Webasto DBW 46 Repair Manual Page 33
- Page / 72
- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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www.webasto.us 33 Webasto Thermo & Comfort N.A., Inc.
DBW 2010/2020/300 COOLANT HEATERS FUNCTIONAL ADJUSTMENTS
6.2.4 IGNITION COIL CHECK
WARNING: In some cases, high tension
voltage of approx. 8,000 volts produced at
the ignition electrodes can be fatal.
CAUTION: Do not operate the ignition coil
without connection to the ignition
electrodes. Doing so will cause damage to
the ignition coil.
C
HECK
NOTE: Take care when connecting DC voltage
to the ignition coil leads. Connect positive to
the black lead and negative to the brown lead.
– Swing burner head open (see Sec. 8.5.1)
– Supply DC voltage to coil leads. Positive to black
lead and negative to brown lead.
– With ignition coil energized, an ignition spark will
jump the ignition electrodes.
A
LTERNATE METHOD USING TESTER (P/N 1302691A)
– Exchange control unit with tester and swing burner
head open (see Sec. 8.5.1).
– Press and hold the ignition button to activate the
ignition coil and observe spark condition.
CAUTION: Do not energize ignition coil for
a period longer than 15 seconds.
Figure 24: Ignition Coil Check
6.2.5 FUEL PUMP CHECK
A pressure gauge and the tester P/N 1302691A is
required for performing this test. A suitable gauge with
a range from 0 to 15 bar (0 to 220 PSI) can be procured
from your authorized Webasto dealer.
NOTE: The fuel pump and the fuel hoses must
be replaced every 5 years.
C
HECK
– Exchange control unit with tester and swing burner
head open (see Sec. 8.5.1).
– Remove nozzle.
– Screw pressure test gauge into nozzle holder.
– Switch on heater motor via tester.
– Press fuel solenoid button on tester.
– Read pressure gauge. If adjustment is required,
release button and turn pump pressure screw 1/8 of
a turn at a time in or out to increase or decrease
pressure (see Fig. 10 for location of pressure screw).
– Repeat testing and adjustment steps until pressure is
within specified range.
– Switch off heater switch on tester.
– Unscrew pressure test gauge.
CAUTION: Do not damage nozzle bore.
– Screw in nozzle and torque to 20 Nm. (15 lb-ft)
Figure 25: Fuel Pressure Check
+ Black Wire
– Brown Wire
0
40
80
120
160
200
220
+
-
Pressure Test Gauge
P/N 600190
Nozzle Holder
DBW 2010 w/ 0.40 gph nozzle 8 –0.5 bar (116 –7 psi)
DBW 2010 w/ 0.35 gph nozzle 10 ±0.5 bar (145 ±7 psi)
DBW 2020 & DBW 300 10 ±0.5 bar (145 ±7 psi)
Gauge Face
Fuel Pump
Pressure
Regulator
- Contents Page 3
- 6. Functional Adjustments 31 4
- 7. Circuit Diagrams 35 4
- 8. Servicing 43 4
- 9. Repair 49 5
- 10.Instruments and Tools 65 6
- 11.Product Information 67 6
- 1. INTRODUCTION 7
- ORRECTIONS AND IMPROVEMENTS 8
- 2. GENERAL DESCRIPTION 9
- DBW 2010 10
- DBW 2020 11
- DBW 300 11
- 2.1 PARTS OF THE HEATER 12
- Flame Detector 13
- Photo Disc 13
- Locking screw 13
- Combustion air 13
- Drive motor 14
- Fan wheel 14
- DBW 2020/300 14
- Strainer 15
- Pressure 15
- Regulation 15
- Plunger Valve 15
- Nozzle Holder 16
- Power consumption 17
- 130 Watts 17
- Red - 12 V 17
- Green - 24 V 17
- OOLANT CIRCULATING PUMP 18
- 3. FUNCTIONAL DESCRIPTION 19
- 4. TECHNICAL DATA 20
- ECHNICAL DATA OF THE HEATERS 21
- Scholastic 22
- 5. TROUBLESHOOTING 23
- * INERTIA SWITCH: 24
- NSTRUCTIONS FOR FAULT FINDING 26
- 5.3.6 HEATER SMOKES 29
- 5.3.7 HEATER SMOKES 30
- 6.1 GENERAL 31
- 6.2 ADJUSTMENTS 31
- If necessary 32
- Millimeters 32
- Setting Gauge 32
- P/N 310646 32
- 6.2.4 IGNITION COIL CHECK 33
- 6.2.5 FUEL PUMP CHECK 33
- UEL SOLENOID VALVE CHECK 34
- OZZLE BLOCK PRE-HEATER CHECK 34
- CONTROL UNIT 35
- ONNECTOR BLOCK A 42
- ONNECTOR BLOCK B 42
- ONNECTOR BLOCK C 42
- 8. SERVICING 43
- 3. Torque nuts (3) to: 44
- INSTALLATION 45
- 8.7 REMOVAL AND INSTALLATION 46
- 8.8 FIRST OPERATION 47
- UEL SUPPLY SYSTEM, BLEEDING 48
- 9. REPAIR 49
- 0.15 ± 0.05 mm 50
- (.006 ± .002 inch) 50
- Hexagon nut 50
- 1 Overheat Fuse 51
- 3 Temperature Limiter 51
- + Black Wire 55
- – Brown Wire 55
- 9.2.13.1 REMOVAL 57
- 9.2.13.2 INSTALLATION 57
- DBW 2020 / 300 60
- 9.3.1 REMOVAL 62
- 9.3.2 DISASSEMBLING 62
- 9.3.3 ASSEMBLING 62
- 9.3.4 INSTALLING 62
- 9.4.1 REMOVAL 64
- 9.4.2 DISASSEMBLING 64
- 9.4.3 ASSEMBLING 64
- 9.4.4 INSTALLING 64
- 10. INSTRUMENTS AND TOOLS 65
- LDS18 Special 66
- Bearing Grease 66
- Product Information 67
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