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Webasto Blue Bird Scholastic Series School Bus Heater Automobile Parts User Manual

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Contents

1. Jebasto Feel the drive The Scholastic Series School Bus Heater Operating Instructions Installation Instructions Service Parts Listing For BLUE BIRD Conventional Model Transit Model Engine Front Transit Model Engine Rear WEBASTO SCHOLASTIC SERIES TABLE OF CONTENTS Table of Contents 1 Introduction 1 1 1 2 1 3 1 4 Scope and Purpose saaan aaaea 1 1 Meaning of Warnings Cautions and Notes aaae 1 1 Additional Documentation to be Used 0 eee 1 1 General Safety Regulations and Information 0 000 cece eee ee eee 1 1 1 4 1 General Safety Notes ee eee eee 1 1 2 General Description 2 1 Scholastic Heater Description 0 00 cece eee 2 1 3 Functional Description 3 1 3 2 3 3 3 4 3 5 3 6 3 7 Operating your Webasto Scholastic Heater 0 0 0 0 cee eee 3 1 SN Mill ON ese teuwteend tad i n E teat eee ae E ee ee E eke eee aes BERS 3 1 SWHCMING OM 3 a0 ae oes eee Bde eed KGG BALANG AG Hons PA LAG 44 0 6E ee owe 3 2 Engine Preheating uda ma ek Pee so ee ee ee KWAK oe BO 6 ORE Eee ee AA 3 2 Boost Heating for Engine and Passenger Compartment a 3 2 Operation with 7 Day Digital Timer Model 1531 0 000000 3 2 7 Day Digital Timer Programming and Operating Instructions 3 4 4 Technical Data 4 1 scholastic Series Heater Data aaa NG BHE PRA KG LG LAGE NG AKA 4 1 4 1 1 Scholast
2. or 1 2 spare port on fuel tank and install fuel standpipe securely in fuel tank use pipe thread sealant on all pipe threads 3 Route and secure fuel line from heater to fuel tank Do not route fuel line over frame rails always route through or under the frame rail Use grommets to protect fuel line whenever routed through holes 4 Connect fuel line to fuel standpipe using 3 mm 1 8 fuel hose meeting SAE 30RI specifications ACAUTION On School Bus applications fuel lines must not cross over top of the vehicle frame rails Check local and State codes and regulations for exceptions ACAUTION Fuel lines must be secured every 30 cm 12 inches or less and kept clear of hot exhaust components and moving parts driveshaft wheels etc NOTE Use supplied hose clamps to secure fuel line connections Scholastic Series Heater Fig 5 8 Fuel Line Parameters A Suction height 2 0 m 6 6 maximum A B Suction length 10 m 33 maximum 5 8 WEBASTO SCHOLASTIC SERIES 5 INSTALLATION 5 7 3 Fuel Filter ACAUTION Check local and State codes and regulations for fuel filter mounting locations 44CAUTION To prevent fuel nozzle failure always use CLEAN fuel from a known CLEAN source for priming fuel systems and filters Your heater is equipped with a spin on fuel filter Fuel filters require changing at least annually and in cases of dirty fuel more often The fuel filter assembly should be mounted securely
3. Leave round waterproof harness to heater enclosure connector P1 uncoupled until completion of heater installation 1 Route and secure the wire harness from the Webasto heater to constant power source and cut harness to length 2 Connect the positive leads to a 30 amp circuit breaker connected to a constant power source 3 Connect ground lead to ground stud Refer to wiring diagrams on pages 5 13 5 14 5 15 and 5 16 appropriate to your installation 5 10 WEBASTO SCHOLASTIC SERIES 5 INSTALLATION 5 8 3 Timer and Switch Connections For switch connection details pin outs see wiring diagrams fig 5 13 5 14 on pages 5 13 and 5 14 appropriate to your installation Fig 5 10 On Off Switch Pin Out Connect To 1 Vehicle Dash Lights Optional Webasto 2 Terminal 86 of Relay K1 4 Chassis Ground Negative 8 To Control Unit Terminal Location B3 10 To Vehicle Ignition Signal Positive 11 Terminal 87 of Relay K1 or Constant 12 Chassis Ground Negative 3 5 6 Not Used 7 and 9 For timer connection details pin outs see wiring diagrams fig 5 15 5 16 on pages 5 15 and 5 16 appropriate to your installation Fig 5 11 7 Day Digital Timer Model 1531 5 8 4 Timer and Switch Installation ACAUTION Make sure there is enough space behind the dash for the switch or timer and wire connections before cutting any holes ACAUTION To prevent dam
4. 18GA 4 D gt 2302AGY 18G 35 6 wd P31 a 1168L PK BK 18GA 1168L PK BK 18GA 2305A RD 18GA 2305A RD 18GA 1125NN BK 18GA 1125NN BK 18GA 2350C DK GN 18GA 2350C DK GN 18GA 1250D WH 18GA 1250D WH 18GA 7 DAY TIMER 1531 P36 F F P35 1333MM LT BL 18GA 1260MM WH 18GA P64 SWITCH 54 HEATER WATER PUMP 2302A GY 18GA 1125R BK 14GA 2302E GY 18GA 0030512 Option 1345 04 Fig 5 16 Wiring Diagram Chassis Power Harness with Digital Timer Model 1531 5 16 WEBASTO SCHOLASTIC SERIES 5 INSTALLATION 5 9 Initial Operation 1 Check your installation for loose nuts and bolts exhaust pipe routing and clamp tightness loose hose clamps routing and securing of wiring and heater hoses kinked or pinched hoses battery connection and polarity disconnect control thermostat on Webasto heat exchanger red and green wire see page 2 1 figure 2 1 position 13 2 Top off or refill cooling system with coolant as per engine manufacturer s recommendations 3 Connect power switch extension harness to waterproof plug 4 Open shut off valves and driver s heater valve 5 Set heater controls to maximum heat position and turn off Air Conditioning if applicable 6 Switch On Webasto heater and check green indicator light on circulating pump in operation 7 Start the vehicle engine and run it at a fast idle for 10 minutes to purge air from the Webasto coolant hea
5. 5 8 6 P1 1125N BK 14GA gt 1125M BK 10GA 1125P BK 14GA IB 1250B WH 14GA 1250A WH 10GA 1250E WH 14GA H P30 A 2305A RD 18GA 1 B 1125NN BK 18GA 2350C DK GN 18GA C 3 1250D WH 18GA J 4 D gt 2302A GY 18GA gt 5 gt 6 gt 2302A GY 18GA INSTALLATION Wiring Diagram Chassis Power Harness with Switch CIRCUIT BREAKER 1125M BK 10GA Od BATT 1125R BK 14GA 30A 1250A WH 10GA p GROUND STUD 2305Y RD 18GA 1125NN BK 18GA qT lt g a BS eg 5 5 N o 8 P170 SWITCH 54 HEATER WATER PUMP 1125R BK 14GA 2302A GY 18GA 0030777A Option 1345 03 Fig 5 13 Wiring Diagram Chassis Power Harness with Switch 5 13 5 INSTALLATION WEBASTO SCHOLASTIC SERIES 5 8 7 Wiring Diagram Chassis Power Harness with Switch CIRCUIT BREAKER 1125M BK 10GA pad HAY 1125R BK 14GA 0A 1250A WH 10GA p GROUND STUD P1 D 1125N BK 14GA 1125M BK 10GA 1125P BK 14GA D 1250B WH 14GA 1250A WH 10GA 1250E WH 14GA H P30 A 2305A RD 18GA 1 1125NN BK 18GA B 2 c 2350C DK GN 18GA 1250D WH 18GA J 4 D gt 2302AGY18GA 55 63 AUX HEATER SWITCH 67 P 67 1 P36 F F P35 q 5 S S 3 P64 ka 2 S SWITCH 54 g HEATER WATER 1125R BK 14GA 2 2302A GY 18GA 2302E GY 18GA 0030522A Option 1345 03 Fig 5 14 Wiring Diagram Chassis Power Harness with Switch 5 14 WEBASTO SCHOLASTIC SERIES 5 INSTALLATION 5 8 8 Wiring Diagram Chassis Power H
6. 8 SPARE PARTS LIST Scholastic Series Subject to modification ITEM QUANTITY PART NO DESCRIPTION REMARKS 1 2 901265 Elbow Brass 90 with Mounting Through floor connection Flange No Fig 1 901045 Formed Hose Coolant pump to heat exchanger inlet No Fig 2 901213 Formed Hose Gates 21488 No Fig 8 902024 Hose Clamp ET 20 8 SPARE PARTS LIST Scholastic Series ITEM QUANTITY 224 1 906647 225 1 906118 226 1 900029 227 1 900004 228 X 903709 229 6 379670 230 1 603362 231 1 603364 232 1 902014 233 1 902015 234 1 902016 235 1 902013 236 1 901299 PART NO WEBASTO SCHOLASTIC SERIES DESCRIPTION Fuel Standpipe Complete Fuel Standpipe Single Line Check Valve One way Barb Fitting Fuel Line 1 4 ID Per meter Clamp Fuel Line 12 mm Barb Fitting 90 Fuel Line Bulkhead Fitting Assembly NPTF Nut 3 4 Flat Washer Rubber Gasket Tank Boss Fitting Barb Fitting JIC 4 x 1 4 Hose Subject to modification REMARKS Includes items 225 226 227 232 233 234 235 Includes 1 2 x 1 4 NPT bushing not shown Standpipe only does not include tank boss Used with mounting tray enclosure Connects fuel line to heater WEBASTO SCHOLASTIC SERIES 8 SPARE PARTS LIST Scholastic Series Subject to modification ITEM QUANTITY PART NO DESCRIPTION REMARKS 1 1 900400 Fuel Filter Head Used with part 900001 2 1 900001 Fuel Filter FF 104 Used with part 900400 3 2 9004
7. Timer Instructions 3 4 WEBASTO SCHOLASTIC SERIES 4 TECHNICAL DATA 4 Technical Data 4 1 Scholastic Series Heater Data The following data is subject to the normal tolerance for heaters if no tolerance is specified This is approximately 10 in an ambient of 20 C 68 F at nominal voltage Heater Scholastic Series Design Coolant heater with high pressure nozzle Heat Output kW BTU hr 13 1 45 000 Fuel Diesel 1 Diesel 2 and Arctic Fuel Consumption hr gal hr 1 5 0 4 Rated Voltage V 12 Operating Voltage V 10 14 Power Consumption w o Water pump W 60 Permissible Ambient Temperature during Operation C F 40 60 40 140 Storage Temperature C F 85 max 185 max Min Capacity of Cooling System gal 10 2 6 Permissible Operating Pressure of Coolant bar psi 0 4 2 06 29 CO in Exhaust Gas ppm 32 CO2 in Exhaust Gas by Vol 10 0 5 NOx in Exhaust Gas ppm 70 HC in Exhaust Gas ppm lt 5 Emission Bacharach 1 Dimensions of Heater L 584 23 W 205 8 1 mm inch H 228 9 Dimensions of Heater Enclosure L 603 23 75 W 305 12 mm inch H 254 10 Dimensions of Heater Tray Mount L 603 23 75 W 305 12 mm inch H 228 9 Weight on Tray kg Ib 27 60 Weight of Heater incl Control Unit kg Ib 15 33 Table 4 1 Scholastic Series Heater Data 4 TEC
8. brief after run cool down cycle 3 5 Boost Heating for Engine and Passenger Compartment 1 Switch the toggle switch or the Instant On button of the timer in the vehicle dash to On The heater will start up if the coolant temperature is below 75 C 167 F Above this temperature only the water pump will run 2 When boost heating is no longer required switch the Webasto heater Off The heater will begin a brief after run cool down cycle 3 6 Operation with 7 Day Digital Timer Model 1531 The digital timer with 3 time settings permits the Webasto heater to be switched on and off instantly or automatically at 3 programmable starting times The operating time of the heater can be pre selected It is possible to program 3 different heating programs according to your individual needs Only one preset starting time can be activated at any one time When the ignition is switched on the current time of the day and the day of the week are displayed When the heater is in operation the display and the buttons of the timer are illuminated Programmed Heater Operation Three memory locations numbered 1 to 3 are available Each memory location can be assigned a given time together with the day of the week Pre selected Starting Times The pre selected starting time is the time at which the heater will be switched on automatically We recommend that memory locations 1 and 2 be used for presetting starting times within
9. installation housing must provide adequate ventilation for combustion air requirements 20 cm 4 in 5 6 Plumbing into the Coolant System Fig 5 3 Typical School Bus Heating Circuit 5 6 1 General Information An efficient heating system must have an adequate supply of hot water to all heater cores The amount of hot water available to a typical three or four heater core system depends on the water pumps capability and the amount of restriction within the coolant system The Webasto heater is equipped with a high performance circulating pump designed specifically for bus heating applications and when plumbed in accordance with the following instructions will maximize the heating systems efficiency The coolant circulating pump bottom of Enclosure or Tray must be mounted at least 150 mm 6 below the lowest permissible coolant level of the vehicles cooling system A minimum of 10 of a good quality antifreeze should be maintained in the cooling system at all times Heater and water pump fit 25 4 mm 1 ID heater hose meeting SAE 20 R3 specifications Silicone hose requires special hose clamps NOTE Heater hose must meet SAE 20 R3 specifications Silicone heater hose requires special hose clamps Hose clamps must be tightened to 5 Nm 45 Ib in torque 5 INSTALLATION WEBASTO SCHOLASTIC SERIES 5 6 2 Engine and Passenger Compartment Heating AWARNING Potential skin and eye burn risk When working on the coolant syst
10. manual test run has been successfully completed set the heater switch timer to OFF remove the tester and reconnect the control unit Once done set the switch timer to ON if heater or a heater component does not respond the control unit is defective replace the control unit and retest the heater NOTE Since the heater operates in the 68 C 155 F to 75 C 167 F On to Off Off to On range and the vehicle engine may be hot e g coolant above 75 C 167 F the heater will not start until the coolant temperature is below 68 155 F THIS IS NORMAL and does not indicate a problem WEBASTO SCHOLASTIC SERIES 8 SPARE PARTS LIST Scholastic Series Figure 1 Subject to modification ITEM QUANTITY PART NO DESCRIPTION REMARKS No Fig 1 92119B Basic Scholastic Heater 12V Complete replacement heater only No Fig 1 NA Burner Head with Control Unit 12V Completely mounted and connected 2 1 287962 Control Unit 12V 3 1 362107 Clip for Control Unit 4 4 470562 Screw Self tapping M3 5 x 14 5 1 101838 Electronic Ignition Unit 12V 6 2 404918 Socket 7 X 178624 High Tension Ignition Cables 7mm per meter 8 2 176494 Electrode Plug 10 1 350427 Air Intake Bellows 11 4 432377 Screw M4 x 12 12 4 152269 Serrated Lock Washer 13 1 316199 Clamp 14 1 436216 Protection Cap 15 2 101660 Warning Label 22 3 488631 Screw with Washer M5 x 12 24 1 42505A Flange 8 1 8 SPARE PARTS LIST WEBASTO SCHOLAS
11. 01 1 2 x 1 4 Bushing Used with part 900400 4 2 901293 Barb Fitting 1 4 MNPT x 1 8 Hose Used with part 900400 No Fig 1 905707 Mount Bracket for Fuel Filter Head Used with part 900400 8 13 8 SPARE PARTS LIST Scholastic Series WEBASTO SCHOLASTIC SERIES Figure 11 Subject to modification ITEM QUANTITY PART NO 1 1 900731 No Fig 1 901235 No Fig 1 901233 No Fig 4 905388 No Fig 1 15527A No Fig X 353221 No Fig 1 367400 No Fig 1 126830 No Fig 1 24046A No Fig 1 600050 DESCRIPTION Tray Mount Enclosure Cover Enclosure Base Rubber Grommet 1 3 4 Dia Groove Stainless Steel Exhaust Tube 38mm x 1m Stainless Steel Exhaust Tube 038 mm Exhaust Clamp P Clamp End cap open Frame Mounting Brackets 1 Pair REMARKS Includes end cap Per meter 039 42 mm To secure exhaust tube to vehicle Exhaust tube outlet To mount heater to vehicle frame some modification required WEBASTO SCHOLASTIC SERIES 8 SPARE PARTS LIST Scholastic Series Subject to modification ITEM QUANTITY PART NO DESCRIPTION REMARKS 1 1 901000 Housing Impeller MP 28842 2 1 901013 O ring MP 28613 3 1 901015 Impeller MP 28727 4 1 901017 Seal Assembly MP 28984 5 1 901019 Adapter MP 28733 6 4 901021 Screw MP 28834 7 2 Hex Nut 10 32 8 1 901023 Motor 12V MP 28985 No Fig 2 176591 Connector Female 6 3 No Fig 1 178713 Fema
12. 1 12V Timer only To item 168 169 To item 168 169 To item 168 169 for flush panel mounting To item 168 169 for under over or surface of panel mounting Use in conjunction with external harness item 174 Use in conjunction with internal harness item 173 From control unit to vehicle wiring To relay Preheat harness WEBASTO SCHOLASTIC SERIES 8 SPARE PARTS LIST ITEM QUANTITY PART NO DESCRIPTION REMARKS 182 2 24981A Fuse 15 Amp Use with item 181 182 1 103992 Fuse 20 Amp Use with item 181 183 7 178705 1 Pin Female Connector Housing 184 3 620295 Ring Connector Yellow M8 186 1 82399A Preheat Harness No Fig 1 900012 Inertia Switch No Fig 1 906026 Inertia Switch Harness 8 9 8 SPARE PARTS LIST WEBASTO SCHOLASTIC SERIES Scholastic Series Subject to modification ITEM QUANTITY PART NO DESCRIPTION REMARKS 179 1 620286 3 Pin Female Connector Housing Used on preheat harness item 186 180 1 620285 3 Pin Male Connector Housing Used on item 173 at preheat connection 182 2 24981A Fuse 15 Amp Used with item 181 182 1 103922 Fuse 20 Amp Used with item 181 187 2 901398 Relay 12V Used with item 176 188 4 176389 Connector Male Used with male connector housings 189 16 176591 Connector Female 6 3 Used with female connector housings 190 1 178799 1 Pin Male Connector Housing Used on inertia switch harness 195 1 342777 8 Pin Male Connector Housing Used on timer harness item 170 WEBASTO SCHOLASTIC SERIES
13. 2 Connecting Power Harness to a Constant Power Source 5 10 5 8 3 Timer and Switch Connections 000 ees 5 11 5 8 4 Timer and Switch Installation 234 aaa kna mha G Ka dee daedeaeene Da 5 11 5 8 5 Wiring Diagram Scholastic Series Heater 00 e eee eee 5 12 5 8 6 88 Wiring Diagram Chassis Power Harness with Switch 5 13 5 8 7 Wiring Diagram Chassis Power Harness with Switch 5 14 5 8 8 Wiring Diagram Chassis Power Harness with Digital Timer Model 1531 5 15 5 8 9 Wiring Diagram Chassis Power Harness with Digital Timer Model 1531 5 16 5 9 Initial Operaion xah maa han Senden kg LA mms NADA NG AWAN ce hea a aa BABALA 5 17 Maintenance of the Heater 6 1 Annual Maintenance 0 0 ee eee teen ne 6 1 Basic Troubleshooting 7A General Information ccc eee eee 7 1 7 2 Quick Check Troubleshooting Matrix e ee 7 1 7 3 Heater Test Unit Webasto P N 440280 0 cee ee 7 2 7 4 Test Procedures ee ee ee ens 7 3 Spare Parts Listing Spare Parts Listing 2 45 2 aden ma seh leh ine WATA ee bee Be RC NAA ee eee eas 8 1 WEBASTO SCHOLASTIC SERIES TABLE OF CONTENTS 2 3 1 4 1 4 2 4 3 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 5 10 5 11 5 12 5 13 5 14 5 15 5 16 7 1 3 1 4 1 4 2 7 1 7 2 List of Figures Webasto Scholastic Series Heater ee 2 1 7 Day Digital Timer Typical aman
14. 24 hours of setting the timer Memory location 3 can be used for a starting time within the next 7 days of setting the timer 3 2 WEBASTO SCHOLASTIC SERIES 3 FUNCTIONAL DESCRIPTION NOTE We recommend that memory locations 1 and 2 be used for presetting starting times within a 24 hour period of setting the timer Memory location 3 can be reserved for a starting time within the next 7 days of setting the timer Location 3 is useful for occasional weekend or field trip operations outside of the normal schedule By repeatedly pressing the D button starting time program 1 2 or 3 can be viewed and preset Operating Time The period of time during which the heater is in operation is referred to as operating time The heater remains in operation for as long as the operating time has been preset Heater operation can be pre selected for any time from as little as 1 minute to a maximum of 120 minutes factory preset is 60 minutes Remaining Operating Time The remaining operating time refers to the period of time the heater still continues to remain in operation It can only be changed while heater is in operation NOTE If the ignition is switched off while the heater is in operation the remaining operating time of 5 minutes flashes on the timer display and the heater continues to operate for this period of time See Remaining Operating Time to adjust this time setting Setting the Digital Timer After the power has been conn
15. CH 9 WAY C H NECTOR D10 9 96P Fig 4 3 Tray Mount Dimensions Inches WEBASTO SCHOLASTIC SERIES 5 INSTALLATION 5 Installation 5 1 General Information Webasto will take you step by step through the installation process to ensure successful operation for years to come The installation must be performed in accordance with the installation instructions provided in this manual NOTE This manual does not cover all possible installations This manual is a general guideline only For special applications or installations differing from what is described in this manual contact Webasto Thermosystems directly at 1 800 555 4518 for further information 5 2 Installation Locations Fig 5 1 Installation Locations AWARNING Due to the risk of carbon monoxide poisoning and asphyxiation the heater must never be installed inside the passenger compartment Heater is to be installed in an existing enclosure spare battery compartment on the driver s road side of vehicle The installation template provided with heater kit must be used Do not mount to the slide out tray The heater and tray must be mounted solidly The heater inertia safety switch will only function properly if the heater and tray are mounted solidly The heater should be installed as low as possible in the cooling system to assure static bleeding of the heater and the circulating pump NOTE The coolant circul
16. Gasket Ring A10 x 14 68 1 92170A Fuel Supply Line Complete 4 JIC 70 2 277282 Hexagon Socket Head Cap Screw M4 x 30 71 2 152544 Spring Washer B4 72 1 63314A Fuel Pump Single line 10 bar 145 psi 74 1 355836 Pressure Control Valve WEBASTO SCHOLASTIC SERIES ITEM QUANTITY PART NO 8 SPARE PARTS LIST DESCRIPTION REMARKS 75 77 80 82 83 84 85 86 No Fig 87 88 89 90 No Fig oa x A sA Br a o o HSH N 310344 260738 488631 412198 410799 19723B 298816 104012 82399A 488631 102861 371289 152390 143820 Filter Screen Gasket Screw with Washer Nozzle Holder Pre heat Element 12V Holding Strap Bracket Pre heat Thermostat Pre heat Harness See item 186 for reference Screw with Washer Nozzle Holder Plate Straight Spur Gear Retaining Ring 6 x 0 7 ISOFLEX LDS 18 Special Hi temp Grease In 100g tube Use on fuel pump gears 8 5 8 SPARE PARTS LIST WEBASTO SCHOLASTIC SERIES Scholastic Series 121 S 127 P Se Subject to modification ITEM QUANTITY PART NO DESCRIPTION REMARKS 100 1 487627 Protection Cap 104 1 147702 Screw M4 x 8 105 1 319430 Clamp 8mm 107 1 273481 Screw 108 1 273473 Bracket 109 1 298816 Joint 121 1 406287 Overheat Fuse 138 C Identification color white wires 127 1 354902 Control Thermostat 75 C Green and red wires 130 1 608719 Temperature Limiter 104 C Green wires 8 6 WEBASTO SCHOLASTIC SERIES 8 SPARE PARTS LIS
17. HNICAL DATA WEBASTO SCHOLASTIC SERIES 4 1 1 Scholastic Series Heater Dimensions Scholastic Series O Space required for removal of overheat fuse Q Fuel inlet connection JIC 4 Mounting holes 4 Space required for removal of combustion chamber Maximum mounting angles Fig 4 1 Scholastic Series Heater Dimensions Millimeters WEBASTO SCHOLASTIC SERIES 4 2 Coolant Circulation Pump Data Flow Rate hr US gal min 3406 4542 15 20 Rated Voltage V 10 14 Power Consumption W 72 Dimensions L 214 8 42 W 106 4 16 mm inch H 106 4 16 Weight kg Ib 2 5 5 5 Hose connection mm inch OD 28 5mm 1 1 8 Table 4 2 Coolant Circulation Pump Data 4 2 1 Coolant Circulating Pump Dimensions RED POSITIVE BLACK NEGATIVE DISCHARGE 1 148 0 8 ZZ i iwi A Se CLL III IIE af a GROMMET 4 TECHNICAL DATA SUCTION 1 1 8 0 0 SECTION A A Fig 4 2 Coolant Circulating Pump Assembly P N 906017 Dimensions Inches 4 TECHNICAL DATA 4 3 Tray Mount Dimensions WEBASTO SCHOLASTIC SERIES MOUNTING SI 4 PLCS 9 8 2 PLCS 7 172 57 8 TYP 1 1 787 2 PLCS EL SUPPLY LIN EXHAUST HOLE 3 8 TYP E 1 4 FNPTD bie 2 PLES SCHOLASTIC SERIES ELECTRICAL CONNECTIO DEUTS
18. MOSTAT LED test switch timer lights up test control thermostat on heater Normal operating range approx 75 C 167 F or higher open no heat required approx 68 C 155 F or lower closed heat required Push FUEL SOLENOID VALVE clicking of solenoid should be heard test temperature fuse if equipped test overheat limiter button several times test solenoid valve Push IGNITION SPARK COIL sparking should be heard check electrode gap button test ignition spark coil Turn MOTOR switch ON motor should run reset inertia switch test motor Turn WATER PUMP switch ON pump should run test pump Table 7 2 Test Procedures and Results Inertia Switch All 12 volt Scholastic Series heaters are equipped with a manual reset inertia switch usually located in the vicinity of the burner head look for a device with a round diaphragm red in color and about the size of a 25 cent piece on top The purpose of this switch is to stop heater operation in the event the vehicle is involved in an accident or receives a strong impact shock i e hitting a curb This is done automatically by opening the combustion fan motor circuit stopping air and fuel delivery When troubleshooting check to make certain inertia switch has not been tripped Resetting is accomplished by depressing the red diaphragm on top of the switch You should hear an audible click when s
19. T Subject to modification Scholastic Series Figure 5 ITEM QUANTITY PART NO DESCRIPTION REMARKS 139 1 114499 Bleeding Valve 140 352497 Securing Cotter Pin 6 3 x 90 141 352152 Cable Clamp i H R 142 26553A Combustion Chamber 143 91216A Heat Exchanger Assembly Yellow color with 1 inch coolant connections 149 2 461555 Nut with Washer M6 150 2 32087A Eye Bolt AM6 x 45 151 2 420565 Slotted Pin 6x16 152 1 279110 Well Plug 153 1 289329 Angle Support 8 7 8 SPARE PARTS LIST Scholastic Series WEBASTO SCHOLASTIC SERIES DESCRIPTION REMARKS ITEM QUANTITY PARTNO 167 1 905103 168 1 905797 169 1 88195A 170 1 88436A 171 1 467936 172 1 474630 No Fig 1 475866 173 1 906008 174 1 905815 175 1 328529 176 2 901542 177 1 178713 179 1 620286 180 1 620285 181 1 14878A 8 8 ON OFF Switch 12V 7 Day Digital Timer Kit 7 Day Digital Timer Harness Timer Light Bulb 12V Mounting Frame Mounting Housing Harness Internal from control unit to main power switch connector Harness External from main power switch connector to batteries and switch timer 6 Pin Female Connector Housing 5 Pin Female Connector Housing 2 Pin Female Connector Housing 3 Pin Female Connector Housing 3 Pin Male Connector Housing Fuse Box Use with item 182 Model 1531 12V Includes harness item 170 and frame item 172 Model 153
20. TIC SERIES Scholastic Series Figure 1 Subject to modification ITEM QUANTITY PART NO DESCRIPTION REMARKS 25 2 432377 Screw M4 x 12 26 2 152269 Serrated Lock Washer M4 3 27 1 425060 Motor 12V 28 1 113665 Plastic Tie 29 2 350516 Coupling Exchange in pairs 8 2 WEBASTO SCHOLASTIC SERIES 8 SPARE PARTS LIST Scholastic Series Subject to modification ITEM QUANTITY PART NO DESCRIPTION REMARKS 35 1 412147 Cable Harness 6 Way plug Item 36 36 1 352969 Terminal Block 6 Way 38 4 148210 Hex Socket Head Cap Screw M5 x 35 39 4 152552 Spring Washer B5 40 1 301841 Motor Support 41 1 373001 Impeller with Shaft 42 1 378313 Bearing Set Parts for mounting the fan shaft assembly 43 1 412244 O ring 44 1 22567A Blower Casing 45 2 298964 Rubber Grommet Left side 46 2 299995 Rubber Grommet Right side 8 3 8 SPARE PARTS LIST WEBASTO SCHOLASTIC SERIES Scholastic Series Subject to modification ITEM QUANTITY PART NO DESCRIPTION REMARKS 50 1 322083 Solenoid Valve 12V 51 1 386650 Small Parts for Solenoid Valve For item 50 52 1 260487 O ring 12x 1 5 53 1 267279 Hexagon Screw M6 x 16 54 1 152560 Spring Washer B6 55 1 278971 Clamp 56 2 274313 Ignition Electrode 58 1 147699 Screw M4 x 6 59 1 215171 Flame Detector 60 1 453048 Retaining Ring 61 1 378232 Disc 62 1 88641A High Pressure Fuel Nozzle 0 35 GPH 60 65 1 275476 Pressure Pipe Complete 66 1 150754 Banjo Screw 67 2 151157
21. age to electrical and mechanical components check for clearance before drilling into panels and frame members 1 Locate appropriate switch knock out blank on instrument panel for heater On Off switch or select a suitable location in the vehicle dash for the optional timer 2 Remove switch knock out and replace with appropriate switch Timer is supplied with a removable stick on drilling template 3 Route and secure switch harness from the heater to the vehicle dashboard If possible use existing hole in fire wall panel or drill in suitable location Protect the harness with a grommet whenever passing through fire wall panel holes 4 Connect the terminals to the switch or timer See pages 5 13 5 14 5 15 and 5 16 for complete wiring details 5 11 5 INSTALLATION WEBASTO SCHOLASTIC SERIES 5 8 5 Wiring Diagram Scholastic Series Heater CIRCULATING PUMP MOTOR H SUPPLIED W WEBASTO a FUSE BLOCK SUPPLIED W WEBASTO WEBASTO CONTROL UNIT UEF1 15A SG 1553 PRA F2 15A l F3 29A RED E EE 3 RED F 2 BROWN 3G Ke a 1 i BROWN s5 7 RED gt A BLACK B INERTIA SWITCH ES x g BROWN K2 a 87 i O Si D kak ae BROWN WHITE i Hear AA SA AA S POS AE Kr Ha gt cE PURPLE PURPLE g 1 1 PEE sat SES wf w 3a da NG S2 i EEE ee E O E EN NA a OP 2 I i Fig 5 12 Wiring Diagram Scholastic Series Heater 5 12 WEBASTO SCHOLASTIC SERIES 5
22. alled in the passenger compartments of the vehicle Should the heater be installed in such a compartment the installation box must be sealed tight against the vehicle interior There must be sufficient ventilation of the installation box from the exterior in order not to exceed a maximum temperature of 60 C 140 F in the installation box Excessive temperatures may cause malfunctions AWARNING Due to the danger of poisoning and suffocation the heater must not be operated in enclosed areas such as garages or workshops without an exhaust venting system not even if the start up is activated by the timer or remote start device At filling stations and fuel depots the heater must be switched off as there is a potential danger of explosions Where flammable fumes or dust may build up e g in the vicinity of fuel coal wood cereal grain deposits or similar situations the heater must be switched off to prevent explosions 1 1 1 INTRODUCTION In the vicinity of the coolant heater a temperature of 85 C 185 F must not be exceeded under any circumstances e g during body paint work A violation of this temperature limit may cause permanent damage to the electronics When checking the coolant level proceed in accordance with the vehicle manufacturer s instructions The coolant in the heating circuit of the heater must contain a minimum of 10 of a quality brand glycol based anti freeze Extracting combustion air fro
23. arness with Digital Timer Model 1531 P1 A E gt EN BK MGA 1125M BK 10GA 1125P BK 14GA 3 1250B WH 14GA 1250A WH 10GA H 1250E WH 14GA P30 A 2305A RD 18GA 1 B 1125NN BK 18GA 2 c 2350C DK GN 18GA 3 J 1250D WH 18GA 4 D gt 2302A GY 18GA gt 5 gt 6 gt 2302A GY 18GA 2305A RD 18GA 1125NN BK 18GA 2350C DK GN 18GA 1250D WH 18GA HESR BK 145A 2302A GY 18GA 1168L PK BK 18GA 1125M BK 10GA 1125R BK 14GA 1250A WH 10GA P31 1168L PK BK 18GA 2305A RD 18GA 1125NN BK 18GA 2350C DK GN 18GA 1250D WH 18GA y 1168L PK BK 18GA CIRCUIT BREAKER 30A 1168L PK BK 18GA TERMINAL STRIP 1 1250G WH 18GA 10 1 11 NG 8 4 12 H P75 P170 SWITCH 54 HEATER WATER PUMP 1 1260MN WH 18GA NO bd i J 1333MM LT BL 18GA 0030778 7 DAY TIMER 1531 GROUND IGNITION SIGNAL Option 1345 04 Fig 5 15 Wiring Diagram Chassis Power Harness with Digital Timer Model 1531 5 15 5 INSTALLATION WEBASTO SCHOLASTIC SERIES 5 8 9 Wiring Diagram Chassis Power Harness with Digital Timer Model 1531 CIRCUIT BREAKER 1125M BK 10GA Sd BATT 1125R BK 14GA 30A 1250A WH 10GA l GROUND STUD Pi IS 1168L PK BK 18GA 1168L PK BK 18GA E S 1129NBK 14GA 1125M BK 10GA IGNITION SIGNAL 1125P BK 14GA 3 1250B WH 14GA 1250A WH 10GA H 5 1280EWH GA P30 TERMINAL STRIP 1 A 2305ARD18GA_ 9g B 1125NN BK 18GA 2 c 2350C DK GN 18GA 3 J 1250D WH
24. ating pump is not self priming Always prime coolant circulating pump heater and cooling circuit before initial starting of heater See section 5 9 Initial Operation 5 1 5 INSTALLATION WEBASTO SCHOLASTIC SERIES 5 3 Mounting the Heater Tray Kit mounting in existing enclosure on vehicle i e battery box 1 Ensure that the enclosure is large enough to accommodate the heater Use the installation template provided with the heater kit The installation enclosure must provide adequate ventilation for combustion air requirements 20 cm 4 in 3 Lay the supplied installation template in the enclosure Center punch the exhaust fuel electrical and 4 mounting hole locations Drill all required holes to the dimensions as shown on the template Solidly bolt the tray with heater mounted inside the enclosure D FOLD 90 ro ELECTRIC ap sa AE A 1 MOUNTING TEMPLATE FOR TRAY MOUNT SCHOLASTIC SERIES HEATER 17 16 EXHAUST Bae ALLOW 2 gt UE apiece To FOR SERVICE u NOTE HEATER TRAY MUST BE SOLIDLY MOUNTED DO NOT MOUNT ON SLIDE OUT TRAY HEATER INERTIA SWITCH WILL ONLY FUNCTION PROPERLY IF UNIT IS MOUNTED SOLIDLY 12 23 3 4 t WEBASTO ITEM NO 907 905 Fig 5 2 Tray Mount Template Supplied with Heater Kit 5 4 Exhaust Pipe Connection AWARNING Due to the risk of carbon monoxide poisoning and asphyxiation exhaust system components mus
25. between the vehicle frame rails close to the fuel tank After installation before the heater is fired for the first time the fuel filter MUST be filled with CLEAN diesel fuel When replacing the fuel filter this procedure must be repeated to ensure proper firing and operation NOTE The Webasto Scholastic Series heater is equipped with an internal self priming fuel pump 5 9 5 INSTALLATION WEBASTO SCHOLASTIC SERIES 5 8 Wiring Connections 5 8 1 General Information The control unit is equipped with low voltage protection therefore it is imperative to keep vehicle batteries in good condition Red labeling or markings indicating 12 volts identify electrical components for the Scholastic Series heater Green labeling or markings indicates 24 volt components which are not suitable for this version of heater ACAUTION To protect the electronic control unit when welding is performed on the vehicle the heaters main power supply wires must be disconnected from the main power source and temporarily grounded to the chassis NOTE The Webasto heating system will not perform to your satisfaction with weak batteries i Fuses Harness Connector P1 SCHOLASTIC SERIES HEATER Heater Enclosure Circuit Breaker 30A Main Power Switch or a Optional Timer a Chassis Ground Power Source Fig 5 9 Harness Connection Points Overview 5 8 2 Connecting Power Harness to a Constant Power Source 44 CAUTION
26. ctions load test the batteries and replace if necessary NOTE The heater will not function properly or to your satisfaction with weak batteries Exhaust System check the exhaust system carefully for restrictions or corroded areas Replace worn or damaged exhaust components as necessary Fuel System replace the fuel filter prime and inspect the fuel line for wear and damage Repair or replace if necessary Burner System swing open the burner head clean the flame detection photo eye pull out the combustion chamber inspect and clean the inside area of the heat exchanger Replace the fuel nozzle if necessary annually Reinstall the combustion chamber and close up the burner head Operational Check Run your heating system for at least 15 minutes Check all water and fuel connections for leakage Check tightness of all hose clamps if necessary NOTE Operate your Webasto heater at least once a month for 10 minutes WEBASTO SCHOLASTIC SERIES 7 Basic TROUBLESHOOTING a Basic Troubleshooting 7 1 General Information 44CAUTION Troubleshooting requires profound knowledge about structure and theory of operation of the heater Troubleshooting may only be performed by Webasto trained and certified skilled personnel This section describes troubleshooting procedures for the Scholastic Series coolant heater Troubleshooting is normally limited to the isolation of defective components Before troubleshooting check fo
27. e area where they can be easily connected to the coolant pump inlet and heater outlet once you are satisfied with the location making certain there are no obstructions you can now bore 2 holes 32 mm 1 1 4 through the floor from inside the bus drop elbows down through the floor and align with the heating circuit supply hose inlet elbow pointing forward and outlet elbow rearward secure elbow flanges to floor with sheet metal screws 4 From inside the heater enclosure connect the inlet eloow supply to the coolant pump and the outlet elbow to the Webasto heater outlet with rubber elbows and fittings provided 5 From inside the bus cut the previously identified heating supply hose at a point where it can be connected to the inlet and outlet elbows 6 Connect the heater supply line running from the engine to the inlet elbow Connect the other cut end of the supply line to the outlet elbow 7 Secure all hose connections with hose clamps 5 5 5 INSTALLATION WEBASTO SCHOLASTIC SERIES 8 Remove hose clamping pliers and or open shut off valves 9 Purge air from the Webasto heater by opening the bleeder valve screw see page 2 1 figure 2 1 item 26 10 Top off engine coolant as per engine manufacturer s recommendations and re install the radiator cap Do not install the previously removed heater hose access covers at this time Hose connections will require inspection and re tightening of clamps once installation is co
28. ected all symbols on the digital display are flashing The time of the day and the day of the week must be set All flashing displays and symbols of the timer can be set by means of the BI and amp buttons If the E and amp buttons are not pressed within 5 seconds the currently displayed time or function will be stored When the amp and amp buttons are pressed for more than 2 seconds the quick digit advance mode is activated Time Display Heater ON Indicator Program Instant Reverse Forward Selection Heating Fig 3 1 7 Day Digital Timer Model 1531 3 3 3 FUNCTIONAL DESCRIPTION WEBASTO SCHOLASTIC SERIES 3 7 7 Day Digital Timer Programming and Operating Instructions Setting the time and Press the button for more than 2 seconds day of the week Time display flashes Press the amp or amp button to set time of day Wait 5 seconds Time is now stored Day of week flashes Press or amp button to set day of week Wait 5 seconds Day of week is now stored Viewing the time With ignition ON Continuous display of current time and day of the week With ignition OFF Briefly press button Display of current time and weekday appears for 5 seconds Switching heater on With ignition ON for instant heater Press button Heater is switched on continuous heating operation and continues to operate until amp button is pressed again or ignition is switched off With i
29. em allow the engine and coolant to cool down and open the radiator cap carefully Heater Cores arranged in Series A series heating system works in this fashion Heated water coolant from the engine travels through the first heater core in the circuit then on to the next heater core in the circuit and on to the next etc Each core adds some restriction resulting in decreased water flow Not only is water flow reduced but also water temperature is reduced by each successive heater core resulting in the last core receiving water that is usually too cool to be effective A fuel fired Webasto heater equipped with a high capacity coolant pump can significantly increase the available heat supplied to a series plumbed system The advantages are increased coolant volume and flow through the system ensuring efficient interior heating through all heater cores REAR AXLE t FRONT BOW r pa ha Nemes es ad N SCHOLASTIC HEATER OPTIONAL 1 OPTIONAL HEATER HEATER 111 samang ba N e 1 Fig 5 4 Series Plumbing Circuit Conventional Model REAR AXLE FRONT FRONT P T AXLE Bow DRIVER S HEATER 7 5 gt p3 aga NG o he ee _ t H SCHOLASTIC HEATER OPTIONAL OPTIONAL 4 ENGINE HEATER HEATER pang STANDARD FRONT HEATER gt a Fig 5 5 Series Plumbing Circuit Transi
30. et vehicle heating system to the Heat position and open any shut off valves Depending on the type of control installed in the instrument panel of the vehicle the heater can be operated by the following methods 3 2 Switching On Timer Webasto Na 2 00 AET Using a Timer Upon pressing the Instant Heat button on the timer face the Operation Indicator on the timer lights up and the heater begins operation Using a Switch When the switch is used for switching ON the Webasto heater the Operation Indicator integrated in the switch is illuminated Heater Start up Sequence The heater motor and coolant circulating pump begin operation After approximately 10 to 25 seconds the fuel solenoid valve opens and fuel is sprayed into the combustion chamber At the same time the electronic ignition coil produces a high voltage 8000 V spark at the tip of the ignition electrodes and the mixture of fuel and air in the combustion chamber is ignited As soon as combustion is detected by the photo resistor flame detector the electronic ignition coil is de energized and combustion continues on its own ignition process is only required to ignite the flame At this point the heater is working and producing heat The Webasto heater will cycle on and off until The Webasto heater is switched off Time has elapsed on the timer The vehicle battery voltage drops below 10 5V The Webasto heater runs out of
31. fuel A fault lock out occurs indicated by the operating indicator light being off during the cool down cycle as would happen during an overheat situation arwn gt 3 1 3 FUNCTIONAL DESCRIPTION WEBASTO SCHOLASTIC SERIES NOTE If the heater is switched on while the engine is at operating temperatures above 68 C 155 F only the operation indicator and the coolant circulation pump will be activated The engine coolant temperature must fall below 68 C 155 F at the heater before the heater will begin heating operation NOTE Switching the Webasto heater on during the cool down or after run period is allowed The heater will revert to normal operational mode 3 3 Switching Off When heating is no longer required switch the Webasto heater off The fuel solenoid valve halts the fuel supply combustion stops and the indicator light turns off The Combustion air fan and the water pump remain on for another 2 3 minutes after run cycle purging the combustion chamber of any fumes 3 4 Engine Preheating 1 Set the timer 30 min to 1 hr before you want to start the engine The heater will start up at the set time See timer operating instructions Or switch the toggle switch or Instant On switch on your timer in the vehicle dash to ON The heater will start up 2 When the run time has elapsed on your timer or engine preheating is no longer required switch the Webasto heater OFF The heater will begin a
32. gnition OFF Press button Heater is switched on for the preset operating time the factory set heater operating duration is 60 minutes Switching the Press button Heater begins cool down after run cycle heater off and is switched off thereafter Programming Press button Memory location number flashes heater starting time Press amp or amp button to preset starting time Wait 5 seconds Preset starting time is now stored Day of week flashes Press amp or amp button to set day of week Wait 5 seconds Day of week is now stored The number of memory location remains on the display The timer is now in the programmed mode and switches heater on at the preset time Recalling canceling To recall Press button until the desired memory location pre selected times number is displayed Read off preset time To cancel Press button repeatedly until no memory location numbers are visible on the display Programming The heater must be switched off Press the amp button duration of Operating time flashes operating time Press amp or amp button to set operating duration time between 1 and 120 minutes Setting the Heater must be in operation remaining Press amp button Remaining operating time flashes operating time Press amp or amp button to set remaining operating time Wait 5 seconds Remaining operating time is now stored Table 3 1 Digital
33. ic Series Heater Dimensions 0000 eee eee eee 4 2 4 2 Coolant Circulation Pump Data 2 2 0c80eeeseee bee eee tee betwee een eee 4 3 4 2 1 Coolant Circulation Pump Dimensions 00000 eee eee ee 4 3 4 3 Tray Mount Dimensions 2 2 seds eins Ye BABALANG NG PIL ob ee eee tok Sean vem NG 4 4 5 Installation 5 1 General Information as paawa KAG eos ba GAB ba BREEDING PER RENO SN eke ewe heehee he 5 1 5 2 Installation Locations 274 aka KAN AA ened hed d ete udde kA LA NAIA AA KAG 5 1 5 3 Mounting the Heater 6 8 60 ha eet es beaten ees SOO R eee Oe ea LNG NAG 5 2 5 4 Exhaust Pipe Connection 4 494203 dive Sve toiaw tad tee Red bad BUKANA NAG bagong 5 2 5 5 COMDUSIONAI SURI essc drede iue Eria ena eet ees EEEE EEEE Sew EE NA 5 3 5 6 Plumbing into the Coolant System anaana NG KAG BNG LG even veneenbes de 5 3 5 6 1 General Information n asaan 5 3 5 6 2 Engine and Passenger Compartment Heating onanan anaana 5 4 5 6 3 Instructions for Integrating into the Coolant System 5 5 TABLE OF CONTENTS WEBASTO SCHOLASTIC SERIES Did Fuel Systemi AA eee een eek es eek 5 7 5 7 1 General Description a ka KAM KG ME 5645008 DAG MAGKA FOS KG LG a KG ANG NG 5 7 5 7 2 Fuel Supply ooon anaana 5 7 5 7 3 Fuel Fiter 20 04 oo eed esta a CER SER ERE oe e erak EE EEEE i 5 9 5 8 Wiring Connections 222 oa 82 3 eka NAGNANAKAW See KW ERA AKA aden NG kA KAG 5 10 5 8 1 General Information 00 0000 ee 5 10 5 8
34. irs without using genuine Webasto service parts This will void the coolant heaters Official Marks of Conformity 1 2 Meaning of Warnings Cautions and Notes Warnings Cautions and Notes in this manual have the following meaning 44WARNING This heading is used to highlight that non compliance with instructions or procedures may cause injuries or lethal accidents to personnel ACAUTION This heading is used to highlight that non compliance with instructions or procedures may cause damage to equipment NOTE This heading is used to highlight and draw specific attention to information 1 INTRODUCTION 1 3 Additional Documentation to be Used This manual contains all of the information and procedures necessary for the installation of the Scholastic Series heater The use of additional documentation is normally not necessary Vehicle specific installation guides when available may be used as complementary information if necessary 1 4 General Safety Regulations and Information The general safety regulations for the prevention of accidents and relevant operating safety instructions must be observed at all times The specific safety regulations applicable to this manual are highlighted in the individual chapters by Warnings Cautions and Notes 1 4 1 General Safety Notes The heater may only be installed in vehicles with a minimum coolant capacity of 10 litres 2 6 US Gal The heater must not be inst
35. le Connector Housing No Fig 1 620322 Insul Tube 8mm x 42mm Protective loom for wires 8 15 8 SPARE PARTS LIST WEBASTO SCHOLASTIC SERIES Scholastic Series Figure 13 Subject to modification ITEM QUANTITY PART NO DESCRIPTION REMARKS 255 1 310646 Gauge for Setting Ignition Electrodes 256 1 440280 Diagnostic Testing Unit 258 1 600190 Fuel Pressure Gauge with Adapter No Fig 1 905491 Extension Harness for Testing Unit 5 feet in length No Fig 1 406244 Combustion Chamber Puller No Fig 1 Exhaust Gas Analyzer No Fig 1 699745 Workshop Manual Org 2 2001 50000058A Webasto Thermosystems Inc North America 3333 John Conley Drive Lapeer MI 48446 Phone 810 245 2400 Toll free 800 HEATER 1 Fax 810 664 7720 Technical Assistance Hotline USA 800 555 4518 Canada 800 667 8900 Wwww webasto com
36. m the vehicle interior is not permissible under any circumstance The exhaust line outlet is to be positioned below the vehicle floor to the nearest possible location of the vehicle s left side Exhaust pipes must be routed so that exhaust fumes will not penetrate into the vehicle s interior The function of any parts vital for vehicle operation must not be impaired Condensation accumulation in the exhaust line must be directly drained A condensation drain hole may be provided as required Electrical lines switch gear and control gear of the heater must be located in the vehicle so that their proper function cannot be impaired under normal operating conditions The coolant heater may only be operated within the specified operating voltage range designated by type WEBASTO SCHOLASTIC SERIES The coolant heater may only be operated with the specified fuel Diesel 1 Diesel 2 Arctic grade Kerosene and certain military spec fuels For the routing of fuel lines the following important regulations must be adhered to e Fuel lines are to be installed in such a way that they remain unaffected by torsional stresses created by vehicle and engine movement They must be protected against mechanical damage Fuel lines must be securely fastened to the vehicle every 30 cm 12 inches or more often along the total length from heater to fuel tank Fuel carrying parts are to be protected against excessive heat and are to be installed so
37. mpleted and tested see section 5 9 Initial Operation NOTE Heater hose must meet SAE 20 R3 specifications Silicone heater hose requires special hose clamps Hose clamps must be tightened to 5 Nm 45 Ib in torque 5 6 WEBASTO SCHOLASTIC SERIES 5 INSTALLATION 5 7 Fuel System 5 7 1 General Description The fuel is drawn from the vehicles fuel tank through a fuel standpipe This standpipe can be utilized on vehicles with a threaded port in the fuel tank for this purpose IMPORTANT Keep the fuel standpipe 50 mm 2 from bottom of the fuel tank 5 7 2 Fuel Supply Check Valve Direction of Fuel Flow Pa Threaded Port Fuel Tank a es oo ee Fig 5 7 Fuel Standpipe Installation The fuel standpipe and fuel line must be installed according to these instructions to ensure proper heater operation 1 Cut or extend universal fuel standpipe to length approx 50 mm 2 off fuel tank bottom Slash cut standpipe end on a 45 angle to help prevent clogging NOTE After fuel standpipe has been cut to length remove all burrs from cut inlet end Check valve directional indication mark arrow or symbol must point in direction of fuel source fuel tank 5 7 5 INSTALLATION WEBASTO SCHOLASTIC SERIES 2 Install the universal fuel standpipe and 3 8 check valve Check valve directional indication mark arrow or symbol must point in direction of fuel source fuel tank use 1 4
38. nA KARA KNANG decks RAK baka ck we hh KRAS 3 3 Scholastic Series Heater Dimensions Millimeters 00 a 4 2 Coolant Circulating Pump Assembly P N 906017 Dimensions Inches 4 3 Tray Mount Dimensions Inches 0 22320c0 sesaeeeeaebeetaar de tet eeaadseiee 4 4 Installation Locations 2 ak ee KAGAT ELA ced chee OES See eee ak Cee eels 5 1 Tray Mount Template Supplied with Heater Kit 0 0 0 0 c cee eee eee 5 2 Typical School Bus Heating Circuit eee 5 3 Series Plumbing Circuit Conventional Model 000000 eee 5 4 Series Plumbing Circuit Transit Model Engine Front 0000 eee eee 5 4 Series Plumbing Circuit Transit Model Engine Rear 00 0a 5 5 Fuel Standpipe Installation s 234054 ccicitpircteeadaa dae BLING tiieine ot ogee 5 7 Fuel Line Parameters aan kah 2st bud Chat aa viaw KG NG KG GNG PLANG eva cadets 5 8 Harness Connection Points agama BRIANA WE A MAGNDA oes ADA eet NG GATA BARA 5 10 OWOH SWIC cae oon eee oe hee MAMA AP BO Pee CORE See ee GP eee 5 11 7 Day Digital Timer Model 1531 0020s 5 11 Wiring Diagram Scholastic Series Heater cece ee 5 12 Wiring Diagram with Switch e2s e258 2sa2eee eres oe ae Vee edi cieete ee ee ga 5 13 Wiring Diagram with Switeh 24 22 2 2 e e80d0eudas ob0ee0e s ecb bsaataa de 5 14 Wiring Diagram with Timer Model 1531 ee ee 5 15 Wiring Diagram with Timer Model 1531 ee 5 16 Te
39. o Thermosystems There is an area on the last page of this manual for recording information that is useful when calling for technical support NOTE Necessary information to complete the warranty card can be found on the name plate on top of the heater burner head The completion of the warranty card will ensure full warranty coverage Please mail completed warranty card within 30 days of purchase to register your heater 16 Install the enclosure cover if equipped Installation is now complete WEBASTO SCHOLASTIC SERIES 6 HEATER MAINTENANCE 6 Heater Maintenance 6 1 Annual Maintenance CAUTION Annual maintenance requires basic product knowledge and maintenance procedures and should only be performed by Webasto trained and certified skilled personnel Ask your Webasto representative about training clinics The Webasto heater requires a minimum of maintenance to operate To keep your Webasto heater in good working order the following maintenance procedures should be performed annually before each heating season NOTE For major repairs and service parts return to your authorized Webasto Thermosystems Specialist Enclosure Area clean the heater and enclosure area of any accumulated debris or dust with compressed air inspect all components for wear and damage Electrical System check all wiring harnesses for damage and corrosion repair or replace if required check the condition of the batteries and the conne
40. r and eliminate the following causes for problems fuel supply plugged fuel filter or pinched fuel line corrosion of battery terminals corrosion of electrical wiring connections and fuses loose contacts or wrong crimping on connectors shut down initiated by temperature limiter automatic reset shut down initiated by overheat fuse replace fuse shut down initiated by inertia switch manual reset NOTE After the correction of a problem or defect a functional test of the heater as installed in the vehicle must be performed 7 2 Quick Check Troubleshooting Matrix PROBLEM Switch On No Function e Control Light OFF after 30 Seconds Blower Motor in Unit Does Not Run e Blower Motor in Unit No Prime Cycle e Blower Motor in Unit No After Run Coolant Circulation Pump Does Not Run Ignition Spark Absent Combustion Does Not Take Place Combustion Stops after 30 Seconds e g Combustion Cannot Be Stopped During Combustion Light Colour Smoke During Combustion Dark Colour Smoke Heating Unit Overheating Table 7 1 Quick Check Troubleshooting Matrix J i 7 1 7 Basic TROUBLESHOOTING WEBASTO SCHOLASTIC SERIES 7 3 Heater Test Unit Webasto P N 440280 The tester unit has been designed to quickly check the proper operation of the various heater components By using the tester in place of the heater control unit you are able to manually control the heater to tes
41. st Umit FIN 4402BD add ng ieee we EOE OES BNG HRS KING ote eee KG 7 2 List of Tables Digital Timer Instructions 20s 215 o52 0adO233haeh lee NAG bee Setedeksceere PLA 3 4 Scholastic Series Heater Data cc ee 4 1 Coolant Circulation Pump Data paa a maa waa aa maa Rm ded ets ens eweseediesae 4 3 Quick Check Troubleshooting Matrix c eee 7 1 Test Procedures and Results 000 eee 7 3 WEBASTO SCHOLASTIC SERIES 1 Introduction 1 1 Scope and Purpose This manual is intended to support authorized Webasto trained distributors dealers and personnel in the installation of the Scholastic Series coolant heater Webasto Thermosystems Inc does not recommend the installation and servicing of Webasto products by untrained unauthorized personnel or end users Installations and servicing of Webasto products by untrained unauthorized personnel and end users will release Webasto Thermosystems Inc and Webasto authorized distributors dealers and personnel from responsibility for damage to Webasto product or collateral property and personal injury Any use operation installation modification or application of the product not described in Webasto manuals or subjecting the product to extreme or unusual conditions beyond the limits of specified performance characteristics is misuse of the product Failure to comply with all installation instructions is a misuse of Webasto product The same applies for repa
42. t Model Engine Front WEBASTO SCHOLASTIC SERIES 5 INSTALLATION REARAXLE FRONT BOW f DRIVER S HEATER Pa TEES T N Poy Ni po if aae l t WEBASTO OPTIONAL OPTIONAL SCHOLASTIC HEATER ENGINE HEATER HEATER ihi i U U Paan FRONT HEATER 7 lt i yo NN i B Fig 5 6 Series Plumbing Circuit Transit Model Engine Rear 5 6 3 Instructions for Integrating into the Coolant System STOP CAREFULLY READ AND UNDERSTAND THE FOLLOWING INSTRUCTIONS BEFORE PROCEEDING WITH INSTALLATION 1 Remove the radiator cap and release system pressure 2 Close the shut off valves for heating system if so equipped or pinch off the supply and return line with hose clamping pliers 3 Plumb into the system as shown in figure 5 4 or 5 5 Two long brass 90 elbows with mounting flanges have been provided for making connections into existing coolant lines To install remove heater hose access cover s running down left side of floor inside bus at a location over top of heater installation find and identify heating circuit supply hose This is the hose you will use to plumb the Webasto heater into the system locate and mark suitable location on floor above heater where brass elbows will be installed NOTE When properly installed the elbows should protrude down into the heater enclosur
43. t be routed in a manner that prevents exhaust fumes from entering the passenger compartment 1 Insert the supplied flexible exhaust pipe to the heater and fasten with the exhaust clamp Fasten the outlet end to the chassis with the P clamp provided 2 The exhaust system must discharge on the street driver side of vehicle The discharge opening of the exhaust pipe must not point in the direction of travel and so located that any clogging caused by snow or mud is not to be expected The exhaust pipe I D 38 mm 1 1 2 can have a length up to 5 m 16 and may have several bends totaling no more than 270 overall Rigid exhaust pipe may be used bends must be formed smallest bending radius 85 mm 3 3 8 Do not weld pipe to make 90 corners Any condensation water in the exhaust pipe must be discharged If necessary drill a drain hole at the lowest point NOTE Route the exhaust components in a way that prevents them from touching vehicle parts that may be damaged by heat brake lines electrical wiring hoses etc Do not direct exhaust outlet towards heat sensitive vehicle components WEBASTO SCHOLASTIC SERIES 5 INSTALLATION 5 5 Combustion Air Supply AWARNING Due to the risk of carbon monoxide poisoning and asphyxiation never draw combustion air from inside the vehicles passenger compartment 1 Never draw combustion air from inside the vehicle or from areas where fumes or gases can accumulate 2 The
44. t components and actually operate the unit in heating mode The actual testing is completed in two steps first you perform an individual component test and then a manual start and run test both designed to pinpoint actual problems in the heater system 4 5 7 LED input power to heater Q LED control thermostat G LED flame detector On Off switch water pump On Off switch motor Push button ignition spark coil Push button fuel solenoid valve Fig 7 1 Test Unit P N 440280 WEBASTO SCHOLASTIC SERIES 7 Basic TROUBLESHOOTING 7 4 Test Procedures AWARNING Do not attempt to test fire or run heater with burner head open Ensure burner head is properly closed and secured in place NOTE Make sure the Water Pump and Motor Switches are in the off position before connecting to the heater 1 Setup Remove connector blocks from heater control unit inspect for loose wires corrosion and proper wire connections Plug control unit connector blocks into tester Set heater switch timer to ON and turn vehicle heater valve to FULL mode if equipped Proceed to component test procedures 2 Component Test Procedures and Results Test Step Result If not Tester connected BATTERY LED unit lights up test input voltage at control terminals B4 and B2 check battery connections check battery voltage CONTROL THER
45. ter and all of the heat exchangers While the engine is running check hose connections for leaks coolant level in the expansion tank and add coolant as needed use bleeder valve screw on top of Webasto heat exchanger to purge out any trapped air see page 2 1 figure 2 1 item 26 8 Shut off the engine 9 Plug in control thermostat the blower motor starts and the fuel pump primes the fuel lines After 10 to 25 sec the fuel solenoid opens and the electronic ignition coil ignites the air fuel mixture NOTE Installations with long fuel lines may require a second start attempt to prime the fuel system Cycle switch or timer off and on to reset control unit Coolant temperature must be below 68 C 155 F at heater before heater will begin heating operation 10 Allow heater to run until coolant is hot and heater cycles off During this period monitor system for any coolant or fuel leaks NOTE The engine temperature gauge may read a lower temperature depending on the location of the temperature sensor on the engine 11 Temperature differential between water inlet and outlet should not exceed 10 C 18 F during heating operation 12 Switch Off Webasto heater 13 Re tighten hose clamps to 5 Nm 45 Ib in and inspect installation for leaks 14 Install any panels and access covers removed during installation 5 17 5 INSTALLATION WEBASTO SCHOLASTIC SERIES 15 Complete the warranty card and send to Webast
46. that any dripping or evaporating fuel can neither accumulate nor be ignited by hot components or electrical equipment e In buses fuel lines are not to be located in the passenger area or in the driver s compartment Fuel supply must not be by means of gravity or pressurization of the fuel tank e The fuel tank must either be equipped with a vent cap or be ventilated in another way ventilation line e The operational state of the heater i e an indication On or Off must be clearly visible to the operator WEBASTO SCHOLASTIC SERIES 2 General Description 2 1 Scholastic Heater Description 1 5 23 6 7 24 8 10 11 2 GENERAL DESCRIPTION 12 14 21 Fig 2 1 Webasto Scholastic Series Heater Electronic control unit Motor Electronic ignition coil Coupler Combustion air fan Solenoid valve Electrode holder O OND AOKRON Outlet water pipe 25 mm 1 in OD 17 Inlet water pipe 25 mm 1 in OD 18 20 19 16 17 Ignition electrodes Fuel nozzle Overheat fuse Control thermostat Overheat limiter Heat exchanger Exhaust pipe Combustion air swirler Combustion tube 18 15 Flame detection photocell Fuel pump single line no return Fuel connection pipe JIC 4 Combustion air intake Reduction gearing Nozzle preheat cartridge Preheat thermostat Bleed screw The Webasto Scholastic Series Heater has been designed for use on diesel powered school buses Equipped
47. witch resets 7 Basic TROUBLESHOOTING WEBASTO SCHOLASTIC SERIES 3 Manual test running of heater Turn the WATER PUMP switch ON Turn the MOTOR switch ON Push and hold the FUEL SOLENOID VALVE button ON starts fuel flow to combustion chamber Hya pi hold the IGNITION SPARK COIL button ON starts electrodes sparking until combustion has taken place NOTE Hold IGNITION SPARK COIL button ON until FLAME DETECTOR LED Lights or combustion is heard then release in any case do not hold button on for more than 15 seconds or damage to the coil may result Test Results LED lights and combustion achieved Operation normal Combustion achieved but no LED G light check flame detector Combustion not achieved and no LED light check fuel nozzle check fuel pressure check for blocked fuel lines dirt or ice check ignition electrodes for damage and set gap Heater should now be in heating mode and will continue to run until you release the fuel solenoid valve button which stops fuel flow and extinguishes the flame immediately NOTE If flame does not stop when the FUEL SOLENOID VALVE button is released turn MOTOR switch OFF to stop heater Check and repair fuel solenoid valve accordingly Allow the heater to continue running for approximately 30 seconds cool down after which turn the WATER PUMP switch and the MOTOR switch OFF Once the
48. with 1 inch coolant line connections heavy duty coolant pump single fuel line and additional safety features makes this an ideal choice for school bus applications Webasto Scholastic Series Heaters are designed to 1 Preheat Engine block of liquid cooled engines to ensure reliable starting in cold weather and to reduce cold start wear and emissions white smoke 2 Boost heating levels with the engine running The heater will boost the heating system in cold weather when an engine is running at light loads even at high speeds or idling The heat rejection of modern diesel engines to the coolant especially in school buses is often not adequate to heat the vehicle s interior 3 Increase Safety by providing higher levels of heat for quick defrosting of windshield and side glass for greatly improved visibility 2 1 WEBASTO SCHOLASTIC SERIES 3 FUNCTIONAL DESCRIPTION 3 Functional Description 3 1 Operating your Webasto Scholastic Heater AWARNING Due to the risk of carbon monoxide poisoning and asphyxiation the heater must never be operated in closed spaces such as garages and workshops without adequate exhaust extraction AWARNING Due to the risk of fire or explosion the heater must be switched off while refueling and at fueling stations AWARNING Due to the risk of explosion the heater must never be operated in areas where explosive materials fumes or dusts may be present Before switching the Webasto heater on s

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