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Heizsysteme / Heating Systems

HL 90
Ersatzteilliste
Spare Parts List
05/2011
Ident. Nr. 70962E
www.butlertechnik.com
Inhalt / Contents Abbildung auf Seite / llustration on page
Ersatz-Heizgeräte
3
Replacement heaters
Teile zum Heizgerät
3-5
Parts for heater
Elektrische Teile
6-7
Electrical Parts
Brennstoffsystem
8
Fuel supply
Brennluftsystem
8
Combustion Air System
Abgassystem
8
Exhaust system
Montageteile
8
Mounting parts
Normteile, Dichtmittel 9
Standard Parts, Sealing Material
Geräteausführung: / Heater version

HL 90 Diesel 24 V Bilder / Figures 1 - 3
© 2011 Webasto AG Global Comfort Solutions 2
Teile zum Heizgerät / Parts for Heater

Bild / Figure 1
2
1
114 104
104
3
111 4
101
6
104
110 9 8 103
Pos. Stück Bestell-Nr. Benennung Description Bemerkung

Item Quantity Part number Remark
12V 24V
no
x 35962A HL 90 D.01 24 V HL 90 D.01 24V
fig.
1 1 1 34060C Kabelbaum Wiring harness
Mit Spreizanker /
2 2 2 34523A Kabelbinder L = 204 mm Cable clamp L = 204 mm
With expansion bolt
3 1 1 169587 Glühkerze 359 G Glow plug 359 G
4 1 1 20200A Haube Hood
Flame detection photo-
5 1 1 1316888A Flammwächter Beutel / Bag
cell
6 1 1 34489A Außenmantel Outer sheath
7 1 1 1316889A Rohr Pipe [1]
Steuergerät SG Electronic control unit
8 1 1316887A
1561 GK 24V 1561 GK 24V
9 1 1 1316885A Mantelhälfte Half shield [2]
[1] Inklusive Überwurfschraube und Doppelkegelring / Including inverted nut and double bevel ring
[2] Inklusive Schild und Montagematerial / Including label and mounting components
Die Liste der ab Pos. 101 verwendeten Normteile ist auf Seite 9 aufgeführt.

Bild / Figure 2
3 5
108 14
112
2 6/7 13 15
1 108
117 12
4 119 11
102
10 16
9
109
119 107
8
17
104 116
105
106
21 113 18
22 120 114 20 19

12V 24V
1 1 1 21176A Haube Hood
2 1 1 33714A Läufer Fan rotor
3 1 1 86554A Einströmring (Beutel) Air inlet ring (bag)
4 1 1 309761 Kabelbinder L = 178 Cable clamp L = 178
5 1 9024066A Motor 24V (Beutel) Motor 24V (bag)
6 1 34530A Widerstand 0,45 Ohm resistor 0,45 Ohm
7 1 34531A Widerstand 1,8 Ohm resistor 1,8 Ohm
mit Dichtring / with
8 1 1 1316891A Ansauggehäuse Air intake housing
gasket ring
9 1 1 345962 Runddichtring DIN 3770 Gasket ring 120 x 4
10 2 2 82531A Kupplungshälfte Clutch half
11 1 1 412244 Rundschnurring Sealing ring
12 1 1 84986A Seitenkanalgebläse Side channel fan
13 1 1 33094A Zerstäuber Atomiser
14 1 1 344958 Verdränger Displacer
15 1 1 102423 Scheibe Washer
Temperaturbegrenzer Overheat protection
16 1 1 97703A
(Beutel) (bag)
mit Dichtring / with
17 1 1 1316890A Brennstoffleitung Fuel line
sealing ring
Ersatz für / replace-
18 1 1 97704A Wärmeübertrager Heat exchanger ment for
348 45A

Bild / Figure 2
3 5
108 14
112
2 6/7 13 15
1 108
117 12
4 119 11
102
10 16
9
109
119 107
8
17
104 116
105
106
21 113 18
22 120 114 20 19

12V 24V
19 x x 82451A Dichtschnur Ø 8 Sealing rope Ø 8
Vor Eingabe mit Pos. 131 bestreichen / To be coated with pos. 131 prior to installation
mit Montagemate-
20 1 1 1316886A Rückwand Back wall rial / With mounting
components
Glühkerzenvorwider- glow plug protective
21 1 35954A
stand 0,46 Ohm resistor 0,46 Ohm
Glühkerzenvorwider- glow plug protective
22 1 35953A
stand 1,15 Ohm resistor 1,15 Ohm
Elektrische Teile / Electrical Parts

Bild / Figure 3
3/4 9
1 2 7 8 10 12
11
5/6
13 14 15 16 / 17 14 20 21 22 23 24 25 26 27 28
18 / 19

12V 24V
1 1 63873A Glassockellampe 12V Light bulb 12V
1 1 63874A Glassockellampe 24V Light bulb 24V
Ersatz für / replace-
2 1 1 70948A Raumthermostat Room thermostat
ment for 157895
Vorwahluhr 12V Digital timer 12V
3 1 63400A
3 Zeiten, 9-polig 3 selction times, 9 poles
Vorwahluhr 24V Digital timer 24V
4 1 63399A
3 Zeiten, 9-polig 3 selection times, 9 poles
5 1 467936 Lampe 12V Light bulb
6 1 469009 Lampe 24V Light bulb
Verbindungslasche zu Connecting clip to fuse
7 3 3 28271A
Sicherungshalter holder
Deckel zu
8 3 3 28267A Cover for fuse holder
Sicherungshalter
9 2 2 103922 Flachsicherung 20A gelb Flat fuse 20A yellow Info 281
10 1 118828 Flachsicherung 10A rot Flat fuse 10A red
Flachsicherung 5A
11 1 103737 Flat fuse5A light brown Info 281
hellbraun
12 3 3 28264A Sicherungshalter Fuse holder
Anbausatz für Vorwah-
13 1 1 474630 Mounting plate for timer
luhr
Elektrische Teile / Electrical Parts

Bild / Figure 3
3/4 9
1 2 7 8 10 12
11
5/6
13 14 15 16 / 17 14 20 21 22 23 24 25 26 27 28
18 / 19

12V 24V
Schwingmetallpuffer Antivibration mount
14 x x 1310378A
M6 H = 10 M6 H = 10
1 Stück zu Pos.15 erforderlich, 2 Stück für Pos. 20 /
One piece required for pos.15, two pieces for pos. 20
15 1 1 21499A Schelle Clamp
16 1 28174B Dosierpumpe DP2 12V Dosing pump DP2 12V
17 1 9012872B Dosierpumpe DP2 24V Dosing pump DP2 24V
Brennstoffdosierpumpe Fuel dosing pump
18 1 9012868C
DP 30.2 12V DP 30.2 12V
Brennstoffdosierpumpe Fuel dosing pump
19 1 9012869C
DP 30.2 24V DP 30.2 24V
20 1 1 1310582A Spannschelle Clip Altertiv zu / alterna-
21 1 1 131320 Zwischenlage Interlayer tive for Pos. 15
Steckhülsengehäuse / Plug connector:
22 1 1 497088 2,8 2-polig 2,8 with 2 poles
23 3 3 454982 2,8 2-polig 2,8 with 2 poles
24 1 1 103792 2,8 4-polig 2,8 with 4 poles
25 1 1 376264 6,3 1-polig 6,3 with 1 poles
26 1 1 178713 6,3 2-polig 6,3 with 2 poles
27 1 1 178721 6,3 2-polig 6,3 with 2 poles
28 1 1 178764 6,3 8-polig 6,3 with 8 poles
Brennstoffsystem / Brennluftsystem / Abgassystem / Montageteile

Fuel system / Combustion Air System / Exhaust System / Mounting Parts
Bild / Figure 4
29 / 30 31 32
33 34 35 36 37

12V 24V
Brennstoffsystem / Fuel supply
29 x x 1310947A Schlauchschelle Ø 10 Hose clamp Ø 10
30 x x 1310763A Schlauchschelle Ø 12 Hose clamp Ø 12
Brennstoffschlauch Fuel hose Meterware /
31 x x 483931
Øi = 2 Øa = 5 Øi =2 Øe = 5 per metre
Brennluftsystem / Combustion air system
Intake pipe
32 1 1 38623A Ansaugrohr mit Splint
with securing pin
Ansaugschalldämpfer Air intake silencer
33 1 1 86759A
Øi = 30 L = 500 Øi = 30 L = 500
Abgassystem / Exhaust system
34 1 1 370169 Rohrkrümmer Ø38 Elbow Ø38
Montageteile / Mounting parts
35 2 2 163204 Spannschloß Turnbuckle
36 2 2 19697B Spannband Tightening clamp
37 2 2 337986 Auflage Support
Normteile / Standard Parts

12V 24V
Blechschraube Self tapping screw
101 x x 1310735A Bilder / Figures 1, 2
DIN 7981 4,2 x 9,5 DIN 7981 4,2 x 9,5
102 1 1 35142B Bild / Figure 2
DIN 7981 4,2 x 70 DIN 7981 4,2 x 70
103 2 2 1310769A Bild / Figure 1
DIN 7963 4,8 x 16 DIN 7963 4,8 x 16
Linsenkopfschraube Oval head screw
104 x x 1310704A Bild / Figure 1
DIN 7985 M 4 x 8 DIN 7985 M 4 x 8
Linsenkopfschraube Oval head screw
105 3 3 13103819A Bild / Figure 2
DIN 7985 M 6 x 50 DIN 7985 M 6 x 50
Linsenblechschraube Slotted pan head screw
106 1 2 84097B Bild / Figure 2
DIN 7981 6,3 x 120 DIN 7981 6,3 x 120
Schraube Screw
107 2 2 16423B Bild / Figure 2
DIN 7500 M 3 x 8 DIN 7500 M 3 x 8
Schraube Screw
108 6 6 1310768A Bild / Figure 2
DIN 7985 M 5 x 16 DIN 7985 M 5 x 16
Kombischraube Combination screw
109 3 3 488631 Bild / Figure 2
M 5 x 12 M 5 x 12
110 2 2 34771A Rapid-Mutter EX-2508 EX-2508 rapid nut Bild / Figure 1
111 3 3 387177 Blechmutter B 4,2 Plate nut B 4,2 Bild / Figure 1
Hutmutter Cap nut
112 1 1 34519A Bild / Figure 2
DIN 917 M 8 DIN 917 M 8
Gewinde mit Hochtemperaturfett Copaslip einstreichen /
Thread to be greased with high-temperature grease Copaslip
Sechskantmutter Hexagon nut
113 3 3 1310694A Bild / Figure 2
ISO 4032 M 4 ISO 4032 M 4
Federring Spring washer
114 x x 152544 Bild / Figure 1, 2
DIN 128 A4 DIN 128 A4
Federring Spring washer
116 3 3 152560 Bild / Figure 2
DIN 128 A6 DIN 128 A6
Scheibe Washer
117 1 1 153567 Bild / Figure 2
DIN 9021 A 4,3 DIN 9021 A 4,3
Zahnscheibe Tooth lock washer
119 x x 31567A Bild / Figure 2
DIN 6797 V 4,3 DIN 6797 V 4,3
Bild / Figure 2;
Blechschraube Self tapping screw als Verschluß-
120 1 9012598A
DIN 7981 6,3 x 13 DIN 7981 6,3 x 13 schraube /
as closing screw
Bild / Figure 1;
Hochtemperaturfett Co- High temperature grease
130 x x 105898 zu / for Pos 7
paslip Tube 100g Copaslip tube with100g
[1]
Kleb - und Dichtstoff Jointing paste
131 x x 66605A
Kartusche 0,3 l Cartouche 0,3 l
[1] Für die Überwurfschraube bei Position 7 / For the inverted nut near position 7
Bei mehrsprachigen Dokumentversionen ist die englische Version bindend.

In case of multilingual document versions the English version is binding.
Webasto Product Benelux B.V.

Constructieweg 47
NL-8263 BC Kampen
The Netherlands
Tel.:+31 (0)38 337 11 37

Fax +31 (0)38 332 51 81
E-mail: kundendienst@webasto.com
Internet: www.webasto.com
Technical Extranet: http://dealers.webasto.com
Änderungen vorbehalten
Subject to modification
€ 5,-
© Webasto AG Global Comfort Solutions 2011
Air Heaters Repair Shop Manual
HL 90
(Diesel)
07/2000
HL 90 List of Contents
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 Legal Provisions for Installation.................................................................................................. 101

1.4.2 General Safety Notes ................................................................................................................. 102
1.5 Corrections and Improvements.............................................................................................................. 103
2 General Description
2.1 Drive ...................................................................................................................................................... 201

2.2 Heat Exchanger ..................................................................................................................................... 201
2.3 Control Unit............................................................................................................................................ 201
2.4 Flame Sensor ........................................................................................................................................ 202
2.5 Glow Plug .............................................................................................................................................. 202
2.6 Temperature Limiter .............................................................................................................................. 202
2.7 Dosing Pump ......................................................................................................................................... 202
3 Functional Description
3.1 Controls ................................................................................................................................................. 301

3.2 Switch On ...............................................................................................................................................301
3.3 Heating Operation.................................................................................................................................. 301
3.3.1 Operation with Room Thermostat (mechanical) ......................................................................... 301

3.3.2 Operation with Switch................................................................................................................. 301
3.3.3 Operation with Timer .................................................................................................................. 301
3.4 Switch Off .................................................................................................................. ............................ 301

3.5 Ventilation Operation ............................................................................................................................. 301
4 Technical Data
4.1 Electrical Components........................................................................................................................... 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 CO2 Contents ...................................................................................................... 601
6.3 Components Testing.............................................................................................................................. 601
6.3.1 Temperature Limiter Resistance Check ..................................................................................... 601

6.3.2 Flame Sensor Resistance Check ............................................................................................... 601
List of Contents HL 90
7 Circuit Diagrams and Examples for Electrical Installation
7.1 General ................................................................................................................................................. 701
8 Servicing
8.1 General ................................................................................................................................................. 801

8.2 Work on the Air Heater ......................................................................................................................... 801
8.3 Work on the Vehicle.............................................................................................................................. 801
8.4 Air Heater Test Run .............................................................................................................................. 801
8.5 Servicing ................................................................................................................... ............................ 801
8.6 Visual Inspections and Installation Regulations.................................................................................... 801
8.6.1 Heating Air System .................................................................................................................... 801

8.6.2 Fuel Supply................................................................................................................................ 802
8.6.3 Dosing Pump ............................................................................................................................. 804
8.6.4 Fuel Filter................................................................................................................................... 804
8.6.5 Combustion Air Supply .............................................................................................................. 805
8.6.6 Exhaust Line .............................................................................................................................. 805
8.6.7 Combustion Air Intake and Exhaust Lines................................................................................. 805
8.7 Removal and Installation....................................................................................................................... 806
8.7.1 Heater, Removal and Installation .............................................................................................. 806

8.7.2 Control Unit, Replacement ........................................................................................................ 806
8.7.3 Glow Plug, Replacement ........................................................................................................... 806
8.7.4 Flame Sensor, Replacement ..................................................................................................... 806
8 7.5 Temperature Limiter, Replacement ........................................................................................... 806
8.8 First Operation ...................................................................................................................................... 806
9 Repair
9.1 General ................................................................................................................................................. 901
9.1.1 Work on Components after Disassembly .................................................................................. 901
9.2 Disassembly and Assembly .................................................................................................................. 902
9.2.1 Control Unit, Replacement ........................................................................................................ 902

9.2.2 Glow Plug, Replacement ........................................................................................................... 903
9.2.3 Flame Sensor, Replacement ..................................................................................................... 903
9.2.4 Temperature Limiter, Replacement ........................................................................................... 903
9.2.5 Drive, Replacement ................................................................................................................... 903
9.2.6 Drive, Disassembly and Assembly ............................................................................................ 905
9.2.7 Heat Exchanger, Replacement.................................................................................................. 907
10 Packaging, Storage and Shipping
10.1 General ............................................................................................................................................... 1001
II
HL 90 List of Figures
List of Figures
301 Functional Diagram.......................................................................................................................................... 302
501 General Failure Symptoms .............................................................................................................................. 501
701 Operation with Timer and Room Thermostat................................................................................................... 702

702 Operation with Switch (Full Load - Part Load) and Ventilation ........................................................................ 703
703 Operation with Room Thermostat (Full Load - Part Load) and Ventilation ...................................................... 704
704 Example for Electrical Installation "Operation with Switch and Ventilation"..................................................... 705
705 Example for Electrical Installation "Standard Wiring Harness" ........................................................................ 706
801 Hot Air Temperatures with Drop of Pressure (12V Heaters)............................................................................ 802
802 Fuel Supply ...................................................................................................................................................... 802
803 Webasto Fuel Tank Tap................................................................................................................................... 803
804 Fuel Tapping from Plastic Tank (tapping via fuel drain plug)........................................................................... 803
805 Fuel Tapping from Plastic Tank (tapping via fitting plate) ................................................................................ 803
806 Pipe/Hose Connection ..................................................................................................................................... 804
807 Dosing Pump, Installation and Attachment ...................................................................................................... 804
808 Fuel Filter ......................................................................................................................................................... 804
809 Air Intake Muffler.............................................................................................................................................. 805
810 Exhaust Muffler, Direction of Flow ................................................................................................................... 805
811 Exhaust Pipe Outlet, Installation Position ........................................................................................................ 805
901 Replacement of Control Unit, Glow Plug, Flame Sensor and Temperature Limiter......................................... 902
902 Disassembly of Drive ....................................................................................................................................... 904
903 Replacement of Heat Exchanger ..................................................................................................................... 907
III
List of Contents HL 90
IV
HL 90 1 Introduction
1 Introduction 1.4.1 Legal Provisions for Installation
Within the scope of the StVZO (Road Licensing

1.1 Scope and Purpose Regulations of the Federal Republic of Germany) "Design
General Approvals", laid down by the Federal Office for
This repair shop manual is intended to support Motor Traffic, exist for the Air Heaters HL 90 with the
familiarised personnel in the repair of air heaters HL 90 of following official marks of conformity:
the Diesel type.
~ S 269 (Diesel)
1.2 Meaning of Warnings, Cautions, The installation of the heaters is to be performed in

accordance with the installation instructions and must be
and Notes
checked in case of
a) the vehicle type inspection in accordance with
WARNINGS, CAUTIONS, and NOTES in this manual § 20 StVZO
have the following meaning: b) the individual inspection in accordance with
§ 21 StVZO or
WARNING c) the examination in accordance with § 19 StVZO per-
This heading is used to highlight that non-compliance formed by an officially authorised expert or examiner
with instructions or procedures may cause injuries or for road traffic, a vehicle inspector or a public servant
lethal accidents to personnel. as per section 4 of Annex VIII to the StVZO.
In the event of c) the installation must be certified on the
CAUTION acceptance certificate formsheet included in the copy of
This heading is used to highlight that non-compliance the "General Operating License" or on a formsheet
with instructions or procedures may cause damage to according to the specimen of an “approval” included in the
equipment. Traffic rules 1994, Page 148.
This validates the "Design General Approval". The
NOTE acceptance certificate must be kept with the vehicle. The
This heading is used to highlight and draw specific year of first operation must be permanently marked on the
attention to information. identification label by removing the numerals of the years
not applicable.
1.3 Additional Documentation to be used The heat exchanger of the air heater remains
serviceable for a maximum of 10 years and must then
This workshop manual contains all information and be replaced with an original spare part by the manu-
procedures necessary for the repair of air heaters HL 90. facturer or by one of its authorized workshops.
The use of additional documentation is normally not The heater must then be provided with a label marked
necessary. Operating instructions/ installation instructions with the sales date and with the words "Original
and the vehicle specific installation proposal may be used Spare".
as complementary information as necessary. When replacing the heat exchanger it is mandatory
to also replace the overheat protection element
(temperature limiter) to avoid possible malfunctions
of old temperature limiters in use.
1.4 Safety Information and Regulations
Should exhaust pipes be routed through rooms
accommodating persons, these pipes shall also be
The general safety regulations for the prevention of renewed after 10 years by original spare parts.
accidents and the relevant operating safety instructions When removing the heater the gasket below must be
have to be observed at all times. "General Safety renewed.
Regulations" beyond the scope of these regulations are
detailed in the following. The heaters are cleared for heating the passenger and
The specific safety regulations applicable to this manual driver cabins but not for heating compartments intended
are highlighted in the individual chapters by Warnings, for the transportation of dangerous goods.
Cautions, and Notes. The use of the heater in special vehicles (e.g. vehicles for
the transportation of dangerous goods ADR) or vehicles
not subject to the StZVO (e.g. ships) are ruled by partially
regional regulations.
101
1 Introduction HL 90
Heating Air System Metal lines must be used. These may not heat to more
Heating air intake openings must be arranged so that than 110° C should there be the possibility of contact
under normal operating conditions exhaust fumes of the within the room interior. Protective devices against con-
vehicle engine or air heater are not likely to be expected. tact may be fitted.
Extracting combustion air from the vehicle interior is not Combustion Air Inlet and Exhaust Outlet
permissible. During installations these ports for combustion air entry
and exhaust fume exit must be of such type, that a ball
Combustion Air Line with a diameter of 16 mm cannot be inserted.
The combustion air required must be taken from the Electrical lines, switch gear and control gear of the heater
exterior. must be located in the vehicle so that their proper function
Within rooms accommodating persons, the combustion cannot be impaired under normal operating conditions.
air lines must not have more than four disconnects
and a splash-water protected exterior wall feedthrough. For the routing of fuel lines and the installation of
The disconnects must be sealed in a way not to exceed additional fuel tanks §§ 45 and 46 of the StVZO are to be
a leak rate of 200 l/h at an overpressure of 0.5 mbar. adhered to.
The line including feedthrough, disconnects, material The most important regulations are: Fuel lines are to be
and specific type must be described in the installation designed in such a way that they remain unaffected by
instructions. torsional stresses in the vehicle, engine movement and
The line must require tools for installation and removal, the like. They must be protected against mechanical
must be protected against damage, and must be shock- damage.
proof. Fuel-carrying parts are to be protected against excessive
heat and are to be arranged so that any dripping or
Exhaust Line evaporating fuel can neither accumulate nor be ignited by
Heaters must be designed to discharge the exhaust to hot components or electrical equipment.
the exterior. In busses, fuel lines and fuel tanks may be located neither
Exhaust pipes must be routed so that exhaust fumes are in the passenger area nor in the driver's compartment.
unlikely to penetrate into the vehicle's interior. In these type of vehicles the fuel tanks must be located
The function of any parts of the vehicle essential for its such that they do not pose a direct hazard to the exits in
operation must not be impaired. Condensate or water the event of a fire. Fuel supply must not be by means of
penetrated must not be able to accumulate in the gravity or pressurization of the fuel tank.
exhaust line.
Drain holes are permissible; these must drain the fluid to 1.4.2 General Safety Notes
the exterior via lines sealed against the vehicle interior.
The exhaust line outlet is to be positioned to the top, to The heater must not be installed in the passenger or
the side, or in case of exhaust venting below the vehicle driver compartments of busses. Should the heater never-
floor, to the nearest possible location of the vehicle's or theless be installed in such a compartment, the installa-
cockpit's side or rear end. tion box must be sealed tight against the vehicle interior.
There must be sufficient ventilation of the installation box
In compartments accommodating persons, exhaust lines from the exterior in order not to exceed a maximum
must not have more than one disconnect and must have temperature of 40° C in the installation box. Excessive
a splash-water protected feedthrough in the exterior temperatures may cause malfunctions.
wall/floor. For water, that has penetrated into the exhaust
line, the connection of a drain line with a metal-sealing The heaters are cleared for heating the passenger and
joint is permissible. The drain pipe must be routed sealed driver cabin in the fresh air mode of operation and for load
through the exterior wall or the vehicle floor. top compartments in the fresh air or circulation air mode
The heat exchanger, the exhaust line connected, as well of operation. They are however not cleared for heating
as the possible drain pipe must be sealed so that with an loading compartments for dangerous goods. The installa-
overpressure of double the overpressure of the exhaust tion in enclosed areas accommodating persons is not
having the maximum permissible exhaust line length – at permitted.
least however at an overpressure of 0.5 bar – a total leak If an air heater is installed in a loading compartment for
rate of 30 l/h is not exceeded. circulation air mode of operation the inside of the entrance
door shall be labeled as follows: "With heater on no
The line including feedthrough, disconnects, material personnel allowed in loading area with door closed."
and specific type must be described in the installation
instructions. The line must require tools for installation and The heaters HL 90 are marked with the word "Diesel"
removal, must be protected against damage, and must be on their identification plate. The heaters may only be
shockproof. operated with the specified type of Diesel (or with fuel oil
EL) and the appropriate type of electrical installation.
102
HL 90 1 Introduction
Installation Instructions for Webasto Fuel Tanks for The heater must not be cleaned with water, fluids or high
Fuel Supply of Heaters in Vehicles pressure cleaners, etc.
In busses the installation is not permitted in the passen-
gers or driver's compartment. Do not switch off heater with the battery master switch or
The fuel filler neck must not be located in the passengers the battery emergency off switch to prevent possible long
or driver's compartment of any type of vehicle. Fuel reser- time damage and malfunctions of the heater.
voirs for carburettor fuel must not be located immediately
behind the vehicle front fairing. They must be away from The operating condition of the heater – least on or off –
the engine to prevent fuel fires in case of accidents. must be clearly visible.
The same applies to towing vehicles with open cockpit.
It is mandatory to install the seal between the heater Non-compliance with the installation instructions and its
mounting and the vehicle floor to prevent poisonous procedures will void the warranty by Webasto. The same
exhaust fumes from entering the vehicle interior. applies for repairs performed by unskilled personnel or
All fuel line connections must be tight, must show no not using original spare parts. This will also invalidate the
damage and have to be inspected in regular intervals official marks of conformity and thus the vehicle’s permit
(at least in the same frequency as vehicle inspections). of operation.
When detecting damages or leaks the heater must not be
operated until repair will have been performed by an Make sure to read the operating instructions before you
authorised Webasto repair shop. operate the heater.
NOTE
Make heater inoperative by removing fuse. The fuel lines 1.5 Corrections and Improvements
(Mecanyl hoses) must not be in direct contact with the
exhaust pipe and be provided with a heat insulation as
Deficiencies, improvements, or proposals for correction
required to prevent fires.
of this workshop manual are to be mailed to:
Keep air intakes and exit ports for warm and heating air
Webasto Thermosysteme GmbH
clean and free from foreign objects. Contaminated and
Abt. Technische Dokumentation
clogged air ducts may cause overheating and response of
D-82131 Stockdorf
the temperature limiter. After an overheat condition with
automatic switch-off check air ducting is free from
Telefon: 0 89 / 8 57 94 - 5 42
contamination and remove all objects that might block the
Telefax: 0 89 / 8 57 94 - 7 57
airstream or have damage repaired by an authorized
Webasto repair shop. Then reset the temperature limiter.
Should these corrective actions not cure the problem
(overheating occurs again), consult an authorized
Webasto repair shop. Never remove the air intake screen
upstream of the heater.
The air jets with adjustable flops must always be open in

a way that the airflow through the heater is not blocked.
A frequently restricted or blocked airflow may cause long
time damage. Should a heater be located in a stowage
compartment, it must be ensured that no flammable
material is stowed in this compartment and that other
material does not restrict the air supply of the heater.
Air lines must be securely fastened to the heater and
the air jets (e.g. with pipe clamps).
Do not step on the heater and do not deposit heavy

objects on or throw against the heater.
Do not throw garments, fabrics or similar material on top
of the heater or in front of the heating air intake or exit.
The warm air flow of the heater must not be restricted or
blocked by easily flammable substances or material like
rags, cleaning wool, etc., to prevent fires and smoke.
Flammable or explosive material or gasses must be kept

away from the vicinity of the heater, the warm air ducting
or the heating airflow.
103
1 Introduction HL 90
Page free for notes
104
HL 90 2 General Description
2 General Description 2.1 Drive
The drive provides for fuel supply with atomisation and

The air heater HL90 is used to
combustion air supply to the combustion chamber in the
heat exchanger.
– heat the driver compartment and the vehicle interior/
The drive basically consists of the air intake housing with
passenger compartment
fuel and combustion air connection, the bypass fan and
– defrost the windscreen
the atomiser.
– heat vehicle loading compartments
The motor is flanged to the air intake housing driving the
The heaters are cleared for heating the passenger
bypass fan and the atomiser via a clutch. The motor also
compartment and the driver compartment in the fresh air
drives a rotor to suck in fresh air or circulation air across
mode of operation of and vehicle loading compartments
an orifice plate.
in the fresh air or circulation air mode of operation. The
heating of loading compartments for dangerous goods is
Resistors for the glow plug and the motor are also
not permitted.
mounted to the air intake housing.
The heater operates independent from the vehicle engine
and is connected to the vehicle's electrical system and
fuel system. 2.2 Heat Exchanger
The heaters may be operated in vehicles with water or
air-cooled engines. The heat exchanger transfers the heat generated by
combustion to the heating air circulated by the fan.
The heater designed to the rotation atomiser principle
operates intermittently controlled by the temperature
sensor.
The heater HL90 basically consists of the:
– drive
– heat exchanger
For control and monitoring the heater includes a:
– control unit
– flame sensor
– glow plug
– temperature limiter
Fuel supply is provided externally by a fuel dosing pump.
2.3 Control Unit
The control unit ensures controlled operation and

monitoring of combustion.
K
61G
15
SG
201
2 General Description HL 90
2.4 Flame Sensor 2.6 Temperature Limiter
The flame sensor is a photo transistor changing its The temperature limiter protects the heater against undue
resistance depending on the flame intensity. The signals high operating temperatures. The temperature limiter
are supplied to the control unit for processing.The flame responds at a temperature in excess of 175° C to
sensor continuously monitors the flame condition during disconnect the electrical circuit and switch off the heater
heater operation. with a run-down.
After the temperature limiter has cooled down, it may be
reset by pressing the reset pin. The heater may then be
switched on again.
Reset Pin
2.5 Glow Plug
The glow plug ignites the fuel/air mixture during heater 2.7 Dosing Pump
start. The glow plug voltage is 4.2 Volts.
The dosing pump is a combined delivery, dosing and
shut-off system for the fuel supply of the heater out of the
vehicle fuel tank.
Dosing Pump DP 2
Dosing Pump DP 30
202
HL 90 3 Functional Description
3 Functional Description • Part load / off operation

After reaching the temperature set with the room
(Fig. 301) thermostat (upper switching point) the heater is switched
off. The operating indicator light remains on to indicate a
3.1 Controls run-down with full speed operation of the heating and
combustion air fan motor.
When the temperature reaches the lower switching
The heaters may be equipped with the following controls: threshold of the room thermostat, a new start procedure
– room thermostat (mechanical) commences. The heater operates in full load.
– switch After a short time of full load combustion operation there
– timer will be transition to part load operation.
Activation and deactivation is by means of the switch,
3.3.2 Operation with Switch
timer or room thermostat with on/off switch.
During heating operation with a switch manual selection
An operating indicator light (in timer, switch or room
between full load and part load is possible.
thermostat) indicates the heater on condition.
3.3.3 Operation with Timer
3.2 Switch On The timer is used for switch on with a switch (instant heat)
or for time preset operation. A control in the operating
Upon switch on the operating indicator light goes on and modes full load / part load may be provided by integration
the glow plug is powered. After approximately 35 seconds of the room thermostat (mechanical).
the fuel dosing pump is put into operation. After another
5 seconds the motor of the heating and combustion air fan
is activated. Combustion commences. After flame-up the 3.4 Switch Off
glow plug is switched off.
If no proper combustion is achieved within 100 seconds, Switching the heater off extinguishes the operating
indicator light of the room thermostat, the switch or the
an automatic restart is performed. If the no combustion
condition persists, an error lockout will occur within timer. Fuel supply is cut off stopping combustion.
another 80 seconds with a subsequent run-down of
150 seconds. The motor of the heating and combustion air fan continues
operation to cool the heater down (run-down).
The operating indicator light remains on in case of an
error lockout condition. Run-down time: 150 to 190 seconds
Run-down operation is controlled automatically.
3.3 Heating Operation NOTE

The motor of the heating and combustion air fan always
During operation combustion gasses flow through the operates in full load during run-down.
heat exchanger to dissipate heat onto the heat exchanger Re-activation of the heater during run-down is permitted.
casing from where it is picked up by the heating air flow to Run-down is then completed with a subsequent new start.
the vehicle interior maintained by the heating air fan.
3.3.1 Operation with Room Thermostat 3.5 Ventilation Operation

(mechanical)
When equipped with a room thermostat ventilation
The room thermostat (mechanical) allows selection of operation is only possible with a separate switch
full load / part load or part load / off. (order no. 109 995 (24V), 109 999 (12V)).
• Full load / part load operation
After reaching the temperature set with the room
thermostat (upper switching point of the room thermostat)
part load operation will be initiated. When the temperature
drops below the lower switching point, the heater resumes
full load operation. In part load operation motor speed and
dosing pump fuel delivery is reduced.
301
3 Functional Description HL 90
1 3 5 7 9 11 7 14 16
2 4 6 8 10 12 13 15
A
B
C
D
E
F
✽
1 Switch on A Operating indicator light on

2 Preheating 35 s B Switch or room thermostat
(full load / part load) or timer
3 Fuel priming
C Flame sensor
4 Full load initiation
D Glow plug
5 Safety period max. 100 s
E Dosing pump (full load / part load)
6 Minimum full load time 60 s
F Combustion air fan (full load / part load)
7 Combustion operation – full load
8 Room temperature (at rated value)
* In case of no flame condition
9 Transition from full load to part load 8 s automatic repeat start
(25 s preheating, 80 s safety period)
10 Combustion operation – part load
11 Room temperature (below rated value)
12 Transition from part load to full load 10 s
13 Switch off
14 Optical run-down max. 40 s
15 Electronic run-down 150 s
16 Off
Fig. 301 Functional Diagram
302
HL 90 4 Technical Data
4 Technical Data 4.1 Electrical Components
Control unit, motor, dosing pump, glow plug resistor,

Where no threshold values are specified technical data
part load resistor, timer and switch with indicator light are
are understood to include standard tolerances for heater
12 V or 24 V components.
units of ±10% at ambient temperature of +20° C and at
nominal voltage.
Temperature limiter, flame sensor and glow plug are
identical in 12 V and 24 V heaters.
Glow plug default voltage is 4.2 V +0.1/–0.15 at nominal

voltage at control unit input (A1).
Air Heater HL 90
Heater type HL 90
Type ~ S 269
Mark of conformity Air Heater with rotation atomiser
Heat flow full load operation kW 9
part load operation kW 6.5
Type of fuel Diesel / Fuel oil EL
Fuel consumption full load operation kg/h (l/h) 1.00 (1.20)
part load operation kg/h (l/h) 0.71 (0.86)
Nominal voltage V– 12 or 24
Operation voltage V– 10 ... 14.5 or 20.5 ... 29
Rated power consumption full load operation W 160 110
24 V 12 V
(not in start operation) part load operation W 095 085
Permitted ambient temperature (operation):
– Heater °C –40 ... +50
– Control unit °C –40 ... +85
– Dosing pump °C –40 ... +40
Permitted ambient temperature (storage):
– Heater °C –40 ... +85
– Control unit °C –40 ... +85
– Dosing pump °C –40 ... +85
Setting range of indoor temperature °C +30 max.
Volume flow of heating air
– against 0.5 mbar full load operation m3/h 310 280
24 V 12 V
– against 0.25 mbar part load operation m3/h 215 195
CO2 in exhaust
– permitted functional range full load operation Vol.-% 7 ... 10
CO in exhaust
– at no wind Vol.-% 0.1 max.
– at 100 km/h Vol.-% 0.2 max.
HC in exhaust at nominal load and no wind Vol.-% 0.01 (100 ppm) max.
NOx in exhaust at nominal load and no wind Vol.-% 0.02 (200 ppm) max.
Soot number – to Bacharach < 6.0
– to Bosch < 0.5
Dimensions heater: length mm 650
(tolerance ± 3 mm) width mm 235
height mm 260
Dimensions dosing pump: length mm 113
(tolerance ± 3 mm) width mm 40
height mm 35
Dimensions control unit 1561: length mm 97
(tolerance ± 3 mm width mm 102
height mm 36
Weight: Heater kg 13
Control unit kg 0.30
Dosing pump kg 0.35
401
4 Technical Data HL 90
Page free for notes
402
HL 90 5 Troubleshooting
5 Troubleshooting check fuel, combustion air and

exhaust lines for obstructions
corrosion on connectors
5.1 General loose contacts on connectors
wrong crimping on connectors
This section describes troubleshooting procedures for corrosion on wiring and fuses
the heater HL90. corrosion on battery terminals
CAUTION For individual component checks the electrical

Troubleshooting requires profound knowledge about connections on the control unit have to be disconnected.
components and their theory of operation and may only
be performed by trained personnel. After any fault correction a functional checkout in the
vehicle has to be performed.
In case of doubt functional interrelations may be derived
from Sections 2 and 3.
5.2 General Fault Symptoms
CAUTION
Troubleshooting is normally limited to the isolation of The following table (Fig. 501) lists possible fault
defective components. symptoms of general nature.
The following possible causes for trouble have not been
taken into consideration and must always be excluded
as a possible cause for malfunction:
Symptom Probable Cause Remedy
Heater switches off No combustion after start and Switch off heater momentarily and
automatically restart switch on once again
Flame-out during operation Switch off heater momentarily and

switch on once again
Heater overheats Check combustion air ducting for

Dosing pump does not deliver fuel obstructions,
allow heater to cool down,
reset temperature limiter,
Press reset pin on
temperature limiter
HL 90
Check dosing pump
Vehicle’s electrical system voltage Charge battery

too low
Heater is immediately Replace sensor defective Replace flame sensor

in run-down
Heater develops Combustion air and/or exhaust Check combustion air and exhaust
black smoke ducting clogged ducting for obstructions
Fig. 501 General Failure Symptoms
501
5 Troubleshooting HL 90
Page free for notes
502
HL 90 6 Functional Checkouts
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 exhaust
ventilation facilities.
6.2 Adjustments
6.2.1 Adjustment of CO2 Contents
The HL90 heater does not require a CO2 adjustment.
6.3 Components Testing
CAUTION
For individual components checks the electrical
connections on the control unit must be disconnected.
6.3.1 Temperature Limiter Resistance Check
With the reset pin pressed check temperature limiter for

electrical continuity.
6.3.2 Flame Sensor Resistance Check
The check is to be performed with an ohmmeter.
NOTE
The resistance is to be checked alternately on the
connector (reversed polarity).
No light for flame sensor (photo transistor)

• resistance 5 kΩ
601
6 Functional Checkouts HL 90
Page free for notes
602
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. 704) as well as the use of the standard wiring
harness (Fig. 705).
701
7 Circuit Diagrams and Examples for Electrical Installation HL 90
1,5mm2 58
58
1,5mm2 75 (15)
75 (15)
4mm2
30 30
1 10 11 F1 F2
1,5mm2
2,5mm2
0,75mm2
2
XA
2 1
H2 8 A2
0,75mm2
6
H1
H3 6 3 K4 K3 K2 K1
9
T
1 6 5 10 2 4 12 14 1 2 4
P 0,75mm2
sw 1mm2
gn 1mm2
br
X12
12 7 4 XC XB
X2
1 2
rt/bl 0,75mm2
bl 0,75mm2
rt 1,5mm2
vi 1,5mm2
B3 S2
br 1mm2
2
bl 1mm
5 0,75mm2
ge 1,5mm2
br 0,75mm2
br 2,5mm2
2,5mm2
S3
0,75mm2
X6 X5 X7 br br
1,5mm2
1
X4 X3 0,75mm 2
1 2
1 2 3 1 4 2 2 1 2 1
X00
gn
S4 rt/bl
sw
bl
or
WS
rt
ge
3 0,75mm 2 R1
M R2 X0
br
vi
H1
1,5mm2
B2 M B1 ge E
4 0,75mm 2
Y A1
4mm2
31 31
4mm2
S6
Wire Colours
bl blue
br brown
ge yellow
Wire Gauges gn green
gr grey
< 7.5 m 7.5 - 15 m
XA XB XC X2 X4 X3; X5 X6 X7 X12 or orange
0.75 mm2 1.5 mm2
2
1 3 5 7 9 11 13 rt red
6 5 4 2 1 1 2 3
1.0 mm2 1.5 mm2
3 2 1 1 1 4 3 4 5 6
sw black
2
7 8 9 1.5 mm2 2.5 mm2
2 4 6 8 10 12 14 10 11 12 vi violet
2.5 mm2 4.0 mm2
ws white
4.0 mm2 6.0 mm2
Item Nomenclature Remark Item Nomenclature Remark Item Nomenclature Remark

Y Dosing pump 12V S2 Switch, ON/OFF F1 Flat fuse 24V 20A
Y Dosing pump 24V R2 Glow plug resistor 12V E Glow plug 4V
X12 Connection 12-pole R2 Glow plug resistor 24V B3 Room thermostat 12/24V
X7 Connection 4-pole R1 Resistor 12V B2 Temperature limiter 12/24V
X6 Connection 2-pole R1 Resistor 24V B1 Flame sensor 12/24V
X5 Connection 2-pole P Timer (1531) 12V A2 Control unit 12V
X4 Connection 2-pole P Timer (1531) 24V A2 Control unit 24V
X3 Connection 2-pole M Motor 12V A1 Heater HL 90 12V
X2 Connection 2-pole M Motor 24V A1 Heater HL 90 24V
X1 Connection 1-pole K4 Relay in control unit
X0 Clamping connection Glow plug + K3 Relay in control unit
X00 Clamping connection Glow plug – K2 Relay in control unit
XC Connect. for tab receptacle 14-pole K1 Relay in control unit
XB Connect. for tab receptacle 2-pole H3 Symbol illumination for digital display
XA Connect. for tab receptacle 6-pole H2 Operating indicator light, heating / ventilation
T Transistor in control unit H1 Light Operation indicator
S6 Battery switch in vehicle F2 Flat fuse 12V 20A
S4 Thermostat, heating full load / part load F2 Flat fuse 24V 20A
S3 Switch, heating full load / part load F1 Flat fuse 12V 20A
Fig. 701 Operation with Timer and Room Thermostat
702
58 58
75 (15) 75 (15)
4mm3
30 30
1,5mm2
F3 F1 F2
S1
Ventilation
Off
1,5mm2
Heating full load
2,5mm2
Heating part load
XA
2 3
0,75mm2 2 1
4
A2
0,75mm2
5 6
0,75mm2 1
6 0,75mm2 3 K4 K3 K2 K1
0,75mm2 T
7 1 6 5 10 2 4 12 14 1 2 4
gn 1mm2
sw 1mm2 0,75mm
0,75mm2
H1 Heating 1,5mm2
XC br
XB
0,75mm2
H2 X2
Heating 1 2
Ventilation
rt/bl 0,75mm2
bl 0,75mm2
vi 1,5mm2
rt 1,5mm2
br 1mm2
bl 1mm2
ge 1,5mm2
br 0,75mm2
2,5mm2
2,5mm2
1,5mm2
X6 X5 X7 br
X4 br
X3 0,75mm2
1 2
1 2 3 1 4 2 2 1 2 1
rt/bl X00
sw
bl
or
gn
WS
ge
R1 br
M R2 X0
1,5mm2
vi
B2 M B1 E
Y A1 ge
2
4mm
31 31
4mm2
S6
Wire Colours
bl blue
br brown
ge yellow
gr grey
< 7.5 m 7.5 - 15 m
or orange
XA XB XC X2 X4 X3; X5 X6 X7 X12 0.75 mm2 1.5 mm2
1 3 5 7 9 11 13 rt red
6 5 4 2 2 1 1 2 3 1.0 mm2 1.5 mm2
1 sw black
1.5 mm2
1 3
2.5 mm2
3 2 1 4 4 5 6
2 4 6 8 10 12 14 2
7 8 9
vi violet
2.5 mm2 4.0 mm2
10 11 12
ws white
4.0 mm2 6.0 mm2

Y Dosing pump 12V R1 Resistor 24V E Glow plug 4V
Y Dosing pump 24V M Motor 12V B2 Temperature limiter 12/24V
X7 Connection 4-pole M Motor 24V B1 Flame sensor 12/24V
X6 Connection 2-pole K4 Relay in control unit A2 Control unit 24V
X4 Connection 2-pole K2 Relay in control unit A1 Heater HL 90 24V
X3 Connection 2-pole K1 Relay in control unit A1 Heater HL 90 12V
X2 Connection 2-pole H2 Operating indicator light, 12V
XC Connection for tab rectable 14-pole heating / ventilation
XB Connection for tab rectable 2-pole H2 Operating indicator light, 24V
XA Connection for tab rectable 6-pole heating / ventilation
X0 Clamping connection Glow plug + H1 Operating indicator light Operation indicator
X00 Clamping connection Glow plug – H1 Operating indicator light Operation indicator
T Transistor in control unit F3 Flat fuse 12V 10A
S6 Battery switch in vehicle F3 Flat fuse 24V 7.5A
S1 Switch, heating / Off / ventilation F2 Flat fuse 12V 20A
R2 Glow plug resistor 12V F2 Flat fuse 24V 20A
R2 Glow plug resistor 24V F1 Flat fuse 12V 20A
R1 Resistor 12V F1 Flat fuse 24V 20A
Fig. 702 Operation with Switch (Full Load - Part Load) and Ventilation
703
58 58
75 (15) 75 (15)
4mm2
30 30
B3 S2 5 1,5mm2
F3 F1 F2
S3 1 0,75mm2
S4
1,5mm2
2,5mm2
XA
H1 3 0,75mm2
2 1
4 A2
0,75mm2
3 K4 K3 K2 K1
T
1 6 5 10 2 4 12 14 1 2 4
Ventilation / Part load
1,5mm2
1,5mm2
B S5 0,75mm 2
sw1mm2
gn 1mm2
A br
XC XB
0,75mm2
H2 1,5mm2
F E
rt/bl
X2
rt/bl 0,75mm2
1 2 bl 0,75mm2
rt 1,5mm2
vi 1,5mm2
br 0,75mm2
ge 1,5mm2
br 2,5mm2
2,5mm2
br 1mm2
bl 1mm2
X6 X5 X7 br ge
1,5mm2
X4 X3 0,75mm2
1 2 1 2 3 1 4 2 2 1 2 1
rt/bl X00
sw
bl
gn
WS
or
rt
R1 M R2
ge
X0
br
vi
1,5mm2
B2 M B1 ge E
Y A1
4mm2
31 31
4mm2
S6
Wire Colours
bl blue
br brown
ge yellow
gr grey
< 7.5 m 7.5 - 15 m
XA XB XC X2 X4 X3; X5 X6 X7 X12 or orange
0.75 mm2 1.5 mm2
6 5 4 2
1 3 5 7 9 11 13
1
rt red
1.0 mm2 1.5 mm2
2 1 2 3
1
3 2 1 1 4 3 4 5 6
sw black
2 4 6 8 10 12 14 2
7 8 9
1.5 mm2 2.5 mm2
10 11 12
vi violet
2.5 mm2 4.0 mm2
ws white
4.0 mm2 6.0 mm2

Y Dosing pump 12V S2 Switch ON / OFF F2 Flat fuse 24V 20A
Y Dosing pump 24V R2 Glow plug resistor 12V F1 Flat fuse 12V 20A
X7 Connection 4-pole R2 Glow plug resistor 24V F1 Flat fuse 24V 20A
X6 Connection 2-pole R1 Resistor 12V E Glow plug 4V
X5 Connection 2-pole R1 Resistor 24V B3 Room thermostat 12/24V
X4 Connection 2-pole M Motor 12V B2 Temperature limiter 12/24V
X3 Connection 2-pole M Motor 24V B1 Flame sensor 12/24V
XC Connection for tab rectable 14-pole K3 Relay in control unit A2 Control unit 24V
XB Connection for tab rectable 2-pole K2 Relay in control unit A1 Heater HL 90 12V
XA Connection for tab rectable 6-pole K1 Relay in control unit A1 Heater HL 90 24V
X0 Clamping connection Glow plug + H2 Operating indicator light, 12V
X00 Clamping connection Glow plug – heating / ventilation
T Transistor in control unit H2 Operating indicator light, 24V
S6 Battery switch in vehicle heating / ventilation
S5 Switch, ventilation, full load / part load 12V H1 Light Operation indicator
S5 Switch, ventilation, full load / part load 24V F3 Flat fuse 12V 10A
S4 Thermostat, heating, full load / part load F3 Flat fuse 24V 7,5A
S3 Switch, heating, full load / part load F2 Flat fuse 12V 20A
Fig. 703 Operation with Room Thermostat (Full Load - Part Load) and Ventilation
704
3
2
4 17
5
1
6
4 X7
6 4
S1-1 =
S1-7 =1
S1
S1-3 1
S1
A B
XA C
4=br
XA
S1-4 6
H2 3 2 4
=6 1
S1-3 S1-6 S1-4
S1-3 =3 1=2
S1-6 F
S1-4
1
F2=1
7
14878A
2 3
4
30
(+)
30
3
F
2
F
1
S1-2
F
XA1
XA2
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 Installation "Operation with Switch and Ventilation"
705
X4
X2 X7
ge
=1 ge=2
2
1
X5 br=
2
vi=4
1
rt=3 A B
2 C
bl=C 5
1 B
rt/bl=
10
C
2
1
sw=
br=2
ge=1
C1
gn=
1 3 5 7
2 4 9
C6
sw=1 6 8 10 11 13
12 14
rt/bl=05 rt=2
vi=4
gn=6 C
br=14
bl=10
br=12
br
=X
00
br
=C
12
X3
X00
br=X7-2
X0 -1
ge=X4
1
3-
=X
br 12
C-
=X
br
X00
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 Installation "Standard Wiring Harness"
706
HL 90 8 Servicing
8 Servicing 8.5 Servicing
NOTE
8.1 General In order to avoid seizure of mechanical components, the
air heater should be operated every 4 weeks for at least
This section describes the servicing procedures allowed 10 minutes.
on the heater when installed.
The heater does not require maintenance. It should
however be checked by Webasto-trained skilled
8.2 Work on the Air Heater personnel in regular intervals, the latest before the heating
season begins (point of time, when the heater is more
For any type of work on the heater the main power supply frequently in use due to weather conditions).
cable is to be disconnected from the vehicle battery.
As long as the heater is in operation or in run-down the To ensure functional reliability of the heater the following
battery main power supply must not be disconnected to servicing must be performed:
prevent the heater from overheating by response of the
overheat protection. When performing long time repairs • check combustion air inlet and exhaust outlet for
on the heater its removal is considered appropriate. contamination (contaminated and clogged heating air
ducts may cause overheating and response of the
Repairs requiring a change of location the relevant temperature limiter).
installation instructions and the vehicle specific heater • clean air heater exterior (prevent the ingress of water).
installation proposal have to be observed. • check clamps for security.
• examine electrical connections for corrosion of
contacts and for security.
• check combustion air and exhaust ducts for damage
8.3 Work on the Vehicle and obstructions.
• check fuel lines and fuel filter for leakage and
CAUTION contamination.
In the vicinity of the heater a temperature of 85° C must • replace fuel filter if installed.
under no circumstances be exceeded (e.g. during paint
work on the vehicle).
8.6 Visual Inspections and Installation
Regulations
8.4 Air Heater Test Run
8.6.1 Heating Air System
WARNING
The heater must not be operated, not even with the timer, CAUTION
in enclosed areas like garages or workshops not provided
The integration of the air heater into the vehicle's own air
with exhaust ventilation facilities.
system requires an accurate adaptation and is not
recommended.
The heater may be used for heating the passenger and

driver cabin in the fresh air mode of operation and for
load top compartments in the fresh air or circulation air
mode of operation. If an air heater is installed in a loading
compartment for circulation air mode of operation the
inside of the entrance door shall be labeled as follows:
"With heater on no personnel allowed in loading area with
door closed!"
Due to the danger of poisoning or suffocation the air

heating system air intake must be arranged in a way that
under normal operating conditions exhaust fumes from
the vehicle engine are unlikely to be sucked in, not even
when a downstream fan is in use, e.g. by drawing air from
the engine compartment.
801
8 Servicing HL 90
∆P = 0 mm wc 124 °C (Max. temperature)

1. Free flow
20 °C
500
∅100
2. Partial restriction ∆P = 6 mm wc
135 °C
800
20 °C
00
500
800 R1
3. Max. pressure drop

Total pipe length 2,5 m
(Temperature limiter B2 responds at 175 °C)
∆P = 25 mm wc
172 °C
20 °C
50% of cross section = ∅ = 70 mm
Fig. 801 Hot Air Temperatures with Drop of Pressure (12V Heaters)
The heating air intake temperature must not exceed 8.6.2.1 Fuel Tapping
+30° C.
Vehicles with big engines (trucks) fuel tapping must be
Heating air duct minimum inner diameter: 100 mm from the fuel reservoir or a separate unpressurised fuel
tank (Fig. 803, 804 and 805). This separate fuel tapping
Past a brandnig (Y union) a heating air duct inner avoids an influence on the pressure.
diameter of 80 mm is permitted.
Maximum air pressure difference between suction and

pressure side of heating air duct: HL 90
2.5 mbar (25 mm wc) 12V/24V to 09.97

4.0 mbar (40 mm wc) 24V from 10.97
or retrofit
max. 3 m
max. 10 m
When exceeding this value the temperature limiter is very

likely to respond. The heating air hose must be secured at
its joints. i ø 2 mm
max. 2,5 m
iø 2-3mm
The air heater, when used in the ventilation mode of
operation, may also be used without any further
accessories when observing the air intake temperature
limitation (a heating air flow short circuit should be
HL 90
max. 3 m
avoided). i ø 2 mm
8.6.2 Fuel Supply

iø 2-3mm
max. 10 m
S
Fuel is tapped from the fuel reservoir of the vehicle or max. 3 m

from a separate fuel tank. Permitted pressures at the fuel
tapping location are listed in Fig. 802.
Permitted fuel feed At max. permissible negative

suction height S (m) pressure (bar) in fuel tank Fig. 802 Fuel Supply
0.00 –0.10
0.50 –0.06
1.00 –0.02
802
HL 90 8 Servicing
25
Hole Pattern Fuel Tank Tap
NOTE
The fitting plate must be
> 25 mm 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!
8.6.2.2 Fuel Lines

Plastic Tank
Fuel lines may only be steel, copper, or plastic lines made
of unhardened, light and temperature stabilised PA 11
or PA 12 (e.g. Mecanyl RWTL) according to DIN 73378.
As in most cases a permanently rising fuel line routing
cannot be ensured, the inner diameter must not exceed
a certain value. Starting from an inside diameter of 4 mm,
air or gas bubbles accumulate resulting in malfunctions
Gasket should the lines be descending or having sags. The
diameters specified in Fig. 801 ensure no disturbing
formation of bubbles.
A descending line routing from the dosing pump to the

heater should be avoided.
Loose fuel lines must be secured in order to avoid

sagging. The installation must ensure protection against
Fig. 804 Fuel Tapping from Plastic Tank stone impacts and undue temperatures (exhaust line).
(tapping via fuel drain plug) The fuel line joints are to be secured against slipping with
hose clamps.
803
8 Servicing HL 90
Connection of 2 Pipes with Hose 8.6.3.1 Installation Location
The proper connection of fuel lines with hoses is shown Prior to installation of dosing pump ensure that the
in Fig. 806. pressure at the tapping location does not exceed 0.2 bar.
It is advantageous to mount the dosing pump in a cool

correct
location. The ambient temperature must never exceed
+40° C during operation.
clamp
Dosing pump and fuel lines must not be installed in
locations exposed to heat radiated by hot vehicle
wrong components. A heat shield is to be provided as necessary.
The preferred installation location is near the tank.
bubble bubble
8.6.3.2 Installation and Attachment
The dosing pump is to be attached with anti-vibration

mounts. The installation location is limited according to
Fig. 806 Pipe / Hose Connection Fig. 807 to ensure sufficient self venting capability. Due
to the danger of corrosion the plug connection between
8.6.3 Dosing Pump dosing pump and dosing pump cable loom may only use
Webasto original parts.
The dosing pump is a combined delivery, dosing and
shut-off system and is subject to certain installation
criteria (Fig. 802 and 807). 8.6.4 Fuel Filter
If there is the probability of contaminated fuel only the

Webasto filter, Order No. 487 171, may be used.
Installation possibly vertical up to horizontal the most
(observe direction of flow).
15° - 90°
15°
0 - 90°
Dosing pump DP 2
0-180° 0-180°
ø5
Dosing pump DP 30
Fig. 808 Fuel Filter
Fig. 807 Dosing Pump, Installation and Attachment
804
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 Length of combustion air intake line:
extracted from rooms with persons. The combustion air with muffler: max. 3.0 m
inlet must not point towards the forward direction of without muffler: max. 5.0 m
motion. It must be located so that no clogging by
contamination is to be expected. Length of exhaust line: max. 5.0 m
If the air heater is located in a closed installation box, Both lines are to be routed away from the heater in a
combustion air must be taken in from and the exhaust decline. If this is not possible, a condensate drain hole
routed to the exterior. The splash water proof Ø 4 mm must be provided at the lowest point.
feedthroughs must not allow exhaust fumes to enter the
vehicle interior. Inner diameter of lines:
In order to silence the air intake noises an air intake combustion air line: 30 mm
muffler (included in delivery of 24 v units) is recommended exhaust line: 38 mm
(Fig. 809). The muffler is fitted onto the air intake pipe.
Smallest bending radius:
NOTE combustion air line: 45 mm
For 12 V units it is recommended to install an air intake exhaust line: 85 mm
muffler (Order No. 876 59A).
In order to ensure an angle of 90° ±10°, an attachment
is required not further than 150 mm away measured from
the exhaust pipe end.
Direction of exhaust flow

Fig. 809 Air Intake Muffler
nearly vertical 90° ±10°
8.6.6 Exhaust Line
Rigid pipes made of unalloyed or alloyed steel with a

minimum wall thickness of 1.0 mm have to be used as
10° 10°
exhaust line or flexible pipes made of alloyed steel only.
The exhaust pipe is secured to the air heater e.g. with a
clamp.
The exhaust muffler is preferably mounted near the air

heater. The direction of flow is optional.
Fig. 811 Exhaust Pipe Outlet, Installation Position
WARNING
Other installation position of exhaust pipe outlet than
shown in Fig. 811 may cause fires.
Sum of bends:
Fig. 810 Exhaust Muffler, Direction of Flow combustion air line: max. 360°
exhaust line: max. 360°
Operation of the air heater is also permitted without
muffler.
805
8 Servicing HL 90
8.7 Removal and Installation 8.7.4 Flame Sensor, Replacement
CAUTION NOTE
In installed condition only the following disassembly or The replacement procedure for the flame sensor is
removal procedures are permitted should enough space identical with the heater installed or removed.
for removal allow such action: Perform replacement in accordance with 9.2.3.
• replacement of control unit 8 7.5 Temperature Limiter, Replacement

• replacement of glow plug
• replacement of flame sensor and its receptacle NOTE
• replacement of temperature limiter The replacement procedure for the temperature limiter is
identical with the heater installed or removed.
8.7.1 Heater, Removal and Installation Perform replacement in accordance with 9.2.4.
8.7.1.1 Removal
8.8 First Operation
1. Disconnect vehicle battery.
2. Disconnect electrical connector of wiring harness from After heater installation the fuel supply system must be
control unit. thoroughly bled.
3. Disconnect cable to dosing pump at its disconnect.
4. Disconnect fuel supply inlet on heater. Close fuel line NOTE
with plug. Long fuel lines may require several switch-ons for priming
5. Disconnect combustion air inlet and exhaust outlet on the fuel line to the heater.
heater.
6. Open tightening straps. During a test run of the air heater all connections are to
7. Remove heater from supports. be checked for no leakage and tight fit. Should the heater
during operation enter an error lockout condition, perform
8.7.1.2 Installation troubleshooting.
1. Retighten screws of supports with 12 Nm.

2. Locate heater for installation and secure with
tightening straps (locate straps between wiring
harness and outer case).
3. Connect fuel supply line to heater fuel inlet and secure
with clamp tightening to 2 Nm.
4. Secure combustion air inlet and exhaust outlet on
heater.
5. Route cable to dosing pump and reconnect at its
disconnect point.
6. Connect wiring harness connector to control unit.
7. Tighten screws of turnbuckles with 5 Nm.
8. Reconnect vehicle battery.
9. Bleed fuel supply system.
8.7.2 Control Unit, Replacement
NOTE
The replacement procedure for the control unit is identical
with the heater installed or removed.
Perform replacement in accordance with 9.2.1.
8.7.3 Glow Plug, Replacement
NOTE
The replacement procedure for the glow plug is identical
with the heater installed or removed.
Perform replacement in accordance with 9.2.2.
806
HL 90 9 Repair
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 Disassembly
All gaskets located between disassembled components

must always be replaced and discarded.
9.1.1.1 Cleaning
• All components disassembled must be cleaned with

cleaning spirit and subsequently blown dry with air.
9.1.1.2 Visual Inspection
• Examine all components for damages (cracks,

deformation, wear, etc.) and replace as necessary.
• Examine connectors and wiring for corrosion,
loose contacts, wrong crimping, etc. and repair as
necessary.
• Check terminals for corrosion and contacts for
security. Repair as required.
901
9 Repair HL 90
9.2 Disassembly and Assembly 3. Perform procedures on components after

disassembly (refer to 9.1.1).
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).
1. Disconnect electrical connector on control unit.
2. Remove screws (14, Fig. 901) and control unit (13). 2. Torque screws with 2.5 ± 0.2 Nm.
3. Connect electrical connector to control unit.
4 5 6
1
Detail A 3
ge
2
br
br
17 9
11
10
12
C
16 B
A
15
13
14
1 Glow plug 10 Grommet
2 Lock washer 11 Outer case
1 Spring washers (17) not 3 Screw 12 Screw (3)
applicable for orifice plate 4 Temperature limiter 13 Control unit
made of plastic. 5 Silicone cap 14 Screw (2)
6 End cap 15 Half case
7 Retaining clip 16 Screw (3)
8 Flame sensor 17 Spring washer (3)
9 Flame sensor receptacle
Fig. 901 Replacement of Control Unit, Glow Plug, Flame Sensor and Temperature Limiter
902
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.
1. Remove knurled nut from glow plug. 2. Form-fit silicone cap (5).
2. Withdraw cable and isolator. 3. Make electrical connection of temperature limiter to
3. Unscrew glow plug (1, Fig. 901) and remove. wiring harness.
4. Perform procedures on components after disassembly
(refer to 9.1.1). 9.2.5 Drive, Replacement
9.2.2.2 Installation 9.2.5.1 Removal
1. Apply high temperature grease (Copaslip) to thread 1. Remove control unit (see 9.2.1.1).
of glow plug. 2. Disconnect electrical connector (9 and 25, Fig. 902)
2. Manually screw glow plug (1, Fig. 901) in and tighten and carefully push into half case together with
with 20 ± 2.0 Nm. grommet (8).
3. Bring cable and isolator in assembly position as 3. Remove screws (12 and 16, Fig. 901) and spring
shown in Fig. 901, Detail A and secure with knurled washers (17). Slightly widen half case and slide off
nut. over air intake pipe.
4. Tighten knurled nut with 2.0 ± 0.5 Nm. 4. Remove screws (19, Fig. 902) and lock washers (20).
5. Withdraw drive from heat exchanger and remove.
9.2.3 Flame Sensor, Replacement 6. Perform procedures on components after disassembly
(refer to 9.1.1) or continue to disassemble drive
9.2.3.1 Removal (see 9.2.6).
1. Disconnect electrical connection to flame sensor. 9.2.5.2 Installation

2. Remove spring (7, Fig. 901) from flame sensor (8) and
withdraw flame sensor. 1. Apply vaseline to O-ring (22, Fig. 902).
3. Unscrew flame sensor receptacle (9) and remove. 2. Bring drive with heat exchanger in assembly position
4. Remove grommet (10) and discard. secure with screws (19, Fig. 902) and lock washers
5. In counterlight visually check quartz glass rod of flame (20).
sensor receptacle for transparency. 3. Tighten screws with 5.5 ± 0.5 Nm.
6. Perform procedures on components after disassembly 4. Slightly widen half case (15, Fig. 901), route electrical
(refer to 9.1.1). connector (9 and 25, Fig. 902) with cable to exterior
and push grommet (8) into opening for proper fit in
9.2.3.2 Installation place.
5. Position half case (15, Fig. 901) for assembly and
1. Locate new grommet (10, Fig. 901) flush in installation secure with screws (12).
position. 6. Secure half case (15) with screws (16) and spring
2. Apply high temperature grease (Copaslip) to thread of washers (17).
flame sensor receptacle. 7. Tighten screws (12 and 16) with 2.5 ± 0.2 Nm.
3. Manually screw flame sensor receptacle in place and 8. Secure cap (1, Fig. 902) with screws (14) and tooth
torque with 20 ± 2.0 Nm. washers (13).
4. Plug on flame sensor (8) and secure with retaining 9. Tighten screws (14) with 2.5 ± 0.2 Nm.
clip (7). 10. Install control unit (see 9.2.1.2).
5. Make electrical connection of flame sensor to wiring
harness.
9.2.4 Temperature Limiter, Replacement
9.2.4.1 Removal
1. Disconnect electrical connection to temperature limit-

er.
2. Slide silicone cap (5, Fig. 901) up enough to make
hexagon of temperature limiter (4) accessible.
3. Unscrew temperature limiter and remove.
4. Perform procedures on components after disassembly
(refer to 9.1.1).
903
9 Repair HL 90
1 1 1 6 rt-rt/bl
4 5 br-vi
37
3
2 7
8
1
9
rt/bl sw
12 11 10
rt vi
21 22 23
14 13 1
20
19
18
2
2 17
2 16
15
24
36
NOTE
1 Orifice plate (4) made 25 29
of plastic has no tooth
washers (13) and
28
spacer ring (5). Screws 30
(3) are then locked 27
with tooth washers (37).
31
2 If screws (15) are 32
sheet metal type 26
screws, there are no
locking rings (16) and
washers (17). 33
34
35
1 Cap 14 Screw (4) 27 Bypass fan
2 Rotor 15 Screw (2) 28 Screw (3)
3 Screw (3) 16 Locking ring (2) 29 Atomiser assembly
4 Orifice plate 17 Washer (2) 30 Cap nut
5 Spacer ring 18 Glow plug resistor (2) 31 Washer
6 Motor 19 Screw (3) 32 Displacer
7 Resistor 20 Lock washer (3) 33 Screw (2)
8 Grommet 21 Screw (3) 34 Fuel line
9 Electrical connector 22 O-ring 35 O-ring
10 Washer 23 Clutch 36 Fuel inlet with double conical
11 Tooth washer 24 Air intake housing ring and coupling nut
12 Screw 25 Electrical connector 37 Tooth washer (3)
13 Tooth washer (4) 26 Round cord ring
Fig. 902 Disassembly of Drive
904
HL 90 9 Repair
9.2.6 Drive, Disassembly and Assembly 10. Remove O-ring (22) and discard.
11. Perform procedures on components after
The disassembly of the drive is broken down into two disassembly (refer to 9.1.1).
subjects:
– heating air supply/ electrical components CAUTION
– combustion air supply / fuel ducting / motor Clean bypass fan with pressurized air only.
9.2.6.1 Heating Air Supply / Electrical Components, 9.2.6.3 Assembly

Disassembly
1. Position new O-ring (22, Fig. 902) on air intake
The following steps should be performed with the heater housing for assembly.
fully assembled. 2. Assemble air intake housing (24) and motor (6) with
screws (21).
1. For removal of cap (1, Fig. 902) remove screw (14) 3. Slide half of clutch (23) onto motor shaft in air intake
and tooth washers (13) as required. housing (24).
2. Using two levers (wide blade screw drivers, etc.) lever 4. Position new O-ring (35) at fuel transfer point in air
plastic rotor (2) off from motor shaft by pushing intake housing.
against orifice plate (4). Remove orifice plate and 5. Position new round cord ring (26) in bypass fan (27).
spacer ring (5) by removing screws (3). 6. Slide other half of clutch (23) onto shaft in bypass
fan (27).
NOTE
When disassembling and disconnecting wiring and NOTE
connectors make sure to observe wiring arrangement, Fuel line must be aligned with fuel transfer point (O-ring);
see Fig. 902. clutch (23) must also engage.
3. Loosen screws (15) and remove glow plug resistor 7. Assemble bypass fan (27) and air intake housing (24)
(18), locking ring (16) and washer (17). with screws (28). Torque screws to 4 Nm.
4. Remove screw (12), tooth washer (11) and washer 8. Secure fuel line (34) in bypass fan (27) with screws
(10). (33) torqued to 1.5 Nm.
5. Disconnect blade terminal from electrical connectors 9. Slide atomiser assembly (29) onto shaft until arrested
(9 and 25). Check condition of grommet (8) and by drive pin.
replace as necessary. 10. Slide displacer (32) onto shaft and secure with washer
6. Disconnect electrical connectors from resistor (7) and (31) and cap nut (30). Torque cap nut to 2.5 Nm.
remove resistor. 11. Mount resistor (7) with screw (12), tooth washer (11)
and washer (10). Torque screw to 2 Nm.
9.2.6.2 Combustion Air Supply / Fuel Ducting / Motor, 12. Connect electrical connectors to resistor (7) (refer to
Disassembly Section 7 as required).
1. Remove cap nut (30), washer (31) and displacer (32). NOTE
2. Withdraw atomiser assembly (29). Torque for cap screws and sheet metal screws is
3. Remove screws (33) and fuel line (34). 5.5 ± 0.5 Nm.
4. Remove screws (28).
5. Carefully pull bypass fan (27) out of air intake housing 13. Secure glow plug resistors (18) with screws (15).
(24). No locking rings (16) and washers (17) when sheet
metal screws are in use.
CAUTION 14. Slide on grommet (8) at wiring connect points of
Remove bypass fan by a slight axial pull on shaft. electrical connectors (9 and 25); reconnect cable
Remove major contamination on edge zone to air intake wires to relevant connectors to restore proper
housing and slightly grease as required. electrical functions (refer to Section 7 as required).
15. Locate spacer ring (5) and orifice plate (4) for
6. Withdraw one half of clutch (23); remove round cord assembly so that spacer ring is centered on fan of
ring (26) and discard. motor (6). There is no spacer ring (5) if plastic orifice
7. Remove O-ring (35) from air intake housing and plate is in use.
discard. 16. Secure orifice plate (4) and spacer ring (5) with
8. Pull other half of clutch (23) from motor shaft. screws (3) and torque to 5.5 ± 0.5 Nm. Locate tooth
9. Remove screws (21) and separate air intake housing washers (37) between orifice plate (plastic) and
(24) from motor (6). screw (3).
17. Press rotor (2) onto shaft until seated against stop.
905
9 Repair HL 90
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°
17
16
0.5 to 1
Fuel line Gauge

(Ident. No.
866 45A)
906
HL 90 9 Repair
9.2.7 Heat Exchanger, Replacement 9.2.7.2 Installation
9.2.7.1 Removal 1. Apply sealing and bonding compound

(Ident. No. 666 05A) to mating surfaces of sealing
1. Remove control unit (refer to 9.2.1.1). cord (4, Fig. 903) and heat exchanger (5) and locate
2. Remove glow plug (refer to 9.2.2.1). with rear wall (3) in heat exchanger (5) for assembly.
3. Remove flame sensor (refer to 9.2.3.1). 2. Secure rear wall (3) with nuts (1) and lock washers (2).
4. Remove temperature limiter (refer to 9.2.4.1). 3. Torque nuts (1) to 1.5 ± 0.2 Nm.
5. Remove drive (refer to 9.2.5.1).
6. Remove screws (3, Fig. 901) and lock washers (2) NOTE
from outer case (11) and remove from end cap (6). When performing the following step ensure that all
7. Pull off end cap (6). connections and screw holes in outer case are centered.
8. Carefully widen outer case and remove heat
exchanger. 4. Locate heat exchanger with outer case (11, Fig. 901)
9. Remove nuts (1, Fig. 903) and lock washers (2). and end cap (6) and assemble with screws (3) and
10. Pull rear wall (3) out of heat exchanger and remove lock washers (2).
sealing cord (4). 5. Torque screws (3) to 2.5 ± 0.2Nm.
11. Discard sealing cord. 6. Install drive (refer to 9.2.5.2).
12. Perform procedures on components after 7. Install temperature limiter (refer to 9.2.4.2).
disassembly (refer to 9.1.1). 8. Install flame sensor (refer to 9.2.3.2).
9. Install glow plug (refer to 9.2.2.2).
10. Install control unit (refer to 9.2.1.2).
1 Nut (3)
2 Lock washer (3)
3 Rear wall
4 Sealing cord
5 Heat exchanger
2
1
Apply sealing and bonding compound

! (Ident. No. 666 05A) to these surfaces.
Fig. 903 Replacement of Heat Exchanger
907
9 Repair HL 90
Page free for notes
908
HL 90 10 Packaging/Storage/Shipping
10 Packaging, Storage and

Shipping
10.1 General
The heater or its components shipped to Webasto

Thermosysteme GmbH for testing or repair must be
cleaned and packaged so that they are protected against
damage during handling, shipping and storage.
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.
1001
10 Packaging/Storage/Shipping HL 90
Page free for notes
1002

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Heizsysteme / Heating Systems

Inhalt / Contents Abbildung auf Seite / llustration on page

Geräteausführung: / Heater version

© 2011 Webasto AG Global Comfort Solutions 2

Teile zum Heizgerät / Parts for Heater

Pos. Stück Bestell-Nr. Benennung Description Bemerkung

© 2011 Webasto AG Global Comfort Solutions 3

Teile zum Heizgerät / Parts for Heater

Pos. Stück Bestell-Nr. Benennung Description Bemerkung

© 2011 Webasto AG Global Comfort Solutions 4

Teile zum Heizgerät / Parts for Heater

Pos. Stück Bestell-Nr. Benennung Description Bemerkung

© 2011 Webasto AG Global Comfort Solutions 5

Elektrische Teile / Electrical Parts

Pos. Stück Bestell-Nr. Benennung Description Bemerkung

© 2011 Webasto AG Global Comfort Solutions 6

Elektrische Teile / Electrical Parts

Pos. Stück Bestell-Nr. Benennung Description Bemerkung

© 2011 Webasto AG Global Comfort Solutions 7

Brennstoffsystem / Brennluftsystem / Abgassystem / Montageteile

Pos. Stück Bestell-Nr. Benennung Description Bemerkung

© 2011 Webasto AG Global Comfort Solutions 8

Normteile / Standard Parts

Pos. Stück Bestell-Nr. Benennung Description Bemerkung

© 2011 Webasto AG Global Comfort Solutions 9

Bei mehrsprachigen Dokumentversionen ist die englische Version bindend.

Webasto Product Benelux B.V.

Tel.:+31 (0)38 337 11 37

© Webasto AG Global Comfort Solutions 2011

Air Heaters Repair Shop Manual

1.1 Scope and Purpose ............................................................................................................................... 101

1.4.1 Legal Provisions for Installation.................................................................................................. 101

1.5 Corrections and Improvements.............................................................................................................. 103

2.1 Drive ...................................................................................................................................................... 201

3.1 Controls ................................................................................................................................................. 301

3.3.1 Operation with Room Thermostat (mechanical) ......................................................................... 301

3.4 Switch Off .................................................................................................................. ............................ 301

4.1 Electrical Components........................................................................................................................... 401

5.1 General .................................................................................................................................................. 501

6.1 General .................................................................................................................................................. 601

6.2.1 Adjustment of CO2 Contents ...................................................................................................... 601

6.3 Components Testing.............................................................................................................................. 601

6.3.1 Temperature Limiter Resistance Check ..................................................................................... 601

7 Circuit Diagrams and Examples for Electrical Installation

7.1 General ................................................................................................................................................. 701

8.1 General ................................................................................................................................................. 801

8.6.1 Heating Air System .................................................................................................................... 801

8.7 Removal and Installation....................................................................................................................... 806

8.7.1 Heater, Removal and Installation .............................................................................................. 806

8.8 First Operation ...................................................................................................................................... 806

9.1 General ................................................................................................................................................. 901

9.1.1 Work on Components after Disassembly .................................................................................. 901

9.2 Disassembly and Assembly .................................................................................................................. 902

9.2.1 Control Unit, Replacement ........................................................................................................ 902

10 Packaging, Storage and Shipping

10.1 General ............................................................................................................................................... 1001

301 Functional Diagram.......................................................................................................................................... 302

501 General Failure Symptoms .............................................................................................................................. 501

701 Operation with Timer and Room Thermostat................................................................................................... 702

1 Introduction 1.4.1 Legal Provisions for Installation

Within the scope of the StVZO (Road Licensing

1.2 Meaning of Warnings, Cautions, The installation of the heaters is to be performed in