Webasto Diesel Cooker x100 Service Manual
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Webasto Diesel Cooker x100 Service Manual

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Diesel Cooker x100
Service Manual
08-05-2008

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Summary of Contents for Webasto Diesel Cooker x100

  • Page 1 Diesel Cooker x100 Service Manual 08-05-2008...

  • Page 3: Table Of Contents

    Table of Contents Webasto Diesel Cooker X 100 1. General 1.1 Contents and purpose 1.2 Use of the cooker 1.3 Additional documentation 1.4 Safety notes and legal issues 1.5 Suggestions for improvements and changes 2. Function description 2.1 System description 2.2 Main components...

  • Page 4: Contents And Purpose

    1.4 Safety notes and legal issues In principle, the general accident prevention regulations and current works safety instructions are applicable. Webasto Diesel Cooker X100 is tested by SGS, test spesification standard EN 1:1998 + EN 60335-2- 6:2003 Failure to follow the installation instructions and the...

  • Page 5: System Description

    2 Functions description 2 Functions description 2.1 System description The Webasto Diesel Cooker X 100 is a safe diesel A cooling fan in the ventilation box ensures that the cooker with no open flame. The exhaust gases are temperature in the mounting space will not rise too led out of the vehicle through the exhaust gas tube, high.

  • Page 6: Main Components

    Webasto Diesel Cooker X 100 2 Functions description 2.2 Main components Operating panel The cooker starts to heat up automatically when the power button is switched to ON position. The yellow indicator lamp lights up as soon as the cooker is switched on.
  • Page 7 Webasto Diesel Cooker X 100 2 Functions description Fuel pump Combustion air fan The voltage range of the burning fan may be altered The fuel pump is a combined transport, metering between 4.8 V and 10.7 V by changing the param- and shut-off system for supplying fuel from the eters;...
  • Page 8 Webasto Diesel Cooker X 100 2 Functions description Temperature sensors Hot plate indication lamp The T4 circuit measures the voltage of the heat An orange hot plate indication lamp lights on the sensor (thermocouple) and will light the red LED lower edge of ceramic plate when the plate is hot.
  • Page 9 Webasto Diesel Cooker X 100 2 Functions description Cooling system The cooker is cooled down by a ventilation box located under the cook top. On the front side of the ventilation box is an axial fan wich draws fresh air into the box.
  • Page 10 Webasto Diesel Cooker X 100 2 Functions description Burner Thermal radiator for the burner Detaching the thermal radiator: There are two locking plates on the inside of the burner’s “perforated” cylinder which have been spot welded to the sides of the cylinder. Prying one of the...

  • Page 11: Operating Scheme

    Webasto Diesel Cooker X 100 2 Functions description 2.3 Operating scheme How the device works Turn the device on by turning the switch on the control panel to the ON position. The yellow LED light next to the switch will illuminate signifying that the device is on.
  • Page 12 Webasto Diesel Cooker X 100 2 Functions description 12 V The yellow LED light is ON Main switch 240 sec. (alterable parameter) Glow Plug Combustion air 4 min. 50 sec. Cooling fan 4 min. 50 sec. Fuel pump 4 min. 50 sec.

  • Page 13: Technical Data

    Webasto Diesel Cooker X 100 3 Technical Data 3 Technical Data Except where limit values are specified, the techni- cal data listed in the table refer to the usual heater tolerances of ±10% at an ambient temperature of +20° C (68° F) and at the rated voltage and in rated conditions.
  • Page 14 Webasto Diesel Cooker X 100 3 Technical Data THE DEVICE´S FUNCTION TECHNICAL VALUES Dimensions 466 x 316 x 205 mm Weight 8 kg Size of replacement air aperture 100 cm² (minimum area) Heating capacity Max. 0.9 ... 1.9 kW (calculated)
  • Page 15 4 Failure detection 4 Failure detection This section describes how to identify and remedy faults on the Webasto Diesel Cooker X 100. If a fault occurs, an error code will be output via the LED’s of the operating panel. CAUTION...

  • Page 16: Trouble Shooting Chart

    Webasto Diesel Cooker X 100 4 Failure detection 4.1 Trouble shooting chart...

  • Page 17: General Failures

    Webasto Diesel Cooker X 100 4 Failure detection 4.2 General failures Failure symptom Possible reason How to repair Is operating voltage under 10.7 VDC ? Cooker does not respond at all. Check the main cable connections (Measure the voltage from control unit’s and the main switch.
  • Page 18 Webasto Diesel Cooker X 100 4 Failure detection Combustion air blower Combustion air blower does not run. Measure blower’s voltage, (Fault blinking). (compare to the parameter table). Replace the combustion air blower. Control unit (PCB) Control unit faulty. Replace the Control unit.
  • Page 19 Webasto Diesel Cooker X 100 4 Failure detection Cooker goes OFF by itself. No fuel. Check and add fuel if necessary. Check the fuel pump’s operation. Battery voltage too low, must be more Check the battery condition and main than 10.7 VDC.

  • Page 20: Failure Blink Codes

    Webasto Diesel Cooker X 100 4 Failure detection 4.3 Failure blink codes Signal lights in case of malfunctions. Glow plug Yellow 0.125 s 0.125 s 0.125 s problem Combustion air fan Yellow problem 0.125 s 0.125 s 0.125 s 0.125 s 0.125 s 0.125 s...
  • Page 21 Webasto Diesel Cooker X 100 4 Failure detection Descriptions of the flashing LED lights beginning from XPS v 1.2. Leds on the control panel Third attempt to start the device After two unsuccessful attempts to start the device, the Yellow LED third attempt will lock it.
  • Page 22 Webasto Diesel Cooker X 100 4 Failure detection Red LED Burning indicator and after-cooling Incorrect device parameters In the heating phase, when the burning indicator has If the device’s parameters are not set within the turned on during glowing or ignition, the red LED light...

  • Page 23: Updating

    Webasto Diesel Cooker X 100 5 Updating and repair 5 Updating and repair WARNING The cooker must not be operated in enclosed areas such as garages and workshops without an emissions extraction system. 5.1 Updating There may be a maximum of 32 parameter files programmed on the control unit.
  • Page 24 Webasto Diesel Cooker X 100 5 Updating and repair Copy all files from the CD on to your computer’s hard There are two ways to update a single device: disk to the location of your choice. You can update all parameters by clicking on “Choose Install the PC cable into an available COM port.

  • Page 25: Test Program

    Webasto Diesel Cooker X 100 5 Updating and repair 5.2 Test program A device named “Test” The test device assists the maintenance person when investigating the condition of the control unit, e.g. directly from the maintenance coupler J6. The test device is a device / in the device parameter selection X1, Device 1.

  • Page 26: Burner

    Webasto Diesel Cooker X 100 5 Updating and repair 5.3 Burner Thermal radiator for the burner Detaching the thermal radiator: There are two locking plates on the inside of the burner’s “perforated” cylinder, which have been spot welded to the sides of the cylinder. Prying one of the...
  • Page 27 Webasto Diesel Cooker X 100 5 Updating and repair Installing the fuel needle The direction of the slanted tip of the needle in the burner must be considered when installing the fuel needle. The slant of the needle goes towards the upper edge...

  • Page 28: Glow Plug

    Webasto Diesel Cooker X 100 5 Updating and repair 5.4 Glow plug The glow plug consumes approximately 8 A of power during the glowing stage. The length of the glowing phase is the time stated in the parameters. The temperature of the glow plug rises extremely quickly.

  • Page 29: Heat Exchanger And Glass Panel

    Webasto Diesel Cooker X 100 5 Updating and repair 5.5 Heat exchanger and glass panel Changing the glass In the event you need to change a broken glass range or if you need to reach the structures underneath the glass range, i.e. you must break the range.

  • Page 30: Pump Boost

    Webasto Diesel Cooker X 100 5 Updating and repair 5.6 Pump Boost The Pump Boost (PB) function has been designed to facilitate filling the fuel hoses during installation and maintenance. Connect the PB by turning the maintenance per- Pump Boost son’s switch to the vent position and connecting the...

  • Page 31: Electrical Connections

    Webasto Diesel Cooker X 100 6 Electrical connections 6 Electrical connections Note! You must be sure you have ESD protection while handling the control unit. Static electricity can damage the control unit. J6, Test pin header X1, Device selection S11, Flame monitor switch,...
  • Page 32 Webasto Diesel Cooker X 100 6 Electrical connections Note! You must be sure you have ESD protection while handling the control unit. Static electricity can damage the control unit. Control panel Wires for control panel Thermo element Electrical connections for the control unit...

  • Page 33: Basic Maintenance

    Webasto Diese Cooker X 100 7 Maintenance and service 7 Maintenance and service 7.1 Basic maintenance The cooker shall be serviced every two years by an Later, as the pump gets older, it may raise the authorized service center. amount of fuel input by 5 - 10 %. Therefore, you...
  • Page 34 Webasto Diese Cooker X 100 7 Maintenance and service 4. Analyze the O and CO 5. Soot test An O analysis reveals more quickly the reason for The soot test determines whether the combustion is impure burning. The O analysis should be performed pure.

  • Page 35: Control Unit Settings

    Make sure you always use the latest parameters. See Figures for the correct places for the jumpers. 17: Device 17 DEVICE 17: Webasto Diesel Cooker X100 9500 5500 11000 9500 1450 3000 The parameters in the Figures are AI.xpd...
  • Page 36 Webasto Diesel Cooker X 100 Page for notes...
  • Page 37 Webasto Diesel Cooker X 100 Page for notes...
  • Page 38 Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 WWW.Webasto. US Part no.: WA490060 WWW.techwebasto.com...

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