CLAAS Webasto Water heater Thermo Pro 90 Thermo Pro 90 HDD Service Instructions Manual -PDF DOWNLOAD

Description

CLAAS Webasto Water heater Thermo Pro 90 Thermo Pro 90 HDD Service Instructions Manual -PDF DOWNLOAD

DESCRIPTION:

CLAAS Webasto Water heater Thermo Pro 90 Thermo Pro 90 HDD Service Instructions Manual -PDF DOWNLOAD

1 Introduction

1.1 Contents and purpose

This workshop manual is designed to assist trained personnel in the repair of Thermo Pro 90 water heaters. This workshop manual contains all the information and instructions necessary to repair Thermo Pro 90 water heaters

2 General description

The water heater has been designed for installation in commercial vehicles. Depending on equipment, the ADR function is provided for the 12 V and 24 V variant.

Parking heating

In parking heating mode, the water heater works together with the vehicle’s heating system for

• cab and engine preheating,
• use of residual heat from the vehicle engine

The water heater works independently of the vehicle engine and is integrated in the cooling system, the fuel system and the electrical system of the vehicle.

TABLE OF CONTENTS:

CLAAS Webasto Water heater Thermo Pro 90 Thermo Pro 90 HDD Service Instructions Manual -PDF DOWNLOAD

1 Introduction…………………………………………………………………………………….. 7
1.1 Contents and purpose………………………………………………………………………… 7
1.2 Meaning of signal words……………………………………………………………………… 7
1.3 Additional documentation to be used…………………………………………………………… 7
1.4 Legal requirements and safety information……………………………………………………… 7
1.4.1 Statutory regulations governing installation……………………………………………… 7
1.4.2 General safety information……………………………………………………………… 7
1.5 Spare parts………………………………………………………………………………… 8
2 General description………………………………………………………………………………. 9
2.1 Combustion air fan…………………………………………………………………………..10
2.2 Overheating protection, coolant temperature sensor and heat exchanger……………………………..10
2.3 Glow plug and burner unit…………………………………………………………………….10
2.4 Combustion chamber…………………………………………………………………………..10
2.5 Exhaust gas temperature sensor………………………………………………………………..11
2.6 U4840 coolant pump…………………………………………………………………………..11
2.7 Control unit………………………………………………………………………………..11
2.8 DP42 fuel pump………………………………………………………………………………11
3 Functional description…………………………………………………………………………….12
3.1 Switching on and residual heat utilization……………………………………………………..12
3.2 Start and control mode……………………………………………………………………….13
3.3 Switching off……………………………………………………………………………….13
3.4 Heater functions in ADR vehicles………………………………………………………………13
4 Technical data……………………………………………………………………………………14
5 Malfunctions and troubleshooting……………………………………………………………………15
5.1 Procedure in the case of fault, malfunction and lock-out…………………………………………15
5.1.1 Fault code output at the control element………………………………………………….15
5.2 Cause of malfunctions………………………………………………………………………..15
5.3 Deleting fault code………………………………………………………………………….16
5.3.1 Without Webasto Thermo Test PC Diagnostics………………………………………………..16
5.3.2 with Webasto Thermo Test computer diagnostics……………………………………………..16
5.4 Heater lock-out……………………………………………………………………………..16
5.5 Fault code table (fault codes, flash codes)…………………………………………………….17
5.6 Troubleshooting (fault symptoms)………………………………………………………………19
6 Function checks…………………………………………………………………………………..23
6.1 General information………………………………………………………………………….23
6.2 Function checks in the vehicle………………………………………………………………..23
6.3 Setting CO2 content………………………………………………………………………….23
6.4 Testing individual components…………………………………………………………………25
6.4.1 Checking resistance of the coolant temperature sensor………………………………………25
6.4.2 Checking resistance of the glow plug……………………………………………………..25
6.4.3 Checking resistance of the exhaust gas temperature sensor…………………………………..25
6.4.4 Checking the combustion air fan………………………………………………………….25
6.4.5 Checking the DP42 fuel pump……………………………………………………………..25
6.4.6 Checking the overheating protection………………………………………………………25
6.4.7 Checking the U4840 coolant pump………………………………………………………….25
7 Servicing………………………………………………………………………………………..27
7.1 Working on the heater………………………………………………………………………..27
7.2 Working on the vehicle……………………………………………………………………….27
7.3 Heater test run……………………………………………………………………………..27
7.4 Checks……………………………………………………………………………………..27
7.5 Removing and installing heater………………………………………………………………..28
7.5.1 Removal……………………………………………………………………………….28
7.5.2 Installation…………………………………………………………………………..28
7.6 Visual inspection to assess the burner unit…………………………………………………….28
7.6.1 Metal fiber evaporator………………………………………………………………….28
7.6.2 Combustion chamber……………………………………………………………………..29
7.7 Restarting………………………………………………………………………………….29
8 Repairing and replacing components………………………………………………………………….30
8.1 General information………………………………………………………………………….30
8.2 Component layout…………………………………………………………………………….30
8.3 Work on stripped down components………………………………………………………………31
8.4 Electrical connections……………………………………………………………………….31
8.5 Control unit………………………………………………………………………………..31
8.6 U4840 coolant pump…………………………………………………………………………..32
8.7 Overheating protection……………………………………………………………………….32
8.8 Coolant temperature sensor……………………………………………………………………33
8.9 Combustion air fan…………………………………………………………………………..33
8.10 Burner unit and glow plug……………………………………………………………………34
8.11 Burner head………………………………………………………………………………..34
8.12 Heat exchanger……………………………………………………………………………..35
8.13 Exhaust gas temperature sensor……………………………………………………………….35
9 Thermo Pro 90 HDD…………………………………………………………………………………37
9.1 General information………………………………………………………………………….37
9.2 Technical data………………………………………………………………………………38
9.3 U4840 coolant pump with EMC suppressor module…………………………………………………..39
9.3.1 Replacing the EMC suppressor module………………………………………………………39
9.4 Combustion air fan…………………………………………………………………………..39
9.5 Fuel……………………………………………………………………………………….39
9.6 Control unit………………………………………………………………………………..40
9.7 Electrical components………………………………………………………………………..40
9.8 Thermo Pro 90 HDD wiring diagrams……………………………………………………………..40
9.8.1 Legend to connector VG95328R2016PN (if installed)………………………………………….40
10 Packaging/storage and shipping…………………………………………………………………….41
10.1 General information…………………………………………………………………………41
10.2 Storage and transportation…………………………………………………………………..41
11 Wiring diagrams………………………………………………………………………………….42
11.1 Thermo Pro 90………………………………………………………………………………42
11.2 Thermo Pro 90 HDD…………………………………………………………………………..42
11.3 System wiring diagram for Thermo Pro 90 with MultiControl control element with battery disconnector….43
11.4 System wiring diagram for Thermo Pro 90 with SmartControl control element (ADR)……………………44
11.5 System wiring diagram for Thermo Pro 90 with on/off switch (ADR)…………………………………45
11.6 System wiring diagram for Thermo Pro 90 with ThermoCall TC4……………………………………..46
11.7 System wiring diagram for Thermo Pro 90 with UniBox…………………………………………….47
11.8 System wiring diagram for Thermo Pro 90 with MultiControl control element (analogue connection)……..48
11.9 System wiring diagram for Thermo Pro 90 HDD with MultiControl control element……………………..49
11.10 System wiring diagram for Thermo Pro 90 HDD with SmartControl control element (ADR)……………….50
11.11 System wiring diagram for Thermo Pro 90 HDD with on/off switch (ADR)…………………………….51
11.12 Cable cross-sections……………………………………………………………………….52
11.13 Cable colours……………………………………………………………………………..52
11.14 Heater connections…………………………………………………………………………52
11.15 Plug assignments at control unit…………………………………………………………….52
11.16 Legend to wiring diagrams…………………………………………………………………..53
11.17 Legend for comments………………………………………………………………………..54
11.18 Legend for plug X8, 12-pin………………………………………………………………….54

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CLAAS WEBASTO WATER HEATER THERMO PRO 90 THERMO PRO 90 HDD SERVICE INSTRUCTIONS MANUAL -PDF DOWNLOAD:

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