Servicing; General; Heater Servicing; Vehicle Servicing - Webasto DBW 2010 Service And Repair Manual

DBW 2010/2020/300 COOLANT HEATERS

8. SERVICING

8.1 G
ENERAL
This section describes the servicing work that can be
carried out on the heater when it is installed.
8.2 H S
EATER ERVICING
Maintenance of the heater is necessary for proper
operation and long life. Read and understand the
recommendations and procedures explained in this
manual before attempting to service or repair.
If you wish to carry out extensive repair work on the
heater, it may be a good idea to remove it completely.
The battery must not be disconnected while the heater is
running, otherwise the heater will overheat.
After working on the heating circuit replenish with a
coolant mix prepared with water and anti-freeze and
bleed circuit afterwards according to manufacturer's
instructions.
8.3 V S
EHICLE ERVICING
CAUTION: A temperature of 85 °C (185 °F)
must not be exceeded in the vicinity of the
heater in any circumstances (for example
when completing painting work on the
vehicle).
If the vehicle requires electric welding, the heater must
be electrically disconnected from the vehicle (both "+"
and "–").
8.4 H T R
EATER EST UN
The heater must not be operated, not even with the
timer, in enclosed areas like garages or workshops not
equipped with exhaust ventilation facilities.
8.5 M
AINTENANCE
NOTE: The heater should be operated for
approximately 20 minutes every 4 weeks to
prevent mechanical parts seizing.
To ensure functional reliability of the heater the following
maintenance must be performed:
• check combustion air inlet and exhaust outlet for
contamination and clean as required.
• outside the heating season the heater should be
operated with the vehicle engine cold approximately
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every four weeks for 20 minutes setting the heating
system to "warm". This avoids difficulties in the start-
up.
• at least once a year, in case of contaminated fuel more
often, the fuel filter or filter cartridge as well as the
filter screen of the fuel pump must be replaced to
avoid malfunctions.
• at least once a year the heat exchanger must be
cleaned inside.
• in case of leakage the fuel pump and the fuel lines
must be replaced immediately, otherwise every 5
years.
• the heater should be checked on regular intervals by a
Webasto service agent, the latest before the beginning
of the heating season.
8.5.1 B H
URNER EAD
WARNING: The ignition system operates
with high voltage. Prior to opening the
burner head the power source to the
heater has to be disconnected to prevent
lethal injuries.
After closing and fixing burner head,
reconnect connectors in the vehicle.
NOTE: Maintenance on the heater is easy. By
swinging the burner head open the following
components become accessible:
– fuel pump and fuel nozzle
– solenoid valve
– ignition electrodes
– flame detector (photo eye)
– combustion chamber
– nozzle block pre-heater (if installed)
In order to obtain a convenient burner head opening
angle it may be required to disconnect the electrical
connections at the control unit.
O
PENING OR REMOVAL
1. Disconnect electrical connections at control unit if
required.
2. Loosen nuts (item 3, Fig. 34) enough to release
hinge bolts (2).
3. Swing hinge bolts (2) out of way.
4. Swing burner head (4) open.
C
LOSING OR INSTALLATION
1. Swing burner head to the closed position.
2. Swing hinge bolts (2) to locking position.
43
SERVICING
O C
PENING AND LOSING
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