Webasto Air Top 2000 STC User manual

Luftheizgeräte
Air Heaters
Luchtverwarmingsapparaten
Einbauanweisung
Installation Instructions
Montagehandleiding
Air Top 2000 STC
Handelsbezeichnungen/Trade names/Handelsnamen:
Air Top 2000 STC B (Benzin/petrol/benzine)
Air Top 2000 STC D (Diesel/FAME)
9032312A_II_AT2000STC.book Page 1 Thursday, September 29, 2016 1:21 PM

Das unsachgemäße Einbauen oder Reparieren von Webasto Heiz- und Kühlsystemen kann Feuer verursachen oder zum
Austritt von tödlichem Kohlenmonoxid führen. Dadurch können schwere oder tödliche Verletzungen hervorgerufen
werden.
Für den Einbau und die Reparatur von Webasto Heiz- und Kühlsystemen bedarf es eines Webastotrainings, technischer
Dokumentation, Spezialwerkzeuge und einer Spezialausrüstung.
Es dürfen nur Originalteile von Webasto verwendet werden. Siehe dazu auch Zubehörkatalog Luft- und Wasserheiz-
geräte von Webasto.
Versuchen Sie NIEMALS, Webasto Heiz- oder Kühlsysteme einzubauen oder zu reparieren, wenn Sie das Webasto-
training nicht erfolgreich abgeschlossen und dabei die notwendigen technischen Fähigkeiten erworben haben und die
für einen sachgerechten Einbau und Reparatur nötigen technischen Dokumentationen, Werkzeuge und Ausrüstungen
nicht zur Verfügung stehen.
Befolgen Sie IMMER alle Webasto Einbau- und Reparaturanleitungen, und beachten Sie alle Warnhinweise.
Webasto übernimmt keine Haftung für Mängel und Schäden, die auf einen Einbau durch ungeschultes Personal zurück-
zuführen sind.
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.
To install and repair Webasto heating and cooling systems you need to have completed a Webasto training course and
have the appropriate technical documentation, special tools and special equipment.
Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue.
NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course,
you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment
available to ensure that you can complete the installation and repair work properly.
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 STC
I
Inhaltsverzeichnis
1 Gesetzliche Bestimmungen für den Einbau . . . . . . . . . . . . . 1
2 Verwendung der Luftheizgeräte . . . . . . . . . . . . . . . . . . . . . 5
3 Einbau. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Typschild. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Einbaubeispiel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Warmluftsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Brennstoffversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Brennluftversorgung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9 Abgasleitung. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10 Brennluftansaug- und Abgasleitungen . . . . . . . . . . . . . . . 20
11 Elektrische Anschlüsse . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
12 Anschlussschema / Schaltplan . . . . . . . . . . . . . . . . 25
13 Legende für Schaltpläne . . . . . . . . . . . . . . . . . . . . . . . . 30
14 Erstinbetriebnahme. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
15 Störabschaltung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
16 Technische Daten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
17 Ausführung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
18 Bohrschablone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table of Contents
1 Statutory regulations governing installation . . . . . . . . . . .41
2 Use of air heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
4 Type label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5 Installation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
6 Hot air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
7 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
8 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
9 Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
10 Combustion air intake and exhaust pipes. . . . . . . . . . . . . .60
11 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
12 Connection diagram/wiring diagram . . . . . . . . . . . . . . .65
13 Legend to wiring diagrams . . . . . . . . . . . . . . . . . . . . . .70
14 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
15 Fault switch-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
16 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
17 Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
18 Drilling template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
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Air Top 2000 STC Statutory regulations governing installation
41
1 Statutory regulations governing installation
The Air Top 2000 STC heater has been type-tested and approved in accord-
ance with ECE-R 10 (EMC) and ECE-R 122 (heater).
For approval number see Chapter 16, "Technical data".
Primarily, the stipulations of Part I and of Annex 7 to the Regulation ECE-R
122 must be observed for the installation.
NOTE:
The stipulations of this regulation are binding under the framework
of the Directive 70/156/EEC and/or 2007/46/EC (for new vehicle mod-
els from 29/04/2009) and should also be observed in countries where
there are no specific regulations.
See Chapter 1.2, "Excerpt from the directive ECE-R 122 Part I and Annex
7" and Chapter 1.3, "Excerpt from the directive ECE-R 122 Annex 9".
ATTENTION:
Failure to follow the installation instructions and the notes contained therein
will lead to all liability being refused by Webasto. The same applies if repairs
are carried out incorrectly or with the use of parts other than genuine spare
parts. This will result in the invalidation of the type approval for the heater
and therefore of its homologation / EC type licence.
1.1. Application of combustion heaters in vehicles for the transpor-
tation of dangerous goods.
Vehicles used for the purpose of transporting dangerous goods are type
approval tested in accordance with ECE R 105. The following measures are
derived for our combustion heaters.
• The electrical cable/wiring harness must be sufficiently dimensioned to pre-
vent overheating. The electrical cable/wiring harness must be sufficiently
insulated. All electrical circuits must be protected by fuses or automatic cir-
cuit breakers.
• The cables must be installed and firmly secured such that the wirings are
adequately protected against mechanical and thermal stress.
• The combustion heaters must be type-tested in accordance with ECE R 122
(equivalent to EC/2001/56 in the version EC/2006/119) and comply with
Annex 9 - Additional regulations for vehicles used for transporting danger-
ous goods.
• The combustion heaters and their exhaust gas piping system must be de-
signed, arranged, protected or covered so as to prevent any unacceptable
risk of heating or ignition of the load.
• In the event of a leak in the fuel line, the fuel must drain to the ground
without coming into contact with hot parts of the vehicle or the load.
• The exhaust system as well as the exhaust pipes shall be so directed or pro-
tected to avoid any danger to the load through heating or ignition. Parts of
the exhaust system situated directly below the fuel tank must have a mini-
mum clearance of 100 mm or be protected by a heat shield.
• It must only be possible to switch the combustion heater on manually. Pro-
gramming devices shall be prohibited.
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Statutory regulations governing installation Air Top 2000 STC
42
Requirements relating to the basic unit:
When switched off, it is permissible for combustion heaters to continue
running for max. 40 seconds. Only combustion heaters are to be used with
heat exchangers that are not damaged during their standard operating
period by the reduced afterrunning time of 40 seconds.
1.2. Excerpt from the directive ECE-R 122 Part I and Annex 7
Start of excerpt.
Part I
5.3 Vehicle Installation Requirements for Combustion Heaters and
for Electric Heaters
5.3.1 Scope
5.3.1.1 Subject to paragraph 5.3.1.2, heaters shall be installed according
to the requirements of paragraph 5.3.
5.3.1.2 Vehicles of category O having liquid fuel heaters are deemed to
comply with the requirements of paragraph 5.3.
5.3.2 Positioning of heater
5.3.2.1 Body sections and any other components in the vicinity of the heat-
er must be protected from excessive heat and the possibility of fuel or oil
contamination.
5.3.2.2 The heater shall not constitute a risk of fire, even in the case of
overheating. This requirement shall be deemed to be met if the installation
ensures an adequate distance to all parts and suitable ventilation, by the
use of fire resistant materials or by the use of heat shields.
5.3.2.3 In the case of M2 and M3 vehicles, the combustion heater must
not be positioned in the passenger compartment. However, an installation
in an effectively sealed envelope which also complies with the conditions
in paragraph 5.3.2.2 may be used.
5.3.2.4 The label referred to in Annex 7, paragraph 4, or a duplicate, must
be positioned so that it can be easily read when the combustion heater is
installed in the vehicle.
5.3.2.5 Every reasonable precaution should be taken in positioning the
heater to minimize the risk of injury and damage to personal property.
5.3.3 Fuel supply
5.3.3.1 The fuel filler must not be situated in the passenger compartment
and must be provided with an effective cap to prevent fuel spillage.
5.3.3.2 In the case of liquid fuel heaters, where a supply separate from that
of the vehicle is provided, the type of fuel and its filler point must be clearly
labelled.
5.3.3.3 A notice, indicating that the heater must be shut down before re-
fuelling, must be affixed to the fuelling point. In addition a suitable instruc-
tion must be included in the manufacturer’s operating manual.
5.3.4 Exhaust system
5.3.4.1 The exhaust outlet must be located so as to prevent emissions from
entering the vehicle through ventilators, heated air inlets or opening win-
dows.
5.3.5 Combustion air inlet
5.3.5.1 The air for the combustion chamber of the heater must not be
drawn from the passenger compartment of the vehicle.
5.3.5.2 The air inlet must be so positioned or guarded that blocking by rub-
bish or luggage is unlikely.
5.3.6 Heating air inlet
5.3.6.1 The heating air supply may be fresh or re-circulated air and must
be drawn from a clean area not likely to be contaminated by exhaust
fumes emitted either by the propulsion engine, the combustion heater or
any other vehicle source.
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Air Top 2000 STC Statutory regulations governing installation
43
5.3.6.2 The inlet duct must be protected by mesh or other suitable means.
5.3.7 Heating air outlet
5.3.7.1 Any ducting used to route the hot air through the vehicle must be
so positioned or protected that no injury or damage could be caused if it
were to be touched.
5.3.7.2 The air outlet must be so positioned or guarded that blocking by
rubbish or luggage is unlikely.
5.3.8 Automatic control of the heating system
5.3.8.1 The heating system must be switched off automatically and the
supply of fuel must be stopped within five seconds when the vehicle’s en-
gine stops running. If a manual device is already activated, the heating sys-
tem can stay in operation.
ANNEX 7
ADDITIONAL REQUIREMENTS FOR COMBUSTION HEATERS
7 Warning light
7.1 A clearly visible tell-tale in the operator’s field of view shall inform
when the combustion heater is switched on or off.
End of excerpt.
NOTE:
If the installation location of the heater is not located behind the driver's seat
and can be reached by the driver under normal operating conditions,
supplementary to Point 5.3.2.3, the heater must only be installed in an
effectively sealed housing (that also conforms to the regulations of
Paragraph 5.3.2.2) in vehicles of Class M1 (passenger vehicles and motor
homes), M2 and M3 (coaches) as well as N (transporters and commercial
vehicles).
The installation of the heater in a place that is inaccessible while driving or
in a suitable enclosure conforming to Paragraphs 5.3.2.2 and 5.3.2.5 is
recommended in order to avoid unintentional contact with the heater
surface and possible injuries.
1.3. Excerpt from the directive ECE-R 122 Annex 9
Start of excerpt.
Additional provisions applicable to certain vehicles as specified in the ADR.
3. Technical Provisions
3.1 General (EX/II, EX/III, AT, FL, OX and MEMU vehicles)
3.1.1 [1] The combustion heaters and their exhaust gas routing shall be de-
signed, located, protected or covered so as to prevent any unacceptable
risk of heating or ignition of the load. This requirement shall be considered
as fulfilled if the fuel tank and the exhaust system of the appliance conform
to the following provisions:
- Any fuel tanks for supplying the appliance shall meet the following
requirements:
a) In the event of any leakage, the fuel shall drain to the ground
without coming into contact with hot parts of the vehicle or
the load;
b) Fuel tanks containing petrol shall be equipped with an effec-
tive flame trap at the filler opening or with a closure enabling
the opening to be kept hermetically sealed.
- The exhaust system as well as the exhaust pipes shall be so directed
or protected to avoid any danger to the load through heating or ig-
nition. Parts of the exhaust system situated directly below the fuel
tank (diesel) shall have a clearance of at least 100 mm or be protect-
ed by a thermal shield.
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Statutory regulations governing installation Air Top 2000 STC
44
3.1.2 The combustion heater shall be switched on manually. Programming
devices shall be prohibited.
3.2 EX/II, EX/III and MEMU vehicles
Combustion heaters using gaseous fuels are not permitted.
3.3 FL vehicles
3.3.1 The combustion heaters shall be put out of operation by at least the
following methods:
a) Intentional manual switching off from the driver’s cab;
b) Stopping of the vehicle engine; in this case the heating device
may be restarted manually by the driver;
c) Start up of a feed pump on the motor vehicle for the danger-
ous goods carried.
[1] Compliance with this paragraph shall be verified on the completed ve-
hicle.
End of excerpt.
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Air Top 2000 STC Use of air heaters
45
2 Use of air heaters
The Webasto Air Top 2000 STC air heaters are designed
– to heat cabins, boats, commercial vehicles, minibusses, vans/transporters
and motor homes
– to defrost vehicle windows.
The heaters operate independently of the engine and are connected directly
to the fuel tank and the electrical system of the vehicle.
They are not approved for heating dangerous goods/hazardous substances.
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Installation Air Top 2000 STC
46
3 Installation
ATTENTION:
Comply with the legal requirements for installation on Page 41 and 42. The
requirements stipulated in the latest version of the ADR must be additionally
observed for the installation of the heater in vehicles used to transport
dangerous goods/hazardous substances.
The heater must not be operated without the control unit cover (this will
cause the heater to overheat).
3.1. Air Top 2000 STC installation situation
NOTE:
Check the given conditions for installation in the respective type of vehicle.
3.2. Installation location
The heater may be installed both in the interior or on the exterior of the
vehicle.
When using the vehicle in normal road traffic, the heater may only be
installed with a contact guard to prevent contact if it is located within the
reach of the driver.
If installed on the exterior, ensure that the heater is fitted in a position where
it is protected from splash water and spray.
The heater must be installed in such a way that no water can enter the
heater when the vehicle is driven through water conforming to the
permissible fording level.
The openings for the combustion air inlet, the exhaust gas outlet and the
fuel pipe must be sealed. The seal designed and supplied for this purpose
must be used.
(See Fig. 3).
3.3. Heater installation
When installing the Air Top 2000 STC heater, tighten the M6 nuts to a torque
of 6 Nm +1.
The installation dimensions and space requirements for service access are
shown in the installation drawing (Fig. 1). The specified horizontal and axial
angles of inclination must not be exceeded (Fig. 2).
A seal (Fig. 3) must be fitted between the heater and the vehicle body. The
seal must be replaced each time the heater is reinstalled. The support
surface for the heater base must be flat. The seal can compensate for
unevenness of max. 1 mm.
ATTENTION:
After installation check that the casing is not in contact with any part of the
body. Failure to do this may result in the heating air fan blocking.
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Air Top 2000 STC Installation
47
Fig. 1: Heater dimensions
A
B
C
120
121
>155
29
>30
120
310
2
>20
>20
>20
Ø22 Ø22
123
456
Cold air inlet
Cable outlet (optionally on right or left)
Hot air outlet
Exhaust gas outlet
Fuel inlet
Combustion air inlet
A Space requirements for hot air outlet
B Space requirements for cold air inlet
C Space requirements for removing heater
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Installation Air Top 2000 STC
48
Fig. 2: Permissible heater installation positions
Diesel:
Petrol: horizontal
Fig. 3: Seal
Fig. 4: Installation
Ensure ease of movement of
all moving parts!
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Air Top 2000 STC Type label
49
4Typelabel
If the type label is not visible with the heater in installed position, a duplicate
of the type plate must be displayed in a position where it is clearly visible and
protected from damage.
Year figures that do not apply must be removed from the type label.
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Installation example Air Top 2000 STC
50
5 Installation example
Fig. 5: Installation example of air heater in recirculated air mode
12 3
4
567
10 9 8
Control element
Heater
Fuse
Tank extracting device
Fuel filter (accessory)
Fuel pump
Exhaust silencer (accessory)
Combustion air intake line
Combustion air intake silencer (accessory)
Maximum permissible fording level
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Air Top 2000 STC Hot air system
51
6 Hot air system
NOTE:
it is not permitted to integrate the heater into the vehicle's air circulation
system.
A temperature sensor, which measures the room temperature, is mounted
on the inside of the control unit. The required interior temperature is
selected at the control element. The heating capacity is adapted
automatically to the heating requirements of the room.
Both recirculation and fresh air modes are permitted.
Care must be taken for fresh air mode to ensure that the cold air is taken
from an area protected from splash water and spray and in such a way that
no water can enter the heater when the vehicle is driven through water
conforming to the permissible fording level.
NOTE:
For fresh air mode, a room temperature sensor must be installed in the area
to be heated.
The inside diameter of the main section of the hot air duct should be 60 mm.
NOTE:
Only materials that can permanently withstand temperatures of at least
130 °C are to be used for the hot air duct. The hot air opening is to be
positioned such that heat-sensitive parts are not damaged.
ATTENTION:
Every reasonable precaution should be taken in positioning the heater to
minimize the risk of injury and damage to personal property.
Maximum pressure drop between the intake and pressure side of the hot air
duct: 1.5 hPa
If this pressure drop is exceeded, the heater will reduce the heating capacity
or shut down.
The hot air hose is to be secured at the connection points.
Avoid a short-circuit in the hot air flow when the heater is used in
recirculated air mode.
Fig. 6: Cold air inlet and hot air outlet
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Hot air system Air Top 2000 STC
52
ATTENTION:
Suitable grilles must be fitted on the cold air inlet and hot air outlet if the
heater is used without air guides.
NOTE:
The installation must be checked for:
– excessively high cold air intake temperature due to the vehicle heating
system
– for air short-circuit between the cold air inlet and hot air outlet of the
heater (Fig. 6).
If a casing is used, the hot air duct leading out of the box must be sealed.
6.1. Room temperature sensor
For fresh air mode, a room temperature sensor must be installed in the area
to be heated.
6.1.1. Room temperature sensor installation
The room temperature sensor must be installed at medium height in the
vehicle cabin on vertical surfaces in the area to be heated.
The room temperature sensor must not
– be in the direct flow of hot air (from vehicle heating system or hot air
heater).
– be installed in the vicinity of heat sources (e.g. vehicle heating system).
– be placed in direct sunlight (e.g. dashboard).
– be installed behind curtains or similar.
Fig. 7: Cold air inlet with mesh guard
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Air Top 2000 STC Fuel supply
53
7Fuelsupply
The fuel is taken from the vehicle's fuel tank or from a separate fuel tank.
Refer to Chapter 7.1.4, "Pipe lengths and delivery head" for the permissible
pressure at the fuel take-off point.
A notice, indicating that the heater must be shut down before refuelling,
must be affixed to the filler neck.
7.1. Fuel lines
7.1.1. Vehicles with carburetor engine
The fuel may only be extracted with the special Webasto fuel extractor (Fig.
8) as close to the fuel tank as possible. The connection can be made either
in the supply or return line, where the return line must extend almost to the
bottom of the fuel tank.
The fuel extractor must be installed in such a way that any air or gas bubbles
are automatically expelled towards the fuel tank (Fig. 8).
Fuel should be extracted in the vicinity of the engine as gas bubbles can form
in the lines in this area due to the heat radiated from the engine. This can
cause combustion problems.
7.1.2. Vehicles with fuel injection engine
When installing the heater in a vehicle with a fuel injection system, it is
important to establish whether the fuel pump is located inside or outside the
fuel tank.
If the fuel pump is located inside the fuel tank, fuel can only be extracted
from the return line using the Webasto fuel extractor (Fig. 8). In this case it
is necessary to ensure that the return line extends almost to the bottom of
the fuel tank (otherwise the Webasto tank extracting device (Fig. 9, Fig. 10
and Fig. 11) can be used.
If the fuel pump is installed outside the fuel tank, the fuel connection can be
made between the fuel tank and the fuel pump, again using only the
Webasto fuel extractor (Fig. 8).
7.1.3. Extracting fuel with tank extracting device
Fuel must be extracted from the fuel tank or a separate tank (Fig. 8, Fig. 9
and Fig. 10). Separate fuel extraction has no influence on the pressure.
Fig. 8: Webasto fuel extractor
to fuel pump
to motor
from fuel tank
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Fuel supply Air Top 2000 STC
54
Fig. 9: Webasto tank extracting device
Fig. 10: Extracting fuel from plastic fuel tank
(fuel take-off via tank drain plug)
Hole pattern
Minimum distance 25 mm
Use tank extracting device only with
metal fuel tanks
Seal
Plastic fuel tank
Fig. 11: Extracting fuel from plastic fuel tank
(fuel take-off via tank fitting)
Seal
Tank extracting device
Tank fitting
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Air Top 2000 STC Fuel supply
55
7.1.4. Pipe lengths and delivery head
When installing the fuel line make sure that it is kept as short as possible.
See Fig. 12.
The pipe must be installed such as to protect it from being damaged.
The fuel line must be installed in cool areas to avoid bubbles being formed
by the effect of heat. High fuel temperatures can cause the heater to
malfunction.
Fig. 12: Fuel supply
H
1
D
1
l
1
l
2
l
2
H
2
l
1
D
2
S
2
D
2
D
1
S
1
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Fuel supply Air Top 2000 STC
56
The fuel lines must be secured using state-of-the-art fastening elements.
Do not damage the fuel line.
Intake side:
D1: Inside diameter of fuel line = 2 mm.
H1: Fuel level (tank above fuel pump) [m]
S1: Fuel level (tank below fuel pump) [m]
l1: Length of fuel line [m]
Pressure side:
D2: Inside diameter of fuel line = 2 mm.
H2: Height difference between heater and fuel pump
(heater above fuel pump) [m]
S2: Height difference between heater and fuel pump
(heater below fuel pump) [m]
l2: Length of fuel line [m]
7.1.5. Pipe material
Only use steel or plastic fuel lines made from light and temperature-resistant
material in accordance with DIN 73379 as the fuel pipes.
7.1.6. Connecting 2 fuel lines with a hose
Fig. 13 shows the correct connection of fuel lines with a hose.
Make sure there are no leaks!
Fuel level (tank above fuel
pump), H1[m]
Maximum permissible fuel pressure at take-off
point, p1[bar]
H1 = 0 -0.1 < p1 <+0.5
0 < H1 <1 -0.1 < p1 <+0.4
1 < H1 <2 -0.1 < p1 <+0.3
Fuel level (tank below fuel
pump), H2[m]
Maximum permissible fuel pressure at take-off
point, p1[bar]
0 <H2<1.3 -0.1 < p1<+0.5
Parameter Value
Length of intake pipe l1[m] max. 5
Length of pressure pipe l2[m] max. 10
Length of intake pipe l1+ length of pressure pipe l2[m] max. 12
Height difference between heater and fuel pump
(heater above fuel pump) H2[m]
max. 3
Height difference between heater and fuel pump
(heater below fuel pump) S2[m]
max. 1
Fig. 13: Pipe/hose connection
right
wrong
Clip
Bubble Bubble
9032312A_II_AT2000STC.book Page 56 Thursday, September 29, 2016 1:21 PM

Air Top 2000 STC Fuel supply
57
– Secure the line at regular intervals to prevent sagging. Avoid kinks.
– Keep away from heat sources. Use heat shield if necessary!
7.2. Fuel pump
The fuel pump is a combined delivery, metering and a shut-off system and is
subject to certain installation criteria (see Fig. 14).
7.2.1. Installation location
The fuel pump must be installed in a cool place as close as possible to the
fuel tank (see Chapter 7.1.4, "Pipe lengths and delivery head"). For petrol
heaters, the ambient temperature must not exceed +20 °C at any time
during operation.
The fuel pump and fuel lines must not be installed within the range of
radiated heat from hot vehicle parts. A heat shield should be fitted if
necessary.
7.2.2. Installation and attachment
The fuel pump must be secured with a vibration-damping mounting (e.g.
rubberised clip). The installation position is limited as shown in Fig. 14 to
ensure effective automatic bleeding.
Due to the risk of corrosion only genuine Webasto parts must be used for
the plug connection between the fuel pump and fuel pump wiring harness.
Use the flexible mount to install the fuel pump (reduces the transmission of
structure-borne noise/ticking)!
(see Fig. 15).
7.3. Fuel filter
Only a Webasto strainer is to be fitted if poor-quality fuel is used. Install
vertically if possible, maximum deviation not exceeding 90° (ensure correct
direction of flow).
Fig. 14: DP42 fuel pump installation position
Diesel
0-45°
15-90°
0-180°
0-180°
Fig. 15: Flexible mount of fuel pump
Fig. 16: Fuel filter
0° - 90°
9032312A_II_AT2000STC.book Page 57 Thursday, September 29, 2016 1:21 PM