Assembly and Installation Manual
Contents
1. LOMBARDINI Assembly Installation Manual TYPE ECOWIND 350 ECC MODEL 350 C AUS 12 24 V AIR CONDITIONING SYSTEM LOMBARDINI LOMBARDINI S r l ADDRESS Via Cav Del Lavoro A Lombardini 2 42100 Reggio Emilia Italia Tel 39 0522 3891 Telefax 39 0522 389503 E mail ecowind lombardini it DOCUMENT TYPE Assembly and Installation Manual PRODUCT AIR CONDITIONING SYSTEM Pn 793866 793867 ECOWIND 350 ECC MODEL 350 AUS 12 24 V CONFORMITY C SERVICE LOMBARDINI TEL 0039 0522 389550 TEL 0039 0522 389547 TEL 0039 0522 389568 LOMBARDINI CONTENTS D LOMBARDINI 1 WARNINGS AND GENERAL INFORMATION 6 9 1 1 INTRODUC ION iin tete ettet de tin ma b es 6 1 2 ee enean pad e Lone c v ette dr d Dec d e neis 6 7 1 3 IDENTIFICATION FLATE lasa 9 1 4 DIRECTIVE AND STANDARD REFERENCES APPLIED eee een 9 2 GENERAL DESCRIPTION AND TECHNICAL DATA 10 14 2 1 TECHNICAL CHARACTERISTICS uuu iat rrt ette 10 12 2 2 CHARACTERISTICS OF COOLANT 13 2 3 CONVENTIONAL COOLING CYCLE 350 14 3 ASSEMBLY AND INSTALLATION 15 59 3 1 REQUIREMENTS AND REGULATIONS FOR ASSE2. maintenance engine Attention When Power Unit has been fixed 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 EC OUJICO LOMBARDINI ASSEMBLY AND INSTALLATION 3 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 M6x16 washer see fig 24 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 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 24 3 ASSEMBLY AND INSTALLATION LOMBARDINI Install fix the condenser on the back of the cab using the bolts supplied M6x35 washer 6 18 before the fixing interpose the four spacers 30 15 supplied as showed fig 29
3. yooq janj au eoejdes duund ui senssi nu o pesuojne w jqosd yng si sI 1911 N ens 1911 N jan4 eu Joys any 191 yooq u N eui yug pue 2 esi es uo 003 9208 10 19 86 bed 0 9 92 162 ees LIVd 0 ve sod 6 X 19 0 GNNOND uonoeuuoo sod 0 090000 509 6 X 10j2euuoo suonoeuuoo p 6X 08 aNu JO OW uonoeuuoo 08 JOJOW Jeyejs 1e zz X Joj euuoo oj Jewod 22 X Jojeuuoo 54 01 uonoeuuoo eoejdei Auesseooeu SI JI 54 esnj uue 1 193 10
4. LOMBARDINI WARNINGS GENERAL INFORMATION 1 All power unit engines are pre charged Guarantee that maintenance has been effected is confirmed by an adhesive with oil specifications put on engine valves cover fornito dalla LOMBARDINI con olio KRYPTON SAE 10W 60 al livello prescritto The quantity for 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 fig 2 1 WARNINGS GENERAL INFORMATION LOMBARDINI 1 3 IDENTIFICATION PLATE CAWIN 2 The WIND 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 gt NOTE Do not damage or remove the CE identification plate even when the system is resold fig 3 1 4 DIRECTIVE AND STANDARD REFERENCES APPLIED Legal provisions Reference Title P D no 459 of 24 7 96 Implementation of E
5. pea 10 Josues 19 1osu s 99 9 JO 328 109 pue esie 1290 19 95 uonoeuuoo GLX 4 uoroeuuoo esie 4 Jesuepuoo 4 01 1esuepuoo seb 0 ay Aj ddns ay Josuopuoo JO uonejo E sS LSNIW yey si elqo Jou 0 3 514 0 Josues Josu s uoo Buruuew Josues Josu s uool yun gt 66 LOMBARDINI 5 TROUBLESHOOTING Lites je esuodseJ ON uo 994 LEZ 993 103409 ejoulei eoe des Loew 104405 avez
6. ALON Noumnos uool uejs 3SVSS3IN 0102220 2087 293 SNILOOHSSISNOYL eJnjej peys 440 U9UM UO YO IMS ON 62 LOMBARDINI BY TROUBLESHOOTING 5 19 86 Bed 21 10 921 164 ees 19 uo 003 S14 ay S74 JO 109 ay 504 LX Joj euuoo 511 uonoeuuoo sod X 1 sod Xx Joj euuoo 511 uonoeuuoo soles 19 uo 923 993 pebeweq piouejos janj uonoeuuoo Jen ON pessedie o sunou euiBue 223 19 89 10 921 16 ees 0 20303 Jeuels 0 uonoeuuoo 19 89 10 921 162 ees sod GLX Jopeuuoo G 0 uonoeuuoo SH Jaye ou Bures uonoejep ou
7. 20 m s 1 H J li d LOMBARDINI Step Description 7 Insert the supplied coupling box on the muffler bend See Figure 13 Mount Coupling Box 1 Coupling box 2 Muffler bend Step Description 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 Description Temporarily disassembly the side bracket B Dx as showed in fig 15 and keep the bolts T1 and T2 KA Insert the power unit P into the support frame S as indicate in fig 16 21 LOMBARDINI 3 ASSEMBLY AND INSTALLATION Step Description 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 Stud M10 x4 Fix again the side bracket B frame S with the bolts T1 and T2 previously stored as showed in fig 18 19 Step Description __ 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 22 3 ASSEMBLY INSTALLATION 23 5 5 4 4 LOMBARDINI Note In the pictures 21 22 is reported position to
8. 6 Complete gas condenser installed rear cab with gas pipes on back see fig 38 27 8 LOMBARDINI ASSEMBLY AND INSTALLATION 3 GAS PIPES FIXING TO SIDE OF THE CAB 2nd OPTION Insert directly the two pipes gas G6 and G8 to condenser and Lock the fittings 1 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 Bended the wiring cable CE to gas pipe half plastic band FP supplied as showed in fig 41 28 3 ASSEMBLY AND INSTALLATION ay LOMBARDINI Make the eye on plastic cover condenser CC for crossing pipes gas G6 G8 and wiring cable CE with Air shroud Electric fan V measurements reported in fig 42 43 NB Operation required only for install pipes side to condenser Gas C like fig 40 41 Slot K 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 29 ECOWIN LOMBARDINI 4 Dry gt gt 30 ASSEMBLY AND INSTALLATION 3 Reassemble at the condenser C the plastic cover condenser CC modified see Fig 48 complete with electric connections half connectors PK fan condenser
9. LOMBARDINI 0 e oqe san y S Jeq 7c lt einsseJd y peeoxe ONI LV3H yids uo 003 549 eJnsseJd seb 19 89 Bed 4211092 62 ees GN 0O39 1504 LX SdH uonoeuuoo sod x 19 sod Sq uonoeuuoo 49 ainssaid seb eoe de 223 yoyms ainssaid epela ainssaid sec 19 85 bed 4211092 62 ees 0 Ajddns eq 15 143 o Buipee2oud 940124 0 g 509 uonoeuuoo esi es 28 sod 1olo uuoo sod uonoeuuoo esi es Sd9 inss id eoejdex Jesuepuoo y JO BU jue eJd yey Jo 508140 jou yey Y92949 10 JOU pue Jesuepuoo ejsui SI eui 72y YOOYD sef JO eu pue Jesuepuoo sef jo eui 409
10. SPLIT cable battery cable 45 LOMBARDINI ASSEMBLY AND INSTALLATION 3 CONNECTING PIPES AND CABLES TO THE CONDENSER 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 26 30 Continue attaching the pipes on the outside boring through the rear ofthe 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 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 Condenser Power Unit Attention The condenser mounting operation given above is only indicated for vehicles with a fixed cab bound to the frame and not for models with forward tipping cabs Fig 86 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 LOMBARDINI 3 ASSEMBLY AND INSTALLATION 3 10 FASTENING THE PIPES AND CABLES Tipping cabs Step Description After fixing the Power Unit Condenser Split unit proceed to fasten and close pi
11. 10 92 164 ees OY uopeuuoo 9 yds 319 223 uonoeuuoo DY 1 ON 105591 02 9 Joss iduio5 fT uoo eunjrej 195 Jossaidwog dS 65 5 TROUBLESHOOTING my LOMBARDINI 119 uo 523 eoeldes 2 003 19 96 Bed GNNOUD 0 S LV 10sues uonoeuuoo uonoeuuoo 10 92 1614 ees Oy sod GLX Josues eunjeJeduJej jueiquie JOJOBUUOD S V Josues uonoeuuoo 1osu s eu S V 2105095 eunjejeduje jueiquie yooq 10 328 000 pue uonisod Josuas 19 uo 523 eoeldes 003 pedi 10 JOSU S jueiquue S13 1osu s uonoeuuoo 9 86 uonoeuuoo 10 921 164 ees sod Josues ON ot SLX Jojoeuuoo 0 13 10895 uonoeuuoo 19 1osu s eJnjeJedue eu
12. NMd eoejdes 19 uo 003 SLO uols einjejeduie 19 86 Bed 21 10 921 164 ees sod 1 9 10 uonoeuuoo 94 uexoug 993 pebeweq e10jeq eJnjeJeduue yooq 891S senss jou Y29949 y 19 uo 923 eJnsseJd eoejdes 19 86 Bed 21 921 164 ees az sod G X ZK eJnsseJd 0 o uonoeuuoo JO sea 919 u yooq eumeJeduije uBiH 223 Bues e1ojeq uonoejep eunsseid uoo jen jen plovelos and JojeuJejl v UOOI eunjeJeduue llo uool eJnsseJd eJnsseJd 5 63 5 TROUBLESHOOTING my
13. SLD 1 5 95 eJnjejeduue au Zeer pedi JO JOSU S eunje1eduje seb S19 10895 yooq 5 SD Jo pue uonisod Josuas uool jeus M IPuBIS M uoo eJnjrej jeuJeju uoo peeoxe peeoxe 1 uoo f epeq Josues sec Josu s 585 0c 6L 8l ZL 9L SL Y L 67 LOMBARDINI ECOWIND LOMBARDINI For your comfort while resting VENTA SERVICIO VENDITA E SERVIZIO MANUAL CODE C DIGO DEL MANUAL CODICE MANUALE 5302 897 DOCUMENT CODE C DIGO DEL DOCUMENTO CODICE DEL DOCUMENTO ECOWIND I U S I 2010 EDITION EDICI N EDIZIONE 01 12 2010 Rev 00
14. 3 Screw UNI 5740 65 M14x50 n 4 4 Nut self lock M14 n 10 5 Nut lock n 12 6 Washer 15 25 2 5 n 18 T Nut lock M10 n 4 8 Wascher 10 n 4 Screws to fix the frame 16 0 3 ASSEMBLY INSTALLATION LOMBARDINI ATTENTION Assemble the entire support structure on the workbench before attaching to the frame The holes F1 22 indicate brackets 7 not drilled because their to be drilled during the installation and also must considered kind 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 MAXIMUM VALUES THE DRIVING TOURQUES FOR SCREWS N m Screw steel class Wrench nneninn mm Thread Wrench opening mm 4 0 7 5 0 8 M 6 x1 M 7 x1 8 1 25 8 1 10 1 5 10 1 25 M10 x1 M12 x1 5 M12 x1 25 M12 x1 75 M16 x1 5 M20 x1 5 M22 x1 5 M24 x2 17 LOMBARDINI ASSEMBLY AND INSTALLATION 3 3 4 MOUNTING DIRECTLY TO THE SIDE FRAME
15. 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 advice to install the frame power unit 5 with deep H less 300 more safety against the conformation of kind of floor F Frame Truck H 300 mm min 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 a correct installation of frame we recommended to drill at measurements as indicate fig 7 n 4 hole 15 25 18 3 ASSEMBLY INSTALLATION LOMBARDINI Step Deseripfon ia 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 19 LOMBARDINI ASSEMBLY AND INSTALLATION 3 Lift the Power Unit using the eyebolts G on the protective casing C fig 9 step Deseo Unscrew and discard the four plastic protection D located under the Power Unit support on the stud M10 K fig 10 Power Unit Muffler Bend fig 11 1 Muffler bend 2 Coupling box 3 Coupling box nuts Attach the supplied muffler bend to the power unit muffler See Figure 12 Insert Muffler Bend 1 Muffler bend 2 Muffler 3 Power Unit
16. and SS pressure switch see fig 46 Ensure the plastic cover condenser CC at the condenser C half bolts V R preserved Complete gas condenser installed rear cab with gas pipes to side condenser see fig 47 3 ASSEMBLY AND INSTALLATION Q LOMBARDINI 31 LOMBARDINI ASSEMBLY AND INSTALLATION 3 3 6 FITTINGS GAS HOSES Step Description 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 with the equipment 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 20 0 78 0 59 inc 32 3 ASSEMBLY AND INSTALLATION LOMBARDINI WARNING Only use the clic 205 pliers B 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 report
17. 30 If you choose for fixing to condensing unit in other position truck than the recommended 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 E Z H P H HB L LOMBARDINI ASSEMBLY AND INSTALLATION 3 GAS PIPES FIXING TO BACK OF THE CAB 1st OPTION Disassembly scrap from the condenser the two rubbers and then mounting the new two rubbers protection pipe G supplied as showed in fig 31 32 Unscrew scrap the plastic cap drier protection then inlet 100 ml of oil compressor supplied see fig 33 34 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 26 3 ASSEMBLY INSTALLATION D LOMBARDINI 4 Bended the wiring cable 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
18. 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 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 Owing to numerous types equipment developed vehicles available 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 ECO 3 2 LIFTING HANDLING AND INSTALLATION OF THE COMPONENTS LOMBARDINI ASSEMBLY AND INSTALLATION 3 Procedure for installation and assembly INSTALLATION OF THE SUPPORT STRUCTURE OF THE POWER UNIT Step Description 1 sure the vehicle is level surface is at a complete rest 3 3 POWER UNIT ASSEMBLY KIT Legend 1 Screw UNI 5740 65 14 25 n 4 2 Screw TE UNI 5740 65 M14x40 n 6
19. 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 ACEA E4 B3 engine could damaged if allowed to with insufficient It is also dangerous to too much 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
20. split unit as a template taking care to place it against a flat wall and to keep it ABSOLUTELY HORIZONTAL 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 rou TUE to the holes P on the counter frame and keeping to the measurements shown in diagram fig 81 4 Using a 6mm bit bore E holes in the marked places 5 Firmly secure and attach the counter frame using the supplied Graf J rivets fig 80 Before attaching the split unit to the cab make holes to pass pipes and cables n 9 holes 2 6 WARNING Pay special attention and take particular care during the drilling phases to prevent the cab internal upholstery from being damaged RECOMMENDATION FOR BORING PROCEDURE Description 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 9 gas pipes make opening only in inner wall 34 electrical system 2 50 mm S condensation drainage pipe 0 34 mm Bore 8 50 Q 3 rubber cable guides G 50 ONLY LM 34 Q WIRING Bore 34 S step OOOO 7 After the drilling operat
21. 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 Red Cable min 200 A 12 V min 100 A 24 V 38 3 ASSEMBLY INSTALLATION Q LOMBARDINI After attaching toghether insert 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 39 nv Q LOMBARDINI ASSEMBLY AND INSTALLATION 3 3 8 CONNECTING DIESEL TO THE POWER UNIT Legend 1 rubber hose 5 mm 6m 2 self threading screws qty 5 3 clamps uu qty 4 4 SUCTION PIPE qty 1 5 gasket n eum RETE qty 2 Supplied in Kit Find flat position on upper part of the vehicle s tank Bore using a hollow mill 34 mm taking care to prevent the cut disc and milling chips from falling into the tank fig 71 Bore using 2 3 mm bit after tracing the fixing points of the suction pipe using the gasket G as the template fig 72 40 3 ASSEMBLY AND INSTALLATION LOMBARDINI Step Description 4 Cut the metal
22. 2 ejoKo zey Jesuepuoo ui epe seo jo 1081100 2940 suonoeuuoo ZZ lt Jo eunsseJd pepeeox3 Ayquenb Seo Jo eui y sjueuoduioo yOBYD u syee seb gt 559 526 ainssaid jana ege Ls u seb ON uoo eJnsseJd sec eunssaJd sec 64 LOMBARDINI 5 IROUBLESHOOTING 19 uo 523 319 uo 523 p ds WAd ag sod 1olo uuoo 19 99 Bed ZX uonoeuuoo esi es 10 9ZL 162 ees 3AILISOd 9 04 0ZX 0 uonoeuuoo uonoeuuoo 195 19 ue 195 0 5 5 ay Ajddns ay Ho 314 ay JO uonejoJ LSNIW zey 509140 jou 129 72942 514 0 4 iiigBNINHVM 19 uo 003 19 89 Bed GLX
23. ARNESS 24 COD 7971 127 Vi 98 7 118 25 eH _ 60 amp LOMBARDINI ECOUWI COD 7971 127 CABLE HARNESS 24 Volt 4 DIAGRAMS AND WIRING ae xz SORES 01 x Ir c 5 i x uil deber npe un ___ _______ 54 uoa LE esses Nd 0022 DNIGNOH snis 9 SAVM Z NOlLdIHOS3Q 3AVN INIGHVSWOT 61 TROUBLESHOOTING 5 LOMBARDINI uo 003 993 10joui 19 5 eoe des 10104 19 815 pebeweq 9 89 bed 4211092 164 ees OS 10joui 27 sod x uonoeuuoo 29 sod g sod 20 uonoeuuoo Jeyeq 10 yooq yooq
24. BARDINI SPLIT CLOSING Step Description Connect the SPLIT EXTENSION cable connections by joining the FRAMATOME FR connectors see fig 110 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 LEGEND 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 6 Washer 13 6x16 Screw Description 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 2 yh 2 LOMBARDINI ASSEMBLY AND INSTALLATION 3 Step Description After completing the gas circuit tape the metal union G10 90 using the supplied anti condensation mastic MC fig 114 to prevent condensation infiltrating into the cab Description 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 Description Before remounting the split s protective co
25. EC Directive no 89 392 known as the Machinery Directive 476 of 4 12 92 Implementation of EEC Directive no 89 336 regarding Electromagnetic Compatibility 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 2004 104 EC Directive regarding electromagnetic compatibility EMC for motor vehicles and their trailers Directive 95 54 EC Directive regarding electromagnetic compatibility EMC for motor vehicles ECE R10 ECE UN regulation regarding electromagnetic compatibility for motor vehicles Table 1 2 ECO 2 1 TECHNICAL CHARACTERISTICS G LOMBARDINI GENERAL DESCRIPTION AND TECHNICAL DATA 2 Table of technical data Air conditioning system ECO Model 350 C AUS 0000000 EEUU s O Dimensions and weight Powerunit Condeser Split diffuser 140mm Without support structure 350 AUS Diesel for automotive use taken from the vehicle s own tank for models installed directly in vehicles Maximum fuel consumption 0 7 litre h Cooling capacity 13 000 btu h 3 800 W Coolant R 134a Quantity of coolant min 1000 max 1200 gr The amount of gas may vary according to pipe length see Tab 1 and Tab 2 Opt
26. EWATERING FILTER 4 EXPANSION VALVE gt GAS R134a HIGH PRESSURE HP 5 EVAPORATOR AC 14 ECO 3 ASSEMBLY AND INSTALLATION LOMBARDINI 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 air conditioning system 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 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 good working condition Lifting equipment must have lifting capacity 20 above the weight of the object that is lifted
27. MBLY AND INSTALLATION 15 3 2 LIFTING HANDLING AND INSTALLATION OF THE COMPONENTS 16 3 3 POWER UNIT ASSEMBLY 16 17 3 4 POWER UNIT FRAME GLAMP KIT 18 23 3 5 INSTALLATION OF CONDENSING UNIT 24 31 3 6 CONNECTION FITTINGS GAS HOSES 32 36 3 7 HOSES AND CABLE CONNECTIONS TO POWER UNIT 37 39 3 8 CONNECTING DIESEL TO THE POWER 40 41 3 9 INSTALLATION OF THE SPLIT UNIT 42 44 3 10 FASTENING THE PIPES AND CABLES 45 56 3 11 FILLING THE GAS CIRCUIT WITH R 134A 56 57 4 DIAGRAMS AND WIRING uy 58 61 4 0 DIAGRAMS AND WIRING 12 V ein 58 59 DIAGRAMS WIRING 24 tene cette cnet 60 61 5 TROUBLESHOQOTING I 62 67 LOMBARDINI 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
28. cription ___ Tighten the fitting R half pliers P and ensure that the clic clip is closed correctly between metallic details B F as showed in fig 58 Step Description __ j At the end of operations the clamping must be guarantee between the metallic details T C R as showed in fig 59 35 ECOWIND nv LOMBARDINI ASSEMBLY AND INSTALLATION 3 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 MAXIMUM VALUES THE DRIVING TORQUES FOR GAS PIPES FITTINGS in N m 606 5 8 608 610 78 Tab 8 uf Lubricate all fittings and O rings with new refrigerant oil before con When tightening or loosening the fittings of the gas pipes use two wren ches necting them to equilize the torsion couple Tab 9 Tab 10 36 3 ASSEMBLY INSTALLATION LOMBARDINI 3 7 HOSES AND CABLES CONNECTIONS TO POWER UNIT Step Description 1 Connect the gas delivery pipe G8 fig 62 to the Power Unit using 90 union supplied 2 Connect gas suction pipe G10 62 to Power Unit using 90 union supplied Step Description _ Both diesel fuel couplings Tg Tg out must be connected by means supplied 5 rubber hose to corre sponding couplings on the diesel fuel suction pipe see fig 73 on page 41 and clamps supp
29. ective goggles and gloves The coolant has a boiling temperature in normal environmental conditions of about 26 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 CABLE HARNESS 12 Volt DIAGRAMS AND WIRING 4 COD 7971 126 58 4 DIAGRAMS AND WIRING CABLE HARNESS 12 7971 126 bial amp 5 SERIES 280 MALE 8 35 FEMALE ISOLATED 8 36 FEMALE ISOLATED 150V MALE TERMINAL YS METRIPACK ASTON ASTON _____2 WAYS METRIPACK SERIES 280 MALE _____ _______ 6 35 FEMALE ISOLATED 25 2 2 2 18 15 24 WAYS FEMALE HOUSING SICMA SERIES WAYS HOUSING SICMA SERIES ___54 WAYS FEMALE HOUSING SICMA SERIES E WAYS SUPERSEAL 1 5 SERIES HOUSING PLUG 2 1 2 15 2 1 2WAYSMETRIPACK SERIES 200 FEMALE SOCKET OA 180 FEMALE TERMINAL LOMBARDINI DIAGRAMS AND WIRING 4 CABLE H
30. ed in this manual are not used 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 CLIC R N 201 BREVETE 33 tis w AL t LOMBARDINI ASSEMBLY AND INSTALLATION 3 FITTINGS MOUNTING Step Description Insert the clic clamp C as measurements indicate in fig 49 on rubber gas hose T as showed in fig 54 Step Description Concluded the fitting appropriate inside rubber gas hose T complete of clic clamp C see fig 55 Step Description Ended insert fitting R operation ensure that the cir 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 34 3 ASSEMBLY AND INSTALLATION D LOMBARDINI Step Description 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 Step Des
31. elf threading screws supplied with the system down floor cab 48 3 ASSEMBLY AND INSTALLATION Q LOMBARDINI Description After fastening the pipes and cables under the cab floor proceed with the tube bundle towards the condenser Attached previously fig 96 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 Step Description 8 at finished installation floor back cab 97 49 LOMBARDINI ASSEMBLY AND INSTALLATION 3 Step Description 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 Description Regardless of the method used to attach condenser it is absolutely essential to create pipe 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 Lombardini S r l declines all responsibility for damage caused to things perso
32. eojedes 104009 eez 3T8VTIVAV LON 19 uo 553 e ejdes Lp 8L 003 LIV Log 10 2 19 89 89504 10 0 m 10 921 162 ees o YB esos 1431 0090400 euis MON 48 Vest UOISSIUISEJ eq u yoig e g 1185 uo 003 993 3T8VTIVAV LON J snes DILIVINOLOQV 9 uonoun 19881 uo 0 440 ul 5 Jo euin 810 993 Buug ui WNL 5 JO jeuuou 10 Jang uBnoue vi yids uo 003 993 0 S19 108 98 uonoeuuoo 9 86 Bed 10 921 167 ees Josues eJnjeJeduue vel JOJOBUUOD 19 Josues
33. imum operating pressure Delivery pressure HP 14 17 bar 30 C ext temp Intake pressure LP 1 3 bar 30 C ext temp It is important to comply with above quantities Non observance of this recommendation could compromise the performance of the system Onboard electrical power supply Battery recharge capacity alternator Control system power supply 10 EC OUJICO 2 GENERAL DESCRIPTION AND TECHNICALDATA TEST QtyR134a LENGHT TEMPERATURE EXT SUC LOW PRESS DISC HIGH PRESS TAB 1 HP kg cm TAB 2 A C pressures according to ambient temperature for 8 1340 11 LOMBARDINI TAB 3 TAB 4 OIL FOR R 134 A PHYSICAL PROPERTY LUBRICANT SP20 SPECIAL GRAVITY 15 C 1 044 COLOUR ASTM 05 KINEMATIC 40 C 1045 VISCOSITY cs 100 2115 VISCOSITY INDEX 235 POINT COl 230 POUR POINT C 50 FALEX LOAD 1350 TEST LBS IN2 CRITICAL UPPER 52 3 SOLUBILITY POINT LOWER 40 12 GENERAL DESCRIPTION AND TECHNICAL 2 UQUID 971 9820 22 2222 2 22 006 77 26 2 X XX K DM X x p pre bors R134o tekigero 5 BETULA 5 100 Viscosity at 40 C Viscosity at 100 C Viscosity Index Flash Point COC Pour Point Flock Poin
34. ions are completed insert the 3 supplied rubber cable guides into the holes to 34 made in the exterior metal of the cab fig 84 N B The rubber to wiring R are already assembled on the external cable EC 43 5 LOMBARDINI ASSEMBLY AND INSTALLATION 3 sep _ _ During the SPLIT fastening phase accurately check if the latter is fixed as shown in figure 85 pos 1 If the wall inside the cab is tilted on the front use two bored spacers D with min internal 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 is strictly forbidden to the SPLIT as shown fig 85 pos 3 Non observance of this regulation could lead to drainage problems the condensation produced by the SPLIT that may leak inside the cab Lombardini 5 declines all responsibility for damage to persons or things caused by non observance of this regulation 44 ECOWIN LOMBARDINI 3 ASSEMBLY AND INSTALLATION 3 10 FASTENING THE PIPES AND CABLES Fixed cab version Description 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 cab condenser split unit power unit access points gas Battery
35. lied The diesel fuel on off cock supplied which is 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 Step Description The connector bundle 2c fig 64 must be connected to the respective FRAMATOME 3c connectors of the extension P supplied fig 66 37 LOMBARDINI ASSEMBLY AND INSTALLATION 3 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 1 2 be secured with a nylon clamp CN as shown in figure 69 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 Next attach the other eyelet of the black cable Pa of the extension to the negative pole L of the battery fig 67 WARNING The black cable must be connected to the battery And not to the frame Make sure the supply red cable is firmly attached Pa avoiding points
36. ns animals the vehicle and the WIND system as a result of non observance of this regulation fig 101 50 3 ASSEMBLY AND INSTALLATION LOMBARDINI Step Description 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 Description 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 51 LOMBARDINI ASSEMBLY AND INSTALLATION 3 Step Description Secure the split S to the counter frame O by sliding it onto the 4 Stud M6 P and then fasten it using 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 m x 8980 C033 Warning INSTALL KIT ANTIPOLLUTION FILTER D SUPPLIED WITH THE Fig 108 WITH SELF THREADING SCREWS C AS INDICATED IN FIG 107 Fig 108 52 3 ASSEMBLY AND INSTALLATION LOM
37. 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 can cause skin cancer if repeatedly left in contact with the skin and for long periods of If contact with the 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 American Petroleum Institute MIL Engine oil U S military specifications released for logistic reasons ACEA European Automobile Manufacturers Association ECO 1 WARNINGS AND GENERAL INFORMATION LOMBARDINI ACEA REGULATIONS ACEA SEQUENCES PETROL HEAVY DUTY DIESEL ENGINES Low viscosity for frictions reduction E1 OBSOLETE A2 Standard 2 Standard High performances Heavy conditions Euro 1 Euro 2 engines LIGHT DUTY DIESEL ENGINES E4 Heavy conditions Euro 1 Euro 2 Eu
38. pes and cables according to the fol lowing two procedures fig 91 CONDENSER CAB METHOD cab condenser split unit cab fulcrum power unit access points gas Battery split cable Battery cable Pipe G8 PS Pipe G10 PS 47 LOMBARDINI ASSEMBLY AND INSTALLATION 3 Step Description __ 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 con densing 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 Step Description __ 0 0000 WARNING 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 sup plied 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 Step Description __ When the cab rotation fulcrum point F has been rea ched fig 95 fix the tube bundle to the the cab and down floor cab fig 95 boring holes 3 5 mm and using steel rubber clamps along with s
39. recautions 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 LOMBARDINI GENERAL DESCRIPTION TECHNICAL DATA 2 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 30 6 1 COMPRESSOR 2 AC CONDENSER GAS R134a LOW PRESSURE LP 3 D
40. rect 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 e PS Access points on the gas circuit PH PL Recovery taps on the charger recovery station TS Service pipes 56 3 ASSEMBLY AND INSTALLATION Frequency of system refilling It is recommended to refill the system with R 134 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 10 11 Safety warnings the system is pressurised specific operations on the thermodynamic plant must be carried out full compliance with the regulations for systems containing HFCs and must only be performed by an ECOWIN authorised service centre Lombar dini S r l declines all responsibility for accidents and or damage deriving from non observance of this regulation PRESSURIZED SYSTEM ECO LOMBARDINI Before performing any maintenance operations gas circuit it is absolutely essential to empty the pressurised system R 134 A using the specific chargerlrecovery 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 prot
41. ro 3 engines B1 Low viscosity for frictions reduction E5 High performances in heavy conditions Euro 1 Euro 2 Euro 3 engines B2 Standard B3 High performances indirect injection B4 High quality direct injection SEQUENZE API MIL SEQUENCES API MIL API MIL SEQUENCES API MIL SEQUENZEN SECUENCIAS MIL SEQU NCIAS MIL DIESEL BENZINA ESSENCE PETROL GASOLINA e Gradazioni SAE Viscosit SAE SAE Grade SAE Viskositatsklasse Viscosidad SAE SAE 40 35 30 25 20 1510 5 0 5 1015 20 25 30 35 40 45 50 SAE 10W SAE 20W SAE 30 we SAE 15W 40 SAE 15W 40 SAE 10W 60 SAE 40 SAE 20W 60 SAE 5W 30 SAE 10W 30 SAE 0W 30 SAE 10W 40 base minerale base semi sintetica base min rale base semi synth tique base sintetica SAE 15W 40 mineral base semi synthetic base base synth tique SAFEARWAn Mineral lbasis Halbsynthetische Basis synthetic base semi sintetica Synthetische Basis 20W 60 mineral semi sint tica sintetica sint tica
42. suction pipe to the appropriate size as figure 73 Suction pipe A Tank S min 100 mm Panel Power Unit Description Attach the suction pipe P to the tank using the supplied self threading screws placing the rubber gasket G between the two fig 74 75 Description For tank with cylindrical shape we suggest to use 2 rubber gaskets G fig 70 Description 7 Connect the suction pipe P to the Power Unit PW via the supplied rubber hose and metal clamps fig 76 The fuel intake pipe IN of the suction pipe must be connected to safety cock 73 and to the coupling IN on the Power Unit NON OBSERVANCE OF THIS STEP COULD PREVENT THE SYSTEM FROM FUNCTIONING 41 nv LOMBARDINI ASSEMBLY AND INSTALLATION 3 3 9 INSTALLATION OF THE SPLIT UNIT Step Description 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 42 3 ASSEMBLY AND INSTALLATION LOMBARDINI INSTALLATION OF THE SPLIT UNIT Step Description Position the counter frame O fig 78 supporting the split unit inside the cab Use the
43. t oil R134a 1 9 Mass density at 15 C The AGIP BETULA 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 2 GENERAL DESCRIPTION AND TECHNICAL DATA LOMBARDINI 2 2 CHARACTERISTICS Recommended products Fluorocarbon coolant R 134a TETRAFLUORETHANE Non recommended Products Compressor PAG SP 20 equivalent see chart 5 ATTENTION All coolants not mentioned in the recommended products section are not to be considered for use are inappropriate and hence prohibited Lombardini 5 declines all responsibility for damage to persons or things caused by non observance of this regulation Safety warnings is important to observe the following safety regulations when carrying out maintenance the system fluorocarbon coolants evaporate rapidly freezing anything with which they come 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 p
44. ver c make sure that the FRAMATOME FR connectors of the control panel 15 hooked up with connector wiring W See fig 116 54 D AJ 9 LJ 3 ASSEMBLY AND INSTALLATION LOMBARDINI 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 NB Itis 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 55 LOMBARDINI ASSEMBLY AND INSTALLATION 3 COMPULSORY OPERATIONS Description 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 5 if not already inserted fig 120 Attention Non observance of this regulation could lead to drainage problems of condensation inside the vehicle cab Lombardini 5 declines all responsibility for damage to persons or things caused by non observance of this regulation 3 11 FILLING THE GAS CIRCUIT WITH 134A 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 cor
Download Pdf Manuals
Related Search