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Service and Repair Manual DBW 2010 DBW 2020

1. 1 4 51 EP MEE CUTEM 51 9 2 4 2 InstallatlQni see Rx Ete Ap dA cho iba laco t 51 9 2 5 Burner Replacement isses ee hec a ad ae pr ec 51 9 2 5 T REMOVALS s ces desse SA a s o 51 9 2 5 2 Installation CETT 51 9 2 6 Fuel Valve and Solenoid Replacement ouaaa 53 9 2 6 1 RemoVal x ioni Sus o Bop Rab gran ose bali 53 9 2 6 2 Installation EA RID ROLE 53 9 2 7 Fuel Pump Replacement ek eR EXC ames Rabun Rika CAO E RR 53 9 2 7 1 scc abun rares a i SOE pube nd iP i ubl 53 9 2 7 2 ilnstallationi R RER A W AE R EA lo ao vi av 53 9 2 8 Fuel Nozzle 0 54 ELEM CDI 54 9 2 8 2 Installation rage see Rees eee nte einn Erbe an eerie rex ad 54 9 2 9 Flame Detector Replacement onunu annaa 54 9 29 REMOVE xc Sonate sica R lo R Rog soU cus le a utn 54 9 2 9 2 Installation so ces DRE RC Rod naf oe RO doe Rh L ae ee es 54 9 2 10 Ignition Electrodes
2. Legend Indicator Light S1 Toggle Switch TI Timer 7 Day NOI XI 9 Pin Duetsch Connector 2 Additional Jumper Product Information Toggle Switch Detail Wiring diagram ISS Timer with optional Toggle Switch Setting the Timer The ISS timer is a 7 day NOI no operator interface timer This means you can set this timer to specific needs and the timer will do the rest This timer has battery backup and will hold its memory if the vehicle battery is disconnected and will recharge when 12 volt power is restored To set the timer clock Press and hold the Clock button and by pressing the Hour and Min buttons set the clock appropriately In the upper left corner you will see the PM sign Setting the timer On Off functions Press the Timer button one time You will see the screen now reads 1 On using the day button select the appropriate day or days Look in the upper left hand corner for the AM or PM sign Using the day button you can select one or multiple days After you have selected the proper day days and set the appropriate on time push the Timer button once again You should now see 1 Off using the day button select the appropriate days again BE SURE THE DAYS SELECTED MATCH THE SAME DAYS YOU SELECTED FOR TIMER 1 ON Now set the timer to the appropriate Off
3. 1 7 7 55 9 2 10 1 Removal i ee exuere e dudo dA 55 9 2 10 2 MSE ALON Echos o 55 9 2 11 Ignition Coil Replacement 55 9 23 1 1 Remoyvali s ote neta rentes C Roten DAE iu Er sitos 55 9 2 11 2I Stal aEION TS 55 9 2 12 Drive Motor 1 4 54 56 92 121 Cun 56 9 2122 AA a idonee 4 ALINA Aye Rega dean Saku Ue ec 56 9 2 13 Combustion Air Fan Replacement 57 9 2 13 1 RemOV l bspw pr RE e equ RE edu Og rd wd 57 9 2 13 2 INSEAM ATOM oec xbox ede CRURA XR a RUE WURDE og dak oriana 57 9 2 14 Fan Replacement iiis xe ERR ERREUR wea 58 9 2 15 Fan Shaft Bearings and Gearing Exploded View DBW 2010 59 9 2 16 Fan Shaft Bearings and Gearing Exploded View DBW 2020 DBW 300 60 www webasto us 5 Webasto Product N A Inc TABLE OF 5 9 3 9 4 9 2 17 Combustion Chamber Replacem
4. gt A tw SH GK A pi Mer EA Limitations Webasto specifically excludes and limits from warranty the following 4 VE X pe NIST Normal wear of service parts fuel nozzles filters and overheat fuses are not covered Removal and replacement of heater with the exception of the Thermo ira 2 525 O A MN M M 4 59 i i 4 5 Damage to product in transit All claims must be filed with carrier E D A MN EM E ZW Wwe gt Improper installation which is not in accordance with valid supplied installation instructions or E approved OEM applications EW 555 Za 2 i ci eres ES Qs 4 Deterioration due to normal wear corrosion abuse damage accident improper storage or 2 ESTNE operation BA i i AOC lt lt Modification of product by alteration use of non genuine parts or repair by unauthorized pr personnel M De E m ne Economic loss for expenses related to travel vehicle disability personal injury or other B 2776 incidental or consequential damages arising from any breach of this expressed warranty iN ge op spege Em Owner s Responsibilities 1 Service heater at the
5. EL Jeoedg g Jaysem buuds ews g 10 02 55618 IBUSEM ZL buisnou Jaysem buuds Z buu LL buueag 9 ue Vo eb Cb LL Ol 6 8 L 9 amp lt Webasto Product N A Inc 59 Figure 47 Exploded view fan support assembly DBW 2010 www webasto us REPAIR DBW 2010 2020 300 COOLANT HEATERS 9 2 16 FAN SHAFT BEARINGS AND GEARING EXPLODED VIEW DBW 2020 DBW 300 st xX 8 2 N N 9 gt mL gt oY t RB lt U SO VI so De 4 TI 5 NNT O g 00 Oo RA Ps GOCGE c O OM 00 O st U ta n fo em on 3 2c O m gt lt CN ST LO Figure 48 Exploded view fan support assembly DBW 2020 300 Webasto Product N A Inc 60 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 9 2 17 COMBUSTION CHAMBER REPLACEMENT 9 2 17 1 REMOVAL 1 Swing burner head open see Sec 8 5 1 2 Withdraw combustion chamber Fig 50 from heat exchanger and remove Hn NOTE The DBW 2010 burner tube may require careful prying around the parameter of the tube to release it from the heat exchanger see Fig 49 Ad 25 4 DBW 2010 burner tube A removal Carefully pry R out with screw driver Figure 49 DBW 2010 Burner tub
6. 8 Install ignition coil DBW 2010 DBW 2020 300 Figure 45 Drive Motor Assembly Webasto Product N A Inc 56 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 9 2 13 COMBUSTION AIR FAN REPLACEMENT Li 9 2 13 1 REMOVAL 1 Swing open or remove burner head see Sec 9 2 5 2 Move ignition coil out of the way Refer to Sec 9 2 11 for guidance 3 Remove four screws item 6 Fig 45 and withdraw protection cap 1 from burner NOTE For replacement of the combustion air fan the burner may be left installed In removed condition ensure that igniter electrodes are not bent and nozzle is not damaged 4 Disconnect motor leads 5 Remove drive motor see Sec 9 2 12 6 Remove four Allen Socket screws item 1 Fig 46 and washers 2 from motor carrier 3 7 Remove four screws 10 from nozzle holder plate 9 and pull plate free DBW 2010 ONLY 8 Remove lock nut 8 drive gear 7 and washer 6 9 With a hammer and small drift tap fan shaft and fan 4 free from housing 5 Perform further disassembly of shaft bearings and gears if necessary see Sec 9 2 15 DBW 2020 300 ONLY 11 10 Grasp motor carrier item 3 Fig 46 and with a slight rocking motion work the motor carrier and fan with bearing free from housing 5 Perform further disassembly of shaft bearings and gears if necessary see Sec 9 2 16 12 www webasto us 57 REPAIR 9 2 13 2 INSTALLATI
7. Swing burner head open see Sec 8 5 1 nsulation body of the ignition electrodes for damages Electrode spacing with setting gauge according to Fig 23 CAUTION Do nottouch the nozzle drilling A while measuring the electrode spacing Keep the electrode setting gauge clean and free of contaminates SETTING Place setting gauge over nozzle as shown Loosen clamp bolt until electrode can be moved with slight effort If necessary electrodes can be bent slightly to conform to the setting gauge notches Grip with pliers at the bending point only Once set snug up clamp bolt and check electrode spacing once again to confirm setting out clamp bolt Doing so will distort the clamp causing the electrodes to spread apart A CAUTION Do not over tighten or bottom f necessary grip here to bend Setting Gauge 7 k P N 310646 zl 45405 Millimeters Figure 23 Setting of Ignition Electrodes www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 6 2 4 AN A CHECK Li Swing burner head open see Sec 8 5 1 Supply DC voltage to coil leads Positive to black lead and negative to brown lead IGNITION COIL CHECK WARNING some cases high tension voltage of approx 8 000 volts produced at the ignition electrodes can be fatal CAUTION Do not operate the ignition coil without connection to the ignition electrodes Doing so will cause damage to the ig
8. ee Pressure O Regulation R Valve RR Figure 10 Fuel Pump Assembly 2 1 11 FUEL CONTROL VALVE AND SOLENOID 8 The fuel solenoid valve interrupts the fuel supply to the atomizer nozzle when the heater is switched off and during a control pause period When there is no current present the solenoid valve is closed Plunger Valve Sa lt gt Figure 11 Fuel Solenoid Assembly Webasto Product N A Inc GENERAL DESCRIPTION 2 1 12 FUEL NOZZLE AND NOZZLE HOLDER 14 The fuel atomizing nozzle is screwed into the nozzle holder Under pressure the fuel nozzle atomizes the fuel entering the combustion chamber Nozzle Holder Nozzle Figure 12 Nozzle Holder and Nozzle 2 1 13 FUEL LINE CONNECTIONS 25 Fuel lines from the fuel tank are connected to the suction and return pipes of the heater in the case of the DBW 2010 2020 300 The Scholastic Series heater use a single fuel line that is connected to the suction pipe of the heater There isno return fuel line on this model if WY aih Zug gt DI Single Line System gt Scholastic Heater Fuel Pumps Figure 13 Webasto Product N A Inc DBW 2010 2020 300 COOLANT HEATERS 2 1 14 ELECTRONIC IGNITION UNIT 3 The electronic ignition unit develops high voltage of approximately 8000 volts to produce a spark at the tips of the ignition electrodes The electronic ignition unit is only in operation during the starting phase IMP
9. 31 6 2 1 JAdj stmient of CO2 Contents cs ox KE ie RUN ER be e o eros CRGA 31 6 2 2 Flame Detector Resistance 32 6 2 3 Ignition Electrode Check and 0 32 6 2 4 Ignition Coil Check vende pean teased agen pide Daria 33 6 2 5 Fuel Pump Checks SOC 33 6 2 6 Fuel Solenoid Valve 34 6 2 7 Nozzle Block Pre heater 2 4 34 7 Circuit Diagrams 35 71 DBW 2010 12 V and 24 V Early Canadian 35 7 2 DBW 2010 12 V and 24 V Present North American 36 7 3 DBW 2020 300 12 V and 24 V without Nozzle 37 7 4 DBW 2020 300 12 V and 24 V with 2 38 7 5 Scholastic Heater 12 V with On Off 2 22 2 22 2 2 39 7 6 Scholastic Heater 12 V with 7 Day Timer Model 1529 40 7 7 Scholastic Heater 12 V with 7 Day Timer Mod
10. 46 8 7 Removal and Installations sarah nr eek Rh Rx RR RE DX RR Ga RE ETUR E A REO KR RARUS 46 8 7 1 Heater Removal and Installation 2 2 2 46 8 7 2 1 sei T 46 8 7 1 2 Installation brutos on e ona A o i ioio 46 8 7 2 Temperature Limiter 2 2 47 8 7 3 Temperature Thermostat 4 47 8 7 4 Overheat Fuse 4 47 8 7 5 Burner Head Replacement 47 8 7 6 Ignition Coil 47 8 7 7 Flame Detector Photo Eye Replacement 47 8 7 8 Combustion Chamber Replacement naua aa anaa 47 8 8 First Operation arri 47 8 8 1 Water Circuit Bleeding 4 47 8 8 2 Fuel Supply System 0 2 48 Webasto Product N A Inc 4 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS TABLE OF CONTENTS 9 Repair 49 9 1 General I formatiOf lt sacre secs reb n
11. 2 m Maximum permissible priming pressure 0 3 bar for suction and return line 8 6 2 2 FUEL FILTER A fuel filter supplied as deliverable item or cleared for use by Webasto is to be fitted Installation position possibly vertical with horizontal direction of flow To avoid operating malfunctions replace filter or filter cartridge once a year or more often if fuel is contaminated 8 6 3 COMBUSTION AIR SUPPLY CAUTION Observe official regulations A concerning the installation see 1 6 Combustion air must under no circumstances be extracted from rooms with persons The combustion air inlet must not point towards the forward direction of motion It must be located so that no clogging by contamination impact of snow or intake of splash water isto be expected The combustion air intake and exhaust outlet is to be located so that no air pressure difference builds up in any operating condition of the vehicle Webasto Product N A Inc SERVICING The combustion air inlet must be located so that no exhaust fumes can enter If the heater is located near the fuel tank in a common installation compartment combustion air must be taken in from and the exhaust routed to the exterior The feed through holes must be sealed against splash water If the heater is located in a closed installation box a vent port is required DBW 2010 20 cm 3 1 inch DBW 2020 300 30 cm 4 65 inch If the temperature in the in
12. 3 Temperature Limiter Figure 36 Temperature Control Elements www webasto us REPAIR 9 2 4 CONTROL UNIT REPLACEMENT 9 2 4 1 REMOVAL 1 Disconnect all electrical connections from control unit 2 Carefully withdraw control unit from holding clip or slide out with holding clip Fig 37 9 2 4 2 1 Carefully push control unit into holding clip or slide into position with clip attached Fig 37 2 Restore electrical connections INSTALLATION 9 2 5 BURNER REPLACEMENT 9 2 5 1 REMOVAL 1 Disconnect electrical connections on burner and loosen fuel lines 2 Loosen two nuts item 3 Fig 38 until hinge bolts are free 3 Swing hinge bolts 2 open and remove cotter pin 1 4 Remove burner 4 9 2 5 2 1 Position burner 4 Fig 38 for installation swing hinge bolts 2 closed and secure temporarily using hinge bolts 2 2 Insert cotter pin 1 according to the intended opening swing direction 3 Tighten nuts DBW 2010 5 6 Nm 44 53 Ib in DBW 2020 300 7 5 8 5 Nm 66 75 Ib in 4 Connect fuel lines INSTALLATION 5 Restore electrical connections Webasto Product N A Inc REPAIR DBW 2010 2020 300 COOLANT HEATERS 1 Control Unit 1553 2 Holding Clip 3 Burner head Figure 37 Control Unit Removal Installation Cotter pin Hinge Bolts 2 MM Nut 2 Burner head BURN NOTE Depending on the burner head direction of swing the cotter pin
13. 4 3 Permissible Extension of the Connections LL 22 5 Troubleshooting 23 5 1 Quick Check Troubleshooting 2 2 2 2 hh hrs 23 5 2 Tester Instructions Tester P N 1302691 23 esbPrIOCedules ned cpu UP tuus paa ESSERE 23 5 3 Instructions for Fault Finding bise 26 5 31 Combustion Starts Immediately When Heater Is Switched 26 5 3 2 Heater Does Not Start When Switched 26 5 3 3 After Switching ON The Heater Switches OFF after Approx 30 Seconds On 27 5 3 4 Heater Starts Only After Several Starting 5 28 www webasto us 3 Webasto Product N A Inc TABLE OF 5 DBW 2010 2020 300 COOLANT HEATERS 5 3 5 Heater Switches Off By Itself During Operation 43 28 5 3 6 Heater SMOKES iii E SPA od ERU Pope HO UR CROP RIA RR e 29 5 3 7 Heater SMOKES zie exe FE OKA xcu rac e cl Ro 30 5 3 8 Heater Cannot Be Switched 30 6 Functional Adjustments 31 NECI ICD 31 6 2 Adjustments i eo add toe ue IR i Gide E RAD lE RUN hoa
14. Closes at 60 5 C 140 9 F Opens at 70 3 C 158 6 F Control thermostat with red and green wires Closes at 68 5 C 154 9 F Opens at 75 3 C 167 6 F 42 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 8 SERVICING 8 1 GENERAL This section describes the servicing work that can be carried out on the heater when it is installed 8 2 HEATER SERVICING Maintenance of the heater is necessary for proper operation and long life Read and understand the recommendations and procedures explained in this manual before attempting to service or repair If you wish to carry out extensive repair work on the heater it may be a good idea to remove it completely The battery must not be disconnected while the heater is running otherwise the heater will overheat After working on the heating circuit replenish with a coolant mix prepared with water and anti freeze and bleed circuit afterwards according to manufacturer s instructions 8 3 VEHICLE SERVICING must not be exceeded in the vicinity of the heater in any circumstances for example when completing painting work on the vehicle CAUTION temperature of 85 C 185 F If the vehicle requires electric welding the heater must be electrically disconnected from the vehicle both and u_n 8 4 HEATER TEST RUN The heater must not be operated not even with the timer in enclosed areas like garages or workshops not equipp
15. Jebasto Feel the drive Service and Repair Manual Coolant Heaters DBW 2010 DBW 2020 DBW 300 Circulation Pumps U4810 U4814 U4846 U4851 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 DBW 2010 2020 300 COOLANT HEATERS TABLE OF CONTENTS Contents Page 1 Introduction 7 1 1 lt 5 0 ri saa a ein aa REE 7 1 2 Applicability of Manual pipi siio arci dks cite SCR RD Roe A Sula RR RR 7 13 Meaning of Warnings Cautions and 2 4 7 1 4 Additional Documentation to be 2 4
16. On signal If the toggle switch is the Off position and the timer has turned the heater on the toggle will illuminate green This is an easy way to identify the heater is in operation While the timer is On the toggle switch will NOT operate the heater The toggle switch is a master switch whenever the timer is not in operation Safety Precautions Product Information The heater must be switched off at filling stations and tank farms as a result of the risk of explosion The heater may not be operated in enclosed spaces such as garages as a result of the risk of poisoning and asphyxiation even if a timer is used Wherever inflammable vapors or dust may form for example in the vicinity of fuel carbon wood dust or cereal stores or the like the heater must be switched off as a result of the risk of explosion As with other devices whose activation is automated if a particular application presents a risk should the heater be automatically activated and such a vehicle or application is equipped with a power cut off type switch which prevents devices from activating automatically then this timer heater should be wired into this power cut off circuit to ensure automated activation of the heater does not occur Webasto Product N A Inc 15083 North Road Fenton Michigan 48430 Page 3 of 3 For Technical Assistance in USA Call 800 555 4518 In Canada Call 800 667 8900 Visit us on the Web at www techwe
17. REPLACEMENT NOTE The replacement procedure for the flame detector is identical with the heater installed or removed Perform replacement in accordance with 9 2 9 www webasto us SERVICING WARNING The igniter box operates on high voltage Prior to replacement of flame detector disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents 8 7 8 il A COMBUSTION CHAMBER REPLACEMENT NOTE The replacement procedure for the combustion chamber is identical with the heater installed or removed Perform replacement in accordance with 9 2 17 WARNING The heater operates on high voltage Prior to replacement of combustion chamber disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents 8 8 FIRST OPERATION After heater installation the coolant circuit and the fuel supply system must be thoroughly bled observing the vehicle manufacturer s instructions During test runs all coolant and fuel line connections have to be checked for security and no leakage Should the heater in operation enter a fault condition perform troubleshooting refer to Section 5 8 8 1 WATER CiRCUIT BLEEDING Li Set vehicles own heating system to warm and replenish coolant which must consist of at least 2096 anti freeze glycol base for protection against corrosion When using pure water there will be no protection against corrosion and due to the lower boiling point of
18. Watts 120 Watts 130 Watts PERM ISSIBLE AM BIENT TEM PERATURE DURING OPERATION OF HEATER CONTROL 40 60 40 140 UNIT AND COOLANT CIRCULATION PUMP ec F PERM ISSIBLE STORAGE TEM PERATURE CONTROL UNIT C F 85 max 185 max HEATER COOLANT CIRCULATION PUMP C F 40 85 40 185 MIN CAPACITY OF COOLING SYSTEM liter 10 15 gal US 2 65 3 96 gal Imp 2 2 3 3 PERM ISSIBLE OPERATING PRESSURE OF THE COOLANT bar psi 0 4 2 0 6 29 CO IN EXHAUST GASES BY VOL 10 5 11 0 CO IN EXHAUST GASES BY VOL 0 2 max SM OKE NUM BER BOSCH 3 0 max DIM ENSIONS OF THE HEATER L 584 23 680 26 7 INCL CONTROL UNIT W 205 8 1 240 9 5 mm inch H 228 9 0 279 11 0 WEIGHT OF HEATER INCL CONTROL UNIT kg lb 15 33 22 48 5 Li www webasto us 21 NOTE Specifications for the Scholastic Heater are the same as the DBW 2010 heater unless otherwise specified TECHNICAL DATA Webasto Product N A Inc TECHNICAL DATA DBW 2010 2020 300 COOLANT HEATERS 4 2 TECHNICAL DATA OF THE CIRCULATING PUMPS CIRCULATING PUMP U 4810 U 4846 U 4814 U 4851 MP Pump FLOW RATE l h gal h US 1600 7 0 1650 7 26 5200 22 9 6000 26 4 3406 4542 against 0 15 against 0 15 against 0 2 bar against 0 4 bar 15 20 bar bar NOMINAL VOLTAGE 12 or 24 12 or 24 12 or 24 24 12 OPERATING VOLTAGE 10 14 or 10 14 or 10 14 or 20 28 10 14 20 28 20
19. Webasto Product N A Inc CIRCUIT DIAGRAMS DBW 2010 2020 300 COOLANT HEATERS 7 7 SCHOLASTIC HEATER 12 V WITH 7 DAY TIMER MODEL 1531 NMOU lo NMOYE 5 FEN S 5 7 5 R t vo 599 ep ma N 3IIHN N3385 FOIA Ji u BE c EB gt 8 5 5 BI 5 laj 2 I NMOud C A M NO T NMOYA gt ZE 1 a VIE a a v LINN TOHLNOD NMOua YOLDANNOD SSANYVH H3WIL YOLDINNOD AVM E punoJ YOLDINNOD SS3NHVH sasim pue usa16 YIUNN JHNLVHHdNIL pal pue uaaJb 1VISOINYIHI 1OHLNOD saam anjq pue anjg LVLSOWYSHL T303 LVIHIYd 40103130 3IAV 3 I4GOW AVQ Z vx ex LX vs ES cs Cd YOLOW H31V3H ZN LN diNNd NOILVINDYID INVIOOI MOD NOILINDI GION31OS LI ayeay aud AVIIY DI uoneanoe Jejeeu AVIIY 1A HDLIMS 4 5 VILYANI ININI1I DNILVIH YH VOE 3S 64 DoBELASNALVAHYSAO tid VSL 3505 4 VOC 3505 CH VSL 3505 ld 53004812313 3 Agillva 19 IVNOILdO 1 SdINVI Hsva ROT yovig Pis u t gl T gt JHL OL lt 3190 DNIHIM al m
20. head Locking screw irregularities in combustion functional checks nozzle replacement Figure 21 Combustion Air Fuel Mixture Adjustment 6 2 1 1 SETTING PROCEDURE Loosen locking screw refer to Figure above and reposition shutter with locking screw until rated 13 value is obtained 12 Tighten locking screw with 1 0 0 5 Nm and apply screw seal varnish to mark new position NOTE CO setting depends on fuel viscosity nm and on geodetic altitude 0 196 per 100 m If proper setting cannot be obtained proceed as follows Check burner head air side for damage and replace if CO Vol gt required 18 20 22 24 26 28 30 i d 48 1 pump pressure and replace pump if Voltage q setting at 500 m above sea level Check fuel filter and strainer in fuel pump for contamination and replace if required DBW 2010 Nozzle 0 35 gph DBW 2020 Rev 2 33 Adjust fuel pressure DBW 300 Replace fuel nozzle Fuel pump pressure set to 10 bar 145 psi PARE Measure burner motor speed www webasto us 31 Webasto Product N A Inc FUNCTIONAL ADJUSTMENTS 6 2 2 FLAME DETECTOR RESISTANCE CHECK and the viewing glass of the window refer to n NOTE The glass bulb of the flame detector Fig 22 are to be cleaned if contaminated In case of damage cracked glass bulb or not obtaining the rated values replace the flame detecto
21. hose clamping pliers if used Connect the electrical leads and seal connector with dielectric grease such as Permatex Dielectric Tune up Grease or 3M Silicone Paste Dielectric Grease Refill coolant system and bleed trapped air out of the coolant circuit according to instructions in Sec 8 8 1 Switch on and check function and for any leakage Ui Screw Impeller Housing 7 Rubber Seal Impeller Housing 8 O ring Nut Impeller 9 Screw Pump Base Impeller 10 Washer Pump Base Spring Seal 11 Pump Base Stationary Ceramic Seal 12 Rubber Shaft Seal Figure 53 U4810 Circulation Pump Exploded View 62 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS REPAIR 12 1 Screw Impeller Housing 5 Spring Seal 9 Screw Pump Base 2 Impeller Housing 6 Stationary Ceramic Seal 10 Washer Pump Base 3 Nut Impeller 7 Rubber Seal 11 Pump Base 4 Impeller 8 O ring 12 Rubber Shaft Boot Figure 54 U4814 and U4851 Circulation Pump Exploded View U 4846 U 4846 Pump Only Pump is magnetically coupled to the motor no shaft seals to leak or replace The driven magnet of the pump must be free of metallic contaminates otherwise the heater may overheat due to loss of coolant circulation The heater s overheat protection is likely to respond O ring Impeller Housing O ring Magnetic Drive Impeller Housing Screw Impeller Housing Figure 55 04846 Circulation Pump Exploded Vi
22. in 12 volt and 24 volt versions isthe central component to ensure controlled operation and monitoring of combustion Control Unit Figure 1 2 1 2 OVERHEAT FUSE 15 The overheat fuse protects the heater from too high and inadmissible temperatures The overheat fuse contains a fusible link that reacts when the temperature exceeds 138 C 280 F and switches the heater off with a purge cycle Overheat Fuse white wires Response temperature 138 C 280 F CS Figure 2 Overheat Fuse Webasto Product N A Inc DBW 2010 2020 300 COOLANT HEATERS 2 1 3 TEMPERATURE LIMITER 17 The temperature limiter is a thermostat that responds opens at a temperature of 95 C 203 F The temperature limiter will automatically reset closes once temperature falls well below 95 C 203 F Once the limiter has reset the heater will have to be switched off and back on to restore operation Temperature Limiter green wires Switching temperature opens at 95 C 203 F Temperature Limiter Figure 3 2 1 4 TEMPERATURE CONTROL THERMOSTAT 16 After the operating temperature has been reached the temperature control thermostat opens and shuts off the heating cycle and a purge cycle begins Once the operating temperature drops to the lower temperature threshold of the control thermostat the thermostat closes and another heating cycle begins thus maintaining a consistent coolant temperature Temp
23. may be located to the opposite side CAUTION Always use hinge bolts to lock burner head in place Figure 38 Burner Head Removal Installation Webasto Product N A Inc 52 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 9 2 6 FUEL VALVE AND SOLENOID REPLACEMENT 9 2 6 1 REMOVAL 1 2 7 9 2 6 2 1 Swing open or remove burner head see Sec 9 2 5 Disconnect the ignition leads from the ignition electrodes Loosen the retaining clamp bolt and dismount the ignition electrodes Remove disc retaining ring and disc Allow the disc to hang from the electrical leads Disconnect the electrical leads from the fuel solenoid Unscrew the lock nut item 1 Fig 39 securing the solenoid to the valve chamber 4 and slide magnetic head 3 back Unscrew valve chamber 4 from nozzle holder 9 INSTALLATION Unscrew lock nut item 1 Fig 39 from new valve assembly Make sure new O ring seal 5 is in place on valve chamber 4 and items 6 7 and 8 are present and correctly oriented inside the valve chamber Screw assembled valve into nozzle holder and torque to 11 5 Nm 8 5 Ib ft Slide the magnetic head 3 into place making sure the boss registers in the end plate recess Secure with the lock nut 1 and washer 2 Install the round disc and retaining ring Connect electrical leads to fuel solenoid Install and adjust ignition electrodes see Sec 6 2 3 I
24. ruere EUR RR RR PR DX Pare a 49 9 1 1 Work on Components after 49 9 1 1 1 Visual Inspection 49 9 1 1 2 Combustion Chamber 41 49 9 1 1 3 Heat Exchanger Visual 49 9 1 1 4 Combustion Air Fan Wheel Visual 50 9 2 Disassembly and 50 9 2 1 Overheat Fuse 1 4 50 EAE CDL ETT 50 92 12 NSPS AEON mE LET 50 9 2 2 Temperature Control Thermostat 50 9 2 2 TL Removals ciare P RR iii 50 92 22 MastallatlOni s 3 e 50 9 2 3 Temperature Limiter 51 9 2 3 L REMOVA sus iot xor Cat todos Cen ua de ane epu dent a ya 51 9 2 3 2 Installation i zad e ER orc dro ER dowieds RA a 51 9 2 4 Control Unit
25. the Webasto Accessories Catalogue are suitable for a maximum operating pressure of 0 15 bar overpressure All fuel containers offered in the Webasto Accessories Catalogue are subjected during manufacture to individual pressure testing with at least 0 3 bar overpressure The operational state of the heater i e at least an indication on or off must be easily and clearly visible For heaters in vehicles not ruled by the EU Directive but other regulations the acceptance by the relevant authority is required as applicable 1 7 CORRECTIONS AND IMPROVEMENTS Deficiencies improvements or proposals for correction of this workshop manual are to be mailed to WEBASTO PRODUCT NORTH AMERICA INC TECHNICAL DOCUMENTATION GROUP 15083 NoRTH ROAD FENTON MI 48430 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 2 GENERAL DESCRIPTION The water heaters Webasto DBW 2010 DBW 2020 DBW 300 and Scholastic Heater are used in combination with the vehicle s own heating installation to heat the passenger compartment defrost the windshield preheat water cooled engines in self contained cargo heating applications The water heater operates independent from the vehicle engine and is connected to the vehicle cooling system the fuel system and the electrical system The heater is designed to the heat exchanging principle and operates intermittently controlled by the temperature control thermostat The heaters
26. the fuel pressure delivered to the nozzle Part Number 600190 Webasto Product N A Inc DBW 2010 2020 300 COOLANT HEATERS 10 7 GREASE AND LOCKING VARNISH LDS 18 Special used for lubricating the reduction gearing of the fuel pump drive Dielectric Silicone Grease used to protect electrical terminals and connectors from corrosion Red Locking Varnish used to indicate setting positions such as on the air intake locking screw once adjusted 66 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS PRODUCT INFORMATION 11 PRODUCT INFORMATION 11 1 ISS WHITE TIMER FOR THE SCHOLASTIC HEATER Category Thermosystems Jebasto Document Number PIOO7RC Feel the drive Date Posted 02 02 2007 Description ISS WHITE TIMER INSTALLATION OPERATION INSTRUCTIONS Overview The ISS White timer is a 7 day NOI no operator interface timer This means you can set this timer to specific needs and the timer will do the rest This timer has battery backup and will hold its memory if the vehicle battery is disconnected and will recharge when 12 volt power is restored Installation The timer should be installed in an area protected from the effects of weather and contamination The timer can be surface mounted on the vehicle instrument panel or inside the circuit panel Bus applications or any place convenient and accessible The timer can be mounted using customer installer supplied Velcro tape by
27. the title page 1 3 MEANING OF WARNINGS CAUTIONS AND NOTES WARNINGS CAUTIONS and NOTES in this manual have the following meaning DANGER This heading and text style is used to highlight that non compliance w ith instructions or procedures will cause injuries or lethal accidents to personnel WARNING This heading and text style is used to highlight that non compliance with instructions or procedures may cause injuries or lethal accidents to personnel CAUTION This heading and text style is used to highlight that non compliance w ith instructions or procedures may cause damage to equipment NOTE This heading and text style is used to highlight and draw attention to information we feel you would like to have It could have to do with procedures and tipsthat will help you work more efficiently gt gt gt 1 4 ADDITIONAL DOCUMENTATION TO BE USED This workshop manual contains all information and procedures necessary for the repair of heaters DBW 2010 2020 and 300 The use of additional documentation is normally not necessary Operating instructions and installation instructions may be used as complementary information as necessary www webasto us INTRODUCTION 1 5 SAFETY INFORMATION AND REGULATIONS The general safety regulations for the prevention of accidents and the relevant operating safety instructions have to be observed at all times General Safety Regulations beyond the scope of these r
28. time After you have set the timer functions needed push the Clock this will save your settings and return to the clock These steps can be repeated 6 more times giving you multiple on and off settings It is very important that you set this timer to the specific needs of each vehicle to optimize the heaters efficiency Webasto Product N A Inc 15083 North Road Fenton Michigan 48430 Page 2 of 3 For Technical Assistance in USA Call 800 555 4518 In Canada Call 800 667 8900 Visit us on the Web at www techwebasto com North America www webasto com Global Webasto Product N A Inc 68 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS PRODUCT INFORMATION Category Thermosystems Jebasto Document Number PIOO7RC Feel the drive Date Posted 02 02 2007 Description 155 WHITE TIMER INSTALLATION OPERATION INSTRUCTIONS Operation in manual mode The largest button on the timer is the Manual button At the bottom of the LCD screen you will see a small line that moves as you push this button Underneath the small line you will see the corresponding function On Auto Off The manual button can be used as a toggle switch to operate the heater or after you have programmed the timer for automatic service push the manual button until the line is over auto on the timer The timer will now turn the heater on and off at the times preset earlier NOTE The toggle switch will illuminate green when the heater has an
29. 0 300 With Nozzle Preheat Figure 29 38 www techwebasto com Webasto Product N A Inc CIRCUIT DIAGRAMS DBW 2010 2020 300 COOLANT HEATERS 7 5 SCHOLASTIC HEATER 12 V WITH ON OFF SWITCH NMOua AWD 3 w 2 8 s 3 uH 1 va v y 2 gu ego lt zw 99 393 eb 2 5 5 NMOVA n O sila NE X iii Ri T gt a gt a v LINN TOHLNOD JONVYO YOLDANNOD AVM E punoJ YOLDINNOD SSINYVH Nid 6 salim usa16 pue uaaJb HALI IUNLVYIdINIL pal pue u3316 IVISONYIHL 1OHLNOD anjg pue anjg 1VISOIAH3H 13404 1V3H38d 181884 HDLIMS 440 NO 40103130 3IAVH YOLOW 431 V3H NOLLVINDYID LNVIOOD NOD NOLLINDI 105 jan AVTIY UDIIMS YO uo AVTIY HDLIMS 4 5 VILYINI 193e8u aJd 1N3NA14 DNILV3H VOE 3505 22861 3505 LVIHYIAO VSL 3503 voz 3503 VSL 3505 51400812313 NOLLINDI 1 HOLVDIGNI AYILLVA ex LX vs ES cs 15 LN TA LA YH Sd 3 cd 5 18 aay ady rar dau NMOUS oe a Schematic Scholastic Heater With On Off Switch Figure 30 Webasto Product N A Inc 39 www webasto us DBW 2010 2020 300 COOLANT HEATERS CIRCUIT DIAGRAMS 7 6 SCHOLAS
30. 1 11 Fuel Control Valve and Solenoid 8 15 2 1 12 Fuel Nozzle and Nozzle Holder 14 16 2123 Fuel ne Connections 25 dropcap cu ava a REC E RARE EC EC HC A GRE aan cater ama 16 2 1 14 Electronic Ignition Unit 3 2 4 44 16 2 1 15 Ignition Electrodes 13 4 4 16 2 1 16 Combustion Chamber 20 Combustion Air Swirler 21 17 2 1 17 Heat Exchanger 19 hh hes 17 2 1 18 Preheat Thermostat 7 asus seda meee de eae dead dapib Gg dcr GAGA 17 2 1 19 Pre heater Cartridge 10 2 4 4 17 2 1 20 Coolant Circulating Pump 4i urs o agua herd wed Pape RERO CER Peau 23 18 3 Functional Description 19 ON sais n ded pter gares nt e daran rss e d eitis ee aus 19 3 2 Heating Operation sas sw aw wada e RUE E T OR EUR ERR AER UR a 19 3 3 MT 19 4 Technical Data 20 4 1 Technical Data of the 21 4 2 Technical Data of the Circulating 22
31. 17 Temperature limiter 9 Electrode holder green wires 20 18 19 20 21 22 23 24 25 26 19 18 Coolant inlet Heat exchanger Combustion chamber Combustion air swirler Exhaust outlet Flame detector Fuel pump Fuel pipes Combustion air intake with adjusting shutter Lower temperature version of the temperature control thermostat has white and orange wires Webasto Product N A Inc 10 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 18 13 GENERAL DESCRIPTION 16 17 11 26 DBW 2020 DBW 300 co DECOR OUT R Dn NE ES Electronic control unit Motor Electronic ignition unit Coupling clutch Combustion air fan Toothed gearing Preheat thermostat blue and green wires Fuel control valve and solenoid Electrode holder www webasto us 24 10 11 12 13 14 15 16 17 10 23 22 7 21 Pre heater Coolant outlet Bleeding valve Ignition electrodes Fuel nozzle Overheat fuse white wires Temperature control thermostat green and red wires Temperature limiter green wires 11 18 19 20 21 22 23 24 25 26 Coolant inlet Heat exchanger Combustion chamber Combustion air swirler Exhaust outlet Flame detector Fuel pump Fuel pipes Combustion air intake with adjusting shutter Webasto Product N A Inc GENERAL DESCRIPTION 2 1 PARTS OF THE HEATER 2 1 1 ELECTRONIC CONTROL UNIT 1 The control unit SG 1553
32. 28 20 28 POWER CONSUMPTION Watt 25 30 104 209 72 DIM ENSIONS L 166 6 5 180 7 0 248 9 76 285 11 22 214 8 42 mm inch W 94 3 7 74 2 9 100 3 9 115 4 53 106 4 16 H 71 3 0 112 4 4 106 4 17 118 4 64 106 4 16 WEIGHT kg Ib 0 8 1 8 22 48 5 2 1 4 6 2 8 6 17 2 5 5 5 RECOM M ENDED FOR HEATER DBW 2010 DBW2010 DBW 2020 DBW 2020 Scholastic DBW 300 DBW 300 Heater Choice of circulating pump depends on resistance of coolant circuit 4 3 PERMISSIBLE EXTENSION OF THE CONNECTIONS HEATER DBW 2010 DBW2020 DBw3oo Scholastic Series FUEL LINE internal diameter mm inch 6 0 25 6 0 25 6 0 25 6 0 25 maximum length m ft 10 33 10 33 10 33 10 33 suction head m ft 2 6 6 2 6 6 2 6 6 2 6 6 COMBUSTION AIR INTAKE PIPE internal diameter mm inch 80 3 2 80 3 2 80 3 2 80 3 2 maximum length m ft 5 16 5 5 16 5 5 16 5 5 16 5 maximum degree of bends total m ft 270 270 270 270 EXHAUST PIPE internal diameter mm inch 38 1 5 70 or 80 70 or 80 38 1 5 2 75 or 3 2 2 75 or 3 2 maximum length m ft 5 16 5 5 16 5 5 16 5 5 16 5 maximum degree of bends total m ft 270 270 270 270 HOSE CONNECTIONS INLET OUTLET outside diameter mm inch 18 0 75 38 1 5 38 1 5 25 1 0 TEM PERATURE DIFFERENCE BETWEEN INLET and OUTLET AT C F 10 18 10 18 10 18 10 18 Other dimensions upon request Heaters built until model n
33. 4 IFIOIA 5 _ a _ _ _ dl _ z 8 z SST MLE 98 18 e 4 FR EE gt 2 z m 5 5 i ede 8 T 2 Nowa gt EVA nmoua a n 7 7 7 i F 7 xil E _ _ V LA sl nm wa P Nova i 1 w Ja i9 diu 3 d i 2 E See M diy gt J dii I sa e i Ed Hl N peas k ly E E kV LS R MOTIAG3U PV gt 2 7 35vig d3s DI 395 19 395 69 Lo aj Rf ITON JIIHM L gt 35vi8 28 K amp hl Vus sou l Nova Ai Ion ee LINN TOHLNOO NMOYA 4 Schematic DBW 2010 Present Version Figure 27 36 www techwebasto com Webasto Product N A Inc CIRCUIT DIAGRAMS DBW 2010 2020 300 COOLANT HEATERS 7 3 DBW 2020 300 12 V AND 24 V WITHOUT NOZZLE PREHEAT HaLvaH JONVYO p 3l Y 4 ssa NMOYA ADVI INN TOHLNOD NAAOW8 NMOua NMOua JONVYO YOLDANNOD AVM Z YOLDANNOD AVV C punoJ YOLDINNOD SSINYVH Nid 6 usa16 pue 38011 VH3dIA3LL pal pue uaaJb IVISONHIHL TOYLNOD 121234 HDLIMS 440 40101130 1WV HH YOLOW H3L1V3H NOLLVINDHID INVIOOD NOILINDI JNIVA GION41OS YOUMS UO AVTIY VSL 3505 VOE 1504 Jo8 L 350
34. 4 LVJHHJAO VSL 3504 Voc 3505 VSL 3505 S400410414 NOILINDI YOLVDIGNI AYILLVA gt pow o Schematic DBW 2020 300 Without Nozzle Preheat Figure 28 Webasto Product N A Inc 37 www webasto us DBW 2010 2020 300 COOLANT HEATERS CIRCUIT DIAGRAMS 7 4 DBW 2020 300 12 V AND 24 V WITH NOZZLE PREHEAT pun e cS uH ss EE m mm i C NEN IAN SS E vd NAR Ra ica gt gt w w gt E 5 A 2 a n B NAAOW8 Du 5 EEE LINN 1OHLNOO amp LL8 HOLD3NNOD AVNV C YOLDANNOD AVM E punou HOLO3NNOO SSINYVH Nld 6 usa16 pue u3316 YALA 3HOLLVH3dIA L SaJIM pal pue IVISOINYIHI TOYLNOD pue anjq IVISOMNY3HL 1404 LVAH1Hd 181884 HDLIMS 440 NO 401031130 INVII YOLOW YILVIH dNNd NOILVINDYID INV1OOD MOD NOILIND JNIVA 105 191e8u aJd Jans 138 UNMS YO uo AVTI INIINITI DNILV3H VSL 3503 VOE 3504 Do8EL ISNA LVIHYIAO VSL 3503 VOc 3513 VSL 35 4 534 0 123134 NOLLINDI HOLVDIQNI AYILLVA ssy _ NMOua JONVYO H NMOUA NMOYA d diy __ qa qm LX SH EX ex vs ES cs 15 CIN LW c DI YH 94 64 vd 3 Cd SQ 18 2 NMOua 1a Schematic DBW 202
35. 7 1 5 Safety Information and Regulations 2 4 15 1 General Safety 1 6 Legal Provisions for Installation Luaaaaaaaaaaaaaaaaaaaaaaaaa Hmmm 1 7 Corrections and Improvements usa ii er ach PSY POO 2 General Description 221 Parts Of the Heater dus ost s Sonia nd ai 12 2 1 1 Electronic Control Unit 1 44 2 12 2 1 2 Overheat Fuse 15 2 2 4 4 12 2 1 3 Temperature 17 4 4 4 2 4 12 2 1 4 Temperature Control Thermostat 16 12 2 1 5 23 cava r eir d ae dra aa PRI 13 2 1 6 Combustion Air Intake 26 0 0 RR heh hes 13 2 1 7 Combustion Air Fan 5 2 4 4 14 2 1 8 Coupling 4 i i EA Vie Rcs RR at 15 2 1 9 loothed Gearing 6 ssa e erre Meee A AR PP Ropa eX PR ed rad d 15 2 110 Fuel Purip 24 Re EON RAS ac e ORA n i uc e BRAT ERROR D e GR In Ar EC D r CON OR CN A 15 2
36. DBW 2010 DBW 2020 DBW 300 and Scholastic Heater basically consist of the combustion air intake adjustable the combustion air fan and motor the fuel pump the fuel control valve and solenoid the nozzle holder and nozzle the ignition coil and ignition electrodes the combustion chamber the heat exchanger www webasto us GENERAL DESCRIPTION For control and monitoring the heater includes acontrol unit an overheat fuse non reset atemperature limiter a temperature control thermostat aflame detector photo eye A coolant circulating pump is installed directly to the heater or inside an enclosure or on a tray mount The heaters may also be equipped with an optional cold starting aid consisting of preheat thermostat anozzle holder preheat cartridge arelay and wiring harness Webasto Product N A Inc GENERAL DESCRIPTION DBW 2010 2020 300 COOLANT HEATERS 1 2 3 4 5 6 7 8 91011 12 13 14 del N REES SQ sen 0 7 ma 6 Se f p a is 26 25 24 23 22 21 DBW 2010 1 control unit 10 Pre heater 2 Motor 11 Coolant outlet 3 Electronic ignition unit 12 Bleeding valve 4 Coupling clutch 13 Ignition electrodes 5 Combustion air fan 14 Fuel nozzle 6 Toothed gearing 15 Overheat fuse white wires 7 Preheat thermostat blue and 16 Temperature control thermostat green wires green and red wires 8 Fuel control valve and solenoid
37. EATERS 8 7 2 TEMPERATURE LIMITER REPLACEMENT NOTE The replacement procedure for the n temperature limiter is identical with the heater installed or removed Perform replacement in accordance with 9 2 3 TEM PERATURE THERMOSTAT REPLACEM ENT NOTE The replacement procedure for the temperature control thermostat is identical with the heater installed or removed Perform replacement in accordance with 9 2 2 w 8 7 4 OVERHEAT FUSE REPLACEMENT NOTE The replacement procedure for the overheat fuse is identical with the heater installed or removed Perform replacement in accordance with 9 2 1 8 7 5 BURNER HEAD REPLACEMENT NOTE The replacement procedure for the burner head is identical with the heater installed or removed Perform replacement in accordance with 9 2 5 WARNING The ignition system operates on high voltage Prior to replacement of burner disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents gt 8 7 6 IGNITION COIL REPLACEMENT NOTE The replacement procedure for the ignition coil is identical with the heater installed or removed Perform replacement in accordance with 9 2 11 WARNING ignition system operates on high voltage Prior to replacement of the ignition coil and related components disconnect electrical connectors of cable harness in vehicle to avoid lethal accidents gt 8 7 7 Li FLAME DETECTOR PHOTO EYE
38. HAMBER VISUAL INSPECTION Check swirl ring for security Check swirl ring for melting and deformation DBW 2010 nspect combustion chamber for oxidizing and coke deposits and remove as required Check welding seem for cracks NOTE Longitudinal cracks up to 38 mm 1 5 in are allowed 9 1 1 3 HEAT EXCHANGER VISUAL INSPECTION nspect exhaust ducting in heat exchanger for sooting deposits damage and corrosion NOTE Deposits are to be removed with water jet and brush ES nspect heat exchanger for exterior damage deformation etc NOTE Heavy deformation may cause restricted flow of coolant CAUTION When replacing the combustion chamber on heaters installed vertically remove deposits in heat exchanger using a suitable tool DE Webasto Product N A Inc REPAIR 9 1 1 4 COMBUSTION AIR FAN WHEEL VISUAL INSPECTION The fan wheel has to be checked for contamination traces of grinding and cracks DBW 2010 ONLY The clearance between the blower wheel and blower case must be measured measurable with a feeler gauge at the narrowest point Clearance 0 15 0 05 mm DBW 2010 0 15 x 0 05 mm 006 002 inch Figure 35 Clearance Adjustment DBW 2010 Fan DBW 2020 300 ONLY The hub of the impeller has to be checked for cracks and the cover disc back wall as to its stability Webasto Product N A Inc DBW 2010 2020 300 COOLANT HEATERS 9 2 DISASSEMBLY AND AS
39. Ld sd 18 Schematic DBW 2010 Early Canadian Version Figure 26 Webasto Product N A Inc 35 www webasto us DBW 2010 2020 300 COOLANT HEATERS CIRCUIT DIAGRAMS 7 2 DBW 2010 12 V AND 24 V PRESENT NORTH AMERICAN VERSION VILVIH 7 YOLDANNOD 32 VAYALNIAVM E CX 102 NOLLINDI NMOUd 1 punoJ 80123 02 SSINYYH Nid 6 IX JAVA CIONITOS 8 5 E s m uaal6 pue y aud Jan AyJH 5 9 WILINIT3UNIVYJAWIL 5 uayeay aid jan T psy ES 2 M sou 26UEJO pue ym lN3AI3ONIIV3H YH I IVISOINH3HL TOMINOO ES 7043504 td f LX S S TY aniq pue YGL3SNH 8 4 v z 2 E 2 NK IVISOWYSHL 19 05 ZS VOLISNA a a le 2 81884 H2IIMS HO NO 15 YGL3SNH I gt E 5 6 Im W01031303NVH HU S3QOuID3H NOLLINDI 3 rm p zo Ed T 25795 t YOLOW ZN LHONYOLVDIGNI SQ BE S i 4 diNNd NOLLVTNDHID INVIOOO IN AYILIVA 19
40. MATION This section describes the repairs that may be performed on the heaters DBW 2010 2020 and 300 when removed Any further disassembly will void the warranty For re assembly only components of the proper service part kits are to be used on high voltage Prior to replacement disconnect connectors of cable harness in vehicle to avoid lethal accidents i WARNING The ignition system operates The following components may also be replaced with the heater installed unless restricted space prevents access replacement of temperature limiter replacement of temperature control thermostat replacement of overheat fuse replacement of burner replacement of fuel atomizing nozzle replacement of nozzle preheat cartridge replacement of nozzle preheat thermostat replacement of ignition coil replacement of flame detector replacement of combustion chamber replacement of control unit 9 1 1 WORK ON COMPONENTS AFTER DISASSEMBLY disassembled components must always be CAUTION All gaskets located between discarded and replaced with new gaskets www webasto us REPAIR 9 1 1 1 VISUAL INSPECTION GENERAL Examine all components for damages cracks deformation wear etc and replace as necessary Examine connectors and wiring for corrosion loose contacts wrong crimping etc and repair as necessary Check terminals for corrosion and contacts for security Repair as required 9 1 1 2 COMBUSTION C
41. Magnetic coil of fuel solenoid valve defective 27 Volume on solenoid valve Clean or replace TROUBLESHOOTING AFTER SWITCHING ON THE HEATER SWITCHES OFF AFTER APPROX 30 SECONDS ON FAULT Insulator of electrode defective Is there the same effect with a new ignition spark coil Ignition spark coil defective Magnetic coil of fuel solenoid valve defective Fuel solenoid valve defective Check feed connections Voltage on solenoid valve Are ignition electrodes correctly Adjust ignition electrodes to correct setting with gauge set with gauge Fuel in the tank Refill fuel tank Are all fuel lines tightly connected Tighten lines repair leaks or replace leaking gaskets Remove fuel pump is the shaft seal okay Is the gasket surface of the fuel valve piston or of the air relief drill hole dirty Fuel suction line blocked or fuel waxing or water in fuel freezing or fuel tank vent blocked Replace fuel pump Fuel quality or grade not appropriate for cold weather operation Switch to a winter grade Webasto Product N A Inc TROUBLESHOOTING DBW 2010 2020 300 COOLANT HEATERS 5 3 4 HEATER STARTS ONLY AFTER SEVERAL STARTING ATTEMPTS Does smoke emit from the Possible leakage in fuel Possible leakage in fuel exhaust pipe after failed suction or return fuel lines suction or return fuel lines attempts to start resulting in air pockets Continue f
42. N A Inc NOTE Hold IGNITION SPARK COIL button 5 ON until FLAME DETECTOR LED 3 lights or combustion is heard then release in any case do not hold button on for more than 15 seconds or damage to the coil may result il TEST RESULTS 1 LED 3 lights and combustion achieved operation normal 2 Combustion achieved but no LED 3 light check flame detector 3 Combustion not achieved and no LED 3 light check fuel nozzle check fuel pressure check for blocked fuel lines dirt or ice check ignition electrodes for damage and set gap E Heater should now be in heating mode and will continue to run until you release the fuel solenoid valve button 7 which stops fuel flow and extinguishes the flame immediately Allow the heater to continue running for approximately 30 seconds cool down after which turn the WATER PUMP switch 4 and the MOTOR switch 5 OFF www techwebasto com DBW 2010 2020 300 COOLANT HEATERS Li NOTE If flame does not stop when the FUEL SOLENOID VALVE button 7 is released turn MOTOR switch 5 OFF to stop heater Check and repair fuel solenoid valve accordingly Oncethe manual test run has been successfully completed set the heater switch or timer to OFF remove the tester and reconnect the control unit Once done set the switch or timer to ON If the heater or a heater component does not respond the control unit is defective Replace the control unit and retest the hea
43. ON DBW 2010 ONLY 1 Assemble bearings and components if required see Sec 9 2 15 2 Push fan with shaft through bearings and spacer of housing item 5 Fig 46 3 Install washer 6 drive gear 7 and lock nut 8 4 Adjust fan clearance according to instructions in Sec 9 1 1 4 DBW 2020 300 ONLY 5 Assemble fan shaft bearings and drive gear components if required see Sec 9 2 16 6 Makesure O ring item 10 Fig 48 in bearing recess of housing item 5 Fig 46 is present and in place 7 Push fan assembly into housing 5 until motor carrier 3 is fully seated DBW 2010 2020 300 8 Install motor carrier item 3 Fig 46 over fan 4 9 Install and tighten screws to DBW 2010 5 5 6 5 Nm 48 5 57 5 Ib in DBW 2020 300 8 0 Nm x 10 71 Ib in 10 Install drive motor see Sec 9 2 12 Connect electrical leads Install protection cap and secure with four screws item 6 Fig 45 removed earlier Install ignition coil Refer to Sec 9 2 11 for guidance 10 11 12 13 Webasto Product N A Inc REPAIR DBW 2010 2020 300 COOLANT HEATERS 9 2 14 FAN REPLACEMENT DBW 2010 DBW 2020 300 Figure 46 Fan Replacement Webasto Product N A Inc 58 www techwebasto com REPAIR 9 2 15 FAN SHAFT BEARINGS AND GEARING EXPLODED VIEW DBW 2010 DBW 2010 2020 300 COOLANT HEATERS Jaysem 5 01 bululejoy 6 110 320 pl buueeg 6 JIBUSEM Jeob
44. ORTANT Never switch on the electronic ignition unit without being connected to the ignition electrodes 4 Black Wire Brown Wire Figure 14 Electronic Ignition Unit 2 1 15 IGNITION ELECTRODES 13 The ignition spark is formed between the points of the ignition electrodes thus starting the combustion process Electrodes Setting Gauge Figure 15 Ignition Electrodes and Setting Gauge 16 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 2 1 16 COMBUSTION CHAMBER 20 COMBUSTION AIR SWIRLER 21 Within the burner tube of the combustion chamber the air fuel mixture is burned DBW 2010 DBW 2020 300 Figure 16 Combustion Chambers 2 1 17 HEAT EXCHANGER 19 The heat produced by the combustion process is transferred to the coolant water antifreeze mixture flowing through the heat exchanger DBW 2020 300 Figure 17 Heat Exchangers www webasto us GENERAL DESCRIPTION 2 1 18 PREHEAT THERMOSTAT 7 The preheat thermostat is installed in the burner head on the back wall DBW 2010 or on the photo disc DBW 2020 300 It switches the nozzle holder pre heating element 10 on which warms the fuel inside the nozzle holder to ensure fuel atomization in severe cold conditions Preheat Thermostat blue and green wires Switching temperature closes at 0 C 32 F opens at 8 C 48 F Figure 18 Preheat Thermostat 2 1 19 PRE HEATER CARTRIDGE 10 The pre heater i
45. SEMBLY 9 2 1 OVERHEAT FUSE REPLACEMENT 9 2 1 1 REMOVAL 1 Disconnect electrical connection to overheat fuse at connector block 2 Turn counterclockwise to remove overheat fuse item1 Fig 36 from dry well 9 2 1 2 1 Turn overheat fuse clockwise into dry well until snug but not tight 2 Turn out 1 2 turn 3 Plug connector into connector block Li 9 2 2 TEMPERATURE CONTROL THERMOSTAT REPLACEMENT INSTALLATION NOTE Observe electrical wiring color coding when making connections 9 2 2 1 REMOVAL 1 Disconnect electrical connection to temperature control thermostat at connector block 2 Turn counterclockwise to remove temperature control thermostat item 2 Fig 36 9 2 2 2 1 Turn temperature control thermostat clockwise into bracket until snug 2 Plug connector into connector block il INSTALLATION Observe electrical wiring color coding when making connections www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 9 2 3 TEMPERATURE LIMITER REPLACEMENT 9 2 3 1 REMOVAL 1 Disconnect electrical connection to temperature limiter at connector block 2 Turn counterclockwise to remove temperature limiter item 3 Fig 36 9 2 3 2 1 Turn temperature limiter clockwise into bracket until snug 2 Plug connector into connector block Li INSTALLATION NOTE Observe electrical wiring color coding when making connections 1 Overheat Fuse 2 Temperature Control Thermostat
46. THABITIS 7 NOTIBAG3S NMOYA m NOLLINDI 6 rel oo Ee ps NMOUd 3IDIH3A __0 4 _ 203 DA CURA ES NMOYA eli pue u 15 NMOYA YALINI 3YNIVYAdNIL NOLIdO a pue a1luM S MOTBA MALL OL S pl IVISOINY3HL 1OHLNOJ gt i anjq pue 19 1VISOWH3HL 1303 1v3H3Hd a gt DE 121284 HDLIMS 440 NO m 40101130 SEL e asn 104 peunbijuo i _ 5 Jaydepe UJIM YIINIL Av Q Z asn u eoo pue snq 104 paunbijuo gt EZ Nao G9 ca Jaydepe ui YIINIL AVQ Z NT YOLOW 3 o NOLLVINDYID LNVIOOD I yovid s dii 1102 NOLLIND yl ca IMYA GIONJ1OS Z ld area U eid any AVY I DO _ Li DNILV3H V ISN E LIN VS L ISNI I ADv1a voz 3573 LINN TOHINOO ie S400410313 NOLLINDI x HOM YOLWIION AYILLVA US ES eS LS ld IN LN z YH 4
47. TIC HEATER 12 V WITH 7 DAY TIMER MODEL 1529 HOLD3NNOD YX YOLDANNOD SSINYVH HdWIL YOLDANNOD AVM E ZX punou YOLDANNOD SS3NHVH LX pue MALIA 3801 VW34dIW3L vs pad pue NOLLINDI 3AIVAGION3IOS Qejeeu eud AVIIY DI AVIIY LX HOLIMS AL34VS VILYANI I ININITI DNILV3H YH LVLSOWYSHL 1 S VOE 4504 SI anjq pue 9 20861 45 4 LVIHYIAO IvISOWH1HL 1303 LVIHIYd cs VSL 3505 4 YOLDILIO INVA VOC 3503 6441 YAWIL AVG Z ld VSL 3503 ld YOLOW H31V3H ZN 54400812413 NOILINDI 3 dINNd NOLLVIQ2WID LNVIOOD AYILLVA 18 IVNOlLdO a SAINVI MOTI a je DVI 9 vi Iz 5 GH lt a NMOHUd JHL OL TIVO DNRHIM m N dii id NOILINDI A JHIA AVHD O NMOUA ee AB 184 Og _ _ 1 12 ee NMOYA gt 9i 4 a ILIHM EV DI N3345 I p OVE 4 1 gt v LINN TOHLNOD Pa N3385 TI Schematic Scholastic Heater With Digital 7 Day 3 Program Timer Model 1529 Figure 31 40 www techwebasto com
48. ame detector in slot of disc and secure with screw and lock washer 3 Tighten screw to 5 Nm 6 Nm 44 53 Ib in 4 Swing burner head closed see Sec 8 5 1 Flame Detector Figure 42 Flame Detector Replacement 54 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS REPAIR 9 2 10 IGNITION ELECTRODES REPLACEM ENT 9 2 11 IGNITION COIL REPLACEMENT 9 2 10 1 REMOVAL NOTE If the ignition is faulty check also the nm flame detector see Sec 6 2 2 1 Swing burner head open see Sec 8 5 1 2 Disconnect the ignition leads from the ignition 9 2 11 1 REMOVAL electrodes l Swing open or remove burner head see Sec 9 2 5 3 Loosen the retaining clamp bolt and dismount the 2 Disconnect the ignition leads from the ignition ignition electrodes electrodes 9 2 10 2 INSTALLATION 3 Remove the four screws securing the ignition coil to ACE the protection cap see Fig 44 1 Install the new ignition electrodes us 4 Lift coil off cap enough to access electrical 2 Connect the ignition leads to the electrodes connectors and disconnect 3 Adjust ignition electrodes see Sec 6 2 3 4 Swing burner head closed see Sec 8 5 1 9 2 11 2 INSTALLATION 1 Press electrical connectors together Brown Brown Black Yellow 2 Place ignition coil into position making sure not to jam or trap electrical cables 3 Secure ignition coil with four screws removed earlier 4 Plug ignition leads onto
49. ault finding according to section 5 3 7 Repair leakage points YES Does the ignition spark Does the ignition spark Ignition spark coil defective flash over on the high flash over on the electrode voltage wire insulation High voltage wire defective Ignition electrode s defective 5 3 5 HEATER SWITCHES OFF BY ITSELF DURING OPERATION Does the heater start after Does heater reteact at all Continue fault finding repeated starting attempts according to section 5 3 2 Fuel supply from tank has Heater switches OFF after been interrupted for an approx 30 sec on fault extended period of time continue fault finding according to section 5 3 3 Webasto Product N A Inc 28 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 5 3 6 HEATER SMOKES Is combustion air intake or exhaust outlet dirty Clean if necessary correct installation according to instructions Does heater smoke only during start up Let heater burn freely warm up to temp www webasto us Has the air intake bellows been incorrectly set Are the permissible combustion values adjustable see section 10 3 Does the heater continue to smoke after adjustment Motor r p m too low Are the gas passages fins of the heat exchanger highly soiled Clean according to instructions see Sec 9 1 1 3 Are there restrictions or kinks in the fuel return line Because of the return fuel pressure the flow of the
50. basto Product N A Inc 70 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS NOTES YOUR NOTES www webasto us 71 Webasto Product N A Inc Jebasto Feel the drive WEBASTO PRODUCT N A INC 15083 North Road Fenton MI 48430 Technical Assistance Hotline USA 800 860 7866 Canada 800 667 8900 ww w techwebasto com Org 01 2008 N A P N LIT669745A O 2008 Webasto Product N A Inc WW W Webasto us
51. basto com North America www webasto com Global www webasto us 69 Webasto Product N A Inc WARRANTY DBW 2010 2020 300 COOLANT HEATERS TEM EM ZOO ETE wo Co quam quee quum quum que qu quum quan qu quum quam quu qua qu SEAT COSTO SOLITI SODIO OO Sa PROCY ON TED SED TORT A SRC cce ME NE JANNE JANE NE JANE JANE JANE JANNE JANE JANNE JANNE JANIE JUNE ssec io 22 22 22 22 22 22 SZ Er AN 55545225 EFR WARRANTY COVERAGE AND LIMITATIONS ZE SE 4 Webasto Product North America Inc herein after referred to Webasto warrants their heaters B S and heater kits against defects material and workmanship for two 2 years effective at the time p and heater EAC workman 2 Of installationor vehicle registration date for Original Equipment installations OE This warranty k zm LET NA AC V UTE period may not exceed three 3 years from the original date of sale by Webasto This warranty PRZEZE i il Mites period may be supe
52. cant P N 143820 45 gram tube Insert assembly into burner head being careful to mesh gears and secure with the four bolts removed earlier Connect fuel pipes Install disc with flame detector and retain with ring Install and adjust ignition electrodes see Sec 6 2 3 Install burner head see Sec 9 2 5 Webasto Product N A Inc REPAIR Figure 40 Fuel Pump Replacement 9 2 8 FUEL NOZZLE REPLACEMENT 9 2 8 1 REMOVAL 1 Swing burner head open see Sec 8 5 1 2 Unscrew and remove nozzle using a nozzle wrench or two wrenches 16 mm amp 19 mm installing the nozzle Only touch the nozzle at its hexagon surface The fuel nozzle should be replaced annually n NOTE Ensure cleanliness is maintained when NOTE If ignition electrodes are disturbed n during nozzle replacement they will require adjustment see Sec 6 2 3 9 2 8 2 INSTALLATION 1 Screw in new high pressure nozzle and tighten to 20 Nm 15 Ib ft 2 Swing burner head closed see Sec 8 5 1 Webasto Product N A Inc DBW 2010 2020 300 COOLANT HEATERS Nozzle Holder y Nozzle Figure 41 Nozzle Replacement 9 2 9 FLAME DETECTOR REPLACEMENT 9 2 9 1 REMOVAL 1 Swing burner head open see Sec 8 5 1 2 Remove screw and lock washer and slide flame detector out of slot in disc 3 Disconnect electrical leads to flame detector 9 2 9 2 INSTALLATION 1 Connect electrical leads to new flame detector 2 Position fl
53. d from mounting Motor defective Replace defective fan internal fault shaft bearings parts Is the large spur gear Fuel pump defective easily spun replace fuel pump Motor defective internal fault Webasto Product N A Inc 26 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 5 3 3 Overheat fuse opened Has temperature limiter green wires opened Remove cause for release e g lack of coolant replace YES overheat fuse or allow temp limiter to reset Flame detctor defective replace www webasto us Can you detect the buzzing sound of the ignition coil after approx 20 seconds Is combustion noise audible Does flame detector show resistance gt 1 56 kQ under bright 50 Lux light Does the fuel solenoid valve in the heater open Check feed connections of control unit for open or interruption Remove intruption or open in circuit Voltage across terminal C8 and C5 Flame detector defective Does flame detector show resistance gt 100 when dark Control unit defective Does the fuel solenoid valve in the heater open Is fuel splashing out of the fuel nozzle Does the pump deliver fuel Fuel nozzle is blocked replace nozzle Check air intake and exhaust outlet for blockage Clean if necessary Viscosity below 20 centiStokes Fuel nozzle is blocked replace Does fuel nozzle produce good fuel atomization
54. e heater should be in a location as low as possible to ensure self venting of the heater and circulation pump This applies in particular for the circulation pump because it is not self priming The cooling system coolant capacity must be at least 10 liters The vehicle cooling system or the separate heating circuit must use only pressure relief valves with an opening pressure of at least 0 4 bar and of max 2 0 bar It is a basic requirement to use the coolant hoses supplied by Webasto otherwise the hoses must at least meet the specifications of DIN 73411 The hoses have to be installed free of kinks and for proper venting in an inclination Hose connections must be secured against slippage with hose clamps H Prior to the heater s first operation or after replacement of the coolant attention must be paid to carefully bleed the cooling system Heater and lines must be installed so that static venting is guaranteed NOTE The specified tightening torques of the hose clamps used must be complied with Improper venting may cause malfunctions by overheating in equipment operation Proper venting may be identified by a circulation pump almost noiseless in operation 8 6 2 CONNECTION TO VEHICLE FUEL SYSTEM Fuel is tapped from the fuel reservoir of the vehicle or from a separate fuel tank 8 6 2 1 FUEL LINES In order to avoid air from being captured in fuel lines they should only be installed with an incline The fuel line j
55. e is within specified range Switch off heater switch on tester Unscrew pressure test gauge CAUTION Do not damage nozzle bore Screw in nozzle and torque to 20 Nm 15 Ib ft DBW 2010 w 0 40 gph nozzle 8 0 5 bar 116 7 psi DBW 2010 w 0 35 gph nozzle 10 0 5 bar 145 7 psi DBW 2020 amp DBW 300 10 0 5 bar 145 7 psi Pressure Test Gauge P N 600190 Pressure Regulator Figure 25 Fuel Pressure Check Webasto Product N A Inc FUNCTIONAL ADJUSTMENTS 6 2 6 FUEL SOLENOID VALVE CHECK NOTE A leaking solenoid valve seat or valve n results in a rather long smoke emission period during run down In this case fuel keeps dripping through the fuel nozzle Short smoke emissions are normal caused by clearing the area between the solenoid valve and the nozzle bore CHECK Exchange control unit with tester P N 1302691A and swing burner head open see Sec 8 5 1 Press fuel solenoid button on tester several times You should hear an audible clicking sound indicating that the fuel solenoid valve is functioning If no clicking can be heard valve and or solenoid may require replacement see Sec 9 2 6 Webasto Product N A Inc 34 DBW 2010 2020 300 COOLANT HEATERS 6 2 7 NOZZLE BLOCK PRE HEATER CHECK At a temperature of 0 C 32 F the heater cartridge in the nozzle block is activated The heating period depends on the heat reflected within the combustion chamber P
56. e removal 3 Perform procedures on components after disassembly see Sec 9 1 1 NOTE DBW 2010 Only In case the n combustion air swirler has been damaged distorted or melted by high heat of a burn back condition the complete combustion chamber and the flame detector must be replaced 9 2 17 2 INSTALLATION 1 Slide combustion chamber fully into the heat exchanger 2 Swing burner head closed see Sec 8 5 1 Figure 50 Burner tube replacement www webasto us REPAIR 9 2 18 HEAT EXCHANGER REPLACEMENT 9 2 18 1 REMOVAL 1 Disconnect cables from temperature control thermostat temperature limiter and overheat fuse Detach cables from heat exchanger Remove burner head see Sec 9 2 5 4 Withdraw combustion chamber from heat exchanger 5 Remove heat exchanger 6 Perform procedures on components after disassembly see Sec 9 1 1 and combustion chamber are cleaned and n NOTE It is important that the heat exchanger inspected periodically and at least annually 9 2 18 2 INSTALLATION 1 2 3 4 Slide combustion chamber fully into heat exchanger Install burner head see Sec 9 2 5 Attach cables to heat exchanger Install and connect temperature control thermostat temperature limiter and overheat fuse DBW 2020 300 Figure 51 Heat exchanger replacement Webasto Product N A Inc REPAIR 9 3 COOLANT CIRCULATING PUMP REPAIR A defective coolant pump may caus
57. e the heater to overheat The heater s overheat protection is likely to respond in this case 9 3 1 REMOVAL 1 Drain the coolant Alternatively the hoses leading to the pump can be pinched closed with hose clamping pliers Disconnect the circulation pump electrical leads Disconnect coolant hoses from pump Dismount coolant pump 9 3 2 DISASSEMBLING 1 Clean the exterior of the pump and hold pump in a soft jaw vice Unscrew the impeller housing screws and remove housing and O ring Unscrew the impeller nut and carefully pry off impeller with two screwdrivers 4 Remove the spring seal ceramic and rubber seals On the U4810 pump unscrew the pump base screws and remove the base and the O ring Inspect all parts and replace if necessary Seals are always replaced 9 3 3 ASSEMBLING 1 Connect pump motor to a power source With a strip of very fine emery cloth polish the pump shaft to remove any contamination Remove power source from pump motor Assemble pump with all parts in order as shown in Fig 53 through Fig 55 The ceramic seal and the spring seal must be fitted as shown in Fig 52 with the hard side of the spring seal B against the ceramic seal face A A a v 0 Figure 52 Seal Orientation Webasto Product N A Inc 9 3 4 2 DBW 2010 2020 300 COOLANT HEATERS INSTALLING Mount the pump Connect coolant hoses to pump and tighten hose clamps Remove
58. ed air out of the coolant circuit according to instructions in Sec 8 8 1 Switch on and check function and for any leakage Impeller Housing 5 Pump Base O ring 6 Screw Impeller Housing Impeller 7 Nut Pump Base Spring Seal Assembly 8 Motor 64 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 10 INSTRUMENTS AND TOOLS 10 1 SETTING GAUGE Used for setting the gap between the points of the electrodes and the distance from the fuel nozzle Part Number 310646 SS I 10 2 TESTER Used for testing components of the heater test running the heater making fuel pressure adjustments when used with a pressure gauge and general troubleshooting Tester is connected in place of the control unit Tester Part Number 1302691A An optional 5 ft extension harness P N 905491A is available for tester where additional reach is required www webasto us INSTRUMENTS AND TOOLS 10 3 TEST APPARATUS Used for sampling and measuring the CO content of the exhaust gases In the case of irregularities of the combustion process or after major repairs the CO content should be measured and adjusted as necessary 10 4 SMOKE NUMBER TEST APPARATUS Used for checking smoke number ip 1 65 Webasto Product N A Inc INSTRUMENTS AND TOOLS 10 5 NOZZLE WRENCH Used for replacing high pressure fuel nozzle Part Number 66971A 10 6 FUEL PRESSURE GAUGE Used for checking and adjusting
59. ed with exhaust ventilation facilities 8 5 MAINTENANCE Li To ensure functional reliability of the heater the following maintenance must be performed NOTE The heater should be operated for approximately 20 minutes every 4 weeks to prevent mechanical parts seizing check combustion air inlet and exhaust outlet for contamination and clean as required outside the heating season the heater should be operated with the vehicle engine cold approximately www webasto us SERVICING every four weeks for 20 minutes setting the heating system to warm This avoids difficulties in the start up at least once a year in case of contaminated fuel more often the fuel filter or filter cartridge as well as the filter screen of the fuel pump must be replaced to avoid malfunctions atleast once a year the heat exchanger must be cleaned inside in case of leakage the fuel pump and the fuel lines must be replaced immediately otherwise every 5 years the heater should be checked on regular intervals by a Webasto service agent the latest before the beginning of the heating season 8 5 1 BURNER HEAD OPENING AND CLOSING with high voltage Prior to opening the burner head the power source to the heater has to be disconnected to prevent lethal injuries After closing and fixing burner head reconnect connectors in the vehicle WARNING ignition system operates NOTE Maintenance on the heater is easy By swin
60. egulations are detailed in the following The specific safety regulations applicable to this manual are highlighted in the individual chapters by Warnings Cautions and Notes 1 5 1 GENERAL SAFETY NOTES The year of first operation must be permanently marked on the identification label by removing the relevant number of the year The heaters are cleared for heating the vehicle engine and the passenger cabin The use of the heater in vehicles not subject to the EU Directive 70 156 EEC e g ships is partly governed by regional regulations The heater may only be fitted in vehicles or in independent heating systems with a minimum coolant capacity of 10 liters for DBW 2010 and 15 liters for DBW 2020 and 300 The heater must not be installed in the passenger or driver compartments of vehicles Should the heater nevertheless be installed in such a compartment the installation box must be sealed tight against the vehicle interior There must be sufficient ventilation of the installation box from the exterior in order not to exceed a maximum temperature of 85 C 185 F in the installation box Excessive temperatures may cause malfunctions poisoning and suffocation the heater must not be operated not even with timed operation in enclosed areas such as garages or workshops not equipped with an exhaust venting facility i WARNING Dueto the danger of WARNING At filling stations and fuel depots the heater must be switched off t
61. el 1531 4 41 7 8 Control Unit Identification of 4 42 8 Servicing 43 8 1 bas Pr pa or BOR ed RUE Ed e 43 8 2 Heater Servicifigr ax x RR n EO lU Po olo are 43 8 3 Vehicle S rvicing taba dk ne Ro eR Eon EE REOR A ER cR a ep d 43 8 4 Heater TeSE RUD s s iios eic eco doe dolce EORR iuh ete Rc ata cioe 43 85 Mainte ange INE 43 8 5 1 Burner Head Opening and 0 4 43 8 6 Visual Inspections and Regulations for Installation iilis Hn 45 8 6 1 Connection to Vehicle Cooling 45 8 6 2 Connection to Vehicle Fuel 45 8 6 2 1 FUELLINES rasa ewe re bead haa ea 45 8 02 2 Ruel Filter ir eol Rat oor qb UR cn 45 8 6 3 Combustion Air Supply cass access c Rok dob Pc E Red 64 45 864 Exhaust LING soe ck tabs oec es RR Rote oto
62. ent 9 2 17 1 Removal 9 2 17 2 Installation 9 2 18 Heat Exchanger Replacement 9 2 18 1 Removal 9 2 18 2 Installation Coolant Circulating Pump Repair 9 3 1 9 3 2 0 9 3 3 0 9 3 4 0 MP School Bus Circulation Pump 9 4 1 9 4 2 0 9 4 3 0 9 4 4 1 10 Instruments and Tools 10 1 Setting Gauge 10 2 Tester 10 3 CO2 Test Apparatus 10 4 Smoke Number Test Apparatus 10 5 Nozzle Wrench 10 6 Fuel Pressure Gauge 10 7 Grease and Locking Varnish 11 Product Information 11 1 155 White Timer for the Scholastic Heater Webasto Product N A Inc DBW 2010 2020 300 COOLANT HEATERS 6 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 1 INTRODUCTION 1 1 5 AND PURPOSE This repair shop manual is intended to support familiarized personnel in the repair of water heaters DBW 2010 2020 and 300 The water heater may only be operated with the fuel specified on the model plate and the relevant designated type of electrical connection 1 2 APPLICABILITY OF MANUAL This manual is applicable only for heaters identified on
63. erature Control Thermostat Version 1 red and green wires opens at 75 3 C 167 6 F closes at 68 5 C 154 9 F Version 2 orange and white wires opens at 70 3 C 158 6 F closes at 60 5 C 140 9 F Figure 4 Temperature Control Thermostat il NOTE DBW 2020 300 Only An optional control thermostat could be mounted in the heating system in place of the control thermostat located on the heater 12 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 2 1 5 FLAME DETECTOR 23 Figure 5 Flame Detector and Photo Disc The flame detector is a photosensitive varying resistance element that supplies a flame or no flame signal to the control unit IMPORTANT The photo disc to which the flame detector is attached must be flat and free floating over the nozzle and electrodes www webasto us 13 GENERAL DESCRIPTION 2 1 6 COMBUSTION AIR INTAKE 26 The air intake socket provides regulation of the combustion air quantity to the fuel quantity atomized by the high pressure atomizer nozzle Locking screw Combustion air Figure 6 Combustion Air Intake Bellows Webasto Product N A Inc GENERAL DESCRIPTION DBW 2010 2020 300 COOLANT HEATERS 2 1 7 COMBUSTION AIR FAN 5 AND MOTOR 2 The motor through a coupling drives the combustion air f n fan and through a toothed gearing the fuel pump The combustion air fan supplies the air necessary for combustio
64. ew www webasto us 63 Webasto Product N A Inc REPAIR 9 4 MP SCHOOL BUS CIRCULATION PUMP 9 4 1 REMOVAL l Drain the coolant Alternatively the hoses leading to the pump can be pinched closed with hose clamping pliers 2 Disconnect the circulation pump electrical leads 3 Disconnect coolant hoses from pump 4 Dismount coolant pump 9 4 2 DISASSEMBLING 1 Clean the exterior of the pump and hold pump in a soft jaw vice 2 Unscrew the impeller housing screws and remove housing and O ring 3 Unscrew the impeller lock screw and remove impeller 4 Remove the seal assembly Remove the pump adapter base Inspect all parts and replace if necessary Seals are always replaced ad Y 1 2 3 4 Figure 56 MP School Bus Circ Pump Exploded View Webasto Product N A Inc 9 4 4 Mount the pump DBW 2010 2020 300 COOLANT HEATERS 9 4 3 ASSEMBLING Connect pump motor to a power source With a strip of very fine emery cloth polish the pump shaft to remove any contamination Remove power source from pump motor Assemble pump with all parts in order as shown in Fig 53 INSTALLING Connect coolant hoses to pump and tighten hose clamps Remove hose clamping pliers if used Connectthe electrical leads and seal connector with dielectric grease such as Permatex Dielectric Tune up Grease or 3M Silicone Paste Dielectric Grease Refill coolant system and bleed trapp
65. fuel nozzle is too high Gap distance between the impeller and the housing too great DBW 2010 and Scholastic only 29 TROUBLESHOOTING Motor r p m too low Has the correct fuel been used according to the operating instructions Check fuel pump pressure is the pump pressure too high Adjust according to instructions see Sec 6 2 5 Observe the recommendations in the operating instructions Is battery voltage when charged below 10 V resp 20 V Charge battery Replace fuel nozzle Webasto Product N A Inc TROUBLESHOOTING 5 3 7 HEATER SMOKES Does heater smoke during operation also in waves Does heater smoke more than 20 seconds Are ignition electrodes Set ignition electrodes set correctly according correctly with setting to setting gauge gauge Replace fuel nozzle Flow through fuel nozzle insufficient replace does heater continue to smoke Did other unsuccessful start attempts precede Any accumulated fuel in Replace fuel nozzle the combustion chamber must be allowed to burn off Does heater continue to smoke Open burner remove combustion chamber are there coke deposits visible in the combustion chamber Clean combustion chamber 5 3 8 HEATER CANNOT BE SWITCHED OFF Does heater continue to run more than 180 sec after switching OFF Do exhaust gases still emit from the exhaust pipe after switching OFF Is there current through the sw
66. fuse if equipped test overheat limiter test solenoid valve Push IGNITION SPARK COIL button 6 sparking should be heard check electrode gap test ignition spark coil Turn MOTOR switch 5 motor should run reset inertia switch Scholastic Heater Only test motor Turn WATER PUMP switch 4 ON pump should run test pump Table 1 Test procedures and result INERTIA SWITCH All Scholastic heaters are equipped with a manual reset inertia switch located on the tray floor near the coolant pump The switch has a round red diaphragm and about the size of a 25 cent piece on top The purpose of this switch is to stop heater operation in the event the vehicle is involved in an accident or receives a strong impact shock e g hitting a curb When the switch responds the fan motor circuit is interrupted thus stopping air and fuel delivery Always check to make certain the inertia switch has not been tripped Resetting is accomplished by depressing the red diaphragm on top of the switch You should hear an audible click whenever the switch is reset MANUAL TEST RUN or HEATER A Turn the WATER PUM P switch 4 ON B Turn the M OTOR switch 5 ON C Push and hold the FUEL SOLENOID VALVE button 7 ON starts fuel flow to combustion chamber D Push and hold the IGNITION SPARK COIL button 6 ON starts electrodes sparking until combustion has taken place Webasto Product
67. ging the burner head open the following components become accessible il fuel pump and fuel nozzle solenoid valve ignition electrodes flame detector photo eye combustion chamber nozzle block pre heater if installed In order to obtain a convenient burner head opening angle it may be required to disconnect the electrical connections at the control unit OPENING OR REMOVAL 1 Disconnect electrical connections at control unit if required 2 Loosen nuts item 3 Fig 34 enough to release hinge bolts 2 3 Swing hinge bolts 2 out of way 4 Swing burner head 4 open CLOSING OR INSTALLATION 1 Swing burner head to the closed position 2 Swing hinge bolts 2 to locking position Webasto Product N A Inc SERVICING DBW 2010 2020 300 COOLANT HEATERS 3 Torque nuts 3 to 4 Reconnect electrical connections to the control unit DBW 2010 4 0 4 5 Nm 35 5 40 0 Ib in DBW 2020 300 7 5 8 5 Nm 66 75 Ib in Cotter pin Hinge Bolts 2 Nut 2 Burner head SWN NOTE Depending on the burner head direction of swing the cotter pin may be located to the opposite side CAUTION Always use hinge bolts to lock burner head in place Figure 34 Burner Head Attachment Webasto Product N A Inc 44 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 8 6 VISUAL INSPECTIONS AND REGULATIONS FOR INSTALLATION 8 6 1 CONNECTION TO VEHICLE COOLING SYSTEM The installation of th
68. idle period The operating indicator light also remains on 3 3 SWITCH OFF Switching off the heater stops combustion The operating indicator light remains on and run down commences The combustion air fan and circulation pump are deactivated after approximately 150 seconds The operating indicator light goes out to indicate the heater is now fully off Reactivation of the heater during run down is permitted The burner immediately resumes operation after the run up time C Heater motor D Electronic ignition unit E Fuel solenoid valve Flame detector G Control thermostat 1 Switch on 6 Switch off 2 Start 7 Heater stops 3 Combustion 8 Initial cycle 4 Control pause starts 9 Safety delay time 5 Control pause ends 10 Purge cycle www webasto us 19 Webasto Product N A Inc TECHNICAL DATA 4 TECHNICAL DATA Unless tolerances are shown within the technical data table a tolerance of 10 applies at an ambient temperature of 20 C 68 F and at the rated voltage and conditions ELECTRICAL COM PONENTS Control unit fan and circulation pump motors solenoid valve ignition coil heater cartridge for nozzle block pre heater and timer are designed either for 12 volt or 24 volt operation Temperature limiter overheat fuse flame detector photo eye temperature control thermostat preheat thermostat and switches are voltage independent components NOTE The allocation of circulation pumps to n heater uni
69. ignition electrodes making sure to fully engage into their niches 5 Check electrode gap with gauge and adjust if necessary see Sec 6 2 3 6 Swing burner head closed see Sec 9 2 5 Figure 43 Ignition Electrode Replacement Black Wire Brown Wire Figure 44 Ignition Coil Replacement www webasto us 55 Webasto Product N A Inc REPAIR DBW 2010 2020 300 COOLANT HEATERS 9 2 12 DRIVE MOTOR REPLACEMENT 9 2 12 2 INSTALLATION 9 2 12 1 REMOVAL NOTE Recessed edge of mounting flange item 3 Fig 45 must be oriented towards top NOTE Take note of alignment of all All items must be aligned as before disassembly n components before disassembly 1 Attach mounting flange 3 to drive motor 2 1 Move ignition coil out of the way See Sec 9 2 11 2 Tighten screws 8 to 5 6 Nm 44 53 Ib in 3 Align motor shaft coupler 4 and flange 3 with 2 Remove four screws item 6 Fig 45 and withdraw housing 5 and attach with screws 7 Frate ion L Trom burner 4 Tighten screws 7 to 5 6 Nm 44 53 Ib in 3 Disconnect motor leads 4 Remove three screws 7 with lock washers and withdraw drive motor 2 5 Remove two screws 8 from motor 2 and flange 3 6 Inspect all parts for wear and damage and replace as necessary 5 Connect motor electrical leads 6 Locate protection cap 1 and secure with the four screws 6 removed earlier 7 Tighten screws 6 to 2 Nm 18 Ib in
70. itch or timer when switched OFF Switch or timer defective Electronic control unit defective Control thermostat defective Electronic control unit defective Solenoid valve defective Does control thermostat open when the upper set point is reached No positive voltage on the fuel solenoid valve Does fuel solenoid valve close stuck open Webasto Product N A Inc 30 DBW 2010 2020 300 COOLANT HEATERS Does heater smoke after switching OFF Fuel solenoid valve piston is leaky www techwebasto com DBW 2010 2020 300 COOLANT HEATERS FUNCTIONAL ADJUSTMENTS 6 FUNCTIONAL ADJ USTMENTS Measure control unit power supply voltage Operate heater for approximately 5 min 6 1 GENERAL Measure CO contents and compare with CO diagram This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability operated in closed areas like garages or workshops with no exhaust ventilation facilities To prevent fires do not switch heater on with burner swung open WARNING The heater must not be 6 2 ADJUSTMENTS 6 2 1 ADJUSTMENT OF CO CONTENTS It is allowed to change the manufacturer s setting for combustion air quantity by rotation of the setting ring M easurement of the CO value of the exhaust gas must be performed followed by an adjustment of the combustion air quantity as required in case of repairsto the burner
71. m PP eli zi N3385 al W KB ii ATDIHIA lo 0 za vx pi A 0 5 MSIL N3349 N3349 EL an ae Vau K NWOB NMOYA NMOud 18 Schematic Scholastic Heater With Digital 7 Day 3 Program Timer Model 1531 Figure 32 Webasto Product N A Inc 41 www webasto us CIRCUIT DIAGRAMS DBW 2010 2020 300 COOLANT HEATERS 7 8 CoNTROL UNIT IDENTIFICATION OF TERMINALS 2 W B Figure 33 Control Unit Identification of Terminals 2 Ac 1 1 2 3 1 411516 5 6 7 8 CONNECTOR BLOCK A1 coolant circulating pump A2 coolant circulating pump CONNECTOR BLOCK B 1 B2 B3 4 5 6 On Off switch with low voltage protection Battery negative Control light Operation indicator Battery positive Optional coolant pump control input Control light Operation indicator Webasto Product N A Inc CONNECTOR BLock C C1 To temperature control thermostat C2 To Blower motor overheat fuse temperature limiter and fuel solenoid valve C5 For all heater components C6 Flame detector C7 From normally closed control thermostat C8 To ignition coil Control thermostat with white and orange wires
72. n Rated motor r p m DBW 2010 4500 RPM There are two different fan designs in use DBW 2020 5000 RPM DBW 2010 lateral canal fan DBW 300 5800 RPM DBW 2020 300 radial fan DBW 2010 DBW 2020 300 Figure 7 Combustion Air Fans Webasto Product N A Inc 14 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 2 1 8 COUPLING 4 The coupling clutch provides the mechanical connection between the motor and the combustion air fan Figure 8 Li Motor to Fan Coupling Clutch NOTE Before reusing the coupling it has to be checked for cracks wear and the condition of the flat portion of the center shaft hole Too much play on the shaft will result in a load continuous noise 2 1 9 GEARING 6 The gears drive the fuel pump with a gear ratio of 1 3 5 Figure 9 www webasto us Fuel Pump Drive Gearing sector of the toothed gearing as well as at the flat portion of the shaft hole of the large gear the gears will have to be replaced NOTE If signs of wear are showing within the GENERAL DESCRIPTION 2 1 10 FUEL Pump 24 The fuel pump single staged toothed gear pump delivers the fuel from the tank to the heater and brings it to a pressure of 10 0 5 bar 145 7 psi for DBW 2010 DBW 2020 and DBW 300 DBW 2010 equipped with a 0 35 Gal hr nozzle only For DBW 2010 with 0 40 Gal hr nozzle the fuel pressure should be set to 8 0 5 bar 116 7 psi
73. n the ignition electrodes The flame is detected by the flame detector F then the electronic ignition unit stops producing high voltage and combustion continues on its own spark on electrodes is required only to ignite the flame Atthis time the heater is working and produces heat 3 2 HEATING OPERATION After reaching operating temperature the control unit in conjunction with the temperature control thermostat takes over to provide controlled operation by activation and deactivation of the burner in order to maintain a nearly constant temperature of the heat exchanger coolant The heating operation is terminated as soon as the upper operating point on the temperature control thermostat is exceeded A Green light operation indicator control thermostat Coolant circulation pump negative heater 00 FUNCTIONAL DESCRIPTION The heater now starts the control idle period Heater operation is resumed when the temperature drops below the lower operating point of the temperature control thermostat CONTROL IDLE PERIOD A rise in temperature above the upper operating point makes the solenoid valve in the fuel pump shut off the fuel supply initiating the run down The flame extinguishes the combustion air fan and the circulation pump however continue their operation After approximately 150 seconds run down is completed with deactivation of the combustion air fan The circulation pump remains in operation during the control
74. nition coil NOTE Take care when connecting DC voltage to the ignition coil leads Connect positive to the black lead and negative to the brown lead With ignition coil energized an ignition spark will jump the ignition electrodes ALTERNATE METHOD USING TESTER P N 1302691A Exchange control unit with tester and swing burner head open see Sec 8 5 1 Press and hold the ignition button to activate the ignition coil and observe spark condition CAUTION Do notenergize ignition coil for A a period longer than 15 seconds Black Wire Brown Wire Figure 24 Ignition Coil Check www webasto us 33 FUNCTIONAL ADJUSTMENTS 6 2 5 FUEL PUMP CHECK A pressure gauge and the tester P N 1302691A is required for performing this test A suitable gauge with a range from 0 to 15 bar 0 to 220 PSI can be procured from your authorized Webasto dealer il CHECK NOTE The fuel pump and the fuel hoses must be replaced every 5 years Exchange control unit with tester and swing burner head open see Sec 8 5 1 Remove nozzle Screw pressure test gauge into nozzle holder Switch on heater motor via tester Press fuel solenoid button on tester Read pressure gauge If adjustment is required release button and turn pump pressure screw 1 8 of a turn at a time in or out to increase or decrease pressure see Fig 10 for location of pressure screw Repeat testing and adjustment steps until pressur
75. nstall burner head see Sec 9 2 5 S 8 9 A N lt 1 Lock nut S 2 Washer 6 Stepped Roll Pin S 97 3 Magnetic Head 7 Spring 9 4 Valve Chamber 8 Plunger 69 5 O ring 9 Nozzle Holder M Figure 39 Fuel Valve and Solenoid Assembly www webasto us 53 REPAIR 9 2 7 FUEL PUMP REPLACEMENT 9 2 7 1 REMOVAL 1 2 Remove burner head see Sec 9 2 5 Disconnect electrical leads from solenoid valve flame detector nozzle pre heater and ignition electrodes Loosen the retaining clamp bolt and dismount the ignition electrodes Remove disc retaining ring and disc NOTE During the following steps ensure that escaping fuel is captured or immediately neutralized and properly disposed of Disconnect the fuel return and supply pipes from the fuel pump Disconnect the fuel delivery pipe from the pump to the nozzle holder Unscrew the four screws on the back wall and take the complete assembly out Remove the retaining ring from the fuel pump shaft and dismount the gear wheel 9 Removethe two bolts securing the fuel pump to the back wall 9 2 7 2 INSTALLATION NOTE Do not disturb the pump pressure nm regulating screw The pump has been pre set to the correct pressure 1 Attach new fuel pump to back wall with the two por screws removed earlier Install gear wheel on pump shaft and secure with retaining ring Dot gear wheel in four places with ISOFLEX LDS 18 Special A lubri
76. o prevent explosions dust may build up e g in the vicinity of fuel coal w ood cereal depots or similar installations the heater must be switched off to prevent explosions The heater must not be operated near flammable materials such as dry grass and leaves cardboard boxes paper etc CAUTION Where flammable fumes or Webasto Product N A Inc INTRODUCTION In the vicinity of the water heater a temperature of 85 C 185 F 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 cooling water level proceed in accordance with the vehicle manufacturer s instructions The water in the heating circuit of the heater must contain a minimum of 2096 of a quality brand anti freeze Additives in the heating circuit must not affect metals plastics and rubber and must leave no deposits The opening pressure in the vehicle cooling system normally indicated on the radiator filler cap must be between 0 4 and 2 0 bar above operating pressure also applicable to separate heating circuits 1 6 LEGAL PROVISIONS FOR INSTALLATION DBW series heaters have been type tested and approved in accordance with EG Directives 72 245 EW G EM V and 2001 56 EG heater with the following EG permit numbers e1 2001 56 0006 xx Installation is governed above all by the provisions in Annex VII of Directi
77. oints are to be secured against slipping with hose clamps should no screwed mechanical unions be in use Should fuel hoses be installed always use the hoses supplied or offered by Webasto If other hoses are used they must at least meet the specifications of DIN73379 1C type 3 Fuel hoses must not be kinked or twisted and must be secured with clamps every 25 cm 10 in Also fuel lines may be used consisting of materials standard in the manufacturing of vehicles e g steel or plastic lines made of unhardened light and temperature stabilized PA11 or PA12 e g M ecanyl RWTL according www webasto us SERVICING to DIN 73378 observing the applicable jointing instructions Basic rules for the routing of fuel lines are Protect against undue temperatures WARNING In overheat condition the N heater outer shell may reach the flash point temperature of Diesel fuel Protect lines from stone strikes and debris that could damage them and result in leakage Dripping or evaporating fuel must not be allow ed to accumulate or ignite on hot components or electrical equipment The installation of an additional fuel pump is not allowed Fuel lines permissible dimensions Inner diameter for suction and return line 6 mm except Scholastic Heater Scholastic Heater inner diameter for suction line 3 16 inches Maximum permissible length for each suction and return line 10 m Maximum permissible suction height
78. r CHECK Swing burner head open see Sec 8 5 1 Disconnect flame detector leads Connect flame detector leads to ohm meter Cover flame detector glass bulb with your thumb Check resistance rated value 20 kOhm Uncover flame detector and expose to strong light Check resistance rated value 200 Ohm ALTERNATE METHOD USING TESTER P N 1302691A Exchange control unit with tester and swing burner head open see Sec 8 5 1 Watch Flame Control LED while holding your thumb over the flame detector glass bulb LED will darken considerably Remove your thumb LED will brighten considerably Shine a bright light on the flame detector if in a dimly lit area The fluctuation of the LED between dim and bright will indicate the flame detector is working properly Flame Detector Figure 22 Flame Detector Check Webasto Product N A Inc DBW 2010 2020 300 COOLANT HEATERS 6 2 3 IGNITION ELECTRODE CHECK AND SETTING electrodes must not show any damage Damaged insulation of the electrodes requires their replacement Setting ignition electrodes with a spacing beyond the tolerances shown in Fig 23 may or will cause ignition failures mn NOTE The insulation body of the ignition the setting gauge as shown In addition the front edge of the setting gauge must rest against the atomizer nozzle and the tips of the electrodes in both notches Hn NOTE The ignition electrodes can be set with CHECK
79. reheating is deactivated when the thermostat ambient temperature is 8 C 46 F Power consumption is 130 13 Watts CHECK Swing burner head open see Sec 8 5 1 Disconnect electrical connector Connect ohmmeter to connector Using cooling spray to cool down thermostat Resistance max 4 5 www techwebasto com CIRCUIT DIAGRAMS DBW 2010 2020 300 COOLANT HEATERS CIRCUIT DIAGRAMS 7 1 DBW 2010 12 V AND 24 V EARLY CANADIAN VERSION 7 AIWNOUO _ HAIV4FH 1 HSV 2 MOTISA B NMOSS la NMOWA i li xi 0 2 w Wan 2 Z 25 TIVO DNMIM NE qd jo 9 i T e 5 si NMOVA NMOYI 15 ES UA T Pax kk kb T i aX eim rs c 9 k n m m E gt pa m m AVES m oO TAL A m W N pol w lt 2 I 5 z Y 9 STTOR J lo zo 9 V 99 4 Y Y p IOA LN S D i B a SdINVI HSvd 2 MOTHA 8 o D z NEJ vis qu 2 UHALVAH AHL OL d 318VO DNRHIM GAY 9 oct 937 0 2 d NMOYA 4 NMONS lt la jo w w i lt E m EB E n o E dz n 18 lt 5 E AUD m GH d ZN MO
80. rheat fuse replacement of burner replacement of fuel atomizing nozzle replacement of nozzle preheat cartridge replacement of nozzle preheat thermostat replacement of ignition coil replacement of flame detector replacement of combustion chamber replacement of control unit 8 7 1 HEATER REMOVAL AND INSTALLATION 8 7 1 1 REMOVAL 1 Disconnect connectors of cable harness in vehicle and of circulation pump 2 Disconnect combustion air intake on heater if equipped 3 Loosen clamp on exhaust outlet 4 Loosen fuel supply and return line connections and fit dummy plugs Close water valves as applicable 5 Loosen hose clamps on coolant hoses disconnect hoses and fit dummy plugs 6 Remove 3 screws and washers or 4 screws and washers of heater base 7 Remove heater 8 7 1 2 1 Locate heater for installation and secure with 3 screws and washers or 4 screws and washers INSTALLATION 2 Secure line on exhaust outlet using clamp 3 Slide on coolant hoses and fasten with hose clamps Torque clamps with 1 5 Nm Open water valves 4 Connect fuel supply and return lines and tighten connections or screw tight with banjo bolt and new gaskets 5 Secure combustion air inlet line on heater if applicable 6 Connect electrical connectors of cable harness in vehicle and to circulation pump 7 Bleed fuel supply system 8 Bleed coolant circuit www techwebasto com DBW 2010 2020 300 COOLANT H
81. rseded by a contractual agreement E SA WS ZAC wm Warranty coverage for Marine and Off road applications containing DBW series heaters and the ESS GO tha dl SK R CSL Cargo Heaters are limited to a maximum of 3 000 hours of usage All other models are ME Z w dim limited to 2 000 maximum hours su Replacement parts are covered for six 6 months or the remainder of the original warranty period Em usw which ever is longer Replacement heaters are considered a Replacement Part A 4i W Qs M The intent of the Webasto warranty is to protect the end user heater from such defects and provide BE 30 CE s i SZM free repair and replacement of defective parts in the manner provided herein During the warranty SN e m i ir discreti i mo Sa period the exclusive remedy will be for Webasto at their discretion to repair or replace those parts ee which are demonstrated to be defective in material or workmanship A u EE T ZK While warranty is provided to the end user it is to be administered and serviced through an SEZ TEE SESSI 3 authorized Webasto dealer in accordance with the Webasto warranty policy or contractual E M s t Ee v agreement between Webasto and a second party reru
82. s a heating element located in the fuel nozzle holder Operated by the preheat thermostat 7 it heats the fuel inside the nozzle holder when the temperature drops below 0 C 32 F Power consumption 130 Watts Red 12V Green 24 V Figure 19 Heating Cartridge 17 Webasto Product N A Inc GENERAL DESCRIPTION DBW 2010 2020 300 COOLANT HEATERS 2 1 20 COOLANT CIRCULATING PUMP The externally mounted circulation pump ensures proper coolant circulation in the vehicle and heater circuit The pump is activated by the control unit to operate as long as the heater is in operation The heaters may be operated with circulation pump U 4810 or U 4846 for the DBW 2010 heater the U 4814 or U 4851 for the DBW 2020 and 300 heaters and a school bus specific M P coolant pump for the Scholastic Heater MP School Bus Pump Scholastic Heater Figure 20 Coolant Circulating Pumps Webasto Product N A Inc 18 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 3 FUNCTIONAL DESCRIPTION 3 1 SWITCH Upon switching on the Webasto heater the operation indicator lamp A comes on the heater motor C and the coolant circulating pump B begin to run After about 10 25 seconds the solenoid valve E opens and fuel is sprayed into the combustion chamber At the same time the electronic ignition unit D produces high voltage 8000V and the fuel air mixture in the combustion chamber is ignited by the spark o
83. stallation box exceeds the permitted ambient temperature of the heater see Technical Data the vent port must be enlarged 8 6 4 EXHAUST LINE A The exhaust pipe outlet opening must not point in the direction of motion CAUTION Observe official regulations concerning the installation see 1 6 The exhaust pipe outlet opening must be located so as not to expect clogging by snow or mud The combustion air intake and exhaust outlet is to be located so that no air pressure difference builds up in any operating condition of the vehicle Rigid pipes made of unalloyed or alloyed steel with a minimum wall thickness of 1 0 mm have to be used as exhaust line or flexible pipes made of alloyed steel only The exhaust pipe is secured to the air heater e g with a clamp Permissible exhaust line dimensions DBW 2010 38 mm 1 5 in DBW 2020 up to 32 DBW 300 up to 15 280 mm 3 15 in DBW 2020 from 33 DBW 300 from 165 70 mm 2 75 in max length 5 m 16 ft max bend 270 As alternative an exhaust deflector can be installed when cleared by Webasto 8 7 REMOVAL AND INSTALLATION CAUTION In installed condition only the A following disassembly or removal procedures are permitted should enough space for removal allow such action Webasto Product N A Inc DBW 2010 2020 300 COOLANT HEATERS replacement of temperature limiter replacement of temperature control thermostat replacement of ove
84. start of each season by an authorized Webasto dealer Service parts m TA ZE including fuel nozzles filters and overheat fuses are not covered under warranty A 2 A Warranty Registration Card is included with the sale of each heater It is the owner s zn Mr i TE gt pw responsibility to complete this card and return it to Webasto for registration A proof of ZEK i EE Ba purchase is required for all heaters that are not registered Ti O This warranty gives you specific legal rights and you may also have other rights which vary by State or Province E n a E or ETA OS Maas SO Re THE WARRANTY DESCRIBED IN THIS POLICY SHALL BE IN LIEU OF ANY OTHER WARRANTY W Em 223 EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY SB s MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE B 22 E i Wi gt Ste Hn Pow WA E li n pua ET T T T TT T TT ito A OO ESSA RI RO AA MARS ANS CARN a o ie a Ae NSS AM EN WAR AOR PN RON RON RON P e AOR O KW Misc un ee de scsi ia ao a geje cje jeja 2 REP EID SS 2 e ND ZEG EEE Z ARSA ERE We
85. sticking one half of the Velcro to the timer and the other to a secure mounting location The timer can be mounted with screws in place of Velcro Connect the Webasto heater switching harness to the timer Refer to the wiring diagram below for directions Product Information After all connections are made mount the new timer Using customer installer supplied Velcro tape or screws Optionally an On Off toggle switch can be installed with the timer The timer will work without using the toggle switch however it s a nice option to have To mount the toggle switch locate an appropriate mounting location and drill a mounting hole Refer to the wiring diagram on next page to connect the appropriate wires to the toggle switch On Signal Not Used 12 Volt Positive Ground 12 Volt Positive e 55 BULI M Webasto Legend TI Timer 7 Day NOI 1 9 Duetsch Connector Wiring diagram ISS Timer www webasto us 67 Webasto Product N A Inc PRODUCT INFORMATION DBW 2010 2020 300 COOLANT HEATERS Category Thermosystems Jebasto Document Number PIOO7RC Feel the drive Date Posted 02 02 2007 Description 155 WHITE TIMER INSTALLATION OPERATION INSTRUCTIONS On Signal Not Used 12 Volt Positive Ground 12 Volt Positive D o a I w 3 m a
86. ter Li NOTE Since the heater operates in the 68 C 155 F to 75 C 167 F On to Off Off to On range and the vehicle engine may be hot e g coolant above 75 C 167 F the heater will not start until the coolant temperature is below 68 155 F THIS IS NORMAL and does not indicate a problem www webasto us 25 TROUBLESHOOTING Webasto Product N A Inc TROUBLESHOOTING DBW 2010 2020 300 COOLANT HEATERS 5 3 INSTRUCTIONS FOR FAULT FINDING 5 3 1 COMBUSTION STARTS IMMEDIATELY WHEN HEATER 15 SWITCHED ON NO Electronic control unit defective YES 5 3 2 HEATER DOES NOT START WHEN SwiTCHED ON Voltage on terminal Are electric fuses Volume on control Volume on control Control thermostat B1 B2 and B4 defective thermostat thermostat after defective cooling of coolant in the cycle Replace fuses and Feed connection Temperature in the switch heater ON defective cooling cycle too high does fuse release Are electric fuses defective Voltage too low Voltage on motor Voltage across lt 18 1V resp terminal C2 and C5 lt 9 0 5V of control unit Under voltage Control unit defective protection in the replace control unit has Check feed reacted charge battery connections to motor for circuit interruptions Is the motor easy to Is the motor easy to Is the motor shaft easy Motor defective spin up spin up with the nozzle to spin up when internal fault holder plate removed remove
87. the water when overheating loss of cooling water may result requiring continuous replenishment Additives in the coolant must not affect metals plastics or rubber and leave no deposits NOTE Bleeding must always be performed in accordance with manufacturer s instructions For bleeding the circulation pump must not be switched on Then operate engine at increased idle until radiator thermostat opens Shut down engine check coolant level and replenish as required Switch on heater and vehicle heating fan with engine shut down After a certain cool down period the heater must automatically switch on and control to off In case of no restart attempt the temperature limiter on the Webasto Product N A Inc SERVICING heater has responded because the heater has not been bled properly Reset temperature limiter allow temperature limiter to cool self resetting and repeat complete bleeding procedure NOTE The heater may be equipped with an n automatically resetting temperature limiter The manual reset is not necessary Webasto Product N A Inc 48 DBW 2010 2020 300 COOLANT HEATERS 8 8 2 FUEL SUPPLY SYSTEM BLEEDING When switching the heater on the fuel pump pulls fuel from the fuel tank to prime the complete fuel supply system Should no combustion be achieved with the first start attempt switch the heater off and on again www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 9 REPAIR 9 1 GENERAL INFOR
88. ts must be in accordance with coolant resistances Webasto Product N A Inc 20 DBW 2010 2020 300 COOLANT HEATERS FUEL FOR DBW SERIES DIESEL HEATING OIL KEROSENE Diesel fuel heating oil and kerosene are suitable fuels for the heater The Diesel fuel specified by the vehicle manufacturer is suitable as fuel for the heater Any negative effect caused by additives is not known When the fuel for the heater is drawn from the vehicle s fuel tank the vehicle manufacturer s specifications concerning additives are to be observed Any addition of waste oil is not permitted When changing to cold resistant fuels the heater must be operated for approx 10 minutes to ensure that the fuel pump nozzle holder nozzle and lines are filled with the new fuel When using fuel from a separate fuel tank and at temperatures below 0 C winter Diesel fuel must be used www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 4 1 TECHNICAL DATA OF THE HEATERS HEATER DBW 2010 DBW 2020 DBW 300 DESIGN Coolant heater with high pressure nozzle HEAT OUTPUT kW 13 0 23 3 30 0 Btu h 45 000 80 000 104 000 FUEL Diesel 1 2 Arctic and Kerosene FUEL CONSUMPTION 1 5 3 0 4 0 gal h US 0 4 0 8 1 2 gal h Imp 0 3 0 7 0 9 RATED VOLTAGE V 12 or 24 OPERATING VOLTAGE V 10 14 or 20 28 POWER CONSUM PTION OF HEATER WITHOUT COOLANT CIRCULATION PUMP 60
89. umber DBW 2020 31 and DBW 300 10 inclusively Webasto Product N A Inc 22 www techwebasto com DBW 2010 2020 300 COOLANT HEATERS 5 TROUBLESHOOTING 5 1 Quick CHECK TRoUBLESHOOTING MATRIX PROBLEM Switch On No Function TROUBLESHOOTING CHECK REPAIR OR REPLACE AS NECESSARY Control Light OFF after 30 Seconds Blower Motor in Unit Inoperative Blower Motor in Unit No Prime Cycle Blower Motor in Unit No After run Coolant Circulating Pump Inoperative Ignition Spark Absent Combustion Does Not Take Place Combustion Stops After 30 Seconds Combustion Cannot Be Stopped During Combustion Light Color Smoke During Combustion Dark Color Smoke Heating Unit Overheating 5 2 TESTER INSTRUCTIONS TESTER P N 1302691A TESTER 440280 for DBW 2010 2020 300 in 12 or 24 Volt Appareil de Contr le 440280 pour DBW 2010 2020 300 in 12 or 24 Volt Ui gt WN www webasto us LED input power to heater LED control thermostat LED flame detector On Off switch water pump On Off switch motor Push Button ignition spark coil Push Button fuel solenoid valve 23 The tester unit has been designed to quickly check the proper operation of the various heater components By using the tester in place of the heater control unit you are able to manuall
90. ve 2001 56 EC Li Directive 70 156 EEC and should similarly be observed in countries without specific regulations NOTE The provisions of these Directives are binding within the territory governed by EU Extract from Directive 2001 56 EC Annex VII 1 7 1 A clearly visible indicator within the user s field of vision must show when the heater is switched On or Off Li IMPORTANT Failure to follow the installation instructions and the notes contained therein will lead to all liability being refused by Webasto The same applies if repairs are carried out incorrectly or with the use of parts other than genuine spare parts This will result in the invalidation of the type approval for the heater and therefore of its homologation EC type licence NOTE For further notes and provisions relating to the installation of the heater in vehicles refer to the installation instructions Webasto Product N A Inc DBW 2010 2020 300 COOLANT HEATERS Installation Instructions for Webasto fuel tanks for the fuel supply of water heaters in vehicles in vehicles the installation is not permitted in the passengers or driver s compartment the fuel filler neck must not be located in the passengers or driver s compartment of any vehicle fuel containers must either be equipped with a vent cap or any other type of ventilation vent line Only vent caps in accordance with DIN 73400 may be used All fuel containers offered in
91. y control the heater to test components and actually operate the unit in heating mode The actual testing is completed in two steps first you perform an individual component test and then a manual start and run test both designed to pinpoint actual problems in the heater system The tester should be used in conjunction with this Service and Repair M anual P N 699745 which details complete troubleshooting and repair procedures 5 2 1 TEST PROCEDURES SETUP A Remove connector blocks from heater control unit inspect for loose wires corrosion and proper wire connections B Plug control unit connector blocks into tester C Set heater switch timer to ON and turn vehicle heater valve to FULL mode if equipped D Proceed to component test procedures Webasto Product N A Inc TROUBLESHOOTING COMPONENT TEST PROCEDURES DBW 2010 2020 300 COOLANT HEATERS Test Step Result Tester connected lights up BATTERY LED 1 unit lights up CONTROL THERM OSTAT LED 2 If not test input voltage at control terminals B4 and B2 check battery connections check battery voltage test switch timer test control thermostat on heater Normal operating range approx 75 C 167 F or higher open no heat required approx 68 C 155 F or lower closed heat required times heard Push FUEL SOLENOID VALVE button 7 several clicking of solenoid should be test temperature

Service and Repair Manual DBW 2010 DBW 2020

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