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Webasto Air Top Evo 3900/5500 B Installation Manual

Summary of Air Top Evo 3900/5500 B

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    Air heater air top evo 3900/5500 b (gasoline) air top evo 3900/5500 d (diesel) installation manual warning! – 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. – installation and repair o...

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    Air top 3500/5000 st table of contents www.Webasto.Us 1 webasto product n.A., inc. Contents page 1. Safety and general information 3 1.1 warning symbols in this installation manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2 g...

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    Table of contents air top 3500/5000 st www.Webasto.Us 2 webasto product n.A., inc. 12.Starting the heater for the first time 28 12.1 control element description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 12....

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    Www.Webasto.Us 3 webasto product n.A., inc. Air top evo 3900/5500 safety and general information 1. Safety and general information 1.1 warning symbols in this installation manual the purpose of safety symbols is to attract your attention to possible hazardous conditions. This manual uses a series of...

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    Webasto product n.A., inc. 4 www.Techwebasto.Com regulation for installation in the vehicle air top evo 3900/5500 2. Regulation for installation in the vehicle read this installation manual in its entirety before installing this equipment. 2.1 legal provisions 2.1.1 the installation and service of w...

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    Www.Webasto.Us 5 webasto product n.A., inc. Air top evo 3900/5500 regulation for installation in the vehicle 2.3.6 when a separate fuel supply is used the fuel filler neck must not be located in the passenger compartment and must have a tightly fitting cap to prevent any fuel leaks. 2.3.7 the type o...

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    Webasto product n.A., inc. 6 www.Techwebasto.Com purpose of the air heater air top evo 3900/5500 3. Purpose of the air heater the webasto air top evo 3900/5500 air heaters are designed – to heat cabins, boats (diesel only), trucks, minibuses, vans and motor homes – to defrost vehicle windows – to he...

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    Www.Webasto.Us 7 webasto product n.A., inc. Air top evo 3900/5500 installation 4. Installation important! The regulations governing installation on pages 4 and 5 must be adhered to. The heater must not be operated without the control unit cover (#9 below) (this will cause the heater to overheat). 4....

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    Webasto product n.A., inc. 8 www.Techwebasto.Com installation air top evo 3900/5500 4.4 to install the heater the m6 nuts used to install the heater must be tightened with a torque of 6 nm ±1 nm (4.4 lb.-ft ± 74 lb.-ft). The installation dimensions and space requirement for service access are shown ...

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    Www.Webasto.Us 9 webasto product n.A., inc. Air top evo 3900/5500 installation 4.5 optional mounting plate figure 5. Mounting with optional mounting plate when using the optional mounting plate and closed cell foam gasket, do not over tighten the mounting bolts. Doing so will cause the mounting plat...

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    Webasto product n.A., inc. 10 www.Techwebasto.Com installation air top evo 3900/5500 4.7 installation example figure 7. Installation example with heater in stalled under-bunk. (recirculation mode) 1 2 3 4 5 6 7 1 control element (rheostat) 2 a t 3900/5500 evo heater 3 fuel metering pump 4 fuel filte...

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    Www.Webasto.Us 11 webasto product n.A., inc. Air top evo 3900/5500 hot air system 5. Hot air system note: the heater must not be integrated into the vehicle’s air system. Both recirculation and fresh air modes are possible. For fresh air mode it must be ensured that the inlet (hot) air is taken from...

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    Webasto product n.A., inc. 12 www.Techwebasto.Com hot air system air top evo 3900/5500 important! If you use the heater without a hot air inlet hose, the inlet grille supplied with the heater must be used at all times. Note: the installation must be checked for: – air short circuit between the vehic...

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    Www.Webasto.Us 13 webasto product n.A., inc. Air top evo 3900/5500 fuel supply 6. Fuel supply the fuel is taken from the vehicle fuel tank or from a separate fuel tank. The values for the maximum pressure at the fuel extraction point are shown in figure 11. A sign must be affixed to the fuel tank’s ...

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    Webasto product n.A., inc. 14 www.Techwebasto.Com fuel supply air top evo 3900/5500 6.2 vehicles with fuel injection engines when installing the heater in a vehicle with fuel injection system, it is important to establish whether the fuel pump is located inside or outside the tank. If the fuel pump ...

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    Www.Webasto.Us 15 webasto product n.A., inc. Air top evo 3900/5500 fuel supply 6.4.1 connecting two fuel lines with a coupler hose the correct procedure for connecting fuel lines with hosing is shown in figure 16. Ensure that there are no leaks. Figure 16. Fuel line / coupler hose connection 6.5 fue...

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    Webasto product n.A., inc. 16 www.Techwebasto.Com fuel supply air top evo 3900/5500 6.5.2 installation and attachment the metering pump must be secured with a vibration-damping mounting. Its installation position is limited as shown in figure 18 in order to ensure effective automatic bleeding. As a ...

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    Www.Webasto.Us 17 webasto product n.A., inc. Air top evo 3900/5500 combustion air supply 7. 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 t...

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    Webasto product n.A., inc. 18 www.Techwebasto.Com exhaust pipe air top evo 3900/5500 8. Exhaust pipe rigid pipes of unalloyed or alloyed steel with a minimum wall thickness of 1.0 mm (3/64 in.) or flexible piping of alloyed steel only must be used as exhaust line. The exhaust pipe is secured to the ...

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    Www.Webasto.Us 19 webasto product n.A., inc. Air top evo 3900/5500 combustion air inlet and exhaust lines 9. Combustion air inlet and exhaust lines both lines are to be installed falling away from the heater. If this is not possible, a condensate drain hole with a diameter of 4 mm (5/32 in.) must be...

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    Webasto product n.A., inc. 20 www.Techwebasto.Com electrical connections air top evo 3900/5500 10. Electrical connections all the cables and wires that are not required must be insulated against accidental shorting or grounding. Note: the electrical connection is made as shown in the system circuit ...

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    Www.Webasto.Us 21 webasto product n.A., inc. Air top evo 3900/5500 electrical connections 10.3 control element (rheostat) connection the wiring harness is prepared for connection to the control element. Simply pull on the connector housing to unplug the connector. The connector housing can be locked...

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    Webasto product n.A., inc. 22 www.Techwebasto.Com electrical connections air top evo 3900/5500 10.4 installation instructions for control panel mc04/05 the control panel should be installed in a suitable location (on a flat surface if possible) in the area visible to the driver. – use drilling templ...

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    Www.Webasto.Us 23 webasto product n.A., inc. Air top evo 3900/5500 electrical connections 10.4.1 mc04/05 control panel connections figure 33. Connection diagram for air top evo 3900/5500 with control panel mc04/05 10.4.2 combination timer 1531 connections figure 34. Air top evo 3900/5500 with combin...

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    Webasto product n.A., inc. 24 www.Techwebasto.Com circuit diagrams air top evo 3900/5500 11. Circuit diagrams 11.1 legend for circuit diagrams cable colors (where applicable) bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white item description comment a1 heater a...

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    Www.Webasto.Us 25 webasto product n.A., inc. Air top evo 3900/5500 circuit diagrams figure 35. Standard system wiring diagram for the air top evo 3900/5500, 12 / 24 volt with control element..

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    Webasto product n.A., inc. 26 www.Techwebasto.Com circuit diagrams air top evo 3900/5500 figure 36. Standard system wiring diagram for the air top evo 3900/5500, 12 / 24 volt with combination timer..

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    Www.Webasto.Us 27 webasto product n.A., inc. Air top evo 3900/5500 circuit diagrams figure 37. Standard system wiring diagram for the air top evo 3900/5500, 12 / 24 volt with control panel mc04/05..

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    Webasto product n.A., inc. 28 www.Techwebasto.Com starting the heater for the first time air top evo 3900/5500 12. Starting the heater for the first time after you have installed the heater, bleed the fuel supply system carefully. Note: as a result of the low fuel consumption the heater must be swit...

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    Www.Webasto.Us 29 webasto product n.A., inc. Air top evo 3900/5500 fault lock-out 13. Fault lock-out the control unit continuously monitors the heater operation. The control unit identifies errors on individual heater components and faults during operation. Should the control unit experience compone...

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    Webasto product n.A., inc. 30 www.Techwebasto.Com technical data air top evo 3900/5500 14. Technical data except where limit values are specified, the technical data refer to the usual heater tolerances of ± 10% at an ambient temperature of +20 °c (68 °f) and at the rated voltage and in rated condit...

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    Www.Webasto.Us 31 webasto product n.A., inc. Air top evo 3900/5500 version 15. Version air top evo 3900/5500 b (gasoline) air heater for gasoline (12 v) air top evo 3900/5500 d (diesel) air heater for diesel/heating oil (12 or 24 v).

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    Webasto product n.A., inc. 32 www.Techwebasto.Com drilling template air top evo 3900/5500 16. Drilling template figure 39. Drilling template for heater installation (dimensions in millimeters) figure 40. Drilling template for mc04/05 control panel Ø 7.5 Ø 7.5 Ø 7.5 Ø 26 Ø 26 18 12 44 55 98 r2 63.

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    Www.Webasto.Us 33 webasto product n.A., inc. Air top evo 3900/5500 notes: 17. Notes:.

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    Webasto product n.A., inc. 15083 north road fenton, mi 48430 technical assistance hotline usa: (800) 555-4518 canada: (800) 667-8900 www.Webasto.Us www.Techwebasto.Com org. 05/2009 rev. N/a p/n lit909385a copyright 2009.