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  4. Air Top 2000 ST D
  5. Service And Repair Manual

Webasto Air Top 2000 ST D Service And Repair Manual

Summary of Air Top 2000 ST D

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    – 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 tool...

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    Air top 2000 st table of contents www.Webasto.Us i webasto product n.A., inc. Contents page 1. Introduction 1 1.1 contents and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1.1 use of the ai...

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    Table of contents air top 2000 st webasto product n.A., inc. Ii www.Techwebasto.Com 8. Servicing work 27 8.1 general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 8.2 work on the ...

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    Air top 2000 st table of contents www.Webasto.Us iii webasto product n.A., inc. 9.2.4 changing the overheating sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 9.2.4.1 removal . . . . . . . . . . . . . . . . . . . . . . . . ....

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    Www.Webasto.Us 1 webasto product n.A., inc. Air top 2000 st introduction 1. Introduction 1.1 c ontents and p urpose this repair shop manual is intended to assist trained personnel with repairing both the gasoline and the diesel versions of the air top 2000 st air heaters. 1.1.1 u se of the a ir h ea...

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    Webasto product n.A., inc. 2 www.Techwebasto.Com introduction air top 2000 st the electric cables and controls for the air-conditioning system must be arranged in the vehicle so that their proper functioning cannot be adversely affected in normal operating conditions. The following points for the in...

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    Www.Webasto.Us 3 webasto product n.A., inc. Air top 2000 st introduction authorized webasto workshop. After this the heater lock-out can be cancelled by switching it off and then on again. If this action does not produce the required success (if the heater overheats again) take it to a webasto-autho...

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    Www.Webasto.Us 5 webasto product n.A., inc. Air top 2000 st general description 2. General description the air top 2000 st air heater is based on the evaporator principle and essentially consists of the following: – the drive unit with a combustion and hot air blower – the heat exchanger – the burne...

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    Webasto product n.A., inc. 6 www.Techwebasto.Com general description air top 2000 st 2.2 h eat e xchanger the heat generated by the combustion process is transferred to the air transported by the combustion and hot air blowers in the heat exchanger. Figure 4: heat exchanger 2.3 b urner i nsert with ...

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    Www.Webasto.Us 7 webasto product n.A., inc. Air top 2000 st general description 2.6 c eramic g low p in the mixture of fuel and air is ignited by the glow plug when the heater is started. The glow pin takes the form of an electrical resistor and is positioned in the burner insert on the side away fr...

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    Www.Webasto.Us 9 webasto product n.A., inc. Air top 2000 st functional description 3. Functional description 3.1 c ontrol e lement (r heostat ) the control element is designed to switch the heater on and off, adjust the required room temperature (intake temperature between 5 °c and 35 °c) and to res...

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    Webasto product n.A., inc. 10 www.Techwebasto.Com functional description air top 2000 st 3.5 c ontrol p ause after the temperature set on the control element has been reached, the heat output is reduced. The speed of the heating and combustion air blower and the delivery rate of the metering pump ar...

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    Www.Webasto.Us 11 webasto product n.A., inc. Air top 2000 st functional description 3.7.1 e rror m onitor the overheat, incorrect start and flame failure errors are counted and cause the heater to suffer a fault lock-out after an error has occurred the maximum number of times. The incorrect start co...

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    Www.Webasto.Us 13 webasto product n.A., inc. Air top 2000 st technical data 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 (+68 °f) and at the rated voltage and in rate...

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    Www.Webasto.Us 15 webasto product n.A., inc. Air top 2000 st troubleshooting 5. Troubleshooting 5.1 g eneral 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 hea...

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    Webasto product n.A., inc. 16 www.Techwebasto.Com troubleshooting air top 2000 st 5.3 e rror s ymptoms during f unction the following table 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 an...

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    Www.Webasto.Us 17 webasto product n.A., inc. Air top 2000 st troubleshooting 5.4 e rror c ode o utput 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 con...

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    Webasto product n.A., inc. 18 www.Techwebasto.Com troubleshooting air top 2000 st f 04 premature flame recognition 05 a flame was detected before combustion had started diesel: replace overheating sensor / control unit gasoline: replace flame sensor f 05 flame sensor interrupt or short circuit (gaso...

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    Www.Webasto.Us 19 webasto product n.A., inc. Air top 2000 st troubleshooting f 10 overheating 06 the overheating fault lock-out has tripped (heater overheated) 17 incorrect application or illegal insulation (Ühs gradient too high) find and remove the cause of the overheating note if no other cause c...

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    Www.Webasto.Us 21 webasto product n.A., inc. Air top 2000 st functional tests 6. Functional tests 6.1 g eneral 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 a...

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    Webasto product n.A., inc. 22 www.Techwebasto.Com functional tests air top 2000 st 6.3.3 o verheating s ensor r esistance t est if you conduct this test with a digital multimeter, the overheating sensor must have the values shown in the following diagram: characteristic resistance values of a pt 200...

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    Www.Webasto.Us 23 webasto product n.A., inc. Air top 2000 st circuit diagrams 7. Circuit diagrams 7.1 g eneral the air top 2000 st heater can be controlled with the control element (nominal value adjuster/switch) or a combination timer. The circuit diagrams (fig. 12 and fig. 13) show the possible ci...

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    Webasto product n.A., inc. 24 www.Techwebasto.Com circuit diagrams air top 2000 st figure 12: system circuit diagram 12v/24v with control element (rheostat switch) ground battery x2/x3/x4/x5 1 2 x10 1 2 2 1 x11 1 2 0,5mm2 sw 0,5mm2 0,5mm2 0,5mm2 rt bl ws 4 2 3 1 x9 h1 s1 30 s3 4 ge rt b2 1 ge br 2 e...

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    Www.Webasto.Us 25 webasto product n.A., inc. Air top 2000 st circuit diagrams figure 13: system circuit diagram 12v/24v with combination timer model 1531 diagnostic k cable w bus co 2 setting input pin (pin 16/plug x6), cable color on wiring harness: pink): “ventilation” (fan speed depends on the po...

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    Webasto product n.A., inc. 26 www.Techwebasto.Com circuit diagrams air top 2000 st figure 14: schematic connection of the combination timer model 1531 3 2 1 6 5 4 9 8 7 12 11 10 12v 24v combination timer 1531 adapter harness p/n 9008440a brown battery negative (12, 4) red battery positive (11) black...

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    Www.Webasto.Us 27 webasto product n.A., inc. Air top 2000 st servicing work 8. Servicing work 8.1 g eneral this section describes the servicing work that can be carried out on the heater when it is installed. 8.2 w ork on the h eater disconnect the main power cable from the vehicle’s battery before ...

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    Webasto product n.A., inc. 28 www.Techwebasto.Com servicing work air top 2000 st caution: 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 heater checks the internal temperature rise automatically ea...

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    Www.Webasto.Us 29 webasto product n.A., inc. Air top 2000 st servicing work figure 15: fuel supply figure 16: webasto fuel standpipe note: only use this style of standpipe with metal fuel tanks. Figure 17: fuel extractor from a plastic or metal tank (extraction through tank drain screw) figure 18: f...

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    Webasto product n.A., inc. 30 www.Techwebasto.Com servicing work air top 2000 st 8.6.2.2 f uel l ines only steel, copper and plastic lines of plasticized, light and temperature-stabilized pa11 or pa12 (for example mecanyl rwtl) according to din 73378 may be used for the fuel lines. Since the lines c...

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    Www.Webasto.Us 31 webasto product n.A., inc. Air top 2000 st servicing work 8.6.5 c ombustion a ir s upply 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 ...

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    Webasto product n.A., inc. 32 www.Techwebasto.Com servicing work air top 2000 st 8.6.8 e lectrical c onnections 8.6.8.1 h eater c onnection , c ontrol e lement the electrical connection is to be made as shown in the appropriate circuit diagram (see section 7). To connect the wiring harness, remove t...

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    Www.Webasto.Us 33 webasto product n.A., inc. Air top 2000 st servicing work figure 27: example installation for heater in an air circulation system 1 2 3 4 5 6 7 1 c ontr o l ele m ent 2h e a te r 3 m eteri ng pump and d a mp er 4 fu e l filte r (a cce sso ry) 5 tank connector 6 e xhaust muf fler 7f...

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    Webasto product n.A., inc. 34 www.Techwebasto.Com servicing work air top 2000 st 8.7 r emoval and i nstallation caution: when the heater is installed it must not be dismantled. 8.7.1 h eater , r emoval and i nstallation 8.7.1.1 r emoval 1. Disconnect the battery. 2. Pull the cover off the top shell ...

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    Www.Webasto.Us 35 webasto product n.A., inc. Air top 2000 st repair 9. Repair 9.1 g eneral 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...

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    Webasto product n.A., inc. 36 www.Techwebasto.Com repair air top 2000 st 9.2 d ismantling and a ssembling 9.2.1 r emove the c asing p arts 9.2.1.1 c over for e lectrical c onnection the cover (1, fig. 29) can be levered off using a blunt blade in the areas . 9.2.1.2 g rates for h ot a ir i nlet and ...

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    Www.Webasto.Us 37 webasto product n.A., inc. Air top 2000 st repair figure 29: remove / fit the casing parts 1 2 3 5 4 6 5 7 positioning of insulators insulator extension of corner rib 1 cover, electrical connection 2 top shell 3 cover, hot air outlet 4 bottom shell 5 grate 6 cover, hot air inlet 7 ...

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    Webasto product n.A., inc. 38 www.Techwebasto.Com repair air top 2000 st 9.2.3 c hanging the c ontrol u nit 9.2.3.1 r emoval 1. Remove the heater (see 8.7.1.1). 2. Remove the casing parts (see 9.2.1). 3. Open the catches on the hot air blower. 4. Pull the hot air blower (1, fig. 30) off the motor sh...

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    Www.Webasto.Us 39 webasto product n.A., inc. Air top 2000 st repair 3. Bring the combustion air fan (5) into the assembly position and secure with screws (4), attaching the electrical bonding of the wiring harness to the motor at the same time. 4. Tighten the screws (4) to 6 ± 0.6 nm (53 ± .5 lb-in)...

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    Webasto product n.A., inc. 40 www.Techwebasto.Com repair air top 2000 st figure 30: changing the control unit, combustion air fan and overheating sensor detail a 1 2 3 4 5 6 7 9 8 1 hot air fan rotor 2 torx screw (3) 3 electronic control unit 4 torx screw (5) 5 combustion air fan (drive unit) 6 seal...

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    Www.Webasto.Us 41 webasto product n.A., inc. Air top 2000 st repair 9.2.7 c hanging the c eramic g low p in 9.2.7.1 r emoval 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 ...

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    Webasto product n.A., inc. 42 www.Techwebasto.Com repair air top 2000 st figure 31: changing the glow plug, flame sensor, combustion insert and the heat exchanger 1 2 3 4 5 6 7 9 8 10 11 12 13 1 flame sensor (gasoline heaters only) 2 torx screw (4) 3 securing strap 4 air baffle 5 burner insert 6 cer...

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    Www.Webasto.Us 43 webasto product n.A., inc. Air top 2000 st repair 9.2.8 c hanging the b urner i nsert , c ombustion p ipe and the h eat e xchanger 9.2.8.1 r emoval 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 ov...

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    Webasto product n.A., inc. 44 www.Techwebasto.Com repair air top 2000 st figure 32: starting air hole in burner insert starting air hole.

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    Www.Webasto.Us 45 webasto product n.A., inc. Air top 2000 st product information 10. Product information no new or updated information available at this time..

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    Air top 2000 st warranty w arranty c overage and l imitations webasto product north america, inc. (herein after referred to webasto) warrants their heaters and heater kits against defects in material and workmanship for two (2) years effective at the time of installationor vehicle registration date ...

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    W ebasto p roduct n.A., i nc . 15083 north road fenton, mi 48430 technical assistance hotline usa: (800) 860-7866 canada: (800) 667-8900 www.Techwebasto.Com www.Webasto.Us org. 06/2005 rev. 02/2012 p/n lit9010439b © 2012 webasto product n.A., inc..