BULLETIN NUMBER: 2491 (Rev.

01)
DATE: January 13, 2020 (previously released October 03, 2018)

PRODUCT: All machines equipped with Webasto

SERIAL NUMBER: All machines equipped with Webasto

SUBJECT: Webasto System Updates, Diagnostics and Best Practices

DESCRIPTION: This document serves to update all Webasto systems and provide dealers and
customers a tool to diagnose common faults maintain good system practices.

Please note this document references Webasto’s online technical documentation. Reference their
website for full details on manufacturer’s product. Tigercat encourages its dealers to share this
information with their customers.

Website: http://www.techwebasto.com

PROCEDURE:

Before starting work, read and follow all “servicing safety precautions” as listed in the
machine and attachment operating/service manuals and parts catalogs

REVISIONS
Rev 01 Added section 11 – Common faults - TIMER COUNTDOWN WITH NO HEATER ACTIVITY
(Thermo pro 90 model only)

Page 1 of 31
TABLE OF CONTENTS

TABLE OF CONTENTS......................................................................................................................... 2
TABLE OF FIGURES ............................................................................................................................ 2
1. PC DIAGNOSTIC TOOL ................................................................................................................ 3
2. AIR INTAKE ROUTING .................................................................................................................. 4
3. TIMER PROGRAMMING ............................................................................................................... 6
4. LOW VOLTAGE DISPLAY ADJUSTMENT ................................................................................... 10
5. LOCKOUT RESET PROCEDURE................................................................................................ 13
6. FUEL SYSTEM ............................................................................................................................ 14
7. REMOTE TANK / KEROSENE ..................................................................................................... 18
8. C02 ADJUSTING SCREW (for Thermo 90ST models only) .......................................................... 19
9. MAINTENANCE SCHEDULE ....................................................................................................... 20
10. COOLANT CIRCUIT..................................................................................................................... 22
11. COMMON FAULTS (REV.01) ...................................................................................................... 29
11.1 Timer countdown with no heater activity (Thermo pro 90 model only).................................... 29

TABLE OF FIGURES

Figure 1: Webasto Intake Hose Routing - 822 / 830 .............................................................................. 4

Figure 2: Webasto Intake Hose Routing - 845/855 ................................................................................ 5
Figure 3: Webasto Intake Hose Routing - 870 ....................................................................................... 5
Figure 4: Webasto Intake Hose Routing - 875/880 ................................................................................ 6
Figure 5: Recommended fuel connection point .................................................................................... 15
Figure 6: Recommended fuel connection point .................................................................................... 15
Figure 7: heater control knob ............................................................................................................... 20
Figure 8: 45046AENG label for 1x shutoff valve .................................................................................. 23
Figure 9: 54832AENG label for 2x shutoff valves ................................................................................. 23

Page 2 of 31
1. PC DIAGNOSTIC TOOL
Ensure the following Webasto diagnostic tool is available when performing this PSB. Further details
found on the Tigercat dealer website; search the word “tool” in the “Service and Warranty” section.

Diagnostic tool: 213142

Diagnostic to machine harness adapter: 213143

Page 3 of 31
2. AIR INTAKE ROUTING
***Refer to PSB2506 for affected machine range and details for reimbursement***

A. Tigercat has identified in some instances, exhaust gases from the Webasto heater may
recirculate in the intake because of the close proximity of the two orifices. As a result, burnt
carbon may enter the combustion chamber over time and restrict the airflow rendering the unit
inoperative.

B. Order the following intake hose to reduce this effect and route as shown on the different machine
models while re-using existing hardware. Gently secure and DO NOT OVERTIGHTEN zipties on
hose to prevent any rupturing.

C. If the intake hose is already 1 meter in length as illustrated below, the machine is already up to
date and no action is required.

D. The new Tigercat one meter long intake hose part number 221962 can be installed on the
following machine “C” and “D” series models that are equipped with Webastos: 822/830, 845/855,
860/870, 875/880.

Figure 1: Webasto Intake Hose Routing - 822 / 830

Page 4 of 31
Figure 2: Webasto Intake Hose Routing - 845/855

Figure 3: Webasto Intake Hose Routing - 870

Page 5 of 31
 Figure 4: Webasto Intake Hose Routing - 875/880

3. TIMER PROGRAMMING
As a safety precaution, Tigercat sets all Webasto timers to “manual” when leaving the factory so they do
not start automatically while in transit to its destination. As such, dealers and customers must program
the Webasto timers upon delivery. Webasto’s online documentation outlines the following procedures;
please visit their website for full details.

Page 6 of 31
For older Thermo 90ST Webasto models:

Page 7 of 31
For new Thermo Pro 90 Webasto models:

Page 8 of 31
Page 9 of 31
4. LOW VOLTAGE DISPLAY ADJUSTMENT
If the Webasto SmarTemp Control fx display shows a “Low Voltage” fault and the system shuts down the
threshold for the “Low Voltage Disconnection” may be set too high in the SmarTemp Controller. Too
high a setting can lead to premature alarms for the system voltage during normal use of the pre heater.
The following steps explain how to change the LVD setting to a lower level to prevent these alarms.

For Tigercat application, set

the LVD setting to 22 volts.
Instructions on how to
adjust in the following
pages.

Page 10 of 31
1. Turn the SmarTemp Control fx ON. 2. Press the Selection button one more time
to access the main menu.

3. Turn the Rotary Knob Clockwise a couple 4. Then, Turn the Rotary Knob counter
clicks. clockwise to select “Options”.

5. Press the Selection button to enter the 6. Select LVD using the Rotary Knob.
Options page.

Page 11 of 31
7. Enter LVD adjustment by pressing the 8. Turn the Rotary Knob to turn down the LVD
Selection button. threshold.

9. Adjust the LVD threshold to 22.0 Volts 10. Press the Selection button three times to
return to the main page and confirm the
change.

Page 12 of 31
5. LOCKOUT RESET PROCEDURE
The control unit continuously monitors the heater operation. If the control unit identifies consecutive faults
occurring during operation, the heater will shut down. After the cool-down cycle, the heater will turn off.
At that point, the control module may be set in lockout mode.

When the heater is in lockout the control panel will show F00 on the display accompanied by continuous
sets of 5 rapid flashes, or F12 displayed on the display accompanied by 12 slow flashes separated by 5
rapid flashes.

HEATER LOCKOUT RESET PROCEDURE:

4. Plug the wiring

1. Switch the heater harness in at the
ON heater (electronic
control unit)

2. Unplug the wiring

harness at the 5. Switch the heater
heater (electronic off
control unit)

6. Switch the heater

3. Wait 10 seconds
on

7. Rectify the cause of the fault

Page 13 of 31
6. FUEL SYSTEM

Fuel Type
A. Webasto recommends the following fuel types; this will assist the coolant system to work in optimal
conditions during the winter months under very cold temperatures. Alternatively, other brands of
diesel may begin to gel and not have the proper flow characteristics to work with the fuel pump. This
can result in a lack of fuel supplied to the heater therefore locking out the unit.

B. Dealers and Customers should review and compare these fuel types with their diesel suppliers to
ensure the optimal product is used for the application.

HEATER DIESEL
 Diesel according to DIN EN 590
 30 % admixing of petrol in diesel
permitted
 (EL) fuel oil according to DIN51603
Thermo 90ST
 F54 diesel (~ DIN EN 590)
 F34, F35 kerosene
 F58 petroleum
 F63 diesel
 Diesel according to DIN EN 590
 FAME DIN V 51606
Thermo Pro 90
 (EL) fuel oil according to DIN51603

C. It is important to note that very cold temperatures may restrict fuel flow to the filter and pump and
cause a fault for lack of fuel. Under these circumstances, the Webasto may need to be started
several times to prime the system. If the unit becomes locked out, perform the “lockout reset
procedure” to continue priming the system.

Fuel Lines
D. Confirm 2mm I.D. fuel lines are installed from the fuel tank to the Webasto units and order the correct
parts from the Tigercat online parts catalog (TPO) if it is not. Any other fuel line size that is not 2mm
may cause inadequate fuel flow to the filter and pump in colder environments.

E. Ensure the fuel lines are connected as shown in the following illustration to avoid any entrained air
in the system.

Page 14 of 31
Ensure butted fuel lines
Ensure there are no
inside the sleeve in a
kinks in the sleeve to
straight connection to
prevent entrained air
prevent entrained air

Figure 6: Recommended fuel connection point

Figure 5: Recommended fuel connection point

Fuel Priming
F. Use the Webasto PC Diagnostic tool as an alternative to prime the fuel system by following the “fuel
priming” and “fuel pump test” procedure below. Refer to the Webasto online documentation for further
details on the Diagnostic tool.

Page 15 of 31
Page 16 of 31
Page 17 of 31
7. REMOTE TANK / KEROSENE
Tigercat recommends using Kerosene as the primary fuel in machines equipped with a dedicated
Webasto fuel tank. Its lower gel point and cleaner burning capabilities than diesel greatly assists the
system to operate in colder climates. The following units are equipped with a remote tank:
822D, 830D, 855E, 870D, 480B, 470, T726G, M726G.

Page 18 of 31
 8. C02 ADJUSTING SCREW (for Thermo 90ST models only)
On older Webasto models (Thermo 90ST) there is a screw to control the air/fuel mixture into the
combustion chamber. To ensure the unit operates as intended, it is important to ensure the screw is set
correctly with the following procedure. Contact Tigercat Service department if a new unit arrives from
the factory and it is not set correctly.

Procedure: Screw the adjusting screw fully in clockwise and then back out one full turn.

Newer Webasto models (Thermo Pro) do not have an adjusting screw, as they are self-adjusting units.

Air/Fuel adjusting
screw

Page 19 of 31
9. MAINTENANCE SCHEDULE
The following maintenance schedule outlines items to review to help customers keep their units
operating at optimal conditions.

PREVENTIVE MAINTENANCE INTERVAL

1. Clean and remove any debris, snow, ice buildup around the fuel tank
cap. Any restriction preventing the tank to breath properly may cause
Daily
a vacuum to suck the fuel out of the lines overnight preventing the unit
to start the next morning. There are two vent holes present.
2. Inspect/release fuel tank cap valve if frozen in cold temperatures
If valve cannot be thawed, leave cap loose overnight to prevent Daily (during cold
vacuum to suck fuel back to tank and rendering the Webasto fuel temperatures)
system dry.
3. Inspect and clean any debris/buildup near the air intake and exhaust
Daily
outlet.
4. Inspect the coolant pump for any leaks. A few drops are normal upon
Daily
startup under cold temperatures.
5. Inspect timer for any faults and perform lockout reset procedure if
Daily
necessary. Resolve fault afterwards.
6. Set the heater control knob (figure 6 below) inside the cab to the hot
(red) position BEFORE turning the machine off at the end of the shift.
Daily
This will allow coolant flow and prevent Webasto overheat faults if
there is a coolant blockage anywhere else in the coolant circuit
once a month for 20
7. Periodic runtime schedule. minutes (even in the
summer months
8. Clean the exterior of the heater (avoid the ingress of water). 6 months
9. Check the exhaust and combustion air lines for signs of damage and
6 months
to ensure that they are clear.
10. Check overall coolant system including coolant pump is clean, free of
debris and no leaks are present. Check and repair any cracked 6 months
coolant lines.
11. Change fuel filter and check fuel lines for leaks. 1 year
12. Check the electrical connections for corrosion and ensure that they
1 year
are tight and secure.

Figure 7: heater control knob

Page 20 of 31
 2

On Webasto models “Thermo 90ST” there is an air hole at the top of the burner assembly that must be
completely clear in order for the unit to start. Pay particular attention to this area and inspect this if the
unit does not start or a fault has occurred.

In some instances, this orifice may be plugged due to the following reasons:
 The unit has not been operated for a long period
 There has been an accumulation of burnt carbon
 Foreign debris has entered the system plugging the hole

Page 21 of 31
10. COOLANT CIRCUIT
Tigercat has released two labels to notify operators to open the engine coolant valve(s) when using the
Webasto in the summer months to prevent overheating events that may damage the coolant pump seal.

The following serial numbers indicate the production break-in point for these labels and are available to
order if they are not present in the cab beside the Webasto timer on previous models.

# OF
MODEL DRAWING SERIAL NUMBER BREAK-IN POINT
VALVES
822/830 1x 45046A 82213417, 83073189
845/855 2x 54832A 84532666, 85533160
870C/870D 2x 54832A 87013299, 87063599
875/880 2x 54832A 8750597, 8800564
1055/1075/1085 1x 45046A 10751056, 10551006
200 series 2x 54832A 2342850, 2503096, 234T7033, 250T2253
470, 480 1x 45046A 4701022, 4801013
700 series 1x 45046A 7206940, 7244305, 726603, 726T0603,
726M5024
600 NA NA NA

UPDATED COOLANT CIRCUIT

The following serial numbers identify the break-in point for machines updated with a new coolant circuit
with the shutoff valves removed to prevent overheating events. Greater serial numbers do not need to
have the above labels installed.

MODELS SERIAL NUMBER BREAK-IN POINT

1055/1075/1085 10551007, 10751071, 10850538

NOTE:
Current machine coolant circuits have been outlined below for reference.

Page 22 of 31
Figure 8: 45046AENG label for 1x shutoff valve Figure 9: 54832AENG label for 2x shutoff valves

Page 23 of 31
870D CURRENT

822D / 830D
CURRENT

Page 24 of 31
855E / 845D
CURRENT

875/880D
CURRENT

Page 25 of 31
Page 26 of 31
200 GROUP
CIRCUIT

600E GROUP
CIRCUIT

Page 27 of 31
Page 28 of 31
11. COMMON FAULTS (REV.01)

11.1 TIMER COUNTDOWN WITH NO HEATER ACTIVITY (Thermo pro 90 model only)

Symptoms: The timer counts down when setting the duration period but there is no activity
from the heater.

Problem: The 24V “ON” signal is not travelling from the timer, wire YEL 530, to the heater
control module at the head (pin 3 at the 12 pin connector)

Root Cause: There is an electrical short to ground in the circuit between the output of the timer
module and the heater. This drops the 24V “on” signal destined to go to the 12
pin connector at the heater module as it will take the quickest path to ground. The
problem may be caused by but is not limited to a short developed at the solenoid
valve (AT219) or diode (AM1464); replace these components if necessary. The
technician should diagnose the full circuit to validate no other faults are present
between the timer and the heater.

Circuit Description – 800 Series Machines

See schematic details on the next page. The heater “ON” signal from the timer, wire YEL 530,
travels to the 4 pin busbar. From here, it splits to two locations; first one is to the hydraulic tank
water solenoid (item 15) via the diode pack (item 45) and the second location is at the 12 pin
connector at the heater computer module to activate it.

Page 29 of 31
NOTE: The following schematic is for illustrative purposes only and the wire numbers may not
reflect directly what is on your machine. Refer to the specific machine electrical
schematic for specific information

Page 30 of 31
REIMBURSEMENT POLICY: Not Applicable

This Service News Letter presents improvements offered to update machines to the latest
design or technology. These improvements are offered on an optional basis and no
Reimbursement Policy is offered.

Refer to PSB 2506 for reimbursement on the new intake hose installation mentioned in section 2 of
this PSB.

Page 31 of 31