Webasto Air Top Evo 3900/5500 B Wartungshandbuch

Luft-HeizgeräteAir heaters03/2003Workshop Manual Air Top Evo 3900 Air Top Evo 5500 Type Air Top Evo 3900/5500 B (Petrol) Type Air Top Evo 3900/5500 D

Introduction Air Top Evo 3900/5500104NOTEIf any damage or leaks are found on the fuel line, the heater must not be used until the damage has been rect

Air Top Evo 3900/5500 General description2012 General descriptionThe Air Top Evo 3900 and Air Top Evo 5500 air heaters are based on the evaporator pri

General description Air Top Evo 3900/55002022.2 Heat exchangerThe heat generated by the combustion process is trans-ferred to the air transported by t

Air Top Evo 3900/5500 General description2032.5 Glow plug / Flame monitorThe glow plug also acts as a flame monitor. The mixture of fuel and air is ig

General description Air Top Evo 3900/5500204Page for notes

Air Top Evo 3900/5500 Function Description3013 Function Description3.1 Control elementThe control element is designed to switch the heater on and off,

Function Description Air Top Evo 3900/5500302Automatic restartIf the flame sensor does not find a flame, the starting pro-cedure will be repeated. The

Air Top Evo 3900/5500 Function Description303IMPORTANTThe use of an Air Top Evo 3900 AM or Air Top Evo 5500 AM system is not approved for dangerous go

Function Description Air Top Evo 3900/55003043.1.1.2. The exhaust system as well as the exhaust pipes shall be so directed or protected to avoid any d

Air Top Evo 3900/5500 Function Description3053.10.2 Reset a fault lock-outThe various fault statuses can be reset as follows. Fault lock-out: Switch o

Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious inju

Function Description Air Top Evo 3900/5500306Page for notes

Air Top Evo 3900/5500 Technical data4014Technical dataExcept where limit values are specified, the technical data listed in the table refer to the usu

Technical data Air Top Evo 3900/5500402Setpoint values:Volume flow of hot air against 0.5 mbarmax. 132 (139) m3/hmax. 200 (220) m3/hmax. 132 (139) m3

Air Top Evo 3900/5500 Troubleshooting5015 Troubleshooting5.1 GeneralThis section describes how to identify and deal with errors on the Air Top Evo 390

Troubleshooting Air Top Evo 3900/55005025.3 Error symptoms during functionThe following table (Fig. 502) lists the possible error symptoms in the orde

Air Top Evo 3900/5500 Troubleshooting5035.4 Error code output If the heater is fitted with a combination timer, an error code output will appear on th

Troubleshooting Air Top Evo 3900/5500504 Error codeError (group) Additional information during PC diagnosticTroubleshootingF 07 Metering pump interr

Air Top Evo 3900/5500 Function Tests6016 Function Tests6.1 GeneralThis section describes the tests conducted on the heater when it is installed and no

Function Tests Air Top Evo 3900/5500602 6.3 Settings6.3.1 Setting CO2 contentThe CO2 content in the emissions is set using the temperature selector o

Air Top Evo 3900/5500 Function Tests6036.3.2 CO2 setting of reference heater The reference heater is set to 10.3 vol. % CO2 at a geodetic altitude of

Air Top Evo 3900/5500 Table of ContentsITable of Contents1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Function Tests Air Top Evo 3900/55006046.4.1 Burner component See Fig. 904, Item 33 and Item 7 2211Burner Burner mechanically damaged?no yes No bloc

Air Top Evo 3900/5500 Function Tests6056.4.2 Combustion and hot air fan componentSee Fig. 903, Item 1 6.4.3 Glow plug component See Fig. 904, Item 8

Function Tests Air Top Evo 3900/5500606 A222121AGlow plug Contacts detached?no yes Procedure Testing and measuring equipmentVisualVisual inspectionVis

Air Top Evo 3900/5500 Function Tests6076.4.4 Drive component See Fig. 903, Item 1 121211Drive unit Externally damaged?no yes Procedure Testing and m

Function Tests Air Top Evo 3900/55006086.4.5 Overheating sensor component See Fig. 903, Item 8 If you conduct this resistance test with a digital mul

Air Top Evo 3900/5500 Function Tests6096.4.6 Control unit component See Fig. 701 and Fig. 903, Item 3 212Control unit Externally damaged?no yes Pro

Function Tests Air Top Evo 3900/55006106.4.7 Heater component 33233BComplete heater Testing of all electrical componentsDescription Procedure Tes

Air Top Evo 3900/5500 Function Tests61123CBCheck function on heater test bench Description Procedure Testing and measuring equipmentFunction test – H

Function Tests Air Top Evo 3900/55006122232CReinstalling control unitin heater to be tested Description Procedure Testing and measuring equipmentCondu

Air Top Evo 3900/5500 7 Circuit diagrams7017 Circuit diagrams7.1 GeneralThe Air Top Evo 3900 and Air Top Evo 5500 heater units can be operated with t

Table of Contents Air Top Evo 3900/5500II6 Function Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Circuit diagrams Air Top Evo 3900/5500702 Fig. 702 System circuit diagram 12V/24V with control element and vehicle blower Fig. 703 System ci

Air Top Evo 3900/5500 7 Circuit diagrams703 Fig. 704 System circuit diagram 12V/24V with combination timer and vehicle blower Fig. 705 System

7 Circuit diagrams Air Top Evo 3900/5500704 Fig. 706 System circuit diagram (diesel) 12V/24V with Control Panel MC04/05 and vehicle blower Fig

Air Top Evo 3900/5500 7 Circuit diagrams705 Fig. 708 System wiring diagram Air Top Evo 3900 / 5500 AM “Slave heater unit”, 12V/24V Diesel Fig

7 Circuit diagrams Air Top Evo 3900/5500706 Fig. 710 Schematic connection of the Control Panel MC04/05 Fig. 711 Connection diagram of Air To

Air Top Evo 3900/5500 7 Circuit diagrams7077.2 Legend for circuit diagrams Cable cross-sections< 7.5 m 7.5 - 15 m0.75 mm21.0 mm21.0 mm21.5 mm21

7 Circuit diagrams Air Top Evo 3900/5500708Page for notes

Air Top Evo 3900/5500 8 Servicing work8018Servicing work 8.1 General This section describes the servicing work that can be carried out on the heater

8 Servicing work Air Top Evo 3900/5500802The heater can be used with grills on the air inlet and outlet side if it is used in an air circulation syst

Air Top Evo 3900/5500 8 Servicing work803Vehicles with carburettor enginesThe fuel may only be extracted on cars using the special We-basto fuel extr

Air Top Evo 3900/5500 Table of ContentsIII9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Servicing work Air Top Evo 3900/55008048.6.2.2 Fuel linesOnly steel, copper and plastic lines of plasticised, light and temperature-stabilised PA11

Air Top Evo 3900/5500 8 Servicing work8058.6.4 Fuel filterOnly a Webasto filter, ident. no. 487 171, is allowed to be used if the fuel is expected to

8 Servicing work Air Top Evo 3900/5500806Fig. 809 Exhaust pipe ends, installation positionWARNINGIf the exhaust pipe ends is other than as shown i

Air Top Evo 3900/5500 8 Servicing work8078.6.8.3 Control element connectionThe wiring harness is prepared for connection to the control element.Simpl

8 Servicing work Air Top Evo 3900/5500808Fig. 814 Installation example for heater in recirculation mode1 Control element2 Heater3 Metering pump4 Fu

Air Top Evo 3900/5500 8 Servicing work8098.7 Removal and installationIMPORTANTWhen the heater is installed it must not be dismantled.8.7.1 Heater, re

8 Servicing work Air Top Evo 3900/5500810Page for notes

Air Top Evo 3900/5500 9 Repair9019Repair9.1 GeneralThis section describes the repair work that may be carried out on the Air Top 3900/5500 heater aft

9 Repair Air Top Evo 3900/55009029.2 Dismantling and assembling9.2.1 Remove the casing parts9.2.1.1 Cover for electrical connectionThe cover (1, Fig.

Air Top Evo 3900/5500 9 Repair903YYXXX1235461 Cover, electrical connection2 Top shell3 Cover, hot air outlet4 Bottom shell5 Cover, hot air inlet6 Gri

List of Illustrations Air Top Evo 3900/5500IVList of IllustrationsFig. 201 Air Top Evo 3900/5500 air heater. . . . . . . . . . . . . . . . . . . . . .

9 Repair Air Top Evo 3900/55009049.2.3 Change the control unit9.2.3.1 Removal1. Remove heater (see 8.7.1.1).2. Remove casing parts (see 9.2.1).3. Dis

Air Top Evo 3900/5500 9 Repair905Fig. 903 Change control unit, overheating sensor and combustion and hot air fan (drive unit) 1 Combustion and hot

9 Repair Air Top Evo 3900/55009069.2.6 Change burner and glow plug/flame sensor9.2.6.1 Removal1. Remove heater (see 8.7.1.1).2. Remove casing parts (

Air Top Evo 3900/5500 9 Repair907Fig. 904 Change burner, glow plug/flame sensor, combustion chamber and heat exchanger1 Torx screw (4)2 Clamping ba

9 Repair Air Top Evo 3900/5500908Page for notes

Air Top Evo 3900/5500 10 Packaging, storage and shipping100110 Packaging, storage and shipping10.1 GeneralIf the heater or its components are sent to

10 Packaging, storage and shipping Air Top Evo 3900/55001002Page for notes

Air Top Evo 3900/5500 10 Packaging, storage and shipping1003

Ident. no. 1313560B • 11/09 • Errors and omissions excepted • Printed in Germany • © Webasto AG, GCS 2009 Webasto AGPostfach 80D - 82132 Stockdorf Ger

Air Top Evo 3900/5500 Introduction1011 Introduction1.1 Contents and purposeThis workshop manual is designed to assist trained person-nel, with repairi

Introduction Air Top Evo 3900/55001022. / 5.3. (Part I) VEHICLE INSTALLATION REQUIRE-MENTS2.1. / 5.3.1. (Part I) Scope 2.1.1. / 5.3.1.1. (Part I) Subj

Air Top Evo 3900/5500 Introduction1031.4.2 General safety informationThe mouth of the exhaust pipe should be installed upwards, to the side or, if the