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Summary of Contents for Webasto Thermo 300.102
- Page 1 Coolant Heater Thermo 300.102 Installation Instructions for use with The Detroit Diesel Series 4000 Engine...
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Page 2: Table Of Contents
4.2.1 Thermo 300.102 Heater Dimensions ....... . 4-2 U 4814 & U 4852 Coolant Pump Data ........4-3 4.3.1... - Page 3 Operational Malfunction Code via Flash/ Malfunction Code ..... . 6-3 Reading and Removing Malfunction Codes Stored in Memory with the Webasto PC Diagnostics Kit and Adapter .
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Page 4: Introduction
Scope and Purpose This manual contains all of the information and procedures necessary for the installation of the This manual is intended to support authorized Webasto Thermo 300 heater. trained distributors, dealers and personnel in the installation and servicing of Thermo 300 coolant heaters. - Page 5 NTRODUCTION EBASTO HERMO In the vicinity of the coolant heater, a temperature of The coolant heater may only be operated with the 185 °F (85 °C) must not be exceeded under any specified fuel (Diesel 1, Diesel 2, Arctic grade, Kerosene circumstances (e.g.
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Page 6: General Description
14 Photo disc Fig. 2-1: Major Components of the Thermo 300 Coolant Heater The Webasto Thermo 300 heater has been designed for use on large displacement diesel engines where a high degree of operational flexibility is desired. Additionally, the Thermo 300 heaters supplied to Detroit Diesel Corporation have been optimized to meet the specific requirements of the Series 4000 Detroit Diesel engine. - Page 7 ENERAL ESCRIPTION EBASTO HERMO...
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Page 8: Functional Description
EBASTO HERMO UNCTIONAL ESCRIPTION Functional Description Activation and deactivation is by means of a • switch • timer dependent on the type of installation. For monitoring operation an operating indicator light is provided. Switch off initiates the rundown procedure (see ”Switch off”). The heaters may be •... - Page 9 UNCTIONAL ESCRIPTION EBASTO HERMO...
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Page 10: Technical Data
EBASTO HERMO ECHNICAL Technical Data General Information Where no threshold values are specified, technical data are understood to include standard tolerances for heater units of ± 10% at ambient temperature of + 20 °C (+ 68 °F) and at nominal voltage. Electrical components: Control unit, fan and circulation pump motors, solenoid valve, igniter box, heater cartridge, nozzle pre-heater and timer are 24V components. -
Page 11: Thermo 300.102 Heater Dimensions
ECHNICAL EBASTO HERMO 4.2.1 Thermo 300.102 Heater Dimensions Fig. 4-1 Thermo 300.102 Heater Dimensions... -
Page 12: U 4814 & U 4852 Coolant Pump Data
EBASTO HERMO ECHNICAL U 4814 & U 4852 Coolant Pump Data NOTE: The allocation of circulation pumps to heater units must be in accordance with coolant resistances. Circulation pump U 4814 U 4852 Volume flow l/h (US. Gal/min) 5200 (22.9) against 0.15 bar 6000 (26.4) against 0.4 bar Nominal voltage Operating voltage range... -
Page 13: Coolant Circulation Pump U4852 Dimensions
ECHNICAL EBASTO HERMO 4.3.2 Coolant Circulation Pump U4852 Dimensions Fig. 4-3 Coolant Circulation Pump U4852 Dimensions Fig. 4-4 Pump U4852 Operating Data... -
Page 14: Installation
Installation General Information Webasto will take you step by step through the installation process to ensure successful operation for years to come. The installation must be performed in accordance with the installation instructions provided in this manual. IMPORTANT! The proposed heater installation must be approved by Webasto Thermosystems. -
Page 15: Exhaust Pipe Connection
Route the exhaust system away from vehicle components that may be damaged by heat e.g., brake lines, electrical wiring, coolant hoses and fuel lines. NOTE: Webasto approved flexible exhaust tubing is available from your Webasto Thermosystems supplier under part number 479721. Combustion Air Supply... -
Page 16: Plumbing Into The Coolant System
For installations where ducting is not required, the heater is factory equipped with a splash deflector that simply snaps onto the combustion air inlet. NOTE: Webasto approved flexible combustion air ducting is available from your Webasto Thermosystems supplier under part number 88729A. Plumbing Into the Coolant System 5.7.1... -
Page 17: Supplemental Heating Schematic
NSTALLATION EBASTO HERMO 5.7.2 Supplemental Heating Schematic - Jacket Water and Intercooler Coolant Heaters (fig. 5-1) CAUTION The coolant pump(s) must be operating and a continuous unobstructed coolant path provided during heater operation. Overheating of the heater will quickly develop if coolant flow is interrupted. Fig. -
Page 18: Supply And Return Plumbing Connection Points
EBASTO HERMO NSTALLATION 5.7.3 Supply and Return Plumbing Connection Points (Charge Air Cooler) WARNING Burn risk! When working on the coolant system, allow the engine to cool down and open the radiator cap carefully. NOTE: Heater hose must meet SAE 20 R3 specifications. Silicone hose requires special hose clamps. Hose clamps must be tightened to 45 lb/in. -
Page 19: Example Of A Heater Installation
NSTALLATION EBASTO HERMO 5.7.4 Example of a Heater Installation Thermo 300 in Enclosure Fig. 5-4: Example of Heater Installation... -
Page 20: Fuel System
The fuel standpipe and fuel line must be installed according to these instructions to insure proper heater operation. CAUTION Whenever the fuel tank is situated higher than the Webasto heater, the top of the fuel tank must not be more than 500 mm (20 in.) above the heater. -
Page 21: Fuel Filter
NSTALLATION EBASTO HERMO 2. Install the fuel standpipe. use 1/4” or 1/2” spare port on fuel tank (if available) and install fuel standpipe securely in fuel tank, use pipe thread sealant on all pipe threads. 3. Route and secure fuel lines from heater to fuel tank. Route according to applicable regulations. Use grommets to protect fuel lines whenever routed through holes. -
Page 22: Wiring Connections
EBASTO HERMO NSTALLATION Wiring Connections 5.9.1 General Information The control unit is equipped with low voltage protection, therefore it is imperative to keep vehicle batteries in good condition. Thermo 300 heaters are available in 24 volt configurations only. CAUTION Whenever welding is to be performed on the vehicle, the main battery cables must be disconnected from the battery to protect the electronic control unit. -
Page 23: Coolant Pump Connections
NSTALLATION EBASTO HERMO 5.9.4 Coolant Pump Connections Use Eyelet (901.038) supplied with coolant pump harness kit for ground. Run 12 Gauge wire from eyelet to Pin B on connector #905455 for the ground. Run 12 Gauge wire from Pin A on the same connector into Pin D on the flat 4 pin connector of the electrical connector kit. -
Page 24: Wiring Diagram - With Switch
EBASTO HERMO NSTALLATION 5.9.5 Wiring Diagram - with Switch Fig. 5-9: Wiring Diagram with Switch 5-11... -
Page 25: Wiring Diagram - With 7-Day Digital Timer Model 1531
NSTALLATION EBASTO HERMO 5.9.6 Wiring Diagram - with 7-Day Digital Timer Model 1531 Fig. 5-10: Wiring Diagram with Timer Model 1531 5-12... -
Page 26: Initial Operation
4. Set vehicle heater controls to maximum heat position. 5. Start the vehicle engine and run it at a fast idle for 10 minutes to purge air from the Webasto coolant heater and coolant circuits. While the engine is running check: hose connections for leaks. - Page 27 NSTALLATION EBASTO HERMO 15. Complete the warranty card and mail to Webasto Thermosystems. 16. Install the heater or engine compartment cover if equipped. Installation is now complete. NOTE: Necessary information to complete warranty registration card and ensure full warranty coverage can be found on the name plate on top of the burner head.
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Page 28: Basic Troubleshooting
Basic Troubleshooting CAUTION Troubleshooting requires profound knowledge about structure and theory of operation of the heater and components. Troubleshooting and fault correction should only be performed by Webasto trained, skilled personnel unless otherwise stated in this manual. General Information This section describes troubleshooting procedures for the Thermo 300 coolant heater. Troubleshooting is normally limited to the isolation of defective components. -
Page 29: Malfunction Codes Stored In Memory
ASIC ROUBLESHOOTING EBASTO HERMO switch or timer is cycled “Off” and “On” and the heater successfully starts and runs with no further malfunctions, the malfunction code will disappear from the timer display. 6.2.2 Malfunction Codes Stored in Memory Once the Thermo 300 completes the after run (cool down) period initiated by a malfunction, the current flash code will be downloaded (stored) in memory. - Page 30 EBASTO HERMO ASIC ROUBLESHOOTING Operational Malfunction Symptoms via Flash/ Malfunction Code The following table lists the possible malfunctions which can be read by flashing code or read directly off of an appropriate timer or with the PC diagnostics kit. Failure Symptom Probable Cause Check and Correct 1X Flash (F 01)
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Page 31: Reading And Removing Malfunction Codes Stored In Memory With The Webasto Pc Diagnostics Kit And Adapter
Thermo 300 and an IBM compatible computer having the necessary software installed. The PC Diagnostic Interface Kit comes with software and instructions for use with Webasto heaters equipped with internal diagnostics capabilities such as the Thermo 300. - Page 32 EBASTO HERMO ASIC ROUBLESHOOTING...
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