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Webasto DBW2010 furnace

Yahoo Message Number: 104634
Looking for information, help, suggestions with/for our Webasto furnace. It is original to our 2000 Country Coach Affinity. It has seemed to work when it wants, usually more often than not but now we are in some colder weather and it is not working. This is the longest stretch that we have had that it would not cooperate.

What has been worked on:

March 2014: Country Coach, Junction City, OR Fuel lines replaced
Burn chamber replaced
Fuel Filter replaced
Photo eye cleaned

January 2015: Eagle's Pride, Titusville, FL Igniter coil replaced

Photo flame sensor replaced

October 2015: Diamond RV, Hatfield, MA Replaced burner nozzle

Cleaned combustion chamber and igniters, adjusted igniters January 2016: Eagle's Pride, Titusville, FL Tested control unit
cleaned connections

After each service the Webasto worked for several days, we could turn it on at night or in the morning and it would turn on, ignite, run through its cycles and keep the coolant at temperature. When it didn't work it would turn on and not ignite or it would turn on, ignite, run through a cycle or two and then stop igniting and cold air would eventually be blowing.

At this moment, it will turn on and that is it, not igniting.
We are in Columbus, MS heading towards I-10 to travel west through LA, TX, NM, AZ and then CA. If ANYONE knows of a place or a person we can contact who knows these systems, we would be VERY grateful!

Sincerely, Bob and Susan Chilson

Re: Webasto DBW2010 furnace

Reply #1 –
Yahoo Message Number: 104636
check with Roger Berke at RV Hydronic Heater Repair.

http://www.hydronicheaterrepair.com

He used to be in California but looks like his business address is now in South Dakota.

If you can meet up with him somewhere that would even be better.

He's the "guru" in my opinion.

Lonny & Diane Livingston
'04 Allure #31065

Re: Webasto DBW2010 furnace

Reply #2 –
Yahoo Message Number: 104641
I would do fuel filters again might be bad diesel or algae plugging your filter. I'very seen it posted on here a few times as culprit.

Alex Ritchey 2000 Affinity 42' tag B&B



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Re: Webasto DBW2010 furnace

Reply #3 –
Yahoo Message Number: 104642
Has anyone checked fuel pressure and flow rate?

The fuel pump may be failing or intermittent.

Mikee

Re: Webasto DBW2010 furnace

Reply #4 –
Yahoo Message Number: 104643
Robert, It seems you have replaced everything but I did not see in your post that anyone checked the fuel pump.I'm not sure what unit you have but it sounds like either Hydro-hot or Aqua-hot.I fought a similar problem for three years before I found that the fuel lines were looped under the water tanks (fresh, black and grey).When the tanks were empty everything worked well but as fluid weight built up the lines were crunched and did not deliver enough fuel. Your post said fuel lines were replaced.I would be curious as to how. From where to where?In any event it might help to have the fuel pump pressure checked when the unit was in the fail mode.

Lyle Wetherholt
04 Intrigue 11740

Re: Webasto DBW2010 furnace

Reply #5 –
Yahoo Message Number: 104644
RV Medic in Casa Grande AZ is who we use for AquaHot and other mobile service and repair.
DavidW

06 Intrigue11993

Re: Webasto DBW2010 furnace

Reply #6 –
Yahoo Message Number: 104646
I have had the same problem and found the fuel leak by first blowing into the fuel supply line and listening for bubbles in the main tank to clear any debris from the pickup end. There were bubbles so I gently pressurized the main tank and found a leak at the hose fitting that supplies the Webasto. Now all I have to do is run another fuel line from the main tank to the burner....... Not an easy task I am told..... Any suggestions??

Steve 2000 Magna

Re: Webasto DBW2010 furnace

Reply #7 –
Yahoo Message Number: 104658
any time you get the water in fuel warning light you replace both filters, according to Cummins Northwest, Eric and Chris Snyder. TWI 2004 Intrigue 11731 A friend of mine with an Allegro Bus with only one filter engine shut down outside of Phoenix. He got towed in and the injection pump was rebuilt. But the engine shut down again on a test drive. Seems there is an in line filter screen, that had become polluted. Do you want to pay to have your injection pump rebuilt, because of the lack of filtration. This time it was unnecessary. The next time it might be.

Re: Webasto DBW2010 furnace

Reply #8 –
Yahoo Message Number: 104694
I too have been having trouble with my Webasto furnace in our 2000 Magna. Our furnace has been working very well for the past 10 years. Last summer, I noticed a fuel leak around the Webasto. I traced the leak to the fuel nozzle. The problem was the solenoid was not sealing shut when the furnace was off. A repair kit is available and was easy to install. The fuel leak was stopped (from the nozzle). I then discovered another (much much slower) leak that was coming from around the fuel pump pressure regulation screw. For this leak too, Webasto has a simple repair kit, and it was easy to insert the fresh O-ring that indeed stopped all further leaking of fuel around the Webasto. Following these fuel related repairs, I replaced the fuel filters (our coach has two filters in series on the supply side fuel line). I also purchased and used a fuel pressure guage to ensure the fuel pump on the Webasto was properly calibrated following the pump pressure regulator repair kit installation. Subsequent to installing all these fuel related repairs we went camping (in September). The Webasto performed flawlessly for about 3 days, and then on the fourth morning the Webasto started ok, but during one of it's re-light cycles it emitted a burst of white smoke and the Webasto light on the control switch went out. I tried to restart the Webasto, but it would not ignite. Following this problem in September, I could not get the Webasto to re-ignite. I spent much of October, November, and December going through a series of tests and parts substitution. I found a wiring diagram and was able to do electrical checks throughout the Webasto system. All of the thermostats and thermo-fuses checked ok. So too, the flame sensor checked ok. Even though the parts all checked out ok, I nevertheless purchased new ignition coil, new ignition wires, new electrodes, new flame sensor, new thermostats, and new nozzle and new fuel filters. The Webasto would not start. Fuel is flowing, fuel pressure is 145 psi, and all voltages come on the control box as specified in the Webasto manual. I could take the burner head off of the burn chamber and turn the Webasto on. With the ignition circuit disabled (to ensure no flame thrower experience for myself while holding the burner in my hands), the fuel spray is uniform, well dispersed and plentiful. I then disconnected the fuel circuit and connected the ignition circuit. This time when the Webasto was turned on, the ignition electrodes provided a visible spark. (Note: both spark and fuel spraying take place after an appropriate delay in accordance with the control box specifications.) So, assured that everything appeared functioning, I reassembled the unit. I could not get it to work. However, if I momentarily applied a jumper wire between the control box terminals that take 12v power in and power to the ignition coil, I could start the Webasto. It would run for awhile, even turning on and off as appropriate for a normal furnace that was properly moderating the circulating water temp in the coach. However, the next morning, it would not start. In January, we were camping in Florida and visiting Butch at Fountain RV for some unrelated work issues. I asked Butch for some advice and he suggested replacing the nozzle (even though we had a new/fresh nozzle installed over the summer). He said nozzles were notoriously unreliable and sometimes brand new nozzles were defective. I replaced the nozzle, and voila, we had a functioning furnace ... (for 3 days)....then back to unreliable or non-existant furnace starts in the mornings. Lastly, I decided that perhaps I had all the right voltages but was somehow getting weak current, so I disconnected the ground strap wires and discovered the screw to the frame was corroded. I sanded the chassis connection and cleaned up the ground wires. SUCCESS!!!... for almost a week, we had a functioning furnace. Except the problem reappeared yesterday. As before, I can not get the Webasto to ignite. I'm about to go outside and see if I can fiddle with the electrodes, recheck the nozzle area is clean, and reassemble the burner.... Anyone have any idea about what I'm missing?

Re: Webasto DBW2010 furnace

Reply #9 –
Yahoo Message Number: 104697
Hi, we have a 2000 Magna with a hurrican unit, just wounder what coach number you have, and when or why the differnt brands of heaters were used. Good luck on your project. Charles 5886

Re: Webasto DBW2010 furnace

Reply #10 –
Yahoo Message Number: 104700
I second Roger Berke !! You can post on his web forum but he'll need the exact model of your heater ( usually on a sticker on the unit) also he frequently asks for the lights that are on when you have an issue. He will usually give advice or recommend someone in your area that is qualified to work on them. He also has parts for various models.

Re: Webasto DBW2010 furnace

Reply #11 –
Yahoo Message Number: 104711
Who is Roger Burke? I am also having an issue with my Wabasto and hope he is a go to guy. How do I get in touch with him? Where is he located?

Steve Wilcomb, 2000 36' Magna

Re: Webasto DBW2010 furnace

Reply #13 –
Yahoo Message Number: 104717
Hi, Steve i have a 36'magna also 5886 2000,i rework the tv to the front area, if you want some info and pic give me a call. Charles 828=2736099

Re: Webasto DBW2010 furnace

Reply #14 –
Yahoo Message Number: 104726
I'm not sure why Country Coach experimented with different heaters. I believe all of the heaters/furnace systems used a Webasto as the burner. The Hurricane and Aquahot both proide more than merely the burner, hence their Webasto units are internal to the box. But as far as I know, every heater-furnace arrangements in our coaches use the Webasto as the burner.

In my case, the system is rather simple: Webasto heats water that circulates in the engine and throughout the coach. (If engine has been running, the Webasto recognizes the water is already hot and does not attempt to operate.) Water that is heated (either by Webasto or engine) then circulates throughout the coach where a few heat exchangers offer hot air at strategic locations (in kitchen, in bathroom, in dash, in bedroom, in bays). The circulating water also passes through an Atwood water heater. The Atwood water heater thus uses engine heat or Webasto heat to generate hot water. The Atwood uses electricity or propane if circulating hot water is not warm enough. It is a pretty basic, simple, efficient system that works well (if the Webasto is operational).

Our coach is 5778, 36' 2000 Magna.

Thanks
-skip-

Re: Webasto DBW2010 furnace

Reply #15 –
Yahoo Message Number: 104742
From what I have seen in pictures Webastos, including, the burn chambered look quite different than my Hurricane to me.
Rich 2002 Magna

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