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DOC P/N 5000940A KIT P/N 5000937A Printed in USA Webasto Product N.A., Inc.

Thermo 50 Coolant Heater

Table of Contents

HMMWV6.2 and 6.5 Liter Diesel

Special instructions for these modelsPart locations may differ slightly dependent on the vehicle model.

ForewordParts List 3Vehicle Information 3Scope and Purpose 3Symbol Identification 4General References 5Preparation 5Heater Installation Site 5

InstallationElectrical - Overview 6Swingfire Heater Component Removal 7Heater Preparation and Mounting 8Integration into the Coolant System 9Integration into the Fuel System 12

Exhaust System Installation 13Electrical Harness Connections 14Power Connection 15

ConclusionProgramming Digital Timer 16Final Inspection, Initial Start-up and Concluding Work 17Heater Lockout Reset Procedure 18Thermo Top 50 Overview 19Thermo Top 50 Fault Codes 20Thermo Top 50 Diagnostic Flow Chart 21Electrical Wiring Schematic 24Service Parts 25

– 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.

3

HMMWV Coolant Heater

Parts List

Vehicle Information

ForewordThis 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 PurposeThese 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 installationdocument 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.

ATTENTIONAll relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary heating devices must be observed!

CAUTIONLocation 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.

Quantity Part Part Number

1 Heater Kit (with installation hardware) 5000937A

Manufacturer Model Year Engine Type

AM General HMMWV N/A 6.2 Liter6.5 Liter

4

Coolant Heater HMMWV

Symbol Identification

Symbols that define sections in manual

Mechanical Preparation

Electrical

Coolant

General Symbol Descriptions

Warning

Caution

Flammable or Combustible

Fuel

Exhaust

Combustion Air Intake

Refer to Webasto or Manufacturer Manual

Attention

Line of Sight/Item Location on Vehicle


5

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

ATTENTION The Webasto Auxiliary Coolant Heater is to be installed under the hood and behind the washer bottle.

– (1) Webasto Auxiliary Coolant Heater (Installed)

1

Fig. 1

6


Electrical - Overview

ATTENTIONThe 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


7

Swingfire Heater Component RemovalIf 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

– (2) Swingfire Heater Coolant Connections

– (3) Swingfire Heater Water Pump

Connect the engine coolant outlet hose to the heater core inlet hose.

– (4) Engine Coolant Outlet Hose

Fig. 2

1

Fig. 3

2

Fig. 4

3

Fig. 5

4

8


Heater Preparation and MountingInstall heater mounting bracket on heater with three self tapping screws supplied.

– (1) Heater Mounting Bracket– (2) Self Tapping Screws– (3) Webasto Heater

Connect heater air intake tube, and wiring harness to heater.

– (4) Air Intake Tube– (5) Heater Harness

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

CAUTIONCheck 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) Webasto Heater– (1) Heater Mounting Bracket– (9) Vehicle Cowling

Fig. 6

2

1

3

Fig. 7

4

5

Fig. 86 7 8

3

1

9 Fig. 9


9

Integration into the Coolant System

ATTENTIONTorque 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.

ATTENTIONClamp vehicle coolant hose with hose clamping pliers prior to cutting to prevent coolant spillage.

Fig. 10

10


Remove two flanges from back of cylinder heads.

– (1) Flange Location– (2) Back of Cylinder Head

ATTENTIONApply gasket sealant to new coolant fittings before installing on engine block.

Install supplied coolant fittings, flanges, and gaskets with existing vehicle hardware.

– (3) Supplied Coolant Fittings

ATTENTIONTighten 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.)

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

2

1

Fig. 11

3

Fig. 36

3

Fig. 37

5

3

4 6

3 7

8

5 Fig. 14

9


11

Connect inlet hose to water pump and secure with hose clamp.

– (1) Webasto Heater Inlet Hose– (2) Heater Water Pump– (3) Hose Clamp

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.)

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

Fig. 15

1

32

74

Fig. 16

645

8

Fig. 17

12


Integration into the Fuel System

Fuel Pump InstallationInstall heater fuel pump on vehicle bulkhead as shown in Figure 18.

– (1) Heater Fuel Pump– (2) P-Clamp– (3) Drill hole 8.0 mm (5/16 in.)– (4) Bulkhead

Fuel Line ConnectionsATTENTIONAlways 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.

Tighten fuel line clamps to 1.0-1.4 Nm (8.8-12.4 lb-in.).

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)

ATTENTIONFuel flow through the vehicle fuel filter is identified by the arrows marked on the filter body.

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

ATTENTIONRoute fuel line from fuel tee to inlet side of heater fuel pump and cut to length. Secure fuel line with nylon wire ties.

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

Fig. 18

32 41

Fig. 19

5 6

7

8

5 Fig. 2010

9

7

Fig. 21

7 6

5


13

Exhaust InstallationRemove Swingfire exhaust guard and exhaust tube, if equipped.

– (1) Exhaust Tube– (2) Exhaust Guard

ATTENTIONEnsure 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

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.

Install exhaust guard.

– (5) Exhaust Tube Covered With Heat Protective Sleeving– (2) Exhaust Guard

1

Fig. 22

2

Fig. 23

3 4 5

Fig. 24

5

2

14


Electrical Harness ConnectionsCut 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

CAUTIONCheck behind cowling for obstructions before drilling hole.

Route heater control harness through cowling, using grommet provided, into vehicle interior.

Apply sealant to grommet.

Timer InstallationCAUTIONCheck 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

Fig. 25

1

Fig. 26

Image Not Available

Fig. 27

2 3 4 5


15

CAUTIONEnsure 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.

Power Connection

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

Ground Connection

Connect the brown ground wire from heater control harness to alternator ground location.

– (3) Heater Control Harness Ground– (4) Alternator Ground Location

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

Fig. 28

1

2

Fig. 29

3

4

16


Programming Timer

Concluding Work – Check that all hose lines, hose clamps, pipe clips and electrical connections are secure. Secure all loose lines

and cables with nylon cable ties.– Spray the heater components and electrical connections with an anti-corrosive wax coating.– Install all vehicle parts, panels and components removed during heater installation.

Press and hold for 2 seconds.Time of day will start flashing.

Press Or To adjust time setting.Once time is set, release button.

Flashing will stop after 5 seconds and dayof the week will begin flashing.

Press

Press

Setting the Time and Day of the Week:

Operating Heater in Manual Mode:

Or To select day of the week.Once set, wait for flashing to stop.

To turn the heater on.The operation indicator will light up.

To turn the heater off. The operation indicator light will go out.

Day of the week

On/OffOperationIndicator

Day/TimeAdvanceButton

Day/Time

ButtonReverse

Heater

ButtonOn/Off

Program

ButtonSelection

ClockButton

Timer MemoryLocation

Alarm

Time of Dayand TimerDisplay

Programming Heater Starting Time:

Recalling or cancelling a programmed start time:

Press

Press

Press

Press

Press

To begin timer programming.The timer memory location number startsflashing. Continue to press button until

the desired memory location 1, 2 or 3 is visible.

Or

Or

To adjust start time setting.Once start 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.Heater will start on the time

and day selected. Once set, wait for flashing to stop. To program the other 2 memory locations, repeat theabove 3 steps for each memory location.

To cycle through memory locations.Any one of the 3 memory locations can

be activated each time the button is pressed. Afterselecting the memory location you desire, you willbe able to change the day and time setting if desired by repeating steps 1, 2 and 3 above.

repeatedly until no memory location number is visible on timer display.

Webasto Product N. A., Inc.15083 North RoadFenton MI, 48430Technical Assistance: 1-800-555-4518 (USA) 1-800-667-8900 (CAN)www.webasto.us


17

Final Inspection Initial Start-up and Concluding Work

Connect battery ground terminal

Final InspectionInspect 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-up1 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.

ATTENTIONMore 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.

ATTENTIONEngine 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.

18


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


19

Thermo Top 50 - OverviewCAUTIONTroubleshooting requires comprehensive knowledge about the structure and theory of operation of the ThermoTop heater. Troubleshooting and repairs may only be performed by Webasto trained and certified, professionals.

Functional Description - Thermo TopSwitch OnPush 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 OperationWhen 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 OffPushing 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.

20


Thermo 50 - Fault Codes

ATTENTIONThe 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.

ATTENTIONThis 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.

Fault Code Description Possible causeF01 No Start-up • Fuel Supply

• Restricted Air Flow Through Intake or Exhaust

F02 Flame Extinguished • Fuel Supply• Restricted Air Flow

Through Intake or Exhaust

F03 Under / Over Voltage • Vehicle Charging System

F04 Premature Flame Detection • Replace Heater

F05 Circulating Pump Interruption or ShortCircuit

• Open or Shorted Wiring• Defective Pump

F06 Temperature Sensor Interruption or ShortCircuit

• Replace Heater

F07 Metering Pump (fuel pump) Interruptionor Short Circuit

• Open or Shorted Wiring

F08 Combustion Fan Motor Interruption, ShortCircuit or Incorrect Fan Speed

• Replace Heater

F09 Pencil Type Glow Plug / Flame DetectorInterruption or Short Circuit

• Replace Heater

F10 Overheating Condition • Coolant Flow Restriction• Circulation Pump


21

Thermo Top 50 - Diagnostic Flow ChartATTENTIONTroubleshooting 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 StepsAfter 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. 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.

2. Cycle switch off and then back on once more. Remove fuse F1 once again and reinsert after 5seconds. 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

YES

Check for 24V on signal at heater connector X1, pin 3 with timer/switch on.

Did heater attempt to start?(Combustion fan running)

Check for 24V at heater connector X2, pin 1.

Check for ground at heater connector X2, pin

Replace Thermo Top

Repair or replace harness, connectors, fuses, or timer/switch accordingly.

Repair or replace harness, connectors, connections or fuses accordingly.

Repair or replace harness, connectors or connections accordingly.

Continued on page 22

22


Thermo Top 50 - Diagnostic Flow Chart

Is combustion air intake free from damage and

obstructions?

Is combustion exhaust pipe free from damage and

obstructions?

Does fuel pump operate (clicking) during start-up cycle

approx. 30 sec. after switching on?

Repair/replace air intake tube or remove obstruction

accordingly.

Repair/replace exhaust pipe or remove obstruction

accordingly.

Connect test light to fuel pump leads (leads connected

normally).Does the light blink

slowly after 30 sec. of switching the heater

on?

Is fuel pump harness free of

damage?

Repair or replace harness

accordingly.

Replace heater.

Reconnect fuel pump and turn heater on. After 30 sec.

lightly tap fuel pump.Does fuel pump begin to

operate (Click).

Replace fuel pump.

System should resume normal operation. Pump may have

been stuck due to dirt in fuel or long periods of no

operation.

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?

Perform visual check of fuel pump. Is fuel moving through the fuel line with each pulse

of the fuel pump?

Repair/replace damaged or obstructed fuel lines. Tighten loose fuel line clamps. Fill fuel

tank with sufficient fuel to reach fuel standpipe inlet.

Continued on page 23 Replace fuel pump.

NO

YES

23


Thermo Top 50 - Diagnostic Flow Chart

CAUTIONAllow heater to cool down before disassembly of coolant circulating pump. Allow heater to cool down before attempting to restart.

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 coolant circulating pump.

Problem resolved. Test

run heater.

Replace heater.

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.

NO

YES

24


SCHEMATICWITHDIGITALTIMER

RELEASED5/7/03G.MILLER

HEATER

DWGNO:908268A

B2

E M1

M2

X1CONNECTOR6-WAY

CERAMICIGNITER/FLAMESENSOR

COMBUSTIONAIRFAN

COOLANTCIRCULATIONPUMP

TEMPERATURESENSOR

FUELPUMP

Y1

X3CONNECTOR2-WAY

5AFUSE

F2

15AFUSE

F1

CONNECTOR2-WAY

X7

X2CONNECTOR2-WAY

X4CONNECTOR2-WAY

CONNECTOR2-WAY

X5

ONSIGNALTOHEATER

M

M2

M1

M

1

E

X3

21

B2

41

52 3

6

1

2 2

1 1 2

1 2

X1

X2

X3

X4

X5

CONTROL

Y1

F1

F2

BLUE18GA

BLACK18GA

RED12GA

RED14GA

+ -

A B

654312RED14GA

21

X4

21

X5

2

X7

X8

X1

X2

X8CONNECTOR1-WAY

BROWN18GA

GREEN18GA

-HMMWV

WEBASTOTHERMO50

BROWN12GA

ON/OFFSWITCH-TOGGLE

S1

AB

CD

EF

X9FUSEHOLDER

X9

A FEB

CD

X1

12

3

456

12

AB

X8

X2

X7

X3,X4andX5

INTERNALTO

HEATER

X9

MATINGENDSHOWN

COMPUTERDIAGNOSTICSDOWNLOADLINK

INDICATOR/DIAGNOSTICLIGHT+

FUELPUMP+

BATTERY+FUSEDPOWER

BATTERY-

YELLOW18GA

BROWN14GA

BROWN18GA

1282

11

BLK

GRY

RD

BRN

Dig

ital

Tim

er

25


Service Parts

1 2 3 4 5

68 7

9

Item Quantity Part No. Description Remarks1 1 50126840A Formed Heater Hose2 3MT 901073 Heater Hose 5/8” I.D.3 2 5000939A Gasket4 2 901136 Elbow Fitting 3/4 MNPT x 3/4 BARB 90 Degree5 1 355240 Tee6 1 669088 Hose Coupler7 1 900611 Hose Coupler8 12 901097 Hose Clamp9 2 5000938A Flange Adapter

26


Service Parts

Item Quantity Part No. Description Remarks1 1 50900126A Exhaust Tube2 1 5000413A Heat Protective Sleeving3 10 147249 Screw M6x204 20 35814A Washer M65 10 277142 Locknut6 1 18137A Exhaust Grommet7 1 20965A Exhaust Clamp8 1 405256 Exhaust P-Clamp

21

345678

27


Service Parts

Item Quantity Part No. Description Remarks1 1 50000064B Heater Control Harness2 1 85002A FP Harness Connector Housing3 2 32099A FP Harness Weather Seals4 2 85004A Terminal End5 1 905002 Grommet6 5 901686 Electrical Connector7 1 901038 Ring Terminal 3/8”8 1 901743 Ring Terminal 1/4”9 1 906218 Timer Mounting Bracket Mounting hardware included10 1 905798 Digital Timer Harness included

1

2

4

5

6

7

8

3

910

28


Service Parts

Item Quantity Part No. Description Remarks1 1 118978 Fuel Line Tee2 2 600146 Worm Clamp3 4MT 50483931A Fuel Line4 1 5023298A Air Intake Tube5 20 620404 Nylon Cable Tie6 5 484032 Fuel Line Connector7 10 330027 Hose Clamp

2

7

1 3

5

4

6

29


Service Parts

Item Quantity Part No. Description Remarks1 1 97359A Thermo 50 Coolant Heater KIT - Includes items 2-42 1 87394B Heater Mounting Bracket3 1 21499A P-Clip Used to mount fuel pump4 1 89373A Fuel Pump

1

2

3

4

30


Service Parts

Item Quantity Part No. Description Remarks1 1 98234A Burner (Diesel) With screws and gaskets2 1 98235A Combustion Air Fan3 1 98236B Burner Head + Heat Exchanger +

Control Unit - 24 VWith screws, gaskets and sealants

4 3 86889B Screw - EJOT PT 10 DG 60x18 For fastening bracket to heater5 1 93011C Pump Housing (193 Degree)6 1 93012C Pump Housing (Axial)7 1 98237A Circulation Pump - 24V U4847 With seals and screws

3

67

21

5 4

31


NOTES:

Webasto Product N.A., Inc.Technical Assistance HotlineUSA: (800) 555-4518Canada: (800) 667-8900

www.webasto.usOrg. 8/2004 Rev. N/A P/N 5000940A

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