907512, Webasto

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Thermo Top C Installation / Operation Manual
Contents
Contents
1. Introduction
1.1 General Description........................................................................................................ 101
1.2 Legal Provisions ............................................................................................................. 102
1.3 Meaning of Warning, Caution and Note.......................................................................... 102
2. Operating the Webasto Thermo Top C (TTC)
2.1 Switching On................................................................................................................... 201
2.2 Switching Off................................................................................................................... 202
2.3 Operation with Optional Digital Timer............................................................................. 202
2.4 Digital Timer Setting / Operating Instructions ................................................................. 204
3. Technical Data
3.1 Technical Data................................................................................................................ 301
3.2 Heater Dimensions ......................................................................................................... 302
3.3 Fuel Pump Dimensions................................................................................................... 302
4. Installation
4.1 General Information........................................................................................................ 401
4.2 Installation Locations ...................................................................................................... 401
4.3 Mounting the Heater ....................................................................................................... 402
4.4 Exhaust Pipe Connection ............................................................................................... 403
4.5 Combustion Air Supply ................................................................................................... 403
4.6 Plumbing the System...................................................................................................... 404
4.6.1 General Information ............................................................................................. 404
4.6.2 Plumbing the Thermo Top C into The Coolant System........................................ 405
4.6.3 Contents - Engine Connections ........................................................................... 407
4.7 Fuel System.................................................................................................................... 415
4.7.1 General Description ............................................................................................. 415
4.7.2 Fuel System Limitations....................................................................................... 415
4.7.3 Fuel Pump............................................................................................................ 416
4.7.4 Fuel Standpipe..................................................................................................... 416
4.7.5 Fuel Line .............................................................................................................. 418
4.7.6 Fuel Filter............................................................................................................. 418
4.8 Wiring Connections......................................................................................................... 419
4.8.1 General Information ............................................................................................. 419
4.8.2 Power Connection to Battery ............................................................................... 419
4.8.3 Switch and Timer Connections ............................................................................ 419
4.8.4 Wiring Diagram - Thermo Top C (12 Volt) with On/Off Toggle Switch................. 421
4.8.5 Wiring Diagram - Thermo Top C (12 Volt) with Optional Digital Timer ................ 422
4.9 Initial Operation............................................................................................................... 423
5. Maintenance of the Heater
5.1 Annual Maintenance....................................................................................................... 501
I
Contents
Thermo Top C Installation / Operation Manual
Contents
6. Basic Troubleshooting
6.1 General Information........................................................................................................ 601
6.2 General Failure Symptoms............................................................................................. 601
6.3 Heater Lockout Reset Procedure ................................................................................... 602
6.4 PC Diagnostics Kit.......................................................................................................... 602
List of Figures
101 Webasto Thermo Top C Coolant Heater........................................................................ 101
201 Optional 7-Day Timer...................................................................................................... 203
301 Heater Dimensions ......................................................................................................... 302
302 Fuel Pump Dimensions................................................................................................... 302
401 Installation Locations ...................................................................................................... 401
402 Permissible Heater Installation Positions........................................................................ 402
403 Engine Block Preheating and/or Boost Heating.............................................................. 405
404 Fuel System Limitations.................................................................................................. 415
405 Fuel Pump Mounting (DP 30) ......................................................................................... 416
406 Fuel Standpipe................................................................................................................ 417
407 Fuel Line Connection...................................................................................................... 418
408 On/Off Toggle Switch...................................................................................................... 420
409 Optional 7-Day Digital Timer........................................................................................... 420
410 Wiring Diagram - Thermo Top C with On/Off Toggle Switch.......................................... 421
411 Wiring Diagram - Thermo Top C with Optional Digital Timer ......................................... 422
List of Tables
201 Digital Timer Setting Instructions.................................................................................... 204
301 Technical Data - Heater ................................................................................................. 301
302 Technical Data - Circulating Pump ................................................................................ 301
601 General Failure Symptoms............................................................................................. 601
Item No. 907512
Org. 9/1/99 Subject to modification.
II
Thermo Top C (TTC) 1 Introduction
1. Introduction
1.1 General Description
Fig. 101: Webasto Thermo Top C Coolant Heater
1. Control Unit.
6. Coolant Outlet Connection Pipe
2. Combustion Air Fan Assembly
7. Fuel Inlet Connection Pipe
3. Combustion Air Inlet Connection Pipe
8. Exhaust Outlet Pipe
4. Coolant Circulating Pump
9. Combustion Chamber
5. Coolant Inlet Connection Pipe
10. Heat Exchanger
The Webasto TTC is designed for Class 3-7 vehicles. This dynamic system allows you to
preheat engines on or offsite. The TTC offers high performance with low power and fuel
consumption. Approximately 2-hours of operation eliminates overnight idling for heating and the
need for expensive electrical plug-ins. The compact design allows the heater to be frame rail or
engine compartment mounted. The TTC is easy to install, maintain and operate. The universal
package fits most of today vehicles.
101
1 Introduction Thermo Top C (TTC)
1.2 Legal provisions
Heater installation must be performed in accordance with the manufacturer`s installation
instructions.
Any deviation from these instructions are only permitted with the written approval from Webasto
Thermosystems Inc.
It is the dealer's responsibility to approve installations not performed by Webasto trained
personnel.
Installation not complying with the installation instructions release Webasto Thermosystems Inc.
from any product liability.
OEM installations must be approved by Webasto Thermosystems Inc.
1.3 Meaning of Warning, Caution and Note
WARNING!
This heading is used to highlight that noncompliance with instructions or procedures may cause
injuries or lethal accidents to personnel.
CAUTION!
This heading is used to highlight that noncompliance with instructions or procedures may cause
damage to equipment.
NOTE:
This heading is used to highlight and draw specific attention to information.
102
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