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DBW 2010
Webasto DBW 2010 Service And Repair Manual
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Webasto Product N.A., Inc.
52
www.techwebasto
.com
REPAIR
DBW 2010/2020/300 COOLANT HEATERS
Figure 37:
Control Unit Removal / Installation
Figure 38:
Burner Head Removal / Installation
1
2
3
1
Control Unit 1553
2 Holding
Clip
3 Burner
head
1
2
3
4
NOTE:
Depending on the burner head direction of swing,
the cotter pin may be located to the opposite side.
1 Cotter
pin
2
Hinge Bolts (2)
3 Nut
(2)
4 Burner
head
CAUTION: Always use hinge bolts to lock burner head in place.
51
53
Table of Contents
Default Chapter
3
Table of Contents
3
1 Introduction
7
Scope and Purpose
7
Applicability of Manual
7
Meaning of Warnings, Cautions and Notes
7
Additional Documentation to be Used
7
Safety Information and Regulations
7
General Safety Notes
7
Legal Provisions for Installation
8
Corrections and Improvements
8
2 General Description
9
Parts of the Heater
12
Electronic Control Unit (1)
12
Overheat Fuse (15)
12
Temperature Limiter (17)
12
Temperature Control Thermostat (16)
12
Flame Detector (23)
13
Combustion Air Intake (26)
13
Combustion Air Fan (5) and Motor (2)
14
Coupling (4)
15
Toothed Gearing (6)
15
Fuel Pump (24)
15
Fuel Control Valve and Solenoid (8)
15
Fuel Nozzle and Nozzle Holder (14)
16
Fuel Line Connections (25)
16
Electronic Ignition Unit (3)
16
Ignition Electrodes (13)
16
Combustion Chamber (20), Combustion Air Swirler (21)
17
Heat Exchanger (19)
17
Preheat Thermostat (7)
17
Pre-Heater Cartridge (10)
17
Coolant Circulating Pump
18
3 Functional Description
19
Switch on
19
Heating Operation
19
Switch off
19
4 Technical Data
20
Technical Data of the Heaters
21
Technical Data of the Circulating Pumps
22
Permissible Extension of the Connections
22
5 Troubleshooting
23
Quick Check Troubleshooting Matrix
23
Tester Instructions (Tester P/N 1302691A)
23
Test Procedures
23
Instructions for Fault Finding
26
Combustion Starts Immediately When Heater Is Switched on
26
Heater Does Not Start When Switched on
26
After Switching ON, the Heater Switches off after Approx. 30 Seconds on Fault
27
Heater Starts Only after Several Starting Attempts
28
Heater Switches off by Itself During Operation
28
Heater Smokes
30
Heater Cannot be Switched off
30
6 Functional Adjustments
31
General
31
Adjustments
31
Adjustment of CO2 Contents
31
Flame Detector Resistance Check
32
Ignition Electrode Check and Setting
32
Ignition Coil Check
33
Fuel Pump Check
33
Fuel Solenoid Valve Check
34
Nozzle Block Pre-Heater Check
34
7 Circuit Diagrams
35
DBW 2010 12 V and 24 V - Early Canadian Version
35
DBW 2010 12 V and 24 V - Present North American Version
36
Dbw 2020 / 300 12 Vand 24 V - Without Nozzle Preheat
37
Dbw 2020 / 300 12 Vand 24 V - with Nozzle Preheat
38
Scholastic Heater 12 V - with On/Off Switch
39
Scholastic Heater 12 V - with 7-Day Timer Model 1529
40
Scholastic Heater 12 V - with 7-Day Timer Model 1531
41
Control Unit - Identification of Terminals
42
8 Servicing
43
General
43
Heater Servicing
43
Vehicle Servicing
43
Heater Test Run
43
Maintenance
43
Burner Head Opening and Closing
43
Visual Inspections and Regulations for Installation
45
Connection to Vehicle Cooling System
45
Connection to Vehicle Fuel System
45
Fuel Lines
45
Fuel Filter
45
Combustion Air Supply
45
Exhaust Line
46
Removal and Installation
46
Heater, Removal and Installation
46
Removal
46
Installation
46
Temperature Limiter, Replacement
47
Temperature Thermostat, Replacement
47
Overheat Fuse, Replacement
47
Burner Head, Replacement
47
Ignition Coil, Replacement
47
Flame Detector (Photo Eye), Replacement
47
Combustion Chamber, Replacement
47
First Operation
47
Water Circuit, Bleeding
47
Fuel Supply System, Bleeding
48
9 Repair
49
General Information
49
Work on Components after Disassembly
49
Visual Inspection, General
49
Combustion Chamber, Visual Inspection
49
Heat Exchanger, Visual Inspection
49
Combustion Air Fan Wheel, Visual Inspection
50
Disassembly and Assembly
50
Overheat Fuse, Replacement
50
Removal
50
Installation
50
Temperature Control Thermostat, Replacement
50
Temperature Limiter, Replacement
51
Removal
51
Installation
51
Control Unit, Replacement
51
Burner, Replacement
51
Fuel Valve and Solenoid, Replacement
53
Removal
53
Installation
53
Fuel Pump, Replacement
53
Fuel Nozzle, Replacement
54
Removal
54
Installation
54
Flame Detector, Replacement
54
Ignition Electrodes, Replacement
55
Removal
55
Installation
55
Ignition Coil, Replacement
55
Drive Motor, Replacement
56
Removal
56
Installation
56
Combustion Air Fan, Replacement
57
Removal
57
Installation
57
Fan Replacement
58
Fan Shaft, Bearings and Gearing, Exploded View (DBW 2010)
59
Fan Shaft, Bearings and Gearing, Exploded View (DBW 2020 / DBW 300)
60
Combustion Chamber, Replacement
61
Removal
61
Installation
61
Heat Exchanger, Replacement
61
Coolant Circulating Pump Repair
62
Removal
62
Disassembling
62
Assembling
62
Installing
62
MP School Bus Circulation Pump
64
Removal
64
Disassembling
64
Assembling
64
Installing
64
10 Instruments and Tools
65
Setting Gauge
65
Tester
65
CO2 Test Apparatus
65
Smoke Number Test Apparatus
65
Nozzle Wrench
66
Fuel Pressure Gauge
66
Grease and Locking Varnish
66
11 Product Information
67
ISS "White" Timer for the Scholastic Heater
67
Other manuals for Webasto DBW 2010
Operating Instructions
40 pages
Workshop Manual
78 pages
Installation Manual
32 pages
Operating And Servicing Manual
88 pages
Installation Instructions
40 pages
Workshop Handbook
84 pages
4
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Webasto DBW 2010 Specifications
General
Brand
Webasto
Model
DBW 2010
Category
Water Heater
Language
English
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