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  5. Installation And Service Instructions Manual

Webasto KK2000 E Installation And Service Instructions Manual

Manual is about: Roof-Mounted

Summary of KK2000 E

  • Page 1

    Installation and service instructions roof-mounted air conditioner kk2000 e id no. 98278c.

  • Page 2

    Roof-mounted air conditioner kk2000 e page 2 / 30 table of contents 1. Introduction..........................................................................................................................3 1.1 contents and purpose .......................................................................

  • Page 3: 1. Introduction

    Roof-mounted air conditioner kk2000 e page 3 / 30 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 roof- mounted air conditioner kk2000 e. 1.2 re...

  • Page 4

    Roof-mounted air conditioner kk2000 e page 4 / 30 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 th...

  • Page 5: 2. General

    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...

  • Page 6

    Roof-mounted air conditioner kk2000 e page 6 / 30 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...

  • Page 7

    Roof-mounted air conditioner kk2000 e figure 2.2 page 7 / 30

  • Page 8

    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 us...

  • Page 9

    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 ...

  • Page 10

    Roof-mounted air conditioner kk2000 e figure 2.4. Page 10 / 30

  • Page 11

    Roof-mounted air conditioner kk2000 e page 11 / 30 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...

  • Page 12

    Roof-mounted air conditioner kk2000 e page 12 / 30 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 lique...

  • Page 13

    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)...

  • Page 14: 3. Technical

    Roof-mounted air conditioner kk2000 e page 14 / 30 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 operat...

  • Page 15

    Roof-mounted air conditioner kk2000 e page 15 / 30 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 / ...

  • Page 16

    Roof-mounted air conditioner kk2000 e 3.3 circuit diagram figure 3.1. Page 16 / 30

  • Page 17

    Roof-mounted air conditioner kk2000 e page 17 / 30 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 t...

  • Page 18: 4. Installation

    Roof-mounted air conditioner kk2000 e 4. Installation instructions 4.1 installation diagrams for cabins without roof gaps figure 4.1. Page 18 / 30

  • Page 19

    Roof-mounted air conditioner kk2000 e page 19 / 30 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 ...

  • Page 20: 5. Initialization

    Roof-mounted air conditioner kk2000 e page 20 / 30 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 ...

  • Page 21

    Roof-mounted air conditioner kk2000 e page 21 / 30 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 va...

  • Page 22: 6. Maintenance

    Roof-mounted air conditioner kk2000 e page 22 / 30 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...

  • Page 23

    Roof-mounted air conditioner kk2000 e page 23 / 30 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 – coo...

  • Page 24

    Roof-mounted air conditioner kk2000 e page 24 / 30 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, et...

  • Page 25

    Roof-mounted air conditioner kk2000 e page 25 / 30 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 (§ ...

  • Page 26

    Roof-mounted air conditioner kk2000 e page 26 / 30 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...

  • Page 27

    Roof-mounted air conditioner kk2000 e page 27 / 30 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 fo...

  • Page 28: 7. Spare

    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...

  • Page 29

    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

  • Page 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 ...