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List of Figures

301

Functional Diagram (Air Top 2000 without Diagnosis)....................................................................................303

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 Diagnosis.........................................................................................701

702

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

703

Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24V with Control Element .........................703

704

Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24V with Combination Timer.....................704

705

Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 
12V/24V with Control Element and Standard Timer .......................................................................................705

706

Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 
24V TRS Operation with Control Element ......................................................................................................706

707

Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 
24V TRS Operation with Combination Timer..................................................................................................707

708

Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 
24V TRS Operation with Combination Timer and 2 Auxiliary Drives ..............................................................708

709

Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 12V with Control Element ....................709

710

Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 
12V with Control Element and Timer ..............................................................................................................710

711

Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 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 without Diagnosis, 
24V with Control Element, TRS ......................................................................................................................713

714

Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 
24V TRS Operation with Control Element in Vehicles without Auxiliary Drive................................................714

715

Connection Diagram, Air Top 2000 Diagnosis with Combination Timer (not TRS!)........................................715

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 Pumpe, Installation Position and Attachment .....................................................................................804

807

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

808

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

809

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

810

Removal of Fuse Holder Attachment Plate.....................................................................................................806

811

Fuse Holder, Installation Position ...................................................................................................................806

812

Control Element ..............................................................................................................................................806

813

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

814

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

815

Replacement of Control Unit and Temperature Limiter (Air Top 2000 without Diagnosis) .............................809

816

Replacement of Control Unit and Temperature Limiter (Air Top 2000 Diagnosis)..........................................810

901

Removal of Housing Components/Covers......................................................................................................903

902

Replacement of Combustion Air Fan (Removal) ............................................................................................904

903

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

904

Disassembly of Heat Exchanger.....................................................................................................................907

List of Figures

Air Top 2000

IV

Содержание Air Top 2000

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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