Repair manual

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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

Webasto training, technical information, special tools and special equipment.

– NEVER attempt to install or repair a Webasto heating or cooling system unless you

have successfully completed the factory training course and have the technical skills,

technical information, tools and equipment required to properly complete the

necessary procedures.

– ALWAYS carefully follow Webasto installation and repair instructions and heed all

WARNINGS.

– Webasto rejects any liability for problems and damage caused by the system being

installed by untrained personnel.

This manual covers BlueCool Truck models with part number:

• BCT010300A (06/2005 to 06/2006)

• BCT010300B (06/2006 to 07/2006)

• BCT010300C (07/2006 to 06/2007)

Summary of content (54 pages)

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Bunk Cooler BlueCool Truck Service and Repair Manual This manual covers BlueCool Truck models with part number: • BCT010300A (06/2005 to 06/2006) • BCT010300B (06/2006 to 07/2006) • BCT010300C (07/2006 to 06/2007) – 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.
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™ Table of Contents Contents Page 1. Introduction 3 1.1 1.2 1.3 1.4 Safety and General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Symbols in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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™ Table of Contents 6.2.8 System Flushing, Purging, and Pressure Testing for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.9 System Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.10 Prevention of System Explosions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.11 Start Capacitor Overheating. .
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™ Introduction 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 refused by Webasto. The same applies if repairs are carried out incorrectly or with the use of parts other than genuine Webasto service parts. 1.
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™ Introduction 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 ampere load of the BlueCool system during system charging mode. 1.4.1 Electrical Tests - Prior to Troubleshooting and Servicing Batteries must be in good condition.
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™ General Description 2. General Description 2.1 The BlueCool Truck system is based on the refrigeration principle and the simple storage of cold energy. The refrigeration unit is comprised of an electric refrigeration compressor, a condenser core with an electric automotive type radial fan, an evaporator (inside the cold storage core) and a thermal expansion valve.
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™ General Description 2.3 Air-handler Assembly 2.5 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 system control module with operator interface during discharge. DC to AC Power Inverter A power inverter to change 12 volts DC vehicle power into 110 volts AC is utilized to supply power to drive the electric refrigeration compressor.
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™ General Description 2.7 Digital Core Temperature Sensor 2.8 Ambient Temperature Thermostat 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 accordingly. Located behind the compressor, an ambient temperature thermostat is provided for the purpose of deactivating the BlueCool Truck System during cooler weather periods when bunk cooling is not desired.
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™ General Description 2.9 High/Low Refrigerant Pressure Switch 2.10 External Thermal Protector – Hermetic Compressor Motor 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 refrigerant. WARNING 110 VAC Device! Lethal current may be present.
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™ Functional Description 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 begins the 30 minute time delay count down. However, if during this 30 minute period, the key is cycled OFF and ON regardless the number of times, the 30 minute countdown sequence will not be interrupted.
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™ Functional Description 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 available on demand to the vehicle operator when desired. Two control dials on the face of the control module are provided for climate control within the sleeper area.
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™ Technical Data 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 of the BlueCool Truck System Specifications BlueCool Truck Parking Cooler Thermal Storage (parking A/C) 17,000 Btu (5 kWh) Power Consumption during Sleeper Cooling Coolant circulating pump and fans 3.5 - 6.
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™ Technical Data 4.1.3 Technical Data of the Circulating Pump Specifications U 4846 Coolant Circulating Pump Flow rate against 0.0 PSI (0.0 Bar) 528 g/hr (2,000 l/hr) Rated Voltage 12 Volts Power Consumption during operation 28 Watts @ 12 Volts Dimensions L 7.08” x W 2.9” x H 4.4” (180 x 74 x 112 mm) Weight 1.53 lb. (0.692 kg) Table 3. Technical Data - Circulating Pump 4.2 4.2.1 Dimensions Refrigeration/Cold Storage Assembly 559 mm (22 in.) 660.5mm (26 in.) 648 mm (25.5 in.
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™ Technical Data 4.2.2 Air-handler Assembly 616.4 mm (24.26 in.) 179.8 mm (7.04 in.) 498.5 mm (19.62 in.) 623.6 mm (24.55 in.) 203.94 mm (8.03 in.) 509.22 mm (20.05 in.) Figure 15. Dimensions - Air-handler Assembly www.webasto.us 13 Webasto Product N.A., Inc.
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™ Troubleshooting – BlueCool Truck Electrical System 5. Troubleshooting – BlueCool Truck Electrical System 5.2 5.1 The following tables list the possible error symptoms. General Information This section describes how to identify and remedy faults on the BlueCool Truck System. If the actions listed in the following tables do not restore proper operation, consult your authorized Webasto dealer.
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™ Troubleshooting – BlueCool Truck Electrical System Table 5. Symptom: System does not begin operation after 1/2 hour delay period expires and anytime thereafter. Condenser fan, power inverter and refrigerant compressor DO NOT respond. Symptom/Malfunction Inspection Remedy IMPORTANT! Storage core temperature must be above 30 °F (–1 °C) and ambient temperature above 60 °F (15.5 °C). Check 10 amp. fuse at fuse holder X2. 12 volts negative and/or positive not present at control module.
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™ Troubleshooting – BlueCool Truck Electrical System 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 inverter switched off Switch power inverter on. Note: Green LED indicator will only illuminate during an active system charge cycle.
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™ Troubleshooting – BlueCool Truck Electrical System Checking for battery voltage (constant) at control module connector. Volts DC V DC V + _ LEGEND 4 3 2 1 8 7 6 5 X1 Viewed from wire insertion side 1 Red 14GA - Constant Power Positive (Fused 10 amp.
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™ Troubleshooting – BlueCool Truck Electrical System Checking for a 12 volt switched output signal at control module (vehicle key ON or engine running) Volts DC OFF AC C ON V DC V > 30 min. Key Switch Position + _ LEGEND 4 3 2 1 8 7 6 5 X1 Viewed from wire insertion side 1 Red 14GA - Constant Power Positive (Fused 10 amp.
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™ Troubleshooting – BlueCool Truck Electrical System Checking 12 volt constant positive from batteries (20 amp. fuse) to system control relay X10 LEGEND 87 86 87a 85 Volts DC X10 Viewed from wire insertion side ON 30 V DC PO W ER OF F V 30 Blue 12GA - 12V Switched Output to Condensor Fan (X9) 85 Brown 14GA - Ground to Battery Negative Post 86 Purple 16GA - 12V Input from Control Module (X1), Pressure Sensor (X6) and Ambient Thermostat (X7) 87 Red 12GA - Constant Power Positive (Fused 20 amp.
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™ Troubleshooting – BlueCool Truck Electrical System Checking power inverter switching relay activation circuit Volts DC LEGEND 87 X11 86 87a 85 V DC PO ON Viewed from wire insertion side W ER OF 30 V F 30 On/Off Switch Circuit to Power Inverter 85 Brown 16GA - Ground 86 Blue 16GA - 12V Switched Output from System Control Relay (X10) + _ 87 On/Off Switch Circuit to Power Inverter 87a Not Used OFF AC C ON X11 X10 > 30 min. Key Switch Position To Inverter ON/OFF Circuit Figure 22.
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™ Troubleshooting – BlueCool Truck Electrical System Checking continuity through ambient temperature thermostat Continuity OFF AC C ON Key Switch Position or + _ Figure 24. Ambient temperature thermostat checks (continuity) Checking continuity through high/low refrigerant pressure switch Continuity OFF AC C ON Key Switch Position or + _ Figure 25. High/low refrigerant pressure switch checks (continuity) www.webasto.us 21 Webasto Product N.A., Inc.
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™ Troubleshooting – BlueCool Truck Electrical System Checking 110 volts AC output of power inverter Volts AC V AC V + _ PO O A W E ER TE R OFF W ER ON AC C ON T DC O CP NV RI OFF Key Switch Position Inverter ON Allumez l'inverter To Refrigerant Compressor WARNING > 30 min. High Voltage! 115 Volts AC Haut Voltage! Courant alternatif de 115 volts Figure 26.
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™ Troubleshooting – BlueCool Truck Electrical System 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 air-handler by turning both knobs of the control panel on. A small green LED should illuminate. If the green LED does not illuminate and there is no air circulation through the air-handler, check fuses and battery connections. Repair as necessary.
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™ Troubleshooting – BlueCool Truck Electrical System Checking circulation pump circuit at control module Volts DC AC ON C OFF V DC V Key Switch Position + _ LEGEND 4 3 2 1 8 7 6 5 X1 Viewed from wire insertion side 1 Red 14GA - Constant Power Positive (Fused 10 amp.
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™ Troubleshooting – BlueCool Truck Electrical System Checking circulation pump circuit at pump Volts DC V DC OFF AC C + _ ON V Key Switch Position To Main System Harness To Circulation Pump X8 Figure 30. Circulation pump circuit checks (DC voltage) www.webasto.us 25 Webasto Product N.A., Inc.
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™ Troubleshooting – Refrigerant Compressor 6. Troubleshooting – Refrigerant Compressor 6.1 6.2.2 Refrigeration and air conditioning devices are extremely complicated by nature. Servicing, repairing, and troubleshooting these products should be done only by those with the necessary knowledge, training, and equipment. General Information WARNING 110 VAC Device! Lethal current may be present.
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™ Troubleshooting – Refrigerant Compressor • 6.2.6 Never reset a breaker or replace a fuse without first checking for a ground fault (a short circuit to ground). Contact with refrigerant, mixtures of refrigerant and oil, or other chemicals can cause a variety of injuries including burns and frostbite. For example, if refrigerant contacts skin or eyes it can cause severe frostbite. Also, in the event of a compressor motor failure, some refrigerant and oil mixtures can be acidic and cause chemical burns.
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™ Troubleshooting – Refrigerant Compressor 6.2.8 System Flushing, Purging, and Pressure Testing for Leaks Gauges 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 acid-saturated refrigerant or oil mists. Regulating Valve To System DRY NITROGEN Webasto recommends that the system be serviced using a flush and purge station such as a Robinair® unit or similar equipment designed for R134a refrigerant systems.
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™ Troubleshooting – Refrigerant Compressor 6.2.9 System Charging the vicinity. Failure to properly charge the system can result in serious injury or death from explosion or fire. Water-utilizing systems that have single-wall heat exchangers may present a risk of explosion. Such systems may include: Follow these precautions when charging a system. • Do not operate the compressor without a charge in the system. Operating the compressor without a charge in the system can damage the hermetic terminal.
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™ Troubleshooting – Refrigerant Compressor 6.3 Troubleshooting Table – Refrigerant Compressor and Related Components For your safety, read and follow the “General Service and Safety Precautions Concerning Refrigeration Compressors” on page 26. This section provides information to assist service personnel in identifying compressor problems. It provides a general troubleshooting table that relates complaints or problems to possible causes and solutions.
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™ Troubleshooting – Refrigerant Compressor Table 9. Troubleshooting Table – Refrigerant Compressor and Related Components Symptom Possible Causes Remedy Unit runs OK, but run cycle System components, such as digital temperature sensor, is shorter than normal (due control module, relays, not functioning properly. to component (s) other High pressure cut-out due to: than thermal protector) a. Insufficient air or coolant supply. b. Overcharge or refrigerant. c. Air in system.
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™ Troubleshooting – Refrigerant Compressor 6.4.1 Checking for a Ground Fault (a Short to Ground) fault. Do not reconnect the power leads. Tape and insulate each power lead separately. 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 more than one power supply.) If a ground fault does not exist, leave the power off and all external components disconnected from the terminal pins.
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™ Troubleshooting – Refrigerant Compressor 6.4.2 Checking for Continuity and Proper Resistance heater element of the thermal protector is open. Use the procedure in Table 10, “Checking for Proper Continuity and Resistance,” on page 33 to check the single phase motor. 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 Table 10.
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™ Troubleshooting – Refrigerant Compressor Checking for Other Electrical Problems in Single Phase Motors mounted thermal and current overload protection. This system also uses a run capacitor and a start capacitor with an internal relay. This section provides procedures for checking the components such as the thermal protector, relay and capacitor in a single phase compressor. The electrical system of this type of compressor motor is shown in Fig. 34.
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™ Troubleshooting – Refrigerant Compressor Table 11. Troubleshooting PSC Compressor Circuits Step 4: Check Run Capacitor CAUTION Using a 20,000 ohm resistor; discharge the capacitor before removing it from the system to avoid damage to measuring devices and risk of electric shock. Disconnect the run capacitor from the system. Use a capacitance meter to check capacitor. Capacitance should be ±10% of the marked capacitor value.
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™ Compressor Replacement and System Service 7. Compressor Replacement and System Service 7.1 evidence of contamination, the compressor was running at the time of the motor failure and contaminants were pumped throughout the system (System Contamination). If System Contamination has occurred, several changes of the liquid and suction line filter-driers will be needed to cleanup the system. In addition, the thermal expansion valve will need to be replaced.
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™ Compressor Replacement and System Service Compressor and Components” on page 36. 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 five minutes. Reduce pressure to 0 gauge pressure. On the other hand, where Systems Contamination occurred, an increased pressure drop will be measured.
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SIGNAL "ON" FROM CONTROLLER (30MIN DELAY) X1 1 2 X7 X6 HI/LOW PRESSURE LIMITER X6 X7 AMBIENT SENSOR 5 VIOLET p t A B X5 BLACK RED 1 2 M BLUE X9 CONDENSER FAN BATTERY - BATTERY + DIGITAL THERMOMETER STORAGE/CHARGE X8 COOLANT PUMP M B A 8 7 2 4 CONTROL UNIT (IN AIR HANDLER) KEY ON SIGNAL +12VDC BY INSTALLER BATTERY - 8 7 6 5 REAR VIEW 4 3 2 1 3 PINK BROWN VIOLET BATTERY + ORANGE X2 10A BROWN RED BLACK BATTERY + AC BLUE 120VAC 60HZ 85 30 86 87 87a X11
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™ Component Replacement - Refrigeration Unit 9. Component Replacement Refrigeration Unit • Be sure refrigerant is recovered using the appropriate equipment before removing any of the refrigeration circuit components. Attempting to remove components before removing all refrigerant from the system can cause a sudden release of refrigerant and oil. Among other things, this can: • Cause a variety of injuries including burns and frost bite. • Expose service personnel to toxic gas.
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™ Component Replacement - Refrigeration Unit 9.3 10. Install new compressor in reverse order of removal and service system according to the precautions and recommendations beginning with Section 6.2.9. Condenser Replacement Read over Section 9.1 before proceeding with condenser replacement. Torque 6.0 lb-ft. 1. Switch the power inverter OFF. 2. Remove refrigeration unit cover. Be sure refrigerant is recovered using the appropriate equipment before removing the condenser.
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™ Component Replacement - Refrigeration Unit 9.4 Thermal Expansion Valve (TXV) Replacement 6. Remove the 2 allen head bolts securing the TXV to the storage core pipes. 7. Pull the TXV free of the storage core pipes. Read over Section 9.1 before proceeding with TXV replacement. 8. Inspect TXV and lines for possible contamination by dirt, water, etc. If contaminated, service system according to the precautions and recommendations in Section 6.2.8 after replacing the condenser. 1.
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™ Component Replacement - Refrigeration Unit 9.5 Pressure Switch Replacement 9.6 Read over Section 9.1 before proceeding with TXV replacement. Condenser Fan Replacement 1. Switch the power inverter OFF. 2. Disconnect the condenser fan connector. 1. Switch the power inverter OFF. 3. Remove refrigeration unit cover. 2. Remove refrigeration unit cover. 4. Remove the cover plate over the fan and condenser.
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™ Component Replacement - Refrigeration Unit 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 the runcapacitor. Refer to Fig. 42. 4. Replace as required. 5. Apply an anti-corrosive electrical grease to the terminals and connect to switch. 6. If necessary, re-secure to the run-capacitor with a wire tie as before. 7.
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™ Component Replacement Air-handler Assembly 10.Component Replacement Air-handler Assembly 10.2 Air-handler Cover Removal 1. Pull 10 amp. fuse from fuse holder of BCT harness located at vehicle batteries. 2. Remove air-handler cover (M6 hex-nut X 6 places). 3. Carefully disconnect the 8-pin harness plug from control unit receptacle. 4. Move to a workbench for further work if necessary. Figure 43.
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™ Component Replacement Air-handler Assembly 10.4 Fan Replacement 3. Turn cover over and remove control knobs. Knobs are held on by a small set-screw. Removal 4. Remove the two panel nuts and washers from rotary switch shafts. 1. Follow directions in Sec. 10.2 "Air-handler Cover Removal" on page 44. 2. Carefully disconnect the 2-pin fan wiring plug of the defective fan from control unit receptacle. 3. Remove the four screws holding the fan to the cover. 4. Remove fan from fan recess of cover.
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™ Coolant Circuit 11.Coolant Circuit A UNDER NO CIRCUMSTANCES SHOULD CAUTION 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 damaging internal components. ALWAYS purchase and use a 50/50 premixed glycol based antifreeze where possible.
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™ Coolant Circuit 11.2 Heat Exchanger Replacement Installation 1. Reassembly in reverse order of removal. Removal AVOID DAMAGING HEAT EXCHANGER! Lubricate heat exchanger connection tubes and coolant hoses with silicone spray before connecting hoses to heat exchanger. 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. 2. Refer to Sec. 11.
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™ Coolant Circuit 85° 0° 0° Correct Wrong Figure 53. Circulating pump - orientation Webasto Product N.A., Inc. 48 www.techwebasto.
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™ Warranty 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 forth below, to be free from defects in workmanship and material, provided such products are installed, operated, and maintained in accordance with Webasto “BlueCool” written instructions. Terms and Conditions 1.
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™ Warranty Webasto Product N.A., Inc. 50 www.techwebasto.
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™ Warranty www.webasto.us 51 Webasto Product N.A., Inc.
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Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 860-7866 Canada: (800) 667-8900 Org. 02/2007 Rev. 2/2012 Ver. BCT_ABC © 2012 Webasto Product N.A., Inc. www.webasto.us www.techwebasto.