Webasto DBW 2010 2016 Workshop Repair Manual

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com
Water Heaters Workshop Manual
DBW 2010
DBW 2016
www.butlertechnik.com
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.
To install and repair Webasto heating and cooling systems you need to have completed a
Webasto training course and have the appropriate technical documentation, special tools
and special equipment.
Only genuine Webasto parts may be used. See also Webasto air and water heaters
accessories catalogue.
NEVER try to install or repair Webasto heating or cooling systems if you have not completed
a Webasto training course, you do not have the necessary technical skills and you do not
have the technical documentation, tools and equipment available to ensure that you can
complete the installation and repair work properly.
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 / 2016 Table of Contents
Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.1 Contents and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

1.2 Validity of manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.3 Meaning of signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.4 Additional documentation to be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.5 Safety precautions and regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.5.1 General safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
1.6 Statutory regulations governing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
1.7 Suggestions for improvement and change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.1 Combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205

2.2 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
2.3 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
2.3.1 Nozzle holder pre-heating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
2.4 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
2.5 Combustion chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
2.6 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
2.7 Flame monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
2.8 Ignition spark generator with ignition electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
2.9 Temperature sensor (sensor technology variant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
2.10 Temperature limiter/thermal fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
2.11 Control thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
2.12 Fan thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
2.13 Circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
3 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
3.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301

3.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
3.2.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
3.2.2 Heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
3.2.3 Switch off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
3.2.4 Fault switch-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
4.1 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

4.2 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
5 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501

5.2 General error symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
5.3 Troubleshooting – rapid diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .503
I
Table of Contents DBW 2010 / 2016
5.4 Malfunction symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504

5.4.1 Heater does not start up when switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504
5.4.2 Heater switches into fault mode repeatedly after approx. 30 s (20 s with 1563/1564 control unit)
when switched on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
5.4.3 Heater does not start until after several starting attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
5.4.4 Heater goes out by itself during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
5.4.5 Heater emits black smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
5.4.6 Heater emits white smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
5.4.7 Heater cannot be switched off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
6 Operating Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.2 Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.2.1 Adjusting CO2 content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
6.3 Checking individual components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.3.1 Resistance test of temperature sensor (only heaters with 1563/1564 control unit) . . . . . . . . . . . . . 603
6.3.2 Resistance test of flame monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
6.3.3 Checking and setting ignition electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
6.3.4 Checking ignition spark generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
6.3.5 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
6.3.6 Checking burner motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
6.3.7 Checking solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
6.3.8 Checking nozzle holder pre-heating unit (optional component). . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
7 Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
8 Servicing Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.2 Work on heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.3 Work on vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.4 Test run of heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.5 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
8.5.1 Swinging burner head away and in. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
8.6 Visual inspections and installation instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
8.6.1 Connection to the vehicle cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
8.6.2 Connection to the vehicle fuel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
8.6.3 Combustion air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8.6.4 Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
8.7 Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
8.7.1 Heater, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
8.7.2 Replacing temperature limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
8.7.3 Replacing temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 806
8.7.4 Replacing thermal fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
8.7.5 Replacing control thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
8.7.6 Replacing fan thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
8.7.7 Replacing thermal fusible link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
8.7.8 Replacing burner head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
8.7.9 Replacing ignition spark generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
8.7.10 Replacing flame monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
8.7.11 Replacing combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 807
8.8 Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
8.8.1 Bleeding water circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
8.8.2 Bleeding fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 808
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DBW 2010 / 2016 Table of Contents
9 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901

9.1.1 Works on components when dismantled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .902
9.1.2 Carrying out modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .902
9.2 Dismantling and assembling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .909
9.2.1 Replacing temperature limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .909
9.2.2 Replacing temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .909
9.2.3 Replacing thermal fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .909
9.2.4 Replacing control thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .909
9.2.5 Replacing fan thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .911
9.2.6 Replacing thermal fusible link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .911
9.2.7 Replacing control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .911
9.2.8 Replacing burner head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .911
9.2.9 Replacing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .913
9.2.10 Replacing high-pressure nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .914
9.2.11 Replacing nozzle holder pre-heating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .914
9.2.12 Replacing ignition spark generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .914
9.2.13 Replacing flame monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .914
9.2.14 Replacing ignition electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .914
9.2.15 Replacing fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .916
9.2.16 Replacing solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .916
9.2.17 Replacing combustion chamber. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .916
9.2.18 Thermostat of nozzle holder pre-heating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .916
9.2.19 Replacing heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .918
9.2.20 Replacing nozzle holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .919
9.2.21 Replacing combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .919
10 Packing, Storage and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
10.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001
A Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Periodic Heater Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Maintenance plan Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
III
Table of Illustrations DBW 2010 / 2016
Table of Illustrations
Fig. 201 DBW 2010 heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Fig. 202 DBW 2010 heaters with sensor technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Fig. 203 DBW 2016 Standard / Rail heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Fig. 204 Combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Fig. 205 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Fig. 206 Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Fig. 207 Nozzle holder pre-heating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Fig. 208 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Fig. 209 Combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Fig. 210 1553 control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Fig. 211 1563/1564 control unit for heaters with sensor technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Fig. 212 Flame monitor standard device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Fig. 213 Flame monitor heaters with sensor technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Fig. 214 Ignition spark generator with ignition electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Fig. 215 Temperature sensor (sensor technology variant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Fig. 216 Temperature limiter/thermal fuse only for heaters with 1563/1564 control unit. . . . . . . . . . . . . . . . . . . . . . . . . . 208
Fig. 217 Control thermostat on heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Fig. 218 External control thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Fig. 219 Fan thermostat on heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Fig. 220 Fan thermostat in coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Fig. 221 U 4840, suitable for DBW 2010 and DBW 2016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Fig. 301 Operating sequence (heaters with 1553 control unit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Fig. 302 Operating sequence (heaters with 1563/1564 control unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
Fig. 501 General error symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
Fig. 502 Troubleshooting – rapid diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Fig. 601 CO2 setting DBW 2010 (nozzle: 0.3 gph) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Fig. 602 CO2 setting DBW 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
Fig. 603 CO2 setting DBW 2016 (values not available) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Fig. 604 CO2 setting, locking screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
Fig. 605 Resistance test of temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Fig. 606 Checking flame monitor with 1553 control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Fig. 607 Checking flame monitor with 1563/1564 control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Fig. 608 Reassigning and checking electrode spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Fig. 609 Fuel pump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605
Fig. 701 System wiring diagram for DBW 2010 with 1553 control unit and switch, 12 and 24 V. . . . . . . . . . . . . . . . . . . . 702
Fig. 702 System wiring diagram DBW 2016 with 1553 control unit and switch, 24 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Fig. 703 System wiring diagram DBW 2016 Rail with 1553 control unit and switch, 24 V . . . . . . . . . . . . . . . . . . . . . . . . . 704
Fig. 704 System wiring diagram DBW 2010 with 1553 control unit, 12 and 24 V, switch, nozzle holder
pre-heating unit and altitude control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
Fig. 705 System wiring diagram DBW 2016 with 1553 control unit, 24 V, switch, nozzle holder pre-heating unit
and altitude control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 705
Fig. 706 Automatic switching, DBW 2010 with 1563 control unit, 12 and 24 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
Fig. 801 Swinging burner head away and in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
Fig. 802 Installation example for heater in bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
Fig. 803 Notification sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 805
Fig. 901 Visual inspection on combustion-air rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 902
Fig. 902 Installing nozzle holder pre-heating unit with 1553 control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
Fig. 903 Retrofitting DBW 2010 / DBW 2016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 904
Fig. 904 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 905
Fig. 905 Installing nozzle holder pre-heating unit with 1563/1564 control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Fig. 906 Retrofitting DBW 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 907
Fig. 907 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 908
Fig. 908 Replacing temperature limiter, temperature sensor, thermal fuse, fusible link and control thermostat . . . . . . . . . 910
Fig. 909 Replacing control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
Fig. 910 Replacing burner head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
Fig. 911 Replacing motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 913
Fig. 912 Replacing nozzle holder, nozzle holder pre-heating unit, high-pressure nozzle and flame monitor . . . . . . . . . . . . 915
Fig. 913 Replacing thermostat of nozzle holder pre-heating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917
Fig. 914 Replacing solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 917
Fig. 915 Replacing combustion chamber and heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 918
Fig. 916 Replacing combustion air fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 920
IV
DBW 2010 / 2016 1 Introduction
1 Introduction
1.1 Contents and purpose 1.4 Additional documentation to be used
This workshop manual serves to support instructed personnel, This workshop manual contains all information and instruc-
which repairs the water heater DBW 2010/2016. tions required for repairing the water heaters DBW 2010/
2016.
The heater may only be operated with the predetermined fuel The use of additional documentation is normally unnecessary.
(diesel in accordance with DIN EN 590, EL fuel oil, F34, F35 If necessary, the installation instructions and the operating
kerosene, F54 diesel, F58 petroleum, F63 diesel) and only with instructions can also be used.
the respectively specified electrical connection type.
1.5 Safety precautions and regulations

1.2 Validity of manual
In principle, the general accident prevention regulations and
The manual is valid for the heaters listed on the cover page. current works safety instructions are applicable.
The heaters mainly differ due to their different technical data
(see Section 4) and due to the installation of different control "General safety precautions" which go beyond the scope of
units: Control unit 1553 or control unit 1563/1564 (see 2.6). these regulations are listed in the following.
In conjunction with the control unit 1563/1564, a different Any special safety regulations relevant to this instruction man-
flame monitor is installed (see 2.7). ual will be highlighted in the relevant sections or text passages
of the procedures.
1.3 Meaning of signal words

1.5.1 General safety precautions
Throughout this manual, the signal words WARNING, IMPOR-
TANT and NOTE have the following meanings: There are type approvals for the DBW 2010 / 2016 water
heaters according to the directives ECE-R 10 (EMC) and ECE-
WARNING R 122 (heater).
This heading is used to highlight operating instructions or pro-
cedures which, if not or not correctly followed, may result in Approval numbers see chapter 4, "Technical Data".
personal injury or fatal accidents.
The provisions of the directive ECE-R 122 and the provisions
IMPORTANT of the installation instructions must primarily be observed for
This heading is used to highlight operating instructions or pro- the installation.
cedures which, if not or not correctly followed, may result in
damage to the equipment or its components. IMPORTANT
Non-compliance with the installation instructions and the
NOTE warnings contained therein will lead to the exclusion of all lia-
This heading is used to direct your attention to a special fea- bility by Webasto. The same applies if repairs are carried out
ture deemed essential to highlight. incorrectly or with the use of parts other than genuine spare
parts. This will result in the invalidation of the General Type
Approval for the heater and therefore of the General Homolo-
gation of the vehicle.
The year of initial commissioning must be permanently

marked on the type label by removing the correspond-
ing year.
The heaters are approved for heating the motor vehicle

engine and the vehicle cab. If the heater is used in vehicles not
subject to the German Road Vehicle Licensing Act (StVZO)
(e.g. ships), the regionally applicable regulations must be com-
plied with.
101
1 Introduction DBW 2010 / 2016
The heater may only be installed in motor vehicles or in inde- 1.6 Statutory regulations governing
pendent heating systems with a minimum coolant quantity of installation
10 litres.
NOTE:
The heater may not be installed in the cab or the passenger
The regulations of these guidelines are binding in the scope of
compartment of vehicles. If the heater is nevertheless installed
the EU Directive 70/156/EEC and/or EC/2007/46 (for new vehi-
in an area of this type, then the installation box must be sealed
cle models from 29/04/2009) and should also be observed in
off tight to the vehicle interior. The installation box must be
countries in which there are no special regulations!
sufficiently ventilated from the outside so that a maximum
temperature of 85 °C is not exceeded in the installation box.
Excerpt from directive ECE-R 122 point 5 (part I) and
Malfunctions can occur if this temperature is exceeded.
annex 7
WARNING
Beginning of excerpt.
The heater must not be operated in enclosed areas such
as garages and workshops without an emissions
Part I
extraction system, even if you use the timer, because of
the risk of asphyxiation and poisoning. 5.3 Vehicle Installation Requirements for Combustion
Heaters
The heater must be switched off at filling stations and
tank farms as a result of the risk of explosion. 5.3.1 Scope
5.3.1.1 Subject to paragraph 5.3.1.2, heaters shall be in-
IMPORTANT stalled according to the requirements of paragraph 5.3.
Where flammable vapours or dust can form (e.g. near 5.3.1.2 Vehicles of category O having liquid fuel heaters are
fuel, coal, wood-dust or grain warehouses, etc), the deemed to comply with the requirements of paragraph 5.3.
heater must be switched off due to the danger of
explosion. 5.3.2 Positioning of combustion heater
The heater may not be operated near flammable 5.3.2.1 Body sections and any other components in the vicin-
materials, e.g. dry grass, leaves, cardboard, paper, etc. ity of the heater must be protected from excessive heat and
the possibility of fuel or oil contamination.
A temperature of 110 °C (storage temperature) must not be 5.3.2.2 The combustion heater shall not constitute a risk of
exceeded in the vicinity of the control unit (for example, dur- fire, even in the case of overheating. This requirement shall
ing painting work on the vehicle). be deemed to be met if the installation ensures an adequate
Otherwise the electronics may suffer permanent damage. distance to all parts and suitable ventilation, by the use of
When checking the coolant level, the procedure described by fire resistant materials or by the use of heat shields.
the vehicle manufacturer must be followed. The water in the
5.3.2.3 In the case of M2 and M3 vehicles, the combustion
heating circuit of the heater must contain at least 10 % of a
heater must not be positioned in the passenger compart-
brand-name antifreeze according to manufacturer's instruc-
ment. However, an installation in an effectively sealed enve-
tions (corrosion protection).
lope which also complies with the conditions in paragraph
5.3.2.2 may be used.
Additives to the heating circuit must not attack metal, plastic
or rubber and must not form deposits. 5.3.2.4 The label referred to in Annex 7, paragraph 4, or a
duplicate, must be positioned so that it can be easily read
The opening pressure in the vehicle cooling system – generally when the heater is installed in the vehicle.
specified on the radiator cap – must have an operating pres- 5.3.2.5 Every reasonable precaution should be taken in posi-
sure between 0.4 and 2.0 bar (also applies to separate heat- tioning the heater to minimize the risk of injury and damage
ing circuit). to personal property.
5.3.3 Fuel supply
5.3.3.1 The fuel filler must not be situated in the passenger
compartment and must be provided with an effective cap to
prevent fuel spillage.
5.3.3.2 In the case of liquid fuel heaters, where a supply sep-
arate from that of the vehicle is provided, the type of fuel and
its filler point must be clearly labelled.
5.3.3.3 A notice, indicating that the heater must be shut
down before refuelling, must be affixed to the fuelling point.
In addition a suitable instruction must be included in the
manufacturer’s operating manual.
102
DBW 2010 / 2016 1 Introduction
5.3.4 Exhaust system The mouth of the exhaust pipe should be installed upwards,
5.3.4.1 The exhaust outlet must be located so as to prevent to the side or, if the exhaust pipe passes under the floor of the
emissions from entering the vehicle through ventilators, vehicle, to the side or rear limit of the driver’s cab or the vehi-
heated air inlets or opening windows. cle. Exhaust pipes must be routed so that no penetration of
the exhaust gases into the vehicle interior is to be expected.
5.3.5 Combustion air inlet The function of important parts of the vehicle must not be
5.3.5.1 The air for the combustion chamber of the heater adversely affected. Accumulated condensation in the exhaust
must not be drawn from the passenger compartment of the line must be discharged immediately. A condensate drain hole
vehicle. may be drilled if necessary.
5.3.5.2 The air inlet must be so positioned or guarded that
blocking by rubbish or luggage is unlikely. The openings of the combustion air inlet and exhaust air out-
let must be designed so that a ball with a 16 mm diameter
5.3.6 Heating air inlet cannot be inserted.
5.3.6.1 The heating air supply may be fresh or re-circulated
air and must be drawn from a clean area not likely to be con- The electric cables, controls and control units for the heater
taminated by exhaust fumes emitted either by the propulsion must be arranged in the vehicle so that their proper function-
engine, the combustion heater or any other vehicle source. ing cannot be adversely affected in normal operating condi-
5.3.6.2 The inlet duct must be protected by mesh or other tions.
suitable means.
Compliance with §§ 45 and 46 of the German Road Vehicle
5.3.7 Heating air outlet Licensing Act (StVZO) must be ensured for the installation of
5.3.7.1 Any ducting used to route the hot air through the ve- fuel lines and the installation of additional fuel tanks. The
hicle must be so positioned or protected that no injury or main points from this law:
damage could be caused if it were to be touched.
• Fuel pipes must be designed in such a way that torsion in
5.3.7.2 The air outlet must be so positioned or guarded that
the vehicle, movements by the engine and the like do not
blocking by rubbish or luggage is unlikely.
have a negative effect on their durability. They must be
5.3.8 Automatic control of the heating system protected from mechanical damage. Parts that carry fuel
5.3.8.1 The heating system must be switched off automati- must be protected from heat that will adversely affect
cally and the supply of fuel must be stopped within five sec- their function and positioned so that dripping or
onds when the vehicle’s engine stops running. If a manual evaporating fuel cannot collect or ignite on hot parts or
device is already activated, the heating system can stay in on electrical equipment.
operation.
• With buses, fuel lines and fuel tanks must not be located
ANNEX 7 in the passenger or driver's area. Fuel tanks must be
positioned in these vehicles so that the exits are not
ADDITIONAL REQUIREMENTS FOR COMBUSTION
immediately endangered in case of fire. The fuel must not
HEATERS
be pumped into the fuel tank by gravity or gauge
7 Warning light pressure.
7.1 A clearly visible tell-tale in the operator’s field of view
shall inform when the combustion heater is switched on or Installation regulations for Webasto fuel tanks for supplying
off. fuel to water heaters in vehicles:
• The tank must not be installed in the passenger or

End of excerpt. driver’s cabin of buses.
NOTE • The fuel filler neck must not be inside the passenger or
Additional information on and provisions for installation in driver’s cabin in any vehicle.
vehicles are contained in the installation instructions.
• The fuel tanks must either be provided with a vent cap or
Extraction of the combustion air from the vehicle passenger must be ventilated in another way (ventilation line).
compartment is not permitted.
Only caps may be used which comply with the standard DIN
73400.
All fuel tanks offered in the Webasto accessories catalogue

are suitable for a maximum operating pressure of 0.15 bar.
103
1 Introduction DBW 2010 / 2016
All fuel tanks offered in the Webasto accessories catalogue

are individually subjected to a pressure test of at least 0.3 bar
gauge pressure at the factory.
• The respective operating mode of the heater, at least

switched on or off, must be easily recognisable.
For heaters in vehicles not subject to the German Road Vehicle

Licensing Act (StVZO), approval by the respective test facility
is required – provided there are applicable regulations.
1.7 Suggestions for improvement and

change
Complaints, improvements or suggestions for correction to

this technical manual should be directed to Webasto.
104
DBW 2010 / 2016 2 General Description
2 General Description
The Webasto DBW 2010 and DBW 2016 water heaters are The DBW 2010 and DBW 2016 water heaters mainly consist
used in conjunction with the original vehicle heating system of:
– to heat the passenger compartment, – the combustion air fan

– to defrost the windows and – the fuel pump
– for preheating water-cooled engines. – The heat exchanger
– the combustion chamber and
The water heater operates independently of the vehicle – the ignition spark generator with ignition electrodes
engine and is connected to the cooling system, the fuel sys-
tem and the electrical system of the vehicle.
The heater is designed according to the heat transfer princi- Depending on the heater variant, a nozzle holder pre-heating
ple and its operation is controlled by the temperature sensor. unit may be installed.
To control and monitor it, the heater has the following com-
DBW 2016 Rail (24 V) ponents inside it:
This is a special version of the heater with EBA (Germany's – A control unit
Federal Railway Office) approval. The main functions of the – A flame monitor
heater correspond to those of the standard variant.
Depending on the heater variant, the following can be

mounted on the heater:
– a temperature sensor
– a temperature limiter
– a thermal fuse
– a fan thermostat
201
2 General Description DBW 2010 / 2016
1 Burner head 9 Heat exchanger

2 Ignition spark generator 10 Exhaust outlet
3 Coolant, outlet 11 Control unit
4 Control thermostat *
5 Thermal fuse *
6 Control thermostat * * for components installed in accordance with the
7 Temperature limiter * heater variant
8 Fan thermostat *
Fig. 201 DBW 2010 heaters
202
1 Burner head 8 Exhaust outlet

2 Ignition spark generator 9 Control unit
3 Coolant, outlet
4 Temperature sensor *
5 Thermal fuse * * for components installed in accordance with the
6 Temperature limiter * heater variant
7 Heat exchanger
Fig. 202 DBW 2010 heaters with sensor technology
203
6 5
1 Burner head
2 Ignition spark generator
3 Coolant, outlet
4 Heat exchanger
5 Exhaust outlet
6 Control unit
Fig. 203 DBW 2016 Standard / Rail heaters
204
2.1 Combustion air fan 2.3 Fuel pump
The combustion air fan transports the air required for com- The fuel supply is provided with the fuel pump. The pump is
bustion out of the combustion air inlet into the combustion driven by the motor of the combustion air fan via a coupling.
chamber. The fuel is compressed in the fuel pump and is atomised via
the high-pressure nozzle. A solenoid valve controls the fuel
The following fan models are installed in the heaters: supply to the nozzle.
DBW 2010 / 2016 – radial fan.
DBW 2010
Fig. 204 Combustion air fan
Fig. 206 Fuel pump

2.2 Motor
The motor drives the combustion air fan via a coupling and 2.3.1 Nozzle holder pre-heating unit
the fuel pump via a gearbox.
The fuel to the atomiser nozzle is heated with the nozzle
holder pre-heating unit.
At extremely low temperatures, malfunctions can occur with-

out nozzle holder pre-heating.
At a temperature of < 0 °C, the heating cartridge in the noz-
zle holder is connected with a thermostat. The heating dura-
tion is dependent on the reflected heat in the combustion
DBW 2010 chamber and switches off at +8 °C at the thermostat.
DBW 2016
Standard / Rail If no nozzle holder pre-heating unit is installed in the heater,
it can be retrofitted.
Fig. 205 Motor See the spare parts list for the required parts.
Heating cartridge
Nozzle holder
Thermostat
DBW
2010 / 2016
Fig. 207 Nozzle holder pre-heating unit
205
2.4 Heat exchanger 2.6 Control unit
The heat generated in the heat exchanger by combustion is The control unit is the central component and ensures the
transferred to the coolant circuit. operating sequence and the monitoring of combustion oper-
ation.
DBW
2010 / 2016
(may differ, according to
variant) Fig. 210 1553 control unit
Fig. 208 Heat exchanger
2.5 Combustion chamber
The fuel-air mixture is distributed in the combustion chamber

and burned there. The heat exchanger is heated in the proc-
ess.
DBW 2010 / 2016 Fig. 211 1563/1564 control unit for heaters with sensor
technology
Fig. 209 Combustion chamber
206
2.7 Flame monitor 2.8 Ignition spark generator with ignition

electrodes
The flame state is monitored during the entire combustion
operation with the flame monitor. The flame monitor is a The high voltage for igniting the fuel-air mixture is generated
photo resistor for standard device or a photo transistor for in the ignition spark generator. Ignition is carried out with a
sensor technology variant, which reacts depending on the high-voltage spark between the two ignition electrodes.
light spectrum of the flame.
The signals are sent to the control unit and processed there.
Ignition electrodes
Flame monitor
Fig. 214 Ignition spark generator with ignition electrodes
2.9 Temperature sensor (sensor technology

variant)
Fig. 212 Flame monitor standard device
The temperature sensor detects the coolant temperature at

outlet of the heater exchanger as an electrical resistance. This
signal is fed to the control unit, where it is processed.
Ignition elec-
trodes
Flame monitor
Fig. 213 Flame monitor heaters with sensor technology

Fig. 215 Temperature sensor (sensor technology variant)
207
2.10 Temperature limiter/thermal fuse 2.11 Control thermostat
Temperature limiter Control thermostat on heater

The temperature limiter (bi-metal) protects the heater against The control thermostat assumes the control operation after
impermissibly high operating temperatures. The temperature the operating temperature is reached. Alternately switching
limiter reacts at a temperature above 107 °C or 117 °C and the heater on and off maintains the coolant temperature at a
switches off the heater. The temperature limiter can be reset constant level. The thermostat closes at 68 °C ± 5 K and
or is automatically reset. opens at 75 °C ± 3 K.
Optional for DBW 2016 Rail version: The thermostat closes at
Thermal fuse 50 °C ± 5 K andopens at 65 °C ± 3 K.
The thermal fuse protects the heater against impermissibly
high operating temperatures. The thermal fuse contains a External control thermostat
fusible link which reacts when the permissible temperature is The control operation can also be controlled by an externally
exceeded and switches off the heater. mounted control thermostat.
The heater can be retrofitted with a temperature limiter in The control thermostat assumes the control operation after
place of the thermal fuse. the operating temperature is reached. Alternately switching
the heater on and off maintains the coolant temperature at a
constant level. The thermostat closes at 71 °C ± 2 K and
opens at 78 °C ± 2 K; alternatively at 62 °C ± 2 K and
Thermal
70 °C ± 2 K.
fuse
For heaters with an economy mode (temperature holding
mode), a thermostat can be installed which closes at
Reset button 35 °C ± 2 K and opens at 42 °C ± 2 K.
Temperature limiter
opens at 107 °C ± 5 K
can be reset at 60 °C
automatic reset at 0 °C
Reset button
DBW 2010 / 2016
Temperature limiter Thermal fuse

opens at 117 °C ± 5 K
can be reset at 90 °C DBW 2010 / 2016
automatic reset at 0 °C
Fig. 217 Control thermostat on heater
Fig. 216 Temperature limiter/thermal fuse

only for heaters with 1563/1564 control unit
208
2.13 Circulation pump
The heater must be operated with a circulation pump.

The externally positioned circulation pump ensures the
pumping of the coolant in the vehicle and/or heater circuit.
The pump is switched on with the control unit and runs dur-
ing the entire operation of the heater.
Fig. 218 External control thermostat
2.12 Fan thermostat
The fan thermostat switches the original vehicle heater fan

off or on when the coolant temperature is between 30 °C
and 40 °C. The thermostat closes at 40 °C ± 3 K and opens Fig. 221 U 4840, suitable for DBW 2010 and DBW 2016
at 30 °C ± 5 K.
Fig. 219 Fan thermostat on heater
Fig. 220 Fan thermostat in coolant circuit
209
3 Description of Operation DBW 2010 / 2016
3 Description of Operation
3.1 General information Alternately switching on and off maintains the heat
exchanger (coolant) temperature at a constant level. If the
The heaters equipped with a high-pressure atomizing burner temperature exceeds the upper switch point, the solenoid
operate in the intermittent mode. valve shuts off the fuel supply, causing the flame to go out.
Control is carried out either The run-on begins, during which the combustion air fan con-
tinues to run and is switched off automatically after approx.
– thermostatically (heaters with 1553 control unit) or 150 (or 90 for heaters with sensor technology) seconds. The
– with temperature sensor (DBW 2010 heaters with sensor circulation pump remains in operation in the control break
technology with 1563/1564 control unit). and the operating indicator lamp lights up. If the temperature
drops below the lower switch point, the new heater start-up
process begins.
3.2 Operation
3.2.3 Switch off
The heater is switched on and off with
Combustion ends when the heater is switched off. The oper-
– switch (On/Off) or ating indicator lamp goes out and the run-on begins. The
– digital timer. combustion air fan and the circulation pump are switched off
after approx. 150 (or 90 for heaters with sensor technology)
To monitor the operating sequence, an operating indicator seconds.
lamp is installed in the digital timer or separately.
It is permissible to switch on the heater again during the run-
On request, the heaters can be equipped with on.
– a nozzle holder pre-heating unit with a heating cartridge

for extremely low temperatures,
3.2.4 Fault switch-off
There is a partially altered operating sequence for heaters
with sensor technology (see Fig. 302). For heaters with 1553 and 1563/64 control unit
A fault switch-off is carried out

3.2.1 Switching on – if no combustion occurs within approx. 30 seconds after
the heater is switched on,
When the heater is switched on, the operating indicator lamp – if the combustion-air supply during the heating mode is
lights up. The combustion air fan, fuel pump and circulation interrupted for longer than 10 seconds,
pump start up. After approx. 15 seconds, the solenoid valve – by the thermal fuse or the overheating temperature lim-
is opened, and fuel is sprayed into the combustion chamber iter if the heater overheats. Then an identical thermal
via the atomiser nozzle and ignited by a simultaneously trig- fuse must be used as a replacement (observe colour cod-
gered high-voltage ignition spark. With a signal of the flame ing) or a reset must be carried out with the button of the
monitor, the control unit switches the ignition spark genera- temperature limiter (after cooling down to below 60 °C).
tor off again after a flame has been formed.
Fault switch-off for heaters with 1553 control unit
If no combustion is produced, see 3.2.4.
– in case of undervoltage approx. 10 to 25 seconds after
the switching threshold is dropped below.
3.2.2 Heating mode
After the operating temperature is reached, the control mode

is assumed by the control thermostat (or by the control unit
with heaters with sensor technology).
301
DBW 2010 / 2016 3 Description of Operation
Fault switch-off only for heaters with sensor

technology with 1563/64 control unit
– 12 seconds after start-up due to detection of extraneous

light or in case of undervoltage
– during combustion operation as the result of undervolt-
age for at least 12 seconds. After a run-on of 90 seconds,
the heater is in fault lock-out.
After the fault cause is eliminated, the fault release is carried

out by switching the heater off and then on again.
(A) Switch-on indicator

(B) Circulation pump
(C) Combustion air fan
(D) Ignition spark generator
(E) Solenoid valve
(F) Flame monitor
(G) Control thermostat
(1) Switch-on
(2) Run-up
(3) Start
(4) Safety time
(5) Combustion operation
approx. approx.
10 -25 s 5 -25 s 150 s 10 -25 s 5 -25 s 150 s
(6) Start of control break
(7) Run-on
(8) End of control break
(9) Switch-off
(10) Off
Fig. 301 Operating sequence (heaters with 1553 control unit)
302
3 Description of Operation DBW 2010 / 2016
(A) Switch-on indicator

(B) Circulation pump
(C) Combustion air fan
(D) Ignition spark generator
(E) Solenoid valve
(F) Flame monitor
(1) Switch-on
(2) Run-up
(3) Extraneous light query
(4) Pre-ignition
(5) Start
(6) Safety time
12 s <1 s 1 s 12 s 90 s* 12 s <1 s 1 s 12 s 90 s* (7) Combustion operation
(8) Start of control break
(9) Run-on
* ADR heaters: 20 s (10) End of control break
(11) Switch-off
(12) Off
Fig. 302 Operating sequence (heaters with 1563/1564 control unit)
303
DBW 2010 / 2016 4 Technical Data
4 Technical Data
The technical data listed in the table refer to the usual heater We know of no negative influences due to additives.
tolerances of ±10 % at an ambient temperature of +20 °C
and at nominal voltage. If fuel is extracted from the vehicle’s tank, follow the additive
instructions issued by the vehicle manufacturer.
If fuel is taken from a separate fuel tank, winter diesel fuel

4.1 Electrical components
must be used at temperatures below 0 °C or petroleum or
petrol fuel must be added to the diesel fuel in accordance
Control unit, motors for combustion air fan and circulation with the proper mixing ratio. The use of flow improvers is
pump, solenoid valve, ignition spark generator, heating car- permissible.
tridge, nozzle holder pre-heating unit and digital timer are
designed for a 12 V (DBW 2010) or 24 V (DBW 2010 / Mixing ratio for separate fuel tank
DBW 2016) power supply. The components temperature lim-
iter, flame monitor, temperature sensor and switch are inde-
pendent of the voltage. Temperature Winter diesel Addition of petro-
fuel leum or petrol fuel
NOTE
0 °C to –20 °C 100 % –
The circulation pumps must be assigned to the heaters in
accordance with the coolant-side resistances. –20 °C to –30 °C 70 % 30 %
or special low-temperature diesel fuel

4.2 Fuel
-30 °C to -40 °C special low-temperature diesel fuel or
100 % petroleum
The diesel fuel specified by the vehicle manufacturer is suita-
ble as fuel. Only the fuel specified on the factory plate may be
used (diesel in accordance with DIN EN 590, EL fuel oil, F34,
F35 kerosene, F54 diesel, F58 petroleum, F63 diesel).
Heater DBW 2010 DBW 2016 DBW 2016 DBW 2016

Rail High Altitude
Approval mark
EMC: E1 10R- 04 6955 E1 10R- 04 6955
Heating: E1 122R- 00 0006 E1 122R- 00 0001
Model High-pressure atomiser
Heat output [KW] 11.6/9.3 16.0
([kcal/h]) (10,000/8,000) (13.800)
Fuel Diesel according to DIN EN 590, EL fuel oil, F34, F35 kerosene, F54 diesel, F58 petroleum, F63
diesel
Fuel consumption [kg/h] 1.3/1.0 1,9
Rated voltage [V] 12 or 24 24
Operating voltage range [V] 10 to 14 or 20 to 28
20 to 28
Nominal power consumption (without circula- [W] 60 90
tion pump)
Perm. ambient temperature during operation
(heater, control unit, circulation pump) [°C] -40 to +60
Perm. storage temperature
(heater, control unit, circulation pump) [°C] -40 to +85
Perm. operating pressure [bar] 0.4 to 2.0
Capacity of the heat exchanger L: 1,1
Dimensions of heater incl. control unit
(tolerance r 3 mm)
- Length [mm] 584
- Width [mm] 205
- Height [mm] 228
Weight [kg] 15
401
4 Technical Data DBW 2010 / 2016
Circulation pump U 4840

Volume flow rate [l/h] 1,600 (against 0.1 bar)
Rated voltage [V] 12 or 24
Operating voltage range [V] 9 to 15 or 16 to 30
Rated power consumption [W] 30
Dimensions
- Length [mm] 135
- Width [mm] 95
- Height [mm] 48
Weight [kg] 0,4
402
DBW 2010 / 2016 5 Troubleshooting
5 Troubleshooting
5.1 General information
This section describes troubleshooting on the DBW 2010/ IMPORTANT

2016/2016 Rail heaters. Error detection is generally limited to the localisation of the
defective components.
IMPORTANT The following potential sources of malfunctions are not taken
Troubleshooting work demands precise knowledge of the into account and should always be checked so that they can
structure and theory of operation of the various components then be excluded as the cause of the particular fault:
and must be carried out by trained personnel only.
Corrosion on connector
If in doubt, refer to sections 2 or 3 for a description of how Loose contact on connector
the functions interact. Poor crimp contacts on plugs
Corrosion on lines and fuses
Corrosion on battery terminals
Conduct a function test in the vehicle after rectifying each

fault.
5.2 General error symptoms
The following table (Fig. 501) lists the possible general error
symptoms.
Error symptom Possible cause
Malfunction in electrical system
Switch-on indicator lamp does not light up and heater does • No supply voltage,
not operate. • Fuses,
• Supply line to plug contacts of connector A of control
unit.
Fuse F2 blows. Short circuit in circulation pump or in supply line to heater.
Fuse F3 blows. Short circuit in supply line to heater/engine/nozzle holder

pre-heating unit (if installed).
Heater operation OK, however operating indicator lamp Operating indicator lamp defective or wiring to operating
does not light up. indicator lamp interrupted or short-circuited.
Fig. 501 General error symptoms (Section 1 of 2)
501
5 Troubleshooting DBW 2010 / 2016
Error symptom Possible cause
Malfunction in water system
Heater shuts off, as heat exchangers (heater and vehicle) do Flow rate insufficient, as
not give off sufficient heat. • air or gas in heater, in heat exchangers or in system
sections.
• valves (flow controller) throttled, soiled or closed.
• impurities in system, e.g. filter or with bottlenecks.
• delivery capacity of circulation pump insufficient (air or
gas in pump casing), rotating direction incorrect – check
polarity.
• insufficient frost protection.
• system resistance too high (especially high at low
temperatures).
• circulation pump defective.
Vehicle's heat exchangers (water/air) give off insufficient

heat, as
• air or gas in heat exchangers or in system sections.
• soiled heat exchanger surfaces /(inside/outside).
• insufficient air inlet or air outlet.
• fan: delivery capacity insufficient/rotating direction
incorrect/resistance too high.
• percentage of antifreeze too high.
• heat exchanger too small.
Approximate determination of flow rate
Heating capacity [kW] as per type label

Flow rate in [l/h] = x 860
Temperature difference ǻT in [K] or [°C] measured
between water inlet and outlet on heater (e.g. with
contact thermometer)
Malfunction in fuel supply
No fuel delivered to heater. • Fuel tank empty.

• Kinked, sealed-off, clogged or leaky lines.
• Paraffin precipitation or frozen water inclusions in fuel
filter and/or lines.
• Ventilation opening in tank closed.
• Fuel line interchanged.
• Fuel filter soiled.
Malfunction in combustion
CO2 value cannot be set to nominal value. • Air bubbles in intake line (intake line leaky).
Combustion irregular. • Fuel filter soiled or leaky.
• Fuel connection leaky (suction height, vacuum in tank);
see installation instructions.
• Fuel pump defective (pump pressure).
• Return line constricted.
• Screen in pump soiled.
• Atomiser nozzle defective.
• Combustion-air and exhaust lines constricted or closed
off.
• Motor speed of combustion motor insufficient.
Fig. 501 General error symptoms (Section 2 of 2)
502
5.3 Troubleshooting – rapid diagnosis
Heater types:
All heaters
Only heaters with sensor technology with 1563/1564 control unit
Description of malfunction Check and repair or replace if necessary

S
Ignition spark generator, ignition cable

Control thermostat or temp. sensor
Electr. lines and connections
Combustion-air routing
Thermal fuse or limiter
Exhaust-gas routing
Solenoid fuel valve
Ignition electrodes
Circulation pump
Atomiser nozzle
Heating system
Flame monitor
Drive (engine)
Power supply
Control unit
Fuel supply
Fuel pump
Switch
Fuses
After switching on – no function
Switch-on check – goes out after

approx. 25 sec. (30 sec. o)
Combustion air fan – not running
Combustion air fan – no run-up
Combustion air fan – no run-on
Circulation pump – not running
Ignition spark – not present
Combustion – does not begin (after

15 sec. o)
Combustion – stops after approx.
25 sec. (30 sec. o)
Combustion – cannot be shut off
Combustion is carried out – with light-

coloured smoke
Combustion is carried out – with dark-
coloured smoke
Heater – overheated
Fig. 502 Troubleshooting – rapid diagnosis
503
5.4 Malfunction symptoms

5.4.1 Heater does not start up when switched on
no
Is voltage connected Are both fuses F2/ Does the control Does the control ther- Control thermo-
to terminals B1, B2 F3 defective? thermostat have mostat have continui- stat defective; re-
and B4? (with 1563/1564 continuity? ty after water circuit place.
(with 1563/1564 control unit: F1/ (with 1563/1564 cools down?
control unit: termi- F2). control unit: tem-
nals A1, A2, A3, A4). perature sensor).
Replace fuses and Supply line defec- Temperature in water

switch on heater. tive (with 1563/ circuit was too high.
Does the fuse 1564 control unit:
blow again? control unit defec-
yes tive).
Locate short cir- Only with 1563/1564

cuit and elimi- control unit: Supply
nate. line or temperature
sensor defective.
Voltage insufficient? Is voltage con- Is voltage con-

< 18 ± 1.0 V or nected to the mo- nected to termi-
< 9 ± 0.5 V tor (combustion nals C2 and C5 of
(with control unit air fan)? the control unit?
1563/1564: < 20 - 1 V (1563/1564 con-
or < 10 - 1 V). trol unit: D2 and
D5).
Undervoltage protec- Control unit de-

tion in control unit fective; replace,
has been activated; check supply lines
charge battery. to motor (com-
bustion air fan)
for
interruption.
Can the motor Can the motor Can the motor shaft Motor (combus-
shaft be turned shaft be turned be turned easily with tion air fan) defec-
easily? easily with the the motor removed? tive; replace.
nozzle holder
plate removed?
Motor (combus- Bearing of fan impel-

tion air fan) defec- ler defective.
tive; replace.
Can the large spur Fuel pump defective;

gear be turned replace.
easily?
Motor (combus-
tion air fan) defec-
tive; replace.
504
5.4.2 Heater switches into fault mode repeatedly after approx. 30 s (20 s with 1563/1564 control
unit) when switched on
no
Has thermal fuse F1 Is the buzzing of Is voltage con- Check supply lines Is the same effect Ignition spark gener-
blown? the (mechanical) nected to termi- from control unit. produced with a new ator defective; re-
Has temperature lim- ignition spark nals C8 and C5? Open circuit? ignition spark gener- place.
iter been tripped? generator audi- (1563/64 control ator?
ble after approx. unit: terminals D8
20 s or 12 s? and D5).
Eliminate cause of Eliminate open cir- Insulator of ignition

tripping, e.g. water cuit. electrodes defective.
shortage.
Replace thermal fuse
or reset temperature Is the resistance/voltage of the flame monitor Flame monitor defec-
limiter. without the effect of light > 100 kohms? tive; replace.
(with 1563/64 control unit: > 3.5 V)
yes
Control unit de- Does the solenoid
fective; replace. valve in the heater
open and - if due to
the tank located high-
Is a combustion Does fuel spray er - does the existing Coil of magnetic head
noise audible? out of the atomis- solenoid valve in the defective.
er nozzle? intake and return po-
sition open?
no Do the solenoid Solenoid valve defec-

valves have continui- tive; replace.
ty?
Is voltage connected Check supply lines.

to the solenoid valve?
yes Does the setting of Adjust ignition elec-

the ignition electrodes using gauge.
trodes match the
gauge?
Is fuel pumped by the If there fuel in the Refill.

pump? tank?
Atomiser nozzle Are all fuel lines Tighten, install new

clogged; replace. tightly connected? seals.
Is the sealing surface Remove fuel pump. Is

of the control piston the driver on the
or the ventilation shaft OK?
hole soiled?
Is the resistance/ Does the nozzle Check intake and ex- Clean or replace. Intake line clogged.
voltage on the atomise with a haust connection Kerosene precipita-
flame monitor limited spraying piece for continuity; tion or frozen water
with the effects angle? clean if necessary. inclusions.
of light of 50 Lux Or: Ventilation open-
< 1.56 kohms? ing in tank closed.
(with 1563/64
control unit:
< 3.5 V)
Voltage at heater no Is the viscosity below Fuel quality does not Screen in intake con-
is within limits of 20 cSt.? match mixing ratio in nection of fuel pump
yes undervoltage accordance with op- soiled; clean.
protection of erating manual at
control unit. low temperatures.
Flame monitor defec- yes Charge battery. Atomiser nozzle Replace fuel pump. no
tive; replace. clogged; replace.
505
5.4.3 Heater does not start until after several starting attempts
no
Does smoke exit from the no Fuel level has dropped Fuel pump defective;
exhaust pipe during the while heater was replace.
failed starting attempts? stopped: Pressure control valve
Press off intake and re- clogged.
turn line.
Can leaks be found?
no
See 5.4.7 Seal off.
Does the ignition Does the ignition spark Ignition spark genera-
yes spark jump across at jump across at the insulator defective; replace.
the high-voltage tion of the ignition elec-
lines? trodes?
High-voltage line de- Ignition electrode defec-

fective tive; replace.
5.4.4 Heater goes out by itself during operation

no
Does the heater function after Does the heater react at all? See 5.4.1
repeating the starting at-
tempt?
Fuel supply from tank was in- Heater goes into fault mode
terrupted for a longer time. after approx. 30 s (with
1563/1564 control unit:
24 s). See 5.4.2
yes
506
5.4.5 Heater emits black smoke

no
Is the combustion-air intake no Are the gas paths of Does vacuum or gauge Motor speed (see Sec-
pipe or the exhaust connec- the heat exchanger pressure result at the tion 6) too low.
tion piece soiled? heavily soiled? combustion air inlet,
possibly also while driv-
ing?
no
Clean, correct installation if Clean according to Is the swirl chamber
necessary (see Section 8). specifications. (with DBW 2010) defec-
tive?
no
Is the burner protection
flap/are grommets
leaky?
yes
Does the heater emit black Has the air control be- Are there constric- Has the correct fuel Observe information
smoke only during starting? come misadjusted? tions or throttled posi- been used according to in operating manual.
tions in the fuel return the table in the operat-
line or is the intake ing manual?
line leaky or heated up
(formation of bub-
bles)?
Allow heater to Check fuel pump pres- Is the voltage at the

burn clear. sure (see Section 6). Is motor below 10 V or
the pump pressure too 20 V under load?
high?
Due to the increased Set (see Section 6). Charge battery;

fuel pressure, the flow electrical lines corrod-
rate of the atomiser ed or too small;
nozzle is too high. motor defective.
Is the valve seat of the sole- Can the permissible Distance between fan Replace atomiser noz- no
noid valve leaky? combustion values impeller and housing zle.
(seat damaged, armature (see Section 4) be set? too large (for DBW
jams). 2010/2012) or motor
speed insufficient (see
Section 6).
Check valve seat and replace Does the heater con-

small parts of solenoid valve tinue to emit black
if necessary. smoke after setting?
Does the atomiser Clean or replace atom-

nozzle spray uniform- iser nozzle.
ly?
507
5.4.6 Heater emits white smoke

no
Does the heater smoke Does the heater emit Does the heater emit
for longer than 20 s? smoke during opera- smoke after being
tion (including at inter- switched off?
vals)? yes
Is the electrode adjust- Adjust ignition elec- Does the seat of the so- Check valve in atomiser
ment correct according trodes using gauge (see lenoid valve fail to nozzle is leaky. Replace
to the gauge (see Sec- Section 6). close? atomiser nozzle (only
tion 6)? DBW 2010 with return
line nozzle).
Replace atomiser noz- Check seat of solenoid

yes zle. valve and replace small
parts if necessary.
Have unsuccessful Is the flow rate of the

starting attempts pre- atomiser nozzle insuffi-
ceded? cient? - Replace.
Does the heater still
emit smoke?
Collected oil in combus- Replace atomiser noz-

tion chamber must zle.
evaporate first.
Does the heater emit
visible smoke?
Open burner and pull

out combustion cham-
ber. Are the coke de-
posits in the
combustion chamber
visible?
Clean combustion
chamber.
5.4.7 Heater cannot be switched off

no
Do the switches or the digital tim- Are exhaust gases emitted after Do the heater continue to run for longer
er have electrical continuity when switch-off? than 180 s (1563/64 control unit: 90 s) af-
switched off? ter switch-off?
Switch or digital timer defective; Control unit defective; replace.

replace.
Does the control thermostat open Control thermostat defective; replace (not
when the switching point is with 1563/64 control unit).
reached?
yes Is the (+) voltage on the solenoid Control unit defective; replace.
valve eliminated?
Does the solenoid valve close? Solenoid valve defective; replace.
508
DBW 2010 / 2016 6 Operating Tests
6 Operating Tests
This section describes the tests and settings carried out on

the heater when it is installed and not installed to verify that
it is in working order.
WARNING
The heater must not be operated in enclosed areas such as
garages and workshops without an emissions extraction sys-
CO2 [vol. %]
tem.
Do not switch on the heater with the burner swung away due
to the fire danger.
6.2 Settings Voltage [V]

CO2 setting at 500 m above sea level
6.2.1 Adjusting CO2 content
Fig. 601 CO2 setting DBW 2010 (nozzle: 0.3 gph)
A change in the combustion air quantity set at the factory is

permissible and can be achieved by turning the adjustment
ring.
Measure the CO2 value in the exhaust gas and set the com-
bustion-air quantity if necessary:
– following repairs to the burner
– in case of combustion irregularities
– as part of a functional check
– following a nozzle replacement
Adjustment process
– Measure input voltage on heater
CO2 [vol. %]
– Allow heater to run for approx. 5 min.

– Measure CO2 value and amount of soot and compare to
corresponding graph.
Voltage [V]
CO2 setting at 500 m above sea level
Fig. 602 CO2 setting DBW 2010
601
6 Operating Tests DBW 2010 / 2016
NOTE
The CO2 setting is dependent on the fuel (viscosity) and the
geodetic altitude (0.1 % per 100 m).
If the CO2 value cannot be properly set, proceed as follows:
– Check burner head for damage and replace if necessary
– Check pressure of fuel pump and replace pump if neces-
sary
– Replace nozzle
– Measure speed of burner motor
– Check cable passage grommets for proper installation
Fig. 603 CO2 setting DBW 2016 (values not available)
NOTE
Intake connection piece
can be offset by 180°.
Locking screw
Fig. 604 CO2 setting, locking screw
– Loosen locking screw (see Fig. 604) and move adjust-

ment ring with locking screw until setpoint value is
reached.
– Tighten locking screw to 1.0 + 0.5 Nm and lock with
sealing paint.
602
6.3 Checking individual components 6.3.2 Resistance test of flame monitor
6.3.1 Resistance test of temperature sensor (only NOTE

heaters with 1563/1564 control unit) The glass element of the flame monitor and the inspection
window of the disc (see illustration) must be cleaned if soiled.
During an electrical test with a digital multimeter, the tem- The flame monitor must be replaced if it is damaged or the
perature sensor is to have the values in accordance with the setpoint value is not reached.
following graph. The resistance measurement must prefera-
bly be carried out at 20 °C and approx. 100 °C (immerse sen-
sor in water). 6.3.2.1 Checking flame monitor with 1553 control unit
– Connect ohmmeter to flame monitor

– Darken flame monitor well. For this purpose, slide on a
piece of black protective sleeving and pull together at the
ends
– After approx. 20 second the resistance must increase to
> 100 kohms
– Expose flame monitor to light of a match from a distance
of approx. 1 cm. The resistance must drop to approx.
300 ohms in the process.
Resistance [ohms]
Ignition electrodes
Coolant temperature in °C
Fig. 605 Resistance test of temperature sensor
Inspection window
Flame monitor
Fig. 606 Checking flame monitor with 1553 control unit
603
6.3.2.2 Checking flame monitor with 1563/1564 6.3.3 Checking and setting ignition electrodes
control unit
NOTE
When installed • The insulating elements of the ignition electrodes must
– Connect voltmeter to connections D6 (+) and D7 (–) of not be damaged. Ignition electrodes with an electrode
control unit spacing outside the tolerance or ignition electrodes
– Switch on heater which do not operate properly must be adjusted or re-
– The measured voltage must be 5 V. placed.
After approx. 15 s to 26 s, the voltage must drop to • The ignition electrodes can be adjusted with the gauge.
< 1 V. For this purpose, the front edge of the gauge must strike
the atomising nozzle and the tip of the ignition elec-
When removed trodes must be in the two notches.
– Connect flame monitor with a series resistor of 1 kohms
to 5 V Test
– Connect voltmeter parallel to flame monitor – Examine insulating element of ignition electrodes for
– The voltage must drop to > 1 V with the lens darkened damage.
and an open flame or light bulb (5 W).
IMPORTANT
So that the fuel atomisation is not impaired, do not touch the
nozzle hole when measuring the electrode spacing.
– Check electrode spacing in accordance with gauge as per

Fig. 608 and state of ignition electrodes.
Ignition electrodes
Adjusting
Readjust electrode spacing by bending and check with gauge
in accordance with Fig. 608.
Flame monitor
Inspection window
Fig. 607 Checking flame monitor with 1563/1564

control unit
Fig. 608 Reassigning and checking electrode spacing
604
6.3.4 Checking ignition spark generator 6.3.5 Checking fuel pump
WARNING NOTE
High voltage; a voltage of approx. 8,000 V jumps across at The fuel pump is checked when installed. The pump pressure
ignition electrodes. may be adjusted.
IMPORTANT A tester is required for testing. A tester (display range 0 to

Do not charge ignition spark generator without ignition elec- 15 bar) can be purchased from your authorised Webasto
trodes with voltage. dealer.
Test IMPORTANT
The ignition spark generator must be removed.
NOTE
Connect direct current supply with plus to black wire and Test
negative to brown wire. – Remove ignition spark generator (see 9.2.7.1).
– Remove atomiser nozzle.
– Connect direct voltage of 12 V or 24 V – Screw on tester.
– Target state: Ignition sparks jump across to ignition elec- – Cover flame monitor.
trodes. – Switch on heater.
– After approx. 15 sec. the pump pressure is displayed (see
Fig. 609).
DBW2010: 7 bar for nozzle 0.4 gph
10 bar for nozzle 0.3 - 0.35 gph
DBW2016: 11.5 bar
– Switch off heater.
– Screw off tester.
IMPORTANT
Do not damage nozzle hole.
– Screw in atomiser nozzle and tighten to 20 Nm.

– Install ignition spark generator (see 9.2.7.2).
Fig. 609 Fuel pump pressure
605
6.3.6 Checking burner motor 6.3.7 Checking solenoid valve
NOTE NOTE
The combustion air fan is checked when installed. If the set- A leaky valve seat of the solenoid valve is indicated by longer
point states are not reached, then the fan motor must be continued smoking of the heater in run-on. In this case, fuel
replaced. continues dripping via the atomiser nozzle.
Brief continued smoking is normal. This is carried out by emp-
Test tying the space between the solenoid valve and the nozzle
– Examine bearing condition (stickiness) of burner motor. hole.
– Measure input voltage on heater
– Switch on heater Test
– Measure speed (speeds must be within specified speed
ranges at nominal voltage) IMPORTANT
DBW 2010: 4,500 ± 100 / min. Disconnect the connector of the solenoid valve at the control
DBW 2016: 5,000 ± 100 / min. unit and connect to external power supply.
Failure to observe this can result in damage to the control
unit.
– Check electrical operation with 12 V devices in accord-

ance with data below:
• Opening voltage 8.5 V
• Operating voltage 9.6 to 14.4 V
• Power consumption at nominal voltage and 20 °C
10 W
• Nominal current 0.83 ampere
– Check electrical operation with 24 V devices in accord-

ance with data below:
• Opening voltage 17. V
• Operating voltage 19: to 28.8 V
• Power consumption at nominal voltage and 20 °C
10 W
• Nominal current 0.42 ampere
6.3.8 Checking nozzle holder pre-heating unit

(optional component)
NOTE
At a temperature of < 0 °C, the heating cartridge in the noz-
zle holder is connected with a thermostat. The heating dura-
tion is dependent on the reflected heat in the combustion
chamber and switches off at +8 °C at the thermostat.
The power consumption is 130 ± 13 W with 12 V or 24 V.
Test
– Swing or remove burner head
– Disconnect connector from nozzle holder
– Connect ohmmeter to connector
– Cool thermostat with refrigerant spray or bypass
– Resistance value (max. 4.5 ohms).
606
DBW 2010 / 2016 7 Circuit Diagrams
7 Circuit Diagrams
The wiring diagrams or application examples (Fig. 701 to Fig.

706) show the possible circuits of the DBW 2010, DBW 2016
and DBW 2016 Railheaters.
Cable cross-sections Cable colours

< 7.5 m 7.5 m–15 m bl blue
br brown
0.75 mm² 1.0 mm²
ge yellow
0.75 mm² 1.0 mm² gn green
1.0 mm² 1.5 mm² gr grey
or orange
1.5 mm² 2.5 mm² rt red
2.5 mm² 4.0 mm² sw black
vi violet
4.0 mm² 6.0 mm²
ws white
Vehicle’s own cable
701
7 Circuit Diagrams DBW 2010 / 2016
Version with thermal fuse only
Version with temperature limiter and thermal fuse
Version with thermal fuse and fan thermostat
Version with thermal fuse, temperature limiter and fan thermostat
Fig. 701 System wiring diagram for DBW 2010 with 1553 control unit and switch, 12 and 24 V
702
Version with temperature limiter and thermal fuse
Version with thermal fuse and fan thermostat
Version with thermal fuse, temperature limiter and fan thermostat
Fig. 702 System wiring diagram DBW 2016 with 1553 control unit and switch, 24 V
703
Fig. 703 System wiring diagram DBW 2016 Rail with 1553 control unit and switch, 24 V
NOTE
When using the digital timer 1531, the switch S1 in Fig. 703 is replaced by a relay, actuated by the load output of the digital
timer 1531. The switching capacity of the relay must be at least 2 A. The control current may not exceed 0.4 A.
704
Fig. 704 System wiring diagram DBW 2010 with 1553 control unit, 12 and 24 V, switch, nozzle holder pre-heating unit and
altitude control
X5
2
1
4 85 30
3 K6
86 87
B5 R2
ws
Fig. 705 System wiring diagram DBW 2016 with 1553 control unit, 24 V, switch, nozzle holder pre-heating unit and altitude
control
705
Legend Fig. 701 to Fig. 705:

Item Description Comment A B C D
1 Heater Not earthed
2 Control unit SG 1553
4 Ignition spark generator
5 Thermostat Control thermostat (internal)
7 Thermostat Fan thermostat
8 Thermostat Temperature limiter thermostat
10 Ignition electrodes
61.3 Interference suppression set (2x) Radio interference suppression
F1 Thermal fuse Independent of polarity
F2 20 A fuse Flat fuse SAE J 1284
F4 Fuse Flat fuse SAE J 1284
H1 Lamp, green Operation indicator
H2 Lamp, for circulation pump If operated via S4
K1 Relay Circulation pump; minus for heater
K2 Relay Heater motor
K3 Relay Lamp; operation of control thermostat
K4 Relay Ignition spark generator
K5 Relay Solenoid valve; flame monitor
K7 Relay Fan of vehicle heater
M1 Motor Circulation pump
M2 Motor Heater motor
M3 Motor Vehicle fan
R Flame monitor Photo resistor, Independent of polarity
S1 Switch for heater ON - OFF (starting current max. 2 A)
S3 Switch on water valve Contact open when water valve closed
S4 Switch For ON - OFF; circulation pump separate
S6 Switch Vehicle fan
SD Protective diode Diode 5KP36A
X1 Plug connector 2-pin
Y1 Solenoid valve Independent of polarity
A installed in heater Fixed assignment
B loose delivered parts Possible depending on delivery scope or design
C only if required
D present in vehicle
706
Fig. 706 Automatic switching, DBW 2010 with 1563 control unit, 12 and 24 V
707
Legend Fig. 706:

Item Description Comment
A1 Heater Not earthed
A2 Control unit SG 1563
B1 Flame monitor Ensure proper polarity
B2 Temperature sensor Polarity as desired
B3 Fan thermostat In water circuit, for vehicle fan (ON - OFF)
F5 Thermal fuse Polarity as desired
G Battery
H1 LED, green Operation indicator (in Item P)
H2 LED, yellow Operation indicator (in Item P)
H3 Lamps Symbol lighting (in Item P)
H4 LED, green Operation indicator (when using S1)
K1 Relay (in Item A2) For circulation pump
K2 Relay (in Item A2) For combustion air fan
K3 Relay (in Item A2) For ignition spark generator
K4 Relay (in Item A2) For solenoid valve
K5 Relay
Only necessary with battery switch in minus
K6 Relay
K7 Relay for vehicle fan Only necessary together with B3
M1 Motor Circulation pump
M2 Motor Combustion air fan
M3 Motor Vehicle fan
P Timer (digital) for programmed operation, no longer available
S1 Switch (ON - OFF) Alternative to Item P
S2 Switch Battery switch
S3 Switch On water valve
S4 Switch Economy mode
S5 Switch (for vehicle fan) Alternative to Item S6
S6 Switch (for vehicle fan) Alternative to Item S5
S7 Switch For circulation pump, separate ON - OFF
U Ignition spark generator With ignition electrodes
V1 Diode In control unit Item A2
W Wiring harness Control unit - heater
X1 Plug connector, 8-pin For Item P
X2 Plug connector, 2-pin
Y Solenoid valve Polarity as desired
M Digital timer P:
With plus on Connection 9 = continuous operation with immediate heating,
without plus on connection 9 = heating duration: 1 hour
N To vehicle terminal 75, if present – otherwise terminal 15
O Motor vehicle lighting (terminal 58)
P Hashed lines and relay K5 and K6 only when using battery switch S
Q Alternative
R Vehicle terminal 15
708
DBW 2010 / 2016 8 Servicing Work
8 Servicing Work
8.1 General information 8.5 Maintenance work
This section describes the servicing work that can be carried The following maintenance work must be carried out to
out on the heaters when they are installed. maintain the functional reliability of the heater:
• The openings of the combustion-air intake pipe and the

exhaust-gas opening must be checked for soiling and
8.2 Work on heater
cleaned.
The main battery power must not be disconnected whilst the • Outside the heating period, the heater is to be operated
heater is operating or slowing down as a result of the risk of approximately every 4 weeks for 10 minutes with the ve-
the heater overheating and the overheating guard thus being hicle heating set to "hot" and the vehicle engine cold.
tripped. This prevents starting difficulties.
If you wish to carry out extensive repair work on the heater, • When the coolant for the vehicle engine is replaced, care-
it may be a good idea to remove it. ful bleeding of the heater and the circulation pump must
After work is performed on the heating circuit, a coolant mix- be ensured after bleeding the vehicle cooling system.
ture of water and antifreeze must be added in accordance If the fill level of the coolant is low, it must be topped up
with the vehicle manufacturer's specifications and the heat- according to the vehicle manufacturer's specifications.
ing circuit must be bled.
• The fuel filter or the filter insert must be replaced at least
once a year, and with heavily soiled fuel more often, to
prevent malfunctions.
8.3 Work on vehicle
• If leaks occur, the fuel pump and the fuel lines must be
IMPORTANT replaced immediately, and otherwise every 5 years.
A temperature of 85 °C must not be exceeded in the vicinity • The heater should be checked by an authorised Webasto
of the heater under any circumstances (e.g. during painting dealer at regular intervals, however at the latest at the
work on the vehicle). start of the heating period.
8.4 Test run of heater
The heater may not be operated in closed rooms, such as

garages or workshops, without exhaust extraction, not even
with time preselection.
801
8 Servicing Work DBW 2010 / 2016
8.5.1 Swinging burner head away and in
WARNING To achieve a corresponding opening angle, it may be neces-

The ignition spark generator is operated with high voltage. sary to disconnect the electrical connections.
Before being swung away, the connectors of the wiring har-
ness in the vehicle must be disconnected, as otherwise there Swinging away
is a danger of incurring life-threatening injuries. 1 Disconnect electrical connections if necessary.
When the burner head has been swung in again, the connec- 2. Loose nuts (3, Fig. 801) until screws (1) can be swung
tors in the vehicle are connected. away.
3. Swing away screws (1).
NOTE 4. Swing away burner head (4).
The heater is maintenance-friendly. Swinging away the
burner head enables access to the following components: Swinging in
– Fuel pump and atomiser nozzle 1. Swing in burner head (4, Fig. 801) and move into assem-
– Solenoid valve bly position.
– Ignition spark generator 2. Swing in screws (1) and initially tighten hand-tight with
– Ignition electrodes nuts (3) to prevent one-sided twisting.
– Flame monitor 3. Tighten nuts (3) to 5,0 + 1 Nm.
– Combustion chamber 4. Make electrical connections if necessary.
– Nozzle holder pre-heating unit (if installed)
– With DBW 2010/2016, ensure proper seating of cable NOTE
grommets. Make sure that the electrical connections are properly con-
nected in accordance with the colour coding.
1 Screw (2)
2 Cotter pin
3 Nut (2)
4 Burner head
NOTE
• The cotter pin can be positioned on the other side in
accordance with the swinging direction of the burner
head.
• The burner head of the DBW 2010 / DBW 2016 heat-
ers is shown here.
Fig. 801 Swinging burner head away and in
802
8.6 Visual inspections and installation If fuel hoses are used, the hoses supplied or offered by
instructions Webasto must always be used. If other fuel hoses are used,
they must at least comply with DIN 73379. Fuel hoses must
not be kinked or twisted and must be secured with clamps at
distances of approx. 25 cm.
8.6.1 Connection to the vehicle cooling system
The materials commonly used in vehicle construction, e.g.
The heater should be installed as low as possible to permit steel, copper and plastic lines of soft, light and temperature-
automatic bleeding of the heater and circulation pump. This stabilised PA11 or PA12 (e.g. Mecanyl RWTL) in accordance
is particularly important as the circulation pump is not self- with DIN 73378, can be used as fuel lines while observing the
priming. respective connection technology.
The heater must be connected to the vehicle cooling system The following must always be observed when installing fuel
as shown in Fig. 802. The system must contain at least lines:
10 litres of coolant.
• Lines must be protected against the effects of tempera-
In the vehicle cooling system or with a separate heating cir- ture
cuit, only pressure relief valves with an opening pressure of at
least 0.4 bar and a maximum of 2.0 bar may be used. WARNING
The outer jacket of the heater can reach the ignition temper-
The coolant hoses supplied by Webasto must always be used. ature of diesel fuel in case of overheating!
If other hoses are used, they must at least comply with DIN
73411. The hoses must be routed without kinking and, if pos- • Lines must be protected against stone impact
sible, uphill to ensure proper bleeding.
Hose connections must be supported by hose clips so they • Dripping or evaporating fuel must neither collect
cannot slip off. nor ignite on hot parts or electrical equipment.
NOTE
The tightening torques of the hose clamps used must be
observed.
Care must be taken to bleed the cooling system before the

heater is taken into service for the first time or after refilling
with fresh coolant. Heater and lines must be installed in such
a way as to ensure static bleeding.
Malfunctions due to overheating may occur during heating

operation if the heater and lines have not been bled correctly.
Proper bleeding can be recognised from the virtually silent

operation of the circulation pump.
8.6.2 Connection to the vehicle fuel system
The fuel is taken from the vehicle fuel tank or from a separate
fuel tank.
8.6.2.1 Fuel lines
Fuel lines must be installed with an upward inclined if possi-

ble to prevent air inclusions. Connections within the line must
be secured with hose clamps if no mechanical screw fittings
are used.
803
Water heating circuit – wall radiator
Run-up
Return line
1 Wall radiator with fan

2 Heater
3 Circulation pump
4 Motor vehicle engine
5 Driver's seat heating
6 Control element
Fig. 802 Installation example for heater in bus
804
When installing a shut-off device in the return line, a notifica- 8.6.3 Combustion air supply
tion sign must be mounted in a highly visible location.
IMPORTANT
IMPORTANT The statutory regulations for the installation must be
Operation with a closed return line will result in damage to observed (see 1.6).
the fuel pump. Fuel can escape. Danger of fire!
Under no circumstances may the combustion air be taken
from areas occupied by people. The combustion air intake
opening must not point in the direction of travel. It must be
located so that it cannot become clogged with dirt or snow
and intaking of splash water is not to be expected.
The combustion air inlet and exhaust-gas outlet location

must be chosen so that no air pressure difference results in
any vehicle operating mode.
Permissible dimensions of combustion-air intake line:

• Inside diameter: 55 mm
• Maximum permissible line length: 5 m
• Maximum permissible bends: 270 °C
The combustion air inlet must be positioned so that no
exhaust gas can be sucked in.
Fig. 803 Notification sign
NOTE
Unsupported fuel lines must be secured to prevent them sag- If the combustion-air intake pipe cannot be installed uphill,
ging. then a water drain hole with a diameter of 4 mm must be
drilled at the lowest point.
The installation of an additional fuel pump is not permissible.
If the heater is installed in a common installation space near
Permissible dimensions of fuel lines: the vehicle tank, the combustion air must be taken in from
the outside and the exhaust gas discharged into the atmos-
• Inside diameter for intake and return line: 6 mm (other phere. The openings must be splash-proof.
diameters on request).
• Maximum permissible line length for each intake and re- If the heater is installed in a closed installation box, a ventila-
turn line: 10 m tion opening is required:
• Maximum permissible suction height: 2 m (installation of DBW 2010 / 2016 20 cm2

a check valve is recommended with maximum suction
height) If the temperature in the installation box exceeds the permis-
• Maximum permissible inlet pressure: 0.3 bar for intake sible ambient temperature of the heater (see Section 4,
and return line. "Technical Data"), then the ventilation opening must be
enlarged after consulting Webasto.
8.6.2.2 Fuel filter

8.6.4 Exhaust pipe
A fuel filter supplied or approved by Webasto must be
installed. Installation should be vertical if possible, while the IMPORTANT
direction of flow is horizontal. The statutory regulations for the installation must be
To prevent malfunctions, the filter or filter insert must be observed (see 1.6).
replaced at least once a year, and with heavily soiled fuel
more often, to prevent malfunctions. The opening of the exhaust pipe must not point in the direc-
tion of travel.
The exhaust pipe opening for combustion air must be located

so that it cannot become clogged with snow and mud.
805
The combustion air inlet and exhaust-gas outlet location 8.7.1 Heater, removal and installation
must be chosen so that no air pressure difference results in
any vehicle operating mode. 8.7.1.1 Removal
Rigid pipes of unalloyed or alloyed steel with a minimum wall 1. Disconnect the wiring harness plug from the control unit.
thickness of 1.0 mm or flexible piping of alloyed steel only 2. Disconnect the combustion-air inlet line from the heater.
must be used as exhaust line. 3. Loosen the clamp on the exhaust-gas outlet.
The exhaust pipe is secured on the heater, e.g. with clamps. 4. Disconnect the fuel supply and return line and pull off the
fuel lines and seal off with blind plugs.
Permissible dimensions of exhaust pipe: Close water valves if present.
– Inside diameter: 5. Loosen the hose clamps on the coolant hoses, pull off the
DBW 2010 / 2016 = 38 mm hoses and seal off with blind plugs.
– Maximum permissible line length: 5 m 6. Remove the corresponding fastening elements (screws,
– Maximum permissible bend: 270 °C nuts and washers) from the stand.
7. Remove heater.
As an alternative, an exhaust-gas deflection approved by
Webasto can be installed.
8.7.1.2 Installation
8.7 Removal and installation 1. Position heater in installation position and fasten with
appropriate screws, washers and nuts.
2. Secure the line on the exhaust-gas outlet with a clamp.
IMPORTANT
3. Connect the coolant hoses and secure them with hose
When installed, only the following dismantling and removal
clamps. Open the water valves.
procedures are approved, provided sufficient space is availa-
4. Connect the fuel supply and return line and secure.
ble for removal:
5. Fasten the combustion-air inlet line on the heater.
– Replacing temperature limiter 6. Connect the wiring harness plug to the control unit.
– Replacing temperature sensor 7. Bleed the fuel supply system.
– Replacing fan or control thermostat 8. Bleed coolant circuit.
– Replacing thermal fuse
– Replacing thermal fusible link
– Replacing burner head 8.7.2 Replacing temperature limiter
– Replacing ignition spark generator
– Replacing flame monitor NOTE
– Replacing combustion chamber The procedure for replacing the temperature limiter with the
heater installed or removed is identical.
Replacing must be carried out according to 9.2.1.
WARNING
Before replacing the temperature limiter on heaters with the
1563/1564 control unit while installed, the pressure in the
cooling system must be released by opening the radiator cap.
Also allow the heater to cool and provide a catch container
for the escaping coolant if necessary.
8.7.3 Replacing temperature sensor
NOTE
The procedure for replacing the temperature sensor with the
heater installed or removed is identical.
WARNING
Before replacing the temperature sensor on heaters with the
1563/1564 control unit while installed, the pressure in the
cooling system must be released by opening the radiator cap.
Also allow the heater to cool and provide a catch container
for the escaping coolant if necessary.
806
8.7.4 Replacing thermal fuse 8.7.9 Replacing ignition spark generator
NOTE NOTE
The procedure for replacing the thermal fuse with the heater The procedure for replacing the ignition spark generator with
installed or removed is identical. the heater installed or removed is identical.
Replacing must be carried out according to 9.2.3. Replacing must be carried out according to 9.2.12.
WARNING WARNING
Before replacing the thermal fuse on heaters with the 1563/ The ignition spark generator is operated with high voltage.
1564 control unit while installed, the pressure in the cooling Before the ignition spark generator is replaced, the connec-
system must be released by opening the radiator cap. tors of the wiring harness must be disconnected from the
Also allow the heater to cool and provide a catch container control unit, as otherwise there is a danger of incurring life-
for the escaping coolant if necessary. threatening injuries.
8.7.5 Replacing control thermostat 8.7.10 Replacing flame monitor
NOTE NOTE
The procedure for replacing the control thermostat with the The procedure for replacing the flame monitor with the
heater installed or removed is identical. heater installed or removed is identical.
Replacing must be carried out according to 9.2.4. Replacing must be carried out according to 9.2.13.
WARNING
8.7.6 Replacing fan thermostat The ignition spark generator is operated with high voltage.
Before the flame monitor is replaced, the connectors of the
NOTE wiring harness must be disconnected from the control unit,
The procedure for replacing the fan thermostat with the as otherwise there is a danger of incurring life-threatening
heater installed or removed is identical. injuries.
8.7.11 Replacing combustion chamber

8.7.7 Replacing thermal fusible link
NOTE
NOTE The procedure for replacing the combustion chamber with
The procedure for replacing the thermal fusible link with the the heater installed or removed is identical.
heater installed or removed is identical. Replacing must be carried out according to 9.2.17.
WARNING
The heater is operated with high voltage. Before the combus-
tion chamber is replaced, the connectors of the wiring har-
8.7.8 Replacing burner head ness must be disconnected from the control unit, as
otherwise there is a danger of incurring life-threatening inju-
NOTE ries.
The procedure for replacing the burner head with the heater
installed or removed is identical.
WARNING
The ignition spark generator is operated with high voltage.
Before the burner head is replaced, the connectors of the wir-
ing harness must be disconnected from the control unit, as
otherwise there is a danger of incurring life-threatening inju-
ries.
807
8.8 Start-up
After the heater has been installed, the coolant circuit and
the fuel supply system must be carefully bled. The specifica-
tions of the vehicle manufacturer must be observed when
doing so. All coolant and fuel connections must be checked
for leaks and secure attachment during the test run. Should
a fault occur in the heater during operation, then trouble-
shooting must be carried out (see Section 5).
8.8.1 Bleeding water circuit
NOTE
Bleeding must always be carried out according to the manu-
facturer's instructions. The circulation pump must not be
switched on for bleeding.
Set the original vehicle heating system to "hot" and top up

the coolant according to manufacturer's instructions. Oper-
ating the heater without antifreeze is not permitted.
Then allow the vehicle engine to run at increased idling speed

until the radiator thermostat has opened. Switch off the vehi-
cle engine and check the coolant level; top up the coolant if
necessary.
Switch on the heater and the original vehicle heater fan with
the vehicle engine switched off. After a certain cooling time,
the heater must automatically switch on and deactivate. If
the heater is then not switched on again, the temperature
limiter on the heater has been tripped, as the heater has not
been properly bled yet. Reset the temperature limiter (press
the button on the temperature limiter) and repeat the entire
bleeding process.
NOTE
The heater can be equipped with an automatically resettable
temperature limiter. In this case, manual resetting is elimi-
nated.
8.8.2 Bleeding fuel supply system
When the heater is switched on, the fuel pump primes the
fuel and fills the entire fuel supply system.
Should combustion not yet begin with the first starting proc-
ess, the heater must be switched off and then switched on
again.
808
DBW 2010 / 2016 9 Repair
9 Repair
This section describes the repair work that can be carried out
on the heaters when they are installed. Any further disman-
tling will invalidate the warranty.
During assembly only the spare parts from the corresponding
spare parts kit may be used.
WARNING
The ignition spark generator is operated with high voltage.
The following components may also be replaced with the

heater installed, provided sufficient space is available:
– Temperature limiter
– Temperature sensor
– Fan or control thermostat
– Thermal fuse
– Thermal fusible link
– Burner head
– Ignition spark generator
– Flame monitor
– Combustion chamber
Before the replacement, the connectors of the wiring harness

must be disconnected from the control unit, as otherwise
there is a danger of incurring life-threatening injuries.
Before replacing the temperature sensor or the temperature

limiter on heaters with the 1563/1564 control unit, the pres-
sure in the cooling system must also be released by opening
the radiator cap.
Also allow the heater to cool if necessary.
901
9 Repair DBW 2010 / 2016
9.1.1 Works on components when dismantled

DBW 2010 / 2016
IMPORTANT
All sealing elements between the dismantled components
must always be removed and replaced.
9.1.1.1 General visual inspection
• Check all components for damage (cracks, deformation,

wear, etc.) and fit new ones if necessary.
• Inspect the plugs and cables for corrosion, loose
contacts, crimping faults, etc. and repair them if
necessary.
• Inspect connector contacts for corrosion and check Special spanner
contacts for firm seating; repair if necessary. Gap
0.15 ± 0.05
9.1.1.2 Visual inspection of combustion chamber Fig. 901 Visual inspection on combustion-air rotor
– Check swirl chamber for firm seating.

– Inspect the combustion chamber for scaling and remove 9.1.2 Carrying out modifications
coke deposits if necessary.
– Check welding seam for cracks. NOTE
The constant development of our heaters is aimed at optimis-
NOTE ing them so as to prevent failures and malfunctions.
Cracks on the welding seam of up to approx. 80 mm in the Generally it is possible to modify heaters that are already in
longitudinal direction are permissible. use. We can supply the appropriate modification kits for this
purpose.
9.1.1.3 Visual inspection on heat exchanger The modifications which can be carried out as part of the
repair work are listed in the following:
– Check exhaust-gas routing in heat exchanger for sooting,
deposits, damage and corrosion. • Installation of nozzle holder pre-heating unit for DBW
2010 / 2016 with 1553 control unit (see 9.1.2.1).
NOTE • Installation of nozzle holder pre-heating unit for DBW
Remove deposits with a water jet and a brush. 2010 with 1563/1564 control unit (see 9.1.2.2).
– Examine heat exchanger for external damage, deforma-

tions, etc.
NOTE
Heavy deformations can impair the coolant flow.
9.1.1.4 Visual inspection on combustion-air rotor
– Inspect combustion-air rotor for soiling and cracks.

– Check cover plate for firm seating.
– Check gate valve for proper seating.
– Adjust gap between fan impeller and fan housing (can be
measured with a feeler gauge) at the narrowest point to
0.15 ± 0.05 mm.
For tools, see spare parts lists and accessories catalogue.
902
DBW 2010 / 2016 9 Repair
9.1.2.1 Installation of nozzle holder pre-heating unit Following retrofitting, the following bags of spare parts are
for DBW 2010 / DBW 2016 with 1553 control provided for the heaters specified above:
unit
• 12 V heaters with 1553 control unit,
General information Order No. 968 89A
• 24 V heaters with 1553 control unit,
The fuel to the atomiser nozzle is heated with the nozzle Order No. 989 71A
holder pre-heating unit. At extremely low temperatures, mal-
functions can occur without nozzle holder pre-heating for The bags of spare parts contain the following parts:
heaters specified above.
1 heating cartridge
At a temperature of < 0 °C, the heating cartridge in the noz- 1 clamping yoke
zle holder is connected with a thermostat. The heating dura- 1 relay
tion is dependent on the reflected heat in the combustion 1 thermostat
chamber and switches off at + 8 °C at the thermostat. 1 wiring harness
1 lug
If no nozzle holder pre-heating unit is installed in the heater, 1 disc
it can be retrofitted using the following procedure. 1 nut
1 serrated lock washer
1 socket housing, 4-pin
4 tab receptacles
Heating cartridge
Nozzle holder
Thermostat
DBW 2010 / 2016
Fig. 902 Installing nozzle holder pre-heating unit with 1553 control unit
903
9 Repair DBW 2010 / 2016
Retrofitting works DBW 2010 / DBW 2016 NOTE

The polarity is irrelevant in the following work step.
NOTE
On DBW 2010 / DBW 2016 heaters, the washer and the nut 7. Engage tab receptacle for heating cartridge connection
in the retrofit kit are not required. in 2-pin socket housing accordingly.
1. Swing away burner head as described in 8.5.1. NOTE

2. Remove ignition electrodes as described in 9.2.14.1. Route wiring harness (1) behind solenoid valve and guide to
3. Remove snap ring and pull disc with flame monitor off outside via a rubber grommet with 2-pin socket housing.
nozzle holder.
4. Fasten thermostat (5) with lug (7) and screw (6) on nozzle 8. Make the electrical connections between wiring harness
holder plate. (1), heating cartridge (3), thermostat (5) and relay (11).
5. Insert heating cartridge (3) in nozzle holder (4) and fasten 9. Fit disc with flame monitor on nozzle holder and secure
with clamping yoke (2). with snap ring.
6. Fasten relay (11) with self-tapping screw (9) and serrated 10. Install ignition electrode as described in 9.2.14.2.
lock washer (10) on protective cap of burner head (12). 11. Swing in burner head as described in 8.5.1.
12. Make the electrical connections as shown in Fig. 904.
Connector X1
1 Wiring harness 7 Lug

2 Clamping yoke 8 Nozzle holder plate *
3 Heating cartridge 9 Self-tapping screw *
4 Nozzle holder * 10 Serrated lock washer
5 Thermostat 11 Relay
6 Screw * 12 Protective cap of burner head *
* Not included in bag of spare parts
Fig. 903 Retrofitting DBW 2010 / DBW 2016
904
DBW 2010 / 2016 9 Repair

A1 Heater
A2 Control unit SG 1553
B Plug connector, 6-pin
B5 Thermostat for nozzle holder pre-heating unit
F3 16 A (12 V); 8 A (24 V) fuse Flat fuse SAE J 1284
G Battery
H1 Lamp Operation indicator
K6 Relay for nozzle holder pre-heating unit
R2 Heating cartridge for nozzle holder pre-heating unit
S1 Switch ON/OFF
W2 Wiring harness
Fig. 904 Electrical connection
905
9 Repair DBW 2010 / 2016
9.1.2.2 Installation of nozzle holder pre-heating unit Following retrofitting, the following bags of spare parts are
for DBW 2010 / DBW 2016 with 1563/1564 provided for the heaters specified above:
control unit
• 24 V heaters with 1563/1564 control unit, Order No. 968
General information 90A
The fuel to the atomiser nozzle is heated with the nozzle The bags of spare parts contain the following parts:
holder pre-heating unit. At extremely low temperatures, mal-
functions can occur without nozzle holder pre-heating for 1 heating cartridge
heaters specified above. 1 clamping yoke
1 relay
At a temperature of < 0 °C, the heating cartridge in the noz- 1 relay with free-wheeling diode
zle holder is connected with a thermostat. The heating dura- 1 thermostat
tion is dependent on the reflected heat in the combustion 1 wiring harness
chamber and switches off at + 8 °C at the thermostat. 1 lug
1 disc
If no nozzle holder pre-heating unit is installed in the heater, 1 nut
it can be retrofitted using the following procedure. 1 serrated lock washer
7 tab receptacles
1 relay socket
Heating cartridge
Nozzle holder
Thermostat
DBW 2010
Fig. 905 Installing nozzle holder pre-heating unit with 1563/1564 control unit
906
DBW 2010 / 2016 9 Repair
Retrofitting works DBW 2010 7. Engage tab receptacle for heating cartridge connection
in 2-pin socket housing accordingly.
NOTE
On DBW 2010 heaters, the washer and the nut in the retrofit NOTE
kit are not required. Route wiring harness (1) behind solenoid valve and guide to
outside via a rubber grommet with 2-pin socket housing.
1. Swing away burner head as described in 8.5.1.
2. Remove ignition electrodes as described in 9.2.14.1. 8. Make the electrical connections between wiring harness
3. Remove snap ring and pull disc with flame monitor off (1), heating cartridge (3), thermostat (5) and relay (11).
nozzle holder. 9. Fit disc with flame monitor on nozzle holder and secure
4. Fasten thermostat (5) with lug (7) and screw (6) on nozzle with snap ring.
holder plate. 10. Install ignition electrode as described in 9.2.14.2.
5. Insert heating cartridge (3) in nozzle holder (4) and fasten 11. Swing in burner head as described in 8.5.1.
with clamping yoke (2). 12. Pull connector A off 1564 control unit.
6. Fasten relay (11) with self-tapping screw (9) and serrated 13. Make the electrical connections between socket housing
lock washer (10) on protective cap of burner head (12). for connector X4, relay K10 (13) and connector A as
shown in Fig. 907.
NOTE 14. Fasten relay K10 on cover of burner head if necessary.
The polarity is irrelevant in the following work step.
Connector X4
1 Wiring harness 8 Nozzle holder plate *

2 Clamping yoke 9 Self-tapping screw *
3 Heating cartridge 10 Serrated lock washer *
4 Nozzle holder * 11 Relay K5
5 Thermostat 12 Protective cap of burner head *
6 Screw * 13 Relay K10
7 Lug 14 Serrated lock washer
* Not included in bag of spare parts
Fig. 906 Retrofitting DBW 2010
907
9 Repair DBW 2010 / 2016

A1 Heater
A2 Control unit SG 1563/1564
A Plug connector, 6-pin
B3 Thermostat for nozzle holder pre-heating unit
F4 16 A (12 V); 8 A (24 V) fuse Flat fuse SAE J 1284
G Battery
H4 Lamp Operation indicator
K5 Relay for nozzle holder pre-heating unit
K10 Relay with free-wheeling diode for nozzle holder pre-heating unit
R1 Heating cartridge for nozzle holder pre-heating unit
S1 Switch ON/OFF
S2 Switch Separate switch-on/UPFA
W2 Wiring harness
Fig. 907 Electrical connection
908
DBW 2010 / 2016 9 Repair
9.2 Dismantling and assembling 2. Tighten temperature sensor (11) to 20 + 5 Nm.

3. Make the electrical connection.
9.2.1 Replacing temperature limiter
NOTE 9.2.3 Replacing thermal fuse

With the sensor technology device, release pressure from
cooling system according to manufacturer's instructions NOTE
before replacement. With the sensor technology device, release pressure from
cooling system according to manufacturer's instructions
IMPORTANT before replacement.
Danger of injury from escaping hot coolant.
IMPORTANT
9.2.1.1 Removal Danger of injury from escaping hot coolant.
1. If necessary, remove nut (4, Fig. 908) and protective cap

(3). 9.2.3.1 Removal
2. Disconnect electrical connection to temperature limiter
(8). 1. Disconnect electrical connection to thermal fuse (12, Fig.
3. Screw temperature limiter (8) out of angle bracket (5) or 908).
screw plug (6) and remove. 2. Screw thermal fuse (12) out of heat exchanger (10) and
4. Carry out works on stripped down components (see remove with sealing ring (15).
9.1.1). 3. Carry out works on stripped down components (see
9.1.1).
1. Screw temperature limiter (8, Fig. 908) into angle bracket
(5) or into screw plug (6) by hand. 1. Screw in thermal fuse (12, Fig. 908) with "o" ring (14) or
2. Make the electrical connection. sealing ring (15) by hand.
3. Lay on the protective cap (3, ) and secure with the nut (4) 2. Tighten thermal fuse hand-tight.
if necessary. 3. Make the electrical connection.
9.2.2 Replacing temperature sensor 9.2.4 Replacing control thermostat
NOTE 9.2.4.1 Removal

With the sensor technology device, release pressure from
cooling system according to manufacturer's instructions 1. Remove nut (4, Fig. 908) and protective cap (3).
before replacement. 2. Disconnect electrical connection to control thermostat
(1) on terminal block (2).
IMPORTANT 3. Screw control thermostat (1) out of angle bracket (5) or
Danger of injury from escaping hot coolant. heat exchanger (10) and remove.
4. Carry out works on stripped down components (see
9.1.1).
9.2.2.1 Removal
1. Disconnect electrical connection to temperature sensor 9.2.4.2 Installation

(11, Fig. 908).
2. Screw temperature sensor (11) out of heat exchanger 1. Screw control thermostat (1, Fig. 908) onto angle bracket
(10) or coolant outlet (16) and remove with sealing ring (5) or heat exchanger (10) by hand.
(15) or "o" ring (14).
3. Carry out works on stripped down components (see NOTE
9.1.1). When installing in heat exchanger, tighten control thermo-
stat hand-tight.
9.2.2.2 Installation 2. Make the electrical connection.

3. Lay on the protective cap (3, ) and secure with the nut (4).
1. Screw temperature sensor (11, Fig. 908) with sealing ring
(15) or "o" ring (14) into coolant outlet (16) or heat
exchanger (10) by hand.
909
9 Repair DBW 2010 / 2016
DBW 2010 / DBW 2016
DBW 2010
1 Control thermostat
2 Terminal block
3 Protective cap
4 Nut
5 Angle bracket
6 Screw plug
7 Thermal fusible link
8 Temperature limiter
9 Fan thermostat
10 Heat exchanger
11 Temperature sensor
12 Thermal fuse
13 Sealing ring
14 “O” ring
15 Sealing ring
Fig. 908 Replacing temperature limiter, temperature sensor, thermal fuse, fusible link and control thermostat
910
DBW 2010 / 2016 9 Repair
9.2.5 Replacing fan thermostat 9.2.7.2 Installation
9.2.5.1 Removal 1. Guide 1563/1564 control unit (3, Fig. 909) or 1553 con-
trol unit (1) with holding clamp (2) laterally into guide of
1. Remove nut (4, Fig. 908) and take off protective cap (3). protective cap (4) and push in up to stop.
2. Insert connector on control unit.
2. Disconnect electrical connection to fan thermostat (9).
3. Screw fan thermostat off angle bracket (5) and remove. 9.2.8 Replacing burner head
4. Carry out works on stripped down components (see 9.1.1). 9.2.8.1 Removal
NOTE
9.2.5.2 Installation Before disconnecting the plug-in electrical connections or the
connections between the wiring harness and the measuring
1. Screw fan thermostat (9, Fig. 908) into angle bracket (5) by and control sensors, the connector assignments should be
hand. marked or noted.
2. Make the electrical connection. 1. Disconnect plug-in connections to measuring and control
sensors on heat exchanger and disconnect wiring har-
3. Lay on the protective cap (3) and secure with the nut (4). ness.
2. Disconnect fuel lines if necessary.
3. Loosen nuts (3, Fig. 910) until bolts can be swung away.
9.2.6 Replacing thermal fusible link 4. Swing away screws (1), pull out cotter pin (2) and
remove.
5. Remove burner head (4).
9.2.6.1 Removal 6. Carry out works on stripped down components (see
9.1.1).
1. Remove nut (4, Fig. 908) and protective cap (3).
2. Disconnect electrical connection to thermal fusible link
(7) on terminal block (2). 9.2.8.2 Installation
3. Screw thermal fusible link out of screw plug (6) by hand
and remove. 1. Move burner head (4, Fig. 910) into mounting position,
4. Carry out works on stripped down components (see swing in screws (1) and tighten nuts (3) by hand.
9.1.1). 2. Mount cotter pin (2) in accordance with intended swing-
ing direction and secure.
3. Swing in bolts (1) and initially tighten hand-tight with
9.2.6.2 Installation nuts (3) to prevent one-sided twisting.
4. Tighten nuts (3) to 5,0 + 1 Nm.
1. Screw thermal fusible link (7, Fig. 908) into screw plug (6) 5. Connect fuel lines if necessary.
by hand. 6. Make the electrical connections.
3. Lay on the protective cap (3, ) and secure with the nut (4).
9.2.7 Replacing control unit
9.2.7.1 Removal
1. Disconnect connector on control unit (1 or 3, Fig. 909).

2. Using a suitable tool (e.g. flat-blade screwdriver), press
lug between control unit (1 or 3) and protective cap (4)
towards control unit and pull off control unit axially.
3. With 1553 control unit, spread open holding clamp (2) to
side and pull off control unit towards front.
9.1.1).
911
9 Repair DBW 2010 / 2016
1 1553 control unit

2 Retaining clip
3 1563/1564 control unit
4 Burner head
Fig. 909 Replacing control unit
1 Screw (2)
2 Cotter pin
3 Nut (2)
4 Burner head
NOTE
• The cotter pin can be positioned on the other side in
accordance with the swinging direction of the burner
head.
• The burner head of the DBW 2010 heaters is shown
here.
Fig. 910 Replacing burner head
912
DBW 2010 / 2016 9 Repair
9.2.9 Replacing motor 9.2.9.2 Installation
9.2.9.1 Removal 1. Move motor (16, Fig. 911) into installation position and
fasten with toothed washers (11) and screws (12) on
1. Remove ignition spark generator (see 9.2.12.1). flange (14).
2. Remove screws (17, Fig. 911) from protective cap (4) and 2. Tighten screws to 5 + 1 Nm.
pull off protective cap towards front. 3. Mount coupling (13) on motor shaft.
3. Disconnect electrical connection to motor (16). 4. Fasten flange (14) with screws (10).
4. Remove screws (10) and take off motor (16) with flange 5. Tighten screws to 5 + 1 Nm.
(14). 6. Make the electrical connections to motor in accordance
5. Pull coupling (13) off motor shaft and remove. with colour coding.
6. Remove screws (12) with toothed washers (11), take off 7. Slide on protective cap (4) and fasten with screws (17).
motor (16) and remove. 8. Install ignition spark generator (see 9.2.12.2).
9.1.1).
1 1553 control unit 10 Screw (3)

2 Holding clamp for 1553 con- 11 Toothed washer (2)
trol unit 12 Screw (2)
3 1563/1564 control unit 13 Coupling
4 Protective cap 14 Flange
5 Screw (4) 15 Cable tie
6 Ignition spark generator 16 Motor
7 Ignition cable (2) 17 Screw (4)
8 Retaining clip (2)
9 Ignition electrode (2)
NOTE
The motor of the DBW 2010 / DBW 2016 heaters is shown here.
Fig. 911 Replacing motor
913
9 Repair DBW 2010 / 2016
9.2.10 Replacing high-pressure nozzle 5. Slide ignition cable onto ignition electrode (9) and secure
with retaining clips (8).
9.2.10.1 Removal 6. Swing in burner head (see 8.5.1).
1. Swing away burner head (see 8.5.1).

2. Screw off high-pressure nozzle (11, Fig. 912) and 9.2.13 Replacing flame monitor
remove.
3. Carry out works on stripped down components (see 9.2.13.1 Removal
9.1.1).
2. Disconnect electrical connection from flame monitor (10/
9.2.10.2 Installation 10a, Fig. 912).
3. Remove screw (14) and flame monitor (10) or clip out
1. Screw in high-pressure nozzle (11, Fig. 912) and tighten flame monitor (10a).
to 20 Nm. 4. Carry out works on stripped down components (see
2. Swing in burner head (see 8.5.1). 9.1.1).
9.2.11 Replacing nozzle holder pre-heating unit 9.2.13.2 Installation
9.2.11.1 Removal 1. Move flame monitor (10, Fig. 912) into installation posi-
tion and fasten with screw (14) or clip in flame monitor
1. Swing away burner head (see 8.5.1). (10a).
2. Pull off clamping yoke (3, Fig. 912) and remove. 2. Tighten screws to 1.3 Nm.
3. Disconnect electrical connection. 3. Make the electrical connection.
4. Pull heating cartridge (2) out of nozzle holder (15) later- 4. Swing in burner head (see 8.5.1).
ally and remove.
9.1.1). 9.2.14 Replacing ignition electrodes
9.2.14.1 Removal
1. Make the electrical connection. 2. Remove screw (8, Fig. 912).
2. Slide heating cartridge (2, Fig. 912) into nozzle holder 3. Take off washer (7) and clamp (6) and remove.
(15) and secure with clamping yoke (3). 4. Remove snap ring (13) and take off disc (12) and remove.
3. Swing in burner head (see 8.5.1). 5. Push back insulating grommets onto ignition cable if nec-
essary.
6. Lever retaining clips (8) off of ignition electrodes (9) and
9.2.12 Replacing ignition spark generator remove.
7. Take off ignition electrodes (9) and remove.
9.2.12.1 Removal 8. Carry out works on stripped down components (see
9.1.1).
2. Lever connector off electrodes.
3. Remove screws (5) from ignition spark generator (6) and 9.2.14.2 Installation
take off ignition spark generator.
4. Disconnect electrical connections. 1. Lay on disc (12, Fig. 912) and secure with snap ring (13)
5. Carry out works on stripped down components (see if necessary.
9.1.1). 2. Guide in ignition electrodes (9) through disc (12), align
and fasten with clamp (6), washer (7) and screw (8).
3. Tighten screw (8) to 1.7 Nm.
9.2.12.2 Installation 4. Fit ignition cable (4) and secure with retaining clips (8).
5. Slide insulating grommets onto ignition electrodes if nec-
1. Make the electrical connections. essary.
2. Move ignition spark generator (6, Fig. 911) into installa- 6. Swing in burner head (see 8.5.1).
tion position and secure with screws (5).
3. Tighten screws to 0.8 Nm.
4. Guide ignition cable (7) through grommets into ignition
spark generator (6).
914
DBW 2010 / 2016 9 Repair
NOTE
The parts marked with * are not present with
single-line fuel pumps.
1 Solenoid valve 11 High-pressure nozzle 21 Washer (4)

2 Heating cartridge 12 Disc 22 Banjo bolt (2)
3 Clamping yoke 13 Snap ring 23 Screw (4)
4 Ignition cable (2) 14 Screw 24 Nozzle holder plate
5 Retaining clip (2) 15 Nozzle holder 25 Spur gear
6 Clip 16 Pressure line 26 Circlip
7 Washer 17 Screw (2) 27 Screw (2)
8 Screw 18 Washer (2)
9 Ignition electrode (2) 19 Fuel pump
10 Flame monitor 20 Fuel line (2)
Fig. 912 Replacing nozzle holder, nozzle holder pre-heating unit, high-pressure nozzle and flame monitor
915
9 Repair DBW 2010 / 2016
9.2.15 Replacing fuel pump 9.2.16.2 Installation
9.2.15.1 Removal 1. Place “o” ring (5, Fig. 914) on solenoid valve body (4).
2. Fit spring (7) and pin (6) in bolt (8).
1. Swing away burner head (see 8.5.1). 3. Guide bolt with spring and pin into solenoid valve body
2. Remove ignition electrodes (see 9.2.14.1). (4).
3. Remove banjo bolts (22, Fig. 912) and washers (21), take 4. Screw solenoid valve body (4) into nozzle holder (9).
off fuel lines (20) and remove. 5. Tighten screws to 11.5 Nm.
4. Loosen screw fittings on pressure line (16), take off pres- 6. Place solenoid valve head (3) on solenoid valve body and
sure line and remove. fasten with washer (2) and nut (1).
5. Remove screws (23) and take off nozzle holder plate (24). 7. Tighten nuts to 2 Nm.
6. Remove circlip (26), take off spur gear (25) and remove. 8. Fasten nozzle holder plate (24, Fig. 912) with screws (23).
7. Remove screws (17) and washers (18), take off fuel pump 9. Tighten screws to 5.5 Nm.
(19) and remove. 10. Install nozzle holder pre-heating unit (see 9.2.9.2).
8. Carry out works on stripped down components (see 11. Install ignition electrodes (see 9.2.12.2).
9.1.1). 12. Make the electrical connections to solenoid valve.
13. Swing in burner head (see 8.5.1).
9.2.17 Replacing combustion chamber
1. Move fuel pump (19, Fig. 912) into installation position
and fasten with screws (17) and washers (18). 9.2.17.1 Removal
3. Lay on spur gear (25) and secure with circlip (26). 1. Swing away burner head (see 8.5.1).
4. Fit nozzle holder plate (24) and fasten with screws (23). 2. Pull combustion chamber (1, Fig. 915) out of the heat
5. Tighten screws to 5.5 Nm. exchanger (2) and remove it.
6. Move pressure line (16) into installation position and 3. Carry out works on stripped down components (see
tighten screw fittings to 6 ± 0.6 Nm. 9.1.1).
7. Move fuel lines (20) into installation position and fasten
with banjo bolts (22) and washers (21).
8. Tighten banjo bolts to 15 ± 1.5 Nm. 9.2.17.2 Installation
9. Install ignition electrodes (see 9.2.14.2).
10. Swing in burner head (see 8.5.1). 1. Slide combustion chamber (1, Fig. 915) into heat
exchanger (2) up to stop.
9.2.16 Replacing solenoid valve
9.2.16.1 Removal 9.2.18 Thermostat of nozzle holder pre-heating

unit
2. Remove ignition electrodes (see 9.2.14.1). 9.2.18.1 Removal
3. Remove nozzle holder pre-heating unit (see 9.2.11.1).
4. Remove screws (23, Fig. 912) and take off nozzle holder 1. Swing away burner (see 8.5.1).
plate (24). 2. Disconnect electrical connection.
5. Disconnect electrical connections on solenoid valve. 3. Screw thermostat (4, Fig. 913) off nozzle holder plate (7)
6. Remove nut (1, Fig. 914), take off solenoid valve head (3) or disc (1) and remove with screw (5), lug (6) or nut (3)
and washer (2) and remove. and serrated lock washer (2).
7. If necessary, screw off solenoid valve body (4) “o” ring 4. Carry out works on stripped down components (see
(5), pin (6), spring (7) and bolt (8) . 9.1.1).
9.1.1).
1. Move thermostat (4, Fig. 913) into installation position

and fasten with lug (6) and screw (5) on nozzle holder
plate (7) or with nut (3) and serrated lock washer (2) on
disc (1).
3. Swing in burner (see 8.5.1).
916
DBW 2010 / 2016 9 Repair
1 Disc
2 Serrated lock washer
3 Nut
DBW 2010 / DBW 2016 4 Thermostat
5 Screw
6 Lug
7 Nozzle holder plate
Fig. 913 Replacing thermostat of nozzle holder pre-heating unit
1 Nut 6 Pin
2 Washer 7 Spring
3 Solenoid valve head 8 Bolt
4 Solenoid valve body 9 Nozzle holder
5 “O” ring
Fig. 914 Replacing solenoid valve
917
9 Repair DBW 2010 / 2016
9.2.19 Replacing heat exchanger 9.2.19.2 Installation
9.2.19.1 Removal 1. Slide combustion chamber (1, Fig. 915) into heat
exchanger (2) up to stop.
1. If necessary, remove nut (6, Fig. 915) from cover (5) and 2. Fit burner head (see 9.2.8.2).
take off cover and remove.
2. Remove temperature limiter or thermal fuse (see 9.2.1.1 NOTE
or 9.2.3.1). Work steps 3 to 6 only apply to the devices DBW 2010 / DBW
3. Remove temperature sensor (see 9.2.2.1). 2016 without sensor technology.
4. Remove thermal fusible link if necessary (see 9.2.6.1).
5. Remove control thermostat if necessary (see 9.2.4.1). 3. Move angle bracket (8) into installation position and
6. Remove fan thermostat if necessary (see 9.2.5.1). screw in screw plug (7).
4. Tighten screw hand-tight.
NOTE 5. Move bracket (3) with electrical connections into installa-
Work steps 7 to 8 only apply to the devices DBW 2010 / DBW tion position and fasten with screw (4).
2016 without sensor technology. 6. Tighten screw hand-tight.
7. Install temperature sensor (see 9.2.2.2).
7. Remove screw (4) and take off bracket (3) with electrical 8. Install temperature limiter or thermal fuse (see 9.2.1.2 or
connections and remove. 9.2.3.2).
8. Remove screw plug (7) and take off with angle bracket 9. Install thermal fusible link if necessary (see 9.2.6.2).
(8) and remove. 10. Install control thermostat if necessary (see 9.2.4.2).
9. Remove burner head (see 9.2.8.1). 11. Install fan thermostat if necessary (see 9.2.5.2).
10. Pull combustion chamber (1) out of the heat exchanger 12. Lay on cover (5) and fasten with nut (6) if necessary.
(2) and remove.
11. Remove heat exchanger (2).
9.1.1).
NOTE
The combustion chamber and the
heat exchanger of the DBW 2010 /
DBW 2016 heaters are shown here.
1 Combustion chamber
2 Heat exchanger
3 Bracket
4 Screw
5 Cover
6 Nut
7 Screw plug
8 Angle bracket
Fig. 915 Replacing combustion chamber and heat exchanger
918
DBW 2010 / 2016 9 Repair
9.2.20 Replacing nozzle holder 9.2.21.2 Installation
9.2.20.1 Removal 1. Only DBW 2010/2016:

Check gap at fan impeller (see 9.1.1.4)
1. Swing away burner head (see 8.5.1). 2. Move combustion air fan (4, Fig. 916) into assembly posi-
2. Remove ignition electrodes (see 9.2.14.1). tion and fasten on nozzle holder plate (5) with screws (6).
3. Remove high-pressure nozzle (see 9.2.10.1). 3. Tighten screws (6) to 5.5 Nm.
4. If necessary, remove nozzle holder pre-heating unit (see 4. Fit motor support (3) on shaft and fasten with screws (1)
9.2.11.1). and washers (2).
5. Remove solenoid valve (see 9.2.16.1). 5. Tighten screws (1) to 5.5 + 1 Nm.
6. Loosen screw fittings on pressure line (16, Fig. 912) and 6. Install motor (see 9.2.9.2).
take off pressure line and remove. 7. Install burner head (see 9.2.8.2).
7. Remove screws (23) and take off nozzle holder plate (24).
8. Remove screws (27), take off nozzle holder (15) and
remove.
9.1.1).
1. Move nozzle holder (15, Fig. 912) into installation posi-

tion and fasten with screws (27).
3. Move nozzle holder (24 ) into installation position and
fasten with screws (23).
5. Move pressure line (16) into installation position and
tighten screw fittings to 6 ± 0.6 Nm.
6. Install solenoid valve (see 9.2.16.2).
7. If necessary, install nozzle holder pre-heating unit (see
9.2.11.2).
8. Install high-pressure nozzle (see 9.2.10.2).
9. Install ignition electrodes (see 9.2.14.2).
9.2.21 Replacing combustion air fan
9.2.21.1 Removal
1. Remove burner head (see 9.2.8.1).

2. Remove motor (see 9.2.9.1).
3. Remove screws (6, Fig. 916) from nozzle holder plate (5).
4. Remove screws (1) and washers (2).
5. Pull motor support (3) off shaft.
6. Remove combustion air fan (4).
9.1.1).
919
9 Repair DBW 2010 / 2016
DBW 2010 / DBW 2016
1 Screw (3) 4 Combustion air fan

2 Washer (3) 5 Nozzle holder plate
3 Motor carrier 6 Screw (4)
Fig. 916 Replacing combustion air fan
920
10 Packing, Storage and Shipping
10 Packing, Storage and Shipping
If the heater or its components are sent to Webasto for test-

ing or repair, it must be cleaned and packed in such a way
that it is protected against damage during handling, trans-
port and storage.
IMPORTANT
If an entire heater is returned, then it must be completely
drained. It must be ensured that no fuel or coolant can es-
cape during packing and/or shipping.
The coolant inlet and outlet connections and the fuel lines
must be sealed off with blind plugs.
The ambient temperatures indicated in section 4 must not be

exceeded for storage.
1001
Appendix A DBW 2010 / 2016
Appendix A
Periodic Heater Maintenance The maintenance intervals specified in the following refer to
usual applications and requirements at average usage. If the
The heater should be checked at regular intervals, however at heater use differs from the average, the intervals can be
the latest at the start of the heating period (point in time of shortened or extended accordingly.
weather-dependent increased use of heater). Please contact your responsible Webasto partner in corre-
sponding cases.
Test/Maintenance Work Important Notes Test Results Measured Values,

OK Not OK Conducted Repairs
1. Electrical connections Use suitable contact spray,
a) Disconnect plug-in electrical connections e.g. Special Contact Spray
(Order No. 101322).
to wiring harness, examine for oxidation,
spray and reconnect after carrying out
Point 5.
b) Check electrical fuses for oxidation and/or
transfer resistance.
2. Heat exchanger Determine the cause of
a) Examine for dark burn spots on paint (lo- overheating if necessary
(e.g. water circuit);
cal overheating). check temperature limiter.
b) Examine for leaks.
c) Clean heater outside and inside.
3. Fuel system Ensure leak-tight connec-
a) Check the fuel lines and connections for tion in fuel supply and re-
turn line!
leaks.
Tighten screw fittings and
b) Replace the fuel filter insert with seal. hose clamps.
c) Open fuel shut-off valves if present. Replace pump and lines
d) Fuel pump and fuel lines. every 5 years.
e) Replace fuel screen with seals in the
pump.
4. Burner head
a) Check combustion-air intake opening for
clear passage.
Swing away burner head:
b) Examine housing inside for collections of
fuel caused by leaks.
c) Clean inspection window of flame moni-
tor.
d) Check condition of ignition electrodes. Replace bent electrodes.
e) Replace atomiser nozzle. In case of coke build-up,
shorten replacement inter-
val for fuel filter.
5. Exhaust system
a) Check exhaust pipe for clear passage and
clean if necessary.
b) Remove combustion chamber from heat
exchanger, examine both parts for dam-
age and soiling and clean or replace if nec-
essary.
c) Mount combustion chamber and install
burner head. Ensure firm connection to
heat exchanger when doing so.
d) Reconnect electrical plug-in contacts.
A-1
DBW 2010 / 2016 Appendix A
Test/Maintenance Work Important Notes Test Results Measured Values,

OK Not OK Conducted Repairs
6. Water system
a) Clean water-filter insert if present.
b) Open water shut-off valves if present.
7. Operating check
a) Open shut-off valve in return line if
present.
b) Check heater operation. After at least 10 min. Heat-
ing mode.
c) Watch for smoke in run-on; replace nozzle
if necessary.
A-2
Appendix B DBW 2010 / 2016
Appendix B
Maintenance plan Rail
Maintenance plan / measurement report
for Webasto heaters of the type DBW 2016 in rail vehicles
General
The heater must be inspected at least annually according to the following table.
To carry out the maintenance, the appropriate Workshop Manual has to be used.
* This maintenance plan is to ensure that the maintenance and operation of the heaters matches with the relevant provisions
of the Eisenbahn-Bundesamt (EBA, Federal Railway Authority, Germany).
Address of the operator Date of measurement
Installes in rail vehicle
Heater data
Type of heater
Rated power in kW
Year of commissioning
Winter diesel Arctic diesel
Fuel
Test/Maintenance Work Important notes Measured values, Test results

conducted repairs
OK not OK
1. Electrical connections
a) Disconnect plug-in electrical connections Use suitable contact spray,
to wiring harness, examine for oxidation, e.g. Special Contact Spray
spray and reconnect after carrying out (Order No. 101322Z)
Point 5.
b) Check electrical fuses for oxidation and/or
transfer resistance.
2. Wärmeübertrager
a) Examine for dark burn spots on paint (lo- Determine the cause of
cal overheating). overheating if necessary
b) Examine for leaks. (e. g. water circuit); check
c) Clean heater outside and inside. temperature limiter.
Maintenance plan (part 1 of 3)
A-3
DBW 2010 / 2016 Appendix B

conducted repairs
OK not OK
3. Fuel system
a) Check the fuel lines and connections for Ensure leak-tight connection
leaks. in fuel supply and return
b) Replace the fuel filter insert with seal, line!
resp. throw-away filter. Tighten screw fittings and
c) Open fuel shut-off valves if present. hose clamps.
d) Check fuel pump and fuel lines. Pumpe und Leitungen alle 5
Jahre austauschen.
4. Burner head
a) Check combustion-air intake opening for
clear passage.
Swing away burner head:
b) Examine housing inside for collections of
fuel caused by leaks.
c) Clean inspection window of flame moni-
tor.
d) Check condition of ignition electrodes. Replace bent electrodes.
e) Replace atomiser nozzle (only by nozzle In case of coke build-up,
approved by Webasto). shorten replacement
interval for fuel filter.
5. Exhaust system
a) Check exhaust pipe for clear passage and
clean if necessary.
b) Remove combustion chamber from heat Replace combustion
exchanger, examine both parts for dam- chamber every 3 years.
age and soiling and clean or replace if nec-
essary.
c) Mount combustion chamber and install
burner head. Ensure firm connection to
heat exchanger when doing so.
d) Reconnect electrical plug-in contacts.
e) Measurements. Limits according to directive
Setpoints and procedure are listed in 2001/56/EG
Chapter 6 of the workshop manual.
recommended measuring
device:*
ambient temperature [°C]
exhaust temperature [°C] approx. 400 °C
CO2 [Vol.-%] 9,5 to 11,5 Vol.-%
CO [ppm] < 1000
amount of soot (-) <4
pressure fuel pump [bar] 11,5 bar
6. Water system
a) Clean water-filter insert if present.
b) Open water shut-off valves if present.
A-4
Appendix B DBW 2010 / 2016

conducted repairs
OK not OK
7. Operating check
a) Open shut-off valve in return line if
present.
b) Check heater operation. After at least 10 min.
Heating mode.
c) Watch for smoke in run-on; replace nozzle
if necessary.
Summary
The result corresponds with the requirements
The result does not correspond with the requirements (further action required)
The inspection or adjustment was performed:
Date:
Name:
Place:
Department:
*) MSI 150
Euro Flue gas analyzer 5600593
A-5

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Water Heaters Workshop Manual

1.1 Contents and purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

2.1 Combustion air fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205

3 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301

3.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301

4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

4.1 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

5.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501

5.4 Malfunction symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504

6 Operating Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

7 Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701

8 Servicing Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

8.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

9.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .901

10 Packing, Storage and Shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001

10.1 General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001

Periodic Heater Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Maintenance plan Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

1.1 Contents and purpose 1.4 Additional documentation to be used

1.5 Safety precautions and regulations

1.3 Meaning of signal words

The year of initial commissioning must be permanently

The heaters are approved for heating the motor vehicle

• The tank must not be installed in the passenger or

All fuel tanks offered in the Webasto accessories catalogue

All fuel tanks offered in the Webasto accessories catalogue

• The respective operating mode of the heater, at least

For heaters in vehicles not subject to the German Road Vehicle

1.7 Suggestions for improvement and

Complaints, improvements or suggestions for correction to

– to heat the passenger compartment, – the combustion air fan

Depending on the heater variant, the following can be

1 Burner head 9 Heat exchanger

Fig. 201 DBW 2010 heaters

1 Burner head 8 Exhaust outlet

Fig. 202 DBW 2010 heaters with sensor technology

Fig. 203 DBW 2016 Standard / Rail heaters

2.1 Combustion air fan 2.3 Fuel pump

Fig. 204 Combustion air fan

Fig. 206 Fuel pump

At extremely low temperatures, malfunctions can occur with-

Fig. 207 Nozzle holder pre-heating unit

2.4 Heat exchanger 2.6 Control unit

Fig. 208 Heat exchanger

2.5 Combustion chamber

The fuel-air mixture is distributed in the combustion chamber

Fig. 209 Combustion chamber

2.7 Flame monitor 2.8 Ignition spark generator with ignition

Fig. 214 Ignition spark generator with ignition electrodes

2.9 Temperature sensor (sensor technology

The temperature sensor detects the coolant temperature at

Fig. 213 Flame monitor heaters with sensor technology

2.10 Temperature limiter/thermal fuse 2.11 Control thermostat

Temperature limiter Control thermostat on heater

DBW 2010 / 2016

Temperature limiter Thermal fuse