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- Thermo 300.102
- Installation instructions manual
Webasto Thermo 300.102 Installation instructions manual
Summary of Thermo 300.102
Page 1
Thermo 300.102 installation instructions for use with the detroit diesel series 4000 engine coolant heater.
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T able of c ontents i table of contents 1. Introduction 1.1 scope and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 meaning of warnings, cautions and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-...
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T able of c ontents w ebasto t hermo 300 ii 5.9.5 wiring diagram - with switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 5.9.6 wiring diagram - with 7-day digital timer model 1531 . . . . . . . . . . . . . . . . . . . 5-12 5.10 initial operation . . . . . . . ....
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W ebasto t hermo 300 1 i ntroduction 1-1 1. Introduction 1.1 scope and purpose this manual is intended to support authorized webasto trained distributors, dealers and personnel in the installation and servicing of thermo 300 coolant heaters. Webasto thermosystems, inc. Does not recommend the install...
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1 i ntroduction w ebasto t hermo 300 1-2 in the vicinity of the coolant heater, a temperature of 185 °f (85 °c) must not be exceeded under any circumstances (e.G. During body paint work). A violation of this temperature limit may cause permanent damage to the electronics. When checking the coolant l...
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2 g eneral d escription 2-1 1 combustion air fan 2 motor 3 electronic control unit 4 electronic ignition coil 5 ignition electrodes 6 water pipes 7 fuel nozzle the webasto thermo 300 heater has been designed for use on large displacement diesel engines where a high degree of operational flexibility ...
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2 g eneral d escription w ebasto t hermo 300 2-2.
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W ebasto t hermo 300 3 f unctional d escription 3-1 3. 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 ”switc...
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3 f unctional d escription w ebasto t hermo 300 3-2.
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W ebasto t hermo 300 4 t echnical d ata 4-1 4. Technical data 4.1 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 compone...
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4 t echnical d ata w ebasto t hermo 300 4-2 4.2.1 thermo 300.102 heater dimensions fig. 4-1 thermo 300.102 heater dimensions.
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W ebasto t hermo 300 4 t echnical d ata 4-3 circulation pump volume flow l/h (us. Gal/min) nominal voltage v operating voltage range v nominal power consumption w dimensions of coolant pump length width height hose connection o.D. Weight kg (lb.) u 4814 5200 (22.9) against 0.15 bar 24 20 ... 28 104 ...
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4 t echnical d ata w ebasto t hermo 300 4-4 4.3.2 coolant circulation pump u4852 dimensions fig. 4-3 coolant circulation pump u4852 dimensions fig. 4-4 pump u4852 operating data.
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W ebasto t hermo 300 5 i nstallation 5-1 5. Installation 5.1 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 ...
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5 i nstallation w ebasto t hermo 300 5-2 5.5 exhaust pipe connection rigid exhaust pipe is recommended in installations where the use of an exhaust deflector is not suitable. The exhaust pipe must have a minimum internal diameter no less than 2 3/4” (70mm) and a length no greater than 16’ (5m). The ...
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W ebasto t hermo 300 5 i nstallation 5-3 for a straight connection, order a straight adapter under part number 101377 and snap it onto the combustion air inlet and attach air ducting. In the event there is insufficient room for a straight attachment, a 90° snap-on fitting (p.N. 101404) and an adapte...
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5 i nstallation w ebasto t hermo 300 5-4 fig. 5-1: supplemental heating schematic 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. ...
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W ebasto t hermo 300 5 i nstallation 5-5 fig. 5-3: engine 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 ti...
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5 i nstallation w ebasto t hermo 300 5-6 fig. 5-4: example of heater installation 5.7.4 example of a heater installation thermo 300 in enclosure.
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W ebasto t hermo 300 5 i nstallation 5-7 5.8 fuel system 5.8.1 general information the fuel is drawn from the vehicles fuel tank through a fuel standpipe. This standpipe can be utilized on vehicles with a spare threaded port as shown in figure 5-5. The webasto heater utilizes 37° flare jic fuel conn...
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5 i nstallation w ebasto t hermo 300 5-8 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...
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W ebasto t hermo 300 5 i nstallation 5-9 5.9 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. 5.9.2 timer and...
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5 i nstallation w ebasto t hermo 300 5-10 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. Use eyelet (901.038) supplied with coolant pump harness kit...
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W ebasto t hermo 300 5 i nstallation 5-11 5.9.5 wiring diagram - with switch fig. 5-9: wiring diagram with switch.
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5 i nstallation w ebasto t hermo 300 5-12 5.9.6 wiring diagram - with 7-day digital timer model 1531 fig. 5-10: wiring diagram with timer model 1531.
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W ebasto t hermo 300 5 i nstallation 5-13 5.10 initial operation 1. Check your installation for: - loose nuts and bolts. - exhaust pipe routing and clamp tightness. - loose hose clamps. - routing and securing of wiring and heater hoses. - kinked or pinched hoses. - battery connection and polarity. 2...
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5 i nstallation w ebasto t hermo 300 5-14 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 covera...
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W ebasto t hermo 300 6 b asic t roubleshooting 6-1 6. Basic troubleshooting 6.1 general information this section describes troubleshooting procedures for the thermo 300 coolant heater. Troubleshooting is normally limited to the isolation of defective components. 6.2 operational malfunction symptoms ...
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6 b asic t roubleshooting w ebasto t hermo 300 6-2 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...
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W ebasto t hermo 300 6 b asic t roubleshooting 6-3 failure symptom 1x flash (f 01) no combustion after completion of start up sequence 2x flashes (f 02) flame out during burner operation and no restart possible 3x flashes (f 03) low voltage for more than 20 seconds 4x flashes (f 04) flame detector r...
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6 b asic t roubleshooting w ebasto t hermo 300 6-4 6.4 reading and removing malfunction codes stored in memory with the webasto pc diagnostics kit and adapter it is possible to read and remove (reset) stored malfunction codes from the thermo 300 memory. This is achieved through the use of a diagnost...
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W ebasto t hermo 300 6 b asic t roubleshooting 6-5.