PETERBILT COMFORT CLASS
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1 PETERBILT COMFORT CLASS Storage Cooler System Service Improper installation or repair of auxiliary heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death. Installation and repair of auxiliary heating and cooling systems requires special training, technical information, special tools and special equipment. NEVER attempt to install or repair an auxiliary 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 the installation and repair instructions and heed all WARNINGS. The manufacture rejects any liability for problems and damage caused by auxiliary systems being installed or serviced by untrained personnel. 08/06/ :45 A COMPANY
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3 1 Foreword Foreword Specific Information Column A/N: Column Description: Indicates which parts are modified, which parts are new: A = modification N = new part Complete assembly replacement kits are identified in bold text with a part number and all included items listed below. The remarks column will state Complete Replacement Kit. Included items (marked by a bullet point) are contained in the complete replacement kit. Example: Compressor Assembly = Complete Replacement Kit Compressor = Included Item Single item service parts are identified with a part number. The remarks column will state Service Part. Items without a part number cannot be ordered separately. They are included in their respective Complete Replacement Kit assembly only.
4 2 Charging Unit Assembly Overview - Related Components Refrigerant Pressure Switch - High 2. Refrigerant Pressure Switch - Low 3. Capacitor - Run 4. Coil - Condenser 5. Tube - Refrigerant Condenser Outlet 6. Tube - Refrigerant Compressor Connection - Suction 7. Harness - 12VDC Components - Charge Unit 8. Tube - Refrigerant Bypass Valve - Suction 9. Tube - Refrigerant Bypass Valve - Discharge 10. Magnetic Solenoid Bypass Valve 11. Tube - Refrigerant Compressor to Condenser Inlet
5 Tube - Refrigerant Compressor to Condenser Inlet 2. Motor - Condenser Fan 3. PTCR - Start Assist 4. Coil - Condenser 5. Tube - Refrigerant Condenser Outlet to Filter 6. Tube - Refrigerant Filter to Quick-Connect 7. Harness - 120VAC Charge Unit 8. Fitting - Quick-Connect - Discharge 9. Fitting - Quick-Connect - Suction 10. Compressor - 8,600 Btu/hr - R134a 11. Bracket Assembly - Compressor Mounting 12. Limiter - Ambient Temperature Sensor
6 AMP AMP AMP P/N BCT010070A WARNING IMMEDIATELY GET AWAY FROM THE VEHICLE if you hear sounds of arcing inside (sizzling, sputtering or popping). Hot gases may vent from compressor terminal causing burns or ignition. Improper servicing can lead to fire, electrocution or explosion. Never service, repair or troubleshoot a system unless you are a trained service person Charging Unit - Refrigeration Compressor Components 1 1 PPC401001A Compressor Service Assembly Complete Replacement Kit 2 1 PPC301081C Compressor - 8,600 Btu/hr with caps Included Item 3 1 PPC401003A Capacitor - Run Included Item - 1 PPC301054A Nut - Hex Head M6-1 Tensilock Self-locking Dacromet Included Item - 1 PPC301025A P-Clip with Rubber - Capacitor Mounting Included Item 4 1 PPC401006A Filter Assembly Included Item - 1 PPC301022A Filter - R134a Included Item - 2 PPC301028A P-Clip - 60mm Diameter Rubber Coated Galvanized Steel Included Item - 2 PPC301054A Nut - Hex Head M6-1 Tensilock Self-locking Dacromet Included Item 5 1 PPC301093A Harness - 120VAC Charge Unit Included Item A Screw - Hex Head - Compressor ground Included Item Washer - Flat - Compressor ground Included Item 8 1 BCT010070A Decal - Warning Explosion Included Item 5 1 PPC301093A Harness - 120VAC Charge Unit Service Part 10 1 PPC401002A Compressor Mounting Hardware Complete Replacement Kit 11 2 PPC301054A Nut - Hex Head M6-1 Tensilock Self-locking Dacromet Included Item 12 1 PPC301016A Strap - Compressor Mounting Included Item 13 1 PPC301017A Bracket - Compressor Mounting Included Item A Washer - Fender M10 x 33 x 11 ZP Yellow Included Item 15 3 PPC301075A Nut - Hex Head M Tensilock Self-locking Dacromet Included Item 16 3 PPC301010A Spacer - Compressor Mounting Included Item
7 , Charging Unit - Electrical Components and Condenser 1 1 PPC301026B Harness - 12VDC Components Service Part 2 1 PPC301107A Sensor - Pressure - Low Service Part 3 1 PPC301110A Sensor - Pressure - High Service Part 4 1 PPC301098A PTCR - with Harness and Bracket Service Part 5 1 PPC301024A Limiter - Ambient Temperature Sensor - with Harness Service Part 6 1 PPC401003A Capacitor - Run Complete Replacement Kit 7 1 PPC301023A Capacitor Included Item 8 1 PPC301054A Nut - Hex Head M6-1 Tensilock Self-locking Dacromet Included Item 9 1 PPC301025A P-Clip with Rubber - Capacitor Mounting Included Item 10 1 PPC401004A Condenser Fan Assembly Complete Replacement Kit 11 1 PPC301124A Condenser Fan and Motor Included Item 12 4 PPC301053A Bolt - Hex Head M6-1 x 16mm Tensilock Self-locking Dacromet Included Item 13 1 PPC301034A Condenser Assembly Service Part
8 Charging Unit - Enclosure Panels and Hardware 1 1 PPC301008B Enclosure Tray Service Part 2 1 PPC301006A Enclosure Top Cover Service Part 3 1 PPC301082A Plate - Reinforcement - Refrigerant tube Service Part 4 1 PPC301003A Shroud - Fan Service Part 5 1 PPC301007A Grille - Front Service Part 6 1 PPC301000B Panel - Left Side Service Part Grommet ID. x 1.75 OD. Rubber Service Part 8 2 PPC301075A Nut - Hex Head M Tensilock Self-locking Dacromet Service Part 9 44 PPC301053A Bolt - Hex Head M6-1 x 16mm Tensilock Self-locking Dacromet Service Part 15 1 PPC401002A Compressor Mounting Hardware Complete Replacement Kit 16 2 PPC301054A Nut - Hex Head M6-1 Tensilock Self-locking Dacromet Included Item 17 1 PPC301016A Strap - Compressor Mounting Included Item 18 1 PPC301017A Bracket - Compressor Mounting Included Item A Washer - Fender M10 x 33 x 11 ZP Yellow Included Item 20 3 PPC301075A Nut - Hex Head M Tensilock Self-locking Dacromet Included Item 21 3 PPC301010A Spacer - Compressor Mounting Included Item 22 1 PPC401005A Bracket Assembly - Compressor Mounting Complete Replacement Kit 23 2 PPC301054A Nut - Hex Head M6-1 Tensilock Self-locking Dacromet Included Item 24 1 PPC301016A Strap - Compressor Mounting Included Item 25 1 PPC301017A Bracket - Compressor Mounting Included Item
9 7 2 PPC301126A * * PPC301125A * 10 Charging Unit - Refrigeration Circuit Components 1 1 PPC301126A Quick Connect Assembly - Fairing Mount Complete Replacement kit 2 1 PPC301101A Bracket - Enclosure Connection Included Item 3 1 PPC301092B Tube - Refrigerant - Quick Connect to Enclosure Fitting mm O.D. Included Item 4 1 PPC301014B Tube - Refrigerant - Quick Connect to Enclosure Filter - 10mm I.D. Included Item * - Assembled with items listed with an asterisk (*) in the item column Included Items 5 1 PPC301125A Quick Connect Assembly - Non-Fairing Mount Complete Replacement kit 6 1 PPC301101A Bracket - Enclosure Connection Included Item 7 1 PPC301090B Tube - Refrigerant - Quick Connect to Enclosure Fitting mm I.D. Included Item 8 1 PPC301091B Tube - Refrigerant - Quick Connect to Enclosure Filter - 10mm I.D. Included Item * - Assembled with items listed with an asterisk (*) in the item column Included Items * 1 PPC301130A P-Clip - 13mm Diameter Rubber Coated Galvanized Steel Included Item * 1 PPC201076A P-Clip - 19mm Diameter Rubber Coated Galvanized Steel Included Item * 2 PPC301053A Bolt - Hex Head M6-1 x 16mm Tensilock Self-locking Dacromet Included Item * 1 PPC301084A Flange - Mounting Included Item * 1 PPC301083A Flange - Mounting Included Item * Washer - Serrated External Tooth M4 x 8 x 0.5 PHOS Included Item * 12 PPC301127A Bolt - Hex Head M4-0.7 x 10mm Stainless Steel Included Item 10 1 PPC301004A Bracket - Quick Connect Mount Adapter - Non-Fairing Mount Service Part
10 PPC301190A PPC301037A PPC301021A PPC301036A PPC301037A PPC301036A PPC301040A Charging Unit - Refrigeration Circuit Components 1 1 PPC301094A Bypass Valve Assembly Complete Replacement kit 2 1 PPC301036A Tube - Refrigerant - Bypass Inlet Suction - 8mm I.D. Included Item 3 1 PPC301002A Bracket - Lower - Bypass Valve Mounting Included Item 4 1 PPC301001A Bracket - Upper - Bypass Valve Mounting Included Item 5 1 PPC301035A Valve - Bypass Included Item 6 1 PPC301102B Coil - Solenoid Valve - with Harness Included Item 7 1 PPC301037A Tube - Refrigerant - Bypass Outlet Discharge - 8mm I.D. Included Item 8 1 PPC301036A Tube - Refrigerant - Bypass Inlet Suction - 8mm I.D. Service Part 9 1 PPC301037A Tube - Refrigerant - Bypass Outlet Discharge - 8mm I.D. Service Part 10 1 PPC301021A Tube - Refrigerant - Compressor Connection mm O.D. Liquid Service Part 11 1 PPC301040A Tube - Refrigerant - Condenser Outlet - Filter mm I.D. Service Part 12 1 PPC301190A Tube - Refrigerant - Quick Connect to Enclosure Fitting mm I.D. Service Part 13 1 PPC401006A Filter Assembly Complete Replacement Kit 14 1 PPC301022A Filter - R134a Included Item 15 2 PPC301028A P-Clip - 60mm Diameter Rubber Coated Galvanized Steel Included Item 16 2 PPC301054A Nut - Hex Head M6-1 Tensilock Self-locking Dacromet Included Item
11 9 Fill with PREMIXED 50/50 mixture of extended life anti-freeze and distilled water ONLY! NEVER add pure anti-freeze and water separately! See service manual for further information. CAUTION A mixture of coolant and water provides the following: Freeze protection down to -34 F (-36 C). Protection against rust and other forms of corrosion. Enables calibrated controls and sensors to work properly. P/N PPC201088A WARNING CONTAINS HIGH PRESSURE GAS. UNAUTHORIZED ACCESS IS PROHIBITED. Tampering or improper service may result in sudden release of high pressure gas causing serious injury or damage to product. ONLY AUTHORIZED DEALERS MAY PERFORM MAINTENANCE OR SERVICE OF THIS PRODUCT. All recommended service procedures and safety precautions must be followed to prevent the possibility of serious injury, damage to servicing equipment or damage to the product. WPNA P.N. PPC201130B System is factory filled with 2.2 lbs (1.0 kg) of ultraviolet R134a refrigerant and POE refrigerant oil. No additional oil needs to be added to the system when completing recovery and recharging of refrigerant. After refrigerant recovery, a vacuum should be pulled on the system for approximately 0.5 hours minimum to ensure that the system is properly sealed and leak free. P/N PPC301013A WARNING NO STEP! P/N BCT010063A WARNING Electrical shock hazard. 120 Volts AC inside. Disconnect power source to inverter before servicing equipment. P/N BCT000066B WARNING IMMEDIATELY GET AWAY FROM THE VEHICLE if you hear sounds of arcing inside (sizzling, sputtering or popping). Hot gases may vent from compressor terminal causing burns or ignition. Improper servicing can lead to fire, electrocution or explosion. Never service, repair or troubleshoot a system unless you are a trained service person. P/N BCT010070A Label Kits - Overall System 1 PPC401007A Set of Labels - English Complete Replacement Kit - 1 PPC201130B A Label - SCCU Included Item - 1 PPC201088A Label - Antifreeze Reservoir Included Item - 1 PPC301013A Label - Unauthorized Access Included Item - 1 BCT010063A Label - No Step Included Item - 1 BCT010066B Label - Electrical Shock Included Item - 1 BCT010070A Label - Explosion Included Item 1 PPC401008A Set of Labels - Français Complete Replacement Kit - 1 PPC201132B A Estiquet - SCCU Included Item - 1 TBD Estiquet - Réservoir d'antigel Included Item - 1 PPC301137A Estiquet - CET APPAREIL CONTIENT UN GAZ À HAUTE PRESSION... Included Item - 1 PPC301131A Estiquet - NE PAS MARCHER DESSUS! Included Item - 1 PPC301133A Estiquet - Risque de décharge électrique... Included Item - 1 PPC301135A Estiquet - LE PRÉPOSÉ DOIT S ÉLOIGNER IMMÉDIATEMENT DU VÉHICULE... Included Item 1 PPC401009A Set of Labels -Español Complete Replacement Kit - 1 PPC201131B A Etiqueta - SCCU Included Item - 1 TBD Etiqueta - Embalse de Anticongelante Included Item - 1 PPC301138A Etiqueta - CONTIENE GAS A ALTA PRESION. PROHIBIDO EL ACCESO NO AUTORIZADO. Included Item - 1 PPC301132A Etiqueta - NO PISAR! Included Item - 1 PPC301134A Etiqueta - Peligro de electrocución... Included Item - 1 PPC301136A Etiqueta - ALEJARSE INMEDIATAMENTE DEL VEHICULO... Included Item
12 10 Storage Unit Assembly Overview - Related Components Storage Core Assembly 2. Liquid Refrigerant Line from Charging Unit to TXV 3. Return Refrigerant Line with Temperature Sensor 4. Coolant Circulating Pump 5. Coolant Reservoir 6. Coolant Supply Line to Air Handler 7. Coolant Return Line from Air Handler 8. Thermal expansion valve (TXV) 9. Tray
13 Cold Storage Unit - Core Components 1 1 PPC401027A Storage Core Service Assembly Complete Replacement Kit A Storage Core - 21,000 BTU Included Item 3 7 PPC201099A Trim Retainer Button - Small Included Item 4 2 PPC201102A Trim Retainer Button - Large Included Item 5 1 BCT010168A O-ring mm ID x 1.78mm THK Included Item 6 1 BCT010171A O-ring mm ID x 1.78mm THK Included Item 7 1 PPC201065A Mounting Plate - Outer - TXV Included Item A Washer - Flat - M6 x 17 x 3 - ZP Included Item Screw - Socket Cap - - M6-1.0 (6g) x 20 (8.8) Included Item 15 1 PPC401011A Thermal Expansion Valve Assembly Complete Replacement Kit B Mounting Plate - Inner - TXV Included Item 17 1 BCT010169A O-ring mm ID x 1.78mm THK Included Item 18 1 BCT010170A O-ring mm ID x 1.78mm THK Included Item 19 1 BCT010028A TXV - 20F Superheat Included Item Washer - Curved Spring Lock - M6 x 8 x 1.3 ZP Included Item 21 2 BCT010014A Screw - Socket Cap - - M5-0.8 (6g) x 40 (12.9) Included Item 22 1 BCT010168A O-ring mm ID x 1.78mm THK Included Item 23 1 BCT010171A O-ring mm ID x 1.78mm THK Included Item 24 1 PPC201065A Mounting Plate - Outer - TXV Included Item A Washer - Flat - M6 x 17 x 3 - ZP Included Item Screw - Socket Cap - - M6-1.0 (6g) x 20 (8.8) Included Item
14 12 Cold Storage Unit - Tray 1 PPC401028A Tray Assembly - Large Complete Replacement Kit - 1 A Tray - Large Included Item A Bolt HFH - M (6g) x 30 (8.8) ZP Included Item
15 Cold Storage Unit - Coolant Circuit Components 1 1 PPC401017A Coolant Reservoir Assembly Complete Replacement Kit 2 1 PPC201023A Cap - Coolant Reservoir Included Item 3 1 PPC201022B Reservoir - Coolant Included Item A Screw - Hex Socket RWH - M6-1.0 (6g) x 16 (10.9) Z/P Included Item 5 1 PPC401014A Coolant Hose Assembly - Storage Core Outlet, Reservoir and Complete Replacement Kit Coolant Pump Inlet - 1 PPC201027A Coolant Hose - 3/4 - Storage Core Outlet to T Connector Included Item - 1 PPC201028A Coolant Hose - 3/4 - Coolant Reservoir Outlet to T Connector Included Item - 1 PPC201029A Coolant Hose - 3/4 - T Connector to Coolant Pump Inlet Included Item Connector - Hose - T 19 x 19 x 19mm Included Item A Clamp - Hose - 27mm CTC 12mm Band Lo-Pro Black Included Item Clamp - Hose mm WGSL 1/2 Band - Z/P Screw Included Item - 1 BCT010110A Insulation - Self-seal 7/8 ID x 3/8 Wall Thickness x 2 Feet Long Included Item 6 1 PPC401029A Coolant Hose Assembly - Coolant Pump Outlet to Shut-off Valve Complete Replacement Kit - 1 PPC201054A Coolant Hose - 3/4 Included Item A Clamp - Hose - 27mm CTC 12mm Band Lo-Pro Black Included Item - 1 BCT010110A Insulation - Self-seal 7/8 ID x 3/8 Wall Thickness x 2 Feet Long Included Item 7 1 PPC401030A Coolant Hose Assembly - Shut-off Valve to Storage Core Return Complete Replacement Kit - 1 PPC201055A Coolant Hose - 3/4 Included Item A Clamp - Hose - 27mm CTC 12mm Band Lo-Pro Black Included Item - 1 BCT010110A Insulation - Self-seal 7/8 ID x 3/8 Wall Thickness x 2 Feet Long Included Item 2 PPC201056A Valve - 3/4-1/4 Turn Ball Service Part
16 Storage Unit - Coolant Circulating Pump and Refrigeration Lines 1 1 PPC401018A Coolant Circulating Pump Assembly Complete Replacement Kit 2 1 BCT010156A Pump - Coolant Circulation with Electrical Potting and Connector Included Item 3 1 PPC201036A Bracket - Coolant Pump Included Item A Sleeve Insert - Coolant Pump Bracket Included Item A Screw - Hex Socket RWH - M6-1.0 (6g) x 16 (10.9) Z/P Included Item 10 1 PPC401031A P-clip Assembly Complete Replacement Kit - 2 PPC301025A P-clip - With Rubber - 44mm Dia. x 20mm Wide Included Item - 3 PPC201077A P-clip - With Rubber - 33mm Dia. x 20mm Wide Included Item A Screw - Hex Socket RWH - M6-1.0 (6g) x 16 (10.9) Z/P Included Item 15 1 PPC201063B Line - Suction with Charge Detection Thermostat Assembly Complete Replacement kit 1 BCT010171A O-ring mm ID x 1.78mm THK Included Item 1 PPC201086B Thermostat - Charge Detection Assembly Included Item 16 1 PPC201064B Line - Liquid - Charging Unit to TXV Complete Replacement kit - 1 BCT010168A O-ring mm ID x 1.78mm THK Included Item 20 1 PPC201086B Thermostat - Charge Detection Assembly Service Part
17 15 Air Handler Assembly U Overview - Related Components Complete Air Handler Assembly Peterbilt Part Number: U Blower Assembly 2. Tray - Air Handler 3. Load Center Volt Power Source 4. Relay Box - Charge Unit 5. Coolant Lines 6. Gasket - Tray to Sleeper Floor 7. Storage Cooler Control Unit (SCCU) 8. Coolant Lines 9. Duct - Fresh Air Intake
18 Air Handler - Housing and Blower Components 1 1 PPC401021A Housing Assembly - Air Handler Complete Replacement Kit 2 1 PPC201032A Tape - Foam - 3mm x 3/4 x 24 Included Item 3 1 PPC201001A Housing - Lower - Air Handler Included Item 4 9 PPC201012A Clips - Snap Included Item 5 1 PPC201004A Cap - Filter Included Item 6 1 PPC201007A Plug - Heat Exchanger Bleed Valve Access Included Item 7 1 PPC201000A Housing - Upper - Air Handler Included Item 10 1 PPC201043A Blower Assembly Complete Replacement kit 11 1 PPC201009A Fan and Wheel Assembly Included Item 12 1 PPC201150A Harness - Jumper with Diodes Included Item 13 1 PPC201002A Housing - Scroll Included Item 14 1 PPC201034A Tape - Foam - 3mm x 3/4 x 17.5 Included Item Washer - Serrated External Tooth - M4 x 8 x 0.5 PHOS Included Item Screw - C/R Pan Head HD - M4-0.7 (6g) x 12 (4.8) Z/P Included Item No Fig. 1 PPC201137A Housing - Connector - Metri Pack 280 Included Item No Fig. 1 PPC201138A Position Assurance - Terminal Included Item No Fig. 1 PPC201139A Position Assurance - Connector Included Item 20 1 PPC401022A Housing Fasteners Complete Replacement Kit 21 1 PPC201049A P-clip - Plastic White 0.25 ID x 0.75 LNG Included Item A Screw - #8 x 5/8 (HI-LO) Included Item
19 Air Handler - Internal Parts and Tray Components 1 1 PPC401023A Exchanger Assembly Complete Replacement Kit 2 2 PPC201015A Grommet - Heat Exchanger Tubing Included Item 3 1 PPC201016A Heat Exchanger Included Item 5 1 PPC201010A Filter Assembly Service Part 10 1 PPC201003A Mode Door and Seal Service Part 15 1 PPC401026A Actuator Assembly - Mode Door - Air Handler Complete Replacement Kit A Screw - #8 x 5/8 (HI-LO) Included Item 17 2 PPC201079A P-clip - Plastic White 0.13 ID x 0.75 LNG Included Item 18 1 PPC201011A Actuator - Mode Door - Air Handler Included Item 20 1 PPC401025A Cabin Temperature Sensor Assembly Complete Replacement Kit 21 1 PPC201020A Sensor - Recirculated Air Temperature Included Item 22 1 PPC201136A Terminal - Position Assurance Included Item 23 1 PPC201135A Housing - Connector - Metri Pack 280 Included Item 25 1 U Duct - Fresh Air Service Part 26 1 U Tray - Air Handler Service Part 27 1 F Gasket - Tray Service Part Gasket must be replaced when removal or replacement of tray is required.
20 * CHARGING UNIT RELAY BOX K1 K3 K7 K6 TC1 K10 K9 6 * TO INVERTER TO LOAD CENTER (*6,7) Air Handler - Electrical and Coolant Circuit Components 1 1 PPC201035B SCCU - Storage Cooler Control Unit Complete Replacement Part A SCCU Relay - Condenser Fan Service Part - Included in PPC201035B 3 1 PPC201134A SCCU Relay - Magnetic Valve, Compressor Control Service Part - Included in PPC201035B SCCU Relay - Coolant Pump Service Part - Included in PPC201035B A SCCU Relay - K7 Fresh/Recirc Door, K6 Blower Fan, K10 Charge Cycle Service Part - Included in PPC201035B Controls, K9 Charge Cycle Controls Harness - To Relay Box / To Charge Unit Service Part Harness - To Load Center / To Inverter Service Part Load Center Assembly - 20 Amp, 120 Volt AC Service Part Relay Box - Charge Unit Service Part 10 1 P Donaldson Vacuator Valve - Rubber Service Part 15 1 F Coolant Hose Assembly - Air Handler Complete Replacement kit 2 Required per assembly A Hose Clamp - 27mm CTC 12mm Band, Lo-Pro Black Included Item B Coupler - Hose 20 X 20mm Included Item Hose - 90 Degree, 3/4in. Included Item Hose Coolant - 3/4in. ID., Silicone mm (51.2in.) Long Included Item FT BCT010108A Insulation Tape - 25mm Wide Included Item FT PPC201094A Insulation Tubing, Closed Cell - 1-1/8in. ID. X 0.5in. Wall Service Part A Hose Clamp - 27mm CTC 12mm Band, Lo-Pro Black Service Part Grommet - Rubber - Coolant Hose Access Service Part
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22 Org. 02/2008 Rev. 08/2008 P/N: PCC_PARTS_DISTRIBUTION Webasto Product N.A., Inc North Road Fenton, MI 48430
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