Webasto BCT010300C Repair Manual

Bunk CoolerBlueCool TruckService and Repair Manual– Improper installation or repair of Webasto heating and cooling systems can cause fire or the leaka

General DescriptionWebasto Product N.A., Inc. 8 www.techwebasto.com™2.9 High/Low Refrigerant Pressure SwitchLocated on top of the compressor, the refr

Functional Descriptionwww.webasto.us 9 Webasto Product N.A., Inc.™3. Functional Description3.1 General InformationThe control module is designed with

Functional DescriptionWebasto Product N.A., Inc. 10 www.techwebasto.com™3.3 Discharge Mode (Bunk Cooling)3.3.1 Vehicle Key OFF - no 12V reference sign

Technical Datawww.webasto.us 11 Webasto Product N.A., Inc.™4. Technical Data4.1 General InformationUnless tolerances are shown within the technical da

Technical DataWebasto Product N.A., Inc. 12 www.techwebasto.com™4.1.3 Technical Data of the Circulating PumpTable 3. Technical Data - Circulating Pump

Technical Datawww.webasto.us 13 Webasto Product N.A., Inc.™4.2.2 Air-handler AssemblyFigure 15. Dimensions - Air-handler Assembly179.8 mm(7.04 in.)61

Troubleshooting – BlueCool Truck Electrical SystemWebasto Product N.A., Inc. 14 www.techwebasto.com™5. Troubleshooting – BlueCool Truck Electrical Sys

Troubleshooting – BlueCool Truck Electrical Systemwww.webasto.us 15 Webasto Product N.A., Inc.™Special instructions:1. If no refrigerant pressure is d

Troubleshooting – BlueCool Truck Electrical SystemWebasto Product N.A., Inc. 16 www.techwebasto.com™Table 6. Symptom:System begins operation after 1/2

Troubleshooting – BlueCool Truck Electrical Systemwww.webasto.us 17 Webasto Product N.A., Inc.™Checking for battery voltage (constant) at control modu

Troubleshooting – BlueCool Truck Electrical SystemWebasto Product N.A., Inc. 18 www.techwebasto.com™Checking for a 12 volt switched output signal at c

Troubleshooting – BlueCool Truck Electrical Systemwww.webasto.us 19 Webasto Product N.A., Inc.™Checking 12 volt constant positive from batteries (20 a

Troubleshooting – BlueCool Truck Electrical SystemWebasto Product N.A., Inc. 20 www.techwebasto.com™Checking power inverter switching relay activation

Troubleshooting – BlueCool Truck Electrical Systemwww.webasto.us 21 Webasto Product N.A., Inc.™Checking continuity through ambient temperature thermos

Troubleshooting – BlueCool Truck Electrical SystemWebasto Product N.A., Inc. 22 www.techwebasto.com™Checking 110 volts AC output of power inverterFigu

Troubleshooting – BlueCool Truck Electrical Systemwww.webasto.us 23 Webasto Product N.A., Inc.™5.3 Malfunctions with System in Discharge Mode and Vehi

Troubleshooting – BlueCool Truck Electrical SystemWebasto Product N.A., Inc. 24 www.techwebasto.com™Checking circulation pump circuit at control modul

Troubleshooting – BlueCool Truck Electrical Systemwww.webasto.us 25 Webasto Product N.A., Inc.™Checking circulation pump circuit at pumpFigure 30. Cir

Troubleshooting – Refrigerant CompressorWebasto Product N.A., Inc. 26 www.techwebasto.com™6. Troubleshooting – Refrigerant Compressor6.1 General Infor

Troubleshooting – Refrigerant Compressorwww.webasto.us 27 Webasto Product N.A., Inc.™• Never reset a breaker or replace a fuse without first checking

Table of Contentswww.webasto.us 1 Webasto Product N.A., Inc.™Contents Page1. Introduction 31.1 Safety and General Information . . . . . . . . . . .

Troubleshooting – Refrigerant CompressorWebasto Product N.A., Inc. 28 www.techwebasto.com™6.2.8 System Flushing, Purging, and Pressure Testing for Lea

Troubleshooting – Refrigerant Compressorwww.webasto.us 29 Webasto Product N.A., Inc.™6.2.9 System ChargingFailure to properly charge the system can re

Troubleshooting – Refrigerant CompressorWebasto Product N.A., Inc. 30 www.techwebasto.com™6.3 Troubleshooting Table – Refrigerant Compressor and Relat

Troubleshooting – Refrigerant Compressorwww.webasto.us 31 Webasto Product N.A., Inc.™6.4 Identifying Compressor Electrical ProblemsThis section descri

Troubleshooting – Refrigerant CompressorWebasto Product N.A., Inc. 32 www.techwebasto.com™6.4.1 Checking for a Ground Fault (a Short to Ground)Step 1:

Troubleshooting – Refrigerant Compressorwww.webasto.us 33 Webasto Product N.A., Inc.™6.4.2 Checking for Continuity and Proper ResistanceIf no ground f

Troubleshooting – Refrigerant CompressorWebasto Product N.A., Inc. 34 www.techwebasto.com™6.4.3 Checking for Other Electrical Problems in Single Phase

Troubleshooting – Refrigerant Compressorwww.webasto.us 35 Webasto Product N.A., Inc.™6.5 Checking for Adequate Compressor PumpingBefore checking for a

Compressor Replacement and System ServiceWebasto Product N.A., Inc. 36 www.techwebasto.com™7. Compressor Replacement and System Service7.1 System Clea

Compressor Replacement and System Servicewww.webasto.us 37 Webasto Product N.A., Inc.™1. Evacuate the system to 29 inches vacuum. Break vacuum with r

Table of Contentswww.webasto.us 2 Webasto Product N.A., Inc.™6.2.8 System Flushing, Purging, and Pressure Testing for Leaks . . . . . . . . . . . . .

Circuit DiagramsWebasto Product N.A., Inc. 38 www.techwebasto.com™8. Circuit DiagramsFigure 35. Wiring Schematic (Early Version)VVVVVVREAR VIEW1234567

Component Replacement - Refrigeration Unitwww.webasto.us 39 Webasto Product N.A., Inc.™9. Component Replacement - Refrigeration UnitFigure 36. Refrige

Component Replacement - Refrigeration UnitWebasto Product N.A., Inc. 40 www.techwebasto.com™10. Install new compressor in reverse order of removal and

Component Replacement - Refrigeration Unitwww.webasto.us 41 Webasto Product N.A., Inc.™9.4 Thermal Expansion Valve (TXV) ReplacementRead over Section

Component Replacement - Refrigeration UnitWebasto Product N.A., Inc. 42 www.techwebasto.com™9.5 Pressure Switch ReplacementRead over Section 9.1 befor

Component Replacement - Refrigeration Unitwww.webasto.us 43 Webasto Product N.A., Inc.™9.7 Ambient Temperature Switch Replacement1. Switch the power i

Component Replacement Air-handler AssemblyWebasto Product N.A., Inc. 44 www.techwebasto.com™10.Component ReplacementAir-handler AssemblyFigure 43. Air

Component Replacement Air-handler Assemblywww.webasto.us 45 Webasto Product N.A., Inc.™3. Turn cover over and remove control knobs. Knobs are held on

Coolant CircuitWebasto Product N.A., Inc. 46 www.techwebasto.com™11.Coolant CircuitUNDER NO CIRCUMSTANCES SHOULD PURE WATER BE ALLOWED TO ENTER THE BL

Coolant Circuitwww.webasto.us 47 Webasto Product N.A., Inc.™11.2 Heat Exchanger ReplacementRemoval1. Follow directions in Sec. 10.2 "Air-handler

Introductionwww.webasto.us 3 Webasto Product N.A., Inc.™1. Introduction1.1 Safety and General InformationRead this manual in its entirety before insta

Coolant CircuitWebasto Product N.A., Inc. 48 www.techwebasto.com™Figure 53. Circulating pump - orientation0°85°0°CorrectWrong

Warrantywww.webasto.us 49 Webasto Product N.A., Inc.™12.WarrantyWEBASTO BlueCool ® TRUCK AIRCONDITIONING LIMITED WARRANTY Webasto warrants Webasto Bl

WarrantyWebasto Product N.A., Inc. 50 www.techwebasto.com™

Warrantywww.webasto.us 51 Webasto Product N.A., Inc.™

Webasto Product N.A., Inc.15083 North RoadFenton, MI 48430Technical Assistance HotlineUSA: (800) 860-7866Canada: (800) 667-8900www.webasto.uswww.techw

IntroductionWebasto Product N.A., Inc. 4 www.techwebasto.com™1.4 Vehicle Requirements (Installation Review)An alternator rated 30Amps above original e

General Descriptionwww.webasto.us 5 Webasto Product N.A., Inc.™2. General DescriptionThe BlueCool Truck system is based on the refrigeration principle

General DescriptionWebasto Product N.A., Inc. 6 www.techwebasto.com™2.3 Air-handler AssemblyThe air-handler assembly is mounted inside the sleeper com

General Descriptionwww.webasto.us 7 Webasto Product N.A., Inc.™2.7 Digital Core Temperature SensorLocated on the back wall of the cold storage assembl