Webasto HL 90 Owner's Manual

Other manuals for HL 90: Operating And Servicing Manual
Manual is about: Webasto HL 90 Air heater Owner's manual

Summary of HL 90

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    Hl 90 list of contents i list of contents 1 introduction 1.1 scope and purpose ............................................................................................................................... 101 1.2 meaning of warnings, cautions, and notes ...............................................

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    List of contents hl 90 ii 7 circuit diagrams and examples for electrical installation 7.1 general ................................................................................................................................................. 701 8 servicing 8.1 general ...............................

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    Hl 90 list of figures iii list of figures 301 functional diagram.......................................................................................................................................... 302 501 general failure symptoms ...................................................................

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    Your notes.

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    Hl 90 1 introduction 101 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 mean...

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    1 introduction hl 90 102 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. Extracting combustion air from the vehicle interior is not permissible. Combustion air l...

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    Hl 90 1 introduction 103 installation instructions for webasto fuel tanks for fuel supply of heaters in vehicles in busses the installation is not permitted in the passen- gers or driver’s compartment. The fuel filler neck must not be located in the passengers or driver’s compartment of any type of ...

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    Your notes.

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    Hl 90 2 general description 201 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...

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    2 general description hl 90 202 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. 2.5 glow p...

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    Hl 90 3 functional description 301 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 operatin...

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    3 functional description hl 90 302 fig. 301 functional diagram a b c d e f ✽ 1 2 3 4 6 7 8 9 10 11 12 14 15 16 13 7 5 1 switch on 2 preheating 35 s 3 fuel priming 4 full load initiation 5 safety period max. 100 s 6 minimum full load time 60 s 7 combustion operation – full load 8 room temperature (at...

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    Hl 90 4 technical data 401 4 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. 4.1 electrical components control unit, motor, dosing pump, glow plug res...

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    Your notes.

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    Hl 90 5 troubleshooting 501 5 troubleshooting 5.1 general 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. In case of doubt functio...

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    Your notes.

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    Hl 90 6 functional checkouts 601 6 functional checkouts 6.1 general 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 exhau...

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    Your notes.

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    Hl 90 7 circuit diagrams and examples for electrical installation 701 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 • ...

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    7 circuit diagrams and examples for electrical installation hl 90 702 fig. 701 operation with timer and room thermostat ws b2 bl 1 2 4 r1 3 1 br 58 30 31 31 s6 75 (15) k4 rt/bl bl sw ge vi br 3 x6 y bl br 1 6 6 2 10 5 t k3 2 4 x2 a1 b1 m 2 x3 14 e x4 xc f1 xa a2 m x5 12 1 2 4 1 f2 k1 rt ge br br k2 ...

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    Hl 90 7 circuit diagrams and examples for electrical installation 703 fig. 702 operation with switch (full load - part load) and ventilation 4 r1 3 br ws b2 bl 1 2 58 30 s1 3 2 31 31 4 5 6 1 s6 75 (15) 7 k4 rt/bl bl sw ge vi br 3 x6 y 1 6 6 2 10 5 t k3 2 4 x2 a1 b1 m 2 x3 14 e x4 xc xa a2 x5 m 12 1 ...

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    7 circuit diagrams and examples for electrical installation hl 90 704 fig. 703 operation with room thermostat (full load - part load) and ventilation 58 30 s2 31 31 s5 s6 75 (15) k4 ws rt/bl bl sw ge vi br 3 x6 y bl br 1 6 b2 6 2 10 5 t k3 2 4 x2 a1 b1 m 4 2 x3 14 e x4 xc f1 xa a2 bl r1 m x5 12 1 2 ...

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    Hl 90 7 circuit diagrams and examples for electrical installation 705 connection control unit / fuse holder / switch 1 control unit 2 fuse holder 3 to battery (+) 4 ground (–) 6 switch 17 remove two inhibit pins 7 operating indicator light (heating and ventilation) fig. 704 example for electrical in...

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    7 circuit diagrams and examples for electrical installation hl 90 706 x2 intermediary connector dosing pump x3 connector flame sensor x4 connector glow plug resistor x5 connector temperature limiter x7 connector relay/fuse x0; x00 connector glow plug 1 control unit fig. 705 example for electrical in...

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    Hl 90 8 servicing 801 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 op...

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    8 servicing hl 90 802 fig. 801 hot air temperatures with drop of pressure (12v heaters) the heating air intake temperature must not exceed +30° c. Heating air duct minimum inner diameter: 100 mm past a brandnig (y union) a heating air duct inner diameter of 80 mm is permitted. Maximum air pressure d...

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    Hl 90 8 servicing 803 fig. 803 webasto fuel tank tap * * use fuel tank tap only on metal fuel tanks fig. 804 fuel tapping from plastic tank (tapping via fuel drain plug) fig. 805 fuel tapping from plastic tank (tapping via fitting plate) note the fitting plate must be made of sheet metal! 8.6.2.2 fu...

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    8 servicing hl 90 804 connection of 2 pipes with hose the proper connection of fuel lines with hoses is shown in fig. 806. Fig. 806 pipe / hose connection 8.6.3 dosing pump the dosing pump is a combined delivery, dosing and shut-off system and is subject to certain installation criteria (fig. 802 an...

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    Hl 90 8 servicing 805 8.6.5 combustion air supply 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. If the air he...

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    8 servicing hl 90 806 8.7 removal and installation caution in installed condition only the following disassembly or removal procedures are permitted should enough space for removal allow such action: • replacement of control unit • replacement of glow plug • replacement of flame sensor and its recep...

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    Hl 90 9 repair 901 9 repair 9.1 general 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 disass...

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    9 repair hl 90 902 9.2 disassembly and assembly 9.2.1 control unit, replacement 9.2.1.1 removal 1. Disconnect electrical connector on control unit. 2. Remove screws (14, fig. 901) and control unit (13). 3. Perform procedures on components after disassembly (refer to 9.1.1). 9.2.1.2 installation 1. L...

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    Hl 90 9 repair 903 9.2.2 glow plug, replacement 9.2.2.1 removal 1. Remove knurled nut from glow plug. 2. Withdraw cable and isolator. 3. Unscrew glow plug (1, fig. 901) and remove. 4. Perform procedures on components after disassembly (refer to 9.1.1). 9.2.2.2 installation 1. Apply high temperature ...

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    9 repair hl 90 904 fig. 902 disassembly of drive 1 cap 2 rotor 3 screw (3) 4 orifice plate 5 spacer ring 6 motor 7 resistor 8 grommet 9 electrical connector 10 washer 11 tooth washer 12 screw 13 tooth washer (4) 14 screw (4) 15 screw (2) 16 locking ring (2) 17 washer (2) 18 glow plug resistor (2) 19...

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    Hl 90 9 repair 905 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 shoul...

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    9 repair hl 90 906 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 ga...

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    Hl 90 9 repair 907 9.2.7 heat exchanger, replacement 9.2.7.1 removal 1. Remove control unit (refer to 9.2.1.1). 2. Remove glow plug (refer to 9.2.2.1). 3. Remove flame sensor (refer to 9.2.3.1). 4. Remove temperature limiter (refer to 9.2.4.1). 5. Remove drive (refer to 9.2.5.1). 6. Remove screws (3...

  • Page 38

    Your notes.

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    Hl 9 0 10 storage and shipping 1001 10 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...

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    Your notes.