooling capacity by freezing water As the system is used the ice melts into water which is later recharged froze
8. full refrigerant continuously service on system System components such as digital temperature sensor control module relays not functioning properly See Compressor Replacement and System ITs RETETE Service and Component Replacement Restriction in refrigeration circuit Refrigeration Unit Dirty condenser Suction line frosted or sweating System problems such as See Compressor Replacement and System a Expansion valve stuck open Service and Component Replacement b Overcharge of refrigerant Refrigeration Unit Liquid line frosted or sweating System problems such as restriction in dehydrator or strainer See Compressor Replacement and System Service and Component Replacement Refrigeration Unit System rattles or vibrates during Loose parts or mountings tubing rattle bent fan blade causing Repair or replace loose worn defective parts operation vibration fan motor bearings worn etc See Kenworth Clean Power System Storage Cooler Service Manual for details Now available on ServiceNet to download 20 Workbook No 2 2007 Volume 80 Troubleshooting Refer to the Webasto AT 2000 ST D Air Heater Service Manual for complete troubleshooting information available for download on ServiceNet Heating System Se Vee Heater y lapter Harness Troubleshooting SC PIN 92555A Before troubleshooting the sleeper heating system check the following items so they c
9. FF position the Air Conditioning Charge Unit is disabled Main Battery Box The power supply consists of four deep cycle batteries and a power inverter to supply 120 VAC to the refrigerant compressor The power supply is also equipped with a shore power connection and a battery charger for stand alone engine off operation and battery charging Check In with Kenworth ServiceNet for Critical Service Documents This Workbook is designed to give you a brief overview of components and troubleshooting techniques for the Kenworth Clean Power System The complete documentation you will need can be found on Kenworth ServiceNet P94 1613 Charge amp Start Wiring Diagram P94 1667 Clean Power System Wiring Diagram Kenworth Clean Power System Service Manual Kenworth Clean PowerTM System Storage Cooler Service Manual Webasto AT 2000 ST D Air Heater Service Manual Webasto 8 Workbook No 2 2007 e Volume 80 Components Heating Components if Webasto s optional interface kit is used The Air Top 2000 ST air heater consists of the See Error Code chart on page 21 22 for more following components information e Drive unit with combustion and hot air Drive Unit blower The drive unit consists of e Heat exchangers e The drive motor e Burner insert with combustion pipe e Control unit e The combustion air blower e Fuel metering pump e The hot air blower e Fuel filter The inta
10. JaMo g weibeig 9281S Jly po ejynooeyY Iy Workbook No 2 2007 e Volume 80 24 Flow Charts PMS HuljooDd pue 440 ES U31IAS Jamojg ES1 10150901 Winey 440 071 MD ES YUMs 1 M0 g JeISOWWAaY 1e1oy NO yams NO ES YUMs 1SAA0 8 ES1 191500090 winjeay NO 0 MDD yelsouu u l 1e1oul ESL 101500090 uin j u W4D OL unnuuul NO Jamolg NO pW dung 440 pI dund Buen Buen HO 34O PA duind NO PW ding Hugen 1ue ooD Bune n524i2 0 W4D OL uinullullAj NO Jamojg ESL 1elsouu ul Ju winjay JO MD 242704 105009 ESL 1015000190 O i uinl yu NO Vue Buljoo gt NO ES pums 98 pue PMS 661 1015091 UIN Y 44O PMS 6 NO G31 MDD yeJSOWJaY a e 0y NO dq31 uaa NO dung 4aj00D 9660015 e 440 duind 419 1 oo2 9660015 O weibeig opge obieyosig 5 25 Workbook No 2 2007 e Volume 80 Test Your Knowledge Instructions Follow the steps on the Answer Sheet on the next page to take your test online to fax or to mail your test 1 26 The storage cooler portion of the Clean Power System operates as a standard refrigerat
11. NES H PROFESSIONAL Workbook No 2 2007 Volume 80 Featuring Kenworth TM Clean Power System Fuel Fired Heater in passenger s side tool box il Enhanced Insulation Air Conditioning Charge Unit Starter Batteries Disconnect Switch cab floor Main Battery Disconnect Switch Shore Power Connector 120 VAC Main Battery Box Starter Batteries Main Batteries Circuit Breaker Box Storage Cooler in driver s side tool box under lower bunk Components Kenworth Clean Power System Components Kenworth s Clean Power System is designed to keep a vehicle s sleeper cool in summer and warm in winter for up to 10 hours with no need to idle the engine It s a battery powered climate control system independent from the cab s air conditioner and heater with its own separate heating and cooling sources In addition there s enough battery power so the driver can operate any 120 Volt AC accessories Clean Power features and benefits e Clean Power keeps the vehicle in compliance with all state and federal anti idling regulations because it operates with the engine off e t provides engine off sleeper heating cooling and operation of A C devices The driver can relax in climate controlled comfort with a TV and DVD player before turning in
12. ace the compressor Check the run winding by measuring continuity between terminal pins C and R If there is no continuity replace the compressor Step 3 Measure the resistance Measure the resistance ohms between each pair of terminal pins C and S C and R and S and R Add the resistance between C and S to the resistance between C and R This sum should equal the resistance found between S and R A small deviation in this comparison is acceptable Proper resistance may also be confirmed by comparing measured resistance to the resistance specifications for the specific compressor model For this compressor the resistance values at a nominal temperature of 21 C 70 F should be within C amp S 4 0 to 5 2 ohms C amp R 0 7 to 0 85 ohms S amp R 4 7 to 6 05 ohms If the resistance is not correct replace the compressor If the resistance is correct leave the leads off and continue troubleshooting procedures as outlined in the following Steps 1 6 Troubleshooting PSC Compressor Circuits Workbook No 2 2007 Volume 80 Troubleshooting PSC Compressor Circuits Step 1 Ground fault and continuity checks Before continuing troubleshooting you should have already disconnected electrical power and should have checked for ground faults You also should have checked the windings for continuity and proper resistance making sure the system is getting proper voltage And you should have made sure all control
13. an be eliminated as possible causes for the particular fault Webaso Diagnostic Interface Kit Corrosion on plugs P N 9009064D e Loose plug contacts e Poor crimp contacts on plugs If a fault occurs an error code will be visible in the display of the combination timer and the heater element ON control light will flash The heater also can be diagnosed using a e Corroded cables and fuses e Corroded battery terminals To check individual components first PC if Webasto s optional diagnostic interface disconnect electrical plug connectors on the kit and software are used The interface kit control unit and adapter harness can be ordered through PACCAR Parts Error Code Output a fault occurs an error code will appear on the combination timer display The table below lists Error Codes F 00 through F 15 as well as their personal computer diagnostic counterparts Error code Error group Additional information during PC diagnostic Control unit error 01 Control unit error Replace control unit 81 EOL checksum error 11 Incorrectly coded control unit or incorrect heater fuel type installed the heater will not work if this error occurs 91 Neutrally coded or disabled control unit the heater will not work if this error occurs 92 Maintain command failed the heater will not work if this error occurs 18 Customer bus defective No start 02 Even after the restart no flame has formed Check fuel supply t
14. ank empty lines blocked Clean burner insert 82 No start in test Replace overheating sensor control unit Flame failure 03 The flame has gone out during operation and has not reformed after a Check fuel supply tank empty lines restart attempt blocked Clean burner insert 83 The flame has gone out during a heating cycle more than 3 times Replace overheating sensor control See 3 7 1 Error FAZ Flame Failure Counter unit Workbook No 2 2007 Volume 80 21 Troubleshooting Error code Error group Additional information during PC diagnostic Remedy Undervoltage or 84 The voltage was less than 10 5 V or 21 V for longer than 20 seconds Charge battery overvoltage 04 The voltage was more than 16 V or 32 V for longer than 6 seconds Premature flame 05 A flame was detected before combustion had started Replace overheating sensor control recognition unit Not Applicable External temperature sensor break or short circuit Metering pump interrupt or short circuit Drive unit combustion and hot air blower break or short circuit Glow plug interrupt or short circuit Overheating Overheating sensor interrupt or short circuit Heater fault lock out Permanent heater fault lock out Nominal sensor break 22 14 Temperature sensor circuit Short circuit to earth 94 Temperature sensor circuit break or short circuit to Ub 88 Break or short circuit to Ub 08 Short circuit to earth 89 B
15. er 12V on pins 1 3 and Repair open or short circuits pins H 16 and variable voltage 0 10V to pin 5 Ground on pin 2 Replace defective relay K6 L 16 Blower control signal 2Coolant pump circuit check Check for open fuse F5 Replace fuse F5 Connect a 2K linear potentiometer between pins Check thermostat module TC1 and socket for power 12V Repair open or short circuits Replace K 16 and J 16 Connect temperature sensor TS3 on pins 1 2 and OUT defective thermostat module TC1 to X5 connector pins A 2 and B 2 Connect power 12V to pin G 16 Check for power out 12V en Ground on pin 31 pin N 16 and power out 12V on connector X3 pin A 2 1 When E 12 and M 12 are powered the Condenser Fan M2 is ON and the Magnetic Valve MV is open for the first two minutes When two minutes have elapsed the Condenser Fan is ON and Relay K2 is closed Compressor ON At this time MV remains closed no power on D 12 until power is removed from pins E 12 and M 12 2 When potentiometer is set to 0 ohms no power out on connector SCCU2 pins D 16 and N 16 and no power out on connector X3 pin A 2 12 Workbook No 2 2007 Volume 80 Troubleshooting Table 1 SCCU Troubleshooting Functional Checks continued Function Possible Cause for Malfunction Remedy Fresh Air Recirc actuator circuit check Connect power 12V to pin A 16 and ground to pin B 16 Check for power out 12V on connector X4 pin5 Check f
16. ership Dealer Code Address City State Province Zip or Postal Code Mark the box for the correct answer to each test item on previous page Then fold and mail this Answer Sheet to the address on the back or fax to the Kenworth Professional Service Coordinator at Burgio Cooney and Associates 816 353 4206 Kenworth Clean Power System 1 A B C D 4 A B C D 8 A B C D 2 A B C D 5 A B C D 9 A B C D 3 A B C D 6 A B C D 10 A B C D Z A B C OD Workbook No 2 2007 Volume 80 27 KENWORTH PROFESSIONAL SERVICE Workbook x Featuring Kenworth Clean Power System KENWORTH PROFESSIONAL SERVICE WORKBOOK BURGIO COONEY ASSOCIATES 13665 E 42ND TERRACE S SUITE D INDEPENDENCE MO 64055 7343
17. g procedures in Table 3 Table 3 Discharge Mode Troubleshooting Concern Possible Cause Blower fan does not turn on No power to blower fan M3 Check blower fan electrical connector X2 for power out 12V on pin A 3 and ground on pin C 3 Check for open fuse F6 and replace Check for damaged open or shorted wiring and repair Blower fan defective Replace blower fan Blower fan operates with Air ducts blocked Ensure correct vents and return grilles in sleeper are open little or no air flow Air filter dirty Clean or replace air filter No cooling of air No power to coolant circulating Check circulating pump electrical connector X3 for power out 12V on pin A 2 pump M4 and ground on pin B 2 Check for open fuse F5 and replace Check for damaged open or shorted wiring and repair Coolant circulating pump defective Replace coolant circulating pump Low coolant pump cavitation Replenish coolant with premixed 50 50 solution of water and extended life coolant ELC to proper level and purge air from circuit 2No circulation due to ice blocked Thaw system drain and fill with correct strength of premixed 50 50 extended storage core coolant tubes Weak life coolant ELC solution Allow system to circulate for minimum of 15 min and antifreeze solution or water added check coolant strength If still weak repeat drain fill circulate and test to system without prior mixing with extended life coolant as recommended Can
18. ger e A low power consumption air circulation fan e Fresh air and recirculated air intake ducts 9 8 7 1 Cover Air filter housing and filter 2 Port Access to heat exchanger bleeder valve 3 Conditioned air outlet 4 Fan and scroll housing 5 Small pallet Base Workbook No 2 2007 e Volume 80 o Ng 9 10 e Amotor actuated door to switch from fresh air to recirculated air When fresh air mode is selected filtered air is drawn in from an opening in the lower rear sleeper panel The filter is a replaceable Hepa cartridge Condensation drains through an opening in the bottom of the air handler and vehicle floor 3 6 Coolant inlet from cold storage unit Coolant outlet to cold storage unit Connection Socket Mode door actuator Motor Mode door actuator Fresh Recirculated Fresh air inlet Cabin temperature sensor Recirculated air mode Recirculated air inlet Components Storage Cooler Control Assembly The Storage Cooler system is designed to automatically recharge when the cold energy in the Storage Cooler is depleted To monitor and control the parking cooler the cold transfer system uses e Storage Cooler Control Unit GCCU e Temperature control thermostat e Ambient temperature limiter e High refrigerant pressure switch e Low refrigerant pressure switch e Charge enable switch located on the dash e Sleeper control panel located in the sleeper e High low refrigera
19. he enabled up position NOTE The LED light will not illuminate unless the compressor is running 2 Ensure that battery voltage is at an acceptable voltage level as determined by voltage regulator when engine is running OR shore power connected 3 Ensure that 120 VAC voltage is present if connected to Shore Power 4 Ensure that the control panel is operative and functioning properly NOTE As a minimum all supporting components e g the Main Battery Box and control panel that the bunk cooling system relies upon must be operational and within required parameters before proper troubleshooting of the system can be performed When the truck engine is running and you are using the inverter only no shore power the voltage regulator for the alternator is what determines if the battery has an acceptable charge The voltage regulator will go through several stages of charging The first is known as bulk charging The regulator ramps up the alternator to provide maximum current and will charge the batteries at 14 6V It then looks at the battery temperature and battery voltage to see how rapidly the batteries are taking a charge Bulk charging lasts a minimum of 30 minutes Workbook No 2 2007 Volume 80 Once bulk charging is complete the regulator ramps current and voltage down and activates an output pin to ground which controls the K9 relay to start the compressor When in Shore Power mode you just need sho
20. heck for power out 12V on pin M 16 Check for open fuse F6 Replace fuse F6 Check for open or short circuit within SCCU wiring Repair SCCU wiring Check for power out 12V on pin B 12 Check for open fuse F3 Replace fuse F3 Condenser fan with power 12V Check relay K10 and socket for power 12V on pins 1 3 Repair open or short circuits applied to pins E 12 and M 12 1Check for power out 12V on pin D 12 Magnetic Valve for first 2 minutes with power 12V applied to pins E 12 and M 12 and 5 Ground on pin 2 Check relay K1 and socket for power 12V on pins 86 30 and 87 Ground on pin 85 Check for open fuse F2 Check relay K3 and socket for power 12V on pins 30 15 and 87a Ground on pin 31 Replace defective relay K10 Repair open or short circuits Replace defective relay K1 Replace fuse F2 Repair open or short circuits Replace defective relay K3 Note Pin 87a will have power for 2 minutes only after which it will switch to pin 87 Check for power out 12V on pin A 12 Compressor after 2 minutes with power 12V Check relay K3 and socket for power 12V on pins 30 15 Repair open or short circuits Check for open fuse F2 Replace fuse F2 applied to pins E 12 and M 12 and 87 Ground on pin 31 Replace defective relay K3 Check for power out 12V on pin A 3 Blower Check for open fuse F6 Replace fuse F6 Motor connector X3 with power 12V applied to Check relay K6 and socket for pow
21. ion system with what difference a It is battery powered b It is both battery and AC powered c It stores cold energy for later use Is a PC necessary for reading error codes if a heating system fault occurs a Yes b No If water is used to top off coolant level instead of a premixed 50 50 extended life coolant and water solution what can happen a The system can become corroded b Freezing and blockage may occur resulting in poor sleeper cooling c The cabin temperature sensor may not work Where is fuel stored for the heating system a Inthe vehicle s diesel fuel tanks b In a tank under the bunk If the blower fan operates properly but there is reduced or no air flow what should you do a Check that the correct vents and return grills in the sleeper are open and not blocked b Check for a dirty air filter c Both of the above 6 In shore power mode the inverter is bypassed a b True False 7 A tripped breaker should be reset before beginning electrical troubleshooting a b Yes No 8 In the event of a fault in the heater system component an error code appears as a b A steady light on the heater switch A flashing pulse on the heater switch 9 If the compressor operates for an unusually long period of time or runs continuously and you have determined there is no leakage or undercharge of refrigerant the cause of the problem might be a b c d
22. ke casing e Fuel tank stand pipe Internally the control and monitoring system is made up of e A control unit with temperature sensor e A glow plug e An overheating sensor The heater also can be controlled using an external temperature sensor Fuel is supplied to the heater via a metering pump In the event of a fault an error code appears on the CPS control panel Air Conditioning Heater switch LED as a flashing pulse The LED is on the lower heater half of the switch A personal computer PC can be used for diagnostics Workbook No 2 2007 e Volume 80 Components Heat Exchanger The heat exchanger transfers heat from the combustion process to the air stream generated by the hot air blower Burner Insert with Combustion Pipe The fuel air mixture distributed over the cross section of the combustion pipe in the burner insert burns to heat the heat exchanger Control Unit The control unit ensures proper function of the heater and monitors its operation A temperature sensor controls sleeper temperature and an external sensor may also be connected to the heater If a fault occurs the Air Conditioning Heater switch LED will flash The heater also can be checked using a PC with Webasto s optional interface kit Glow Plug A glow plug positioned in the burner insert on the side away from the flame ignites the fuel air mixture when the heater is started Overheating Sensor When the heate
23. m unless the protective terminal cover is securely fastened and the compressor is properly connected to ground Be alert for sounds of arcing sputtering or popping inside the compressor If you hear such sounds move away from the area immediately Oil and refrigerant can spray out of the compressor if one of the terminal pins is ejected from the hermetic terminal This can occur as the result of a ground fault and spray can be ignited by electricity Never energize a compressor that has a ground fault Never reset a breaker or fuse without first checking for a ground fault an open fuse or tripped circuit breaker is a strong ground fault indicator Checking for a Ground Fault Disconnect all electrical power supplies to the system making sure all power legs are open Then remove the protective terminal cover If you find evidence of overheating at any lead that could indicate a compressor motor problem exists Do not replace or attach any leads or connectors that have been damaged by overheating until the problem has been repaired Disconnect leads and or remove all components such as relays and capacitors from the terminal pins When removing a current type relay keep it upright 16 WARNING If a capacitor is present discharge it using a 20 000 ohm resistor before removing it from the system An undischarged capacitor presents a risk of electrical shock and damage to measuring devices Use either a megaohmmete
24. mping Check against wiring diagram and wire properly Low voltage to compressor Turn off system until proper voltage is restored See Identifying Compressor Electrical Problems See Checking for Adequate Compressor Pumping Check for extra sources of current passing through thermal protector such as fan motors pumps This would be extremely rare as the system is not designed for such use See Identifying Compressor Electrical Problems Turn off system until proper voltage is restored See Identifying Compressor Electrical Problems Check condenser fan for malfunction See Kenworth Clean Power System Storage Cooler Service Manual for details Now available on ServiceNet to download 19 Troubleshooting Table 4 Refrigerant Compressor Troubleshooting continued Possible Causes Remedy Unit runs OK but run cycle is System components such as storage temperature control shorter than normal due to thermostat SCCU relays not functioning properly components other than thermal High pressure cut out due to rotector dee protector a Insufficient air flow over condenser b Overcharge or refrigerant 0 Air in system See Troubleshooting Low pressure cut out due to a Refrigerant leaking b Undercharge of refrigerant c Restriction in thermal expansion valve Unit operates long or Undercharge of refrigerant Check for leak and correct Perform
25. n by the Air Conditioning Charge Unit located on the right hand frame rail behind the sleeper Cold energy is dispersed as the driver relaxes The Storage Cooler consists of e Acold storage assembly e An air handler assembly e A cold transfer system located between the Storage Cooler and the Air Conditioning Charge Unit which uses an automotive antifreeze solution Workbook No 2 2007 Volume 80 Components e A refrigeration system between the Storage Cooler and the Air Conditioning Charge Unit which uses R134a refrigerant e A control unit which houses relays and fuses Charging Refrigeration Unit The charging unit consists of e A120 VAC electrical refrigeration compressor e Acondenser core with an electrical automotive type radial fan e An evaporator located inside the cold storage core e A thermal expansion valve e A pressure equalization valve e Electrical circuitry and components 11 y Coane eae 10 __ Ut Condenser inlet connection Condenser fan Radial Positive Temperature Coefficient Resistor PTCR compressor hard starting aid Refrigerant filter dryer Accumulator 120 VAC power connection Refrigerant supply line to TXV and evaporator High refrigerant pressure switch Low refrigerant pressure switch Refrigerant return line from TXV and evaporator O 440
26. ned Id DC Current Amps la AC Current Amps S Switch K Relay MV Magnetic Solenoid Valve O Function OFF Storage Cooler Charging Workbook No 2 2007 e Volume 80 A C Enable Switch Open S1 Storage Core Temperature Control Thermostat Open S4 Ambient Temperature Limiter Open S6 High amp Low Pressure Switches Open S7 S2 Battery or Alternator Not Operating at Acceptable Levels per Voltage Regulator or Shore Power Disconnected Inverter 120 VAC Output Not Present Compressor Bypass MV Valve OFF valve closed Compressor K2 ON Id 60 70 la 8 A C Enable Switch Open S1 or Storage Core Temperature Control Thermostat Open S4 or Ambient Temperature Limiter Open S6 or High amp Low Pressure Switches Open S7 S2 or Battery or Alternator Not Operating at Acceptable Levels per Voltage Regulator or Shore Power Disconnected or Inverter 120 VAC Output Not Present K8 Open 23 330 ES YOUMS 1908 NO ES YMS JaMo g SS uonejnouday SS div yseuy 01 Uwe O YMS dn uonisod 65 U2114S uwoq uonlsoq SS Lie Ju us l1d 19 440 lt YO A SS Yous PON y 1591 UONISOd sS dn uonisod SS U31AS UO e NDUDe8yY poN Jg Ysel4 Flow Charts gs uoRe NuDay E GS Yseu4 01 YMS NO ES YMS
27. not control sleeper Coolant circulating pump runs Check for unplugged cabin temperature sensor TS3 connector X5 or open cooling temperature Cold continuously regardless of temperature circuit in wiring storage unit quickly depleted setting Cabin temperature sensor defective Check sensor with digital ohm meter 1 001kQ at 24 C 75 F Replace sensor if reading is incorrect or sensor is open 1 The coolant circulating pump responds according to cabin temperature and position of the temperature control dial The further counter clockwise the dial is turned the more frequently and longer the pump is activated to circulate coolant through the heat exchanger For diagnostic purposes it may be necessary to turn the dial full on to activate the pump depending on ambient temperatures in the sleeper 2 Pure water must never be introduced into the coolant circuit under any circumstances Doing so may cause freezing and blockage within the cold storage unit resulting in no circulation and no sleeper cooling Use a premixed 50 50 extended life coolant and water solution only Workbook No 2 2007 Volume 80 1 5 Troubleshooting Before troubleshooting for compressor problems refer to the Kenworth Clean Power System Storage Cooler Service Manual available for download on ServiceNet Identifying Compressor Electrical Problems It is critical to follow all safety precautions when checking for electrical problems Never energize a syste
28. nt pressure cutout switches and compressor overheat overload protection e Relay Assembly located in driver s side tool compartment Storage Cooler Control Unit SCCU The SCCU is located on top of the cold storage unit and is critical for ensuring that the storage cooler portion of the Clean Power System functions properly Temperature Control Thermostat The thermostat is mounted on the refrigerant suction line It allows system charging or no system charging depending on storage core temperature at the suction line Cold Transfer System The cold transfer system or coolant circuit is made up of a circulating pump coolant hoses coolant reservoir and transfer medium 50 50 mixture of extended life coolant ELC and water A sensor mounted in the recirculated air duct monitors sleeper temperature prompting the A C pump to switch on and off and circulate coolant 4 Inlet to air handler 5 Return from air handler 6 Return to cold storage unit 1 Supply from cold storage unit 2 Coolant reservoir 3 A C circulating pump 12 Volt Workbook No 2 2007 e Volume 80 Components Relay Assembly The Relay Assembly houses two relays which respond to the dash mounted Charge Enable Switch and Temperature Control Thermostat The K2 relay responds to the Storage Cooler Temperature Control Thermostat and the K8 relay responds to the dash mounted Charge Enable Switch Ambient Temperature Limiter An ambient
29. or open or short circuit within SCCU wiring Repair open or short circuits Actuator rotation CW Connect power 12V to pin B 16 and ground to Check for open or short circuit within SCCU wiring Repair open or short circuits pin A 16 Check for power out 12V on connector X4 pin 6 Actuator rotation CCW Check In with Kenworth ServiceNet for Critical Service Documents This Workbook is designed to give you a brief overview of components and troubleshooting techniques for the Kenworth Clean Power System The complete documentation you will need can be found on Kenworth ServiceNet P94 1613 Charge amp Start Wiring Diagram P94 1667 Clean Power System Wiring Diagram Kenworth Clean Power System Service Manual Kenworth Clean Power System Storage Cooler Service Manual Webasto AT 2000 ST D Air Heater Service Manual Webasto Workbook No 2 2007 Volume 0 1 3 Troubleshooting Charge Unit The control system has a built in delayed operation feature The charging unit compressor is delayed 2 minutes before starting operation During this 2 minute period the condenser fan motor M2 is activated and the bypass valve MV is opened to allow equalization of the refrigerant pressures between the suction circuit and discharge circuit Concern Charge unit does not begin operation Charge unit does not begin operation Storage cooler unit discharged Charge unit shuts down after partial system charge
30. points are too high or a hot air filter is soiled Replace overheating sensor Remove the fuse and then refit it NOTE The following error has occurred several times Fault counter 3 times Incorrect start counter 9 times Overheating counter 3 times Delete the error with the PC diagnostic NOTE Permanent flame failure counter more than 3 times Overheating sensor 97 Incorrect position of overheating sensor UHS gradient too low Position the overheating sensor incorrect position correctly Check cables replace control element Workbook No 2 2007 Volume 80 Flow Charts Charge State Diagram A C Enable Switch Closed S1 and Storage Core Temperature Control Thermostat Closed S4 and Ambient Temperature Limiter Closed S6 and High amp Low Pressure Switches Closed 57 52 and Battery Voltage Acceptable per Voltage Regulator or Shore Power Connected and Inverter 120 VAC Output Present K8 Closed A C Enable Switch Closed 51 and Storage Core Temperature Control Thermostat Closed S4 and Ambient Temperature Limiter Closed S6 and High amp Low Pressure Switches Closed 57 52 and Battery Voltage Acceptable per Voltage Regulator or Shore Power Connected and Inverter 120 VAC Output Present K8 Closed and Elapsed Time gt 2 min Time Delay Relay Closed K3 O O Condenser Fan K1 ON e Time Delay Relay K3 Counting Down Charging Unit Compressor Bypass MV OFF Valve ON valve ope
31. r megger or a Hi Potential Ground Tester Hi Pot to check for a ground fault Always follow the manufacturer s procedures and safety recommendations when using these devices Connect one lead of the megger or Hi Pot to the copper suction line and the other lead to one of the terminal pins Repeat for all terminal pins If resistance reads less than two megaohms between any pin and the housing copper suction line a ground fault exists Never energize a compressor with a ground fault If a ground fault is found keep the power off and replace the compressor If you do not replace it immediately mark and red tag it insulating and taping each power lead separately If no ground fault is found leave the power off and components disconnected from the terminal pins Check for continuity and proper resistance to determine whether there is an open or short circuit in the motor windings or if the heater element of the thermal protector is open Workbook No 2 2007 Volume 80 Troubleshooting Checking for Proper Continuity and Resistance Step 1 Allow the thermal protector to reset Be sure to allow time for the thermal protector to reset before starting electrical checks For some compressors the internal thermal protector may take as long as an hour to reset Step 2 Check continuity Check the start winding by measuring continuity between terminal pins C and S If there is no continuity repl
32. r is in operation an overheating sensor monitors temperatures in the rib area of the heat exchanger The combustion process 10 will be shut down and cold air blown over the heat exchanger if the control unit detects a hot air outlet temperature of more than 150 C 802 F and surface temperatures over 80 C 176 F Should this shutdown occur the heater can be restarted by being switched off and then on again Fuel Metering Pump The metering pump supplies fuel from the truck s fuel tank to the heater It is a combined transport metering and shut off system Fuel Filter A Webasto filter P N 487171 is the only 0 90 approved fuel filter for use in the heating system Fuel Extractor Stand Pipe The fuel extractor stand pipe allows fuel to be supplied to the heater from the vehicle s tank Because it is a separate fuel pickup device any effect of pressure is eliminated gt 25mm Workbook No 2 2007 e Volume 80 Troubleshooting Before performing any troubleshooting it is essential to study the Kenworth Clean Power System Storage Service Manual as well as the Kenworth Clean Power System Operator s Manual which are now available for download on ServiceNet Sleeper Cooling System Before beginning any troubleshooting on the Storage Cooler perform the following checks 1 Ensure that the Charge Enable Disable switch located on the dashboard is functional and in t
33. re power plugged in to activate the shore power signal which comes from the Sleeper Control Panel to the K10 relay which will start the compressor Shore power works this way because the power to start the compressor is coming directly from the wall plug and the inverter is bypassed altogether N X4 M5 FRESH RECIRC DOOR ACTUATOR X5 TS3 TEMPERATURE SENSOR A F Fuses A Amps K Relays TCI Thermostat Module ee 55 F3 20A om F7 2A F5 5A J F2 5A pe 2 M3 Fe 58 BLOWER FAN X3 M4 COOLANT PUMP SCCU1 CA D SCCU2 IV PS R NOT USED 11 Troubleshooting Storage Cooler Control Unit SCCU Before troubleshooting the SCCU e Disconnect connectors SCCU 1 12 pin and SCCU 2 16 pin e Remove the SCCU cover e Apply 12 volt power to pins G 12 and H 12 of connector SCCU 1 NOTE Power and ground must be maintained throughout the SCCU testing process e Apply ground to pins J 12 and K 12 of connector SCCU 1 e Follow the procedures in Table 1 Table 1 SCCU Troubleshooting Functional Checks Function Possible Cause for Malfunction Remedy Check for power out 12V on pin F 12 Check for open fuse F2 Replace fuse F2 Check for open or short circuit within SCCU wiring Repair SCCU wiring C
34. reak or short circuit to Ub 09 The switched drive unit cable combustion and hot air blower has a short circuit to earth or the drive unit is overloaded 15 Burner motor block guard has tripped 95 Burner motor blocking detection has tripped 8A Glow plug Break or short circuit to Ub 19 Glow circuit The switched cable of the element has a short circuit to earth 06 The overheating fault lock out has tripped heater overheated 17 Incorrect application or illegal insulation UHS gradient too high AB Overheating sensor circuit break or short circuit to Ub 1B Overheating sensor circuit The switched cable of the element has a short circuit to earth 07 The heater fault lock out has been activated 87 The permanent heater fault lock out has been activated 9B Nominal value potentiometer circuit break or short circuit to Ub Not Applicable Not Applicable Check cables replace temperature sensor Check cables and terminating resistor replace temperature sensor Check cables replace metering pump Check cables replace metering pump Replace drive unit combustion and hot air blower Eliminate the cause of the blockage difficulty in movement Replace drive unit combustion and hot air blower Replace glow plug Find and remove the cause of the overheating NOTE If no other cause can be found for the overheating the pressure losses caused by the hot air distribution too many resistance
35. s and thermostats are working properly Be sure to perform these checks before continuing troubleshooting Step 2 Check wiring Confirm that there is continuity between C and the thermal protector common lead wire Step 3 Check external thermal protector Check for continuity across the thermal protector If there is no continuity then the thermal protector may be tripped Wait at least 5 minutes then check continuity again If there is still no continuity replace the thermal protector Step 4 Check run capacitor WARNING Using a 20 000 ohm resistor discharge the capacitor before removing it from the system to avoid damage to measuring devices and the risk of electric shock Disconnect the run capacitor from the system Use a capacitance meter to check the capacitor Capacitance should be 10 of the marked capacitor value 17 Troubleshooting As an alternative check the run capacitor by Step 5 Reconnect run capacitor measuring continuity across the capacitor Reconnect the run capacitor into the circuit terminals as before Observe color code markings on A Rx1 scale If there is continuity then the schematic capacitor is shorted out and needs to be replaced Step 6 Continue troubleshooting B Rx100 000 scale If a digital multi meter If all the above tests prove satisfactory and DMM indicates infinite resistance then the unit still fails to operate properly check for the run capacitor is open
36. temperature limiter is located on the condenser fan shroud It deactivates the sleeper cooling system during cold weather Low Refrigerant Pressure Switch Located in the high pressure line after the condenser this switch deactivates the compressor in a low pressure situation due to refrigerant loss High Pressure Located in the Charging Unit Workbook No 2 2007 e Volume 80 High Refrigerant Pressure Switch Located in the high pressure line before the condenser the switch will deactivate the compressor if pressure rises beyond the high set point External Thermal Protector Hermetic Compressor Motor A thermal protector mounted on top and in firm contact with the compressor housing protects the compressor motor from overheating Thermal Protector Sleeper Control Panel The driver controls heating and cooling functions from the Sleeper Control Panel located in the sleeper The Operator s Manual contains complete operating instructions 5 Shore Power LED 1 Temperature Control Dial 120 VAC 2 AC Circulation 6 Air Conditioning Pump LED Heating Switch 3 Green Snowflake 4 Inverter Charger LED 7 Inverter Charger Switch 8 Fresh Air Recirculated Components Charge Enable Switch The charge enable switch 5 located on the dash in lt the cab enables the Air CHARGE Conditioning Charge Unit to refreeze replenish the Storage Cooler In the O
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