Webasto DBW 46 Repair Manual Page 47
- Page / 72
- Table of contents
- TROUBLESHOOTING
- BOOKMARKS
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DBW 2010/2020/300 COOLANT HEATERS SERVICING
8.7.2 TEMPERATURE LIMITER, REPLACEMENT
NOTE: The replacement procedure for the
temperature limiter is identical with the heater
installed or removed.
Perform replacement in accordance with 9.2.3.
8.7.3 TEMPERATURE THERMOSTAT, REPLACEMENT
NOTE: The replacement procedure for the
temperature control thermostat is identical with
the heater installed or removed.
Perform replacement in accordance with 9.2.2.
8.7.4 OVERHEAT FUSE, REPLACEMENT
NOTE: The replacement procedure for the
overheat fuse is identical with the heater
installed or removed.
Perform replacement in accordance with 9.2.1.
8.7.5 BURNER HEAD, REPLACEMENT
NOTE: The replacement procedure for the
burner head is identical with the heater installed
or removed.
Perform replacement in accordance with 9.2.5.
WARNING: The ignition system operates
on high voltage. Prior to replacement of
burner, disconnect electrical connectors of
cable harness in vehicle to avoid lethal
accidents.
8.7.6 IGNITION COIL, REPLACEMENT
NOTE: The replacement procedure for the
ignition coil is identical with the heater installed
or removed.
Perform replacement in accordance with
9.2.11.
WARNING: The ignition system operates
on high voltage. Prior to replacement of
the ignition coil and related components,
disconnect electrical connectors of cable
harness in vehicle to avoid lethal accidents.
8.7.7 FLAME DETECTOR (PHOTO EYE), REPLACEMENT
NOTE: The replacement procedure for the
flame detector is identical with the heater
installed or removed.
Perform replacement in accordance with 9.2.9.
WARNING: The igniter box operates on
high voltage. Prior to replacement of flame
detector, disconnect electrical connectors of
cable harness in vehicle to avoid lethal
accidents.
8.7.8 COMBUSTION CHAMBER, REPLACEMENT
NOTE: The replacement procedure for the
combustion chamber is identical with the heater
installed or removed.
Perform replacement in accordance with
9.2.17.
WARNING: The heater operates on high
voltage. Prior to replacement of
combustion chamber, disconnect electrical
connectors of cable harness in vehicle to
avoid lethal accidents.
8.8 FIRST OPERATION
After heater installation the coolant circuit and the fuel
supply system must be thoroughly bled observing the
vehicle manufacturer’s instructions. During test runs all
coolant and fuel line connections have to be checked for
security and no leakage. Should the heater in operation
enter a fault condition, perform troubleshooting (refer to
Section 5).
8.8.1 WATER CIRCUIT, BLEEDING
NOTE: Bleeding must always be performed in
accordance with manufacturer’s instructions.
For bleeding the circulation pump must not be
switched on.
Set vehicles own heating system to "warm" and
replenish coolant which must consist of at least 20%
anti-freeze (glycol base for protection against corrosion).
When using pure water there will be no protection
against corrosion and due to the lower boiling point of
the water when overheating loss of cooling water may
result requiring continuous replenishment. Additives in
the coolant must not affect metals, plastics or rubber and
leave no deposits.
Then operate engine at increased idle until radiator
thermostat opens. Shut down engine, check coolant level
and replenish as required.
Switch on heater and vehicle heating fan with engine
shut down. After a certain cool-down period the heater
must automatically switch on and control to off. In case
of no restart attempt the temperature limiter on the
- 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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