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
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– 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.
The heater may only be fitted in vehicles or in the following meaning: independent heating systems with a minimum coolant capacity of 10 liters for DBW 2010 and 15 liters for DBW DANGER: This heading and text style is 2020 and 300.
DBW 2010/2020/300 COOLANT HEATERS In the vicinity of the water heater a temperature of 85° C Installation Instructions for Webasto fuel tanks for the (185 °F) must not be exceeded under any circumstances fuel supply of water heaters in vehicles: (e.g.
– a relay and wiring harness temperature control thermostat. The heaters DBW 2010, DBW 2020, DBW 300 and Scholastic Heater™ basically consist of: – the combustion air intake (adjustable) – the combustion air fan and motor –...
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GENERAL DESCRIPTION DBW 2010/2020/300 COOLANT HEATERS 9 10 11 12 13 14 15 16 DBW 2010 1. Electronic control unit 10. Pre-heater 18. Coolant inlet 2. Motor 11. Coolant outlet 19. Heat exchanger 3. Electronic ignition unit 12. Bleeding valve 20.
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DBW 2010/2020/300 COOLANT HEATERS GENERAL DESCRIPTION DBW 2020 DBW 300 1. Electronic control unit 10. Pre-heater 18. Coolant inlet 2. Motor 11. Coolant outlet 19. Heat exchanger 3. Electronic ignition unit 12. Bleeding valve 20. Combustion chamber 4. Coupling (clutch) 13.
GENERAL DESCRIPTION DBW 2010/2020/300 COOLANT HEATERS 2.1 P 2.1.3 (17) ARTS OF THE EATER EMPERATURE IMITER The temperature limiter is a thermostat that responds 2.1.1 LECTRONIC ONTROL (opens) at a temperature of 95° C (203° F). The temperature limiter will automatically reset (closes) once The control unit SG 1553 in 12 volt and 24 volt versions temperature falls well below 95°...
DBW 2010/2020/300 COOLANT HEATERS GENERAL DESCRIPTION 2.1.5 (23) 2.1.6 (26) LAME ETECTOR OMBUSTION NTAKE The air intake socket provides regulation of the combustion air quantity to the fuel quantity atomized by the high-pressure atomizer nozzle. Screw Photo Disc Flame Detector...
4500 RPM combustion. DBW 2020 5000 RPM There are two different fan designs in use: DBW 300 5800 RPM DBW 2010 — lateral canal fan DBW 2020/300 — radial fan DBW 2010 Fan wheel Drive motor DBW 2020/300 Figure 7: Combustion Air Fans Webasto Product N.A., Inc.
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).
GENERAL DESCRIPTION DBW 2010/2020/300 COOLANT HEATERS 2.1.12 F (14) 2.1.14 E OZZLE AND OZZLE OLDER LECTRONIC GNITION The fuel atomizing nozzle is screwed into the nozzle The electronic ignition unit develops high voltage of holder. Under pressure, the fuel nozzle atomizes the fuel approximately 8000 volts to produce a spark at the tips entering the combustion chamber.
(21) WIRLER The preheat thermostat is installed in the burner head on the back wall (DBW 2010) or on the photo disc (DBW Within the burner tube of the combustion chamber, the 2020/300). It switches the nozzle holder pre-heating air-fuel mixture is burned.
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, MP coolant pump for the Scholastic Heater™.
3.1 S WITCH thermostat. Upon switching on the Webasto heater, the operation ONTROL IDLE PERIOD indicator lamp (A) comes on, the heater motor (C) and A rise in temperature above the upper operating point the coolant circulating pump (B) begin to run.
TECHNICAL DATA DBW 2010/2020/300 COOLANT HEATERS 4. TECHNICAL DATA DBW S UEL FOR ERIES IESEL EATING EROSENE Diesel fuel, heating oil and kerosene are suitable fuels for Unless tolerances are shown within the technical data the heater. table, a tolerance of ± 10% applies at an ambient The Diesel fuel specified by the vehicle manufacturer is temperature of +20 °C (+68 °F) and at the rated voltage...
(inch) 228 (9.0) 279 (11.0) WEIGHT OF HEATER INCL. CONTROL UNIT kg (lb) 15 (33) 22 (48.5) NOTE: Specifications for the Scholastic Heater are the same as the DBW 2010 heater unless otherwise specified. www.webasto.us Webasto Product N.A., Inc.
TECHNICAL DATA DBW 2010/2020/300 COOLANT HEATERS 4.2 T ECHNICAL ATA OF THE IRCULATING UMPS 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...
TESTER 440280 for DBW 2010/2020/300 in 12 or 24 Volt Appareil de Contrôle 440280 pour DBW 2010/2020/300 in 12 or 24 Volt Flame Control The actual testing is completed in two steps, first you Control + –...
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TROUBLESHOOTING DBW 2010/2020/300 COOLANT HEATERS OMPONENT ROCEDURES Test Step Result If not Tester connected BATTERY LED (1) unit lights up - test input voltage at control terminals B4(+) and B2(-) - check battery connections - check battery voltage CONTROL THERMOSTAT LED (2)
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DBW 2010/2020/300 COOLANT HEATERS TROUBLESHOOTING 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. Once the manual test run has been successfully completed, set the heater switch or timer to OFF, remove the tester and reconnect the control unit.
TROUBLESHOOTING DBW 2010/2020/300 COOLANT HEATERS 5.3 I NSTRUCTIONS FOR AULT INDING 5.3.1 OMBUSTION TARTS MMEDIATELY EATER WITCHED Electronic control unit defective 5.3.2 EATER TART WITCHED Voltage on terminal Are electric fuses Volume on control Volume on control Control thermostat B1, B2 and B4?
DBW 2010/2020/300 COOLANT HEATERS TROUBLESHOOTING 5.3.3 ON, T . 30 S FTER WITCHING EATER WITCHES AFTER PPROX ECONDS AULT Overheat fuse Can you detect the Voltage across Check feed Is there the same Insulator of opened? Has buzzing sound of...
TROUBLESHOOTING DBW 2010/2020/300 COOLANT HEATERS 5.3.4 EATER TARTS FTER EVERAL TARTING TTEMPTS 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?
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DBW 2010/2020/300 COOLANT HEATERS TROUBLESHOOTING 5.3.6 EATER MOKES Is combustion air Are the gas passages Motor r.p.m. too low intake or exhaust (fins) of the heat outlet dirty? exchanger highly soiled? Clean if necessary, Clean according to correct installation instructions.
TROUBLESHOOTING DBW 2010/2020/300 COOLANT HEATERS 5.3.7 EATER MOKES Does heater smoke more Does heater smoke Does heater smoke than 20 seconds? during operation (also after switching OFF? in waves)? Are ignition electrodes Set ignition electrodes Fuel solenoid valve set correctly according...
DBW 2010/2020/300 COOLANT HEATERS FUNCTIONAL ADJUSTMENTS 6. FUNCTIONAL ADJUSTMENTS – Measure control unit power supply voltage – Operate heater for approximately 5 min. 6.1 G ENERAL – 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.
FUNCTIONAL ADJUSTMENTS DBW 2010/2020/300 COOLANT HEATERS 6.2.2 6.2.3 LAME ETECTOR ESISTANCE HECK GNITION LECTRODE HECK AND ETTING NOTE: The glass bulb of the flame detector NOTE: The insulation body of the ignition and the viewing glass of the window (refer to electrodes must not show any damage.
FUNCTIONAL ADJUSTMENTS DBW 2010/2020/300 COOLANT HEATERS 6.2.6 6.2.7 OLENOID ALVE HECK OZZLE LOCK HEATER HECK At a temperature of <0° C (<32° F) the heater cartridge NOTE: A leaking solenoid valve seat or valve in the nozzle block is activated. The heating period...
DBW 2010/2020/300 COOLANT HEATERS CIRCUIT DIAGRAMS 7. CIRCUIT DIAGRAMS 7.1 DBW 2010 12 V 24 V - E ARLY ANADIAN ERSION Figure 26: Schematic - DBW 2010 Early Canadian Version www.webasto.us Webasto Product N.A., Inc.
CIRCUIT DIAGRAMS DBW 2010/2020/300 COOLANT HEATERS 7.6 S 12 V - 1529 CHOLASTIC EATER WITH IMER ODEL Figure 31: Schematic - Scholastic Heater™ With Digital 7-Day, 3 Program Timer Model 1529 Webasto Product N.A., Inc. www.techwebasto.com...
DBW 2010/2020/300 COOLANT HEATERS CIRCUIT DIAGRAMS 7.7 S 12 V - 1531 CHOLASTIC EATER WITH IMER ODEL Figure 32: Schematic - Scholastic Heater™ With Digital 7-Day, 3 Program Timer Model 1531 www.webasto.us Webasto Product N.A., Inc.
CIRCUIT DIAGRAMS DBW 2010/2020/300 COOLANT HEATERS 7.8 C ONTROL DENTIFICATION OF ERMINALS Figure 33: Control Unit - Identification of Terminals ONNECTOR LOCK ONNECTOR LOCK A1 (–) coolant circulating pump C1 (+) To temperature control thermostat* A2 (+) coolant circulating pump...
• the heater should be checked on regular intervals by a If you wish to carry out extensive repair work on the Webasto service agent, the latest before the beginning heater, it may be a good idea to remove it completely.
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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 lb-in.). DBW 2020/300: 7.5 - 8.5 Nm (66 - 75 lb-in.). 1 Cotter pin...
It is a basic requirement to use the coolant hoses supplied components or electrical equipment. by Webasto, otherwise the hoses must at least meet the The installation of an additional fuel pump is not specifications of DIN 73411. The hoses have to be allowed.
1. Locate heater for installation and secure with 3 screws and washers or 4 screws and washers. DBW 2010 = 38 mm (1.5 in.) 2. Secure line on exhaust outlet using clamp. DBW 2020 up to .32 / DBW 300 up to .15 = 80 mm (3.15 in.)
DBW 2010/2020/300 COOLANT HEATERS SERVICING 8.7.2 WARNING: The igniter box operates on EMPERATURE IMITER EPLACEMENT high voltage. Prior to replacement of flame detector, disconnect electrical connectors of NOTE: The replacement procedure for the cable harness in vehicle to avoid lethal temperature limiter is identical with the heater accidents.
SERVICING DBW 2010/2020/300 COOLANT HEATERS heater has responded because the heater has not been 8.8.2 UPPLY YSTEM LEEDING bled properly. When switching the heater on the fuel pump pulls fuel Reset temperature limiter (allow temperature limiter to from the fuel tank to prime the complete fuel supply cool, self resetting) and repeat complete bleeding system.
This section describes the repairs that may be performed contacts, wrong crimping, etc. and repair as necessary. on the heaters DBW 2010, 2020 and 300 when • Check terminals for corrosion and contacts for removed. Any further disassembly will void the warranty.
(.006 ± .002 inch) 2. Turn counterclockwise to remove temperature control thermostat (item 2, Fig. 36). 9.2.2.2 I NSTALLATION Figure 35: Clearance Adjustment - DBW 2010 Fan 1. Turn temperature control thermostat clockwise into DBW 2020/300 ONLY bracket until snug.
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REPAIR DBW 2010/2020/300 COOLANT HEATERS 1 Control Unit 1553 2 Holding Clip 3 Burner head Figure 37: Control Unit Removal / Installation 1 Cotter pin 2 Hinge Bolts (2) 3 Nut (2) 4 Burner head NOTE: Depending on the burner head direction of swing, the cotter pin may be located to the opposite side.
DBW 2010/2020/300 COOLANT HEATERS REPAIR 9.2.6 9.2.7 ALVE AND OLENOID EPLACEMENT EPLACEMENT 9.2.6.1 R 9.2.7.1 R EMOVAL EMOVAL 1. Swing open or remove burner head (see Sec. 9.2.5). 1. Remove burner head (see Sec. 9.2.5). 2. Disconnect the ignition leads from the ignition 2.
REPAIR DBW 2010/2020/300 COOLANT HEATERS Nozzle Holder Nozzle Figure 41: Nozzle Replacement 9.2.9 LAME ETECTOR EPLACEMENT 9.2.9.1 R EMOVAL 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.
DBW 2010/2020/300 COOLANT HEATERS REPAIR 9.2.10 I 9.2.11 I GNITION LECTRODES EPLACEMENT GNITION EPLACEMENT NOTE: If the ignition is faulty, check also the 9.2.10.1 R EMOVAL 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 R...
REPAIR DBW 2010/2020/300 COOLANT HEATERS 9.2.12 D 9.2.12.2 I RIVE OTOR EPLACEMENT NSTALLATION NOTE: Recessed edge of mounting flange 9.2.12.1 R EMOVAL (item 3, Fig. 45) must be oriented towards top. All items must be aligned as before disassembly. NOTE: Take note of alignment of all components before disassembly.
DBW 2010/2020/300 COOLANT HEATERS REPAIR 9.2.15 F (DBW 2010) HAFT EARINGS AND EARING XPLODED Figure 47: Exploded view - fan support assembly - DBW 2010 www.webasto.us Webasto Product N.A., Inc.
2. Withdraw combustion chamber (Fig. 50) from heat exchanger and remove. 2. Detach cables from heat exchanger. 3. Remove burner head (see Sec. 9.2.5). NOTE: The DBW 2010 burner tube may 4. Withdraw combustion chamber from heat require careful prying around the parameter of exchanger.
REPAIR DBW 2010/2020/300 COOLANT HEATERS 9.3 C 9.3.4 OOLANT IRCULATING EPAIR NSTALLING 1. Mount the pump. A defective coolant pump may cause the heater to 2. Connect coolant hoses to pump and tighten hose overheat. The heater’s overheat protection is likely to clamps.
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DBW 2010/2020/300 COOLANT HEATERS REPAIR U4851 U4814 Screw - Impeller Housing Spring Seal Screw - Pump Base Impeller Housing Stationary Ceramic Seal 10 Washer - Pump Base Nut - Impeller Rubber Seal 11 Pump Base Impeller O-ring 12 Rubber Shaft Boot...
REPAIR DBW 2010/2020/300 COOLANT HEATERS 9.4 MP S 9.4.3 CHOOL IRCULATION SSEMBLING 1. Connect pump motor to a power source. With a 9.4.1 EMOVAL strip of very fine emery cloth, polish the pump shaft to remove any contamination. 1. Drain the coolant. Alternatively, the hoses leading to the pump can be pinched closed with hose 2.
DBW 2010/2020/300 COOLANT HEATERS INSTRUMENTS AND TOOLS 10. INSTRUMENTS AND TOOLS 10.3 CO PPARATUS 10.1 S Used for sampling and measuring the CO content of the ETTING AUGE exhaust gases. Used for setting the gap between the points of the In the case of irregularities of the combustion process or electrodes and the distance from the fuel nozzle.
INSTRUMENTS AND TOOLS DBW 2010/2020/300 COOLANT HEATERS 10.5 N 10.7 G OZZLE RENCH REASE AND OCKING ARNISH Used for replacing high-pressure fuel nozzle. • LDS 18 Special - used for lubricating the reduction gearing of the fuel pump drive. Part Number 66971A •...
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.
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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 •...
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“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.techwebasto.com (North America) www.webasto.com (Global)
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(2) years effective at the time of installationor vehicle registration date for Original Equipment installations (OE). This warranty period may not exceed three (3) years from the original date of sale by Webasto. This warranty period may be superseded by a contractual agreement.* *Warranty coverage for Marine and Off-road applications containing DBW series heaters and the CSL Cargo Heaters are limited to a maximum of 3,000 hours of usage.