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 1.2 1.3 1.4 1.5 1.6 1.7 The Contents and Purpose................................................................................................................................101 The field of validity of the handbook ....................................................
Contents 5.4.3 5.4.4 5.4.5 5.4.6 5.4.7 DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 The heating device starts to work only after a few trials.......................................................................506 The heating device stops by itself while working..................................................................................506 The heating device produces soot (dense black smoke comes out) ...................................................
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..........................................................................................
The Diagrams and Figures DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 The Diagrams and Figures Figure 301 Figure 302 Figure 501 Figure 701 Figure 702 Figure 703 Figure 704 Figure 705 Figure 706 Figure 707 Figure 708 Figure 709 Figure 710 Figure 711 Figure 801 Figure 802 Figure 901 The function flow (the heating device equipped with the control device 1553) ........................................302 The function flow 8the heating device equipped with the control device 1563/64) ..............................
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 1 The Introduction 1.1 The Contents and Purpose The purpose of this workshop handbook is to provide support to the trained personnel with regard to the repair of the DBW 2010/2012/2020/2022/300/350 water type heating devices. The heating device can only be operated with the fuel indicated on the type label (diesel or EL type fuel-oil) and the mentioned electrical connection type. 1.2 1 The Introduction 1.
1.The Introduction DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 This heating device can only be mounted on motor vehicles, of which the minimum amount of the cooling liquid is 10 liters or on independent heating systems. The heating device cannot be installed in the driver or passenger cabin of the vehicles. In the case that the heating device should be installed in such location at any rate, the assembly box must be completely insulated in the direction of the interior of the cabin of the vehicle.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 • • • • • The fuel pipes and the fuel tanks of the busses should not be located within the passenger or driver cabin. The fuel tanks in such vehicles must be located in such way that the exit will not be exposed to direct danger in case of a fire. The fuel transportation should not be achieved with gravitation or the positive pressure in the fuel tank.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 2 The General Definition The Webasto DBW 2010, 2012, 2020, 300 and 350 water type heating devices will be used in connection with the heating system of the vehicle - for heating the passenger cabin - for defrosting the windows, and - for pre-heating the water cooled engines. The water type heating device works independent of the engine of the vehicle and will be connected to the cooling system, fuel system and electrical installation of the vehicle.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 1 2 3 4 5 6 7 2.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 1 2 3 4 5 6 7 8 9 2.
2.The General Definition 2.1 DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Brülör fanı The burner fan The burner fan conveys the air that is necessary for the combustion from the entrance of the combustion chamber to the combustion chamber. The following fan types will be installed on the heating devices: DBW 2010 / 2012 – fan with lateral channel DBW 2020 / 2022 / 300 – radial fan DBW 350 – two stage radial fan . 2.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 2.3.1 The pre-heating of the nozzle block The fuel going to the vaporizer nozzle will be heated with the pre-heating of the nozzle block. Work failures could occur at excessive low temperatures if there is no pre-heating of the nozzle block. The heater cartridge in the nozzle block will be activated over a 0 thermostat when the temperature is < 0 C.
2.The General Definition 2.5 DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 2.6 The combustion chamber The fuel-air combination will be sprayed in the combustion chamber and burned here. The heat exchanger will be heated in the meanwhile. The control device The control device is the central element and ensures that functioning and combustion actions will be supervised. DBW 2010 / 2012 The control device 1553 Up to DBW 2020.32 Up to DBW 300.15 Beginning with DBW 2020.33 Beginning with DBW 300.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 2.7 2.The General Definition The flame regulator 2.8 The induction bobbin and ignition electrodes The flame status will be supervised with the flame regulator during the entire combustion action. The flame regulator in the non-sensoric types photo-resistance or is photo-transistor at the sensoric types and reacts according to the illumination power of the flame. The signals will be conveyed to the control device and processed here.
2.The General Definition DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 2.10 The temperature constrainer / thermal 2.11 The regulation thermostat fuse The regulation thermostat at the heating device The temperature constrainer The temperature constrainer (bi-metal) protects the heating device against high work temperatures that are not permitted. The temperature constrainer reacts at a 0 0 temperature over 107 C or 117 C and shuts off the heating device.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 2.The General Definition U 4810 It will be recommended for the heating devices DBW 2010 and DBW 2012. U 4814 Heating devices The fan thermostat in the heating device 2.12 The fan thermostat The fan thermostat shuts off and opens the fan of the heating system of the vehicle when the temperature of 0 0 the cooling liquid is between 30 C and 40 C. The 0 0 thermostat shuts off at 40 C ± 3 C and opens at 30 ± 5 0 C.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 3 The Definition of the Function 3.1 General The heating devices with high pressure vaporizer burner work intermittently. The regulation will be achieved by thermostatic sensor (heating device equipped with the control device 1553), or temperature sensor (the sensoric heating devices equipped with the control device 1563/1564) 3.2 Operation 3.
3.The Definition of the Function 3.2.5 DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 The Economy Circuit Only for the sensoric heating devices equipped with the control device 1563 The control device can be operated in the economy mode as an alternative to normal functioning. The setting temperatures of the water circuit will be kept at a lower temperature in the economy mode.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 4. The Technical Data As long as no limit value is indicated, the technical data are given at +20 0C and with ± 10 % tolerance that is normal at the heating devices for nominal voltage. 4.1 The Electrical Elements The control device, the engines of the burner fan and circulation pump, magnetic valve, induction bobbin, heater of the nozzle block, heating cartridge and the program timer have been designed to be suited for 24 Volts.
4. Technical Data Circulation pump Volume flow Nominal voltage Working voltage field Nominal power intake Dimensions Length Width Height Weight 402 l/h VVW mm mm mm kg DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 U 4810 U 4814 1600 5200 (against 0.15 bar) (against 0.15 bar) 12 or 24 10 ... 14 or 20 ... 24 25 104 with Bühler engine 173 228 94 100 77 105 0,8 2,1 U 4851 6000 (against 0.4 bar) Aquavent 6000 S 6000 (against 0.4 bar) 209 Aquavent 5000 S 5200 (against 0.15 bar) 24 20 ...
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 5 Error Search and Error Elimination 5.1 General The error search and error elimination in the DBW 2010/2012/2020/2022/300/350 heating devices will be defined in this section. ATTENTION The error search and error elimination requires knowledge on the structure and work of each component of the heating device and can only be carried out by trained personnel. The functional relationships can be seen in Section 2 or 3 in case of uncertainty. 5.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 5.3 5.
5.Error Search and Error Elimination DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 5.4 The Error Indications 5.4.1 The heating device does not start working when opened YES Is there voltage on B1, B2 and B4? (At control device 1563/64: Clamp A1, A2, A3, A4) NO Are F2/F3 fuses burned out? (at control device 1563/64: F1/F2) Is there passage at regulation thermostat? (the heat sensor at control device 1563/64) Replace the fuses and start the heating device.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 5.4.2 5.Error Search and Error Elimination 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). YES Is the thermal fuse F1 disconnected? Is the heat classifier disconnected? Is the temperature classifier disconnected? NO The sound of the induction bobbin can be heard approximately after 20 or 12 seconds.
5.Error Search and Error Elimination DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 5.4.3 The heating device starts to work only after a few trials NO Does dense smoke come out of the exhaust at the unsuccessful trials? YES The fuel level is fallen during the time the heating device has not worked. Check the suction and return line. Do you see any leakage? No Refer to 5.4.7 No Seal it. Does the arc jump from the high voltage cables? The induction bobbin is defective. Replace it.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 5.Error Search and Error Elimination 5.4.5 The heating device produces soot (dense black smoke comes out) NO Is the combustion air suction pipe or the suction clamping sleeve dirty? Clean it. Check the assembly if necessary 8refer to Section 8). No Are the gas paths in the heat exchanger excessively dirty? Does low or excessive pressure occur at the entry of the combustion air (during the drive too)? Clean according to the instructions.
5.Error Search and Error Elimination DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 5.4.6 The heating device produces light colored dense smoke NO Does the heating device produce dense smoke for 20 seconds after shut off? Open the burner and take out the combustion chamber.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 6. Function Test 6 The Function Test General 6.2 The Settings 6.2.1 Setting the CO2 proportion CO2 (in terms of volume %) The amount of the combustion air that will be set in the factory can be changed, which will be achieved by turning the setting ring.
6.Function Test DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 WARNING 6.3 Testing the individual elements The suction clamping sleeve 0 can be rotated by 180 . 6.3.1 The resistance check of the heat sensor (only the heating devices equipped with the control device 1563/64) Squeezing bolt - Loosen the tightening bolt (refer to Figure) and push the adjustment ring with the squeezing bolt until the nominal value has been reached. Squeeze the bolt with 1.0 + 0.5 Nm and put security varnish on it.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 6.3.2 The resistance test of the flame regulator WARNING The glass element of the flame regulator and the observing glass of the disc (see the figure) should be cleaned when they get dirty. The flame regulator should be replaced when it is damaged or cannot reach the nominal value. 6.3.2.1 The flame regulator in the control device 1553 - Connect the ohmmeter to the flame regulator - Darken the surrounding of the flame regulator.
6.Function Test DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 6.3.3 Checking and setting the ignition electrodes WARNING ł There should be no damage on the insulation elements of the ignition electrodes. Adjust or replace the ignition electrodes, of which the electrode distance is outside the tolerance or which do not work in an orderly manner. ł The ignition electrodes can be adjusted using a gauge.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 6.3.5 Testing the fuel pump WARNING The fuel pump will be tested in installed status. The adjustment of the pump pressure will be permitted. A test device is necessary for the test. It is possible to supply a test device for this from the Webasto support dealer (indicator dial between 0 and 15 bar). ATTENTION The induction bobbin must be dismantled. Test - Dismantle the induction bobbin (refer to 9.2.7.1) - Remove the vaporizer nozzle. - Connect the test device.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 7.The Circuit Diagrams 7 The Circuit Diagrams 7.1 General The circuit diagrams or the application examples (Figure 701 to 711) exhibit the circuits that are possible in the DBW 2010, 2012, 2020, 2022, 300 and 350 heating devices..
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 7.The Circuit Diagrams Cable colors bl Br ge gn gr or rt sw vi Cable cross-sections Pos. Definition Note 1 Heating device Without chassis 2 Control device SG 1553 4 Induction bobbin 5 Thermostat 7 Thermostat 8 Thermostat 10 Ignition electrodes Regulation thermostat (internal) Fan thermostat Temperature constraining thermostat 61.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 7.The Circuit Diagrams Cable cross-sections Pos.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 7.The Circuit Diagrams Kablo kesitleri < 7,5 m 7,5 - 15 m 0,75 mm2 1,5 mm2 1,0 mm2 1,5 mm2 1,5 mm2 2,5 mm2 2,5 mm2 4,0 mm2 4,0 mm2 6,0 mm2 Poz. Tanım Not Poz. Tanım Not A1 Isıtma cihazı ùasesiz K7 Röle (Poz.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 7.The Circuit Diagrams Cable colors Cable Cross-section < 7,5 m 7,5 - 15 m 0,75 mm2 1,5 mm2 1,0 mm2 1,5 mm2 1,5 mm2 2,5 mm2 2,5 mm2 4,0 mm2 4,0 mm2 6,0 mm2 Bl Br Ge Gn Gr Or Rt Sw Vi ws Blue Brown Yellow Green Grey Orange Red Black Violet White Pos. Definition Note Pos.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 7.The Circuit Diagrams Cable colors Cable Cross-section < 7,5 m 7,5 - 15 m 0,75 mm2 1,5 mm2 1,0 mm2 1,5 mm2 1,5 mm2 2,5 mm2 2,5 mm2 4,0 mm2 4,0 mm2 6,0 mm2 Bl Br Ge Gn Gr Or Rt Sw Vi ws Pos. Definition Note Poz.
7.The Circuit Diagrams DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Cable Cross-section WARNING The circuit diagram of the application example is related to Figure 701 or 702 Pos. Definition Note H1 Illuminated diode, green Illuminated diode yellow Work indicator (at Pos. p) Indicator for ready status (at Pos. p) Symbol illumination (at Pos.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Cable colors Pos. Definition Note F2 Fuse 8 A F3 Fuse 8 A DBW 2022 ---, 16 A at 12 V) Fuse 12 V = 16 A / 24 V = 8A Battery Illuminated diode, green Relay Switch Switch Vehicle fuse in compliance with DIN 72581 Vehicle fuse in compliance with DIN 72581 Vehicle fuse in compliance with DIN 72581 F4 G H1 K9 S1 S6 S7 S8 V4 Switch, at guide mechanism Separation switch, with 1 or 2 pins Work indicator (at Pos.
7.The Circuit Diagrams DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Cable Cross-section < 7,5 m 7,5 - 15 m 1,5 mm2 Pos.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 7.The Circuit Diagrams Cable Cross-section Pos. Definition Note F2 Fuse 8 A Vehicle fuse in compliance with DIN 72581 Vehicle fuse in compliance with DIN 72581 Vehicle fuse in compliance with DIN 72581 < 7,5 m 7,5 - 15 m 0,75 mm2 1,5 mm2 1,0 mm2 1,5 mm2 1,5 mm2 2,5 mm2 2,5 mm2 4,0 mm2 Work indicator (at Pos.
7.The Circuit Diagrams DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Cable Cross-section Pos. Definition Note F2 Fuse 8 A Vehicle fuse in compliance with DIN 72581 Vehicle fuse in compliance with DIN 72581 Vehicle fuse in compliance with DIN 72581 < 7,5 m 7,5 - 15 m 0,75 mm2 1,5 mm2 1,0 mm2 1,5 mm2 1,5 mm2 2,5 mm2 2,5 mm2 4,0 mm2 Work indicator (at Pos.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Pos.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 8 Service Tasks 8 The Service Tasks 8.5 8.1 The following maintenance tasks should be carried out due to the work security of the heating device: General The service tasks will be defined in this section that can be carried out on the heating devices that are installed on the vehicle • 8.
8. Service Tasks DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 8.5.1 Opening and closing of the burner head to the side DANGER The induction bobbin works with high voltage. The cable bunch sockets must be removed from the vehicle before opening the burner head in order to avert a possible death danger. Install the socket on the vehicle after you have closed the burner head. WARNING The maintenance of the heating device is easy.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 8.6 The Visual Examination Assembly Instructions or the 8 Service Tasks 8.6.2 The connection to the fuel system of the vehicle 8.6.1 The connection to the cooling system of The fuel will be supplied from the fuel tank of the vehicle or from a separate fuel tank. the vehicle The heating system must be installed at a place that is as deep as possible in order to ensure that the evacuation of air from the heating device and circulation pump will occur by itself.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 A conspicuous warning sign must be placed when a closing mechanism has been installed in the return line. ATTENTION The operation of the return line of the device in closed status will damage the fuel pump. The fuel could leak out. That means fire danger. The warning sign The suspended fuel lines must be fixed to prevent hanging. The installation of an additional fuel pump is prohibited.
8. Service Tasks DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Rigid pipes manufactured from steel or steel alloy or flexible pipes from steel with a flesh thickness of at least 1.0 mm must be used as the exhaust line. The exhaust pipe will be fixed on the heating device using for instance connection clamps. The dimensions permitted for the exhaust line are: - Internal diameter: DBW 2010 / 2012 = 38 mm DBW 2020 .32 / DBW 300 .15 = 80 mm DBW 2020 .33 / DBW 2022 / DBW 300 .
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 8.7.4 The replacement of the thermal fuse 8.7.9 8 Service Tasks The replacement of the induction bobbin WARNING The acts of replacement regarding the thermal sensor are the same whether it is mounted or dismounted. The act of replacement will be carried out according to 9.2.3.
8. Service Tasks 8.8 DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Commissioning The air in the cooling liquid circuit and the fuel supply system must be carefully evacuated after the heating device has been mounted. The instructions of the vehicle manufacturer must be observed during the course of this act. The imperviousness and tightness of all cooling liquid and fuel connections must be checked during the test operation.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.The Repair 9 The Repair 9.1 General The acts of repair will be defined in this section that will be carried out on the heating devices dismounted from the vehicle. Any dismounting act that is more detailed than the way as explained here will invalidate all rights of guarantee. Only the spare parts from the proper spare part kit can be used for the mounting of the device. DANGER The induction operates with high voltage.
9.The repair 9.1.1 The measures pertaining to the elements that are dismantled to parts ATTENTION All gaskets between the elements that are dismantled to parts must as a matter of principle be removed and replaced with new ones. 9.1.1.1 General Visual Examination ł All parts must be checked to see whether or not there is any damage (crack, deformation, wearing, etc.) and the parts must be replaced in case of any damage.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.1.2.1 The installation of the pre-heating element of the nozzle block in the DBW 2010 / 2012 / 2020 / 300 / 350 heating devices equipped with the control device 1553 General The fuel going to the vaporizer nozzle will be heated with the pre-heating of the nozzle block. Defects can occur at the heating devices indicated above at excessively low temperatures if there is no pre-heating of the nozzle block.
9.The repair DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Application, DBW 2010 WARNING There is no need for washers and nuts in the equipment set of the DBW 2010 heating devices. 1. Open the burner head as indicated in 8.5.1. 2. Remove the ignition electrodes as indicated in 9.2.14.1 3. Dismount the segments and remove the disc together with the flame regulator from the nozzle block. 4. Fixate the thermostat with catch (5) and bolt (6) on the nozzle block plate. 5.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Application, DBW 2020 / 300 / 350 WARNING There is no need for catch in the equipment set of DBW 2020 / 300 heating devices. 1. Open the burner head as indicated in 8.5.1. 2. Remove the ignition electrodes as indicated in 9.2.14.1. 3. Dismount the flame regulator from the discs as indicated in 9.2.13.1. 4. Remove the segment and put the existing disc at a separate place after taking it from the nozzle block. 5.
9.The repair DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Pos.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.1.2.2 The installation of the pre-heating of the nozzle block at the devices DBW 2010 / 2012 / 2020 / 300 / 350 equipped with the control device 1563/64 General The fuel going to the vaporizer nozzle will be heated with the pre-heating of the nozzle block. Defects can occur at excessively low temperatures at the heating devices mentioned above if there is no pre-heating of the nozzle block.
9.The repair DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Application, DBW 2010/2012 WARNING There is no need for washers and nuts in the equipment set of the DBW 2010 heating devices. 1. Open the burner head as indicated in 8.5.1. 2. Remove the ignition electrodes as indicated in 9.2.14.1 3. Dismount the segments and remove the disc together with the flame regulator from the nozzle block. 4. Fixate the thermostat with catch (5) and bolt (6) on the nozzle block plate. 5.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Application, DBW 2020 / 300 / 350 WARNING There is no need for catch in the equipment set of DBW 2020 / 300 heating devices. 1. Open the burner head as indicated in 8.5.1. 2. Remove the ignition electrodes as indicated in 9.2.14.1. 3. Dismount the flame regulator as indicated in 9.2.13.1. 4. Dismount the high pressure nozzle as indicated in 9.2.10.1. 5. Remove the existing disc from the nozzle block and put it at a separate place. 6.
9.The repair DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 Pos.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.2 Dismantling in parts and assembly 9.2.1 The replacement of the heat constrainer WARNING Discharge the pressure of the cooling circuit in accordance with the instructions and information provided by the manufacturer before carrying out the replacement work at the devices of the sensoric type. ATTENTION The danger of injury as a result of the cooling liquid that will be discharged. 9.2.1.1 Dismantling 1.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.2.5 The replacement of the fan thermostat 9.2.5.1 Dismounting 1. Remove the nut (4, Figure 901) and take off the protection cap (3). 2. Cut off the electrical connection of the fan thermostat (9). 3. Take off and remove the fan thermostat from the angle bar (5). 4. Apply the measures pertaining to the elements in dismounted status (refer to 9.1.1). 9.2.5.2 Mounting 1. Screw the fan thermostat (9, Figure 901) manually to the angle bar (5). 2.
9.The repair DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 1. 2. 3. 4. Figure 902 The replacement of the control device 1 2 3 4 Figure 903 914 Control device 1553 Pliers Control device 1563/1564 Burner head Cotter pin Nut (2) Nut (2) Burner head WARNING • The cotter pin can be at the other side according to the opening direction of the burner head • The burner head of the heating device DBW 2010 is exhibited in the figure.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.2.9 The replacement of the engine 9.2.9.1 Dismounting 1. Remove the bolts (7, Figure 904) at the protection cap (4) and take off the protection cap by pulling forward. 2. Cut off the electrical connections of the engine (16). 3. Remove the bolts (10) and take off the engine (16) together with the flange (14). 4. Take off and remove the clutch (13) from the engine shaft. 5. Take off and remove the clutch (12) together with the knurled washers (11). 6.
9.The repair DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.2.10 The replacement of the high pressure nozzle 9.2.10.1 Dismounting 1. Open the burner head sideward (refer to 8.5.1). 2. Remove the high pressure nozzle (11, Figure 905) by turning it. 3. Apply the measures pertaining to the elements in dismounted status (refer to 9.1.1). 9.2.10.2 Mounting 1. Screw the high pressure nozzle (11, Figure 905) and tighten it with 20 Nm. 2. Turn the burner head toward inside (refer to 8.5.1). 9.2.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.The Repair WARNING The parts marked with * are not available in the one-way fuel pumps.
9.The repair DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.2.15 The replacement of the fuel pump 9.2.15.1 Dismounting 1. Open the burner head to the side (refer to 8.5.1). 2. Remove the ignition electrodes (refer to 9.1.14.1). 3. Remove the hollow bolts (22, Figure 905) and washers (21) and take off and remove the fuel lines (20). 4. Remove the screwed connections at the pressure line (16) and take off the pressure line. 5. Remove the bolts (23) and take off the plain butt gear (25). 6.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.
9.The repair DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.2.19 The replacement of the heat exchanger 9.2.19.1 Dismounting 1. Take off the nut (6, Figure 908) from the cap (5) if necessary and remove the cap. 2. Dismount the heat constrainer or thermal fuse (refer to 9.2.1.1 or 9.2.3.1). 3. Dismount the heats sensor (refer to 9.2.2.1). 4. Dismount the thermal fuse element if necessary (refer to 9.2.6.1). 5. Dismount the regulation thermostat if necessary (refer to 9.2.4.1) 6.
DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.The Repair 9.2.20 The replacement of the nozzle block 9.2.21 The replacement of the burner fan 9.2.20.1 Dismounting 1. Open the burner head to the side (refer to 8.5.1). 2. Remove the ignition electrodes (refer to 9.2.14.1). 3. Remove the high pressure nozzle (refer to 9.2.10.1). 4. Remove the pre-heating of the nozzle block if necessary (refer to 9.2.11.1). 5. Dismount the magnetic valve (refer to 9.2.16.1). 6.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 9.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 10.The Packing/Storage/Shipment 10 The Packaging / Storage / Shipment 10.1 General The heating device or its structural elements, which will be sent to Webasto Thermosysteme GmbH in order the checked, must be cleaned and packaged in such way that they will not be damaged during the shipment, transport and storage. ATTENTION In the case that the heating device will be returned as a whole, the device must be totally emptied.
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DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 A ANNEX ANNEX A The Periodical Maintenance A-1
A ANNEX DBW 2010 / 2012 / 2020 / 2022 / 300 / 350 The maintenance intervals indicated below apply for the The Periodical Maintenance of the Heating normal utilization of the busses under the normal Device conditions. These intervals may be shortened or The heating device must be checked in regular intervals but at least at the beginning of the heating season (this is the period, in which the heating device will be used as a result of the climatic conditions).
