HL 90 List of Contents List of Contents 1 Introduction 1.1 1.2 1.3 1.4 Scope and Purpose ............................................................................................................................... 101 Meaning of Warnings, Cautions, and Notes .......................................................................................... 101 Additional Documentation to be used ....................................................................................................
List of Contents 7 Circuit Diagrams and Examples for Electrical Installation 7.1 8 General ................................................................................................................................................. 701 Servicing 8.1 8.2 8.3 8.4 8.5 8.6 8.7 General ................................................................................................................................................. Work on the Air Heater ..................................................
HL 90 List of Figures List of Figures 301 Functional Diagram.......................................................................................................................................... 302 501 General Failure Symptoms .............................................................................................................................. 501 701 702 703 704 705 Operation with Timer and Room Thermostat..................................................................................
Your Notes
HL 90 1 Introduction 1.1 Scope and Purpose This repair shop manual is intended to support familiarised personnel in the repair of air heaters HL 90 of the Diesel type. 1.2 Meaning of Warnings, Cautions, and Notes 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.
HL 90 1 Introduction Heating Air System Heating air intake openings must be arranged so that under normal operating conditions exhaust fumes of the vehicle engine or air heater are not likely to be expected. Metal lines must be used. These may not heat to more than 110° C should there be the possibility of contact within the room interior. Protective devices against contact may be fitted. Extracting combustion air from the vehicle interior is not permissible.
HL 90 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. The fuel filler neck must not be located in the passengers or driver’s compartment of any type of vehicle. Fuel reservoirs for carburettor fuel must not be located immediately behind the vehicle front fairing. They must be away from the engine to prevent fuel fires in case of accidents.
Your Notes
HL 90 2 General Description The air heater HL90 is used to – – – heat the driver compartment and the vehicle interior/ passenger compartment defrost the windscreen heat vehicle loading compartments The heaters are cleared for heating the passenger compartment and the driver compartment in the fresh air mode of operation of and vehicle loading compartments in the fresh air or circulation air mode of operation. The heating of loading compartments for dangerous goods is not permitted.
HL 90 2 General Description 2.4 Flame Sensor The flame sensor is a photo transistor changing its resistance depending on the flame intensity. The signals are supplied to the control unit for processing.The flame sensor continuously monitors the flame condition during heater operation. 2.6 Temperature Limiter The temperature limiter protects the heater against undue high operating temperatures.
HL 90 3 Functional Description (Fig. 301) 3.1 Controls The heaters may be equipped with the following controls: – room thermostat (mechanical) – switch – timer Activation and deactivation is by means of the switch, timer or room thermostat with on/off switch. An operating indicator light (in timer, switch or room thermostat) indicates the heater on condition.
HL 90 3 Functional Description 1 3 2 4 6 11 9 7 5 10 8 12 14 7 13 16 15 A B C D E F ✽ 1 Switch on A Operating indicator light on 2 Preheating 35 s B 3 Fuel priming Switch or room thermostat (full load / part load) or timer 4 Full load initiation C Flame sensor 5 Safety period max.
HL 90 4 4 Technical Data 4.1 Technical Data Where no threshold values are specified technical data are understood to include standard tolerances for heater units of ±10% at ambient temperature of +20° C and at nominal voltage. Electrical Components Control unit, motor, dosing pump, glow plug resistor, part load resistor, timer and switch with indicator light are 12 V or 24 V components. Temperature limiter, flame sensor and glow plug are identical in 12 V and 24 V heaters.
Your Notes
HL 90 5 Troubleshooting 5.1 General 5 Troubleshooting check fuel, combustion air and exhaust lines for obstructions corrosion on connectors loose contacts on connectors wrong crimping on connectors corrosion on wiring and fuses corrosion on battery terminals This section describes troubleshooting procedures for the heater HL90. CAUTION Troubleshooting requires profound knowledge about components and their theory of operation and may only be performed by trained personnel.
Your Notes
HL 90 6 Functional Checkouts 6.1 General 6 Functional Checkouts This section describes the tests and adjustments on the heater in installed and removed condition to prove its serviceability. WARNING The heater must not be operated in closed areas like garages or workshops not provided with exhaust ventilation facilities. 6.2 Adjustments 6.2.1 Adjustment of CO2 Contents The HL90 heater does not require a CO2 adjustment. 6.
Your Notes
HL 90 7 Circuit Diagrams and Examples for Electrical Installation 7 Circuit Diagrams and Examples for Electrical Installation 7.1 General Circuit diagrams (Fig. 701 to 703) show possible heater circuits for HL90 with • • • timer and room thermostat switch (full load - part load) and ventilation room thermostat (full load - part load) and ventilation Examples (Fig. 704 and 705) show the proper electrical installation for operation with switch and ventilation (Fig.
HL 90 7 Circuit Diagrams and Examples for Electrical Installation 1,5mm2 58 1,5mm2 75 (15) 4mm2 30 58 75 (15) 30 F2 F1 11 2,5mm2 0,75mm2 XA 2 1 2 H1 H3 6 A2 6 K4 3 9 1 6 5 T 10 K1 K2 K3 4 2 12 14 0,75mm 4 0,75mm2 B2 Y M A1 br 2,5mm2 br 0,75mm2 2 1 or 2 2 1 X00 gn 2 sw 1 4 rt/bl R1 2 3 ge 1,5mm2 rt 1,5mm2 3 rt br X3 0,75mm X4 R2 X0 1,5mm2 H1 2 1 WS S4 br X7 X5 2 ge 1 vi 1,5mm2 rt/bl 0,75mm2 bl X6 1 vi br 0,75mm2 S3 0,75mm2 4 2 1mm
HL 90 58 75 (15) 7 Circuit Diagrams and Examples for Electrical Installation 58 75 (15) 4mm3 30 30 1,5mm2 F3 S1 F2 F1 3 K4 3 10 4 2 1,5mm2 1 14 0,75mm2 br XC 2 4 XB R1 B2 2 2 4 M 2 1,5mm2 2,5mm2 br 0,75mm2 R2 M A1 1 1 X00 gn 1 rt/bl X3 0,75mm2 or 3 br X4 X0 1,5mm2 2 bl WS br X7 1 Y ge 1,5mm2 rt/bl 0,75mm2 bl 1mm2 X5 2 2,5mm2 2 X6 1 12 X2 Ventilation br 1mm2 5 ge 1 Heating 6 sw sw 1mm2 H1 Heating H2 1 K1 K2 K3 vi 1,5mm2 7 T vi br
HL 90 7 Circuit Diagrams and Examples for Electrical Installation 58 75 (15) 58 75 (15) 4mm2 30 1,5mm2 1 0,75mm2 3 0,75mm2 1,5mm2 S4 H1 F2 F1 F3 XA 1 A2 6 K4 3 4 2 12 1 14 0,75mm2 br XC 2 4 XB R1 B2 Y 2 M A1 2 1 br 2,5mm2 2 1 X00 gn 1 4 rt/bl X3 0,75mm2 or 3 rt ge 2 1 ge X4 sw 2 WS 1 br X7 R2 1,5mm2 X5 vi br X6 br 0,75mm2 bl ge 1,5mm2 2 1mm2 br 1mm2 1 vi 1,5mm2 X2 rt 1,5mm2 1,5mm2 rt/bl bl 0,75mm2 E 10 K1 K2 K3 bl H2 5 rt/bl 0,75m
HL 90 7 Circuit Diagrams and Examples for Electrical Installation 3 2 17 4 5 1 6 7 4 4 6 S1-1 = =1 S1-3 S1-7 4=br S1 S1 S1-4 H2 S1-6 S1-3 S1-3 S1-4 1 A B C 6 3 2 4 1 30 (+) F 3 30 XA XA F2=1 3 4 =6 S1-4 =3 S1-6 F1=2 1 F 1 F 2 2 14878A 7 X7 S1-2 XA1 XA2 Connection Control Unit / Fuse Holder / Switch 1 2 3 4 6 17 7 Control unit Fuse holder to battery (+) Ground (–) Switch Remove two inhibit pins Operating indicator light (heating and ventilation) Fig.
HL 90 7 Circuit Diagrams and Examples for Electrical Installation X4 X2 =1 ge X7 ge=2 2 1 X5 rt=3 1 A B 10 bl=C 5 C rt/bl= 2 1 vi=4 2 br= B br=2 ge=1 C6 gn= C1 sw= 2 1 1 2 sw=1 rt/bl=05 rt=2 gn=6 vi=4 bl=10 3 4 5 6 7 9 8 10 11 13 12 14 C br=14 br=12 br =X 00 br X3 =C 12 X00 br=X7-2 X0 -1 ge=X4 1 3- =X br 12 C- =X br X00 X2 X3 X4 Intermediary connector dosing pump Connector flame sensor Connector glow plug resistor X5 Connector temperature limiter X7 Connector re
HL 90 8 Servicing 8.1 General This section describes the servicing procedures allowed on the heater when installed. 8.2 Work on the Air Heater For any type of work on the heater the main power supply cable is to be disconnected from the vehicle battery. As long as the heater is in operation or in run-down the battery main power supply must not be disconnected to prevent the heater from overheating by response of the overheat protection.
HL 90 8 Servicing ∆P = 0 mm wc 1. Free flow 124 °C (Max. temperature) 20 °C ∆P = 6 mm wc 135 °C ∅100 500 2. Partial restriction 800 20 °C 00 500 800 R1 3. Max. pressure drop (Temperature limiter B2 responds at 175 °C) ∆P = 25 mm wc Total pipe length 2,5 m 172 °C 20 °C 50% of cross section = ∅ = 70 mm Fig. 801 Hot Air Temperatures with Drop of Pressure (12V Heaters) 100 mm Past a brandnig (Y union) a heating air duct inner diameter of 80 mm is permitted.
HL 90 8 Servicing Hole Pattern Fuel Tank Tap 25 > 25 mm NOTE The fitting plate must be made of sheet metal! Fig. 803 Webasto Fuel Tank Tap * * Gasket Use fuel tank tap only on metal fuel tanks Fig. 805 Fuel Tapping from Plastic Tank (tapping via fitting plate) NOTE The fitting plate must be made of sheet metal! Plastic Tank 8.6.2.2 Fuel Lines Fuel lines may only be steel, copper, or plastic lines made of unhardened, light and temperature stabilised PA 11 or PA 12 (e.g.
HL 90 8 Servicing Connection of 2 Pipes with Hose 8.6.3.1 Installation Location The proper connection of fuel lines with hoses is shown in Fig. 806. Prior to installation of dosing pump ensure that the pressure at the tapping location does not exceed 0.2 bar. It is advantageous to mount the dosing pump in a cool location. The ambient temperature must never exceed +40° C during operation.
HL 90 8 Servicing 8.6.5 Combustion Air Supply 8.6.7 Combustion Air Intake and Exhaust Lines Combustion air must under no circumstances be extracted from rooms with persons. The combustion air inlet must not point towards the forward direction of motion. It must be located so that no clogging by contamination is to be expected. Length of combustion air intake line: with muffler: max. 3.0 m without muffler: max. 5.
HL 90 8 Servicing 8.7 Removal and Installation 8.7.4 Flame Sensor, Replacement CAUTION In installed condition only the following disassembly or removal procedures are permitted should enough space for removal allow such action: NOTE The replacement procedure for the flame sensor is identical with the heater installed or removed. Perform replacement in accordance with 9.2.3. • • • • 8 7.
HL 90 9 Repair 9.1 General 9 Repair This section describes the repairs that may be performed on the air heater HL 90 when removed. Any further disassembly will void the warranty. For re-assembly only components of the original spare part kits are to be used. 9.1.1 Work on Components after Disassembly All gaskets located between disassembled components must always be replaced and discarded. 9.1.1.
HL 90 9 Repair 9.2 3. Perform procedures on components after disassembly (refer to 9.1.1). Disassembly and Assembly 9.2.1 Control Unit, Replacement 9.2.1.2 Installation 9.2.1.1 Removal 1. Locate control unit (13, Fig. 901) in installation position and secure with screws (14). 2. Torque screws with 2.5 ± 0.2 Nm. 3. Connect electrical connector to control unit. 1. Disconnect electrical connector on control unit. 2. Remove screws (14, Fig. 901) and control unit (13).
HL 90 9 Repair 9.2.2 Glow Plug, Replacement 9.2.4.2 Installation 9.2.2.1 Removal 1. Screw temperature sensor (4, Fig. 901) in by hand and tighten with 0.8 ± 0.2 Nm. 2. Form-fit silicone cap (5). 3. Make electrical connection of temperature limiter to wiring harness. 1. 2. 3. 4. Remove knurled nut from glow plug. Withdraw cable and isolator. Unscrew glow plug (1, Fig. 901) and remove. Perform procedures on components after disassembly (refer to 9.1.1). 9.2.5 Drive, Replacement 9.2.2.
HL 90 9 Repair 1 3 2 37 1 4 rt-rt/bl 6 1 5 br-vi 7 8 1 9 12 11 10 sw rt/bl vi rt 13 14 21 1 19 22 23 20 18 2 2 2 15 17 16 24 36 1 2 NOTE Orifice plate (4) made of plastic has no tooth washers (13) and spacer ring (5). Screws (3) are then locked with tooth washers (37). 25 29 28 30 27 31 If screws (15) are sheet metal type screws, there are no locking rings (16) and washers (17).
HL 90 9.2.6 Drive, Disassembly and Assembly The disassembly of the drive is broken down into two subjects: – heating air supply/ electrical components – combustion air supply / fuel ducting / motor 9.2.6.1 Heating Air Supply / Electrical Components, Disassembly The following steps should be performed with the heater fully assembled. 1. For removal of cap (1, Fig. 902) remove screw (14) and tooth washers (13) as required. 2. Using two levers (wide blade screw drivers, etc.
HL 90 9 Repair CAUTION Align interlock surfaces in rotor and on motor shaft. WARNING The 12 V type heater has only one glow plug resistor (18) fitted. Make sure to close second opening in air intake housing with a screw plug. NOTE Check fuel line position with gauge No. 866 45A by positioning gauge on drive shaft of bypass fan and reading the value 0.5 + 0.5. Bend as required to adjust distance (see Figure). 30° 16 17 0.5 to 1 Fuel line 906 Gauge (Ident. No.
HL 90 9 Repair 9.2.7.2 Installation 9.2.7 Heat Exchanger, Replacement 1. Apply sealing and bonding compound (Ident. No. 666 05A) to mating surfaces of sealing cord (4, Fig. 903) and heat exchanger (5) and locate with rear wall (3) in heat exchanger (5) for assembly. 2. Secure rear wall (3) with nuts (1) and lock washers (2). 3. Torque nuts (1) to 1.5 ± 0.2 Nm. 9.2.7.1 Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Remove control unit (refer to 9.2.1.1). Remove glow plug (refer to 9.2.2.1).
Your Notes
HL 90 10 10 Storage and Shipping Storage and Shipping CAUTION When shipping a complete heater assembly it must be drained completely. No fuel is allowed to escape from a packaging or during shipping. Dummy plugs must be fitted to the fuel lines. In storage the ambient temperatures specified in Section 4 must not be exceeded.
Your Notes