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Ebasto Air Top Evo 3900 Workshop Manual

Manual is about: Air heaters

Summary of Air Top Evo 3900

  • Page 1

    Air heaters air heaters 04/2008 1313560a 03/2003 workshop manual air top evo 3900 air top evo 5500 type air top evo 3900/5500 st b (petrol) type air top evo 3900/5500 st d (diesel/pme).

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    Air top evo 3900/5500 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 ...

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    Air top evo 3900/5500 table of contents i table of contents 1 introduction 1.1 contents and purpose ........................................................................................................................... 101 1.1.1 use of the air heaters ..............................................

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    Table of contents air top evo 3900/5500 ii 5 troubleshooting 5.1 general ................................................................................................................................................. 501 5.2 general error symptoms .....................................................

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    Air top evo 3900/5500 table of contents iii 9 repair 9.1 general .................................................................................................................................................. 901 9.1.1 work on stripped down components ................................................

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    List of illustrations air top evo 3900/5500 iv list of illustrations 501 general error symptoms ............................................................................................................................ 501 502 error symptoms during function ...........................................

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    Air top evo 3900/5500 1 introduction 101 1 introduction 1.1 contents and purpose this workshop manual is designed to assist trained personnel with repairing both the petrol and the diesel versions of the air top evo 3900/5500 air heaters. 1.1.1 use of the air heaters the webasto air top evo 3900 and...

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    1 introduction air top evo 3900/5500 102 2.2.2. The combustion heater shall not constitute a risk of fire, even in the case of overheating. This requirement shall be deemed to be fulfilled if the installation ensures an adequate distance to all parts and suitable ventilation, by the use of fire resi...

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    Air top evo 3900/5500 1 introduction 103 compliance with §§ 45 and 46 of the road vehicle licensing act must be ensured for the installation of fuel lines and the installation of additional fuel tanks. The main points from this law: – fuel pipes must be designed in such a way that torsion in the veh...

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    1 introduction air top evo 3900/5500 104 overheating keep the hot air inlet and hot air outlet free of dirt and foreign bodies. Dirty, blocked air lines can cause the heater to shut down due to overheating. After an overheating lock-out, check that the air system is clear, remove any materials that ...

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    Air top evo 3900/5500 2 general description 201 2 general description the air top evo 3900 and air top evo 5500 air heaters are based on the evaporator principle and essentially consist of the following – the drive unit with a combustion and hot air blower – the heat exchanger – the burner insert wi...

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    2 general description air top evo 3900/5500 202 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 the burner ...

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    Air top evo 3900/5500 2 general description 203 2.4 control unit the control unit is the central component for ensuring the function is maintained and for monitoring the heater’s operation. A temperature sensor in the control unit is designed to control the room temperature. An external temperature ...

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    2 general description air top evo 3900/5500 204 page for notes.

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    Air top evo 3900/5500 3 function description 301 3 function description 3.1 control element the control element is designed to switch the heater on and off, adjust the required room temperature (intake temperature between 5 °c and 35 °c) and to reset the heater after a fault. In addition, other comf...

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    3 function description air top evo 3900/5500 302 3.5 control pause after the temperature set on the control element has been reached the heat output is reduced.The speed of the heat- ing and combustion air blower and the delivery rate of the metering pump are reduced. If, at minimum heat output, the...

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    Air top evo 3900/5500 3 function description 303 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 restar...

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    3 function description air top evo 3900/5500 304 3.8.2 reset a fault lock-out the various fault statuses can be reset as follows. Fault lock-out: switch heater off using the control element and then on again after more than 2 seconds heater fault lock-out: heater unit is switched on, fault code f12 ...

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    Air top evo 3900/5500 4 technical data 401 4 technical data except where limit values are specified, the technical data listed in the table refer to the usual heater tolerances of ±10% at an ambient temperature of +20 °c and at the rated voltage and in rated conditions. Electrical components: the co...

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    4 technical data air top evo 3900/5500 402 page for notes.

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    Air top evo 3900/5500 5 troubleshooting 501 5 troubleshooting 5.1 general this section describes how to identify and deal with errors on the air top evo 3900 and air top evo 5500 heaters. If a fault occurs, an error code will be output in the display of the combination timer. If the heater has a con...

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    5 troubleshooting air top evo 3900/5500 502 5.3 error symptoms during function the following table (fig. 502) lists the possible error symptoms in the order in which they may occur during operation. In the event of a fault, the error is to be located using this table and rectified. It is important t...

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    Air top evo 3900/5500 5 troubleshooting 503 5.4 error code output if the heater is fitted with a combination timer, an error code output will appear on the display of the timer after a fault occurs. Note the error code is output if the heater is fitted with a control element after an error has occur...

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    5 troubleshooting air top evo 3900/5500 504 error code error (group) additional information during pc diagnostic troubleshooting f 07 metering pump interrupt or metering pump short-circuit 88 break or short circuit to +ub 08 short circuit to earth check cables, replace metering pump check cables, re...

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    Air top evo 3900/5500 6 function tests 601 6 function tests 6.1 general this section describes the tests conducted on the heater when it is installed and not installed to verify that it is in working order. Warning the heater must not be operated in enclosed areas such as garages and workshops witho...

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    6 function tests air top evo 3900/5500 602 page for notes.

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    Air top evo 3900/5500 7 circuit diagrams 701 7 circuit diagrams 7.1 general the air top evo 3900 and air top evo 5500 heater units can be operated with the heater control (setpoint generator/switch), a combination timer or the mc04/05 heater control. The circuit diagrams (fig. 702 to 707) show the p...

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    7 circuit diagrams air top evo 3900/5500 702 fig. 702 system circuit diagram 12v/24v with control element and vehicle blower fig. 703 system circuit diagram 24v adr operation with control element.

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    Air top evo 3900/5500 7 circuit diagrams 703 fig. 704 system circuit diagram 12v/24v with combination timer and vehicle blower fig. 705 system circuit diagram (diesel) 12v/24v with combination timer and electrical battery isolation switch.

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    7 circuit diagrams air top evo 3900/5500 704 fig. 706 system circuit diagram (diesel) 12v/24v with control panel mc04/05 and vehicle blower fig. 707 system circuit diagram (diesel) 24v adr-operation with control panel mc04/05.

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    Air top evo 3900/5500 7 circuit diagrams 705 fig. 708 schematic connection of the combination timer fig. 709 schematic connection of the control panel mc04/05 combination timer 1531 black: terminal 15 red: terminal 30 brown: terminal 31 grey: terminal 58 adapter wiring harness observe coloured marki...

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    7 circuit diagrams air top evo 3900/5500 706 7.2 legend for circuit diagrams 1. With positive from terminal (15/75) to connection 10: permanent operation for immediate heat as long as the ignition is switched on without positive at connection 10: heating time is variably programmable (10 min to 120 ...

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    Air top evo 3900/5500 8 servicing work 801 8 servicing work 8.1 general this section describes the servicing work that can be carried out on the heater when it is installed. 8.2 work on the heater disconnect the main power cable from the vehicle’s battery before carrying out any work on the heater.T...

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    8 servicing work air top evo 3900/5500 802 if this value is exceeded the heat output may be reduced as a result of the hot air outlet temperature control. The heater can be used with grates on the air inlet and outlet side if it is used in an air circulation system.Do not short circuit the current o...

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    Air top evo 3900/5500 8 servicing work 803 8.6.2.1 fuel extraction. Vehicles with diesel engines the fuel must be taken from the vehicle fuel tank or from a separate tank (fig. 802, 803 or 804). This separate fuel pickup precludes any effect of pressure. Fig. 801 fuel supply max. 3 m h s i i 2 2 i Ø...

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    8 servicing work air top evo 3900/5500 804 vehicles with carburettor engines the fuel may only be extracted on cars using the special webasto fuel extractor (for example part no. 470 910) as close to the tank as possible.The connect may be made in either the supply or return line, in which case the ...

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    Air top evo 3900/5500 8 servicing work 805 8.6.2.2 fuel lines only steel, copper and plastic lines of plasticised, light and temperature-stabilised pa11 or pa12 (e.G. Mecanyl rwtl) pursuant to din 73378 may be used for the fuel lines. Since the lines cannot always be routed with a constant rising gr...

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    8 servicing work air top evo 3900/5500 806 8.6.5 combustion air supply under no circumstances may the combustion air be taken from areas occupied by people. The combustion air intake opening must not point in the direction of travel. It must be located so that it cannot become clogged with dirt. Not...

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    Air top evo 3900/5500 8 servicing work 807 8.6.8 electrical connections 8.6.8.1 heater connection, control element the electrical connection is to be made as shown in the appropriate circuit diagram (see section 7). To connect the wiring harness, remove the cover (see 9.2.1.1) on the heater and conn...

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    8 servicing work air top evo 3900/5500 808 fig. 814 specimen installation for heater in an air circulation system 1 control element 2 heater 3 metering pump 4 fuel filter (accessory) 5 tank connector 6 exhaust silencer 7 fuse 5 4 3 7 2 6 1.

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    Air top evo 3900/5500 8 servicing work 809 8.7 removal and installation important when the heater is installed it must not be dismantled. 8.7.1 heater, removal and installation 8.7.1.1 removal 1. Disconnect the battery. 2. Pull the cover off the top shell as described in 9.2.1.1 3. Disconnect the wi...

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    8 servicing work air top evo 3900/5500 810 page for notes.

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    Air top evo 3900/5500 9 repair 901 9 repair 9.1 general this section describes the repair work that may be carried out on the air top 3900/5500 heater after it has been removed from the vehicle. Any further dismantling will invalidate the warranty.Only use the spare parts from the appropriate spare ...

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    9 repair air top evo 3900/5500 902 9.2 dismantling and assembling 9.2.1 remove the casing parts 9.2.1.1 cover for electrical connection the cover (1, fig. 901) can be levered off using a blunt blade in the areas marked “x”. 9.2.1.2 grate for hot air inlet and outlet the grate (6, fig. 901) can be re...

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    Air top evo 3900/5500 9 repair 903 y y x x x 1 2 3 5 4 6 1 cover, electrical connection 2 top shell 3 cover, hot air outlet 4 bottom shell 5 cover, hot air inlet 6 grate 7 insulators (4) fig. 901 remove / fit the casing parts 7 6 insulator positioning insulator widening of corner rib 7.

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    9 repair air top evo 3900/5500 904 9.2.3 change the control unit 9.2.3.1 removal 1. Remove the heater (see 8.7.1.1). 2. Remove the casing parts (see 9.2.1). 3. Disconnect the plug connections on the control unit (3, fig. 902). 4. Remove the screws (4). 5. Slide the control unit (3) towards the hot a...

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    Air top evo 3900/5500 9 repair 905 fig. 902 change the control unit, overheating sensor and the combustion and hot air blower (drive unit) 1 combustion and hot air fan (drive unit) 2 torx screw (8) 3 control unit 4 torx screw (2) 5 terminating resistor 6 flat seal 7 heat exchanger 8 overheating sens...

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    9 repair air top evo 3900/5500 906 9.2.6 change the burner and the glow plug/ flame sensor 9.2.6.1 removal 1. Remove the heater (see 8.7.1.1). 2. Remove the casing parts (see 9.2.1). 3. Remove the control unit (see 9.2.3.1). 4. Remove the combustion and hot air blower (see 9.2.5.1). 5. Remove 2 scre...

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    Air top evo 3900/5500 9 repair 907 fig. 903 change the burner, glow plug/flame sensor, the combustion tube and the heat exchanger 1 torx screw (4) 2 retaining bar 3 diesel burner 4 combustion pipe 5 round sealing ring 6 heat exchanger 7 petrol burner 8 glow plug/flame monitor 9 retaining clip 1 2 3 ...

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    9 repair air top evo 3900/5500 908 page for notes.

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    Air top evo 3900/5500 10 packaging, storage and shipping 1001 10 packaging, storage and shipping 10.1 general if the heater or its components are sent to webasto ag for testing or repair, it must be cleaned and packed in such a way that it is protected against damage during handling, transport and s...

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    Webasto ag kraillinger strasse 5 82131 stockdorf germany http://dealers.Webasto.Com http://www.Webasto.Com subject to modification © 2008 all rights reserved id e n t. -n r . 1 3 1 3 5 6 0 a.