Webasto Thermo 90 Service Manual

Water Heaters09/2001Workshop ManualThermo 90Thermo 90-TRS(Transport of hazardous goods)Thermo 90 SThermo 90 S-TRS(Transport of hazardous goods)Type BW

Thermo 90 2 General Description2012 General DescriptionThe water heater Webasto Thermo 90 and Thermo 90 S in combination with the vehicle's own

2 General Description Thermo 90202Heater Thermo 90 S2.1 Combustion Air FanThe combustion air fan delivers the air required for combustion from the c

Thermo 90 2 General Description2032.3 Temperature SensorThe temperature sensor senses the coolant temperature in the heat exchanger of the heater un

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Thermo 90 3 Functional Description3013 Functional Description (Fig. 301)3.1 Switch-onWhen operating the push button "Immediate Heating", t

3 Functional Description Thermo 903023.4 Switch-offWhen switching the heater off, the operation indicator on the timer/switch extinguishes. Combusti

Thermo 90 3 Functional Description303 G Vehicle BlowerSetting of Control Temperatures Thermo 90On the standard wiring harness B6 is not in use.NOTET

3 Functional Description Thermo 903043.6.3 Diagnosis after Switch-off upon Failure(Thermo 90 S)When equipped with a standard timer an error will cau

Thermo 90 3 Functional Description305Page free for notes

Thermo 90 4 Technical Data4014 Technical DataAs long as no threshold values are given, the following technical data are understood to include tolera

Thermo 90 List of ContentsIList of Contents1 Introduction1.1 Scope and Purpose ...

4 Technical Data Thermo 90402Page free for notes

Thermo 90 5 Troubleshooting5015 Troubleshooting5.1 GeneralThis section describes troubleshooting procedures for the Water Heater Thermo 90 and Therm

5 Troubleshooting Thermo 905025.3 Failure Symptoms after Switch-off upon FailureNOTEWhen operated with a switch the type of failure is indicated by

Thermo 90 5 Troubleshooting503Fig. 502 Failure Symptoms after Switch-off upon Failure (Sheet 2 of 2)5.4 Visual Inspection for Assessment of Burne

5 Troubleshooting Thermo 905045.4.2 Rear Wall with Metal Evaporator• The pilot flame exit bore (Fig. 504) must not be clogged, otherwise there will

Thermo 90 6 Functional Tests6016 Functional Tests6.1 GeneralThis section describes the on-vehicle and off-vehicle testing of the heater to check its

6 Functional Tests Thermo 90602Page free for notes

Thermo 90 7 Circuit Diagrams7017 Circuit Diagrams7.1 GeneralThe circuit diagrams (Figs. 702 and 703) show possible circuits of the heater Thermo 90

7 Circuit Diagrams Thermo 90702Fig. 702 Circuit Diagram Automatic Control for Thermo 90, 12 and 24 V with Triple TimerϑϑblbrgegngrorrtswviwsWire c

Thermo 90 7 Circuit Diagrams703Fig. 703 Circuit Diagram Automatic Control Thermo 90-TRS, 24 VϑϑFor fuel heaters remove this connectionTemperature

List of Contents Thermo 90II6 Functional Tests6.1 General ...

7 Circuit Diagrams Thermo 90704Fig. 704 Circuit Diagram Automatic Control for Thermo 90 S, 12 and 24 V with Standard TimerϑϑTemperature coding (te

Thermo 90 7 Circuit Diagrams705Fig. 705 Circuit Diagram Automatic Control for Thermo 90 S-TRS, 24 VϑϑTemperature coding (temperature at water outl

7 Circuit Diagrams Thermo 90706Fig. 706 Circuit Diagram Automatic Control for Thermo 90 S-TRS, 24 V without Auxiliary DriveϑϑTemperature coding (t

Thermo 90 8 Servicing8018 Servicing8.1 GeneralThis section describes the servicing procedures that may be performed with the heater installed.8.2 Wo

8 Servicing Thermo 908028.4 Heater Test RunWARNINGThe heater must not be operated, not even with timer, in enclosed areas like garages or workshops

Thermo 90 8 Servicing803NOTEManufacturer mounts control unit of heaters Thermo 90 S to combustion air fan.With Check Valve and ThermostatWithout Che

8 Servicing Thermo 90804Fig. 801 Example for Heater Installation in Lorry8.6 Visual Inspections and Installation Regulations8.6.1 Connection to th

Thermo 90 8 Servicing8058.6.2.1 Fuel TappingFuel tapping must be from the fuel reservoir or from a separate tank (Figs. 803, 804, and 805). This sep

8 Servicing Thermo 90806The fuel tap should not be located in the engine compartment because the radiation of engine heat may cause gas bubbles to b

Thermo 90 8 Servicing8078.6.3.1 Installation LocationIt is advantageous to mount the dosing pump in a cool location as near as possible to the tank.

Thermo 90 List of ContentsIII9Repair9.1 General...

8 Servicing Thermo 908088.7 Removal and InstallationCAUTIONIn installed condition, only the following removal and disassembly procedures are allowed

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Thermo 90 9 Repair9019 Repair9.1 GeneralThis section describes the repairs that may be performed on the heater Thermo 90 when removed. Any further d

9 Repair Thermo 909029.2 Disassembly and Assembly9.2.1 Electrical Connections (Fig. 901)9.2.1.1 Disconnecting Electrical Connections (Connection X1)

Thermo 90 9 Repair9039.2.2 Replacement of Circulation Pump9.2.2.1 Removal1. Remove heater (see 8.7.1.1).2. Disconnect electrical connections (see 9

9 Repair Thermo 909049.2.3 Replacement of Temperature Limiter9.2.3.1 RemovalNOTEPerform the following procedure only when the tempera-ture limiter n

Thermo 90 9 Repair905Fig. 903 Replacement of Temperature Limiter and Temperature SensorThermo 906512341 Protective Cap2 Clamp3 Temperature Limiter

9 Repair Thermo 909069.2.5 Replacement of Combustion Air Fan9.2.5.1 Removal1. Remove heater (see 8.7.1.1).2. Disconnect electrical connections (see

Thermo 90 9 Repair9079.2.6 Replacement of Burner, Flame Sensor,and Glow Plug9.2.6.1 Removal1. Remove heater (see 8.7.1.1).2. Remove combustion air f

9 Repair Thermo 90908Fig. 905 Replacement of Burner, Flame Sensor, and Glow PlugThermo 90 1Burner 2 Swirl Ring 3 Burner Head 4 Washer 5Screw 6 Gl

List of Figures Thermo 90IVList of Figures301 Functional Sequence ...

Thermo 90 9 Repair9099.2.7 Replacement of Burner Head9.2.7.1 Removal1. Remove heater (see 8.7.1.1).2. Remove combustion air fan (see 9.2.5.1).3. Rem

9 Repair Thermo 909109.2.8 Replacement of Heat Exchanger9.2.8.1 Removal1. Remove heater (see 8.7.1.1).2. Remove circulation pump (see 9.2.2.1).3. Re

Thermo 90 10 Packaging/Storage and Shipping100110 Packaging/Storage and Shipping10.1 GeneralThe heater and its components shipped to Webasto Thermo

10 Packaging/Storage and Shipping Thermo 901002Page free for notes

Thermo 90 1 Introduction1011Introduction1.1 Scope and PurposeThis repair shop manual is intended to support familiarised personnel in the repair of

1 Introduction102For the installation of the Thermo 90-TRS or Thermo 90 S-TRS in vehicles used for the transportation of dangerous goods, in additi

Thermo 90 1 Introduction103• Installation Instructions for Webasto fuel tanks for the fuel supply of water heaters in vehicles: In busses the instal

1 Introduction104Page free for notes