Air heaters
Integrated Heater
03/2003
Workshop Manual
Dual Top Evo 6 / 7 / 8
Страница 1: ...Air heaters Integrated Heater 03 2003 Workshop Manual Dual Top Evo 6 7 8...
Страница 2: ...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 ALWAYS...
Страница 3: ...ode output 401 4 2 1 Manual control panel 402 4 2 2 Programmable control panel 405 5 Function tests 501 5 1 General 501 5 2 Repair Shop Level Testing 501 5 2 1 Testing individual components 501 5 2 1...
Страница 4: ...nsulating elements 803 8 2 4 Removing ventilation overpressure valve and solenoid valve 803 8 2 5 Removing thermo unit sensors and sensor wiring harness 804 8 2 6 Removing electrical heating elements...
Страница 5: ...prevention regulations and current works safety instructions are applicable The General safety regulations that go beyond the scope of the above regulations are stated below Any special safety regulat...
Страница 6: ...te during a water crossing permissible for the respective vehicle The heater must be switched off at filling stations and tank farms as a result of the risk of explosion Wherever inflammable vapours o...
Страница 7: ...in front of the cold air inlet and the hot air outlet The stream of hot air of the heater may not be restricted or blocked by highly flammable substances or materials such as rags cleaning wool etc I...
Страница 8: ...he glow plug flame monitor the boiler the electrical heating elements not with Dual Top Evo 6 the housing The following are located in the heater for control and monitoring a control unit with a tempe...
Страница 9: ...r outlet hot 9 Boiler 10 Insulating element 11 Heater housing 12 Heat exchanger 13 Combustion pipe 14 Water temperature switch 15 Water temperature sensor 16 Housing cover with hot air outlet 17 Air t...
Страница 10: ...1 03 5000 Model Air heater with evaporator burner Heat output diesel electric Control range 1 5 to 6 0 kW Fuel Diesel DIN EN 590 Fuel consumption Control range 0 19 to 0 66 l h Rated voltage 12 V Oper...
Страница 11: ...r Stand by 1 A 0 5 to 7 A 0 001 A Rated power consumption Control range 15 to 65 W EN 1646 Max ambient temperature Heater Operation Storage control panel Operation Storage 30 to 50 C 40 to 85 C 30 to...
Страница 12: ...Heater lifted by heating air blow er Heater warped noise Heater installed without vibration damper Noise Water lines connected with incor rect hose connectors Leakage Unfavourable position of cold air...
Страница 13: ...ontrol panel and heater and leave ON control panel in any ON operating mode Disconnect heater from battery and restore connection Or Switch on manual control panel and heater and leave ON control pane...
Страница 14: ...rt heater 2 Start blower component test in diagnostic mode Run blower 5 minutes at 80 Listen if there is any unusual noise grinding etc Restart heater 3 Dismount application parts until the blower on...
Страница 15: ...ternal room temperature sensor 12 Open circuit in air temperature sensor in heater AB 1 Check routing of cable ensure that it is not pinched or crushed check the connectors 2 Check resistance of air t...
Страница 16: ...ating If necessary wait until the blowers stop running Unlocking Switch on programmable control panel and heater and leave ON control panel in any ON operating mode Remove 15 A fuse red wire thermo un...
Страница 17: ...e failure Restart not successful 03 83 See message 02 Message 04 High battery volt age Operation voltage is above permit ted value 04 Reset heater by pressing OK or switching off for at least 5 sec Me...
Страница 18: ...PWM module Replace defective part 5 If heating air blower assembly and wiring harness have been checked and Dual Top still doesn t run Replace complete Dual Top Message 09 Failure fan ampli fier No co...
Страница 19: ...cuit in air temperature sensor in heater AB 1 Check routing of cable ensure that it is not pinched or crushed check the connectors 2 Check resistance of air temperature sensor 3 Reset heater by pressi...
Страница 20: ...ge 31 32 33 n a n a n a Message 34 System overheat ed or relay circuit disconnected One of the three overheating switches detects too high tempera tures overheating relay circuit in terrupted 43 Dual...
Страница 21: ...ter the air temperature sensor see Fig 503 must have the values shown in the following diagram 5 2 1 4 Water temperature sensor resistance test A Resistance in k B Temperature of water temperature sen...
Страница 22: ...855 00 6 613 00 7 097 00 10 5 373 00 5 190 00 5 556 00 15 4 241 00 4 102 00 4 379 00 20 3 372 00 3 266 00 3 479 00 25 2 700 00 2 619 00 2 781 00 30 2 175 00 2 107 00 2 244 00 35 1 763 00 1 706 00 1 8...
Страница 23: ...of the fuel pump when triggered 3 Air temperature switch Also interrupts the plus line of the fuel pump when triggered 4 Air temperature sensor Is only monitored by the control unit in the winter mod...
Страница 24: ...wiring harness of RHA 100 wiring harness connector inside older version Fig 607 for Dual Top RHA 100 wiring harness connector outside newer version and Dual Top Evo 6 Fig 608 for Dual Top Evo 7 8 See...
Страница 25: ...5 A 6 Fuse 15 A 7 Fuse 15 A 8 Fuel pump 9 External room temperature sensor 10 Cable for external room temperature sensor 10 11 12 13 15 14 1 Heater Dual Top 2 Wiring harness 3 Control panel 4 Vehicle...
Страница 26: ...ntrol panel X2 is for Webasto Thermo Test PC diagnosis and Webasto Telestart Thermo Call for optional programmable control panel X4 4 pin of wiring harness to control panel X5 X0 X0 2 pin of room temp...
Страница 27: ...op Evo 6 7 8 6 Circuit diagrams 604 Fig 606 Wiring harness for Dual Top RHA 100 older version heater Ident No 9015314A and 9015314B A2 A1 B2 B4 S1 S4 S2 S3 M1 P1 M2 B1 E X4 X2 X0 X3 Y3 Y4 Y5 Y6 Y7 Y8...
Страница 28: ...grams Dual Top Evo 6 7 8 605 Fig 607 Wiring diagram for Dual Top RHA 100 newer version heater Ident No 9015314C and Dual Top Evo 6 A2 A1 B2 B4 S1 S4 S2 S3 M1 P1 M2 B1 E X4 X2 X0 X11 X3 Y3 Y4 Y5 Y6 Y7...
Страница 29: ...Dual Top Evo 6 7 8 6 Circuit diagrams 606 Fig 608 Wiring diagram for Dual Top Evo 7 8 A1 B4 A2 B2 S1 S4 S2 S3 M1 P1 K1 M2 B1 E X4 X5 X6 X2 X1 X0 X11 X3 Y3 Y4 Y5 Y6 Y7 Y8 Y9 Y10 Y11...
Страница 30: ...8 pin To relay box not for Dual Top Evo 6 X11 Plug connector 12 pin On external wiring harness to Dual Top heater X12 Wire end 4 pcs to relay box 1 to ground not for RHA 100 Y1 Fuel pump DP 40 Y1 Plu...
Страница 31: ...Dual Top Evo 6 7 8 6 Circuit diagrams 608 Table 602 Cable colours Abbreviation Colour bl blue br brown ge yellow gn green gr grey or orange rt red sw black vi violet ws white...
Страница 32: ...ation above 2 200 m above sea level can result in heavy smoke and soot The measured CO2 value at an ambient temperature of 20 C must be 5 0 to 8 0 vol under partial load 2 kW At full load 6 kW it shou...
Страница 33: ...age to ensure that they are secure and clear Exhaust lines Combustion air lines Cooling air lines Cold air intake lines Hot air distribution lines inspect fuel lines for leaks check cold and hot water...
Страница 34: ...as shown see Fig 701 3 Disconnect the wiring harness plug X11 4 Disconnect plug X0 of the room temperature sensor 7 8 2 2 Programmable control panel for Dual Top Evo 6 7 8 1 Disconnect the battery 2...
Страница 35: ...n wear etc and replace if necessary Inspect the plugs and cables for corrosion loose contacts crimping faults etc and repair them if necessary Check plug strips for signs of corrosion and contacts to...
Страница 36: ...ews T25 then remove housing cover with hot air outlet incl boiler gasket Fig 802 Remove housing cover with inlet interfaces NOTE When removing housing cover with inlet interfaces friction is caused by...
Страница 37: ...op Pull boiler including insulating elements out of housing Remove both insulation elements 8 2 4 Removing ventilation overpressure valve and solenoid valve Remove drain hose from ventilation overpres...
Страница 38: ...sure valve 8 2 5 Removing thermo unit sensors and sensor wiring harness Loosen 4 T30 screws that attach thermo unit to boiler Pull out thermo unit including heat exchanger Fig 808 Remove connector Fig...
Страница 39: ...s 8 2 6 Removing electrical heating elements Only for Dual Top Evo 7 8 Disconnect 2 X1 plugs 2 pin 1x grey and black 1x brown and blue of cable from relay box to electrical heating elements Loosen T10...
Страница 40: ...to control unit Remove internal wiring harness Disconnect 2 remaining 2 pin plugs loosen second T20 screw to and then remove control unit from thermo unit Control unit 1 Temperature sensor control uni...
Страница 41: ...sen 2 T20 screws to remove clamping yoke from heat exchanger Press grommet on the glowplug wire inwards and guide plug through the hole in the heat exchanger Press grommet of fuel line inwards Remove...
Страница 42: ...8 Repair Dual Top Evo 6 7 8 808 Loosen 2 T20 screws to remove combustion pipe assembly and metal crimp sealing from heat exchanger Fig 825 Remove combustion pipe assembly and gasket...
Страница 43: ...ottom of heat exchanger Position evaporator housing assembly in combustion pipe assembly Press grommet fuel line in hole heat exchanger Guide wiring glowplug from inside to outside through small hole...
Страница 44: ...t gasket heat exchanger and drive assembly to heat exchanger and fix with 8 screws T20 Fig 829 Install combustion air intake and and gasket NOTE Align 2 holes in gasket with protrusions on the heat ex...
Страница 45: ...Put control unit on drive assembly and fix with 2 screw T20 Use 1 of these screws to fix brown wire Attach cooling shell to heat exchanger with 8 screws T20 Put gasket exhaust on exhaust and cooling a...
Страница 46: ...ect 2 pin plug of wiring overheating protector to internal wiring harness Fix wires to ribs of heat exchanger using cable ties Fit 4 springs on heat exchanger Select a uniform positioning of the sprin...
Страница 47: ...ush hot water pipe as far as posible into air ventilation overpressure valve and cold water pipe into connection of boiler Push solenoid valve as far as posible into connection of boiler NOTE Always r...
Страница 48: ...on solenoid valve B Position open end in cooling air outlet C Dual Top Evo immersion pump version Connect drain hose to 1 opening on ventilation overpressure valve A and to 1 opening on solenoid valve...
Страница 49: ...T30 screws NOTE Arrows on insulation elements must face toward rear Position sensor wiring harness between bottom of boiler and lower part insulation groove in insulation element NOTE The Dual Top ho...
Страница 50: ...pes through rubber gasket Only Dual Top Evo immersion pump version Guide ventilation hose of Dual Top through housing cover with inlet interfaces NOTE Sensor and switch shall face towards housing cove...
Страница 51: ...heating air blower assembly to Dual Top housing NOTE Housing cover with inlet interfaces must fit into respective groove of grommets for wiring harnesses 1 pc for Dual Top Evo 6 Fig 849 Install housi...
Страница 52: ...3 Cut off old wiring harness as close as possible to Dual Top heater approx 5 cm 4 Secure lines for fuel pump of old wiring harness orange and green white cables 5 Strip 6 wires of old wiring harness...
Страница 53: ...sting must be cleaned and packaged so that they are protected against damage when handled transported and stored An ambient temperature of 85 C or 40 C must not be exceeded for storage IMPORTANT Fully...
Страница 54: ...9 Packaging storage and shipping Dual Top Evo 6 7 8 902...
Страница 55: ...tfach 1410 82199 Gilching Germany Visiting address Friedrichshafener Str 9 82205 Gilching Germany Technical Extranet http dealers webasto com The telephone number of each country can be found in the W...
