1. DL manuals
  2. Webasto
  3. Marine Equipment
  4. Air Top 3500 ST
  5. Workshop Manual

Webasto Air Top 3500 ST Workshop Manual

Summary of Air Top 3500 ST

  • Page 1

    Air heaters 07/2000 workshop manual air top 3500 air top 5000 type at 3500 d (diesel) type at 5000 d (diesel).

  • Page 2

    Air top 3500/5000 list of contents i list of contents 1 introduction 1.1 scope and purpose ............................................................................................................................... 101 1.1.1 use of the air heaters ...................................................

  • Page 3

    List of contents air top 3500/5000 ii 6 functional checkouts 6.1 general ................................................................................................................................................. 601 6.2 adjustments ................................................................

  • Page 4

    Air top 3500/5000 list of contents iii 9.2 disassembly and assembly................................................................................................................... 903 9.2.1 housing components / covers, removal .........................................................................

  • Page 5

    List of figures air top 3500/5000 iv list of figures 301 functional diagram.................................................................................................................................... 302 501 general failure symptoms ..............................................................

  • Page 6

    Air top 3500/5000 1 introduction 101 1 introduction 1.1 scope and purpose this repair shop manual is intended to support familiarised personnel in the repair of the air heaters air top 3500, air top 3500 volume plus and air top 5000 of the diesel type. 1.1.1 use of the air heaters the air heaters ai...

  • Page 7

    1 introduction air top 3500/5000 102 when installing the air top 3500 and air top 5000 in vehicles intended for the transportation of dangerous goods, the trs 002 and trs 003 (technical guidelines for regulations concerning the transportation of dangerous goods on roads) must be met in addition to t...

  • Page 8

    Air top 3500/5000 1 introduction 103 exhaust line the heaters must be designed for exhaust emission to the exterior. Exhaust lines must be routed so that exhaust fumes are unlikely to penetrate into the vehicle's interior. The function of any part of the vehicle essential for operation must not be i...

  • Page 9

    1 introduction air top 3500/5000 104 page free for notes.

  • Page 10

    Air top 3500/5000 2 general description 201 2 general description the air heaters air top 3500 and air top 5000 working to the evaporator principle of operation basically consist of the: – combustion and heating air fan – heat exchanger – burner – combustion tube – control unit for control and monit...

  • Page 11

    2 general description air top 3500/5000 202 2.1 combustion and heating air fan the combustion and heating air fan delivers the air necessary for combustion from the combustion air inlet into the burner. The fan also supplies heating air to the heating air outlet. 2.2 heat exchanger within the heat e...

  • Page 12

    Air top 3500/5000 2 general description 203 2.4 control unit the control unit ensures control and monitoring of combustion operation. A temperature sensor plugged on the control unit is used for temperature control. On all heaters this temperature sensor may be substituted with an externally mounted...

  • Page 13

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

  • Page 14

    Air top 3500/5000 3 functional description 301 3 functional description (fig. 301) 3.1 control element the control element is used to switch the heater on and off, to set the desired room temperature (air intake temperature between 5° c and 35° c), to reset the heater after a malfunction with error ...

  • Page 15

    3 functional description air top 3500/5000 302 1 start 2 controlled operation 3 rated (set) value achieved 4 rated (set) value exceeded (e.G. Due to reduced heat consumption) 5 run-down 6 control idle 7 start 8 controlled operation (increased heat consumption) 9 switch off 10 run-down a = control el...

  • Page 16

    Air top 3500/5000 3 functional description 303 3.3 heating operation during operation there is a flow of combustion gasses through the heat exchanger. The heat of combustion is thereby dissipated onto the heat exchanger walls and is absorbed by the heating air delivered from the heating air fan to b...

  • Page 17

    3 functional description air top 3500/5000 304 3.7 error lockout the control unit detects malfunctions of individual heater components and errors in the start sequence and in heater operation. The heater is switched off and enters error lockout under the following conditions: • control unit error • ...

  • Page 18

    Air top 3500/5000 4 technical data 401 4 technical data where no threshold values are specified technical data in the table are understood to include standard tolerances of ±10 % for heater units at an ambient temperature of +20° c and at nominal voltage and nominal conditions. Electrical components...

  • Page 19

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

  • Page 20

    Air top 3500/5000 5 troubleshooting 501 5 troubleshooting 5.1 general this section describes the troubleshooting for the heater air top 3500 and air top 5000. After heater malfunction an error code is output to the display of the combination or standard timer. When equipped with a control element th...

  • Page 21

    5 troubleshooting air top 3500/5000 502 5.3 failure symptoms during operational sequence the following table (fig. 502) lists possible failure symptoms in the time pattern of the functional sequence. In case of a malfunction this table is to be used for isolation and removal of the malfunction. It i...

  • Page 22

    Air top 3500/5000 5 troubleshooting 503 5.4 error code output when equipped with a combination timer a malfunction will output an error code to the timer display. Note when equipped with a control element the error code output after a malfunction will be a flashing operating indicator light/error co...

  • Page 23

    5 troubleshooting air top 3500/5000 504 page free for notes.

  • Page 24

    Air top 3500/5000 6 functional checkouts 601 6 functional checkouts 6.1 general this section describes the tests on the heater in installed and removed condition to prove its serviceability. Warning the heater must not be operated in enclosed areas like garages or workshops not provided with exhaust...

  • Page 25

    6 functional checkouts air top 3500/5000 602 page free for notes.

  • Page 26

    Air top 3500/5000 7 circuit diagrams 701 7 circuit diagrams 7.1 general the heater air top 3500 and air top 5000 may be operated with the control element (rated value setting/ switch) or with a combination timer. The circuit diagrams (fig. 702 to 706) show possible 12 v or 24 v circuits with: • cont...

  • Page 27

    7 circuit diagrams air top 3500/5000 702 item nomenclature remark a1 heater air top 3500/5000 a2 control unit b2 temperature sensor b3 temperature limiter overheat protection e glow plug / flame sensor f1 fuse 24v 15a / 12v 20a flat fuse sae j 1284 h1 led green (in item s1) operating indicator light...

  • Page 28

    Air top 3500/5000 7 circuit diagrams 703 item nomenclature remark a1 heater air top 3500/5000 a2 control unit b2 temperature sensor b3 temperature limiter overheat protection e glow plug / flame sensor f1 fuse 24v 15a / 12v 20a flat fuse sae j 1284 f3 fuse max. 15a flat fuse sae j 1284 h3 led red (i...

  • Page 29

    7 circuit diagrams air top 3500/5000 704 item nomenclature remark a1 heater air top 3500/5000 a2 control unit b2 temperature sensor b3 temperature limiter overheat protection e glow plug / flame sensor f1 fuse 24v 15a / 12v 20a flat fuse sae j 1284 f3 fuse max. 15a flat fuse sae j 1284 h3 led red (i...

  • Page 30

    Air top 3500/5000 7 circuit diagrams 705 item nomenclature remark a1 heater air top 3500/5000 a2 control unit b2 temperature sensor b3 temperature limiter overheat protection e glow plug / flame sensor f1 fuse 24v 15a / 12v 20a flat fuse sae j 1284 h1 led green (in item s1) operating indicator light...

  • Page 31

    7 circuit diagrams air top 3500/5000 706 item nomenclature remark a1 heater air top 3500/5000 a2 control unit b2 temperature sensor b3 temperature limiter overheat protection e glow plug / flame sensor f1 fuse 24v 15a / 12v 20a flat fuse sae j 1284 h1 led green (in item p1) operating indicator light...

  • Page 32

    Air top 3500/5000 8 servicing 801 8 servicing 8.1 general this section describes the servicing procedures allowed on the heater when installed. 8.2 work on the heater for any type of work on the heater the fuses for the heater must be removed. As long as the heater is in operation or in run-down the...

  • Page 33

    8 servicing air top 3500/5000 802 maximum pressure drop between suction and pressure side of heating air duct: 2.0 mbar (20 mm water column) air top 3500 3.0 mbar (30 mm water column) air top 5000 note exceeding this value will cause the temperature limiter to respond. The heating air hose connectio...

  • Page 34

    Air top 3500/5000 8 servicing 803 fig. 802 webasto fuel tap* *fuel tap to be used only for metal fuel tanks fig. 803 fuel tapping from plastic tank (tapping via fuel drain plug) fig. 804 fuel tapping from plastic tank (tapping via fitting plate) note tank fitting plate to be made from sheet metal! 8...

  • Page 35

    8 servicing air top 3500/5000 804 connection of 2 pipes with hose the correct connection of fuel lines with hoses is shown in fig. 805. Fig. 805 pipe/hose connection 8.6.3 dosing pump the dosing pump is a combined delivery, dosing and shut-off system and is subject to certain installation criteria (...

  • Page 36

    Air top 3500/5000 8 servicing 805 8.6.5 combustion air supply the combustion air must not be taken in from rooms accommodating persons. The intake must not point in the direction of forward motion. The combustion air intake must be located so that clogging by contamination is not to be expected. The...

  • Page 37

    8 servicing air top 3500/5000 806 8.6.8 electrical connections 8.6.8.1 connection of heater, control element the electrical connection is according to the circuit diagram (see section 7). For connection to the wiring harness the cover on the heater must be removed and the wiring harness connector be...

  • Page 38

    Air top 3500/5000 8 servicing 807 1 control element 2 heater 3 dosing pump 4 fuel filter (accessory) 5 fuel tap 6 exhaust muffler (accessory) 7 flat fuse holder 5 4 3 7 2 6 1 fig. 814 sample installation of air heater for air circulation mode of operation.

  • Page 39

    8 servicing air top 3500/5000 808 8.7 removal and installation caution with the heater installed no component removal or disassembly procedures are permitted. 8.7.1 heater, removal and installation 8.7.1.1 removal 1. Disconnect vehicle battery. 2. Remove cover from upper housing shell according to 9...

  • Page 40

    Air top 3500/5000 9 repair 901 9 repair 9.1 general this section describes the repairs that may be performed on the heaters air top 3500 and air top 5000 when removed. Any further disassembly will void the warranty. For assembly only spares from the original spares kits must be used. 9.1.1 work on c...

  • Page 41

    9 repair air top 3500/5000 902 9.1.2.2 installation of burner with shield general retrofit kit, 12 v (ident. No. 679 84a) retrofit kit, 24 v (ident. No. 679 56a) the retrofit kit includes: 1 burner with shield 1 combustion tube 3 ejot fds screws sf procedure 1. Remove burner with burner tube and dis...

  • Page 42

    Air top 3500/5000 9 repair 903 9.2 disassembly and assembly 9.2.1 housing components / covers, removal 9.2.1.1 cover for electrical connection the wiring harness leaves the heater either on the left or right side depending on installation conditions. The cover (1, fig. 901) may be levered off on bot...

  • Page 43

    9 repair air top 3500/5000 904 9.2.2 temperature sensor, replacement note • the temperature sensor may be replaced without removal of the heater. • the internal temperature sensor may be substituted against an external temperature sensor (see 9.1.2.1). 9.2.2.1 removal 1. Remove cover (1, fig. 901). ...

  • Page 44

    Air top 3500/5000 9 repair 905 9.2.6 glow plug / flame sensor, replacement 9.2.6.1 removal 1. Remove housing components / covers (see 9.2.1). 2. Remove insulation mat (15, fig. 902). 3. Remove control unit (see 9.2.4.1). 4. Remove combustion and heating air fan (see 9.2.5.1). Note perform steps 5 th...

  • Page 45

    9 repair air top 3500/5000 906 fig. 902 disassembly and assembly 11 glow plug / flame sensor 12 burner tube 13 seal 14 heat exchanger 15 insulation mat 16 seal 17 torx screw (4) 18 burner with shield 19 burner 20 fastening clamp 1 control unit 2 torx screw (2) 3 temperature limiter 4 torx screw 5 te...

  • Page 46

    Air top 3500/5000 9 repair 907 9.2.7 burner, replacement 9.2.7.1 removal 1. Remove housing components / covers (see 9.2.1). 2. Remove insulation mat (15, fig. 902). 3. Remove control unit (see 9.2.4.1). 4. Remove combustion and heating air fan (see 9.2.5.1). Note perform steps 5 through 11 for a bur...

  • Page 47

    9 repair air top 3500/5000 908 9.2.9 heat exchanger, replacement caution replacement of heat exchanger requires additional replacement of temperature limiter. 9.2.9.1 removal 1. Remove housing components / covers (see 9.2.1). 2. Remove insulation mat (15, fig. 902). 3. Remove control unit (see 9.2.4...

  • Page 48

    Air top 3500/5000 10 packaging, storage and shipping 1001 10 packaging, storage and shipping 10.1 general the heater or its components shipped to webasto thermosysteme gmbh for testing or repair must be cleaned and packaged so that they are protected against damage during handling, shipping and stor...

  • Page 49

    10 packaging, storage and shipping air top 3500/5000 1002 page free for notes.