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. The Webasto Air Top Evo 3900 and Air Top Evo 5500 air heaters are designed
- to heat cabins, boats, trucks, minibuses, vans, ambulances and motorhomes
- to defrost vehicle windows
- to heat cargo
They are not designed for heating cargo areas used to carry hazardous substances. The heaters operate independently of the engine and are connected to the fuel tank and the electrical system of the vehicle. They may be used for vehicles with either water or aircooled engines.
Statutory regulations governing installation
The Air Top Evo 3900 and Air Top Evo 5500 heaters have been type-tested and approved in accordance with EC Directives 72/245/EEC (EMC) and 2001/56/EC (heater) with the following EC permit numbers:
e1*72/245*2006/28*5079*
e1*2001/56*2006/119*0219*
e1*2001/56*2006/119*0220*
Statutory regulations and safety instructions
In principle, the general accident prevention regulations and current works safety instructions are applicable. The "General safety regulations" that go beyond the scope of the above regulations are stated below. Any special safety regulations relevant to this instruction manual will be highlighted in the relevant sections or text passages of the procedures.
Additional documentation to be used
This workshop manual contains all the information and instructions required for repairing the Air Top Evo 3900 and Air Top Evo 5500 air heaters. Normally, there is no need to use additional documentation. If necessary the operating / installation instructions and the installation suggestion for the specific vehicle may also be used.
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 may block the air current and have any damage to the air lines repaired by an authorised Webasto workshop. After this the heater lockout can be cancelled by switching it off and then on again.If this action does not produce the required success (if the heater overheats again) take it to an Webastoauthorised workshop.
The air outlet jets or air vents with adjustable flaps must always be opened to some extent so that the air current through the heater is not completely blocked.At least one air vent must be non-closable. If the heater is installed in a storage area, you must ensure that no inflammable substances are kept in this area and that other material does not restrict the air supply to the heater. Air lines must be securely fixed to the heater (using pipe clips, for example) and all other connection points (for example vents).
NOTE
Failure to follow the installation instructions and the notes contained therein will lead to all liability being refused by Webasto. The same applies if repairs are carried out incorrectly or with the use of parts other than genuine spare parts. This will result in the invalidation of the type approval for the heater and therefore of its homologation / EC type licence.
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 with combustion pipe
- The control unit
The fuel supply is provided from an external source using a metering pump. If a fault occurs, an error code will be output in the display of the combination or standard timer. If the heater has a control element, the ON control light will flash.In addition the heater can be checked using a personal computer (see PC heater diagnostic operating manual). The heater may be controlled using an external temperature sensor instead of the internal temperature sensor.