Drain, evacuate and recharge roof-mounted air conditioning system and check for proper operation and leak tightness

AR83.50-D-0002TSR

Drain, evacuate and recharge roof-mounted air conditioning system and check for proper operation and leak tightness

13.07.2018

Model

907.6/7

with code HK4 (Rear air conditioning, reinforced)

1

Caps

2

Test and filler connection for high-pressure line

3

Test and filler connection for low-pressure line

 Danger

Risk of fire due to ignition of R1234yf refrigerant on hot components. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with escaped R1234yf refrigerant and when working on pressurized parts. Risk of explosion due to formation of ignitable refrigerant/air mixtures

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0007-01A

 Warning

Risk of poisoning caused by inhaling overheated refrigerant vapors from an air conditioning system containing R134a. Risk of injury to skin and eyes caused by contact with liquid R134a refrigerant and when working on pressurized parts

Never perform welding work on or near a closed air conditioning system. No smoking or open flames. Wear safety glasses and protective gloves. Work only in well ventilated rooms. Carry out repair work on the air conditioning system circuit only after the system has been evacuated.

AS83.00-Z-0006-01A

Topical note

Procedure for a damaged or leaky air conditioning system

AH83.30-N-0004-01A

Topical note

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

Notes on handling refrigerant R1234yf

AH83.30-P-0003-02A

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

Draining

1

Unscrew covers (1) on test and filler connection for the high-pressure line (2) and the test and filler connection for the low-pressure line (3), and connect the corresponding air conditioning service unit.



000 588 10 82 00 R1234yf air conditioning service unit

WS83.00-P-0034B



000 588 04 82 00 Air conditioning service unit R134a

WS83.00-P-0031B

 Depending on the vehicle's intended purpose, various refrigerants are used to comply with the respective, country-specific legal regulations.

 When connecting and when operating the air conditioning service unit, the complete work procedure must be conducted in accordance with the air conditioning service unit manufacturer's operator's manual.

2

Analyze the refrigerant in the roof-mounted air conditioning system.

Model 907.6/7 with code HX1 (R-1234yf refrigerant)

 The refrigerant analysis must be performed using an analysis device integrated into the air conditioning service unit or an external analysis device with data transfer to the air conditioning service unit.

 A positive gas analysis is given when the refrigerant exhibits a degree of purity of min.98,5 %.

If the gas analysis is positive,



extract refrigerant from air conditioning system into internal container of air conditioning service unit.

If the gas analysis is negative,



the gas analysis must be performed up to three times. After a third negative gas analysis, the analysis device must be verified in accordance with the operator's manual.

If the analysis device is functional and the gas analysis is negative,



extract contaminated refrigerant from air conditioning system into a recycling cylinder.

3

Drain roof A/C system.

 The extracted quantity of compressor oil must be noted down.



Check

4

Check the refrigerant reservoir of the roof-mounted air conditioning system for re-usability.

Topical note

Protect air conditioning circuit and components from moisture when carrying out repair work

AH83.30-N-0005-01A

In the case of a corresponding finding,



Replace the fluid reservoir.

AR83.50-D-8020TSR

Evacuate

5

Use the air conditioning service unit to clean the refrigerant and evacuate the refrigerant circuit.

6

Conduct vacuum test using air conditioning service unit.

If the air conditioning service unit shows a fault message,



check roof-mounted air conditioning system for leak tightness.

AR83.30-D-1761TS

Filling

7

Add new compressor oil to the refrigerant circuit according to the oil filling capacity noted during extraction.



Compressor oils (specification 362.1)

BB00.40-P-0362-01A


Only the approved compressor oil may be used.
If it is proven that a different compressor oil has been used, we will refuse to reimburse costs within the warranty and goodwill period. Daimler AG reserves the right to perform reexaminations.


Correct compressor oil in the refrigerant circuit.
Otherwise, a wrongly measured oil filling capacity could damage the refrigerant compressor.


If the refrigerant compressor is removed, no more additional oil quantities may be added.
Otherwise, this may lead to malfunction or damage of the air conditioning system.

 Depending on the repair case, the oil filling quantity may need to be adjusted accordingly.

 Total filling capacity of compressor oil in new refrigerant compressor

*BF83.50-N-1001-01TSR

 Total filling capacity of compressor oil in air conditioning system (incl. refrigerant compressor)

*BF83.50-N-1002-01TSR

 Additional quantity of oil to be added when system suddenly looses fluid (e.g. line ruptured)

*BF83.50-N-1003-01TSR

 Additional oil filling quantity after replacing condenser

*BF83.50-N-1004-01TSR

 Additional oil filling quantity after replacing evaporator

*BF83.50-N-1005-01TSR

 Additional oil filling quantity after replacement of suction line

*BF83.50-N-1006-01TSR

 Additional oil filling quantity after replacement of pressure line

*BF83.50-N-1007-01TSR

 Additional oil filling capacity after replacing refrigerant reservoir

*BF83.50-N-1008-01TSR

 Additional oil filling quantity with detectable leakage

*BF83.50-N-1009-01TSR

 Additional oil filling quantity after replacement of complete roof air conditioner

*BF83.50-N-1010-01TSR

8

Fill roof-mounted air conditioning system with the corresponding air conditioning service unit.



Refrigerant (specification 361.1)

Model 907.6/7 with code HX1 (R-1234yf refrigerant)

BB00.40-P-0361-01A



Refrigerant (specification 361.0)

Model 907.6/7 except code HX1 (R-1234yf refrigerant)

BB00.40-P-0361-00A

 Total filling capacity - refrigerant

*BF83.50-N-1011-01TSR

9

Conduct pressure test using air conditioning service unit.

If there is a pressure drop during the pressure test,



check roof-mounted air conditioning system for leak tightness.

AR83.30-D-1761TS

10

Disconnect air conditioning service unit and screw covers (1) onto test and filler connection for high-pressure line (2) and the test and filler connection for the low-pressure line (3).



Check

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

Secure vehicle to prevent it from starting off by itself. Wear closed and snug-fitting work clothes. Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

11

Run engine at idle speed for about 4 minutes and check all the component functions which are of relevance for proper operation of the air conditioning system.

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1001-01TSR

Total filling capacity of compressor oil in new refrigerant compressor

Compressor oil

cm3

190

190

Sheet

BB00.40-P-0362-01A

BB00.40-P-0362-01A

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1002-01TSR

Total filling capacity of compressor oil in air conditioning system (incl. refrigerant compressor)

Compressor oil

cm3

190

190

Sheet

BB00.40-P-0362-01A

BB00.40-P-0362-01A

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1003-01TSR

Additional quantity of oil to be added when system suddenly looses fluid (e.g. line ruptured)

Compressor oil

cm3

65

65

Sheet

BB00.40-P-0362-01A

BB00.40-P-0362-01A

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1004-01TSR

Additional oil filling quantity after replacing condenser

Compressor oil

cm3

20

20

Sheet

BB00.40-P-0362-01A

BB00.40-P-0362-01A

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1005-01TSR

Additional oil filling quantity after replacing evaporator

Compressor oil

cm3

40

40

Sheet

BB00.40-P-0362-01A

BB00.40-P-0362-01A

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1006-01TSR

Additional oil filling quantity after replacement of suction line

Compressor oil

cm3

10

10

Sheet

BB00.40-P-0362-01A

BB00.40-P-0362-01A

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1007-01TSR

Additional oil filling quantity after replacement of pressure line

Compressor oil

cm3

10

10

Sheet

BB00.40-P-0362-01A

BB00.40-P-0362-01A

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1008-01TSR

Additional oil filling capacity after replacing refrigerant reservoir

Compressor oil

cm3

20

20

Sheet

BB00.40-P-0362-01A

BB00.40-P-0362-01A

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1009-01TSR

Additional oil filling quantity with detectable leakage

Compressor oil

cm3

20

20

Sheet

BB00.40-P-0362-01A

BB00.40-P-0362-01A

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1010-01TSR

Additional oil filling quantity after replacement of complete roof air conditioner

Compressor oil

cm3

140

140

Sheet

BB00.40-P-0362-01A

BB00.40-P-0362-01A

 Roof air conditioning

Number

Designation

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR4 (Wheelbase 3665 mm)

Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR6 (Wheelbase 4325 mm, overhang 1615 mm)
Model 907.6/7
with code HK4 (Rear air conditioning, reinforced)
with code IR7 (Wheelbase 4325 mm, overhang 2015 mm)

BF83.50-N-1011-01TSR

Total filling capacity - refrigerant

Refrigerant

g

1100

1200

Sheet R134a

BB00.40-P-0361-00A

BB00.40-P-0361-00A

Sheet R1234yf

BB00.40-P-0361-01A

BB00.40-P-0361-01A