Webasto Air Top 2000 ST B Installation Manual
Gasoline, diesel air heater
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Also See for Air Top 2000 ST B:
- Workshop manual (70 pages) ,
- Installation instructions manual (60 pages) ,
- Installation manual (54 pages)
Table of Contents
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Air Heater
Air Top 2000 ST B (Gasoline)
Air Top 2000 ST D (Diesel)
Installation 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.
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Table of Contents
Related Manuals for Webasto Air Top 2000 ST B
Summary of Contents for Webasto Air Top 2000 ST B
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Page 1: Installation Manual
– 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
13.1 Legend for Circuit Diagrams ..............23 www.webasto.us Webasto Product N.A., Inc. - Page 4 16.2 Fuel for Air Top 2000 ST B (Gasoline)....... . .
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Page 5: Safety And General Information
General Information Webasto Product North America, Inc. is pleased to provide this installation manual with the Air Top 2000 ST heating system. When used according to the guidelines stated in this manual, you can expect to provide years of trouble-free, enjoyable operation for your customer. -
Page 6: Regulations For Installation In The Vehicle
The supply of heating air must consist of either fresh air or recirculated air and must be taken from a clean area which cannot be contaminated by exhaust fumes from the engine, the internal combustion heater or any other source Webasto Product N.A., Inc. www.techwebasto.com... -
Page 7: Hot Air Outlet
Webasto. The same applies if repairs are carried out incorrectly or with the use of parts other than genuine Webasto service parts. This will result in the invalidation of the type approval for the heater and therefore of its homologation / type licence. -
Page 8: Purpose Of The Air Heater
Purpose of the Air Heater Air Top 2000 ST Purpose of the Air Heater The Webasto Air Top 2000 ST air heaters are designed – to heat cabins, boats, trucks, minibuses, vans and motor homes – to defrost vehicle windows The air heaters operate independently of the engine and are connected to the fuel tank and the electrical system of the vehicle. -
Page 9: Installation
The seal designed and supplied for this purpose must be used (see Figure 4). The same applies when using the optional mounting plate and closed cell foam gasket (see Figure 5). www.webasto.us Webasto Product N.A., Inc. -
Page 10: To Install The Heater
A seal (Figure 4) must be fitted between the heater and the vehicle body. This seal must be replaced each time the heater is installed. The support area for the heater foot must be flat. A special tools can be purchased from Webasto to drill the holes and, if necessary, smooth the support area. -
Page 11: Optional Mounting Plate
After installation, check that the heater casing is not in contact with any parts of the vehicle body. A failure to do this may result in the hot air fan binding internally (Figure 6). Ensure that all moving part can move freely Figure 6. Installation www.webasto.us Webasto Product N.A., Inc. -
Page 12: Factory Plate
The model/serial number plate of the heater must be positioned so that it cannot be damaged and must be clearly legible when the heater is installed (otherwise a duplicate model plate must be used). Inapplicable years must be erased from the model plate. Webasto Product N.A., Inc. www.techwebasto.com... -
Page 13: Installation Example
Air Top 2000 ST Installation Example Installation Example Figure 7. Installation example with heater in stalled under-bunk. (Recirculation mode) www.webasto.us Webasto Product N.A., Inc. -
Page 14: Hot Air System
Figure 8. Hot air inlet and hot air outlet (recirculation mode) IMPORTANT! If you use the heater without a hot air inlet hose, the inlet grille supplied with the heater must be used at all times. Webasto Product N.A., Inc. www.techwebasto.com... -
Page 15: External Temperature Sensor
– by close to heat sources (for example the vehicle’s own heating system). – be placed in direct sunlight (for example on the dashboard). – be installed behind curtains or the like. Figure 10. External temperature sensor - optional www.webasto.us Webasto Product N.A., Inc. -
Page 16: Fuel Supply
Vehicles with a Carburetor Equipped Engine The fuel may only be extracted using the special Webasto fuel extractor (see Figure 12) 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 (see Figure 13). -
Page 17: Vehicles With Fuel Injection Engines
(see Figure 12), in which case it must be ensured that the return line continues almost to the bottom of the tank (see Figure 13 for details of the minimum distance from the bottom of the tank). If this is not the case Webasto fuel extractors or standpipes (see Figures 13, 14 and 15) may be used. -
Page 18: Connecting Two Fuel Lines With A Coupler Hose
The metering pump and fuel lines must not be installed within range of the radiated heat from hot vehicle parts. A heat shield must be used if necessary Figure 17. Fuel metering pump DP 30.2 / 30.3 Webasto Product N.A., Inc. www.techwebasto.com... -
Page 19: Installation And Attachment
The metering pump must be secured with a vibration-damping mounting. Its installation position is limited as shown in Figure 17 in order to ensure effective automatic bleeding. As a result of the risk of corrosion, only genuine Webasto parts may be used for the plug connections between the metering pump and the metering pump wiring harness. -
Page 20: Combustion Air Supply
Do not use an exhaust line as the combustion air line since otherwise the metering pump cable from the combustion air inlet port may be damaged. The combustion air opening must not be under the minimum water drive-through level permitted for the vehicle. See the regulations for the installation for further regulations. Webasto Product N.A., Inc. www.techwebasto.com... -
Page 21: Exhaust Pipe
The exhaust pipe is secured to the heater using a clamping collar, for example. See the ‘regulations for installation’ for other requirements. The exhaust muffler should ideally be installed near the heater. The heater may also be operated without a muffler. Ø 0-90° 0-90° Figure 19. Exhaust muffler - exhaust flow is non-directional (arbitrary) www.webasto.us Webasto Product N.A., Inc. -
Page 22: Combustion Air Inlet And Exhaust Lines
Exhaust line: max. 270°. Discharge direction almost vertical 90° ± 10° Figure 23. Exhaust pipe opening IMPORTANT! If the exhaust pipe ends other than as shown in Figure 23, it will pose a fire risk. Webasto Product N.A., Inc. www.techwebasto.com... -
Page 23: Electrical Connections
Cigar lighter sockets and auxiliary power outputs for C.B. radio’s and other electronic accessories are not considered adequate power supplies for the Air Top 2000 ST. www.webasto.us Webasto Product N.A., Inc. -
Page 24: Control Element (Rheostat) Connection
As an option an external temperature sensor may be installed in the passenger cabin (see page13). See installation instructions included with the sensor or see the service instructions in the Workshop manual for further information. Figure 29. External temperature sensor - optional Webasto Product N.A., Inc. www.techwebasto.com... -
Page 25: Circuit Diagrams
Battery Positive or Ignition Signal (10) Grey Lights (1) (optional) Battery Positive (11) Brown Battery Negative (12, 4) Adapter Harness P/N 9008440A Figure 30. Air Top 2000 ST with combination timer 1531 - connection diagram www.webasto.us Webasto Product N.A., Inc. - Page 26 If ventilation mode is not desired, leave pink wire disconnected and protect from grounding. No heating operation with pink wire grounded! Figure 31. Standard system wiring diagram for the Air Top 2000 ST, 12 / 24 Volt with control element. Webasto Product N.A., Inc. www.techwebasto.com...
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Page 27: Starting The Heater For The First Time
Where desired, a separate switch installed between the 20 ga pink wire (X6, Pin-16) and a ground point allows the user to chose between heating and ventilation mode. Refer to Figure 31, item S3 for connection detail. In ventilation mode (switch S3 ‘On’) the fan speed is regulated by the control element knob. www.webasto.us Webasto Product N.A., Inc. -
Page 28: Fault Lock-Out
Ceramic glow pin interrupt or short circuit F 10 Overheating: Resulting in permanent heater fault lock-out F 11 Overheating sensor interrupt or short circuit F 12 Heater lock-out F 14 Overheating sensor incorrect position F 15 Set point generator interrupt Webasto Product N.A., Inc. www.techwebasto.com... -
Page 29: Technical Data
V or 24 V. The timer, overheating sensor and temperature sensor component are not dependent on voltage. 16.2 Fuel for Air Top 2000 ST B (Gasoline): The fuel specified by the vehicle manufacturer must be used. 16.3 Fuel for Air Top 2000 ST D (Diesel/Heating Oil): The diesel fuel specified by the vehicle manufacturer must be used. -
Page 30: Version
Version Air Top 2000 ST 17. Version Air Top 2000 ST B (Gasoline) Air heater for gasoline (12 V) Air Top 2000 ST D (Diesel) Air heater for Diesel/heating oil (12 or 24 V) Webasto Product N.A., Inc. www.techwebasto.com... -
Page 31: Drilling Template
Air Top 2000 ST Drilling Template 18. Drilling Template Ø Ø Ø Ø Ø Figure 33. Drilling Template (Dimensions in millimeters) www.webasto.us Webasto Product N.A., Inc. - Page 32 Notes Air Top 2000 ST www.webasto.us Webasto Product N.A., Inc.
- Page 33 Air Top 2000 ST Notes www.webasto.us Webasto Product N.A., Inc.
- Page 34 Notes Air Top 2000 ST www.webasto.us Webasto Product N.A., Inc.
- Page 36 Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 860-7866 Canada: (800) 667-8900 www.webasto.us www.techwebasto.com Org. 03/2006 Rev. 11/2006 P/N 5001118A...