Webasto air top 5000 service manual

To revisit this article, visit My Profile, then Vie. Exposure to particulate matter from air pollution is associated with a higher risk of heart attacks and strokes. People can protect themselves by avoiding high-pollution areas, restricting time outside when air quality is poor, and exercisi.

NOTE Overheating and dosing pump failure are always and additionally indicated by a flashing LED of the control element after run-down. In all cases of malfunction, a faulty control unit could be the cause should the remaining components be serviceable.

Symptom Symptom shows after The flash pulses correspond to the number of the table below. After a rapid pulse train there will always be an error code output. The heater is preset by the manufacturer as applicable for the combustion and heating air fan installed. The manufacturer's setting may be corrected by changing the control element adjustment CO2 pin connected to vehicle ground.

For adjustment a suitable CO2 detector must be used. Connect CO2 pin brown cable in two pin connector of secondary line at wiring harness end of heater to vehicle ground using suitable adapter cable. Switch heater on. Adjust rotary setscrew on control element to centre position. Wait until operating indicator light LED flashes. Rotating the setscrew clockwise increases the fan speed and decreases the CO2 contents.

Rotating the setscrew counterclockwise decreases the fan speed and increases the CO2 contents. Air Top min-1 max. When exceeding the max. After CO2 contents adjustment allow heater to operate for another five minutes and readjust CO2 setting as required. Disconnect CO2 pin from vehicle ground. Wait until flashing operating indictor light LED changes to a steady indication. Wait for completion of run-down and switch heater off.

NOTE If setting range is not sufficient e. If the second attempt of CO2 adjustment is unsatisfactory, a heater component is defective. Return the heater to Webasto Thermosysteme GmbH for testing and repair.

The circuit diagrams Fig. As long as the heater is in operation or in run-down the battery main power supply must not be disconnected to prevent the heater from overheating by response of the overheat protection. Repairs requiring a change of location the relevant installation instructions and the vehicle specific heater installation proposal have to be observed. The heater does not require any maintenance. It should however be inspected in regular intervals by Webasto trained maintenance personnel, the latest date for inspection being the start of the heating season point of time with increased use of heater.

Contaminations or obstructions in heating air lines may cause overheating and thus response of the temperature limiter. Visual Inspections and Installation Regulations 8. Both the circulation and ventilation mode of operation are permitted.

In fresh air ventilation mode ensure to use heating air only from areas protected against splash and spray water. On the air intake side of the heater a temperature sensor is located, which in combination with the control element, makes the heater operate with adequate heating performance dependent on air intake temperature and control element setting.

Heating performance is set so that after fast heat-up to the preselected indoor temperature this temperature will be maintained. NOTE In the fresh air ventilation mode of operation or when installing the heater in an installation box, an external temperature sensor must be mounted in the room area to be under heat control!

The temperature sensor must not be mounted on exterior walls without insulation. It must also be protected against direct exposure to sun and draught wind. The heating air opening is to be located so that components not temperature resistant are exposed to the heating air flow.

The heating air hose connections must be secured. This separate fuel tapping avoids an influence on the pressure. HG HG In the air circulation mode the heater may be used without any accessories for heating air ducting. A short circuit of the heating air flow should be avoided. A descending line routing from the dosing pump to the heater should be avoided. As a permanently rising fuel line routing cannot always be ensured, the inner diameter must not exceed a certain value.

Too large inner diameters cause air or gas bubbles to accumulate resulting in malfunctions should the lines be descending or having sags. The diameters specified in Fig. Gasket Fig. The installation must ensure protection against stone impacts and undue temperatures exhaust line.

Fuel line connections must be secured against slippage using hose clamps. It is advantageous to mount the dosing pump in a cool location. Dosing pump and fuel lines must not be installed in locations exposed to heat radiated by hot vehicle components e. A heat shield is to be provided as necessary.

The installation location is limited according to Fig. Due to the danger of corrosion only Webasto original parts may be used for the plug connection between dosing pump and dosing pump wiring harness. Fuel Filter If fuel contaminations are expected, only Webasto filter order no. The filter installation should be vertical and never exceed horizontal observe direction of flow. 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 use of an air intake muffler or an equivalent air intake extension is necessary. The line feedthroughs must not allow exhaust fumes to enter the vehicle interior.

In order to avoid damage to the dosing pump cable, no exhaust line must be used for extension of the combustion air supply line. Both lines are to be routed away from the heater in a descent. If this is not possible, a condensate drain hole with a diameter of 4 mm must be provided at the lowest point.

Inner diameter of the lines: combustion air intake line: exhaust line metal : 25 mm 24 mm NOTE Exhaust line lengths exceeding 2 m require the use of insulated exhaust lines dew point below minimum. The exhaust line is fastened to the heater e.

Sum of bends: combustion air intake line: exhaust line: 50 mm max. Operation of the heater is also permitted without exhaust muffler. For disconnection of the connector simply pull on the connector terminal Fig. Pulling on the wiring harness will lock the connector self-locking. 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 plugged onto the heater.

Prior to first operation of the heater the cover must be fitted to avoid undue escape of heating air heater overheating. The cable passage may be on the left or right.

For heater protection an additional flat fuse holder included in the heater delivery must be fitted. The fuse holder may only be installed in the vehicle interior. Disconnect vehicle battery. Remove cover from upper housing shell according to 9. Disconnect wiring harness connector from heater. Disconnect fuel supply line from heater. Disconnect combustion air intake line and exhaust line from heater.

Remove four nuts and washers from heater. Remove heater and discard gasket. Locate heater with new gasket for installation and secure with four nuts and washers use Webasto original nuts only.

Connect and secure fuel supply line to heater. Connect and secure combustion air intake line and exhaust line to heater. Route cable to dosing pump and connect to dosing pump. Connect wiring harness connector to control unit. Plug on cover and arrest. Reconnect vehicle battery. Bleed fuel supply system. NOTE Due to the low fuel consumption it is required to switch the heater several times on and off for priming the fuel line.

During the heater test run inspect all connections for leakage and security. Should the heater during operation enter an error lockout condition, perform troubleshooting. Any further disassembly will void the warranty. Due to bubble the danger of corrosion only Webasto original parts may be used for the plug connection between dosing pump and dosing pump wiring harness.

The intake must not point in the line: direction of forward motion. For disconnection of the connector simply pull on the The electrical connection is according to the circuit connector terminal Fig.

Page Removal And Installation 7. Remove heater and discard gasket. Locate heater with new gasket for installation and secure with four nuts and washers use Webasto original nuts only.

Connect and secure fuel supply line to heater. Page General 9. Fit new seal 13 in groove of flange of heat exchanger General 6. Position burner tube 12 for assembly and fasten with Retrofit kit, 12 V Ident. Steps 6 through 13 refer to 1. This washer must be replaced with a new washer during installation.

Next Page. Webasto Air Top Workshop Manual 49 pages. Page 3: Introduction Used Scope and Purpose This manual contains all of the information and procedures necessary for the installation of the Air Top heater in This manual is intended to support authorized Webasto on and off highway vehicles. A violation of heater. Page 5: General Description 2. Marine: The Air Top can be used as the primary heating source for watercraft. Boat installations may only be performed by a Webasto authorized marine dealer.

Page 7: Functional Description Due to the risk of explosion causing death or serious injury to personnel, the heater must never be operated in areas where explosive materials, fumes or dusts may be present.

The control element acts as a thermostat, similar to a dimmer switch. The built in light indicates heater operation status by illuminating while the heater is on. It is possible to program 3 different starting times, only one of which can be activated. The combination timer has a temperature controller. Page Technical Data — Webasto recommends installing gasoline-operated heaters so that the exhaust gas outlet points vertically down.

Other installation positions may cause increased wear to the burner. Page Installation Due to the confined spaces within marine vehicles, an increased risk of carbon monoxide poisoning causing death or serious injury to personnel is possible.

Therefore, installations in marine vessels are to be performed by Webasto authorized marine equipment specialists only.