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Air Top 2000

– Improper installation or repair of Webasto heating and cooling systems can cause

fire or the leakage of deadly carbon monoxide leading to serious injury or death.

– Installation and repair of Webasto heating and cooling systems requires special

Webasto training, 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.

Air Heater

Air Top 2000 D (Diesel)

Air Top 2000 B (Gasoline)

Service and Repair Manual

NOTE

Technical changes in this issue of the

manual compared with its previous issue

are identified with a vertical change bar on

the lefthand side of columns.

Summary of content (60 pages)

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Air Top 2000 List of Contents Air Heater Air Top 2000 D (Diesel) Air Top 2000 B (Gasoline) Service and Repair Manual NOTE Technical changes in this issue of the manual compared with its previous issue are identified with a vertical change bar on the lefthand side of columns. – 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.
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Air Top 2000 List of Contents List of Contents 1. Introduction 1.1 Scope and Purpose................................................................................................................................. 101 1.1.1 1.2 1.3 1.4 Meaning of Warnings, Cautions, and Notes ............................................................................................ 101 Additional Documentation to be used.................................................................................................
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List of Contents 5. Troubleshooting 5.1 5.2 5.3 5.4 6. General....................................................................................................................................................501 General Failure Symptoms......................................................................................................................501 Failure Symptoms during Operation........................................................................................................
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Air Top 2000 9. Repair 9.1 General.................................................................................................................................................... 901 9.1.1 9.1.2 9.2 Work on Components after Disassembly.................................................................................... 901 Incorporation of Modifications ..................................................................................................... 901 Disassembly and Assembly..................
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Air Top 2000 List of Figures List of Figures 301 Functional Diagram (Air Top 2000 without Diagnosis)....................................................................................303 501 502 General Failure Symptoms .............................................................................................................................501 Failure Symptoms during Operation ...............................................................................................................
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Air Top 2000 1. Introduction 1.1 Scope and Purpose 1 1.4 Introduction Safety Information and Regulations This repair shop manual is intended to support familiarized personnel in the repair of air heaters Air Top 2000 of the fuel and Diesel type as well as of Air Top 2000 Diagnosis with serial no. 30.000 and up. The general safety regulations for the prevention of accidents and the relevant operating safety instructions have to be observed at all times.
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1 Introduction The heater must not be installed in the passenger or driver compartments of busses. Should the heater nevertheless be installed in such a compartment, the installation box must be sealed tight against the vehicle interior. There must be sufficient ventilation of the installation box from the exterior in order not to exceed a maximum temperature of 40 °C in the installation box. At filling stations and fuel depots the heater must be switched off as there is a potential danger of explosion.
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Air Top 2000 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 contact may be fitted. Should exhaust pipes be routed through rooms accommodating persons, these pipes shall be renewed after 10 years using genuine spare parts.
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Air Top 2000 2. General Description The air heater Air Top 2000 and Air Top 2000 Diagnosis with serial no. 30.000 and up operating to the evaporator principle basically consist of: 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 operating indicator flashes.
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2 2.2 Air Top 2000 General Description Heat Exchanger 2.4 The heat exchanger dissipates the heat provided by combustion to the air delivered by the combustion and heating air fan. Control Unit / Control Circuit Board Air Top 2000 without 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 side is used for temperature control.
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Air Top 2000 2 Potentiometer 2.7 Temperature Sensor General Description Temperature Limiter 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).
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Air Top 2000 3. Functional Description 3.1 Functional Description Air Top 2000 without Diagnosis (Fig. 301) 3.1.1 Control Element The control element is used to switch the air heater on and off, set the desired room temperature (air intake temperature between 10 °C and 45 °C), and to unlock a failure interrupt condition. The green LED indication is used to indicate the operating condition (LED permanently on) and an overheat condition (LED flashes).
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3 Air Top 2000 Functional Description 3.1.5 Control Operation During control operation fan speed and dosing pump rate of delivery are subject to heating performance. The glow plug is deactivated. 3.1.6 Control Idle In case the air intake temperature set with the control element is exceeded and the minimum heating performance had been achieved for longer than 5 seconds, the fuel supply is cut off to terminate combustion.
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Air Top 2000 3 3 A 1 0 1 On 2 Functional Description 4 9 5 6 7 8 10 B C 1 0 D 100% 90% 60% 30% 0 E 1,3 Hz 1,0 Hz 0,8 Hz 0,6 Hz 0 F 1 0 0 20 45 65 85 102 typical (20) (60) (120) 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 (e.g.
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3 3.2 Functional Description Air Top 2000 Diagnosis 3.2.1 Control Element The control element is used to switch the air heater on and off, set the desired room temperature (air intake temperature between 10 °C and 45 °C), and to unlock a failure interrupt condition. The green LED indication is used to indicate the operating condition (LED permanently on) and an overheat condition (LED flashes).
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Air Top 2000 3 Functional Description 3.2.4 Heating Operation 3.2.7 Switch-Off During operation the combustion exhaust gasses flow through the heat exchanger charging its walls with combustion heat, which in turn is taken up by the heating air delivered by the heating air fan to be routed to the vehicle interior.
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3 Functional Description 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.
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Air Top 2000 4. 4 Technical Data Electrical Components: Technical Data As long as no threshold values are given, the following technical data are understood to include tolerances of ±10% usual for heaters at an ambient temperature of +20 °C and at nominal voltage and conditions. Control unit, combustion air fan, dosing pump, timer*, glow plug and control element are for 12 or 24 Volts operation. The components temperature limiter and flame detector are independent of voltage.
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Air Top 2000 5 5. Troubleshooting 5.1 General This section describes troubleshooting procedures for the Air Heater Air Top 2000 and Air Top 2000 Diagnosis. A malfunction in air heaters Air Top 2000 Diagnosis 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).
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5 Air Top 2000 Troubleshooting 5.3 Failure Symptoms during Operation The following table (Fig. 502) lists the possible failure symptoms as they might occur during the functional sequence of operation. In case of malfunction the failure is to be isolated and removed using this table. It is important to accurately identify the failure symptom.
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Air Top 2000 5.4 5 Troubleshooting 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.
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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. WARNING The air heater shall not be operated in enclosed areas like garages or workshops not provided with exhaust venting facilities. 6.
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6 6.3 Air Top 2000 Functional Tests Components Testing CAUTION During electrical testing always ensure that the control unit and the component under test are electrically disconnected 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) Resistance at 25 °C: 0.324 ... 0.360 Ω Test current: < 5 mA 24 Volt (green) 1.3 ... 1.44 Ω < 5 mA 6.3.
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Air Top 2000 7 7. Circuit Diagrams 7.1 General 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. The circuit diagrams (Figs. 709 to 713) show the possible circuits 12 or 24 Volt with l l l The air heater Air Top 2000 Diagnosis may be operated using the control element (rated value transmitter/switch) or with the control element and a combination or standard timer.
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7 Air Top 2000 Circuit Diagrams X1 violet X1 X2 X3 X4 X5 = = = = = X2 black X3 X4 X5 brown yellow blue Connection, Combustion and Heating Air Fan Connection, Dosing Pump Connection, Flame Sensor Connection, Glow Plug Connection, Temperature Limiter Fig.
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Air Top 2000 7 Circuit Diagrams 2 ϑ ϑ ϑ Item A1 A2 B1 B2 B3 E F2 H1 M S1 X1-X5 X6 X7 X8 X9 X11 X12 Y1 Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Glow Plug Fuse 24V 10A/12V 15A LED green (in item S1) Motor Control Element Connection 2-pole Connection 8-pole Connection 4-pole Connection 2-pole Connection 2-pole Connection 6-pole Connection 1-pole Dosing Pump Remark Air Top 2000 Wire Gauges < 7.5 m 7.5 - 15 m 0.75 mm2 1.0 mm2 1.5 mm2 1.5 mm2 1.5 mm2 2.
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7 Air Top 2000 Circuit Diagrams 1 2 ϑ ϑ ϑ Item A1 A2 B1 B2 B3 E F2 H7 Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Glow Plug Fuse 24V 10A/12V 15A LED red (in item P) H8 Heating symbol in display (in item P) H9 M P1 S3 X1-X5 X6 X8 X9 X11 X12 X13 Y1 Light (in item P) Motor Combination Timer (1531) Switch Connection 2-pole Connection 8-pole Connection 2-pole Connection 2-pole Connection 6-pole Connection 1-pole Connection 12-pole Dosing Pump Remark Air T
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Air Top 2000 7 Circuit Diagrams 1 2 ϑ ϑ ϑ Item A1 A2 B1 B2 B3 E F2 H7 Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Glow Plug Fuse 24V 10A/12V 15A LED red (in item P) H8 Heating symbol in display (in item P) H9 M P2 S1 S3 X1-X5 X6 X7 X8 X11 X12 X13 Y1 Light (in item P) Motor Standard timer Control Element Switch Connection 2-pole Connection 8-pole Connection 4-pole Connection 2-pole Connection 6-pole Connection 1-pole Connection 12-pole Dosing Pump Rem
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7 Air Top 2000 Circuit Diagrams ϑ ϑ ϑ Item A1 A2 B1 B2 B3 E F2 H1 H6 Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Glow Plug Fuse 24V 10A LED green (in item S1) Light (at least 1.
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Air Top 2000 7 Circuit Diagrams 1 CAUTION: Pin 4 no ground connection ϑ ϑ ϑ Item A1 A2 B1 B2 B3 E F2 H6 Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Glow Plug Fuse 24V 10A Light (at least 1.
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7 Air Top 2000 Circuit Diagrams 1 CAUTION: Pin 4 no ground connection ϑ ϑ ϑ Item A1 A2 B1 B2 B3 E F2 H7 Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Glow Plug Fuse 24V 10A LED red (in item P) H8 Heating symbol in display (in item P) H9 M P1 S2 Light (in item P) Motor Combination Timer (1531) Disconnect Switch 1 or 2-pole S3 S4 S5 X1-X5 X6 X8 X9 X11 X12 X13 Y1 Y2 Y3 Switch Switch Switch Connection 2-pole Connection 8-pole Connection 2-pole Connection
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Air Top 2000 7 Circuit Diagrams ϑ ϑ ϑ ϑ Item A1 A2 B1 B2 B3 B4 E F2 H1 H4 M S1 X1-X5 X6 X7 X8 Y Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Temperature Sensor Glow Plug Fuse 15A LED green (in item S1) Light (in item P) Motor Rated Value Setting Switch Connection 2-pole Connection 8-pole Connection 4-pole Connection 2-pole Dosing Pump Wire Gauges Remark Air Top 2000 < 7.5 m 7.5 - 15 m 0.75 mm2 1.0 mm2 1.5 mm2 2.5 mm2 4.0 mm2 1.5 mm2 1.5 mm2 2.5 mm2 4.
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7 Air Top 2000 Circuit Diagrams ϑ ϑ ϑ ϑ Item A1 A2 B1 B2 B3 B4 E F2 H1 H4 M P S1 X1-X5 X6 X7 X8 X10 Y Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Temperature Sensor Glow Plug Fuse 15A LED green (in item S1) Light (in item P) Motor Timer 1529 Rated Value Setting Switch Connection 2-pole Connection 8-pole Connection 4-pole Connection 2-pole Connection 8-pole Dosing Pump Remark Air Top 2000 Wire Gauges 7.5 - 15 m 1.5 mm2 1.5 mm2 2.5 mm2 4.0 mm2 6.
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Air Top 2000 7 ϑ Circuit Diagrams ϑ ϑ Item A1 A2 B1 B2 B3 E F1 H1 M S1 X1-X5 X6 X7 X8 X11 Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Glow Plug Fuse 10A LED green (in item S1) Motor Rated Value Setting Switch Connection 2-pole Connection 8-pole Connection 4-pole Connection 2-pole Connection 2-pole Y Dosing Pump Remark Air Top 2000 Wire Gauges < 7.5 m 7.5 - 15 m 0.75 mm2 1.0 mm2 1.5 mm2 1.5 mm2 1.5 mm2 2.5 mm2 4.0 mm2 6.0 mm2 2.5 mm2 4.
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7 Air Top 2000 Circuit Diagrams ϑ ϑ ϑ Item A1 A2 B1 B2 B3 E F1 H1 H4 M P S1 X1-X5 X6 X7 X8 X10 X11 Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Glow Plug Fuse 10A LED green (in item S1) Light (in item P) Motor Timer 1529 Rated Value Setting Switch Connection 2-pole Connection 8-pole Connection 4-pole Connection 2-pole Connection 8-pole Connection 2-pole Y Dosing Pump Remark Air Top 2000 Wire Gauges < 7.5 m 7.5 - 15 m 0.75 mm2 1.0 mm2 1.5 mm2 1.
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Air Top 2000 7 ϑ Circuit Diagrams ϑ ϑ Item A1 A2 B1 B2 B3 E F1 H1 M S1 S2 Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Glow Plug Fuse 10A LED green (in item S1) Motor Rated Value Setting Switch Disconnect Switch 1 or 2-pole X1-X5 X6 X7 X8 X11 Connection 2-pole Connection 8-pole Connection 4-pole Connection 2-pole Connection 2-pole Y Dosing Pump Remark Air Top 2000 Wire Gauges < 7.5 m 7.5 - 15 m 0.75 mm2 1.0 mm2 1.5 mm2 1.5 mm2 1.5 mm2 2.5 mm2 4.
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7 Air Top 2000 Circuit Diagrams ϑ ϑ ϑ Item A1 A2 B1 B2 B3 E F2 H1 M S1 S2 Nomenclature Air Heater Control Unit Flame Sensor Temperature Sensor Temperature Limiter Glow Plug Fuse 10A LED green (in item S1) Motor Rated Value Setting Switch Disconnect Switch 1 or 2-pole X1-X5 X6 X7 X8 X9 X11 X12 Y1 Connection 2-pole Connection 8-pole Connection 4-pole Connection 2-pole Connection 2-pole Connection 2-pole Connection 1-pole Dosing Pump Remark Air Top 2000 Wire Gauges 7.5 - 15 m 1.5 mm2 1.5 mm2 2.
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Air Top 2000 7 Jumper Circuit Diagrams Terminal 15 Terminal 30 Terminal 58 Terminal 31 Fig.
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Air Top 2000 8 Servicing 8. Servicing For reasons of the air heater’s functional reliability perform the following servicing: 8.1 General l This section describes the servicing procedures that may be performed with the air heater installed. 8.2 Work on the Air Heater Prior to performing any work it is mandatory to disconnect the vehicle battery main lead.
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8 Air Top 2000 Servicing 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. HG 8.6.2 Fuel Supply Fuel is tapped from the fuel reservoir of the vehicle or from a separate fuel container. The rated pressure at the fuel tapping location is shown in Fig. 801. Permissible fuel feed height H (m) 0.00 1.00 2.00 Permissible fuel suction height S (m) 0.00 0.50 1.
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Air Top 2000 8 Servicing Hole Pattern 25 Fuel Tank Tap Gasket > 25 mm Tank Fitting Plate 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) Plastic Tank NOTE The fitting plate must be made of sheet metal! 8.6.2.2 Fuel Lines Gasket 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.
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8 Air Top 2000 Servicing Connection of 2 Pipes with Hose 8.6.3.1 Installation Location The proper connection of fuel lines with hoses is shown in Fig. 805. It is advantageous to mount the dosing pump in a cool 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 components. A heat shield is to be provided as required. clamp 8.6.3.
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Air Top 2000 8 8.6.5 Combustion Air Supply Combustion air must under no circumstances be extracted from rooms with persons. The combustion air inlet must not point towards the forward direction of motion. It must be located so that no clogging by contamination is to be expected. Servicing Both lines must be routed away from the heater in a descending attitude. If this is not possible, a condensate drain hole ø 4 mm must be provided at the lowest point.
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8 Servicing Air Top 2000 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). For plug disconnection pull on terminal plug only (Fig. 813). By pulling on the cable loom the terminal plug is arrested (self-locking). Electrical connection is according to Circuit Diagram Automatic Control (see Section 7). For connection of the cable loom the cover (see 9.
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Air Top 2000 8 Servicing 1 7 2 3 4 5 6 1 2 3 4 5 6 7 Control Element Air Heater Dosing Pump and Anti-Vibration Mount Fuel Filter (Accessory) Fuel Tap Exhaust Muffler Fuse Fig.
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8 8.7 Removal and Installation CAUTION In installed condition only the following removal and disassembly procedures are allowed, the upper housing shell being accessible for removal: l l Replacement of control unit Replacement of temperature limiter 8.7.1 Air Heater, Removal and Installation 8.7.1.1 Removal 1. 2. 3. 4. 5. 6. 7. 8. Disconnect battery terminal leads. Withdraw cover from upper housing shell according to 9.2.1.1. Disconnect plug of cable loom from control unit.
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Air Top 2000 8 1 Servicing 4 3 X6 5 2 6 1 2 3 4 5 6 Plug Connections Control Unit Screw (2) Lock Washer (2) Temperature Limiter Arrester Groove Fig.
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8 Air Top 2000 Servicing 1 4 3 X11 5 X9 X6 2 6 1 2 3 4 5 6 Plug Connections Control Unit Screw (2) Lock Washer (2) Temperature Limiter Arrester Groove Fig.
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Air Top 2000 8.8 8 Installation of new Control Units l CAUTION When replacing the control unit the following must be observed: l l When replacing the control unit Air Top 2000 (12 Volt) without external temperature sensor with a new control unit Air Top 2000 Diagnosis (12 Volt) without external temperature sensor no further instructions for replacement as detailed in 8.7.2 are applicable.
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8 Air Top 2000 Servicing 8.8.3 Replacement of Control Unit Air Top 2000 (24 Volt) TRS 8.9 1. Remove control unit according to 8.7.2.1. 2. Remove leaf spring contacts of grey and violet wire from connector X6, contacts 4 and 6. 3. Arrest leaf spring contacts in connector X11 as follows: grey wire in contact 3, violet wire in contact 2. 4. Install new control unit according to 8.7.2.2. 5. Connect connector X6 and X11. 6. Perform functional check.
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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 regulates the desired temperature 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.
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9 Air Top 2000 Repair 9.1.2.2 Removal of External Temperature Sensor (Air Top 2000 without Diagnosis) 6. General The heater Air Top 2000 regulates 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.
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Air Top 2000 9 Repair 1 2 X X 3 Y 5 Y 1 2 3 4 5 Cover, Electrical Connection Upper Housing Shell Cover, Heating Air Outlet Lower Housing Shell Cover, Heating Air Inlet Z Z 4 Fig.
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9 Air Top 2000 Repair 9.2.2 Replacement of Control Unit 9.2.3 Replacement of Temperature Limiter NOTE The procedure for replacement of the control unit is identical for the air heater in installed or removed condition. NOTE The procedure for replacement of the temperature limiter is identical for the air heater in installed or removed condition. Replacement is to be performed in accordance with Replacement is to be performed in accordance with 8.7.3.
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Air Top 2000 9 Repair NOTE Apply Loctite to screws (1). 9.2.4 Replacement of Combustion Air Fan 9.2.4.1 Removal 3. 1. 2. 3. 4. 5. 6. 7. 8. Remove air heater (see 8.7.1.1). Remove control unit (see 8.7.2.1). Remove seal (3 Fig. 902) from lower housing shell and discard. Remove air heater from lower housing shell. Remove heating air intake (1, Fig. 902) and remove insulation (2). Remove screws (1, Fig. 903). Withdraw combustion air fan (3) and remove gasket (2).
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9 9.2.5 Replacement of Flame Sensor 9.2.5.1 Removal 1. 2. 3. 4. 5. 6. 7. 8. Air Top 2000 Repair Remove air heater (see 8.7.1.1). Remove control unit (see 8.7.2.1). Remove combustion air fan (see 9.2.4.1). Remove 2 screws (3, Fig. 904) and spoiler (2) for cable protection. Push out cable grommet (10) towards inside. Carefully bend up locking tab (4) and withdraw flame sensor (1) from burner insert (5). Remove flame sensor. Perform work on components after disassembly (see 9.1.1).
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Air Top 2000 9 Repair 8 7 9 6 10 11 5 4 3 1 2 3 4 5 6 7 8 9 10 11 12 13 Flame Sensor Spoiler Screw (4) Locking Tab Burner Insert Combustion Tube Gasket Heat Exchanger Cable Grommet Cable Grommet Glow Plug Grommet Screw 13 2 12 1 Fig.
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9 Air Top 2000 Repair Detail A Starting Air Bore Detail B Twist Lock Fig.
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Air Top 2000 9 Repair 9.2.7 Replacement of Burner Insert, Combustion Tube, and Heat Exchanger 9.2.7.1 Removal 1. 2. 3. 4. 5. Remove air heater (see 8.7.1.1). Remove control unit (see 8.7.2.1). Remove combustion air fan (see 9.2.4.1). Remove flame sensor (see 9.2.5.1). Remove glow plug (see 9.2.6.1). CAUTION When performing the following step ensure that fuel connection is not bent. 6. 7. 8. 9. Remove burner insert (5, Fig. 904). Withdraw combustion tube (6) from heat exchanger (8) and remove gasket.
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Air Top 2000 10. 10 Packaging/Storage and Shipping 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.