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The Scholastic Series
School Bus Heater
Operating Instructions
Installation Instructions
Service Parts Listing
For:
Webasto Thermosystems Inc.
Conventional Model
North America
3333 John Conley Drive
Transit Model (Engine Front)
Lapeer, MI 48446
Transit Model (Engine Rear)
Phone (810) 245-2400
Toll-free (800) HEATER-1
Fax (810) 664-7720
Technical Assistance Hotline
USA: (800) 555-4518
Canada: (800) 667-8900
Org. 2/2001 50000058A www.webasto.com
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WEBASTO SCHOLASTIC SERIES TABLE OF CONTENTS Table of Contents 1. Introduction 1.1 Scope and Purpose .................................................... 1-1 1.2 Meaning of Warnings, Cautions and Notes .................................. 1-1 1.3 Additional Documentation to be Used ...................................... 1-1 1.4 General Safety Regulations and Information ................................. 1-1 1.4.1 General Safety Notes ........................................... 1-1 2. General Descri
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TABLE OF CONTENTS WEBASTO SCHOLASTIC SERIES 5.7 Fuel System ......................................................... 5-7 5.7.1 General Description ............................................. 5-7 5.7.2 Fuel Supply ................................................... 5-7 5.7.3 Fuel Filter .................................................... 5-9 5.8 Wiring Connections ................................................... . 5-10 5.8.1 General Information ............................................
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WEBASTO SCHOLASTIC SERIES TABLE OF CONTENTS List of Figures 2-1 Webasto Scholastic Series Heater ......................................... 2-1 3-1 7-Day Digital Timer – Typical ............................................. 3-3 4-1 Scholastic Series Heater Dimensions (Millimeters) ............................. 4-2 4-2 Coolant Circulating Pump Assembly (P.N. 906017) Dimensions (Inches) ............ 4-3 4-3 Tray Mount Dimensions (Inches) .......................................... 4-4 5-1 Installati
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WEBASTO SCHOLASTIC SERIES 1INTRODUCTION 1.3 Additional Documentation to be 1. Introduction Used 1.1 Scope and Purpose This manual contains all of the information and procedures necessary for the installation of the This manual is intended to support authorized Webasto Scholastic Series heater. trained distributors, dealers and personnel in the installation of the Scholastic Series coolant heater. The use of additional documentation is normally not necessary. Vehicle specific installation guides
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1INTRODUCTION WEBASTO SCHOLASTIC SERIES In the vicinity of the coolant heater, a temperature of The coolant heater may only be operated with the 85 °C (185 °F) must not be exceeded under any specified fuel (Diesel 1, Diesel 2, Arctic grade, Kerosene circumstances (e.g. during body paint work). A violation and certain military spec. fuels). of this temperature limit may cause permanent damage to the electronics. For the routing of fuel lines, the following important regulations must be adhered to
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WEBASTO SCHOLASTIC SERIES 2GENERAL DESCRIPTION 2. General Description 2.1 Scholastic Heater Description Fig. 2-1: Webasto Scholastic Series Heater 1 Electronic control unit 10 Ignition electrodes 19 Flame detection photocell 2 Motor 11 Fuel nozzle 20 Fuel pump (single line, no return) 3 Electronic ignition coil 12 Overheat fuse 21 Fuel connection pipe (JIC #4) 4 Coupler 13 Control thermostat 22 Combustion air intake 5 Combustion air fan 14 Overheat limiter 23 Reduction gearing 6 Solenoid valve 1
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WEBASTO SCHOLASTIC SERIES 3FUNCTIONAL DESCRIPTION 3. Functional Description 3.1 Operating your Webasto Scholastic Heater WARNING Due to the risk of carbon monoxide poisoning and asphyxiation, the heater must never be operated in closed spaces such as garages and workshops without adequate exhaust extraction. WARNING Due to the risk of fire or explosion, the heater must be switched off while refueling and at fueling stations. WARNING Due to the risk of explosion, the heater must never be operated
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3FUNCTIONAL 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.
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WEBASTO SCHOLASTIC SERIES 3FUNCTIONAL 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 button, starting time program 1, 2 or 3 can be viewed and preset. Operating Time The perio
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3FUNCTIONAL 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 or button to set time of day. Wait 5 seconds. Time is now stored. Day of week flashes. Press or button to set day of week. Wait 5 seconds. Day of week is now stored. Viewing the time With ignition “ON”: Continuous display of current time and day of the week. With ignition “OF
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WEBASTO SCHOLASTIC SERIES 4TECHNICAL 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 l/hr (gal/hr) 1.5 (0.4) Rated Voltage (V) 12 Operating Voltage (V
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4TECHNICAL DATA WEBASTO SCHOLASTIC SERIES 4.1.1 Scholastic Series Heater Dimensions Fig. 4-1: Scholastic Series Heater Dimensions (Millimeters) 4-2
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WEBASTO SCHOLASTIC SERIES 4TECHNICAL DATA 4.2 Coolant Circulation Pump Data Flow Rate l/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 (lb.) 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 Fig. 4-2: Coolant Circulating Pump Assembly (P.N. 906017) Dimensions (Inches) 4-3
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4TECHNICAL DATA WEBASTO SCHOLASTIC SERIES 4.3 Tray Mount Dimensions Fig. 4-3: Tray Mount Dimensions (Inches) 4-4
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WEBASTO SCHOLASTIC SERIES 5INSTALLATION 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,
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5INSTALLATION 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. 2. The installation enclosure must provide adequate ventilation for combustion air requirements [20 cm² (4 in²)]. 3. Lay the supplied installation template in the enclosure. Center punch the exhaust, fuel, electrical and 4 mounting ho
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WEBASTO SCHOLASTIC SERIES 5INSTALLATION 5.5 Combustion Air Supply WARNING 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 installation housing must provide adequate ventilation for combustion air requirements [20 cm² (4 in²)]. 5.6 Plumbing into the Coolant System Fig. 5-3: Typical School Bus Heatin
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5INSTALLATION WEBASTO SCHOLASTIC SERIES 5.6.2 Engine and Passenger Compartment Heating WARNING Potential skin and eye burn risk. When working on the coolant system, 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 a
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WEBASTO SCHOLASTIC SERIES 5INSTALLATION 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 o
