Webasto HL30 Workshop Manual
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Webasto HL30 Workshop Manual

Webasto HL30 Workshop Manual

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Workshop Manual—HL30/38/65/95/125 Model Air Heaters
WORKSHOP MANUAL
For Webasto Heater Models
HL30
HL38
HL65
HL95
HL125
Including sections on Operating
Principles, Common Installation
Problems and Faultfinding
Uncontrolled Copy—for reference purposes only
1
www.butlertechnik.com

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Summary of Contents for Webasto HL30

  • Page 1 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters WORKSHOP MANUAL For Webasto Heater Models HL30 HL38 HL65 HL95 HL125 Including sections on Operating Principles, Common Installation Problems and Faultfinding Uncontrolled Copy—for reference purposes only www.butlertechnik.com...

  • Page 2: Table Of Contents

    Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters CONTENTS Page Number Introduction Operating Principles Semi-Automatic Control Fully-Automatic Control Larger Heaters—Differences from HL30 Fuel Pump & Fuel Supply Ventilation Glowplug Circuit Thermostatic Operation Exhaust Arrangement Service Procedures HL30/38...

  • Page 3: Introduction

    Workshop Manual—HL30/38/65/95/125 Model Air Heaters Introduction The HL series of Webasto Air Heaters were manufactured from the 1960’s and as a result formed a large proportion of Webasto Heating Installations within the UK at that time. The heaters were solidly designed using well proven technology, and as such have a reputation for rugged reliability and ser- viceability.

  • Page 4: Operating Principles

    Workshop Manual—HL30/38/65/95/125 Model Air Heaters Operating Principles The principle of operation for all heaters is similar. Figures 1, 2 and 3 refer to model HL30, minor differences with other models are discussed separately. When the heater is turned on, power is switched to the glowplug (2). This pre-heats the combustion chamber in it’s vicinity.

  • Page 5: Fully-Automatic Control

    HL9511 were introduced in about 1983. At this time, all external wiring components were re- designed, made smaller, and incorporated beneath a single black external cover. The HL30 remained unchanged. The main modifications were as follows (see fig 7).

  • Page 6: Fuel Pump & Fuel Supply

    9 & 10. Ventilation Ventilation is an option on all heaters, both SA and FA. On the HL30/38 the motor is energised, and this also turns the fuel pump although the fuel solenoid remains closed. On larger heaters with higher pump revolutions a clutch was introduced using a rubber cone and brass cup.

  • Page 7: Service Procedures Hl30/38

    A more comprehensive discussion of these problems is given on p. 17. In general, Webasto heaters have a recommended service interval of about 1000 running hours. This generally corresponds to 2 seasons work, although exceptionally one year in the case of applications such as buses and minibuses which are constantly in use.

  • Page 8: Opening The Heater

    Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Service Procedures—HL30/38 (ctd) External Components (ctd) in the base and resetting the body accordingly. Note that the contacts should reset themselves when the probe is released. If they do not, replace the thermostat. As a final check, undo the top securing screw and lift off the red plastic cover.

  • Page 9: Heat Exchanger

    Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Service Procedures—HL30/38 (ctd) Heat Exchanger De-carbon. This is best achieved with either a pressure washer, or hot soapy water and vigorous shaking. It is not sufficient merely to poke about inside with a screwdriver.

  • Page 10: Fuel Pump

    Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Service Procedures—HL30/38 (ctd) Fuel Pump There are three types of fuel pump (fig 13), all superficially different, but procedures are basically the same for them all. Remove the inspection plate (b, fig 3) and clean it. It is recommended that this plate being aluminium is inscribed with the date of the service for future reference.

  • Page 11: Motor

    Remove the motor mount (34, fig 2). Remove motor brushes and caps (79, 80, fig 3). Examine and replace the brushes if less than 10mm remains. Note that earlier HL30 heaters had smaller brushes than later models. Undo the motor screws (fig 3, D). These are held together by castle headed nuts and will require a screwdriver with the centre of the blade filed out.

  • Page 12: Testing

    Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Service Procedures—HL30/38 (ctd) Re-Assembly (ctd) Push the motor case into the heat exchanger and align the exhaust stub and combustion air downpipe correctly before refitting the motor.

  • Page 13: Service Procedures Hl65/95/125

    Proceed as for HL30, but remember that there is no external fuel solenoid on later designs. External Components Repeat checks as for the HL30. Note however that the fuel inlet pipe is solid, not flexible as in the HL30. Newer heaters with black covers are slightly different. Care must be taken when removing the OH thermo-switch, which should only be finger tight.

  • Page 14: Atomiser Assembly

    Apply the same tests to these pump components as for the HL30. The pump shaft bush can be replaced in the same way as the HL30. The only difference is that the pump drive wheel is held in with a roll pin, and a new shaft should be drilled to accept this.

  • Page 15: Motor

    Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Service Procedures—HL65/95/125 (ctd) Motor Run the motor on the appropriate voltage. If it runs smoothly and there is not excessive wear on the brushes, polishing the commutator with crocus paper will suffice. To change the bearings of an old type motor (fig 11), proceed as follows;...

  • Page 16: Testing

    Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Service Procedures—HL65/95/125 (ctd) Testing As for HL30 HL125 The basic differences between the HL95 and 125 are as follows; The fresh air fan is mounted on the other end of the motor and has the clutch immediately below it.

  • Page 17: Common Installation Problems

    Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Common Installation Problems It is frequently found that installation problems manifest themselves as unreliable heaters. This section is intended to give some idea of the common pitfalls.

  • Page 18: Wiring And Electrics

    In general, any pipe placed on an exhaust stub will, to a certain extent, restrict the exit of exhaust gasses and cause carbonning. As a general rule, 1/2 metre of exhaust on an HL30 and 1 metre on larger heaters is a recommended maximum, but even this will cause some build up of deposit. An exhaust break was developed for use with larger heater exhausts, but was of limited success.

  • Page 19: Faultfinding

    Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Faultfinding This section is intended to give some guide to common problems and their solutions. It is not intended as a comprehensive guide. Problem Heater appears to be attempting to fire, but cuts out.
  • Page 20 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 1—HL3003 www.butlertechnik.com...
  • Page 21 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 2—HL3003 www.butlertechnik.com...
  • Page 22 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 3—HL3003 www.butlertechnik.com...
  • Page 23 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 4 Figure 5 www.butlertechnik.com...
  • Page 24 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 6 www.butlertechnik.com...
  • Page 25 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 7—HL6511 www.butlertechnik.com...
  • Page 26 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 8—HL6511 www.butlertechnik.com...
  • Page 27 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 9 www.butlertechnik.com...
  • Page 28 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 10 www.butlertechnik.com...
  • Page 29 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 11—HL9503.32 www.butlertechnik.com...
  • Page 30 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 12 Figure 13 www.butlertechnik.com...
  • Page 31 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 14 www.butlertechnik.com...
  • Page 32 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 15 Figure 16 www.butlertechnik.com...
  • Page 33 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 17—HL12503 www.butlertechnik.com...
  • Page 34 Visit www.butlertechnik.com for more technical information and downloads. Workshop Manual—HL30/38/65/95/125 Model Air Heaters Figure 18 www.butlertechnik.com...

This manual is also suitable for:

Hl38Hl65Hl95Hl125

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