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Old 02-09-2015, 05:34 PM   #1
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Aqua Hot Maintenance....Grrrrrr

My Aqua Hot has been smoking a lot recently and it has been nearly one year since Tom Johnson's did annual service so I decided to do it today.

Could not get fuel filter off. Magilla Gorilla must have put it on. Even my large channel lock pliers would not budge it. Finally had to disconnect the fuel lines, remove the entire filter assembly, and put the filter head in a vice in my shop to get the filter off . So, a 15" task turns into an hour of work.

Removed the burner assembly and the combustion chamber was absolutely choked with soot. I am thinking Magilla Gorilla at TJ's did not check that or do any cleaning. Brushing and shop vac got it all. Replaced nozzle, cleaned electrodes, and put burner back in. It is tight in there and nothing is easy. Looked down under the coach and see that the nice clean combustion chamber was still laying there.....I forgot to reinstall it . So, burner out again, chamber in, burner back in after a few choice words.

Runs fine and no smoke. However, the burner, which has been noisy recently, was really loud with the cover off. I think I may have some bearings going bad. Hoping to send a sound clip to Roger Berke to see if he thinks I am due a new or rebuilt Webasto. Its only money, right??


http://youtu.be/62FQDZyJ0DU
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Old 02-09-2015, 06:19 PM   #2
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Quote:
Originally Posted by smlranger View Post
My Aqua Hot has been smoking a lot recently and it has been nearly one year since Tom Johnson's did annual service so I decided to do it today.

Could not get fuel filter off. Magilla Gorilla must have put it on. Even my large channel lock pliers would not budge it. Finally had to disconnect the fuel lines, remove the entire filter assembly, and put the filter head in a vice in my shop to get the filter off . So, a 15" task turns into an hour of work.

Removed the burner assembly and the combustion chamber was absolutely choked with soot. I am thinking Magilla Gorilla at TJ's did not check that or do any cleaning. Brushing and shop vac got it all. Replaced nozzle, cleaned electrodes, and put burner back in. It is tight in there and nothing is easy. Looked down under the coach and see that the nice clean combustion chamber was still laying there.....I forgot to reinstall it . So, burner out again, chamber in, burner back in after a few choice words.

Runs fine and no smoke. However, the burner, which has been noisy recently, was really loud with the cover off. I think I may have some bearings going bad. Hoping to send a sound clip to Roger Berke to see if he thinks I am due a new or rebuilt Webasto. Its only money, right??


http://youtu.be/62FQDZyJ0DU

There is a bearing kit for the blower. Much, much cheaper than an new/rebuilt Webasto.


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Old 02-10-2015, 03:38 PM   #3
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There is a bearing kit for the blower. Much, much cheaper than an new/rebuilt Webasto.


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Full time since '07
Saw that on Roger Berke's site. $1,600 for rebuilt complete Webasto and $120 for bearing kit. However, for my peace of mind, with an 8 year old unit I'd rather spring for the rebuilt unit and be done with it.

Now, if I can get near Roger in our travels this year and he can do the bearing swap and verify that all else is OK, that will be an option. For now, it works fine just a bit noisy.
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Old 02-12-2015, 10:35 AM   #4
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Noisy bearings should be easy...but that depends on having the bearings in hand.

Often in fan motors the passing air dries out the grease then it becomes chunky and results in noise.

If you can get some thin oil on the bearing it may get past the seals and help "for now"

Most any bearing supply will have the bearings in stock.

Remove part with bearings in place and they can either lookup the number on the bearing or measure it.

Usually they are pressed on but cheap puller can pop them off and sometimes the folks at the bearing place will do that for you for cheap or free.

Small motor bearings like 38KDD are only about 8 to 10 bucks a pop.
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Old 02-12-2015, 12:00 PM   #5
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Quote:
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Noisy bearings should be easy...but that depends on having the bearings in hand.

Often in fan motors the passing air dries out the grease then it becomes chunky and results in noise.

If you can get some thin oil on the bearing it may get past the seals and help "for now"

Most any bearing supply will have the bearings in stock.

Remove part with bearings in place and they can either lookup the number on the bearing or measure it.

Usually they are pressed on but cheap puller can pop them off and sometimes the folks at the bearing place will do that for you for cheap or free.

Small motor bearings like 38KDD are only about 8 to 10 bucks a pop.
Thanks for the tips but taking the Webasto apart and replacing the bearings is more than I want to do at this time. So, I have ordered a remanufactured Webasto which gives me a fully refurbished and calibrated unit. I send my old unit back to Roger and get a $300 core credit. It is 8 years old so it is due for a real 'tune up.'
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