Transcript
Thermo 50 Coolant Heater
HMMWV 6.2 and 6.5 Liter Diesel Special instructions for these models Part locations may differ slightly dependent on the vehicle model.
Table of Contents Foreword Parts List Vehicle Information Scope and Purpose Symbol Identification General References Preparation Heater Installation Site
3 3 3 4 5 5 5
Installation Electrical - Overview Swingfire Heater Component Removal Heater Preparation and Mounting Integration into the Coolant System Integration into the Fuel System
DOC P/N 5000940A
KIT P/N 5000937A
6 7 8 9 12
Exhaust System Installation Electrical Harness Connections Power Connection
13 14 15
Conclusion Programming Digital Timer Final Inspection, Initial Start-up and Concluding Work Heater Lockout Reset Procedure Thermo Top 50 Overview Thermo Top 50 Fault Codes Thermo Top 50 Diagnostic Flow Chart Electrical Wiring Schematic Service Parts
Printed in USA
16 17 18 19 20 21 24 25
Webasto Product N.A., Inc.
– Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death. – Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. – NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures. – ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS. – Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel.
HMMWV
Coolant Heater
Parts List
Quantity
Part
Part Number
1
Heater Kit (with installation hardware)
5000937A
Vehicle Information Manufacturer
Model
Year
Engine Type
AM General
HMMWV
N/A
6.2 Liter 6.5 Liter
Foreword This installation requires special expertise from a Webasto training course to install a Webasto Thermo 50, which means that it may only be installed by specially trained personnel. Webasto cannot accept any liability for faults and damage caused by the system being installed by untrained personnel.
Scope and Purpose These non-binding installation instructions are intended to support authorized Webasto trained personnel in the installation of the Thermo 50 Coolant Heaters. These non-binding installation instructions apply to the vehicles listed on the front cover of this installation document unless technical modifications on the vehicle influence the installation, excluding all liability claims. Depending on the version and equipment in the vehicle, changes may be required to the installation work set out in these installation instructions. In any event, however, the directives in the “installation manual” and “operating manual” Thermo 50 must be followed. Acknowledged engineering conventions must be observed for the installation work. ATTENTION All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary heating devices must be observed! CAUTION Location of heater, installation of coolant lines, fuel system and components, wiring and control devices are important for proper operation. Failure to comply with the installation instructions provided may result in poor operation or damage to heater and vehicle components.
3
Coolant Heater
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Symbol Identification Symbols that define sections in manual
Mechanical Preparation
Fuel
Electrical
Exhaust
Coolant
Combustion Air Intake
General Symbol Descriptions
Warning
Refer to Webasto or Manufacturer Manual
Caution
Attention
Line of Sight/Item Location on Vehicle
Flammable or Combustible
4
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Coolant Heater
General References – Bare body parts, for example around drilled holes, must be treated with anti-corrosive coating. – Secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them at chafing points. – Fit edge protectors (opened fuel hose) to sharp edges.
Preparation Heater Kit – Verify and identify all contents of kit.
Vehicle – Disconnect negative terminal of vehicle battery(s). – Drain engine coolant into a suitable container. – Remove engine access cover (doghouse).
Heater Installation Site 1
ATTENTION The Webasto Auxiliary Coolant Heater is to be installed under the hood and behind the washer bottle. – (1) Webasto Auxiliary Coolant Heater (Installed)
Fig. 1
5
Coolant Heater
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Electrical - Overview ATTENTION The routing of cables and wires are done in accordance to the general valid rules of engineering. If not described differently, securing of wiring and cables is done with cable ties to the vehicle’s own wires and cable harnesses.
Power and Ground Connections
Fuel Metering Pump
Heater Connection
Digital Timer
6
HMMWV
Coolant Heater Swingfire Heater Component Removal
1
If vehicle is equipped with a Swingfire heater, disconnect and remove the Swingfire tube, hoses and water pump. Refer to the appropriate Service Manual for removal instructions. Proceed to the Webasto Heater Preparation and Mounting section of this manual if the vehicle is not equipped with the Swingfire heater. – (1) Swingfire Heater Tube Fig. 2 2 – (2) Swingfire Heater Coolant Connections
Fig. 3
3 – (3) Swingfire Heater Water Pump
Fig. 4 4
Connect the engine coolant outlet hose to the heater core inlet hose. – (4) Engine Coolant Outlet Hose
Fig. 5
7
Coolant Heater
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Heater Preparation and Mounting Install heater mounting bracket on heater with three self tapping screws supplied.
1
2
– (1) Heater Mounting Bracket – (2) Self Tapping Screws – (3) Webasto Heater
3
Fig. 6
Connect heater air intake tube, and wiring harness to heater.
4
– (4) Air Intake Tube – (5) Heater Harness
5
Fig. 7
Connect Mecanyl fuel line to heater with fuel line coupler and two clamps. – (6) Mecanyl Fuel Line – (7) Fuel line clamp - Torque 1.0 - 1.4 Nm (8.8 - 12.4 lb-in.) – (8) Fuel Line Coupler
6
7
8
Fig. 8
CAUTION Check behind bulkhead for obstructions before drilling holes. Position Webasto heater on bulkhead in location shown in Figure 9. Using the mounting bracket as a template, mark and drill four holes through vehicle cowling. Secure Webasto heater to vehicle cowling with hardware provided in kit.
3
– (3) Webasto Heater – (1) Heater Mounting Bracket – (9) Vehicle Cowling
1 9
8
Fig. 9
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Coolant Heater
Integration into the Coolant System ATTENTION Torque hose clamps to 2.0 - 2.5 Nm (18 - 22 lb-in.) Avoid sharp bends and kinks when installing coolant hoses. Position hose clamps in such a way to avoid cutting or damaging adjacent components. ATTENTION Clamp vehicle coolant hose with hose clamping pliers prior to cutting to prevent coolant spillage.
Fig. 10
9
Coolant Heater
HMMWV 1
Remove two flanges from back of cylinder heads. – (1) Flange Location – (2) Back of Cylinder Head
2
Fig. 11 ATTENTION Apply gasket sealant to new coolant fittings before installing on engine block. 3
Install supplied coolant fittings, flanges, and gaskets with existing vehicle hardware. – (3) Supplied Coolant Fittings
3
Fig. 36 5
4
6
ATTENTION Tighten hose clamps to 2.0 - 2.5 Nm (18 - 22 lb-in.). Couple left and right cylinder heads with tee fitting and coolant hose provided. – (4) Hose – (5) Tee Fitting – (6) Hose – (3) Coolant Fittings (2 ea.) – (7) Hose Clamps (4 ea.)
3 3
7
Fig. 37
Connect supplied hose to tee fitting and inlet (water pump) side of Webasto heater. – (8) Coolant Hose From Tee Fitting To Heater Inlet – (9) Hose Clamp – (5) Tee Fitting
8 9
5 10
Fig. 14
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Coolant Heater
Connect inlet hose to water pump and secure with hose clamp.
1
– (1) Webasto Heater Inlet Hose – (2) Heater Water Pump – (3) Hose Clamp
2 3 Fig. 15 4
5
4
6
7
Connect 90 degree hose to Webasto heater outlet and tighten hose clamp. Connect 90 degree outlet hose to straight hose section with coupler and clamps provided. – (4) Coolant Hose Coupler – (5) Coolant Hose To Engine Water Pump – (6) Heater Outlet 90 Degree Hose – (7) Hose Clamp (3 ea.)
Fig. 16
Connect Webasto coolant outlet hose to hose leading to lower radiator hose with adapter and two hose clamps. – (8) Coolant Hose Leading to Lower Radiator Hose
8
Fig. 17
11
Coolant Heater
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Integration into the Fuel System Fuel Pump Installation
1
2 3
Install heater fuel pump on vehicle bulkhead as shown in Figure 18.
4
– (1) Heater Fuel Pump – (2) P-Clamp – (3) Drill hole 8.0 mm (5/16 in.) – (4) Bulkhead
Fig. 18
Fuel Line Connections ATTENTION Always cut Mecanyl fuel line with a sharp razor knife or razor edged cutter. DO NOT cut with side cutters, scissors or similar tools as doing so will cause a restriction inside the fuel line.
5
6
Tighten fuel line clamps to 1.0-1.4 Nm (8.8-12.4 lbin.). Connect fuel line (cut to length) from heater to outlet side of fuel pump with fuel line connector and two clamps. – (5) Fuel Line Connector – (6) Fuel Line Clamp (2 ea.) – (7) Mecanyl Fuel Line (from heater)
7
Fig. 19
Cut the rubber fuel line (3/8” I.D.) at the inlet side of the vehicle fuel filter. Install fuel tee fitting as shown in Figure 20. – (8) Fuel Tee – (9) Vehicle Fuel Line – (10) Fuel Line Clamps – (5) Fuel Line Connector – (7) Mecanyl Fuel Line
ATTENTION Route fuel line from fuel tee to inlet side of heater fuel pump and cut to length. Secure fuel line with nylon wire ties.
9
8
ATTENTION Fuel flow through the vehicle fuel filter is identified by the arrows marked on the filter body.
7 7
5
10
Fig. 20
6
Connect Mecanyl fuel line to inlet side of heater fuel pump with fuel line connector and two clamps. – (7) Mecanyl Fuel Line – (6) Fuel Line Clamps – (5) Fuel Line Connector 5 12
Fig. 21
HMMWV
Coolant Heater Exhaust Installation Remove Swingfire exhaust guard and exhaust tube, if equipped.
1
– (1) Exhaust Tube – (2) Exhaust Guard
2
Fig. 22
3
4
5
ATTENTION Ensure exhaust tube does not extend below the bottom of the exhaust guard. Cut flexible exhaust tube to length and secure to the heater with clamp provided. – (3) Webasto Heater – (4) Exhaust Clamp – (5) Flexible Exhaust tube
Fig. 23
Cover flexible exhaust tube with heat protective sleeving and secure to side of vehicle with P-clips and hardware provided. Install orange rubber grommet near end of exhaust tube. 5 Install exhaust guard.
2
– (5) Exhaust Tube Covered With Heat Protective Sleeving – (2) Exhaust Guard
Fig. 24
13
Coolant Heater
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Electrical Harness Connections
1
Cut fuel pump harness (blue and brown wires) to length. Crimp terminals on to wires and insert terminals into plug housing. Attach plug housing to fuel pump. – (1) Fuel Pump Electrical Harness
Fig. 25 CAUTION Check behind cowling for obstructions before drilling hole. Route heater control harness through cowling, using grommet provided, into vehicle interior. Image Not Available
Apply sealant to grommet.
Fig. 26
Timer Installation
2
3
4
5
CAUTION Check behind panels for obstructions before drilling holes. Ensure there is adequate clearance for hand brake and throttle lock operation before installing timer mounting bracket on vehicle interior. Install timer mounting bracket with hardware provided. Snap timer into mounting bracket. – (2) Throttle Lock – (3) Timer Mounting Bracket – (4) Digital Timer – (5) Vehicle Handbrake
14
Fig. 27
HMMWV
Coolant Heater
CAUTION Ensure heater control harness is clear of moving parts (e.g. steering mechanism). Route heater control harness to timer harness area and cut to length. Connect heater control harness to timer harness using the supplied terminals and Table1.
Table 1. Timer Harness Connections Heater Control Harness
Timer Harness
Function
Red
Red
+ 24 Volts
Green
Gray
On Indicator / Diagnostic Code
Brown
Brown
Ground
Black
Black
Timer Output / “ON - OFF” Signal
Yellow
Not Used
Purple
Not Used
Power Connection
1
Connect the red power wire from heater control harness to battery positive cable (+ 24 volts) at alternator. – (1) Battery Positive Cable – (2) Heater Control Power Wire
2
Fig. 28
Ground Connection 3
Connect the brown ground wire from heater control harness to alternator ground location. – (3) Heater Control Harness Ground – (4) Alternator Ground Location
4
Fig. 29
15
Coolant Heater
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Programming Timer Programming Heater Starting Time: To begin timer programming. The timer memory location number starts ConcludingDay Work On/Off flashing. Continue to press button until of Operation the week the desired memory or 3 is lines visible. – Check that all hose lines, hose clamps, pipe clips and electrical connections are secure.location Secure1,all2 loose Indicator Time of Day andand Timer cables with nylon cable ties. To adjust start time setting. Display – Spray the heater components and electrical connections withPress an anti-corrosive wax coating. Or Once start time is set, release Alarm – Install all vehicle parts, panels and components removed during heater button. installation. Flashing will stop after 5 seconds Timer and day of the week will begin flashing. Memory Location To select day of the week. Clock Or Press Heater will start on the time Button Heater Day/Time Program Day/Time and day selected. Once set, wait for flashing to stop. Selection On/Off Reverse Advance To program the other 2 memory locations, repeat the Button Button Button Button above 3 steps for each memory location.
Press
Setting the Time and Day of the Week: Press Press
and hold for 2 seconds. Time of day will start flashing. Or
To adjust time setting.
Once time is set, release button.
Flashing will stop after 5 seconds and day of the week will begin flashing. To select day of the week. Or Once set, wait for flashing to stop. Operating Heater in Manual Mode: Press Press
To turn the heater on. The operation indicator will light up. To turn the heater off. The operation indicator light will go out.
16
Recalling or cancelling a programmed start time: To cycle through memory locations. Any one of the 3 memory locations can be activated each time the button is pressed. After selecting the memory location you desire, you will be able to change the day and time setting if desired by repeating steps 1, 2 and 3 above.
Press
Press
repeatedly until no memory location number is visible on timer display.
Webasto Product N. A., Inc. 15083 North Road Fenton MI, 48430 Technical Assistance: 1-800-555-4518 (USA) 1-800-667-8900 (CAN) www.webasto.us
HMMWV
Coolant Heater
Final Inspection Initial Start-up and Concluding Work Connect battery ground terminal
Final Inspection Inspect installation for: – Loose fasteners. – Exhaust system routing and clamp tightness. – Combustion air intake tube routing and clamp tightness. – Loose coolant line clamps. – Pinched coolant lines. – Routing of coolant lines and coolant lines securely tied and protected against chafing and related damage. – Loose fuel line clamps. – Routing of fuel lines and fuel lines securely tied and protected against chafing and related damage. – Loose wiring connections and battery connections. – routing of wiring harness and wiring harness securely tied and protected against chafing and related damage. – Check operation of vehicle heater fan with Webasto heater OFF.
Initial Start-up 1 Top off cooling system with coolant per engine/vehicle manufacturers recommendations. 2 Set interior heater control to maximum heat position (hot). 3 Start the vehicle engine and run on fast idle for 5 minutes to purge any remaining air from the Webasto heater and coolant system. While the engine is running check: • Hose connections for leaks. • Coolant level in expansion tank. (Add coolant as needed) 4 Switch off the engine. ATTENTION More than one start-up attempt of the heater may be required to purge air from fuel system before heater will start. Cycle heater Off and On after each failed start attempt until heater starts successfully. After 3 consecutive unsuccessful start attempts, the Webasto control unit enters into heater lockout. See Heater Lockout section for reset instructions. 5 Switch on the Webasto heater by means of the instant heat button on timer and check: • Timer panel and instant heat indicator illuminates. • Circulating pump in operation. • Initiation of start-up sequence. • Successful start-up and operation. 6 Allow heater to run for 20 minutes or until coolant is heated to temperature. Re-tighten all hose clamps. ATTENTION Engine coolant temperature gauge may read lower than actual Webasto heater output temperature. This is due to the location of the temperature gauge sensor on engine.
17
Coolant Heater
HMMWV
Heater Lockout Reset Procedure The heater is designed with a lockout safety feature built into the control unit. After 3 consecutive unsuccessful startup attempts, the heater will lock itself out from any further start attempts. The heater may also enter the lockout mode after experiencing an overheat condition. Reset Heater “Lockout” mode by performing the following procedure: 1 Ensure timer or switch is in the “OFF” position. Turn timer or switch to the “On” position. Remove main fuse F1 (15 Amp), reinsert after 5 seconds. 2 Cycle timer or switch off and then back on once more. Remove fuse F1 once again and reinsert after 5 seconds. Heater should attempt to start after inserting fuse. ATTENTION – The engine coolant must be below 86 °F (30 °C) before the Webasto heater will attempt to start. – Should the heater fail to start or operate correctly, contact your Webasto technical representative at: 1-800-555-4518
18
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Coolant Heater
Thermo Top 50 - Overview CAUTION Troubleshooting requires comprehensive knowledge about the structure and theory of operation of the Thermo Top heater. Troubleshooting and repairs may only be performed by Webasto trained and certified, professionals.
Functional Description - Thermo Top Switch On Push the timer ON/OFF button to illuminate the indicator lamp; activate the heater glow pin, combustion air fan and the circulation pump. After 30 seconds the fuel pump starts and the combustion air fan operation is suspended for 3 seconds. Subsequently, the combustion air fan speed is increased in two ramps within 56 seconds to part load operation. After a stabilization phase (constant speed) of 15 seconds the combustion air fan speed is again increased in a ramp within 50 seconds to full load. After reaching full load, the glow pin is deactivated and the combustion air fan operation is increased. During the next 45 seconds and during normal heater operation, the glow pin functions as a flame sensor to monitor the flame condition. Once the start-up and stabilization periods have been completed the heater begins the automatically controlled heating operation. In case of a no-flame condition during start-up or a flameout during normal combustion operation, the heater will go into a “shut-down upon malfunction” state with a run-down of the combustion air fan.
Heating Operation When the coolant reaches temperature the heater switches to the energy saving part load operation. A rise in coolant temperature above the upper threshold causes the heater to enter a control idle period. The circulation pump and the operation indicator light remain on during control idle. After cool-down of the coolant, the heater resumes full load operation. Another rise in coolant temperature above the upper threshold causes the heater to enter the control idle period again. A drop in the coolant temperature during part load operation due to an increased demand in heat will cause the heater to switch to full load operation.
Switch Off Pushing the timer ON/OFF button extinguishes the indicator lamp, combustion terminates and the shutdown phase commences. The circulation pump and the combustion air fan continue operation during the shutdown phase to cool the heater down and will be automatically switched off afterwards. The duration time and the combustion air fan speed during the shutdown phase depend on the heater operating condition at the time the heater is turned off. Shut-down time duration is normally 180 seconds (3 minutes) when deactivated in full load operation and 100 seconds (1.6 minutes) when deactivated in part load operation. Dependent on the software variant implemented in the control unit there might be time duration deviations from those shut-down periods as stated.
19
Coolant Heater
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Thermo 50 - Fault Codes ATTENTION The Thermo top 50 is equipped with an electronic control module which is capable of providing the following diagnostic fault codes. If a malfunction is detected by the control module during heater operation a fault code will appear on the digital timer display.
Fault Code F01 No Start-up
Description
Possible cause • Fuel Supply • Restricted Air Flow Through Intake or Exhaust
F02
Flame Extinguished
• Fuel Supply • Restricted Air Flow Through Intake or Exhaust
F03 F04 F05
Under / Over Voltage Premature Flame Detection Circulating Pump Interruption or Short Circuit Temperature Sensor Interruption or Short Circuit Metering Pump (fuel pump) Interruption or Short Circuit Combustion Fan Motor Interruption, Short Circuit or Incorrect Fan Speed Pencil Type Glow Plug / Flame Detector Interruption or Short Circuit Overheating Condition
• Vehicle Charging System
F06 F07 F08 F09 F10
• Replace Heater • Open or Shorted Wiring • Defective Pump • Replace Heater • Open or Shorted Wiring • Replace Heater • Replace Heater • Coolant Flow Restriction • Circulation Pump
ATTENTION This manual is intended for installation and basic troubleshooting of the Thermo 50 coolant heater. Refer to www.techwebasto.com for detailed repair and maintenance procedures.
20
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Coolant Heater
Thermo Top 50 - Diagnostic Flow Chart ATTENTION Troubleshooting is normally limited to the isolation of defective components, wiring and connections. The following possible causes for trouble have not been taken into consideration and must always be excluded as a possible cause for malfunctions: • power supply to heater is less than 22 volts at main power connections (charge batteries and perform load test). See wiring diagram on page 24 for reference to power connections. • blown fuses. • corrosion on battery terminals for heater, electrical wiring, connections and fuses. • loose contacts or connectors, wrong crimping on connectors. • ensure heater and components have been correctly installed following all pertaining installation instructions.
Troubleshooting Steps After 3 consecutive unsuccessful startup attempts, the heater will lock itself out from any further start attempts. The heater may also enter the lockout mode after experiencing an overheat condition. Before troubleshooting the heater, ensure heater is not in the “Lockout” mode by performing the following reset procedure: 1. 2.
Ensure switch is in the off position. Turn switch to the on position. Remove fuse F1 (15 Amp), refer to wiring diagram on page 24 for identification. Reinsert after 5 seconds. Cycle switch off and then back on once more. Remove fuse F1 once again and reinsert after 5 seconds. Heater should attempt to start in 10 seconds after inserting fuse. Coolant temperature must be belowthe lower threshold before heater will attempt to start.
NO Did heater attempt to start? (Combustion fan running)
YES
Continued on page 22
Check for 24V on signal at heater connector X1, pin 3 with timer/switch on.
Repair or replace harness, connectors, fuses, or timer/switch accordingly.
Check for 24V at heater connector X2, pin 1.
Repair or replace harness, connectors, connections or fuses accordingly.
Check for ground at heater connector X2, pin
Repair or replace harness, connectors or connections accordingly.
Replace Thermo Top
21
Coolant Heater
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Thermo Top 50 - Diagnostic Flow Chart
NO
YES
Is combustion air intake free from damage and obstructions?
Repair/replace air intake tube or remove obstruction accordingly.
Is combustion exhaust pipe free from damage and obstructions?
Repair/replace exhaust pipe or remove obstruction accordingly.
Does fuel pump operate (clicking) during start-up cycle approx. 30 sec. after switching on?
Connect test light to fuel pump leads (leads connected normally). Does the light blink slowly after 30 sec. of switching the heater on? Reconnect fuel pump and turn heater on. After 30 sec. lightly tap fuel pump. Does fuel pump begin to operate (Click).
Is fuel pump harness free of damage?
Repair or replace harness accordingly.
Replace heater.
Replace fuel pump.
System should resume normal operation. Pump may have been stuck due to dirt in fuel or long periods of no operation. Perform visual check of fuel pump. Is fuel moving through the fuel line with each pulse of the fuel pump?
Are fuel lines free of obstructions? Are fuel lines free of damage, pinched sections, or leaks? Are the fuel line clamps tight? Is there sufficient fuel in the fuel tank?
Continued on page 23
Replace fuel pump.
22
Repair/replace damaged or obstructed fuel lines. Tighten loose fuel line clamps. Fill fuel tank with sufficient fuel to reach fuel standpipe inlet.
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Coolant Heater
Thermo Top 50 - Diagnostic Flow Chart CAUTION Allow heater to cool down before disassembly of coolant circulating pump. Allow heater to cool down before attempting to restart.
NO Does coolant pump operate when heater is running (can feel or hear pump running)?
Remove center plastic cover from heater. Disconnect coolant pump connector X5. Apply 24V directly to the pump (+ to black and – to brown). Does pump operate?
Remove coolant pump and 4 cover screws. Clean pump accordingly. Assemble and reconnect pump. Does pump now operate?
Replace heater.
Problem resolved. Test run heater.
YES
Does heater start and operate normally?
Check coolant hoses for obstructions, kinked hoses, low coolant level and proper hose routing, etc.
Heater is operating normally. Possible intermittent problem. Should problem reoccur, rerun through this troubleshooting tree.
23
Replace coolant circulating pump.
F2
B
E
X1
4 5 6
1 2 3
MATING END SHOWN
-
+
RED 12GA
BROWN 12GA
F1
F
A
X2 1
RED 14GA
RED 14GA
RD
D C
BLK 2
12
8
INTERNAL TO HEATER
X3, X4 and X5
Digital Timer
2
11
GRY BRN
24 BROWN 18GA
X8
X9
GREEN 18GA
BLACK 18GA
YELLOW 18GA
BROWN 14GA
SCHEMATIC WITH DIGITAL TIMER
BROWN 18GA
Y1
A
B
X7
X7
B2 E F1 F2 M1 M2 S1 X1
A
B
X8
E
2
X3
X9
1
DWG NO: 908268A
1
BATTERY -
2
FUEL PUMP +
A
INDICATOR/DIAGNOSTIC LIGHT +
ON SIGNAL TO HEATER
BATTERY + FUSED POWER
X2
X2 X3 X4 X5 X7 X8 X9 Y1
M
2
B
M1
X4
COMPUTER DIAGNOSTICS DOWNLOAD LINK
1
6
5
4
3
1
2
X1
TEMPERATURE SENSOR CERAMIC IGNITER/FLAME SENSOR 15A FUSE 5A FUSE COMBUSTION AIR FAN COOLANT CIRCULATION PUMP ON/OFF SWITCH-TOGGLE CONNECTOR 6-WAY
BLUE 18GA
WEBASTO THERMO 50 - HMMWV
D
M
2
2 4 5 6
1
2
2
M2
X5
1 2 3
2
1
1
1
E
F
HEATER
B2
CONTROL
RELEASED 5/7/03 G. MILLER
C
1
X1
X2
X3
X5 X4
CONNECTOR 2-WAY CONNECTOR 2-WAY CONNECTOR 2-WAY CONNECTOR 2-WAY CONNECTOR 2-WAY CONNECTOR 1-WAY FUSE HOLDER FUEL PUMP
Coolant Heater HMMWV
HMMWV
Coolant Heater
Service Parts 1
2
3
4
5
9
8
Item 1 2 3 4 5 6 7 8 9
Quantity 1 3MT 2 2 1 1 1 12 2
Part No. 50126840A 901073 5000939A 901136 355240 669088 900611 901097 5000938A
7
Description Formed Heater Hose Heater Hose Gasket Elbow Fitting Tee Hose Coupler Hose Coupler Hose Clamp Flange Adapter
25
6
Remarks 5/8” I.D. 3/4 MNPT x 3/4 BARB 90 Degree
Coolant Heater
HMMWV
Service Parts 2
1
8
Item 1 2 3 4 5 6 7 8
Quantity 1 1 10 20 10 1 1 1
Part No. 50900126A 5000413A 147249 35814A 277142 18137A 20965A 405256
7
6
5
Description Exhaust Tube Heat Protective Sleeving Screw Washer Locknut Exhaust Grommet Exhaust Clamp Exhaust P-Clamp
26
4
3
Remarks
M6x20 M6
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Coolant Heater
Service Parts 1 2 3 4 5 6 7 8
10
Item 1 2 3 4 5 6 7 8 9 10
Quantity 1 1 2 2 1 5 1 1 1 1
Part No. 50000064B 85002A 32099A 85004A 905002 901686 901038 901743 906218 905798
9
Description Heater Control Harness FP Harness Connector Housing FP Harness Weather Seals Terminal End Grommet Electrical Connector Ring Terminal Ring Terminal Timer Mounting Bracket Digital Timer
27
Remarks
3/8” 1/4” Mounting hardware included Harness included
Coolant Heater
HMMWV
Service Parts 1
2
3
7 6
5
4
Item 1 2 3 4 5 6 7
Quantity 1 2 4MT 1 20 5 10
Part No. 118978 600146 50483931A 5023298A 620404 484032 330027
Description Fuel Line Tee Worm Clamp Fuel Line Air Intake Tube Nylon Cable Tie Fuel Line Connector Hose Clamp
28
Remarks
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Coolant Heater
Service Parts 1
4
3
2
Item 1 2 3 4
Quantity 1 1 1 1
Part No. 97359A 87394B 21499A 89373A
Description Thermo 50 Coolant Heater Heater Mounting Bracket P-Clip Fuel Pump
29
Remarks KIT - Includes items 2-4 Used to mount fuel pump
Coolant Heater
HMMWV
Service Parts 3
2
1
7
5
4
Description Burner (Diesel) Combustion Air Fan Burner Head + Heat Exchanger + Control Unit - 24 V Screw - EJOT PT 10 DG 60x18 Pump Housing (193 Degree) Pump Housing (Axial) Circulation Pump - 24V U4847
Remarks With screws and gaskets
6
Item 1 2 3
Quantity 1 1 1
Part No. 98234A 98235A 98236B
4 5 6 7
3 1 1 1
86889B 93011C 93012C 98237A
30
With screws, gaskets and sealants For fastening bracket to heater
With seals and screws
HMMWV
Coolant Heater
NOTES:
31
Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 Org. 8/2004
Rev. N/A
P/N 5000940A
www.webasto.us
