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List of Contents
BBW46/DBW46
List of Contents
1.
Introduction
1.1 Scope and Purpose ............................................................................................................................... 101
1.2 Meaning of Warnings, Cautions, and Notes .......................................................................................... 101
1.3 Additional Documentation to be used .................................................................................................... 101
1.4 Safety Information and Regulations....................................................................................................... 101
1.4.1 General Safety Notes .................................................................................................................. 101
1.5 Legal Provisions for Installation ............................................................................................................. 102
1.6 Corrections and Improvements.............................................................................................................. 103
2.
General Description
2.1 Combustion Air Fan with Intake Muffler ................................................................................................. 202
2.2 Heat Exchanger ..................................................................................................................................... 202
2.3 Burner Head with Combustion Pipe....................................................................................................... 202
2.4 Circulation Pump.................................................................................................................................... 202
2.5 Flame Sensor......................................................................................................................................... 203
2.6 Glow Plug............................................................................................................................................... 203
2.7 Temperature Sensor .............................................................................................................................. 203
2.8 Temperature Limiter............................................................................................................................... 203
2.9 Temperature Fuse ................................................................................................................................. 203
3.
Functional Description
3.1 Sequence of Operation .......................................................................................................................... 301
3.1.1 Switch On .................................................................................................................................... 301
3.1.2 Combustion Operation................................................................................................................. 301
3.1.3 Switch Off .................................................................................................................................... 302
3.1.4 Error Lockout ............................................................................................................................... 302
4.
Technical Data ................................................................................................................................................ 401
5.
Troubleshooting
5.1 General .................................................................................................................................................. 501
5.2 General Fault Symptoms ....................................................................................................................... 501
6.
Functional Checkouts
6.1 General .................................................................................................................................................. 601
6.2 Adjustments ........................................................................................................................................... 601
6.2.1 Adjustment of CO 2 Contents ....................................................................................................... 601
6.3 Components Testing.............................................................................................................................. 601
6.3.1 Temperature Sensor Resistance Check...................................................................................... 601
6.3.2 Flame Sensor Check ................................................................................................................... 601
7.
Circuit Diagrams
7.1 General .................................................................................................................................................. 701
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BBW46/DBW46
List of Contents
8.
Servicing
8.1 General ...................................................................................................................................................801
8.2 Work on the Heater.................................................................................................................................801
8.3 Work on the Vehicle................................................................................................................................801
8.4 Heater Test Run .....................................................................................................................................801
8.5 Servicing .................................................................................................................................................801
8.6 Visual Inspections and Installation Regulations......................................................................................802
8.6.1 Connection to the Vehicle Cooling System ..................................................................................802
8.6.2 Connection to Vehicle Fuel System..............................................................................................805
8.6.3 Dosing Pump ................................................................................................................................807
8.6.4 Fuel filter.......................................................................................................................................807
8.6.5 Combustion Air Supply .................................................................................................................807
8.6.6 Exhaust Line.................................................................................................................................807
8.7 Removal and Installation ........................................................................................................................808
8.7.1 Removal and Installation of Heater ..............................................................................................808
8.7.2 Replacement of Circulation Pump ................................................................................................808
8.7.3 Replacement of Temperature Limiter or Temperature Fuse ........................................................809
8.7.4 Replacement of Temperature Sensor ..........................................................................................809
8.7.5 Replacement of Combustion Air Fan............................................................................................809
8.7.6 Replacement of Flame Sensor .....................................................................................................809
8.7.7 Replacement of Glow Plug ...........................................................................................................809
8.7.8 Replacement of Felt Disk in Burner Head ....................................................................................809
8.8 First Operation ........................................................................................................................................810
8.8.1 Bleeding the Fuel Supply System.................................................................................................810
9.
Repair
9.1 General ...................................................................................................................................................901
9.1.1 Work on Components after Disassembly .....................................................................................901
9.1.2 Modification Procedures ...............................................................................................................901
9.2 Disassembly and Assembly....................................................................................................................902
9.2.1 Electrical Connections ..................................................................................................................902
9.2.2 Replacement of Temperature Limiter ...........................................................................................904
9.2.3 Replacement of Temperature Fuse..............................................................................................905
9.2.4 Replacement of Temperature Sensor ..........................................................................................905
9.2.5 Replacement of Flame Sensor .....................................................................................................905
9.2.6 Replacement of Circulation Pump ................................................................................................905
9.2.7 Replacement of Combustion Air Fan............................................................................................907
9.2.8 Replacement of Glow Plug ...........................................................................................................908
9.2.9 Replacement of Burner Head with Combustion Pipe ...................................................................909
9.2.10Disassembly of Heat Exchanger ..................................................................................................910
9.2.11Replacement of Felt Disk in Burner Head ....................................................................................911
10. Packaging, Storage and Shipping
10.1 General .................................................................................................................................................1001
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List of Figures
BBW46/DBW46
List of Figures
301
Functional Diagram..................................................................................................................................... 303
501
General Failure Symptoms ......................................................................................................................... 501
701
Connector Pin Assignment ......................................................................................................................... 701
702
Automatic Switching Circuit for BBW 46/DBW 46, 12 and 24 Volt ............................................................. 702
801
Connection to Cooling System „Inline“ Integration...................................................................................... 803
802
Connection to Cooling System „Thermostat“ Integration ............................................................................ 804
803
Fuel Supply ................................................................................................................................................. 805
804
Webasto Fuel Tap....................................................................................................................................... 805
805
Webasto Fuel Tank Tap.............................................................................................................................. 806
806
Fuel Tapping from Plastic Tank (tapping via fuel drain plug)...................................................................... 806
807
Pipe/Hose Connection ................................................................................................................................ 807
808
Installation Position and Attachment of Dosing Pump ................................................................................ 807
809
Installation Arrangement of Exhaust Pipe Outlet ........................................................................................ 808
901
Electrical Connections ................................................................................................................................ 903
902
Replacement of Temperature Limiter, Temperature Fuse, Temperature Sensor and Flame Sensor ........ 904
903
Replacement of Circulation Pump .............................................................................................................. 906
904
Replacement of Combustion Air Fan .......................................................................................................... 907
905
Replacement of Glow Plug ......................................................................................................................... 908
906
Replacement of Burner Head with Combustion Pipe.................................................................................. 909
907
Replacement of Heat Exchanger ................................................................................................................ 910
908
Removal of Felt Disk in Burner Head.......................................................................................................... 911
909
Assembly Procedure for Burner Head, Fuel Version .................................................................................. 912
910
Assembly Procedure for Burner Head, Diesel Version ............................................................................... 912
III
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BBW46/DBW46
1 Introduction
1. Introduction
1.4 Safety Information and Regulations
1.1 Scope and Purpose
The general safety regulations for the prevention of
accidents and the relevant operating safety instructions
have to be observed at all times.
"General Safety Regulations" beyond the scope of these
regulations are detailed in the following.
This repair shop manual is intended to support
familiarised personnel in the repair of water heaters
BBW46 and DBW46 of the fuel and Diesel type.
The specific safety regulations applicable to this manual
are highlighted in the individual chapters by Warnings,
Cautions, and Notes.
The heater may only be operated with the specified type
of fuel (Diesel or with fuel oil EL) and the appropriate type
of electrical installation.
1.4.1 General Safety Notes
1.2 Meaning of Warnings, Cautions, and
Notes
Within the scope of the StVZO (Road Licensing
Regulations of the Federal Republic of Germany)
"Design General Approvals" laid down by the Federal
Office for Motor Traffic exist for the water heaters BBW 46
and DBW 46 with the following official marks of
conformity:
WARNINGS, CAUTIONS, and NOTES in this manual
have the following meaning:
WARNING
This heading is used to highlight that non-compliance with
instructions or procedures may cause injuries or lethal
accidents to personnel.
– S185 for heater BBW 46 (fuel)
– S186 for heater DBW 46 (Diesel)
Installation of the heater is to be performed in accordance
with the installation instructions and, in case of a retrofit,
must be checked by an officially authorised expert or
inspector of the Technical Supervisory Association (TÜV)
in accordance with § 19, para. 2 StVZO submitting the
"Operating Instructions" and "Installation Instructions".
With this expertise a new vehicle operating license must
be applied for with the administrative authority (vehicle
licensing agency).
CAUTION
This heading is used to highlight that non-compliance with
instructions or procedures may cause damage to
equipment.
NOTE
This heading is used to highlight and draw specific
attention to information.
Deviations are only permitted after written
authorisation of the installation plans by an officially
authorised expert or inspector of the Technical
Supervisory Association (TÜV).
1.3 Additional Documentation to be used
This workshop manual contains all information and
procedures necessary for the repair of water heaters
BBW 46 and DBW 46. The use of additional
documentation is normally not necessary.
Operating instructions/installation instructions and the
vehicle specific installation proposal may be used as
complementary information as necessary.
The year of the initial operation must be durably
marked on the heater identification plate by removing
the relevant date of the year.
The heaters are cleared for heating the vehicle engine
and the passenger compartment. When using the heaters
in vehicles not subject to the Road Licensing Regulations
(StVZO) (e.g. ships), the applicable partially regional
regulations must be observed.
The heater may only be installed in vehicles or in
independent heating systems with a minimum coolant
capacity of 4.0 litres.
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1 Introduction
BBW46/DBW46
The heater must not be installed in the passenger or driver
compartments of vehicles. Should the heater
nevertheless be installed in such a compartment, the
installation box must be sealed tight against the vehicle
interior. There must be sufficient ventilation of the
installation box from the exterior in order not to exceed a
maximum temperature of 60 °C in the installation box.
Excessive temperatures may cause malfunctions.
Extracting combustion air from the vehicle interior is
prohibited.
The exhaust line outlet is to be positioned to the top, to the
side, or in case of exhaust venting below the vehicle floor,
to the nearest possible location of the vehicle's or cockpit
side or rear end. Exhaust pipes must be routed so that
exhaust fumes are unlikely to penetrate into the vehicle's
interior. The function of any part of the vehicle essential
for operation must not be impaired.
Accumulations of condensate in the exhaust line must be
directly drained, if required a drain hole may be provided.
WARNING
Due to the danger of poisoning and suffocation the
heater must not be operated, not even with timer or
telestart, in enclosed areas such as garages or
workshops not equipped with an exhaust venting
facility.
Installations fitted after March 18, 1993 must have a
combustion air inlet and exhaust outlet port, into which a
ball of 16 mm in diameter cannot be inserted.
At filling stations and fuel depots the heater must be
switched off as there is a potential danger of
explosion.
Electrical wiring and heater switching and control gear
must be located in the vehicle so that its normal
functioning is not impaired under normal operating
conditions.
CAUTION
Where flammable fumes or dust may build up (e.g. in
the vicinity of fuel, coal, wood, cereal depots, or
similar installations) the heater must be switched off
to prevent explosions.
For the routing of fuel lines and the installation of
additional fuel tanks §§ 45 and 46 of the StVZO are to be
adhered to. The most important regulations are:
In the vicinity of the control unit a temperature of 85 °C
(storage temperature) must not be exceeded (e.g. during
body paint work). Excessive temperatures may cause
permanent damage to the electronics.
• Fuel lines are to be designed in such a way that they
remain unaffected by torsional stresses in the vehicle,
engine movement, and the like. They must be
protected against mechanical damage. Fuel-carrying
parts are to be protected against excessive heat and
are to be arranged so that any dripping or evaporating
fuel can neither accumulate nor be ignited by hot
components or electrical equipment.
When checking the cooling water level proceed in
accordance with the vehicle manufacturer's instructions.
The water in the heating circuit of the heater must contain
at least 10% of a quality brand anti-freeze.
• In busses fuel lines and fuel tanks may be located
neither in the passenger area nor in the driver's
compartment. In these type of vehicles the fuel tanks
must be located such that they do not pose a direct
hazard to the exits in the event of a fire. Fuel supply
must not be by means of gravity or pressurisation of
the fuel tank.
Non-authorised installations will void the heater's marks of
conformity and thus the vehicle's permit of operation. The
same applies to unskilled repairs or repairs not using
original spare parts.
• Installation instructions for Webasto fuel tanks for fuel
supply of heaters in vehicles:
In busses the installation is not permitted in the
passengers or driver's compartment.
1.5 Legal Provisions for Installation
For testing the heater in accordance with §§ 19, 20, or 21
of the StVZO the following regulations are to be observed
in particular (§ 22 a StVZO):
Testing is performed upon presentation of the operating
and installation instructions of the manufacturer. The year
of the initial operation must be durably marked on the
heater identification plate by the installing person.
• The fuel filler neck must not be located in the
passenger’s or driver's compartment of any type of
vehicle.
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