Webasto CC8 Installation And Service Instructions Manual
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Webasto CC8 Installation And Service Instructions Manual

Webasto CC8 Installation And Service Instructions Manual

Air-conditioning system
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CC8

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Summary of Contents for Webasto CC8

  • Page 1 Air-conditioning system Installation and service instructions...

  • Page 2: Table Of Contents

    Roof-top air-conditioning system CC8 Contents Contents Introduction Scope and purpose..........................101 Meaning of Warnings, Cautions and Notes ................... 101 Additional documentation required ......................101 Safety information and regulations ......................101 Certification............................102 Corrections and improvements......................102 General description Roof-top unit ............................202 Air distribution panel (standard)......................
  • Page 3 Contents Roof-top air-conditioning system CC8 4.10 Installation of roof-top unit with air ducting system or air distribution panel ......... 413 4.10.1 Air duct sealing .......................... 413 4.10.2 Working on the sealing frame ....................414 4.10.3 Mounting the base frame ......................415 4.10.4 Pre-assembly of air distribution panel ..................
  • Page 4 Roof-top air-conditioning system CC8 Contents List of illustrations Roof-top air-conditioning system CC8 ......................201 Roof-top unit ..............................202 Air distribution panel ............................203 Air ducting system............................204 Compressor versions ............................205 Functional schematic ............................206 Preparations on vehicle / cabin roof......................... 404 Compressor, permissible installation position....................
  • Page 5 Contents Roof-top air-conditioning system CC8...

  • Page 6: Introduction

    Operating instructions for the roof-top air-conditioning system CC5/CC8 Safety information and regulations The roof-top air-conditioning system CC8 has been designed and built in accordance with the EC Directives. The system can be operated safely when installed and operated properly in accordance with the installation and service manual.

  • Page 7: Certification

    This may also cause void the vehicle's "general permit for operation". If additional material not supplied by Webasto is used in the passenger cabin, care must be taken to ensure that all materials used meet the statutory requirements in respect of flammability.

  • Page 8: General Description

    2 General description General description The roof-top air-conditioning system CC8 is used for cooling / air-conditioning vans and small passenger buses. The system is available in three versions: a basic version, a version with thermostat control and a deluxe version with additional fresh air ventilation flap.

  • Page 9: Roof-Top Unit

    2 General description Roof-top air-conditioning system CC8 Roof-top unit The roof-top unit is shown in Fig. 202. It comprises: – A hood as cowling with openings and protective screens for air inlet and outlet. – A baseplate on which the various parts are mounted.

  • Page 10: Air Distribution Panel (Standard)

    Roof-top air-conditioning system CC8 2 General description Air distribution panel (standard) Air can be distributed via the air distribution panel (Fig. 203). When installing the panel, the system controls may be mounted directly on the panel or integrated in the dashboard via the (optional) wiring harness for external controls.

  • Page 11: Air Ducting System

    2 General description Roof-top air-conditioning system CC8 Air ducting system (option) The modular air ducting system (Fig. 204) can be installed in the vehicle to distribute air. The system comprises an air distribution panel, the central air duct and the end air duct. Several central air ducts may be installed, depending on the required length of the air distribution system.

  • Page 12: Compressor

    Roof-top air-conditioning system CC8 2 General description Compressor The compressor (Fig. 205), a swashplate compressor, is available in eight versions: – TM-16HD h, with horizontal refrigerant connections and twin V-belt pulley, 12 V – TM-16HD h, with horizontal refrigerant connections and twin V-belt pulley, 24 V –...
  • Page 13 2 General description Roof-top air-conditioning system CC8 Fig. 206 Functional schematic...

  • Page 14: Design, Purpose And Principle Of Operation Of The Assemblies

    Roof-top air-conditioning system CC8 2 General description As the liquid refrigerant flows through the receiver-drier (7) to the expansion valve (14), it decompresses with the controlled drop in pressure and returns to the gaseous state in the evaporator (2), absorbing considerable heat at the same time.

  • Page 15: Axial Fans

    2 General description Roof-top air-conditioning system CC8 2.7.7 Axial fans Each axial fan (12, Fig. 202) includes a single-stage DC motor. After switching the air-conditioning system on, they are constantly driven by the vehicle's electrical system via a relay to supply the condenser with the required outside air.

  • Page 16: Technical Data

    Roof-top air-conditioning system CC8 3 Technical data Technical data Air-conditioning system Designation Type CC8 Dimensions, roof-top unit – length x width x height 1025 mm X 970 mm X 197 mm Weight Approx. 40 kg Operating voltages (depending on vehicle's electr. system)
  • Page 17 3 Technical data Roof-top air-conditioning system CC8 Page for own notes...

  • Page 18: Installation Instructions

    CC8 roof-top air-conditioning system 4 Installation instructions Installation instructions Safety instructions Read the safety instructions (see 1.4) before starting any work and comply with them. The system must be installed or the installation work supervised by personnel familiar with vehicle air- conditioning systems.
  • Page 19 When selecting a compressor be sure to choose one that has a built-in high-pressure relief valve as a safety feature. All the compressors supplied by Webasto have a relief valve of this type. The relief valve opening pressure must be as specified in the technical data for the compressor (see 3.3).
  • Page 20 CC8 roof-top air-conditioning system 4 Installation instructions Required equipment, special tools and accessories • For installation – Sheet metal cutter for cut-outs in the vehicle/cab roof – Mechanics tool kit – Clip pliers to install the refrigerant hoses – Hose shears •...
  • Page 21 4 Installation instructions CC8 roof-top air-conditioning system Ø 10 (6x) Cut-out in roof Sealing frame Cut-out in main frame Schematic outline of roof top unit NOTE The cut-out for the air outlet is off-centre.
  • Page 22 CC8 roof-top air-conditioning system 4 Installation instructions NOTE Section A-A does not show the dirt protection strip Connection with fitting Ident. No. 98512 SECTION A - A Cable ties and edge protection for fixing in position Coolant hose NW16 Coolant hose NW12 R min 114.3 mm...
  • Page 23 Check whether compressor mounting brackets can be obtained from the vehicle manufacturer. The vehicle chassis and engine identification numbers specified in the vehicle's registration documents will be required for this purpose. – Check the availability of the universal compressor mounting bracket from Webasto (Fig. 403) and whether it can be used. –...
  • Page 24 CC8 roof-top air-conditioning system 4 Installation instructions CAUTION Comply with the permitted installation positions of the compressor. Non-compliance will result in compressor failure. Fig. 402 Permitted compressor installation position...
  • Page 25 4 Installation instructions CC8 roof-top air-conditioning system Fig. 403 Universal compressor mounting bracket NOTE Use shims to compensate for tolerances exceeding 0.3 mm between compressor mounting bracket and each flange hole on the compressor. Manufacture of hose lines Select/determine location/routing of the hose lines (bear the diameter of screwed connections at cut-outs in mind).
  • Page 26 CC8 roof-top air-conditioning system 4 Installation instructions 4. Install the fittings General notes on the installation process NOTE Fit the hose lines with the following connections: – Intake line: Refrigerant hose NW 16 – 90° screw fitting with flange O-ring ZSB (on expansion valve), Tightening torque at flange bolt 5 Nm* –...
  • Page 27 4 Installation instructions CC8 roof-top air-conditioning system Fig. 403A Install the clip system NOTE If you do not hold the pliers at right-angles to close the clips the clips’ closure may be slightly out of position (8). In this case correct the clip closure with the pliers.
  • Page 28 CC8 roof-top air-conditioning system 4 Installation instructions For 4.3 Install the screw system – Remove anti-corrosive coatings from metal components (nipples and fitting) using a cleaning product (for example petroleum ether). – Do not strip the hose. Clamp the threaded fitting in place and screw the hose into the socket as far as it will go by turning it anti-clockwise, then turn it back (Fig.
  • Page 29 4 Installation instructions CC8 roof-top air-conditioning system Fig. 404 Making the hose lines Fig. 405 Testing hoses for leaks...
  • Page 30 CC8 roof-top air-conditioning system 4 Installation instructions 4.10 Install the roof-top unit with air ducting system or air distribution panel 4.10.1 Air duct sealing A weatherseal is to be produced using the supplied sealing strips (see Fig. 407) for curved roofs or roofs with beads and channels.
  • Page 31 4 Installation instructions CC8 roof-top air-conditioning system 4.10.2 Preparing the weatherseal 1. Cut out the weatherseal taking care to adapt its thickness to the contours of the roof (beads, channels and roof curvature), so that the contours (Fig. 406) are properly sealed.
  • Page 32 CC8 roof-top air-conditioning system 4 Installation instructions 4.10.3 Install the base frame 1. Remove the cover from the air-conditioning unit. 2. Position the base plate on the roof with the weatherseal, align it and position spacer discs underneath the six fixing points.
  • Page 33 4 Installation instructions CC8 roof-top air-conditioning system 4.10.4 Assemble the air distribution panel NOTE Depending on the version and the components supplied, the rocker switches and, if applicable, the setpoint generator switch may have to be installed in the air distribution panel.
  • Page 34 CC8 roof-top air-conditioning system 4 Installation instructions 4.10.5 Install the air distribution panel 1. Prepare the air duct weatherseal (if necessary) in such a way that it securely seals the intake and discharge sections between the vehicle roof and the intermediate ceiling at the top and all sides.
  • Page 35 4 Installation instructions CC8 roof-top air-conditioning system 10. Secure the assembled air ducting frame through the intermediate ceiling to the vehicle roof bows with self-tapping screws and fan-disk washers. Fit shims between ducting frame and intermediate ceiling to compensate for any unevenness if necessary.
  • Page 36 Hose length Oil quantity Additional oil * Air-conditioning system 240 cm + 60 cm 11 m 270 cm + 90 cm 16 m 300 cm + 120 cm *If you use the Webasto compressor (see 2.4) ** Tolerance + 30 cm...
  • Page 37 – Use strain-relief clamps. NOTE If the controls are not to be installed in the air distribution panel, a wiring harness for the external installation of the controls is available from Webasto to extend the electrical wiring to the controls in the dashboard.
  • Page 38 CC8 roof-top air-conditioning system 4 Installation instructions 4.13 Prepare and install the refrigerant lines and condensation hoses in the vehicle CAUTION – The line openings must remain capped until immediately before their connection. – Follow the vehicle manufacturer's instructions for their installation.
  • Page 39 4 Installation instructions CC8 roof-top air-conditioning system 4.14 System leak-testing and evacuation 4.14.1 General • Moisture and air or other gaseous impurities in the refrigerant circuit cause malfunctions and may damage the air- conditioning system components. The system therefore must be thoroughly dried and evacuated (for at least 1.5 hours) before it is filled with refrigerant.
  • Page 40 CC8 roof-top air-conditioning system 4 Installation instructions 4.15 Fill the system with refrigerant 4.15.1 General NOTE The ambient temperature should be at least 20°C during the filling process. The air-conditioning system must be filled with the correct amount of refrigerant for it. Therefore it is important to weigh the refrigerant bottle before starting the filling procedure and to check its weight continuously.
  • Page 41 4 Installation instructions CC8 roof-top air-conditioning system 4.15.4 Final filling CAUTION If liquid refrigerant is topped up on the intake side (bottle upside down), the compressor will be destroyed by the hammering action of the liquid. NOTE The air-conditioning system can only be filled completely when the compressor is running.

  • Page 42: Safety Precautions

    Roof-top air-conditioning system CC8 5 Operating information Operating information Safety precautions Observe safety regulations contained in 1.4. System control CAUTION • The air-conditioning system may only be operated with the engine running to prevent the battery from discharging. • A distinction must be made between two cases to prevent leaks at the shaft seal of the compressor: –...
  • Page 43 5 Operating information Roof-top air-conditioning system CC8 Controls and indicators Two rocker switches (Fig. 501) are used to control the roof-top air-conditioning system. As an option a temperature con- troller (command value switch) or a rocker switch for the fresh air ventilation flap may be installed.
  • Page 44 Roof-top air-conditioning system CC8 5 Operating information Operating instructions NOTE Observe operator’s instructions. Before starting operation, ensure that: • the air-conditioning system is in perfect working order; • scheduled maintenance / checks have been performed; • air inlets and outlets are unobstructed (no leaves, etc.);...
  • Page 45 5 Operating information Roof-top air-conditioning system CC8 Page for own notes...
  • Page 46 Roof-top air-conditioning system CC8 6 Maintenance Maintenance Safety precautions Observe safety regulations set out in 1.4. General 1. Work on the refrigerant circuit may only be performed by skilled personnel and authorized workshops. 2. The specific equipment, special tools and accessories detailed in 4.3 are required and must be used for servicing the air-conditioning circuit.
  • Page 47 6 Maintenance Roof-top air-conditioning system CC8 CAUTION A jet of air or water must never be aimed directly towards the fins, otherwise they may be damaged! 5. The receiver-drier must be replaced at least once a year and whenever work is performed on the refrigerant circuit.
  • Page 48 Roof-top air-conditioning system CC8 6 Maintenance 2. Condition of hoses: – No cuts, squeezing, blisters, chafing – Clamps and quick-release couplings undamaged – Openings in metal undamaged. 3. Condition of air distribution panel or air ducting system: – Attachment points / screws secure –...
  • Page 49 6 Maintenance Roof-top air-conditioning system CC8 6.6.4 Refrigerant circuit If faults develop in the refrigerant circuit, the system must be checked and properly repaired by an authorized repair shop. Under no circumstances may refrigerant be discharged into the atmosphere (refer to Section 8 of the regulation dated 6 May 1991 banning the use of CFCs and halones).
  • Page 50 Roof-top air-conditioning system CC8 6 Maintenance Post-repair procedures and testing 6.8.1 Check refrigerant pressures and pressure switches function tests 1. General Every air-conditioning system filled with refrigerant is in a state of overpressure, which is equal throughout the system circuit and which depends on ambient temperature.
  • Page 51 6 Maintenance Roof-top air-conditioning system CC8 6.8.2 Replenishing partially filled systems with refrigerant 1. General information Normally there is no consumption of refrigerant. A loss of refrigerant may only occur due to leaks after some time of operation. The performance of the air-conditioning system will be reduced if the refrigerant level drops below the minimum level.
  • Page 52 Roof-top air-conditioning system CC8 7 Circuit diagrams Circuit diagrams Fig. 701 Circuit diagram, basic version...
  • Page 53 7 Circuit diagrams Roof-top air-conditioning system CC8 Fig. 702 Circuit diagram, thermostat version...
  • Page 54 Roof-top air-conditioning system CC8 7 Circuit diagrams Fig. 703 Circuit diagram, fresh air and thermostat version...
  • Page 55 7 Circuit diagrams Roof-top air-conditioning system CC8 Page for own notes...
  • Page 56 Roof-top air-conditioning system CC8 8 Tightening torques for some spare parts Tightening torques for some spare parts Ident No. Designation Torque 63960B Hood ZSB, basic version 6 Nm (11x) 98529B Hood ZSB, deluxe version 6 Nm (11x) 63956B Exterior air screen, hood...
  • Page 57 8 Tightening torques for some spare parts Roof-top air-conditioning system CC8 Page for own notes...
  • Page 58 Roof-top air-conditioning system CC8 9 Warranty claims Warranty claims • Period of warranty 2 years (except compressor with warranty for 1 year). • Components subject to normal wear (e.g. receiver-drier, air filter, refrigerant, etc.) and components which are not handled properly are excluded from warranty.
  • Page 59 9 Warranty claims Roof-top air-conditioning system CC8 Page for own notes...
  • Page 60 Die Telefonnummer des jeweiligen Landes entnehmen Sie bitte dem Webasto Servicestellenfaltblatt oder der Webseite Ihrer jeweiligen Webasto Landesvertretung. Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Deutschland Besucheradresse: Friedrichshafener Str. 9 82205 Gilching Deutschland Technical Extranet: http://dealers.webasto.com Nur innerhalb von Deutschland Tel.:...

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