1. DL manuals
  2. Webasto
  3. Wine Cooler
  4. BCT010300A
  5. Service And Repair Manual

Webasto BCT010300A Service And Repair Manual

Manual is about: Webasto BlueCool Truck Bunk Cooling Systems

Summary of BCT010300A

  • Page 1

    Bunk cooler bluecool truck service and repair manual – improper installation or repair of webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death. – installation and repair of webasto heating and cooling systems requires special ...

  • Page 3

    Table of contents www.Webasto.Us 1 webasto product n.A., inc. ™ contents page 1. Introduction 3 1.1 safety and general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 warning symbols in this manual . . ...

  • Page 4

    Table of contents www.Webasto.Us 2 webasto product n.A., inc. ™ 6.2.8 system flushing, purging, and pressure testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 6.2.9 system charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 5: Danger

    Introduction www.Webasto.Us 3 webasto product n.A., inc. ™ 1. Introduction 1.1 safety and general information read this manual in its entirety before installing / servicing / repairing this equipment. Failure to follow the instructions and the notes contained therein will lead to all liability being...

  • Page 6

    Introduction webasto product n.A., inc. 4 www.Techwebasto.Com ™ 1.4 vehicle requirements (installation review) an alternator rated 30amps above original equipment is required to provide sufficient power to the existing truck electrical system, installed accessories, and the additional 60 to 67 amper...

  • Page 7

    General description www.Webasto.Us 5 webasto product n.A., inc. ™ 2. General description the bluecool truck system is based on the refrigeration principle and the simple storage of cold energy. The bluecool truck system essentially consists of the following – a refrigeration unit assembly – a cold s...

  • Page 8

    General description webasto product n.A., inc. 6 www.Techwebasto.Com ™ 2.3 air-handler assembly the air-handler assembly is mounted inside the sleeper compartment. The air-handler is comprised of a liquid to air heat exchanger, four air circulation fans, cover with directional louvers, and the syste...

  • Page 9

    General description www.Webasto.Us 7 webasto product n.A., inc. ™ 2.7 digital core temperature sensor located on the back wall of the cold storage assembly, the sensor measures the temperature of the cold storage core. The control module evaluates the signal and adjusts the charging process accordin...

  • Page 10

    General description webasto product n.A., inc. 8 www.Techwebasto.Com ™ 2.9 high/low refrigerant pressure switch located on top of the compressor, the refrigerant pressure switch will deactivate the bluecool truck system in the event of high pressure or in the event of low pressure due to a loss of r...

  • Page 11

    Functional description www.Webasto.Us 9 webasto product n.A., inc. ™ 3. Functional description 3.1 general information the control module is designed with a 30 minute delayed start feature. When a 12 volt positive signal is applied to the pink wire (connector x1, position 3), the control module begi...

  • Page 12

    Functional description webasto product n.A., inc. 10 www.Techwebasto.Com ™ 3.3 discharge mode ( bunk cooling) 3.3.1 vehicle key off - no 12v reference signal present at control module. Whenever the vehicle key is switched off (engine stopped), the discharge cycle (bunk cooling) is automatically avai...

  • Page 13

    Technical data www.Webasto.Us 11 webasto product n.A., inc. ™ 4. Technical data 4.1 general information unless tolerances are shown within the technical data table, a tolerance of ± 10% applies at an ambient temperature of +20 °c (+68 °f) and at the rated voltage and conditions. 4.1.1 technical data...

  • Page 14

    Technical data webasto product n.A., inc. 12 www.Techwebasto.Com ™ 4.1.3 technical data of the circulating pump table 3. Technical data - circulating pump 4.2 dimensions 4.2.1 refrigeration/cold storage assembly figure 14. Dimensions - refrigeration/cold storage assembly specifications u 4846 coolan...

  • Page 15

    Technical data www.Webasto.Us 13 webasto product n.A., inc. ™ 4.2.2 air-handler assembly figure 15. Dimensions - air-handler assembly 179.8 mm (7.04 in.) 616.4 mm (24.26 in.) 623.6 mm (24.55 in.) 203.94 mm (8.03 in.) 498.5 mm (19.62 in.) 509.22 mm (20.05 in.).

  • Page 16

    Troubleshooting – bluecool truck electrical system webasto product n.A., inc. 14 www.Techwebasto.Com ™ 5. Troubleshooting – bluecool truck electrical system 5.1 general information this section describes how to identify and remedy faults on the bluecool truck system. Troubleshooting work demands pre...

  • Page 17

    Troubleshooting – bluecool truck electrical system www.Webasto.Us 15 webasto product n.A., inc. ™ special instructions: 1. If no refrigerant pressure is detected, fill system with 0.25 lb. Of refrigerant to enable leak detection with electronic leak detector. 2. For refrigerant leaks found in the ar...

  • Page 18

    Troubleshooting – bluecool truck electrical system webasto product n.A., inc. 16 www.Techwebasto.Com ™ table 6. Symptom: system begins operation after 1/2 hour delay period expires. Condenser fan does respond but refrigerant compressor does not respond. Symptom/malfunction inspection remedy power in...

  • Page 19

    Troubleshooting – bluecool truck electrical system www.Webasto.Us 17 webasto product n.A., inc. ™ checking for battery voltage (constant) at control module connector. Figure 16. Constant battery voltage at control module - charging mode checking for a 12 volt positive reference signal with the vehic...

  • Page 20

    Troubleshooting – bluecool truck electrical system webasto product n.A., inc. 18 www.Techwebasto.Com ™ checking for a 12 volt switched output signal at control module (vehicle key on or engine running) figure 18. 12 volt switched output signal at control module - charging mode checking 12 volt input...

  • Page 21

    Troubleshooting – bluecool truck electrical system www.Webasto.Us 19 webasto product n.A., inc. ™ checking 12 volt constant positive from batteries (20 amp. Fuse) to system control relay x10 figure 20. 12 volt constant positive from batteries (20 amp. Fuse) to system control relay pin-87 and ground ...

  • Page 22

    Troubleshooting – bluecool truck electrical system webasto product n.A., inc. 20 www.Techwebasto.Com ™ checking power inverter switching relay activation circuit figure 22. Power inverter switching relay activation circuit check checking power inverter switching relay function (continuity through re...

  • Page 23

    Troubleshooting – bluecool truck electrical system www.Webasto.Us 21 webasto product n.A., inc. ™ checking continuity through ambient temperature thermostat figure 24. Ambient temperature thermostat checks (continuity) checking continuity through high/low refrigerant pressure switch figure 25. High/...

  • Page 24

    Troubleshooting – bluecool truck electrical system webasto product n.A., inc. 22 www.Techwebasto.Com ™ checking 110 volts ac output of power inverter figure 26. Dc to ac power inverter performance check (ac voltage) checking condenser fan circuit figure 27. Condenser fan circuit checks (dc voltage) ...

  • Page 25

    Troubleshooting – bluecool truck electrical system www.Webasto.Us 23 webasto product n.A., inc. ™ 5.3 malfunctions with system in discharge mode and vehicle key off (sleeper cooling) the following table lists the possible malfunctions. With the vehicle key in the off position, check operation of the...

  • Page 26

    Troubleshooting – bluecool truck electrical system webasto product n.A., inc. 24 www.Techwebasto.Com ™ checking circulation pump circuit at control module figure 29. Control module output to circulation pump circuit checks (dc voltage) v dc v v volts dc _ + 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 red 14ga -...

  • Page 27

    Troubleshooting – bluecool truck electrical system www.Webasto.Us 25 webasto product n.A., inc. ™ checking circulation pump circuit at pump figure 30. Circulation pump circuit checks (dc voltage) v dc v v volts dc _ + to circulation pump to main system harness x8 off on acc key switch position.

  • Page 28

    Troubleshooting – refrigerant compressor webasto product n.A., inc. 26 www.Techwebasto.Com ™ 6. Troubleshooting – refrigerant compressor 6.1 general information 110 vac device! Lethal current may be present. Switch off the dc to ac power inverter before servicing! The bluecool truck system uses a sp...

  • Page 29

    Troubleshooting – refrigerant compressor www.Webasto.Us 27 webasto product n.A., inc. ™ • never reset a breaker or replace a fuse without first checking for a ground fault (a short circuit to ground). An open fuse or tripped circuit breaker is a strong indication of a ground fault. To check for a gr...

  • Page 30

    Troubleshooting – refrigerant compressor webasto product n.A., inc. 28 www.Techwebasto.Com ™ 6.2.8 system flushing, purging, and pressure testing for leaks failure to properly flush, purge, or pressure test a system for leaks can result in serious injury or death from explosion, fire or contact with...

  • Page 31

    Troubleshooting – refrigerant compressor www.Webasto.Us 29 webasto product n.A., inc. ™ 6.2.9 system charging failure to properly charge the system can result in serious injury or death from explosion or fire. Follow these precautions when charging a system. • do not operate the compressor without a...

  • Page 32

    Troubleshooting – refrigerant compressor webasto product n.A., inc. 30 www.Techwebasto.Com ™ 6.3 troubleshooting table – refrigerant compressor and related components this section provides information to assist service personnel in identifying compressor problems. It provides a general troubleshooti...

  • Page 33

    Troubleshooting – refrigerant compressor www.Webasto.Us 31 webasto product n.A., inc. ™ 6.4 identifying compressor electrical problems this section describes procedures for checking the compressor’s electrical circuits and components. Before doing so, follow the bluecool truck system service informa...

  • Page 34

    Troubleshooting – refrigerant compressor webasto product n.A., inc. 32 www.Techwebasto.Com ™ 6.4.1 checking for a ground fault (a short to ground) step 1: disconnect power disconnect all electrical power supplies to the system, making sure that all power legs are open. (note: the system may have mor...

  • Page 35

    Troubleshooting – refrigerant compressor www.Webasto.Us 33 webasto product n.A., inc. ™ 6.4.2 checking for continuity and proper resistance if no ground fault has been detected using the procedures in section 6.4.1, determine whether there is an open or short circuit in the motor windings or if the ...

  • Page 36

    Troubleshooting – refrigerant compressor webasto product n.A., inc. 34 www.Techwebasto.Com ™ 6.4.3 checking for other electrical problems in single phase motors this section provides procedures for checking the components such as the thermal protector, relay and capacitor in a single phase compresso...

  • Page 37

    Troubleshooting – refrigerant compressor www.Webasto.Us 35 webasto product n.A., inc. ™ 6.5 checking for adequate compressor pumping before checking for adequate compressor pumping, you should have already checked for compressor electrical problems as outlined in “identifying compressor electrical p...

  • Page 38

    Compressor replacement and system service webasto product n.A., inc. 36 www.Techwebasto.Com ™ 7. Compressor replacement and system service 7.1 system cleanup and compressor replacement after compressor failure once you determine that a compressor needs to be replaced you must then determine whether ...

  • Page 39

    Compressor replacement and system service www.Webasto.Us 37 webasto product n.A., inc. ™ 1. Evacuate the system to 29 inches vacuum. Break vacuum with refrigerant to be used for final charging of system and vapor charge to 35-50 pounds gauge pressure. Leave vapor charge in system for a minimum of fi...

  • Page 40

    Circuit diagrams webasto product n.A., inc. 38 www.Techwebasto.Com ™ 8. Circuit diagrams figure 35. Wiring schematic (early version) v vv v vv rear view 1 2 3 4 5 6 7 8 ac dc run cap acit or signal "on" from controller (30min dela y) digit al thermometer st orage/charge hi/low pressure limiter p ba ...

  • Page 41

    Component replacement - refrigeration unit www.Webasto.Us 39 webasto product n.A., inc. ™ 9. Component replacement - refrigeration unit figure 36. Refrigeration unit 9.1 general information and safety precautions refrigeration and air conditioning devices are extremely complicated by nature. Servici...

  • Page 42

    Component replacement - refrigeration unit webasto product n.A., inc. 40 www.Techwebasto.Com ™ 10. Install new compressor in reverse order of removal and service system according to the precautions and recommendations beginning with section 6.2.9. Figure 37. Compressor replacement 9.3 condenser repl...

  • Page 43

    Component replacement - refrigeration unit www.Webasto.Us 41 webasto product n.A., inc. ™ 9.4 thermal expansion valve (txv) replacement read over section 9.1 before proceeding with txv replacement. 1. Switch the power inverter off. 2. Remove refrigeration unit cover. Be sure refrigerant is recovered...

  • Page 44

    Component replacement - refrigeration unit webasto product n.A., inc. 42 www.Techwebasto.Com ™ 9.5 pressure switch replacement read over section 9.1 before proceeding with txv replacement. 1. Switch the power inverter off. 2. Remove refrigeration unit cover. Be sure refrigerant is recovered using th...

  • Page 45

    Component replacement - refrigeration unit www.Webasto.Us 43 webasto product n.A., inc. ™ 9.7 ambient temperature switch replacement 1. Switch the power inverter off. 2. Remove refrigeration unit cover. 3. Locate the ambient temperature switch. It will be in the area of the compressor, wire tied to ...

  • Page 46

    Component replacement air-handler assembly webasto product n.A., inc. 44 www.Techwebasto.Com ™ 10.Component replacement air-handler assembly figure 43. Air-handler before replacement of components, a thorough troubleshooting and diagnosis of the bluecool truck system must be conducted to identify th...

  • Page 47

    Component replacement air-handler assembly www.Webasto.Us 45 webasto product n.A., inc. ™ 3. Turn cover over and remove control knobs. Knobs are held on by a small set-screw. 4. Remove the two panel nuts and washers from rotary switch shafts. Figure 46. Control unit removal - step 2 5. Control unit ...

  • Page 48

    Coolant circuit webasto product n.A., inc. 46 www.Techwebasto.Com ™ 11.Coolant circuit under no circumstances should pure water be allowed to enter the bluecool coolant system! Doing so will not ensure proper mixing with antifreeze which will lead to ice formation in the storage unit and possibly da...

  • Page 49

    Coolant circuit www.Webasto.Us 47 webasto product n.A., inc. ™ 11.2 heat exchanger replacement removal 1. Follow directions in sec. 10.2 "air-handler cover removal" on page 44. 2. Drain sufficient coolant from system to prevent spillage inside sleeper compartment. Figure 50. Heat exchanger replaceme...

  • Page 50

    Coolant circuit webasto product n.A., inc. 48 www.Techwebasto.Com ™ figure 53. Circulating pump - orientation 0° 85° 0° correct wrong.

  • Page 51

    Warranty www.Webasto.Us 49 webasto product n.A., inc. ™ 12.Warranty webasto bluecool ® truck airconditioning limited warranty webasto warrants webasto bluecool truck products manufactured or supplied by webasto, subject to qualifications indicated. Webasto warrants these products for the period set ...

  • Page 52

    Warranty webasto product n.A., inc. 50 www.Techwebasto.Com ™.

  • Page 53

    Warranty www.Webasto.Us 51 webasto product n.A., inc. ™.

  • Page 54

    Webasto product n.A., inc. 15083 north road fenton, mi 48430 technical assistance hotline usa: (800) 860-7866 canada: (800) 667-8900 www.Webasto.Us www.Techwebasto.Com org. 02/2007 rev. 2/2012 ver. Bct_abc © 2012 webasto product n.A., inc..