Webasto Thermo Pro 90 D User Manual

Coolant Heater
Thermo Pro 90 D (Diesel)
12 / 24 Volt
Installation Manual
– 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.
– To install and repair Webasto heating and cooling systems you need to have
completed a Webasto training course and have the appropriate technical
documentation, special tools and special equipment. Only genuine Webasto parts
may be used. See also Webasto air and water heaters accessories catalogue.
– Never try to install or repair Webasto heating or cooling systems if you have not
completed a Webasto training course, you do not have the necessary technical skills
and you do not have the technical documentation, tools and equipment available to
ensure that you can complete the installation and repair work properly.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto heating and cooling systems require qualified and/or professional
installation and repair technicians. Warranty shall be void if not installed by a
certified or trained installer/repair technician who has successfully completed the
factory training course for installation and repair of Webasto heating and cooling
systems, and has been provided with the technical information, tools and equipment
required to properly complete the necessary installation /repairs.
– Product produces temperatures high enough to ignite surrounding combustible
materials such as inflammable liquids, gases, vapor, and other combustible matter.
The heater must
be switched off when loading or unloading inflammable materials
to prevent the risk of explosion.

Webasto Thermo Pro 90 D Specifications

General

Brand	Webasto
Model	Thermo Pro 90 D
Category	Heater
Language	English

Summary

Safety and General Information

1.1 Warning Symbols in this Installation Manual

Explains the meaning of DANGER, WARNING, and CAUTION symbols used in the manual.

Regulation for Installation in the Vehicle

2.2 Position of the Heater

Details requirements for heater placement to prevent fire hazards and ensure visibility.

2.3 Fuel Supply

Specifies requirements for the fuel filler neck and warning signs.

2.4 Exhaust System

Outlines positioning requirements for the exhaust outlet to prevent fume entry.

2.5 Combustion Air Inlet

Defines where combustion air must be extracted from and inlet positioning.

2.6 Water Inlet

Specifies requirements for water supply to be heated, including antifreeze.

2.7 Hot Water Outlet

Addresses positioning and protection of hot water hoses to prevent injury or damage from direct contact.

Installation

4.1 Installation Site and Position

Advises on low installation positions for automatic bleeding and following manual instructions.

4.2 Installing the Heater

Details securing the heater with M8 screws and handling the sensitive exhaust temperature sensor carefully.

Mounting the Heater to the Vehicle

6.1 Allowable Mounting Positions

Illustrates permitted mounting positions for the heater enclosure kit and indicates non-permissible positions.

Connection to the Vehicle Cooling System

7.1 General Information

Explains connecting the heater to the vehicle's cooling system and coolant requirements.

7.2 Various Plumbing Configurations

Fuel Supply

8.1 General Information

8.2 Fuel Standpipe Installation

8.3 Fuel Lines

8.4 Fuel Metering Pump

8.4.1 Installation Location

8.4.2 Metering Pump Attachment

8.5 Fuel Filter

Combustion Air Supply

Exhaust System

Electrical Connections

11.1 Power and Control Harness Connections

Covers power supply, fuse holder, and routing of power/control harnesses.

11.2 Connecting the Controls

11.4 Setting Control Temperatures

Initial Start-up

Troubleshooting

14.2 Heater Interlock

14.2.1 Heater Lock out Reset Procedure

14.3 Diagnostic after a Fault Lock-out for the Thermo Pro 90