BULLETIN NO.: TITLE: A/C Service SECTION: General. DATE: June 15, 1995 PAGE: 1 of 9 RELEASE: Dealer MODEL: ZIV Series

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1 PRODUCT SUPPORT SERVICE NEWS BULLETIN NO.: TITLE: A/C Service SECTION: General DATE: June 15, 1995 PAGE: 1 of 9 RELEASE: Dealer MODEL: ZIV Series GENERAL: The ZIV Series machines have, as an option, Eagle Comfort Systems heater and/or air conditioner units. This bulletin provide information service and troubleshooting. DETAIL: The following information, provided by Eagle Comfort Systems, may be used to assist in troubleshooting or servicing the heater / air conditioner system. KAWASAKI LOADERS, INC. KENNESAW, GEORGIA PHONE: (404) / FAX: (404)

2 Air Conditioning Kit Eagle Climate Controller Operating Instructions Controller Assembly Bezel Note: These two pieces sandwich a 20 gauge panel material, and lock together to hold the controller in place. Table of Contents Specifications & Features 1 Controller Operations 2 Controller Indicators 3 Error Messages 4 Wiring Diagram 4 Troubleshooting 5 Eagle Engineering & Manufacturing, Inc. P.O. Box 295 Welcome, MN Phone Fax Revised 7/

3 Controller Specifications & Features SPECIFICATIONS: DIMENSIONS: 4.1" x 5.6" x 2.6" (H x W x D) INPUT VOLTAGE:12 Volts D.C. or 24 Volts D.C. BLOWER FAN VOLTAGE: PWM 12 V or PWM 24 V at 8 mhz OUTPUT CURRENT: 20 Amps Max. at 12 V, 10 Amps Max. at 24 V SLEEP STATE CURRENT DRAW: 70 milliamps at 12 V, 40 milliamps at 24 V CONTROL BASE: 8 mhz Microprocessor TEMPERATURE BASE: Fahrenheit or Celsius SET POINT ACCURACY: + or - 2 Degrees Fahrenheit MEMBRANE MATERIAL: Embossed Polycarbonate CONNECTOR OPTIONS: Deutsch Hd 30 Series or Customer Specified FEATURES: Auto microprocessor selection of A/C or Heat mode Wide range temperature selection (60F - 90F) or (15C - 32C) Full A/C, heat, and dehumidification control capabilities Soft - touch, tactile feel controls Dual seven segment temperature select readout Eight position fan speed select with LED display System indicator lights Universal design allows integration into most A/C - HEAT systems Packaging facilitates remote mounting, or in-dash vehicle placement Designed specifically for off-road applications Circuit board coating process protects from dust, dirt, moisture, and vibration 36 month limited warranty Last position before off sleep state memory Function Revised 7/ Page 1

4 CONTROLLER OPERATIONS ON - OFF BUTTON Turns the system on and off DEFROSTER MODE BUTTON Causes the controller to cycle the A/C clutch every 3 minutes, with the heat valve open, to remove humidity from the cab. The heat valve is cycled normally, during 3 minute intervals, to maintain temperature set point. TEMPERATURE INCREASE BUTTON Increases the temperature to your desired level. TEMPERATURE DECREASE BUTTON Decreases the temperature to your desired level. FAN BUTTON Toggles the blower fan on & off only, with no A/C, for economy mode. FAN SPEED &CREASE BUTTON Increases your blower fan speed. (airflow) FAN SPEED DECREASE BUTTON Decreases your blower fan speed. (airflow) Revised 7/ Page 2

5 Pushed simultaneously, toggles temperature units between Fahrenheit and Celsius. Pushed simultaneously, shows whether the evaporator thermostat is open (OP) or closed (CL). OP Displayed - Clutch not engaged / coil too cold CL Displayed - Clutch is engaged / coil is at temperature set point, (operating temperature). Pushed simultaneously, shows ambient inside cab temperature reading from the cab thermistor probe. CONTROLLER INDICATORS TEMPERATURE / ERROR DISPLAY Displays your set temperature, and error messages warning you of any error that may cause your system to not function properly. POWER ON LIGHT Illuminates above the ON / OFF switch to indicate when the controller has been turned on. DEFROST ON LIGHT Illuminates above the defrost switch to indicate when the controller is in the defrost mode. FAN SPEED INDICATOR Displays your blower fan speed, ranging from low (30%) to high (100%), with an 8-segment bar graph. Revised 7/ Page 3

6 ERROR MESSAGES l. E0 - Indicates a loss of power to the electric condenser fan. (See Troubleshooting Section) 2. El - Indicates an excessively low or high refrigerant pressure. (See Troubleshooting Section) WIRING DIAGRAM NOTES: 1. Position the ambient temperature probe near waist high level, out of air flow and sun load; or consult Eagle Engineering & Manufacturing Inc. 2. Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between the 1st and 2nd rows, to a depth of the coil height minus 1 inch. WIRE CHART CONNECTOR DETAIL Revised 7/ Page 4

7 Troubleshooting Chart TROUBLESHOOTING (A) Problem - E0 error message displayed on the controller: 1. Open EC power circuit 2. Defective EC relay (circuit) 3. Open EC voltage detection circuit 4. Improper wiring installation 5. Defective controller Check the EC circuit breaker for power, voltage, and continuity. Check for output voltage on the yellow wire at the relay coil. Check the voltage and continuity across the relay contacts. Check for input voltage on the brown wire at the controller. Applicable to systems without an EC. Check for output voltage on the yellow wire at the controller. (B) Problem - E1 error message displayed on the controller: Setup: Controller on, Temp. 60 F, Defrost off, Fan on high. Abbreviations EC - Electric Condenser (a) Repair the wiring. (b) Replace open circuit breaker (a) Repair the connections / wiring (b) Replace the defective relay. (a) Repair the wiring or connector. (a) See note #3 (a) Replace the controller. 1. Abnormal A/C refrigerant pressure(s). *Cool weather operation may cause low pressure short cycling. 2. Opened compressor clutch circuit. 3. Opened pressure switch detection circuit. 4. Defective controller Check the refrigerant pressures with gauges. High side greater than 320psig (R12), or 350psig (R134a). Low side less than 3-6 psig.* Check for output voltage on the green wire at the compressor. Check the wire connections. Check for continuity across the pressure switch(es) and thermostat. Check the continuity of the clutch solenoid to ground. Check for an input voltage on the tan wire, at the controller. Check for an input voltage on the green wire, at the controller. (a) Check the condenser operation for air and refrigerant blockages. (b) Leak check system, repair the leaks and recharge the system. (c) Relocate the low pressure switch to the evaporator outlet. (a) Repair connections / wiring (b) Replace the defective switch(es) or the thermostat. (c) Replace the defective compressor clutch. (a) Repair connections / wiring (a) Replace the controller. Revised 7/ Page 5

8 Troubleshooting Chart (cont.) (C) Problem - No Heat: 1. Open heat solenoid circuit. Poor connection, loss of voltage. 2. Defective heat solenoid or improper installation. 3. Defective controller TROUBLESHOOTING Check for an output voltage on the white wire at the heat solenoid valve. Check the solenoid continuity to ground. Check for coolant blockages in the heat solenoid valve and hoses. Check the direction of coolant flow. (feel the hoses) Check for output voltage of the white wire at the controller. Push, hold defrost / temp. decrease buttons simultaneously. Check display for OP or CL readout. Disconnect red leads, and check for continuity across thermostat terminals. Set controller at 68-70F, in a/c mode. Warm-up ambient temp. probe with fingers or heat gun. Push, hold temp. decrease/increase buttons simultaneously. Display will read 49F if probe is defective. Disconnect the controller, check for continuity across black probe leads. Check resistance of thermistor. (a) Repair connections / wiring (a) Repair or replace the valve. (b) Reverse the coolant hoses to the valve. (a) Replace the controller. (D) Problem - No display, the blower fan will not turn off, when the power is turned on. 1. Fan wires shorted to ground or vehicle chassis. Disconnect the controller from the external harness. Individually check the continuity of the orange and black fan wires to ground, in the external harness. (a) Unground and repair the shorted wiring. (E) Problem - Compressor clutch will not engage, unless defrost button is pushed. 1. Defective preset thermostat inside evaporator. Opened preset thermostat circuit. Broken thermostat wiring. Evaporator coil temperature too cold for a/c operation. 2. Ambient cab temperature too cool (below 60F). 3. Open ambient cab temperature probe (thermistor). (a) If CL, go to step 2. (b) If OP, repair connections or wiring to preset thermostat. (c) Replace preset thermostat. (a) Verify if compressor clutch will pull in or not. (b) If not, go to step 3. (a) If display reads 49F, at room temperature, replace thermistor. (b) Repair connections / wiring. (c) If 10K ohms +/- 20%, thermistor is good. If 100K-1M ohms, replace thermistor. Revised 7/ Page 6

9 NOTES: 1. Wire colors may vary with installation. Refer to the individual wire schematic used with customer air conditioning system. 2. For 24V controllers, resistor (R17) by 12V voltage regulator (Q7), must be clipped and removed from the circuit board. If the resistor is not clipped on the 24V system, the controller display will light up - but the blower fan will not turn on. 3. For air conditioning systems that do not use an electric condenser, the blue and brown wires must be connected together, on the external harness. The brown wire must be connected to the battery voltage, or the EO error message will result. 4. Care must be taken during installation not to pinch or cut wiring from the controller. Shorted wiring may result in damage to the controller. 5. Improper probe location of the evaporator coil thermostat sensor, or ambient cab temperature sensor, may cause short cycling of the compressor. 6. Eagle climate controllers are desired to use normally closed heat solenoid valves. Q7 R17 7. Disconnect the vehicle battery leads, if a machine is to be inactive, or put into storage, for a period of a week or more. The current drain from the controller s memory may result in a dead vehicle battery. An optional ignition relay may be installed to disable the controller s memory function, when the key switch is turned off. Revised 7/ Page 7