COACHAIR SPARE PARTS MANUAL. Heat-Cool and Cool-Only Models. Uncontrolled Copy: Please refer to the Network for the current issue of this manual

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COACHAIR XT SPARE PARTS MANUAL Heat-Cool and Cool-Only Models Document Number: SM425-3283 Revision No.

1 COACHAIR XT SPARE PARTS MANUAL Heat-Cool and Cool-Only Models Document Number: SM Revision No.: 00 Issue Date: Sep 2006 Uncontrolled Copy: Please refer to the Network for the current issue of this manual

2 Rev Date Description 00 Sep 19, 2006 First Release CR Released by S. Morley 20/09/06 Issue Date: September 2006 Page 2

3 NOTICE The information in this manual is subject to change without notice. Air International Transit shall not be liable for technical or editorial errors or omissions contained herein. No part of this manual may be photocopied or reproduced in any form without prior consent from Air International Transit. COACHAIR CUSTOMER SUPPORT INQUIRIES Australia Malaysia China Telephone: Facsimile: Address: 3 Distillers Place Huntingwood 2148 Australia Lot No. 9, Jalan Empat, Kawasan Perindustrian Selayang, Off Jalan Besar, Bandar Selayang, Selangor D.E. Malaysia Changzhou City No. 268 West Hehai Road Xinbei District, Jiangsu Province - P. R. China WEB - Issue Date: September 2006 Page 3

4 WARNING IMPORTANT INFORMATION Use R134a Refrigerant Only! The A/C system is designed for use with R134a refrigerant. Do not use any other refrigerant. The use of any other refrigerant may result in damage to the A/C unit and/or compressor. WARNING Use Ester Oil Only! The A/C system is designed for use with ester compressor oil. Do not use any other lubricating oil. The use of incorrect oil may result in damage to the A/C unit and/or compressor. WARNING NOTE Handle Electronics With Care! Do not attempt to remove, repair, or handle the climate control panel or any components in any way without referring to the correct procedures. The electrical control panel houses sensitive equipment that may be damaged if handled incorrectly. Refer to the CCC007* Climate Control System Manual for electronics service details. CAUTION CAUTION Temperature Probes Each temperature probe in the unit is factory calibrated. Use Probes as they have been allocated. DO NOT swap or mix the probes, as this may lead to unit damage and faulting. 24V DC ONLY This unit is designed for a 24V DC electrical circuit ONLY. Do not under any circumstances use another voltage, as this may cause unit damage and faulting. There is power to the motors all the time. Never attempt to do repairs on motors or motor wiring without manually breaking the correct circuit breaker first. WARNING CAUTION CAUTION CAUTION Black Heat Sink The black heat sink built onto the ESP109 PCB is at earth potential. DO NOT, under any circumstances, place an earth or a bridge circuit on the heat sink, as this will cause serious unit damage. DO NOT use a test light. Use a suitable multimeter only! DO NOT push the red reset button for more than 2 seconds, as this could provide unintentional access to the CCC007* memory settings. Issue Date: September 2006 Page 4

5 CONTENTS SECTION 1: - Rooftop Unit Components...6 SECTION 2: - Electric Motors Brushed Motors Brushless Motors Multi-Motors...12 SECTION 3: - Electrical Control Panels Electrical Wiring Harnesses Fuse for Battery Line Driver Dash Panels...16 SECTION 4: - Refrigeration Refrigeration Pipe Fittings Pressure Cut-out Switches Refrigeration Hoses...18 SECTION 5: - Other Spares Water Modulating Valve Assembly Boost Pump Assembly Condensate Line Pig Tail Compressor Bracket Compressor Clutches...21 Issue Date: September 2006 Page 5

6 SECTION 1: - Rooftop Unit Components Note: Not all components listed are present on all units. Ref Part Number Description 1 FRC9870 A/C Unit Base Assembly 2 - Evaporator Lid 3 - Condenser Lid complete with Fan Guard 4 MRG015 Fan Guard 5 - Rear Cover Panel 6 Refer Page 4,5,6,7 Evaporator Blower Motor Brushed or Brushless 7 Refer Page 4,5,6,7 Condenser Fan Motor Brushed or Brushless 8 MRB279 Condenser Fan Blade 9 MRH0021 Blower Housing 10 MRW0031 Blower Wheel Clockwise Rotation 11 MRW0041 Blower Wheel Anti-clockwise Rotation 12 PRF0070 Fresh Air Panel 13 MRR005 Evaporator Lid Seal 14 PRH999 Evaporator Lid Hinge - stainless steel 15 FRB9930 Bolt brass M6 x 20 HH SS 16 FRB9960 Bolt brass M6 x RRC498(0) Evaporator Coil (right) 18 RRC499(0) Evaporator Coil (left) 19 RRC9710 Condenser Coil (right) 20 RRC9720 Condenser Coil (left) 21 RRC480(0) Heating Coil 22 RRR026 Receiver Tank 23 RRV396 Pressure Relief Valve 24 RRV117 Liquid Port Schrader Valve 25 RRD023 Filter Drier Sight Glass Ball valve 28 RRV453(0) Solenoid Valve 29 ERC453(0) Solenoid Coil Assembly 30 RRV988 Thermal Expansion Valve 31 MSF334 Return Air Grille Assembly 32 MRV007(0) Fresh Air Door 33 ERA233(0) Fresh Air Door Actuator Assembly RRV560 Water Valve Assembly Issue Date: September 2006 Page 6

7 Issue Date: September 2006 Page 7

8 SECTION 2: - Electric Motors 2.1 Brushed Motors Brushed Condenser Fan Motor Ref Part Number Quantity Description - ERM023 Brushed Condenser Motor Assembly - Complete 1 SKB025 Bearing 2 SLA001 Armature - Single Shaft 3 SLB002 Brush Mounting Plate 4 SLB003 Brush Holder 5 SLB001 Brush 6 SLS001 Spring - Brush Issue Date: September 2006 Page 8

9 2.1.2 Brushed Evaporator Blower Motor Ref Part Number Quantity Description - ERM024 Brushed Evaporator Motor Assembly - complete 1 SKB025 Bearing 2 SLA002 Armature - Double Shaft 3 SLB002 Brush Mounting Plate 4 SLB003 Brush Holder 5 SLB001 Brush 6 SLS001 Spring - Brush Issue Date: September 2006 Page 9

10 2.2 Brushless Motors Brushless Condenser Fan Motor Ref Part Number Quantity Description - ERM9950 Brushless Condenser Fan Motor Assembly - Complete 1-2 Oil Seal (ZOS-5/8 ) 2-2 Circlips (ZCI-16) 3-2 Bearing (DRB-6203) 4 RRM Condenser Rotor Armature - Single Shaft 5-4 Wave Washer (ZWW-40) 6-4 Bolt M6 7 ERW022 1 Red wire 400x 2.5 mm 8 ERW024 1 White wire 400 x 2.5 mm 9 ERW020 1 Blue wire 400 x 2.5 mm Issue Date: September 2006 Page 10

11 2.2.2 Brushless Evaporator Blower Motor Ref Part Number Quantity Description - ERM9960 Brushless Evaporator Blower Motor Assembly - Complete 1-2 Oil Seal (ZOS-5/8 ) 2-2 Circlips (ZCI-16) 3-2 Bearing (DRB-6203) 4 RRM Condenser Rotor Armature - Single Shaft 5-4 Wave Washer (ZWW-40) 6-4 Bolt M6 7 ERW022 1 Wire 400mm x 2.5 mm - Red 8 ERW024 1 Wire 400 mm x 2.5 mm - White 9 ERW020 1 Wire 400 mm x 2.5 mm - Blue Issue Date: September 2006 Page 11

12 2.3 Multi-Motors Evaporator Blower Condenser Fan Part Number Description Part Number Description Motor & Blower Assembly Axial Fan 24 V DC Issue Date: September 2006 Page 12

13 SECTION 3: - Electrical 3.1 Control Panels For Brushed Motors Note: Not all components listed are present on all units. Ref Part Number Description 1 PMP081 Panel 2 CCC0074 Coachair Climate Controller for ESP109 CCC0075 Coachair Climate Controller for ESP189 CCC0077 Coachair Climate Controller for ESP209 3 ESP109(0) Power Board (24V) ESP189(0) Power Board (12V) ESP209 Power Board Twin Compressor 4 ERP9980 De-ice Temperature Probe - 550mm 5 ERP030 Temperature Probe - 550mm 6 ERP031 Temperature Probe 1,500mm 7 ERP037(0) Temperature Probe 2,500mm 8 ERH106(0) Data Cable - 20 Wire Ribbon With Plugs 9 ERR010 Mini Relay - 20A - 24V DC 10 ERF034 Fuse - 7.5A - Brown 11 ERR060 Solid State Relay - 25A / 27 V DC 12 ERC015 Circuit Breaker - 15A - Manual Reset ERC011 Circuit Breaker - 20A - Manual Reset 13 ERC541 Spike Protection Capacitor 14 ERS018(0) Switch - Ignition Isolator * Refer to the original item that is to be replaced to locate the correct part number. The part number is marked on the item. If in doubt, contact Coachair. (Typical panel shown) Issue Date: September 2006 Page 13

14 3.1.2 For Brushless Motors Note: Not all components listed are present on all units. Typical Electrical Control Panel EAC Ref Part Number Quantity Description 1 EAC Electrical Panel 2 CCC Coachair Climate Controller Brushless Motor 3 ESP Power Board 4 ESP De-ice Evaporator Temperature Probe - 550mm 5 ESP Return Air Temperature Probe - 550mm 6 ESP Ambient Temperature Probe mm 7 ESP Air off Evaporator Temperature Probe mm 8 ESH Data Cable 9 ESR Mini Relay - 25A 27 V DC 10 ESF0330, ESF0340, ESF ESC0150, ESC Fuse - 3 A Fuse A, Fuse - 15A 1 4 Circuit breaker - 15A and Circuit breaker - 20A 12 ESC Capacitor 5600uF, 40 V 13 ESS Toggle Switch 14 ESP9970* 2 Evaporator Fan Motor controller 15 ESP9960* 2 Condenser Fan Motor controller *Note that ESP9960 and ESP9970 forms the controller assembly marked with Part No. EAC997 Issue Date: September 2006 Page 14

15 3.2 Electrical Wiring Harnesses Wire Compressor Harness Wire Compressor Harness Part Number Length Part Number Length ESH2091 6m ESH3091 6m ESH2092 8m ESH3092 8m ESH m ESH m ESH m ESH m ESH m ESH m ESH m ESH m Dash Harness Battery Cable Part Number Length Part Number Length ERH0030 8m ESC m ERH m ESC m ERH m ESC m ERH m ESC0963 6m ERH m ESC m ERH m ESC m Issue Date: September 2006 Page 15

16 Earth Cable Part Number Length ERH m ERH1000 1m ERH1003 2m ERH m ERH m 3.3 Fuse for Battery Line Part Number ERF100 Description Fuse - 100A 3.4 Driver Dash Panels Part Number Description Part Number Description EAD173(0) Auto systems EAD176(0) Driver controlled systems Issue Date: September 2006 Page 16

17 SECTION 4: - Refrigeration 4.1 Refrigeration Pipe Fittings Single Flange Double Flange Part Number Description Part Number Description MRF404 Single flange - stainless steel - 57 x 65 x 10mm MRF420 Twin flange - stainless steel x 65 x 10mm Flange Gaskets Spacer Part Number MRG404 MRS404 Description Flange gasket - 40mm OD, 35mm ID, 1.5mm thick Spacer Spigot Male/Female Male Spigots Female Spigots Part Number Description MRS4049 Male Spigot - 1 1/8" - 44 mm OD MRS4042 Male Spigot - 1 1/4" - 44 mm OD MRS40412 Male Spigot - 1 3/8" - 44 mm OD MRS4048 Female Spigot - 1 1/8" - 44 mm OD (typical used on discharge line to XT Unit) MRS4041 Female Spigot - 1 1/4" - 44 mm OD MRS40411 Female Spigot - 1 3/8" - 44 mm OD (typical used on suction line from XT Unit) Issue Date: September 2006 Page 17

18 4.2 Pressure Cut-out Switches Part Number Description Cut-In Cut-Out ERS039 HP switch 200 PSI 300 PSI ERS040(0) LP switch 30 PSI 5 PSI ERS178(0) MP switch 100 PSI 150 PSI ERS237 MP switch 140 PSI 190 PSI 4.3 Refrigeration Hoses Suction Hose mm Ref Part Number Description - RSK2031 Suction Hose Assembly (1,150mm) - Complete 1 RRF711 Hose Fitting 20 FK4 2 MRF406 Compressor Flange 3 RRN701 Hose Nut MRH701 Hose R134A - 20 (length = 1,055mm) 5 MRF404 Flange coupling 6 RRF701 Hose fitting 20mm female Discharge Hose mm Ref Part Number Description - RSK2032 Discharge Hose Assembly (1,150mm) - Complete 1 RRF711 Hose Fitting 16 FK4 2 MRF406 Compressor Flange 3 RRN702 Hose Nut MRH702 Hose R134A -16 (length = 1,050mm) 5 MRF404 Flange coupling 6 RRF702 Hose fitting - 16 female Issue Date: September 2006 Page 18

19 SECTION 5: - Other Spares 5.1 Water Modulating Valve Assembly Ref Part Number Description - RRV560 Water Modulating Valve Assembly - Complete 1 ECT0632 Terminal - Male 2 ERP010 Plug - 2-Way Female 3 RRV561 Valve Actuator 4 RRV560 Valve Body 5 RRV5530 Nut 6 RRV5540 Spigot 7 FRW997 Fibre Washer 1/32" 5.2 Boost Pump Assembly Part Number RAB181 Description Water Pump 24V 5.3 Condensate Line Pig Tail Part Number Description RMP001 Condensate Line P Trap (746207) Issue Date: September 2006 Page 19

20 5.4 Compressor Bracket MAB033 Bracket - Horizontal MAB039 Bracket - Inclined 4 Part Number Description MAB033 Compressor Bracket - Horizontal MAB039 Compressor Bracket - Inclined 4 Idler Pulley Part Number MRP471 Description Idler Pulley Issue Date: September 2006 Page 20

200mm Belts 2B Part Number Description Part Number Description SLC064 φ 260mm Belts 2B + 2A SLC023 φ

21 5.5 Compressor Clutches Part Number Description Part Number Description SLC003 φ 222mm Belts 10PK SLC004 φ 160mm Belts 2B Part Number Description Part Number Description SLC006 φ 180mm Belts 2B + 2A SLC008 φ 200mm Belts 2B Part Number Description Part Number Description SLC064 φ 260mm Belts 2B + 2A SLC023 φ 202mm Belts 9PK + A Part Number SLC099 Description φ 200mm Belts 2B High Power Issue Date: September 2006 Page 21

SERVICE PARTS LIST for

T-295PL Manual SERVICE PARTS LIST for MODEL GR-60 (N.A.O.) Rooftop Air Conditioning Unit T-295PL REV. 06/202 202 Mobile Climate Control TABLE OF CONTENTS PARAGRAPH NUMBER Page INTRODUCTION... i MODEL CHART...