WEBASTO schemat.pdf
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Water Type Heating Devices
The Workshop Handbook
DBW 2010
DBW 2012
DBW 2020
DBW 2022
DBW 300
DBW 350
08/2004
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350
Contents
Contents
1 The Introduction ........................................................................................................................................................101
1.1
The Contents and Purpose................................................................................................................................101
1.2
The field of validity of the handbook ..................................................................................................................101
1.3
The Meaning of the Warning Notes...................................................................................................................101
1.4
The additional documentation that will be used ................................................................................................101
1.5
The Security Instructions and Security Provisions ............................................................................................101
1.5.1.
The General Security Provisions ..........................................................................................................101
1.6
The Legal Provisions for the Assembly .............................................................................................................102
1.7
The Recommendations of Improvement and Change.......................................................................................103
2 The General Definition ..............................................................................................................................................201
2.1
Brülör fanı The burner fan .................................................................................................................................206
2.2
The engine.........................................................................................................................................................206
2.3
The fuel pump....................................................................................................................................................206
2.3.1
The pre-heating of the nozzle block .....................................................................................................207
2.4
The heat exchanger...........................................................................................................................................207
2.5
The combustion chamber ..................................................................................................................................208
2.6
The control device .............................................................................................................................................208
2.7
The flame regulator ...........................................................................................................................................209
2.8
The induction bobbin and ignition electrodes ....................................................................................................209
2.9
The heat sensor.................................................................................................................................................209
2.10
The temperature constrainer / thermal fuse ......................................................................................................210
2.11
The regulation thermostat..................................................................................................................................210
2.12
The fan thermostat.............................................................................................................................................211
2.13
The circulation pump .........................................................................................................................................211
3 The Definition of the Function..................................................................................................................................301
3.1
General ..............................................................................................................................................................301
3.2
Operation ...........................................................................................................................................................301
3.2.1
Opening ................................................................................................................................................301
3.2.1
The heating ...........................................................................................................................................301
3.2.3
Shutting off............................................................................................................................................301
3.2.4
Shutting off as a result of failure ...........................................................................................................301
3.2.5
The Economy Circuit ............................................................................................................................302
4. The Technical Data ...................................................................................................................................................401
4.1
The Electrical Elements .....................................................................................................................................401
4.2
The Fuel.............................................................................................................................................................401
5 Error Search and Error Elimination .........................................................................................................................501
5.1
General ..............................................................................................................................................................501
5.2
The General Error Indications ...........................................................................................................................501
5.3
The Error Search – Fast Error Identification......................................................................................................503
5.4
The Error Indications .........................................................................................................................................504
5.4.1
The heating device does not start working when opened ....................................................................504
The heating device gives defect sign approximately 30 seconds after the heating device is started (at
the control device 1563/6430 seconds (20 seconds at control device 1563/64). .............................................505
I
5.4.2
Contents
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350
5.4.3
The heating device starts to work only after a few trials.......................................................................506
5.4.4
The heating device stops by itself while working..................................................................................506
5.4.5
The heating device produces soot (dense black smoke comes out) ...................................................507
5.4.6
The heating device produces light colored dense smoke ....................................................................508
5.4.7
The heating device cannot be shut off..................................................................................................508
6 The Function Test......................................................................................................................................................601
6.1
General ..............................................................................................................................................................601
6.2
The Settings.......................................................................................................................................................601
6.2.1
Setting the CO
2
proportion....................................................................................................................601
6.3
Testing the individual elements .........................................................................................................................602
The resistance check of the heat sensor (only the heating devices equipped with the control device
1563/64).............................................................................................................................................................602
6.3.2
The resistance test of the flame regulator ............................................................................................603
6.3.3
Checking and setting the ignition electrodes ........................................................................................604
6.3.4
Testing the induction bobbin..............................................................................................................................604
6.3.5
Testing the fuel pump ........................................................................................................................................605
6.3.6
Testing the burner engine..................................................................................................................................605
6.3.7
Testing the magnetic valve ................................................................................................................................605
6.3.8
Testing the front heating element of the nozzle block .......................................................................................605
7 The Circuit Diagrams.................................................................................................................................................701
7.1
General ..............................................................................................................................................................701
8 The Service Tasks .....................................................................................................................................................801
8.1
General ..............................................................................................................................................................801
8.2
The tasks that will be carried out on the heating device ...................................................................................801
8.3
The tasks that are carried out on the vehicle ....................................................................................................801
8.4
The test operation of the heating device ...........................................................................................................801
8.5
The Maintenance Tasks ....................................................................................................................................801
8.5.1
Opening and closing of the burner head to the side.............................................................................802
8.6
The Visual Examination or the Assembly Instructions ......................................................................................803
8.6.1
The connection to the cooling system of the vehicle ............................................................................803
8.6.2
The connection to the fuel system of the vehicle .................................................................................803
8.6.3
The supply of combustion air................................................................................................................805
8.6.4
The exhaust line ...................................................................................................................................805
8.7
Dismantling and mounting .................................................................................................................................806
8.7.1
Heating device, disassembling and installation ....................................................................................806
8.7.2
The replacement of the temperature constrainer .................................................................................806
8.7.3
The replacement of the heat sensor.....................................................................................................806
8.7.4
The replacement of the thermal fuse....................................................................................................807
8.7.6
The replacement of the fan thermostat.................................................................................................807
8.7.7
The replacement of the thermal fuse element ......................................................................................807
8.7.8
The replacement of the burner head ....................................................................................................807
8.7.9
The replacement of the induction bobbin .............................................................................................807
8.7.10
The replacement of the flame regulator................................................................................................807
8.7.11
The replacement of the combustion chamber ......................................................................................807
8.8
Commissioning ..................................................................................................................................................808
8.8.1
Evacuating the air from the water circuit ..............................................................................................808
8.8.2
The evacuation of air from the fuel supply system ...............................................................................808
9 The Repair ..................................................................................................................................................................901
9.1
General ..............................................................................................................................................................901
9.1.1
The measures pertaining to the elements that are dismantled to parts ...............................................902
II
6.3.1
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350
Contents
9.1.2
Making the changes ..........................................................................................................................................902
9.2
Dismantling in parts and assembly....................................................................................................................911
9.2.1
The replacement of the heat constrainer..............................................................................................911
9.2.2
The replacement of the heat sensor.....................................................................................................911
9.2.3
The replacement of the thermal fuse....................................................................................................911
9.2.4
The replacement of the regulation thermostat......................................................................................911
9.2.5
The replacement of the fan thermostat.................................................................................................913
9.2.6
The replacement of the fuse element ...................................................................................................913
9.2.7
The replacement of the control device .................................................................................................913
9.2.8
The replacement of the burner head ....................................................................................................913
9.2.9
The replacement of the engine .............................................................................................................915
9.2.10
The replacement of the high pressure nozzle ......................................................................................916
9.2.11
The replacement of the pre-heating of the nozzle block ......................................................................916
9.2.12
The replacement of the induction bobbin .............................................................................................916
9.2.13
The replacement of the flame regulator................................................................................................916
9.2.14
The replacement of the ignition electrodes...........................................................................................916
9.2.15
The replacement of the fuel pump........................................................................................................918
9.2.16
The replacement of the magnetic valve................................................................................................918
9.2.17
The replacement of the combustion chamber ......................................................................................918
9.2.18
The pre-heating thermostat of the nozzle block ...................................................................................918
9.2.19
The replacement of the heat exchanger...............................................................................................920
9.2.20
The replacement of the nozzle block....................................................................................................921
9.2.21
The replacement of the burner fan .......................................................................................................921
10 The Packaging / Storage / Shipment .....................................................................................................................101
10.1
General ..............................................................................................................................................................101
ANNEX A........................................................................................................................................................................101
The Periodical Maintenance of the Heating Device .......................................................................................................2
III
The Periodical Maintenance……………………………………………………………………………………………………..1
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