Working On The Vehicle; Heater Test Run; Checks; General Safety Information - Webasto Dual Top ST 6 Workshop Manual

2 | Safety
NOTE
Always carry out a visual inspection before starting re-
pair work:
- Check the coolant system and fuel system for leaks.
- Check the combustion air and exhaust pipe for dam-
age and ensure they are clear.
NOTE
- Collect the coolant running out of the system in a suit-
able container.
- Block or disconnect coolant hoses.
- Dispose of coolants in an environmentally friendly
way.
You must not disconnect the main battery power as long as the
heater is operating or after running, due the risk of the heater
overheating and consequently tripping the overheating safe-
guard.
After the heater and all coolant-carrying components have been
installed, fill the entire coolant system according to the vehicle
manufacturer's specifications.
Bleed the system according to the vehicle manufacturer's spe-
cifications and check for leaks with the default system pressure
of the vehicle.
NOTE
Replace component:
Within the warranty period, send in only the defective
component (not the entire heater) to Webasto.
NOTE
When on-board power supply is applied, never discon-
nect the connector from the heater.
2.4

Working on the vehicle

The temperature of the heater must not be over 85 °C when
switched off. See chapter 11, "Technical Data" on page 37.
2.5

Heater Test Run

DANGER
Do not operate the heater in enclosed spaces (such as
garages) due to the risk of poisoning and asphyxiation.
2.6

Checks

Webasto recommends to carry out the following servicing jobs
before and after each heating period:
1. Read out the fault code memory.
2. Clean heater exterior (make sure no water gets in).
3. Check the electrical connections for contact corrosion and
firm seating.
4. Check exhaust gas and combustion air line for damage and
ensure that they are clear.
5. Check the fuel line and filters for leaks.
6. Check the coolant circuit and coolant pump.
7. Check hoses for cracks.
8. If fitted and necessary, change the fuel filter.
9. Commission the heater.
2.7

General safety information

Follow the safety information described in the additional docu-
mentation thoroughly.
4 / 39
Route the opening of the exhaust pipe upward, to the side or,
with exhaust gas routing under the vehicle floor, up to the prox-
imity of the side or rear limitation of the cab or the vehicle.
Parts important for vehicle operation must not be impaired from
functioning. Condensate or water must not collect in the ex-
haust pipe. Drain holes are allowed.
Position the electrical lines, switches and control units of the
heater in the vehicle so that their proper operation cannot be
impaired under normal operating conditions.
For the routing of fuel lines and the installation of additional
fuel tanks, refer to the detailed descriptions in the installation
instructions.
The main points are:
– Design the fuel lines so that twisting of the vehicle,
movements of the engine, etc. have no negative effect
on the service life. Protect the fuel lines against mechan-
ical damage.
– Protect fuel-carrying parts against heat that could inter-
fere with operation. Position fuel-carrying parts so that
dripping or evaporating fuel can neither collect on hot
parts nor ignite on electrical devices.
The heat exchanger on Dual Top ST heaters is exposed to
very high thermal stress and must be replaced by genuine
Webasto spare parts ten years after these are used for
the first time. The heater must then be provided with a
sign which bears the date of sale and the word "Original
spare part".
When replacing the heat exchanger, you must also replace the
overheating protection element (temperature sensor) in order to
prevent possible faults when using the old temperature sensor.
If installed inside, the Dual Top ST heaters are prepared for in-
stallation and sealing directly on the cab floor. Webasto ac-
cessories do not allow detachable connections of the combus-
tion air and exhaust lines inside the vehicle. You must install a
seal between the heater mounting and the vehicle floor to pre-
vent harmful emissions entering the vehicle.
Position the cold air, cooling air, and combustion air intake
openings so that no water can penetrate during a water cross-
ing permissible for the respective vehicle. You must switch off
the heater at filling stations and tank farms (fuel storage areas)
due to the risk of explosion.
DANGER
Danger of explosion!
u
Do not operate the heater in locations where highly
flammable gases or dust may form, or in locations
where highly flammable liquids of solid materials are
stored, such as fuel, coal and wood dust, grain
warehouses, cardboard, paper, dry grass and leaves.
DANGER
Do not operate the heater in enclosed spaces (such as
garages) due to the risk of poisoning and asphyxiation.
In case of longer lasting smoke emission, unusual combustion
noises or fuel odours, shut down the heater by removing the
fuse. You must not return the heater to operation again until it
has been checked. Claims can only be made if it can be verified
that the claimant has complied with the servicing and safety in-
structions.
Installation specification for Webasto fuel tank for the fuel sup-
ply of heaters in vehicles:
n You must not install the heater in the passenger or driver's
compartment of motor coaches.
9019782C WSH Dual Top ST