Webasto Thermo Top series Service manual

Webasto Thermo Top series Service manual
Webasto Thermo Top series

The installation and service of Webasto Thermo Top series (BlueHeat) heaters requires special expertise and training. Installations and servicing of Webasto products by untrained, unauthorized personnel and end-users voids all warranties and releases Webasto Product North America, Inc. and Webasto authorized distributors, dealers and their personnel from responsibility for damage to Webasto products, any resulting collateral property damage and personal injury.

Any use, operation, installation, modification or application of the product not described in Webasto manuals, or subjecting the product to extreme or unusual conditions beyond the limits of specified performance characteristics is misuse of the product. Failure to comply with all installation instructions is a misuse of Webasto products. The same applies for repairs without using genuine Webasto service parts. This will void the coolant heaters “official Marks of Conformity.”

Scope and Purpose
These installation instructions are intended to support Webasto trained and authorized distributors and dealers in the installation of the Thermo Top series (BlueHeat) Coolant Heaters. These instructions are not intended for use by untrained or unauthorized personnel. The directives in the “master reference manual” and “operating manual” for the Thermo Top series heater must be followed. Acknowledged engineering conventions must be observed for the installation work.

All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary heating devices must be observed!

Location of heater, installation of coolant lines, fuel system and components, wiring and control devices are important for proper operation. Failure to comply with the installation instructions provided may result in poor operation or damage to heater and vehicle components.

General Safety/Installation Instructions

  • The heater must not be installed in the passenger compartments of the vehicle.
  • Extracting combustion air from the passenger compartment of the vehicle is not permissible under any circumstance.
  • Exhaust pipes must be routed so that exhaust fumes will not penetrate into the vehicle’s interior.
  • Do not route exhaust components within 100 mm (4 inches) of flammable materials such as fuel system components, polyurethane or similar foam insulation, styene sheet installation, wood and paper products, carpet, glycol reservoirs, coolant lines, brake lines, electrical wiring, etc.
  • The operational state of the heater, i.e. an indication “on” or “off”, must be clearly visible to the operator.
  • The coolant heater may only be operated within the specified voltage range designated.
  • The coolant heater may only be operated with the specified fuel as recommended by the vehicle manufacture.

The following important regulations must be adhered to when routing fuel lines:

  1. Fuel lines are to be installed in such a way that they remain unaffected by torsional stresses created by vehicle and engine movement.
  2. Fuel lines be securely fastened to the vehicle every 12 inches (30 cm) or less along the total length from heater to fuel tank.
  3. Fuel-carrying components are to be protected against excessive heat and are to be installed so that any drippings or evaporating fuel can neither accumulate nor be ignited by hot components or electrical equipment.
  4. In buses, fuel lines are not to be located in the passenger area or in the driver’s compartment. Fuel supply must not be by means of gravity or pressurization of the fuel tank.
  5. The fuel tank must be equipped with a vent cap or ventilated in another way (vent line)

Fuel line Tee Adapter
There are various sizes and shapes of fuel line adapters available from Webasto (see Figure 25). A fuel line adapter should not be installed after the vehicle fuel pump. Fuel line pressure from the vehicle fuel pump could overcome the Webasto heater dosing pump, causing excessive fuel delivery to the heater.

If the heater is being installed in a vehicle equipped with a fuel injection system, determine if the vehicle fuel pump is mounted in the fuel tank. If the fuel pump is mounted outside of the fuel tank a fuel line adapter can be used in place of the standpipe. This is only true when the fuel line adapter can be installed prior to the vehicle fuel pump.