Refrigerant compressor - oil change

AP83.55-T-8302BAC

Refrigerant compressor - oil change

08.10.2019

Model

NMB613.367 with engine 457.944

with code HKG (Konvekta ACX 623 air conditioning with roof heater)

except code HA4 (Konvekta air conditioning with roof heater and timer)

Model

NMB613.358/388 with engine 457.944

with code HKD (Konvekta ACX 640 air conditioning with roof heater)

except code HA4 (Konvekta air conditioning with roof heater and timer)

Model

NMB613.358/388 with engine 457.944

with code HKF (Webasto Top 2002 Aerosphere air conditioning with roof heater)

except code HA4 (Konvekta air conditioning with roof heater and timer)

Shown on model 613.358, 613.388 with air conditioning system Konvekta ACX 640 with roof heater, code HKD

1

Pressure-side testing and filling valve

2

Intake-side testing and filling valve

3

Pressure side shutoff valve

4

Intake side shutoff valve

5

Refrigerant compressor

Shown on model 613.358, 613.388 with air conditioning system Webasto Top 2002 Aerosphere with roof heater, code HKF

1

Pressure-side testing and filling valve

2

Intake-side testing and filling valve

3

Pressure side shutoff valve

4

Intake side shutoff valve

5

Refrigerant compressor

Shown on model 613.358, 613.388 with air conditioning system Webasto Top 2002 Aerosphere with roof heater, code HKF

5

Refrigerant compressor

6

Filling screw

7

Inspection glass

8

Drain screw

9

V-belt

10

Alternator

13

Drain screw

 Danger

Risk of explosion caused by welding or soldering work on closed air conditioning system. Risk of poisoning caused by inhaling overheated refrigerant vapors. Risk of injury to skin and eyes caused by contact with liquid refrigerant.

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 areas. Carry out repair work on the air conditioning system circuit only after the system has been drained.

AS83.00-Z-0001-01A

Topical note

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

AH83.30-N-0005-01A

Notes on handling refrigerant R134a

AH83.30-N-0003-01A

1

Turn off engine

2

Open right rear maintenance flap

3

Open rear engine compartment flap

4

Connect A/C suction and recycling equipment to pressure-side testing and filling valve (1) and intake-side testing and filling valve (2)

 Observe operating instructions for air conditioning system vacuum and recycling unit.

5

Remove protective cap from pressure-side shutoff valve (3) and protective cap from intake-side shutoff valve (4)

6

Screw in pressure-side shutoff valve (3) and intake-side shutoff valve (4) completely

7

Extract refrigerant from refrigerant compressor (5) using A/C suction and recycling equipment

 Note the following:
Slowly open valve of A/C suction and recycling equipment.
Extract refrigerant until there is no detectable weight increase to the extracted refrigerant.
After the successful extraction of the refrigerant, close valve of A/C suction and recycling equipment.
Note down extracted quantity of refrigerant.

8

Remove filling screw (6)

 If necessary, remove V-belt (9) and swivel alternator (10) to one side.

9

Extract oil from refrigerant compressor (5)

 Clean extraction hose of engine oil extractor externally before inserting it.

10

Remove drain screw (8)

 Drain remaining oil completely and collect using suitable means.
If the oil is contaminated with metallic wear debris, remove drain screw (13) and check oil screen of drain screw (13) for metallic wear debris; check refrigerant compressor (5) for wear if necessary.

If removal of drain screw (13) is not possible, remove refrigerant compressor (5):



Remove/install refrigerant compressor



AR83.55-T-5300BA

11

Install drain screw (8) with new seal

 Bolt, refrigerant compressor oil drain

*BA83.55-N-1003-01G

 Torque wrench

*000589642100

12

Install drain screw (13) with new seal

 If drain screw (13) was removed.

 Bolt, refrigerant compressor oil drain

*BA83.55-N-1003-01G

 Torque wrench

*000589642100

13

Pour in specified oil filling capacity



Compressor oils (specification 362.0)

BB00.40-P-0362-00A


Only use oils that comply with the Specifications for Operating Fluids
to prevent damage to the refrigerant compressor (5).

 The oil for the refrigerant compressor (5) is hygroscopic (it attracts water). Immediately close the oil reservoir tightly and pour the measured quantity of oil into the refrigerant compressor (5) immediately.

 Total filling capacity - compressor oil for refrigerant compressor

*BF83.30-N-1002-01E

14

Install filling screw (6) with new seal

 Bolt, refrigerant compressor oil replenishment

*BA83.55-N-1004-01G

 Torque wrench

*000589642100

15

Evacuate refrigerant compressor (5)

 Evacuate refrigerant compressor (5) to maximum achievable vacuum, but for at least 30 minutes.

16

Unscrew pressure-side shutoff valve (3) by 3 to 5 turns

17

Pour refrigerant into system via pressure-side testing and filling valve (1)

 Only the quantity noted down during extraction.

18

Close valves of air conditioning vacuum and recycling unit

19

Unscrew pressure-side shutoff valve (3) and intake-side shutoff valve (4) completely

20

Attach protective cap to pressure-side shutoff valve (3) and protective cap to intake-side shutoff valve (4)

21

Remove A/C suction and recycling equipment

 Refrigerant compressor

Number

Designation

ENGINE 457.944 in MODEL 613.358/388 with CODE HKD

ENGINE 457.944 in MODEL 613.358/388 with CODE HKF

BA83.55-N-1003-01G

Bolt, refrigerant compressor oil drain

3/8"

Nm

60

60

M221.5

Nm

100

100

M241.5

Nm

100

100

M261.5

Nm

80

80

 Refrigerant compressor

Number

Designation

ENGINE 457.944 in MODEL 613.367 with CODE HKG

BA83.55-N-1003-01G

Bolt, refrigerant compressor oil drain

3/8"

Nm

60

M221.5

Nm

100

M241.5

Nm

100

M261.5

Nm

80

 Refrigerant compressor

Number

Designation

ENGINE 457.944 in MODEL 613.358/388 with CODE HKD

ENGINE 457.944 in MODEL 613.358/388 with CODE HKF

BA83.55-N-1004-01G

Bolt, refrigerant compressor oil replenishment

3/8"

Nm

60

60

M221.5

Nm

100

100

M241.5

Nm

100

100

M261.5

Nm

80

80

 Refrigerant compressor

Number

Designation

ENGINE 457.944 in MODEL 613.367 with CODE HKG

BA83.55-N-1004-01G

Bolt, refrigerant compressor oil replenishment

3/8"

Nm

60

M221.5

Nm

100

M241.5

Nm

100

M261.5

Nm

80

 Air conditioning

Number

Designation

MODEL 613.358/388 with CODE HKD

MODEL 613.358/388 with CODE HKD and HO4

BF83.30-N-1002-01E

Total filling capacity - compressor oil for refrigerant compressor

dm3

2,0

2,0

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

MODEL 613.358/388 with CODE HKF

MODEL 613.358/388 with CODE HKF and HO4

BF83.30-N-1002-01E

Total filling capacity - compressor oil for refrigerant compressor

dm3

2,0

2,0

Sheet

BB00.40-P-0362-00A

BB00.40-P-0362-00A

 Air conditioning

Number

Designation

MODEL 613.367 with CODE HKG

BF83.30-N-1002-01E

Total filling capacity - compressor oil for refrigerant compressor

dm3

2,0

Sheet

BB00.40-P-0362-00A