Webasto Air Top Evo 40, Service Manual

Page 1: ...Air Heater Air Top Evo 40 55 Air Top Evo 40 B Air Top Evo 55 B Benzin Air Top Evo 40 D Air Top Evo 55 D Diesel Service Manual...

Page 2: ...tems require qualified and or professional installation and repair technicians Warranty shall be void if not installed by a certified or trained installer repair technician who has successfully comple...

Page 3: ...3 Evaporator Mount with Combustion Pipe 12 2 4 Glow Plug 13 2 5 Exhaust Temperature Sensor 13 2 6 Overheat Temperature Sensor 14 2 7 Control Unit 14 2 8 Fuel Pump 15 3 Function Description 15 3 1 Cont...

Page 4: ...2 Resistance Test of Exhaust Temperature Sensor 28 6 4 3 Heating Air Fan Component 29 6 4 4 Glow Plug Component 30 6 4 5 Drive Unit Component 31 6 4 6 Overheat Temperature Sensor Component 32 6 4 7 C...

Page 5: ...2 Carrying out modifications 54 9 2 Dismantling and assembling 55 9 2 2 Fit the housing parts 55 9 2 3 Replacing control unit 56 9 2 4 Replacing Overheat Temperature Sensor 57 9 2 5 Replacing heating...

Page 6: ...V with Smartemp 41 Figure 18 Connection Diagram for Air Top 40 55 with Air Top Evo MultiControl MC04 control element 42 Figure 19 Installation Position of Fuel Pump DP 42 47 Figure 20 Fuel Filter inst...

Page 7: ...rating instructions or procedures which if not correctly followed may result in damage to the equipment or its components NOTE This heading is used to direct your attention to a special feature deemed...

Page 8: ...cally sealed The exhaust system and the exhaust lines must be positioned or protected so that the cargo cannot be subjected to dangerous heat or ignition Parts of the exhaust system located directly u...

Page 9: ...necessary as otherwise there is a fire danger All fuel carrying lines must be connected leak tight may not be damaged and must be inspected regularly at least at the same interval as the vehicle inspe...

Page 10: ...ms 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 t...

Page 11: ...n air fan the heating air fan and the intake housing The combustion air fan supplies the air required for the combustion process from the combustion air inlet to the evaporator mount The heating air f...

Page 12: ...Mount with Combustion Pipe The fuel is distributed via the metal fibre evaporator fleece in the evaporator mount The mixture of fuel and air burns in the combustion chamber thus causing the heat exch...

Page 13: ...with combustion pipe on the side facing the flame Figure 7 Glow Plug 2 5 Exhaust Temperature Sensor The exhaust temperature sensor is a low resistance PTC resistor which changes its resistance in dep...

Page 14: ...e signal and regulates the hot air outlet temperature and controls the overheating switch off Figure 9 Overheat Temperature Sensor 2 7 Control Unit The control unit is the central component for ensuri...

Page 15: ...r an Air Top Evo Multi Control MC04 Operation is described in the operating instructions of the respective control element The control element is used to switch the heater on and off to set the desire...

Page 16: ...switched off and the existence of the flame established Automatic restart If the flame monitor does not find a flame the starting procedure will be repeated The glow plug will be switched on again cy...

Page 17: ...nsor is used If the temperature set on the control element is dropped below the room temperature sensor the heater starts again Note Changes to the setting on the control element are implemented by th...

Page 18: ...is that the heater was in the control mode directly beforehand During the restart the cycle repetition counter is increased by one This process is repeated until the heater either burns properly again...

Page 19: ...ctrical components The control unit timer glow plug and control element are designed for 12V or 24V The drive unit fuel pump exhaust temperature sensor and external room temperature sensor are indepen...

Page 20: ...perature Heater Operation Storage Fuel pump Operation Storage Rotary selector Operation Storage 40 C to 40 C 40 C to 85 C 40 C to 20 C petrol 30 C diesel 40 C to 85 C 40 C to 75 C 40 C to 85 C Permiss...

Page 21: ...you wish to check individual components the electrical plug connectors on the control unit must be disconnected Conduct a function test in the vehicle after rectifying each fault A direct operation of...

Page 22: ...er is permanently locked out and can only be returned to operation following repairs by Webasto trained professionals When equipped with a combination timer a fault code output appears on the display...

Page 23: ...uel pump defective 88 Open circuit in fuel pump 08 Short circuit in fuel pump Check electrical wiring and fuel pump and replace if necessary F 08 Open circuit short circuit overloading blockage in dri...

Page 24: ...er is in a restricted operating mode In case of restricted operation either the automatic altitude adjustment or the external room temperature sensor optional may be defective The heater can continue...

Page 25: ...o account A calibrated fuel pump which is subjected to continual operating checks must be used for testing The technical requirements are contained in the Webasto product documentation It is preferabl...

Page 26: ...load depending on the altitude Petrol units 3 The CO2 content may only be set with the unit at operating temperature The unit must be operated for at least 8 minutes for this purpose Then the CO2 cont...

Page 27: ...and 7 Procedure Test or measuring equipment Visual Visual inspection Blow through Conduct function test with reference heater Adjust the reference unit after 5 minutes to CO2 nominal value in accordan...

Page 28: ...tal multimeter the exhaust temperature sensor is to have the following values Resistance at 20 C 2 160 3 2 ohms Test current 5 mA Procedure Test or measuring equipment Visual Visual inspection Visual...

Page 29: ...Heating Air Fan Component See Figure 30 Item 1 Procedure Test or measuring equipment Visual Visual inspection Deformation Magnets present Locking lug broken 29 Air Top Evo 40 Air Top Evo 55 Service M...

Page 30: ...se values A new glow plug can be measured to act as a reference The glow plug should have the following values in the test Glow Plug 12 V no marking 24 V green marking Resistance at 25 C 0 190 0 250 o...

Page 31: ...Procedure Test or measuring equipment Visual Visual inspection Continuity measurement Drive motor start up Subjective test Digital multimeter Voltage source IMPORTANT Ensure correct polarity black red...

Page 32: ...l multimeter the overheat temperature sensor must have values in accordance with the following chart Resistance in ohms Temperature in C Figure 13 Characteristic resistance value of a PT 2000 Overheat...

Page 33: ...Procedure Test or measuring equipment Visual Visual inspection Visual inspection Visual inspection Resistance measurement Digital multimeter 33 Air Top Evo 40 Air Top Evo 55 Service Manual...

Page 34: ...ction Housing broken All clips engaged Clips torn Conduct function test with the reference unit mount the control unit to be tested in the reference heater and conduct the function test again Heater t...

Page 35: ...Drive unit black red Exhaust temperature sensor white Resistance component and continue Resistance component and continue Resistance component and continue Resistance component and continue Resistanc...

Page 36: ...placement component and continue Continuity measurement Function test Function test Digital multimeter Heater test bench CO2 measuring unit PC personal computer Webasto Diagnosis Adapter Reference hea...

Page 37: ...asurement Heater test bench CO2 measuring unit PC personal computer Webasto Diagnosis Adapter Reference heater 7 0 Wiring Diagrams 7 1 General Information The Air Top Evo 40 Air Top Evo 55 heaters can...

Page 38: ...onnection is no longer ensured This can then result in considerable damage to the heater Figure 14 Connector Assignment on Control Unit X1 Drive motor connection X2 Glow plug connection X3 Overheat Te...

Page 39: ...Figure 15 Wiring Diagram for Air Top Evo 40 55 12V 24V with rheostat 39 Air Top Evo 40 Air Top Evo 55 Service Manual...

Page 40: ...Figure 16 Wiring Diagram for Air Top Evo 40 55 12V 24V with MultiControl MC04 control element 40 Air Top Evo 40 Air Top Evo 55 Service Manual...

Page 41: ...Figure 17 Wiring diagram for Air Top Evo 40 55 12V 24V with Smartemp 41 Air Top Evo 40 Air Top Evo 55 Service Manual...

Page 42: ...0 Continuous heating mode is possible in connection with quick heating function provided the ignition is switched on 2 All heater versions W bus diagnosis connection 3 CO2 setting see workshop manual...

Page 43: ...ndicator 4 Voltage supply terminal 30 5 Voltage supply terminal 31 6 Switch on signal ON OFF 7 Multifunction ventilation boost ECO with control element MC02 only Boost activation for ambulance units 8...

Page 44: ...Item P and S Display and button lighting H7 Symbol on display M1 Motor Combustion air and heating air blower P1 SmartControl P2 SmartControl Multi Control S Air Top Evo Multi Control MC04 ON OFF butt...

Page 45: ...e heater is operating or slowing down as this could result in the heater overheating and the overheating guard thus being tripped If you wish to carry out extensive repair work on the heater it may be...

Page 46: ...t is then kept at this selected value As an alternative the Air Top Evo 40 Air Top Evo 55 heaters can be operated with an external temperature sensor see Section 9 1 2 NOTE Only materials with a conti...

Page 47: ...tallation location The fuel pump may not be installed in the radiation area of hot vehicle parts A heat shield must be provided if necessary The preferred installation space is near the fuel tank For...

Page 48: ...emissions fed to the outside Pipe passage holes must be made in such a way as to ensure that the ingress of exhaust fumes into the interior of the vehicle should not occur If soiled combustion air is...

Page 49: ...alling away from the heater If this is not possible a condensate drain hole with a diameter of 4 mm must be made at its lowest point or a connection element with a condensate drain must be used Intern...

Page 50: ...unit Before using the heater for the first time fit the cover to prevent the escape of hot air heater overheating The wiring harness can be routed either to the left or right from the heater 8 6 6 2 S...

Page 51: ...c cable Figure 25 A must be in contact with the rotary knob NOTE The connector housing can be locked self locking action by simply pulling on the wiring harness Figure 26 Disconnect the Plug 51 Air To...

Page 52: ...eater in recirculated air mode 1 Control element 2 Heater 3 Fuse 4 Fuel standpipe 5 Fuel filter optional 6 Fuel pump 7 Exhaust silencer optional 8 Maximum permissible water passage height 52 Air Top E...

Page 53: ...onnect the wiring harness plug to socket X7 on the control unit 7 Fit the cover as described in Section 9 2 2 5 and secure it 8 If necessary fit cold and hot air hose or hoses and secure them 9 Connec...

Page 54: ...ptimally regulates the desired temperature when its temperature sensor is loaded with the air temperature of the main occupied area In certain circumstances this is not always possible using the room...

Page 55: ...ure 29 can be lifted off after removing the covers for the cold air inlet and hot air outlet 9 2 1 5 Bottom shell Remove base seal By slightly spreading to the side on both sides at the lower shell 4...

Page 56: ...suit the installation situation Slide on the cover 1 Figure 29 until it audibly engages in the upper cover Figure 29 Removing fitting housing parts 1 Cover electrical connection 2 Top shell 3 Cover h...

Page 57: ...liers from the front between the two locking lugs on the motor shaft Hold heating air fan 1 Figure 30 with one hand and simultaneously and carefully spread two lugs with a slight twisting movement Pul...

Page 58: ...5 2 7 Install housing parts see 9 2 2 8 Install heater see 8 7 1 2 9 Check CO2 setting and adjust if necessary see Section 6 3 Figure 30 Replace control unit Overheat Temperature Sensor heating air fa...

Page 59: ...from package with two hands Gripping points on sensor head and connector When installing insert sensor with two hands Gripping points on sensor head and connector Do not pull on cable after installing...

Page 60: ...of evaporator mount 3 or 7 inward out of heat exchanger housing 6 9 Carefully pull evaporator mount 3 or 7 out of combustion pipe 4 Guide fuel pipe out of heat exchanger housing 6 by turning evaporato...

Page 61: ...sensor and retaining spring 7 Remove evaporator mount see 9 2 8 1 8 Remove 2 screws 1 Figure 34 and pull combustion pipe 4 out of heat exchanger 6 9 Remove round sealing ring 5 from heat exchanger 6 a...

Page 62: ...emperature sensor 10 0 Packaging storage and shipping 10 1 General information The heater or its components which are sent to Webasto for testing or repair must be cleaned and packaged so that they ar...

Page 63: ...4 2015...