Table Of Contents - Webasto Thermo Top Pro 120 Workshop Manual

Contents
Contents
1 About this document .......................... 3
1.1 Purpose of the document .......................................... 3
1.2 Using this document.................................................. 3
1.3 Use of symbols and highlighting ................................ 3
2 Safety ................................................. 3
2.1 General safety information ....................................... 3
2.2 Qualification of personel............................................ 4
2.3 Working on the heater .............................................. 4
2.4 Working on the vehicle.............................................. 4
2.5 Heater test run .......................................................... 4
2.6 Checks ...................................................................... 4
3 Information regarding the heater ....... 5
3.1 Basis .......................................................................... 5
3.2 Special variants (Rail, CPoff, Chiller, ADR)................... 5
4 Description of the components........... 6
4.1 Overview of the subassemblies .................................. 6
4.2 Burner head............................................................... 8
4.3 Combustion air fan .................................................... 8
4.4 Drive motor ............................................................... 8
4.5 Fuel pump with solenoid valve................................... 9
4.6 Nozzle block preheater .............................................. 9
4.7 Ignition spark generator with ignition electrodes ....... 9
4.8 Fuel nozzle and baffle plate ....................................... 9
4.9 Control unit ............................................................. 10
4.10 Flame monitor ......................................................... 10
4.11 Pressure equalization element.................................. 10
4.12 Heat exchanger ....................................................... 10
4.13 Combustion tube..................................................... 10
4.14 Coolant temperature sensors ................................... 11
4.15 Exhaust gas temperature sensor .............................. 11
4.16 Coolant pump ......................................................... 11
4.17 Coolant ................................................................... 12
4.18 Fuel filter ................................................................. 12
5 Functional description ...................... 13
5.1 Introduction ............................................................ 13
5.2 Control elements ..................................................... 13
5.3 Switch the heater on and off ................................... 13
5.4 Using the heater in hazardous material vehicles (ADR)
............................................................................... 13
5.5 Functional sequence ................................................ 14
5.6 Fault switch-off ....................................................... 15
6 Malfunctions and troubleshooting.... 15
6.1 Basics ...................................................................... 15
6.2 Fault list on the control element .............................. 15
6.3 Cause of malfunctions in the heater and systems..... 16
6.4 Instructions for cancelling the fault lock-out ............ 16
6.5 Heater unlocking instructions .................................. 17
6.6 Overview of faults and fault codes........................... 17
2
7 Function checks ................................. 24
7.1 Basics ....................................................................... 24
7.2 Check and set CO₂ in exhaust gas............................. 24
7.3 Checking exhaust gas temperature sensor ................ 25
7.4 Checking control unit ............................................... 25
7.5 Check combustion tube ............................................ 25
7.6 Check the blower fan wheel ..................................... 26
7.7 Checking baffle plate ................................................ 26
7.8 Checking drive motor ............................................... 26
7.9 Fuel pump and check solenoid valve ......................... 26
7.10 Checking heater cartridge......................................... 27
7.11 Check coolant pump................................................. 28
7.12 Checking coolant temperature sensors ..................... 28
7.13 Checking ignition electrode ...................................... 28
8 Repairing and replacing components
.......................................................... 29
8.1 Required tools .......................................................... 29
8.2 Installation notes ...................................................... 29
8.3 Disconnecting control unit connections .................... 30
8.4 Disconnect burner head............................................ 30
8.5 Install burner head.................................................... 30
8.6 Removing control unit .............................................. 30
8.7 Electrical wiring in the burner head........................... 31
8.8 Removing baffle plate............................................... 31
8.9 Removing ignition electrodes.................................... 32
8.10 Removing fuel nozzle................................................ 32
8.11 Removing ignition spark generator ........................... 33
8.12 Removing fuel pump ................................................ 33
8.13 Installing fuel pump .................................................. 33
8.14 Removing nozzle block preheater ............................. 34
8.15 Removing blower fan wheel ..................................... 34
8.16 Removing drive motor .............................................. 35
8.17 Remove heat exchanger ........................................... 35
8.18 Remove combustion tube ......................................... 35
8.19 Remove coolant temperature sensors ....................... 36
8.20 Install coolant temperature sensors........................... 36
8.21 Removing exhaust gas temperature sensor ............... 36
8.22 Installing exhaust gas temperature sensor................. 37
9 Packaging / storage / shipping .......... 37
9.1 General information ................................................. 37
9.2 Ideal position............................................................ 37
9.3 Storage and transportation....................................... 38
10 Electrical incorporation...................... 38
10.1 Information on the electrical connection................... 38
10.2 The heater in hazardous material vehicles (ADR) ....... 38
10.3 Legend and remarks regarding wiring diagrams........ 38
10.4 Cable colours / cable cross-sections ......................... 39
10.5 Connector and pins .................................................. 39
10.6 Wiring diagrams ...................................................... 40
11 Technical data ................................... 48
12 List of abbreviations .......................... 48
9039412C Workshop manual TTP 120 _ 150