1. DL manuals
  2. Webasto
  3. Heater
  4. Air Top 2000
  5. Service And Repair Manual

Webasto Air Top 2000 Service And Repair Manual

Summary of Air Top 2000

  • Page 1

    List of contents air top 2000 – 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, techn...

  • Page 2

    I list of contents 1. Introduction 1.1 scope and purpose................................................................................................................................. 101 1.1.1 use of air heaters.........................................................................................

  • Page 3

    Ii 5. Troubleshooting 5.1 general....................................................................................................................................................501 5.2 general failure symptoms .........................................................................................

  • Page 4

    9. Repair 9.1 general.................................................................................................................................................... 901 9.1.1 work on components after disassembly.......................................................................................

  • Page 5

    List of figures 301 functional diagram (air top 2000 without diagnosis)....................................................................................303 501 general failure symptoms ...................................................................................................................

  • Page 6

    1. Introduction 1.1 scope and purpose this repair shop manual is intended to support famil- iarized personnel in the repair of air heaters air top 2000 of the fuel and diesel type as well as of air top 2000 diagnosis with serial no. 30.000 and up. 1.1.1 use of air heaters the air heaters air top 200...

  • Page 7

    The heater must not be installed in the passenger or driver compartments of busses. Should the heater never- theless be installed in such a compartment, the installa- tion box must be sealed tight against the vehicle interior. There must be sufficient ventilation of the installation box from the ext...

  • Page 8

    Metal lines must be used. These may not heat to more than 110 °c should there be the possibility of contact within the room interior. Protective devices against con- tact may be fitted. Should exhaust pipes be routed through rooms accom- modating persons, these pipes shall be renewed after 10 years ...

  • Page 9

    2. General description the air heater air top 2000 and air top 2000 diagnosis with serial no. 30.000 and up operating to the evaporator principle basically consist of: - combustion and heating air fan - heat exchanger - burner insert with combustion tube - control unit air heater air top 2000 for co...

  • Page 10

    2.2 heat exchanger the heat exchanger dissipates the heat provided by combustion to the air delivered by the combustion and heating air fan. Heat exchanger 2.3 burner insert with combustion tube within the burner insert fuel is distributed in the combus- tion tube across the burner cross-section. In...

  • Page 11

    Control unit air top 2000 diagnosis 2.5 flame sensor the flame sensor is a low-ohm ptc resistor changing its resistance dependent on its heating by the flame. The signals are routed to the control unit for processing. The flame sensor monitors the flame operating condition over the complete duration...

  • Page 12

    3. Functional description 3.1 functional description air top 2000 without diagnosis (fig. 301) 3.1.1 control element the control element is used to switch the air heater on and off, set the desired room temperature (air intake tem- perature between 10 °c and 45 °c), and to unlock a failure interrupt...

  • Page 13

    3.1.5 control operation during control operation fan speed and dosing pump rate of delivery are subject to heating performance. The glow plug is deactivated. 3.1.6 control idle in case the air intake temperature set with the control ele- ment is exceeded and the minimum heating perfor- mance had bee...

  • Page 14

    303 on a 0 1 1 2 3 4 5 6 7 8 9 10 b c 0 1 100% 90% 60% 30% 0 d 1,3 hz 1,0 hz 0,8 hz 0,6 hz 0 e f 0 1 0 20 45 65 85 102 seconds typical (20) (60) (120) fig. 301 functional diagram (air top 2000 without diagnosis) 1 start 2 control operation 3 rated value reached 4 rated value exceeded (e.G. Due to re...

  • Page 15

    304 3.2 functional description air top 2000 diagnosis 3.2.1 control element the control element is used to switch the air heater on and off, set the desired room temperature (air intake tem- perature between 10 °c and 45 °c), and to unlock a failure interrupt condition. The green led indication is u...

  • Page 16

    3.2.4 heating operation during operation the combustion exhaust gasses flow through the heat exchanger charging its walls with com- bustion heat, which in turn is taken up by the heating air delivered by the heating air fan to be routed to the ve- hicle interior. The temperature of the heating air s...

  • Page 17

    3.2.9 switch-off upon failure the control unit recognises failures of individual air heater components and malfunctions in the start se- quence and in normal operation. The air heater is deactivated and enters the error loc- kout mode under the following conditions: l flame sensor open or short circ...

  • Page 18

    4. Technical data as long as no threshold values are given, the following technical data are understood to include tolerances of ± 10% usual for heaters at an ambient temperature of +20 °c and at nominal voltage and conditions. Electrical components: control unit, combustion air fan, dosing pump, ti...

  • Page 19

    5. Troubleshooting 5.1 general this section describes troubleshooting procedures for the air heater air top 2000 and air top 2000 diagnosis. A malfunction in air heaters air top 2000 diagnosis out- puts an error code to the display of the combination or standard timer. When equipped with a control e...

  • Page 20

    5.3 failure symptoms during operation the following table (fig. 502) lists the possible failure symptoms as they might occur during the functional sequence of operation. In case of malfunction the failure is to be isolated and removed using this table. It is important to accurately identify the fail...

  • Page 21

    5.4 error code output (air top 2000 diagnosis) 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 element the error code output is indicated by flashing of the operating indi...

  • Page 22

    6. Functional tests 6.1 general this section describes the on-vehicle and off-vehicle testing of the air heater to check its proper operation. Warning the air heater shall not be operated in enclosed areas like garages or workshops not provided with exhaust venting facilities. 6.2 adjustments 6.2.1 ...

  • Page 23

    6.3 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 sho...

  • Page 24

    7. Circuit diagrams 7.1 general the air heater air top 2000 diagnosis may be operated using the control element (rated value transmitter/switch) or with the control element and a combination or standard timer. The circuit diagrams (figs. 703 to 708 and 714) show the possible circuits 12 or 24 volt w...

  • Page 25

    Violet yellow brown black blue x1 x4 x3 x2 x5 x1 = connection, 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 without diagnosis 702 7 circuit diag...

  • Page 26

    ϑ ϑ ϑ item nomenclature remark a1 air heater air top 2000 a2 control unit b1 flame sensor b2 temperature sensor b3 temperature limiter e glow plug f2 fuse 24v 10a/12v 15a flat fuse sae j 1284 h1 led green (in item s1) operation indication m motor s1 control element rated value setting switch x1-x5 c...

  • Page 27

    Wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colours blue brown yellow green grey orange red black violet white fig. 704 circuit diagram automatic control air top 2000 diagnosis, 12v/24v with comb...

  • Page 28

    Wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colours blue brown yellow green grey orange red black violet white fig. 705 circuit diagram automatic control air top 2000 diagnosis, 12v/24v with cont...

  • Page 29

    706 ϑ ϑ ϑ wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colours blue brown yellow green grey orange red black violet white fig. 706 circuit diagram automatic control air top 2000 diagnosis, 24v trs...

  • Page 30

    ϑ ϑ ϑ wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colours blue brown yellow green grey orange red black violet white fig. 707 circuit diagram automatic control air top 2000 diagnosis, 24v trs ope...

  • Page 31

    Wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colours blue brown yellow green grey orange red black violet white fig. 708 circuit diagram automatic control air top 2000 diagnosis, 24v trs operation...

  • Page 32

    Wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colours blue brown yellow green grey orange red black violet white ϑ ϑ ϑ ϑ fig. 709 circuit diagram automatic control air top 2000 without diagnosis, 1...

  • Page 33

    Wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colours blue brown yellow green grey orange red black violet white item nomenclature remark a1 air heater air top 2000 a2 control unit b1 flame sensor ...

  • Page 34

    Wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colours blue brown yellow green grey orange red black violet white item nomenclature remark a1 air heater air top 2000 a2 control unit b1 flame sensor ...

  • Page 35

    Fig. 712 circuit diagram automatic control air top 2000 without diagnosis, 24v with control element and timer wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colours blue brown yellow green grey oran...

  • Page 36

    Wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colours blue brown yellow green grey orange red black violet white ϑ ϑ ϑ fig. 713 circuit diagram automatic control air top 2000 without diagnosis, 24v...

  • Page 37

    Fig. 714 circuit diagram automatic control air top 2000 diagnosis, 24v trs operation with control element in vehicles without auxiliary drive 714 wire gauges 7.5 - 15 m 0.75 mm 2 1.0 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 4.0 mm 2 6.0 mm 2 bl br ge gn gr or rt sw vi ws wire colou...

  • Page 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.

  • Page 39

    8. Servicing 8.1 general this section describes the servicing procedures that may be performed with the air heater installed. 8.2 work on the air heater prior to performing any work it is mandatory to discon- nect the vehicle battery main lead. As long as the air heater is in operation or in run-dow...

  • Page 40

    The air heater, when used in the ventilation mode of operation, may also be employed for heating air ducting without any further accessories. A short circuit of the heating air flow is to be avoided. 8.6.2 fuel supply fuel is tapped from the fuel reservoir of the vehicle or from a separate fuel cont...

  • Page 41

    803 > 25 mm 25 hole pattern fig. 802 webasto fuel tank tap * use fuel tank tap only on metal fuel tanks fig. 803 fuel tapping from plastic tank (tapping via fuel drain plug) plastic tank gasket fuel tank tap gasket tank fitting plate fig. 804 fuel tapping from plastic tank (tapping via fitting plate...

  • Page 42

    Connection of 2 pipes with hose the proper connection of fuel lines with hoses is shown in fig. 805. Fig. 805 pipe/hose connection 8.6.3 dosing pump the dosing pump is a combined delivery, dosing, and shut-off system and is subject to certain installation crite- ria (see figs. 801 and 806). At 2000....

  • Page 43

    8.6.5 combustion air supply combustion air must under no circumstances be ex- tracted from rooms with persons. The combustion air inlet must not point towards the forward direction of mo- tion. It must be located so that no clogging by contamina- tion is to be expected. Note for fuel operated heater...

  • Page 44

    8.6.8 electrical connections 8.6.8.1 connection air heater, control element electrical connection is according to circuit diagram automatic control (see section 7). For connection of the cable loom the cover (see 9.2.1.1) of the air heater has to be removed for connecting the cable loom plug(s) to t...

  • Page 45

    807 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 servicing.

  • Page 46

    8.7 removal and installation caution in installed condition only the following removal and dis- assembly procedures are allowed, the upper housing shell being accessible for removal: l replacement of control unit l replacement of temperature limiter 8.7.1 air heater, removal and installation 8.7.1.1...

  • Page 47

    809 4 5 1 3 2 fig. 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 2000 8 servicing.

  • Page 48

    810 fig. 816 replacement 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 servicing air top 2000

  • Page 49

    811 8.8 installation of new control units caution when replacing the control unit the following must be ob- served: l when replacing the control unit air top 2000 (12 volt) without external temperature sensor with a new control unit air top 2000 diagnosis (12 volt) without external temperature senso...

  • Page 50

    8.8.3 replacement of control unit air top 2000 (24 volt) trs 1. Remove control unit according to 8.7.2.1. 2. Remove leaf spring contacts of grey and violet wire from connector x6, contacts 4 and 6. 3. Arrest leaf spring contacts in connector x11 as follows: grey wire in contact 3, violet wire in con...

  • Page 51

    9. Repair 9.1 general this section describes the repairs that may be per- formed on the air heater air top 2000 and air top 2000 diagnosis serial no. 30.000 and up when removed. Any further disassembly will void the warranty. For reassembly only components of the proper spare kits are to be used. 9....

  • Page 52

    9.1.2.2 removal of external temperature sensor (air top 2000 without diagnosis) general the heater air top 2000 regulates the desired tempera- ture the best when its temperature sensor is exposed to the air temperature of the most probable surrounding in use. This might not always be possible due to...

  • Page 53

    903 1 2 5 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 9 repair.

  • Page 54

    Fig. 902 replacement of combustion air fan (removal) 1 heating air intake 2 insulation 3 seal 2 1 3 904 9.2.2 replacement of control unit note the procedure for replacement of the control unit is identical for the air heater in installed or removed condi- tion. Replacement is to be performed in acco...

  • Page 55

    9.2.4 replacement of combustion air fan 9.2.4.1 removal 1. Remove air heater (see 8.7.1.1). 2. Remove control unit (see 8.7.2.1). 3. Remove seal (3 fig. 902) from lower housing shell and discard. 4. Remove air heater from lower housing shell. 5. Remove heating air intake (1, fig. 902) and remove ins...

  • Page 56

    9.2.5 replacement of flame sensor 9.2.5.1 removal 1. Remove air heater (see 8.7.1.1). 2. Remove control unit (see 8.7.2.1). 3. Remove combustion air fan (see 9.2.4.1). 4. Remove 2 screws (3, fig. 904) and spoiler (2) for cable protection. 5. Push out cable grommet (10) towards inside. 6. Carefully b...

  • Page 57

    907 8 7 6 3 1 2 12 5 4 10 9 11 13 1 flame 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 exchanger (sheet 1 of 2) air top 2000 9 repair.

  • Page 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

  • Page 59

    9.2.7 replacement of burner insert, combustion tube, and heat exchanger 9.2.7.1 removal 1. Remove air heater (see 8.7.1.1). 2. Remove control unit (see 8.7.2.1). 3. Remove combustion air fan (see 9.2.4.1). 4. Remove flame sensor (see 9.2.5.1). 5. Remove glow plug (see 9.2.6.1). Caution when performi...

  • Page 60

    10. Packaging/storage and shipping 10.1 general the air heater and its components shipped to webasto 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...