Webasto Air Top 2000 S D Service And Repair Manual
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Webasto Air Top 2000 S D Service And Repair Manual

Diesel/gasoline
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Air Heater
Air Top 2000 S D (Diesel)
Air Top 2000 S B (Gasoline)
Service and Repair Manual
– Improper installation or repair of Webasto heating and cooling systems can cause
fire or the leakage of deadly carbon monoxide leading to serious injury or death.
– Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
– NEVER 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 equipment required to properly complete the
necessary procedures.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.
Air Top 2000

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Summary of Contents for Webasto Air Top 2000 S D

  • Page 1 – Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. – NEVER 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 equipment required to properly complete the necessary procedures.

  • Page 3: Table Of Contents

    Air Top 2000 S List of Contents List of Contents Introduction Scope and Purpose..........................101 1.1.1 Use of Air Heaters........................101 Meaning of Warnings, Cautions, and Notes .................... 101 Additional Documentation to be used...................... 101 Safety Information and Regulations ......................101 1.4.1 General Safety Notes........................

  • Page 4: 8. Servicing

    Air Top 2000 S List of Contents Circuit Diagrams General..............................701 Servicing General..............................801 Work on the Air Heater ..........................801 Work on the Vehicle ..........................801 Air Heater Test Run..........................801 Servicing..............................801 Visual Inspections 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...
  • Page 5 12V/24V with Control Dial and Standard Timer ....................704 Connection Diagram, Air Top 2000 S with Combination Timer..............705 Fuel Supply..............................802 Webasto Fuel Tank Tap ..........................803 Fuel Tapping from Plastic Tank (tapping via fuel drain plug)................803 Fuel Tapping from Plastic Tank (tapping via fitting plate) ................803 Pipe/Hose Connection ............................804...
  • Page 6 Air Top 2000 S List of Figures...

  • Page 7: Scope And Purpose

    Air Top 2000 S Introduction Introduction Safety Information and Regulations The general safety regulations for the prevention of acci- Scope and Purpose 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 This repair shop manual is intended to support famil- following.The specific safety regulations applicable to iarized personnel in the repair of the Air Top 2000 S.

  • Page 8: Legal Provisions For Installation

    Air Top 2000 S Introduction The heater must not be installed in the passenger or Heating Air System driver compartments of busses. Should the heater never- Heating air intake openings must be arranged so that theless be installed in such a compartment, the installa- under normal operating conditions exhaust fumes of the tion box must be sealed tight against the vehicle interior.
  • Page 9 Fuel supply must not be by means of gravity or pressurization of the fuel tank. Installation Rules for Webasto Fuel Tanks for the Fuel Supply of Heaters in Vehicles In busses the installation is not permitted in the pas- senger or driver compartment.

  • Page 10: Combustion And Heating Air Fan

    Air Top 2000 S General Description General Description 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 operating indicator flashes. In addition a heater check The air heater Air Top 2000 S operates under the out may be performed using a personal computer (refer evaporator principle and basically consists of:...

  • Page 11: Heat Exchanger

    Air Top 2000 S General Description Heat Exchanger Control Unit / Control Circuit Board The heat exchanger dissipates the heat provided by The control unit/control circuit board is the central con- combustion to the air delivered by the combustion and trolling unit for functional sequencing and monitoring of heating air fan.

  • Page 12: Flame Sensor

    Air Top 2000 S General Description Flame Sensor Temperature Limiter The flame sensor is a low-Ohm PTC resistor changing The temperature limiter protects the air heater against its resistance dependent on its heating by the flame. excessive operating temperatures. Overheat protection The signals are routed to the control unit for processing.

  • Page 13: Functional Description

    Air Top 2000 S Functional Description Functional Description Functional Description Air Top 2000 S Should no 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 3.1.1 Control Element approx.

  • Page 14: Heating Operation

    Air Top 2000 S Functional Description 3.1.4 Heating Operation 3.1.7 Switch-Off During operation the combustion exhaust gasses flow Switching the heater off extinguishes the operation indi- through the heat exchanger charging its walls with com- cation of the control element. bustion heat, which in turn is taken up by the heating air If no fuel has been delivered or if the air heater is in con- delivered by the heating air fan to be routed to the ve-...

  • Page 15: Technical Data

    The components temperature limiter and flame detector are independent of voltage. The Air Top 2000 S D heater is also licensed for use with PME (bio-diesel), which complies with ASTM D6751 and DIN EN 14214.

  • Page 16: Troubleshooting

    Air Top 2000 S Troubleshooting Troubleshooting CAUTION Troubleshooting is normally limited to the isolation of defective components. The following causes for trouble are not considered and General should always be checked for to exclude them as cause for trouble: A malfunction of the Air Top 2000 S is indicated by an corrosion on connector error code displayed on the combination or standard loose contact on connector...

  • Page 17: Failure Symptoms During Operation

    Air Top 2000 S Troubleshooting Failure Symptoms during Operation failure symptom listed, in emergencies, assistance by our service technicians may be requested. The following table (Fig. 502) lists the possible failure NOTE symptoms as they might occur during the functional Overheating and dosing pump failure are always indi- sequence of operation.

  • Page 18: Error Code Output

    Air Top 2000 S Troubleshooting Error Code Output When equipped with a combination or standard timer a malfunction will cause an error code output to the dis- play of the timer for indication. NOTE When equipped with a control dial, the error code output is indicated by flashing of the operating indica- tor/error code indication.

  • Page 19: Functional Tests

    Air Top 2000 S Functional Tests Functional Tests CAUTION Set potentiometer slowly; observe end positions. General Adjustment may be performed at any electrical system voltage. This section describes the on-vehicle and off-vehicle Clockwise rotation increases the fan speed and de- testing of the air heater to check its proper operation.

  • Page 20: Components Testing

    Air Top 2000 S Functional Tests Components Testing CAUTION During electrical testing always ensure that the control unit and the component under test are electrically discon- nected from each other. 6.3.1 Glow Plug Resistance Test During electrical testing of the glow plug using a digital multimeter, the following readings should be obtained: Glow plug 12 Volt (red)

  • Page 21: Heater Overview & Diagrams

    Air Top 2000 S Circuit Diagrams Circuit Diagrams General The air heater Air Top 2000 S may be operated using the control dial (rated value transmitter/switch) or with the control dial and a combination or standard timer. The circuit diagrams (Figs. 702 to 704) show the possible circuits 12 or 24 Volt with control element combination timer...

  • Page 22: Circuit Diagram Automatic Control Air

    Air Top 2000 S Circuit Diagrams Wire Gauges < 7.5 m 7.5 - 15 m Control Unit 0.75 mm 1.5 mm Flame Sensor 1.0 mm 1.5 mm 1.5 mm 2.5 mm Temperature Sensor 2.5 mm 4.0 mm Temperature Limiter 4.0 mm 6.0 mm Glow Plug Wire Colours...
  • Page 23 Air Top 2000 S Circuit Diagrams Wire Gauges < 7.5 m 7.5 - 15 m Control Unit 1.5 mm 0.75 mm Flame Sensor 1.0 mm 1.5 mm 1.5 mm 2.5 mm Temperature Sensor 2.5 mm 4.0 mm Temperature Limiter 4.0 mm 6.0 mm Glow Plug Wire Colours...
  • Page 24 Air Top 2000 S Circuit Diagrams Wire Gauges Control Unit < 7.5 m 7.5 - 15 m Flame Sensor 0.75 mm 1.5 mm 1.0 mm 1.5 mm Temperature Sensor 1.5 mm 2.5 mm Temperature Limiter 2.5 mm 4.0 mm 4.0 mm 6.0 mm Glow Plug Wire Colours...

  • Page 25: Connection Diagram

    Air Top 2000 S Circuit Diagrams Combination Timer 1531 Black Battery Positive or Ignition Signal (10) Grey Lights (1) (optional) Battery Positive (11) Brown Battery Negative (12, 4) Adapter Harness P/N 9008440A Fig. 705 Connection Diagram, Air Top 2000 S with Combination Timer...
  • Page 26 Air Top 2000 S Circuit Diagrams...

  • Page 27: Servicing

    The heating air hose is to be se- cured at its joints. The air heater does not require maintenance. It should however be checked by Webasto-trained skilled person- nel on regular intervals, the latest before the heating season begins (point of time, when the heater is more...

  • Page 28: Fuel Supply

    Vehicles with a Carburetor Engine The fuel may only be extracted on cars using a special Webasto 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.
  • Page 29 Hole Pattern Fuel Tank Tap Gaskets 25 mm (1 in.) Tank Fitting Plate Fig. 802 Webasto Fuel Tank Tap * Use fuel tank tap only on metal fuel tanks Fig. 804 Fuel Tapping from Plastic Tank (tapping via fitting plate) NOTE...

  • Page 30: Dosing Pump

    Webasto original parts. 8.6.4 Fuel Filter Fig. 805 Pipe/Hose Connection Only a Webasto filter, P/N 50487171A, is allowed to be used if the fuel is expected to be contaminated. Install vertically if possible, however at most horizontally (check 8.6.3 Dosing Pump flow direction).

  • Page 31: Exhaust Line

    If a contamniated combustion air supply is expected, a combustion air filter (Ident No. 21963A) can be fitted (Air Top 2000 S D only). 8.6.6 Exhaust Line Rigid pipes made of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm have to be used as...

  • Page 32: Electrical Connections

    Air Top 2000 S Servicing 8.6.8 Electrical Connections 8.6.8.3 Connection Control Dial The cable loom is prefabricated to connect to the control 8.6.8.1 Connection Air Heater, Control Dial dial (rated value transmitter). For plug disconnection pull on terminal plug only Electrical connection is according to Circuit Diagram (Fig.
  • Page 33 Air Top 2000 S Servicing Fig. 813 Example of an Installation...

  • Page 34: Removal And Installation

    8.7.1.2 Installation Locate air heater with new gasket in installation position and secure with four nuts and lock washers (use original Webasto nuts only). Tighten nuts with 6 + 1 Nm. Secure connection for fuel inlet on air heater. Secure connections for combustion air inlet and ex- haust outlet on air heater.

  • Page 35: Repair

    Air Top 2000 S Repair Repair 9.1.2.1 Installation of an External Temperature Sensor General General The heater can control the required temperature perfectly if its temperature sensor is exposed to the air of This section describes the repairs that may be per- the main area of the vehicle.

  • Page 36: Disassembly And Assembly

    Air Top 2000 S Repair Disassembly and Assembly 9.2.1.3 Covers for Heating Air Inlet and Outlet Both covers (3 and 6, Fig. 901) can be released and 9.2.1 Removal of Housing Components/Covers removed by pressing the four detents on top and bottom using a suitable tool.

  • Page 37: Replacement Of Control Unit

    Air Top 2000 S Repair 9.2.2 Replacement of Control Unit 9.2.3 Replacement of Temperature Limiter 9.2.2.1 Removal 9.2.3.1 Removal Remove heater from vehicle (see 8.7.1.1). During removal avoid the build-up of static charge (i.e. Remove covers for heating air inlet and outlet do not touch strip conductors).
  • Page 38 Air Top 2000 S Repair Plug Connections Control Unit Screw (2) Screw (2) Temperature Limiter Bracket Screw Fig. 902 Replacement of Control Unit and Temperature Limiter...

  • Page 39: Replacement Of Combustion Air Fan

    Air Top 2000 S Repair MAX. 1 Insulation 2 Seal Fig. 903 Replacement of Combustion Air Fan (Disassembly) 9.2.4 Replacement of Combustion Air Fan 9.2.4.1 Removal Remove insulation (1, Fig. 903) Remove screws (1, Fig. 904). Remove air heater (see 8.7.1.1). Withdraw combustion air fan (3) and remove gasket Remove control unit (see 9.2.2.1).
  • Page 40 Air Top 2000 S Repair 9.2.4.2 Installation • Loose wire strands of the mesh must be cut off to prevent contact with the temperature sensor. Ensure that sealing surfaces on combustion air fan • Ensure a secure fit between the heat exchanger, and on heat exchanger are not damaged.

  • Page 41: Replacement Of Flame Sensor

    Air Top 2000 S Repair 9.2.5 Replacement of Flame Sensor CAUTION The glow plug has to be pulled out with utmost care and must under no circumstances be twisted (danger of 9.2.5.1 Removal breaking). After a long period of combustion operation the glow plug may be caked by fuel deposits.
  • Page 42 Air Top 2000 S Repair Flame Sensor Spoiler Screw (4) Locking Tab Burner Insert Combustion Tube Gasket Heat Exchanger Cable Grommet Cable Grommet Glow Plug Grommet Screw Fig. 905 Disassembly of Heat Exchanger (Sheet 1 of 2)
  • Page 43 Air Top 2000 S Repair Detail A Starting Air Bore Detail B Twist Lock Fig. 906 Disassembly of Heat Exchanger (Sheet 2 of 2)

  • Page 44: Replacement Of Burner Insert, Combustion Tube, And Heat Exchanger

    Air Top 2000 S Repair 9.2.7 Replacement of Burner Insert, Combustion Tube, and Heat Exchanger CAUTION If the heat exchanger is going to be replaced, the temperature limiter must also be replaced. 9.2.7.1 Removal Remove air heater (see 8.7.1.1). Remove control unit (see 9.2.2.1). Remove combustion air fan (see 9.2.4.1).

  • Page 45: Packaging/Storage And Shipping

    10.1 General When it is necessary to ship the heater and its components to a Webasto repair center for inspection or repair, they are to be cleaned and packaged so that they are protected against damage during handling, transportation, and storage.
  • Page 46 Air Top 2000 S Notes...
  • Page 48 N.A., I EBASTO RODUCT 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 860-7866 Canada: (800) 667-8900 www.techwebasto.com Org. 06/2008 Rev. N/A P/N LIT9000557A © 2008 Webasto Product N.A., Inc. www.webasto.us...

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Air top 2000 s b

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