Air Heater

Air Top 2000 ST D (Diesel)

Air Top 2000 ST 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 ST TABLE OF CONTENTS

Contents Page

1. Introduction 1
1.1 Contents and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Use of the Air Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Meaning of Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Additional Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Safety Information and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4.1 Statutory Regulations and Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4.2 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Suggestions for Improvements and Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. General Description 5
2.1 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Burner Insert with Combustion Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Flame Sensor (Gasoline Heaters Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Ceramic Glow Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7 Overheating Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.8 Fuel Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Functional Description 9
3.1 Control Element (Rheostat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Switch On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Heating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 Control Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 Switch Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7 Fault Lock-out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.7.1 Error Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7.2 Reset a Fault Lock-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4. Technical Data 13
5. Troubleshooting 15
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 General Error Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Error Symptoms during Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 Error Code Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6. Functional Tests 21
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.1 Setting the CO2 Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Testing Individual Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3.1 Ceramic Glow Pin Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3.2 Resistance Test on Flame Sensor (gasoline heaters only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3.3 Overheating Sensor Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7. Circuit Diagrams 23
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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 TABLE OF CONTENTS AIR TOP 2000 ST

8. Servicing Work 27
8.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.2 Work on the Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.3 Work on the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.4 Heater Trial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.5 Servicing Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.6 Visual Inspections and Installation Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.6.1 Hot Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.6.2 Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
8.6.2.1 Fuel Extractor (Standpipe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
8.6.2.2 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.3 Fuel Metering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.3.1 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.3.2 Installation and Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.4 Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.6.5 Combustion Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.6.6 Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.6.7 Combustion Air Inlet and Exhaust Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
8.6.8 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8.6.8.1 Heater Connection, Control Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8.6.8.2 Supply Voltage Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8.6.8.3 Control Element (Rheostat) Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
8.7 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.7.1 Heater, Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.7.1.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.7.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.8 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
9. Repair 35
9.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.1.1 Work on Stripped-down Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.1.1.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.1.1.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.1.2 Remove the Casing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.1.2.1 Installation of an External Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
9.2 Dismantling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1 Remove the Casing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1.1 Cover for Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1.2 Grates for Hot Air Inlet and Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1.3 Cover for Hot Air Inlet and Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1.4 Top Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.1.5 Bottom Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2 Fit the Casing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2.1 Bottom Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2.2 Top Shell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2.3 Cover for Hot Air Inlet and Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2.4 Grates for Hot Air Inlet and Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.2.5 Cover for Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
9.2.3 Changing the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
9.2.3.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
9.2.3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

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9.2.4 Changing the Overheating Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9.2.4.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2.4.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2.5 Changing the Combustion Air Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2.5.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2.5.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2.6 Changing the Flame Sensor (gasoline heaters only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.2.6.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.2.6.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
9.2.7 Changing the Ceramic Glow Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.2.7.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.2.7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.2.8 Changing the Burner Insert, Combustion Pipe and the Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.2.8.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.2.8.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.Product Information 45

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 AIR TOP 2000 ST INTRODUCTION

1. INTRODUCTION 1.3 ADDITIONAL DOCUMENTATION

1.1 CONTENTS AND PURPOSE This workshop manual contains all the information and
instructions required for repairing Air Top 2000 ST air
This repair shop manual is intended to assist trained heaters. The use of additional documentation is not
personnel with repairing both the gasoline and the diesel normally required. If necessary, the operating /
versions of the Air Top 2000 ST air heaters. installation instructions and the installation suggestion
for the specific vehicle may also be used.
1.1.1 USE OF THE AIR HEATERS
1.4 SAFETY INFORMATION AND REGULATIONS
The Webasto Air Top 2000 ST air heaters are designed
– to heat cabins, boats, trucks, minibuses, vans, In principle, the general accident prevention regulations
ambulances and motor homes. and current works safety instructions are applicable.
– to defrost vehicle windows. The “General safety regulations” that go beyond the
scope of the above regulations are stated below
They are not designed for heating cargo areas used to
(see 1.4.2).
carry hazardous substances.
The heaters operate independently of the engine and are Any special safety regulations relevant to this instruction
connected to the fuel tank and the electrical system of manual will be highlighted in the relevant sections or text
the vehicle. passages of the procedures.

They are not designed for installation in vehicles with 1.4.1 STATUTORY REGULATIONS AND SAFETY
water or air-cooled engines. INSTRUCTIONS

1.2 MEANING OF SIGNAL WORDS NOTE: The provisions of these Directives are
binding within the United States of America by
Throughout this manual, the signal words DANGER, FMCSA Directive 393.77 and should similarly be
WARNING, CAUTION, and NOTE have the following observed in countries without specific
meanings: regulations.

DANGER: This heading and text style is Extract from the Federal Motor Carrier Safety
used to highlight that non-compliance with Administration
instructions or procedures will cause
Part 393: Parts and Accessories Necessary for Safe
injuries or lethal accidents to personnel.
Operation
WARNING: This heading and text style is §393.77 Heaters
used to highlight that non-compliance with
(b)(15) Certification required.
instructions or procedures may cause
injuries or lethal accidents to personnel. Every combustion type heater, shall be marked plainly to
indicate the type of service for which such heater is
CAUTION: This heading and text style is designed and with a certification by the manufacturer
used to highlight that non-compliance with that the heater meets the applicable requirements for
instructions or procedures may cause such use. For example, "Meets FMCSA Bus Heater
damage to equipment. Requirements.”

NOTE: This heading and text style is used to 1.4.2 GENERAL SAFETY INFORMATION
highlight and draw attention to information we
The mouth of the exhaust pipe should be installed
feel you would like to have. It could have to do
upwards, to the side or, if the exhaust pipe passes under
with procedures and tips that will help you work
the floor of the vehicle, to the side or rear limit of the
more efficiently.
driver’s cab or the vehicle.
The function of important parts of the vehicle must not
be adversely affected. It must not be possible for
condensate or water to collect in the exhaust pipe. Drain
holes may be used.

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 INTRODUCTION AIR TOP 2000 ST

The electric cables and controls for the air-conditioning When you change the heat exchanger it is essential that
system must be arranged in the vehicle so that their you also replace the overheating protection element
proper functioning cannot be adversely affected in (overheating sensor) to prevent possible function faults
normal operating conditions. caused by using the old overheating sensor.
The following points for the installation of fuel lines and The Air Top 2000ST air heaters are prepared for interior
the installation of additional fuel tanks must be observed. installation and sealing directly on the cabin floor or a
cabin wall. Non-release connections must be used in the
• Fuel pipes must be designed in such a way that
interior for combustion air and exhaust pipes with the
torsion in the vehicle, movements by the engine and
accessories available from Webasto.
the like do not have a negative effect on their
durability. They must be protected from mechanical The seal between the heater mounting and the vehicle
damage. floor must always be installed; otherwise harmful
• Parts that carry fuel must be protected from heat emissions may get into the interior of the vehicle.
that will adversely affect their function and The hot and combustion air intake openings must be
positioned so that dripping or evaporating fuel positioned in such a way that no water can ingress into
cannot collect or ignite on hot parts or on electrical them if the vehicle drives through a water hazard for
equipment. which it has been approved.
• The fuel lines (Mecanyl hose) must not be For passenger carrying vehicles such as shuttle busses,
immediately next to the exhaust pipe and must be transit busses, and coaches, where the heater is to be
thermally insulated if necessary, otherwise they will installed in the passenger cabin, a protective cover or
pose a fire risk. installation box should be installed over the heater to
• All pipes that come into contact with fuel must have prevent contact with hot surfaces by passengers and
sealed connections, they must not be damaged in heat sensitive objects.
any way and the must be checked at regular intervals The protective cover or installation box must have
(at least the same intervals as for inspection of the sufficient external ventilation to ensure that a maximum
vehicle as a whole). temperature of 40°C (104°F) is not exceeded in the box.
Malfunctions may occur if the temperature exceeds this
NOTE: If any damage or leaks are found on level.
the fuel line, the heater must not be used until
the damage has been rectified by an authorized The heater must be switched off at filling stations and
Webasto workshop. fuel tank farms because of the risk of explosion.
Put the heater out of action by removing the Wherever inflammable vapors or dust may form (for
fuse. example near fuel, coal, wood dust or cereal stores or the
like), the heater must be switched off because of the risk
Installation regulations for Webasto fuel tanks for of explosion.
supplying fuel to heaters in vehicles:
The heater must not be operated in enclosed areas, such
• The tank must not be installed in the passenger or as garages or workshops without an exhaust emissions
driver’s cabin of buses. extraction system, not even using the timer, because of
• The fuel filler neck must not be inside the passenger the risk of asphyxiation and poisoning.
or driver’s cabin in any vehicle. In the event of lengthy heavy smoke development,
• Fuel tanks for normal or super grades of petrol must unusual combustion noise or a smell of fuel, the heater
not be immediately behind the front trim of the must be put out of action by removing the fuse and must
vehicle. They must be separated from the engine in not be started again until it has been examined by
such a way that in the event of an accident the fuel Webasto-trained personnel. Liability claims can only be
will not be expected to ignite. This does not apply to lodged if the claimant can prove that he has complied
tractor units with an open driver’s seat. with the servicing and safety instructions.
The air heater’s heat exchanger can be used for a Overheating
maximum of 10 years and must then be replaced by the
Keep hot air inlet and hot air outlet free of dirt and other
manufacturer or one of its authorized workshops using a
items. Dirty, blocked air lines can cause the heater to
genuine spare part. A label must then be affixed to the
shut down due to overheating.
heater showing the date of sale and the wording
“Genuine spare part”. After an overheating lock-out, check that the air system
is clear, remove any materials that may block the air flow
and have any damage to the air lines repaired by an

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 AIR TOP 2000 ST INTRODUCTION

authorized Webasto workshop. After this the heater • The heater must not be cleaned with a high pressure
lock-out can be cancelled by switching it off and then on cleaner.
again. If this action does not produce the required • Do not switch the heater off at the main battery
success (if the heater overheats again) take it to a switch or battery isolation switch since otherwise it is
Webasto-authorized workshop. Never remove the possible that it may suffer long term damage if it is
grating over the air inlet of the heater. switched off frequently using the battery isolation
The air outlet jets or air vents with adjustable flaps must switch and this can cause damage and negative
always be opened to some extent so that the air flow influences on the function of the heater.
through the heater is not completely blocked. At least
one air vent must be prevented from being closed. NOTE: Failure to follow the installation
instructions and the notes contained therein will
If the heater is installed in a storage area, you must
lead to all liability being refused by Webasto
ensure that no inflammable substances are kept in this
The same applies if repairs are carried out
area and that other material does not restrict the air
incorrectly or with the use of parts other than
supply to the heater.
genuine spare parts. This invalidates the type
Air lines must be securely fixed to the heater (using pipe approval for the heater and its homologation /
clips, for example) and all other connection points (for EC type permit.
example vents).
You must read the operating manual before starting the
IMPORTANT! The errors described below are to heater for the first time.
be avoided at all costs:
1.5 SUGGESTIONS FOR IMPROVEMENTS AND
• Do not stand on the heater or place or throw any
heavy objects on the heater.
CHANGES
• Do not place any items of clothing, textiles or similar Complaints, improvement suggestions or corrections
materials over the heater or in front of the hot air relating to this workshop manual should be addressed to
inlet side and hot air outlet.
• The flow of hot air from the heater must not be Webasto Product North America, Inc.
restricted or blocked by highly inflammable Technical Documentation Group
substances or materials such as rags, cleaning wool, 15083 North Road
etc. Fenton MI 48430

• Inflammable or explosive substances and gases must Phone: 810.593.6000

not be placed near or in contact with the heater, the Fax: 810.593.6001
hot air line, the flow of hot air or the exhaust pipe.

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 AIR TOP 2000 ST GENERAL DESCRIPTION

2. GENERAL DESCRIPTION
The Air Top 2000 ST air heater is based on the evaporator
principle and essentially consists of the following:
– the drive unit with a combustion and hot air blower
– the heat exchanger
– the burner insert with combustion pipe
– the control unit

Figure 2: Air Top 2000 ST Air Heater without Casing

2.1 DRIVE UNIT

The drive unit consists of the drive motor, the

combustion air blower, the heat air blower and the
intake casing.
The combustion air blower supplies the air required for
the combustion process from the combustion air inlet to
Figure 1: Air Top 2000 ST Air Heater the burner insert.
The removable hot air blower transports the hot air from
the hot air inlet via the heat exchanger to the hot air
To control and monitor it, the heater has outlet.
– a control unit with temperature sensor
– a flame sensor (gasoline heaters only)
– a ceramic glow pin
– an overheating sensor
inside it.

All Air Top 2000 ST heaters can also be controlled using

an external temperature sensor.
The fuel supply is provided from an external source using
a metering pump.
If a fault occurs, an error code will be output in the
display of the combination or standard timer. If the
heater has a control element, the ON control light will
flash.
In addition, the heater can be checked using a personal
computer (see PC heater diagnostic operating manual).

Figure 3: Drive Unit

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 GENERAL DESCRIPTION AIR TOP 2000 ST

2.2 HEAT EXCHANGER 2.4 CONTROL UNIT

The heat generated by the combustion process is The control unit is the central component for ensuring
transferred to the air transported by the combustion and the function is maintained and for monitoring the
hot air blowers in the heat exchanger. heater’s operation. A temperature sensor in the control
unit is designed to control the room temperature. An
external temperature may also be connected to all the
heaters.
If a fault occurs, an error code will be output in the
display of the combination timer. If the heater has a
control element, the ON control light will flash.
In addition, the heater can be checked using a personal
computer (see PC heater diagnostic operating manual).

Wiring Internal
harness temperature sensor
Component
plug sockets

Figure 4: Heat Exchanger

Figure 6: Control Unit

2.3 BURNER INSERT WITH COMBUSTION PIPE

The fuel is distributed over the burner cross-section in the 2.5 FLAME SENSOR (GASOLINE HEATERS ONLY)
combustion pipe in the burner insert. The mixture of fuel
and air burns in the combustion pipe, thus causing the
The flame sensor is a low-ohm PTC resistor, which
heat exchanger to become hot.
changes its resistance depending on the heat emitted by
the flame.
This change in resistance is analyzed by the control unit
so that the flame status is monitored whenever the
heater is operating.
Combustion
pipe

Burner insert

Figure 5: Burner Insert with Combustion Pipe Figure 7: Flame Sensor

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 AIR TOP 2000 ST GENERAL DESCRIPTION

2.6 CERAMIC GLOW PIN 2.7 OVERHEATING SENSOR

The mixture of fuel and air is ignited by the glow plug The overheating sensor measures the temperatures in the
when the heater is started. The glow pin takes the form rib area of the heat exchanger whenever the heater is
of an electrical resistor and is positioned in the burner operating. The control unit evaluates the signal and
insert on the side away from the flame. protects the heater from hot air outlet temperatures
above 150 °C and surface temperatures above 80 °C by
shutting down the combustion process and blowing cold
air over the heater.
The heater then suffers a fault lock-out and can be
restarted by being switched off and then on again (see
3.2).

Figure 9: Overheating Sensor

Figure 8: Ceramic Glow Pin

2.8 FUEL METERING PUMP

The metering pump is a combined transport, metering

and shut-off system for supplying fuel from the vehicle’s
tank to the heater.

Figure 10: Fuel Metering Pump DP 30.2/3 (with Damper)

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 AIR TOP 2000 ST FUNCTIONAL DESCRIPTION

3. FUNCTIONAL DESCRIPTION Automatic Restart

If no flame is detected, the starting procedure will be
3.1 CONTROL ELEMENT (RHEOSTAT) repeated. The glow plug will be switched on again
(cycled). The motor for the hot and combustion air
The control element is designed to switch the heater on blower will be set to approx. 25% of its maximum speed.
and off, adjust the required room temperature (intake
temperature between 5 °C and 35 °C) and to reset the
heater after a fault. After approx. 30 seconds (petrol) or 50 seconds (diesel)
the fuel metering pump will start, and the flame
formation will begin. After a further 65 seconds (petrol)
The green LED serves as the On indicator (LED or 90 seconds (diesel) the glow plug will be switched off
permanently lit up) and as a fault signal (LED flashes). and the existence of the flame established.

3.2 SWITCH ON
If the heater has again failed to ignite properly, the
heater will be shut down using a fault slow down
Set the control element to the required temperature.
procedure at maximum speed after 180 seconds and will
If the hot air temperature is lower than the nominal suffer a fault lock-out.
temperature, the heater will start.
NOTE: After a restart the heater will suffer a
NOTE: If the temperature of the hot air intake fault lock-out. To reset the fault switch the
is above the set nominal temperature, only the heater off briefly (min. 2 seconds) and switch
motor for the hot and combustion air blower back on.
will start (control pause). Special feature: The
control pause speed is 0 rpm if boat heaters are 3.3 HEATING MODE
used.
While the heater is operating, the combustion gases pass
The function of the flame sensor is checked. If
through the heat exchanger. During this process the
the flame sensor now reports “light”, the
combustion heat is given off to the walls of the heat
system will attempt to cool the flame sensor for
exchanger, absorbed by the hot air transported by the
60 seconds. If the flame sensor still reports
hot air blower and fed into the interior of the vehicle.
“light” the control unit will suffer a fault lock-
out. If another monitored component has
suffered a fault, the fault lock-out will take The temperature of the hot air intake is measured by a
effect without any slow down time. temperature sensor on the intake side of the heater or an
external temperature sensor. If the measured
Start temperature is lower than the value set on the control
When the heater is switched on, the ON signal light will element, the output of the heater is increased to
be lit and the glow plug will be switched on (cycled). The maximum heat output.
motor for the hot and combustion air blower will be set
to approx. 50% of its maximum speed.
To increase the burner service life when it is used
continuously the transport capacity of the metering
After approx. 40 seconds the fuel metering pump will pump is reduced for 10 seconds every 10 minutes.
start, and the flame formation will begin. To improve the In addition, heating mode is interrupted every 8 hours in
starting quality the metering pump and combustion air the same way as for a control pause.
blower are started with different frequencies and speeds.
After a further 95 seconds (gasoline) or 110 seconds 3.4 CONTROL MODE
(diesel) the glow pin will be switched off and the
existence of the flame established. In control mode the blower speed and the metering
pump delivery rate are dependent on the heat output.
The glow pin is switched off.

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 FUNCTIONAL DESCRIPTION AIR TOP 2000 ST

3.5 CONTROL PAUSE 3.7 FAULT LOCK-OUT

After the temperature set on the control element has The control unit has identified errors on individual heater
been reached, the heat output is reduced. The speed of components and faults during the starting procedure and
the heating and combustion air blower and the delivery in operation. The heater is switched off and goes into
rate of the metering pump are reduced. fault lock-out if the following conditions occur:
If, at minimum heat output, the intake temperature set • No repeated or incorrect start
on the control element is exceeded, the metering pump • Temperature sensor defective
is shut down and the combustion process ended. To
burn off the flame properly the blower speed falls after • Overheating sensor interrupt or short circuit
20 seconds to low-fire rate speed and then returns to the • Overheating sensor installed incorrectly
initial speed after 15 seconds, after which it falls to the • Glow pin interrupt or short circuit
control pause speed in 3 minutes, where it remains for
the entire control pause. • Blower motor overload or blocked or short circuit or
break
The control pause speed on boat heaters is 0.
• Flame sensor interrupt or short circuit
If the temperature set on the control element is not
• Error in the metering pump or overheating guard
observed at the temperature sensor, the heater will
circuit (start phase only)
restart.
• Under voltage below 10.5 V / 21 V for longer than
NOTE: Changes to the setting on the control 20 seconds
element are implemented by the control unit • Over voltage above 16 V / 32 V for longer than 6
and heater after a delay. seconds
• Control module defective
3.6 SWITCH OFF

When the heater is switched off, the ON control LED on The fuel supply is stopped if the heater overheats. The
the control element goes out. If no fuel has been heater continues to run in the same way as if it is
transported or if the heater is in the control pause, the switched off manually. After it stops the control unit will
heater is switched off immediately without a slow down be set to fault lock-out. After the slow-down phase the
time. control module is set to fault lock-out if the overheating
counter is greater than the value programmed in the
data record (currently 20).
If the fuel transport has been started, it is ended
immediately when the heater is switched off. The heater
is switched off using the same method as the transition The overheating is indicated by the indicator flashing
from control mode to control pause. The device is then 10 times.
switched off automatically.

NOTE: The heater may be switched on again Rectify the cause of the fault.
during the slow down time. In this case the To reset the fault, switch the heater off briefly (at least
slow down time is completed and the heater is 2 seconds) and then on again.
then restarted.

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 AIR TOP 2000 ST FUNCTIONAL DESCRIPTION

3.7.1 ERROR MONITOR 3.7.2 RESET A FAULT LOCK-OUT

The overheat, incorrect start and flame failure errors are The various fault lock-outs can be reset as follows.
counted and cause the heater to suffer a fault lock-out
Fault lock-out: Switch heater off using the
after an error has occurred the maximum number of
control element and then on
times.
again after more than 2 sec.
The incorrect start counter FSZ is incremented by 1 each
Heater fault lock-out: Remove the fuse and reinsert it
time the heater fails to start and decremented by 1 each
time it starts correctly, but does not fall below 0. If the Permanent heater
incorrect start counter reaches its maximum value of 7, fault lock-out: Delete the error with the
the heater will go into the heater lock-out status HGV. PC diagnostic tool
The error counter SZ is incremented by 1 with each error
for which there is no separate counter. The error counter
is reset to 0 at the start of control mode. If the error
counter reaches its maximum value of 10, the heater will
go into the heater lock-out status HGV.
The overheating counter ÜHZ is incremented by 1 each
time the heater overheats. If the overheating counter
reaches its maximum value of 20, the heater will go into
the heater lock-out status HGV.
The flame failure counter FAZ is increased by 1 each time
the flame fails during heating mode. The counter is
decremented by 1 each time the heater is in control
mode.
If the FAZ reaches a value of 6, the heater will go into
fault lock-out mode and the permanent flame failure
counter FAZP will be incremented by 1. In control mode
the permanent flame failure counter FAZP will be
decremented by 1. When the heater is burning properly
again, the FAZP will return to 0 after a few control cycles.
If the permanent flame failure counter exceeds its
maximum value of 6, however, the heater will go to
permanent heater lock-out status (error code F13).

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 AIR TOP 2000 ST TECHNICAL DATA

4. TECHNICAL DATA Fuel for Air Top 2000 ST D (diesel/PME):

The diesel fuel specified by the vehicle manufacturer
Except where limit values are specified, the technical data must be used.
listed in the table refer to the usual heater tolerances of
We know of no negative influences due to additives.
±10% at an ambient temperature of +20 °C (+68 °F) and
at the rated voltage and in rated conditions. If fuel is extracted from the vehicle’s tank, follow the
additive instructions issued by the vehicle manufacturer.
Electrical components:
If you change to low-temperature fuel, the heater must
The control unit, combustion air blower (drive), metering be operated for approx. 15 minutes so that the fuel
pump, timer, glow plug and control element are system is filled with the new fuel.
designed for 12 V or 24 V.
The Air Top 2000 ST D heater is also licensed for use with
The components temperature sensor and flame monitor PME (bio-diesel), which complies with ASTM D6751 and
(only petrol heater) are not designed for a specific DIN EN 14214.
voltage.

Fuel for Air Top 2000 ST B (gasoline):

The fuel specified by the manufacturer must be used.

HEATER Operation AT 2000 ST B AT 2000 ST D

Type Test Permit EMC e1*72/245*95/54*1085*--
Heater e1*2001/56*0022*--
Model Air heater with evaporator burner
Heat Output kW Control Range 1.0 - 2.0 kW 0.9 - 2.0 kW
Btu/h 3415 - 6830 3074 - 6830
Fuel Gasoline Diesel #1, #2, Arctic, PME
and Kerosene
Fuel Consumption l/h Control Range 0.14...0.27 0.12...0.24
gal/h – US 0.037...0.071 0.032...0.063
Rated Voltage 12 V 12 V 24 V
Operating Voltage Range V 10.5 - 16 V 10.5 - 16 V 21 - 32 V
Rated Power Consumption Control Range 14 - 29 Watts
Maximum Ambient Temperature:
Heater -operation –40 °C... +40 °C (–40 °F... +104 °F)
-warehouse –40 °C... +85 °C (–40 °F... +185 °F)
Dosing Pump -operation –40 °C... +20 °C (–40 °F... +68 °F)
-warehouse –40 °C... +85 °C (–40 °F... +185 °F)
Control Element -operation –40 °C... +75 °C (–40 °F... +167 °F)
-warehouse –40 °C... +85 °C (–40 °F... +185 °F)
Max. Combustion Air Inlet Temperature –40 °C... +20 °C (–40 °F... +68 °F)
Adjustment Range For Interior Control Range +5 °C... +35 °C (+41 °F... +95 °F)
Temperature
Delivery Rate For Hot Air At Fan Speed against 0.5 mbar Max. 93 m3/h at 4750 rpm
against .00725 PSI Max. 55 cfm at 4750 rpm
Co2 In Exhaust Gas 1 kW 5.0... 8.0 5.0... 8.0
(permanent function range) 2 kW 9.0... 12.5 9.0... 12.5
Heater Dimensions 311 mm L X 120 mm W X 121 mm H
Length X Width X Height 12.25 in L X 4.72 in W X 4.76 in H
Weight Of Heater 2.6 kg (5.73 lb)
Table 1. Technical data

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 AIR TOP 2000 ST TROUBLESHOOTING

5. TROUBLESHOOTING CAUTION: The troubleshooting guide is

restricted to the localization of defective
components. The following potential
5.1 GENERAL
sources of malfunctions have not been
included and should always be checked so
This section describes how to identify and remedy faults
that they can then be excluded as the cause
on the Air Top 2000 ST air heater.
of the particular fault:
If a fault occurs, an error code will be output in the
display of the combination timer. If the heater has a • Corrosion on plugs
control element, the ON control light will flash. In
• Loose plug contacts
addition, the heater can be checked using a personal
computer (see PC heater diagnostic operating manual). • Poor crimp contacts on plugs
• Corroded cables and fuses
CAUTION: Troubleshooting work demands
• Corroded battery terminals
precise knowledge of the structure and
theory of operation of the various
components and must be carried out by If you wish to check individual components, the electrical
trained personnel only. plug connectors on the control unit must be
disconnected.

If in doubt, refer to sections 2 and 3 for a description of

how the functions interact. Conduct a function test in the vehicle after rectifying
each fault.

5.2 GENERAL ERROR SYMPTOMS

The following table lists the possible error symptoms.

Error Symptom Possible Cause Remedy

Heater cuts out automatically No combustion after start Switch heater off and then on again
and restart
ON indicator flashes

Flame extinguishes during operation Switch heater off and then on again
ON indicator flashes

Heater overheats Check that the hot air system is clear,

ON indicator flashes allow the heater to cool, switch heat off
briefly and then on again

Battery voltage too low Charge battery

ON indicator flashes Switch heater off and then on again

Heater produces black smoke Combustion air and/or exhaust system Check that the combustion air and
blocked exhaust systems are clear

Table 2. General Error Symptoms

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 TROUBLESHOOTING AIR TOP 2000 ST

5.3 ERROR SYMPTOMS DURING FUNCTION NOTE: Every fault is indicated by the flashing
LED on the control element after the slow down
The following table lists the possible error symptoms in time has finished. If the other components are
the order in which they may occur during operation. OK, a defective control unit may be the cause of
all the faults.
In the event of a fault, the error is to be located using this
table and rectified. It is important that the error There are statuses that are the same as errors.
symptom is correctly identified.
If the error symptom is not included in this table or the
fault is not found under the specific error symptom
heading, in an emergency you can contact our
technicians on our service hotline (see last page).

Error Symptom Occurrence Remedy

No start and no illumination of the Immediate Incorrect cabling, defective fuse

LED on the control element

No start but LED is lit Immediate The heater goes straight to control pause when
it is switched on, whereby the control pause
speed is 0 rpm for a boat heater.

Table 3. Error Symptoms during Function

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 AIR TOP 2000 ST TROUBLESHOOTING

5.4 ERROR CODE OUTPUT NOTE: The error code is output if the heater is
fitted with a control element after an error has
If the heater is fitted with a combination timer, an error occurred by the switch-on indicator/error code
code output will appear on the display of the timer after indicator flashing. After 5 seconds of fast
a fault occurs. flashing, the error code will be output by a
sequence of long flash pulses, the number of
flashes is shown in the table below (for example
F04 – 4 long flash pulses).

Error Additional Information during PC

Error (group) Remedy
Code Diagnostics

F 00 Control unit error 01 Control unit error Replace control unit

81 EOL checksum error

11 Incorrectly coded control unit or

incorrect heater (fuel type) installed (the
heater will not work if this error occurs)

91 Neutrally coded or disabled control unit

(the heater will not work if this error
occurs)

92 Maintain command failed (the heater

will not work if this error occurs)

18 Customer bus defective

F 01 No start 02 Even after the restart, no flame has Check fuel supply
formed (tank empty, lines blocked)
Clean burner insert,
82 No start in test Gasoline:
Replace flame sensor
Diesel:
Replace overheating sensor / control unit

F 02 Flame failure 03 The flame has gone out during Check fuel supply
operation and has not reformed after a (tank empty, lines blocked)
restart attempt Clean burner insert,
Gasoline:
83 The flame has gone out during a Replace flame sensor
heating cycle more than FAZ times Diesel:
(EEPROM) Replace overheating sensor / control unit

F 03 Under-voltage or 84 The voltage was less than 10.5 V or Charge battery

over-voltage 21 V for longer than 20 seconds

04 The voltage was more than 16 V or

32 V for longer than 6 seconds

Table 4. Troubleshooting (page 1 of 3)

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 TROUBLESHOOTING AIR TOP 2000 ST

Error Additional Information during PC

Error (group) Remedy
Code Diagnostics

F 04 Premature flame 05 A flame was detected before Diesel: Replace overheating sensor /
recognition combustion had started control unit
Gasoline: Replace flame sensor

F 05 Flame sensor 1A Flame sensor circuit Replace flame sensor

interrupt or short The switched cable of the element has a
circuit short circuit to earth
(gasoline heaters
only) 9A Flame sensor circuit Replace flame sensor
Break or short circuit to +Ub

F 06 External 14 Temperature sensor circuit Check cables / replace temperature sensor

temperature sensor Short circuit to earth
break or short circuit
94 Temperature sensor circuit break or Check cables and terminating resistor /
short circuit to +Ub replace temperature sensor

F 07 Metering pump 88 Break or short circuit to +Ub Check cables / replace metering pump
interrupt or short
circuit 08 Short circuit to earth Check cables / replace metering pump

F 08 Drive unit 89 Break or short circuit to +Ub Replace drive unit (combustion and hot air
(combustion and blower)
hot air blower)
break or short circuit 09 The switched drive unit cable Eliminate the cause of the blockage /
(combustion and hot air blower) has a difficulty in movement
short circuit to earth or the drive unit is Replace drive unit (combustion and hot air
overloaded blower)

15 Burner motor block guard has tripped

95 Burner motor blocking detection has

tripped

F 09 Glow pin interrupt 8A Glow pin: Replace glow pin

Break or short circuit to +Ub

or short-circuit 19 Glow circuit Replace glow pin

The switched cable of the element has a
short circuit to earth

Table 5. Troubleshooting (page 2 of 3)

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 AIR TOP 2000 ST TROUBLESHOOTING

Error Additional Information during PC

Error (group) Remedy
Code Diagnostics

F 10 Overheating 06 The overheating fault lock-out has Find and remove the cause of the
tripped (heater overheated) overheating
NOTE
17 Incorrect application or illegal If no other cause can be found for the
insulation (ÜHS gradient too high) overheating, the pressure losses caused by
the hot air distribution (too many
resistance points) are too high or a hot air
filter is soiled

F 11 Overheating sensor AB Overheating sensor circuit break or Replace overheating sensor

interrupt or short short circuit to +Ub
circuit
1B Overheating sensor circuit. Replace overheating sensor
The switched cable of the element has a
short circuit to earth

F 12 Heater fault 07 The heater fault lock-out has been Remove the fuse and then refit it
lock-out activated
NOTE
The following error has occurred several
times:
Fault counter more than
3 times
Incorrect start counter more than
9 times
Overheating counter more than
3 times

F 14 Overheating sensor 97 Incorrect position of overheating Position the overheating sensor correctly
incorrect position sensor (ÜHS gradient too low)

F 15 Nominal sensor 9B Nominal value potentiometer circuit Check cables / replace control element
break break or short circuit to +Ub

Table 6. Troubleshooting (page 3 of 3)

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 AIR TOP 2000 ST FUNCTIONAL TESTS

6. FUNCTIONAL TESTS 5. If the CO2 value is within this range, disconnect the
CO2 line from minus. This saves the setting.
6.1 GENERAL
NOTE: The heater will now run in normal
This section describes the tests conducted on the heater mode again and can be switched off as normal
when it is installed and not installed to verify that it is in using the control element. The heater is set at
working order. the factory to match the fitted combustion air
blower.
WARNING: The heater must not be
operated in enclosed areas such as garages 6.3 TESTING INDIVIDUAL COMPONENTS
and workshops without an emissions
extraction system. CAUTION: For function tests always break
the connection between the control unit
6.2 SETTINGS and the component you wish to test.

6.2.1 SETTING THE CO2 CONTENT 6.3.1 CERAMIC GLOW PIN RESISTANCE TEST

The CO2 content in the emissions is set using the NOTE: The resistance test must be carried out
adjustment knob on the control element. At a constant with an ohmmeter suitable for small resistance
blower speed the volume of fuel is controlled by values. A resistance test with a simple digital
changing the metering pump cycle. multimeter is too inaccurate to find the precise
values. A new glow plug can be measured to
CAUTION: The CO2 measuring instruments act as a reference.
must be calibrated.
The glow pin should have the following values in the
The heater must be switched off. test:
1. Connect the CO2 line to minus. Glow plug: 12 V (red) 24 V (green)
Resistance at 25 °C (77 °F):
2. Turn the adjustment knob on the control element to 0.263 ... 0.323 Ohm 1.125 ...1.375 Ohm
the centre setting. The heater will start and go Test current: < 5 mA < 5 mA
automatically to low-fire rate mode.
6.3.2 RESISTANCE TEST ON FLAME SENSOR
NOTE: If the heater can be adjusted, the
operating indicator will flash as if the control
(GASOLINE HEATERS ONLY)
unit has suffered an error. If you conduct this test with a digital multimeter, the
flame sensor must have the following values:
Diesel Unit:
Cold Testing:
3. Set the CO2 value by turning the adjustment knob.
Turning it anti-clockwise will reduce the CO2 value, Resistance at 25 °C (77 °F): 2.6 ... 3.4 Ohm
Test current: < 5mA
whilst turning it clockwise will increase it. The
measured CO2 content at low-fire rate (1.5 kW) Hot Testing:
must be between 5.0% and 8.0%. In high-fire
Resistance at 800 – 1000 °C: 12 ... 15 Ohm
mode, the CO2 content should be 10.3 +/- 0.5% v/v
Resistance at 1472 – 1832 °F: 12 ... 15 Ohm
after the setting has been made. Test current: < 5 mA
Gasoline Unit (ceramic rod at red heat over length of approx. 20 mm)
4. The CO2 content may only be measured when the
unit is at operating temperature. The unit must be
run for at least 8 minutes for this purpose. After
this the CO2 content is to be set to 6.1 - 6.2% v/v in
low-fire mode (1 kW). In high-fire mode, the CO2
content should be 9.9 +/- 0.4% v/v after the setting
has been made.

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 FUNCTIONAL TESTS AIR TOP 2000 ST

6.3.3 OVERHEATING SENSOR RESISTANCE TEST

If you conduct this test with a digital multimeter, the
overheating sensor must have the values shown in the
following diagram:
Conversion chart (°C to °F):
10 °C = 50 °F

2260
12 °C = 53.6 °F
Resistance in Ohm

2240
2220
14 °C = 57.2 °F
2200
2180
16 °C = 60.8 °F
2160
2140
18 °C = 64.4 °F
2120
2100
20 °C = 68 °F
2080
2060
22 °C = 71.6 °F
10 12 14 16 18 20 22 24 26 28 30
50 53.6 57.2 60.8 64.4 68 71.6 75.2 78.8 82.4 86
24 °C = 75.2 °F
Temperature in °C 26 °C = 78.8 °F
Temperature in °F
28 °C = 82.4 °F
30 °C = 86 °F
Characteristic resistance values of a
PT 2000 overheating system
in a temperature range of 10 °C to 30 °C (50 °F to 86 °F)

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 AIR TOP 2000 ST CIRCUIT DIAGRAMS

7. CIRCUIT DIAGRAMS
7.1 GENERAL

The Air Top 2000 ST heater can be controlled with the The circuit diagrams (Fig. 12 and Fig. 13) show the
control element (nominal value adjuster/switch) or a possible circuits for 12 and 24 V with:
combination timer. • Control element
• Combination timer
Fig. 11 shows the plug assignment on the control unit.
Fig. 14 shows the schematic connection of the
combination timer.

X6

X2

X4

X5

X3 X1

X1 = Combustion and hot air blower connection

X2 = Ceramic glow pin connection
X3 = Overheating sensor connection
X4 = Metering pump connection
X5 = Flame sensor connection (gasoline heaters only)
X6 = Wiring harness connection

Figure 11: Plug Assignment

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 CIRCUIT DIAGRAMS AIR TOP 2000 ST

BATTERY 30
X1

If ventilation mode is not desired, leave pink wire disconnected and protect from grounding.
3 2
F1 S6
1 2 X11

*To use vent mode, connect to ground through a switch (S3) for proper operation.
0,5mm2
X2/X3/X4/X5

0,5mm2

0,5mm2
gn/ws
br
rt
X6 1
1 14 15 7 5 6 2
S1 X9 1
3 13 A2
0,5mm2 rt 4
X6
4 12 3
0,5mm2 sw
H1 16 4
1 10
0,5mm2 bl

No heating operation with pink wire grounded!

17
X8

20 Ga Pink - *for ventilation mode only!

2 11
0,5mm2 ws
2 X6
B2
2
1 2 3 1 2 2 1 9 8 2 1 1 2 1 X9
12V rt br br ge X2 ge br X5 br X6 X4 bl X3 bl
X1 4 1

0,5mm2
0,5mm2
24V gn

sw/bl
M

ge
M1 E B1 B3
A1 3 2

0,5mm2

0,5mm2
sw

sw
X10
2 1 1 2
X8
X10
br

br

bl

R1
1 2
X8 2 1
S3 X11
5
Y1
B4
2 1
GROUND

1 Diagnostic K cable
Cable Cross-sections Cable Colors
2 W bus
3 CO2 setting < 7.5 m 7.5 – 15 m bl Blue
4 Input pin (pin 16/plug X6), cable color on wiring harness: pink): 0.75 mm 2 1.0 mm 2 br Brown
“Ventilation” (fan speed depends on the position of the control element) 2
0.75 mm 2 1.0 mm ge Yellow
5 If you use an external temperature sensor (B4), the resistor (R1) is replaced by the temperature sensor (B4).
1.0 mm 2 1.5 mm 2 gn Green
6 NOTE - Typical Connection for Trucks
1.5 mm 2 2.5 mm 2 gr Grey
If this connection is made to battery positive (terminal 30), permanent heating is possible with the
ignition switched off. In this case no connection must be made to terminal 15/75. 2.5 mm 2 4.0 mm 2 or Orange
7 NOTE - Typical Connection for Buses 4.0 mm 2 6.0 mm 2 rt Red
With positive from terminal (15/75) to connection 10: Standard cable sw Black
Permanent operation for immediate heat as long as the ignition is switched on.
Without positive at connection 10: vi Violet
Heating time is variably programmable (10 min to 120 min), default setting 120 min. ws White

Item Designation Comment Item Designation Comment

A1 Heater Air Top 2000 ST R1 Resistor 620 Ω With internal temperature sensor
A2 Control unit only
B1 Flame sensor Gasoline heaters only S1 Control element Switch and temperature control
B2 Temperature sensor Internal S4 Switch (optional) Ventilation
B3 Overheating sensor Overheating guard S6 Switch CO2 setting
B4 Temperature sensor External X1 Plug connector, 4-pin to item A2
E Ceramic glow pin X2 Plug connector, 2-pin to item A2
F1 Fuse 15A (max. 20A) Flat fuse SAE J 1284 X3 Plug connector, 2-pin to item A2
F2 Fuse max. 15 A Flat fuse SAE J 1284 X4 Plug connector, 2-pin to item A2
H1 LED, green (in item S1) Indicator X5 Plug connector, 2-pin to item A2
H3 LED, red Immediate heat button light X6 Plug connector, 18-pin to item A2
Ready indicator, switch-on indicator X8 Plug connector, 2-pin
H4 Heating symbol in the Indicator X9 Plug connector, 4-pin to item S1
display (in item P) X10 Plug connector, 2-pin to item Y1
H5 Light (in item P) Display and button lights X11 Plug connector, 2-pin
M1 Motor Combustion and hot air fan X12 Plug connector, 12-pin to item P
P Combination timer Timer and temperature control Y1 Fuel metering pump
(1531)

Figure 12: System Circuit Diagram 12V/24V with Control Element (Rheostat Switch)

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 AIR TOP 2000 ST CIRCUIT DIAGRAMS

BATTERY 30 X1
IGNITION 15
LIGHTS 58

If ventilation mode is not desired, leave pink wire disconnected and protect from grounding.
OPTIONAL 6 7

3 2 X2/X3/X4/X5
F1 S6
F2 1 2 X11

*To use vent mode, connect to ground through a switch (S3) for proper operation.
0,5mm²

0,5mm²

0,5mm²
gn/ws
2

br
1

rt
X6 1
1 10 11
1 14 15 7 5 6
X6
A2
2 0,5mm² 13 4
rt
H4 0,5mm² 12 3
H5 H3 8 sw
16 4 X8
0,5mm² 10
6

No heating operation with pink wire grounded!

bl
17
0,5mm² ws 11

20 Ga Pink - *for ventilation mode only!

P 2
2
9
B2 X6 1
12 7 4
X10
X12 3
1 2 1 2 2 1 9 8 2 1 1 2 1 2
12V rt br br ge X2 ge br X5 br X6 X4 bl X3 bl
X1

0,5mm²
0,5mm²
24V gn

sw/bl
M

ge
M1 E B1 B3
A1 1 2

X11

0,5mm²

0,5mm²
sw

sw
X8 2 1
X10 2 1
br

br

bl
R1 X12

X8 2 1
S3
5
Y1 3
B4 6
9
GROUND 12

1 Diagnostic K cable
Cable Cross-sections Cable Colors
2 W bus
3 CO2 setting < 7.5 m 7.5 – 15 m bl Blue
4 Input pin (pin 16/plug X6), cable color on wiring harness: pink): 0.75 mm 2 1.0 mm 2 br Brown
“Ventilation” (fan speed depends on the position of the control element) 2
0.75 mm 2 1.0 mm ge Yellow
5 If you use an external temperature sensor (B4), the resistor (R1) is replaced by the temperature sensor (B4).
1.0 mm 2 1.5 mm 2 gn Green
6 NOTE - Typical Connection for Trucks
1.5 mm 2 2.5 mm 2 gr Grey
If this connection is made to battery positive (terminal 30), permanent heating is possible with the
ignition switched off. In this case no connection must be made to terminal 15/75. 2.5 mm 2 4.0 mm 2 or Orange
7 NOTE - Typical Connection for Buses 4.0 mm 2 6.0 mm 2 rt Red
With positive from terminal (15/75) to connection 10: Standard cable sw Black
Permanent operation for immediate heat as long as the ignition is switched on.
Without positive at connection 10: vi Violet
Heating time is variably programmable (10 min to 120 min), default setting 120 min. ws White

Item Designation Comment Item Designation Comment

A1 Heater Air Top 2000 ST R1 Resistor 620 Ω With internal temperature sensor
A2 Control unit only
B1 Flame sensor Gasoline heaters only S1 Control element Switch and temperature control
B2 Temperature sensor Internal S4 Switch (optional) Ventilation
B3 Overheating sensor Overheating guard S6 Switch CO2 setting
B4 Temperature sensor External X1 Plug connector, 4-pin to item A2
E Ceramic glow pin X2 Plug connector, 2-pin to item A2
F1 Fuse 15A (max. 20A) Flat fuse SAE J 1284 X3 Plug connector, 2-pin to item A2
F2 Fuse max. 15 A Flat fuse SAE J 1284 X4 Plug connector, 2-pin to item A2
H1 LED, green (in item S1) Indicator X5 Plug connector, 2-pin to item A2
H3 LED, red Immediate heat button light X6 Plug connector, 18-pin to item A2
Ready indicator, switch-on indicator X8 Plug connector, 2-pin
H4 Heating symbol in the Indicator X9 Plug connector, 4-pin to item S1
display (in item P) X10 Plug connector, 2-pin to item Y1
H5 Light (in item P) Display and button lights X11 Plug connector, 2-pin
M1 Motor Combustion and hot air fan X12 Plug connector, 12-pin to item P
P Combination timer Timer and temperature control Y1 Fuel metering pump
(1531)

Figure 13: System Circuit Diagram 12V/24V with Combination Timer Model 1531

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 CIRCUIT DIAGRAMS AIR TOP 2000 ST

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

Figure 14: Schematic Connection of the Combination Timer Model 1531

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 AIR TOP 2000 ST SERVICING WORK

8. SERVICING WORK The following servicing work is to be carried out to

maintain the functional reliability of the heater:
8.1 GENERAL • Check the hot air inlet and outlet for dirt and foreign
bodies. (Dirty or blocked hot air lines may cause
This section describes the servicing work that can be overheating.)
carried out on the heater when it is installed. • Clean the exterior of the heater (avoid the ingress of
water).
8.2 WORK ON THE HEATER • Check the electrical connections for contact
corrosion and to ensure that they are secure.
Disconnect the main power cable from the vehicle’s
• Check the exhaust and combustion air lines for signs
battery before carrying out any work on the heater. The
of damage and to ensure that they are clear.
main battery power must not be disconnected whilst the
heater is operating or slowing down as a result of the risk • Replace the fuel filter if there is one.
of the heater overheating and the overheating guard • Check the fuel line and filter for leaks.
thus being tripped. If you wish to carry out extensive
repair work on the heater, it may be a good idea to
remove it completely.
8.6 VISUAL INSPECTIONS AND INSTALLATION
INSTRUCTIONS
Refer to the relevant installation instructions and the
installation proposal for the heater for the specific vehicle
8.6.1 HOT AIR SYSTEM
for repairs that necessitate the installation position being
changed.
CAUTION: The integration of the heater
into the vehicle’s own air system is not
8.3 WORK ON THE VEHICLE permitted as a result of the high pressure in
the vehicle’s system.
CAUTION: A temperature of 85 °C (185 °F)
must not be exceeded in the vicinity of the Inside the control unit there is a temperature sensor,
heater in any circumstances (for example which operates the heater in the appropriate heat output
when completing painting work on the range in conjunction with the control element depending
vehicle). on the intake temperature and the position of the control
element’s dial. The heat output is set so that after the
8.4 HEATER TRIAL selected interior temperature has been reached quickly, it
is then kept at this selected value. Alternatively, the
WARNING: The heater must not be heaters can be operated with an external temperature
operated in enclosed areas such as garages sensor (see 9.1.2).
and workshops without an emissions
extraction system, even if the heater is NOTE: Only materials that can permanently
equipped with a timer. withstand temperatures of at least 130 °C may
be used for the hot air line.
CAUTION: The heater must not be
operated without the cover for the control Maximum pressure drop between the inlet and outlet
unit as this will cause it to overheat. side of the hot air line 1.5 hPa (corresponds to 1.5 mbar /
15 mm WC).
8.5 SERVICING WORK If this value is exceeded, the heat output may be reduced
as a result of the hot air outlet temperature control.
NOTE: The heater should be operated for The internal diameter of the main section of the hot air
approximately 20 minutes every 4 weeks to line should be 60 mm.
prevent mechanical parts seizing. When using narrower lines, the permissible pressure drop
is exceeded more quickly.
The heater requires no servicing. However, it should be
checked at regular intervals, at the latest at start of the The hot air hose must be secured at its connection
heating period (the time after which the heater will be points.
used due to adverse weather conditions) by Webasto- The heater can be used on the air inlet and outlet side if
trained personnel. it is used in an air circulation system with grates. Do not
short circuit the flow of hot air.

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 SERVICING WORK AIR TOP 2000 ST

CAUTION: In vehicles used to transport 8.6.2.1 FUEL EXTRACTOR (STANDPIPE)

people, the air outlet opening is to be
installed in such a way that it is at least 20 Vehicles with Diesel Engines
cm away from all body parts. The fuel must be taken from the vehicle fuel tank or from
a separate tank (Fig. 16, 17 or 18). This separate fuel
The heater checks the internal temperature rise pickup precludes any effect of pressure.
automatically each time it is switched on. If this is above
the specified limits, the start is cancelled and error Vehicles with injection Engines
messages F10 is displayed. To ensure that the heater
When installing the heater in a vehicle with fuel injection
functions stably, the flow resistance of the connected hot
systems, it is important to establish whether the fuel
air system must be reduced.
pump is located inside or outside the tank.
If a filter is used for the hot air, it must have the following
If the fuel pump is located inside the tank, fuel can only
properties:
be extracted from the return line using a Webasto fuel
• The air flow must not carry any inflammable and/or tee fitting in which case it must be ensured that the
harmful fibers or particles into the heater or the return line continues almost to the bottom of the tank. If
interior of the vehicle. this is not the case, a Webasto fuel standpipe
• The filter material must be able to withstand (see Fig. 16, 17 or 18) may be used.
temperatures of at least 60 °C. If the fuel pump is installed outside the tank, the fuel
• The filter must be resistant to all the substances that connection may also be made between the tank and the
may be drawn in with the hot air (for example fuel pump, again using only the Webasto fuel tee fitting.
moisture, salt, fuel vapors, etc.).
Vehicles with Carburetor Engines
• The resistance of the filter must be taken into
The fuel may only be extracted on cars using a special
consideration when designing the hot air system.
Webasto fuel tee fitting as close to the tank as possible.
The connection may be made in either the supply or
8.6.2 FUEL SUPPLY return line, in which case the return line must lead almost
The fuel is taken from the vehicle fuel tank or from a to the base of the tank. If this is not the case, the return
separate fuel tank. The values for the maximum pressure line may be extended.
at the fuel extraction point are shown in Fig. 15. The fuel tee must be fitted in such a way that any air or
gas bubbles are automatically discharged towards the
tank.
Permissible fuel inflow At max. pressure (bar) in
height H (m) fuel line The fuel tee should not be located near the engine, as
gas bubbles may form in the lines on account of heat
0.00 m (0.00 in.) 0.20 bar (2.9 PSI)
radiated from the engine. This may cause problems
1.00 m (39.4 in.) 0.11 bar (1.6 PSI) during combustion.
2.00 m (78.7 in.) 0.03 bar (0.44 PSI)
Maximum fuel intake At max. negative pressure
height S (m) (bar) in fuel tank
0.00 m (0.00 in.) -0.10 bar (-1.45 PSI)
0.50 m (19.7 in.) -0.06 bar (-0.87 PSI)
1.00 m (39.4 in.) -0.02 bar (-0.29 PSI)

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 AIR TOP 2000 ST SERVICING WORK

Plastic tank

max. 3m (9.8 ft.)

I2

iØ2mm

iØ2mm H

iØ2mm I1 Sealing ring

I2
iØ2mm

S
I 1 + I 2 ≤ 10 m (32.8 ft.) I1
I 1 ≤ 1.2 m (3.9 ft.) Figure 17: Fuel extractor from a plastic or metal tank
I 2 ≤ 8.8 m (28.8 ft.) (extraction through tank drain screw)

Figure 15: Fuel supply

Sealing ring

Hole pattern

Metal tank fitting

or sender plate
25 mm (1 in.)
> 25 mm (> 1 in.)

Max. depth

Figure 18: Fuel standpipe for a plastic or metal tank

Figure 16: Webasto fuel standpipe (extraction through metal tank fitting)

NOTE: Only use this style of standpipe with NOTE: The tank or fitting must be made of
metal fuel tanks. metal.

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 SERVICING WORK AIR TOP 2000 ST

8.6.2.2 FUEL LINES

12 V and 24 V – Diesel DP 30 (with damper)
Only steel, copper and plastic lines of plasticized, light
and temperature-stabilized PA11 or PA12 (for example
Mecanyl RWTL) according to DIN 73378 may be used for
the fuel lines. Since the lines cannot normally be routed
with a constant rising gradient, the internal diameter
must not be allowed to exceed a certain size. Air or gas
bubbles will accumulate in lines with an internal diameter 0-90° 0-90°
of more than 4 mm and these will cause malfunctions if 0°
the lines sag or are routed downwards. The diameters
specified in Fig. 15 will ensure that bubbles do not form. Install in horizontal position only!
The lines should not be routed downwards from the
Figure 20: Metering pump, installation position and
metering pump to the heater. attachment
Unsupported fuel lines must be secured to prevent them
sagging. They must be installed in such a way that they 8.6.3.1 INSTALLATION LOCATION
cannot be damaged by flying road debris and high
It is advisable to install the metering pump in a cool
temperatures (exhaust line).
place. The maximum ambient temperature must not
The fuel lines must be secure at the connections using exceed +20 °C (+68 °F) at any time during operation.
hose clips to prevent their slipping.
The metering pump and fuel lines must not be installed
Connecting two pipes with a hose within range of the radiated heat from hot vehicle parts.
A heat shield must be used if necessary.
The correct procedure for connecting fuel lines with
hosing is shown in Fig. 19.
8.6.3.2 INSTALLATION AND ATTACHMENT
The metering pump must be secured with a vibration-
Correct damping mounting. Its installation position is limited as
shown in Fig. 20 in order to ensure effective automatic
Clamp bleeding. As a result of the risk of corrosion, only
genuine Webasto parts may be used for the plug
connections between the metering pump and the
metering pump wiring harness.
Wrong
8.6.4 FUEL FILTER
Bubble Bubble Only a Webasto filter, P/N 50487171A, is allowed to be
used if the fuel is expected to be contaminated. Install
vertically if possible, however at most horizontally (check
flow direction).

Figure 19: Pipe/Hose connections

0° - 90°
8.6.3 FUEL METERING PUMP
The metering pump is a combined delivery, metering and
shut-off system and is subject to certain installation
criteria (Fig. 15 and 20).
A

Ø5
Figure 21: Fuel filter

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 AIR TOP 2000 ST SERVICING WORK

8.6.5 COMBUSTION AIR SUPPLY Length of the combustion air inlet and exhaust lines:
Under no circumstances may the combustion air be With muffler: max. 2.0 m (6.5 ft)
taken from areas occupied by people. The combustion Without muffler: max. 5.0 m (16.4 ft)
air intake opening must not point in the direction of Both lines are to be installed falling away from the
travel. It must be located so that it cannot become heater. If this is not possible, a condensate drain hole
clogged with dirt. with a diameter of 4 mm must be made at its lowest
point or a connection element with a condensate drain
NOTE: The combustion air must be extracted used.
using a combustion air line from a position that
is as cool as possible and protected from Internal diameter of the lines:
splashing water for petrol heaters. Combustion air line: 22 mm (7/8 in)
Exhaust line: 22 mm (7/8 in)
If the heater is in a sealed installation box, the
combustion air must be drawn in from the outside and NOTE: If the exhaust line is over 2 m in length,
the emissions fed to the outside. Pipe passage holes must insulated lines must be used (to prevent falling
be made in such a way as to ensure that the ingress of below the dew-point).
exhaust fumes into the interior of the vehicle should not
occur. Minimum bending radius: 50 mm (2 in)
If dirty combustion air is expected, a combustion air filter An attachment is required no further than 150 mm (6 in)
may be fitted (only Air Top 2000 ST D). If the intake hose from the end of the exhaust pipe to ensure that the
length is < 0.6 m (2 ft), an intake silencer must be used. angle of 90° ± 10° is achieved.

8.6.6 EXHAUST LINE

Rigid pipes of unalloyed or alloyed steel with a minimum
wall thickness of 1.0 mm (3/64 in) or flexible piping of
alloyed steel only must be used as the exhaust line. The
exhaust pipe must be secured to the heater and exhaust
muffler with a pipe clip, P/N 20965A.
The exhaust muffler (Fig. 22) should ideally be installed
near the heater. The flow direction is arbitrary.
Discharge direction
more or less vertical
ø 6.5
90° ± 10°

10°
10°

Figure 22: Exhaust muffler

The heater may also be operated without a muffler.

Figure 23: Exhaust pipe mouth, installation position
8.6.7 COMBUSTION AIR INLET AND EXHAUST LINES
WARNING: If the exhaust pipe mouth is
To prevent damaging the metering pump cable, exhaust
positioned other than as shown in Fig. 23,
line must not be used to extend the combustion air
it will pose a fire risk.
supply line.
Total bends:
Combustion air line: max. 270°
Exhaust line: max. 270°

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 SERVICING WORK AIR TOP 2000 ST

8.6.8 ELECTRICAL CONNECTIONS 8.6.8.3 CONTROL ELEMENT (RHEOSTAT) CONNECTION

The wiring harness is prepared for connection to the
8.6.8.1 HEATER CONNECTION, CONTROL ELEMENT control element (rheostat switch).
The electrical connection is to be made as shown in the Simply pull on connector housing to disconnect the
appropriate circuit diagram (see section 7). connector (Fig. 26).
To connect the wiring harness, remove the cover
(see 9.2.1.1) on the heater and connect the wiring
harness plug to the control unit.
Before using the heater for the first time fit the cover to
prevent the illegal escape of hot air (heater overheating).
The wiring harness can be fed out of the left or right side
of the heater.

8.6.8.2 SUPPLY VOLTAGE CONNECTION

Ideally from the vehicle’s central electrical system. Fiber optic lens
(operation indicator)
An additional blade terminal fuse holder is to be fitted to
protect the heater and harness (supplied with the
heater). The fuse holder should be installed as close as is
practical to the power source e.g. in the vehicle battery Figure 25: Control element (rheostat switch)
enclosure.
NOTE: The fiber optic lens must be in contact
The fuse holder is constructed of weather resistant with the rotary knob.
components.
NOTE: The connector housing can be locked
(self-locking action) by simply pulling on the
wiring harness.

AT 2000 ST
F = 15A (12V)
F = 10A (24V)

Figure 24: Weather Resistant Fuse holder

Figure 26: Disconnecting the plug

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 AIR TOP 2000 ST SERVICING WORK

Exhaust muffler
Tank connector
5

Fuse
3 4

5
6
7
Metering pump and damper
2

Fuel filter (accessory)

Control element
6

Heater
1

1
2
3
4
7

Figure 27: Example installation for heater in an air circulation system

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 SERVICING WORK AIR TOP 2000 ST

8.7 REMOVAL AND INSTALLATION 8.8 START-UP

CAUTION: When the heater is installed it After you have installed the heater, bleed the fuel supply
must not be dismantled. system carefully.

8.7.1 HEATER, REMOVAL AND INSTALLATION NOTE: As a result of the low fuel consumption
the heater must be switched on several times to
8.7.1.1 REMOVAL fill the fuel line.

1. Disconnect the battery. Conduct a trial of the heater to check all the connections
2. Pull the cover off the top shell as described in for leaks and to ensure that they are secure. If the heater
9.2.1.1 suffers a fault during operation, the fault must be located
and remedied.
3. Disconnect the wiring harness plug from the control
unit.
4. Disconnect the cable to the metering pump at the
disconnection point.
5. If necessary disconnect the hot air hose or hoses.
6. Disconnect the connection for the combustion air
inlet on the heater.
7. Disconnect the connections for the combustion air
inlet and exhaust outlet on the heater.
8. Remove four nuts and locking washers from the
heater.
9. Remove the heater and discard the seal on the
exhaust outlet.

8.7.1.2 INSTALLATION
1. Place the heater with a new seal on the exhaust
outlet in the installation position and secure it with
4 nuts and locking washers (use only genuine
Webasto nuts).
2. Tighten the nuts to 6 + 1 Nm (63 + 9 lb-in).
3. Secure the connection for the combustion air inlet
on the heater.
4. Secure the connections for the combustion air inlet
and exhaust outlet on the heater.
5. Connect the metering pump cable to the metering
pump wiring harness.
6. Connect the wiring harness plug to socket X6 of the
control unit.
7. Fit the cover and secure it.
8. If necessary fit the hot air hose or hoses and secure
them.
9. Connect the battery.
10. Bleed the fuel supply system (see 8.8).

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 AIR TOP 2000 ST REPAIR

9. REPAIR 9.1.2.1 INSTALLATION OF AN EXTERNAL

TEMPERATURE SENSOR
9.1 GENERAL General

This section describes the repair work that may be carried The heater can control the required temperature
out on the Air Top 2000 ST heater after it has been perfectly if its temperature sensor is exposed to the air of
removed from the vehicle. Any further dismantling will the main area of the vehicle. In certain circumstances,
invalidate the warranty. Only use the spare parts from this is not always possible using the temperature sensor
the appropriate spare parts kits for assembling the integrated in the control unit due to the installation
heater. circumstances (addition of fresh air). In this case proper
temperature control can be ensured using an external
9.1.1 WORK ON STRIPPED-DOWN COMPONENTS temperature sensor fitted in the appropriate area.

Method
CAUTION: All sealing elements between
the stripped-down components and the 1. Select a suitable position for an external
seal on the exhaust outlet must always be temperature sensor.
discarded and replaced. IMPORTANT
• The temperature sensor should not be in the
9.1.1.1 CLEANING
direct line of hot air and not close to heat
• Clean all stripped-down components with benzene sources (for example the vehicle’s own heating
and then dry them with compressed air. system).
• Remove all seal residue on the components carefully • The sensor is to be installed at medium height
using a suitable tool. in the vehicle cabin on surfaces that are as
vertical as possible.
9.1.1.2 VISUAL INSPECTION • The installation site should not be exposed to
• Check all components for damage (cracks, direct sunlight.
deformation, wear, etc.) and fit new ones if • Do not install the temperature sensor behind
necessary. curtains or the like.
• Inspect the plugs and cables for corrosion, loose 2. Install the external temperature sensor and route
contacts, crimping faults, etc. and repair them if the cable to the control element.
necessary. 3. Remove the terminating resistor at plug X8 of the
• Check plug strips for signs of corrosion and contacts wiring harness (see Fig. 28).
to ensure they are secure. Repair them if necessary. 4. Connect the external temperature sensor at plug X8
of the wiring harness.
9.1.2 CARRYING OUT MODIFICATIONS
5. Conduct a trial and check the control properties.
The constant development of our heaters is aimed at
optimizing them so as to prevent failures and
malfunctions. Plug X8 for external
Generally it is possible to modify heaters that are already temperature sensor
in use. We can supply the appropriate modification kits
for this purpose.
The following describes modifications that can be carried
out without any great effort during standard repair work:
• Installation of an external temperature sensor for
better temperature control (see 9.1.2.1).

External temperature sensor

Terminating resistor

Figure 28: External Temperature Sensor

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 REPAIR AIR TOP 2000 ST

9.2 DISMANTLING AND ASSEMBLING • Slide the four insulators (8, Fig. 29) onto the four
corner ribs of the heat exchanger and position
9.2.1 REMOVE THE CASING PARTS exactly next to the rib extension.
• Check that all four insulators (8, Fig. 29) are
9.2.1.1 COVER FOR ELECTRICAL CONNECTION securely positioned.

The cover (1, Fig. 29) can be levered off using a blunt CAUTION: When you fit the bottom shell
blade in the areas X . (4, Fig. 29), spread it slightly so that the
spacers on the overheating sensor (8, Fig.
9.2.1.2 GRATES FOR HOT AIR INLET AND OUTLET 30) are not damaged.

The grates (5) can be released from the mounting by 1. Expand the bottom shell (4, Fig. 29) slightly at the
twisting and pulling off forwards. side and fit it to the heater from underneath until
the securing pins on the heater engage in the holes
9.2.1.3 COVER FOR HOT AIR INLET AND OUTLET in the shell.
Both covers (3 and 6, Fig. 29) can be released from their 2. Fit a new seal on the exhaust outlet.
mountings and removed by pressing the four detents at
the top and bottom using a suitable tool. 9.2.2.2 TOP SHELL
1. Place the top shell (2, Fig. 29) on the heater and
9.2.1.4 TOP SHELL secure it in the grooves in the bottom shell.
NOTE: The covers for the hot air inlet and
outlet must have been removed.
9.2.2.3 COVER FOR HOT AIR INLET AND OUTLET

NOTE: The covers for the hot air inlet and

The shell (2, Fig. 29) can be raised by pulling up.
outlet are different. Fit the cover with the
smaller opening at the front on the hot air
9.2.1.5 BOTTOM SHELL blower.
By gently pulling the bottom shell (4, Fig. 29) on both
1. Push on the covers (3 and 6, Fig. 29) until the four
sides in the areas Y , you can release the fixing and the
securing holes engage properly in the detents on
shell can be taken off the motor casing.
the bottom and top covers.

9.2.2.4 GRATES FOR HOT AIR INLET AND OUTLET

9.2.2 FIT THE CASING PARTS
Fit the grates (5, Fig. 29) on the covers for the hot air
inlet and outlet and twist them to secure them.
9.2.2.1 BOTTOM SHELL
9.2.2.5 COVER FOR ELECTRICAL CONNECTION
IMPORTANT! To ensure that the heater and the
overheating sensor work perfectly, please note the
NOTE: The wiring harness is to be taken out of
following when fitting the casing:
the left or right of the heater to suit the
installation situation.
• Four insulators are used as spacers between the
heat exchanger and the casing parts.
1. Fit the cover (1, Fig. 29) until it audibly engages in
the top cover.

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 AIR TOP 2000 ST REPAIR

1
2

1 Cover, electrical connection

2 Top shell
3 Cover, hot air outlet
4 Bottom shell
5 Grate
6 Cover, hot air inlet
7 Insulators

Positioning of insulators

Insulator
Extension of
corner rib
Figure 29: Remove / Fit the Casing Parts

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 REPAIR AIR TOP 2000 ST

9.2.3 CHANGING THE CONTROL UNIT 5. Lever the overheating sensor (8) out of the ribs of
the heat exchanger (7) using a suitable tool (see
9.2.3.1 REMOVAL detail A, Fig. 30).
6. Remove the overheating sensor (8).
1. Remove the heater (see 8.7.1.1).
2. Remove the casing parts (see 9.2.1). 9.2.4.2 INSTALLATION
3. Open the catches on the hot air blower.
1. Measure the resistance of the overheating sensor
4. Pull the hot air blower (1, Fig. 30) off the motor (8, Fig. 30) (see 6.3.3).
shaft by hand.
2. Position the overheating sensor (8, Fig. 30) on the
5. Disconnect the plug connectors on the control unit heat exchanger (7) and press it into place by hand.
(3).
6. Remove screws (2) and the control unit (3). IMPORTANT! There must not be an electrical
7. Complete the work on stripped-down components connection between the sensor cables and the
(see 9.1.1). sheet metal holder.

NOTE: Do not carry out any repair work to the 3. Ensure that the overheating sensor is correctly
control unit. positioned in the heat exchanger (7).
4. Connect the plug connector X5 at the control unit
9.2.3.2 INSTALLATION (3). Check that the cables are routed in parallel
between the ribs on the heat exchanger.
1. Place the control unit (3, Fig. 30) in the installation
5. Push the insulators (9) on to the heat exchanger.
position and attach with screws (2).
6. Position the casing parts (see 9.2.2).
2. Tighten the screws to 0.7 ± 0.07 Nm (6 ± .6 lb-in).
7. Install the heater (see 8.7.1.2).
3. Slide the hot air blower (1) onto the motor shaft
until the detente on both sides is heard to engage in
the shaft groove at the stop. 9.2.5 CHANGING THE COMBUSTION AIR FAN
4. Connect the plug connectors at the sockets of the
control unit (3) as shown in Fig.11.
9.2.5.1 REMOVAL
5. Position the casing parts (see 9.2.2). 1. Remove the heater (see 8.7.1.1).
6. Install the heater (see 8.7.1.2). 2. Remove the casing parts (see 9.2.1).
7. Check the CO2 setting and adjust it if necessary (see 3. Remove the control unit (see 9.2.3.1).
6.2).
NOTE: A total of 9 screw heads are visible on
8. Check that the hot air blower moves easily with the combustion air fan (5, Fig. 30). Of these the
your hand. Check for any noise when you switch it 5 outer screws are used to attach the
on later. The sensor magnets on the hot air blower combustion air fan to the heat exchanger (7).
must be clear of ferrous chips, etc. Only these screws should be removed.

9.2.4 CHANGING THE OVERHEATING SENSOR 4. Remove the screws (4).

5. Remove the combustion air fan (5) from the heat
9.2.4.1 REMOVAL exchanger (7), remove the seal (6) and dispose of it
9.2.4.1 Removal separately.
6. Complete the work on stripped-down components
1. Remove the heater (see 8.7.1.1). (see 9.1.1).
2. Remove the casing parts (see 9.2.1).
3. Remove the insulators (9, Fig. 30).
9.2.5.2 INSTALLATION
4. Disconnect the plug connector X5 on the control 1. Ensure that the sealing surfaces on the combustion
unit (3). fan (5, Fig. 30) and on the heat exchanger (8) are
not damaged.
CAUTION: Do not pull the cables. 2. Fit a new seal (7) on the flange of the combustion
air fan (5).

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 AIR TOP 2000 ST REPAIR

3. Bring the combustion air fan (5) into the assembly 9.2.6.2 INSTALLATION
position and secure with screws (4), attaching the
electrical bonding of the wiring harness to the CAUTION: Install the flame sensor cable
motor at the same time. under the fuel line.
4. Tighten the screws (4) to 6 ± 0.6 Nm (53 ± .5 lb-in).
1. Slide the flame sensor (1, Fig. 31) through under the
5. Fit the control unit (see 9.2.3.2).
fuel line, insert the plug through the hole in the
6. Position the casing parts (see 9.2.2). heat exchanger (9) and press the cable grommet
7. Install the heater (see 8.7.1.2). (11) into the heat exchanger (9) from inside.
8. Check the CO2 setting and adjust it if necessary. 2. Insert the cable with the protective sheath through
(see 6.2). the securing strap (4) and insert the flame monitor
(1) into the burner insert (5).
9.2.6 CHANGING THE FLAME SENSOR (GASOLINE 3. Press the securing strap (4) back together.
HEATERS ONLY) 4. Secure the air baffle (3) with screws (2).
5. Tighten the screws (2) to 6 ± 0.6 Nm (53 ± .5 lb-in).
9.2.6.1 REMOVAL
6. Pull the cable of the flame sensor tight.
1. Remove the heater (see 8.7.1.1). 7. Install the combustion air fan (see 9.2.5.2).
2. Remove the casing parts (see 9.2.1). 8. Fit the control unit (see 9.2.3.2).
3. Remove the control unit (see 9.2.3.1). 9. Position the casing parts (see 9.2.2).
4. Remove the combustion air fan (see 9.2.5.1). 10. Install the heater (see 8.7.1.2).
5. Remove two screws (2, Fig. 31) and take off the air
baffle (3).
6. Press the cable grommet (11) on the flame sensor
connecting cable inwards out of the heat exchanger
(9).
7. Carefully bend up the securing strap (4) and pull out
the flame sensor (1) from the burner insert.
8. Remove flame sensor
9. Complete the work on stripped-down components
(see 9.1.1).

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 REPAIR AIR TOP 2000 ST

9
Detail A

5
4
3
2 8
1

1 Hot air fan rotor

2 Torx screw (3)
3 Electronic control unit
4 Torx screw (5)
5 Combustion air fan (drive unit)
6 Seal
7 Heat exchanger
8 Overheating sensor
9 Insulator (4)

Figure 30: Changing the Control Unit, Combustion Air Fan and Overheating Sensor

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 AIR TOP 2000 ST REPAIR

9.2.7 CHANGING THE CERAMIC GLOW PIN 9.2.7.2 INSTALLATION

1. Fit a new seal (12, Fig. 31) into the heat exchanger
9.2.7.1 REMOVAL (9) and bring the combustion pipe (13) into the
1. Remove the heater (see 8.7.1.1). assembly position.
2. Remove the casing parts (see 9.2.1). 2. Check that the starting air hole in the burner insert
(5) is free. If necessary, clean with a wire,
3. Remove the control unit (see 9.2.3.1).
approximately 4 mm Ø (5/32 in Ø) (see Fig. 32).
4. Remove the combustion air fan (see 9.2.5.1).
5. Press the cable grommet (10, Fig. 31) inwards out of CAUTION: When installing the glow plug,
the heat exchanger (9). make sure that the contacts point to the
heat exchanger. Otherwise there is a risk
6. Remove four screws (2) and take off the air baffle
of a short-circuit.
(3).
3. Introduce the glow plug (6) in the burner insert (5)
NOTE: Check that the burner insert (5) is
and position the protective sheath in the slit of the
detached from the combustion pipe (13).
burner insert.
7. Carefully remove the burner insert (5) by tilting.
CAUTION: In the following procedure
make sure that the glow plug is placed in
CAUTION: The glow plug should be
the burner insert up to the stop.
removed with extreme care and must not
be twisted under any circumstances (risk of
4. Secure the glow plug (6) with the screw (7). Tighten
breakage). After lengthy operation of the
the screw (7) to 0.5 Nm (4.4 lb-in).
burner the glow plug may be fixed in place
by fuel deposits. In this case apply 5. Introduce the burner insert (5) in the heat
penetrating oil and allow to work until the exchanger (9). Make sure that the cable of the
glow plug can be removed. flame sensor (1) (only present with petrol heater) is
positioned under the fuel line.
8. Release the screw (7), pull out the glow plug (6) 6. Guide the plug of the glow plug and the flame
from the burner insert and remove. sensor through the holes and press the cable
9. Remove the combustion pipe (13) and seal (12) grommets (10) into the heat exchanger.
from the heat exchanger (9) and dispose of the seal
separately. CAUTION: In the following procedure
make sure that the grommet (8) seals off
10. Complete the work on stripped-down components
tight with the heat exchanger (9).
(see 9.1.1).
7. Secure the burner insert (5) and the air baffle (3)
with screws (2). Tighten the screws (2) to
6 ± 0.6 Nm (53 ± .5 lb-in).
8. Install the combustion air fan (see 9.2.5.2).
9. Fit the control unit (see 9.2.3.2).
10. Position the casing parts (see 9.2.2).
11. Install the heater (see 8.7.1.2).

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 REPAIR AIR TOP 2000 ST

5
4

3
7
9
2
8

10

11
12

13

1 Flame sensor (gasoline heaters only) 8 Grommet

2 Torx screw (4) 9 Heat exchanger
3 Securing strap 10 Cable grommet
4 Air baffle 11 Cable grommet (gasoline heaters only)
5 Burner insert 12 Seal
6 Ceramic glow pin 13 Combustion pipe
7 Screw

Figure 31: Changing the glow plug, flame sensor, combustion insert and the heat exchanger

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 AIR TOP 2000 ST REPAIR

9.2.8 CHANGING THE BURNER INSERT, COMBUSTION 9.2.8.2 INSTALLATION

PIPE AND THE HEAT EXCHANGER 1. Fit a new seal (12, Fig. 31) into the heat exchanger
(9) and bring the combustion pipe (13) into the
9.2.8.1 REMOVAL assembly position.
1. Remove the heater (see 8.7.1.1).
NOTE: The burner insert (5) is only fixed in
2. Remove the casing parts (see 9.2.1).
place when installing the flame sensor and glow
3. Remove the control unit (see 9.2.3.1). plug.
4. Remove the overheating sensor (see 9.2.4.1).
2. Fit the glow plug (see 9.2.7.2).
5. Remove the combustion air fan (see 9.2.5.1).
3. Fit the flame sensor (gasoline heaters only)
6. Remove the flame sensor (only petrol heater) (see 9.2.6.2).
(see 9.2.6.1).
7. Remove the glow plug (see 9.2.7.1). CAUTION: In the following procedure
make sure that the fuel connection is not
CAUTION: In the following procedure bent.
make sure that the fuel connection is not
bent. 4. Introduce the burner insert (5) in the heat
exchanger (9). Make sure that the cable of the
8. Remove the burner insert (5, Fig. 31). flame sensor is positioned under the fuel line.
9. Remove the combustion pipe (13) and seal (12) 5. Secure the burner insert (5) and the air baffle (3)
from the heat exchanger (9) and dispose of the seal with screws (2).
(12) separately.
6. Tighten the screws (2) to 6 ± 0.6 Nm (53 ± .5 lb-in).
10. Complete the work on stripped-down components 7. Install the combustion air fan (see 9.2.5.2).
(see 9.1.1).
8. Fit the control unit (see 9.2.3.2).
9. Fit the overheating sensor (see 9.2.4.2).
10. Fit the insulators (11).
11. Position the casing parts (see 9.2.2).
12. Install the heater (see 8.7.1.2).

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 REPAIR AIR TOP 2000 ST

Starting air hole

Figure 32: Starting air hole in burner insert

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 AIR TOP 2000 ST PRODUCT INFORMATION

10. PRODUCT INFORMATION

No new or updated information available at this time.

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 AIR TOP 2000 ST WARRANTY

WARRANTY COVERAGE AND LIMITATIONS

Webasto Product North America, Inc. (herein after referred to Webasto) warrants their heaters
and heater kits against defects in material and workmanship for two (2) years effective at the time
of installationor vehicle registration date for Original Equipment installations (OE). This warranty
period may not exceed three (3) years from the original date of sale by Webasto. This warranty
period may be superseded by a contractual agreement.*

*Warranty coverage for Marine and Off-road applications containing DBW series heaters and the
CSL Cargo Heaters are limited to a maximum of 3,000 hours of usage. All other models are
limited to 2,000 maximum hours.

Replacement parts are covered for six (6) months or the remainder of the original warranty period,
which ever is longer. Replacement heaters are considered a “Replacement Part.”

The intent of the Webasto warranty is to protect the end-user heater from such defects and provide
free repair and replacement of defective parts in the manner provided herein. During the warranty
period the exclusive remedy will be for Webasto, at their discretion, to repair or replace those parts
which are demonstrated to be defective in material or workmanship.

While warranty is provided to the "end-user", it is to be administered and serviced through an

authorized Webasto dealer in accordance with the Webasto warranty policy or contractual
agreement between Webasto and a second party.

Limitations: Webasto specifically excludes and limits from warranty the following:
· Normal wear of service parts: (fuel nozzles, filters and overheat fuses are not covered).
· Removal and replacement of heater (with the exception of the Thermo Top C).
· Damage to product in transit. All claims must be filed with carrier.
· Improper installation, which is not in accordance with valid, supplied installation instructions or
approved OEM applications.
· Deterioration due to normal wear, corrosion, abuse, damage, accident, improper storage or
operation.
· Modification of product by alteration, use of non-genuine parts or repair by unauthorized
personnel.
· Economic loss for expenses related to travel, vehicle disability, personal injury or other
incidental or consequential damages arising from any breach of this expressed warranty.

Owner's Responsibilities:
1) Service heater at the start of each season by an authorized Webasto dealer (Service parts
including; fuel nozzles, filters and overheat fuses are not covered under warranty).
2) A Warranty Registration Card is included with the sale of each heater. It is the owner's
responsibility to complete this card and return it to Webasto for registration. A proof of
purchase is required for all heaters that are not registered.

This warranty gives you specific legal rights and you may also have other rights which vary by State or Province

THE WARRANTY DESCRIBED IN THIS POLICY SHALL BE IN LIEU OF ANY OTHER WARRANTY,
EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO, ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

www.webasto.us 47 Webasto Product N.A., Inc.

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 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. 06/2005 Rev. 02/2012 P/N LIT9010439B © 2012 Webasto Product N.A., Inc. www.webasto.us

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