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Thermo Top Pro 150
Webasto Thermo Top Pro 150 Workshop Manual
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Water Heater
Thermo Top Pro 120 | 150
English
Workshop Manual
2
Table of Contents
Table of Contents
2
About this Document
3
Purpose of the Document
3
Using this Document
3
Use of Symbols and Highlighting
3
Safety
3
General Safety Information
3
Qualification of Personel
4
Working on the Heater
4
Working on the Vehicle
4
Heater Test Run
4
Checks
4
Information Regarding the Heater
5
Basis
5
Special Variants (Rail, Cpoff, Chiller, ADR)
5
Description of the Components
6
Overview of the Subassemblies
6
Burner Head
8
Combustion Air Fan
8
Drive Motor
8
Fuel Pump with Solenoid Valve
9
Nozzle Block Preheater
9
Ignition Spark Generator with Ignition Electrodes
9
Fuel Nozzle and Baffle Plate
9
Control Unit
10
Flame Monitor
10
Pressure Equalization Element
10
Heat Exchanger
10
Combustion Tube
10
Coolant Temperature Sensors
11
Exhaust Gas Temperature Sensor
11
Coolant Pump
11
Coolant
12
Fuel Filter
12
Functional Description
13
Introduction
13
Control Elements
13
Switch the Heater on and off
13
Using the Heater in Hazardous Material Vehicles (ADR)
13
Functional Sequence
14
Fault Switch-Off
15
Malfunctions and Troubleshooting
15
Basics
15
Fault List on the Control Element
15
Cause of Malfunctions in the Heater and Systems
16
Instructions for Cancelling the Fault Lock-Out
16
Heater Unlocking Instructions
17
Overview of Faults and Fault Codes
17
Function Checks
24
Basics
24
Check and Set CO₂ in Exhaust Gas
24
Checking Exhaust Gas Temperature Sensor
25
Checking Control Unit
25
Check Combustion Tube
25
Check the Blower Fan Wheel
26
Checking Baffle Plate
26
Checking Drive Motor
26
Fuel Pump and Check Solenoid Valve
26
Checking Heater Cartridge
27
Check Coolant Pump
28
Checking Coolant Temperature Sensors
28
Checking Ignition Electrode
28
Repairing and Replacing Components
29
Required Tools
29
Installation Notes
29
Disconnecting Control Unit Connections
30
Disconnect Burner Head
30
Install Burner Head
30
Removing Control Unit
30
Electrical Wiring in the Burner Head
31
Removing Baffle Plate
31
Removing Ignition Electrodes
32
Removing Fuel Nozzle
32
Removing Ignition Spark Generator
33
Removing Fuel Pump
33
Installing Fuel Pump
33
Removing Nozzle Block Preheater
34
Removing Blower Fan Wheel
34
Removing Drive Motor
35
Remove Heat Exchanger
35
Remove Combustion Tube
35
Remove Coolant Temperature Sensors
36
Install Coolant Temperature Sensors
36
Removing Exhaust Gas Temperature Sensor
36
Installing Exhaust Gas Temperature Sensor
37
Packaging / Storage / Shipping
37
General Information
37
Ideal Position
37
Storage and Transportation
38
Electrical Incorporation
38
Information on the Electrical Connection
38
The Heater in Hazardous Material Vehicles (ADR)
38
Legend and Remarks Regarding Wiring Diagrams
38
Cable Colours / Cable Cross-Sections
39
Connector and Pins
39
Wiring Diagrams
40
Technical Data
48
List of Abbreviations
48
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Operating Instructions
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Webasto Thermo Top Pro 150 Specifications
General
Brand
Webasto
Model
Thermo Top Pro 150
Category
Water Heater
Language
English
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