Professional Documents
Culture Documents
Heating/Cooling
Temperature
Management System
TK 53024-19-OD (Original, 10-05)
Diagnostic Manual
This manual is published for informational purposes only and the information so provided
should not be considered as all-inclusive or covering all contingencies. If further
information is required Thermo King Corporation should be consulted.
Sale of product shown in this manual is subject to Thermo King's terms and conditions
including, but not limited to, the THERMO KING LIMITED EXPRESS WARRANTY. Such
terms and conditions are available upon request.
Thermo King's warranty will not apply to any equipment which has been "so repaired or
altered outside the manufacturers plants as, in the manufacturers judgment, to effect it's
stability".
Section 4 - Operation
This section shows you how to operate and program the microprocessor control system. This
information is referenced by material in Section 5 Diagnostics.
Section 5 - Diagnostics
This section explains how to diagnose TriPac units. It includes both alarm code diagnostics
and other symptom diagnostics. This section will reference material in Section 4 Operation
and Section 6 Service Procedures.
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Welding Precautions
Precautions must be taken before electric
welding is performed on any portion of the
unit or the vehicle to which unit is attached. It
is necessary to ensure that welding currents
are not allowed to flow through the electronic
circuits of the TriPac. For more information,
see TriPac Service Procedure A26A in
Section 6 of this manual.
Optional Truck
Standby Switch
Diesel-Fueled
Air Heater
PWM PWM
1 2
H 8S 8D 8 7A
BL1
PCF
BL2
8DP
FS2
26 Run Relay
Preheat
FS1
Relay
7D
CH
7CF
CH
8FET
Cycle Sentry Module L1
Starter
7CL Relay
H1
7X
W1
LWT
5
SBY 5A Fuse
Power Strip uP
DIM
J1
7CLA
D+
SEN
Air Heater
Several different diesel fueled air heaters are
available. The diesel-fueled air heater
provides hot air through a heat outlet grille
near floor level in the truck cab sleeper
compartment. The return inlet air vent is also
located at floor level, but some distance from
the discharge outlet vent. The air heater
temperature setpoint is programmed at the
HMI Controller
Programming Steps at the HMI Controller:
1. Press the Main Power On/Off Key to On.
2. Press the Up Arrow Key and Down Arrow Key simultaneously to access the Program Codes.
3. Press the Mode Key to advance through the Program Codes (the arrows below indicate the sequence of the
Program Codes)
Program Features 4. Press the Up Arrow Key or Down Arrow Key to view the Program Selections for a specific Program Code.
5. Press the Fan Speed Key to save a Program Selection. As required, press the Mode Key to escape from a
Menu
Program Selection without saving it.
Simultaneously 6. After all Program Codes are reviewed, press the Mode Key to return to the PPP Program Code.
press and hold Up 7. Press the Fan Speed Key to save all of the desired Program Selections.
and Down Arrow
Keys to access
Bold Underlined type = default setting
ctd
(HMI Controller
Temperature Display)
PPP ddL cts dbd
(Program Mode)
cts = Control Temperature (Display Dimmer (HMI Controller (HMI Controller
Sensor Level) Temperature Scale) Deadband Degrees)
A cXX = Controller
SPt = Setpoint
configuration
dbg = Debug 1 to 15 = Dimness F (Fahrenheit) or 1.0 to 10.0 degrees
(c01)
OFF = Off (unless setpoint levels (3) C (Celsius) (5 degrees)
rXX = Software
changed)
revision
ots = Optional temperature
number
sensor
OSU
cto (Optional Sensor Use) oto cdt
C
(HMI Controller (Optional (A/C Clutch Delay
(Cool Mode
Temperature Offset) OFF = Off Temperature Offset) Timer)
Enabled)
ctS = Control Temperature
-10 to 10 degrees Sensor -10 to 10 degrees 0 to 999 seconds
y (yes) or n (no)
(0 degrees) otS = Optional Temperature (0 degrees) (8 seconds)
Sensor
d dtp
dtr H
(Defrost Mode (Defrost Time
(Defrost Time Ratio) (Heat Mode
Enabled) Period)
Enabled)
10 to 100 % (50)
y (yes) or n (no) 1 to 10 minutes (1)
[do not change] y (yes) or n (no)
[do not change] [do not change]
Eto
EHC F AFS
(Air Heater
(Air Heater Control (Fan Only Mode (Auto Fan Speed
Temperature Offset)
Enabled) Enabled) Enabled)
-10 to 10 degrees
y (yes) or n (no) y (yes) or n (no) y (yes) or n (no)
(0 degrees)
HSS
LSL Edo
(Engine High Speed EPS
(Engine Low Speed (Engine Delay Off
Timer) (External Power
Lockout) Timer)
Source A
0 to 999 minutes
y (yes) or n (no) 0 to 999 minutes
(2 minutes) y (yes) or n (no)
[do not change] (15 minutes)
[do not change]
Defrost Time Ratio [dtr] Espar Air Heater Control Enabled [EHC]
Program dtr Program EHC
Feature Feature
HMI All HMI All
Controller Controller
Rev Rev
Interface All Interface All
Board Rev Board Rev
Program 10 to 100 (percent) Program y
Choices Choices n
Default 50 Default y
Exceptions n/a Exceptions n/a
Description Not currently used. Do not Description Determines if Heat mode will
change the default (factory) be used to control the air
setting. heater. To control the air
heater, the heat output stays
on continuously and the digital
potentiometer is enabled.
The y (yes) setting must be
selected, in order for Heat
mode to control the air heater.
Do not change the default
(factory) setting.
Do not use the n (no) setting.
1 2 3 4 5 6 7 8 9 10 11 12
18 13
17 16 15 14
Figure 2-1: HMI Controller (wall-mounted in the truck cab sleeper compartment)
Main Power On/Off key The Main Power On/Off key is used to
and LED power up the HMI Controller and to turn
on the TriPac system. The green LED
indicator is illuminated when the TriPac
system is turned on.
Mode key and LEDs The Mode key is used to select the
desired operating mode. When the TriPac
is turned on the mode will default to the
last setting that was used. A/C
(air-conditioning), Heat and Fan modes
are selected by pressing the Mode key.
Defrost (DEF) is not used with TriPac.
The LEDs above the Mode key indicate
the current mode.
If the unit is on and no LEDs are lit, the
unit is in Null mode (neither cooling or
heating).
Up Arrow key and Down The Up Arrow key and Down Arrow key
Arrow key are used to raise and lower the
temperature setpoint in the HMI Controller
Display. Each press of the Up Arrow key
or Down Arrow key will raise or lower the
setpoint temperature by one degree. The
alphanumeric readings in the HMI
Controller Display scroll up or down when
the Up Arrow key or Down Arrow key is
pressed continuously.
The HMI Controller setpoint temperature
range is 50 to 90 degrees.
Fan key and LEDs The Fan key is used to select the desired
evaporator blower speed. When the
TriPac system is turned on, the fan speed
defaults to the setting last used. High,
Medium and Low fan speeds are selected
with the Fan key. The Auto setting is not
currently used.
DANGER: Always turn the Main Power On/Off key on the HMI Controller to off
while the truck is being refueled. Fuel vapors can ignite if they come in contact
with TriPac electrical or heater components.
WARNING: TriPac can start automatically without warning if the Engine On/Off
switch is in the On position.
WARNING: Immediately stand clear when the preheat buzzer sounds. This
indicates that the engine is preheating. If the engine is warm, the preheat time
might only be a few seconds.
The Engine On/Off switch is located inside the APU housing on the right side of the frame. This
switch must be in the On position for the TriPac system to operate. The On position is the
default position.
• If the Engine On/Off switch is off, there is no A/C operation, fan operation, or battery
charging available. Heat mode operation, however, is available.
• If the Engine On/Off switch is off when the APU On/Off key is on, an [Eng] alarm code
occurs.
The Engine On/Off switch also functions as a service switch. It allows maintenance personnel to
disable the APU engine, even if the Main Power On/Off key is on.
6 7
Alarm Alarm
Code Type Description Conditions Possible Causes
Eng Shutdown The engine failed to The Reset Switch has The Reset Switch has
start or should be tripped. tripped. This may be
running and is not. caused by low engine oil
pressure, high engine
coolant temperature, or an
engine start failure.
AcS Shutdown Air conditioning Unit not cooling. Can be caused by high
system failure. compressor discharge
pressure or low system
pressure.
ALt Shutdown Charging system The battery is not This alarm code is
failure. being charged. activated
2 minutes after no
alternator output occurs.
The alternator might be
malfunctioning or the
alternator belt may be
broken.
Check the engine Reset Switch. If the alarm tripped the switch, the switch must be reset to allow
the TriPac engine to be restarted. The engine Reset Switch is located on the side of the Control
Box enclosure.
Typical causes for an open engine Reset Switch are low engine oil pressure, high engine
coolant temperature, or an engine start failure.
Time determined by
Block Temp Thermistor
Hold Pull-in
Flywheel Starter
Sensor
ELECTROSTATIC DISCHARGE
The following electrostatic precautions must be taken.
• Keep all TriPac interface boards and HMI controllers in anti-static bags at all times.
• Protect any defective TriPac interface boards and HMI controllers from physical damage by
placing them in the shipping carton supplied with the replacement. They will be returned for
failure analysis and possible re-manufacture.
Circuit Description
The 8FET output from the Interface Board is energized when the TriPac unit is turned on.
8FET power is supplied to the Engine On/Off switch located inside the APU. If the Engine
On/Off switch is closed power is supplied by the 8X wire to the normally closed contacts in
the Reset switch. As long as the Reset switch is closed power is supplied on the 8 wire to the
8 terminal on the Interface Board.
See the drawing on the next page for details.
Considerations
8D 20
Note 3
LOP
Diagnostic Procedure
1. Verify the Engine On/Off switch is turned on. It is located inside the APU enclosure in
the upper right hand corner. Turn on if necessary.
2. Press the button on the Reset switch.
3. Check the engine oil level. Add oil if necessary.
4. Check coolant level. Add coolant if necessary.
5. Attempt an engine start. If the engine does not start troubleshoot and correct the cause
as necessary.
6. If the engine starts but the Reset switch trips again, check the Low Oil Pressure Switch
and High Water Temperature switch.
7. Check the associated circuitry for continuity and shorts using the diagram on the
previous page.
8. Check the 20 circuit for a short to ground.
9. Check the reset switch for continuity.
Circuit Description
The 7CL output from the Interface Board is energized to engage the compressor clutch when
the TriPac unit requires air conditioning. 7CL power is supplied to the Binary switch which
includes the High Pressure Cutout Switch and Low Pressure Cutout Switch. As long as these
switches are closed 7CLA power is supplied to the Freeze-stat switch. 7CLA power is also
supplied to the Interface Board 7CLA terminal.
The Freeze-stat is a normally closed temperature switch that opens at 31°F (-1°C) and closes
at 39°F (4°C). It is used to prevent the evaporator coil from icing. As long as the Freeze-stat is
closed 7CLB power is supplied to the compressor clutch to allow cooling operation.
See the drawing on the next page for details.
Considerations
A/C
Binary Switch Freeze-Stat
Note 3 Clutch
7CL 7CLA 7CLB
Note 1
Note 1 +12 Vdc from the 7CL output on the Interface Board to energize the compressor clutch
when cooling is required.
Note 2 +12 Vdc to the 7CLA input on the Interface Board. If the 7CL output is +12 Vdc then the
7CLA input must also be +12 Vdc. If it is not, the HPCO or LPCO switch is open and Alarm Code
[AcS] is set.
Note 3 The Freeze-Stat opens at 31°F (-1°C) and closes at 39°F (4°C) to prevent ice buildup on
the evaporator coil.
Diagnostic Procedure
1. Connect a gauge set to determine if the problem is caused by high discharge pressure
or low system pressure.
2. If discharge pressure is high check for dirty or blocked condenser coil.
3. Verify proper operation of the Condenser Fan Motor.
4. If system pressure is low check refrigerant level and correct as required.
5. Check the associated circuitry for continuity using the diagram above.
Circuit Description
On engine startup initial excitation voltage is supplied from the D+ terminal on the Interface
Board to the alternator excite terminal. After 2 minutes the Interface Board monitors the D+
terminal as an input.
12.6 Vdc or more must be present after 2 minutes to indicate that the alternator is functioning
properly. If this voltage is low or missing, Alarm Code [Alt] is set.
See the drawing on the next page for details.
Considerations
Diagnostic Procedure
1. Check alternator output with a meter. With the engine running the voltage at the
alternator output should be approximately 13.8 to 14.2 Vdc. If the voltage is less than
12.6 Vdc or greater than 15 Vdc with the engine running test and repair the alternator.
2. Check for broken or slipping alternator belt.
3. Check that all alternator connections are secure.
4. Check the associated circuitry for continuity and shorts using the diagram on the next
page.
D+ B+
Note 1
EXC SENSE
W
GND
To Fusible
OUTPUT F2
Links, Starter
and Battery
B+
The Main Power is not turned on. Press the HMI Controller Main Power key
to turn the unit on.
Faulty power circuits from the battery. Check the battery circuits using the Wiring
Diagram as a reference.
Disconnected HMI Controller. Check to be sure the HMI Controller
harness is securely connected at the HMI
Controller and at the Interface Board.
Wiring problem. Check the associated circuitry for continuity
using the wiring diagram.
Defective HMI Controller. Replace the HMI Controller.
The Engine On/Off switch is turned off. Turn the Engine On/Off switch on.
The Reset Switch is open. Check for the [Eng] Alarm Code. If present
see the [Eng] Alarm Code in this section for
diagnostic details.
Wiring problem. Check the associated circuitry for continuity
using the wiring diagram.
Extremely long preheat time – 5 minutes or The preheat thermistor circuit is open and
more. must be replaced.
Very short preheat time – 3 to 5 seconds. The preheat thermistor is shorted and must
be replaced.
Unit sticks in preheat – will not crank. The preheat thermistor circuit is shorted to
ground and must be replaced.
Blower motor does not run. 1. Check fuse in the Power Harness.
2. Check power to control unit.
3. Check power to and from switch.
4. Check electrical connections.
Blower motor runs approximately 20 seconds 1. Ensure that voltage at the control unit
and shuts off. remains above 10 Vdc during startup
with the glow plug circuit energized.
Blower motor runs and fuel metering pump 1. Check fuel lines and fuel filter.
starts and then shuts down after two start 2. Check fuel level.
attempts.
3. Check for combustion air or exhaust
tube blockage.
Blower motor runs but fuel metering pump 1. Check for electrical pulses at the fuel
does not. metering pump.
2. Check for frozen fuel metering pump.
3. Check for blocked fuel line.
Heater Ignites
Heater smokes and carbons up. 1. Check for blocked exhaust pipe.
2. Check for blocked combustion air
intake.
3. Check for exhaust entering
combustion air intake pipe.
4. Check for short cycling – rapid on/off
operation.
5. Check fuel system.
6. Check fuel metering pump quantity.
7. Check motor RPM.
The Diagnostic Unit is used for reading, displaying and deleting fault codes saved in the
electronic control unit of the heater. The electronic control unit can save up to 5 fault codes,
labeled F1 to F5. The most recent fault code is in memory location F1. The current or actual
fault code is shown as “AF” and is always written into the F1 memory location. Previous fault
codes are transferred to memory locations F2 to F5.
Connection
Connect the Heater Diagnostic Tool cable to the diagnostic pigtail (8-pin black connector) on the
heater’s main wiring harness as shown below.
Press the “D” key on the Diagnostic Unit to switch on the heater. The display
shows [ -:- -].
After 8 seconds the display will show [AF:00] if there are no fault codes set.
If fault codes are set, the display will show [AF:xx], where xx = the current fault
code. Fault Code 64 is shown here.
If the display shows [ - - - ] the fault codes can not be read. Possible causes
are:
Adaptor cable not connected properly.
Defective heater control unit.
Press the Left Arrow or Right Arrow keys to scroll forward or backward through
the existing fault codes. In the example shown here the display indicates that
the second fault code set (F2:) is Fault Code 10 (10).
Up to 5 fault codes may be shown. However, only existing codes will be
shown. For example, if only three fault codes are set, then only three fault
codes will be displayed.
Eliminate the cause of the fault. Be sure to correct the root cause, not just the
symptom.
Press and hold both “L” keys until the display shows [ - : - - ].
When the fault codes are deleted, the last current fault code is still shown. The
last current fault code is not reset to [ AF:00 ] until the next restart of the
heater, provided no other fault code has occurred.
After the next heater start, the display will show [ AF:00 ]. No fault codes are
set.
Press the “D” key to turn the heater off. The display will show [ dIA ]. Wait for
the end of the heater cool down period and then remove the Heater Diagnostic
Unit cable from the harness.
Fault
Fault Description Causes/Repair
Code
000 Normal operation If there are no heater faults, the heater will go
through a normal start cycle and regulate
based on thermostat setting.
004 Warning – short circuit in Disconnect the connection S1/B1 at the
controller, fresh air outlet AIRTRONIC heater. At connector B1 pin 16
check for a short between the pin and the
blower relay. If no short exists then replace
the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
005 Warning – short circuit at Check the line through to the relay isolating
controller, anti theft alarm output switch or theft warning in line for a short circuit
to chassis. If no short exists then replace the
control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
009 TRS – shutdown The unit switched off due to a signal change.
Check for a change of signal from (+) to (-) at
pin 13 (S1) or a (+) signal at pin 14 (S1).
010 Over voltage shutdown Start the vehicle engine. Check the voltage at
(B1) between terminals 1 and 10. This voltage
must be less than 16 volts (15.2 volts with
glow plug on).
Check the vehicle charging system.
011 Under voltage shutdown Start the vehicle engine. Check the voltage at
connector (B1) between terminals 1 and 10.
This voltage must be more than 10 volts.
Check the vehicle charging system.
Check the batteries and battery connections.
Fault
Fault Description Causes/Repair
Code
012 Overheat at overheating sensor The Overheating sensor has detected
excessive temperatures.
Check for clogged hot air ducting.
Check that the total number of ducting pieces
in unison is not too large. Re-route if
necessary.
Check the overheat sensor resistance values.
(See the Resistance Values for the Overheat
Sensor table at the end of this section).
Measure fuel quantity.
013 Overheat at flame sensor The Flame sensor has detected excessive
temperature at the heat exchanger.
Check for clogged hot air ducting.
Check that the total number of ducting pieces
in unison is not too large. Re-route if
necessary.
Measure fuel quantity.
Check flame sensor resistance. (See the
Resistance Values for the Flame Sensor table
at the end of this section).
014 Potential overheat detected – Check for clogged hot air ducting.
temperature difference between Check that the total number of ducting pieces
the flame sensor and overheating in unison is not too large.
sensor too large
Check the flame sensor.
If O.K. check the overheating sensor. If the
over-heating sensor is defective replace the
combi-sensor.
If the overheating sensor is O.K. measure fuel
quantity. (See the Fuel Quantity Test at the
end of this section).
If fuel quantity is O.K. replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
Fault
Fault Description Causes/Repair
Code
015 Too many overheat shutdowns Fault code 015 is shown when the
AIRTRONIC is switched on again after fault
Overheat with excessive
code 017.
temperature
The hardware limit value for the overheating
sensor has been exceeded – the control unit
is damaged.
Check sensor.
Replace control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
017 Overheat with excessive The hardware limit value for the overheating
temperature sensor, has been exceeded because the
control unit has not detected fault code 012,
013.The control unit is locked. If AIRTRONIC
is switched on again, fault code
015 is displayed.
Check the overheat sensor.
Replace control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
020 Open circuit – glow pin Check continuity of glow pin while still
installed. The resistance values should be as
shown below.
AIRTRONIC 12 volt - approximately
0.5 Ω ± 0.05 Ω
Replace open glow pin.
Fault
Fault Description Causes/Repair
Code
021 Short circuit – glow pin / glow plug Check functions of glow pin in installed
condition. To do so disconnect connector from
Caution!
controller.
For AIRTRONIC 12 volt
AIRTRONIC 12 Volt. Apply voltage of 8 volts
applications, check functions
to glow pin respectively, and measure current
with max. 8 volt
after 40 seconds. Glow pin is O.K. with the
If voltage values are exceeded the following values:
component will be destroyed.
Glow pin 8 volt - current = 9 amps + 1.5 / - 1.2
amps
If the values differ, replace glow pin.
If the values of the continuity test and function
test are O.K., check glow pin cable harness
for damage and continuity.
If harness O.K., replace control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
031 Open circuit – blower motor Check the blower motor cable harness for
interrupted correct routing and damage.
If O.K., disconnect the cable harness from the
control unit and check for continuity.
If O.K., replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
032 Short circuit – blower motor Check the functions of the blower motor. To
do so, disconnect connector from control unit.
Caution!
Apply voltage of 8 volts ± 0.1 to the blower
For AIRTRONIC 12 volt motor and measure the current after 40
applications, check functions seconds.
with max. 8 volt
Current < 6.5 amp – blower motor O.K.,
If voltage values are exceeded replace controller.
the component will be
Current > 6.5 amp, replace blower.
destroyed.
Fault
Fault Description Causes/Repair
Code
033 Blower motor speed deviation Motor speed varies from specification by more
(>10%) or blower motor does not than 10% for longer than 30 seconds.
turn If too slow, check for air flow restriction, and
check for short in motor circuit or control unit.
If none found, replace blower.
If too fast, check for damaged or missing
magnetic sensor on the control unit. Replace
blower motor if damaged.
Replace control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
047 Short circuit – fuel metering pump Disconnect the connector from the fuel
metering pump. If fault code 048 (interruption)
is displayed then the fuel metering pump is
defective and must be replaced.
If fault code 047 is still displayed, then
disconnect connection S1/B1. At connector
B1, Pin 5, check line1 (green/red) through to
FMP for short circuit to (pin 10). If O.K.
replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
048 Open circuit – fuel metering pump Disconnect connector from fuel pump and
measure the resistance value of fuel pump.
12 volt pumps should measure 10 + 0.5
ohms. If the resistance values are O.K.
reconnect the cable harness to the fuel pump.
Disconnect the connection S1/B1, and
measure the resistance value between pin 5
and pin 10. If O.K., replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
Fault
Fault Description Causes/Repair
Code
050 Too many failed start attempts The control unit is locked after too many
unsuccessful start attempts.
Check the fuel, glow plug, combustion air and
exhaust flow.
Use the Diagnostic Unit to unlock the control
unit. Maximum “No Start” attempts = 255
051 Faulty flame recognition If the resistance value of the flame sensor is
1274 Ω after switching on (> 70°C), then the
blower of the AIRTRONIC runs for
approximately 15 minutes to cool down. If
resistance does not fall below the above value
within 15 minutes a fault shut down occurs.
Check the flame sensor, diagrams and
values. (See the Resistance Values for the
Flame Sensor table at the end of this section).
If O.K., replace control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
052 No start safety time exceeded No flame detected on start attempt.
Check the exhaust and combustion air lines.
Check the fuel supply. Measure fuel quantity.
(See the Fuel Quantity Test at the end of this
section).
Check the glow pin (see Fault Codes 20 and
21).
Check the flame sensor. (See the Resistance
Values for the Flame Sensor table at the end
of this section). If O.K., replace the control
unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
Fault
Fault Description Causes/Repair
Code
053 Flame cutout in boost mode Heater has started successfully but the flame
has extinguished.
Check exhaust and combustion air lines.
Check fuel supply and measure fuel quantity.
(See the Fuel Quantity Test at the end of this
section).
Check the flame sensor. (See the Resistance
Values for the Flame Sensor table at the end
of this section).
If O.K., replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
054 Flame cutout in high mode Flame cutout in high mode.
See corrective action for Fault Code 053.
055 Flame cutout in medium mode Flame cutout in medium mode.
See corrective action for Fault Code 053.
056 Flame cutout in low mode Flame cutout in low mode.
See corrective action for Fault Code 053.
060 Open circuit – external Disconnect connection S1/B1 (main harness)
temperature control sensor and measure resistance value at connector
B1, pins 6 & 12. If there is an open circuit, the
resistance value between the pins is > 7175
Ω. If the resistance value is O.K., then the
control unit is defective.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
Fault
Fault Description Causes/Repair
Code
061 Short circuit – external Disconnect connection S1/B1 (main harness)
temperature control sensor and measure the resistance value at
connector B1, between pins 6 & 12. If there is
a short circuit, the resistance value between
the pins is < 486 Ω.
If Fault Code 061 continues to be displayed,
then the control unit is defective.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
062 Open circuit – Thermostat, The digital potentiometer values are out of
Rheostat, Timer range on Thermostat switch.
The temperature setpoint control Disconnect connection S1/B1 (main harness)
used by the heater is a simulated and check the resistance between pins 6 and
digital potentiometer located on 7 at B1.
the TriPac Interface Board. It is The resistance value for interruption between
connected to the Interface Board pins is > 7175 Ω. The normal value is 1740 Ω -
via the Gry/Red and Brn/Wht wires 2180 Ω (± 80 Ω).
from the heater via the S1/B1
connector. If the resistance value is O.K. replace the
control unit. See the “Sleeper Cab Air Heater
Service Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
If the resistance value is not O.K. replace the
TriPac Interface Board.
063 Short circuit – Switch Control If a ventilating switch has been built in,
Fault recognition only works in disconnect and check function. If faulty,
heating mode. However, if a short replace switch.
circuit already exists and the Disconnect the wires from thermostat or
AIRTRONIC is subsequently switch. If Fault Code 062 is displayed, replace
switched on, ventilating mode will the switch.
be active (no fault code). If the switch is O.K., check connection lines
grey/red and brown/white for short-circuit. If
O.K., reconnect the wires to the
thermostat/switch.
Disconnect connection B1. If fault 063 is still
displayed, replace the control unit. The
resistance value for a short circuit between
pins 6 and 7 is < 486 Ω. The normal value is
1740 Ω - 2180 Ω (± 80 Ω).
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
Fault
Fault Description Causes/Repair
Code
064 Open circuit – flame sensor Sensor is sensing value outside of range.
Open the Airtronic shell and remove the
control unit from the casing.
Disconnect the green connector from control
unit. At the green connector measure the
resistance value between the green wire and
the brown/white wire. Resistance value for an
open circuit is > 7175 Ω. (See the Resistance
Values for the Flame Sensor table at the end
of this section).
If the flame sensor is O.K., replace the control
unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
065 Short circuit – flame sensor Open the Airtronic shell and remove the
control unit from the casing.
Disconnect the green connector from the
control unit. If Fault Code 64 is displayed,
replace the combination sensor
(flame/temperature).
If Fault Code 65 is still displayed, replace the
control unit. See the “Sleeper Cab Air Heater
Service Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
The resistance value for a short circuit is <
486 Ω. (See the Resistance Values for the
Flame Sensor table at the end of this section).
071 Open circuit – overheat sensor Open the Airtronic shell and remove the
control unit from the casing.
Disconnect the blue and green connectors
from the control unit. Measure the resistance
value at the blue connector (pin 1- blue wire)
and at the green connector pin 2 (brown/white
wire).
If O.K., replace the control unit. See the
“Sleeper Cab Air Heater Service Operations”
procedure in the TriPac Maintenance manual,
TK 53036, for the air heater control unit
replacement procedure.
The resistance value for an open circuit is >
223 Ω. (See the Resistance Values for the
Flame Sensor table at the end of this section).
Fault
Fault Description Causes/Repair
Code
072 Short circuit – overheat sensor Open the Airtronic shell and remove the
control unit from the casing.
Disconnect the blue connector from control
unit. If Fault Code 071 is displayed, replace
the combination sensor (flame/temperature).
If Fault Code 072 is still displayed, replace the
control unit. See the “Sleeper Cab Air Heater
Service Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
The resistance value for a short circuit is <
183 Ω.
090 Control unit defect – internal fault Internal failure. Replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
091 External voltage disturbance Check the vehicle charging system. Look for a
poor battery, or a connected battery charger.
092 Control unit defect – ROM error Internal failure. Replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
094 Control unit defect – EEPROM Replace the control unit.
error See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
096 Control unit defect – internal Replace the control unit or use external
temperature sensor temperature sensor.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
Fault
Fault Description Causes/Repair
Code
097 Control unit defect – power failure Internal failure. Replace the control unit.
See the “Sleeper Cab Air Heater Service
Operations” procedure in the TriPac
Maintenance manual, TK 53036, for the air
heater control unit replacement procedure.
Preparation
• Detach the fuel line from the AIRTRONIC.
• Insert the fuel line into a measuring glass (25 cm3).
• Switch the AIRTRONIC on and allow fuel system to bleed out air for approximately
60 seconds.
• Switch the AIRTRONIC off and drain the measuring glass.
Measurement
• Switch the AIRTRONIC on
• The fuel is pumped approximately 60 seconds after switching on.
• Hold the fuel line in the measuring glass level with the glow pin while fuel is being delivered.
• The pump will stop automatically after delivering fuel for 90 seconds. (110 seconds for AIR-
TRONIC 4)
• Once fuel pump stops, switch off the heater.
Evaluation
• Read out the quantity of fuel in measuring glass.
• Fuel quantity should be between
3.7 ml and 4.3 ml. on AIRTRONIC 2
5.4 ml and 6.3 ml. on AIRTRONIC 4
• If the fuel quantity is outside this range, check for and remove any restriction in fuel system
or replace the fuel metering pump.
NOTE: The fuel quantity is not affected by voltage variances.
Purpose
This procedure should be used to retrieve and record the programmable feature settings of an
HMI Controller. These settings will then be duplicated in the replacement HMI Controller. This
must be done prior to replacement of the HMI Controller.
Use a copy of the Programmable Features Setup Sheet at the end of this service procedure to
record the existing settings.
Important Information
The settings at the HMI Controller vary in accordance with the TriPac user’s personal choices
for the truck cab sleeper compartment cooling, heating, and ventilation flow.
default = OFF
oto Optional Temperature Offset -10 to 10 [degrees]
default = 0
C A/C Mode Enabled y or n
default = y
cdt A/C Clutch Delay Timer 0 to 999 [seconds]
default = 8
default = y
EHC Air Heater Control Enabled y or n
default = y
Eto Air Heater Temperature -10 to 10 [degrees]
Offset
default = 0
F Fan Only Mode Enabled y or n
default = y
AFS Auto Fan Speed Enabled y or n
default = n
HSS Engine High Speed Timer 0 to 999 [minutes]
default = 2
LSL Engine Low Speed y or n
Lockout
default = n
Edo Engine Delay Off Timer 0 to 999 [minutes]
default = 15
EPS External Power Source y or n
default = y
Purpose
This procedure should be used to remove and replace a TriPac HMI Controller.
Important Information
After the replacement HMI Controller is installed, see TriPac Service Procedure A04A to set up
the Program Codes.
Procedure
Purpose
This procedure should be used to set up the programmable feature settings of a new or
replacement HMI Controller.
Use a completed copy of the Programmable Features Setup Sheet from Service Procedure
A02A or customer specifications to set the programmable features. For additional
programmable feature details see Section 3 of this manual.
Important Information
The settings at the HMI Controller vary in accordance with the TriPac user’s personal choices
for the truck cab sleeper compartment cooling, heating, and ventilation flow.
Purpose
To prevent damage to the microprocessor during welding operations. Electric welding generates
extremely high amperage currents which can damage electrical and electronic components. In
order to minimize the possibility of damage the following procedures must be followed.
Purpose
This procedure should be followed when replacing the Interface Board.
Purpose
This procedure is used to confirm the proper operation of the Control Sensor used with the HMI
Controller. The HMI Controller and Control Sensor are mounted in the truck cab sleeper
compartment.
Te m p Re s is tance Te m p Re s is tance
(de g. C) (Ohm s ) (de g. C) (Ohm s )
-25 86,430 45 4,911
-20 67,770 50 1,460
-15 53,410 55 3,536
-10 42,470 60 3,020
-5 33,900 65 2,588
0 27,280 70 2,228
5 22,050 75 1,924
10 17,960 80 1,668
15 14,690 85 1,451
20 12,090 90 1,266
25 10,000 95 1,108
30 8,313 100 9,731
35 6,940 105 8,572
40 5,827 110 7,576
Purpose
To test and adjust the Flywheel Sensor.
Materials Required
Fluke digital multimeter.
Operation
The Flywheel Sensor rarely fails, but might require adjustments for proper operation.
Procedure
Purpose
To illustrate the correct procedures for checking harness continuity on equipment utilizing solid
state devices.
Purpose
This procedure is used to confirm the proper operation of the Smart FETs on the Interface
Board.
Materials
• Fluke digital MultiMeter
• Test leads with alligator clips
• 1000 Ohm Resistor, 1/2 watt or larger
Procedure
A Smart FET (Field Effect Transistor) is a solid state device used to apply and remove power to
various circuit devices such as solenoids. If the device draws too much current when
energized, the Smart FET will turn off to prevent damage to the connected device and related
circuitry. When the problem is resolved the Smart FET will resume normal operation. Smart
FET outputs typically do not use a fuse to protect the output device.
Care must be taken to insure that a load is present in order to properly check the operation of
Smart FET outputs. If there is no load connected to the output, the output will read +12 Vdc
even though the output is actually turned off. The Smart FET output is functioning properly. The
+12 Vdc reading is caused by the lack of a load on the Smart FET output. The Interface Board
should not be replaced.
To ensure accurate readings when checking Smart FET outputs, connect a 1000 ohm resistor
from the positive meter lead to chassis ground. This provides a load to the Smart FET output,
even if the actual load is disconnected or open. The meter will read +12 Vdc when the output is
turned on and 0 Vdc when the output is turned off.
COMPLETE CIRCUIT
Here the circuit is complete, with a load connected to M
TriPac the Smart FET output. Current flows from the Smart Vdc
Interface FET output, through the solenoid coil to chassis
Board ground. When the Smart FET output is "on", the meter
(M) will indicate 12 Vdc. When the Smart FET output
Smart FET
is "off", the meter (M) will indicate 0 Vdc.
Output
Solenoid
Coil
OPEN CIRCUIT
OPEN CIRCUIT
Here the circuit is open. There is no load connected to
Here
the theFET
Smart circuit is open.
output. WhenThere
the is no load
Smart FETconnected
output is to M
TriPac the Smart FET output. When the Smart FET output M
Vdc
TriPac "on", the meter (M) will indicate 12 Vdc. When the FETis Vdc
Interface "on", the meter (M) will indicate 12 Vdc. When the
Interface output is "off", the meter (M) may still indicate 12 Vdc
Board FET
due to output
the open is "off",
circuit.theThe
meter (M) FET
Smart will still
outputindicate
is 12
Board Vdc due to the open circuit. The Smart FET output
working properly. The Interface Board should not
Smart FET beisreplaced.
working properly. The Interface Board should
Smart
OutputFET not be replaced.
Output Open
Open Solenoid
Solenoid
Coil
Coil
HMI Controller
Item Features TK Part Number Interchange With:
HMI Controller Production release 45-2126 n/a
TriPac Bulletins
TriPac Service Bulletins
Service Bulletin Title Date
Number
T&T 386 TriPac Evaporator Wiring Harness 08/29/05
T&T 387 TriPac Governor Spring—Tier 2 Engines 09/16/05