Installation and Service Instructions
Roof-Mounted Air Conditioner KK2000 E
ID No. 98278C
Roof-Mounted Air Conditioner KK2000 E
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TABLE OF CONTENTS
1. INTRODUCTION..........................................................................................................................3
1.1 Contents and Purpose ...............................................................................................................3
1.2 Relevance of Emphasized Text.................................................................................................3
1.3 Additional Documents for Reference.........................................................................................3
1.4 Safety Information and Requirements .......................................................................................3
2. GENERAL DESCRIPTION..........................................................................................................5
2.1 Roof-Mounted Air Conditioner ...................................................................................................6
2.2 Air Manifold Plate.......................................................................................................................8
2.3 Electrics......................................................................................................................................8
2.4 Workings of the Air Conditioning................................................................................................8
2.5 Design, Task, and Function of the Components .....................................................................12
3. TECHNICAL DATA....................................................................................................................14
3.1 Air Conditioning........................................................................................................................14
3.2 Compressor..............................................................................................................................15
3.3 Circuit Diagram ........................................................................................................................16
4. INSTALLATION INSTRUCTIONS .............................................................................................18
4.1 Installation Diagrams for Cabins without Roof Gaps...............................................................18
4.2 Checklist for the Installation of the KK2000 E with Heater Unit...............................................19
5. INITIALIZATION.........................................................................................................................20
5.1 Safety Information....................................................................................................................20
5.2 Operator Information................................................................................................................20
5.3 Operating, Control, and Safety Switch.....................................................................................21
5.4 Operating the Air Conditioning System....................................................................................21
5.5 Operating the Air Top 3500 Heater Unit..................................................................................21
6. MAINTENANCE.........................................................................................................................22
6.1 Safety Information....................................................................................................................22
6.2 General ....................................................................................................................................22
6.3 Care and Maintenance.............................................................................................................22
6.4 Checklist for Care and Maintenance........................................................................................23
6.5 Trouble-Shooting and Correction Measures............................................................................23
6.6 Checks Before Initialization......................................................................................................24
6.7 Maintenance Work...................................................................................................................25
6.8 Checks and Work after Initialization ........................................................................................25
6.9 Visual Check............................................................................................................................27
7. SPARE PARTS..........................................................................................................................28
Roof-Mounted Air Conditioner KK2000 E
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1. INTRODUCTION
1.1 Contents and Purpose
These installation and service instructions contain important information to support
trained personnel in the assembly, control, operation, and maintenance of the roofmounted air conditioner KK2000 E.
1.2 Relevance of Emphasized Text
These instructions contain texts emphasised with CAUTION, WARNING, and NOTE,
which mean as follows:
CAUTION
This header is used when not following instructions or
procedures correctly or at all can result in injuries or death.
WARNING
This header is used when not following instructions or
procedures correctly or at all can result in damages to
components.
NOTE
This header is used to point out a special situation.
1.3 Additional Documents for Reference
Installation instructions for the Air Top 3500 (77625):
Operating Manual for the Air Top 3500 (776,246):
1.4 Safety Information and Requirements
The roof-mounted air conditioner KK2000 E is constructed according to the latest
technology and is safe for operation when mounted and used correctly according to the
information in these installation and service instructions.
As a rule, the general national accident prevention regulations and applicable operating
safety instructions are to be adhered to.
This includes safety regulations from the civil engineers professional association for the
construction and operation of earth-moving machinery.
(Technischer Aufsichtsdienst, Landsberger Str. 309, 80687 Munich, Germany)
DIN ISO 3471 roll protection attachments
DIN ISO 3449 protective attachments for falling objects
DIN ISO 3411 machine operator, height and size, minimum free area, guidelines, safety
regulations, basic requirements and information sheets from the specialist committee at
the center for safety and health – BGZ – under the umbrella of the association of
professional associations.
(Carl Heymanns Verlag KG, Luxemburger Str. 449, 50939 Cologne, Germany)
“General Safety Requirements” beyond the scopes of these regulations are explained
below.
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The special safety requirements for these instructions are explained in the individual
sections or in procedures in specially emphasized text.
General Safety Requirements
By not following the installation instructions and the information contained therein you
release Webasto from all liability. This also applies for non-specialist repairs or when
original spare parts are not used. This can result in loss of the vehicle’s general
operating permit (ABE).
Regulations from professional associations, especially regarding head clearance, falling
objects, and vehicle tipping, must be considered.
When installing the roof-mounted air conditioner, adhere to the applicable regulations.
Electrical lines and operating elements on the air conditioner must be arranged in the
vehicle so that the function of this is not adversely affected under normal operating
conditions.
Safety Information for Maintenance Work
If there are malfunctions in the coolant cycle, the system must be checked and properly
repaired by a specialist repair center. The coolant may never be released into the air
(§ 8, CFC chlorofluorocarbon prohibition from May 06, 1991).
Never warm up coolant bottles with an open flame.
Liquid coolant may not come into contact with skin. Read and observe the safety data
sheet.
When working with coolant, wear protective clothing and goggles.
CAUTION
Do not perform any welding or soldering on the enclosed
coolant system or in the vicinity. The heat increases the
pressure in the system. There is a danger of explosion.
Before starting work, let the system completely cool down.
There is a danger of burns on the condenser, compressor,
and the hoses.
Assembly, service and repair work must be performed by
trained personnel. Work may only be performed when the
motor is stopped and the power supply has been switched
off.
Disconnect the battery before opening the roof-mounted air
conditioner and working on the electric wiring.
Do not wear metal jewellery when working on electric
components (remove bracelets, watches, necklaces, rings).
Roof-Mounted Air Conditioner KK2000 E
2. GENERAL DESCRIPTION
The air conditioner and the heater unit are operated independently with separate control
elements. A relay ensures that both units cannot be operated simultaneously.
The compressor has a hydraulic drive.
The air conditioning and the heater unit are designed for operation with circulating air.
Option: The KK2000 E can also be delivered without a heater unit.
Figure 2.1
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Roof-Mounted Air Conditioner KK2000 E
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2.1 Roof-Mounted Air Conditioner
The roof-mounted air conditioner is shown in figure 2.2.
It contains:
– The cover (1) with openings as well as protective screens for the condenser air intake
and exhaust, this is the outer contour section.
– The base plate (8) as a load-bearing structural component.
Integrated in this are:
– Radial fan (5),
– Accumulator dryer (13) with glass front (14), high pressure switch (15) and low
pressure switch (20)
– Condenser (3)
– Vaporizer (6)
– Expansion valve (11)
– Coolant lines (9, 10)
– Cable harness with flat fuse holder (2) and relay holder (16)
– Axial blower (4)
– Compressor (18) with hydraulic engine (19)
– AT 3500 heater (optional) (12)
Roof-Mounted Air Conditioner KK2000 E
Figure 2.2
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Roof-Mounted Air Conditioner KK2000 E
2.2 Air Manifold Plate
The air manifold plate (figure 2.3) contains:
– Air manifold plate (1) with dividing sheet (8)
– Adjustable air blowers (5,6)
F
Figure 2.3.
2.3 Electrics
The circuit diagrams for the KK2000 E are shown in figure 3.1.
The connection must use a battery discharge protection switch with a fuse. This way the
system can only be operated when the vehicle engine is running.
2.4 Workings of the Air Conditioning
2.4.1 Ventilation
Turn the thermostat to the far left (OFF).
Turn the blower switch from OFF to the right to level 1, 2, or 3, depending on the
amount of air desired. By adjusting the dischargers (5,6 figure 2.3), you can change the
air flow to suit your individual needs. The flow from the slots remains constant for the
front windshield.
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Roof-Mounted Air Conditioner KK2000 E
2.4.2 Cooling
Adjust the blower switch as described in section 2.4.1. The thermostat switch must be
switched on for the compressor to work. Turn to the right until you reach the desired air
temperature. The lowest temperature is when it is turned all the way to the right.
For maximum cooling effects, the blower switch must be set to 3.
Switch on/switch off:
Blower strength:
Selecting the temperature with the set value indicator:
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Roof-Mounted Air Conditioner KK2000 E
Figure 2.4.
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Roof-Mounted Air Conditioner KK2000 E
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Coolant lifecycle (figure 2.4)
When the air conditioner is switched on, the compressor (18) links up using the
magnetic coupling and is run by the vehicle’s engine drive belts. It compresses the
coolant gas and transports it to a condenser (3) where it is condensed by heat exhaust.
The condenser transfers the condensation heat to the exhaust air ventilated through the
condenser (19 and 20). The axial blower (4) provides sufficient ventilation even if the
vehicle is not moving.
The liquid coolant flows through the accumulator dryer (13) to the expansion valve (11),
it relaxes with regulated pressure drops and returns to the gas form after intense
heating in the vaporizer (6).
The warm air (21) in the vehicle cabin is sucked in by the radial blowers (5), cooled in
the vaporizer, dried and returned to the cabin through a air manifold plate (22). The
condensation is separated and sent out.
During operation, the coolant cycle is monitored by the thermostat switch (12) (S2, see
circuit diagram, figure 3.1) and the pressure switch (15) (S3, see circuit diagram, figure
3.1). These two switches are used to turn the magnetic coupling on and off and to
couple and uncouple the compressor.
When the air conditioner is switched off, the magnetic coupling and the blower motors
will have no power. The coolant system and the air circulation system are switched off.
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2.5 Design, Task, and Function of the Components (figure 2.4)
Condenser
The condenser (3) consists of a continuous helical tube and blades that are connected
together to a large heat exchange surface.
It cools down the hot coolant gas until it liquefies and is undercooled, and it transfers the
condensation heat over the blades to the outside air that flows through them.
Accumulator dryer
The accumulator dryer with glass front (13) is a compensation and storage container for
coolant. The lower section contains drying granulates that extracts small amounts of
water from the coolant and chemically binds it. This reduces the danger of icing in the
expansion valve and protects the compressor from damages. During operation, the
glass front (14, figure 2.4) shows if enough coolant is in the system.
Thermostatic expansion valve
The thermostatic expansion valve (11) regulates the flow of coolant to the vaporizer
according to the coolant needs or the temperature in the vaporizer. The thermostatic
expansion valve is the control element between the high pressure and low pressure
sections in the coolant circuit.
Vaporizer
The vaporizer (6) has the same basic design as the condenser. In this, the coolant
flowing through the lines from the expansion valve converts from liquid to gas and is
overheated.
The necessary steam heat is drawn over the blades from the flowing cabin air and
transferred to the coolant through the pipe walls. The cooling air is dried and the
condensation water from this is lead outside.
Pressure switch
The high pressure and low pressure switch monitors the pressure ratios in the high
pressure section of the coolant circuit and uses the magnetic coupling to switch the
compressor off if the pressure drops too low (such as a loss of coolant) or if the
pressure is too high (such as overheating in the condenser).
Thermostat switch
The thermostat switch (12) is a temperature switch. It measures the temperature
between the vaporizer blades and switches off the power to the compressor’s magnetic
coupling if there is a danger of icing and, after a slight warm up, switches it on again.
Roof-Mounted Air Conditioner KK2000 E
Axial blower
The axial blower (4) consists of a direct current motor and fan wheel.
Once the air conditioner is switched on, it will constantly be run with board voltage and
supply the condenser with the required external air.
Radial blower
The radial blower (5) contains a multi-stage DC motor that can be run at three different
speeds. It vacuums the cabin air through the vaporizer and blows it through the nozzles
in the air manifold plate back into the cabin.
Compressor
The compressor (figure 2.5) consists of the swash plate compressor and the magnetic
coupling with fan belt washer. It is switched on and off as needed with the magnetic
coupling when the air conditioning system is on.
Figure 2.5.
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Roof-Mounted Air Conditioner KK2000 E
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3. TECHNICAL DATA
3.1 Air Conditioning
Description Type KK2000 E
Dimensions, roof-mounted air conditioner
− Length x Width x Height
1301 mm X 814 mm X 284 mm
Weight (body) with AT 3500
Weight (body) without AT 3500
approx. 95 kg
approx. 90 kg
Operating voltage 24 Volt DC
Fuses See key to circuit diagram, p. 17
Power consumption at vaporizer blower level
1 2 3
– Air conditioning (W)
– Air circulation (W)
220 260 330
100 140 210
Operating control Rotational direction
Left Right
High Low
Temperature Temperature
Switch points for low pressure switch
– Off
– On
2 bar
4 bar
Switch points for high pressure switch
– Off
– On
24 bar
17 bar
Coolant R134a
Coolant filling amount approx. 0.9 kg
Coldness at compressor speed of n=3000 rpm and
outside temperatures of 40° Celsius.
6.4 kW
Vaporizer – Air flow volume (free blowing)
– level 1
– level 2
– level 3
approx. 460 m3/h
approx. 660 m3/h
approx. 900 m3/h
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3.2 Compressor
Description Type Seltec TM15 HD
Dimensions (length x width x height) 235 mm X 124 mm X 136 mm
Weight (body): 4.5 kg
Rotational direction left/right
Piston displacement/rotation 131 cm
3
Refrigerator oil (type/amount) PAG ZXL 100 PG / 150 + 20 cm
3
Coolant connections
– Pressure end (standard)
– Intake end (standard)
3/4" UNF O-Ring
7/8" UNF O-Ring
Installation position, movement area:
− Around the lateral axis
− Around the horizontal
max. ± 30°
max. ±10°
Magnetic coupling
– Power supply
– Power consumption
24 Volt DC
max. 45 Watt
Operational rotation speed 700 to max. 6000 /min.
Outlet valve for cut-in pressure 34.5 - 39.2 bar
Roof-Mounted Air Conditioner KK2000 E
3.3 Circuit Diagram
Figure 3.1.
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Roof-Mounted Air Conditioner KK2000 E
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Key to circuit diagram:
1 Switch mounted in the vehicle console. 1x set value indicator, 2x switch
2 Hydro line
3 Take appropriate steps to ensure that there cannot be feedback to the board power
and the air conditioner.
4 Possible safety switch
5 Terminal 61 or terminal 15
6 The additional blower must be triggered by the heater unit at least at level 2.
7 K line diagnosis
8 CO2 adjustment
9 COMPRESSOR
Item Description Item Description Comment
A1 Heater unit M1 Engine Condenser blower
A2 Controller M2 Engine Vaporizer blower
M3 Engine Fuel and hot air
blowers
B1 Thermostat module M4 Engine Additional blowers
B2 Temperature gauge
B3 Temperature gauge Overheat protection P Combi time switch Time Switch and
set value indicator
B4 Temperature gauge
S1 Pressure switch Blower 1/2/3
E Light pin/flame detector
S2
Thermostat switch Icing protection
S3 High pressure switch
F1 Fuse 15A
Blade-type fuse as SAE J 1284
S4 Low pressure switch
F2 Fuse 15A
Blade-type fuse as SAE J 1284
S5 Pressure switch Cooling ON/OFF
F3 Fuse 7.5A
Blade-type fuse as SAE J 1284
S6 Switch Additional blowers
F4 Fuse 15A
Blade-type fuse as SAE J 1284
F5 Fuse 8A S7 set value indicator Cool
F6 Fuse 25A X1 2 pin plug-in connection at A2 (STB)
X2 2 pin plug-in connection at A2 (STV)
H1 LED red (at pos. P) Light up immediate heater
button, ready indicator
Power on control
X3 2 pin plug-in connection at A2 (STU)
H2 Heating symbol in the
display (at P)
Operating indicator X4 2 pin plug-in connection at A2 (STZ)
H3 Lights (at P) Key and display lighting X5 2 pin plug-in connection at A2 (STY)
H4 Lights (at S1) Power on control for the
cooling
X7 12 pin plug-in
connection
at A2 (ST1)
H5 Lights (at S5) Power on control for the
cooling
X11 2 pin plug-in connection at Y
X12 12 pin plug-in
connection
at P
K1 Relay X13 15 pin plug-in
connection
K2 Relay X14 15 pin terminal strip
K3 Time relay X15 2 pin plug-in connection
K4 Relay X16 4 pin plug-in connection at S7
K5 Relay
K6 Relay Y Metering pump
Roof-Mounted Air Conditioner KK2000 E
4. INSTALLATION INSTRUCTIONS
4.1 Installation Diagrams for Cabins without Roof Gaps
Figure 4.1.
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Roof-Mounted Air Conditioner KK2000 E
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4.2 Checklist for the Installation of the KK2000 E with Heater Unit
• In the heater unit’s combustion air intake line, make an hole of 11 mm inner diameter
if the exhaust and intake lines do not exceed 4.5 meters.
• The heater unit’s combustion air intake line must be at least 600 mm.
• Make sure the complete fuel guide to the heater unit is filled before the first
initialization.
• Fasten the fuel line for the heater unit in the KK2000 E with the clamp provided on
the base plate in the system so that the fuel line cannot be damaged by the hot
exhaust pipe.
• If a fuel filter is installed for the heater unit, then this must be replaced yearly.
• To install the heater unit, the information in the installation instructions, ID no. 776
252, must also be observed.
• The hot air tube duct from the KK2000 E system to the cabin must be sealed
completely.
Roof-Mounted Air Conditioner KK2000 E
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5. INITIALIZATION
5.1 Safety Information
Observe the safety information in chapter 1.4.
5.2 Operator Information
WARNING
– Only start the air conditioning system when the vehicle
engine is running otherwise the battery will be drained.
– To prevent leaks in the shaft seals or the compressor,
there are two cases to consider:
(1) If the vehicle has not been operational for a longer
period of time, then the compressor does not need to be
switched on as well.
(2) However, if the vehicle will be used for a longer period
of time without using the air conditioner, then it is
recommended that the compressor be started once every
two weeks. Otherwise the shaft seals could be damaged if
the compressor is not operated for a long period of time.
NOTE
– Corresponding to the electrical connection (see figure
3.1), the system should only be turned on or operated
when the vehicle engine is running.
– Note that this drains the vehicle battery.
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5.3 Operating, Control, and Safety Switch
5.3.1 The system is operated with the rotary switch and indicator on the operating
panel.
5.3.2 The blower switch is the main switch for the air conditioner. This can also be
used to vary the speed of the vaporizer blowers and the corresponding air flow.
– level 1 50% air flow
– level 1 70% air flow
– level 1 100% air flow
5.3.3 Use the thermostat switch to switch off the coolant compressor and to regulate
the room temperature. The control operation is started by switching the coolant
compressor off and on. The switching is regulated by the air temperature and the
compressor speed.
5.3.4 A pressure switch is installed in the accumulator dryer to protect the compressor
and the entire air conditioning system. This switches the coupling off in abnormal
operating situations.
5.4 Operating the Air Conditioning System
See Chapter 2.4.
5.5 Operating the Air Top 3500 Heater Unit
See the Operating Manual for the Air Top 3500
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6. MAINTENANCE
6.1 Safety Information
Observe the safety information and regulations in chapter 1.4.
6.2 General
a) Only trained personnel in authorized repair depots may perform any work on the
coolant system.
b) As with all parts of a vehicle, the air conditioner is also subjected to constant
stress. To ensure perfect operation of the system and to prevent damages to the
parts, the prescribed service work must be performed regularly.
c) The correct handling of the system with records of all prescribed service work is
required for the any warranty claims for damages to parts subject to service.
6.3 Care and Maintenance
a) Independent of the following time plan, shortly after the first use of the vehicle,
check all device mountings and coolant lines for tightness.
b) Even when the air conditioner is not in operation, wear to or loosening of
individual components may occur from normal aging or from driving. Therefore,
the corresponding checks are to be performed independent of the system
operating time.
c) Independent of the operating time for the system, there may be a loss of coolant
even if the line connections are perfectly sealed. Due to the material structure of
the coolant hose lines, these have a diffusion rate that can vary according to the
ambient temperatures. If there is a relatively large loss of coolant in a short
interval, then it can be assumed that there is a leak in the system.
d) If the condenser or vaporizer blades are only slightly soiled, clean them by
applying compressed air against the normal air flow.
If these are highly soiled or greasy, first use soapy water or a suitable cleaning
solution (not aggressive to copper or aluminium) to clean them and then use
compressed air or water.
e) The filter dryer must be changed at least once per year. When working on the
coolant system, change the accumulator dryer as a rule.
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WARNING
The coolant may never be released into the air (§ 8, CFC
chlorofluorocarbon prohibition from May 06, 1991).
6.4 Checklist for Care and Maintenance
System component Maintenance work Occurrence
m 6m a
Coolant system
– Lines
– Connections
– Coolant level
– Condenser
– Accumulator Dryer
– Condensation water
drainage
– Roof-Mounted Air
Conditioner
Check condition and sealing (leak search device)
Check sealing with leak search device
Check coolant amounts on glass front and pressure
Check condition of blades (clean if dirty)
Replace
Check opening is not clogged and clean if dirty
Check entire condition and connections for tightness.
X
X
X
X
X
X
X
Compressor
– Magnetic coupling
– Compressor
– Fan belts
– Fastening element
Check that the coupling/start of compressor does not slip
Check for noise when running
Check for perfect condition and tension.
Check for condition and tightness.
X
X
X
X
Elect. Connections
– Connection lines
– plug-in connections
Check for perfect condition.
Check for perfect condition and tightness.
X
X
Legend: m – monthly, a – annually (a – if operated all year, perform twice a year)
6.5 Trouble-Shooting and Correction Measures
General
a) Proceed systematically for trouble-shooting and correction. Take the
corresponding steps for general malfunctions or deviations from expected
conditions in the pressure check as described below.
b) Certain problems can only be detected and corrected by trained personnel with
special tools.
c) If there damages to the compressor (for example, defective valve plates), the
expansion valve must be replaced as the possible cause of damage.
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Steps in the event of malfunctions in the electrical system
Systematically check individual circuits using the circuit diagram (see figure 3.1)
and localize any errors. Place special emphasis on the function of plug
connections, switches, relays, etc.
Generally check the following malfunction causes or rule out a malfunction for the
following reasons:
– Defective fuses
– Corrosion at the plug contacts
– Loose contact on the plugs
– Crimping problem on the plugs
– Corrosion on the lines and fuses
– Corrosion at the battery plugs
Steps in the event of malfunctions in the air conditioning system
– Defective vaporizer or condenser blower
– Soiled or clogged air filter, condenser or vaporizer blades.
– Loss of coolant or too little coolant in the system
If the system continues to switch off, have it checked by an authorized repair
center.
Note
To prevent icing in the vaporizer blades, avoid a combination of a lower blower level (1)
and lowest thermostatic setting (max. right) at especially high humilities.
If ice does build up, resulting in a noticeable reduction in air flow, then switch the
blower to maximum (3) and the thermostat switch to the max. left setting for 2 to
3 minutes.
Steps in the event of Malfunctions in the Coolant System
– If there are malfunctions in the coolant cycle, the system must be checked and
properly repaired by an authorized repair center. The coolant may never be released
into the air.
(§ 8, CFC chlorofluorocarbon prohibition from May 06, 1991)
6.6 Checks Before Initialization
To prevent unnecessary disassembly or redundant work, check the condition of the air
conditioner before starting maintenance work.
Visual check
a) External condition of the roof unit:
– No tears on the cover
– Air inlets and outlets clean and not damaged
– Mounting points are tight, no corrosion
– Hose and cable connections in perfect condition
– Metal holes in perfect condition.
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b) Condition of the air manifold plate
– Mounting points/screws are tight
– Ventilation switches in perfect condition.
– Ventilation inlet /outlet screens not damaged, clean
6.7 Maintenance Work
WARNING
Coolant may never be released into the air (§ 8, CFC
chlorofluorocarbon prohibition from May 06, 1991).
NOTE
Observe the safety information and regulations in chapter
1.4. and requirements in chapter 6.2.
- For maintenance purposes, only use original spare parts
and return the system to the original condition.
a) For maintenance, as a rule only use the original spare parts or standard parts
listed in Chapter 7.
b) When work is performed, the system must be returned to its original condition.
6.8 Checks and Work after Initialization
Check the coolant pressure and function of the pressure switch
a) Check if warm air is flowing
b) Check the system for leaks
General instructions:
Moisture and air or other foreign gasses in the coolant system cause
disturbances and can damage parts in the air conditioner. Therefore the system
must be carefully dried and evacuated before filling with coolant (at least 1.5
hours). This does not apply to a newly assembled air conditioner, but also to
repairs when the coolant must be drained.
The final vacuum in the system may not be more than 0.005 bar over the
absolute vacuum. The absolute pressure in the system should therefore be ≤
0.005 bar.
The value shown on the manometer for the absolute pressure depends on the
external atmospheric pressure. Note the following:
Coolant can leak through the smallest holes, therefore the coolant system must
be absolutely sealed. To prevent unnecessary loss of coolant, it is
recommended that the sealing be checked repeatedly during the evacuation.
The quick-snap valves are attached to the fittings on the coolant hoses. The
quick-snap valves for the pressure lines or the suction lines differ in diameter so
that they cannot be switched.
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c) Evacuation
Switch on the vacuum pump and vacuum the system for 30 minutes. The
absolute pressure must be at least 0.005 bar.
During the evacuation with the pump running again close all valves on the test
device and check the manometer display. If the vacuum does not change in one
minute, then it can be assumed that the system is sealed. Open the valves again
after every pressure check.
Increase in pressure means the system is not sealed. In this case, stop the
evacuation and find and seal the leaks. Then evacuate the system again.
Close all valves on the test device. Switch off the vacuum pump. Let the system
stand for one (1) hour and check the vacuum. If the vacuum changes, then there
is a leak in the system which must be sealed before repeating the evacuation.
d) Checking the high pressure monitor
– Connect the test panels to the system.
– Remove fuse F2 (condenser blower) and attach the cover.
– Keep the engine running at average speed and switch on the air conditioning.
– Check whether the compressor switches off at a pressure of 24 bar.
– Remove cover and replace fuse F2 (condenser blower).
– Check whether the compressor switches on again when the pressure drops to
17 bar.
Refilling coolant in partially filled systems
a) General instructions
Coolant is normally not consumed. Only leaks that may develop during operation
can cause a loss of coolant.
Insufficient amounts of coolant can result in reduced air conditioner performance.
Extreme loss will lead switch off the low pressure switch.
A glass front is on the accumulator dryer to check the coolant level. When this is
filled correctly and with a higher rpm, the coolant will flow smoothly about 5
minutes after the air condition is started. Individual air bubbles are irrelevant. The
coolant only needs to be filled when foam is noticeable.
The coolant is normally refilled as a gas. When this is completely emptied, the
system must be properly evacuated before filling the coolant. (see 6.8.c)
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b) Refilling coolant
Coolant in a gaseous state can only be refilled when the compressor is running
and only on the vacuum side of the system.
The coolant bottle must be vertical to fill the system with the valve on top. The
check boards are used for filling.
WARNING
If coolant is added as a liquid on the vacuum side (bottle
upside down), then the compressor will be destroyed by the
liquid.
c) Prepare and fill according to the operating instructions for the R134 maintenance
device. Filling is complete when no more bubbles can be seen forming in the
glass front.
d) Final work
– Switch off the air conditioner and vehicle engine
– Removing the test manometer
– Screw on the gasket caps.
6.9 Visual Check
When the maintenance is complete, check again visually according to chapter 6.6.
Roof-Mounted Air Conditioner KK2000 E
7. SPARE PARTS
Item Part name Ident. No.:
1 Cover, complete 65653A
2 Cable harness, KK2000 E (not illustrated) 9013192A
3 Heater unit AT 3500 65441D
4 Metering pump 26590B
5 Protective rubber sleeve, exhaust 89509A
6 Vaporizer complete, KK2000 9002502A
7 Thermal expansion valve 9002737A
8 Filter dryer R134a 45358A
9 High pressure switch 45404A
10 Coolant line NW 10 9002060A
11 Coolant line NW 8 72045A
12 Low pressure switch 38883A
13 Relay, start delayed 25536B
14 Condenser KK2000 9002487B
15 Axial blower (condensation blower) 44590A
16 Radial blower, spal 80522A
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Roof-Mounted Air Conditioner KK2000 E
Item Part name Ident. No.:
18 Compressor TM-15HD 80739B
21 Coolant hose NW 13 KK2000 67780B
22 Coolant hose NW 10 KK2000 67779B
Page 29 / 30
Roof-Mounted Air Conditioner KK2000 E
Item Part name Ident. No.:
23
Operating control for thermostat module
67638A
24 Thermostat module 66784A
27 Air manifold plate construction 9013676A
28 Dischargers, round 49932A
30 Combination operating control 85340C
31 Discharger, long 45374A
32 Fan switch, 3 level, procurement through Plasser&Theurer
33 Air conditioner switch ON / OFF (green), procurement through
Plasser&Theurer
34 External control housing from Plasser&Theurer
Page 30 / 30
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