Webasto CC4E, Installation And Service Instructions Manual

Page 1: ...Air conditioning system Installation and service instructions CC4E prefilled...

Page 2: ...oning system 13 3 2 Electrical fuses 13 3 3 Compressor 14 3 4 Circuit diagram for basic version 15 3 5 Circuit diagram for deluxe version 16 4 INSTALLATION INSTRUCTIONS 17 4 1 Safety precautions 17 4...

Page 3: ...NANCE 26 6 1 Safety precautions 26 6 2 General 26 6 3 Maintenance and care 26 6 4 Maintenance and service checklist 27 6 5 Inspections before repair 27 6 6 Troubleshooting 28 6 7 Repairs 29 6 8 Post r...

Page 4: ...cordance with Section 19 of the German Road Traffic Licensing Regulations StVZO The following general and operational safety regulations for the prevention of accidents have to be observed at all time...

Page 5: ...rforming any work allow the system to cool down completely Risk of injury due to burns on the condenser compressor and hoses Installation maintenance and repair work must be carried out by duly qualif...

Page 6: ...The system is prefilled with refrigerant R134a and need only be connected to the on board power supply when installed 2 1 Roof top air conditioner unit The roof top unit is shown in Fig 2 2 It compris...

Page 7: ...Webasto Thermosysteme Roof top air conditioning system CC4E Page 7 32 Fig 2 2 Compact Cooler Direction of travel...

Page 8: ...FF rocker switch 1 and fan rocker switch 2 can be integrated into the air distribution panel An electronic room thermostat is additionally integrated into the roof top unit in the deluxe version A set...

Page 9: ...ing system is switched on via the ON OFF rocker switch on the air distribution panel the electric motor starts up and drives the compressor via a poly V belt The compressor compresses the refrigerant...

Page 10: ...Roof top air conditioning system CC4E Webasto Thermosysteme Page 10 32 Fig 2 4...

Page 11: ...vel can be checked in the viewglass 14 Fig 2 2 to ensure that there is sufficient refrigerant in the circuit Thermostatic expansion valve The thermostatic expansion valve 11 Fig 2 2 regulates the flow...

Page 12: ...ugh the evaporator and blows the air back into the cabin via the nozzles in the air distribution panel Fig 2 3 Compressor The compressor 27 Fig 2 3 comprises a swashplate compressor and a magnetic cou...

Page 13: ...fan Compressor fan max 68 A 53 A 10 A 5 A Switching points low pressure switch Off On 2 1 0 3 bar 2 0 0 2 bar Switching points high pressure switch Off On 26 5 2 bar 20 2 bar Refrigerant max ambient t...

Page 14: ...Stroke volume per revolution 131 cm3 Lubricating oil for refrigerating compressors type quantity PAG ZXL 100 PG 150 cm3 Refrigerant connections Delivery side standard Intake side standard 3 4 O ring 7...

Page 15: ...icing switch S4 65345 Relay K1 34098 Rocker switch S1 S2 66596 66595 Axial fan M1 M2 64506 Radial fan M3 80866 Prot against reversed polarity F3 75 A Cable size vehicle side Ground Compressor 24 V ver...

Page 16: ...old FA 81676 LP HP HD ND switch S3 66553 Anti icing switch S4 65345 Relay K1 34098 Rocker switch S1 S2 66596 66595 Axial fan M1 M2 64506 Radial fan M3 80866 Prot against reversed polarity F3 75 A Cabl...

Page 17: ...routing the connecting cables Reinforcing elements hoops inside the roof to ensure sufficient roof stability 4 4 Required equipment special tools and accessories a For installation the system is prefi...

Page 18: ...emplate or roof top air conditioning unit without hood with the marked point and drill nine holes with dia 9 mm Remove template or roof top unit as applicable Deburr smooth the cut edges of the openin...

Page 19: ...nit with air distribution panel Air duct sealing On cambered roofs or roofs with beads and gutters a sealing frame must be produced using the sealing profiles provided see Fig 4 3 Fig 4 2 Sealant Arma...

Page 20: ...ull length Adjust the spacers so that they also sit tight on the cambers in the roof contour c Affix the sealing profile to the roof with the Sikaflex 221 included in the installation kit as shown in...

Page 21: ...ghtening torque 9 Nm IMPORTANT Ensure that moisture can escape between the vehicle roof and the baseplate When sealing the sealing frame care must be taken to ensure that the drains for condensation a...

Page 22: ...ted self locking NOTE The light conductor must make contact with the rotary selector Installation of air distribution panel a Prepare the air duct frame if necessary so that it creates an effective se...

Page 23: ...ed cables approved for use in motor vehicles may be used see Fig 3 1 or 3 2 Work on the electrical system may only be performed by authorized personnel Rubber grommets must be used when routing cables...

Page 24: ...see Figs 2 2 and 3 1 in such a way that it can only be switched on and operated when the vehicle engine is running 5 3 Controls and indicators The roof top air conditioning system is operated via the...

Page 25: ...hreshold temperature of the anti icing thermostat is exceeded d Manual control of the cooling performance may be achieved by means of fan power stage selection Stage 1 low cooling performance at low a...

Page 26: ...corresponds with that specified in the installation and service instructions 6 3 Maintenance and care a Regardless of the following schedule all screw connections securing the roof top air conditionin...

Page 27: ...nnections undamaged and secure Attachment parts screws secure Poly V belt correctly tensioned Poly V belt and V belt pulleys undamaged Electrical connection undamaged System component Maintenance task...

Page 28: ...faults in the air conditioning system Defective evaporator or condenser fan Contaminated or clogged air filters evaporator or condenser fins Loss of refrigerant or refrigerant level in system too low...

Page 29: ...dition must be restored a Always use genuine spare parts or standard parts for repairs b The system s original condition must always be restored when performing repairs IMPORTANT Refrigerant must neve...

Page 30: ...authorized repair shop must be consulted to investigate the reasons When the pressure test is complete disconnect the pressure gauges and refit the sealing caps b Testing the high pressure monitor Co...

Page 31: ...uilds up Refrigerant is normally replenished with the refrigerant in the gaseous state When completely drained the circuit must be properly evacuated before refilling with refrigerant b Replenishment...

Page 32: ...r or which have been handled incorrectly are excluded from the warranty The warranty period is not extended by repairs or delivery of replacement parts b If a warranty case occurs contact the national...

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Page 34: ...eutschland Besucheradresse Friedrichshafener Str 9 82205 Gilching Deutschland Technical Extranet http dealers webasto com Nur innerhalb von Deutschland Tel 0395 5592 444 E mail technikcenter webasto c...