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Webasto Air Top 2000, Service And Repair Manual, Page: 25 / 60

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Webasto Air Top 2000 Service And Repair Manual Download Page 25

violet

yellow

brown

black

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X1

X4

X3

X2

X5

X1

=  Connection, Combustion and Heating Air Fan

X2

=  Connection, Dosing Pump

X3

=  Connection, Flame Sensor

X4

=  Connection, Glow Plug

X5

=  Connection, Temperature Limiter

Fig. 702  Terminal Pin Assignment, Air Top 2000 without Diagnosis

702

7    Circuit Diagrams

Air Top 2000

Summary of Contents for Air Top 2000

Page 1: ...have successfully completed the factory training course and have the technical skills technical information tools and equipment required to properly complete the necessary procedures ALWAYS carefully...

Page 2: ...ture Limiter 203 2 8 Dosing Pump 203 3 Functional Description 3 1 Functional Description Air Top 2000 without Diagnosis Fig 301 301 3 1 1 Control Element 301 3 1 2 Switch On 301 3 1 3 Stabilization 30...

Page 3: ...s and Installation Regulations 801 8 6 1 Heating Air System 801 8 6 2 Fuel Supply 802 8 6 3 Dosing Pump 804 8 6 4 Fuel Filter 804 8 6 5 Combustion Air Supply 805 8 6 6 Exhaust Line 805 8 6 7 Combustio...

Page 4: ...nents Covers 902 9 2 2 Replacement of Control Unit 904 9 2 3 Replacement of Temperature Limiter 904 9 2 4 Replacement of Combustion Air Fan 905 9 2 5 Replacement of Flame Sensor 906 9 2 6 Replacement...

Page 5: ...nosis 24V with Control Element 711 712 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis 24V with Control Element and Timer 712 713 Circuit Diagram Automatic Control Air Top 2000 withou...

Page 6: ...ailed in the following The specific safety regulations applicable to this manual are highlighted in the individual chapters by Warnings Cautions and Notes 1 4 1 General Safety Notes Within the scope o...

Page 7: ...icle 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 ex...

Page 8: ...g fuel can neither accumulate nor be ig nited by hot components or electrical equipment In busses fuel lines and fuel tanks may be located neither in the passenger area nor in the driver s compart men...

Page 9: ...ernal temperature sensor Fuel supply is provided externally by a fuel dosing pump Air Heater Air Top 2000 without Diagnosis covers removed A malfunction in air heaters Air Top 2000 Diagnosis out puts...

Page 10: ...The combustion and heating air fan may be set by means of a potentiometer Control Unit Air Top 2000 without Diagnosis Air Top 2000 Diagnosis The control unit control circuit board is the central con...

Page 11: ...ide Glow Plug 2 7 Temperature Limiter The temperature limiter protects the air heater against excessive operating temperatures Overheat protection is activated at temperature higher than 150 C to inte...

Page 12: ...and heat ing air fan lasting 120 seconds at 2 3 of its max speed 3 1 3 Stabilization Diesel Operated Heaters With the glow plug activated the operating speed of the combustion and heating air fan is i...

Page 13: ...ot change A short run down max 40 seconds is automatically activated if l the vehicle engine is turned off l a conveyor facility is put into operation The short run down time depends on the operationa...

Page 14: ...without Diagnosis 1 Start 2 Control Operation 3 Rated Value reached 4 Rated Value exceeded e g due to reduced heat sumption 5 Run down 6 Control Idle 7 Start 8 Control Operation increased heat consump...

Page 15: ...w plug activated and fuel dosing pump deactivated no fuel supply Should no proper combustion develop within 120 sec onds for fuel operated within 115 seconds the combus tion and heating air fan speed...

Page 16: ...rature set with the control element If temperature falls below the one set with the control element the heater will restart without break away NOTE New settings on the control element are executed by...

Page 17: ...peed wrong l dosing pump open or short circuit l overheating l low voltage below 10 Volt or high voltage above 15 Volt in excess of 20 seconds for 12 Volt heaters l low voltage below 20 Volt or high v...

Page 18: ...Mark of conformity Heater type Heat flow Type of fuel Fuel consumption Nominal voltage Operation voltage Rated power consumption Volume flow of heating air against 0 5 bar CO2 in exhaust perm functio...

Page 19: ...ponents The following causes for trouble are not considered and should always be checked for to exclude them as cause for trouble corrosion on connector loose contact on connector wrong crimping on co...

Page 20: ...Run down after 230 Run down during combustion operation Stoppage without run down during combustion operation Interruption of dosing pump during combustion cycling and max speed for operation 30 sec...

Page 21: ...s to the number 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 att...

Page 22: ...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 Clockwise rotation increases the...

Page 23: ...ing 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 f...

Page 24: ...shows the terminal pin assignment X1 Connection Combustion and Heating Air Fan X2 Connection Dosing Pump X3 Connection Flame Sensor X4 Connection Glow Plug X5 Connection Temperature Limiter The air h...

Page 25: ...onnection Combustion and Heating Air Fan X2 Connection Dosing Pump X3 Connection Flame Sensor X4 Connection Glow Plug X5 Connection Temperature Limiter Fig 702 Terminal Pin Assignment Air Top 2000 wit...

Page 26: ...nnection 4 pole of item S X8 Connection 2 pole X9 Connection 2 pole of item A2 X11 Connection 6 pole of item A2 X12 Connection 1 pole Diagnosis K wire Y1 Dosing Pump Wire Gauges 7 5 m 7 5 15 m 0 75 mm...

Page 27: ...g indicator light H8 Heating symbol in display in item P Operating indicator light overheat indication H9 Light in item P Symbol illumination M Motor P1 Combination Timer 1531 S3 Switch Instant heatin...

Page 28: ...light H8 Heating symbol in display in item P Operating indicator light overheat indication H9 Light in item P Symbol illumination M Motor P2 Standard timer S1 Control Element Rated Value Setting Swit...

Page 29: ...re Limiter E Glow Plug F2 Fuse 24V 10A Flat Fuse SAE J 1284 H1 LED green in item S1 Operation indication H6 Light at least 1 2 W Operation indication conveyor facility M Motor S1 Rated Value Setting S...

Page 30: ...er E Glow Plug F2 Fuse 24V 10A Flat Fuse SAE J 1284 H6 Light at least 1 2 W Operation indication conveyor facility H7 LED red in item P Instant heat switch illumination standy indication operating ind...

Page 31: ...Temperature Sensor B3 Temperature Limiter E Glow Plug F2 Fuse 24V 10A Flat Fuse SAE J 1284 H7 LED red in item P Instant heat switch illumination standy indication operating indicator light H8 Heating...

Page 32: ...nt Item Nomenclature Remark A1 Air Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Temperature Limiter B4 Temperature Sensor E Glow Plug F2 Fuse 15A Flat Fuse SAE J 1284 H...

Page 33: ...4 Temperature Sensor E Glow Plug F2 Fuse 15A Flat Fuse SAE J 1284 H1 LED green in item S1 Operation indication H4 Light in item P Symbol illumination M Motor P Timer 1529 for pre timed operation S1 Ra...

Page 34: ...ure Sensor B3 Temperature Limiter E Glow Plug F1 Fuse 10A Flat Fuse SAE J 1284 H1 LED green in item S1 Operation indication M Motor S1 Rated Value Setting Switch Control Element X1 X5 Connection 2 pol...

Page 35: ...r Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Temperature Limiter E Glow Plug F1 Fuse 10A Flat Fuse SAE J 1284 H1 LED green in item S1 Operation indication H4 Light in item P Sym...

Page 36: ...r Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Temperature Limiter E Glow Plug F1 Fuse 10A Flat Fuse SAE J 1284 H1 LED green in item S1 Operation indication M Motor S1...

Page 37: ...r Heater Air Top 2000 A2 Control Unit B1 Flame Sensor B2 Temperature Sensor B3 Temperature Limiter E Glow Plug F2 Fuse 10A Flat Fuse SAE J 1284 H1 LED green in item S1 Operation indication M Motor S1...

Page 38: ...Fig 715 Connection Diagram Air Top 2000 Diagnosis with Combination Timer not TRS 715 Jumper Terminal 15 Terminal 58 Terminal 30 Terminal 31 Air Top 2000 7 Circuit Diagrams...

Page 39: ...check heating air inlet and outlet for foreign matter and contamination Contaminated or clogged heat ing air ducts may lead to overheating and thus response of the temperature limiter l Clean air hea...

Page 40: ...or return line is optional the return line must be routed almost to the tank floor otherwise the return line may be extended The fuel tap is to be mounted so that air or gas bubbles can escape towards...

Page 41: ...cording to DIN 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 bu...

Page 42: ...peration 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 Attachm...

Page 43: ...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 44: ...ction of Power Supply Preferably from the vehicle s central electrics For protection of the air heater an additional flat fuse holder is to be fitted deliverable item The fuse holder may only be locat...

Page 45: ...Fig 814 Example of an Installation 1 Control Element 2 Air Heater 3 Dosing Pump and Anti Vibration Mount 4 Fuel Filter Accessory 5 Fuel Tap 6 Exhaust Muffler 7 Fuse 1 2 7 6 3 4 5 Air Top 2000 8 Servic...

Page 46: ...t 5 and 3 according to 9 2 1 2 4 Remove upper shell according to 9 2 3 1 5 Disconnect plugged connections 1 Fig 815 or Fig 816 of terminal 6 Remove screws 3 and remove control unit 2 8 7 2 2 Installat...

Page 47: ...815 Replacement of Control Unit and Temperature Limiter Air Top 2000 without Diagnosis 1 Plug Connections 2 Control Unit 3 Screw 2 4 Lock Washer 2 5 Temperature Limiter 6 Arrester Groove 6 X6 Air Top...

Page 48: ...cement of Control Unit and Temperature Limiter Air Top 2000 Diagnosis 1 Plug Connections 2 Control Unit 3 Screw 2 4 Lock Washer 2 5 Temperature Limiter 6 Arrester Groove X9 X11 X6 3 1 4 5 2 6 8 Servic...

Page 49: ...unit Air Top 2000 TRS 24 Volt with a control unit Air Top 2000 Diagnosis TRS 24 Volt perform modifications per 8 8 3 WARNING Failure to perform modifications will result in a potential safety risk In...

Page 50: ...tional check Test TRS switch off as required stopping engine and starting auxiliary drive 8 9 First Operation After installation of the air heater the fuel supply system must be bled thoroughly NOTE D...

Page 51: ...intenace l installation of an external temperature sensor for opti mising temperature control Air Top 2000 Diagnosis see 9 1 2 1 l installation of an external temperature sensor for opti mising temper...

Page 52: ...n the underside of the roof con sole 4 Mount external temperature sensor and route cable to heater 5 Install control unit Control unit 12 Volt type only Remove temperature sensor 6 Arrest leaf spring...

Page 53: ...3 4 Y Y X X Z Z Fig 901 Removal of Housing Components Covers 1 Cover Electrical Connection 2 Upper Housing Shell 3 Cover Heating Air Outlet 4 Lower Housing Shell 5 Cover Heating Air Inlet Air Top 2000...

Page 54: ...i tion Replacement is to be performed in accordance with 9 2 3 Replacement of Temperature Limiter NOTE The procedure for replacement of the temperature limiter is identical for the air heater in insta...

Page 55: ...e not damaged 2 Place new gasket 2 Fig 903 onto flange of combustion air fan 3 NOTE Apply Loctite to screws 1 3 Bring combustion air fan into assembly position and mount using screws 1 4 Torque screws...

Page 56: ...r 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 creep oil to react long enough to free glow...

Page 57: ...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 Grommet 11 Glow Plug 12 Grommet 13 Screw Fig 904 Disassembly of Heat Exch...

Page 58: ...908 Detail A Detail B Starting Air Bore Twist Lock Fig 904 Disassembly of Heat Exchanger Sheet 2 of 2 9 Repair Air Top 2000...

Page 59: ...remove lock washers 4 Fig 815 and pull off temperature limiter 5 9 Perform work on components after disassembly see 9 1 1 9 2 7 2 Installation 1 In case a new heat exchanger is fitted secure tem perat...

Page 60: ...sto Thermosysteme GmbH for inspection or repair are to be cleaned and packaged so that they are protected against damage during handling transportation and storage In storage an ambient temperature of...

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