Webasto Thermo Top C User manual

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
Thermo Top C Installation / Operation Manual Contents

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
Contents Thermo Top C Installation / Operation Manual

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
Thermo Top C (TTC) 1 Introduction

1.2 Legal provisions
1.3 Meaning of Warning, Caution and Note
102
1 Introduction Thermo Top C (TTC)
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.
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™ 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.

2. Operating the Webasto Thermo Top C (TTC)
Before switching on theTTC, set vehicle heating system to the fiheat position and open any shut
off valves. Depending on the type of control installed in the dashboard of the vehicle, the TTC can
be operated by the following methods.
2.1 Switching On
Using a Switch: Using the Optional Digital Timer:
Using the Switch:
When the switch is used for turning ON the TTC, the operation indicator (toggle) lights up.
Shortly thereafter, the heater begins operation and delivers heated coolant to the engine.
Using the Optional 7-Day Digital Timer:
1. Set the timer up to 2 hr. before you want to start the engine. The heater will start up at set time.
(See timer operating instructions.)
Or switch fiinstan onf switch on your timer in the vehicle dash to ON The heater will start up.
2. When time is elapsed on your timer or engine preheat is no longer required, switch the TTC
heater OFF The TTC will go through the after-run cycle.
Pushing the fiinstan heatf button or when timer setting reaches desired start time, the fioperatio
indicatorf on the timer will light, signaling that the heater is in operation.
See section 2.3 fiOperatio with 7-Day Digital Timerf for complete instructions.
Startup Sequence:
The coolant circulating pump, ceramic igniter and combustion air fan start operation and after
approximately 60 seconds combustion starts (audible combustion sound).
After the coolant temperature has reached the set point of 170 °F (77 °C) the TTC will
automatically adjust its heat output to a lower operating range (part-load heat output).
If the temperature of the coolant continues to rise and climb over 174 °F (79 °C) at the heater outlet,
the heater will cycle off.
When the temperature falls below 149 °F (65 °C) the heater will restart and repeat the heating cycle.
201
Thermo Top C (TTC) 2 Operating the Webasto
NOTE:
If heater is being switched on while the engine is warm only the circulating pump will run, coolant
temperature must fall below 86 °F. (30 °C.) before heater starts.

The Thermo Top C (TTC) will cycle on and off until:
1. The toggle switch is switched OFF
2. The fiinstan heatf button is pressed once again, signaling heater to shut off.
3. Time has elapsed on the timer.
4. The vehicle battery voltage drops below 9.6 V or the TTC runs out of fuel.
2.2 Switching Off
Manually: When heating is no longer required, switch the TTC heater off by means of the toggle
switch or by pressing the fiinstan heatf button on the optional timer.
The indicator light turns off, combustion is extinguished followed by an after run cycle of
approximately 90 seconds.
Automatically: When the optional timer has reached the end of the timed cycle (up to 2 hours).
2.3 Operation with Optional 7-Day Digital Timer
The timer enables you to preset the start time of the heater up to 7 days in advance.
In addition, the timer enables the heater to be switched on and off instantly thereby eliminating the
need for a separate switch.
When the heater is in operation, the display and operation buttons of the timer are illuminated.
The timer features a wake up alarm function.
Programmed Heater Operation
Three memory locations numbered 1 to 3 are available. Each memory location can be assigned a
given time together with the day of the week of which only one can be activated at any one time.
202
2 Operating the Heater Thermo Top C (TTC)
NOTE:
Restarting the heater during the after-run period is permitted.
WARNING!
Explosion hazard! The heater must be switched fiOFF while refueling and at fueling stations.
WARNING!
Explosion hazard! Do not operate any Webasto heater in an area where toxic or explosive
materials or fumes may be present.
WARNING!
Due to the danger of poisoning and asphyxiation the heater must not be operated in enclosed
spaces such as garages or workshops without adequate exhaust extraction or ventilation.

Preselected Starting Times
The preselected starting time is the time at which the timer switches the heater on automatically.
We recommend that memory locations 1 and 2 be used for presetting starting times within 24 hours
of setting the timer.
Memory location 3 can be used for a starting time within the next 7 days of setting the timer.
Operating Time
The period of time during which the heater is in operation is referred to as operating time.
The heater remains in operation for as long as the operating time has been preset.
Heater operation can be preselected for any time from as little as 1 minute to a maximum of
120 minutes (factory preset is 60 minutes).
Remaining Operating Time
The remaining operating time refers to the period of time the heater still continues to remain in
operation. It can only be changed while heater is in operation.
Setting the Digital Timer
After the power has been connected, all symbols on the digital display will be flashing.
The time of the day and the day of the week must be set.
The Timer can be programmed in that all flashing symbols can be adjusted by means of the
and buttons.
If the buttons are not pressed within 5 seconds, the currently displayed time or function will be
stored.
When the and buttons are pressed for more than 2 seconds, the quick digit advance mode
is activated.
See table 201 on following page for setting reference or full instructions supplied with timer.
Fig. 201: Optional 7-Day Digital Timer
203
Thermo Top C (TTC) 2 Operating the Heater

2.4 Digital Timer Setting / Operating Instructions
Switching the heater
on
Manually: by pressing the button (continuous heating mode)
Automatically: by programming the heater starting time
Switching the heater
off
Manually: by pressing the button
Automatically: after the programmed operating time has elapsed.
With the heater running: by programming the remaining operating time.
Setting time / day of
the week
Press the button for more than 2 seconds - time of the day is flashing - and set the clock
using the and buttons. After 10 seconds, day of the week begins flashing - set the day of
the week in the same manner as the time.
Viewing the time With the ignition switched off: press the button (bus wiring only).
Programming heater
starting time
Press the button - the memory location is flashing - using the and buttons set start of
the heater operating time. After 10 seconds, day of the week begins flashing - set the day of
the week on which the heater is to turn on.
By repeatedly pressing the button, memory locations 2 and 3 can be programmed or the time
display mode can be reached.
Recalling / erasing
preset times
Repeatedly press the button until the desired memory location is displayed. To erase the
preset time, press the button several times until the time of the day is displayed instead of the
memory location.
Programming
duration of operating
time
The heater must be switched off. Press the button for 3 seconds - operating time is flashing -
and set the desired operating time (10 to 120 minutes) using the and buttons.
Setting the
remaining operating
time (Bus wiring
Option)
Set the desired remaining operating time (1 to 120 minutes) using the and buttons. The
remaining operating time refers to the time the heater still continues to remain in operation after
the vehicle ignition is turned off. It can only be changed while the heater is in operation and the
ignition switched off.
Setting the wake up
time
( Digital Comfort
Timer Only)
A wake up time can only be programmed on the fi1531 comfort digital timer. The wake up time
is not bound to a specific day of the week. Repeatedly press the button until the bell symbol
appears on the display. Set the desired wake up time using the and buttons. The
alarm clock turns off after 5 minutes or when one of the buttons is pressed.
Recalling / erasing
the wake up time
To recall the wake up time, repeatedly press the button until bell symbol appears on the
display - read off wake up time. To erase the wake up time: press the button until the bell
symbol is no longer visible on the display.
Remote control Possible by means of an optional external signal.
Table 201: Digital Timer Setting Instructions
204
2 Operating the Heater Thermo Top C (TTC)

3. Technical Data
3.1 Technical Data
The following data is subject to the normal tolerance for heaters, if no tolerance is specified.
This is approximately +/-10% in an ambient of 20 °C at nominal voltage.
Heater Thermo Top C (TTC) Diesel
Design Coolant heater with evaporator burner (Ferro-Tech Technology)
Heat Rating:
Input - full load
- partial load
Output - full load
- partial load
6.14 kW (20,960 Btu/hr)
3.1 kW (10,480 Btu/hr)
5.0 kW (17,200 Btu/hr)
2.5 kW (8,600 Btu/hr)
Fuel Diesel #1 Diesel #2 and Arctic
Fuel Consumption:
- full load
- partial load
0.61 l/hr (0.16 US gal/hr)
0.30 l/hr (0.08 US gal/hr)
Rated Voltage 12 Volts
Operating Voltage 9.6... 15 Volts
Rated Power Consumption Including
Circulating Pump:
- full load
- partial load
46 Watts (3.8 Amps)
32 Watts (2.6 Amps)
Maximum Permissible Ambient
Temperature:
Heater: - operation
- storage
Fuel Pump - operation
- 40... +60 °C (- 40...+140 °F)
- 40... +120 °C (- 40...+248 °F)
- 40... +20 °C (- 40...+68 °F)
Maximum Allowable Working Pressure
(Coolant System) 0.4... 2.5 bar (6.0... 36 psi)
Capacity of Heat Exchanger 0.15 Liters (.04 US gal)
Minimum Capacity of Coolant System 4.0 Liters (1 US gal)
Minimum Volume of Flow 250 l/hr (66 US gal/hr)
CO
2
Content in Exhaust Gas 8... 12.0 Vol.-%
Dimensions of Heater Length 232 mm (9.1 in)
Width 105 mm (4.1 in)
Height 163 mm (6.4 in)
Weight 3.2 kg (7.0 lbs.)
Table 301: Technical Data - Heater
Circulating Pump Model U 4847
Volume Flow Against 0.13 bar (1.9 lbs.) 450 l/hr (2.0 US gal/min)
Rated Voltage 12 Volts
Operating Voltage Range 9.6... 15 Volts
Rated Power Consumption 14 Watts (1.16 Amps)
Dimensions of Circulating Pump L 95 mmxW61mmxH61mm(3.7f x 2.4f x 2.4fl
Weight 0.3 kg (.66 lbs)
Table 302: Technical Data - Circulating Pump
301
Thermo Top C (TTC) 3 Technical Data

3.2 Heater Dimensions
Fig. 301: Heater Dimensions
Fig. 302: Fuel Pump Dimensions
302
3 Technical Data Thermo Top C (TTC)

4. Installation
4.1 General Information
Webasto will take you step by step through the installation process to ensure successful operation
for years to come. The installation must be performed in accordance with the installation instructions
provided in this manual.
4.2 Installation Locations
Fig. 401: Installation Locations
1. Inside of the engine compartment in a splash protected area (Preferred).
2. On left/right side of the frame.
3. Inside under-step compartment.
401
Thermo Top C (TTC) 4 Installation
NOTE:
This manual does not cover all possible installations. For special applications use this manual as a
general guideline only. Contact an authorized Webasto dealer or Webasto Thermosystems directly
at USA: 1-800-555-4518 Canada: 1-800-667-8900
WARNING!
Asphyxiation risk! The heater must not be installed in either the driver™scompartment or in the
passenger area of the vehicle.
CAUTION!
Do not mount the heater directly 
to the engine! Heavy, constant 
vibration produced by the engine 
may interfere with the proper 
operation of the heater and lead 
to heater component damage.

4.3 Mounting the Heater
Fig. 402: Permissible Heater Installation Positions
The heater should be mounted as low as possible in the vehicle to assure automatic purging of air
from circulating pump and coolant lines. The coolant pump is not self-priming.
Preferably, the heater should be mounted in the engine compartment.
1. Ensure adequate clearance for heater and components in existing enclosure or mounting area.
2. Carefully layout proposed heater mounting position and mark all holes for drilling keeping in
mind location for exhaust, coolant lines and wiring access. Once all requirements are met,
drill holes.
3. Mount heater and components according to your plan, fasteners for mounting heater are
provided.
402
4 Installation Thermo Top C (TTC)
WARNING!
Asphyxiation risk! DO NOT mount heater inside passenger, sleeper or storage areas.
CAUTION!
The openings of the water connecting pipes must never point in a downward direction in any
installation position. Damage to heater will result due to trapped air in heat exchanger.
CAUTION!
The heater must not be installed in the immediate vicinity of or above hot vehicle parts.
The heater must not be installed in the direct splash water area of the wheels.
NOTE:
Heavy Duty frame rail bracket is available. Order under part number 901088.

4.4 Exhaust Pipe Connection
One meter (39 inches) of flexible exhaust tubing has been supplied with the heater. Attach tube to
the heater with exhaust clamp supplied.
The exhaust tube should be routed in a gradual downward slope away from heater allowing
condensation to drain.
Secure exhaust tube to vehicle with fiP clip supplied. Keep exhaust tube at least 2 in. (50 mm) away
from heat sensitive materials.
The outlet opening of the exhaust tube must not point in the direction of travel to avoid any possible
clogging caused by snow, mud or foreign materials.
4.5 Combustion Air Supply
A combustion air tube has been supplied with the heater. Looking at the tube, you will see one end
has a staple holding the inner liner and outer casing together.
The stapled end is the inlet end of the tube, the other end is to be attached to the heater.
To attach tube to the heater, stretch the outer casing about an inch further than the inner liner.
This will then slip over the inlet pipe of the heater and clamped in place.
Do not make any bends immediately after the attachment point to the heater. Doing so may cause a
restriction where the inner liner of the tube begins. Make all bends at least 3 inches away or further
from heater connection point.
The combustion air tube should be routed in a gradual downward slope away from heater allowing
moisture to drain.
The intake opening of the combustion air tube must not point in the direction of travel to avoid any
possible clogging caused by snow, mud or foreign materials.
Combustion air should always be taken from a clean area protected from road splash.
403
Thermo Top C (TTC) 4 Installation
NOTE:
Additional flexible exhaust tubing is available from your Webasto Distributor or Dealer under part
number 900126.
WARNING!
Never draw combustion air from inside the vehicle, or from areas where fumes or gases can
accumulate. Drawing of combustion air from areas where people are present is strictly prohibited!
CAUTION!
Route the exhaust pipe in such a way as to prevent touching or being directed toward any part of
the vehicle that may be damaged by heat (i.e., brake lines, electrical wiring, hoses).
WARNING!
Asphyxiation risk! Exhaust pipes must be so routed that the possibility of exhaust fumes entering
the vehicle is unlikely.

4.6 Plumbing the System
4.6.1 General Information
The TTC with coolant circulating pump must be mounted at least 6" (15 cm) below the lowest
permissible coolant level of the vehicles cooling system.
Minimum amount of coolant in the cooling system should be at least 1.0 US gal. (4.0 l). Independent
heating systems require a minimum of 3.0 US gal. (12.0 l). A minimum of 10% of a good quality
antifreeze should be maintained in the cooling system at all times.
Heater and water pump fit 3/4f (19 mm) I.D. heater hose meeting SAE 20 R3 specifications.
Silicone hose requires special hose clamps.
404
4 Installation Thermo Top C (TTC)
WARNING!
Burn risk! When working on the coolant system, allow the engine to cool down and open the
radiator cap
NOTE:
Heater hose must meet SAE 20 R3 specifications.
NOTE:
Hose clamps must be tightened to 45 in/LB. (5 Nm) torque. Silicone hose requires special hose
clamps.

4.6.2 Plumbing the TTC into The Coolant System
Fig. 403: Engine Block Preheating
Engine Block Preheating:
1. Remove radiator pressure cap and release system pressure.
2. Drain coolant from engine.
3. Plumb the Webasto system as shown above.
4. Refill engine coolant as per engine manufacturer™srecommendations and reinstall the radiator
pressure cap.
405
Thermo Top C (TTC) 4 Installation

406
4 Installation Thermo Top C (TTC)

4.6.3 Contents - Engine Connections
Caterpillar
3116 ............................................................................................................................. 408
3176 ............................................................................................................................. 408
3306 ............................................................................................................................. 409
3408 ............................................................................................................................. 409
C-10/C-12 ....................................................................................................................... 410
Cummins
B Series .......................................................................................................................... 411
C Series .......................................................................................................................... 412
Detroit Diesel
Series 50......................................................................................................................... 413
Series 55......................................................................................................................... 413
Mack
E6 / E7 ............................................................................................................................ 414
407
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