TechPlus ComfortAire Manual del propietario
For GENUINE BLUE BIRD replacements parts, contact your
Blue Bird Authorized Dealer
10004175
TechPlusTechPlus
SERVICE SUPPLEMENT
TECHNICAL COMMUNICATIONS
Comfort AireComfort Aire
AIR CONDITIONING SYSTEMS
L
Technical Communications
TechPlus Supplement
for
ComfortAire
SchoolBusAirConditioningSystems
on
BLueBIrdAllAmericanForwardEngine
BlueBirdAllAmericanRearEngine
BlueBirdVision
BlueBirdMicroBird
lTechPlus service supplement
2
© 2006, 2007 Blue Bird Corporation. All rights reserved.
In the event of any conflict between the requirements of this publication and any applicable legal requirement, the legal require-
ment prevails. Technical requirements that exceed the legal requirements are not considered to conflict.
The material presented in this manual is accurate at the time of publication. Blue Bird Corporation continually endeavors to im-
prove its product and reserves the right to change without notice.
INTRODUCTION
About Blue Bird TechPlus Supplements
School buses are built with a wide array of equipment features which vary not only
according to manufacturer’s models, but also according to state governmental regu-
lations and customer-specifications. Such features often apply to a relative few buses
sold within a particular model category; and some features involve complex systems
or components which require appropriately detailed service information.
For these reasons, including full documentation of every available feature in the
printed version of the primary Service Manual for a particular bus model is not al-
ways practical. Blue Bird’s Technical Communications group prepares and publishes
TechPlus Supplements for such situations.
Intended Readership
This TechPlus Supplement is written for fully qualified professional Service Techni-
cians in specific areas performing maintenance and repair of Blue Bird buses. It is
assumed that the user of this publication is properly equipped and abides by all ap-
propriate safety precautions and procedures.
Content Sources
Blue Bird’s Technical Communications group is a full-time staff within the Customer
Services division at the home plant in Fort Valley, Georgia, where its Tech Publishers
have full access to Blue Bird’s assembly lines and Engineering department.
Blue Bird incorporates into its buses top quality components from leading manu-
facturers in the heavy automotive industry. The Engineering staffs of these compo-
nent vendors are the real experts on their specific components.These manufacturing
partners often provide their own publications to Blue Bird Technical Communica-
tions for republishing as appendixes within Blue Bird’s Service Manuals for direct-
from-the-source, component-specific information.
Therefore, content in TechPlus publications may be written by Blue Bird’s own
Technical Publishers; or may be provided by Blue Bird’s manufacturing partners; or
may be comprised of both Blue-Bird authored and vendor-authored material.
The bulk of this TechPlus Supplement is prepared by Blue Bird’s vendor, Mobile
Climate Controls, which builds the Comfort Aire air conditioner units to Blue Bird
specifications.
Subject of This Supplement
This Service Supplement is prepared to provide additional information to qualified
school bus Service Technicians regarding the Comfort Aire air conditioning systems
installed as an option on some Blue Bird school buses.
Applicable Bus Models
Comfort AIre air conditioning systems are installed on these Blue Bird models:
Blue Bird All American Forward Engine
Blue Bird All American Rear Engine
Blue Bird Vision
Blue Bird MicroBird
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lTechPlus service supplement
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C O M F O R T A I R E A / C S Y S T E M S
Blue Bird Comfort Aire
Maintenance Manual
For
All American (A3FE/RE),
Conventional Vision (BBCV) & Micro
Bird Body Types
(REVISION.003)
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APPENDIX
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Comfort AIrE
lTechPlus service supplement
Important Information about Using This Manual
Please note that this manual is included with all Blue Bird
buses equipped with the Blue Bird factory installed and
supported Comfort Aire, air conditioning system.
Therefore the user will find the manual body to provide
excellent safety practices, driver instructions and simple
trouble shooting, technician instructions and detailed trouble
shooting/replacement procedures. As well as recommended
regular maintenance checks for both the driver and
technician.
The manual body shows detailed three dimensional models
of only the large 55,000 BTU/hr evaporators and the dual
core large bus condenser. All other evaporator and
condenser configurations share the same basic components.
The appendix pages at the end will contain an assembled
view drawing with basic data, exploded view drawings and
part number lists for each evaporator and condenser
configuration offered.
Please refer to the MCC part number on the label attached
to the outside surface of each component’s metal casing to
determine which unit you are working with.
The appendix also contains large wiring schematics for each
bus configuration.
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APPENDIX
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Safety Precautions / 10
General Practices / 10
Refrigerant / 11
First Aid / 11
Refrigeration Oil / 11
First Aid / 11
Electrical Hazards / 12
High Voltage / 12
Precautions / 12
First Aid / 12
Low Voltage / 13
Comfort Aire Specifications / 14
General / 14
R-134a Refrigeration System Charges and Set-points / 14
A3RE/FE & BBCV with TM-21’s Electrical System / 15
Micro Bird Electrical System / 15
Maintenance Inspection Schedule / 16
General Unit Description / 17
General Unit Operation / 18
Cooling / 18
Evaporator Coil Defrost / 18
Unit Features / 18
Protection Features / 18
General System Component Details / 19
Stacked Skirt Mounted Condenser Conguration / 19
Stacked Skirt Mounted Condenser Exploded View / 20
55,000 Bth/hr Free Blow Evaporator Conguration / 21
55,000 Btu/hr Free Blow Evaporator Exploded View / 22
Typical TM-21 Compressor / 23
Manual Control Panel / 23
High Pressure Binary Switch / 24
Electronic Thermostat / 24
Driver Instructions and Information / 25
Starting the Unit / 25
Bi Monthly Post Trip Checks / 26
Regular Maintenance by Driver / 26
Basic Trouble Shooting for Driver / 26
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lTechPlus service supplement
Technician Instructions and Information / 28
Charging the Air Conditioning System / 28
Checking the Refrigerant Charge / 29
Checking the Compressor Oil Charge / 29
High Pressure Binary Switch / 29
Clean Up Procedures / 31
Part Replacement Procedures / 33
Compressor / 33
Condenser Coil / 34
Receiver Drier / 34
High Pressure Binary Switch / 35
Evaporator Coil / 35
Expansion Valve Assembly / 36
Structural Maintenance / 38
Unit Inspection / 38
Evaporator Coil / 38
Condenser Coil / 38
Mounting Bolts / 38
TM-21 & TM-16 Compressor and Clutch Maintenance / 39
Operation / 39
Inspection / 39
Clutch Removal / 40
Clutch Installation / 42
Electrical Connection / 45
Compressor Front seal Removal and Installation / 45
System Compressor and Oil Handling / 50
Installation of the Compressor / 50
Major Loss or Refrigerant / 50
Checking the Oil Level / 50
Oil Contamination / 51
When a system becomes contaminated / 51
Electrical Connection / 51
Clutch Test / 51
Belt Tensions / 52
Engine Compressor Belts and Pulleys / 52
Single V-Belt – Cat C7 A3RE/FE / 52
Poly V-Bel - Some A3RE/FE, All BBCV and All MicroBird / 52
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General Trouble Shooting By Technician / 53
Blower Motor Does Not Operate / 53
Blower Motor Operates Normally, Bur Air Flow is Insucient / 53
Insucient cooling, does not operate at all, or operates improperly / 53
The compressor does not operate at all, or operates improperly / 53
Gauge Pressure Related Troubleshooting / 54
Operation to Return Oil to the Compressor / 54
Electrical System Trouble Shooting / 56
Compressor Trouble Shooting / 57
Refrigeration Diagnosis Chart / 58
System Service and Maintenance Notes / 59
Service Guidelines / 59
Compressor Oil Charge / 59
Refrigeration Chart / 61
Wiring Schematics / 62
Micro Bird Manual / 62
Micro Bird ECC / 63
BBCV, A3RE, A3FE Manual / 64
BBCV, A3RE, A3FE ECC / 65
Slimline System Manual / 66
Slimline System ECC / 67
Electronic Control User Guide / 68
Electronic Climate Control (ECC) / 69
ECC Control / 70
ECC User Display / 71
Basic Operation / 72
System Diagnosis / 73
System Schematics / 75
A3RE ECC Roof Top Condenser / 76
Engine Kit Compressor / 77
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Tabla de contenidos
