AR83.70-S-5940A Removing and installing heater control module 29.3.

96
MODEL 638.0 /1 /2 up to 15.11.97 with CODE (H12) Hot water auxiliary heater

1 Screws
2 Protector screw
3 Support plate

A72 Control module

A72.1 Control module connector

S83.70-2009-06

ed Removal, installation
1 Disconnect ground lead from battery i Installation: Code radio and set clock AR54.10-S-0005A
See @
Owner's Manual l
a Danger! Fuel vapors present an explosion hazard. Do not start up or operate stationary heaters AS83.70-Z-0002-01A
Combustion gases are toxic when inhaled. or engines with heater boosters in closed
Heater can cause severe burns during and rooms or in the vicinity of service stations.
after operation Allow heater to cool off after operation and
wear protective gloves.
2 Lower heater with bracket AR83.70-S-5330-01A
n *BA83.70-N-1005-01A
3 Unscrew screws (1)
4 Remove protective lid (2)
5 Disconnect connectors (A72.1)
6 Disconnect support plate (3) control module
(A72)
7 Reinstall in opposite order
8 Carry out an function test AR83.70-S-5302-02A
n Auxiliary heater

Number Designation Model

638

BA83.70-N-1005-01A Support on floor assembly Nm 8

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AR83.70-S-5980A Removing and installing the heater temperature controlled cut-out 28.3.96
MODEL 638.0 /1 /2 up to 15.11.97 with CODE (H12) Warm water auxiliary heater
D5W or B5W

1 Coolant hoses
2 Connector box
3 lClamp

B95 Temperature controlled cut-out

B95.1 Two-pin plug-in connection

S83.70-2005-06

ed Removal, installation
1 Disconnect the ground cable from the battery i Installation: Code the radio AR54.10-S-0005A
Set the clock
Refer to @
Owner's Manual l
a Danger! Risk of explosion due to fuel vapors Do not put stationary heater or engine with AS83.70-Z-0002-01A
igniting, risk of poisoning due to heater booster into operation in confined
combustion gases and risk of injury from spaces or while refuelling. Allow heater unit
burns during and after heater operation. to cool down after operation and wear safety
gloves.
a Danger! Danger of severe burns to skin and eyes Open cooling system only when coolant AS20.00-Z-0001-01A
from hot coolant spewing out. Coolant is temperature is below 90 °C. Open cover
toxic when swallowed slowly and reduce pressure. Do not fill
beverage containers with coolant. Wear
protective gloves, protective clothing and
protective goggles.
2 Eliminate the pressure from the coolant
circuit
3 Lower the heater with support AR83.70-S-5330-01A
n *BA83.70-N-1005-01A
4 Disconnect the coolant hoses (1) with clamp l *000589543700
(3)
5 Remove the connector box lid (2) i Installation: Make sure the joints are AR83.70-S-5940-01A
correctly seated
6 Disconnect the plug-in connection (B95.1)
7 Unscrew the temperature controlled cut-out i Collect any coolant
(B95) in a suitable container
i Installation: grease the joint of the *BR00.45-Z-1015-06A
temperature controlled cut-out
n *BA83.70-N-1002-01A
8 Reinstall in opposite order
a Danger! Accident hazard resulting from vehicle Secure vehicle against starting to move AS00.00-Z-0005-01A
starting to move by itself with engine running. unintentionally.
Danger of injury resulting from pinching and Wear closed and tight fitting work clothing.
burning when reaching in during the starting
Do not touch hot or rotating parts.
operation or with the engine running.

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9 Start up the engine; purge the air from the Heat the engine with variable revolutions for
cooling and heating system. approximately 1 minute.
Continuously fill with coolant until it reaches
the upper mark on the coolant filler neck.
a Gefahr! Risk of explosion due to fuel vapors Do not put stationary heater, auxiliary heater AS83.70-Z-0002-01A
igniting, risk of poisoning due to inhaling or engine with heater booster into operation
combustion gases and risk of injury from in confined spaces or while refuelling. Allow
burns during and after heater operation. heater unit to cool down after operation and
wear safety gloves.
10 Stop the engine
11 Carry out an operation test AR83.70-S-5302-02A
n Independent heater

Number Designation Model

638

BA83.70-N-1002-01A Temperature controlled cut-out in heat exchanger Nm 3

box

BA83.70-N-1005-01A Support on floor set Nm 8

000 589 54 37 00

Clamp

Repair materials

Number Designation Order number

BR00.45-Z-1015-06A Vaseline -

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AR83.70-S-5335A Removing heater from support 29.3.96
MODEL 638.0 /1 /2 up to 15.11.97 with CODE (H12) Hot water auxiliary heater

1 Air intake muffler for combustion

2 Exhaust gas system
3 Clamp
4 Support

A34 Hot water auxiliary heater

A72 Control module

S83.70-2013-03

ed Removal, installation
1 Remove heater with support AR83.70-S-5330A
2 Remove exhaust gas system (2) from AR83.70-S-7000A
support (4)
3 Remove control module (A72) from support AR83.70-S-5940A
(4)
4 Remove cable clamp, remove clamp (3), i Installation: replace the cable clamp
remove hot water auxiliary heater (A34) from
support
5 Reinstall in opposite order

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AF83.70-S-6400A Stationary, auxiliary heater does not operate occasionally 20.5.98
MODEL 638.### ## as of 41715 up to 95807 with CODE (H12) Hot water auxiliary heater

Revisions

26.2.99 Supersedes STIV no. 83.70-015 dated 18.2.99 and

STIN no. 83.70V001 dated 15.2.99

Damage code Cause Remedy

83 513 90 Control module defective 1 Replace control module. AR83.70-S-5940A
p Affected control modules can be ordered
i Overheat protection trips from GLC Germersheim specifying Index 05
i Return defective control modules to GLC
Germersheim specifying part number (with
Index 06).
Parts ordering notes

Part no. Designation Quantity

000 446 34 29 05 Control module B5W 638 835 09 01 with "Heatmatic" as required
000 446 35 29 05 Control module D5W 638 835 08 01 without "Heatmatic" as required
000 446 36 29 05 Control module D5W 638 835 10 01 with "Heatmatic" as required
000 446 46 29 05 Control module B5W 638 835 07 01 without "Heatmatic" as required

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AD83.70-S-3004A Heater booster (HB) diagnosis operational check 18.8.98
MODEL 638 with ENGINE 611.980
with CODE (MQ3) Engine OM611 DE22 A (60 kW)
with CODE (MQ4) Engine OM611 DE22 LA (75 kW)
with CODE (MQ5) Engine OM611 DE22 LA (90 kW)
MODEL 638 with ENGINE 611.980 with CODE (HZ5) Hot water auxiliary heater 10 kW with timer

a Danger! Risk of explosion due to fuel vapors, risk of Do not put stationary heater or engine with AS83.70-Z-0002-01A
poisoning from combustion gases and risk heater booster into operation in confined
of injury from burning during or after heater spaces or in the vicinity of tank installations.
operation Allow heater unit to cool down after operation
and wear protective gloves.
Heater booster (ZUH) diagnosis, previous AD83.70-S-2002A
knowledge
ZUH function notes AD83.70-S-2002-04A
Function control
Scope of test Operation/requirement Specified value Possible cause /
remedy
1 Engine: RUNNING AD83.70-S-6002-02A
Switching heater
booster on and off via Sufficient fuel in tank
climate control
pushbutton control unit Press heater booster switch (A20s6) on Display illuminated in climate control
climate control pushbutton control unit pushbutton control unit and heater booster
switches on

Press heater booster switch (A20s6) on Display goes out and heater booster turns
climate control pushbutton control unit again itself off
Run-on time of the air blower: 120sec.
Not available if no fuel has been drawn

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PE83.70-S-2001D Wiring diagram of auxiliary heater (AHE) 27.10.97
MODEL 638.014 /034 /064 /074 /114 /134 /164 /174 /214 /234 /244 /274 as of 23.4.98 with CODE (H12) Warm water auxiliary
heater

S83.70-0042-09

PE83.70-S-2001-99D Wiring diagram auxiliary heater (AHE) PE83.70-S-2001-99D

PE83.70-S-2001-60D Legend of wiring diagram auxiliary heater PE83.70-S-2001-60D
(AHE)
OV00.01-N-1901-03A Use of wiring diagrams OV00.01-N-1901-03A
OV00.01-N-1901A Search aid through all wiring diagram groups OV00.01-N-1901A
OV00.01-N-1001-27A Abbreviations for wiring diagrams OV00.01-N-1001-27A
GF00.19-S-1100A Arrangement and assignment of plug GF00.19-S-1100A
connections and sockets
GF00.19-S-2000A Arrangement and assignment of ground GF00.19-S-2000A
points
GF00.19-S-3100A Arrangement and assignment of terminal GF00.19-S-3100A
blocks
PE00.19-S-1100A Survey of wiring diagrams covering all Connecting wiring diagrams PE00.19-S-1100A
function groups
GF54.15-S-1255FA Assignment and cable connections of fuse i see microfilm group 54 GF54.15-S-1255FA
blocks Valid for model designation 638.244
GF54.15-S-1255GA Assignment and cable connections of fuse i see microfilm group 54 GF54.15-S-1255GA
blocks Valid for all model designations except
638.094/194/244/294 as of 23.4.98

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