OFF HWY - 909474_Idle Reducing Technology Brochure 8pg

Marine Sunroof Catalog Webasto Product Range & Reference List

Performance You Can Rely On Heating, climate and energy management for off-highway equipment

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Contact

webasto.com

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Webasto off-highway portfolio Powering efficiency, comfort, and sustainability

In today’s demanding off-highway industries—construction, agriculture, mining, and material handling—operators face constant challenges: rising fuel costs, emissions regulations, machine downtime, and harsh working conditions. Webasto’s broad product portfolio, from traditional fuel-based heaters to cutting-edge electric thermal management solutions, is engineered to reduce costs, enhance efficiency, and optimize operator comfort.

Industry strategies: the benefits of fuel-operated heaters Adding fuel-operated heaters to off-highway equipment delivers significant operational and cost-saving benefits: n Reduced Engine Idling: Eliminates unnecessary engine runtime, reducing wear and tear.

n Less Overall Engine Hours: Extends the lifespan of critical components. n Lower Fuel Costs: Decreases fuel consumption by minimizing idle time. n Reduced Emissions on Cold Start-Up: Helps meet stringent environmental regulations. n Extended Life of DPFs: Lowers regeneration cycles and maintenance costs. n Reduced Cost of Ownership: Lowers maintenance expenses and improves efficiency.

n Increased Resale Value: Equipment with optimized performance and lower operating hours retains higher value. Webasto products help operators cut costs, reduce downtime, and meet emissions regulations—all while keeping equipment running efficiently in extreme conditions.

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Comprehensive product line Preserve engine hours

Coolant heaters – engine pre-heat Webasto coolant heaters efficiently pre-heat engines, reducing idle times, cold starts, fuel consumption, and wear on components.

Thermo Pro 50 | 24 V Compact, high-efficiency heating for small to mid-size equipment.

Output

17,000 BTU/h (5 kW)

Fuel Type

Diesel, B20

Fuel Consumption Power Consumption Dimensions (L x W x H) (including coolant pump)

0.08 - 0.17 gal/h (0.27 - 0.63 l/h)

12-21 W

9.1 x 4.1 x 6.4 in (232 x 105 x 193 mm)

Weight

7 lbs (3.2 kg)

Thermo Pro 90 | 12 or 24 V Ideal for medium-duty applications requiring rapid heat-up.

Output

31,000 BTU/h (9.1 kW)

Fuel Type

Diesel, B20

Fuel Consumption Power Consumption Dimensions (L x W x H) (part load - full load / Boost)

0.05 - 0.29 gal/h (0.2 - 1.1 l/h)

37-80 / 90 W

15 x 5.5 x 9.13 in (381 x 140 x 232 mm)

Weight

10.8 lbs (4.9 kg)

Thermo Top Pro 150 | 12 or 24 V Powerful heating for large vehicles and machinery.

Output

51,000 BTU/h (15 kW)

Fuel Type

Diesel, B20

Fuel Consumption Power Consumption Dimensions (L x W x H) (without coolant pump)

0.4 gal/h (1.4 l/h) 100 W @ 12 or 24 V

18.5 x 7.9 x 7.9 in (470 x 200 x 200 mm)

Weight

24.3 lbs (11 kg)

Thermo E+ 320 | 12 or 24 V High-output heating for extreme conditions and heavy-duty applications.

Output

109, 189 BTU/h (32 kW)

Fuel Type

Diesel, B20

Fuel Consumption Power Consumption Dimensions (L x W x H) (with U4814 coolant pump)

0.83 gal/h (3.2 l/h)

214 W

25.2 x 14.8 x 8.8 in (640 x 376 x 224 mm)

Weight

42.7 lbs (19.4 kg)

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Air heaters – on-demand operator comfort Webasto air heaters provide instant warm airflow inside cabs without running the engine, significantly reducing fuel use and idle time saving valuable engine hours.

Air Top 2000 STC | 12 or 24 V Ideal for small cabs and equipment.

Output

7,000 BTU/h (2 kW) Diesel, Gasoline, B20

Fuel Type

Fuel Consumption Power Consumption Dimensions (L x W x H)

0.03 - 0.06 gal/h (0.12 - 0.24 l/h)

14-29 W @ 12 or 24 V

12.3 x 4.8 x 4.9 in (311 x 120 x 121 mm)

Weight

5.7 lbs (2.6 kg)

Air Top Evo 40/55 | 12 or 24 V Powerful air heating solutions for medium to large vehicles.

Air Top Evo 40

Air Top Evo 55

12 V

24 V

12 V

12 V

24 V

12 V

Output

5,100 - 12,000 / 13,650 BTU/h (1.5 - 3.5 / 4.0 kW)

5,800 - 12,000 / 13,650 BTU/h (1.7 - 3.5 / 4.0 kW)

5,100 - 17,000 / 18,800 BTU/h (1.5 - 5.0 / 5.5 kW)

5,800 - 17,000 / 18,800 BTU/h (1.7 - 5.0 / 5.5 kW)

Fuel Type

Diesel, B20

Gasoline

Diesel, B20

Gasoline

Fuel Consumption

0.05 - 0.11 / 0.13 gal/h 0.18 - 0.43 / 0.49 l/h)

0.07 - 0.14 / 0.15 gal/h 0.25 - 0.51 / 0.58 l/h)

0.05 - 0.16 / 0.18 gal/h 0.18 - 0.61 / 0.67 l/h)

0.07 - 0.19 / 0.21 gal/h 0.25 - 0.73 / 0.80 l/h)

Power Consumption (Control rage / booth @ 12 V) Dimensions (L x W x H)

15 - 40 / 55 W

15 - 95 / 130 W

16.7 x 5.8 x 6.4 in (423 x 148 x 162 mm)

16.7 x 5.8 x 6.4 in (423 x 148 x 162 mm)

Weight

13 lbs (5.9 kg)

13 lbs (5.9 kg)

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Timers and controllers Precise temperature management for air and coolant heaters

SmarTemp Control 3.0 Bluetooth

Works with both air and coolant heaters

On/Off Button

Ergonomic Comfort Dial

Smart Indicator LED’s n Red for Heat Mode n Blue for Vent Mode* n Blinking Red for Fault Codes n Low Voltage Alert

Ambient Temperature*

Heater On Icon

Set Temperature*

Select Button

Bluetooth Logo**

Temperature Sensor*

*Product display and noted features are applicable when managing Webasto air heaters. **Bluetooth Logo indicates functionality on SmarTemp Control 3.0 Bluetooth only and is not an activation button. Bluetooth Connection to the Webasto SmarTemp Control 3.0 App

Easily download the Webasto App to your device to combine the technology of Bluetooth with the SmarTemp Control 3.0. A quick glance at the App will show ambient temperature for air heater only along with battery voltage, as well as the ability to view full controller settings of Bluetooth connected heater. Effortlessly manage heater diagnostics with the ability to troubleshoot and clear error codes, as well as reporting capabilities for warranty purposes. Access content, including a list of error codes and heater management tools. Other features include a link to TechWebasto.com for trouble shooting, install/ user manuals, service locations and contact information. Download for FREE the Webasto SmarTemp Control 3.0 App

Additional control options

Toggle Switch for Coolant Heaters

Rocker Switch On/Off for Coolant Heaters

Rheostat Controller for Air Heaters

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Integrated heat only systems High efficiency with flexible mounting options

YEARS

This line of heat only systems can be used on applications in a variety of commercial vehicles ranging from mini busses to specialty vehicles such as ambulances, fire engines, agricultural and construction vehicles. Offering high efficiency, high durability fans and blowers, these heat only units are reliable and have an extensive service life. A variety of available accessories and kits for vehicle-specific installation includes control units, air vents and ducting.

„ Heat only unit „ Best suited for commercial, agricultural and construction vehicles

„ 12 V (24 V models available) „ Flexible mounting options „ High efficiency „ Compact „ Durable, high quality components „ Low maintenance

Houston 22,000 BTU/h (6.5 kW) heating capacity

Cyprus 44,300 BTH/h (13.0 kW) heating capacity

Stockholm 13,000 BTU/h (3.8 kW) heating capacity

Phoenix 29,500 BTH/h (8.6 kW) heating capacity

Control option

Individual Switch On/Off, 3 fan speed

* Standard 3 year warranty available on Webasto HVAC and heat only products. Not available for fuel operated heaters.

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Electric High Voltage Heater (HVH) Efficient heating for electric & hybrid machines

As electric and hybrid technology expands in off-highway applications, Webasto’s High-Voltage Heaters (HVH) provide fast, efficient heating while optimizing battery performance.

Features:  Powerful 5/7/10/12 kW heating performance and wide voltage range up to 880 V independent of coolant temperature  Highest efficiency through quick and direct heat transfer  Stepless and exact controllability with no inrush currents  Reliable safety concept with redundant controls  Certified for automotive requirements with ECE-R10 and ECE-R122 type approval  CE certified for various segments and applications

Technical specifications

HVH 50 Gen 1.5 HVH 70 Gen 1.5 HVH 100 Compact HVH 100 Compact+

HVH 120

Heating performance HV voltage range (DC)

5 / 7 kW

10 kW

12 kW

100 – 490 V

250 - 880 V

LV voltage Efficiency

12 V

12 / 24 V

> 95%

Controllability steps

50 W

100 W

Dimensions

11.2 x 7.9 x 2.1 in (284 x 200 x 54 mm)

11.2 x 7.9 x 2.8 in. (284 x 201 x 72 mm)

12.8 x 7.9 x 2.8 in. (326 x 201 x 72 mm)

Weight

4.4 lbs (2.0 kg)

5.0 lbs (2.3 g)

13.2 (2.6 g)

Temperature range for heating Temperature range for ambient

-40 to 194 °F (-40 to 90 °C) -40 to 257 °F (-40 to 125 °C)

Communication

LIN 2.1

LIN 2.2

LIN 2.2, CAN, Main Switch

Passive discharge (V) according to ISO 6469-3.3

< 60 in 4 Sec

Dielectric strength (DC) Coolant connection

2,500 V

VDA 19 mm

VDA 20 mm

IP protection class

IP 6K9K IP 6K7

HV connection NV connection

TYCO HVA280 Type A

TYCO HVA280 Typ E

LV FEP connector 8 PIN with integrated de-aerating membrane

Interlock

Passive

Electrical safety Functional safety

ISO 6469 Part 3

According to ISO 26262 ASIL B for overheat

According to ISO 26262 ASIL D for overheat

Cyber security

UN-ECE WP.29 / ISO 21434

EMC

ECE R10 Rev. 5

Insulation resistance

> 50 MΩ

> 30 MΩ

Service life

15 years or 12,000 heating hours

15 years or 15,000 heating hours

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electrical Vehicle Thermal Management System (eVTM) Integrated battery & cabin climate control

Webasto’s Electrical Vehicle Thermal Management (eVTM) system integrates heating and cooling units to maintain optimal temperatures for the driver’s cabin, batteries, powertrain, and electronics in electric vehicles.

Waste Heat Recovery n Electrical drives n PEEM Systems

Passenger HVAC n Integrated n Roof-top

Heat Pump n Primary 1234yf loop n Secondary water/glycol loop

Driver HVAC n Air Conditioning n Heating

Traction Battery n Webasto CV Battery n Any other water cooled battery

High Voltage Heater n Additional 7, 10 or 12 kW heating power

Floor Heaters n Additional heating in winter times

Radiator n Cold absorption n Heat rejection

Intelligent Valves System

Energy efficiency through heat recovery eVTM uses the waste heat from electronic components to control the temperature of the battery, electronics and vehicle interior. This maximizes the efficiency of the heat pump.

Flexible and upgradeable system The components can also be easily integrated into existing series productions. Software updates are possible at any time.

Intelligent coolant utilization An innovative valve system distributes and mixes the coolant optimally. It is only used in the electric heat pump system. The system itself is based on water.

Extended range Conditioning the battery cells increases the service life of the batteries, shortens charging cycles and reduces the total cost of ownership (TCO).

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Electrifying the construction industry

Webasto Standard Battery Pro 40 The Webasto Standard Battery Pro 40 is designed according to the high requirements of the commercial vehicle market. The modular and scalable concept is suitable as a traction battery for a wide range of vehicle types - from light commercial vehicles to various mobile machines.

Battery pack circuit

BMC

S-Box

Precharge

HV+

Fuse

Plus contactor

A

Minus contactor

Sensor

HV-

Technical specifications

Battery pack

Features:  Scalable system with up to 18 Standard Battery Pro 40, a voltage of 400 or 800 V and with up to 720 kWh  Robust housing enables use in rough terrain  Intensively tested and certified to the highest safety and quality standards  Vertical and horizontal mounting positions allow flexible and easy integration  Convincing total cost of ownership thanks to standardized product

Dimensions (L x W x H)

37.79 x 27 x 11.88 in ( 960 x 687 x 302 mm)

Weight (kg)

655 lbs. (297 kg)

Installed energy Nominal capacity Voltage range Energy density

~ 40 kWh

116 Ah

333 – 407 V

~232 Wh/l, >135 Wh/kg

Continuous use (CH / DCH) (@25 °C, SoC dependent) Peak power (CH / DCH) (10s, @25 °C, SoC dependent) Lifetime (DoD, temperature and C-rate dependent)

45 / 55 kW

60 / 112 kW

Up to 3.000 cycles

Volume flow Pressure loss

10 l/min. < 50 mbar

Cell type

prismatic NMC

Our solution for commercial vehicles comprises Standard Battery Pro 40 and Vehicle Interface Box or Vehicle Interface Gateway Vehicle with two Standard Battery Pro 40 Expandable up to 10 Standard Battery Pro 40

-22 °F to 131 °F (-30 °C to +55 °C) 3,500 meters above sea level 0 - 100 % humidity

Operating temperature

Vehicle with two Standard Battery Pro 40

Expandable up to 18 Standard Battery Pro 40

Vehicle Interface Box (VIB)

Vehicle Interface Gateway (VIG)

Vehicle Interface Box (VIB)

Vehicle Interface Gateway (VIG)

400 V system Max. 5 batteries

800 V system Max. 10 batteries

400 V system Max. 9 batteries

800 V system Max. 18 batteries

System specifications

Installed energy (entire system) Topology in 400 / 800 V system

n*40 kWh

n*40 kWh

1snp

2snp

1snp

2snp

System performance*

Up to 200 kWh

Up to 400 kWh

Up to 360 kWh Up to 720 kWh *Standard Battery Pro 40 still under development. Subject to change without notice.

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Advanced high power test system

Power Cycling & Battery Test Systems Webasto Power Test Systems, located in Fenton, MI, is a pioneer of bi-directional and regenerative DC power test equipment. With a wide power range (5kW to 2.6MW), our Power Cyclers can handle virtually any DC supply or load requirement. This equipment enables manufacturers to develop, design, and test their batteries, fuel cells, ultra capacitors, hybrid energy systems, motors, generators, and powertrain components. At Webasto, we are committed to developing advanced power, transportation, and energy storage solutions for a brighter, more sustainable tomorrow. Webasto can enable your success as a clean technology provider.

ABC-170 ABC-170 CE

900 EX

I-TS-3870

fuel cell

Fuel cell test

Electrolyzer test

Battery test

Battery emulation

Power- train test

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Why choose Webasto?

Webasto is committed to helping fleets, equipment operators, and manufacturers achieve greater efficiency, sustainability, and performance in the ever-changing off-highway industry.

n Optimized Climate Control: Keep operators comfortable and machines running efficiently, regardless of conditions. n Fuel & Cost Savings: Advanced heating technology minimizes fuel use and reduces unnecessary idling. n Reduced Emissions: Lowers cold-start emissions and helps meet evolving regulatory standards. n Proven Reliability: Decades of industry expertise and rigorous product testing ensure performance in extreme conditions. n Global Support Network: Extensive aftermarket support and service options to ensure long-term success.

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Success with Webasto Customer excellence is our main focus. Our goal is to surpass the expectations of our partners and customers. For this reason, Webasto products are sold and installed through our network of authorized dealers and distributors, staffed with professionally trained sales people and technical experts worldwide. We value the relationships we have built with suppliers, partners, and end users. We are confident that long-lasting relationships can only be maintained based on quality products, excellent service, professionalism and integrity of our employees.

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Webasto sales support

Commercial vehicle sales team

Rob Kazanjian 604-345-2400 Mobile Robert.Kazanjian@webasto.com

Mike Comstock 403-463-5627 Mobile Mike.Comstock@webasto.com

Alaska

Yukon Territory

Francois Deslauriers 613-677-1375 Mobile Francois.Deslauriers@webasto.com

Nunavut

Northwest Territories

Bill Fortney 810-399-9332 Mobile Bill.Fortney@webasto.com

British Columbia

New Foundland

Alberta

Manitoba

Quebec

Saskatchewan

Ontario

New Brunswick

Washington

Nova Scotia

Maine

Montana

North Dakota

Minnesota

Paul Hemond 313-400-8349 Mobile Paul.Hemond@webasto.com

Michigan

Vermont

Oregon

New Hampshire

Wisconsin

Massachusetts Rhode Island

Idaho

South Dakota

New York

Wyoming

Michigan

Connecticut New Jersey

Pennsylvania

Iowa

Nebraska

Nevada

Indiana Ohio

Delaware Maryland

Utah

Illinois

West Virginia

Colorado

California

Virginia

Kansas

Michael Bodenbach 810-358-8576 Mobile Michael.Bodenbach@webasto.com

Kentucky

Missouri

North Carolina

Chip Raches 303-241-0003 Mobile Chip.Raches@webasto.com

Tennessee

Oklahoma

Arizona

South Carolina

Arkansas

New Mexico

Georgia

Alabama

Mississippi

Texas

Louisiana

Florida

Tommy Smith 248-703-7926 Mobile Thomas.Smith@webasto.com

Michael Martinez 810-922-2518 Mobile Michael.Martinez@webasto.com

Mexico

Sales management support

Chris Giannola Sales Manager Off-Highway 810-845-3881 Mobile Chris.Giannola@webasto.com

Mike Bacon Director of Sales Americas 810.444.7467 Direct Mike.Bacon@webasto.com

Don Kanneth Sales Director OE/OES & Master Distributors 810-593-6002 Direct 810-444-7493 Mobile Don.Kanneth@webasto.com

John DeLong Sales Director Commercial Vehicles, Aftermarket 810-593-6023 Direct 248-326-8504 Mobile John.DeLong@webasto.com

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Customer resources

www.techwebasto.com Tech Webasto

Webasto Website www.webasto.com

www.webastoliterature.com Webasto Literature

www.techwebasto.com/warranty.html Warranty & Registration

www.webasto-comfort.com/en-us/content/dealer-locator/ Dealer Locator

Download for FREE the Webasto SmarTemp Control 3.0 App

Facebook

Instagram

LinkedIn

Contact

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Webasto R&D and manufacturing locations

As a global innovative systems partner to the mobility industry, Webasto is one of the 100 largest suppliers to the automotive sector worldwide. In development, manufacturing and sales, the company focuses on roof systems on the one hand and on vehicle electrification on the other hand. The product range includes, openable and fixed panoramic roofs, electric high-voltage heaters and batteries, as well as thermo management solutions. Among the customers of Webasto are manufacturers of passenger cars, commercial vehicles, and boats, as well as dealers and end customers. In 2022, the Group generated sales of over 4 billion euros and employed about 16,800 people at more than 50 locations. The headquarters of the company, which was founded in 1901, is located in Stockdorf near Munich (Germany). For more information, please visit www.webasto.com

Discover how Webasto promotes sustainability webasto.com/sustainability

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webasto.com

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