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  4. Air Top 2000 ST B
  5. Workshop Manual

Webasto Air Top 2000 ST B Workshop Manual

Summary of Air Top 2000 ST B

  • Page 1

    Luft-heizgeräte air heaters 03/2003 workshop manual air top 2000 st type air top 2000 st b (petrol) type air top 2000 st d (diesel).

  • Page 2

    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. To install and repair webasto heating and cooling systems you need to have completed a webasto training course and have the appropriate t...

  • Page 3

    Air top 2000 st table of contents i table of contents 1 introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 1.1 contents and purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 4

    Table of contents air top 2000 st ii 6 function tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 6.1 general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 5

    Air top 2000 st table of contents iii 9 repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901 9.1 general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 6

    List of illustrations air top 2000 st iv list of illustrations fig. 201 air top 2000 st air heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 fig. 202 air top 2000 st air heater without casing . . . . . . . . . . . . . . ...

  • Page 7

    Air top 2000 st introduction 101 1 introduction 1.1 contents and purpose this workshop manual is designed to assist trained person- nel, with repairing both the petrol and the diesel versions of the air top 2000 st air heaters. 1.1.1 use of the air heaters the webasto air top 2000 st air heaters are...

  • Page 8

    Introduction air top 2000 st 102 2.2. / 5.3.2. (part i) positioning of heater 2.2.1. / 5.3.2.1. (part i) body sections and any other components in the vicinity of the heater must be pro- tected from excessive heat and the possibility of fuel or oil contamination. 2.2.2. / 5.3.2.2. (part i) the combu...

  • Page 9

    Air top 2000 st introduction 103 1.4.2 general safety information the mouth of the exhaust pipe should be installed upwards, to the side or, if the exhaust pipe passes under the floor of the vehicle, to the side or rear limit of the driver’s cab or the vehicle. The function of important parts of the...

  • Page 10

    Introduction air top 2000 st 104 note if any damage or leaks are found on the fuel line, the heater must not be used until the damage has been rectified by an authorised webasto workshop. Put the heater out of action by removing the fuse. Overheating keep the hot air inlet and hot air outlet free of...

  • Page 11

    Air top 2000 st general description 201 2 general description the air top 2000 st air heaters are based on the evaporator principle and essentially consist of the following – the drive unit with a combustion and hot air blower – the heat exchanger – the burner insert with combustion chamber – the co...

  • Page 12

    General description air top 2000 st 202 2.2 heat exchanger the heat generated by the combustion process is transferred to the air transported by the combustion and hot air blowers in the heat exchanger. Fig. 204 heat exchanger 2.3 burner insert with combustion chamber the fuel is distributed over th...

  • Page 13

    Air top 2000 st general description 203 2.6 glow plug the mixture of fuel and air is ignited by the glow plug when the heater is started. The glow plug takes the form of an electrical resistor and is positioned in the burner insert on the side away from the flame. Fig. 208 glow plug 2.7 overheating ...

  • Page 14

    General description air top 2000 st 204 page for notes.

  • Page 15

    Air top 2000 st description of operation 301 3 description of operation 3.1 control element the control element is designed to switch the heater on and off, adjust the required room temperature (intake temperature between approx. 5 °c and 35 °c) and to reset the heater after a fault. The green led s...

  • Page 16

    Description of operation air top 2000 st 302 if, at minimum heat output, the intake temperature set on the control element is exceeded, the metering pump is shut down and the combustion process ended. To burn off the flame properly the blower speed falls after 20 seconds to low-fire rate speed and t...

  • Page 17

    Air top 2000 st description of operation 303 if the faz reaches a value of 6, the heater will go into fault lock-out mode and the permanent flame failure counter fazp will be incremented by 1. In control mode the permanent flame failure counter fazp will be decremented by 1. When the heater is burni...

  • Page 18

    Description of operation air top 2000 st 304 page for notes.

  • Page 19

    Air top 2000 st technical data 401 4 technical data except where limit values are specified, the technical data listed in the table refer to the usual heater tolerances of ± 10% at an ambient temperature of + 20 °c and at the rated voltage and in rated conditions. Electrical components: the control ...

  • Page 20

    Technical data air top 2000 st 402 setpoint values: 12 v 24 v glow plug at 25 ºc test current: red marking 0.263 - 0.323 ohms green marking 1.125 - 1.375 ohms drive unit outside overheating temperature sensor at 25 ºc 2- 2.5 ohms. Undervoltage switch-off (triggering time > 20 s ) ≤ 10.5 v ≤ 20.5 v o...

  • Page 21

    Air top 2000 st troubleshooting 501 5 troubleshooting 5.1 general this section describes how to identify and remedy faults on the air top 2000 st air heater. If a fault occurs, an error code will be output in the display of the combination timer. If the heater has a control element, the on control l...

  • Page 22

    Troubleshooting air top 2000 st 502 5.3 error symptoms during function the following table (fig. 502) lists the possible error symptoms in the order in which they may occur during operation. In the event of a fault, the error is to be located using this table and rectified. It is important that the ...

  • Page 23

    Air top 2000 st troubleshooting 503 5.4 error code output if the heater is fitted with a combination timer, an error code output will appear on the display of the timer after a fault occurs. Note the error code is output if the heater is fitted with a control element after an error has occurred by t...

  • Page 24

    Troubleshooting air top 2000 st 504 f 05 flame monitor interrupt or short circuit (only petrol heater) 1a flame monitor circuit the switched cable of the element has a short circuit to earth 9a flame monitor circuit interrupt or short circuit to +ub replace flame monitor replace flame monitor f 06 e...

  • Page 25

    Air top 2000 st troubleshooting 505 f 12 heater unit lock-out 07 the permanent heater fault lock-out has been activated remove the fuse and reinsert it note the following error has occurred several times: fault counter more than 3 times incorrect start counter more than 9 times overheating counter m...

  • Page 26

    Troubleshooting air top 2000 st 506 page for notes.

  • Page 27

    Air top 2000 st function tests 601 6 function tests 6.1 general this section describes the tests conducted on the heater when it is installed and not installed to verify that it is in working order. Warning the heater must not be operated in enclosed areas such as garages and workshops without an em...

  • Page 28

    Function tests air top 2000 st 602 6.3 settings 6.3.1 setting co 2 content the co 2 content in the emissions is set using the adjustment knob on the control element. At a constant blower speed the volume of fuel is controlled by changing the metering pump cycle. Important the co 2 measuring instrume...

  • Page 29

    Air top 2000 st function tests 603 6.3.2 co 2 setting of reference heater the reference heater is set to 10.3 vol.% co 2 at a geodetic altitude of 0 metres at the factory. For later resetting, a co 2 value must be set in accordance with the following table as per the geodetic altitude. Also see para...

  • Page 30

    Function tests air top 2000 st 604 6.4.1 burner insert component see fig. 904, item 5 2 1 1 2 1 1 burner insert combustion chamber mechanically damaged? No yes starting air hole open? No check function on heater test bench can co 2 value be adjusted with to the correct value? No yes procedure testin...

  • Page 31

    Air top 2000 st function tests 605 6.4.2 glow plug resistance test (only petrol heater) see fig. 904, item 1 if you conduct this test with a digital multimeter, the flame monitor must have the values shown as following: cold testing: resistance at 25 °c: 2.6 - 3.4 ohms. Test current: hot testing: re...

  • Page 32

    Function tests air top 2000 st 606 a 2 2 2 1 2 1 a flame monitor contacts detached? No yes procedure testing and measuring equipment visual visual inspection visual inspection visual inspection resistance measurement digital multimeter visual inspection no yes no yes no yes cables damaged? Ceramic b...

  • Page 33

    Air top 2000 st function tests 607 6.4.3 glow plug component see fig. 904, item 6 note the resistance test must be carried out with an ohmmeter suitable for small resistance values. A resistance test with a simple digital multimeter is too inaccurate to find the precise values. A new glow plug can b...

  • Page 34

    Function tests air top 2000 st 608 a 2 2 2 1 2 1 a glow plug contacts detached? No yes procedure testing and measuring equipment visual visual inspection visual inspection visual inspection resistance measurement digital multimeter visual inspection no yes no yes no yes cables damaged? Ceramic broke...

  • Page 35

    Air top 2000 st function tests 609 6.4.4 combustion air fan component (drive) see fig. 903, item 5 2 1 1 2 1 combustion air fan (drive) externally damaged? No yes procedure testing and measuring equipment visual visual inspection continuity measurement digital multimeter motor start-up voltage sourc...

  • Page 36

    Function tests air top 2000 st 610 6.4.5 overheating sensor component see fig. 903, item 8 if you conduct this resistance test with a digital multimeter, the overheating sensor must have the values shown in the following diagram (fig. 601). Fig. 601 characteristic resistance values of a pt 2000 over...

  • Page 37

    Air top 2000 st function tests 611 6.4.6 control unit component see fig. 701 and fig. 903, item 3 2 1 2 control unit externally damaged? No yes procedure testing and measuring equipment visual visual inspection conduct function test with the reference unit, mount the control unit to be tested in the...

  • Page 38

    Function tests air top 2000 st 612 6.4.7 heater component 3 3 3 3 a complete heater testing of all electrical components description procedure testing and measuring equipment remove upper shell from heater and pull component connector off control unit pcb. Wire colours of individual components: glow...

  • Page 39

    Air top 2000 st function tests 613 2 b a check function on heater test bench description procedure testing and measuring equipment function test – heater test bench – pc (personal computer) – webasto diagnosis adapter reading out control unit data: burning hours, number of starts, errors send printo...

  • Page 40

    Function tests air top 2000 st 614 3 2 c b reinstalling control unit in heater to be tested description procedure testing and measuring equipment replace component and continue function test – heater test bench – co 2 measuring unit – pc (personal computer) – webasto diagnosis adapter – reference he...

  • Page 41

    Air top 2000 st function tests 615 2 2 3 c description procedure testing and measuring equipment conduct function test with reference heater. Set reference unit to nominal co 2 value locally after 5 minutes of full-load operation in accordance with graphic, install burner to be tested in reference u...

  • Page 42

    Function tests air top 2000 st 616 page for notes.

  • Page 43

    Air top 2000 st circuit diagrams 701 7 circuit diagrams 7.1 general the air top 2000 st heater units can be operated with the heater control (setpoint generator/switch) or a combination timer. The circuit diagrams (fig. 702 to fig. 705) show the possible circuits for 12 or 24 volt with • control ele...

  • Page 44

    Circuit diagrams air top 2000 st 702 fig. 702 system circuit diagram air top 2000 st, 12v/24v with control element and vehicle blower fig. 703 system circuit diagram air top 2000 st, 12v/24v with combination timer and vehicle blower.

  • Page 45

    Air top 2000 st circuit diagrams 703 fig. 704 system circuit diagram air top 2000 st, 12v/24v adr operation with control element fig. 705 system circuit diagram air top 2000 st, 12v/24v with combination timer and electrical battery isolation switch.

  • Page 46

    Circuit diagrams air top 2000 st 704 fig. 706 air top 2000 st with combination timer connection diagram adapter wiring harness red: terminal 30 grey: terminal 58 black: terminal 15 brown: terminal 31 combination timer 1531.

  • Page 47

    Air top 2000 st circuit diagrams 705 7.2 legend for circuit diagrams cable cross-sections 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 2.5 mm 2 4.0 mm 2 4.0 mm 2 6.0 mm 2 cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white item ...

  • Page 48

    Circuit diagrams air top 2000 st 706 page for notes.

  • Page 49

    Air top 2000 st servicing work 801 8 servicing work 8.1 general this section describes the servicing work that can be carried out on the heater when it is installed. 8.2 work on the heater disconnect the main power cable from the vehicle’s battery before carrying out any work on the heater. The main...

  • Page 50

    Servicing work air top 2000 st 802 important in vehicles used to transport people, the air outlet opening is to be installed in such a way that it is at least 20 cm away from all body parts. The heaters check the internal temperature rise automatically each time they are switched on. If this is abov...

  • Page 51

    Air top 2000 st servicing work 803 fig. 801 fuel supply note only use a tank extractor with metal fuel tanks fig. 802 webasto tank connector fig. 803 fuel extractor from the plastic tank (extraction through tank drain screw) note the fitting must be made from metal! Fig. 804 fuel extractor from the ...

  • Page 52

    Servicing work air top 2000 st 804 8.6.2.2 fuel lines only steel, copper and plastic lines of plasticised, light and temperature-stabilised pa11 or pa12 (e.G. Mecanyl rwtl) pursuant to din 73378 may be used for the fuel lines. Since the lines normally cannot be routed with a constant rising gradient...

  • Page 53

    Air top 2000 st servicing work 805 8.6.5 combustion air supply under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel. It must be located so that it cannot become clogged with dirt. Note the co...

  • Page 54

    Servicing work air top 2000 st 806 8.6.8 electrical connections 8.6.8.1 heater connection, control element the electrical connection is to be made as shown in the appropriate circuit diagram (see section 7). To connect the wiring harness, remove the cover (see 9.2.1.1) on the heater and connect the ...

  • Page 55

    Air top 2000 st servicing work 807 fig. 815 installation example for heater in recirculation mode 1 control element 2 heater 3 metering pump and damper 4 fuel filter (accessory) 5 tank connector 6 exhaust silencer 7 fuse.

  • Page 56

    Servicing work air top 2000 st 808 8.7 removal and installation important when the heater is installed it must not be dismantled. 8.7.1 heater, removal and installation 8.7.1.1 removal 1. Disconnect the battery. 2. Pull the cover off the top shell as described in 9.2.1.1 3. Disconnect the wiring har...

  • Page 57

    Air top 2000 st repair 901 9 repair 9.1 general this section describes the repair work that may be carried out on the air top 2000 st heater after it has been removed from the vehicle. Any further dismantling will invalidate the warranty. Only use the spare parts from the appropriate spare parts kit...

  • Page 58

    Repair air top 2000 st 902 9.2 dismantling and assembling 9.2.1 remove the casing parts 9.2.1.1 cover for electrical connection the cover (1,fig. 902) can be carefully levered off using a blunt blade in the areas marked . 9.2.1.2 grille for hot air inlet and outlet the grille (5) can be released fro...

  • Page 59

    Air top 2000 st repair 903 . Fig. 902 remove/fit the casing parts 1 2 3 4 5 6 1 cover, electrical connection 2 top shell 3 cover, hot air outlet 4 bottom shell 5 grille 6 cover, hot air inlet 7 insulators 5 7 widening of corner rib insulator positioning insulator.

  • Page 60

    Repair air top 2000 st 904 9.2.3 replace control unit 9.2.3.1 removal 1. Remove heater (see 8.7.1.1). 2. Remove casing parts (see 9.2.1). 3. Spread apart the lock of the hot air blower. 4. Pull the hot air blower (1, fig. 903) off the motor shaft by hand. 5. Disconnect plug connections on control un...

  • Page 61

    Air top 2000 st repair 905 9.2.6 replace flame sensor (petrol heater only) 9.2.6.1 removal 1. Remove the heater (see 8.7.1.1). 2. Remove the casing parts (see 9.2.1). 3. Remove the control unit (see 9.2.3.1). 4. Remove the combustion air fan (see 9.2.5.1). 5. Remove the two screws (2, fig. 903) and ...

  • Page 62

    Repair air top 2000 st 906 fig. 903 change control unit, combustion air fan and overheating sensor 5 1 hot air blower 2 torx screw (3) 3 control unit 4 torx screw (5) 5 combustion air fan (drive) 6 seal 7 heat exchanger 8 overheating sensor 9 insulator (4) 6 4 3 9 8 7 1 2 detail a.

  • Page 63

    Air top 2000 st repair 907 9.2.7 change glow plug 9.2.7.1 removal 1. Remove the heater (see 8.7.1.1). 2. Remove the casing parts (see 9.2.1). 3. Remove the control unit (see 9.2.3.1). 4. Remove the combustion air fan (see 9.2.5.1). 5. Press the cable grommet (10, fig. 904) out of the heat exchanger ...

  • Page 64

    Repair air top 2000 st 908 fig. 904 change the glow plug, flame sensor, burner insert and heat exchanger 1 flame sensor (only petrol heater) 2 torx screw (4) 3 air baffle 4 securing strap 5 burner insert 6 glow plug 7 screw 8 grommet 9 heat exchanger 10 cable grommet 11 cable grommet (only petrol he...

  • Page 65

    Air top 2000 st repair 909 9.2.8 change burner insert, combustion pipe and heat exchanger 9.2.8.1 removal 1. Remove the heater (see 8.7.1.1). 2. Remove the casing parts (see 9.2.1). 3. Remove the control unit (see 9.2.3.1). 4. Remove the overheating sensor (see 9.2.4.1). 5. Remove the combustion air...

  • Page 66

    Repair air top 2000 st 910 fig. 905 starting air hole in burner insert starting air hole.

  • Page 67

    Air top 2000 st packing, storage and shipping 1001 10 packing, storage and shipping 10.1 general if the heater or its components are sent to webasto ag for testing or repair, it must be cleaned and packed in such a way that it is protected against damage during handling, transport and storage. An am...

  • Page 68

    Packing, storage and shipping air top 2000 st 1002 page for notes.

  • Page 70

    Ident -no . 9 010 439 c • 11 /0 9 • err o rs an d omis sion s except ed • prin ted in germany • © w e b a st o ag, gcs 2 009 webasto ag postfach 80 d - 82132 stockdorf germany national: hotline: 01805 93 22 78 (€ 0,14 aus dem deutschen festnetz) hotfax: 0395 5592 353 hotmail: technikcenter@webasto.C...