Webasto Thermo Top Evo Workshop Manual
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Webasto Thermo Top Evo Workshop Manual

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Water Heaters
Workshop Manual
Thermo Top Evo
Type Thermo Top Evo (Petrol)
Type Thermo Top Evo (Diesel)

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Summary of Contents for Webasto Thermo Top Evo

  • Page 1 Water Heaters Workshop Manual Thermo Top Evo Type Thermo Top Evo (Petrol) Type Thermo Top Evo (Diesel)
  • Page 2 Only genuine Webasto parts may be used. See also Webasto air and water heaters accessories catalogue. NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly.
  • Page 4 Thermo Top Evo Table of Contents Table of Contents Introduction ................101 Contents and purpose.

  • Page 5: Table Of Contents

    Table of Contents Thermo Top Evo Circuit diagrams............... 701 Servicing work .
  • Page 6 Fig. 701 Wiring diagram of Thermo Top Evo parking heater and 12 V digital timer......702 Fig. 801 CO2 setting values .
  • Page 7 Type approvals according to ECE-R 10 (EMC) and ECE- Top Evo parking heater water heaters and auxiliary heaters. R 122 (Heater) exist for the Thermo Top Evo heater. For the installation, primarily the regulations of the directive ECE-R 122 and the regulations contained in the installation Meaning of signal words instructions must be observed.
  • Page 8 The heater must not be restarted until the unit has been checked exclusively by personnel duly trained by Webasto. • must be switched off during work in the engine compartment and may not be cleaned with high- pressure cleaning units or compressed air.

  • Page 9: Fig. 201 Thermo Top Evo

    – to preheat water-cooled vehicle engines. vehicle manufacturer. The Thermo Top Evo auxiliary heater can be upgraded to a parking-auxiliary heater with an additional kit. The heater designed according to the evaporator principle operates in the full-load and partial-load mode, controlled As the external appearance is identical, the heaters are by the temperature sensor.

  • Page 10: Fig. 202

    Thermo Top Evo 2 General description 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...

  • Page 11: Fig. 204 Heat Exchanger

    Fig. 204 Heat exchanger 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 2.3.1 Temperature sensor and overheating sen- metering pump, the CO settings must be checked.

  • Page 12: Fig. 206

    Thermo Top Evo 2 General description Fig. 206 DP42 metering pump Heater controls Fig. 210 Thermo Call TC 3 NOTE Additional information on the respective heater control is contained in the specific installation and operating instruc- tions. Fig. 207 Digital timer Fig.

  • Page 13: Fig. 301 Functional Illustration Of Thermo Top Evo Heater

    (below 5 °C) and engine running. delivery, etc.). NOTE The Thermo Top Evo heaters described in this manual can Heating mode only be put into operation with a W-bus-capable heater control, or with the Webasto Thermo Test PC Diagnosis.
  • Page 14 Commissioning must them be carried out with the Webasto Thermo Test PC Diagnosis. Prime the heater with fuel using the Webasto Thermo Test PC Diagnosis: Press the fill line button and fill the lines until fuel is present at the heater.
  • Page 15 4 Technical Data Thermo Top Evo Technical Data The technical data is contained in the installation instructions.
  • Page 16 The heater faults stored in the fault memory must be read combustion operation; an fault message is stored. out and printed with the Webasto Thermo Test PC Diagno- 2) A fault which occurs causes automatic restarting or a sis. To delete the heater lock-out without clearing the fault restart;...
  • Page 17 Reading out fault memory The fault memory of the heater can be read out with the Webasto Thermo Test PC Diagnosis. The fault memory displays up to 8 different faults. The older an fault is, the higher its number. The current operating duration and the current start-up number are entered in the control unit summary.

  • Page 18: Fig. 501 Overview Of Component Faults Entered In The Fault Memory

    Thermo Top Evo 5 Troubleshooting Component fault entered in the fault memory Fault Fault WTT* fault message Fault details with double- Recommended workshop code code click in WTT* action (HEX) (DEZ) No error No error No activity required Defective control unit...
  • Page 19 Overheat sensor interrupted or Conduct electrical test of temper- tion short circuit to supply voltage ature sensors (see Section 5.7, Fig. 504, Point 7) Fig. 501 Overview of component faults entered in the fault memory * WTT = Webasto Thermo Test PC Diagnosis...

  • Page 20: Fig. 502 Overview Of General Faults Entered In Fault Memory

    Thermo Top Evo 5 Troubleshooting General faults entered in fault memory Fault Fault WTT* fault message Fault details with double- Recommended workshop code code click in WTT* action (HEX) (DEZ) No error No error No activity required No start After start-up has been...
  • Page 21 5 Troubleshooting Thermo Top Evo Fault Fault WTT* fault message Fault details with double- Recommended workshop code code click in WTT* action (HEX) (DEZ) ECU wrong coded Incorrect parameter block or This fault can only occur on wrong heater (diesel/gasoline)
  • Page 22 Thermo Top Evo 5 Troubleshooting Fault Fault WTT* fault message Fault details with double- Recommended workshop code code click in WTT* action (HEX) (DEZ) Initial starting attempt failed No additional information avail- In case of frequent occurrence able (> 10):...
  • Page 23 5 Troubleshooting Thermo Top Evo Fault Fault WTT* fault message Fault details with double- Recommended workshop code code click in WTT* action (HEX) (DEZ) Customer specific fault 3 No additional information avail- In case of frequent occurrence able (> 3):...
  • Page 24 Thermo Top Evo 5 Troubleshooting Fault Fault WTT* fault message Fault details with double- Recommended workshop code code click in WTT* action (HEX) (DEZ) Flame failure Flame interruption during com- In case of frequent occurrence bustion operation, more than (> 3):...
  • Page 25 Overheat sensor interrupted or Conduct electrical test of tem- tion short circuit to supply voltage perature sensors (see Section 5.7, Fig. 504, Point 7) Fig. 502 Overview of general faults entered in fault memory * WTT = Webasto Thermo Test PC Diagnosis...

  • Page 26: Fig. 503 Overview Of Possible Faults

    Possible faults Before each repair on the heater, the fault memory must be read out with the Webasto Thermo Test PC Diagnosis. Exist- The overview only shows some of the possible faults. The ing faults must be printed before deleting and made availa- Webasto Service Hotline must be contacted in individual ble to the Webasto Hotline or the Warranty Department.

  • Page 27: Fig. 504 Overview Of Functional Test Of Heater And Its Components

    20 ± 2 °C Petrol feed rate: Metering pump 7 Hz, 60 sec: 11.6 to 14.3 ml Measure feed rate with Webasto Thermo Test PC Diagnosis, also see Section 8.4 Diesel feed rate: 7 Hz, 60 sec: 12.0 to 14.6 ml...
  • Page 28 Component Recommended workshop action Parameter Conduct component test to check function of circu- Touch with hand; pump lation pump with Webasto Thermo Test PC Diagno- functions if slight vibration sis. can be felt Measure resistance on circulation pump connector Circulation 10 ±...
  • Page 29 5 Troubleshooting Thermo Top Evo Fault Component Recommended workshop action Parameter Read out fault memory with Webasto Thermo Test PC Diagnosis, then print out and clear fault memory Control unit Include printed fault log when sending heater to (fault memory) Webasto.
  • Page 30 Thermo Top Evo 5 Troubleshooting...
  • Page 31 6 Operating tests Thermo Top Evo Operating tests General This section describes the tests of the heater and its compo- nents in the installed and the removed state. Operating checks in vehicle 1. Set the vehicle van to fan speed 1 - 2 or to the speed rec- ommended in the vehicle-specific operating instructions.

  • Page 32: Circuit Diagrams

    Thermo Top Evo 7 Circuit diagrams Circuit diagrams Fig. 701 shows the circuit of the Thermo Top Evo heater, parking heater and heater control. Legend for wiring diagram. Cable colours blue brown yellow green grey orange black violet white Item...

  • Page 33: Fig. 701 Wiring Diagram Of Thermo Top Evo Parking Heater And 12 V Digital Timer

    7 Circuit diagrams Thermo Top Evo Fig. 701 Wiring diagram of Thermo Top Evo parking heater and 12 V digital timer.

  • Page 34: Servicing Work

    The CO measurement and setting must be carried out in the full load heater operating mode (display in Webasto Thermo Test: Full Load). The CO value is corrected in selec- Work on the heater tion point 2.7.1.

  • Page 35: Dp42 Metering Pump

    Check the installation positions and installation conditions Heater, removal and installation of the metering pump in accordance with the general instal- lation instructions for the Thermo Top Evo. The Thermo Top Evo heater may only be operated with the DP42 metering 8.6.1 Removal pump.

  • Page 36: Installation

    Webasto Thermo Test PC Diagnosis. With the fuel line completely drained, the line must be filled with the Webasto Thermo Test PC Diagnosis: Press the fill line button and prime line with fuel until fuel is present at the heater.

  • Page 37: Repair

    Please see the spare parts list! NOTE It is not permissible to change the specified units for the pet- rol heaters listed below. For these petrol heaters: – Thermo Top Evo 4 Petrol 9021034 A/B – Thermo Top Evo 5 Petrol 9021032 A/B –...

  • Page 38: Dismantling And Assembling Heater

    A3 = Retaining plate B = Burner unit A4 = Water connection piece G1 = Fan housing A5 = O-ring SG = Control unit A6 = Screw W1= Heat exchanger A7 = Gasket Fig. 901 Component illustration of Thermo Top Evo heater...

  • Page 39: Dismantling Heater

    9 Repair Thermo Top Evo 9.1.1 Dismantling heater Burner unit Loosen screw (A2, Fig. 901) and remove water connec- tion piece (A4) with retaining plate (A3) and O-rings (A5). Loosen heater cover (A1) at side detents on fan hous- ing (G1) with a screwdriver. Then remove heater cover (A1) from heater toward front.

  • Page 40: Installing Burner Unit

    Thermo Top Evo 9 Repair Retaining disc open closed Fig. 904 Petrol burner unit Retaining ring open closed Fig. 903 Detailed illustration of cable routing for glow plug Fig. 905 Diesel burner unit 9.2.2 Installing burner unit Pre-position burner unit with grommet (B7) in fan housing (G1).

  • Page 41: Glow Plug/Flame Monitor

    9 Repair Thermo Top Evo Glow plug/Flame monitor Fig. 908 Remove cooling flag 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.

  • Page 42: Installing Glow Plug/Flame Monitor

    Thermo Top Evo 9 Repair 9.3.3 Installing glow plug/flame monitor Fig. 910 Installing glow plug Fig. 914 Installing glow plug Fig. 911 Installing cooling flag Fig. 912 Installing retaining spring Fig. 915 Routing glow plug cable with slight bend Position combustion pipe with evaporator mount hori- zontally toward rear (see Fig.

  • Page 43: Combustion-Air Fan Unit And Control Unit

    Section 8.2. IMPORTANT Carry out the "Reset glow plug" routine with the Webasto Only use a new glow plug during installation. Uninsulated Thermo Test PC Diagnosis. areas of the glow plug cable must not touch and must not...

  • Page 44: Checking Sensors

    Thermo Top Evo 9 Repair Checking sensors When checking the cold resistance, a distinction must be made between the variants sensors W5 and W6 (see Section Fig. 204 and Fig. 918). To do this, the contacts of connector X3 of the sensors are connected to a multimeter and the resistance is measured.

  • Page 45: Water Connection Piece

    9 Repair Thermo Top Evo Water connection piece A distinction is made between two different retaining 9.7.1 Installing water connection piece Variant plates. Variant A - without locking and Variant B - with lock- A - without lock ing of connection piece on retaining plate. If water connec-...

  • Page 46: Packing, Storage And Shipping

    (for position, see Fig. 1001). The type label and the surface of the heater must be protected against damage with a suita- ble surface (e.g. cardboard). Fig. 1001 Preferred position for Thermo Top Evo heater for storage and transport 1001...
  • Page 47 10 Packing, Storage and Shipping Thermo Top Evo Page for notes 1002...
  • Page 48 82199 Gilching Germany Visitors’address: Friedrichshafener Str. 9 82205 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com The telephone number of each country can be found in the Webasto service center leaflet or the website of the respective Webasto representative of your country.

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Thermo top evo 4Thermo top evo 5

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