- DL manuals
- Webasto
- Water Heater
- thermo top evo
- Workshop Manual
Webasto thermo top evo Workshop Manual
Summary of thermo top evo
Page 1
Water heaters 03/2003 workshop manual thermo top evo type thermo top evo (petrol) type thermo top evo (diesel) visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 2
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. To install and repair webasto heating and cooling systems you need to have completed a webasto training course and have the appropriate t...
Page 3: Thermo Top Evo
Thermo top evo table of contents i table of contents 1 introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 1.1 contents and purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 4: Table of Contents
Table of contents thermo top evo ii 7 circuit diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701 8 servicing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5: Thermo Top Evo
Thermo top evo list of illustrations iii list of illustrations fig. 201 thermo top evo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 fig. 202 combustion-air fan unit . . . . . . . . . . . . . . . . . . . . . ...
Page 6: List of Illustrations
List of illustrations thermo top evo iv visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 7: Thermo Top Evo
Thermo top evo 1 introduction 101 1 introduction 1.1 contents and purpose this workshop manual is used to support trained personnel which repairs the petrol and diesel models of the thermo top evo parking heater water heaters and auxiliary heaters. 1.2 meaning of signal words throughout this manual,...
Page 8: 1 Introduction
1 introduction thermo top evo 102 the heater: • may not be subjected to temperatures of more than 120 °c (storage temperature). Otherwise the electron- ics may suffer permanent damage. • may only be operated with the fuel and the nominal voltage specified on the type label. • must be shut down by im...
Page 9: Thermo Top Evo
Thermo top evo 2 general description 201 2 general description the thermo top evo water heater is used to compensate the heat deficit which results with consumption-optimised vehicle engines. The thermo top evo parking heater is used: – to heat the vehicle interior, – to defrost the vehicle windows,...
Page 10: 2 General Description
2 general description thermo top evo 202 2.1 combustion-air fan unit/control unit the combustion-air fan unit contains: • the heater type label • the connection piece for the combustion air pipe • the control unit with the plug-in contacts • the engine and the impeller the combustion air fan supplie...
Page 11: Thermo Top Evo
Thermo top evo 2 general description 203 2.2.1 glow plug/flame monitor the glow plug/flame monitor is connected to the control unit (sg) via an electrical line with a connector (b9). The glow plug is fastened to the evaporator mount with a retaining spring (b2). A cooling flag (b3) provides for heat...
Page 12: 2 General Description
2 general description thermo top evo 204 important only the model dp42 fuel metering pump may be used for the thermo top evo heater. Observe the model designation on the component for this purpose. When replacing the metering pump, the co 2 settings must be checked. See section 8.2. 2.6 heater contr...
Page 13: Thermo Top Evo
Thermo top evo 3 description of operation 301 3 description of operation 3.1 switching on/starting process the heater is started with the parking heater via a switch-on signal of the heater control. And with the auxiliary heater when the auxiliary heating signal is present at the heater unit inlet. ...
Page 14: 3 Description of Operation
3 description of operation thermo top evo 302 3.3 restarting after fault lock-out after the fault cause has been eliminated, the heater must be switched on again with the normal switch-on signals. This does not apply after overheating or if a fault occurs sev- eral times without intermediate combust...
Page 15: Thermo Top Evo
Thermo top evo 4 technical data 401 4 technical data the technical data is contained in the installation instructions. Visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 16: 4 Technical Data
4 technical data thermo top evo 402 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 17: Thermo Top Evo
Thermo top evo 5 troubleshooting 501 5 troubleshooting 5.1 faults 5.1.1 fault lock-out and heater lock-out faults which occur are assigned to various categories: fault 1) a fault which occurs has no effect on the current combustion operation; an fault message is stored. 2) a fault which occurs cause...
Page 18: 5 Troubleshooting
5 troubleshooting thermo top evo 502 5.3 troubleshooting possible fault during heater operation are sorted in this chapter according to the following criteria: 1) component faults entered in the fault memory (see section 5.5). A specific component which is defective is contained in the control-unit ...
Page 19: Thermo Top Evo
Thermo top evo 5 troubleshooting 503 5.5 component fault entered in the fault memory fault code (hex) fault code (dez) wtt* fault message fault details with double- click in wtt* recommended workshop action 00 - no fault no fault no activity required 01 1 defective control unit defective control uni...
Page 20: 5 Troubleshooting
5 troubleshooting thermo top evo 504 2e 46 the glow/ignition-ele- ment power circuit is defective glow plug resistance is outside the value range in case of multiple occur- rences (> 3): 1) troubleshooting in air intake or in exhaust sys- tem (see section 5.7, fig. 504, point 12) 2) conduct electric...
Page 21: Thermo Top Evo
Thermo top evo 5 troubleshooting 505 * wtt = webasto thermo test pc diagnosis 90 144 coolant changeover valve open circuit the coolant changeover valve power circuit is openor has a short circuit to +ub conduct electrical test of coolant changeover valve (see section 5.7, fig. 504, point 16) 94 14...
Page 22: 5 Troubleshooting
5 troubleshooting thermo top evo 506 5.6 general faults entered in fault memory fault code (hex) fault code (dez) wtt* fault message fault details with double- click in wtt* recommended workshop action 00 no error no error no activity required 02 2 no start after start-up has been repeated, combusti...
Page 23: Thermo Top Evo
Thermo top evo 5 troubleshooting 507 11 17 ecu wrong coded incorrect parameter block or wrong heater (diesel/gaso- line) used this fault can only occur on vehicles with can bus or lin bus connection to heater: 1) compare heater type label with vehicle fuel type 2) proceed according to vehi- cle manu...
Page 24: 5 Troubleshooting
5 troubleshooting thermo top evo 508 38 56 initial starting attempt failed no additional information available in case of frequent occurrence (> 10): 1) troubleshooting in air intake or in exhaust system (see section 5.7, fig. 504, point 12) 2) conduct troubleshooting in fuel system (see section 5.7...
Page 25: Thermo Top Evo
Thermo top evo 5 troubleshooting 509 62 98 customer specific fault 3 no additional information available in case of frequent occurrence (> 3): 1) troubleshooting in air intake or in exhaust system (see section 5.7, fig. 504, point 12) 2) conduct troubleshooting in fuel system (see section 5.7, fig. ...
Page 26: 5 Troubleshooting
5 troubleshooting thermo top evo 510 * wtt = webasto thermo test pc diagnosis 83 131 flame failure flame interruption during combustion operation, more than faz (eeprom) times in case of frequent occurrence (> 3): 1) troubleshooting in air intake or in exhaust system (see section 5.7, fig. 504, poin...
Page 27: Thermo Top Evo
Thermo top evo 5 troubleshooting 511 5.7 faults without fault entry in control unit note before each repair on the heater, the fault memory must be read out with the webasto thermo test pc diagnosis. Exist- ing faults must be printed before deleting and made availa- ble to the webasto hotline or the...
Page 28: 5 Troubleshooting
5 troubleshooting thermo top evo 512 functional test of heater and its components fault component recommended workshop action parameter 1 power supply measure supply voltage under load at heater unit connector x2 (also see fig. 916) undervoltage switch-off 2 clock press flame button, display lightin...
Page 29: Thermo Top Evo
Thermo top evo 5 troubleshooting 513 9 circulating pump conduct component test to check function of circu- lating pump with webasto thermo test pc diagno- sis. Touch with hand; pump functions if slight vibration can be felt measure resistance on circulating pump connector x4, also see section 8.2 10...
Page 30: 5 Troubleshooting
5 troubleshooting thermo top evo 514 15 control unit (fault memory) read out fault memory with webasto thermo test pc diagnosis, then print out and clear fault memory include printed fault log when sending heater to webasto. Complete replacement of fan unit if control unit is defective. 16 coolant c...
Page 31: Thermo Top Evo
Thermo top evo 5 troubleshooting 515 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 32: 5 Troubleshooting
5 troubleshooting thermo top evo 516 visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 33: Thermo Top Evo
Thermo top evo 6 operating tests 601 6 operating tests 6.1 general this section describes the tests of the heater and its compo- nents in the installed and the removed state. 6.2 operating checks in vehicle 1. Set the vehicle van to fan speed 1 - 2 or to the speed rec- ommended in the vehicle-specif...
Page 34: 6 Operating Tests
6 operating tests thermo top evo 602 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 35: Thermo Top Evo
Thermo top evo 7 circuit diagrams 701 7 circuit diagrams fig. 701 shows the circuit of the thermo top evo heater, parking heater and heater control. Legend for wiring diagram. Cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black violet white item description comm...
Page 36: 7 Circuit Diagrams
7 circuit diagrams thermo top evo 702 fig. 701 wiring diagram of thermo top evo parking heater and 12 v digital timer. Visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 37: Thermo Top Evo
Thermo top evo 8 servicing work 801 8 servicing work this section describes the servicing work that can be carried out on the heater and its components while installed. 8.1 work on the heater the power supply must always be disconnected at the vehi- cle battery before carrying out any work on the he...
Page 38: 8 Servicing Work
8 servicing work thermo top evo 802 note ensure the correct direction of flow of the circulating pump to the vehicle coolant circuit. The installation position of the circulation pump must be chosen so that the circulation pump is self-bleeding. It must be possible for the air volume trapped in the ...
Page 39: Thermo Top Evo
Thermo top evo 8 servicing work 803 8.6.2 installation 1 move heater into specified installation position and tighten heater screws to 8 nm. Note the screw must be carefully inserted in the existing threads and screwed in by hand. 2 mount fuel line and secure with hose clamp. 3 mount coolant hoses a...
Page 40: 8 Servicing Work
8 servicing work thermo top evo 804 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 41: Thermo Top Evo
Thermo top evo 9 repair 901 9 repair note the seals must always be replaced before assembling the heater. 9.1 dismantling and assembling heater fig. 901 component illustration of thermo top evo heater a3 a1 a2 a4 a5 a6 w1 a7 b a8 sg g1 a9 a1 = heater cover a2 = screw a3 = retaining plate a4 = water ...
Page 42: 9 Repair
9 repair thermo top evo 902 9.1.1 dismantling heater 1. Loosen screw (a2,fig. 901) and remove water connec- tion piece (a4) with retaining plate (a3) and o-rings (a5). 2. Loosen heater cover (a1) at side detents on fan hous- ing (g1) with a screwdriver. Then remove heater cover (a1) from heater towa...
Page 43: Thermo Top Evo
Thermo top evo 9 repair 903 fig. 903 detailed illustration of cable routing for glow plug 9.2.2 installing burner unit important when changing a burner, the correct model must be ensured! The assignment of the spare part burner must be carried out using the spare parts list via the id number of the ...
Page 44: 9 Repair
9 repair thermo top evo 904 9.3 glow plug/flame monitor fig. 906 burner unit with glow plug 9.3.1 electrical test of glow plug the cold resistance must be tested by connecting contacts 1 and 2 of the connector from the glow plug to a multimeter. Cold resistance at 25 ± 5 °c: 0.235 to 0.355 ohms. Sho...
Page 45: Thermo Top Evo
Thermo top evo 9 repair 905 9.3.3 installing glow plug/flame monitor fig. 910 installing glow plug fig. 911 installing cooling flag fig. 912 installing retaining spring fig. 913 installing glow plug properly fig. 914 installing glow plug fig. 915 routing glow plug cable with slight bend 1. Position ...
Page 46: 9 Repair
9 repair thermo top evo 906 4. Slide retaining spring of glow plug (b2) over cooling flag (b3) and glow plug dome (b8) (for orientation of retaining spring b2, see fig. 914). Important the glow plug (b4) must be installed in the glow plug dome as far as possible. 5. Route glow plug cable (b10) as sh...
Page 47: Thermo Top Evo
Thermo top evo 9 repair 907 9.6 temperature sensor/ o verheating sensor 9.6.1 removing temperature sensor/ overheating sensor for information on removing heater cover, see section 9.1.1. Pull connectors of sensors out of control unit. When doing so, make sure connector lock is released. Loosen screw...
Page 48: 9 Repair
9 repair thermo top evo 908 9.7 water connection piece a distinction is made between two different retaining plates. Variant a - without locking and variant b - with lock- ing of connection piece on retaining plate. If water connec- tion pieces or the retaining plate of variant b are/is defective, t...
Page 49: Thermo Top Evo
Thermo top evo 10 packing, storage and shipping 1001 10 packing, storage and shipping 10.1 general if the heater or its components are sent to webasto ag for testing or repair, it must be cleaned and packed in such a way that it is protected against mechanical damage, soiling and environmental influ...
Page 50: Thermo Top Evo
10 packing, storage and shipping thermo top evo 1002 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 51
Visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 52
Ident -nr . 131 637 0a • 0 7 /10 • er ro rs and o m issio n s excep ted • pr int e d i n ger m an y • © w e bast o ag, gcs 20 10 webasto ag postfach 80 d - 82132 stockdorf germany national: hotline: 01805 93 22 78 (€ 0,14 aus dem deutschen festnetz) hotfax: 0395 5592 353 hotmail: technikcenter@webas...