Webasto DBW 300 Diesel Water Heater Manuals

Manuals and User Guides for Webasto DBW 300 Diesel Water Heater. We have 4 Webasto DBW 300 Diesel Water Heater manuals available for free PDF download: Workshop Handbook, Service And Repair Manual, Operating Instructions Manual

Webasto DBW 300 Service And Repair Manual

Webasto DBW 300 Service And Repair Manual (72 pages)

Used in combination with the vehicle’s own heating installation to heat the passenger compartment, defrost the windshield, preheat water-cooled engines, in self-contained cargo heating applications

Brand: Webasto | Category: Water Heater | Size: 4 MB

Table of Contents

Table of Contents
3
1 Introduction

7
2 General Description

9
- Parts of the Heater
  12
  - Electronic Control Unit (1)
    12
  - Overheat Fuse (15)
    12
  - Temperature Limiter (17)
    12
  - Temperature Control Thermostat (16)
    12
  - Flame Detector (23)
    13
  - Combustion Air Intake (26)
    13
  - Combustion Air Fan (5) and Motor (2)
    14
  - Coupling (4)
    15
  - Toothed Gearing (6)
    15
  - Fuel Pump (24)
    15
  - Fuel Control Valve and Solenoid (8)
    15
  - Fuel Nozzle and Nozzle Holder (14)
    16
  - Fuel Line Connections (25)
    16
  - Electronic Ignition Unit (3)
    16
  - Ignition Electrodes (13)
    16
  - Combustion Chamber (20), Combustion Air Swirler (21)
    17
  - Heat Exchanger (19)
    17
  - Preheat Thermostat (7)
    17
  - Pre-Heater Cartridge (10)
    17
  - Coolant Circulating Pump
    18
3 Functional Description

19
- Switch on
  19
- Heating Operation
  19
- Switch off
  19
4 Technical Data

20
5 Troubleshooting

23
6 Functional Adjustments

31
- General
  31
- Adjustments
  31
  - Adjustment of CO2 Contents
    31
  - Flame Detector Resistance Check
    32
  - Ignition Electrode Check and Setting
    32
  - Ignition Coil Check
    33
  - Fuel Pump Check
    33
  - Fuel Solenoid Valve Check
    34
  - Nozzle Block Pre-Heater Check
    34
7 Circuit Diagrams

35
8 Servicing

43
- General
  43
- Heater Servicing
  43
- Vehicle Servicing
  43
- Heater Test Run
  43
- Maintenance
  43
  - Burner Head Opening and Closing
    43
- Visual Inspections and Regulations for Installation
  45
  - Connection to Vehicle Cooling System
    45
  - Connection to Vehicle Fuel System
    45
    
    Fuel Lines
    45
    
    Fuel Filter
    45
  - Combustion Air Supply
    45
  - Exhaust Line
    46
- Removal and Installation
  46
  - Heater, Removal and Installation
    46
    
    Removal
    46
    
    Installation
    46
  - Temperature Limiter, Replacement
    47
  - Temperature Thermostat, Replacement
    47
  - Overheat Fuse, Replacement
    47
  - Burner Head, Replacement
    47
  - Ignition Coil, Replacement
    47
  - Flame Detector (Photo Eye), Replacement
    47
  - Combustion Chamber, Replacement
    47
- First Operation
  47
  - Water Circuit, Bleeding
    47
  - Fuel Supply System, Bleeding
    48
9 Repair

49
- General Information
  49
  - Work on Components after Disassembly
    49
    
    Visual Inspection, General
    49
    
    Combustion Chamber, Visual Inspection
    49
    
    Heat Exchanger, Visual Inspection
    49
    
    Combustion Air Fan Wheel, Visual Inspection
    50
- Disassembly and Assembly
  50
  - Overheat Fuse, Replacement
    50
    
    Removal
    50
    
    Installation
    50
  - Temperature Control Thermostat, Replacement
    50
  - Temperature Limiter, Replacement
    51
    
    Removal
    51
    
    Installation
    51
  - Control Unit, Replacement
    51
  - Burner, Replacement
    51
  - Fuel Valve and Solenoid, Replacement
    53
    
    Removal
    53
    
    Installation
    53
  - Fuel Pump, Replacement
    53
  - Fuel Nozzle, Replacement
    54
    
    Removal
    54
    
    Installation
    54
  - Flame Detector, Replacement
    54
  - Ignition Electrodes, Replacement
    55
    
    Removal
    55
    
    Installation
    55
  - Ignition Coil, Replacement
    55
  - Drive Motor, Replacement
    56
    
    Removal
    56
    
    Installation
    56
  - Combustion Air Fan, Replacement
    57
    
    Removal
    57
    
    Installation
    57
  - Fan Replacement
    58
  - Fan Shaft, Bearings and Gearing, Exploded View (DBW 2010)
    59
  - Fan Shaft, Bearings and Gearing, Exploded View (DBW 2020 / DBW 300)
    60
  - Combustion Chamber, Replacement
    61
    
    Removal
    61
    
    Installation
    61
  - Heat Exchanger, Replacement
    61
- Coolant Circulating Pump Repair
  62
  - Removal
    62
  - Disassembling
    62
  - Assembling
    62
  - Installing
    62
- MP School Bus Circulation Pump
  64
  - Removal
    64
  - Disassembling
    64
  - Assembling
    64
  - Installing
    64
10 Instruments and Tools

65
- Setting Gauge
  65
- Tester
  65
- CO2 Test Apparatus
  65
- Smoke Number Test Apparatus
  65
- Nozzle Wrench
  66
- Fuel Pressure Gauge
  66
- Grease and Locking Varnish
  66
11 Product Information

67
- ISS "White" Timer for the Scholastic Heater
  67

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Webasto DBW 300 Workshop Handbook

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Webasto DBW 300 Operating Instructions Manual

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