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Webasto Air Top 2000 S B, Service And Repair Manual

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Webasto Air Top 2000 S B Service And Repair Manual Download Page 5

III

Air Top 2000 S

List of Figures

List of Figures

501

General Failure Symptoms .............................................................................................................................501

502

Failure Symptoms during Operation ...............................................................................................................502

601

Adjustment of CO

2

 Contents ..........................................................................................................................601

701

Terminal Pin Assignment, Air Top 2000 S.......................................................................................................701

702

Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Control D i a l ............................................702

703

Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Combination Timer ..................................703

704

Circuit Diagram Automatic Control Air Top 2000 S, 

12V/24V with Control Dial and Standard Timer ..............................................................................................704

705

Connection Diagram, Air Top 2000 S with Combination Timer.....................................................................705

801

Fuel Supply.....................................................................................................................................................802

802

Webasto Fuel Tank Tap .................................................................................................................................803

803

Fuel Tapping from Plastic Tank (tapping via fuel drain plug)..........................................................................803

804

Fuel Tapping from Plastic Tank (tapping via fitting plate)...............................................................................803

805

Pipe/Hose Connection ....................................................................................................................................804

806

Dosing Pump, Installation Position and Attachment .......................................................................................804

807

Fuel Filter........................................................................................................................................................804

808

Exhaust Muffler, Direction of Flow ..................................................................................................................805

809

Exhaust Pipe Outlet, Installation Position .......................................................................................................805

810

Weather Resistant Fuse Holder........................................................................................................................806

811

Control D i a l ...................................................................................................................................................806

812

Pulling the Plug...............................................................................................................................................806

813

Example of an Installation...............................................................................................................................807

901

Removal of Housing Components/Covers......................................................................................................902

902

Replacement of Control Unit and Temperature Limiter...................................................................................904

903

Replacement of Combustion Air Fan (Disassembly) ......................................................................................905

904

Replacement of Combustion Air Fan (Assembly............................................................................................906

906

Disassembly of Heat Exchanger (Sheet 2 of 2)..........................................................................................909

905

Disassembly of Heat Exchanger (Sheet 1 of 2)..........................................................................................908

Summary of Contents for Air Top 2000 S B

Page 1: ...attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills technical information tools and equip...

Page 2: ......

Page 3: ...7 Temperature Limiter 203 2 8 Dosing Pump 203 3 Functional Description 3 1 Functional Description Air Top 2000 S 301 3 1 1 Control Element 301 3 1 2 Switch On 301 3 1 3 Stabilization 301 3 1 4 Heating...

Page 4: ...ns 806 8 7 Removal and Installation 808 8 7 1 Air Heater Removal and Installation 808 8 8 Start Up 808 List of Contents Air Top 2000 S 9 Repair 9 1 General 901 9 1 1 Work on Components after Disassemb...

Page 5: ...Fuel Tank Tap 803 803 Fuel Tapping from Plastic Tank tapping via fuel drain plug 803 804 Fuel Tapping from Plastic Tank tapping via fitting plate 803 805 Pipe Hose Connection 804 806 Dosing Pump Inst...

Page 6: ...List of Figures Air Top 2000 S IV...

Page 7: ...dents and the relevant operating safety instructions have to be observed at all times General Safety Regulations beyond the scope of these regulations are detailed in the following The specific safety...

Page 8: ...cle engine or air heater are not likely to be expected Extracting combustion air from the vehicle interior is not permissible Combustion Air Line The combustion air required must be taken from the ext...

Page 9: ...damage Fuel carrying parts are to be protected against ex cessive heat and are to be arranged so that any dripping or evaporating fuel can neither accumulate nor be ig nited by hot components or elec...

Page 10: ...ded externally by a fuel dosing pump A malfunction of the Air Top 2000 S is indicated by an error code displayed on the combination or standard timer When equipped with the standard control dial the o...

Page 11: ...ional sequencing and monitoring of the combustion operation A temperature sensor located on the control unit is used for temperature control All heaters may have the temperature sensor replaced with a...

Page 12: ...ly of the heater out of the vehicle s fuel tank Dosing Pump DP 2 for Gasoline and Diesel operated Heaters Dosing Pump DP 30 for Diesel operated Heaters 203 2 5 Flame Sensor The flame sensor is a low O...

Page 13: ...o proper combustion develop within 120 sec onds for fuel operated within 115 seconds the combus tion and heating air fan speed is increased to full load for approx 30 seconds 15 seconds for fuel opera...

Page 14: ...fan then continues to operate at ap prox 30 of full speed until temperature is below the temperature set with the control element If temperature falls below the one set with the control element the h...

Page 15: ...0 2 kg h 0 16 0 27 l h 10 15 Volt 12 Volt 9 22 W 40 40 C 40 85 C 40 20 C 40 85 C 40 75 C 40 85 C 10 45 C 70 m3 h 9 5 10 5 Length 311 2 mm Width 120 1 mm Height 121 1 mm 2 6 kg Control range Max Max S...

Page 16: ...als If individual components are checked the control unit electrical connections must be disconnected After any correction of a failure a functional test has to be performed in the vehicle 5 2 General...

Page 17: ...n o i t s u b m o c g n i r u d n w o d n u R operation Stoppage without run down during combustion operation Interruption of dosing pump during combustion cycling and max speed for operation 30 sec...

Page 18: ...r indicated in the table below After a quick pulse train there will always be an error code output Error code output on display of combination or standard timer F 01 No start after 2 attempts F 02 Fla...

Page 19: ...potentiometer A suitable tool like a small screw driver 2 5 mm tip is to be used CAUTION Set potentiometer slowly observe end positions Adjustment may be performed at any electrical system voltage Clo...

Page 20: ...ng readings should be obtained Glow plug 12 Volt red 24 Volt green Resistance at 25 C 0 324 0 360 1 3 1 44 Test current 5 mA 5 mA 6 3 2 Flame Sensor Resistance Test During electrical testing of the fl...

Page 21: ...circuits 12 or 24 Volt with control element combination timer control element and standard timer Fig 701 shows the terminal pin assignment X1 Connection Combustion and Heating Air Fan X2 Connection Do...

Page 22: ...o i t c e n n o C 5 X 1 X 2 A m e t i f o e l o p 8 n o i t c e n n o C 6 X S m e t i f o e l o p 4 n o i t c e n n o C 7 X X8 Connection 2 pole 2 A m e t i f o e l o p 2 n o i t c e n n o C 9 X 2 A m...

Page 23: ...ator light H8 Heating symbol in display in item P Operating indicator light overheat indication n o i t a n i m u l l i l o b m y S P m e t i n i t h g i L 9 H M Motor P1 Combination Timer 1531 l o r...

Page 24: ...in display in item P Operating indicator light overheat indication n o i t a n i m u l l i l o b m y S P m e t i n i t h g i L 9 H M Motor P2 Standard timer h c t i w S g n i t t e S e u l a V d e t...

Page 25: ...n Diagram Air Top 2000 S with Combination Timer 3 2 1 6 5 4 9 8 7 12 11 10 12V 24V Combination Timer 1531 Adapter Harness P N 9008440A Brown Battery Negative 12 4 Red Battery Positive 11 Black Battery...

Page 26: ...706 7 Circuit Diagrams Air Top 2000 S...

Page 27: ...weather conditions For reasons of the air heater s functional reliability per form the following servicing check heating air inlet and outlet for foreign matter and contamination Contaminated or clogg...

Page 28: ...ebasto fuel tee fitting as close to the tank as possible The connection may be made in either the supply or return line in which case the return line must lead almost to the base of the tank If this i...

Page 29: ...N 73378 As in most cases a permanently rising fuel line routing cannot be ensured the inner diameter must not exceed a certain value Starting from an inside diameter of 4 mm air or gas bubbles accumul...

Page 30: ...ring operation Dosing pump and fuel lines must not be installed in loca tions exposed to heat radiated by hot vehicle compo nents A heat shield is to be provided as required 8 6 3 2 Installation and A...

Page 31: ...y mounted near the air heater The direction of flow is optional Fig 808 Exhaust Muffler Direction of Flow Operation of the air heater is also permitted without muffler 8 6 7 Combustion Air Intake and...

Page 32: ...8 3 Connection Control Dial The cable loom is prefabricated to connect to the control dial rated value transmitter For plug disconnection pull on terminal plug only Fig 812 By pulling on the cable loo...

Page 33: ...807 Fig 813 Example of an Installation 1 Control Dial 2 Air Heater 3 Dosing Pump and Damper 4 Fuel Filter Accessory 5 Fuel Connector 6 Exhaust Muffler 7 Fuse Air Top 2000 S 8 Servicing 1 2 3 4 5 6 7...

Page 34: ...ion and secure with four nuts and lock washers use original Webasto nuts only 2 Tighten nuts with 6 1 Nm 3 Secure connection for fuel inlet on air heater 4 Secure connections for combustion air inlet...

Page 35: ...the following that modifica tion which may be incorporated easily during maintenace installation of an external temperature sensor for optimising temperature control of the Air Top 2000 S see 9 1 2 1...

Page 36: ...oth covers 3 and 6 Fig 901 can be released and removed by pressing the four detents on top and bottom using a suitable tool 9 2 1 4 Upper Housing Shell NOTE The covers for the heating air inlet and ou...

Page 37: ...ws 3 Torque screws to 0 7 0 07 Nm 3 Connect plug connections to terminal Fig 701 4 Install upper housing shell and fix in position 5 Slide on covers for heating air inlet and outlet and fix in positio...

Page 38: ...904 9 Repair Air Top 2000 S Fig 902 Replacement of Control Unit and Temperature Limiter 1 Plug Connections 2 Control Unit 3 Screw 2 7 Screw 4 Screw 2 5 Temperature Limiter 6 Bracket 3 1 7 X6 2 4 5 6...

Page 39: ...lower housing shell and discard 4 Remove air heater from lower housing shell 5 Remove insulation 1 Fig 903 6 Remove screws 1 Fig 904 7 Withdraw combustion air fan 3 and remove gasket 2 8 Perform work...

Page 40: ...r until guide slots engage with pins on fan housing 6 Fit new seal 2 Fig 903 on heater mount base 7 Install control unit see 9 2 2 2 8 Install upper housing shell air inlet and air outlet 9 Install ai...

Page 41: ...out with utmost care and must under no circumstances be twisted danger of breaking After a long period of combustion operation the glow plug may be caked by fuel deposits In this case allow penetratin...

Page 42: ...Sheet 1 of 2 9 Repair Air Top 2000 S 8 7 6 3 1 2 12 5 4 10 9 11 13 1 Flame Sensor 2 Spoiler 3 Screw 4 4 Locking Tab 5 Burner Insert 6 Combustion Tube 7 Gasket 8 Heat Exchanger 9 Cable Grommet 10 Cable...

Page 43: ...909 Fig 906 Disassembly of Heat Exchanger Sheet 2 of 2 Air Top 2000 S 9 Repair Detail A Detail B Starting Air Bore Twist Lock...

Page 44: ...nents after disassembly see 9 1 1 9 2 7 2 Installation 1 In case a new heat exchanger is fitted secure temperature limiter 5 Fig 902 with screws 4 Torque screws to 1 5 0 15 Nm 2 Fit new gasket 7 Fig 9...

Page 45: ...be exceeded 06 2008 1001 Air Top 2000 S 10 Packaging Storage and Shipping When it is necessary to ship the heater and its components to a Webasto repair center for inspection or repair they are to be...

Page 46: ...Notes Air Top 2000 S...

Page 47: ......

Page 48: ...DUCT N A INC 15083 North Road Fenton MI 48430 Technical Assistance Hotline USA 800 860 7866 Canada 800 667 8900 www techwebasto com www webasto us Org 06 2008 Rev N A P N LIT9000557A 2008 Webasto Prod...

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