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Webasto Thermo Pro 90, Service Installations

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Table of Contents

Thermo Pro 90 

II

6

Function checks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.1

General information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.2

Function checks in the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.3

Setting CO2 content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.4

Testing individual components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.4.1

Checking resistance of the coolant temperature sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

6.4.2

Checking resistance of the glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

6.4.3

Checking resistance of the exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

6.4.4

Checking the combustion air fan  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

6.4.5

Checking the DP42 fuel pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

6.4.6

Checking the overheating protection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

6.4.7

Checking the U4840 coolant pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

7

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

7.1

Working on the heater  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

7.2

Working on the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

7.3

Heater test run  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

7.4

Checks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

7.5

Removing and installing heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
7.5.1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702

7.5.2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702

7.6

Visual inspection to assess the burner unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702
7.6.1

Metal fiber evaporator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 702

7.6.2

Combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703

7.7

Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703

8

Repairing and replacing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.1

General information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.2

Component layout  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.3

Work on stripped down components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802

8.4

Electrical connections  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802

8.5

Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802

8.6

U4840 coolant pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803

8.7

Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803

8.8

Coolant temperature sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804

8.9

Combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804

8.10 Burner unit and glow plug  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8.11 Burner head  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8.12 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
8.13 Exhaust gas temperature sensor  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806

9

Thermo Pro 90 HDD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901

9.1

General information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901

9.2

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902

9.3

U4840 coolant pump with EMC suppressor module  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
9.3.1

Replacing the EMC suppressor module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903

9.4

Combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903

9.5

Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903

9.6

Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904

9.7

Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904

9.8

Thermo Pro 90 HDD wiring diagrams  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
9.8.1

Legend to connector VG95328R2016PN (if installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904

Summary of Contents for Thermo Pro 90

Page 1: ...tallations Thermo Pro 90 Thermo Pro 90 HDD Thermo Pro 90 12 V Diesel ADR Transport of dangerous goods Thermo Pro 90 24 V Diesel ADR Transport of dangerous goods Thermo Pro 90 HDD 24 V Diesel ADR Trans...

Page 2: ...lso Webasto air and water heaters accessories catalogue NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course you do not have the necess...

Page 3: ...Exhaust gas temperature sensor 203 2 6 U4840 coolant pump 203 2 7 Control unit 203 2 8 DP42 fuel pump 203 3 Functional description 301 3 1 Switching on and residual heat utilization 301 3 2 Start and...

Page 4: ...702 7 6 Visual inspection to assess the burner unit 702 7 6 1 Metal fiber evaporator 702 7 6 2 Combustion chamber 703 7 7 Restarting 703 8 Repairing and replacing components 801 8 1 General informatio...

Page 5: ...agram for Thermo Pro 90 with ThermoCall TC4 1105 11 7 System wiring diagram for Thermo Pro 90 with UniBox 1106 11 8 System wiring diagram for Thermo Pro 90 with MultiControl control element analogue c...

Page 6: ...clip 806 Fig 814 Burner head and exhaust gas temperature sensor 807 Fig 815 Checking mica insulator on sensor 807 Fig 901 Thermo Pro 90 HDD heater components 901 Fig 902 U4840 coolant pump with EMC s...

Page 7: ...lation NOTE The stipulations of these regulations are binding in the area covered by EU Directive 70 156 EEC and or 2007 46 EC for new vehicle models from 29 04 2009 and should also be observed in cou...

Page 8: ...s may ONLY be operated with the fuel and the rated voltage specified on the type label must be shut down by switching off immediately and removing the fuse in case of heavy smoking unusual combustion...

Page 9: ...en 1 8 and 7 6 kW depending on the deviation of the current coolant temperature from the setpoint at the coolant temperature sensor The heater switches off burner operation automatically pause when th...

Page 10: ...heater from impermissibly high operating temperatures The over heating protection trips at a heat exchanger temperature in excess of 127 7 C and switches off the heater The overheating protection is...

Page 11: ...se and afterrunning phases as well as during residual heat utilization 2 7 Control unit The control unit controls the functional sequence and moni toring of burner operation 2 8 DP42 fuel pump The DP4...

Page 12: ...tates Deactivation of residual heat utilization Conditions for deactivating residual heat utilization a When the lower operating voltage limit has been exceeded b When the coolant outlet temperature i...

Page 13: ...mp goes out when the heater is switched off The fuel pump stops combustion stops and afterrunning begins The coolant pump glow plug and the combustion air fan continue to run during the afterrunning p...

Page 14: ...ture Heater incl control unit Operation Storage Fuel pump Operation Storage 40 to 80 C 40 to 125 C heater off operating voltage may be applied 40 to 30 C 40 to 85 C Permissible working pressure of coo...

Page 15: ...element either by the indicator lamp flashing of letter combination on the display depending on the type of control element The fault code assists the workshop or Webasto Technical Service in determin...

Page 16: ...control element There is a fault and it is detected by the control unit as a relevant malfunction Heater shuts down due to the fault i e fault switch off followed by fault lock out The fault code is...

Page 17: ...F83 Flame abort Fuel system Check fuel level Check fuel filter Checking tank extracting device and fuel line for leaks Bleed fuel system Burner unit Clean burner unit or replace if necessary F03 or 3...

Page 18: ...f necessary F14 or 14 F1B FAB Overheat sensor short circuit Wiring Check wiring for damage break and short circuit Overheating protection sensor defective Check operation of overheating protection sen...

Page 19: ...er connect directly to 12V or 24V supply Check fuel line connection at fuel pump DP42 Connect Webasto Thermo Test and evaluate Ensure clear passage and seating of the flat spring contacts of the fuel...

Page 20: ...inlet Check that intake line and exhaust pipe are installed in accordance with installation instructions Check that there is sufficient distance from the interior fresh air intake to the vehicle Burn...

Page 21: ...e at Pin 86 audible see wiring diagram in general installation instructions Check coolant temperature signal line green white gr ws Pin 86 at K5 H Excessive smoke from heater during afterrun ning phas...

Page 22: ...5 Malfunctions and troubleshooting Thermo Pro 90 508...

Page 23: ...perature displayed by the vehicle may differ significantly as the corresponding sensors are fitted in different positions and may evaluate different temperatures 6 Switch off the heater again at the...

Page 24: ...ion checks Thermo Pro 90 602 Fig 601 CO2 altitude correction 0 9 5 1013 mbar 10 10 5 11 11 5 12 13 14 12 5 13 5 14 5 500 1000 1500 2000 2500 954 mbar 899 mbar 845 mbar 795 mbar 747 mbar m H CO2 7 6 kW...

Page 25: ...Thermo Test PC diag nostics Specified speed 5500 rpm Listen for grinding noise and start up noise Start up to the specified speed must be heard The error message Fan motor stiff must not be activated...

Page 26: ...6 Function checks Thermo Pro 90 604...

Page 27: ...be installed in a different position NOTE Coolant running out of the system should be collected in a suitable container 7 2 Working on the vehicle ATTENTION With the operating voltage applied and the...

Page 28: ...ap in 5 Connect combustion air line and exhaust pipe 6 Connect vehicle battery 7 Bleed coolant circuit 8 Bleed the vehicle fuel system if necessary ATTENTION Reversing the polarity of the power supply...

Page 29: ...are deformed or missing The burner unit should be replaced in this case 7 7 Restarting Carefully bleed the coolant circuit and the fuel supply system after installing the heater Follow the vehicle ma...

Page 30: ...icle Any further dismantling will invalidate the warranty For assembling the heater only use the spare parts from the corresponding spare parts kits 8 2 Component layout Fig 801 Component layout 1 2 3...

Page 31: ...g electrical connection See Chapter 11 15 Plug assignments at control unit on page 1111 8 5 Control unit Removal 1 Remove control unit cover see Fig 802 2 Unplug electrical connections see section 8 4...

Page 32: ...and detach protective cap 4 Lever off retaining spring with a screwdriver and remove overheating protection 5 Complete work on stripped down components see sec tion 8 3 Installation ATTENTION Incorre...

Page 33: ...er see section 7 5 8 9 Combustion air fan Removal 1 Remove heater see section 7 5 depending on space requirements 2 Unplug electrical connections see section 8 4 3 Remove screws 2x Detach control unit...

Page 34: ...ee section 8 4 8 If removed install heater see section 7 5 8 11 Burner head Removal 1 Remove heater see section 7 5 2 Remove combustion air fan see section 8 9 3 Remove burner unit with glow plug see...

Page 35: ...t exhaust gas temperature sensor Installation 1 Fit exhaust gas temperature sensor in burner head 2 Secure the exhaust gas temperature sensor to the burner head with the holder and screw Tighten the h...

Page 36: ...exhaust gas temperature sensor is fitted without stress and the cable from the exhaust gas temperature sensor is installed loosely to the control unit The cable of the exhaust gas temperature sensor...

Page 37: ...for specifications that are not referred to in this section Fig 901 Thermo Pro 90 HDD heater components 7 1 combustion air fan 2 fuel connection 3 coolant outlet 4 coolant temperature sensor 5 EMC int...

Page 38: ...ted voltage 24 Volt Operating voltage range 19 to 33 Volt Rated power consumption without coolant pump and vehicle blower over control range W max 37 to 83 W Permissible ambient temperature Heater inc...

Page 39: ...htening torque 6 Nm 10 NOTE Make sure the cable lug is seated correctly when tightening the screw connection Avoid twisting the cable lug when screwing down 2 Secure the EMC suppressor module to the i...

Page 40: ...n areas ATTENTION The heater must not be operated in systems with system vol tages stipulated in the standard MIL STD 1275D 5 3 2 4 generator supported systems with voltage peaks up to 100 V 9 8 Therm...

Page 41: ...2 Storage and transportation The heater can be stored in any position There are no restric tions Heaters should always be stored in the original or similar packaging in closed rooms After removing the...

Page 42: ...tiControl analogue connection see Fig 1107 Legend to wiring diagrams See Section 11 12 Cable cross sections Section 11 13 Cable colours Section 11 15 Plug assignments at control unit Section 11 16 Leg...

Page 43: ...ring diagrams 1102 11 3 System wiring diagram for Thermo Pro 90 with MultiControl control element with battery disconnector Fig 1102 System wiring diagram Thermo Pro 90 MultiControl with battery disco...

Page 44: ...11 Wiring diagrams Thermo Pro 90 1103 11 4 System wiring diagram for Thermo Pro 90 with SmartControl control element ADR Fig 1103 System wiring diagram Thermo Pro 90 SmartControl ADR 9032413A03...

Page 45: ...Thermo Pro 90 11 Wiring diagrams 1104 11 5 System wiring diagram for Thermo Pro 90 with on off switch ADR Fig 1104 System wiring diagram Thermo Pro 90 on off switch ADR 9032678A03...

Page 46: ...11 Wiring diagrams Thermo Pro 90 1105 11 6 System wiring diagram for Thermo Pro 90 with ThermoCall TC4 Fig 1105 System wiring diagram Thermo Pro 90 ThermoCall TC4 9033213A02...

Page 47: ...Thermo Pro 90 11 Wiring diagrams 1106 11 7 System wiring diagram for Thermo Pro 90 with UniBox Fig 1106 System wiring diagram Thermo Pro 90 UniBox 9032352A04...

Page 48: ...grams Thermo Pro 90 1107 11 8 System wiring diagram for Thermo Pro 90 with MultiControl control element analogue connection Fig 1107 System wiring diagram Thermo Pro 90 MultiControl analogue connectio...

Page 49: ...Thermo Pro 90 11 Wiring diagrams 1108 11 9 System wiring diagram for Thermo Pro 90 HDD with MultiControl control element Fig 1108 System wiring diagram Thermo Pro 90 HDD MultiControl 9032792A03...

Page 50: ...1 Wiring diagrams Thermo Pro 90 1109 11 10 System wiring diagram for Thermo Pro 90 HDD with SmartControl control element ADR Fig 1109 System wiring diagram Thermo Pro 90 HDD SmartControl ADR 9032791A0...

Page 51: ...Thermo Pro 90 11 Wiring diagrams 1110 11 11 System wiring diagram for Thermo Pro 90 HDD with on off switch ADR Fig 1110 System wiring diagram Thermo Pro 90 HDD on off switch ADR 9032351A03...

Page 52: ...ontrol unit Cable 7 5 m 7 5 15 m 0 75 mm2 1 0 mm2 1 0 mm2 1 5 mm2 1 5 mm2 2 5 mm2 2 5 mm2 4 0 mm2 4 0 mm2 6 0 mm2 Abbreviation Colour bl blue br brown ge yellow gn green gr grey or orange rt red sw bl...

Page 53: ...K5 Relay with free wheeling diode Vehicle blower P MultiControl SmartControl W bus P1 SmartControl W bus S4 Switch On Off min 500 mA S5 Switch Auxiliary drive pumping device S6 Switch 1 or 2 pin ADR S...

Page 54: ...cle blower fuse present in vehi cle Switch for vehicle blower EMC interference suppression module HDD version only Wiring harness Fuse for vehicle blower fuse present in vehi cle Optional extension av...

Page 55: ...ort SE Postfach 1410 82199 Gilching Germany Visiting adress Friedrichshafener Str 9 82205 Gilching Germany The telephone number of each country can be found in the Webasto service centre leaflet or th...

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