Webasto Air Top 2000 S D Manuel de service

Luft-HeizgeräteAir Heaters03/2003Workshop Manual Air Top 2000 ST Type Air Top 2000 ST B (petrol) Type Air Top 2000 ST D (diesel)

Introduction Air Top 2000 ST 104NOTE If any damage or leaks are found on the fuel line, the heater must not be used until the damage has been rectifie

Air Top 2000 ST General description2012 General descriptionThe Air Top 2000 ST air heaters are based on the evaporator principle and essentially consi

General description Air Top 2000 ST 2022.2 Heat exchangerThe heat generated by the combustion process is transferred to the air transported by the com

Air Top 2000 ST General description2032.6 Glow plugThe mixture of fuel and air is ignited by the glow plug when the heater is started. The glow plug t

General description Air Top 2000 ST 204Page for notes

Air Top 2000 ST Description of operation3013 Description of operation3.1 Control elementThe control element is designed to switch the heater on and of

Description of operation Air Top 2000 ST 302If, at minimum heat output, the intake temperature set on the control element is exceeded, the metering pu

Air Top 2000 ST Description of operation303If the FAZ reaches a value of 6, the heater will go into fault lock-out mode and the permanent flame failur

Description of operation Air Top 2000 ST 304Page for notes

Air Top 2000 ST Technical data4014Technical dataExcept where limit values are specified, the technical data listed in the table refer to the usual hea

Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious inju

Technical data Air Top 2000 ST 402Setpoint values: 12 V 24 V Glow plug At 25 ºC Test current: < 5 mAred marking 0.263 - 0.323 ohms Green marking

Air Top 2000 ST Troubleshooting5015 Troubleshooting5.1 General This section describes how to identify and remedy faults on the Air Top 2000 ST air hea

Troubleshooting Air Top 2000 ST 5025.3 Error symptoms during function The following table (Fig. 502) lists the possible error symptoms in the order in

Air Top 2000 ST Troubleshooting5035.4 Error code output If the heater is fitted with a combination timer, an error code output will appear on the disp

Troubleshooting Air Top 2000 ST 504F 05 Flame monitorinterrupt or short circuit(only petrol heater)1A Flame monitor circuit The switched cable of the

Air Top 2000 ST Troubleshooting505F 12 Heater unit lock-out 07 The permanent heater fault lock-out has been activatedRemove the fuse and reinsert itNO

Troubleshooting Air Top 2000 ST 506Page for notes

Air Top 2000 ST Function Tests6016 Function Tests6.1 GeneralThis section describes the tests conducted on the heater when it is installed and not inst

Function Tests Air Top 2000 ST 602 6.3 Settings6.3.1 Setting CO2 content The CO2 content in the emissions is set using the adjustment knob on the con

Air Top 2000 ST Function Tests6036.3.2 CO2 setting of reference heater The reference heater is set to 10.3 vol.% CO2 at a geodetic altitude of 0 metre

Air Top 2000 ST Table of ContentsITable of Contents1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function Tests Air Top 2000 ST 6046.4.1 Burner insert component See Fig. 904, Item 5 211211Burner insert Combustion chamber mechanically damaged?no

Air Top 2000 ST Function Tests6056.4.2 Glow plug resistance test (only petrol heater)See Fig. 904, Item 1 If you conduct this test with a digital mult

Function Tests Air Top 2000 ST 606A222121AFlame monitor Contacts detached?no yes Procedure Testing and measuring equipmentVisualVisual inspectionVisua

Air Top 2000 ST Function Tests6076.4.3 Glow plug component See Fig. 904, Item 6 NOTEThe resistance test must be carried out with an ohmmeter suitable

Function Tests Air Top 2000 ST 608 A222121AGlow plug Contacts detached?no yes Procedure Testing and measuring equipmentVisualVisual inspectionVisual i

Air Top 2000 ST Function Tests6096.4.4 Combustion air fan component (drive) See Fig. 903, Item 5 21121Combustion air fan (drive)Externally damaged?n

Function Tests Air Top 2000 ST 6106.4.5 Overheating sensor component See Fig. 903, Item 8 If you conduct this resistance test with a digital multimete

Air Top 2000 ST Function Tests6116.4.6 Control unit component See Fig. 701 and Fig. 903, Item 3 212Control unit Externally damaged?no yes Procedure

Function Tests Air Top 2000 ST 6126.4.7 Heater component 3333AComplete heater Testing of all electrical componentsDescription Procedure Testing a

Air Top 2000 ST Function Tests6132BACheck function on heater test bench Description Procedure Testing and measuring equipment Function test – Heater

Table of Contents Air Top 2000 ST II6 Function Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function Tests Air Top 2000 ST 61432CBReinstalling control unit in heater to be tested Description Procedure Testing and measuring equipment Replace c

Air Top 2000 ST Function Tests615223CDescription Procedure Testing and measuring equipment Conduct function test with reference heater. Set reference

Function Tests Air Top 2000 ST 616Page for notes

Air Top 2000 ST Circuit diagrams7017 Circuit diagrams 7.1 General The Air Top 2000 ST heater units can be operated with the heater control (setpoint g

Circuit diagrams Air Top 2000 ST 702Fig. 702 System circuit diagram Air Top 2000 ST, 12V/24V with control element and vehicle blowerFig. 703 Syste

Air Top 2000 ST Circuit diagrams703Fig. 704 System circuit diagram Air Top 2000 ST, 12V/24V ADR operation with control element Fig. 705 System ci

Circuit diagrams Air Top 2000 ST 704Fig. 706 Air Top 2000 ST with combination timer connection diagram Adapter wiring harnessred: Terminal 30grey: T

Air Top 2000 ST Circuit diagrams7057.2 Legend for circuit diagrams Cable cross-sections< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.0 mm21.5 mm21.5 mm22.5 mm

Circuit diagrams Air Top 2000 ST 706Page for notes

Air Top 2000 ST Servicing work8018Servicing work 8.1 General This section describes the servicing work that can be carried out on the heater when it i

Air Top 2000 ST Table of ContentsIII9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Servicing work Air Top 2000 ST 802IMPORTANTIn vehicles used to transport people, the air outlet opening is to be installed in such a way that it is at

Air Top 2000 ST Servicing work803Fig. 801 Fuel supplyNOTEOnly use a tank extractor with metal fuel tanksFig. 802 Webasto tank connectorFig. 803

Servicing work Air Top 2000 ST 8048.6.2.2 Fuel linesOnly steel, copper and plastic lines of plasticised, light and temperature-stabilised PA11 or PA12

Air Top 2000 ST Servicing work8058.6.5 Combustion air supplyUnder no circumstances may the combustion air be taken from areas occupied by people. The

Servicing work Air Top 2000 ST 8068.6.8 Electrical connections 8.6.8.1 Heater connection, control element The electrical connection is to be made as s

Air Top 2000 ST Servicing work807Fig. 815 Installation example for heater in recirculation mode1 Control element2 Heater3 Metering pump and damper4

Servicing work Air Top 2000 ST 8088.7 Removal and installationIMPORTANTWhen the heater is installed it must not be dismantled.8.7.1 Heater, removal an

Air Top 2000 ST Repair9019Repair9.1 GeneralThis section describes the repair work that may be carried out on the Air Top 2000 ST heater after it has b

Repair Air Top 2000 ST 9029.2 Dismantling and assembling9.2.1 Remove the casing parts9.2.1.1 Cover for electrical connectionThe cover (1,Fig. 902) can

Air Top 2000 ST Repair903.Fig. 902 Remove/fit the casing parts 1234561 Cover, electrical connection2 Top shell3 Cover, hot air outlet4 Bottom sh

List of Illustrations Air Top 2000 ST IVList of IllustrationsFig. 201 Air Top 2000 ST air heater . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair Air Top 2000 ST 9049.2.3 Replace control unit9.2.3.1 Removal1. Remove heater (see 8.7.1.1).2. Remove casing parts (see 9.2.1).3. Spread apart t

Air Top 2000 ST Repair9059.2.6 Replace flame sensor (petrol heater only)9.2.6.1 Removal1. Remove the heater (see 8.7.1.1).2. Remove the casing parts (

Repair Air Top 2000 ST 906Fig. 903 Change control unit, combustion air fan and overheating sensor 51 Hot air blower2 Torx screw (3)3 Control unit4 T

Air Top 2000 ST Repair9079.2.7 Change glow plug9.2.7.1 Removal1. Remove the heater (see 8.7.1.1).2. Remove the casing parts (see 9.2.1).3. Remove the

Repair Air Top 2000 ST 908Fig. 904 Change the glow plug, flame sensor, burner insert and heat exchanger 1 Flame sensor (only petrol heater)2 Torx sc

Air Top 2000 ST Repair9099.2.8 Change burner insert, combustion pipe and heat exchanger9.2.8.1 Removal1. Remove the heater (see 8.7.1.1).2. Remove the

Repair Air Top 2000 ST 910Fig. 905 Starting air hole in burner insert Starting air hole

Air Top 2000 ST Packing, Storage and Shipping100110 Packing, Storage and Shipping 10.1 GeneralIf the heater or its components are sent to Webasto AG f

Packing, Storage and Shipping Air Top 2000 ST 1002Page for notes

Air Top 2000 ST Introduction1011 Introduction 1.1 Contents and purposeThis workshop manual is designed to assist trained person-nel, with repairing bo

Ident-No. 9010439C • 11/09 • Errors and omissions excepted • Printed in Germany • © Webasto AG, GCS 2009 Webasto AGPostfach 80D - 82132 Stockdorf Germ

Introduction Air Top 2000 ST 1022.2. / 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

Air Top 2000 ST Introduction1031.4.2 General safety information The mouth of the exhaust pipe should be installed upwards, to the side or, if the exha