At2000 GB PDF

Air Heaters Repair Shop Manual
Air Top 2000

Diagnosis
Air Top 2000
Type AT 2000 B (Fuel)
Type AT 2000 D (Diesel)
07/2000
Air Top 2000 List of Contents
List of Contents
1 Introduction
1.1 Scope and Purpose ............................................................................................................................... 101
1.1.1 Use of Air Heaters ........................................................................................................................ 101
1.2 Meaning of Warnings, Cautions and Notes ........................................................................................... 101

1.3 Additional Documentation to be used .................................................................................................... 101
1.4 Safety Information and Regulations....................................................................................................... 101
1.4.1 Legal Provisions for Installation................................................................................................... 101

1.4.2 General Safety Notes .................................................................................................................. 103
1.5 Corrections and Improvements.............................................................................................................. 103
2 General Description
2.1 Combustion and Heating Air Fan........................................................................................................... 201

2.2 Heat Exchanger ..................................................................................................................................... 202
2.3 Burner Insert with Combustion Tube ..................................................................................................... 202
2.4 Control Unit / Control Circuit Board ....................................................................................................... 202
2.5 Flame Sensor ........................................................................................................................................ 203
2.6 Glow Plug .............................................................................................................................................. 203
2.7 Temperature Limiter .............................................................................................................................. 203
2.8 Dosing Pump ......................................................................................................................................... 203
3 Functional Description
3.1 Functional Description Air Top 2000 without Diagnosis ........................................................................ 301
3.1.1 Control Element........................................................................................................................... 301

3.1.2 Switch-On .................................................................................................................................... 301
3.1.3 Stabilization ................................................................................................................................. 301
3.1.4 Heating Operation ....................................................................................................................... 301
3.1.5 Control Operation ........................................................................................................................ 302
3.1.6 Control Idle .................................................................................................................................. 302
3.1.7 Switch-Off .................................................................................................................................... 302
3.1.8 Functions of the Air Heater in ADR Vehicles............................................................................... 302
3.1.9 Switch-off upon Failure................................................................................................................ 302
3.2 Functional Description Air Top 2000 Diagnosis..................................................................................... 304
3.2.1 Control Element........................................................................................................................... 304

3.2.2 Switch-On .................................................................................................................................... 304
3.2.3 Stabilization ................................................................................................................................. 304
3.2.4 Heating Operation ....................................................................................................................... 305
3.2.5 Control Operation ........................................................................................................................ 305
3.2.6 Control Idle .................................................................................................................................. 305
3.2.7 Switch-Off .................................................................................................................................... 305
3.2.8 Functions of the Air Heater in ADR Vehicles............................................................................... 305
3.2.9 Switch-off upon Failure................................................................................................................ 306
4 Technical Data................................................................................................................................................ 401
I
List of Contents Air Top 2000
5 Troubleshooting
5.1 General ................................................................................................................................................. 501

5.2 General Failure Symptoms ................................................................................................................... 501
5.3 Failure Symptoms during Operation ..................................................................................................... 502
5.4 Error Code Output (Air Top 2000 Diagnosis)........................................................................................ 503
6 Functional Tests
6.1 General ................................................................................................................................................. 601

6.2 Adjustments .......................................................................................................................................... 601
6.2.1 Adjustment of the CO2 Contents ................................................................................................ 601
6.3 Components Testing............................................................................................................................. 602
6.3.1 Glow Plug Resistance Test......................................................................................................... 602

6.3.2 Flame Sensor Resistance Test................................................................................................... 602
7 Circuit Diagrams
7.1 General ................................................................................................................................................. 701
8 Servicing
8.1 General ................................................................................................................................................. 801

8.2 Work on the Air Heater ......................................................................................................................... 801
8.3 Work on the Vehicle.............................................................................................................................. 801
8.4 Air Heater Test Run .............................................................................................................................. 801
8.5 Servicing ................................................................................................................... ............................ 801
8.6 Visual Inspections and Installation Regulations.................................................................................... 801
8.6.1 Heating Air System ..................................................................................................................... 801

8.6.2 Fuel Supply................................................................................................................................. 802
8.6.3 Dosing Pump .............................................................................................................................. 804
8.6.4 Fuel Filter.................................................................................................................................... 804
8.6.5 Combustion Air Supply ............................................................................................................... 805
8.6.6 Exhaust Line ............................................................................................................................... 805
8.6.7 Combustion Air Intake and Exhaust Lines.................................................................................. 805
8.6.8 Electrical Connections ................................................................................................................ 806
8.7 Removal and Installation....................................................................................................................... 808
8.7.1 Air Heater, Removal and Installation .......................................................................................... 808

8.7.2 Replacement of Control Unit....................................................................................................... 808
8.7.3 Replacement of Temperature Limiter ......................................................................................... 808
8.8 Installation of new Control Units ........................................................................................................... 811
8.8.1 Replacement of Control Unit Air Top 2000 (12 Volt) with External Temperature Sensor........... 811
8.8.2 Replacement of Control Unit Air Top 2000 (24 Volt) not ADR.................................................... 811
8.8.3 Replacement of Control Unit Air Top 2000 (24 Volt) ADR.......................................................... 812
8.9 First Operation ...................................................................................................................................... 812
II
Air Top 2000 List of Contents
9 Repair
9.1 General .................................................................................................................................................. 901
9.1.1 Work on Components after Disassembly .................................................................................... 901

9.1.2 Incorporation of Modifications...................................................................................................... 901
9.2 Disassembly and Assembly................................................................................................................... 902
9.2.1 Removal of Housing Components/Covers .................................................................................. 902

9.2.2 Replacement of Control Unit ....................................................................................................... 903
9.2.3 Replacement of Temperature Limiter .......................................................................................... 903
9.2.4 Replacement of Combustion Air Fan........................................................................................... 904
9.2.5 Replacement of Flame Sensor .................................................................................................... 906
9.2.6 Replacement of Glow Plug .......................................................................................................... 906
9.2.7 Replacement of Burner Insert, Combustion Tube, and Heat Exchanger .................................... 909
10 Packaging/Storage and Shipping
10.1 General ................................................................................................................................................ 1001
III
List of Figures Air Top 2000
List of Figures
301 Functional Diagram (Air Top 2000 without Diagnosis)............................................................................... 303
501 General Failure Symptoms ........................................................................................................................ 501

502 Failure Symptoms during Operation .......................................................................................................... 502
601 Adjustment of CO2 Contents...................................................................................................................... 601
701 Terminal Pin Assignment, Air Top 2000 Diagnosis.................................................................................... 701

702 Terminal Pin Assignment, Air Top 2000 without Diagnosis ....................................................................... 702
703 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24V
with Control Element.................................................................................................................................. 703
with Combination Timer ............................................................................................................................. 704
with Control Element and Standard Timer ................................................................................................. 705
706 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 24V ADR Operation
with Combination Timer ............................................................................................................................. 707
with Combination Timer and 2 Auxiliary Drives ......................................................................................... 708
709 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 12V
with Control Element and Timer................................................................................................................. 710
with Control Element and Timer................................................................................................................. 712
with Control Element, ADR ........................................................................................................................ 713
with Control Element in Vehicles without Auxiliary Drive ........................................................................... 714
715 Connection Diagram, Air Top 2000 Diagnosis with Combination Timer (not ADR!) .................................. 715
801 Fuel Supply ................................................................................................................................................ 802

802 Webasto Fuel Tank Tap............................................................................................................................. 803
803 Fuel Tapping from Plastic Tank (tapping via fuel drain plug)..................................................................... 803
804 Fuel Tapping from Plastic Tank (tapping via fitting plate) .......................................................................... 803
805 Pipe/Hose Connection ............................................................................................................................... 804
806 Dosing Pump, Installation Position and Attachment .................................................................................. 804
807 Fuel Filter ................................................................................................................................................... 804
808 Exhaust Muffler, Direction of Flow ............................................................................................................. 805
809 Exhaust Pipe Outlet, Installation Position .................................................................................................. 805
810 Removal of Fuse Holder Attachment Plate................................................................................................ 806
811 Fuse Holder, Installation Position .............................................................................................................. 806
812 Control Element ......................................................................................................................................... 806
813 Pulling the Plug .......................................................................................................................................... 806
814 Example of an Installation.......................................................................................................................... 807
815 Replacement of Control Unit and Temperature Limiter (Air Top 2000 without Diagnosis) ........................ 809
816 Replacement of Control Unit and Temperature Limiter (Air Top 2000 Diagnosis)..................................... 810
901 Removal of Housing Components/Covers................................................................................................. 903

902 Replacement of Combustion Air Fan (Removal) ....................................................................................... 904
903 Replacement of Combustion Air Fan (Disassembly) ................................................................................. 905
904 Disassembly of Heat Exchanger................................................................................................................ 907
IV
Air Top 2000 1 Introduction
1 Introduction 1.4 Safety Information and Regulations
The general safety regulations for the prevention of acci-

1.1 Scope and Purpose dents and the relevant operating safety instructions have
to be observed at all times."General Safety Regulations"
This repair shop manual is intended to support familiar- beyond the scope of these regulations are detailed in the
ized personnel in the repair of air heaters Air Top 2000 of following.The specific safety regulations applicable to this
the fuel and Diesel type as well as of Air Top 2000 manual are highlighted in the individual chapters by
Diagnosis with serial no. 30.000 and up. Warnings, Cautions, and Notes.
1.1.1 Use of Air Heaters 1.4.1 Legal Provisions for Installation
The air heaters Air Top 2000 and Air Top 2000 Diagnosis Within the scope of the StVZO (Road Licensing
are used to Regulations of the Federal Republic of Germany) "Design
General Approvals", laid down by the Federal Office for
– heat the cabin Motor Traffic, exist for the Water Heater Air Top 2000 and
– defrost the windscreens. Air Top 2000 Diagnosis with the following official marks of
– conformity:
They are not cleared for heating a transportation compart-
ment for dangerous goods. ~ S 270 (Diesel)
The heaters operate independent from the vehicle engine ~ S 277 (Fuel)
and are connected to the fuel tank and to the electrical
system of the vehicle. Their use is possible in vehicles The installation of the heaters is to be performed in
with water- or air-cooled engines. accordance with the installation instructions and must be
checked in case of
a) the vehicle type inspection in accordance with
1.2 Meaning of Warnings, Cautions and § 20 StVZO
Notes b) the individual inspection in accordance with
§ 21 StVZO or
c) the examination in accordance with § 19 StVZO per-
WARNINGS, CAUTIONS, and NOTES in this manual
formed by an officially authorised expert or examiner
have the following meaning:
for road traffic, a vehicle inspector or a public servant
as per section 4 of Annex VIII b to the StVZO.
WARNING
In the event of c) the installation must be certified on the
This heading is used to highlight that non-compliance
acceptance certificate included in the copy of the "General
with instructions or procedures may cause injuries or
Operating License" or on a formsheet according to the
lethal accidents to personnel.
specimen of an "approval" included in the Traffic rules
1994, Page 148 giving details about
CAUTION
– manufacturer
This heading is used to highlight that non-compliance
– type of vehicle, and
with instructions or procedures may cause damage to
– vehicle identification number.
equipment.
This validates the "Design General Approval". The
acceptance certificate must be kept with the vehicle. The
NOTE
year of first operation must be permanently marked on the
This heading is used to highlight and draw specific atten-
identification label by removing the numerals of the years
tion to information.
not applicable.
The heat exchanger of the air heater remains

1.3 Additional Documentation to be used serviceable for a maximum of 10 years and must then
be replaced with an original spare part by the manu-
This workshop manual contains all information and pro- facturer or by one of its authorized workshops.
cedures necessary for the repair of heaters Air Top 2000 The heater must then be provided with a label marked
and Air Top 2000 Diagnosis. with the sales date and with the words "Original
The use of additional documentation is normally not Spare".
necessary. When replacing the heat exchanger it is mandatory
Operating instructions/installation instructions and the to also replace the overheat protection element
vehicle specific installation proposal may be used as (temperature limiter) to avoid possible malfunctions
complementary information as necessary. of old temperature limiters in use.
101
1 Introduction Air Top 2000
Should exhaust pipes be routed through rooms In compartments accommodating persons, exhaust lines
accommodating persons, these pipes shall also be must not have more than one disconnect and must have
renewed after 10 years by original spare parts. a splash-water protected feedthrough in the exterior
When removing the heater the gasket below must be wall/floor. For water, that has penetrated into the exhaust
renewed. line, the connection of a drain line with a metal-sealing
joint is permissible. The drain pipe must be routed sealed
The heaters are cleared for heating the passenger and through the exterior wall or the vehicle floor.
driver cabins but not for heating compartments intended
for the transportation of dangerous goods. The heat exchanger, the exhaust line connected, as well
The use of the heater in special vehicles (e.g. vehicles for as the possible drain pipe must be sealed so that with an
the transportation of dangerous goods ADR) or vehicles overpressure of double the overpressure of the exhaust
not subject to the StZVO (e.g. ships) are ruled by partially having the maximum permissible exhaust line length – at
regional regulations. least however at an overpressure of 0.5 bar – a total leak
For the installation of the AT 2000 D in vehicles used for rate of 30 l/h is not exceeded.
the transportation of dangerous goods, in addition to the
StVZO, the requirements in ADR 002 and ADR 003 The line including feedthrough, disconnects, material
(Technical Guidelines for the Transportation of Dangerous and specific type must be described in the installation
Goods on Roads) must be met. instructions. The line must require tools for installation and
removal, must be protected against damage, and must be
Heating Air System shockproof.
Heating air intake openings must be arranged so that
under normal operating conditions exhaust fumes of the Metal lines must be used. These may not heat to more
vehicle engine or air heater are not likely to be expected. than 110° C should there be the possibility of contact
within the room interior. Protective devices against con-
Extracting combustion air from the vehicle interior is not tact may be fitted.
permissible.
Combustion Air Inlet and Exhaust Outlet
Combustion Air Line During installations these ports for combustion air entry
The combustion air required must be taken from the and exhaust fume exit must be of such type, that a ball
exterior. with a diameter of 16 mm cannot be inserted.
Within rooms accommodating persons, the combustion Electrical lines, switch gear and control gear of the heater
air lines must not have more than four disconnects must be located in the vehicle so that their proper function
and a splash-water protected exterior wall feedthrough. cannot be impaired under normal operating conditions.
The disconnects must be sealed in a way not to exceed
a leak rate of 200 l/h at an overpressure of 0.5 mbar. For the routing of fuel lines and the installation of
The line including feedthrough, disconnects, material additional fuel tanks §§ 45 and 46 of the StVZO are to be
and specific type must be described in the installation adhered to.
instructions. The most important regulations are: Fuel lines are to be
The line must require tools for installation and removal, designed in such a way that they remain unaffected by
must be protected against damage, and must be shock- torsional stresses in the vehicle, engine movement and
proof. the like. They must be protected against mechanical
damage.
Exhaust Line Fuel-carrying parts are to be protected against excessive
Heaters must be designed to discharge the exhaust to heat and are to be arranged so that any dripping or
the exterior. evaporating fuel can neither accumulate nor be ignited by
Exhaust pipes must be routed so that exhaust fumes are hot components or electrical equipment.
unlikely to penetrate into the vehicle's interior. In busses, fuel lines and fuel tanks may be located neither
The function of any parts of the vehicle essential for its in the passenger area nor in the driver's compartment.
operation must not be impaired. Condensate or water In these type of vehicles the fuel tanks must be located
penetrated must not be able to accumulate in the such that they do not pose a direct hazard to the exits in
exhaust line. the event of a fire. Fuel supply must not be by means of
Drain holes are permissible; these must drain the fluid to gravity or pressurization of the fuel tank.
the exterior via lines sealed against the vehicle interior.
The exhaust line outlet is to be positioned to the top, to
the side, or in case of exhaust venting below the vehicle
floor, to the nearest possible location of the vehicle's or
cockpit's side or rear end.
102
Air Top 2000 1 Introduction
1.4.2 General Safety Notes Do not step on the heater and do not deposit heavy
objects on or throw against the heater.
The heater must not be installed in the passenger or Do not throw garments, fabrics or similar material on top
driver compartments of busses. Should the heater never- of the heater or in front of the heating air intake or exit.
theless be installed in such a compartment, the installa- The warm air flow of the heater must not be restricted or
tion box must be sealed tight against the vehicle interior. blocked by easily flammable substances or material like
There must be sufficient ventilation of the installation box rags, cleaning wool, etc., to prevent fires and smoke.
from the exterior in order not to exceed a maximum
temperature of 40° C in the installation box. Excessive Flammable or explosive material or gasses must be kept
temperatures may cause malfunctions. away from the vicinity of the heater, the warm air ducting
or the heating airflow.
Installation Instructions for Webasto Fuel Tanks for
Fuel Supply of Heaters in Vehicles The heater must not be cleaned with water, fluids or high
In busses the installation is not permitted in the passen- pressure cleaners, etc.
gers or driver's compartment.
The fuel filler neck must not be located in the passengers Do not switch off heater with the battery master switch or
or driver's compartment of any type of vehicle. Fuel reser- the battery emergency off switch to prevent possible long
voirs for carburettor fuel must not be located immediately time damage and malfunctions of the heater.
behind the vehicle front fairing. They must be away from
the engine to prevent fuel fires in case of accidents. The operating condition of the heater – least on or off –
The same applies to towing vehicles with open cockpit. must be clearly visible.
It is mandatory to install the seal between the heater
mounting and the vehicle floor to prevent poisonous Non-compliance with the installation instructions and its
exhaust fumes from entering the vehicle interior. procedures will void the warranty by Webasto. The same
All fuel line connections must be tight, must show no applies for repairs performed by unskilled personnel or
damage and have to be inspected in regular intervals not using original spare parts. This will also invalidate the
(at least in the same frequency as vehicle inspections). official marks of conformity and thus the vehicle’s permit
When detecting damages or leaks the heater must not be of operation.
operated until repair will have been performed by an
authorised Webasto repair shop. Make sure to read the operating instructions before you
operate the heater.
NOTE
Make heater inoperative by removing fuse. The fuel lines
(Mecanyl hoses) must not be in direct contact with the 1.5 Corrections and Improvements
exhaust pipe and be provided with a heat insulation as
required to prevent fires.
Deficiencies, improvements, or proposals for correction
of this workshop manual are to be mailed to:
Keep air intakes and exit ports for warm and heating air
clean and free from foreign objects. Contaminated and
Webasto Thermosysteme GmbH
clogged air ducts may cause overheating and response of
Abt. Technische Dokumentation
the temperature limiter. After an overheat condition with
D-82131 Stockdorf
automatic switch-off check air ducting is free from
contamination and remove all objects that might block the
Telefon: 0 89 / 8 57 94 - 5 42
airstream or have damage repaired by an authorized
Telefax: 0 89 / 8 57 94 - 7 57
Webasto repair shop. Then reset the temperature limiter.
Should these corrective actions not cure the problem
(overheating occurs again), consult an authorized
Webasto repair shop. Never remove the air intake screen
upstream of the heater.
The air jets with adjustable flops must always be open in

a way that the airflow through the heater is not blocked.
A frequently restricted or blocked airflow may cause long
time damage. Should a heater be located in a stowage
compartment, it must be ensured that no flammable
material is stowed in this compartment and that other
material does not restrict the air supply of the heater.
Air lines must be securely fastened to the heater and
the air jets (e.g. with pipe clamps).
103
1 Introduction Air Top 2000
Page free for notes
104
Air Top 2000 2 General Description
2 General Description A malfunction in air heaters Air Top 2000 Diagnosis

outputs an error code to the display of the combination or
standard timer. When equipped with a control element the
The air heater Air Top 2000 and Air Top 2000 Diagnosis operating indicator flashes. In addition a heater checkout
with serial no. 30.000 and up operating to the evaporator may be performed using a personal computer (refer to
principle basically consists of: operating instructions PC air heater diagnosis).
– combustion and heating air fan

– heat exchanger
– burner insert with combustion tube
– control unit
Air Heater Air Top 2000 Diagnosis

(covers removed)
Air Heater Air Top 2000
2.1 Combustion and Heating Air Fan

For control and monitoring a
The combustion and heating air fan delivers the air
– control unit/control circuit board
required for combustion from the combustion air inlet to
– flame sensor
the burner insert. By means of the fan the heating air is
– glow plug
also delivered to the air outlet.
– temperature limiter
– temperature sensor
are located within the unit.
12 Volt heaters (Air Top 2000 without Diagnosis) may be

controlled by means of an external temperature sensor.
All heaters of air Top 2000 Diagnosis may be controlled by
means of an external temperature sensor.
Fuel supply is provided externally by a fuel dosing pump.
Combustion and Heating Air Fan
Air Heater Air Top 2000 without Diagnosis

(covers removed)
201
2 General Description Air Top 2000
2.2 Heat Exchanger 2.4 Control Unit / Control Circuit Board
The heat exchanger dissipates the heat provided by Air Top 2000 without Diagnosis
combustion to the air delivered by the combustion and The control unit/control circuit board is the central
heating air fan. controlling unit for functional sequencing and monitoring
of the combustion operation. A temperature sensor
located on the side is used for temperature control.
12 Volt heaters may have the temperature sensor
replaced against an external temperature sensor. The
combustion and heating air fan may be set by means
of a potentiometer.
Potentiometer
Heat Exchanger
2.3 Burner Insert with Combustion Tube Temperature

Sensor
Within the burner insert fuel is distributed in the
combustion tube across the burner cross-section. In the Control Unit Air Top 2000 without Diagnosis
combustion tube the combustion of the fuel/air mixture
takes place heating up the heat exchanger.
Air Top 2000 Diagnosis
The control unit/control circuit board is the central
controlling unit for functional sequencing and monitoring
of the combustion operation. A temperature sensor
located on the control unit is used for temperature control.
All heaters may have the temperature sensor replaced
Combustion against an external temperature sensor. The combustion
Tube and heating air fan may be set by means of a
potentiometer.
A malfunction in air heaters Air Top 2000 Diagnosis

Burner Insert outputs an error code to the display of the combination or
standard timer. When equipped with a control element the
operating indicator flashes. In addition a heater checkout
may be performed using a personal computer (refer to
operating instructions PC air heater diagnosis).
202
Air Top 2000 2 General Description
2.7 Temperature Limiter

Potentiometer
The temperature limiter protects the air heater against
excessive operating temperatures. Overheat protection is
activated at temperature higher than 150° C to interrupt
the electrical circuit of the dosing pump and switch off
the heater with run-down operation.After cooling down the
electrical circuit is restored. The air heater may be
switched on again (see 3.9).
Temperature
Sensor
Control Unit Air Top 2000 Diagnosis Temperature Limiter
2.5 Flame Sensor 2.8 Dosing Pump
The flame sensor is a low-Ohm PTC resistor changing The dosing pump is a combined supply, dosing and
its resistance dependent on its heating by the flame. shut-off system for the fuel supply of the heater out of the
The signals are routed to the control unit for processing. vehicle's fuel tank.
The flame sensor monitors the flame operating condition
over the complete duration of heater operation.
Flame Sensor
Dosing Pump DP 2 for Fuel and Diesel operated Heaters
2.6 Glow Plug
The glow plug ignites the fuel/air mixture at the start

of the air heater operation. The glow plug is acting as an
electrical resistor and is located in the burner insert
opposed to the flame side.
Dosing Pump DP 30 for Diesel operated Heaters
Glow Plug
203
2 General Description Air Top 2000
Page free for notes
204
Air Top 2000 3 Functional Description
3 Functional Description 3.1.3 Stabilization
Diesel Operated Heaters

3.1 Functional Description Air Top 2000 With the glow plug activated the operating speed of the
without Diagnosis (Fig. 301) combustion and heating air fan is increased. After another
20 seconds the speed of the combustion and heating air
3.1.1 Control Element fan is continuously increased within 17 seconds to full
load for full heat.
The control element is used to switch the air heater on A flame-out during the speed rise control period causes a
and off, set the desired room temperature (air intake repeat start.
temperature between 10° C and 45° C), and to unlock a
failure interrupt condition. Fuel Operated Heaters
With the glow plug activated the operating speed of the
The green LED indication is used to indicate the combustion and heating air fan is continuously increased
operating condition (LED permanently on) and an over- within 4 seconds to full load for full heat. A flame-out dur-
heat condition (LED flashes). ing the speed rise control period causes a repeat start.
NOTE 3.1.4 Heating Operation

After application of power upon switch-on of the battery
switch and selecting the control element "ON", the During operation the combustion exhaust gasses flow
control unit enters the "error lockout" condition. Prior to a through the heat exchanger charging its walls with
re-activation the control element has to be placed to combustion heat, which in turn is taken up by the heating
"OFF". air delivered by the heating air fan to be routed to the
vehicle interior.
3.1.2 Switch-On The temperature of the heating air sucked in is measured
by means of a temperature sensor fitted to the air intake
The control element is set to the desired room tempera- side of the air heater or in case of 12 Volt heaters also
ture. When switching the air heater on, the operating by means of an externally located temperature sensor.
indicator is illuminated and the glow plug is activated A temperature below the one set with the control element
(cycled). The motor of the combustion and heating air fan increases the heater performance up to maximum heat.
starts high-speed operation for 1 second (break-away In order to extend the burner idle period of Diesel oper-
moment) and is then under slow-down control. ated heaters during permanent operation with a heating
performance in excess of 1.2 kW, the fuel dosing pump
NOTE delivery rate is reduced every 30 minutes for 20 seconds.
Should the temperature of the intake air be above the
selected, rated temperature, only the motor of the A heating performance less than 1.2 kW causes the
combustion and heating air fan will operate (control idle). fuel delivery to the dosing pump to be interrupted every
Start operation will be initiated with a heating air 30 minutes for 4 seconds. For both types of heaters
temperature below the rated temperature. (fuel and Diesel) heating operation is shortly interrupted
every 9 hours like in control idle.
After approx. 20 seconds (for fuel operated heaters after
approx. 15 seconds) the fuel dosing pump is activated. After reaching the temperature set with the control
After another 25 seconds the speed of the combustion element, heating performance is controlled to decrease.
and heating air fan is continuously increased to a higher The speed of the combustion and heating air fan slows
rate and combustion begins. As soon as a flame is down and the fuel delivery rate to the pump is reduced.
detected, combustion will be stabilized (see 3.1.3). When exceeding the air intake temperature set with the
control element during minimum heating performance,
Should no normal combustion be achieved within the dosing pump is deactivated after 5 seconds and
120 seconds (for fuel operated heaters after approx. combustion terminates.
115 seconds), the speed of the combustion and heating
air fan is increased for approx. 30 sec and there will be NOTE
an automatic repeat start with the glow plug activated and The control unit/air heater reacts to new settings of the
fuel dosing pump deactivated (no fuel supply). control element with a time delay.
Should the no-combustion-condition persist, after another

80 seconds (for fuel operated heaters after approx.
85 seconds) there will be a switch-off by error lockout
(see 3.1.9) with a run-down of the combustion and heating
air fan lasting 120 seconds at 2/3 of its max. speed.
301
3 Functional Description Air Top 2000
3.1.5 Control Operation The short run-down time depends on the operational
condition at which ADR switch-off occurs.
During control operation fan speed and dosing pump rate A 40 second run-down with maximum speed is initiated
of delivery are subject to heating performance. The glow (ADR switch-off) when:
plug is deactivated.
• air heater is still in the start phase; stabilization not yet
3.1.6 Control Idle achieved
• air heater is in normal run-down
• air heater is in control idle.
In case the air intake temperature set with the control
element is exceeded and the minimum heating perform-
A 20 second run-down is switched on in normal combus-
ance had been achieved for longer than 5 seconds, the
tion operation with the fuel delivery immediately halted
fuel supply is cut off to terminate combustion.
maintaining the fan speed for 5 seconds. Then the speed
The motor of the combustion and heating air fan continues
is increased for 30 seconds within another 5 seconds.
operation for another 155 seconds at 2/3 of maximum
speed to cool down the air heater (run-down). In control
For all heaters after July 1995 the short run-down out
idle the combustion and heating air fan runs at minimum
of all operating conditions is a max. of 20 seconds.
speed. The operation indication remains lit. After reaching
the air intake temperature set with the control element a
After an ADR switch-off the control unit is in the "error
new start procedure is launched (without break-away).
lockout" condition.
Prior to resuming operation the control element has to be
3.1.7 Switch-Off set to "OFF".
Switching the heater off extinguishes the operation

3.1.9 Switch-off upon Failure
indication of the control element.
If no fuel has been delivered (within 20 seconds for Diesel
operated heaters or within 15 seconds for fuel operated The control unit recognises failures of individual air heater
heaters after switch-on) or if the air heater is in control components and malfunctions in the start sequence and
in normal operation.
idle, the air heater is deactivated immediately without
run-down.
The air heater is deactivated and enters the error lockout
If fuel supply has commenced it will be immediately mode under the following conditions:
stopped at switch-off. The fan speed decreases within
35 seconds to 2/3 of maximum. • flame sensor resistance out of tolerance
Subsequently or if the flame sensor detects "no flame" • temperature sensor resistance out of tolerance
• glow plug/glow plug trigger defective
the fan speed is increased to maximum for 60 seconds
and run-down is initiated to last 120 seconds. Run-down • fan speed too low, short circuit or open circuit
is automatically halted. • error in dosing pump electrical circuit or of overheat
protection (in start phase only)
NOTE • low voltage below 10 Volt and in excess of 20 seconds
Re-activation of the heater during run-down is permitted. for 12 Volt heaters
• low voltage below 20 Volt and in excess of 20 seconds
Run-down will be completed first with a subsequent
re-start. for 24 Volt heaters
• control unit defective
3.1.8 Functions of the Air Heater in In case of overheating there will be no fuel supply.
ADR Vehicles A run-down like after manual switch-off will be performed.
NOTE After run-down the control unit is in the error lockout mode.
Applicable only for Air Top 2000 D Air Heaters installed Overheating is indicated by the operation indication flash-
in vehicles for the transportation of dangerous goods ing. For error unlock the air heater has to be switched off
(ADR). momentarily to be switched on again.
If the heater is deactivated using the control element,

un-down will not change.
A short run-down (max. 40 seconds) is automatically
activated if:
• the vehicle engine is turned off

• a conveyor facility is put into operation.
302
3 4 9
1 2 5 6 7 8 10
On
1
A 0
1
C 0
100%
90%
60%
30%
D 0
1.3 Hz
1.0 Hz
0.8 Hz
0.6 Hz
E 0
1
F 0
0 20 45 65 85 102 (20) (60)

(120)
typical seconds
Fig. 301 Functional Diagram (Air Top 2000 without Diagnosis)
1 Start A = Control Element
2 Control Operation B = Temperature Sensor
3 Rated Value reached C = Glow Plug
4 Rated Value exceeded D = Combustion and Heating Air Fan

(e.g. due to reduced heat consumption)
E = Dosing Pump
5 Run-down
F = Flame Sensor
6 Control Idle
7 Start
8 Control Operation (increased heat consumption)
9 Switch-off
10 Run-down
303
3.2 Functional Description Air Top 2000 Should no proper combustion develop within 120 seconds
Diagnosis (for fuel-operated within 115 seconds) the combustion and
heating air fan speed is increased to full load for approx.
30 seconds (15 seconds for fuel-operated heaters) with
3.2.1 Control Element the glow plug on and the dosing pump off (no fuel delivery)
with a subsequent automatic restart.
The control element is used to switch the air heater on
and off, set the desired room temperature (air intake Should the no-combustion-condition persist, after
temperature between 10° C and 45° C), and to unlock a another 80 seconds (for fuel operated heaters after
failure interrupt condition. approx. 85 seconds) there will be a switch-off by error
lockout (see 3.2.9) with a run-down of the combustion and
The green LED indication is used to indicate the heating air fan lasting 120 seconds at 2/3 of its max.
operating condition (LED permanently on) and an over- speed.
heat condition (LED flashes).
2. Start (automatic restart)
NOTE Fan speed is again reduced to approx. 30% (for fuel
ADR Operation: operated heaters to approx. 50%) and fuel is delivered.
After application of power upon switch-on of the battery During the next 20 seconds fan speed is increased to
switch and selecting the control element "ON", the approx. 60% (for fuel-operated heaters to approx. 75%) of
control unit enters the "error lockout" condition. Prior to a full speed. As soon as a flame is detected within the next
re-activation the control element has to be placed to 55 seconds, combustion will be stabilized.
"OFF". Should there be no flame condition after a total fuel
delivery period of 180 seconds, fuel delivery will be
3.2.2 Switch-On stopped and the glow plug deactivated. The combustion
air fan continues full load operation for another 120 sec-
The control element is set to the desired room tempera- onds (run-down) and the heater enters the error lockout
ture. When switching the air heater on, the operating condition.
indicator is illuminated and the glow plug is activated
(cycled). The motor of the combustion and heating air fan 3.2.3 Stabilization
starts high-speed operation for 1 second (break-away
moment) and is then under slow-down control to approx. Diesel Operated Heaters
30% (Diesel) or 50% (fuel) of full speed. With the glow plug activated the operating speed of the
combustion and heating air fan is increased. After another
NOTE 20 seconds the speed of the combustion and heating air
Should the temperature of the intake air be above the fan is continuously increased within 17 seconds to full
selected, rated temperature, only the motor of the load for full heat.
combustion and heating air fan will operate (control idle).
Start operation will be initiated with a heating air NOTE
temperature below the rated temperature. This operating condition is omitted if the set temperature
(control idle) has already been achieved once.
The flame sensor function is checked. If the flame
sensor at this time already signals "flame", there will be a The glow plug is deactivated and heating operation
120 second run-down and an error lockout of the control commences. A flame-out during speed up control causes
unit. A malfunction of any other component monitored a restart, 5 restarts an error lockout of the heater.
causes an error lockout without run-down.
Fuel Operated Heaters
After approx. 20 seconds (for fuel operated heaters after With the glow plug activated the operating speed of the
approx. 15 seconds) the fuel dosing pump is activated. combustion and heating air fan is continuously increased
After another 25 seconds the speed of the combustion within 4 seconds to full load for full heat.
and heating air fan is continuously increased to a higher
rate and combustion begins. As soon as a flame is NOTE
detected, combustion will be stabilized (see 3.2.3). This operating condition will be omitted if the start occurs
after a control idle period.
Should no normal combustion be achieved within
120 seconds (for fuel operated heaters after approx. The glow plug is deactivated and heating operation
115 seconds), the speed of the combustion and heating commences. A flame-out during speed up control causes
air fan is increased for approx. 30 sec and there will be an a restart, 5 restarts an error lockout of the heater.
automatic repeat start with the glow plug activated and
fuel dosing pump deactivated (no fuel supply).
304
3.2.4 Heating Operation 3.2.7 Switch-Off
During operation the combustion exhaust gasses flow Switching the heater off extinguishes the operation
through the heat exchanger charging its walls with indication of the control element.
combustion heat, which in turn is taken up by the heating If no fuel has been delivered or if the air heater is in control
air delivered by the heating air fan to be routed to the idle, the air heater is deactivated immediately without
vehicle interior. run-down.
The temperature of the heating air sucked in is measured If fuel supply has commenced it will be immediately
by means of a temperature sensor fitted to the air intake stopped at switch-off. Fan speed remains constant and
side of the air heater or by means of an externally located then decreases within 30 seconds to approx. 60% of
temperature sensor. A temperature below the one set with full speed.
the control element increases the heater performance up After this or with the flame sensor detecting "no flame",
to maximum heat. In order to extend the burner idle period fan speed rises to maximum speed for 60 seconds and
of Diesel operated heaters during permanent operation run down for 120 seconds is initiated. Run-down is at
with a heating performance in excess of 1.1 kW, the fuel approx. 60% of full speed and is deactivated automati-
dosing pump delivery rate is reduced every 15 minutes for cally.
20 seconds.
NOTE
A heating performance less than 1.1 kW causes the Re-activation of the heater during run-down is permitted.
fuel delivery to the dosing pump to be interrupted every Run-down will be completed first with a subsequent
30 minutes for 4 seconds. Additionally heating operation re-start.
is briefly suspended every 9 hours like in control idle. For
Diesel-operated heaters this is only applicable, if at this 3.2.8 Functions of the Air Heater in
time heating performance is less than 1.1 kW. ADR Vehicles
3.2.5 Control Operation NOTE

Applicable only for Air Top 2000 D Air Heaters installed in
During control operation fan speed and dosing pump rate vehicles for the transportation of dangerous goods (ADR).
of delivery are subject to heating performance. The glow
plug is deactivated. If the heater is deactivated using the control element,
run-down will not change.
3.2.6 Control Idle A short run-down (max. 20 seconds) is automatically
activated if:
After reaching the temperature set with the control
element, heating performance is controlled to decrease. • the vehicle engine is turned off
The speed of the combustion and heating air fan slows • a conveyor facility is put into operation
down and the fuel delivery rate to the dosing pump is
reduced. When exceeding the air intake temperature set The short run-down time depends on the operational con-
with the control element during minimum heating perform- dition at which ADR switch-off occurs.
ance, the dosing pump is deactivated after 5 seconds and A 15 second run-down with maximum speed is initiated
combustion terminates. (TRS switch-off) when:
Fan speed remains constant for 35 seconds and is then
increased to approx. 60% of full speed for cooling the • air heater is still in the start phase; stabilization not yet
heater down. the fan then continues to operate at approx. achieved
30% of full speed until temperature is below the tempera- • air heater is in normal run-down
ture set with the control element. If temperature falls • air heater is in control idle.
below the one set with the control element, the heater will
restart (without break away). A 20 second run-down is switched on in normal
combustion operation and in stabilization with the fuel
NOTE delivery immediately halted maintaining the fan speed for
New settings on the control element are executed by the 5 seconds. Then the speed is increased to maximum
control unit/heater with a time delay. for 15 seconds within for a run-down.
After an ADR switch-off the control unit is in the "error

lockout" condition. Prior to resuming operation the control
element has to be set to "OFF".
305
3.2.9 Switch-off upon Failure
The control unit recognises failures of individual air heater

components and malfunctions in the start sequence and
in normal operation. The air heater is deactivated and
enters the error lockout mode under the following condi-
tions:
• flame sensor open or short circuit

• temperature sensor open or short circuit
• glow plug open or short circuit
• fan motor open or short circuit or fan speed wrong
• dosing pump open or short circuit
• overheating
• low voltage below 10 Volt or high voltage above
15 Volt in excess of 20 seconds for 12 Volt heaters
• low voltage below 20 Volt or high voltage above
30 Volt in excess of 20 seconds for 24 Volt heaters
A switch-off like in "switch-off" will be performed. In case

of overheating there will be no fuel supply.
After run-down the control unit is in the error lockout mode.
The operation indication outputs a flash code.
For error unlock the air heater has to be switched off
momentarily (at least 2 seconds) to be switched on again.
306
Air Top 2000 4 Technical Data
4 Technical Data Propellant for Air Top 2000 B (Fuel):

The proper fuel is the fuel specified by the vehicle
manufacturer.
As long as no threshold values are given, the following
technical data are understood to include tolerances Propellant for Air Top 2000 D (Diesel/Fuel Oil EL):
of ±10% usual for heaters at an ambient temperature The proper Diesel fuel is the one specified by the vehicle
of +20° C and at nominal voltage and conditions. manufacturer. Also fuel oil of class EL – not heating oil L
– can be used as long as it meets the standard German
Electrical Components: quality specified in DIN 51603.
Control unit, combustion air fan, dosing pump, timer*, A persistent influence by additives is not known.
glow plug and control element are for 12 or 24 Volts When tapping fuel from the vehicle fuel tank observe the
operation. manufacturer’s fuel additive specifications.
When switching to low temperature propellants the heater
The components temperature limiter and flame detector must be operated for at least 15 minutes to prime the fuel
are independent of voltage. system with the new type of fuel.
* not for ADR
Air Heater Operation AT 2000 B AT 2000 D
Mark of conformity ~ S 277 ~ S 270
Heater type Air heater with evaporator burner
Heat flow Control range 1.1 – 2.0 kW 0.9 – 2.0 kW
Type of fuel Fuel Diesel/Fuel oil (EL)
Fuel consumption Control range 0.1 ... 0.2 kg/h (0.16 ... 0.27 l/h) 0.1 ... 0.21 kg/h (0.12 ... 0.24 l/h)
Nominal voltage 12 Volt 12 Volt 24 Volt
Operation voltage 10 ... 15 Volt 10 ... 15 Volt 20 ... 30 Volt
Rated power consumption Control range 9 ... 22 W
Permitted ambient temp.:

Heater – operation –40° ... +40° C
– storage –40° ... +85° C
Dosing pump – operation –40° ... +20° C
– storage –40° ... +85° C
Control element – operation –40° ... +75° C
– storage –40° ... +85° C
Permitted combustion air
–40° ... +20° C
intake temperature
Setting range for
Control range +10° ... +45° C
indoor temperature
Volume flow of heating air
Max. 70 m3/h
against 0.5 mbar
CO2 in exhaust
Max. 9.5 ... 10.5 9.5 ... 12.0
(perm. functional range)
Dimensions air heater Length 322 ± 2 mm
Width 130 ± 1 mm
Heigh 122 ± 1 mm
Weight, heater 2.6 kg
401
4 Technical Data Air Top 2000
Page free for notes
402
Air Top 2000 5 Troubleshooting
5 Troubleshooting CAUTION
Troubleshooting is normally limited to the isolation of
defective components.
5.1 General The following causes for trouble are not considered and
should always be checked for to exclude them as cause
This section describes troubleshooting procedures for the for trouble:
Air Heater Air Top 2000 and Air Top 2000 Diagnosis.
• corrosion on connector
A malfunction in air heaters Air Top 2000 Diagnosis • loose contact on connector
outputs an error code to the display of the combination or • wrong crimping on connector
standard timer. When equipped with a control element the • corrosion on electrical wiring and fuses
operating indicator flashes. In addition a heater checkout • corrosion on battery terminals
may be performed using a personal computer (refer to
operating instructions PC air heater diagnosis). If individual components are checked, the control unit
electrical connections must be disconnected.
CAUTION
Troubleshooting requires profound knowledge about After any correction of a failure a functional test has to be
structure and theory of operation of heater components performed in the vehicle.
and may only be performed by skilled personnel.
In cases of doubt refer to Sections 2 or 3 for functional 5.2 General Failure Symptoms
interrelations.
The following table (Fig. 501) lists the possible failure
NOTE symptoms.
Only for ADR operation
After an ADR switch-off or power application by vehicle
main power switch operation and the control element to
"ON", the control unit will be in "error lockout". Prior to
reactivation the control element must be set to "OFF" or
the instant heat switch on the combination or standard
timer be operated.
Failure Symptom Probable Cause Remedy
Air heater switches No combustion after start or repeat Switch off heater momentarily and
off automatically start switch on once again
Flame extinguishes during Switch off heater momentarily and

operation switch on once again
Heater overheats Check heat air ducting for

Operation indication flashes obstuctions, allow heater to cool
down, switch off heater momentarily
and switch on once again
Vehicle electrical Charge battery

system voltage too low Switch off heater momentarily and
switch on once again
Heater expels black fumes Combustion air and/or Check combustion and exhaust
exhaust ducting blocked ducting for obstructions
Fig. 501 General Failure Symptoms
501
5 Troubleshooting Air Top 2000
5.3 Failure Symptoms during Operation symptom listed, in emergencies assistance by our service
technicians may be requested (Tel. 0 18 05 / 93 22 78).
The following table (Fig. 502) lists the possible failure
symptoms as they might occur during the functional NOTE
sequence of operation. Overheating and dosing pump failure are always
indicated additionally after run-down by the flashing LED
In case of malfunction the failure is to be isolated and of the control element.
removed using this table. It is important to accurately
identify the failure symptom. In all cases of trouble also a defective control unit may be
the cause should all other components turn out to be
Should the failure symptom not be contained in this table serviceable.
or the trouble not be detected under the specific failure
Failure Symptom Shows after ...s Possible Causes
No start and no illumination immediately Wrong cabling, defective fuse

of LED on control element
No start but LED illuminates immediately Fan or control unit defective or fan blocked
Very low speed with no start immediately Control idle operation: wrong manual control
(selected temperature is below air intake tempera-
ture) or wrong integration (excessive air intake
temperature)
Motor operates momentarily 1 Glow plug or flame sensor short or open circuit or
and then stops control unit defective
Stoppage without run-down 5 Fan motor obstructed, binding
Run-down after 1 Flame detection erroneous
Run-down after 20 Voltage to control unit too low
Run-down after 120 Cabling to dosing pump, pump itself or overheat

and dosing pump does not cycle protection defective
Run-down after 40 to 120 Intermittent disconnect of connection to dosing

pump or to overheat protection
Run-down after 230 No flame: wrong fuel supply quantity, defective or

slow fan, coked burner (in particular pilot flame out-
let bore), combustion air/exhaust ducting obstructed
or heat exchanger coked, dosing pump seized
Run-down during combustion Overheating or voltage too low or component error

operation (flame sensor, glow plug, overheat sensor, dosing
pump, burner) or no fuel supply or obstructed
combustion air/exhaust ducting
Stoppage without run-down during combustion Fan motor failure or seizure

operation
Interruption of dosing pump cycling during combustion Flame-out by gas bubbles in fuel delivery or strong
and max. speed for 30 s with operation wind against exhaust outlet or defective no-flame
subsequent re-start detection
Fig. 502 Failure Symptoms during Operation
502
Air Top 2000 5 Troubleshooting
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 display
of the timer for indication.
NOTE
When equipped with a control element the error code
output is indicated by flashing of the operating indicator/
error code indication. The number of flash pulses
corresponds to the number indicated in the table below.
After a quick pulse train there will always be an error code
output.
Error code output on display of combination or

standard timer
F 01 No start (after 2 attempts)

F 02 Flame out (at least > 5)
F 03 Voltage too low or too high
F 04 Premature flame detection
F 05 Flame sensor open or short circuit
F 06 Temperature sensor open or short circuit
F 07 Dosing pump open or short circuit
F 08 Fan motor open or short circuit or
wrong speed
F 09 Glow plug open or short circuit
F 10 Overheating
503
5 Troubleshooting Air Top 2000
Page free for notes
504
Air Top 2000 6 Functional Tests
6 Functional Tests CAUTION

Set potentiometer slowly; observe end positions.
6.1 General Adjustment may be performed at any electrical system

voltage.
This section describes the on-vehicle and off-vehicle
testing of the air heater to check its proper operation. Clockwise rotation increases the fan speed and
decreases the CO2 contents. Counterclockwise rotation
WARNING decreases the fan speed and increases the CO2 contents.
The air heater shall not be operated in enclosed areas like
garages or workshops not provided with exhaust venting If the setting range is not sufficient (e.g. after replacement
facilities. of the combustion and heating air fan) the manufacturer's
setting may be cancelled according to the procedure
described in the following.
6.2 Adjustments
6.2.1.2 New Basic Setting
6.2.1 Adjustment of the CO2 Contents CAUTION

The manufacturer's setting cannot be restored.
6.2.1.1 General
1. Withdraw cover from upper shell according to 9.2.1.1.
The CO2 contents of the exhaust is adjusted with the 2. Switch on air heater.
potentiometer on the control circuit board.The air heater is 3. Rotate potentiometer two times and with no interrupt
preset by the manufacturer with respect to the combustion through its complete setting range (e.g. max. - min.-
and heating air fan fitted. After adjustment by the manu- max.).
facturer the potentiometer is in center position (Fig. 601). 4. Adjust desired CO2 contents (Fig. 601).
After an inadvertent loss of this position it is sufficient to 5. Switch off air heater.
restore its original position. 6. Plug on cover and secure.
The manufacturer setting may be corrected by rotating

the potentiometer. A suitable tool like a small screw driver
(2.5 mm tip) is to be used.
CO2
CO2
+ –
+ –
Air Top 2000 Diagnosis Air Top 2000 without Diagnosis
Fig. 601 Adjustment of CO2 Contents
601
6 Functional Tests Air Top 2000
6.3 Components Testing
CAUTION
During electrical testing always ensure that the control
unit and the component under test are electrically dis-
connected from each other.
6.3.1 Glow Plug Resistance Test
During electrical testing of the glow plug using a digital

multimeter, the following readings should be obtained:
Glow plug: 12 Volt (red) 24 Volt (green)

Resistance at 25° C: 0.3 ... 0.6 : 1.3 ... 1.44 :
Test current: < 5 mA < 5 mA
6.3.2 Flame Sensor Resistance Test
During electrical testing of the flame sensor using a digital

multimeter, the following readings should be obtained:
Cold test:
Resistance at 25° C: 2.6 ... 3.4 :
Test current: < 5 mA
Hot test:
Resistance at 800 – 1000° C: 12 ... 15 :
(ceramic rod red hot over a length of approx. 20 mm)
Test current: < 5 mA
602
Air Top 2000 7 Circuit Diagrams
7 Circuit Diagrams The air heater Air Top 2000 without Diagnosis may be
operated using the control element (rated value
transmitter/switch) or with the control element and a timer.
7.1 General The circuit diagrams (Figs. 709 to 713) show the possible
circuits 12 or 24 Volt with
The air heater Air Top 2000 Diagnosis may be operated
using the control element (rated value transmitter/switch) • control element
or with the control element and a combination or standard • control element and timer
timer. The circuit diagrams (Figs. 703 to 708 and 714) • control element for ADR
show the possible circuits 12 or 24 Volt with
Fig. 702 shows the terminal pin assignment.
• control element
• combination timer
• control element and standard timer
• control element for ADR
• combination timer for ADR
• ADR operation for vehicles without auxiliary drive
Fig. 701 shows the terminal pin assignment.
X1 X2 X3 X4 X5
violet black brown yellow blue
X1 = Connection, Combustion and Heating Air Fan

X2 = Connection, Dosing Pump
X3 = Connection, Flame Sensor
X4 = Connection, Glow Plug
X5 = Connection, Temperature Limiter
Fig. 701 Terminal Pin Assignment, Air Top 2000 Diagnosis
701
7 Circuit Diagrams Air Top 2000
X1 X2 X3 X4 X5
violet black brown yellow blue
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
ϑ ϑ
Item Nomenclature Remark Wire Gauges

A1 Air Heater Air Top 2000
A2 Control Unit < 7.5 m 7.5 - 15 m
0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
B2 Temperature Sensor 1.5 mm2 2.5 mm2
B3 Temperature Limiter 2.5 mm2 4.0 mm2
E Glow Plug 4.0 mm2 6.0 mm2
F2 Fuse 24V 10A/12V 15A Flat Fuse SAE J 1284
Wire Colours
H1 LED green (in item S1) Operation indication
bl blue
M Motor
br brown
S1 Control Element Rated Value Setting Switch ge yellow
X1-X5 Connection 2-pole of item A2 gn green
X6 Connection 8-poleg of item A2 gr grey
X7 Connection 4-pole of item S1 or orange
rt red
X8 Connection 2-pole sw black
X9 Connection 2-pole of item A2 vi violet
X11 Connection 6-pole of item A2 ws white
X12 Connection 1-pole Diagnosis (K-wire)
Y1 Dosing Pump
2 Connection X11/2 and X11/3 for

ADR function only
Fig. 703 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24V with Control Element
703
B2 A2 E B1 B3
30 30
15 15
58 58
F2 A2
X11 X5
X4
1,0 mm² X6 X3
1 X2
X9
rt
X13 X1
2 6 4
1 10 11 A2 X11
0,5mm² rt 1 0,5mm² gr
3
0,5mm² vi 2
X12
2 0,5mm² sw 7
2 0,5mm² gn/ws
H8
H9 H7 8 3 5
0,5mm² bl X6
6 6 X1,2,3,4,5
0,5mm² ws 5 4
1
13
8 5
1 2 7
P1 9 2
4 6
12 7 4 X6 1 2 1 2 2 1 2 1 1 2 1 2 8
vi/ws X9
X1 vi ge X4 ge X3 br X9 X2 bl X5 bl
M br ϑ ϑ
B1 B2 B3 X8 2
M E 1
A1 ϑ
1,0 mm²
sw
sw
X11
S3 X8
6
X12 5
br
br
bl
4
3
2
1
Y1
3 X13
31 6
9
12

< 7.5 m 7.5 - 15 m
A2 Control Unit
0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
Wire Colours
H7 LED red (in item P) Instant heat switch illumination, standy indication,
operating indicator light bl blue
br brown
H8 LED (in item P) Operating indicator light, overheat indication
ge yellow
H9 Light (in item P) Symbol illumination gn green
M Motor gr grey
P1 Combination Timer (1531) or orange
rt red
S3 Switch Instant heating remote control
sw black
X1-X5 Connection 2-pole of item A2 vi violet
X8 Connection 2-pole
X9 Connection 2-pole of item A2
1 with plus from terminal (15/75)
X13 Connection 12-pole of item P to connection 10:
Y1 Dosierpumpe permanent operation during
instant heating as long as
ignition on
without plus to connection 10:

heating time programmable as
required (10 min to 120 min),
default setting 120 min.
2 Connection X11/2 and X11/3

for ADR function only
Fig. 704 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24V with Combination Timer
704
B2 A2 E B1 B3
30 30
15 15
58 58
F2 A2
X11 X5
X4
1,0 mm² X6 X3
1 X2
X9
rt
X13 X1
2 6 4
1 10 11 A2 X11
0,5mm² rt 1 0,5mm² gr
3
0,5mm² vi
2
X12
2 0,5mm² sw 7
2 0,5mm² gn/ws
H8
H9 H7 8 3 5
X6
6 6 X1,2,3,4,5
5 1
4 13
0,5mm² ws
5
0,5mm² bl
8 1 7
2
P2 9 2
X6 1
X7 4
4 6
12 7 4 1 2 1 2 2 1 2 1 1 2 1 2 8
vi/ws X1 vi ge X4 ge X3 br X9 X2 bl X5 bl X9
2 3
M br ϑ ϑ
X7 B1 B2 B3 X8 2
M E 1
S1 A1 ϑ
3
1,0 mm²
sw
sw
S3 X11
4 X8
6
X12 5
br
br
bl
4
3
1 2
1
2
Y1
3 X13
31 6
9
12

0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
Wire Colours
br brown
H8 Heating symbol in display (in item P) Operating indicator light, overheat indication ge yellow
M Motor gr grey
P2 Standard timer or orange
rt red
S1 Control Element Rated Value Setting Switch
sw black
S3 Switch Instant heating remote control vi violet
X1-X5 Connection 2-pole of item A2 ws white
X7 Connection 4-pole of item S1
X12 Connection 1-pole Diagnosis (K-wire) to connection 10:
X13 Connection 12-pole of item P permanent operation during
Y1 Dosing Pump instant heating as long as
ignition on

2 Connection X11/2 and X11/3

for ADR function only
Fig. 705 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 12V/24V with Control Element and Standard Timer
705
ϑ ϑ

0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
F2 Fuse 24V 10A Flat Fuse SAE J 1284
Wire Colours
bl blue
H6 Light (at least 1.2 W) Operation indication, conveyor facility
br brown
M Motor ge yellow
S1 Rated Value Setting Switch Control Element gn green
S2 Disconnect Switch 1- oder 2-pole Emergency-off Switch; electr. or pneum. gr grey
or orange
S4 Switch Conveyor facility I
rt red
X1-X5 Connection 2-pole of item A2 sw black
X7 Connection 4-pole of item S1 ws white
Y1 Dosing Pump
Y2 Solenoid valve for conveyor facility I
Fig. 706 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 24V ADR Operation with Control Element
706
S2
30
15 15 B2 A2 E B1 B3
58 58
D+/61 D+/61
F2 A2
X11 X5
S4 X4
1,0 mm² X6 X3
0,5mm² gr
1 X2
X9
rt
X13 X1
2 6 4
1 10 11 A2
0,5mm² rt 1
vi
3 0,5mm²
X12
2 0,5mm² sw 7
2 0,5mm² gn/ws
H8
H9 H7 8 3 5
0,5mm² bl X6
6 6 X1,2,3,4,5
0,5mm² ws 5 4
1
13
8 5
1 2 7
P1 9 X11 2
4 6
12 7 4 X6 1 2 1 2 2 1 2 1 1 2 1 2 8
ACHTUNG:
Pin 4 kein Masseanschluss M br ϑ ϑ
B1 B2 B3 X8 2
M E 1
A1 ϑ
1,0 mm²
sw
sw
X11
S3 X8
6
X12 5
br
br
bl
4
3
2
1
H6
Y2
S2
Y1
3 X13
31 6
9
12

0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
F2 Fuse 24V 10A Flat Fuse SAE J 1284
Wire Colours
H6 Light (at least 1.2 W) Operation indication, conveyor facility
H7 LED red (in item P) Instant heat switch illumination, standy indication, bl blue
br brown
operating indicator light
ge yellow
H8 Heating symbol in display (in item P) Operating indicator light, overheat indication gn green
H9 Light (in item P) Symbol illumination gr grey
M Motor or orange
P1 Combination Timner (1531) rt red
sw black
S2 Disconnect Switch 1- oder 2-pole Emergency-off Switch; electr. or pneum. vi violet
S3 Switch Instant heating remote control ws white
S4 Switch Conveyor facility I
X1-X5 Connection 2-pole of item A2
X9 Connection 2-pole of item A2 1 with plus from terminal (15/75)
X11 Connection 6-pole of item A2 to connection 10:
X12 Connection 1-pole Diagnosis (K-wire) permanent operation during
instant heating as long as
X13 Connection 12-pole of item P ignition on
Y1 Dosing Pump
Y2 Solenoid valve for conveyor facility I heating time programmable as
Fig. 707 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 24V ADR Operation with Combination Timer
707
S2
30
15 15 B2 A2 E B1 B3
58 58
D+/61 D+/61
F2 S4 S5 A2
X11 X5
X4
1,0 mm² X6 X3
0,5mm² gr
1 X2
X9
rt
X13 X1
2 6 4
1 10 11 A2
0,5mm² rt 1
3
X12
2 0,5mm² sw 7
2 gn/ws 0,5mm²
H8
H9 H7 8 3 5
0,5mm² bl X6
6 6 X1,2,3,4,5
0,5mm² vi
0,5mm² ws 5 4
1
13
8 5
1 2 7
P1 9 X11 2
4 6
12 7 4 X6 1 2 1 2 2 1 2 1 1 2 1 2 8
ACHTUNG:
Pin 4 kein Masseanschluss M br ϑ ϑ
B1 B2 B3 X8 2
M E 1
A1 ϑ
1,0 mm²
sw
sw
X11
S3 X8 86 87 87a
6
X12 5
br
br
bl
K 4
3
85 30 2
1
S2
Y1
Y2 Y3 X13
3
31 6
9
12

< 7.5 m 7.5 - 15 m
A2 Control Unit
0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
Wire Colours
br brown
H8 Heating symbol in display (in item P) Operating indicatior light, overheat indication ge yellow
M Motor gr grey
P1 Combination Timer (1531) or orange
rt red
S2 Disconnect Switch 1- or 2-pole Emergency-off Switch; electr. or pneum. sw black
S3 Switch Instant heating remote control vi violet
S4 Switch Conveyor facility I ws white
S5 Switch Conveyor facility II
X1-X5 Connection 2-pole of item A2
X8 Connection 2-pole NOTE
X9 Connection 2-pole an Pos. A2 Minus potential applied to control
unit input X11/2 (ADR identifica-
X11 Connection 6-pole an Pos. A2
tion) across Y2 and K
X13 Connection 12-pole of item P
to connection 10:
Y1 Dosing Pump permanent operation during
Y2 Solenoid valve for conveyor facility I instant heating as long as
ignition on
Y3 Solenoid valve for conveyor facility II
Fig. 708 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 24V ADR Operation
with Combination Timer and 2 Auxiliary Drives
708
ϑ ϑ

0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
E Glow Plug
Wire Colours
F2 Fuse 15A Flat Fuse SAE J 1284
bl blue
br brown
H4 Leuchten (in item P) Symbol illumination ge yellow
M Motor gn green
S1 Rated Value Setting Switch Control Element gr grey
X1-X5 Connection 2-pole of item A2 or orange
rt red
X6 Connection 8-pole of item A2 sw black
X7 Connection 4-pole of item S vi violet
X8 Connection 2-pole ws white
Y Dosing Pump
Fig. 709 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 12V with Control Element
709
ϑ ϑ

< 7.5 m 7.5 - 15 m
A2 Control Unit
0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
E Glow Plug
Wire Colours
bl blue
br brown
H4 Light (in item P) Symbol illumination ge yellow
M Motor gn green
P Timer 1529 for pre-timed operation gr grey
or orange
S1 Rated Value Setting Switch Control Element
rt red
X1-X5 Connection 2-pole of item A2 sw black
X7 Connection 4-pole of item S ws white
X8 Connection 2polig
Y Dosing Pump
Fig. 710 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 12V with Control Element and Timer
710
ϑ ϑ

0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
Wire Colours
M Motor bl blue
br brown
S1 Rated Value Setting Switch Control Element ge yellow
X1-X5 Connection 2-pole of item A2 gn green
X6 Connection 8-pole of item A2 gr grey
X7 Connection 4-pole of item S or orange
rt red
sw black
X11 Connection 2-pole for manufacturer’s installations only vi violet
Y Dosing Pump ws white
Fig. 711 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 24V with Control Element
711
ϑ ϑ

< 7.5 m 7.5 - 15 m
A2 Control Unit
0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
Wire Colours
bl blue
H4 Light (in item P) Symbol illumination
br brown
M Motor ge yellow
P Timer 1529 for pre-timed operation gn green
S1 Rated Value Setting Switch Control Element gr grey
X1-X5 Connection 2-pole of item A2 or orange
rt red
X6 Connection 8-pole of item A2 sw black
X7 Connection 4-pole of item S vi violet
X8 Connection 2-pole ws white
X11 Connection 2-pole for manufacturer’s installations only
Y Dosing Pump
Fig. 712 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 24V with Control Element and Timer
712
ϑ ϑ

0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
Wire Colours
bl blue
M Motor
br brown
S2 Disconnect Switch 1- or 2-pole Emergency-off Switch; electr. or pneum. gn green
X1-X5 Connection 2-pole of item A2 gr grey
X6 Connection 8-pole of item A2 or orange
rt red
X7 Connection 4-pole of item S sw black
X8 Connection 2-pole vi violet
X11 Connection 2-pole for manufacturer’s installations only ws white
Y Dosing Pump
Fig. 713 Circuit Diagram Automatic Control Air Top 2000 without Diagnosis, 24V with Control Element, ADR
713
ϑ ϑ

< 7.5 m 7.5 - 15 m
A2 Control Unikt
0.75 mm2 1.5 mm2
B1 Flame Sensor
1.0 mm2 1.5 mm2
Wire Colours
bl blue
M Motor
br brown
S2 Disconnect Switch 1- or 2-pole Emergency-off Switch; electr. or pneum. gn green
X1-X5 Connection 2-pole of item A2 gr grey
or orange
rt red
X7 Connection 4-pole of item S1 sw black
X8 Connection 2-pole vi violet
Y1 Dosing Pump
Fig. 714 Circuit Diagram Automatic Control Air Top 2000 Diagnosis, 24V ADR Operation with Control Element
in Vehicles without Auxiliary Drive
714
Air Top 2000
Jumper Terminal 15
2 0.75 mm 2
0.75 mm
br sw
Terminal 30
Terminal 58 1.0 mm 2
2 rt
0.75 mm
gr
12V
Terminal 31
1.0 mm 2
24V
br
1
2 2
3 0.5 mm
4 sw
5
6 7 2
8 0 0.5 mm
9 11 bl
1
12 2
0.5 mm
rt
2
0.5 mm
ws
Fig. 715 Connection Diagram, Air Top 2000 Diagnosis with Combination Timer (not ADR!)
7 Circuit Diagrams
715
Page free for notes
716
Air Top 2000 8 Servicing
8 Servicing For reasons of the air heater's functional reliability perform

the following servicing:
8.1 General • check heating air inlet and outlet for foreign matter
and contamination. (Contaminated or clogged heating
This section describes the servicing procedures that may air ducts may lead to overheating and thus response
be performed with the air heater installed. of the temperature limiter).
• Clean air heater exterior (prevent the ingress of
water).
• Examine electrical connections for corrosion of
8.2 Work on the Air Heater
contacts and for security.
• Check combustion air and exhaust ducts for damage
Prior to performing any work it is mandatory to disconnect and obstructions.
the vehicle battery main lead. As long as the air heater is • Check fuel lines and fuel filter for leakage.
in operation or in run-down, the battery main supply must • Replace fuel filter if installed.
not be disconnected due to the danger of overheating
resulting in a response of the overheat protection.
When performing extensive repairs on the heater a 8.6 Visual Inspections and Installation
complete removal is advisable.When performing repairs Regulations
requiring a relocation of the installation position, the
relevant installation instructions and the vehicle-specific 8.6.1 Heating Air System
installation proposal have to be observed.
CAUTION
The integration of the air heater into the vehicle's own air
8.3 Work on the Vehicle system is not permitted due to the system's high pressure.
CAUTION The air heater can only be operated in the ventilation

In the vicinity of the air heater a temperature of 85° C must mode of operation.
not be exceeded under any circumstances (e.g. during
body paint work). Fitted in the air heater on the heating air intake side is
a temperature sensor, which operates the heater in the
relevant range of performance in conjunction with the
8.4 Air Heater Test Run control element dependent on the air intake temperature
and position of the rated value transmitter. Heating
performance is selected so that after quickly reaching the
WARNING
preselected indoor temperature it is maintained at this
The air heater must not be operated, not even with timer, value. 12 Volt heaters (Air Top 2000 without Diagnosis)
in enclosed areas like garages or workshops not equipped may be operated with an external temperature sensor
with an exhaust venting facility.
(see 9.1.2). Air heaters Air Top 2000 Diagnosis 12 Volt
and 24 Volt may also be operated with an external
CAUTION
temperature sensor (see 9.1.2).
Operation of the heater without the control unit cover is
not permitted and causes overheating. Minimum inside diameter of the heating air duct is 55 mm.
Standard diameter is 60 mm.
8.5 Servicing NOTE

For heating air ducting only materials may be used which
NOTE are temperature-proof to at least 130° C.
In order to avoid the seizure of mechanical components,
the air heater should be operated every 4 weeks for at Maximum loss of pressure between suction and delivery
least 10 minutes. side of the heating air duct 1.0 mbar (10 mm water
column).
The air heater does not require maintenance. It should
however be checked by Webasto-trained skilled person- When exceeding this value the temperature limiter is very
nel in regular intervals, the latest before the heating likely to respond. The heating air hose is to be secured at
season begins (point of time, when the heater is more its joints.
frequently in use due to weather conditions).
801
8 Servicing Air Top 2000
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 Heater
a separate fuel container. The rated pressure at the fuel
tapping location is shown in Fig. 801.
Permissible fuel feed At max. permissible

height H (m) overpressure (bar)
in fuel line max. 3 m
0.00 0.20
l2
1.00 0.11
2.00 0.03
Permissible fuel suction At max. permissible low i ø 2 mm
height S (m) pressure (bar) in fuel tank
0.00 –0.10–
i ø 2 mm H
0.50 –0.06–
1.00 –0.02–
Heater
8.6.2.1 Fuel Tapping
l1
i ø 2 mm
Vehicles with Diesel Engine
Fuel tapping must be from the fuel reservoir or from a
l2
i ø 2 mm
separate tank (Figs. 802, 803 and 804). This separate fuel
S
tapping avoids an influence on the pressure.
Vehicles with Carburettor Engine l1

Fuel tapping in motorcars may only be performed using
the special Webasto fuel tap (e.g. Ident No. 470 910)
possibly in the vicinity of the fuel tank. Connection to the l1 + l2 ≤ 10 m
supply or return line is optional, the return line must be l1 ≤ 1.2 m
routed almost to the tank floor, otherwise the return line l2 ≤ 8.8 m
may be extended.
The fuel tap is to be mounted so that air or gas bubbles

can escape towards the fuel tank. Fig. 801 Fuel Supply
The fuel tap should be located in the engine compartment

because the radiation of engine heat may cause gas In case of a fuel pump mounted externally to the tank the
bubbles to build up in the fuel lines causing malfunctions fuel tap between fuel tank and fuel pump may also only be
in the combustion operation. fitted using the Webasto fuel tap (e.g. Ident No. 470 910).
Vehicles with Fuel Injection Engines

When installing the heater in vehicles with fuel injection
system the fuel pump's location within or outside the fuel
tank must be investigated first.
If the fuel pump is fitted inside the fuel tank, the fuel may
be tapped only from the return line using the Webasto fuel
tap only (e.g. Ident No. 470 910) ensuring that the return
line is routed almost to the tank floor. If this is not the case,
the Webasto fuel tap (see Fig. 802, 803 and 804) may be
used.
802
Hole Pattern Fuel Tank Tap
25
Gasket
Tank Fitting Plate

> 25 mm
Fig. 802 Webasto Fuel Tank Tap*
* Use fuel tank tap only on metal fuel tanks
Plastic Tank Fig. 804 Fuel Tapping from Plastic Tank

(tapping via fitting plate)
NOTE
The fitting plate must be made of sheet metal!
8.6.2.2 Fuel Lines
Fuel lines may only be steel, copper, or plastic lines made

of unhardened, light and temperature stabilised PA 11 or
PA 12 ( e.g. Mecanyl RWTL) according to DIN 73378. As
Gasket in most cases a permanently rising fuel line routing cannot
be ensured, the inner diameter must not exceed a certain
value. Starting from an inside diameter of 4 mm, air or
gas bubbles accumulate resulting in malfunctions should
the lines be descending or have sags. The diameters
specified in Fig. 801 ensure no disturbing formation of
bubbles.
A descending line routing from the dosing pump to the

heater should be avoided.
Fig. 803 Fuel Tapping from Plastic Tank Loose fuel lines must be secured in order to avoid
(tapping via fuel drain plug) sagging. The installation must ensure protection against
stone impacts and undue temperatures (exhaust line).
The fuel line joints are to be secured against slipping with
hose clamps.
803
Connection of 2 Pipes with Hose 8.6.3.1 Installation Location
The proper connection of fuel lines with hoses is shown It is advantageous to mount the dosing pump in a cool
in Fig. 805. location. The ambient temperature must never exceed
+20° C during operation.
correct
Dosing pump and fuel lines must not be installed in
locations exposed to heat radiated by hot vehicle
clamp components. A heat shield is to be provided as required.
8.6.3.2 Installation and Attachment

wrong
The dosing pump is to be attached with anti-vibration
bubble bubble mounts. The installation location is limited according to
Fig. 806 to ensure sufficient self-venting capability. Due
to the danger of corrosion the plug connection between
dosing pump and dosing pump cable loom may only use
Webasto original parts.
Fig. 805 Pipe/Hose Connection
8.6.4 Fuel Filter
8.6.3 Dosing Pump
If there is the probability of contaminated fuel only the
Webasto filter, Order No. 487 171, may be used.
The dosing pump is a combined delivery, dosing,
Installation possibly vertical up to horizontal at the most
and shut-off system and is subject to certain installation
(observe direction of flow).
criteria (see Figs. 801 and 806).
0 - 90°
ø5
12 Volt and 24 Volt - Fuel and Diesel DP 2
Fig. 807 Fuel Filter
0-90° 0-90°
0°
12 Volt and 24 Volt - Diesel DP 30

Installation Position only Horizontal
Fig. 806 Dosing Pump, Installation Position and

Attachment
804
8.6.5 Combustion Air Supply Both lines must be routed away from the heater in a
descending attitude. If this is not possible, a condensate
Combustion air must under no circumstances be extracted drain hole Ø 4 mm must be provided at the lowest point.
from rooms with persons. The combustion air inlet must
not point towards the forward direction of motion. It must Inner diameter of lines:
be located so that no clogging by contamination is to be Combustion air line: 22 mm
expected. Exhaust line: 22 mm
NOTE NOTE
For fuel operated heaters the combustion air tap must be When exceeding an exhaust line length of 2 m, insulated
located in a possibly cool and splash water proof position exhaust lines have to be used (below minimum dew
using a combustion air line. point).
If the air heater is located in a closed installation box, Smallest bending radius: 50 mm
combustion air must be taken in from and the exhaust
routed to the exterior. The feedthroughs must not allow In order to ensure the angle of 90° ± 10°, an attachment
exhaust fumes to enter the vehicle interior. is required not further than 150 mm away measured from
the exhaust pipe end.
If a contamniated combustion air supply is expected,
a combustion air filter can be fitted (Air Top 2000 D only).
8.6.6 Exhaust Line
Rigid pipes made of unalloyed or alloyed steel with a

minimum wall thickness of 1.0 mm have to be used as
exhaust line or flexible pipes made of alloyed steel only.
The exhaust pipe is secured to the air heater e.g. with a
clamp.
The exhaust muffler is preferably mounted near the air
heater. The direction of flow is optional. Exhaust exit direction
nearly vertical
90° ± 10°
Ø 6.5
ø 6,5
10° 10°
Fig. 808 Exhaust Muffler Fig. 809 Exhaust Pipe Outlet, Installation Position
Operation of the air heater is also permitted without WARNING

muffler. Any exhaust exit direction other than the one shown in
Fig. 809 may cause fires.
8.6.7 Combustion Air Intake and Exhaust Lines Sum of bends:

Combustion air line: max. 270°
In order to avoid damage to the dosing pump cable, Exhaust line: max. 270°
no exhaust line may be used for the elongation of the
combustion air intake line.
Length of the combustion air intake and exhaust line:

with muffler: max. 2.0 m
without muffler: max. 5.0 m
805
8.6.8 Electrical Connections 8.6.8.3 Connection Control Element
8.6.8.1 Connection Air Heater, Control Element The cable loom is prefabricated to connect to the control
element (rated value transmitter).
Electrical connection is according to Circuit Diagram For plug disconnection pull on terminal plug only
Automatic Control (see Section 7). (Fig. 813).
By pulling on the cable loom the terminal plug is arrested
For connection of the cable loom the cover (see 9.2.1.1) (self-locking).
of the air heater has to be removed for connecting the
cable loom plug(s) to the control unit. Avoid touching the
control unit strip conductors.
Prior to first operation of the air heater the cover must be

fitted to avoid the loss of heated air (air heater overheat-
ing).
The cable feedthrough may be from left or right.

Light Guide
8.6.8.2 Connection of Power Supply
Preferably from the vehicle's central electrics.

For protection of the air heater an additional flat fuse
holder is to be fitted (deliverable item). The fuse holder Fig. 812 Control Element
may only be located in the vehicle interior.
NOTE
The light guide must be in contact with the rotating knob.
Fig. 810 Removal of Fuse Holder Attachment Plate
F = 10A 24V
F = 15A 12V
Fig. 811 Fuse Holder, Installation Position
Fig. 813 Pulling the Plug
806
7
2
4 5
3
6
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
Fig. 814 Example of an Installation
807
8.7 Removal and Installation 8.7.2.2 Installation
CAUTION CAUTION
In installed condition only the following removal and When installing a new control unit in heaters Air Top 2000
disassembly procedures are allowed, the upper housing without diagnosis, it is mandatory to observe the remarks
shell being accessible for removal: in 8.8.
• Replacement of control unit NOTE

• Replacement of temperature limiter During installation avoid the build-up of static charge
(i.e. do not touch strip conductors).
8.7.1 Air Heater, Removal and Installation
1. Locate control unit (2, Fig. 815) in installation
position and secure with screws (3). Ensure control
8.7.1.1 Removal
unit engages in arrester groove (6). Torque screws to
0.7 ± 0.07 Nm.
1. Disconnect battery terminal leads. 2. Connect plug connections to terminal (Fig. 701 or
2. Withdraw cover from upper housing shell according to Fig. 702).
9.2.1.1.
3. Plug on upper housing shell and fix in position.
3. Disconnect plug of cable loom from control unit. 4. Slide on covers for heating air inlet and outlet and fix
4. Disconnect cable to dosing pump at cable disconnect. in position.
5. Disconnect fuel inlet on air heater. 5. Connect plug of cable loom to control unit.
6. Disconnect connections of combustion air intake and 6. Fit cover and fix in position.
exhaust outlet on air heater.
7. Remove four nuts and lock washers on air heater.
8. Remove air heater and discard gasket.
8.7.3 Replacement of Temperature Limiter
8.7.1.2 Installation 8.7.3.1 Removal
1. Locate air heater with new gasket in installation 1. Withdraw cover from upper housing shell according to
position and secure with four nuts and lock washers 9.2.1.1.
(use original Webasto nuts only). 2. Disconnect plug of cable loom from control unit.
2. Tighten nuts with 6 + 1 Nm. 3. Withdraw covers for heating air inlet and outlet
3. Secure connection for fuel inlet on air heater. according to 9.2.1.2.
4. Secure connections for combustion air inlet and 4. Remove upper housing shell according to 9.2.1.3.
exhaust outlet on air heater. 5. Disconnect plugged connection (blue) from terminal.
5. Connect dosing pump cable to dosing pump wiring 6. Remove lock washers or Ejot DG screws (4, Fig. 815
harness. or Fig. 816).
6. Connect plug of cable loom to control unit. 7. Remove temperature limiter (5).
7. Plug on cover and arrest.
8. Reconnect battery terminal leads. 8.7.3.2 Installation
9. Bleed fuel supply system.
1. Locate temperature limiter (5, Fig. 815 or Fig. 816) in
installation position and secure with lock washers or
8.7.2 Replacement of Control Unit
Ejot DG screws (4). Ensure that temperature limiter
rests properly on heat exchanger.
8.7.2.1 Removal
2. Torque Ejot DG screws to 1.5 ± 0.15 Nm.
3. Connect plug connections (blue) to terminal.
NOTE
4. Plug on upper housing shell and fix in position.
During removal avoid the build-up of static charge (i.e. do 5. Slide on covers for heating air inlet and outlet and fix
not touch strip conductors). in position.
6. Connect plug of cable loom to control unit.
1. Withdraw cover from upper housing shell according to 7. Fit cover and fix in position.
9.2.1.1.
2. Disconnect plug of cable loom from control unit.
3. Withdraw covers for heating air inlet and outlet
(5 and 3) according to 9.2.1.2.
4. Remove upper shell according to 9.2.3.1.
5. Disconnect plugged connections (1, Fig. 815 or
Fig. 816) of terminal.
6. Remove screws (3) and remove control unit (2).
808
1 4
X6
5
1 Plug Connections
2 Control Unit
3 Screw (2)
4 Lock Washer or Ejot DG screw (2)
5 Temperature Limiter
6 Arrester Groove
Fig. 815 Replacement of Control Unit and Temperature Limiter (Air Top 2000 without Diagnosis)
809
1 4
X6
5
1 Plug Connections
2 Control Unit
3 Screw (2)
4 Lock Washer or Ejot DG screw (2)
5 Temperature Limiter
6 Arrester Groove
Fig. 816 Replacement of Control Unit and Temperature Limiter (Air Top 2000 Diagnosis)
810
8.8 Installation of new Control Units • When replacing the control unit Air Top 2000 ADR
(24 Volt) with a control unit Air Top 2000 Diagnosis
CAUTION ADR (24 Volt) perform modifications per 8.8.3.
When replacing the control unit the following must be
observed: WARNING
Failure to perform modifications will result in a
• When replacing the control unit Air Top 2000 (12 Volt) potential safety risk.
without external temperature sensor with a new
control unit Air Top 2000 Diagnosis (12 Volt) without In all cases there will be no possibility for diagnosis after
external temperature sensor no further instructions for replacement as the wiring harness installed in the vehicle
replacement as detailed in 8.7.2 are applicable. is not provided with a diagnosis connector.
• When replacing the control unit Air Top 2000 (12 Volt) 8.8.1 Replacement of Control Unit Air Top 2000
with external temperature sensor with the control unit (12 Volt) with External Temperature
Air Top 2000 Diagnosis (12 Volt) with external Sensor
temperature sensor the modifications per 8.8.1 must
be performed. 1. Remove control unit according to 8.7.2.1.
X6 2. Remove leaf spring contacts 4 and 6 from connector

X6.
NOTE
X11 The following step is not applicable when installing a
new temperature sensor.
3. Position leaf spring contacts order no. 880 38A

(must be ordered) and arrest in connector X9 order
no. 881 97A (must also be ordered). Polarity is
irrelevant.
4. Install new control unit according to 8.7.2.2.

X9
5. Connect connectors X6 and X9.
4
6
1
3
X6 5
7 2
1 X9
2
4 2
6 1
8
Control Unit Air Top 2000 Diagnosis 8.8.2 Replacement of Control Unit Air Top 2000
(24 Volt) not ADR
NOTE
If a new temperature sensor is to be used place an 1. Remove control unit according to 8.7.2.1.
order for no. 883 84A (including new cover).
2. Remove leaf spring contacts of grey and violet wire
• When replacing the control unit Air Top 2000 (24 Volt) from connector X6, contacts 4 and 6.
not ADR with a control unit Air Top 2000 Diagnosis
(24 Volt) not ADR the modifications per 8.8.2 must be 3. Install new control unit according to 8.7.2.2.
incorporated.
4. Connect connector X6.
CAUTION 4
6
Not performing the modification may result in a short
circuit. 1
3
5
X6 7
2
4
6
8
811
8.8.3 Replacement of Control Unit Air Top 2000 8.9 First Operation
(24 Volt) ADR
After installation of the air heater the fuel supply system
1. Remove control unit according to 8.7.2.1. must be bled thoroughly.
2. Remove leaf spring contacts of grey and violet wire NOTE

from connector X6, contacts 4 and 6. Due to low fuel consumption several switch-ons are
required to prime the fuel supply line to the air heater.
3. Arrest leaf spring contacts in connector X11 as
follows: grey wire in contact 3, violet wire in contact 2. During the test run of the air heater all connections
are to be checked for no leakage and tight fit. Should
4. Install new control unit according to 8.7.2.2. the air heater during operation assume an error lockout
condition, perform troubleshooting.
5. Connect connector X6 and X11.
6. Perform functional check. Test ADR switch-off as

required stopping engine and starting auxiliary drive.
4
6
X6
1
3
5
7 6
5
4
3
2 gr 2
1
4 X11
6
8 3 vi
2
812
Air Top 2000 9 Repair
9 Repair 9.1.2.1 Installation of an External Temperature Sensor

(Air Top 2000 Diagnosis)
9.1 General General

The heater Air Top 2000 controls the desired temperature
This section describes the repairs that may be performed best when its temperature sensor is exposed to the air
on the air heater Air Top 2000 and Air Top 2000 Diagnosis temperature of the most probable surrounding in use.
serial no. 30.000 and up when removed. Any further dis- This might not always be possible due to the installation
assembly will void the warranty. For reassembly only conditions with the temperature sensor being integrated in
components of the proper spare kits are to be used. the heater. In such case the best temperature control may
be achieved by installation of an external temperature
9.1.1 Work on Components after Disassembly sensor in the relevant room area.
Procedure
CAUTION
1. Select adequate installation location for external
All gaskets located between disassembled components
temperature sensor.
as well as the exhaust outlet seal must always be
replaced and discarded.
NOTE
• Temperature sensor should not directly be exposed
9.1.1.1 Cleaning
to heated air flow or located in the vicinity of heating
sources (e.g. vehicle own heater).
• All components disassembled must be cleaned with
• For installation of the sensor in the motorcar we
cleaning spirit and subsequently dried with
recommend to locate the sensor in mid height in
pressurized air.
possibly vertical location.
• All sealing compound must be carefully removed from
• The installation location should not be exposed to
components using a suitable tool.
direct sun light.
9.1.1.2 Visual Inspection • Do not mount temperature sensor behind curtains or
similar.
• Examine all components for damages (cracks,
2. Mount external temperature sensor and route cable
deformation, wear, etc.) and replace as necessary.
to control unit.
• Examine connectors and wiring for corrosion, loose
3. Remove temperature sensor with connector.
contacts, wrong crimping, etc. and repair as
4. Connect connector X9 and place cover.
necessary.
5. Perform test run and check control behaviour.
• Check terminals for corrosion and contacts for
security. Repair as required.
9.1.2 Incorporation of Modifications
NOTE Control Unit

The continous design improvement of the heaters is
intended to optimise their serviceability avoiding failures
or malfunctions.
In general equipment in service may be retrofitted with X9
Cover
available modification kits.
In the following those modifications which may be

incorporated easily during maintenance:
• installation of an external temperature sensor for

optimising temperature control Air Top 2000
Diagnosis (see 9.1.2.1).
• installation of an external temperature sensor for
optimising temperature (see 9.1.2.2) (only for 12 Volt
heaters Air Top 2000 without Diagnosis).
External Temperature Sensor Connector X9
901
9 Repair Air Top 2000
9.1.2.2 Removal of External Temperature Sensor 7. Connect connector X6 and fit cover.
(Air Top 2000 without Diagnosis) 8. Perform test run and check control behaviour.
General Cover
The heater Air Top 2000 controls the desired temperature
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 the installation
conditions with the temperature sensor being integrated in
the heater. In such case the best temperature control may
be achieved by installation of an external temperature
sensor (Order No. 850 49A) in the relevant living area.
Procedure
1. Remove control unit (see 8.7.2.1).
2. Using a suitable tool (e.g. cutting pliers or similar)
remove temperature sensor from control unit.
1
3
5
7
Control Unit Extermal 2

4
6
8
Temperature Sensor Connector X6
9.2 Disassembly and Assembly
9.2.1 Removal of Housing Components/Covers
9.2.1.1 Cover for Electrical Connection
12 Volt type only Dependent on the type of installation the cable loom exits
the air heater either on the left or right.
The cover may be levered off using a blunt blade in the
areas marked X .
9.2.1.2 Covers for Heating Air Inlet and Outlet

Remove
Temperature Sensor Both covers (3 and 5, Fig. 901) may be removed by a
slight side lift and a slide to left or right out of the locked
3. Select adequate installation location for external position.
temperature sensor.
9.2.1.3 Upper Housing Shell
NOTE
• Temperature sensor should not directly be exposed to NOTE
heated air flow. The covers for the heating air inlet and outlet must be
• For installation of the sensor in the motorcar we removed.
recommend to locate the sensor on the window spar
of the windshield or in the vicinity of the air intake in By simultaneously exerting pressure on the catches of the
the air flow for air circulation operation. upper housing shell (2, Fig. 901) in the areas Y , the shell
• For installation of the sensor in the lorry we disengages and can be lifted off.
recommend to locate the sensor on the window spar
of the windshield or on the underside of the roof 9.2.1.4 Lower Housing Shell
console.
By simultaneously exerting a light pull to the lower
4. Mount external temperature sensor and route cable to housing shell (4, Fig. 901) in the areas Z , the catch is
heater. released and the shell may be separated from the motor
5. Install control unit (see 8.7.2.2). housing.
6. Arrest leaf spring contacts in empty compartments of
connector X6 (contacts 4 and 6). Polarity is irrelevant.
902
1
2
X
X
5
Y
1 Cover, Electrical Connection

2 Upper Housing Shell Z
3 Cover, Heating Air Outlet
4 Lower Housing Shell
5 Cover, Heating Air Inlet
Fig. 901 Removal of Housing Components/Covers
9.2.2 Replacement of Control Unit 9.2.3 Replacement of Temperature Limiter
NOTE NOTE
The procedure for replacement of the control unit is The procedure for replacement of the temperature
identical for the air heater in installed or removed limiter is identical for the air heater in installed or removed
condition. condition.
Replacement is to be performed in accordance with 8.7.2. Replacement is to be performed in accordance with 8.7.3.
903
NOTE
Air heater Air Top 2000 without
Diagnosis shown. Figure is
2
also applicable for replacement
of combustion air fan or Air Top
2000 Diagnosis.
! MAX.
3
1 Heating Air Intake
2 Insulation Mat
3 Seal
Fig. 902 Replacement of Combustion Air Fan (Removal)
9.2.4 Replacement of Combustion Air Fan 5. Remove heating air intake (1, Fig. 902) and remove
insulation mat (2).
9.2.4.1 Removal 6. Remove screws (1, Fig. 903).
7. Withdraw combustion air fan (3) and remove gasket
1. Remove air heater (see 8.7.1.1). (2).
2. Remove control unit (see 8.7.2.1). 8. Perform work on components after disassembly
3. Remove seal (3, Fig. 902) from lower housing (see 9.1.1).
shelland discard.
4. Remove air heater from lower housing shell.
904
9.2.4.2 Installation CAUTION

In order to ensure proper operation of the heater and
1. Ensure that sealing surfaces on combustion air fan temperature limiter observe the following when
and on heat exchanger are not damaged. installing the insulation mat:
2. Place new gasket (2, Fig. 903) onto flange of
combustion air fan (3). • Position insulation mat according to Fig. 903 so
that the maximum distance to the temperature
CAUTION limiter is obtained.
The combustion air fan may be fastened with self-cutting • Loose wires of the wired screen of the insulation
Ejot DG screws or on older heater models with sheet mat must not come into contact with the
metal screws. During assembly observe the different hole temperature limiter and must be cut off.
diameters and torque values. • When mounting the upper housing shell make sure
that the insulation mat is fixed in position.
NOTE Old insulation mats or mats already heavily
Apply Loctite to sheet metal screws (1). flattened must be replaced.
3. Bring combustion air fan (3) into assembly position 5. Place air heater with heating air intake (1, Fig. 902)
and mount using screws (1). and insulation mat (2) into lower housing shell and on
4. Torque sheet metal screws to 4 ± 0.4 Nm; side lock in position in housing.
Ejot DG screws to 6 ± 0.6 Nm. 6. Fit new seal (3) to lower housing shell.
7. Install control unit (see 8.7.2.2).
8. Install air heater (see 8.7.1.2).
9. Check CO2 setting and adjust as required (see 6.2).
1 Sheet Metal Screw or

Ejot DG screw (5)
2 Gasket
3 Combustion Air Fan
Before assembly always

renew gasket.
3
Combustion air fan must not be
disassembled any further.
Fig. 903 Replacement of Combustion Air Fan (Disassembly)
905
9.2.5 Replacement of Flame Sensor CAUTION

The glow plug has to be pulled out with utmost care
9.2.5.1 Removal and must under no circumstances be twisted (danger of
breaking). After a long period of combustion operation the
1. Remove air heater (see 8.7.1.1). glow plug may be caked by fuel deposits. In this case
2. Remove control unit (see 8.7.2.1). allow creep oil to react long enough to free glow plug for
3. Remove combustion air fan (see 9.2.4.1). withdrawal.
4. Remove 2 screws (3, Fig. 904) and spoiler (2) for
cable protection. 7. Loosen screw (13) and withdraw and remove glow
5. Push out cable grommet (10) towards inside. plug (11) from burner insert.
6. Carefully bend up locking tab (4) and withdraw flame 8. Perform work on components after disassembly
sensor (1) from burner insert (5). (see 9.1.1).
7. Remove flame sensor.
8. Perform work on components after disassembly 9.2.6.2 Installation
(see 9.1.1).
NOTE
9.2.5.2 Installation The burner insert may be fastened with self-cutting Ejot
DG screws or on older heater models with sheet metal
NOTE screws (3, Fig. 904).
Burner insert may be fastened with self-cutting Ejot DG
screws or with sheet metal screws (3, Fig. 904). 1. Insert new gasket (7, Fig. 904) into heat exchanger
and bring combustion tube (6) in assembly position.
CAUTION 2. Ensure that starting air bore is not clogged. If required
Route cable of flame sensor below fuel pipe. clean with wire (approx. 1 mm Ø on previous burners,
for new burners approx. 4 mm Ø) (see Detail A).
1. Pass flame sensor (1) below fuel pipe, feed connector
through opening and push in cable grommet (10). CAUTION
2. Feed cable with protection sleeve through locking tab During glow plug installation on previous burners observe
and insert flame sensor (1) into burner insert (5). twist lock (see Detail B). That means that the glow plug
3. Squeeze locking tab (4). has to be inserted so that the contacts point towards the
4. Secure burner insert (5) with four screws (3) and fit heat exchanger. Otherwise there will be the danger of a
spoiler (2) for cable protection. short circuit.
5. Pull cable of flame sensor tight.
6. Torque all 4 screws (3) to 4 ± 0.4 Nm. 3. Feed glow plug (11) into burner insert (5) and arrange
7. Mount combustion air fan (see 9.2.4.2). cable protective sleeve in slot of burner insert.
9. Install air heater (see 8.7.1.2). CAUTION
When performing the following step ensure that glow plug
is inserted in burner insert fully against stop.
9.2.6 Replacement of Glow Plug
4. Secure glow plug (11) with screw (13). Torque screw
9.2.6.1 Removal (13) with 0.8 Nm.
5. Locate burner insert (5) in heat exchanger (8)
observing that cable of flame sensor is positioned
1. Remove air heater (see 8.7.1.1).
below fuel pipe.
6. Feed connectors of glow plug and flame sensor
3. Remove combustion air fan (see 9.2.4.1).
through openings and push in cable grommets
4. Push out cable grommets (9 and 10, Fig. 904) towards
(9 and 10).
inside.
5. Remove four screws (3) and spoiler (2).
CAUTION
6. Tilt and withdraw burner insert (5) carefully.
When performing the following step ensure that there is a
NOTE tight fit between grommet (12) and heat exchanger (8).
Ensure that burner insert (5) has separated from burner
7. Secure burner insert (5) using screws (3) and attach
tube (6).
spoiler (2). Torque screws (3) to 4 ± 0.4 Nm.
8. Mount combustion air fan (see 9.2.4.2).
906
10
11
5
4
3
1 Flame Sensor
2 Spoiler
3 Sheet Metal Screw or
Ejot DG Screw (4)
4 Locking Tab
5 Burner Insert 13
6 Combustion Tube
7 Gasket
8 Heat Exchanger
9 Cable Grommet
10 Cable Grommet 2
12
11 Glow Plug
12 Grommet
13 Screw 1
Fig. 904 Disassembly of Heat Exchanger (Sheet 1 of 2)
907
Detail A
Starting Air Bore

(New Burner)
Starting Air Bore

(Previous Burner)
Detail B
Shaped Hole
(Previous Burner only)
Fig. 904 Disassembly of Heat Exchanger (Sheet 2 of 2)
908
9.2.7 Replacement of Burner Insert,

Combustion Tube, and Heat Exchanger
9.2.7.1 Removal
CAUTION
When replacing the heat exchanger, the temperature
sensor must also be replaced.
1. Remove air heater (see 8.7.1.1).

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 performing the following step ensure that fuel
connection is not bent.
6. Remove burner insert (5, Fig. 904).

7. Withdraw combustion tube (6) from heat exchanger
(8) and remove gasket (7).
8. Perform work on components after disassembly
(see 9.1.1).
9.2.7.2 Installation
1. In case a new heat exchanger is fitted, secure

temperature limiter (5, Fig. 815) with new Ejot DG
screws (4) and torque to 1 ± 0.1 Nm.
2. Fit new gasket (7, Fig. 904).
3. Bring combustion tube (6) in assembly position.
NOTE
The burner insert will be secured when installing flame
sensor and glow plug.
CAUTION
When performing the following step ensure that the fuel
connection is not bent.
4. Install glow plug (see 9.2.6.2).

5. Install flame sensor (see 9.2.5.2).
6. Mount combustion air fan (see 9.2.4.2).
909
Page free for notes
910
Air Top 2000 10 Packaging/Storage/Shipping
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 +85° C and –40° C

must not be exceeded.
1001
10 Packaging/Storage/Shipping Air Top 2000
Page free for notes
1002

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Air Heaters Repair Shop Manual

Air Top 2000

1.1 Scope and Purpose ............................................................................................................................... 101

1.1.1 Use of Air Heaters ........................................................................................................................ 101

1.2 Meaning of Warnings, Cautions and Notes ........................................................................................... 101

1.4.1 Legal Provisions for Installation................................................................................................... 101

1.5 Corrections and Improvements.............................................................................................................. 103

2.1 Combustion and Heating Air Fan........................................................................................................... 201

3.1.1 Control Element........................................................................................................................... 301

3.2 Functional Description Air Top 2000 Diagnosis..................................................................................... 304

3.2.1 Control Element........................................................................................................................... 304

4 Technical Data................................................................................................................................................ 401

5.1 General ................................................................................................................................................. 501

6.1 General ................................................................................................................................................. 601

6.2.1 Adjustment of the CO2 Contents ................................................................................................ 601

6.3 Components Testing............................................................................................................................. 602

6.3.1 Glow Plug Resistance Test......................................................................................................... 602

7.1 General ................................................................................................................................................. 701

8.1 General ................................................................................................................................................. 801

8.6.1 Heating Air System ..................................................................................................................... 801

8.7 Removal and Installation....................................................................................................................... 808

8.7.1 Air Heater, Removal and Installation .......................................................................................... 808

8.8 Installation of new Control Units ........................................................................................................... 811

8.9 First Operation ...................................................................................................................................... 812

9.1 General .................................................................................................................................................. 901

9.1.1 Work on Components after Disassembly .................................................................................... 901

9.2 Disassembly and Assembly................................................................................................................... 902

9.2.1 Removal of Housing Components/Covers .................................................................................. 902

10 Packaging/Storage and Shipping

10.1 General ................................................................................................................................................ 1001

301 Functional Diagram (Air Top 2000 without Diagnosis)............................................................................... 303

501 General Failure Symptoms ........................................................................................................................ 501

601 Adjustment of CO2 Contents...................................................................................................................... 601

701 Terminal Pin Assignment, Air Top 2000 Diagnosis.................................................................................... 701

801 Fuel Supply ................................................................................................................................................ 802

901 Removal of Housing Components/Covers................................................................................................. 903

1 Introduction 1.4 Safety Information and Regulations

The general safety regulations for the prevention of acci-

1.1.1 Use of Air Heaters 1.4.1 Legal Provisions for Installation

The heat exchanger of the air heater remains

The air jets with adjustable flops must always be open in

Page free for notes

2 General Description A malfunction in air heaters Air Top 2000 Diagnosis

– combustion and heating air fan

Air Heater Air Top 2000 Diagnosis

Air Heater Air Top 2000

2.1 Combustion and Heating Air Fan

are located within the unit.

12 Volt heaters (Air Top 2000 without Diagnosis) may be

Fuel supply is provided externally by a fuel dosing pump.

Combustion and Heating Air Fan

Air Heater Air Top 2000 without Diagnosis

2.2 Heat Exchanger 2.4 Control Unit / Control Circuit Board

2.3 Burner Insert with Combustion Tube Temperature

A malfunction in air heaters Air Top 2000 Diagnosis

2.7 Temperature Limiter

Control Unit Air Top 2000 Diagnosis Temperature Limiter

2.5 Flame Sensor 2.8 Dosing Pump

2.6 Glow Plug