Air Top 2000 S D

List of Contents Air Top 2000
Air Heater
Air Top 2000 S D (Diesel)

Air Top 2000 S B (Gasoline)
Service and Repair Manual
– Improper installation or repair of Webasto heating and cooling systems can cause
fire or the leakage of deadly carbon monoxide leading to serious injury or death.
– Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
– NEVER attempt to install or repair a Webasto heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.
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Air Top 2000 S 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 General Safety Notes.................................................................................................................. 101
1.5 Legal Provisions for Installation............................................................................................................... 102
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 S ....................................................................................................... 301
3.1.1 Control Element .......................................................................................................................... 301

3.1.2 Switch-On.................................................................................................................................... 301
3.1.3 Stabilization................................................................................................................................. 301
3.1.4 Heating Operation ....................................................................................................................... 302
3.1.5 Control Operation........................................................................................................................ 302
3.1.6 Control Idle.................................................................................................................................. 302
3.1.7 Switch-Off.................................................................................................................................... 302
3.1.8 Switch-Off upon Failure............................................................................................................... 302
4. Technical Data ............................................................................................................................................... 401
5. Troubleshooting
5.1 General....................................................................................................................................................501
5.2 General Failure Symptoms......................................................................................................................501
5.3 Failure Symptoms during Operation........................................................................................................502
5.4 Error Code Output ......................................................................................................................................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
I
List of Contents Air Top 2000 S
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
8.8 Start-Up...................................................................................................................................................808
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 .......................................................................................... 905
9.2.5 Replacement of Flame Sensor.................................................................................................... 907
9.2.6 Replacement of Glow Plug.......................................................................................................... 907
9.2.7 Replacement of Burner Insert, Combustion Tube, and Heat Exchanger .................................... 910
10. Packaging/Storage and Shipping
10.1 General.................................................................................................................................................. 1001
II
Air Top 2000 S List of Figures
List of Figures
501 General Failure Symptoms .............................................................................................................................501

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

702 Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Control D i a l ............................................702
703 Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Combination Timer ..................................703
704 Circuit Diagram Automatic Control Air Top 2000 S,
12V/24V with Control Dial and Standard Timer ..............................................................................................704
705 Connection Diagram, Air Top 2000 S with Combination Timer.....................................................................705
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 Weather Resistant Fuse Holder........................................................................................................................806
811 Control D i a l ...................................................................................................................................................806
812 Pulling the Plug ...............................................................................................................................................806
813 Example of an Installation...............................................................................................................................807
901 Removal of Housing Components/Covers......................................................................................................902

902 Replacement of Control Unit and Temperature Limiter...................................................................................904
903 Replacement of Combustion Air Fan (Disassembly) ......................................................................................905
904 Replacement of Combustion Air Fan (Assembly............................................................................................906
905 Disassembly of Heat Exchanger (Sheet 1 of 2)..........................................................................................908
906 Disassembly of Heat Exchanger (Sheet 2 of 2)..........................................................................................909
III
List of Figures Air Top 2000 S
IV
Air Top 2000 S 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 famil- beyond the scope of these regulations are detailed in the
iarized personnel in the repair of the Air Top 2000 S. following.The specific safety regulations applicable to
this manual are highlighted in the individual chapters by
Warnings, Cautions, and Notes.
1.1.1 Use of Air Heaters 1.4.1 General Safety Notes
The air heater Air Top 2000 S is used to Within the scope of the StVZO (Road Licensing Regula-
tions of the Federal Republic of Germany) “Design
- heat the cabin General Approvals”, laid down by the Federal Office for
- defrost the windscreens. Motor Traffic, exist for the Air Top 2000 S with the
following official marks of conformity:
They are not cleared for heating a transportation com-
partment for dangerous goods. -S 324 (Diesel)
The heaters operate independent from the vehicle en- -S 325 (Gasoline)
gine and are connected to the fuel tank and to the electri-
cal system of the vehicle. Their use is possible in
vehicles with water- or air-cooled engines. The installation of the heater is to be performed in ac-
cordance 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 § 20 StVZO
b) the individual inspection in accordance with
and Notes § 21 StVZO or
c) the examination in accordance with § 19 StVZO
WARNINGS, CAUTIONS, and NOTES in this manual performed by an officially authorised expert or exam-
have the following meaning: iner for road traffic, a vehicle inspector or a public
servant as per section 7.4 a of Annex VIII to the
WARNING StVZO.
This heading is used to highlight that non-compliance In the event of c) the installation must be certified on the
with instructions or procedures may cause injuries or acceptance certificate included in the copy of the
lethal accidents to personnel. “General Operating License” giving details about
- manufacturer
CAUTION - type of vehicle , and
This heading is used to highlight that non-compliance - vehicle identification number.
with instructions or procedures may cause damage to This validates the “Design General Approval”.
equipment.
The acceptance certificate must be kept with the
NOTE vehicle.
This heading is used to highlight and draw specific atten- The year of first operation must be permanently
tion to information. marked on the identification label.
The heaters are cleared for heating the passenger and

1.3 Additional Documentation to be used driver cabins but not for heating compartments intended
for the transportation of dangerous goods.
This workshop manual contains all information and pro-
cedures necessary for the repair of the Air Top 2000 S.
The use of additional documentation is normally not
necessary.
Operating instructions/installation instructions and the
vehicle specific installation proposal may be used as
complementary information as necessary.
101
1 Introduction Air Top 2000 S
The heater must not be installed in the passenger or Heating Air System
driver compartments of busses. Should the heater never- Heating air intake openings must be arranged so that
theless be installed in such a compartment, the installa- under normal operating conditions exhaust fumes of the
tion box must be sealed tight against the vehicle interior. vehicle engine or air heater are not likely to be expected.
There must be sufficient ventilation of the installation box
from the exterior in order not to exceed a maximum tem- Extracting combustion air from the vehicle interior is not
perature of 40 °C in the installation box. permissible.
At filling stations and fuel depots the heater must be Combustion Air Line
switched off as there is a potential danger of explo- The combustion air required must be taken from the
sion. exterior.
Within rooms accommodating persons, the combustion
Where flammable fumes or dust may build up (e.g. air lines must not have more than four disconnects and a
in the vicinity of fuel, coal, wood, cereal depots, or splash-water protected exterior wall feedthrough. The
similar installations) the heater must be switched off disconnects must be sealed in a way not to exceed a
to prevent explosions. leak rate of 200 l/h at an overpressure of 0.5 mbar.
The line including feedthrough, disconnects, material
Due to the danger of poisoning and suffocation the and specific type must be described in the installation
heater must not be operated in enclosed areas such as instructions.
garages or workshops without exhaust venting, not even The line must require tools for installation and removal,
if the start-up is activated by the timer or telestart device. must be protected against damage, and must be shock-
proof.
When removing the heater the gasket below must be re-
placed. Exhaust Line
Heaters must be designed to discharge the exhaust to
The heat exchanger of the air heater remains service- the exterior.
able for a maximum of 10 years and must then be re-
placed with an original spare part by the manu- Exhaust pipes must be routed so that exhaust fumes are
facturer or by one of its authorized workshops. unlikely to penetrate into the vehicle’s interior.
The heater must then be provided with a label The function of any parts of the vehicle essential for its
marked with the sales date and with the words “Orig- operation must not be impaired. Condensate or water
inal Spare”. penetrated must not be able to accumulate in the
Should exhaust pipes be routed through rooms exhaust line.
accommodating persons, these pipes shall also be Drain holes are permissible; these must drain the fluid to
renewed after 10 years. the exterior via lines sealed against the vehicle interior.
Installations not legally authorized will void the air The exhaust line outlet is to be positioned to the top, to
heater’s “Official Marks of Conformity” and thus the the side, or in case of exhaust venting below the vehicle
vehicle’s permit of operation. The same applies for floor, to the nearest possible location of the vehicle’s or
repairs performed by unskilled personnel and repairs cockpit’s side or rear end. In compartments accommo-
with no original spare parts. dating persons, exhaust lines must not have more than
one disconnect and must have a splash-water protected
feedthrough in the exterior wall/floor. For water, that has
1.5 Legal Provisions for Installation penetrated into the exhaust line, the connection of a
drain line with a metal-sealing joint is permissible. The
drain pipe must be routed sealed through the exterior
For testing the heater in accordance with 19, 20, or 21 wall or the vehicle floor.The heat exchanger, the exhaust
of the StVZO the following regulations are to be ob- line connected, as well as the possible drain pipe must
served in particular (§ 22 a StVZO): be sealed so that with an overpressure of double the
overpressure of the exhaust having the maximum per-
Testing is performed upon presentation of the operating missible exhaust line length - at least however at an over-
and installation instructions of the manufacturer. pressure of 0.5 bar - a total leak rate of 30 l/h is not
exceeded.
The year of the initial operation must be durably marked
on the heater identification plate by the installing person. The line including feedthrough, disconnects, material
and specific type must be described in the installation
instructions.
The line must require tools for installation and removal,
must be protected against damage, and must be shock-
proof.
102
Air Top 2000 S 1 Introduction
Metal lines must be used. These may not heat to more

than 110 °C should there be the possibility of contact
within the room interior. Protective devices against con-
tact may be fitted.
Should exhaust pipes be routed through rooms accom-
modating persons, these pipes shall be renewed after 10
years using genuine spare parts.
Combustion Air Inlet and Exhaust Outlet

During installations these ports for combustion air entry
and exhaust fume exit must be of such type, that a ball
with a diameter of 16 mm cannot be inserted. Electrical
lines, switch gear and control gear of the heater must be
located in the vehicle so that their proper function cannot
be impaired under normal operating conditions.
For the routing of fuel lines and the installation of addi-

tional fuel tanks §§ 45 and 46 of the StVZO are to be
adhered to.
The most important regulations are: Fuel lines are to be
designed in such a way that they remain unaffected by
torsional stresses in the vehicle, engine movement and
the like. They must be protected against mechanical
damage.
Fuel-carrying parts are to be protected against ex-
cessive heat and are to be arranged so that any dripping
or evaporating fuel can neither accumulate nor be ig-
nited by hot components or electrical equipment.
In busses, fuel lines and fuel tanks may be located
neither in the passenger area nor in the driver’s compart-
ment. In these type of vehicles the fuel tanks must be lo-
cated such that they do not pose a direct hazard to the
exits in the event of a fire. Fuel supply must not be by
means of gravity or pressurization of the fuel tank.
Installation Rules for Webasto Fuel Tanks for the

Fuel Supply of Heaters in Vehicles
In busses the installation is not permitted in the pas-
senger or driver compartment.
The fuel fill neck must in no vehicle be located within any
of these compartments.
Fuel containers for gasoline fuel must not be located
immediately behind the front panelling of the vehicle.
They must be sparate from the engine so that even in
case of an accident the inflammation of fuel is unlikely to
be expected. This does not apply for towing vehicles
with an open cockpit.
The operational state of the heater, i.e. an indication “on”
or “off”, must be easily and clearly visible.
103
2 General Description Air Top 2000 S
2. General Description A malfunction of the Air Top 2000 S is indicated by an

error code displayed on the combination or standard
timer. When equipped with the standard control dial,
The air heater Air Top 2000 S operates under the the operating indicator flashes. In addition a heater check
evaporator principle and basically consists of: out may be performed using a personal computer (refer
to 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 S

(covers removed)
Air Heater Air Top 2000 S

2.1 Combustion and Heating Air Fan
The combustion and heating air fan delivers the air re-
quired for combustion from the combustion air inlet to
For control and monitoring a
the burner insert. By means of the fan the heating air is
also delivered to the hot air outlet.
- control unit/control circuit board
- flame sensor
- glow plug
- temperature limiter
- temperature sensor
are located within the unit.
All Air Top 2000 S heaters may be controlled

by means of an optional external temperature sensor.
Fuel supply is provided externally by a fuel dosing pump.
Combustion and Heating Air Fan
201
Air Top 2000 S 2 General Description
2.2 Heat Exchanger 2.4 Control Unit / Control Circuit Board
The heat exchanger dissipates the heat provided by The control unit/control circuit board is the central con-
combustion to the air delivered by the combustion and trolling unit for functional sequencing and monitoring of
heating air fan. the combustion operation. A temperature sensor located
on the control unit is used for temperature control. All
heaters may have the temperature sensor replaced
with an external temperature sensor. The combustion
and heating air fan may be set by means of a poten-
tiometer.
A malfunction in the Air Top 2000 S is indicated by an

error code displayed on the combination or standard
timer. When equipped with a standard control dial
the operating indicator flashes. In addition a heater check
out may be performed using a personal computer (refer
to operating instructions PC air heater diagnosis).
Heat Exchanger
Potentiometer
2.3 Burner Insert with Combustion Tube
Within the burner insert fuel is distributed in the combus-

tion tube across the burner cross-section. In the combus-
tion tube the combustion of the fuel/air mixture takes
place heating up the heat exchanger. Temperature
Sensor
Combustion
Tube
Control Unit - Air Top 2000 S
Burner
Insert
Diesel Fuel
2 mm 1 mm
202
2 General Description Air Top 2000 S
2.5 Flame Sensor 2.7 Temperature Limiter
The flame sensor is a low-Ohm PTC resistor changing The temperature limiter protects the air heater against
its resistance dependent on its heating by the flame. excessive operating temperatures. Overheat protection
The signals are routed to the control unit for processing. is activated at a temperature higher than 150 °C to inter-
The flame sensor monitors the flame operating condition rupt the electrical circuit of the dosing pump and switch
over the complete duration of heater operation. off the heater with run-down operation.
After cooling down the electrical circuit is restored.
The air heater may be switched on again (see 3.1.8).
Flame Sensor
Temperature Limiter
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 2.8 Dosing Pump
opposed to the flame side.
The dosing pump is a combined supply, dosing and shut-
off system for the fuel supply of the heater out of the
vehicle’s fuel tank.
Glow Plug
Dosing Pump DP 2 for Gasoline and Diesel

operated Heaters
Dosing Pump DP 30 for Diesel operated Heaters
203
Air Top 2000 S 3 Functional Description
3. Functional Description
3.1 Functional Description Air Top 2000 S Should no proper combustion develop within 120 sec-
onds (for fuel-operated within 115 seconds) the combus-
tion and heating air fan speed is increased to full load for
3.1.1 Control Element approx. 30 seconds (15 seconds for fuel-operated
heaters) with the glow plug on and the dosing pump off
The control element is used to switch the air heater on (no fuel delivery) with a subsequent automatic restart.
and off, set the desired room temperature (air intake tem-
perature between 10 °C and 45 °C), and to unlock a Should the no-combustion-condition persist, after an-
failure interrupt condition. other 80 seconds (for fuel operated heaters after approx.
85 seconds) there will be a switch-off by error lockout
The green LED indication is used to indicate the opera- (see 3.1.8) with a run-down of the combustion and heat-
ting condition (LED permanently on) and an overheat ing air fan lasting 120 seconds at 2/3 of its max. speed.
condition (LED flashes).
2. Start (automatic restart)
Fan speed is again reduced to approx. 30% (for fuel
3.1.2 Switch-On
operated heaters to approx. 50%) and fuel is delivered.
During the next 20 seconds fan speed is increased to ap-
The control element is set to the desired room tempera- prox. 60% (for fuel-operated heaters to approx. 75%) of
ture. When switching the air heater on, the operating indi- full speed. As soon as a flame is detected within the next
cator is illuminated and the glow plug is activated 55 seconds, combustion will be stabilized. Should there
(cycled). The motor of the combustion and heating air be no flame condition after a total fuel delivery period of
fan starts high-speed operation for 1 second (break- 180 seconds, fuel delivery will be stopped and the glow
away moment) and is then under slow-down control to plug deactivated. The combustion air fan continues full
approx. 30% (Diesel) or 50% (fuel) of full speed. load operation for another 120 seconds (run-down) and
the heater enters the error lockout condition.
NOTE
Should the temperature of the intake air be above the se-
lected, rated temperature, only the motor of the combus-
3.1.3 Stabilization
tion and heating air fan will operate (control idle). Start
operation will be initiated with a heating air temperature Diesel Operated Heaters
below the rated temperature. With the glow plug activated the operating speed of the
combustion and heating air fan is increased. After an-
The flame sensor function is checked. If the flame sen- other 20 seconds the speed of the combustion and heat-
sor at this time already signals “flame”, there will be a ing air fan is continuously increased within 17 seconds
120 second run-down and an error lockout of the control to full load for full heat.
unit. A malfunction of any other component monitored
causes an error lockout without run-down. NOTE
This operating condition is omitted if the set temperature
After approx. 20 seconds (for fuel operated heaters after (control idle) has already been achieved once.
approx. 15 seconds) the fuel dosing pump is activated. The glow plug is deactivated and heating operation com-
After another 25 seconds the speed of the combustion mences. A flame-out during speed up control causes a
and heating air fan is continuously increased to a higher restart, 5 restarts an error lockout of the heater.
rate and combustion begins. As soon as a flame is
detected, combustion will be stabilized (see 3.1.3). Fuel Operated Heaters
With the glow plug activated the operating speed of the
Should no normal combustion be achieved within 120 combustion and heating air fan is continuously increased
seconds (for fuel operated heaters after approx. 115 within 4 seconds to full load for full heat. This operating
seconds), the speed of the combustion and heating air condition will be omitted if the start occurs after a control
fan is increased for approx. 30 sec and there will be an idle period.
automatic repeat start with the glow plug activated and The glow plug is deactivated and heating operation com-
fuel dosing pump deactivated (no fuel supply). mences. A flame-out during speed up control causes a
restart, 5 restarts an error lockout of the heater.
301
3 Functional Description Air Top 2000 S
3.1.4 Heating Operation 3.1.7 Switch-Off
During operation the combustion exhaust gasses flow Switching the heater off extinguishes the operation indi-
through the heat exchanger charging its walls with com- cation of the control element.
bustion heat, which in turn is taken up by the heating air If no fuel has been delivered or if the air heater is in con-
delivered by the heating air fan to be routed to the ve- trol idle, the air heater is deactivated immediately
hicle interior. without run-down.
The temperature of the heating air sucked in is
measured by means of a temperature sensor fitted to If fuel supply has commenced it will be immediately
the air intake side of the air heater or by means of an ex- stopped at switch-off. Fan speed remains constant and
ternally located temperature sensor. then decreases within 30 seconds to approx. 60% of full
A temperature below the one set with the control ele- speed. After this or with the flame sensor detecting “no
ment increases the heater performance up to maximum flame”, fan speed rises to maximum speed for 60 sec-
heat. In order to extend the burner idle period of Diesel onds and run down for 120 seconds is initiated. Run-
operated heaters during permanent operation with a down is at approx. 60% of full speed and is deactivated
heating performance in excess of 1.1 kW, the fuel dos- automatically.
ing pump delivery rate is reduced every 15 minutes for
20 seconds. NOTE
Re-activation of the heater during run-down is permitted.
A heating performance less than 1.1 kW causes the fuel Run-down will be completed first with a subsequent re-
delivery to the dosing pump to be interrupted every 30 start.
minutes for 4 seconds. Additionaly heating operation is
briefly suspended every 9 hours like in control idle. For
Diesel-operated heaters this is only applicable, if at this 3.1.8 Switch-off upon Failure
time heating performance is less than 1.1 kW.
The control unit recognizes failures of individual air
heater components and malfunctions in the start se-
3.1.5 Control Operation quence and in normal operation.
During control operation fan speed and dosing pump The air heater is deactivated and enters the error lock
rate of delivery are subject to heating performance. out mode under the following conditions:
The glow plug is deactivated.
flame sensor open or short circuit
temperature sensor open or short circuit
3.1.6 Control Idle glow plug open or short circuit
fan motor open or short circuit or fan speed wrong
After reaching the temperature set with the control ele- dosing pump open or short circuit
ment, heating performance is controlled to decrease. overheating
The speed of the combustion and heating air fan slows low voltage below 10 Volt or high voltage above
down and the fuel delivery rate to the dosing pump is re- 15 Volt in excess of 20 seconds for 12 Volt heaters
duced. When exceeding the air intake temperature set low voltage below 20 Volt or high voltage above
with the control element during minimum heating perfor- 30 Volt in excess of 20 seconds for 24 Volt heaters
mance, the dosing pump is deactivated after 5 seconds
and combustion terminates. A switch-off like in “switch-off” will be performed.
Fan speed remains constant for 35 seconds and is then In case of overheating there will be no fuel supply. After
increased to approx. 60% of full speed for cooling the run-down the control unit is in the error lockout mode.
heater down. the fan then continues to operate at ap- The operation indication outputs a flash code.
prox. 30% of full speed until temperature is below the For error unlock the air heater has to be switched off
temperature set with the control element. If temperature momentarily (at least 2 seconds) before switching on.
falls below the one set with the control element, the
heater will restart (without break away).
NOTE
New settings on the control element are executed by the
control unit/heater with a time delay.
302
Air Top 2000 S 4 Technical Data
4. Technical Data Fuel for Air Top 2000 S B (gasoline):

The fuel specified by the manufacturer must be used.
As long as no threshold values are given, the following
Fuel for Air Top 2000 S D (diesel/PME):
technical data are understood to include tolerances of
±10% usual for heaters at an ambient temperature of The diesel fuel specified by the vehicle manufacturer
+20 °C and at nominal voltage and conditions. must be used.
We know of no negative influences due to additives.
Electrical Components:
If fuel is extracted from the vehicle’s tank, follow the
Control unit, combustion air fan, dosing pump, timer, additive instructions issued by the vehicle manufacturer.
glow plug and control dial are for 12 or 24 Volts
If you change to low-temperature fuel, the heater must
operation.
be operated for approx. 15 minutes so that the fuel
system is filled with the new fuel.
The components temperature limiter and flame detector
are independent of voltage. The Air Top 2000 S D heater is also licensed for use with
PME (bio-diesel), which complies with ASTM D6751 and
DIN EN 14214.
Air Heater Operation AT 2000 S B AT 2000 S D
Mark of conformity ~ S 325 ~ S 324
Heater type Air heater with evaporator burner
Heat flow Control range 1.1 – 2.0 kW 0.9 – 2.0 kW
Type of fuel Gasoline 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
intake temperature -40 ... +20 °C
Setting range for

indoor temperature Control range +10 ... +45 °C
Volume flow of heating air

against 0.5 bar Max. 70 m3/h
CO2 in exhaust
(perm. functional range) Max. 9.5 … 10.5 9.5 … 12.0
Dimensions air heater Length 311 ± 2 mm

Width 120 ± 1 mm
Height 121 ± 1 mm
Weight, heater 2.6 kg
401
5 Troubleshooting Air Top 2000 S
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
for trouble:
A malfunction of the Air Top 2000 S is indicated by an
error code displayed on the combination or standard corrosion on connector
timer. When equipped with a standard control dial loose contact on connector
the operating indicator flashes. In addition a heater check wrong crimping on connector
out may be performed using a personal computer (refer corrosion on electrical wiring and fuses
to operating instructions PC air heater diagnosis). corrosion on battery terminals
CAUTION If individual components are checked, the control unit

Troubleshooting requires profound knowledge about electrical connections must be disconnected.
structure and theory of operation of heater components
and may only be performed by skilled personnel. After any correction of a failure a functional test has to
be performed in the vehicle.
In cases of doubt refer to Sections 2 or 3 for functional
interrelations.
5.2 General Failure Symptoms
The following table (Fig. 501) lists the possible failure

symptoms.
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 obstructions, 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
Air Top 2000 S 5 Troubleshooting
5.3 Failure Symptoms during Operation failure symptom listed, in emergencies, assistance by our
service technicians may be requested.
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 indi-
cated additionally after run-down by the flashing LED of
In case of malfunction the failure is to be isolated and the control dial.
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 serviceable.
table or the trouble not be detected under the specific
Failure Symptom shows after Possible Causes

....seconds
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 temperature) 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 outlet bore),
combustion air/exhaust ducting obstructed or heat
exchanger coked, dosing pump seized
Run-down during combustion Overheating or

operation voltage too low or
component error (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 during combustion Flame-out by gas bubbles in fuel delivery or strong
cycling and max. speed for operation wind against exhaust outlet or defective no-flame
30 sec with subsequent re-start detection
Fig. 502 Failure Symptoms during Operation
502
5 Troubleshooting Air Top 2000 S
5.4 Error Code Output
When equipped with a combination or standard timer a

malfunction will cause an error code output to the dis-
play of the timer for indication.
NOTE
When equipped with a control dial, the error code
output is indicated by flashing of the operating indica-
tor/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
Air Top 2000 S 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
Clockwise rotation increases the fan speed and de-
testing of the air heater to check its proper operation.
creases the CO2 contents. Counterclockwise rotation de-
creases the fan speed and increases the CO2 contents.
WARNING
The air heater shall not be operated in enclosed areas
If the setting range is not sufficient (e.g. after replace-
like garages or workshops not provided with exhaust
ment of the combustion and heating air fan) the manufac-
venting facilities.
turer’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
6.2.1.1 General The manufacturer’s setting cannot be restored.
The CO2 contents of the exhaust is adjusted with the 1. Withdraw cover from upper shell according to 9.2.1.
potentiometer on the control circuit board. The air heater 2. Switch on air heater.
is preset by the manufacturer with respect to the com- 3. Rotate potentiometer two times and with no interrupt
bustion and heating air fan fitted. After adjustment by the through its complete setting range (e.g. max. - min.-
manufacturer the potentiometer is in center position max.).
(Fig. 601). After an inadvertent loss of this position it is 4. Adjust desired CO2 contents (Fig. 601).
sufficient to restore its original position. 5. Switch off air heater.
6. Install 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
+ –
Fig. 601 Adjustment of CO2 Contents
601
6 Functional Tests Air Top 2000 S
6.3 Components Testing
CAUTION
During electrical testing always ensure that the control
unit and the component under test are electrically discon-
nected from each other.
6.3.1 Glow Plug Resistance Test
During electrical testing of the glow plug using a digital

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

Resistance at 25 °C: 0.324 ... 0.360 Ω 1.3 ... 1.44 Ω
Test current: < 5 mA < 5 mA
6.3.2 Flame Sensor Resistance Test
During electrical testing of the flame sensor using a digi-

tal multimeter, the following readings should be obtained:
Cold test:
Resistance at 25 °C: 2.6 ... 3.4 Ω
Test current: < 5 mA
Hot test:
Resistance at 800 - 1000 °C: 12 ... 15 Ω
(ceramic rod red hot over a length of approx. 20 mm)
Test current: < 5 mA
602
Air Top 2000 S 7 Circuit Diagrams
7. Circuit Diagrams
7.1 General
The air heater Air Top 2000 S may be operated

using the control dial (rated value transmitter/switch)
or with the control dial and a combination or
standard timer. The circuit diagrams (Figs. 702 to 704)
show the possible circuits 12 or 24 Volt with
control element
combination timer
control element and standard timer
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 S
701
7 Circuit Diagrams Air Top 2000 S
? ?
Item Nomenclature Remark

Wire Gauges
A1 Air Heater Air Top 2000 S
< 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
1.5 mm2 2.5 mm2
B2 Temperature Sensor
2.5 mm2 4.0 mm2
B3 Temperature Limiter 4.0 mm2 6.0 mm2
E Glow Plug
F2 Fuse 24V 10A/12V 15A Flat Fuse SAE J 1284 Wire Colours
bl blue
H1 LED green (in item S1) Operation indication br brown
M Motor ge yellow
gn green
S1 Control Element Rated Value Setting Switch 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
ws white
X8 Connection 2-pole
X9 Connection 2-pole of item A2
X11 Connection 6-pole of item A2 2 Connection X11/2 and X11/3
for TRS function only
X12 Connection 1-pole Diagnosis (K-wire)
Y1 Dosing Pump
Fig. 702 Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Control Dial
702
? ?

Wire Gauges
A1 Air Heater Air Top 2000 S
< 7.5 m 7.5 - 15 m
A2 Control Unit 0.75 mm2 1.5 mm2
1.5 mm2 2.5 mm2
B2 Temperature Sensor
2.5 mm2 4.0 mm2
E Glow Plug
bl blue
H7 LED red (in item P) Instant heat switch illumination, br brown
standy indication, ge yellow
operating indicator light gn green
gr grey
H8 Heating symbol in display (in item P) Operating indicator light, or orange
overheat indication rt red
H9 Light (in item P) Symbol illumination sw black
vi violet
M Motor ws white
P1 Combination Timer (1531)
S3 Switch Instant heating remote control
1 with plus from terminal (15/75)
X1-X5 Connection 2-pole of item A2 to connection 10:
permanent operation during
X6 Connection 8-pole of item A2
instant heating as long as
X8 Connection 2-pole ignition on
X9 Connection 2-pole of item A2 without plus to connection 10:
X11 Connection 6-pole of item A2 heating time programmable as
required (10 min to 120 min),
X12 Connection 1-pole Diagnosis (K-wire) default setting 120 min.
X13 Connection 12-pole of item P
2 Connection X11/2 and X11/3
Y1 Dosing Pump for TRS function only
Fig. 703 Circuit Diagram Automatic Control Air Top 2000 S, 12V/24V with Combination Timer
703
? ?

A1 Air Heater Air Top 2000 S Wire Gauges
A2 Control Unit < 7.5 m 7.5 - 15 m
1.0 mm2 1.5 mm2
B2 Temperature Sensor 1.5 mm2 2.5 mm2
4.0 mm2 6.0 mm2
E Glow Plug
H7 LED red (in item P) Instant heat switch illumination, bl blue
standy indication, br brown
operating indicator light ge yellow
gn green
H8 Heating symbol in display (in item P) Operating indicator light, gr grey
overheat indication or orange
rt red
H9 Light (in item P) Symbol illumination sw black
M Motor vi violet
ws white
P2 Standard timer
S1 Control Element Rated Value Setting Switch
S3 Switch Instant heating remote control 1 with plus from terminal (15/75)
to connection 10:
X1-X5 Connection 2-pole of item A2 permanent operation during
X6 Connection 8-pole of item A2 instant heating as long as
ignition on
X7 Connection 4-pole of item S1
X8 Connection 2-pole without plus to connection 10:
heating time programmable as
X11 Connection 6-pole of item A2 required (10 min to 120 min),
X12 Connection 1-pole Diagnosis (K-wire) default setting 120 min.
X13 Connection 12-pole of item P 2 Connection X11/2 and X11/3

Y1 Dosing Pump for TRS function only
Fig. 704 Circuit Diagram Automatic Control Air Top 2000 S,

12V/24V with Control Dial and Standard Timer
704
Combination Timer 1531 Black

Battery Positive
or Ignition Signal (10)
Grey
Lights (1)
Red
(optional)
Battery Positive (11)
12V
Brown
24V
Battery Negative (12, 4)
Adapter Harness
P/N 9008440A
1
2
3 4
5
6 7
8
9 0
1 11
12
Fig. 705 Connection Diagram, Air Top 2000 S with Combination Timer
705
706
Air Top 2000 S 8 Servicing
8. Servicing For reasons of the air heater’s functional reliability per-

form the following servicing:
8.1 General check heating air inlet and outlet for foreign matter
and contamination. (Contaminated or clogged heat-
ing air ducts may lead to overheating and thus
This section describes the servicing procedures that
response of the temperature limiter).
may be performed with the air heater installed.
Clean air heater exterior (prevent the ingress of
water).
8.2 Work on the Air Heater Examine electrical connections for corrosion of con-
tacts and for security.
Prior to performing any work it is mandatory to discon- Check combustion air and exhaust ducts for damage
nect the vehicle battery main lead. As long as the air and obstructions.
heater is in operation or in run-down, the battery main Check fuel lines and fuel filter for leakage.
supply must not be disconnected due to the danger of Replace fuel filter if installed.
overheating resulting in a response of the overheat pro-
tection. 8.6 Visual Inspections and Installation
When performing extensive repairs on the heater a com-
Regulations
plete removal is advisable. When performing repairs re-
quiring a relocation of the installation position, the 8.6.1 Heating Air System
relevant installation instructions and the vehicle-specific
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 press-
ure and temperature.
CAUTION Fitted in the air heater on the heating air intake side is a
In the vicinity of the air heater a temperature of 85 °C temperature sensor, which operates the heater in the
must not be exceeded under any circumstances (e.g. relevant range of performance in conjunction with the
during body paint work). control dial dependent on the air intake temperature
and position of the rated value transmitter. Heating per-
8.4 Air Heater Test Run formance is selected so that after quickly reaching the
preselected indoor temperature it is maintained at this
WARNING value. Air Top 2000 S heaters may be operated with an
The air heater must not be operated, not even with external temperature sensor (see 9.1.2).
timer, in enclosed areas like garages or workshops not
equipped with an exhaust venting facility. Minimum inside diameter of the heating air duct is
55 mm. Standard diameter is 60 mm.
CAUTION
Operation of the heater without the control unit cover is NOTE
not permitted and causes overheating. For heating air ducting only materials may be used
which are temperature-proof to at least 130 °C.
8.5 Servicing Maximum loss of pressure between suction and delivery
side of the heating air duct 1.0 mbar (10 mm water
NOTE column).
In order to avoid the seizure of mechanical components,
the air heater should be operated every 4 weeks for at When exceeding this value the temperature limiter is
least 20 minutes. very likely to respond. The heating air hose is to be se-
cured at its joints.
The air heater does not require maintenance. It should
however be checked by Webasto-trained skilled person-
nel on regular intervals, the latest before the heating
season begins (point of time, when the heater is more
frequently in use due to weather conditions).
801
8 Servicing Air Top 2000 S
8.6.2 Fuel Supply
The fuel is taken from the vehicle fuel tank or from a

separate fuel tank. The values for maximum pressure
at the fuel extraction point are shown in Fig. 801.
Permissible fuel inflow At maximum pressure in

height H fuel line
0.00 m (0.00 in.) 0.20 bar (2.9 PSI) max. 3m (9.8 ft.)
1.00 m (39.4 in.) 0.11 bar (1.6 PSI) I2
2.00 m (78.7 in.) 0.03 bar (0.44 PSI)
Maximum fuel intake At maximum negative iØ2mm
height S pressure in fuel tank
0.00 m (0.00 in.) -0.10 bar (-1.45 PSI)
iØ2mm H
0.50 m (19.7 in.) -0.06 bar (-0.87 PSI)
1.00 m (39.4 in.) -0.02 bar (-0.29 PSI)
iØ2mm I1
8.6.2.1 Fuel Tapping
I2
iØ2mm
Vehicles with a Diesel Engine S
The fuel must be taken from the vehicle fuel tank or
from a separate tank (Figs. 802, 803 and 804). This I 1 + I 2 ≤ 10 m (32.8 ft.) I1
separate fuel pickup precludes any effect of pressure. I 1 ≤ 1.2 m (3.9 ft.)
I 2 ≤ 8.8 m (28.8 ft.)
Vehicles with an Injection Engine
When installing the heater in a vehicle with fuel injection
systems, it is important to establish whether the fuel
pump is located inside or outside the tank. Fig. 801 Fuel Supply
If the fuel pump is located inside the tank, fuel can only
be extracted from the return line using a Webasto fuel
tee fitting in which case it must be ensured that the
return line continues almost to the bottom of the tank.
If this is not the case, a Webasto fuel standpipe
(see Figs. 802, 803 and 804) may be used.
If the fuel pump is installed outside the tank, the fuel

connection may also be made between the tank and
fuel pump, again using only the Webasto fuel tee fitting.
Vehicles with a Carburetor Engine

The fuel may only be extracted on cars using a special
Webasto fuel tee fitting as close to the tank as possible.
The connection may be made in either the supply or

return line, in which case the return line must lead
almost to the base of the tank. If this is not the case,
the return line may be extended.
The fuel tee must be fitted in such a way that any air or
gas bubbles are automatically discharged towards the
tank.
The fuel tee should not be located near the engine, as

gas bubbles may form in the lines on account of heat
radiated from the engine. This may cause problems
during combustion.
802
Hole Pattern Fuel Tank Tap
Gaskets
25 mm (1 in.)
Tank Fitting Plate

> 25 mm (> 1 in.)
Fig. 802 Webasto Fuel Tank Tap
* Use fuel tank tap only on metal fuel tanks
Fig. 804 Fuel Tapping from Plastic Tank

(tapping via fitting plate)
NOTE
Plastic Tank 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 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 mal-
functions should the lines be descending or have sags.
Gasket
The diameters specified in Fig. 801 will ensure that
bubbles do not form.
A descending line routing from the dosing pump to the

heater should be avoided.
Loose fuel lines must be secured in order to avoid sagg-

ing. The installation must ensure protection against
stone impacts and undue temperatures (exhaust line).
Fig. 803 Fuel Tapping from Plastic Tank The fuel line joints are to be secured against slipping
(tapping via fuel drain plug) 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 loca-
tions exposed to heat radiated by hot vehicle compo-
nents. A heat shield is to be provided as required.
Clamp
8.6.3.2 Installation and Attachment
The dosing pump is to be attached with anti-vibration

Wrong mounts. The installation location is limited according to
Fig. 806 to ensure sufficient self-venting capability. Due
Bubble Bubble to the danger of corrosion the plug connection between
dosing pump and dosing pump cable loom may only use
Webasto original parts.
8.6.4 Fuel Filter

Fig. 805 Pipe/Hose Connection
Only a Webasto filter, P/N 50487171A, is allowed to be
used if the fuel is expected to be contaminated. Install
8.6.3 Dosing Pump vertically if possible, however at most horizontally (check
flow direction).
The dosing pump is a combined delivery, dosing, and
shut-off system and is subject to certain installation crite-
ria (see Figs. 801 and 806).
0 - 90°
ø5
AT 2000 S. 12 Volt and 24 Volt - Gasoline and Diesel Fig. 807 Fuel Filter
0-90° 0-90°
0°
AT 2000 S D. 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 de-
scending attitude. If this is not possible, a condensate
Combustion air must under no circumstances be ex- drain hole ø 4 mm must be provided at the lowest point.
tracted from rooms with persons. The combustion air
inlet must not point towards the forward direction of mo- Inner diameter of lines:
tion. It must be located so that no clogging by contamina- Combustion air line: 22 mm
tion is to be expected. Exhaust line: 22 mm
NOTE NOTE
For fuel operated heaters the combustion air tap must When exceeding an exhaust line length of 2 m, insulated
be located in a possibly cool and splash water proof posi- exhaust lines have to be used (below minimum dew
tion 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 (Ident No. 21963A) can be fitted
(Air Top 2000 S 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. Exhaust exit direction
The exhaust pipe is secured to the air heater e.g. with a
nearly vertical 90° ± 10°
clamp.
The exhaust muffler is preferably mounted near the air

10° 10 °
heater. The direction of flow is optional.
ø 6,5
Fig. 809 Exhaust Pipe Outlet, Installation Position
WARNING
Fig. 808 Exhaust Muffler, Direction of Flow
Any exhaust exit direction other than the one shown in
Fig. 809 may cause fires.
Operation of the air heater is also permitted without
Sum of bends:
muffler.
Combustion air line: max. 270°
Exhaust: max. 270°
8.6.7 Combustion Air Intake and Exhaust Lines
In order to avoid damage to the dosing pump cable, no

exhaust line may be used for the elongation of the com-
bustion 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 Dial
8.6.8.1 Connection Air Heater, Control Dial The cable loom is prefabricated to connect to the control
dial (rated value transmitter).
Electrical connection is according to Circuit Diagram For plug disconnection pull on terminal plug only
Automatic Control (see Section 7). (Fig. 812).
By pulling on the cable loom the terminal plug is
For connection of the cable loom the cover (see 9.2.1.1) secured (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.

Fiber optic lens
8.6.8.2 Connection of Power Supply
(operation indicator)
Ideally from the vehicle’s central electrical system.
An additional blade terminal fuse holder is to be Fig. 811 Control Dial

fitted to protect the heater and harness (supplied NOTE
with the heater). The fuse holder should be The fiber optic lens must be in contact with the
installed as close as is practical to the power rotary knob.
source e.g. in the vehicle battery enclosure.
The fuse holder is constructed of weather resistant

components.
AT 2000 S
F = 15A (12V)
F = 10A (24V)
Fig. 810 Weather Resistant Fuse Holder
Fig. 812 Pulling the Plug
806
5
3 4
2
6
1
Dosing Pump and Damper

Fuel Filter (Accessory)
7
Exhaust Muffler
Fuel Connector
Control Dial
Air Heater
Fuse
1
2
3
4
5
6
7
Fig. 813 Example of an Installation
807
8.7 Removal and Installation 8.8 Start-Up
CAUTION After you have installed the heater, bleed the fuel supply
When the heater is installed it must not be dismantled. system carefully.
NOTE
8.7.1 Air Heater, Removal and Installation As a result of the low fuel consumption the heater must
be switched on several times to fill the fuel line.
8.7.1.1 Removal
Conduct a trial of the heater to check all the connections
1. Disconnect battery terminal leads. for leaks and to ensure that they are secure. If the
2. Withdraw cover from upper housing shell according heater suffers a fault during operation, the fault must be
to 9.2.1. located and remedied.
3. Disconnect the wire harness plug from control unit.
4. Disconnect interior air ducts if present.
5. Disconnect cable to dosing pump at cable disconnect.
6. Disconnect fuel inlet on air heater.
7. Disconnect connections of combustion air intake and
exhaust outlet on air heater.
8. Remove four nuts and lock washers on air heater.
9. Remove air heater and discard gasket.
8.7.1.2 Installation
1. Locate air heater with new gasket in installation

position and secure with four nuts and lock washers
(use original Webasto nuts only).
2. Tighten nuts with 6 + 1 Nm.
3. Secure connection for fuel inlet on air heater.
4. Secure connections for combustion air inlet and ex-
haust outlet on air heater.
5. Route cable to dosing pump and connect to dosing
pump.
6. Connect wire harness to control unit.
7. Install cover and secure.
8. Reconnect battery terminal leads.
9. Install interior ducting if present.
10. Bleed fuel supply system (see 8.8).
808
Air Top 2000 S 9 Repair
9. Repair 9.1.2.1 Installation of an External Temperature

Sensor
9.1 General General

The heater can control the required temperature
perfectly if its temperature sensor is exposed to the air of
This section describes the repairs that may be per-
the main area of the vehicle. In certain circumstances,
formed on the air heater Air Top 2000 S after it has
this is not always possible using the temperature sensor
been removed from the vehicle.
integrated in the control unit due to the installation
Any further disassembly will void the warranty.
circumstances (addition of fresh air). In this case proper
For reassembly, only components of the proper spare
temperature control can be ensured using an external
parts and kits are to be used.
temperature sensor fitted in the appropriate area.
9.1.1 Work on Components after Disassembly Procedure
1. Select adequate installation location for external
CAUTION temperature sensor.
All gaskets located between disassembled components
as well as the exhaust outlet seal must always be re- IMPORTANT
placed and discarded. Temperature sensor should not be in the direct
line of heated air flow or located in the vicinity of
9.1.1.1 Cleaning heating sources (e.g. vehicle’s own heater).
The sensor is to be installed at medium height
All components disassembled must be cleaned with in the vehicle interior on surfaces that are as
cleaning spirit and subsequently dried with press- vertical as possible.
urized air. The installation location should not be exposed to
All sealing compound must be carefully removed direct sun light.
from components using a suitable tool. Do not mount temperature sensor behind curtains or
the like.
9.1.1.2 Visual Inspection
2. Mount external temperature sensor and route cable
Examine all components for damages (cracks, defor- to control unit.
mation, wear, etc.) and replace as necessary. 3. Connect connector X9 and install cover.
Examine connectors and wiring for corrosion, loose 4. Perform test run and check control behaviour.
contacts, wrong crimping, etc. and repair as necess-
ary.
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 in-
tended to optimise their serviceability avoiding failures or
malfunctions. X9
In general equipment in service may be retrofitted with
available modification kits. In the following that modifica- Cover
tion which may be incorporated easily during maintenace:
installation of an external temperature sensor for

optimising temperature control of the Air Top 2000 S
(see 9.1.2.1).
External
Temperature Sensor Connector X9
901
9 Repair Air Top 2000 S
9.2 Disassembly and Assembly 9.2.1.3 Covers for Heating Air Inlet and Outlet
Both covers (3 and 6, Fig. 901) can be released and

9.2.1 Removal of Housing Components/Covers
removed by pressing the four detents on top and bottom
using a suitable tool.
9.2.1.1 Cover for Electrical Connection
9.2.1.4 Upper Housing Shell
Dependent on the type of installation the cable loom
exits the air heater either on the left or right. NOTE
The cover (1, Fig. 901) may be levered off using a blunt The covers for the heating air inlet and outlet must be
blade in the areas marked X . removed.
9.2.1.2 Grates for Heating Air Inlet and Outlet The upper shell (2, Fig. 901) can be raised by pulling up.
The grates (5, Fig. 901) can be released from the 9.2.1.5 Lower Housing Shell
covers by twisting and pulling off forwards.
By gently pulling the lower shell (4, Fig. 901) on both
sides in the areas Y , you can release the fixing and
the shell can be taken off the motor casing.
5
X
X
1 Cover, Electrical Connection

2 Upper Housing Shell
3 Cover, Heating Air Outlet
4 Lower Housing Shell
5 Grates
6 Cover, Heating Air Inlet
6
4
Y
5
Fig. 901 Removal of Housing Components/Covers
902
9.2.2 Replacement of Control Unit 9.2.3 Replacement of Temperature Limiter
9.2.2.1 Removal 9.2.3.1 Removal
1. Remove heater from vehicle (see 8.7.1.1).

During removal avoid the build-up of static charge (i.e. 2. Remove covers for heating air inlet and outlet
do not touch strip conductors). (6 and 3, Fig. 901) according to 9.2.1.3.
3. Remove upper housing shell according to 9.2.1.4.
1. Remove heater from vehicle (see 8.7.1.1). 4. Disconnect plug connection (blue) from terminal.
2. Remove covers for heating air inlet and outlet 5. Remove screws (4, Fig. 902).
(6 and 3, Fig. 901) according to 9.2.1.3. 6. Remove temperature limiter (5).
3. Remove upper housing shell according to 9.2.1.4. 7. Perform work on components after disassembly
4. Disconnect terminal connections (1, Fig. 902). (see 9.1.1).
5. Remove screws (3) and remove control unit (2)
with bracket (6). 9.2.3.2 Installation
6. Remove screw (7) to separate control unit (2)
from bracket (6) if necessary. 1. Place temperature limiter (5, Fig. 902) into
installation position and secure with screws (4).
7. Perform work on components after disassembly
Ensure limiter is properly seated.
(see 9.1.1).
2. Torque screws to 1.5 ± 0.15 Nm.
3. Connect plug connections (blue) to terminal.
4. Install on upper housing shell and fix in position.
5. Slide on covers for heating air inlet and outlet and fix
in position.
NOTE
6. Install heater (see 8.7.1.2).
During installation avoid the build-up of static charge (i.e.
do not touch strip conductors).
1. Place control unit (2, Fig. 902) in position on

bracket (6) and secure with screw (7).
2. Place control unit (2) with bracket (6) in installation
position and secure with screws (3).
Torque screws to 0.7 ± 0.07 Nm.
3. Connect plug connections to terminal (Fig. 701).
4. Install upper housing shell and fix in position.
5. Slide on covers for heating air inlet and outlet and fix
in position.
6. Install heater (see 8.7.1.2).
7. Check CO2 setting and if necessary, adjust (see 6.2)
903
1
3 4
X6
7
6
1 Plug Connections
2 Control Unit
3 Screw (2)
4 Screw (2)
5 Temperature Limiter
6 Bracket
7 Screw
Fig. 902 Replacement of Control Unit and Temperature Limiter
904
! MAX.
1 Insulation
2 Seal
Fig. 903 Replacement of Combustion Air Fan (Disassembly)
9.2.4 Replacement of Combustion Air Fan
9.2.4.1 Removal 5. Remove insulation (1, Fig. 903)

6. Remove screws (1, Fig. 904).
1. Remove air heater (see 8.7.1.1). 7. Withdraw combustion air fan (3) and remove gasket
2. Remove control unit (see 9.2.2.1). (2).
3. Remove seal (2 Fig. 903) from lower housing shell 8. Perform work on components after disassembly (see
and discard. 9.1.1).
4. Remove air heater from lower housing shell.
905
9.2.4.2 Installation • Loose wire strands of the mesh must be cut off
to prevent contact with the temperature sensor.
1. Ensure that sealing surfaces on combustion air fan
and on heat exchanger are not damaged. • Ensure a secure fit between the heat exchanger,
2. Place new gasket (2, Fig. 904) onto flange of insulating mesh, and the upper housing.
combustion air fan (3).
3. Place combustion air fan into assembly position and • An overly worn, damaged or flattened insulating
mount using screws (1). Torque screws (1) to 6 Nm. mesh must be replaced with a new mesh.
4. Place wire insulating mesh into position on the

CAUTION heat exchanger (1, Fig. 903).
To ensure the proper function of the heater and to 5. While slightly spreading the lower housing shell,
prevent malfunctions of the temperature sensor, place over heat exchanger until guide slots
the following must be observed when installing the engage with pins on fan housing.
wire insulating mesh: 6. Fit new seal (2, Fig. 903) on heater mount base.
7. Install control unit (see 9.2.2.2).
• The wire insulating mesh must be installed as 8. Install upper housing shell, air inlet and air outlet.
shown in Fig. 903 to prevent unwanted contact 9. Install air heater (see 8.7.1.2).
with the temperature sensor terminals. 10. Check CO2 setting and adjust as required (see 6.2).
1 Screw (5)
2 Gasket
3 Combustion Air Fan
Before assembly always

renew gasket.
3
Combustion air fan must not be
disassembled any further
Fig. 904 Replacement of Combustion Air Fan (Assembly)
906
9.2.5 Replacement of Flame Sensor CAUTION

The glow plug has to be pulled out with utmost care and
9.2.5.1 Removal must under no circumstances be twisted (danger of
breaking). After a long period of combustion operation
1. Remove air heater (see 8.7.1.1). the glow plug may be caked by fuel deposits. In this
2. Remove control unit (see 9.2.2.1). case allow penetrating oil to react long enough to free
3. Remove combustion air fan (see 9.2.4.1). glow plug for removal.
4. Remove screws (3, Fig. 905) and spoiler (2) for
cable protection. 7. Loosen screw (13) and remove glow plug (11)
5. Push out cable grommet (10) towards inside. from burner insert.
6. Carefully bend up locking tab (4) and withdraw flame 8. Perform work on components after disassembly (see
sensor (1) from burner insert (5). 9.1.1).
7. Remove flame sensor.
8. Perform work on components after disassembly 9.2.6.2 Installation
(see 9.1.1).
1. Insert new gasket (7, Fig. 905) into heat exchanger
9.2.5.2 Installation and place combustion tube (6) in assembly position.
2. Ensure that starting air bore is not clogged. If required
CAUTION clean with wire (approx. 1 mm ø) (see Detail A).
Route cable of flame sensor below fuel pipe.
CAUTION
1. Pass flame sensor (1, Fig. 905) below fuel pipe, feed During glow plug installation observe twist lock (see De-
connector through opening and push in cable grom- tail B). That means that the glow has to be inserted so
met (10). that the contacts point towards the heat exchanger.
2. Feed cable with protection sleeve through locking tab Otherwise there will be the danger of a short circuit.
and insert flame sensor (1) into burner insert (5).
3. Squeeze locking tab (4). 3. Feed glow plug (11) into burner insert (5) and arrange
4. Secure burner insert (5) with four screws (3) and fit cable protective sleeve in slot of burner insert.
spoiler (2) for cable protection.
5. Pull cable of flame sensor tight. CAUTION
6. Torque all 4 screws (3) to 6 ± 0.6 Nm. When performing the following step ensure that glow
7. Mount combustion air fan (see 9.2.4.2). plug is inserted in burner insert fully against stop.
9. Install air heater (see 8.7.1.2). 4. Secure glow plug (11) with screw (13). Torque screw
(13) to 0.5 Nm.
5. Locate burner insert (5) in heat exchanger (8) observ-
ing that cable of flame sensor is positioned below
9.2.6 Replacement of Glow Plug fuel pipe.
6. Feed connectors of glow plug and flame sensor
9.2.6.1 Removal through openings and push in cable grommets (9
and 10).
1. Remove air heater (see 8.7.1.1).
2. Remove control unit (see 9.2.2.1). CAUTION
3. Remove combustion air fan (see 9.2.4.1). When performing the following step ensure that there is
4. Push out cable grommets (9 and 10, Fig. 905) a tight fit between grommet (12) and heat exchanger (8).
towards inside.
5. Remove four screws (3) and spoiler (2). 7. Secure burner insert (5) using screws (3) and attach
6. Tilt and withdraw burner insert (5) carefully. spoiler (2). Torque screws (3) to 4 Nm.
8. Mount combustion air fan (see 9.2.4.2).
NOTE 9. Install control unit (see 9.2.2.2).
Ensure that burner insert (5) has separated from burner 10. Install air heater (see 8.7.1.2).
tube (6).
907
10
11
5
4
3
1 Flame Sensor
2 Spoiler
3 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. 905 Disassembly of Heat Exchanger (Sheet 1 of 2)
908
Detail A
Starting Air Bore
Detail B
Twist Lock
Fig. 906 Disassembly of Heat Exchanger (Sheet 2 of 2)
909
9.2.7 Replacement of Burner Insert,

Combustion Tube, and Heat Exchanger
CAUTION
If the heat exchanger is going to be replaced, the
temperature limiter must also be replaced.
9.2.7.1 Removal
1. Remove air heater (see 8.7.1.1).

2. Remove control unit (see 9.2.2.1).
3. Remove combustion air fan (see 9.2.4.1).
4. Remove flame sensor (see 9.2.5.1).
5. Remove glow plug (see 9.2.6.1).
CAUTION
When performing the following step ensure that fuel
connection is not bent.
6. Remove burner insert (5, Fig. 905).

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

temperature limiter (5, Fig. 902) with screws (4).
Torque screws to 1.5 ± 0.15 Nm.
2. Fit new gasket (7, Fig. 905).
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).
8. Install air heater (see 8.7.1.2).
910
Air Top 2000 S 10 Packaging/Storage and Shipping
10. Packaging/Storage and Shipping
10.1 General
When it is necessary to ship the heater and its components

to a Webasto repair center for inspection or repair, they
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.
06/2008 1001
Notes Air Top 2000 S

WEBASTO PRODUCT N.A., INC.
15083 North Road
Fenton, MI 48430
Technical Assistance Hotline
USA: (800) 860-7866
Canada: (800) 667-8900
www.techwebasto.com
Org. 06/2008 Rev. N/A P/N LIT9000557A © 2008 Webasto Product N.A., Inc. www.webasto.us

Air Top 2000 S D

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List of Contents Air Top 2000

Air Top 2000 S D (Diesel)

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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 General Safety Notes.................................................................................................................. 101

1.5 Legal Provisions for Installation............................................................................................................... 102

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

3.1 Functional Description Air Top 2000 S ....................................................................................................... 301

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 General Safety Notes

The heaters are cleared for heating the passenger and

Metal lines must be used. These may not heat to more

Combustion Air Inlet and Exhaust Outlet

For the routing of fuel lines and the installation of addi-

Installation Rules for Webasto Fuel Tanks for the

2. General Description A malfunction of the Air Top 2000 S is indicated by an

Air Heater Air Top 2000 S

Air Heater Air Top 2000 S

are located within the unit.

All Air Top 2000 S heaters may be controlled

Fuel supply is provided externally by a fuel dosing pump.

Combustion and Heating Air Fan

2.2 Heat Exchanger 2.4 Control Unit / Control Circuit Board

A malfunction in the Air Top 2000 S is indicated by an

2.3 Burner Insert with Combustion Tube

Within the burner insert fuel is distributed in the combus-

Control Unit - Air Top 2000 S

2.5 Flame Sensor 2.7 Temperature Limiter

The glow plug ignites the fuel/air mixture at the start of

Dosing Pump DP 2 for Gasoline and Diesel

Dosing Pump DP 30 for Diesel operated Heaters

3.1.4 Heating Operation 3.1.7 Switch-Off

4. Technical Data Fuel for Air Top 2000 S B (gasoline):

Air Heater Operation AT 2000 S B AT 2000 S D

Mark of conformity ~ S 325 ~ S 324

Heater type Air heater with evaporator burner

Heat flow Control range 1.1 – 2.0 kW 0.9 – 2.0 kW