Webastoto Air Top 5000 Service Manual

Air heaters03/2003Workshop manualAir Top 3500 STAir Top 5000 STAir Top 3500/5000 ST B (petrol)Air Top 3500/5000 ST D (diesel)Air Top 3500 ST D Volume

Air Top 3500/5000 ST 2 General description2012 General descriptionThe Air Top 3500 ST and Air Top 5000 ST air heaters are based on the evaporator prin

2 General description Air Top 3500/5000 ST2022.1 Drive unitThe drive unit consists of the drive motor, the combustion air blower, the heat air blower

Air Top 3500/5000 ST 2 General description2032.4 Control unitThe control unit is the central component for ensuring the function is maintained and for

2 General description Air Top 3500/5000 ST204Page for notes

Air Top 3500/5000 ST 3 Function description3013 Function description3.1 Control elementThe control element is designed to switch the heater on and off

3 Function description Air Top 3500/5000 ST3023.5 Control pauseAfter the temperature set on the control element has been reached the heat output is re

Air Top 3500/5000 ST 3 Function description303The error counter SZ is incremented by 1 each error for which there is no separate counter. The error co

3 Function description Air Top 3500/5000 ST304Page for notes

Air Top 3500/5000 ST 4 Technical data4014 Technical DataExcept where limit values are specified, the technical data listed in the table refer to the u

4 Technical data Air Top 3500/5000 ST402Page for notes

Air Top 3500/5000 ST Table of contentsITable of contents1 Introduction1.1 Contents and purpose ...

Air Top 3500/5000 ST 5 Troubleshooting5015 Troubleshooting5.1 GeneralThis section describes how to identify and deal with errors on the Air Top 3500 S

5 Troubleshooting Air Top 3500/5000 ST5025.3 Error symptoms during functionThe following table (Fig. 502) lists the possible error symptoms in the ord

Air Top 3500/5000 ST 5 Troubleshooting5035.4 Error code outputIf the heater is fitted with a combination timer, an error code output will appear on th

5 Troubleshooting Air Top 3500/5000 ST504Error codeError (group) Additional information during PC diagnosticRemedyF 07 Metering pump interrupt or shor

Air Top 3500/5000 ST 6 Function tests6016 Function tests6.1 GeneralThis section describes the tests conducted on the heater when it is installed and n

6 Function tests Air Top 3500/5000 ST602Page for notes

Air Top 3500/5000 ST 7 Circuit diagrams7017 Circuit diagrams7.1 GeneralThe Air Top 3500 ST and Air Top 5000 ST heaters can be controlled with the cont

7 Circuit diagrams Air Top 3500/5000 ST702Item Designation CommentA1 Heater Air Top 3500 ST/5000 STA2 Control moduleB2 Temperature sensor InternalB3 O

Air Top 3500/5000 ST 7 Circuit diagrams703Item Designation CommentA1 Heater Air Top 3500 ST/5000 STA2 Control moduleB2 Temperature sensor InternalB3 O

7 Circuit diagrams Air Top 3500/5000 ST704Item Designation CommentA1 Heater Air Top 3500 ST/5000 STA2 Control moduleB2 Temperature sensor InternalB3 O

Table of contents Air Top 3500/5000 STII5 Troubleshooting5.1 General ...

Air Top 3500/5000 ST 7 Circuit diagrams705Item Designation CommentA1 Heater Air Top 3500 ST/5000 STA2 Control moduleB2 Temperature sensor InternalB3 O

7 Circuit diagrams Air Top 3500/5000 ST706Item Designation CommentA1 Heater Air Top 3500 ST/5000 STA2 Control moduleB2 Temperature sensor InternalB3 O

Air Top 3500/5000 ST 7 Circuit diagrams707Terminal 58: greyTerminal 15: blackTerminal 30: redTerminal 31: brownFig. 707 Schematic connection of the c

7 Circuit diagrams Air Top 3500/5000 ST708Page for notes

Air Top 3500/5000 ST 8 Servicing work8018 Servicing work8.1 GeneralThis section describes the servicing work that can be carried out on the heater whe

8 Servicing work Air Top 3500/5000 ST802Minimum internal diameter of the main section of hot air line:80 mm for the Air Top 3500 ST90 mm for the Air T

Air Top 3500/5000 ST 8 Servicing work803Vehicles with carburettor enginesThe fuel may only be extracted on cars using the special Webasto fuel extract

8 Servicing work Air Top 3500/5000 ST8048.6.2.2 Fuel linesOnly steel, copper and plastic lines of plasticised, light and temperature-stabilised PA11 o

Air Top 3500/5000 ST 8 Servicing work8058.6.5 Combustion air supplyUnder no circumstances may the combustion air be taken from areas occupied by peopl

8 Servicing work Air Top 3500/5000 ST8068.6.8 Electrical connections8.6.8.1 Heater connection, control elementThe electrical connection is to be made

Air Top 3500/5000 ST Table of contentsIII9Repair9.1 General...

Air Top 3500/5000 ST 8 Servicing work8071 Control element2Heater3 Metering pump4 Fuel filter (accessory)5 Tank connector6 Exhaust silencer7Fuse5437261

8 Servicing work Air Top 3500/5000 ST8088.7 Removal and installationIMPORTANTWhen the heater is installed it must not be dismantled.8.7.1 Heater, remo

Air Top 3500/5000 ST 9 Repair work9019 Repair9.1 GeneralThis section describes the repair work that may be carried out on the Air Top 3500/5000 ST hea

9 Repair work Air Top 3500/5000 ST9029.2 Dismantling and assembling9.2.1 Remove the casing parts9.2.1.1 Cover for electrical connectionThe cover (1, F

Air Top 3500/5000 ST 9 Repair work903YYXXX1235461 Cover, electrical connection2 Top shell3 Cover, hot air outlet4 Bottom shell5 Cover, hot air inlet6G

9 Repair work Air Top 3500/5000 ST9049.2.3 Change the control unit9.2.3.1 Removal1. Remove the heater (see 8.7.1.1).2. Remove the casing parts (see 9.

Air Top 3500/5000 ST 9 Repair work905Fig. 902 Change the control unit, overheating sensor and the combustion and hot air blower (drive unit)1 Combusti

9 Repair work Air Top 3500/5000 ST9069.2.6 Change the burner and the glow plug/flame sensor9.2.6.1 Removal1. Remove the heater (see 8.7.1.1).2. Remove

Air Top 3500/5000 ST 9 Repair work907Fig. 903 Change the burner, glow plug/flame sensor, the combustion tube and the heat exchanger1 Torx screw (4)2 R

9 Repair work Air Top 3500/5000 ST908Page for notes

Table of illustrations Air Top 3500/5000 STIVList of illustrations501 General error symptoms ...

Air Top 3500/5000 ST 10 Packing / Storage / Shipment100110 Packaging, storage and shipping10.1 GeneralIf the heater or its components are sent to Weba

10 Packing / Storage / Shipment Air Top 3500/5000 ST1002Page for notes

Air Top 3500/5000 ST 1Introduction1011Introduction1.1 Contents and purposeThis workshop manual is designed to assist trained personnel with repairing

1Introduction Air Top 3500/5000 ST1022.2.2. The internal combustion heater must not pose a fire hazard even when overheated. This requirement is deeme

Air Top 3500/5000 ST 1Introduction103Compliance with §§ 45 and 46 of the Road Vehicle Licensing Act must be ensured for the installation of fuel lines

1Introduction Air Top 3500/5000 ST104OverheatingKeep hot air inlet and hot air outlet free of dirt and other items. Dirty, blocked air lines can cause