Thermo Top E.C Workshop Manual - JPC Direct

2 General Description Thermo Top E and Z/C2.1 Combustion Air Fan AssemblyThe combustion air fan assembly includes thecombustion air fancombustion air line inletfuel supply inlet.The heater Thermo Top E and Z has the circulation pumpmounted on the combustion air fan assembly.2.1.1 Combustion Air FanThe combustion air fan delivers the air required forcombustion from the combustion air inlet to the burnerinsert.CoolantinletExhaust outletCoolantoutletBurner Housing2.3 Burner InsertInside the burner insert fuel is distributed across thecombustion pipe fuel cross section. Combustion of thefuel/air mixture takes place within the combustion pipe toheat the heat exchanger.Combustion Air Fan Assembly2.2 Burner HousingThe glow plug/flame sensor located in the burner insertignites the fuel/air mixture during start of the heater. Afterstart the glow plug / flame sensor operates in the flamesensor function. The glow plug / flame sensor designed asan electrical resistor is located in the burner insertopposite the flame side.The burner housing includes thecoolant inletcoolant outletexhaust outlet.The burner housing accommodates the burner insert andis combined with the control unit / heat exchanger to anassembly.Burner Insert202

Thermo Top E and Z/C 2 General Description2.4 Control Unit / Heat ExchangerThe control unit / heat exchanger includes thecontrol unittemperature sensoroverheat protectionheat exchangerconnector terminal.CAUTIONThe control unit / heat exchanger and the burner housingrepresent an assembly and must not be disassembled.2.4.4 Heat ExchangerThe heat exchanger transfers the heat generated bycombustion to the coolant circuit.2.5 Circulation Pump(Thermo Top E and C only)The circulation pump ensures circulation of the coolantwithin the vehicle and heater coolant circuit. The pump isactivated by the control unit and is in continuousoperation.Connector TerminalControl UnitHeat ExchangerCirculation Pump2.6 Dosing Pump2.4.1 Control UnitThe control unit is the central unit and ensures control andmonitoring of combustion operation.The dosing pump is a combined delivery, dosing andshut-off system for the fuel supply of the heater out of thevehicle fuel tank.The control unit is ventilated by means of a ventilationhose routed from the combustion air collectorcompartment of the burner.2.4.2 Temperature SensorThe temperature sensor senses the coolant temperaturein the heat exchanger of the heater as an electricalresistance. This signal is routed to the control unit forprocessing.Dosing Pump DP 2 for Fuel operated Heaters2.4.3 Overheat ProtectionOverheat protection, controlled by a temperature resistor,protects the heater against undue operating temperatures.Overheat protection responds at a water temperature inexcess of 105° C and switches the heater off.Dosing Pump DP 30.2 for Diesel operated Heaters203

Thermo Top E and Z/C 3 Functional Description3 Functional Description3.1 Functional Description Thermo Top Z(Supplementary Heater)3.1.1 Switch On / StartingFuelWhen starting the vehicle engine the heater goes instandby. With a water circuit temperature below 60° C andan outside temperature below 5° C (option with outsidetemperature sensor) the starting sequence commences.The glow plug and the combustion air fan are activated.After 30 seconds the fuel dosing pump starts operationand combustion air fan operation is suspended for3 seconds. Subsequently the combustion air fan speed isincreased in a ramp within 57 seconds to nearly full loadoperation.After reaching full load fuel delivery within this period theglow plug is deactivated and the combustion air fanoperation increased to full load.During the subsequent 45 seconds as well as in normaloperation the glow plug functions as flame sensor tomonitor the flame condition.After all these events the automatically controlled heatingoperation starts. In case of a no flame condition or aflameout, a restart is automatically initiated. If the no flamecondition persists, fuel delivery is stopped and the heatersenters an error lockout with a run-down of the combustionair fan.DieselWhen starting the vehicle engine the heater goes instandby. With a water circuit temperature below 60° C andan outside temperature below 5° C (option with outsidetemperature sensor) the starting sequence commences.The glow plug and the combustion air fan are activated.After 30 seconds the fuel dosing pump starts operationand combustion air fan operation is suspended for3 seconds. Subsequently the combustion air fan speed isincreased in two ramps within 56 seconds to nearly fullload operation. After a stabilisation phase (constantspeed) of 15 seconds the combustion air fan speed isagain increased in a ramp within 50 seconds to nearly fullload.After reaching full load fuel delivery the glow plug isdeactivated and the combustion air fan operationincreased to full load.During the subsequent 45 seconds as well as in normaloperation the glow plug functions as flame sensor tomonitor the flame condition.After all these events the automatically controlled heatingoperation starts. In case of a no flame condition or aflameout, a restart is automatically initiated. If the no flamecondition persists, fuel delivery is stopped and the heaterenters an error lockout with a run-down of the combustionair fan.A flameout during normal combustion operation causesan automatic restart.3.1.2 Heating OperationFuelWhen the temperature rises to reach 72° C the heaterswitches to the energy saving part load operation. A risein temperature up to 76.5° C causes the heater to enter acontrol idle period. This also happens when exceeding atotal heating operating time of 76 minutes.After cool-down of the coolant to 71° C the heaterresumes part load operation. Another rise in temperatureto 76.5° C causes the heater to enter again the control idleperiod. A drop in the coolant temperature during part loadoperation due to an increased demand in heat will causethe heater to switch to full load operation at 56° C.DieselHeating operation for the Diesel type heater is identical inthe sequence of events. Should the coolant temperaturedrop during the control idle period to but not below 71° Cwithin 900 seconds, a subsequent drop in the coolanttemperature below 71° C causes the heater to perform aregular starting sequence into full load operation.A drop in the coolant temperature during part loadoperation due to an increased demand in heat will causethe heater to switch to full load operation at 65° C.3.1.3 Switch Off / DeactivationWhen turning the engine off the heater is deactivated.Combustion stops and run-down commences. Thecombustion air fan first continues operation to cool theheater down (run-down) to be automatically switched offafterwards.NOTEThe run-down time and the combustion air fan speeddepend on the heater operating condition at the time ofdeactivation.Run-down time is for:Fuel168 seconds when deactivated in full load operation and157 seconds when deactivated in part load operation.Diesel175 seconds when deactivated in full load operation and100 seconds when deactivated in part load operation.Dependent on the software variant implemented in thecontrol unit there might be deviations from those run-downperiods.301

3 Functional Description Thermo Top E and Z/C3.2 Functional DescriptionThermo Top E and C (Auxiliary Heater)3.2.1 Switch OnFuelWhen operating the "instant heat" switch button the timerdisplay shows or when operating the switch on theTelestart transmitter the operating indicator light on thetransmitter flashes. This puts the heater in standly.The glow plug, the combustion air fan and the circulationpump are activated. After 30 seconds the fuel dosingpump starts operation and combustion air fan operation issuspended for 3 seconds.Subsequently the combustion air fan speed is increasedin a ramp within 57 seconds to nearly full load operation.After reaching full load fuel delivery within this period theglow plug is deactivated and the combustion air fanoperation increased to full load.During the subsequent 45 seconds as well as in normaloperation the glow plug functions as flame sensor tomonitor the flame condition.After all these events the automatically controlled heatingoperation starts. In case of a no flame condition or aflameout, a restart is automatically initiated. If the no flamecondition persists, fuel delivery is stopped and the heaterenters an error lockout with a run-down of the combustionair fan.DieselWhen operating the "instant heat" switch button the timerdisplay shows or when operating the switch on theTelestart transmitter the operating indicator light on thetransmitter flashes. This puts the heater in standby.The glow plug, the combustion air fan and the circulationpump are activated. After 30 seconds the fuel dosingpump starts operation and combustion air fan operation issuspended for 3 seconds.Subsequently the combustion air fan speed is increasedin two ramps within 56 seconds to nearly full loadoperation. After a stabilisation phase (constant speed) of15 seconds the combustion air fan speed is againincreased in a ramp within 50 seconds to nearly full load.After reaching full load fuel delivery the glow plug isdeactivated and the combustion air fan operationincreased to full load.During the subsequent 45 seconds as well as in normaloperation the glow plug functions as flame sensor tomonitor the flame condition.After all these events the automatically controlled heatingoperation starts. In case of a no flame condition or aflameout, a restart is automatically initiated. If the no flamecondition persists, fuel delivery is stopped and the heaterenters an error lockout with a run-down of the combustionair fan.A flameout during normal combustion operation causesan automatic restart.3.2.2 Heating OperationFuelWhen the temperature rises to reach 72° C the heaterswitches to the energy saving part load operation. A risein temperature up to 76.5° C causes the heater to enter acontrol idle period. This also happens when exceeding atotal heating operating time of 76 minutes.The circulation pump, the vehicle's own heating air fan,and the operation indicator light remain on during controlidle.After cool-down of the coolant to 71° C the heaterresumes part load operation. Another rise in temperatureto 76.5° C causes the heater to enter again the control idleperiod. A drop in the coolant temperature during part loadoperation due to an increased demand in heat will causethe heater to switch to full load operation at 56° C.DieselHeating operation for the Diesel type heater is identical inthe sequence of events. Should the coolant temperaturehowever not drop within 900 seconds during the controlidle period to below 71° C, a subsequent drop in thecoolant temperature below 71° C causes the heater toperform a regular starting sequence into full loadoperation.3.2.3 Switch OffWhen turning the heater off by pushing the "instant heat"switch button ( in indicator panel extinguishes) orwhen operating the switch on the Telestart (flashingindicator on hand-held transmitter extinguishes) thevehicle heating air fan stops.Combustion terminates and run-down commences. Thecirculation pump and the combustion air fan first continueoperation to cool the heater down (run-down) to beautomatically switched off afterwards.NOTEThe run-down time and the combustion air fan speeddepend on the heater operating condition at the time ofdeactivation.Run-down time is for:Fuel168 seconds when deactivated in full load operation and157 seconds when deactivated in part load operation.Diesel175 seconds when deactivated in full load operation and100 seconds when deactivated in part load operation.Dependent on the software variant implemented in thecontrol unit there might be deviations from those run-downperiods.302

Thermo Top E and Z/C 3 Functional Description3.2.4 Auxiliary Heater in Supplementary HeaterFunction3.2.4.1 Switch OnWhen starting the engine the heater goes in standby(see 3.1.1).With the temperature of the water circuit below 60° C andthe outside temperature below 5° C (option with externaltemperature sensor) the starting procedure is initiated.NOTEWhen operating in the supplementary heater functionthere will be no automatic trigger of the circulation pumpand the vehicle's heating air fan.3.2.4.2 Switch OffTurning the engine off deactivates the heater.Combustion is terminated and run-down commences.The combustion air fan however continues operation tocool the heater down (run-down) to be automaticallyswitched off afterwards (see 3.1.3).303

3 Functional Description Thermo Top E and Z/CPage free for notes304

Thermo Top E and Z/C 4 Technical Data4 Technical Data4.1 Thermo Top EWhere no threshold values are specified technical data inthe table are understood to include standard tolerancesfor heater units of ± 10 % at an ambient temperature of+ 20° C.All electrical components are selected for a nominalvoltage of 12 Volts.Propellant for Thermo Top E (Fuel):The proper fuel is the fuel specified by the vehiclemanufacturer.Propellant for Thermo Top E (Diesel):The proper Diesel fuel is the one specified by the vehiclemanufacturer. When switching to low temperaturepropellants the heater must be operated for at least15 minutes to prime the fuel pipe and pump with the newtype of fuel.A persistent influence by additives is not known.Heater Operation Thermo Top E - B Thermo Top E - D Thermo Top E - DMark of conformity ~ S316 ~ S317TypeWater heater with evaporator burnerHeating flowFull loadPart load4.0 kW2.5 kWFuel Fuel Diesel Diesel/PME*Fuel consumptionFull loadPart load0.54 l/h0.34 l/hNominal voltage12 VOperating voltage range10.5 ... 15 VNominal power consumption withoutcirculation pump (without vehicle air fan)Full loadPart load22 W18 WPermissible ambient temperature:Heater:– operation– storage–40° C ... + 60° C–40° C ... +120° CDosing pump: – operation–40° C ... + 20° CPermissible operating overpressure0.4 ... 2.5 bar(heat carrier)Heat exchanger capacity0.15 lMinimum coolout circuit capacity3.00 lMinimum volume flow for the heater250 l/hCO 2 in exhaust (permissible functional range)8 ... 12 Vol.-%Dimensions of heater length 214 mmwidth 106 mmheight 168 mmWeight2.9 kg0.47 l/h0.30 l/h–20° C ... + 60° C–40° C ... +120° C–20° C*... + 20° CCirculation pump 4847Volume flow against 0.1 bar900 l/hNominal voltage12 VOperating voltage range10.5 ... 15 VNominal power consumption14 WDimensions of circulation pump length 95 mmwidth 61 mmheight 61 mmWeight0.3 kg*) Operation only permitted with mixture Diesel/PME with PME quantity < 50 %.401

4 Technical Data Thermo Top E and Z/C4.2 Thermo Top Z/C(Heating Flow 5.0 kW)Where no threshold values are specified technical data inthe table are understood to include standard tolerancesfor heater units of ± 10 % at an ambient temperature of+ 20° C.All electrical components are selected for a nominalvoltage of 12 Volts.Propellant for Thermo Top Z/C (Fuel):The proper fuel is the fuel specified by the vehiclemanufacturerPropellant for Thermo Top Z/C (Diesel):The proper Diesel fuel is the one specified by the vehiclemanufacturer. When switching to low temperaturepropellants the heater must be operated for at least15 minutes to prime the fuel pipe and pump with the newtype of fuel.A persistent influence by additives is not known.HeaterOperationThermo TopZ/C - BThermo TopZ/C - DThermo TopZ/C - DMark of conformity ~ S292 ~ S289TypeWater heater with evaporator burnerHeating flowFull loadPart load5.0 kW2.5 kWFuel Fuel Diesel Diesel/PME*Fuel consumptionFull loadPart load0.67 l/h0.34 l/hNominal voltage12 VOperating voltage range10.5 ... 15 VNominal power consumption withoutcirculation pump (without vehicle air fan)Full loadPart load26 W18 WPermissible ambient temperature:Heater:– operation– storage–40° C ... + 60° C–40° C ... +120° CDosing pump: – operation–40° C ... + 20° CPermissible operating overpressure0.4 ... 2.5 bar(heat carrier)Heat exchanger capacity0.15 lMinimum coolout circuit capacity4.00 lMinimum volume flow for the heater250 l/hCO 2 in exhaust (permissible functional range)8 ... 12 Vol.-%Dimensions of heater length 214 mmwidth 106 mmheight 168 mmWeight2.9 kg0.59 l/h0.30 l/h–20° C ... + 60° C–40° C ... +120° C–20°C*... + 20°CCirculation pump 4847Volume flow against 0.1 bar900 l/hNominal voltage12 VOperating voltage range10.5 ... 15 VNominal power consumption14 WDimensions of circulation pump length 95 mmwidth 61 mmheight 61 mmWeight0.3 kg*) If viscosity of PME permits due to its natural condition.402

Thermo Top E and Z/C 4 Technical Data4.3 Thermo Top Z/C(Heating Flow 5.2 kW)Where no threshold values are specified technical data inthe table are understood to include standard tolerancesfor heater units of ± 10 % at an ambient temperature of+ 20° C.All electrical components are selected for a nominalvoltage of 12 Volts.Propellant for Thermo Top Z/C (Fuel):The proper fuel is the fuel specified by the vehiclemanufacturerPropellant for Thermo Top Z/C (Diesel):The proper Diesel fuel is the one specified by the vehiclemanufacturer. When switching to low temperaturepropellants the heater must be operated for at least15 minutes to prime the fuel pipe and pump with the newtype of fuel.A persistent influence by additives is not known.HeaterOperationThermo TopZ/C - BThermo TopZ/C - DThermo TopZ/C - DMark of conformity ~ S292 ~ S289TypeWater heater with evaporator burnerHeating flowFull loadPart load5.2 kW2.5 kWFuel Fuel Diesel Diesel/PME*Fuel consumptionFull loadPart load0.70 l/h0.34 l/hNominal voltage12 VOperating voltage range10.5 ... 15 VNominal power consumption withoutcirculation pump (without vehicle air fan)Full loadPart load28 W18 WPermissible ambient temperature:Heater:– operation– storage–40° C ... + 60° C–40° C ... +120° CDosing pump: – operation–40° C ... + 20° CPermissible operating overpressure0.4 ... 2.5 bar(heat carrier)Heat exchanger capacity0.15 lMinimum coolout circuit capacity4.00 lMinimum volume flow for the heater250 l/hCO 2 in exhaust (permissible functional range)8 ... 12 Vol.-%Dimensions of heater length 214 mmwidth 106 mmheight 168 mmWeight2.9 kg0.61 l/h0.30 l/h–20° C ... + 60° C–40° C ... +120° C–20° C*... + 20° CCirculation pump 4847Volume flow against 0.1 bar900 l/hNominal voltage12 VOperating voltage range10.5 ... 15 VNominal power consumption14 WDimensions of circulation pump length 95 mmwidth 61 mmheight 61 mmWeight0.3 kg*) If viscosity of PME permits due to its natural condition.403

4 Technical Data Thermo Top E and Z/CPage free for notes404

Thermo Top E and Z/C 5 Troubleshooting5 Troubleshooting5.1 General Fault SymptomsThe following table (Fig. 501) lists possible faultsymptoms of general nature for heaters in installedcondition.CAUTIONTroubleshooting requires profound knowledge aboutcomponents and their theory of operation and may only beperformed by trained personnel.In case of doubt functional interrelations may be derivedfrom Sections 2 and 3.CAUTIONTroubleshooting is normally limited to the isolation ofdefective components and provides information ondefective wiring and connections.The following possible causes for trouble have not beentaken into consideration and must always be excluded asa possible cause for malfunctions:corrosion on connectorsloose contacts on connectorswrong crimping on connectorscorrosion on wiring and fusescorrosion on battery terminalsAfter any fault correction a functional checkout in thevehicle has to be performed (see 6.2).Smell of fuelSymptomHeater does not achieve full load operationContinuous white smoke during combustion operationHeater cannot be switched offLoss of coolant (dripping);heater develops smoke during combustion operation;smell of exhaust fumes extremely sweetLoss of fuel (dripping)RemedyCheck heater system integration in vehicle's fuel system.Check fuel lines for leakage, kinks or obstructions. If o.k.there is a heater internal leak. Remove heater andperform troubleshooting on repair shop level.Remove heater and perform troubleshooting on repairshop level.Remove heater and perform troubleshooting on repairshop level.Perform functional test of Timer (see 6.2.2) or ofTelestart device (see 6.2.3). Replace or repair defectivecomponent.Inspect coolant hoses for leakage, kinks, loose hoseclamps, etc.If o.k. there is a heater internal leak.Remove heater and perform troubleshooting on repairshop level.Check heater system integration in vehicle's fuel system.Check fuel line connections for leakage. If o.k. there is aheater internal leak.Remove heater and perform troubleshooting on repairshop level.Fig. 501 Fault Symptoms501

5 Troubleshooting Thermo Top E and Z/C5.2 Error Messages duringFunctional Test with Diagnosis TesterThermo TestNOTEThe following table (Fig. 502) lists possible errormessages during the functional test with the diagnosistester and their probable cause.Error MessageProbable CauseControl unit defectiveFlame-out 1Flame-out 2• Faulty electronics• EOL programming errorFlame-out during operation and no flame-up after a new attempt to start• Wrong integration in fuel system (e.g. fuel supply confused with return)• Fuel tapping dependent on fuel level• Pressure in fuel system too low• Check valve in fuel system• Leak in fuel line connections• Degassing fuel lines (routed in environment too hot)• Installation orientation of dosing pump• Combustion air intake not as specified• Exhaust system not as specified• Burner defectiveSeveral flame-outs during operationVoltage too highVoltage too lowFlame before combustionoperation (not applicable forThermo Top Z)OverheatingDosing pump short circuit• Wrong integration in fuel system (e.g. fuel supply confused with return)• Fuel tapping dependent on fuel level• Pressure in fuel system too low• Check valve in fuel system• Leak in fuel line connections• Degassing fuel lines (routed in environment too hot)• Installation orientation of dosing pump• Combustion air intake not as specified• Exhaust system not as specified• Burner defective• Vehicle battery charger probably defective• Battery discharged or defective• High transition resistance in the power supply lines (plus and minus)• Glow plug / flame sensor defective• Coolant level too low• Heater has not been bled• No circulation• Ground short in power supply line to dosing pumpDosing pump open circuit • Open line to dosing pump• Short circuit to plus of power supplyBurner motor short circuit Thermo Top Z:• Switched line short circuit to plus of power supply• Overload or short circuit of burner motorBurner motor open circuitThermo Top E und C:• Ground short in power supply line to burner motor• Open line to burner motor• Short circuit to plus of power supplyFig. 502 Error Messages (Sheet 1 of 2)502

Thermo Top E and Z/C 5 TroubleshootingGlow plug short circuit Thermo Top Z:• Switched line short circuit to plus of power supply• Overload or short circuit of glow plugThermo Top E und C:• Ground short in power supply line to glow plugGlow plug open circuit Open line to glow plug / flame sensor• Short circuit to plus of power supply• Rise in coolant temperature within 9 min after start is < 3 K (Thermo Top C only)Water pump short circuit Thermo Top Z:• Switched line short circuit to plus of power supply• Overload or short circuit of circulation pumpWater pump open circuitFan short circuitThermo Top E und C:• Ground short in power supply line to circulation pump• Overload• Open line to circulation pump• Short circuit to plus of power supply• Line to fan relay shorted against ground• Overload of output to fan trigger ( I > 500 mA)Fig. 502 Error Messages (Sheet 2 of 2)5.3 Malfunctions5.3.1 Error Lockout by Malfunction of HeaterIn case of a "no flame-up" condition fuel is delivered for amaximum of 180 seconds.In the event of overheating (temperature limiter responds)fuel delivery is stopped immediately.5.3.3 Error Lockout ResetNOTEBefore attempting an error lockout reset check fuse F1 inWebasto flat fuse holder. A 15 A fuse must be replacedwith a 20 A fuse.If the heater nevertheless fails to switch on, reset errorlockout according to 5.3.3.4.F1In all cases of malfunction (except for a defect on thecombustion air fan) there will be an error lockout with asubsequent run-down. Dependent on the software variantimplemented there might be deviations from the run-downtimes specified.NOTEAn error lockout due to overheating does not display anindication.5.3.2 Error Lockout due to Low or High VoltageA low voltage level of 9.8 ± 0.3 V (measured at the wiringharness input) over a period of 20 seconds will cause anerror lockout with a run-down of 120 seconds.A high voltage level of 15.5 ± 0.5 V (measured at theheater) over a period of more than 6 seconds will alsocause an error lockout with a run-down of 120 seconds.5.3.3.1 Error Lockout Reset Thermo Top E and C with"Timer"Eliminate cause of trouble.Switch off heater using the instant heat switch on the timerand switch on again. If heater fails to switch on, performerror lockout reset according to 5.3.3.4.An error lockout due to overheating does not have anindication.The fuse is not blown in case of overheating.The error lockout may be cleared by disconnection of thepower supply of the control unit.Perform error lockout reset according to 5.3.3.4.503

BZT480D FW5 Troubleshooting Thermo Top E and Z/C5.3.3.2 Error Lockout Reset Thermo Top E and C with"Telestart"Eliminate cause of trouble.Switch off heater using the instant heat switch on the timeror the Telestart hand transmitter and switch on again.If heater fails to switch on, perform error lockout resetaccording to 5.3.3.4.An error lockout due to overheating does not have anindication.The fuse is not blown in case of overheating.The error lockout may be cleared by disconnection of thepower supply of the control unit.Perform error lockout reset according to 5.3.3.4.5.3.3.3 Error Lockout Reset Thermo Top ZIn case of a malfunction the control unit enters an errorlockout.The error lockout may only be cleared by disconnection ofthe power supply of the control unit (e.g. by removing fuseF1 (20 A) for at least 30 seconds).NOTEThe fuse must be removed within 30 seconds– after starting the engine– after application of 12 Volts to connector X14,contact 3If the supplementary heater nevertheless fails to start,perform error lockout reset according to 5.3.3.4.5.3.3.4 Error Lockout Reset after Overheating or afterThree Error LockoutsONG108 Twait forapprox.3 sec.orONSETwait forapprox.3 sec.wait forapprox.3 sec.25 20 1A A A25 20 1A A A25 20 1A A A25 20 1A A APower supplydisconnect byremoval of 20 A fuse(yellow) in heaterwiring harnessRe-installation offuseMomentarily press ON switch left ontransmitter or press button on timerPower supplydisconnect byremoval of 20 A fuse(yellow) in heaterwiring harnessRe-installation offuse.This switches theheater on.504

Thermo Top E and Z/C 6 Functional Checkouts6 Functional Checkouts6.1 GeneralThis section describes the tests on the heater and itscomponents in installed and removed condition as well asthe test of the Timer and the Telestart T60/T70 to proveserviceability.WARNINGThe heater must not be operated in enclosed areas likegarages or workshops not provided with exhaustventilation facilities.6.2 Functional Tests in the Vehicle6.2.1 Heating Operational Test(Thermo Top E and C)NOTEHeating efficiency depends on several factors: forassessment use outside temperature, type of vehicle,engine temperature or type of heater integration in thevehicle's cooling system, the quantity of the coolant to beheated and the time passed since heater start.NOTETake the time of the following functions with a stop watchor any other suitable means.6. Switch heater off using Timer or Telestart.• Switch off causes a run-down of approx.110 seconds out of part load operatimon or of175 seconds out of full load. Verification bystoppage of exhaust emissions and audiblecontinuation of circulation pump operation.• After run-down the heater will be completelydeactivated (with ignition off).1. Ensure that fan switch is set to the lowest stage or thestage recommended in the operating instructions.2. Ensure that the air intake is free from foreign matter(snow, leaves etc.) and that the pollen or dust filters(if applicable) are unobstructed.3. Ensure that that the vehicle coolant circuit and fuelsystem have been thoroughly bled in accordance withmanufacturer's instructions.NOTETake the time of the following functions with a stopwatch or any other suitable means. The exact times forthe heaters, Diesel and fuel version, are described inSection 3.4. Switch heater on using Timer or Telestart.• Activation of heater causes circulation pump andcombustion air fan to operate. Operating noise isaudible. Vehicle heating air fan operates aftercoolant has reached a temperature of 30° C.• After approx. 130 seconds the heater starts tooperate which can be verified by exhaustemissions from the exhaust muffler or exhaustpipe.5. Allow heater to continue operation. Check heatingefficiency at air exit of vehicle heating air fan.601

6 Functional Checkouts Thermo Top E and Z/C6.2.2 Timer Functional Test(Thermo Top E and C)6.2.2.1 Voltage Check1. Remove cover using a small screw driver.2. Loosen screw.3. Disconnect plug from clock.4. Measure voltage between "+" and "-" (see figure).Voltage indicated is according to voltage of vehiclebattery, approx. 12 V.NOTEIn case no voltage is indicated check or replace fuseF2 and/or timer wiring.6.2.2.2 Switch On Signal Test1. Operate "ON" button and check voltage between"–" and "OUT". Voltage is approx. 7 V with the timerconnected to the control unit or 12 V with the outputnot connected.2. Operate "ON" button again and check voltagebetween "–" and "OUT". Voltage is 0 V.6.2.3 Telestart T60 Functional Test(Thermo Top C)6.2.3.1 Transmitter Check1. Operate switch on transmitter. Ensure operatingindicator light (green or red LED) flashes. If LED is notflashing, batteries are too cold or too weak.2. Using switch on transmitter switch Telestart off.Connection to contact+15 remains open6.2.4 Telestart T70 Functional Test(Thermo Top C and E)brownblack6.2.4.1 Batteries Checkred1. Operate ON or OFF switch.Batteries LED ActionsSETserviceableilluminatesafter 1 secondfor approx.0.5 secondsOUT +15weakflashes inorange after1 second for3 seconds– warm upbatteriesto above 0° C– replacebatteries assoon aspossible+ –deschargedilluminates inorange after1 second for5 seconds– warm upbatteriesto above 0° C– replacebatteries602

Thermo Top E and Z/C 6 Functional Checkouts6.2.5 Functional Test with Diagnosis TesterThermo TestNOTE• For operation of diagnosis tester refer to operatinginstructions.• If error messages are displayed during functionaltesting, perform troubleshooting according toSection 5.CAUTIONWhen connecting diagnosis tester the heater must be inswitched off condition.1. Connect screw coupling of adapter wiring harness todiagnosis tester.2. Connect plug (yellow wire) to diagnosis connector invehicle (connector with yellow wire).3. Connect red battery terminal clamp to battery plus andblack battery terminal clamp to battery minus ofvehicle.NOTEAfter connection of diagnosis tester the following text isindicated alternately:Diagnostic AdapterSW-Version X.XXW e b a s t oThermosystemeBy pressing any key the equipment select menu is calledup.Working StepPress any keyBy pressing left key select heater andlanguageAcknowledge Thermo Top E or Z/C selectionby pressing "OK" keyBy pressing left key select desired functionAcknowledge selected function with "OK" keySelection "Read error"NOTERecord error!Selection "Delete error"Selection "Components test"Selection "Automatic test"IndicationEquipment selection• Thermo Top• Thermo Top E• Thermo Top Z/C• LanguageMain menu• Read error• Delete error• Components test• Automatic test• CO 2 setting• Equipment selectionDependent on selected functionError indication:• maximum of 3 errors or no error• return• Error deleted• return• Dosing pump on• Burner motor on• Glow plug / flame sensor on• Circulation pump on• Fan relay on• Cancel• Indication of component triggeredor• Indication of an errorResultHeaterDosing pump cyclesBurner motor runsGlow plug / flame sensor onCirculation pump runsFan runsComponents are triggered asindicated4. Select main menu "Equipment selection" anddisconnect diagnosis tester from battery and fromdiagnosis connector.603

6 Functional Checkouts Thermo Top E and Z/C6.2.6 CO 2 SettingNOTEThe CO 2 setting is performed with the diagnosis testerThermo Test. For operation of diagnosis tester refer tooperating instructions.CAUTIONFor starting heater diagnostic line must be disconnected.Connection of diagnosis tester with heater on andoperating at full load (approx. 5 min after switch on).Change of CO 2 value in increments by pressing OK key.For settings refer to the following table:Nominal contents of CO 2 in exhaust at full load operation [Vol.-%]Air temperature [°C]Geographic altitude–20 0 20above sea level [m]Fuel Diesel Fuel Diesel Fuel Diesel1500 10.2 11.3 10.4 11.5 10.6 11.71000 9.6 10.6 9.7 10.8 9.9 11.0500 9.0 9.9 9.1 10.1 9.3 10.3250 8.7 9.6 8.8 9.8 9.0 10.00 8.4 9.3 8.6 9.5 8.8 9.71. Switch on heater and allow to operate for approx.5min.2. Connect screw coupling of adapter wiring harness todiagnosis tester.3. Connect plug (yellow wire) to diagnosis connector invehicle (connector with yellow wire).4. Connect red battery terminal clamp to battery plus andblack battery terminal clamp to battery minus ofvehicle.5. Switch on exhaust meter.NOTEAfter connection of diagnosis tester the following text isindicated alternately:9. Select submenu "Decrease CO 2 " or "Increase CO 2 ".By pressing OK key repeatedly CO 2 value changes inincrements. The cursor remains positioned on theselected function.NOTEBy selection of "Initial value" and pressing of the OK key,the CO 2 value stored automatically during start of the CO 2setting may be restored.By selection of "Store/return" and pressing of the OK key,the last setting becomes the default and the main menu iscalled up.10. Select main menu item "Equipment selection" anddisconnect diagnosis tester from battery and fromdiagnosis connection.11. Switch off heater.By pressing any key the equipment select menu iscalled up.6. Press any key.Diagnostic AdapterSW-Version X.XXW e b a s t oThermosysteme6.3 Repair Shop Level Testing6.3.1 Components Testing6.3.1.1 Glow Plug / Flame Sensor Resistance CheckWhen testing the glow plug / flame sensor with a digitalmultimeter, the following readings should be obtained:Resistance at 25° C: 0.3 ... 0.6 ΩTest current: < 5 mA7. Select heater.8. In main menu select “CO 2 setting”.604

Thermo Top E and Z/C 7 Circuit Diagrams7 Circuit Diagrams7.1 GeneralThe connector pin assignment of control unitThermo Top E and Z/C is shown in Fig. 701.The circuit diagrams (Fig. 702 and 703) show theelectrical circuit of the heater in combination with Timerand Telestart T60.The circuit diagram (Fig. 704) shows the electrical circuitof Thermo Top Z.FG2DP3UP BL GS/FW12V+212 21 112124 5 61 2 3X1X5X4X3X2ClockDiagnosis1123outside air temperaturesummer/winter switchnot usedBLDPFGGS/FWUPcombustion air fandosing pumpvehicle air fanglow plug / flame sensorcirculation pumpFig. 701 Control Unit Connector Pin Assignment (Thermo Top E and C)701

7 Circuit Diagrams Thermo Top E and Z/Cϑϑ4Item Nomenclature RemarkA1 Heater Thermo Top E or Z/CA2 Control unitA3 Connector boxA4 Telestart receiver T60B2 Temperature sensorE Glow plug / flame sensorF1 Fuse 15 A Flat fuse SAE J 1284F2 Fuse 1 A Flat fuse SAE J 1284F3 Fuse 25 A Flat fuse SAE J 1284H1 LED (in item P) operating indicator lightK3 Relay (in item A3) vehicle air fanM1 Motor combustion air fanM2 Motor circulation pumpM3 Motor vehicle air fanP Timer, digital for timer operationS1 Switch for vehicle air fan depending on vehicle S1 or S2S2 Switch for vehicle air fan depending on vehicle S1 or S2S5 Switch summer/winter switchX1 Connection, 6-poleX2 Connection, 2-pole water repellantX3 Connection, 2-pole water repellantX4 Connection, 2-pole water repellantX5 Connection, 2-pole water repellantX6 Connection, 2-pole water repellantX8 Connection, 2-pole HF, coaxialX9 Connection, 4-poleY1 Dosing pumpblbrgegngrorrtswviwsWire Gauges< 7.5 m 7.5 - 15 m0,5 mm 2 0,75 mm 20,75 mm 2 1,5 mm 21,5 mm 2 2,5 mm 22,5 mm 2 4,0 mm 24,0 mm 2 6,0 mm 2Wire ColoursbluebrownyellowgreengreyorangeredblackvioletwhiteLegend for circuit diagrams1 Diagnosis2 Outside air temperature3 Vehicle heating air fan fuseprovided in vehicle4 OptionFig. 702 Automatic Switching Circuit for Thermo Top E and Z/C, 12 V Timer and Telestart T60702

Thermo Top E and Z/C 7 Circuit Diagrams(75) 153061rtA33X91ϑ2F1F2rtrt+swX11ge2sw3A2K3brbrbrF3rt86 8785rt87a30sw+15H1-OUTPX9I max. = 0,5 Agn/wsblX254612X6X5X4X3X2X11 21212121212 43 56A B CS1M3MLüftenHeizenY1br1 2EX31 2 1 2X4MM1X5MM2ϑB2brbrS2S54A131brItem Nomenclature RemarkA1 Heater Thermo Top E or Z/CA2 Control unitA3 Connector boxB2 Temperature sensorE Glow plug / flame sensorF1 Fuse 20 A Flat fuse SAE J 1284F2 Fuse 1 A Flat fuse SAE J 1284F3 Fuse 25 A Flat fuse SAE J 1284H1 LED (in item P) operating indicator lightK3 Relay (in item A3) vehicle air fanM1 Motor combustion air fanM2 Motor circulation pumpM3 Motor vehicle air fanP Timer, digital for timer operationS1 Switch for vehicle air fan depending on vehicle S1 or S2S2 Switch for vehicle air fan depending on vehicle S1 or S2S5 Switch summer/winter switchX1 Connection, 6-poleX2 Connection, 2-pole water repellantX3 Connection, 2-pole water repellantX4 Connection, 2-pole water repellantX5 Connection, 2-pole water repellantX6 Connection, 2-pole water repellantX9 Connection, 4-poleY1 Dosing pumpblbrgegngrorrtswviwsWire Gauges< 7.5 m 7.5 - 15 m0,5 mm 2 0,75 mm 20,75 mm 2 1,5 mm 21,5 mm 2 2,5 mm 22,5 mm 2 4,0 mm 24,0 mm 2 6,0 mm 2Wire ColoursbluebrownyellowgreengreyorangeredblackvioletwhiteLegend for circuit diagrams1 Diagnosis2 Outside air temperatureFig. 703 Automatic Switching Circuit for Thermo Top E and Z/C, 12 V Timer3 Vehicle heating air fan fuseprovided in vehicle4 Option703

7 Circuit Diagrams Thermo Top E and Z/Cϑ1 2ϑϑItem Nomenclature RemarkA1 Heater Thermo Top ZA2 Control unitB2 Temperature sensorE Glow plug / flame sensorF1 Fuse 20 A Flat fuse SAE J 1284M1 Motor combustion air fanX13 Connection 2-poleX14 Connection 6-pole water repellantX15 Connection 2-pole water repellantX16 Connection 2-pole water repellantX17 Connection 2-pole water repellantX18 Connection 2-pole water repellantX19 Connection 2-pole water repellantY1 Dosing pumpblbrgegngrorrtswviwsWire Gauges< 7.5 m 7.5 - 15 m0,5 mm 2 0,75 mm 20,75 mm 2 1,5 mm 21,5 mm 2 2,5 mm 22,5 mm 2 4,0 mm 24,0 mm 2 6,0 mm 2Wire ColoursbluebrownyellowgreengreyorangeredblackvioletwhiteLegend for circuit diagrams1 Diagnosis2 Outside air temperatureFig. 704 Automatic Switching Circuit for Thermo Top Z, 12 V704

Thermo Top E and Z/C 8 Servicing8 Servicing8.1 GeneralThis section describes the servicing procedures allowedon the heater when installed.WARNINGThere is a potential danger of skin burns as the heater andits components may be very hot.8.2 Work on the HeaterFor any type of work on the heater the main power supplycable is to be disconnected from the vehicle battery. Aslong as the heater is in operation or in run-down thebattery main power supply must not be disconnected toprevent the heater from overheating by response of theoverheat protection. When performing long time repairson the heater its removal is compulsory. After repairs onthe heating circuit it must be replenished with a mixture ofcoolant and water to manufacturer's instructions followedby careful bleeding of the circuit. Repairs requiring achange of location the relevant installation instructionsand the vehicle specific heater installation proposal haveto be observed.8.3 Work on the VehicleCAUTIONIn the vicinity of the heater a temperature of 120° C mustunder no circumstances be exceeded (e.g. during paintwork on the vehicle).• inspect fuel lines and fuel filter for leakage.• inspect coolant circuit and circulation pump(Thermo Top E and C only) for leakage.• inspect hoses for cracks.• replace fuel filter, if installed.8.6 Visual Inspections and InstallationRegulations8.6.1 Connection to Vehicle Cooling SystemThe installation location of the heater should be as low aspossible to ensure self-venting of the heater and circulationpump. This applies in particular to the circulation pump(Thermo Top E and C only), which is not self-sucking.The circulation pump may be installed in the locationprovided on the heater or remote from the heaterintegrated in the coolant circuit. The correct direction offlow through the heater must be observed (coolant outleton top, coolant inlet on bottom), otherwise malfunctionsmay result.The heater is to be connected to the vehicle coolingsystem according to Fig. 801 or 802. The amount ofcoolant used in the circuit must be at least 4 litres.The heater integration into the cooling circuit must beupstream of the vehicle's own heat exchanger.43*165WEBASTO8.4 Heater Test Run2Engine MotorNormal heating water circuitnormaler HeizwasserkreislaufHeating water circuit when operatingHeizwasserkreislauf bei Betriebwith Webasto der Webasto auxiliary heater StandheizungThe heater must not be operated, not even with the timer,in enclosed areas like garages or workshops not providedwith exhaust ventilation facilities.1 Engine1 MotorwithmitwaterWasserpumpepump2 Radiator 2 Kühler3 Radiator 3 Kühlerthermostat4 Compensation 4 Ausgleichsbehälter vessel55HeaterHeizgerät6 6 Circulation Umwälzpumpe pump (Option)7 (option) WT mit Gebläse7 Heat exchanger with fan78.5 ServicingTo ensure functional reliability of the heater the followingservicing must be performed in regular intervals:Fig. 801"Inline Integration" in the Engine Water Cooling Circuit• clean air heater exterior (prevent the ingress of water).• examine electrical connections for corrosion ofcontacts and for security.• inspect combustion air and exhaust ducting fordamage and obstructions.801

8 Servicing Thermo Top E and Z/CThe coolant hoses supplied by Webasto must be installed,other hoses must meet at least the DIN 73411requirement. The hoses are to be routed upwards as faras possible and without kinks to ensure proper venting.Hose connections must be protected against slippageusing hose clamps.NOTEThe installation of the hose clamps of the heater must bebetween the bead and the heater.The hose clamps must be torque tightened to 2.0 + 0.5 Nm.Prior to the heater's first operation or after renewal of thecoolant the cooling system must be carefully bled. Theheater and the lines must be installed to ensure staticventing.Insufficient venting may cause overheating during heateroperation.1 Radiator2 Coolant thermostat3 Water pump (of vehicle engine)4 Vehicle engine with standard outfit5 Water heater6 Battery7 Fuse holder8 Control unit (in heater)9 Relay (for vehicle air fan)10 Control valve of vehicle heating system11 Heat exchanger of vehicle heating system12 Air fan of vehicle heating system13 Switch for air fan of vehicle heating system14 Fuse box in vehicle15 Timer16 Fuel tapping17 Air intake muffler18 Exhaust muffler19 Circulation pump (only applicable for supplementaryheating)*20 Fuel dosing pump* part of modification kitFig. 802 Example for Heater Installation in Passenger VehicleHGmax. 3 ml 1 + I 2 ≤ 7 ml 1 ≤ 1.2 ml 2 ≤ 5.8 ml 2i ø 2 mmHGi ø 2 mml 2i ø 2 mmi ø 2 mml 1l 1HSFig. 803 Fuel Supply802

Thermo Top E and Z/C 8 Servicing8.6.2 Connection to Vehicle Fuel SystemIn vehicles with carburettor or fuel injection including areturn line the heater fuel system integration must beaccording to Fig. 802.Carburettor engines without return line must have theheater integrated in the fuel system's fuel supply linebetween fuel tank and vehicle fuel pump.NOTEA fuel supply line can normally be identified by theinstallation of a fuel filter. If the degassing vessel isincluded in the vehicle fuel system installation, the fuel tapmust be located upstream of the degassing vessel.The following table lists the pressures permitted at the fueltapping location.Permitted fuel feedheight (H) mat max. permissibleoverpressure (bar) in fuel line0.00 –0.201.00 –0.11Permitted suctionheight S (m)at max. permissible negativepressure (bar) in fuel tank0.00 – 0.100.50 – 0.061.00 – 0.02Fuel tappings from the supply or return line may only usethe special Webasto fuel tap.The fuel tap is to be mounted so that air or gas bubblesmay escape towards the fuel tank.Air or gas bubbles may build up in the vehicle fuel linein case the carburettor or the fuel pump is leaking or ifambient temperatures exceed the fuel evaporationtemperature.The fuel tap should not be located near the engine, as gasbubbles may build up due to the heat radiated by theengine resulting in malfunctions of combustion operation.When installing the heater in vehicles with fuel injectionsystem, the fuel pump location, internal or external of thefuel tank, must be investigated.With a fuel pump located inside the fuel tank, fuel may betapped only from the return line, ensuring that the returnline is routed almost all the way down to the fuel tank floor.Otherwise the return line may be lengthened.NOTEIf the fuel return line is provided with a check valve, abypass must be provided.With a fuel pump located outside of the fuel tank the fueltap may be located between tank and fuel pump.8.6.2.1 Fuel LinesFuel lines may only be steel, copper, or plastic lines madeof unhardened, light and temperature stabilised PA 11 orPA 12 (e.g. Mecanyl RWTL) according to DIN 73378.As in most cases a permanently rising fuel line routingcannot be ensured, the inner diameter must not exceed acertain value. Starting from an inside diameter of 4 mm,air or gas bubbles accumulate resulting in malfunctionsshould the lines be descending or having sags. Thediameters specified in Fig. 803 ensure no disturbingformation of bubbles.A descending line routing from the dosing pump to theheater should be avoided.Loose fuel lines must be secured in order to avoidsagging. The installation must ensure protection againststone impacts and undue temperatures (exhaust line).NOTEHose clamps must be torque tightened to 1.0 + 0.4 Nm.Fig. 804 Webasto Fuel Tap803

8 Servicing Thermo Top E and Z/Ccorrecthose clampPreferredwrongbubblebubbleDosing Pump DP2 – Fuel –Fig. 805 Pipe/Hose Connection8.6.2.2 Dosing PumpThe dosing pump is a combined delivery, dosing andshut-off system and is subject to certain installationcriteria (Fig. 803 and 806).Concerning the installation location of the dosing pump itmust be ensured that the maximum pressure at thetapping location is below the permissible value (see tableof 8.6.2.).It is advantageous to mount the dosing pump in a coollocation. The ambient temperature must never exceed+ 20° C during operation.Dosing pump and fuel lines must not be installed inlocations exposed to heat radiated by hot vehiclecomponents. A heat shield is to be provided as necessary.The preferred installation location is near the tank.The dosing pump is to be attached with an anti-vibrationmount. The installation position is limited according toFig. 806 to ensure sufficient self-venting capability.Fig. 806 Dosing Pump, Installation Position8.6.2.3 Combustion Air SupplyA combustion air intake line is required.0°Dosing Pump DP30 – Diesel –The combustion air intake location must be protectedagainst splash water.The combustion air line may routed in several bends (totalof 270°, smallest bending radius 50 mm). The maximumline length without air intake muffler is 1000 mm.NOTEWhen using the air intake muffler the maximum air linelength is 400 mm.The combustion air must under no circumstances betaken in from rooms accommodating persons. If theheater is contained in an installation box, a vent hole of atleast 3 cm 2 is required.Should the temperature within the installation box exceedthe permitted ambient temperature of the heater, the venthole must be enlarged after consulting Webasto.The combustion air intake must be located so thatclogging by contamination is not to be expected. Theintake must not point in the direction of forward motion.When installing the heater in the vicinity of the vehicle fueltank in a common installation compartment, the804

Thermo Top E and Z/C 8 Servicingcombustion air must be taken in from and the exhaustvented to the exterior. The line feedthroughs must besealed against splash water.8.6.3 Air Intake MufflerThe permitted installation position of the air intake muffleris between 0° and 90° pointing downwards.Fig. 807 Air Intake Muffler, Installation Position8.6.3.1 General Remarks for Installation0-90° 0-90°8.6.4 Exhaust LineThe exhaust line (inner diameter 22 mm) may be routedin several bends (total of 270°, smallest bending radius50 mm). The minimum line length is 500 mm, themaximum length is 1000 mm.The exhaust muffler is to be mounted near the heater,however at least 200 mm away from the heater.The exhaust muffler must not be installed near thecombustion air intake.Heater operation without exhaust muffler is not permitted.NOTEAccumulations of condensate in the exhaust line must bedirectly drained. A condensate drain hole (3 mm Ø) maybe provided as required.The exhaust line outlet must not point in the direction offorward motion (Fig. 808)Rigid pipes of unalloyed steel with a minimum wallthickness of 1.0 mm or flexible hoses of alloyed steel onlymay be used as exhaust ducts.Plug air intake hose with its slotted end (approx. 18 mm)onto air intake connecting pipe of heater and fasten withhose clamp.Screw air intake muffler all the way into unslotted end ofcombustion air intake hose (additional fastening with hoseclamp not required).CAUTIONEnsure sufficient distance to exhaust system.Dependent on installation area fasten air intake mufflerwith retaining clip or with cable ties in suitable location.Exhaust flow directionnearly vertical 90° ± 10°10°10°Fig. 808 Exhaust Pipe Outlet, Installation Position805

8 Servicing Thermo Top E and Z/C8.7 Removal and InstallationCAUTIONIn the heater installed condition only the circulation pumpremoval and installation is permitted should accessibilityallow for such action (see 9.2.1).8.7.1 Heater, Removal and Installation8.7.1.1 Removal1. Disconnect heater power supply by removing 20 A flatfuse (yellow) from Webasto fuse holder.8.7.2 Timer, Removal and InstallationTimer removal and installation is to be performed inaccordance with Fig. 809. For initial installation use drillingstencil. The electrical connection is shown in Section 7.CAUTIONDuring installation do not exert pressure on display.NOTEOnly the timer shown in Fig. 809 may be used incombination with the heater.2. Disconnect electrical connections from heater.Disconnect antenna cable to Telestart receiver T60 atscrew type locking connector.3. Open radiator cap for depressurisation, then closecap.NOTECollect coolant escaping in a vessel or prevent coolantfrom escaping by using squeezing tongs.4. Loosen hose clamps and disconnect coolant hosesfrom heater.5. Loosen heater from its mount.6. Loosen hose clamps, disconnect fuel line and closewith suitable plug or any other means.8.7.1.2 Installation1. Locate heater for installation.2. Connect fuel line to heater and secure with hoseclamp.3. Connect coolant hoses and secure with spring bandsteel clamps.4. Restore all electrical connections at connectorterminal.5. Connect antenna cable to Telestart T60 receiver asrequired.6. Re-install 20 A flat fuse (yellow) in fuse holder.7. Bleed coolant circuit.8. Bleed fuel system as required.Fig. 809 Timer, Removal and Installation8.8 Initial OperationAfter heater installation the coolant circuit as well as thefuel supply system must be carefully bled observing therelevant manufacturer's instructions.During the heater test run inspect all coolant and fuelconnections for leakage and security. Should the heaterduring operation enter an error lockout condition, performtroubleshooting (see Section 5).806

Thermo Top E and Z/C 9 Repair9 Repair9.1 GeneralThis section describes the repairs that may be performedon the heaters Thermo Top Z and Thermo Top E and Cwhen removed. Any further disassembly will void thewarranty. After repairs a functional test must beperformed.9.1.1 Work on Components after DisassemblyCAUTIONAll gaskets located between disassembled componentsmust always be discarded and replaced.9.1.1.1 Cleaning• All components disassembled must be cleaned.• Sealing compound on components must be carefullyand completely removed using suitable means.9.1.1.2 Visual Inspection• Inspect all components for damages (cracks,deformation, wear, etc.) and replace as required.• Inspect connectors and wiring for corrosion, loosecontacts, wrong crimping, etc. and repair as required.• Inspect connector terminal for corrosion and contactsfor security.901

9 Repair Thermo Top E and Z/C9.2 Disassembly and Assembly9.2.1 Circulation Pump, Replacement(Thermo Top E and C)9.2.1.1 Removal1. Remove cover (4, Fig. 901) and disconnect electricalconnector of circulation pump.2. Loosen spring band steel clamp (5, Fig. 901).3. Remove screw (7) and clamp (2).4. Withdraw circulation pump (6) and remove springband steel clamp (5).9.2.1.2 Installation1. Slide spring band steel clamp (5, Fig. 901) onto hoseend.2. Position collar (1) on circulation pump (6) as required.3. Locate circulation pump (6) for installation and securewith clamp (2) and screw (7) on combustion air fan (3).4. Position spring band steel clamp (5).5. Torque screw (7) with 3.5 ± 0.3 Nm.6. Connect circulation pump electrical connection and fitcover (4).5. Withdraw collar (1) as required.6. Perform procedures on components afterdisassembly (refer to 9.1.1).NOTECirculation pump may also bemounted remotely in vehicle.34127151Torque 3.5 Nm61 Collar2 Clamp3 Combustion air fan4 Cover5 Spring band steel clamp6 Circulation pump7 ScrewFig. 901 Replacement of Circulation Pump (Thermo Top E and C)902

Thermo Top E and Z/C 9 Repair9.2.2 Combustion Air Fan, ReplacementCAUTIONIn case of Thermo Top E and C the circulation pump mustbe removed first (see 9.2.1.1).9.2.2.1 Removal4. Plug on electrical connections of combustion air fan.5. Install circulation pump as required (see 9.2.1.2).6. Plug on cover (6) and engage.7. Perform CO 2 setting (see 6.2.6).1. Carefully lever off cover (6, Fig. 902).2. Disconnect electrical connector of combustion air fan.3. Remove screws (11).4. Withdraw combustion air fan (1) from burner housing(5) and fuel pipe (9).5. Remove gasket (2) and discard.6. Perform procedures on components afterdisassembly (refer to 9.1.1).9.2.2.2 InstallationCAUTIONFor the sealing between combustion air fain and burnerhousing two gaskets (2, Fig. 902) are available orcontained in the spares kit. One paper gasket and onerubber gasket with beads on one side to be used asfollows:NOTEA new combustion air fan has a groove for the gasket inthe mounting flange fan to burner housing.Combustion air fan new –Control unit / heat exchanger with burner housingnew = rubber gasketCombustion air fan old –Control unit / heat exchanger with burner housingold = paper gasketCombustion air fan old –Control unit / heat exchanger with burner housingnew = paper gasketCombustion air fan new –Control unit / heat exchanger with burner housingold = rubber gasket1. Position new gasket (2) on burner housing (3).2. Slide combustion air fan (1) onto fuel pipe (9) to bringfan into installation position.3. Secure combustion air fan (1) with screws (11).Torque tighten screws to 4 ± 0.4 Nm.903

9 Repair Thermo Top E and Z/C22233110 19811112Torque 4 NmPaper gasket63Rubber gasket7541 Combustion air fan2 Gasket3 Burner insert4 Gasket5 Burner housing6 Cover7 Control unit / heat exchanger8 Glow plug / flame sensor9 Fuel pipe10 Screw (4)11 Screw (4)Fig. 902 Heater Disassembly904

Thermo Top E and Z/C 9 Repair9.2.3 Burner Insert with Glow Plug /Flame Sensor, ReplacementCAUTIONIn case of Thermo Top E and C the circulation pump mustbe removed first (see 9.2.1.1).9.2.3.1 Removal1. Remove combustion air fan (see 9.2.2.1).2. Push grommet of cable of glow plug / flame sensor(8, Fig. 902) out of burner housing (5).3. Remove screws (10).4. Withdraw burner insert (3) with glow plug / flamesensor (8) from burner housing (5).5. Remove gasket (4) and discard.6. Perform procedures on components afterdisassembly (refer to 9.1.1).9.2.3.2 Installation1. Position new gasket (4) on burner housing (5).2. Position burner insert (3) for assembly and securewith screws (10). Torque tighten screws to4 ± 0.4 Nm.3. Press grommet of glow plug / flame sensor cable intoburner housing (5).4. Install combustion air fan (see 9.2.2.2).5. Install circulation pump as required (see 9.2.1.2).9.2.4 Control Unit / Heat Exchanger with BurnerHousing, ReplacementCAUTIONIn case of Thermo Top E and C the circulation pump mustbe removed first (see 9.2.1.1).9.2.4.1 Removal1. Remove combustion air fan (see 9.2.2.1).2. Push grommet of cable of glow plug / flame sensor(8, Fig. 902) out of burner housing (5).3. Remove screws (10).4. Withdraw burner insert (3) with glow plug / flamesensor (8) from burner housing (5) and remove.5. Remove gasket (4) and discard.6. Perform procedures on components afterdisassembly (refer to 9.1.1).9.2.4.2 Installation1. Position new gasket (4, Fig. 902) on burner housing(5).2. Position burner insert (3) for assembly and securewith screws (10). Torque tighten screws to4 ± 0.4 Nm.3. Press grommet of glow plug / flame sensor cable intoburner housing (5).4. Install combustion air fan (see 9.2.2.2).5. Install circulation pump as required (see 9.2.1.2).905

9 Repair Thermo Top E and Z/CPage free for notes906

Thermo Top E and Z/C 10 Packaging, Storage and Shipping10 Packaging, Storage andShipping10.1 GeneralThe heater or its components shipped to WebastoThermosysteme GmbH for testing or repair must becleaned and packaged so that they are protected againstdamage during handling, shipping and storage.CAUTIONWhen shipping a complete heater assembly it must bedrained completely.No fuel is allowed to escape from a packaging or duringshipping.Dummy plugs must be fitted to the fuel and coolantconnector pipes.1001

10 Packaging, Storage and Shipping Thermo Top E and Z/CPage free for notes1002