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Webasto Air Top 3500 ST D Workshop Manual

Other manuals for Air Top 3500 ST D: Installation Instructions Manual

Summary of Air Top 3500 ST D

  • Page 1

    Air heaters 03/2003 workshop manual air top 3500 st air top 5000 st air top 3500/5000 st b (petrol) air top 3500/5000 st d (diesel) air top 3500 st d volume plus (diesel).

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    Air top 3500/5000 st table of contents i table of contents 1 introduction 1.1 contents and purpose ........................................................................................................................... 101 1.1.1 using the air heaters ................................................

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    Table of contents air top 3500/5000 st ii 5 troubleshooting 5.1 general ................................................................................................................................................. 501 5.2 general error symptoms ......................................................

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    Air top 3500/5000 st table of contents iii 9 repair 9.1 general .................................................................................................................................................. 901 9.1.1 working on components after they have been dismantled.............................

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    Table of illustrations air top 3500/5000 st iv list of illustrations 501 general error symptoms ............................................................................................................................ 501 502 error symptoms during function ...........................................

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    Air top 3500/5000 st 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 3500/5000 st air heaters. 1.1.1 use of the air heaters the webasto air top 3500 st and ai...

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    1 introduction air top 3500/5000 st 102 2.2.2. The internal combustion heater must not pose a fire hazard even when overheated. This requirement is deemed to have been met if care is taken during installation to ensure an adequate distance from all parts, as well as adequate ventilation and if fire-...

  • Page 8

    Air top 3500/5000 st 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 vehi...

  • Page 9

    1 introduction air top 3500/5000 st 104 overheating keep hot air inlet and hot air outlet free of dirt and other items. 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 may bloc...

  • Page 10

    Air top 3500/5000 st 2 general description 201 2 general description the air top 3500 st and air top 5000 st 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 with ...

  • Page 11

    2 general description air top 3500/5000 st 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 i...

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    Air top 3500/5000 st 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 m...

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    2 general description air top 3500/5000 st 204 page for notes.

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    Air top 3500/5000 st 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. The integral green led i...

  • Page 15

    3 function description air top 3500/5000 st 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 heating and combustion air blower and the delivery rate of the metering pump are reduced. If, at minimum heat output, the i...

  • Page 16

    Air top 3500/5000 st 3 function description 303 the error counter sz is incremented by 1 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 9 the heater will go into the heater lock-out st...

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    3 function description air top 3500/5000 st 304 page for notes.

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    Air top 3500/5000 st 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 con...

  • Page 19

    4 technical data air top 3500/5000 st 402 page for notes.

  • Page 20

    Air top 3500/5000 st 5 troubleshooting 501 5 troubleshooting 5.1 general this section describes how to identify and deal with errors on the air top 3500 st and air top 5000 st heaters. If a fault occurs, an error code will be output in the display of the combination timer. If the heater has a contro...

  • Page 21

    5 troubleshooting air top 3500/5000 st 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 th...

  • Page 22

    Air top 3500/5000 st 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 occurr...

  • Page 23

    5 troubleshooting air top 3500/5000 st 504 error code error (group) additional information during pc diagnostic remedy f 07 metering pump interrupt or short circuit 88 break or short circuit to +ub 08 short circuit to earth check cables, replace metering pump check cables, replace metering pump f 08...

  • Page 24

    Air top 3500/5000 st 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 withou...

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    6 function tests air top 3500/5000 st 602 page for notes.

  • Page 26

    Air top 3500/5000 st 7 circuit diagrams 701 7 circuit diagrams 7.1 general the air top 3500 st and air top 5000 st heaters can be controlled with the control element (nominal value adjuster/switch) or a combination timer. The circuit diagrams (fig. 702 to 706) show the possible circuits for 12 and 2...

  • Page 27

    7 circuit diagrams air top 3500/5000 st 702 item designation comment a1 heater air top 3500 st/5000 st a2 control module b2 temperature sensor internal b3 overheating sensor overheating guard b4 temperature sensor external e glow plug / flame monitor f1 fuse 24v 15a / 12v 20a flat fuse sae j 1284 f2...

  • Page 28

    Air top 3500/5000 st 7 circuit diagrams 703 item designation comment a1 heater air top 3500 st/5000 st a2 control module b2 temperature sensor internal b3 overheating sensor overheating guard b4 temperature sensor external e glow plug / flame monitor f1 fuse 24v 15a / 12v 20a flat fuse sae j 1284 f2...

  • Page 29

    7 circuit diagrams air top 3500/5000 st 704 item designation comment a1 heater air top 3500 st/5000 st a2 control module b2 temperature sensor internal b3 overheating sensor overheating guard b4 temperature sensor external e glow plug / flame monitor f1 fuse 24v 15a / 12v 20a flat fuse sae j 1284 f3...

  • Page 30

    Air top 3500/5000 st 7 circuit diagrams 705 item designation comment a1 heater air top 3500 st/5000 st a2 control module b2 temperature sensor internal b3 overheating sensor overheating guard b4 temperature sensor external e glow plug / flame monitor f1 fuse 24v 15a / 12v 20a flat fuse sae j 1284 h1...

  • Page 31

    7 circuit diagrams air top 3500/5000 st 706 item designation comment a1 heater air top 3500 st/5000 st a2 control module b2 temperature sensor internal b3 overheating sensor overheating guard b4 temperature sensor external e glow plug / flame monitor f1 fuse 24v 15a / 12v 20a flat fuse sae j 1284 h1...

  • Page 32

    Air top 3500/5000 st 7 circuit diagrams 707 24v 12v terminal 58: grey terminal 15: black terminal 30: red terminal 31: brown fig. 707 schematic connection of the combination timer.

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    7 circuit diagrams air top 3500/5000 st 708 page for notes.

  • Page 34

    Air top 3500/5000 st 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...

  • Page 35

    8 servicing work air top 3500/5000 st 802 minimum internal diameter of the main section of hot air line: 80 mm for the air top 3500 st 90 mm for the air top 5000 st the hot air hose must be secured at its connection points. Important in vehicles used to transport people, the air outlet opening is to...

  • Page 36

    Air top 3500/5000 st 8 servicing work 803 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 connection may be made in either the supply or return line, in which case t...

  • Page 37

    8 servicing work air top 3500/5000 st 804 8.6.2.2 fuel lines only steel, copper and plastic lines of plasticised, light and temperature-stabilised pa11 or pa12 (for example mecanyl rwtl) pursuant to din 73378 may be used for the fuel lines. Since the lines cannot always be routed with a constant ris...

  • Page 38

    Air top 3500/5000 st 8 servicing work 805 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. Note...

  • Page 39

    8 servicing work air top 3500/5000 st 806 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 conne...

  • Page 40

    Air top 3500/5000 st 8 servicing work 807 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 fig. 814 specimen installation for heater in an air circulation system.

  • Page 41

    8 servicing work air top 3500/5000 st 808 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...

  • Page 42

    Air top 3500/5000 st 9 repair work 901 9 repair 9.1 general this section describes the repair work that may be carried out on the air top 3500/5000 st heater after it has been removed from the vehicle. Any further dismantling will invalidate the warranty. Only use the spare parts from the appropriat...

  • Page 43

    9 repair work air top 3500/5000 st 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...

  • Page 44

    Air top 3500/5000 st 9 repair work 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 insulating mat fig. 901 remove / fit the casing parts 7 1/2 1/2 6.

  • Page 45

    9 repair work air top 3500/5000 st 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 h...

  • Page 46

    Air top 3500/5000 st 9 repair work 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 insulating m...

  • Page 47

    9 repair work air top 3500/5000 st 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 ...

  • Page 48

    Air top 3500/5000 st 9 repair work 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 ...

  • Page 49

    9 repair work air top 3500/5000 st 908 page for notes.

  • Page 50

    Air top 3500/5000 st 10 packing / storage / shipment 1001 10 packaging, storage and shipping 10.1 general if the heater or its components are sent to webasto thermosysteme gmbh for testing or repair, it must be cleaned and packed in such a way that it is protected against damage during handling, tra...

  • Page 51

    10 packing / storage / shipment air top 3500/5000 st 1002 page for notes.