Webasto DBW 46 Wartungshandbuch

List of ContentsBBW46/DBW46IList of Contents1. Introduction1.1 Scope and Purpose ...

BBW 46 / DBW 463 Functional Description3013. Functional Description3.1 Sequence of Operation3.1.1 Switch OnUpon switch on positive control voltage is

3 Functional DescriptionBBW 46 / DBW 46302NOTEThe heater may also remain in part load, full load or control idle operation for longer periods after ac

BBW 46 / DBW 463 Functional Description303 A no flame-up condition will cause an automatic restart (30 sec run-down with glowing / 30 sec pre-glowing

BBW 46 / DBW 464 Technical Data4014. Technical DataWhere no threshold values are specified technical data are understood to include standard tolerance

BBW 46 / DBW 465 Troubleshooting5015. Troubleshooting5.1 GeneralThis section describes troubleshooting procedures for the heaters BBW 46 and DBW 46.CA

BBW 46 / DBW 466 Functional Checkouts6016. Functional Checkouts6.1 GeneralThis section describes the tests and adjustments on the heater in installed

BBW 46 / DBW 467 Circuit Diagrams7017. Circuit Diagrams7.1 GeneralCircuit diagram (Fig. 702) shows possible heater circuits for the heater BBW 46 and

7 Circuit DiagramsBBW 46 / DBW 46702Fig. 702 Automatic Switching Circuit for BBW 46/DBW 46, 12 and 24 Volt Timer and Telestart T6B1B2EX1F3R1M1M2bl/g

BBW 46 / DBW 468 Servicing8018. Servicing8.1 GeneralThis section describes the servicing procedures allowed on the heater when installed.8.2 Work on t

8 ServicingBBW 46 / DBW 468028.6 Visual Inspections andInstallation Regulations8.6.1 Connection to the Vehicle Cooling SystemThe installation location

BBW 46 / DBW 46List of ContentsII8. Servicing8.1 General...

BBW 46 / DBW 468 Servicing803Wiring harnessVehicle fuel lineHeater fuel lineExhaust lineWater circuit1 Radiator2 Coolant thermostat3 Water pump4 Vehic

8 ServicingBBW 46 / DBW 468041 Radiator2 Coolant thermostat3 Water pump4 Vehicle engine with standard outfit5 Water heater5A Check valve6 Battery7 Fus

BBW 46 / DBW 468 Servicing8058.6.2 Connection to Vehicle Fuel SystemIn vehicles with carburettor or fuel injection including a return line the heater

8 ServicingBBW 46 / DBW 46806Air or gas bubbles may build up in the vehicle fuel line in case the carburettor or the fuel pump is leaking or if ambien

BBW 46 / DBW 468 Servicing807Fig. 807 Pipe/Hose Connection 8.6.3 Dosing PumpThe dosing pump is a combined delivery, dosing and shut-off system and i

8 ServicingBBW 46 / DBW 46808Fig. 809 Installation Arrangement of Exhaust Pipe OutletRigid pipes made of unalloyed or alloyed steel with a minimum w

8 ServicingBBW 46 / DBW 468098.7.3 Replacement of Temperature Limiter or Temperature Fuse NOTEThe replacement procedure for the temperature limiter is

8 ServicingBBW 46 / DBW 468108.8 First OperationAfter heater installation the coolant circuit and the fuel supply system must be thoroughly bled obser

BBW 46 / DBW 469 Repair9019. Repair9.1 GeneralThis section describes the repairs that may be performed on the heater BBW 46/DBW 46 when removed. Any f

9 RepairBBW 46 / DBW 469029.1.2.1 Replacement of Temperature Fuse against Temperature Limiter with ResetGeneralSeveral reasons (e.g. unfavourable inst

List of FiguresBBW46/DBW46IIIList of Figures301 Functional Diagram...

BBW 46 / DBW 469 Repair9039.2.1.2 Making Electrical Connections1. Making electrical connection of round connector:Insert connector pins into connector

9 RepairBBW 46 / DBW 469049.2.2 Replacement of Temperature LimiterNOTEThe temperature limiter is installed only on heaters from June 1988 and up or st

BBW 46 / DBW 469 Repair9059.2.2.2 Installation1. Apply Copaslip (Ident. No. 105898) to thread of temperature limiter (2, Fig. 902) and manually screw

9 RepairBBW 46 / DBW 469069.2.6.1 Removal1. Remove heater (see 8.7.1.1).2. Break electrical connections (see 9.2.1.1).3. Open clamping ring (3, Fig. 9

BBW 46 / DBW 469 Repair9079.2.7 Replacement of Combustion Air Fan9.2.7.1 Removal1. Remove heater (see 8.7.1.1).2. Break electrical connections (see 9.

9 RepairBBW 46 / DBW 469089.2.8 Replacement of Glow Plug9.2.8.1 Removal1. Remove heater (see 8.7.1.1).2. Break electrical connections (see 9.2.1.1).3.

BBW 46 / DBW 469 Repair9099.2.9 Replacement of Burner Head with Combustion Pipe9.2.9.1 Removal1. Remove heater (see 8.7.1.1).2. Break electrical conne

9 RepairBBW 46 / DBW 469109.2.10 Disassembly of Heat Exchanger9.2.10.1 Removal1. Remove heater (see 8.7.1.1).2. Break electrical connections (see 9.2.

BBW 46 / DBW 469 Repair9119.2.11 Replacement of Felt Disk in Burner Head9.2.11.1 Removal1. Remove heater (see 8.7.1.1).2. Press clamping spring (6, Fi

9 RepairBBW 46 / DBW 46912Ring must not touch glow plug to prevent short circuitDuring installation on burner head ensure tension spring engages firml

BBW 46 / DBW 461 Introduction1011. Introduction1.1 Scope and PurposeThis repair shop manual is intended to support familiarised personnel in the repai

BBW 46 / DBW 4610 Packaging, Storage and Shipping1001

1 IntroductionBBW 46 / DBW 46102The heater must not be installed in the passenger or driver compartments of vehicles. Should the heater nevertheless b

BBW 46 / DBW 461 Introduction103• Fuel reservoirs for carburettor fuel must not be located immediately behind the vehicle front fairing. They must be

BBW 46 / DBW 462 General Description2012. General DescriptionThe water heaters DBW 46 and BBW 46 are used in combination with the vehicle's own h

2 General DescriptionBBW 46 / DBW 462022.1 Combustion Air Fan with Intake MufflerThe combustion air fan delivers the air required for combustion throu

BBW 46 / DBW 462 General Description2032.5 Flame SensorThe flame sensor consists of a photo transistor protected by a pipe. After flame-up the pipe st