Mack Truck Air Conditioning System Includes US 07 Chassis, GU (Granite Series), CHU AND CXU (Pinnacle Series), MRU AND LEU (Terra Pro Series) Service Manual(18-902) – PDF DOWNLOAD
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Mack Truck Air Conditioning System Includes US 07 Chassis, GU (Granite Series), CHU AND CXU (Pinnacle Series), MRU AND LEU (Terra Pro Series) Service Manual(18-902) – PDF DOWNLOAD
Language : English
Pages : 188
Downloadable : Yes
File Type : PDF
Size: 15.9 MB
DESCRIPTION:
Mack Truck Air Conditioning System Includes US 07 Chassis, GU (Granite Series), CHU AND CXU (Pinnacle Series), MRU AND LEU (Terra Pro Series) Service Manual(18-902) – PDF DOWNLOAD
Includes U.S. ’07 MACK® Chassis
GU (GraniteTM Series)
CHU and CXU (PinnacleTM Series)
MRU and LEU (TerraProTM Series)
INTRODUCTION
Mack Trucks, Inc. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recognizing potentially hazardous situations and taking necessary precautions. Performing service procedures correctly is critical to technician safety and safe, reliable vehicle operation.
The following list of general shop safety practices can help technicians avoid potentially hazardous situations and reduce the risk of personal injury. DO NOT perform any services, maintenance procedures or lubrications until this manual has been read and understood.
- Perform all service work on a flat, level surface. Block wheels to prevent vehicle from rolling.
- DO NOT wear loose-fitting or torn clothing. Remove any jewelry before servicing vehicle.
- ALWAYS wear safety glasses and protective shoes. Avoid injury by being aware of sharp corners and jagged edges.
- Use hoists or jacks to lift or move heavy objects.
- NEVER run engine indoors unless exhaust fumes are adequately vented to the outside.
- Be aware of hot surfaces. Allow engine to cool sufficiently before performing any service or tests in the vicinity of the engine.
- Keep work area clean and orderly. Clean up any spilled oil, grease, fuel, hydraulic fluid, etc.
- Only use tools that are in good condition, and always use accurately calibrated torque wrenches to tighten all fasteners to specified torques. In instances where procedures require the use of special tools which are designed for a specific purpose, use only in the manner described in the instructions.
- Do not store natural gas powered vehicles indoors for an extended period of time (overnight) without first removing the fuel.
- Never smoke around a natural gas powered vehicle.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Mack Truck Air Conditioning System Includes US 07 Chassis, GU (Granite Series), CHU AND CXU (Pinnacle Series), MRU AND LEU (Terra Pro Series) Service Manual(18-902) – PDF DOWNLOAD
INTRODUCTION 1
SAFETY INFORMATION 2
Advisory Labels 2
Service Procedures and Tool Usage 3
PERSONAL SAFETY 5
R-134a vs R-12 System Component Differences (“Do’s” and “Don’ts”) 6
Additional Service Precautions for R-134a Refrigerant 7
EXPLANATION OF NUMERICAL CODE 9
Explanation of Three-Digit Numerical Code 9
ABOUT THIS MANUAL 10
DESCRIPTION AND OPERATION 11
A/C SYSTEM FEATURES AND OPERATION — RED DOT SYSTEM [637] 12
CH, CL and CX System Description [637] 12
CH, CL and CX Cab Climate Control Panels [733] 12
CH, CHN, CL, CX and CXN Millennium Sleeper Climate Control Panels [733] 14
DM, DMM, RB, RD6 and RD8 System Description [637] 15
DM, DMM, RB, RD6 and RD8 Climate Control Panel [733] 15
FDM System Description [637] 15
FDM Climate Control Panel [733] 16
LE, LEU, MR and MRU Roof-Mounted A/C System Description [637] 16
LE and LEU Heater Control Only [733] 16
MR and MRU Cab-Mounted A/C System Description [637] 17
MR and MRU Cab-Mounted A/C System Climate Control Panel [733] 17
CS and MS System Description [637] 17
CS and MS Blower Control Switch [733] 18
A/C SYSTEM FEATURES AND OPERATION — BLEND AIR SYSTEM [637] 19
CH, CHN, CL, CT, CV, CX and CXN System Description [637] 19
CH, CHN, CL, CT, CV, CX and CXN Cab Heater/Air Conditioner Control Panels [733] 20
A/C SYSTEM FEATURES AND OPERATION — BEHR SYSTEM [637] 23
CTP, CXP, CHU, CXU and GU BEHR System Description [637] 23
CTP, CXP, CHU, CXU and GU Behr Cab Climate Control Panel [733] 24
V-MAC CONTROL OF THE ON/OFF FAN [230] 25
Smart Fan Control Parameters [230] 25
Fan Overrides [230] 25
High Refrigerant Pressure Fan On Time [230] 25
A/C SYSTEM FEATURES AND OPERATION — APADS® CM812 MACK PART NO 228RD33
(YELLOW LABEL) AND CM813 MACK PART NO 228RD32 (WHITE LABEL) SYSTEM [637] 25
Functional Description 25
Electrical I/O Definitions 26
Control and Diagnostic Functions 27
Diagnostic Fault Descriptions 27
Blink Codes 28
COMPONENT LOCATOR 29
CH, CHN, CL, CT, CX AND CXN COMPONENT LOCATIONS [637] 30
DM, DMM, RB, RD6 AND RD8 COMPONENT LOCATIONS [637] 31
FDM COMPONENT LOCATIONS [637] 31
LE, LEU, MR AND MRU WITH ROOF-MOUNTED A/C SYSTEM COMPONENT
LOCATIONS [637] 32
MR AND MRU CAB-MOUNTED A/C SYSTEM COMPONENT LOCATIONS [637] 32
CS AND MS COMPONENT LOCATIONS [637] 33
TABLE OF CONTENTS
Page v
CH, CV, CT AND CX MODELS WITH BLEND AIR HVAC SYSTEM COMPONENT
LOCATIONS [637] 34
CHN, CXN, CV (ASET™) AND CT MODELS WITH BLEND AIR HVAC SYSTEM COMPONENT
LOCATIONS [637] 35
CXP AND CTP MODELS WITH BEHR HVAC SYSTEM COMPONENT LOCATIONS [637] 36
CHU, CXU AND GU MODELS WITH BEHR HVAC SYSTEM COMPONENT
LOCATIONS [637] 37
TROUBLESHOOTING 39
TROUBLESHOOTING MODELS WITH ROTARY CONTROL PANEL AND MILLENNIUM
SLEEPER [637] 40
CX Model A/C System without Constant Temperature Control (CTC) — Red Dot
System [637] 40
CX, CH and CL Models with Rotary Control Panel A/C System with Constant Temperature
Control (CTC) — Red Dot System [637] 44
Millennium Sleeper A/C Unit [637] 45
CH, CHN, CL, CT, CV, CX and CXN Models (Bergstrom) with Blend Air Rotary Control
Panel and HVAC Unit — without Automatic Temperature Control (ATC) [637] 46
CH, CHN, CL, CT, CV, CX and CXN Models with Blend Air Rotary Control Panel and HVAC
Unit — with Automatic Temperature Control (ATC) [637] 49
Blend Air HVAC Unit Circuit-By-Circuit Troubleshooting Guide 51
CH, CHN, CX and CXN Models with Blend Air Sleeper Systems Experiencing Evaporator
Freezing and Icing 52
TROUBLESHOOTING BEHR HVAC SYSTEM — CTP, CXP, CXU, CHU AND GU
MODELS [637] 53
Behr System 53
Unit Parts — Behr System 54
Behr System 55
TESTING THE APADS® CM812 AND CM813 MODULE [637] 57
Six-Pin Connector 57
Four-Pin Connector 57
TROUBLESHOOTING APADS® CM812 AND CM813 SYSTEMS 58
Blink Code Identification 58
Troubleshooting Charts 59
Diagnostic Flow Charts 62
REPAIR INSTRUCTIONS 65
REPAIR INSTRUCTIONS — BERGSTROM HVAC UNIT 66
Blower Motor Resistor Card Removal 66
Heater/Air Conditioner Cab Control Board Fuse — CH, CHN, CL, CT, CV, CX and CXN
Models 68
REPAIR INSTRUCTIONS — BEHR HVAC UNIT (CTP, CXP, CXU, CHU AND GU MODELS) 70
Evaporator Replacement (Start of Production 3rd Quarter 2005 to 2nd Quarter 2007) 70
CORRECTIVE ACTIONS FOR KNOWN HVAC MALFUNCTIONS 94
Corrective Action for Sleeper Box Air Conditioner Evaporator Freezing and Icing — CH,
CHN, CV, CX and CXN Models with Blend Air-Type HVAC Systems 94
Corrective Action for Sticking or Binding Blend Air-Type Mode Box — CH, CHN, CL, CT,
CX and CXN Models with Blend Air-Type HVAC Systems 95
A/C SERVICE RECOMMENDATIONS 102
Flushing the A/C System During Compressor Replacement 102
Flushing Equipment 102
Safety Measures 102
Page vi
TABLE OF CONTENTS
Acceptable Flushing Fluid and Solvents 102
Component Flushing Recommendations 103
Back Flushing 103
Flushing Duration 103
Residual Flushing Fluid Removal 103
Rear A/C System Evaporator and Hose Flushing 103
Suction Side Flushing 103
SPECIFICATIONS 105
AIR CONDITIONING SYSTEM SPECIFICATIONS [637] 106
Refrigerant and Oil Charge Levels [637] 106
APADS® CM812 AND CM813 A/C CONTROL SYSTEM [637] 107
Mechanical 107
Electrical 107
Environmental 107
SCHEMATIC & ROUTING DIAGRAMS 109
A/C SYSTEM REFRIGERANT CIRCUIT SCHEMATICS [637] 110
CH, CHN, CHU, CL, CT, CTP, CV, CX, CXN, CXU, GU and CXP Model A/C System 110
DM, DMM, RB, RD6 and RD8 Model A/C System 111
FDM Model A/C System 112
LE, LEU, MR and MRU Models with Roof-Mounted A/C System 113
MR and MRU Model with Cab-Mounted A/C System 114
CS and MS Model A/C System 115
AIR DISTRIBUTION SCHEMATICS [733] 116
CH and CL Air Delivery, Air Delivery Airflow and Air Control Logic — Red Dot System 116
DM, DMM, RB, RD6 and RD8 Air Delivery and Air Control Logic — Red Dot System 119
CH, CHN, CL, CT, CV, CX and CXN Airflow — Blend Air A/C System 121
CTP, CXP, CHU, CXU and GU Airflow — Behr A/C System 125
ELECTRICAL SYSTEM DIAGRAMS [637] 133
CH, CL and CX A/C System Electrical Schematics — Red Dot System 133
DM, DMM, RB, RD6 and RD8 A/C System Electrical Schematics — Red Dot System 139
LE, LEU, MR and MRU Roof-Mounted A/C System Electrical Schematics — Red Dot
System 143
MR and MRU Cab-Mounted A/C System Electrical Schematics — Red Dot System 144
CS and MS A/C System Electrical Schematics — Red Dot System 147
CH, CHN, CL, CT, CV, CX and CXN A/C System Electrical Schematics — Blend Air
System 149
CTP, CXP, CXU, CHU and GU Behr Cab A/C System Electrical Schematics 151
APAds® CM812 and CM813 Electrical Schematics 154
SPECIAL TOOLS & EQUIPMENT 157
AIR CONDITIONING TOOLS REQUIRED FOR R-134a 158
Scavenger A/C Recovery Only Unit 158
R-134a Smart Cart 158
R-134a Pureguard2 Refrigerant Tester 158
Red Dot CTC2 Analyzer 158
ACR4 (Black Shroud) Recovery and Recycling Unit 159
Mode Actuator Removal and Installation Tools (BEHR Climate Unit) 159
TABLE OF CONTENTS
Page vii
DISASSEMBLED VIEWS 161
ASSEMBLY VIEW AND PARTS IDENTIFICATION [637] 162
CH, CL and CX Cab Unit Parts [637] — Red Dot System 162
CH, CHN, CHU, CL, CX, CXN, CXP and CXU Millennium Sleeper Unit Parts [637] — Red
Dot System 164
DM, DMM, RB, RD6 and RD8 Cab Unit Parts [637] — Red Dot System 165
FDM Cab Unit Parts [637] 166
LE, LEU, MR and MRU Roof-Mounted Unit Parts [637] 167
MR and MRU Cab-Mounted Unit Parts [637] 169
CS and MS Cab Unit Parts [637] 170
CH, CHN, CL, CT, CV, CX and CXN Cab Unit Parts [637] — Blend Air System 172
CTP, CXP, CXU, CHU and GU Unit Parts [637] — Behr Cab A/C System Kinematics 173
CTP, CXP, CXU, CHU and GU Behr A/C System [637] — Service View (Complete Unit) 174
INDEX 175
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