Webasto DBW 46 Repair Manual Page 49
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- TROUBLESHOOTING
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www.webasto.us 49 Webasto Thermo & Comfort N.A., Inc.
DBW 2010/2020/300 COOLANT HEATERS REPAIR
9. REPAIR
9.1 GENERAL INFORMATION
This section describes the repairs that may be performed
on the heaters DBW 2010, 2020 and 300 when
removed. Any further disassembly will void the warranty.
For re-assembly only components of the proper service
part kits are to be used.
WARNING: The ignition system operates
on high voltage. Prior to replacement
disconnect connectors of cable harness in
vehicle to avoid lethal accidents.
The following components may also be replaced with the
heater installed unless restricted space prevents access:
– replacement of temperature limiter
– replacement of temperature control thermostat
– replacement of overheat fuse
– replacement of burner
– replacement of fuel atomizing nozzle
– replacement of nozzle preheat cartridge
– replacement of nozzle preheat thermostat
– replacement of ignition coil
– replacement of flame detector
–replacement of combustion chamber
– replacement of control unit
9.1.1 WORK ON COMPONENTS AFTER DISASSEMBLY
CAUTION: All gaskets located between
disassembled components must always be
discarded and replaced with new gaskets.
9.1.1.1 VISUAL INSPECTION, GENERAL
• Examine all components for damages (cracks,
deformation, wear, etc.) and replace as necessary.
• Examine connectors and wiring for corrosion, loose
contacts, wrong crimping, etc. and repair as necessary.
• Check terminals for corrosion and contacts for
security. Repair as required.
9.1.1.2 COMBUSTION CHAMBER, VISUAL INSPECTION
– Check swirl ring for security.
– Check swirl ring for melting and deformation (DBW
2010).
– Inspect combustion chamber for oxidizing and coke
deposits and remove as required.
– Check welding seem for cracks.
NOTE: Longitudinal cracks up to 38 mm (1.5
in.) are allowed.
9.1.1.3 HEAT EXCHANGER, VISUAL INSPECTION
– Inspect exhaust ducting in heat exchanger for
sooting, deposits, damage and corrosion.
NOTE: Deposits are to be removed with water
jet and brush.
– Inspect heat exchanger for exterior damage,
deformation, etc.
NOTE: Heavy deformation may cause
restricted flow of coolant.
CAUTION: When replacing the combustion
chamber on heaters installed vertically,
remove deposits in heat exchanger using a
suitable tool.
- 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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