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- Thermo Top V
- Workshop Manual
Webasto Thermo Top V Workshop Manual
Summary of Thermo Top V
Page 1
Luft-heizgeräte water heaters 03/2003 workshop manual thermo top v type thermo top v (petrol) type thermo top v (diesel) visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 2: Thermo Top V
Thermo top v 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 ...
Page 3: Thermo Top V
Thermo top v 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 v ii 6 operating tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 6.1 general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 5: Thermo Top V
Thermo top v table of contents iii 10 packing, storage and shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001 10.1 general. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 6: List of Illustrations
List of illustrations thermo top v iv list of illustrations fig. 201 cross-sectional functional model of thermo top v water heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 fig. 202 combustion-air fan unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 7: Thermo Top V
Thermo top v 1 introduction 101 1 introduction 1.1 contents and purpose this workshop manual supports personnel trained by webasto, who are responsible for repairing the thermo top v auxiliary and additional water heaters in the petrol and diesel versions. This manual applies exclusively for the rep...
Page 8: 1 Introduction
1 introduction thermo top v 102 • must be put into operation at least once a year for 10 minutes with the engine cold and the lowest fan speed selected. • must be checked by a professional every 2 years, at the commencement of the heating period. Warranty and liability claims: • a failure to observe...
Page 9: Thermo Top V
Thermo top v general description 201 2 general description the heaters operate in accordance with the venturi principle and use the physical effects of film evaporation and droplet evaporation for the processing of the fuel-air mixture. After reaching a coolant temperature of approx. 80 °c, the heat...
Page 10: General Description
General description thermo top v 202 connector plate variants fig. 203 standard connector plate with amp connector basket fig. 204 connector plate with fep connector basket fig. 205 connector plate for vw single board with fep connector basket for connector assignment on control unit, see section 7....
Page 11: Thermo Top V
Thermo top v general description 203 fig. 208 diesel burner without fuel preheating fig. 209 petrol burner with guard plate fig. 210 petrol burner without guard plate for information on removing and installing the burner, see section 9.2.5 and 9.2.7. Important ensure that the correct burner is alway...
Page 12: General Description
General description thermo top v 204 fig. 212 solenoid valve 2.3 temperature sensor and overheating sensor the temperature sensor detects the coolant temperature in the heat exchanger of the heater as an electrical resistance. This signal is fed to the control unit, where it is processed. The temper...
Page 13: Thermo Top V
Thermo top v general description 205 2.6 metering pump the metering pump is a combined transport, metering and shut-off system for supplying fuel from the vehicle’s tank to the heater. For information on checking and installing the metering pump, see section 8.6.2.2. Fig. 216 dp40/dp41 metering pump...
Page 14: General Description
General description thermo top v 206 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 15: Thermo Top V
Thermo top v description of operation 301 3 description of operation 3.1 switching on/starting process the heater start-up can be carried out for the additional heater via a remote control element, the immediate heat button or timer programming of the clock. For the auxiliary heater, the start-up is...
Page 16: Description of Operation
Description of operation thermo top v 302 fig. 302 unlocking heater 1. Voltage interruptions by removing the 20 a fuse (yellow) in the heater-unit wiring harness (ongoing processes in the control unit are ended) 2. Refit the fuse 3. Briefly press the button on the transmitter or the flame button on ...
Page 17: Thermo Top V
Thermo top v description of operation 303 switch-off or new switch-on signals are processed accord- ing to the following rules: 1. A switch-off signal on a heater control always as priority irrespective of the heater operating state. 2. If the original switch-on signal is no longer active, or if the...
Page 18: Description of Operation
Description of operation thermo top v 304 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 19: Thermo Top V
Thermo top v technical data 401 4 technical data except where limit values are specified, the technical data listed in the tables refer to the usual heater tolerances of ± 10% at an ambient temperature of + 20 °c and at the rated voltage and in rated conditions. All electrical components are designe...
Page 20: Technical Data
Technical data thermo top v 402 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 21: Thermo Top V
Thermo top v troubleshooting 501 5 troubleshooting 5.1 general error symptoms note before troubleshooting is conducted on the heater, an oper- ating test should be carried out as described in section 6.2. Important troubleshooting work demands precise knowledge of the structure and theory of operati...
Page 22: Troubleshooting
Troubleshooting thermo top v 502 functional analysis of heater and its components no. System component test/measure/parameter 1. Power supply measure supply voltage under load at heater connector x2 ≥ 11.5 v, see section 5.2.2 (undervoltage switch-off) 2. Clock press flame button; display lighting m...
Page 23: Thermo Top V
Thermo top v troubleshooting 503 5.2 faults 5.2.1 fault lock-out due to fault on heater if no flame forms, fuel will be delivered for a maximum of 240 seconds. Then the heater goes into the fault mode and switches off. The reason for the fault may be faults described in section 5.1.1. The fuel suppl...
Page 24: Troubleshooting
Troubleshooting thermo top v 504 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 25: Thermo Top V
Thermo top v 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. Warning the heater must not be operated in enclosed areas such as garages and workshops without an emissions extraction sys- tem....
Page 26: Operating Tests
Operating tests thermo top v 602 the following table shows the nominal co 2 setting value in full-load combustion operation in dependence on the geo- detic altitude at which the setting is made. Note it is recommended that the co 2 value be set in accordance with the altitude of the location above s...
Page 27: Thermo Top V
Thermo top v operating tests 603 6.3.1.4 electrical test of glow plug the cold resistance must be checked using a multimeter with the 4-conductor measuring principle. Multimeters without the 4-conductor measuring principle may not be used for this purpose. Cold resistance between contact 1 and 2 (co...
Page 28: Operating Tests
Operating tests thermo top v 604 visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 29: Thermo Top V
Thermo top v circuit diagrams 701 7 circuit diagrams 7.1 general fig. 701 shows the plug assignment on the control unit. Fig. 702 shows the circuit of the thermo top v heater, additional heater and 12 v digital timer. See section 7.2 for legend of wiring diagram. Fig. 701 connector assignment of hea...
Page 30: Circuit Diagrams
Circuit diagrams thermo top v 702 fig. 702 wiring diagram of thermo top v additional heater and 12 v digital timer. M m m visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 31: Thermo Top V
Thermo top v circuit diagrams 703 7.2 legend for wiring diagram cable cross-sections 7.5 - 15 m 0.5 mm 2 0.75 mm 2 0.75 mm 2 1.0 mm 2 1.0 mm 2 1.5 mm 2 1.5 mm 2 2.5 mm 2 2.5 mm 2 4.0 mm 2 4.0 mm 2 6.0 mm 2 cable colours bl br ge gn gr or rt sw vi ws blue brown yellow green grey orange red black viol...
Page 32: Circuit Diagrams
Circuit diagrams thermo top v 704 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
Page 33: Thermo Top V
Thermo top v servicing work 801 8 servicing work 8.1 general this section describes the servicing work that can be carried out on the heater when it is installed. Warning there is a danger of burns, as the heater and the attached parts may be extremely hot. 8.2 work on the heater disconnect the 20 a...
Page 34: Servicing Work
Servicing work thermo top v 802 note a defective circulating pump must be replaced with the u4847 econ in accordance with the spare parts list. Electrical checking of circulating pump internal resistance of the circulating pump: 10 ± 1 kohms in addition, the operation of the pump must be tested as f...
Page 35: Thermo Top V
Thermo top v servicing work 803 overview of uses for metering pumps important observe dp41 information sign (do not use for petrol)! Fig. 804 information sign of dp40/dp41 metering pump important the dp40 (id no. 9002853_) may not be used for the heater with solenoid fuel valve , as otherwise fuel m...
Page 36: Servicing Work
Servicing work thermo top v 804 8.7 heater, removal and installation 8.7.1 removal 1 interrupt power supply of heater by removing 20 a blade fuse from webasto fuse holder. 2 separate connectors on heater. 3 open coolant cap, release pressure and close cap again. 4 loosen hose clamps and pull coolant...
Page 37: Thermo Top V
Thermo top v repair 901 9 repair 9.1 general this section describes the permissible repair work on the thermo top v heater while removed. If it is dismantled fur- ther, any and all warranty claims are voided. An operating test must be conducted after all repairs. 9.2 dismantling and assembling 9.2.1...
Page 38: Repair
Repair thermo top v 902 9.2.2 assembling heater 1. For information on installing new temperature sensors (g, fig. 901), see section 9.2.9. 2. For information on installing burner (d), see section 9.2.7. 3. Clean heat exchanger (h) inside and outside and place on fan. Tighten screws (3) with 7 ± 0.7 ...
Page 39: Thermo Top V
Thermo top v repair 903 9.2.3.2 installing water connection-piece variant b without teeth fig. 904 installing water connection-piece variant b with- out teeth fig. 905 detail of lock on water connection-piece variant b without teeth the water connection pieces must be engaged in the retain- ing plat...
Page 40: Repair
Repair thermo top v 904 note only for diesel burner with fuel preheating: the heating cartridge of the fuel preheating may not be removed! Note only for diesel burners with solenoid valve: the solenoid valve cannot be removed! 9.2.6 cable routing for glow plug on burner uninsulated wire end ferrules...
Page 41: Thermo Top V
Thermo top v repair 905 3. Loosen screw (2, fig. 901). 4. Remove retaining spring (f) and pull sensors out of heat exchanger (sensors are not accessible from inside). Do not pull on plastic head or cable when doing so. 9.2.9 installing temperature sensor and over- heating sensor important the sensor...
Page 42: Repair
Repair thermo top v 906 fig. 910 cable routing for temperature sensor and overheating sensor with water connection-piece variant a fig. 911 cable routing for temperature sensor and overheating sensor with water connection-piece variant b correct wrong red blue visit www.Butlertechnik.Com for more te...
Page 43: Thermo Top V
Thermo top v 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 damage during handling, transport and storage. 10.2 sto...
Page 44: Thermo Top V
Packing, storage and shipping thermo top v 1002 page for notes visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
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Visit www.Butlertechnik.Com for more technical information and downloads. Www.Butlertechnik.Com.
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Ident -nr . 131 578 7a • 0 1 /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 - 82131 stockdorf germany national: hotline: 01805 93 22 78 ( € 0,14 aus dem deutschen festnetz) hotfax: 0395 5592 353 hotmail: hotline@webasto.De...