Coolant Heaters

DBW 2010 DBW 2020 DBW 300
North American Headquarters 3333 John Conley Drive Lapeer, MI 48446 Phone (810) 245-2400 Toll-free (800) HEATER-1 Fax (810) 664-7720 Canadian Operations Toll-free (800) 667-8900

Rev. 11/(English)

Operating Instructions

Website: www.webasto.com

WEBASTO DBW SERIES HEATERS

CONTENTS

Introduction Important Information. 1 General Safety Regulations and Information. 3 Meaning of Warnings, Cautions and Notes. 3 Description General Description. 5 Coolant Heater DBW 2010. 5 Coolant Heaters DBW 2020 / 300. 6 Operating Instructions Operating your Webasto DBW Series Heater. Switching On. Switching Off. Engine Preheating. Operation with 7-Day Digital Timer. Setting the Digital Timer (Models 1529 & 1531). 7-Day Digital Timer Programming and Operating Instructions (Models 1529 & 1531). Operation with 7-Day Electronic Timer Model CDN-1224. Timer Operation Modes (Model CDN-1224).
Dip Switch Programming (Model CDN-1224). 18 Timer Operation (Model CDN-1224). 23 Maintenance Maintenance of the Heater. 25 Basic Troubleshooting General Information. Malfunctions. Malfunction Identification - DBW Series Heaters. Sequence of Events - DBW Series Heaters. Technical Data General Information. Heater Data. U 4810 and U 4846 Coolant Pump Data. U 4814, U 4851 and U 4852 Coolant Pump Data.

Introduction

Important Information

INTRODUCTION

The heater must be installed according to the Installation Instructions and must be examined by an officially recognized, Webasto authorized installation/ servicing facility. When the heater is installed in vehicles used for the transportation of dangerous or inflammable goods, or in boats, the appropriate regulations must be observed. Webasto Thermosystems, Inc. does not recommend the installation and servicing of Webasto products by untrained, unauthorized personnel or end-users. Installations and servicing of Webasto products by untrained, unauthorized personnel and end-users will release Webasto Thermosystems, Inc. and Webasto authorized distributors, dealers and personnel from responsibility for damage to Webasto product or collateral property and personal injury. Any use, operation, installation, modification or application of the product not described in Webasto manuals, or subjecting the product to extreme or unusual conditions beyond the limits of specified performance characteristics is misuse of the product. Failure to comply with all operation, installation, and servicing instructions is a misuse of Webasto product. The same applies for repairs without using genuine Webasto service parts. This will void the coolant heaters Official Marks of Conformity. In the vicinity of the coolant heater, a temperature of 185 F (85 C) 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. 1
When checking the coolant level, proceed in accordance with the vehicle manufacturers instructions. The coolant in the heating circuit of the heater must contain a minimum of 10% of a quality brand glycol based anti-freeze. The pressure setting of the coolant filler cap should be between 0.4 and 2 bar (6 p.s.i. and 28 p.s.i.). The coolant heater may only be operated within the specified operating voltage range designated by type. The coolant heater may only be operated with the specified fuel (Diesel 1, Diesel 2, Arctic grade, Kerosene and certain military spec. fuels). The operational state of the heater, i.e. an indication On or Off, must be clearly visible to the operator. If electrical welding is to be done on the vehicle, the main positive and negative feed cables should be disconnected from the battery and securely connected to the chassis. This is necessary to protect the electronic control unit from voltage surges.
WARNING Due to the danger of poisoning and suffocation, the heater must not be operated in enclosed areas, such as garages or workshops, without an exhaust venting system, not even if the start-up is activated by the timer or remote start device.

At filling stations and fuel depots the heater must be switched off as there is a potential danger of explosions. Where flammable fumes or dust may build up (e.g. in the vicinity of fuel, coal, wood, cereal grain deposits or similar situations) the heater must be switched off to prevent explosions.
General Safety Regulations and Information
The general safety regulations for the prevention of accidents and relevant operating safety instructions must be observed at all times. The specific safety regulations applicable to this manual are highlighted in the individual chapters by Warnings, Cautions and Notes.
Meaning of Warnings, Cautions, and Notes
Warnings, Cautions and Notes in this manual have the following meaning: WARNING This heading is used to highlight that non-compliance with instructions or procedures may cause injuries or lethal accidents to personnel. CAUTION This heading is used to highlight that non-compliance with instructions or procedures may cause damage to equipment. NOTE: This heading is used to highlight and draw specific attention to information.

General Description

Coolant Heater DBW 2010

DESCRIPTION

Electronic control unit Motor Electronic ignition coil Coupler Combustion air fan Fuel solenoid valve Electrode holder Coolant outlet Coolant inlet Ignition electrodes Fuel nozzle Overheat fuse (white wires) Control thermostat Temperature limiter Heat exchangers Combustion chamber Combustion air swirler Exhaust pipe Flame detector Fuel pump Fuel supply/ return pipes Combustion air adjusting shutter Fuel pump drive gearing Nozzle pre-heater Preheat thermostat (blue & green wires) Air bleed screw

Fig. 1:

Major Components of the DBW 2010 Coolant Heater
Coolant Heaters DBW 2020 / 300

Fig. 2:

Major Components of the DBW 2020 / 300 Coolant Heaters
Electronic control unit Motor Electronic ignition coil Coupler Combustion air fan Fuel solenoid valve Electrode holder Coolant inlet Ignition electrodes Fuel nozzle Overheat fuse (white wires) Control thermostat Temperature limiter Coolant outlet Heat exchangers Combustion chamber Combustion air swirler Exhaust pipe Flame detector Fuel pump Fuel supply/ return pipes Combustion air adjusting shutter

Operating your Webasto DBW Series Heater

OPERATING INSTRUCTIONS

WARNING Due to the risk of carbon monoxide poisoning and asphyxiation, the heater must never be operated in closed spaces such as garages and workshops without adequate exhaust extraction.
WARNING Due to the risk of fire or explosion, the heater must be switched off while refueling and at fueling stations.
WARNING Due to the risk of explosion, the heater must never be operated in areas where explosive materials, fumes or dusts may be present.

Switching On

Before switching the Webasto heater on, open any shut off valves and set vehicle heater controls to the Hot position. Depending on the type of control installed, the heater can be operated by the following methods. Timer: Switch:
Using a Timer: Upon pressing the Instant Heat button on the timer face, the Operation Indicator on the timer lights up and the heater begins operation. Using a Switch: When the switch is used for switching ON the Webasto heater, the Operation Indicator integrated in the switch is illuminated.
Heater Start-up Sequence:
Upon switching on, an operating indicator light will illuminate. The combustion air fan, fuel pump and circulation pump start operation. (If fitted and temperature is < 0 C (< 32 F) nozzle preheating is also activated). After approximately 15 seconds the fuel solenoid valve opens allowing fuel to flow to the nozzle where it is atomized and sprayed into the combustion chamber. At the same time, a high voltage ignition spark is generated at the electrode tips simultaneously igniting the fuel air mixture. A photo control device detects a flame in the combustion chamber and deactivates the ignition system (combustion process is self-sustaining). At this point the heater is working and producing heat. The Webasto heater will cycle on and off until: 1. 2. 3. 4. 5. 6. System coolant reaches operating temperature. The Webasto heater is switched off. Time has elapsed on the timer. The vehicle battery voltage drops below 10.5V for 12 volt systems or 20.0V for 24 volt systems. The Webasto heater runs out of fuel. A fault lock out occurs, indicated by the operating indicator light being off during the cool down cycle (as would happen during an overheat situation.
NOTE: If the heater is switched on while the engine is at operating temperatures above 140 F (60 C) for orange and white wire thermostat or 155 F (68 C) for red and green wire thermostat, only the operation indicator and the coolant circulation pump will be activated. Depending on the type of thermostat installed, the engine coolant temperature must fall below 140 F (60 C) or 155 F (68 C) at the heater before the heater will begin heating operation. 9

Switching Off

When heating is no longer required, switch the Webasto heater off. The fuel solenoid valve interrupts the fuel supply and combustion stops. The indicator light turns off. The Combustion air fan and the water pump continue operation for approximately 150 seconds (after-run cycle) purging the combustion chamber of any fumes and cooling the heater. NOTE: Switching the Webasto heater on during the cool-down (after-run cycle) period is allowed. The heater will revert to normal operational mode.

Engine Preheating

1. Set the timer 10 min. to 120 min. before you want to start the engine. The heater will start up at the set time. (See timer operating instructions). Or switch the toggle switch or Instant On switch on your timer in the vehicle dash to On. The heater will start up. 2. When the run time has elapsed on your timer or engine preheating is no longer required, switch the Webasto heater Off. The heater will begin the after-run (cool-down) cycle. NOTE: Make sure all coolant and cab heater valves are open before operating the heater in the preheat mode. 10
Operation with 7-Day Digital Timer (Model 1529 Shown)
The digital timer with 3 time settings permits the Webasto heater to be switched on and off instantly, or automatically at 3 programmable starting times. The operating time of the heater can be pre-selected. It is possible to program 3 different heating times according to your individual needs. Only one preset starting time can be activated at any one time. When the ignition is switched on, the current time of the day and the day of the week are displayed. When the heater is in operation, the display and the buttons of the timer are illuminated.
Programmed Heater Operation
Three memory locations numbered 1 to 3 are available. Each memory location can be assigned a given time together with the day of the week. Pre-selected Starting Times The pre-selected starting time is the time at which the heater will be switched on automatically. We recommend that memory locations 1 and 2 be used for presetting starting times within 24 hours of setting the timer. Memory location 3 can be used for a starting time within the next 7 days of setting the timer. NOTE: We recommend that memory locations 1 and 2 be used for presetting starting times within a 24 hour period of setting the timer. Memory location 3 can be reserved for a starting time within the next 7 days of setting the timer. Location 3 is useful for occasional weekend or field trip operations outside of the normal schedule. By repeatedly pressing the button on the 1529 timer or button on the 1531 timer, starting time program 1, 2 or 3 can be viewed and preset. Operating Time The period of time during which the heater is in operation is referred to as the operating time. The heater remains in operation for as long as the operating time has been preset. Heater operation can be pre-selected for any time from a minimum of 1 minutes (a minimum of 10 minutes is recommended) to a maximum of 120 minutes (factory preset is 60 minutes). Remaining Operating Time The remaining operating time refers to the period of time the heater still continues to remain in operation. It can only be changed while heater is in operation. 12

Setting the Digital Timer (Models 1529 & 1531)
After the power has been connected, all symbols on the digital display are flashing. The time of the day and the day of the week must be set. All flashing displays and symbols of the timer can be set by means of the and buttons. If the and buttons are not pressed within 5 seconds, the currently displayed time or function will be stored. When the and buttons are pressed for more than 2 seconds, the quick digit advance mode is activated. 1 Program number for preset time. 2 Time of day / preset time / operating duration display. 3 Day of the week display. 4 Operation indicator. 5 Setting / viewing the time; setting / recalling day of the week. 6 Presetting / recalling starting time; setting / recalling day of the week. Note: Timer model 1531 uses a symbol for the programming key. 7 Heater On/Off. 8 Reverse key for setting time of day or heater start-up time; viewing and reducing operating duration / remaining operating time. 9 Forward key for setting time of day or heater start-up time; presetting day of start-up; viewing and extending operating duration / remaining operating time. 13

Fig. 3:

7-Day Digital Timer (Model 1529)
7-Day Digital Timer Programming and Operating Instructions (Models 1529 & 1531)
Setting the time and day of the week Press the button for more than 2 seconds. Time display flashes. Press the or button to set time of day. Wait 5 seconds. Time is now stored. Day of week flashes. Press or button to set day of week. Wait 5 seconds. Day of week is now stored. With ignition ON: Continuous display of current time and day of the week. With ignition OFF: Briefly press button. Display of current time and weekday appears for 5 seconds. With ignition ON: Press button. Heater is switched on (continuous heating) and continues to operate until button is pressed again or ignition is switched off. With ignition OFF: Press button. Heater is switched on for the preset operating time (the factory-set heater operating duration is 60 minutes). Press button. Heater begins cool-down (after-run) cycle and is switched off thereafter.

Viewing the time

Switching heater on for instant heater operation

Switching the heater off

Table 1:
Digital Timer Instructions
Programming heater-starting time
Press or button. Memory location number flashes. Press or button to preset starting time. Wait 5 seconds. Starting time is now stored. Day of week flashes. Press or button to set day of week. Wait 5 seconds. Day of week is now stored. The number of memory location remains on the display. The timer is now in the programmed mode and switches heater on at the preset time. To recall: Press or button until the desired memory location number is displayed. Read off preset time. To cancel: Press or button repeatedly until the memory location numbers are no longer visible on the display. The heater must be switched off. Press the button. Operating time flashes. Press or button to set operating duration time between 1 and 120 minutes (minimum 10 minutes recommended). Heater must be in operation. Press button. Remaining operating time flashes. Press or button to set remaining operating time. Wait 5 seconds. The remaining operating time is now stored.

Recalling/canceling pre-selected times
Programming duration of operating time Setting the remaining operating time
Digital Timer Instructions (continued)
Operation with 7-Day Electronic Timer Model CDN-1224

M T W T F S

Set Clock Set Timer Heater on/off manual Timer on/off
The 7-Day Electronic Timer Model CDN-1224 permits the Webasto heater to be switched on and off instantly, or automatically. The timer allows for 1 preset start time once within a 24 hour period on any one day up to 7 days in advance. The current time and weekday must be preset before any other programming features can be accomplished. The 7-Day Electronic Timer is designed to operate on both 12 and 24 volt systems.

Display

Operational characteristics of both timer and heater can be tailored to the requirements of the heating application by pre-programming of the timer. This is normally done at the time of installation. Four dip switches located on the back panel of the timer are provided for changing the operational characteristics of the timer. These settings can be revised at any time should your heating requirements change.

Day Hour Minute

CAUTION Timer requires dismounting and disconnecting of power source before revising dip switch settings. For complete timer installation and operation instructions, refer to the 7-Day Electronic Timer Model CDN-1224 Operating Instructions manual available from your Webasto agent under part number 907111. 16
Timer Operation Modes (Model CDN-1224)

Truck or Bus Operation

By flipping one of the dip switches on the back of the unit, the timer can be set for either truck or bus operation. The tables shown below illustrates the timing sequence associated with operation in either of these modes. Bus Application Ignition wire is connected and dip switch #3 is in bus mode. Whether the heater is turned on manually or automatically, it will stay on until the timer duration ends. Except, when the heater is turned on manually while the bus is running (ignition key turned on), the heater will shut off when the ignition key is turned off, or the heater on/off button is pressed. Truck Application for Preheat Mode Only Ignition wire is disconnected and dip switch #3 is in truck mode.

Pre-set Mode Manual Mode

Heater on Heater on
Timer duration ends Timer duration ends
Heater turns off after time duration ends Heater turns off after time duration ends

Truck Application for Preheat and Sleeping Modes Ignition wire is always live and dip switch #3 is in truck mode.
Heater turns off after time duration ends Heater stays on until turned off manually
Dip Switch programming (Model CDN-1224)
Prior to installing the timer, all dip switches must be set to the requirements of your application. The dip switches allow for setting the clock in either AM/PM mode or 24 hour (military) mode. Also included is the ability to select the desired heater run time of 30, 60, 90 or 120 minutes. Dip switch settings are accessed through a cut out on the rear panel of the timer.

Dip Switch Location

Fig. 4:

Rear Panel of Timer

NOTE: Dip switch settings are to be selected PRIOR to connection of power source and programming of all other timer functions. 18
Switch 1 & 2 control timer on duration.

30 Minute

Switch 3 controls truck vs. bus operation.

Bus Mode

Default settings for new timers are: Truck - 60 minute operation time, 12 hour clock Bus - 60 minute operation time, 12 hour clock 19

60 Minute

Truck Mode

90 Minute

120 Minute
Switch 4 controls 12 vs. 24 hour clock.

12 hour clock

24 hour clock
Setting the Electronic Timer (Model CDN-1224)
1 Time Display 2 Heater on/off indicator LED (green) 3 Timer active status LED (yellow) 4 Clock time status LED (red) This LED will be on during PM time when AM/PM dip switch setting is selected 5 Days of the week LEDs (red) 6 Function buttons

Day Fig. 5:

Minute
7-Day Electronic Timer Model CDN-1224
Clock Programming (Present Time and Day) Depress buttons Set and Display simultaneously to start programming NOTE: Time display will begin to flash.

Heater on/off manual Day

Depress button Day to select day of week.
Depress button Hour to select correct hour. NOTE: If the dip switch setting is in the AM/PM mode, the red PM LED will respond.

Timer on/off Hour

Depress button Minute to select correct minute.

Display Minute

Depress button Set to end timer programming. NOTE: If Set button is not depressed within 15 seconds, programming function will end automatically.
Timer Programming (Timed Heater Start Setting)
Depress buttons Set and Timer on/off simultaneously to start programming. NOTE: The yellow T LED will flash

Timer on/off

Depress button Day to select day heater is to come on.
Depress button Hour to select correct hour.

Depress button Set to end timer programming. NOTE: If Set button is not depressed within 15 seconds, programming function will end automatically
Timer Operation (Model CDN-1224)

Manual Operation

To manually turn the heater on, press the heater on/off manual button. The heater on/off indicator LED (green) will come on. Press this button a second time to turn the heater off.
Timer Operation Depress the timer on/off button to activate or deactivate the timer. If the timer is active, the timer status LED (yellow) will light and the heater will come on when the next timing program is reached. The tables on page 17 depicts the performance of the timer based upon truck or bus operation.
Display Stand By Mode To save battery life, the display will go blank after about 5 minutes if there is no activity. To reactivate the display, press the DISPLAY button.

Display MInutes

Maintenance of the Heater
To ensure functional reliability of the heater the following maintenance must be performed:

MAINTENANCE

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 every four weeks for 10 minutes setting the heating system to "warm" and opening all appropriate coolant flow control valves. This avoids difficulties in the startup at the beginning of the heating season and prolongs heater motor and bearing life. after replacing the coolant of the vehicle engine ensure proper bleeding of the heater after bleeding the vehicle cooling system. Start the vehicle engine and turn OEM heater system on in full heat mode. Switch on heater circulation pump (if separate switch is available) or operate heater for 5 seconds to run circulation pump using rundown cycle. Repeat procedure as required until warm air comes out of heating ducts. Replenish coolant to manufacturer's instructions if level is low. before the heating season (point of time when weather conditions cause increased use of equipment) the fuel filter or filter cartridge must be replaced to prevent malfunctions. the heater should be checked on regular intervals by a Webasto service agent, the latest before the beginning of the heating season.

Basic Troubleshooting

BASIC TROUBLESHOOTING
CAUTION Troubleshooting requires profound knowledge about structure and theory of operation of the heater and components. Troubleshooting and fault correction should only be performed by Webasto trained, skilled personnel unless otherwise stated in this manual.

General Information

This section describes troubleshooting procedures for DBW Series coolant heaters. Troubleshooting is normally limited to the isolation of defective components.

Before troubleshooting, check for and eliminate the following defects: fuel supply (plugged fuel filter, kinked fuel line) corrosion on battery terminals blown fuses corrosion on electrical wiring, connections and fuses loose contacts or improper crimping on connectors shut down initiated by temperature limiter thermostat (automatic reset) shut down initiated by overheat fuse

Malfunctions

The DBW Series of coolant heaters are designed with automatic, self-monitoring systems that will shut the heater off in the event of a problem. The heater will switch itself off automatically if combustion does not start after the heater has been switched on, or if the flame goes out, or if the heater overheats. The operation indicator light will go out to signify a problem. The following steps can be taken to determine and correct obvious problems. If the operation indicator light does not come on at the same time as the heater is switched on, check and, if necessary, replace fuse (F2). If the operation indicator light comes on when the heater is switched on, but goes out after about 30 seconds, check and, if necessary, replace fuse (F3). NOTE: In most heater models, the fuses referred to in the above paragraph can be located on the back wall of the heater enclosure or are tray. Some models may also utilize a 30 amp. main fuse at the battery connection. If overheating has occurred, locate and correct the problem. On the DBW 2010 Arctic, DBW 2020 and DBW 300 series heaters, it may be necessary to replace the overheat melt fuse located under the thermostat cover on top of the heater. The fuse can be identified by the two white wires protruding from its top. The fuse is screwed hand tight into a dry well plug. Do not over tighten the fuse when replacing. On all other DBW 2010 heaters not equipped with an overheat fuse, simply correct the cause of overheating and allow the heater to cool down. If a lock-out condition occurs due to a malfunction, this condition can be cleared and the control unit reset by switching the heater off and switching it back on again. If the heater goes to lock-out once again after correcting all obvious problems, consult your nearest Webasto Service Station. 28

Malfunction Identification - DBW Series Heaters
This table is intended to assist the swift diagnosis of simple malfunctions, which have obvious symptoms. It cannot replace the detailed knowledge of an expert workshop. For assistance, please contact one of the workshops recommended in the list of service stations.

Table 2:

Quick Check Matrix
Sequence of Events - DBW Series Heaters
The normal sequence of events illustrated here may be used in conjunction with the malfunction identification table to help determine heater problems.
Table 3: Sequence of Events
NOTE: After the correction of a malfunction, a functional test must always be performed with the heater installed in the vehicle in its operational position.

Technical Data

Where no threshold values are specified, technical data are understood to include standard tolerances for heater units of 10% at ambient temperature of + 20 C (+ 68 F) and at nominal voltage. Electrical components: Control unit, fan and circulation pump motors, solenoid valve, igniter box, heater cartridge, nozzle pre-heater and timer are voltage sensitive components. Temperature limiter, overheat fuse, control thermostat, flame sensor and switches are voltage independent components.
Heater Mark of conformity Heater design principle Heat output Fuel Maximum fuel consumption l/h (US gal/h) Rated nominal voltage Operating voltage Nominal power consumption (without circulation pump) V V W 60 kW/h (BTU/h) DBW 2010 ~ S 129

TECHNICAL DATA

DBW 2020 ~ S 136 DBW 300 ~ S 164
High pressure fuel atomizing nozzle 13.1 (45,000) 23.3 (80,000) 30 (104,000)
Diesel #1, Diesel #2, Arctic grade and Kerosene 1.5 (0.4) 3.0 (0.79) 12 or 24 10. 14 or 20. - 40. + 60 (- 40 + 140) 130 4.0 (1.05)
Permissible operating ambient C (F) temperature range (heater, control unit, circulation pump) Permissible storage temperature Permissible operating pressure of coolant system Minimum capacity of circuit C (F) bar (psi) l (US. Gal)
+ 85 max. (+ 185) 0.4. 2.0 (06 29) 10.00 (2.64) 10.5. 11.0 0.2 maximum 584 (23) 205 (8-1/6) 228 (10) 15 kg (33 lbs.) 680 (26-23/32) 240 (9-1/2) 279 (10-29/32) 22 kg (48 lbs.)
CO2 in exhaust at nominal voltage Vol.-% CO in exhaust at nominal voltage Dimensions of heater Vol.-%

Heater Data

Refer to adjacent table
Weight (without enclosure)
length mm (in.) width mm (in.) height mm (in.)

Table 4:

U 4810 and U 4846 Coolant Pump Data
Recommended coolant circulation pumps for DBW 2010 heaters. Coolant Circulation Pump Volume flow Nominal voltage Operating voltage range Nominal power consumption Dimensions of coolant circulation pump Hose connection Weight

Table 5:

U (6.0) @ 0.15 bar 12 or 24 10. 14 or 20. 173 mm (6.8 in.) 94 mm (3.7 in.) 77 mm (3.0 in.) 38.0 mm (1.5 in.) 2.1 (4.63)
U (7.0) @ 0.15 bar 12 or 24 10. 14 or 20. 128 mm (7.16 in.) 94 mm (3.7 in.) 82 mm (3.32 in.) 20.0 mm (0.78 in.) 0.85 (1.88)
l/h (US. Gal/min) V V W length width height O.D. kg (lb.)
U 4810 & U 4846 Coolant Pump Data
NOTE: The allocation of circulation pumps to heater units must be in accordance with coolant resistances.
U 4814, U 4851 and U 4852 Coolant Pump Data
Recommended coolant circulation pumps for DBW 2020 and DBW 300 heaters. Coolant Circulation Pump Volume flow Nominal voltage Operating voltage range Nominal power consumption Dimensions of coolant circulation pump Hose connection Weight

Table 6:

U (22.9) @ 0.15 bar 12 or 24 10. 14 or 20. 221 mm (8.7 in.) 100 mm (3.94 in.) 105 mm (4.14 in.) 38.0 mm (1.5 in.) 2.1 (4.63)
U 4851 & U (26.4) @ 0.4 bar 24 18. 285 mm (11.22 in.) 115 mm (4.52 in.) 110 mm (4.33 in.) 38.0 mm (1.5 in.) 2.7 (5.95)

see fig. 4 - use with #342637 voir la fig. 4 - employez avec #342637 see fig. 5 - use with #464333 voir la fig. 5 - employez avec #464333 see fig. 4 - use with #394424 voir la fig. 4 - employez avec #394424 see fig. 5 - use with #464333 voir la fig. 5 - employez avec #464333 see fig. 5 - use with #464333 voir la fig. 5 - employez avec #464333
22428A 50275476A 5000216A N
aluminum fuel pump / pompe d'essence en aluminium #5000177A
high-pressure pipe - service kit for zinc or aluminum fuel pump for / pour # 72027B & 5000177A pipe haute pression - service le kit pour la pompe d'essence de zinc includes instructions ou d'aluminium inclut des instructions screw - allen socket vis - douille d'Allen washer - lock rondelle - serrure fuel pump pompe combustible M4 x 30 8.8 DIN 912 A4 DIN bar (145 psi) barre 10 (145 psi) 10 bar (145 PSI.) barre 10 (145 psi) zinc body pump pompe en zinc upgrade - aluminum body pump mise niveau - pompe en aluminium

33 no fig.

72027B 5000177A N
fuel pump pompe combustible
valve - pressure control soupape de rglage de pression filter screen filtre fuel supply line - barb connection canalisation d'alimentation de carburant - raccordement de bavure N fuel supply line - JIC #4 threaded connection canalisation d'alimentation de carburant - JIC #4 raccordement filet fuel return line - barb connection canalisation de retour de carburant - raccordement de bavure N fuel return line - JIC #6 threaded connection canalisation de retour de carburant - JIC #6 raccordement filet hollow screw vis creuse washer - copper rondelle - cuivre DIN 7643 LL6 A10 x 13.5 DIN 7603Cu for gears pour engrenage
111375 92173A 462659 92172A 65513A 151157 143820
grease - special in tube at 100g ISOFLEX LDS 18 grasse - spciale en tube 100g
DBW 2020 / 300 / 350 - fig. 4
built in until DBW 2020.31 / DBW 300.10 inclusively pice fournie jusqu'au modele DBW 2020.31
casting built in until DBW 2020.31 inclusively pice fournie jusqu'au modele DBW 2020.31
casting built in until DBW 300.10 inclusively pice fournie jusqu'au modele DBW 300.10
Parts for heat exchanger / Pices pour l'changeur de chaleur 342637 combustion chamber - for heat exchanger with 80 mm exhaust chambre de combustion - pour l'changeur de chaleur avec 80 mm d'chappement combustion chamber - for heat exchanger with 80 mm exhaust chambre de combustion - pour l'changeur de chaleur avec 80 mm d'chappement heat exchanger - with 80mm exhaust changeur de chaleur - avec 80mm d'chappement eye bolt boulon oeilleton pin - grooved tenno encoche nut - hex flange crou - avec la rondelle angle bracket - copper support querre - cuivre fitting - fuse raccord - fusible cotter pin goupille turnbuckle - short tendeur vis - court tightening clamp collier de serrage Webasto Product N.A., Inc. www.techwebasto.com M8 x x 16 DIN 1475 M8 for overheat and control thermostats pour des thermostats de surchauffe et de commande for overheat fuse pour le fusible thermique hinge pin goupille de charnire zinc plated steel acier plaqu par zinc DBW 2020 (early type) DBW 2020 (premier type) DBW 300 (early type) DBW 300 (premier type)

608719A 408719

308331
DBW 2020 / 300 / 350 - fig. 7
control thermostat (remote option) aquastat (option distance) control unit botier de commande overheat fuse / temperature limiter / control thermostat scurit de temprature / limiteur de temprature / aquastat flame detection photocell cellule photo-lectrique fuel solenoid valve lectrovanne motor moteur electronic ignition unit centrale d'ignition
Heater harness / Harnais de rchauffeur heater harness - with remote control-thermostat option harnais de rchauffeur - avec l'option de raccordement distance de commande-thermostat heater harness - with remote control-thermostat connection harnais de rchauffeur - avec le raccordement distance de commande-thermostat terminal block 6-way connecteur bornes 6 ples

469513

352969
DBW 2020 / 300 / 350 - fig. 8
Parts for nozzle preheat system / Les pices pour le bec prchauffent 19723B 50410799A 50420042A 5010164A 901401 50101804A 109697 620265A 5000665A clip - nozzle preheat element agrafe - le bec prchauffent l'lment element - nozzle preheat lment - le bec prchauffent element - nozzle preheat lment - le bec prchauffent 12 V 24 V
thermostat assembly - preheat thermostat assemble - prchauffez photocell plate plat de cellule photo-lectrique washer - lock rondelle - serrure hexagon nut crou six-pan relay - preheat relais - prchauffez relay - preheat relais - prchauffez preheat harness prchauffez le harnais preheat kit - complete 24 V (nozzle holder not included) prchauffez le kit - accomplissez 24 V (support de bec non inclus) preheat harness - with thermostat prchauffez le harnais - avec thermostat preheat kit - complete 24 V (nozzle holder not included) prchauffez le kit - accomplissez 24 V (support de bec non inclus) A4.3 DIN 6798 M4 DIN V 24 V 3-way power supply connector connecteur de puissance 3-way 3-way power supply connector connecteur de puissance 3-way 2-way power supply connector connecteur de puissance 2-way 2-way power supply connector connecteur de puissance 2-way

Item Repre 14 1

Part No. Rfrence 412198
Description Dsignation holder - nozzle support de bec
DBW 2020 / 300 / 350 - fig. 9

ON OF F

Electrical parts / Pices lectriques 1 905811A wiring harness - internal (inclosure application) harnais de cblage - interne (application de clture) no nozzle preheat provision aucun bec ne prchauffent la disposition

906960A

wiring harness - internal with nozzle preheat harness provision (inclosure application) harnais de cblage - interne avec le bec prchauffez la disposition de (application de clture) harnais wiring harness - external harnais de cblage - externe N (inclosure application) (application de clture)

905799C 5000809A

fuse holder upgrade kit - with mounting hardware and installation replaces former fuse blocks / remplace instructions d'anciens blocs de fusible 901748 & le kit d'adaptation de support de fusible - avec le matriel de support 14878A et les instructions d'installation toggle switch interrupteur levier toggle switch interrupteur levier digital timer - 1529 montre digitale - 1529 digital timer - 1529 montre digitale - 1529 light bulb ampoule light bulb ampoule 12 V (includes On/Off plate) with indicator light 12 V (inclut le plat "Marche/Arrt") avec ampoule 24 V (includes On/Off plate) with indicator light 24 V (inclut le plat "Marche/Arrt") avec ampoule 12 V 24 V 12 V 24 V 7-day / 3-program de sept jours/3-programmes 7-day / 3-program de sept jours/3-programmes for #82774A pour #82774A for #82775A pour #82775A
5010038A 82775A 28443A 28447A 474630
mounting frame for timer bti de support pour le temporisateur

Item Repre 16 1

Part No. Rfrence 475866
Description Dsignation mounting housing for timer logement de support pour le temporisateur
Remarks Remarques rubber le caoutchouc
DBW 2020 / 300 / 350 - fig. 10
Electrical parts / Pices lectriques 13 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X 901542 connector housing - female 1-pole module de raccordement - femelle1-ple connector housing - male 1-pole module de raccordement - mle 1-ple connector housing - female 2-pole module de raccordement - femelle2-ples connector housing - male 2-pole module de raccordement - mle 2-ples connector housing - male 2-pole module de raccordement - mle 2-ples connector housing - female 2-pole module de raccordement - femelle2-ples connector housing - female 4-pole module de raccordement - femelle4-ples connector housing - male 4-pole module de raccordement - mle 4-ples connector housing - female 6-pole module de raccordement - femelle6-ples connector housing - male 6-pole module de raccordement - mle 6-ples connector housing - female 8-pole module de raccordement - femelle8-ples connector housing - male 8-pole module de raccordement - mle 8-ples socket - relay douille - relais 5-pole 5-ples uses insert # 176389 (male) utilisations # 176389 (mle) uses insert # 176613 (female) utilisations # 176613 (femelle) uses insert # 176389 (male) utilisations # 176389 (mle) uses insert # 176613 (female) utilisations # 176613 (femelle) uses insert # 176613 (female) utilisations # 176613 (femelle) uses insert # 176389 (male) utilisations # 176389 (mle) uses insert # 176389 (male) utilisations # 176389 (mle) uses insert # 176613 (female) utilisations # 176613 (femelle) uses insert # 176389 (male) utilisations # 176389 (mle) uses insert # 176613 (female) utilisations # 176613 (femelle) uses insert # 176389 (male) utilisations # 176389 (mle) uses insert # 176613 (female) utilisations # 176613 (femelle) uses insert # 176613 (female) utilisations # 176613 (femelle)

Item Repre 16-21 22-26 no fig. X X X X X X X X X X X X X X 1 X X X X
Quantity Nombre 350 X X X X
Part No. Rfrence 176613 176389
Description Dsignation metal insert - female insertion en mtal - femelle metal insert - male insertion en mtal - mle relay relais relay relais fuse - ATO tan coupe-circuit - ATO tan fuse - ATO brown coupe-circuit - ATO brun fuse - ATO red coupe-circuit - ATO rouge fuse - ATO blue coupe-circuit - ATO bleu fuse - ATO yellow coupe-circuit - ATO jaune 24 V 12 V

5010164A 901401

X X X X X X X X X X X X X X 1
905610 24981A 5000806A 901406 5000807A 901404 5000353A 5000808A 906215
5 amp 7.5 amp 10 amp 15 amp 20 amp
fuse - ATO clear 25 amp coupe-circuit - ATO transparent fuse - ATO green coupe-circuit - ATO vert fuse - ATM tan coupe-circuit - ATM tan fuse - ATM brown coupe-circuit - ATM brun fuse - ATM red coupe-circuit - ATM rouge fuse - ATM blue coupe-circuit - ATM bleu fuse - ATM yellow coupe-circuit - ATM jaune 30 amp 5 amp 7.5 amp 10 amp 15 amp 20 amp mini fuse coupe-circuit - mini
fuse - ATM clear 25 amp coupe-circuit - ATM transparent fuse - ATM green coupe-circuit - ATM vert 30 amp includes 2-pole, 6-pole, and 8-pole connector housings and 16 female terminals inclut des logements du connecteur 2ple, 6-ple et 8-ple et 16 insertions femelles
connector / terminal kit - control unit SG 1553
DBW 2020 / 300 / 350 - fig. 11
Parts for fuel supply / Pices affrentes au alimentation en combustible X X X X X X X X X X X X X X X X X X 903210A 905742A fuel standpipe assembly - universal tube d'extraction de carburant - universel fuel standpipe tube d'extraction de carburant tank boss kit (bag) kit de patron de rservoir (sac) terminal bolt boulon terminal fuel shutoff valve robinet d'isolement de carburant barb fitting connecteur de bavure barb fitting connecteur de bavure barb fitting connecteur de bavure barb fitting connecteur de bavure bushing douille fuel line ligne de carburant hose clamp collier de la conduite 1/4 male NPT x 1/4 hose barb bavure masculine de tuyau de 1/4" NPT X 1/4" JIC #4 x 1/4 hose barb bavure de tuyau de JIC #4 X 1/4" JIC #6 x 1/4 hose barb bavure de tuyau de JIC #6 X 1/4" 1/4 male NPT x 1/4 hose barb bavure masculine de tuyau de 1/4" NPT X 1/4" 1/2 x 1/4 NPT 1/- 12mm sold per meter vendu par mtre stainless steel acier inoxydable 1/4 female NPT 1/4"NPT femelle

900004

Partial rebuild kit / Kit partiel de reconstruction DBW 2020 - 24 Volt

P/N 50000045

Electric motor / Moteur lectrique Bearings / Roulements Clutch couplings / Accouplements d'embrayage Bearing shaft / Axe de roulement 2 Nozzles / Becs 2 Overheat fuses / fusibles thermiques
DBW 2020 - Basic maintenance kit / Kit de base d'entretien

P/N 50000044

2 Nozzles / Becs 2 Overheat fuses / fusibles thermiques DBW 300 - Basic maintenance kit / Kit de base d'entretien

P/N 5000961A

2 Nozzles / Becs 2 Overheat fuses / fusibles thermiques
DBW 2020 - Service pack - Nozzles / Paquet de service - becs

P/N 50000025

12 Nozzles / Becs 0.65 GPH / 80 A 80,000 Btu/h DBW 300 - Service pack - Nozzles / Paquet de service - becs

P/N 5000957A

12 Nozzles / Becs 0.85 GPH / 80 H 104,000 Btu/h
www.webasto.us Webasto Product N.A., Inc. 33
Webasto Product N.A., Inc. 15083 North Road Fenton, MI 48430 Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 Org. 10/2004 Rev. 05/2010 P/N 5000954A www.webasto.us www.techwebasto.com