Assembly and Installation Manual

Assembly and Installation Manual

TYPE:

ECOWIND 350 ECC

MODEL:

350 “C” - AUS 12/24 V

vers. 03 - MY 2010

AIR-CONDITIONING SYSTEM

MANUFACTURER:

ADDRESS:

DOCUMENT TYPE:

PRODUCT:

Pn:

LOMBARDINI S.r.l.

Via Cav. Del Lavoro,

A. Lombardini, 2 . 42100 - Reggio Emilia (Italia)

Tel. + 39 - 0522 3891

Telefax + 39 - 0522 389503

E-mail [email protected]

Assembly and Installation Manual

AIR-CONDITIONING SYSTEM

793866 - 793867

TYPE :

ECOWIND 350 ECC

MODEL:

350 “C” - AUS 12/24 V

CONFORMITY:

G

B

SERVICE LOMBARDINI -

TEL. 0039 - 0522 / 389550

TEL. 0039 - 0522 / 389547

TEL. 0039 - 0522 / 389568

3

4

CONTENTS

1 WARNINGS AND GENERAL INFORMATION .............................................................................................6-9

1.1

1.2

1.3

1.4

INTRODUCTION ..............................................................................................................................6

RECOMMENDED OIL ...................................................................................................................6-7

IDENTIFICATION PLATE ................................................................................................................9

DIRECTIVE AND STANDARD REFERENCES APPLIED ................................................................9

2 GENERAL DESCRIPTION AND TECHNICAL DATA ..............................................................................10-14

2.1

2.2

2.3

TECHNICAL CHARACTERISTICS ...........................................................................................10-12

CHARACTERISTICS OF COOLANT .............................................................................................13

CONVENTIONAL COOLING CYCLE 350 C ...................................................................................14

3 ASSEMBLY AND INSTALLATION ...........................................................................................................15-59

3.1

3.2

3.3

3.4

3.5

3.6

REQUIREMENTS AND REGULATIONS FOR ASSEMBLY AND INSTALLATION ........................15

LIFTING, HANDLING AND INSTALLATION OF THE COMPONENTS ..........................................16

POwER UNIT ASSEMBLY KIT ..................................................................................................16-17

POwER UNIT FRAME CLAMP KIT ...........................................................................................18-23

INSTALLATION OF CONDENSING UNIT .................................................................................24-31

CONNECTION FITTINGS - GAS HOSES ................................................................................32-36

3.7

3.8

3.9

3.10

3.11

HOSES AND CABLE CONNECTIONS TO POwER UNIT ........................................................37-39

CONNECTING DIESEL TO THE POwER UNIT .......................................................................40-41

INSTALLATION OF THE SPLIT UNIT .......................................................................................42-44

FASTENING THE PIPES AND CABLES ...................................................................................45-56

FILLING THE GAS CIRCUIT wITH R 134A .............................................................................56-57

4 DIAGRAMS AND WIRING ........................................................................................................................58-61

4.0

DIAGRAMS AND wIRING 12 V .................................................................................................58-59

DIAGRAMS AND wIRING 24 V .................................................................................................60-61

5 TROUBLESHOOTING ..............................................................................................................................62-67

5

WARNINGS AND GENERAL INFORMATION - 1

1.1. INTRODUCTION

Important warnings

To safeguard authorised installation technicians, and to prevent the possibility of damage to the equipment, make sure that you are familiar with the entire contents of the instruction manual before performing any operations on the system.

Intended readers of the assembly and installation manual

This manual is for:

- authorised technicians specialized in assembly and installation of the equipment.

Limited liability

ECOwIND by Lombardini declines all responsibility for damage caused to persons or things resulting from incorrect installation of the system.

Storage of the manual

This manual must be intact and fully legible in all parts. Authorised specialist technicians must have access to it during their work.

Storage of the manual

The copyright of this manual is owned by ECOwIND by Lombardini.

The text of this manual cannot be used in other printed matter without the written authorisation of ECOwIND by Lombardini.

© ECOwIND by Lombardini

THIS MANUAL IS PROPRIETY OF ECOwIND BY LOMBARDINI – ALL FORMS OF REPRODUCTION, PARTIAL OR OTHERwISE,

IS STRICTLY PROHIBITED.

1.2. Recommended oil

PAKELO KRIPTON 10 W 60 - specification API CH-4/CF SL, ACEA E4,E5,E7,B4.

NOTE! Alternatively, we reccomend using the following oil: MOBIL 1 15W50 specification API CF ACEA E4, B4,

B3.

The engine could be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil as its combustion could sharply increase the rotation speed.

Use a suitable oil in order to protect the engine.

The lubrication oil influences the performances and life of the engine in an incredible way.

The risk of piston seizure, jammed piston rings and rapid wear of the cylinder liner, the bearings and all moving parts increases if oil whose characteristics differ from the recommended type is used, or if the oil is not regularly changed. All this notably reduces engine life.

Oil viscosity must suit the ambient temperature in which the engine operates.

Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the oil is inevitable, you are advised to thoroughly wash your hands with soap and water as soon as possible.

Appropriate protective gloves etc should be wore during this operation.

Old oil is highly polluting and must be disposed of in the correct way. Do not litter.

LUBRICANT INTERNATIONAL SPECIFICATIONS

They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind.

A.P.I

MIL

: ( American Petroleum Institute )

: Engine oil U.S. military specifications released for logistic reasons

ACEA : European Automobile Manufacturers Association

6

1 - WARNINGS AND GENERAL INFORMATION

ACEA REGULATIONS - ACEA SEQUENCES

PETROL

A1 = Low-viscosity, for frictions reduction

HEAVY DUTY DIESEL ENGINES

E1 = OBSOLETE

A2 = Standard

A3 = High performances

LIGHT DUTY DIESEL ENGINES

B1 = Low-viscosity, for frictions reduction engines )

B2 = Standard

E2 = Standard

E3 = Heavy conditions (Euro 1 - Euro 2 engines )

E4 =Heavy conditions (Euro 1 - Euro 2 - Euro 3 engines )

E5 = High performances in heavy conditions (Euro 1 - Euro 2 - Euro 3

B3 = High performances (indirect injection)

B4 = High quality (direct injection)

SEQUENZE API / MIL - SEQUENCES API / MIL - API / MIL SEQUENCES

API / MIL-SEQUENZEN - SECUENCIAS API / MIL - SEQUÊNCIAS API / MIL

API

DIESEL

BENZINA - ESSENCE - PETROL

BENZIN - GASOLINA

CH-4 CG-4 CF-4 CF-2 CF CE CD CC SC SD SE SF SG SH

SJ SL

MIL

L- 46152 D / E

CORRENTI - CURRENT OBSOLETI - OBSOLETE

-

40

-

35

-

30

-

25

-

20

-

15

-

10

SAE 10W*

-

5 0

+

5

SAE 20W*

+

10

+

15

+

20

+

25

+

30

SAE 30*

SAE 40*

SAE 10W-30**

SAE 10W-40**

SAE 15W-40 **

SAE 15W-40 **

+

35

SAE 20W-60 **

SAE 10W-60**

SAE 5W-30 ***

SAE 5W-40 ***

SAE 0W-30 ***

+

40

+

45

+

50

Gradazioni SAE - Viscosité SAE - SAE Grade

SAE Viskositätsklasse - Viscosidad SAE - Gradação SAE

SAE 15W-40 * base minerale base minérale mineral base

Mineralölbasis

Base mineral base mineral

SAE 15W-40 **

SAE 20W-60 ** base semi-sintetica base semi-synthétique semi-synthetic base

Halbsynthetische Basis

Base semi-sintetica base semi-sintética

SAE 10W-60

SAE 5W-30 ***

SAE 0W-30 *** base sintetica base synthétique synthetic base

Synthetische Basis base sintetica base sintética

7

WARNINGS AND GENERAL INFORMATION - 1

ATTENTION !!!

All power unit engines are oil pre-charged.

Guarantee that maintenance has been effected is confirmed by an adhesive with oil specifications put on engine valves cover.

Fig. 1

ATTENTION !!!

The oil quantity for a correct charging is : Qts 1,25 Liters

This quantity has to be strictly respected

ATTENTION !!!

We suggest, after any operation, to refill or replace oil and to alwasy check oil level through proper oil dipstick C.

ATTENTION !!!

Correct oil quantity is when level is near notch MAX, paying particular attention do not overpass it (fig. 2).

P

Fig. 2

8

1 - WARNINGS AND GENERAL INFORMATION

1.3. IDENTIFICATION PLATE

The air-conditioning system is manufactured in a European Union state, and therefore complies with the safety requisites of Machinery Directive 98/37/EC, in force since 23 July 1998.

This conformity is certified by the “CE” mark located on the body of the power unit, inside the front protective casing.

NOTE!

Do not damage or remove the CE identification plate, even when the system is resold (fig. 3).

Fig. 3

1.4. DIRECTIVE AND STANDARD REFERENCES APPLIED

Legal provisions

Reference Title

P. D. no. 459 of 24.7.96 Implementation of EEC Directive no. 89/392 known as the Machinery Directive

L. D. no. 476 of 4.12.92 Implementation of EEC Directive no. 89/336 regarding Electromagnetic Compatibility (EMC)

Table 1-1

EU Directives

Reference Title

EU Directive no. 98/37

Machinery Directive 89/392/EEC codified 98/37

EU Directive no. 89/336 Electromagnetic Compatibility (EMC)

Directive 2000/2/EC

Directive regarding electromagnetic compatibility (EMC) for agricultural and forestry tractors.


Directive regarding electromagnetic compatibility (EMC) for motor vehicles and their trailers.


Directive regarding electromagnetic compatibility (EMC) for motor vehicles.

ECE R10

ECE/UN regulation regarding electromagnetic compatibility for motor vehicles.

Table 1-2

9

GENERAL DESCRIPTION AND TECHNICAL DATA - 2

2.1

TECHNICAL CHARACTERISTICS

Table of technical data

Air-conditioning system

Model

350 “C” - AUS

Dimensions and weight

Length

Height

Depth

Weight

* Without support structure

Power unit

710 mm

560 mm

290 mm

110 kg *

Condenser

560 mm

360 mm

120 mm

6 kg

Split (diffuser)

560 mm

360 mm

140 mm

10 kg

350 “C” AUS

Fuel

Maximum fuel consumption

Cooling capacity

Coolant

Quantity of coolant

Diesel for automotive use

(taken from the vehicle’s own tank for models installed directly in vehicles)

0,7 litre/ h

13.000 btu/h (3.800 w)

R-134a min 1000 ÷ max 1200 gr. *

The amount of gas may vary according to pipe length see

Tab. 1 and Tab. 2

Optimum operating pressure: Delivery pressure HP = 14 ÷ 17 bar - @ 30° C ext. temp.

Intake pressure LP = 1 ÷ 3 bar - @ 30° C ext. temp.

ATTENTION !!!

It is important to comply with the above quantities.

Non-observance of this recommendation could compromise the performance of the system

Onboard electrical power supply

12 V

Battery recharge capacity (alternator)

70 A - MAX

Evaporator airflow

600 m

3

/h - MAX

Control system power supply

12 Vdc

24 V

40 A - MAX

600 m

3

/h - MAX

24 Vdc

10

2 - GENERAL DESCRIPTION AND TECHNICAL DATA

TAB 1

TAB 2

11


TAB 3

TAB 4

TAB 5

The AGIP BETULA ESX are synthetic lubricants formulated with selected polyolesters with superior characteristics which make them suitable for lubrication of compressors where HFC refrigerants are used (supplied in Kit)

12

2 - GENERAL DESCRIPTION AND TECHNICAL DATA

2.2 CHARACTERISTICS OF COOLANT

Recommended products: Fluorocarbon coolant R-134a - ( TETRAFLUORETHANE ).

Non-recommended Products: Compressor oil: PAG SP 20 or equivalent ( see chart oil ) Tab 5

ATTENTION !!!

– All coolants not mentioned in the “recommended products” section are not to be considered for use, are inappropriate and hence prohibited.

Lombardini S.r.l declines all responsibility for damage to persons or things caused by non-observance of this regulation.

Safety warnings: It is important to observe the following safety regulations when carrying out maintenance on the system:

ATTENTION !!!

fluorocarbon coolants evaporate rapidly, freezing anything with which they come into contact, if accidentally released in liquid form into the atmosphere. Furthermore, in the presence of flames or electrical short circuits, they may produce toxic gases capable of causing serious irritation to the respiratory tract.

Moreover, this kind of coolant tends to displace air, causing a reduction in the level of oxygen and the risk of suffocation.

Always take precautions when working with coolants or on air-conditioning systems that contain coolants, particularly in closed or confined spaces.

ATTENTION !!!

First aid treatment in the event of contact with the coolant.

Contact with EYES:

• if there is contact with the liquid, rinse thoroughly with water and seek immediate medical attention.

Contact with SKIN:

• rinse the area with plenty of lukewarm water and stay calm;

• wrap the burns in thick, dry, sterile bandages to protect the area from further infections or wounding;

• seek medical attention.

INHALATION:

• immediately remove the patient to the open air and, if necessary, help him/her to breathe again;

• seek medical attention and remain with the patient until the arrival of professional help.

13

2.3 Summary diagram of the


air-conditioning system for model :

350 “C”

CONVENTIONAL COOLING CYCLE

The diagram in Tab 6 shows the flow chart of the conditioning process:

HP) High pressure - Compression (min 10 ÷ max 27 - bars _coolant R 134 a);

LP) Low pressure - Intake (min 1 ÷ max 5 – bars_coolant R 134 a);

N.B.: Optimal values for a correct functioning of the system ; are 1.5÷2 suc 13÷17 disc (bar) - @ ext Temp - Tp 30° C

Tab. 6

LEGEND:

1 COMPRESSOR AC;

2 AC CONDENSER;

3 DEWATERING FILTER;

4 EXPANSION VALVE;

5 EVAPORATOR AC;

14

GAS R134a LOW PRESSURE (LP)

GAS R134a HIGH PRESSURE (HP)

3 - ASSEMBLY AND INSTALLATION

3.1 REQUIREMENTS AND REGULATIONS FOR ASSEMBLY AND INSTALLATION

Preliminary requirements

Listed below are the fundamental requisites that must be observed by persons installing and assembling the conditioning system.

air-

Before proceeding with the operations it is necessary to:

• make sure there exists no critical interference in any of the operating conditions. In particular, make sure that the safety conditions of all moving components are stable;

• make sure that parts do not rub together, with the risk of wear, by tightening and positioning correctly;

• make sure that there is proper electrical insulation and that fuses and all components on the electrical system are installed correctly;

• after loading the coolant, perform a careful inspection for gas leaks and check system pressure;

• all operations should be carried following standards of good technical practice;

• protect all fissures or perforations made during installation with anti-rust product.

Characteristics of lifting equipment

The power unit should be lifted with equipment that is:

• suitable for the dimensions of the unit;

• in good working condition.

ATTENTION !!!

Lifting equipment must have a lifting capacity 20% above the weight of the object that is lifted.

Rules for authorised installers

Authorised technicians must observe the following regulations:

• do not linger or pass under the units that are handled during lifting or transport;

• do not move or rotate lifted units by their cables or pipes;

• use appropriate and safe equipment when working above the vehicle. Do not climb parts of the system or the vehicle.

ATTENTION !!!

Owing to the numerous types of equipment developed for vehicles available on the market, (oversized fuel tanks, custom-built glove compartments etc...) and to the increasingly smaller anchor spaces, the assembly solutions provided in this manual are principally intended for “STANDARD FACTORY” vehicles.

It is therefore clear that the assembly solutions to be used for an already customised vehicle (by the customer and/or dealer) must be evaluated by the installer and agreed in advance with the final

customer.

15

ASSEMBLY AND INSTALLATION - 3

3.2 LIFTING, HANDLING AND INSTALLATION OF THE COMPONENTS

Procedure for installation and assembly

INSTALLATION OF THE SUPPORT STRUCTURE OF THE POWER UNIT

Step Description

1

Make sure the vehicle is on a level surface and is at a complete rest.

3.3 POWER UNIT ASSEMBLY KIT

Fig. 4

Legend:

1. Screw TE UNI 5740.65 M14x25 ..................... n° 4

2. Screw TE UNI 5740.65 M14x40 ..................... n° 6

3. Screw TE UNI 5740.65 M14x50 ..................... n° 4

4. Nut self lock M14 ........................................... n° 10

5. Nut self lock M6 ............................................. n° 12

6. washer Ø 15x25x2,5 ...................................... n° 18

7. Nut self lock M10 ........................................... n° 4

8. wascher Ø 10 .................................................. n° 4

Screws to fix the frame

16


ATTENTION ! ! !

Assemble the entire support structure on the workbench before attaching it to the frame.

WARNING

The holes, F1 and F2 indicate on brackets “7” are not drilled, because their to be drilled during the installation and also must be considered the kind of vehicle frame .

The minimum height H recommended of power unit frame S to the floor, must be at measurement as showed in fig. 6 pag. 18.

F 1

S

F 2

Fig. 5

Tab. 7

17


3.4 MOUNTING DIRECTLY TO THE SIDE FRAME

STEP 1

After mounting on bench the power unit frame S , attach the vertical bracket V at the vehicle frame F as reported on fig. 6.

WARNING

We advice to install the frame power unit S with a deep H not less at 300 mm for more safety against the conformation of kind of floor.

S

F

Frame Truck

GROUND H = 300 mm (min)

Fig. 6

STEP 2

After the operation to position the frames S regarding F, to drill four holes of 15 mm diameter as showed in fig. 7

WARNING

For a correct installation of frame S, we recommended to drill at measurements as indicate in fig. 7.

25 mm min n° 4 hole Ø 15 mm

S

F

Frame Truck

25 mm min

Fig. 7

18


S

F

N° 4 TE

M 14x50


3

Fix the frame power unit S to the frame vehicle F see fig. 8, using the bolts supplied as reported on the exploded fig. 4 pag.16 positions 1÷8, and torque with values on tab. pag. 17

Fig. 8

19



4

Lift the Power Unit using the eyebolts protective casing C (fig. 9).

G on the

G

Fig. 9

C

1

Fig. 10

Fig. 11

Fig. 12

1

2


5

Unscrew and discard the four plastic protection located under the Power Unit support on the stud

M10 K (fig. 10).

D

K

D

2

Power Unit Muffler Bend (fig. 11)

1. Muffler bend

2. Coupling box

3. Coupling box nuts

3

3


6

Attach the supplied muffler bend to the power unit muffler. See Figure 12.

Insert Muffler Bend

1. Muffler bend

2. Muffler

3. Power Unit

20

1

Fig. 13

Fig. 14

1

Fig. 15

2


7

Insert the supplied coupling box on the muffler bend.

See Figure 13.

Mount Coupling Box

1. Coupling box

2. Muffler bend

1


8

Position the coupling box as shown in the picture and tighten the two nuts with the appropriate tool.

See Figure 14.

Tighten Coupling Box Nuts

1. Coupling box nuts, qty. 2

T1

B

T2


9

Temporarily disassembly the side bracket B (Dx) as showed in fig. 15, and keep the bolts T1 and T2.


10

Insert the power unit P into the support frame S as indicate in fig. 16

Fig. 16

S

P

21

P

Fig. 20

C

Fig. 17

B

A2

B

A1

Stud M10 (x4)



11

Insert the side bracket B before disassembled into the plastic air intake C thought the two eyes A1 and

A2 as showed in fig. 17


12

Fix again the side bracket B at frame S with the bolts

T1 and T2 previously stored as showed in fig. 18 – 19.

Fig. 18

Fig. 19

T2

S

Stud M10 (x4)

B

T1

S

S


13

Fix strongly the power unit P at the support frame S half bolts M 10 supplied end the four threaded stud

K. See fig.20, with torque reported on tab. 7 pag. 17.

K

22


. Note weel

In the pictures (fig. 21 and fig. 22) is reported the position to oil drain for maintenance engine

Fig. 21 oil drain hole

Fig. 22 oil drain cap

Attention !!!

When the Power Unit has been fixed, it is advisable to firmly tighten the eyebolts on the protective casing see fig. 23).

If choosing to remove them from the protective casing, make sure to tighten the four TBEI M8x20 to support the eyebolts by following the same procedure, in order to avoid a possible noise increase from the diesel engine of the Power

Unit.

Fig. 23

23


1

3.5 INSTALLATION OF THE CONDENSING UNIT

Disassembly to condenser unit C fig. 24-25 the air plastic cover B complete with fan condenser F , unscrew and keep the bolts N° 4 TCEI M6x16, washer ( V+R ) see fig. 24

F

B

V + R

B

C

Fig. 24 Fig. 25

2

3

Place the condenser C on the back of cab and in same time to keep it in horizontal position for a correct mounting.

To mark the four point L on the condenser bracket needful to fix the four threaded insert T (supplied) fig. 27 like measurements reported in fig. 26

Use a drill to 9 mm, and to drill the four points marked for fix the four threaded insert T, fix the insert threaded T (supplied) on the metal cab using the specific tool M (not supplied) see fig.27

L

500 mm

C

L

M

L

Fig. 26

L

Fig. 27

T

24


4

Install and fix the condenser C on the back of the cab using the bolts (supplied) F, TE M6x35 and washer Ø 6x18, before the fixing interpose the four spacers D 30 – H 15 (supplied) as showed in fig.29-30

C

C

F

Fig. 29

D

Fig. 28

D

Fig. 30

WARNING

If you choose for fixing to condensing unit, in other position on truck (than the recommended on rear cab as before specified), need that the new position is ensured optimum fastening and at the same time in an area where the air cooling condenser is free to flow in the field open to avoid damaging hot air recirculation function compromising optimal works system!

25


1

GAS PIPES FIXING TO BACK OF THE CAB.

1st OPTION

Disassembly and scrap from the condenser

C the two rubbers T and then mounting the new two rubbers (protection pipe) G supplied as showed in fig.31-32

S

T

G

G

Fig. 31 Fig. 32

2

Unscrew and scrap the plastic cap TP drier protection F, and then inlet the 100 ml of oil compressor O supplied. see fig. 33-34

O

Tp

F

Fig. 33 Fig. 34

3

Insert the gas pipes G6 – G8 and cable wiring CE through the rubbers as showed in fig.35-36

Lock the fittings R1 and R2 to the condenser C with torque value like reported on tab. 8 pag.36

R1

R2

C

G6

G8

G8

FP

CE

G6

Fig. 35 Fig. 36

26

O


4

5

Bended the wiring cable CE to gas pipe , half plastic band FP supplied, as showed in fig. 36

Reassemble the plastic cover condenser CC complete the wiring connection half to connector PK (fan) and SS (pressure switch) see fig. 37. Ensure the plastic cover condenser CC to condenser C half bolts preserved V + R.

PK

CC

SS

Fig. 37 Fig. 38

CC

Fig. 39

6

Complete gas condenser installed (rear cab) with gas pipes on back see fig. 38

27


C

R2

Fig. 40

G6

GAS PIPES FIXING TO SIDE OF THE CAB.

2nd OPTION

R1

T

G8

1

Insert directly the two pipes gas G6 and G8 to condenser C and Lock the fittings R1 and R2 to the condenser C sse. Fig. 40, with torque value like reported on tab. 8 pag.36

WARNING: do not disassembly the two rubbers T

CE

FP

2

Bended the wiring cable CE, to gas pipe half plastic band FP supplied, as showed in fig. 41

Fig. 41

28


Air shroud ( Cc)

Electric fan (V)

3

Make the eye on plastic cover condenser CC for crossing pipes gas G6, G8 and wiring cable CE with measurements reported in fig. 42-43

NB:

Operation required only for install pipes, side to condenser Gas

C like fig. 40÷41

50 mm

Fig. 42

Ø 34 mm

Slot ( K )

Fig. 43

Follow the procedure described below using a 34 mm diameter hollow mill fig. 44 and make a hole conforming to the measurements shown in fig. 42

Cut out the strip from the casing, removing it towards the outside, to obtain the opening

K (fig. 43-45).

Fig. 44

29

Fig. 45

CC

PK

Fig. 46

SS

C


5

Reassemble at the condenser C the plastic cover condenser CC modified see. Fig. 48 complete with electric connections half connectors PK (fan condenser) and SS (pressure switch) see fig. 46

Ensure the plastic cover condenser CC at the condenser C half bolts V + R preserved.

6

Complete gas condenser installed (rear cab) with gas pipes to side condenser see. fig. 47

Fig. 47

CC

Fig. 48

30


31


3.6 CONNECTING FITTINGS - GAS HOSES


1

Insert clamps CX (Clic) into the gas pipes Q, (no. 3 clamps) n° 140 for pipe G6, n° 160 for the pipe G8 and no. n° 185 for pipe G10 as shown in Fig. 49

Then insert the fittings (UNF) into hoses

Q, tighten them with the clamps using the special pliers P (Fig. 50-53) not supplied with the equipment.

NB: The clamps (Clic) must be positioned as showned on Fig. 56 pag. 34

WARNING

Make sure that the sealing gaskets (OR), provided inside the accessory packet, are correctly seated (fig. 60 pag 36 ).

NB. Attention

Use CLIC clamps supplied with the equipment, related to correspondent rubber hose external diameters.

The CLIC clamp code is indicated on the same.

G10 G8

G6 CX

N° 185

N° 160 N° 140

Fig. 49

20 mm

0,78 inc

18 mm

0,70 inc

15 mm

0,59 inc

Q

32


WARNING!!

Only use the “clic 205” pliers



to tighten the clic clamps (fig. 50 ) Green/Orange.

A tight seal between the pipe and the union may not be ensured if this is not respected.

Lombardini is not responsible for any damage to people, animals and things if the tools reported in this manual are not used!!

P

green

NB

orange

Fig. 50 Fig. 51

attention

Lombardini Pn: ED0072 227 0 - Be order separately ( not supplied in Kit Ecowind )

Caillau Pn : 54 0 000 205

Alternatively, use pliers P1 Caillau “ Clic 201 “ -

Caillau Pn: 54 0 000 201 – Not supplied to Lombardini

green green

Fig. 52

P1

Fig. 53

33


FITTINGS MOUNTING


1

Insert the clic clamp C as measurements indicate in fig. 49 on rubber gas hose T as showed in fig. 54

C

T

Fig. 54

C

Fig. 55

R

S

HR

T


2

Concluded the fitting gas R appropriate inside at rubber gas hose T complete of clic clamp C, see fig.55


3

Ended insert fitting clip fitting HR must be attach to the side S of rubber hose T and the stop bracket CF of clic clamp C must be between the two components HR+S as showed in fig. 56.

R operation, ensure that the cir-

CF

R

Fig. 56

34

Q


1

Orange

C

Fig. 57

B

F 2 P

R

C

Green


4

Before to start the clamp fittings operation, ensure that the pliers P (CLIC 205 – not supplied) to be a correct position referring to clamp clic

C as showed in fig. 57

LOCK CLAMP

GREEN = 1-B

ORANGE = 2-F

Nw:

If used a pliers P1 “clic 201” not supplied do not care placement pliers as described for the clic 205 version (step 4) because it have a specular profile see fig. 53.


5

Tighten the fitting R half pliers P and ensure that the clic clip C is closed correctly between metallic details

B + F as showed in fig. 58

P

Fig. 58


6

At the end of operations the clamping, must be guarantee between the metallic details T+C+R as showed in fig. 59

T

R

C

Fig. 59

35


OR

7

Fig. 60

Before to tighten fittings, always verify that there are the oring OR inserted see fig. 60. Remember always to lubricate and close all the fittings as recommended on tab 9 and 10

Tab . 8

Tab . 9 Tab . 10

36


3.7 HOSES AND CABLES CONNECTIONS TO POWER UNIT


1

Connect the gas delivery pipe G8 (fig. 62) to the Power Unit using a 90° union supplied.

2

Connect the gas suction pipe G10 (fig. 62) to the Power Unit using a 90° union supplied.

G 8

Tg In

G 8

Tg Out

G 10

G 10

Fig. 61 Fig. 62


3

Both diesel fuel couplings Tg in – Tg out must be connected by means of the supplied Ø 5 rubber hose to the corresponding couplings on the diesel fuel suction pipe (see fig. 73 on page 41) and clamps supplied.

ATTENTION! ! !

The diesel fuel on/off cock “R” (supplied), which is a system safety device, must be connected to the diesel fuel pipe “IN” (fig. 63), see also fig. 73 pag. 41.

Lombardini declines all responsibility for damage caused as a result of non-observance of the safety system.

Fc

R

2c

Fig. 63 Fig. 64


4

The connector bundle

P supplied fig. 66.

2c (fig. 64) must be connected to the respective FRAMATOME 3c connectors of the extension

37



5

6

Connect the cable bundle Fc from the Power Unit to the extension P supplied by inserting FRAMATOME connectors

2c, in the connectors 3c (fig. 65-66).

Connect the Power Unit’s power cables La to the supplied power cable extension Pa by joining the two connectors A1 and A2. See fig. 65-66.

NB: After this operation is complete, it is RECOMMENDED that the two connectors A1 and A2 be secured with a nylon clamp CN, as shown in figure 69.

7

After completing all connections, connect the red cable of the extension ( Pa), complete with electrical power fuse FS

(fig. 68), to the positive pole of the vehicle’s original batteries (fig. 67).

8

Next attach the other eyelet of the black cable Pa of the extension to the negative pole



of the battery (fig. 67).

WARNING: The black cable must be connected to the battery!!! And not to the frame!!!

9

WARNING

Make sure the supply red cable is firmly attached ( Pa ) , avoiding points that are mobile or subject to rubbing, and not allowing it to hang, to prevent tearing or contact with the vehicle frame which might cause damage to the electrical/electronic circuit in the system or the vehicle’s battery.

La

Fig. 65

Pa

Red Cable

Fc

A1

P

Black Cable

Fig. 66

A2

+ 12

+ 24

Fig. 67

BATTERY



38

Fig. 68

FS min 200 A - 12 V min 100 A - 24 V

2c

3c


1

3

2

1

10

After attaching the connectors toghether, insert the two plastic clamps supplied and fasten the battery connectors fig. 69.

Security Harness Connector

1. Plastic clamps, qty. 2

2. Connector, power unit side

3. Connector, battery power cable

Fig. 69

39


3.8 CONNECTING DIESEL TO THE POWER UNIT

Fig. 70

1 2

3

Legend:

1. rubber hose Ø 5 mm ..................................................6 m

2. self-threading screws ...............................................qty 5

3. clamps .....................................................................qty 4

4. suction pipe .............................................................qty 1

5. gasket ......................................................................qty 2

Supplied in Kit

5

*

4

1

2

Find a flat position on the upper part of the vehicle’s tank.

Bore using a hollow mill Ø 34 mm, taking care to prevent the cut disc and milling chips from falling into the tank (fig. 71).

Fig. 71

3

Bore using a Ø 3 mm bit after tracing the fixing points of the suction pipe, using the gasket G as the template

(fig. 72)

Fig. 72

40



4

Cut the metal suction pipe to the appropriate size as in figure 73.

Suction pipe (P)

IN

OUT

ON/OFF cock

FUEL

IN

OUT

Tank (S) min 100 mm Panel Power Unit

Fig. 73


5

Attach the suction pipe the two (fig. 74-75).

P to the tank S using the supplied self-threading screws, placing the rubber gasket G between

G

Fig. 74


6

For tank with cylindrical shape, we suggest to use 2 rubber gaskets G fig 70

*


7

Connect the suction pipe P to the Power Unit PW, via the supplied rubber hose and metal clamps (fig. 76).

Fig. 75

ATTENTION! ! !

Fig. 76

The fuel intake pipe (IN) of the suction pipe (P) must be connected to the safety cock (R) (fig. 73) and to the coupling IN on the Power Unit.

NON-OBSERVANCE OF THIS STEP COULD PREVENT THE SYSTEM FROM FUNCTIONING! ! !

41


3.9 INSTALLATION OF THE SPLIT UNIT


1

Loosen and remove the 8 self-threading screws N holding the four sides of the cover M and remove it by disconnecting the connectors C. Take care not to disconnect the cables on the inside split fig. 77-79.

WARNING

The position of the split unit inside the cab must be agreed between the installer and the final customer (vehicle owner) before installation.

Fig. 77

Fig. 79

P

M

N

EC

P

Fig. 78

Bore Ø 34

UP

O

P

DOWN

J

42

Fig. 80


INSTALLATION OF THE SPLIT-UNIT


2

Position the counter frame O fig. 78 supporting the split unit inside the cab. Use the split unit as a template taking care to place it against a flat wall and to keep it ABSOLUTELY HORIZONTAL.

3

4

5

WARNING

The counter frame unit (O) must be correctly positioned in conformance with the above instructions, to prevent condensed water from leaking out.

Then mark 9 boring points referring to the holes P on the counter frame and keeping to the measurements shown in the diagram in fig. 81 ( * ).

Using a Ø 6mm bit, bore 9 holes in the marked places.

Firmly secure and attach the counter frame O using the supplied “Graf J” rivets fig. 80.

N.B. : Before attaching the split unit to the cab, make holes to pass pipes and cables !!!

( * F ) n° 9 holes Ø 6 mm

WARNING!

Pay special attention and take particular care during the drilling phases, to prevent the cab internal upholstery from being damaged!!

Fig. 81

RECOMMENDATION FOR BORING PROCEDURE


6

Using a hollow mill, bore through the pressed cardboard wall inside the cab and the sheet metal of the rear of the cab, in the same position as the existing openings on the counter frame for the passage of the following connections: fig. 82 ( Q): gas pipes (make opening only in inner wall) Ø 34 mm;

( R): electrical system Ø 50 mm;

( S): condensation drainage pipe Ø 34 mm.

Bore Ø 50 “R”

3 rubber cable guides G

Bore Ø 34 “Q”

Bore Ø 34 “S”

Ø 50 ONLY

FOR “R” WIRING

CABLE

Fig. 82 Fig. 83 Fig. 84


7

After the drilling operations are completed, insert the 3 supplied in the exterior metal of the cab (fig. 84).

G rubber cable guides into the holes to 34 mm and made

N.B.: The rubber to wiring R are already assembled on the external cable EC

43



8

During the SPLIT fastening phase, accurately check if the latter is fixed as shown in figure 85, pos.

If the wall inside the cab is tilted on the front, use two bored spacers D with a min. internal Ø of 6.5 mm, (not supplied due to the continuous dimensional variability H).

They must be inserted in the two lower pins P on the counter frame, as shown in fig. 78, pos. down.

1.

WARNING!

It is strictly forbidden to fix the SPLIT as shown in fig. 85, pos. 3.

Non-observance of this regulation could lead to drainage problems of the condensation produced by the SPLIT that may leak inside the cab.

Lombardini S.r.l declines all responsibility for damage to persons or things caused by non-observance of this regulation.

OK

OK NO

Fig. 85

44


3.10 FASTENING THE PIPES AND CABLES - Fixed cab version


1

After fixing the Power Unit / Condenser / Split unit, proceed to fasten and close pipes and cables, according to the following two procedures ( fig 86).

CONDENSER/CAB METHOD

V cab

C condenser

S split unit

PU power unit

PS access points gas

B Battery

Fig. 86 battery cable

Pipe G8

Pipe G10

SPLIT cable

B

45


CONNECTING PIPES AND CABLES TO THE CONDENSER


1

After fastening the pipes and cables to the vehicle frame, proceed by passing the tube bundle towards the condenser like options 1st or 2nd to pag 26÷30.

2

Continue attaching the pipes on the outside, boring through the rear of the cab using a 3.5mm bit, and inserting the steel/ rubber clamps FG around the pipes. Fasten using the supplied self-threading screws (fig. 87).

G 6

FG

Fig. 87 Fig. 88

Attention!

Make sure that the curvature of the pipes R during passage from the vehicle frame to the back of the cab has been checked and is adequate (fig. 89)

Non-observance of this point could lead to the pipes being crushed, thereby compromising the performance of the system.

R

Condenser

R

Power Unit

Fig. 89

Attention!

Fig. 90

ECOWIND by Lombardini declines all responsibility for damage caused to things, persons, animals, the vehicle and the ECOWIND system as a result of non-observance of this regulation!!!

46


3.10_B FASTENING THE PIPES AND CABLES - Tipping cabs


1

After fixing the Power Unit / Condenser / Split unit, proceed to fasten and close pipes and cables, according to the following two procedures fig. 91

CONDENSER/CAB METHOD

V cab

C condenser

S split unit

F cab fulcrum

PU power unit

PS access points gas

B Battery

Fig. 91

Battery cable

Pipe G8

Pipe G10

split cable

B

47



2

After fastening the Power Unit, overturn the vehicle cabin and fasten the gas pipes and the electrical cables (regardless of the position in which the condensing unit has been installed) to the vehicle frame using steel, rubber and plastic clamps and a range of nuts and bolts supplied with the system, as far as the rotation fulcrum point F of the cabin, fig 92-93-94.

Fig. 92

Fig. 93

F

Fig. 94 down floor cab

Fig. 95

48


3

WARNING

4

While positioning, remember to protect the ends of the GAS G6 / G8 / G10 pipes with adhesive tape, in order to prevent entry of impurities or residues dangerous to the passage of the coolant.

when possible, use the existing original tube bundles

(fig. 95), in order to use only the plastic clamps supplied, to prevent perforation.

when this method is used, it is necessary to determine the best passage taking the pipes and electrical cables to the peripherals.


5

when the cab rotation fulcrum point ched (fig. 95), fix the tube bundle to the the cab and down floor cab (fig. 95), boring holes (Ø 3,5 mm) and using steel/rubber clamps along with self-threading screws supplied with the system.

F has been rea-



6

After fastening the pipes and cables under the cab floor, proceed with the tube bundle towards the condenser. (Attached previously) fig. 96.

7

Continue attaching the pipes on the outside, boring through the rear of the cab using a 3.5 mm bit, and inserting the steel/rubber clamps FG around the pipes. Fasten using the supplied self-threading screws fig 96.

Fig. 96

FG


8

Pipe and wiring, at the finished installation on the floor and back cab fig. 97

Fig. 97

49



9

Gas delivery pipe G8 and inlet pipe G10 must be connected with 180° unions with access points (Fig. 98 L and 99) necessary for gas recharge AC.

The position of the same must be of easy access to allow to insert gas charger station valves.

For unions tightening operations see instructions reported

G 8

G 10

Fig. 98 Fig. 99


10

ATTENTION

Regardless of the method used to attach the condenser, it is absolutely essential to create the pipe and cable circuit by passing through the cab fulcrum point F, as shown in ( fig. 100 ), in order to avoid serious damage to the system, to parts of the cab and lifting system.

ATTENTION

Lombardini S.r.l. declines all responsibility for damage caused to things, persons, animals, the vehicle and the

system as a result of non-observance of this regulation fig. 101.

Fig. 100

50

Fig. 101



11

After attaching the condenser CO connect the pipes and cables from the condenser to the split unit inside the cab.

Insert pipes G6 – G10, the split command cables W in the hole R and the condensation drainage pipe D in the rubber cable holders G and push them through the slots in the counter frame (fig. 102-103).

G

R

D

Fig. 102 Fig. 103


12

Pass them through the internal holes, previously made in the pressed cardboard attached to the counter frame O.

Make sure that the condensation drainage pipe H exits the lower hole (fig. 104).

W P

O

G10

Fig. 104

G6

H

51



13

Secure the split S to the counter frame O by sliding it onto the 4 Stud M6 P and then fasten it using Ø 6 washers and the M6 AB nuts provided (fig. 105 )

Warning!!

Before performing the operation mentioned above, make sure that the condensation drainage pipe

(H) is securely fastened to the plastic coupling (I) on the split’s base (fig. 106 ).

P

P

S

H

I

P

Fig. 105

P

Fig. 106

Warning!!

INSTALL KIT “ANTIPOLLUTION FILTER D” (SUPPLIED WITH THE EQUIPMENT*) Fig. 108 WITH

SELF-THREADING SCREWS C, AS INDICATED IN FIG. 107

C

Fig. 107

C

D

C

52

Fig. 108

D


SPLIT CLOSING


1

Connect the SPLIT/EXTENSION cable connections by joining the FRAMATOME

Cut rubber hoses T6 and T10 to the right size fig. 112.

Insert the couplings and clic clamps (fig. 111) referring to page 32÷36 for the torque.

Close the cooling circuit, inserting the fittings G6 and G10 into the expansion valve E, and fasten (fig. 113) using the flange Ff, screw Vt and washer (fig. 113).

FR connectors (see fig. 110).

1 2

3 5

6

8

LEGEND

Fig. 109

13

12 4

7

11 10

9

1 Condensation drainage pipe

2 Union G10 90° FL

3 OR G10

4 Clic clamp 185

5 Union G6 90° FL

6 OR G6

7 Clic clamp 140

8 Insulating mastic

9 Diffuser

10 Diffuser support

11 Valve flange

12 Ø 6 washer

13 TCEI M 6x16 Screw


2

Before tightening the flange on the flanged unions fig. 113, make sure that you have inserted (if not already done) the supplied OR G6 and G10 (see fig. 112).

FR

Fig. 110 Fig. 111

OR

T6

E

T10

Fig. 112

OR

53

Fig. 113

G10

Vt

Ff

G6



3

After completing the gas circuit, tape the metal union to prevent condensation infiltrating into the cab.

G10 90 using the supplied anti-condensation mastic MC (fig. 114)

MC

Fig. 114


4

Ended the gas circuit operations, remount the split S fig. 115 unit case cover C that was previously removed and secure it using the screws that were previously removed fig. 117.

FR

S

FR

PC

Fig. 115 Fig. 116


5

Before remounting the split’s protective cover (

c), make sure that the FRAMATOME FR connectors of the control panel

( Pc) is hooked up. with connector of wiring W See fig. 116

Pc c

Fig. 117

54


Fig. 118

CT


6

After mounting the system, attach the plastic pipe covering CT (supplied) as shown in the figure 118, by boring the cab rear using a 3.5mm bit and attaching with the supplied self-threading screws .


7

NB: It is recommended to use a light thread of silicone not supplied on the contact surface of the covering

CT to the sheet metal of the cab to optimise the seal see fig 119.

Use silicone only

CT

Fig. 119

55


COMPULSORY OPERATIONS!!!


1

After mounting the split unit and the pipes, in order to ensure proper drainage of the condensation in the split unit, it is

OBLIGATORY to insert the condensation dissipation terminal into the end of the condensation drainage pipe (fig. 121) and the dissipater D into the support S, if not already inserted (fig. 120).

2 Attention!

Non-observance of this regulation could lead to drainage problems of condensation inside the vehicle cab!

Lombardini S.r.l declines all responsibility for damage to persons or things caused by non-observance of this regulation.

D

S

Fig. 120 Fig. 121

3.11 FILLING THE GAS CIRCUIT WITH R 134 A

Connect the PL and PH taps of the gas charger station AC (not supplied) to the relevant access points PS (fig. 123).

WARNING!

For a correct “system vacuum” operation, a time of at least 30 minutes and a calibrated gas charge in accordance with that reported in the table 1 on page 11 (recommended).

PL

TS

Fig. 122

PS: Access points on the gas circuit

PH + PL: Recovery taps on the charger / recovery station

TS : Service pipes

56

PH

Fig. 123

PS


Frequency of system refilling.

It is recommended to refill the system with R 134 A

(TETRAFLUORETHANE) at least once a season, in order to ensure an optimum system performance.

NB: It is extremely important to observe the quantities given on page 10÷11

Safety warnings

ATTENTION

As the system is pressurised, specific operations on the thermodynamic plant must be carried out in full compliance with the regulations for systems containing HFCs and must only be performed by authorised service centre. Lombaran dini S.r.l declines all responsibility for accidents and/or damage deriving from non-observance of this regulation.

PL + PH

TS

AC

Fig. 124

ATTENTION

PRESSURIZED SYSTEM

Before performing any maintenance operations on the gas circuit, it is absolutely essential to empty the pressurised system (R 134 A) using the specific charger/recovery station.

Pay the utmost attention, when disconnecting the TS service pipes as they may contain pressurized coolant!!

Avoid direct skin and eye contact with coolant!!

NB: Wear protective goggles and gloves.

The coolant has a boiling temperature (in normal environmental conditions) of about

-26 °C (~ -14.8 °F).

Non-observance of this regulation could cause burns and serious harm to the operator!!!

It is strictly forbidden to release and/or dispose of the coolant GAS (R 134a) and the compressor lubricating oil contained in the refrigerating circuit into the environment.

ECOWIND by Lombardini declines all responsibility for damage caused to things, persons,

animals or the equipment itself as a result of non-observance of this regulation.

57

DIAGRAMS AND WIRING - 4

CABLE HARNESS 12 Volt - COD. 7971.126

58

4 - DIAGRAMS AND WIRING


59

DIAGRAMS AND WIRING - 4


60

4 - DIAGRAMS AND WIRING


61

62

TROUBLESHOOTING - 5

5 - TROUBLESHOOTING

63

64



65

66



67

68

SALE AND SERVICE

VENTA E SERVICIO

VENDITA E SERVIZIO

MANUAL CODE - CÓDIGO DEL MANUAL - CODICE MANUALE 5302.897

DOCUMENT CODE - CÓDIGO DEL DOCUMENTO - CODICE DEL DOCUMENTO

EDITION - EDICIÓN - EDIZIONE

ECOWIND - I. U. - S.I. 2010

01-12-2010 - Rev. 00

Assembly and Installation Manual

Assembly and Installation Manual

TYPE:

ECOWIND 350 ECC

MODEL:

350 “C” - AUS 12/24 V

AIR-CONDITIONING SYSTEM

MANUFACTURER:

ADDRESS:

DOCUMENT TYPE:

PRODUCT:

Pn:

TYPE :

CONFORMITY:

1.1. INTRODUCTION

1.2. Recommended oil

ATTENTION !!!

ATTENTION !!!

ATTENTION !!!

ATTENTION !!!

1.3. IDENTIFICATION PLATE

1.4. DIRECTIVE AND STANDARD REFERENCES APPLIED

TECHNICAL CHARACTERISTICS

Table of technical data

350 “C” - AUS

ATTENTION !!!

ATTENTION !!!

ATTENTION !!!

ATTENTION !!!

CONVENTIONAL COOLING CYCLE

Tab. 6

3.1 REQUIREMENTS AND REGULATIONS FOR ASSEMBLY AND INSTALLATION

ATTENTION !!!

ATTENTION !!!

It is therefore clear that the assembly solutions to be used for an already customised vehicle (by the customer and/or dealer) must be evaluated by the installer and agreed in advance with the final

customer.

3.2 LIFTING, HANDLING AND INSTALLATION OF THE COMPONENTS

3.3 POWER UNIT ASSEMBLY KIT

ATTENTION ! ! !

Assemble the entire support structure on the workbench before attaching it to the frame.

F 1

S

F 2

Tab. 7

. Note weel

In the pictures (fig. 21 and fig. 22) is reported the position to oil drain for maintenance engine

Attention !!!

When the Power Unit has been fixed, it is advisable to firmly tighten the eyebolts on the protective casing see fig. 23).

If choosing to remove them from the protective casing, make sure to tighten the four TBEI M8x20 to support the eyebolts by following the same procedure, in order to avoid a possible noise increase from the diesel engine of the Power

Unit.

3.5 INSTALLATION OF THE CONDENSING UNIT

GAS PIPES FIXING TO BACK OF THE CAB.

1st OPTION

GAS PIPES FIXING TO SIDE OF THE CAB.

2nd OPTION

3.6 CONNECTING FITTINGS - GAS HOSES

NB. Attention

N° 185

N° 160 N° 140

FITTINGS MOUNTING

3.7 HOSES AND CABLES CONNECTIONS TO POWER UNIT

ATTENTION! ! !

The diesel fuel on/off cock “R” (supplied), which is a system safety device, must be connected to the diesel fuel pipe “IN” (fig. 63), see also fig. 73 pag. 41.

Lombardini declines all responsibility for damage caused as a result of non-observance of the safety system.

3.8 CONNECTING DIESEL TO THE POWER UNIT

ATTENTION! ! !

The fuel intake pipe (IN) of the suction pipe (P) must be connected to the safety cock (R) (fig. 73) and to the coupling IN on the Power Unit.

NON-OBSERVANCE OF THIS STEP COULD PREVENT THE SYSTEM FROM FUNCTIONING! ! !

The position of the split unit inside the cab must be agreed between the installer and the final customer (vehicle owner) before installation.

WARNING!

Pay special attention and take particular care during the drilling phases, to prevent the cab internal upholstery from being damaged!!

WARNING!

OK

OK NO

3.10 FASTENING THE PIPES AND CABLES - Fixed cab version

3.10_B FASTENING THE PIPES AND CABLES - Tipping cabs

Warning!!

Before performing the operation mentioned above, make sure that the condensation drainage pipe

(H) is securely fastened to the plastic coupling (I) on the split’s base (fig. 106 ).

Warning!!

**INSTALL KIT “ANTIPOLLUTION FILTER D” (SUPPLIED WITH THE EQUIPMENT*) Fig. 108 WITH**