Espar Products, Inc M8 Biodiesel Operating instructions

* M-II (Water Heater)
Hydronic
Espar Heater Systems
Technical Description
Installation Instructions
Operating Instructions
Maintenance Instructions
Troubleshooting and Repair Instructions
Parts List
Espar Products, Inc.
(800) 387-4800
(905) 670-0960
www.espar.com
HYDRONIC M8 Biodiesel
HYDRONIC M10
HYDRONIC M12
25 2470 05 - 12 Volt
25 2471 05 - 24 Volt
25 2434 05 - 12 Volt
25 2435 05 - 24 Volt
25 2472 05 - 12 Volt
25 2473 05 - 24 Volt
P/N 20 2900 81 0102 0A
04.2009 Subject to Change
Printed in Canada
Table of Contents
Page
Introduction
Heater Warnings
Technical Data Hydronic M8 Biodiesel
Technical Data Hydronic M10
Technical Data Hydronic M12
Heater Components
Principal Dimensions
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3
4
5
6
7
8
Installation Procedures
Heater Location / Mounting/ Fastening
Heater & Engine Plumbing
Fuel Quality
Fuel System
Electrical Connections
Exhaust / Intake Connections
Operating Switches: 7 Day Timer
Push/Pull Switch, Programmable Timer
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9
10
11
12
14
15
16
18
Heater Operation
Pre-Start Procedures / Start-Up
Heating Mode / Termperature Drop
Switching Off /Safety Equipment
Heater Wiring
Parts List for Wiring Diagram
Heater Wiring Diagram
Controler wireing diagrams
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20
20
20
21
22
23
24
Maintenance,
Troubleshooting &
Repairs
Periodic Maintenance
Basic Troubleshooting / Self Diagnostics
Fault codes / Description / Repair
Repair Instructions
Repair Steps
Fuel Quantity
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25
25
26
30
31
47
Heater Components
Parts Diagram
Description & Part #’s
Parts Diagram - Boxed units
Description & Part #’s
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48
49
50
51
Special Notes
Note: Highlight areas requiring special attention or clarification.
Caution: Indicates that personal injury or damage to equipment may occur unless specific guidelines are followed.
Warning:
Indicates that serious or fatal injury may result if specific guidelines are not followed.
This publication was correct at the time of going to print. However, Espar Inc. has a policy of continuous improvement
and reserves the right to amend any specifications without prior notice.
Introduction
Heater Warnings
Warning To Installer
•
Correct installation of this heater is necessary to ensure
safe and proper operation.
Read and understand this manual before attempting to
install the heater. Failure to follow all these instructions
could cause serious or fatal injury.
Warning - Explosion Hazard
•
Heater must be turned off while re-fueling.
•
Do not install heater in enclosed areas where combustible
fumes may be present.
•
Do not install heaters in engine compartments of marine
vessals.
Warning - Fire Hazard
•
Install the exhaust system so it will maintain a minimum
distance of 50mm (2”) from any flammable or heat sensitive material.
•
Ensure that the fuel system is intact and there are no leaks.
Please note!
Installation of the heater is permitted in vehicles used
for the transport of dangerous goods as per ADR.
Caution:
During electrical welding work on the vehicle disconnect the power to the heater in order to protect the
control unit.
Note: All measurements contained in this manual contain
metric and approximate SAE equivalents in brackets eg 25mm (1”).
Safety instructions for application and
proper purpose
The heater must only be used and operated for the range of
application stated by the manufacturer in compliance with the
“Operating instructions” included with every heater.
Direct questions to Espar Heater Systems:
Canada & U.S.A.
1-800-387-4800
Warning - Asphyxiation Hazard
•
Route the heater exhaust so that exhaust fumes cannot
enter any passenger compartments.
•
If running exhaust components through an enclosed compartment, ensure that it is vented to the outside.
Warning - Safety Hazard on Coolant Heaters
Used With Improper Antifreeze Mixtures
•
The use of Espar coolant heaters requires that the coolant
in the system to be heated contains a proper mixture of
water and antifreeze to prevent coolant from freezing or
slushing.
•
If the coolant becomes slushy or frozen, the heater’s
coolant pump cannot move the coolant causing a blockage of the circulating system. Once this occurs, pressure
will build up rapidly in the heater and the coolant hose will
either burst or blow off at the connection point to the
heater.
•
This situation could cause engine damage and/or personal injury. Extreme care should be taken to ensure a proper mixture of water and antifreeze is used in the coolant
system.
•
Refer to the engine manufacturer’s or coolant manufacturer’s recommendations for your specific requirements.
This publication was correct at the time of print. However,
Espar has a policy of continuous improvement and
reserves the right to amend any specifications without
prior notice.
3
Introduction
Technical data
HYDRONIC M-II
Heater type
Heater
HYDRONIC M8 Biodiesel
Version
D8W
Heating medium
Water, Cooling fluid
Control of the heat flow
Power
High
Medium
Low
17061
5000
11943
3500
5118
1500
0.24
0.90
0.17
0.65
0.11
0.40
0.05
0.18
55
46
39
35
Heat flow (BTU) (Watt)
BTU 27297
Watt 8000
Fuel consumption (g / h) (l/h)
g/h
l/h
Figures for operation with diesel fuel. If operated with Biodiesel
the heat flow can reduce by up to 15 %.
Electrical power (Watt)
in operation
at start – after 25 Sec.
200
in the control phase “OFF”
32
Rated voltage
12 Volt
24 Volt
Operating range
• Lower voltage limit: An undervoltage protection in
the controller switches the heater off on reaching the
voltage limit.
10 Volt
20 Volt
• Upper voltage limit: An overvoltage protection in the
controller switches the heater off on reaching the
voltage limit.
15 Volt
30 Volt
Tolerable operating pressure
up to 200 kPa - 30 psi
Flow rate of the water pump at 2 psi
1400 l / h
370 g/ h
500 l / h
132 g/ h
Minimum water flow rate of the heater
Tolerable operating temperature
Heater / Control box
Dosing pump
Weight with controller and water pump,
without dosing pump
Caution:
Failure to comply with the technical data can
result in malfunctions.
4
Operation
Not running
Diesel
– 40 °F to +176 °F / –40 °C to +80 °C
–40 °F to +185 °F / –40 °C to +85 °C
Biodiesel
+17.6 °F to +176 °F / –8 °C to +80 °C
–40 °F to +185 °F / –40 °C to +85 °C
Diesel
– 40 °F to +122 °F / –40 °C to +50 °C
–40 °F to +185 °F / –40 °C to +85 °C
Biodiesel
+17.6 °F to +122 °F / –8 °C to +50 °C
–40 °F to +185 °F / –40 °C to +85 °C
approx. 6.2 kg - 13.7 lb
Introduction
Technical data
Heater type
HYDRONIC M-II
Heater
HYDRONIC M10
Version
D 10 W
Heating medium
Water, Cooling fluid
Control of the heat flow
Power
High
Medium
Low
Heat flow
BTU
Watt
32415
9500
27297
8000
11943
3500
5118
1500
Fuel consumption
(g/h)
(l/h)
0.32
1.2
0.24
0.9
0.11
0.4
0.05
0.18
86
60
39
35
Electrical power (Watt)
in operation
at start – after 25 Sec.
120
in the control phase “OFF”
32
Rated voltage
12 Volt
24 Volt
Operating range
• Lower voltage limit: An undervoltage protection in
the controller switches the heater off on reaching the
voltage limit.
10 Volt
20 Volt
• Upper voltage limit: An overvoltage protection in the
controller switches the heater off on reaching the
voltage limit.
15 Volt
30 Volt
Tolerable operating pressure
up to 200 kPa - 30 psi
Flow rate of the water pump at 2 psi
1400 l/h - 370 g/h
Minimum water flow rate of the heater
500 l/h - 132 g/h
Tolerable operating temperature
Operation
Not running
Heater / Control box
–40 °F to +176 °F / –40 °C to +80 °C
–40 °F to +185 °F / –40 °C to +85 °C
Dosing pump
–40 °F to +122 °F / –40 °C to +50 °C
–40 °F to +185 °F / –40 °C to +85 °C
Weight with controller and water pump,
without dosing pump
approx. 6.2 g/h - 13.7 lb
Caution:
Failure to comply with the technical data can
result in malfunctions.
5
Introduction
Technical data
Heater type
HYDRONIC M-II
Heater
HYDRONIC M12
Version
D 12 W
Heating medium
Water, Cooling fluid
Control of the heat flow
Power
High
Heat flow
BTU
42000
32415
17061
11943
5118
4095
Fuel consumption
(g/h)
(l/h)
.40
1.5
.32
1.2
.17
0.65
.11
0.40
.05
0.18
.04
0.15
132
86
46
39
35
34
in operation
Electrical power (Watt)
Medium 1 Medium 2 Medium 3
at start – after 25 Sec.
120
in the control phase “OFF”
32
Rated voltage
12 Volt
24 Volt
Operating range
• Lower voltage limit: An undervoltage protection in
the controller switches the heater off on reaching the
voltage limit.
10 Volt
20 Volt
• Upper voltage limit: An overvoltage protection in the
controller switches the heater off on reaching the
voltage limit.
15 Volt
30 Volt
Tolerable operating pressure
up to 200 kPa - 30 psi
Flow rate of the water pump at 2 psi
1400 l/h - 370 g/h
Minimum water flow rate of the heater
500 l/h - 132 g/h
Tolerable operating temperature
Operation
Not running
Heater / Control box
–40 °F to +176 °F / –40 °C to +80 °C
–40 °F to +185 °F / –40 °C to +85 °C
Dosing pump
–40 °F to +122 °F / –40 °C to +50 °C
–40 °F to +185 °F / –40 °C to +85 °C
Weight with controller and water pump,
without dosing pump
Caution:
Failure to comply with the technical data can
result in malfunctions.
6
Low
approx. 6.2 g/h - 13.7 lb.
Introduction
Heater Components
F
2
3
4
WO
5
6
WI
1
E
9
8
7
CA
WI
WO
CA
F
E
=
=
=
=
=
Water inlet
Water outlet
Combustion air
Fuel
Exhaust
1 Control box
2 Burner motor
3 Glow plug
4 Flame pipe
5 Overheating sensor
6 Heat exchanger
7 Water pump
8 Combustion chamber
9 Flame sensor
7
Introduction
Principal Dimensions
F
WO
M8 (x4)
E Exhaust
F Fuel
CA Combustion air
WO Water outlet
WI Water inlet
WI
CA
E
* All measurements in millimeters 25.4 mm = 1”
Boxed Heaters Insure:
Minimum installation distance (clearance) to
open the lid and to dismount the glow pin and
the control unit.
Insure:
Minimum installation distance (clearance) to
take in combustion air.
Permissible installation positions
1 Water outlet socket, heater
2 Water inlet socket, water pump
8
Installation Procedures
Principal Dimensions - Boxed Version
Arrangement of the heater
Parts of the structure and other components near the heater
must be protected from excess heat exposure and possible
contamination from fuel or oil.
317 mm
(12.4”)
430 mm (16.9”)
197 mm
(7.76”)
Heater Location
Always mount the heater in a protected area. Eg: storage compartment, engine compartments, step box or battery box.
Espar recommends you use the boxed unit. Refer to fig. 1
When mounting the heater adhere to the following conditions:
• Situate the heater below the normal coolant level of the engine.
• Guard against excessive road spray.
• Keep coolant hoses, fuel lines and electrical wiring as short
as possible.
The heater must not pose a fire hazard even when it
overheats.
– This requirement is deemed to be fulfilled when
adequate clearance to all parts is observed during
installation, sufficient ventilation is provided and fireproof
materials or heat plates are used.
The heater must not be located in the passenger compartment.
A unit may however be used in a hermetically sealed housing
which also corresponds to the conditions stated above.
The factory nameplate or duplicate must be affixed so that it
can still be easily read when the heater is installed in the
vehicle.
All appropriate precautions must be taken when
arranging the heater to minimise the risk of injuries
to persons or damage to other property.
Heater Mounting
Mount the heater using the four (4) shock mounts provided
with kit and one of the following mounting methods:
Fig. 1
•
Use the Side Mount Bracket to mount the heater on the
side of the frame rail.
•
Use a spare step box or battery box.
•
Use the saddle bracket and hardware provided
Box Base
P/N 25 2800 40 10 02
Box Lid
P/N 25 2800 40 10 03
Caution: Guard the heater against excessive road spray to
avoid internal corrosion.
Mounting and Fastening
Fix the unit holder from the installation kit to the heater
using 4 hexagon screws M8 and 4 spring washers.
Intake Silencer
always needed
P/N 25 1786 80 02 00
Fix the heater and the mounted unit holder in a suitable
place in the vehicle using 5 hexagon screws M8, 5 spring
washers and 5 hexagon nuts M8
Side Mount Bracket
P/N 20 2900 40 00 75
1 Heater
2 Heater bracket
9
Installation Procedures
Heater Plumbing
The heater is incorporated into the engine’s cooling system for
engine preheating.
Engine Plumbing
Follow these guidelines and refer to the engine plumbing diagram
shown below.
• Install hose fittings into the engine block for pick-up and return
lines.
• Use existing holes in the engine block (ie. remove
blanking plugs when possible).
• Use shut off valves to ensure the system can be isolated from
the engine when not in use. Alternatively “T” piece connectors
in existing coolant hoses can be used if no blanking plugs are
available.
• Provide 20mm (3/4” ) hose barbs for hose connections.
• Use 20mm (3/4” ) hoses to ensure adequate coolant flow.
• Keep the pick up and return points as far apart as possible to
ensure good heat distribution.
ut
Water o
Caution: It is possible for the coolant and components of the
coolant circuit to get very hot.
• Parts conveying water must be routed and fastened in such
a way that they pose no temperature risk to man, animals or
material sensitive to temperature from radiation / direct
contact.
• Before working on the coolant circuit, switch the heater off
and wait until all components have cooled down completely,
if necessary where safety gloves.
Caution:
• When installing the heater, please take note of the direction
of flow of the coolant circuit.
• Fill the heater and water hoses with coolant before connecting to the coolant circuit.
• Route the water hoses without any kinks, and in a rising
position if possible.
• When routing the water pipes, observe a sufficient clearance to hot vehicle parts.
• Protect all water hoses / water pipes from chafing and from
extreme temperatures.
• Secure all hose connections with hose clips.
• After the vehicle has been operating for 2 hours or travelled
100 km, tighten the hose clips again.
in
Water
• Take the coolant from a low point on the engine to reduce
aeration in the system.
• Ensure proper direction of coolant flow by taking coolant from a
high pressure point in the engine and returning it to a low pressure point. (ie. pickup from back of block and return to the
suction side of the engine's water pump).
• Ensure adequate flow rate through the heater by comparing the
incoming and outgoing coolant temperatures while the heater is
running. If the rise in temperature exceeds 10°C (18°F), coolant
flow must be increased by modifying the plumbing.
• The minimum water flow rate is only guaranteed if the tem
perature difference of the heating medium does not exceed
15°C (60°C) between water inlet and water outlet during
heating.
• Only overpressure valves with an opening pressure of min.
6 psi – max. 30 psi bar may be used in the coolant circuit.
• The coolant liquid must contain at least 10 % antifreeze all
year round as corrosion protection.
• The cooling liquid must contain sufficient antifreeze for low
temperatures.
• Ensure the heater and water pump are installed as low as pos
sible to allow the purging of air.
• Before commissioning the heater or after changing the
cooling liquid, the whole coolant circuit including heater must
be vented free of bubbles according to the instructions issued
by the vehicle manufacturer.
• If a bunk heat exchanger is incorporated into the system,
proper plumbing layouts must be followed.
• Only top up with coolant approved by the vehicle manufacturer.
4
2
3
1
10
1
2
3
4
Heater
Non-return valve (Optional)
Heat exchanger
Vehicle engine
Installation Procedures
Caution: The coolant must contain a minimum of 10%
antifreeze at all times as protection against
corrosion.
Fresh water will corrode internal heater parts.
•
The exhaust outlet must end in the open air.
•
The exhaust pipe must not protrude beyond the lateral limits of
the vehicle.
•
Install the exhaust pipe sloping slightly downwards.
If necessary, make a drain hole approx. Ø 5 mm at the lowest
point to drain off condensation.
•
Important functional parts of the vehicle must not be impaired
(keep sufficient clearance).
•
Mount the exhaust pipe with sufficient clearance to heat-sensitive parts. Pay particular attention to fuel pipes (plastic or
metal), electrical cables and brake hoses etc.!
•
Exhaust pipes must be fastened safely (recommended clearance of 50 cm) to avoid damage from vibrations.
If no special diesel fuel is available for low temperatures, then
kerosene or gasoline should be mixed with the fuel according to
the following table:
•
Route the exhaust system so that the emitted fumes are not
sucked in with the combustion air.
Temperature
•
The mouth of the exhaust pipe must not get clogged by dirt
and snow.
•
The mouth of the exhaust pipe must not point in the direction
of travel.
Fuel Quality
This means that difficulties are only to be expected for extreme
drops in temperature, as also apply to the vehicle engine. Please
also refer to the vehicle manual.
Winterdiesel
Addition
0 °C to –25 °C
100 %
–
(32 °F to –13 °F)
100 %
–
–25 °C to –40 °C
50 %*
50 % paraffin or petrol
50 %*
–
•
Always fasten silencer to the vehicle.
(32 °F to –13 °F)
•
The exhaust end pipe should be much shorter than the flexible
exhaust pipe from the heater to the exhaust silencer.
* or 100 % special cold diesel fuel (Arctic diesel).
Note: HYDRONIC M8 Biodiesel
The heater is approved for operation with biodiesel up to a temperature of – 8°C (17.5°F) (the flowability reduces at temperatures below 0 °C (35°F)).
• When using 100 % biodiesel, the heater should be run on diesel fuel twice a year (in the middle and at the end of a heating
period) to burn off possibly accumulated biodiesel deposits. To do so, let the vehicle tank run almost empty and fill with diesel fuel
without adding any biodiesel. While running on this tank filling, switch the heater on 2 to 3 times for 30 minutes at a time at the
highest temperature setting.
• If constantly operated with diesel / biodiesel mixtures of up to 50 % biodiesel, intermediate operation with pure diesel fuel is not
necessary.
HYDRONIC M10 / HYDRONIC M12
Both heaters are not approved for operation with biodiesel. Up to 10 % biodiesel may be added.
11
Installation Procedures
Fuel System
Fuel Line
• Route fuel lines from the fuel pick-up pipe to the heater.
The Hydronic MII boxed unit is most commonly provided with the
fuel metering pump mounted inside the box. This is to reduce
installation time and to protect the pump from corrosion. If specifications cannot be met the pump must be mounted externally.
See illustration for connections and specifications. All parts
necessary to do the installation are included in the kit as shown.
• Use Espar approved fuel lines.
• Other sizes or types of fuel lines may inhibit proper fuel flow.
• Make proper butt joints using clamps and connector pieces
as shown
• Use a sharp utility knife to cut plastic fuel lines to avoid burrs.
Note: Fuel line limits must not be exceeded.
Ensure that the following conditions are met.
Bottom of the fuel metering pump must be within a height
of 2’6” of the bottom of the fuel pick-up pipe.
Note: Butt joints and clamps on all connections.
Fuel metering pump must be within a total distance of
6’6” from the fuel pick-up pipe.
Bubble
Pressure runs of less than 1.3 mtrs (50”) use only 3.5mm
rubber (360 75 300)
Control and Safety Devices
Right
Wrong
Correct
Wrong
Emergency shutdown – EMERGENCY OFF
If an emergency shutdown – EMERGENCY OFF – is necessary
during operation, proceed as follows:
• Switch the heater off with the control
• pull the fuse out
• disconnect the heater from the battery.
Fuel System Tolerances
6
5
Max. 20”
Max. 6’6”
7
6
1. Fuel Pick-Up Pipe
5
4
Max. 6’6”
2
3
Max. 2’6”
12
3. 5.0mm Fuel Line
4. Fuel Metering Pump
5. 9mm Clamp
6. 3.5mm Rubber Connector
2
FUEL
TANK
2. 11mm Clamp
1
7. 2.0mm White Plastic Fuel Line
See notes if length is less than
1.3 mtr (50”)
Installation Procedures
Fuel Metering Pump Installation
If the pump needs to be mounted externally follow these guidelines:
• Choose a protected mounting location close to the fuel pickup pipe and heater.
15° to
vertical
• Using the bracket and rubber mount provided, install pump as
shown.
15°
Note: Proper mounting angle of the pump is necessary to
allow any air or vapor in the fuel lines to pass through
the pump rather than cause a blockage.
Fuel Pick-Up Pipe Installation
(Standard Pick-Up)
Ø
• Choose a protected mounting location close to the pump and
heater. A spare fuel sender gauge plate provides an
ideal mounting location.
2.5 cm (Ø 1.0”)
0.625 cm
(2 HOLES)
(Ø 1 / 4”)
Ø
• Drill the mounting holes as shown.
• Cut the fuel pick-up pipe to length.
• Mount the fuel pick-up pipe as shown
• Lower the fuel pick-up pipe (with reinforcing washer) into
the tank using the slot created by the two 0.6cm (1/4”) holes.
1.5 cm 1.5 cm
9 / 16” 9 / 16”
• Lift the assembly into position through the 2.5cm (1”) hole.
• Assemble the rubber washer, metal cup washer and nut.
Note: Drill the two (1/4”) holes first.
Fuel Pick-Up Pipe
Nut
Sheet Metal Washer
Rubber Gasket
( Optional Pick-Up Pipe with NPT fitting )
Steel Safety Washer
Holding Tabs
Allow 4” from fuel pick-up
to tank bottom. Allow
only 1” for flat bottom
tanks.
End tip of the fuel pick-up
pipe should have angle
so as to avoid picking up
dirt and
subsequent blockage
•
Remove an existing plug from the top of
the fuel tank.
•
Cut the fuel pick-up pipe to length.
•
Secure the fuel pick-up pipe into position
using the combined NPT compression
fitting as shown
Note: NPT fittings are available in various sizes
(Refer to parts catalogue).
13
Installation Procedures
Electrical Connections
Caution: To avoid potential short circuit damage during instal
lation, insert main fuse into the power harness after
all electrical connections are complete.
A) Power Harness...................................................................
Note: Wire must be inserted into fuse holder prior to
terminating.
Note:
All harnesses should be cut to length.
All exposed electrical connections should be coated
with protective grease.
• 2 core harness (red, brown).
• Connect red wire to fuse link and terminal.
• Attach ring terminal to vehicle battery (+).
• Connect brown wire to vehicle battery (-) using ring
terminal provided.
• Insert fuse. (15A-24V, 20A-12V)
B) Switch Harness..................................................................
• 4 core harness (red, brown, yellow, blue/white)
• Run to location of switch. Make terminal connections at
switch. Espar has different available switches.
See switch instructions for more information.
C) Fuel Metering Pump Harness...........................................
• 2 core harness (green, green).
• Fuel Metering Pump Harness is pre-connected when
box is provided with pump pre-mounted.
• If mounted externally, connect wires to fuel metering
pump using connector and terminals supplied, with the
heater - (no polarity required).
7D
ay T
ime
r
C
B
7 Day Timer
switch harness
+
A
Shown is a Hydronic MII boxed version, 12 volt with
Standard - Power, Switch, Fuel Metering Pump harnesses
and optional 7 day timer.
Other timers or switch options are available.
Easy Start
Programable
Timer
Mini Timer
RESET
AUTO MANUAL
CLOCK
TIMER DAY
MANUAL
14
HOUR
MIN
Push and
Pull Switch
Installation Procedures
Exhaust Connection
Intake Connection
A 30 mm flexible tube exhaust pipe with a length of 1M long is supplied with the kit for the exhaust. An exhaust clamp is needed to
secure the exhaust to the the heater. The exhaust hose cannot be
any longer than 2 m. Connect the exhaust as follows:
• Connect the exhaust pipe to the exhaust port on the heater and
attach with clamp provided. Feed the exhaust pipe through the
silicone (white) grommet on the bottom of the box.
• Run exhaust to an open area to the rear or side of the vehicle so
that fumes can not build up and enter the passenger compartment or the heater combustion air intake.
Combustion air must be drawn in from the outside of vehicle.
The combustion air opening must be kept free at all times.
• Connect the air intake pipe to the intake port on the heater
and secure with clamp provided.
Caution: Do not install the intake opening facing the vehicle slipstream. Ensure that the opening cannot
become clogged with dirt or snow and that any
water entering the intake can drain away.
• Install exhaust pipe with a slight slope or drill a small hole in the
lowest point to allow water to run off. Any restriction in exhaust
will cause operational problems.
• Route the exhaust pipe from the heater using holders provided.
Caution: Run exhaust so that it cannot be plugged by dirt, water
or snow. Ensure the outlet does not face into the vehicle slip stream.
Note: 1. Exhaust hose cannot be any longer than 2m (80”)
2. Minimum length 0.2 m (8”)
3. Air intake silencer always needed.
Holding clamps
Exhaust & Intake
Clamps
Flexible Exhaust
& Air intake hose
cannot be any
longer than
Max 2M (80”)
P/N 25 1786 80 02 00
Air Intake silencer
Always needed
End Sleeve
Warning: Asphyxiation Hazard
Route exhaust beyond the skirt of the cab and outside of the
frame area. Route exhaust so that the exhaust fumes cannot
enter the passenger compartment. Failure to comply with this
warning could result in Asphyxiation.
Warning: Fire Hazard
The exhaust is hot, keep a minimum of 5cm (2”) clearance
from any heat sensitive material. Failure to comply with this
warning could result in fire and serious injury.
15
Installation Procedures
Operating Switches
A 7 Day Timer , a Push/Pull switch or an easy start timer are
available for the heater.
a4)
a3)
a5)
a2)
Yellow
Blue
RESET
AUTO MANUA
L
CLOCK
TIMER DAY
HOUR
MIN
Red
Brown
MANUAL
12 11 10 9 8 7 6 5 4 3 2 1
Option #1
Red
Yellow
Brown
Blue
TRS
DIAG
P
Option #2
7 Day Timer Instructions
The 7 Day Timer has been designed to provide a simple means
to control the operation of the heater system and to include the
capability for diagnostics. This timer connects to the diagnostic
circuit of the heater. The timer then displays any heater fault
codes in three digit number form automatically. The timer allows
for pre-selection of turn on time, up to 7 days in advance, as well
as an option for run times up to 2 hours before automatically turning off. In addition, there is an on/off switch for manual operation.
By default the timer is pre-set by Espar to operate for two hours.
Refer to instructions provided with timer for setting options.
• Mount bezel into dash and insert timer or use Espar’s optional
mounting bracket and secure to dash.
• Use hardware supplied for connections.
• Connect the switch harness to the connector at the heater and
run harness to switch location. (Harness should be neatly
routed and secured under dashboard).
• Cut harness to length and terminate wires. Attach using connectors provided.
• Refer to timer instructions for other wiring options.
Mounting Bracket & Bezel
P/N 25 1482 70 01 00
Option #2: Operate heater continuously - connect wire from
ignition circuit to terminal #10.
Note:
An alternative to connecting pin 10 to the vehicle
ignition accessories “On” circuit may also be considered for some applications where extended run
times are desired. Connecting pin 10 with the red
wire will enable the heater to run continuously on
manual mode.
Operating Instructions
Setting Time and Weekday
Push
button once 12:00 will begin to flash (this will occur
upon initial hook up to power).
Using
or
set the present time of day (24 hour clock).
When the time stops flashing the time has been stored.
The weekday will now begin to flash.
Use
or
to set the present weekday.
When the weekday stops flashing the weekday has been stored.
When the vehicle ignition is turned “on” the time display will
appear, if optional connection on pin 10 is insatlled.
When the vehicle ignition is turned “off” the timer display will go
off after 15 seconds.
Changing the Time or Day
Push and hold
button until the time display begins to flash.
Continue to set the time as listed in setting time and weekday.
Using the Timer with the Vehicle Ignition “Off”
Push
button.
will appear on the display as well as the operation countdown
timer.
The running time is factory set to maximum of 120 minutes.
This running time can be reset once or permanently as desired.
Bezel
Mounting Bracket
Note: If installing a remote starter, refer to remote starter
instructions before terminating wires.
Option #1: Dash lights to timer - connect wire between dash
lights circuit and timer at terminal #1.
Note: The timer display is automatically illuminated while the
heater is operating. Connecting pin 1 to the vehicle dimmer switch will allow the timer display to illuminate with
the vehicles dash lights.
16
Adjusting Preheat Time Once
Press
button.
The
will appear in the display and the preselected run
time will appear in the display (maximum time of 120 minutes).
Use the
or
to adjust the desired run time.
Adjusting the Heater Preheat Time Permanently
(Maximum Preheat Time of 120 minutes)
Push
and hold (about 3 seconds) until the display lights up
and flashes. Release button.
Use
or
to set the new fixed preheat time.
When the display goes off the new preheat time is set.
Note: At the end of a preheat cycle the timer will turn the
heater off. The heater will complete a cool down cycle
and turn itself off.
Installation Procedures
Using the Heater Manually with the Vehicle Accesory “On”
(Optional wire on pin 10 is connected to the ignition lock)
Push
buton.
The
symbol will appear in the display next to the time of day.
The time of day will remain displayed during ignition on operation.
The heater will function continually as long as the vehicle ignition
is “On”.
When the vehicle ignition is turned “Off” the heater will continue
to operate for an additional 15 minutes.
The run time can be altered by pressing the
or
buttons.
The heater can be turned off by pressing
button.
Control Unit Locking
The control unit may becomed locked due to one of the following conditions:
1. Overheat – If the heater overheats three times in succession, fault message F15 is displayed and the
control unit is locked.
2. Too many failed start attempts - If the heater performs
many start attempts in succession (i.e. Fault 52), fault
messsage F50 is displayed and the control unit is locked.
Unlocking Control Units and Erasing Fault Memory
Set Preheat Times into Memory
Press
button until the desired memory location is shown in
the display (Three memory locations are available).
Using the
or
buttons set the desired preheat start time
of day.
When the time stops flashing the time of day is set.
Using the
or
buttons set the desired day of the week.
When the day of the week stops flashing the day is set.
To Use Preset Start Times
Press the
button until the desired memory location appears
in the display.
The heater will start at the day and time displayed.
The display will go off in 15 seconds. The memory location
number will stay displayed (1, 2 or 3).
Note: When preset is chosen
this symbol will flash red.
Note: The electrical connection for the ignition / accessory
wire to the timer terminal #10 must be in place.
1. Turn on the vehicle ignition to activate timer display.
key. The current fault code (i.e. F15 or F50) is
2. Press the
now displayed.
3. Press the
key and hold it down and press the
key
within two seconds. The timer is now in the retrieval mode.
4. Turn off the ignition.
5. Press the
key and hold it down and press the
key
within two seconds and hold it down.
6. While holding down
keys, turn ignition on and wait
until the following display appears:
To Turn Heater “Off” - All Modes
Press the
button once.
The heat signal to the heater will be turned “Off”.
The heater will do a normal cooldown and turn itself “Off”.
7. Press the
key to turn the heater off.
8. Press the
key to turn the heater on.
9. Repeat step three. The following display appears:
Note: · This timer is equipped to display fault code numbers if
the heater should shut down due to an operating fault.
The fault code will show in the timer display next to the
flashing heat wave symbol. This applies to all current
model heaters when the blue diagnostic wire is connected.
· If the timer is purchased without the harness kit, the
following heaters will need a load relay intalled (D8Lc,
D7W, D12W, D24W and D30W), These heaters carry a
load on the switch wire. (i.e. fuel metering pump or noid
sole valve).
· An outside temperature sensor is available as an option.
Wiring Connections at Connector
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
1
2
4
6
8
9
10
Terminal 11
Terminal 12
Terminal 3,5,7
Power from vehicle dash lights.
Heater switch wire - Yellow wire.
Connect to vehicle ground.
Temperature setting “+” (air only).
Heater diagnostic lead - blue wire.
Temperature setting “-” (air only).
To vehicle “ACC” accessory for
continuous overnight use, and for
unlocking ECU.
Positive power from heater - red “+”.
Ground lead from heater - brown “-”.
Left blank, not required.
10.The control unit lock is cancelled after three seconds
and the heater starts.
Retreaving the Stored Fault Codes
1. Press the
key. The heater is switched on.
key and hold it down and press the
key
2. Press the
within two seconds. The current fault code is now displayed
(Example: AF:64).
3. The stored fault codes (maximum of 5) can now be retrieved
using the arrow keys and (Example: F1:64).
Note: Consult the Troubleshooting and Repair manuals for
code definition and corrective action. If the heater is
not being operated using the 7-day timer, fault code
retrieval can be obtained using the “Fault Code
Retrieval Device”, part number: 20 2900 70 50 20.
17
Installation Procedures
Push/Pull Switch
• Mount switch in a location where it is easily accessible
Setting the time
• Mount using hardware supplied
Press and hold the CLOCK button.
Press DAY button to select the correct day.
Press HOUR button to select the correct hour.
Press MIN button to select the correct minutes.
When the MIN button is released the time will be set.
• Connect the switch harness to the connector at the heater
and run the harness to the switch location
• Cut harness to length at the switch and install terminals
• Connect wiring as described below
Note:
Holding down or repeatedly pressing the appropriate button will
advance the days, hours and minutes.
Switch light glows when pulled out and is off when
pushed in.
Programming of Switching Times
The Auto Time Switch has the capacity for 8 ON/OFF switches.
By using the blocks of days available, you can save program
capacity. The block days are:
Brown- 31
Power from battery “-”
Red- K(15)
Power from battery “+”
Yellow-15(K)
Switch control to the heater
Blue/White
Diagnostic from heater (disregard - tape end
and tie off to the side)
P/N 5670007 (12v)
P/N 5670008 (24v)
Ø 14.5mm
Ø 9/16”
K (15)
MO, TU, WE, TH, FR, SA, SU – Individual days of the week
MO, TU, WE, TH, FR
SA, SU
MO, TU, WE, TH, FR, SA
MO, WE, FR
TU, TH, SA
Programmable Timer
MO, TU, WE
a3)
Yellow (Signal to Heater)
4
31
15 (K)
5
a5)
a4)
Brown (-)
Red (+)
3
2
5670100 - 12 Volt
5670099 - 24 Volt
Programmable
Timer
1
Programmable Timer
P/N 5670100 (12v)
P/N 5670099 (24v)
Programmable Timer Instructions
Each ON time and each OFF time, the days, hours and minutes
must be set.
RESET
AUTO MANUAL
CLOCK
TIMER DAY
HOUR
Press the TIMER button once to set the first ON time – you will
see “on” and the number “1” appears.
MIN
MANUAL
Enter the first ON time.
Press the DAY button to choose the required day or block of
days.
IMPORTANT: This electronic timer has a maximum loading
printed on the rating label and under no circumstances should this be exceeded.
Features:
• Up to 8 ON and OFF switches a day/56 ON and OFF
switches per week
• Option to program individual days or 8 different weekday
groups
• Minimum switching period of one minute
• Summer/Winter time changeover
• Easy to read LCD display
• Manual Override button
• Battery Back-up
Note: As soon as you have connected 12 volts you will
have to push down the RESET button to activate
the timer.
18
Set the hour and minutes using the HOUR and MIN buttons.
Press TIMER button to save first on time and are ready to set
first off time you will see “OFF” and the number “1” appear.
Use the DAY, HOUR and MIN buttons as above.
Press the TIMER button to save off time.
Repeat the same steps for the remaining 7 ON and OFF settings as desired.
When you have set the required ON/OFF settings, press the
CLOCK button to return the display to the clock.
The timer is now ready to operate.
Note: You can check the settings you have programmed
by pressing the TIMER button repeatedly. Each set
ting will appear on the screen.
Notes:
19
Heater Operation
Pre-Start Procedures
Upon completion of installation prepare the heater as follows:
• Check all fuel, electrical and plumbing connections.
• Refill the engine coolant.
• Bleed air from the coolant system by running the engine and
refilling the antifreeze as needed. Resecure heater hose.
• Run engine to further bleed the system
• Top up engine coolant.
Start Up
Once switched on, the following sequence occurs:
• Control unit does a systems check (flame sensor, tempera
ture, and various other control unit checks).
• Water pump starts circulating coolant fluid.
• Combustion air blower starts.
• Glow pin begins to preheat 20-30 secs.
• After about 20-30 seconds the Fuel Metering Pump starts delivering fuel and the combustion air blower ramps up gradually.
• Once ignition takes place the flame sensor alerts the control
unit and the control unit shuts off the glow pin (ignition time:
1.5 - 2 minutes).
Note: If the heater fails to start the first time it will automatically attempt a second start. If unsuccessful the heater
will shut down completely.
Note: On initial start up the heater may require several
start attempts to self prime the fuel system.
Heating Mode
At the initial start the heater is operated with the “POWER” stage
until the water temperature exceeds the “POWER” / “HIGH”
changeover threshold.
HYDRONIC M8 / M10
Then, depending on the heat requirement, the heater switches to
the “HIGH – MEDIUM – LOW – STAND BY” stages.
If the heating requirement in the “LOW” stage is so small that the
cooling water temperature reaches 85 °C, the heater switches
from “LOW” to “STAND BY”.
HYDRONC M12
Then, depending on the heat requirement, the heater switches to
the “HIGH – MEDIUM 1 / MEDIUM 2 / MEDIUM 3 – LOW –
STAND BY” stages.
If the heating requirement in the “LOW” stage is so small that the
cooling water temperature reaches 85 °C, the heater switches
from “LOW” to “STAND BY”.
This is followed by the after-run with additional after glowing of the
glow plugs (like when heater is switched off).
After the cooling water has cooled to approx. 70 °C the
HYDRONIC M8 / M10 heater starts in the “MEDIUM” stage, the
HYDRONC M12 heater in the “MEDIUM 1” stage.
If the cooling water temperature reaches approx. 55 °C the
temperature sensor switches the vehicle fan on.
Temperature Drop
Temperature drop only becomes active while the vehicle is runing
and if the heater is switched on. The control stages are reached
earlier and the heater‘s control action is adjusted to the lower heat
requirement.
20
The temperature can be lowered by connecting the positive
cable (+) to connector S2, terminal C3 of the heater (see circuit
diagrams).
Switching Off
With the switching off the heater starts the after-run of
180 sec. During the after-run the first glow plug is switched
on after 90 seconds for a period of 45 seconds,
then the second glow plug is switched on until the end
of the after-run.
Safety Equipment
The heater is equipped with the following control and safety
devices.
• If the heater does not ignite within 74 seconds after the fuel
starts to pump, the start is repeated.
If the heater still does not ignite after another 65 seconds of
fuel being pumped, the heater is automatically shut down.
After an unacceptable number of failed start attempts, the
control box is locked.*
• If the flame goes off by itself during operation, the heater is
restarted.
If the heater does not ignite within 74 seconds after the fuel
starts to pump again, the heater is automatically shut down.
The shutdown on faults can be cancelled by briefly switching
off and on again.
• In the case of overheating (e.g. water shortage, poorly ventilated cooling water circuit), the overheating sensor triggers,
the fuel feed is interrupted and the heater is automatically
shut down.
Once the cause of the overheating has been eliminated, the
heater can be re-started by switching it off and on again
(provided that the heater has cooled down sufficiently, cooling
water temperature < 70 °C).
After the heater has been shut down due to overheating an
unacceptable number of times, the control box is locked.*
* The ECU can be unlocked and the fault can be displayed
with:
• EasyStart.
• Diagnostics Unit.
• EDiTH diagnostics software.
For operation and fault list, please refer to the enclosed
operating instructions or these troubleshooting and repair
instructions.
• If the lower or upper voltage limit is reached, the heater
will shut down.
• The heater does not start up if the electric cable to the
metering pump is not connected.
• If one of the two glow plugs is defective, the start sequence
takes place with one glow plug only
.
• The speed of the blower motor is continuously monitored.
If the blower motor does not start up, if it is blocked or if the
speed differs by > 12.5 % of the desired speed, the heater
will automatically shut down after 60 sec.
• The function of the water pump is continuously monitored.
Warning:
The heater must be switched off while any
fuel tank on the vehicle is being filled.
The heater must not be operated in
garages or enclosed areas.
Heater Operation
Heater Wiring
The heater is to be connected up electrically according to the
EMC directives.
12-pin Connection Pin Assignment
Connector is shown
from the lead entry
side.
Caution:
EMC can be affected if the heater is not connected up correctly.
For this reason, comply with the following instructions:
•
Cable harness
HYDRONIC M
Ensure that the insulation of electrical cables is not damaged.
Avoid:
chafing, kinking, jamming or exposure to heat.
•
Cable colour
Connection
Rewiring
12-pin connector
HYDRONIC M HYDRONIC M-II
PIN
PIN
Metering pump
green
C4
A1
Terminal (-)
brown
C3
A2
Terminal (+)
red
C2
A3
Plus signal
main battery switch
white / red
C1
A4
Plus signal
Solenoid valve relay
–
B4
B1
Diagnosis
blue
B3
B4
Note: Comply with the following when wiring the heater and the
control unit: fuses and controlers.
Plus signal
ADR auxiliary drive
violet
B2
B3
• Electrical leads, must be positioned in the vehicle so that they
can function perfectly under normal operating conditions without impairment (e.g. due to heat exposure, moisture, etc.).
Third party control
Water pump
–
B1
B2
remains
unused
Blower relay
red / yellow
A4
C1
D+
for ADR operation
violet / green
A3
C2
Temperature drop
–
A2
C3
yellow
A1
C4
In waterproof connectors, seal any connector chambers not
in use with filler plugs to ensure they are dirt-proof and waterproof.
•
Electrical connections and ground connections must be free
of corrosion and firmly connected.
•
Lubricate connections and ground connections outside the
heater interior with contact grease.
• The following wire gauge are to be used between the battery
and heater.
This ensures that the max. allowable voltage drop in the
cables does not exceed 0.5 V for 12 V or 1 V for 24 V rated
voltage.
Heater ON
Cable cross-sections for a cable length (plus cable + minus
cable) of:
– up to 5 m (plus cable + minus cable) = 10 AWG
– from 5 m up to 8 m (plus cable + minus cable) = 8 AWG
• If the ( + ) cable is to be connected to the fuse box, the
vehicle's cable from the battery to the fuse box must also be
included in the calculation for the total cable length and
re-dimensioned if necessary.
• Insulate unused cable ends.
If replacing the HYDRONIC 10 / M with the HYDRONIC M-II, the
cable harness installed in the vehicle is retained and continues to
be used, it is necessary to remove the 12-pin connector using the
terminal removal tool and to rewire it according to the following
table.
21
Heater Operation
Parts list for wiring diagram, Hydronic M-II - 12 Volt / 24 Volt
1.1
1.2
1.2.1
1.5
1.12
1.13
Blower motor
Glow pin I
Glow pin II (optional 12 kW)
Overheating sensor
Flame sensor
Temperature sensor
2.1
2.2
2.5.7
2.5.18
2.7.1
2.7.5
2.12
Control unit
Fuel metering pump
Relay, vehicle blower (fan)
Relay, changeover water circuit
(To be fitted by customer if required)
Main fuse
12 volt = 20A
24 volt = 15A
Fuse, control option 5A
Fuse, vehicle blower (fan) 25A
Water pump
5.1
5.10
Battery
Vehicle blower (fan)
2.7
a) Connection to 7 day timer, programmable timer, easy start or
push pull switch
b) Water circuit change-over: Relay makes contact at 68°C and
breaks contact at 63 °C water temperature (with temperature
drop 58 °C / 45 °C)
c) Temperature drop
x) Disconnect cable
a2
a3
a4
a5
Diagnosis
Switch on signal
Power supply plus
Power supply minus
Connectors and bush holdings are shown from the cable
inlet side.
Connector pin assignment: 12-pin connector (external).
PIN-No.
A1
B1
C1
A2
A3
B2
B3
C3
B4
C4
22
Connection
Dosing pump
Solenoid valve, optional
Relay, blower
Battery ( - )
Battery ( + )
Diagnosis cable (OEM)
TRS signal (ADR)
Temperature drop
Diagnosis
Heater ON
Heater Operation
Hydronic M-II, Wiring Diagram - 12 Volt / 24 Volt
Circuit diagram HYDRONIC M-II – 12 Volt / 24 Volt
B3
S3
x)
Optional
5.10
Black/Violet
Black
Red
Brown
Brown / Green
Brown
b)
b)
Brown
Brown
Red
Red
Red
Yellow
C4
B3
9
C3
B4
6 3
2.7
2.7.5
2.7.1
B2
C2
B1
5
C1
A4
8
B2
Blue / White
A3
Green
Brown
Red
White / Red
A2
A1
Red / Yellow
c)
S2
a)
White/Red
Blue/White
Yellow
Red
Brown
a1)
a2)
a3)
a4)
a5)
Brown
B3
2.5.18
Red / Yellow
2.5.7
2.2
5.1
2.1
Red
White
Brown
White
Brown
Red
White / Red
Brown / Black
Yellow
Blue / White
Blue
Brown
Pink
Green
Orange
1 1 14 10 7 4 12 13 1 2
1.2.1
1.2
B1
1.5
2.12
1.13
B2
B1
1.12
1.1
B3
S2
S3
23
Heater Operation
Hydronic M-II, Controler Options
Push/Pull switch
RED
a4)
YELLOW
a3)
0
0
BROWN
a5)
15 (K)
K (15)
31
Push / Pull Switch
a4)
a3)
a5)
a2)
Red
Yellow
Brown
Blue
12 11 10 9 8 7 6 5 4 3 2 1
Option #1
Yellow
Blue
Red
Brown
TRS
DIAG
P
7 Day Timer
Option #2
Programmable Timer
a3)
Yellow (Signal to Heater)
5
4
a5)
a4)
5670100 - 12 Volt
5670099 - 24 Volt
3
2
Brown (-)
Red (+)
RESET
Programmable
Timer
1
AUTO MANUA
L
CLOCK
TIMER DAY
HOUR
MIN
MANUAL
Programmable Timer
Easy Start T
1 2 3 4 5 6 7 8 9
LCD
Grey
a1 )
a2 )
White / Red
Blue / White
a5 )
Brown
a4 )
Red
B1
Brown / White
Grey
Grey / Black
Blue / White
Violet
Brown
Yellow
Red
S1
Easy Start T
Optional On/Off Switch
24
Maintenance, Troubleshooting & Repairs
PeriodicRight
Maintenance
Subtitle
Page
Fault Code Retrieval Device
• Check coolant hoses, clamps, and make sure all valves
are open. Maintain the engine manufacturers recommended
coolant level and ensure that the heater is properly bled after
service on or involving the coolant system.
Equipment Face and Controls
• Visual check of all fuel lines for leaks. Check and if necessary
replace fuel filter inserts.
• Visual check of electrical lines and connections for corrosion.
• Run your heater at least once a month during the year (for a
minimum of 15 minutes).
• Maintain your batteries and all electrical connections in good
condition. With insufficient power the heater will not start.
Low and high voltage cutouts will shut the heater down automatically.
• Use fuel suitable for the climate. Blending used engine oil
with diesel fuel is not permitted.
Symbols seen on the display
face are as follows:
D
L
L
AF
Actual fault.
F1-F5
Up to five stored faults can be accessed.
The AF and F1 are the same.
This sign is displayed when the heater is in operation.
DIAG
The word (Diagnostic) will come on when the
diagnostic number is requested.
000
Three digit diagnostic fault code number.
Hook Up
Troubleshooting
• Disconnect the main harness from heater and insert adapter
cable harness between them.
Basic Troubleshooting
• Connect adapter cable to the cable loom of the Fault code
retrieval device.
In the event of failure there are several items which should be
checked first before any major troubleshooting is done.
Check:
• Fuses.
• Electrical lines and connections
• Interference in Combustion air and Exhaust pipes.
• Fuel in the tank.
• Battery voltage on heater side of harness
• Coolant flow
• Start diagnostic unit - switch heater on from switch.
Instructions:
• Switch the fault code retrieval device on and wait 10 seconds.
• Press the "D" button.
• Wait 3-5 seconds for the current fault code to appear (AF).
• To review the previous faults use the arrow buttons
(F1= Most Recent, F5= Oldest).
• To erase the faults that are in memory press both "L" keys at
the same time.
• See the fault code chart on following pages for code number
descriptions.
Self Diagnostics
The heater is equipped with self diagnostic capability. You can
retrieve information on the heaters last 5 faults using the Espar 7
day timer, Espar’s Fault Code Retrieval Device or ISO adapter and
computer.
Multifunction
Espar’s 7 day timer has a fault code
retrieval device built into the unit. This
function automatically activates if the
heater is experiencing problems.
Diagnostic Adapter
P/N 25 2800 70 1004
• Fault codes appear on the LCD display screen.
• Codes can then be translated from the charts on the following
pages.
• Pg 10 - 17 for more detailed instructions.
Fault code
retrieval device
P/N 20 2900 70 5020
25
Maintenance, Troubleshooting & Repairs
Fault Code
Fault Description
Causes / Repair
———
Diagnosis not possible
• Adapter cable not connected properly.
• Diagnostic connection damaged.
• Internal control box fault, replace control box / blower unit.
000
No faults
——
005
Warning
Short circuit in "Burglar Alarm" output
• Check connection and / or lead for continuity, short circuit and
damage.
009
ADR / ADR99 shutdown
• Switch the heater off and then on again –
The shutdown must be cancelled by D+ or HA / NA.
010
Overvoltage cutoff
Overvoltage applied to control box for at least 6 seconds
–> heater not working.
• Disconnect heater / cable harness plug-in connector, start
the vehicle engine, measure the voltage. Connector B2, PIN
A2 and A3:
– If the voltage is >15 volt or >30 volt, check the generator
regulator and / or the battery.
011
Undervoltage cutoff
Undervoltage applied to control box for at least 20 seconds
without interruption –> heater not working.
• Disconnect heater / cable harness plug-in connector, start the
vehicle engine, measure the voltage. Connector B2, PIN
A2 and A3:
– If the voltage is <10 volt or <20 volt, then check the fuses,
the supply cables, the negative connections and the positive
support point at the battery for voltage drop (corrosion).
012
Overheating
Overheating sensor signals temperature greater than 120°C.
• Measure the resistive value of the overheating sensor,
connector B1, PIN 2 and 4, for measured values. See page 44.
– If overheating sensor ok, check connection leads for continuity, short circuit and damage.
014
Possible overheating dettected
(Temperature difference evaluation)
Difference between measured value in overheating sensor and
temperature sensor is too large.
• Measure the resistive value of the temperature sensor,
connector B1, PIN 2 and 4 and connector B1 PIN 1 and 2; for
measured values. See page 44.
– If temperature sensor ok, check connection leads for
continuity, short circuit and damage.
015
Too many overheats,
Control box is locked
Control box locked due to too frequent overheating (fault code
012 or 014) in succession.
• Unlock the control box by deleting the fault memory, see
pages 16 and 25.
017
Overheating,
Sensor threshold exceeded
Max. temperature exceeded at the overheating sensor (180°C).
• Check overheating sensor —> fault code 012.
• Check control box.
019
Glow plug 1,
Ignition energy too low
Glow plug 1 energy input is too low (< 2000 Ws)
• Check glow plug for continuity, short circuit and damage
—> Fault code 020.
• Check control box.
26
Maintenance, Troubleshooting & Repairs
Fault Code
Fault Description
020
Glow plug 1, interruption
021
Glow plug 1, overload / short circuit
downstream of (–)
Glow plug 1, short circuit downstream
of (+)
022
Causes / Repair
• Measure cold resistance of the glow plug at approx. 20°C
ambient temperature – connector B1, PIN 7 and 10.
If the values are as follows the glow plug is ok, if the values
differ – replace the glow plug.
Measured value:
• 12 volt – glow plug = 0.42 – 0.6 ohm
• 24 volt – glow plug = 1.2 – 1.9 ohm
– If the glow plug is ok, check the lead harness of the glow plug
for continuity, short circuit and damage.
023
Glow plug 2, interruption
• Measure cold resistance of the glow plug at approx. 20°C
ambient temperature – connector B1, PIN 11 and 14.
If the values are as follows the glow plug is ok, if the values
differ – replace the glow plug.
Measured value:
• 12 volt – glow plug = 0.42 – 0.6 ohm
• 24 volt – glow plug = 1.2 – 1.9 ohm
– If the glow plug is ok, check the lead harness of the glow plug
for continuity, short circuit and damage.
024
Glow plug 2, overload / short circuit
downstream of ground
025
Diagnostic line fault
Heater remains ready for operation
• Check diagnostics cable for continuity, short circuit and
damage – connector B2, PIN B4.
– if ok, check control box.
026
Glow plug 2, short circuit downstream
of (+)
see fault code 023 / 024
029
Glow plug 2, Ignition energy too low
Glow plug 2 energy input is too low (< 2000 W)
• Check glow plug for continuity, short circuit and damage.
—> Fault code 023.
• Check control box.
033
Burner motor, interruption
033
Burner motor, overload
033
Burner motor, speed error / blocked
• Check the burner motor's connection leads for continuity, short
circuit and damage – connector B1, PIN 3, 6 and 9.
• Check burner motor for easy movement by manually rotating the
impeller.
– if not smooth running, remove the blockage.
– if ok, replace control box / blower unit.
034
Burner motor short circuit
downstream of (+) or (–)
037
Water pump not working
• Check water pump.
Apply voltage to the water pump – connector B1, PIN 12 and 13
(power input = max. 4 A or 2 A)
– If water pump does not rotate, replace water pump.
– If water pump is ok –> replace control box / blower unit.
041
Water pump, interruption
• Check the water pump's connection and lead harness for continuity, short circuit and damage – connector B1, PIN 12 and 13.
042
Water pump
Overload short circuit
– If ok, check water pump —> fault code 037.
043
Water pump
Overload downstream of +Ub
Water pump running dry.
• Vent heater (water shortage), open heater slide valve, check
water flow rate
27
Maintenance, Troubleshooting & Repairs
Fault Code
Fault Description
Causes / Repair
047
Metering pump
Overload short circuit
• Check the metering pump's connection and lead harness for
continuity, short circuit and damage – connector B2, PIN A1.
– If ok, check the resistance of metering pump – setpoint value
approx. 20 ohm.
048
Metering pump interruption
049
Metering pump
Overload downstream of +Ub
050
Too many attempted starts
Control box is locked
Control box locked due to repeated switching on in succession
without flame detection (fault code 052).
• Check fuel supply, exhaust and combustion air system.
• Check glow plug –> see fault code 019 to 024 / 026 / 029.
• Check flame sensor –> fault code 064 / 065.
• Unlock the control box by deleting the fault memory.
052
Exceeding of safety time
No flame detected within the start phase. Flame sensor value <
80°C, therefore automatic shutdown because safety time exceeded.
• Check fuel supply, exhaust and combustion air system.
• Check glow plug –> see fault code 019 to 024 / 026 / 029.
• Check flame sensor –> fault code 064 / 065.
053
Flame cutout in
"POWER" control stage
Heater ignited (flame detected) and signals flame cutout during a
power stage.
• Check fuel quantity, blower speed, fuel supply, exhaust and combustion air system.
054
Flame cutout in "HIGH" control stage
• Check flame sensor –> fault code 064 / 065.
055
Flame cutout in "Medium" control stage
(D 8 W / D 10 W) "Medium1" control stage
(D 12 W)
056
Flame cutout in
"Medium 2" control stage (D 12 W)
057
Flame cutout in
"Medium 3" control stage (D 12 W)
058
Flame cutout in "LOW" control stage
059
Too rapid rise in water temperature
• Vent air from system, open heater slide valve, check water flow
rate.
• Check temperature sensor –> fault code 060 / 061
060
Temperature sensor interruption
Temperature sensor signals temperature value outside the
measuring range.
061
Temperature sensor short circuit
• Measure the resistive value of the temperature sensor,
Connector B1, PIN 1 and 2; for measured values. See page 44.
– If temperature sensor ok, check connection leads for continuity,
short circuit and damage.
064
Flame sensor interruption
Flame sensor signals temperature value outside the measuring
range.
065
Flame sensor short circuit
• Measure the resistive value of the flame sensor – connector B1,
PIN 5 and 8; for measured values. See page 45.
– If flame sensor ok, check connection leads for continuity, short
circuit and damage.
28
Maintenance, Troubleshooting & Repairs
Fault Code
Fault Description
Causes / Repair
071
Overheating sensor interruption
Overheating sensor signals temperature value outside the measuring range.
• Check overheating sensor –> fault code 012.
072
Overheating sensor short circuit
074
Overheating detection hardware is
defective, operating lock-out
• Control box is defective.
Replace control box / blower unit.
090
External reset
• Control box reset by external interference voltage.
Check voltage supply, e.g. battery, leads, generator, fuses.
091
Internal reset
• Internal control box fault, replace control box / blower unit.
092
ROM error
093
RAM error, at least one RAM cell is
not working
094
EEPROM error, checksum error within
the area of the operating data, diagnostic
parameters or calibration values
095
Invalid data record, checksum error
096
Internal temperature sensor is defective
/ ECU too hot
097
Internal device error
098
Main relay is faulty
099
Too many resets, operating lock-out
29
Maintenance, Troubleshooting & Repairs
Repair Instructions
The permitted repair work on the heater is described in the
"Repair Instructions" chapter. The heater must be removed
from the vehicle for the repair work to be carried out.
The heater is assembled in the reverse order, note and follow
any additional instructions.
Terminal Removal Tools are used to release plug-in contacts
in a connector housing.
Terminal Removal Tool 1.6mm 206 00 205
Note: After completing all the work and installing the heater
in the vehicle, perform a functional check on the heater.
Terminal Removal Tool 2.8mm 206 00 215
Always observe the following safety instructions before
working on the heater
Warning - Risk of injury, burns and
poisoning
• Ensure power is disconnected from heater and that coolant is
cool before dismantling the heater.
• The heater must not be operated in closed rooms such as
garages or workshops.
Exception:
Exhaust suction available directly at the entry to the exhaust
pipe on the heater.
Caution: • The seals of dismantled components must be
renewed.
• During repair work, check all components for
damage and if necessary replace.
• Check connector contacts, plug-in connections
and cables for corrosion and damage and if
necessary repair.
• Only use Espar spare parts if replacements are
necessary.
• After working on the coolant circuit the level of the
coolant must be checked and if necessary topped
up according to the vehicle manufacturer's
instructions.
The coolant circuit must then be vented.
• Operation or the “after running” of the heater ma
only be stopped in an emergency (Turn off switch,
remove fuse or disconnect battery) by interrupting
the battery current (risk of heater over-heating).
30
Heater Components
1 Impeller cover
2 O-ring 117.07 x 3.53
3 Cover, side
4 Impeller
5 Glow plug 1
6 Glow plug 2
7 Spark plug socket lining
8 Combustion chamber
9 M5 x 16 TAPTITE / DIN 7500 TORX screw
10 Control box / blower unit
11 Flame sensor
12 Cable tie
13 Electric motor cover
14 M5 x 16 TAPTITE / DIN 7500 TORX screw
15 M4 x 12 TAPTITE / DIN 7985 TORX screw
16 Compression spring
17 Overheating sensor
18 Temperature sensor
19 Overheating / temperature sensor cable loom
20 Jacket with heat exchanger
21 M5 x 25 TAPTITE / DIN 7500 TORX screw
22 Grommet
23 Combustion chamber seal
24 Water pump cable loom connector
25 Hose clip
26 Water pump
27 O-ring 19.8 x 2.3
28 14-pin connector
Maintenance, Troubleshooting & Repairs
Preparatory work for all repairs
Figure 1 and 2
• Clamp the removed heater in a retaining device (vice).
• Using 2 screwdrivers, always undo 2 snap connections
of the impeller cover at a time, starting at the control
box/blower unit. Keep to the order shown in the figure
(1.– 8.)
• Remove cover.
• Remove O-ring (2).
Note: The O-ring (2) must always be renewed.
Remove overheating sensor and temperature sensor
Figure 3 – 5
• Remove the (15) M4 x 12 screws of the compressive springs
(16) and use pliers to pull off the overheating (17) and
temperature sensor (18).
Note: Do not pull out the overheating (17) and temperature
sensor (18) from the holder by pulling on the connection cable, always use pliers to remove them.
31
Maintenance, Troubleshooting & Repairs
Repair step 1
Dismantle control box/blower unit and jacket
Remove water pump connector
Figure 6
• Disconnect the connector (24) at the water pump (26) and pull
the cable loom out of the holder.
Remove side cover and dismantle jacket
Figure 7
• Pull out side cover (3) from above.
• Undo the 4 screws (21) M5 x 25 in the jacket (20) and remove
the jacket from the control box / blower unit.
Note: The control box / blower unit may not be placed on the
exposed impeller.
Remove electric motor cover
Figure 8
• Undo the 2 screws (14) M5 x 16 of the electric motor cover (13)
and remove the cover.
Note: The control box / blower unit may not be placed on the
exposed impeller.
32
Maintenance, Troubleshooting & Repairs
Repair step 1
Dismantle control box/blower unit and jacket
Disconnect 14-pin connector at control box and release cables
Figure 9 – 11 / Sketch 1
• Use side cutters to open the cable tie (12).
• Disconnect the 14-pin connector (29).
• Use the terminal removal tool to remove pins in the 14-pin connector (29) for the electric motor, flame sensor (11), glow plug
1(5) and glow plug 2 (6).
• Expose the cables of the two glow plugs from above (cable duct).
Note:
When replacing the control box / blower unit, the
Temp / Overheat sensor and water pump lead
harnesses can be left in the 14-pin connector (29).
Flame sensor
Cable tie
14-pin connector
Figure 9
A AMP release tool
29 14-pin connector
Figure 10
A
B
Figure 11
11
12
12
Temperature sensor, Yellow
Motor, Phase 2, Green
Flame sensor, Brown
Glow plug 1, long cable , Brown
Motor, Phase 3, Orange
Glow plug 2 +, short cable , White
Water pump, Brown / Black
Glow plug 2, short cable , Brown
Water pump, Black / Red
Glow plug 1 +, long cable , White
Flame sensor +, Blue
Motor, Phase 1, Pink
Overheating sensor, Red
Sensor ground, Blue / White
Sketch 1
Long wire (brown, white)
Short wire (brown, white)
33
Maintenance, Troubleshooting & Repairs
Repair step 1
Control box / blower unit and jacket
Remove flame sensor
Figure 12
• Unscrew the flame sensor (11) from the housing of the control
box / blower unit.
Dismantle combustion chamber
Figure 13 and 14
• Undo the 3 screws (9) M5 x 16 of the combustion chamber (8).
• Lift the combustion chamber (8) with the fuel pipe until the
grommet (22) is exposed, then remove the combustion chamber.
• Remove combustion chamber seal (23).
Note: Remove combustion chamber seal (23) without leaving
residues. Always check the glow plugs during this repair
step, see repair step 3.
34
Maintenance, Troubleshooting & Repairs
Repair step 2
Assemble the control box/blower unit and jacket
Install combustion chamber seal
Figure 15 and 16
• Carefully guide the combustion chamber seal (23) over the
cables of the glow plugs and over the fuel pipes and position
on the combustion chamber (8).
Note: Take care when installing the new combustion chamber
seal (23) as there is a risk of breaking it.
Install grommet
Figure 16 and 17
• Carefully position the grommet (22) on the combustion
chamber seal (23).
Note: Ensure the grommet is installed in the correct position,
see Figure 17.
Insert combustion chamber
Figure 18
• First insert the combustion chamber (8) with the grommet
(22) into the control box / blower unit (10). If the grommet (22)
has been completely inserted, align the combustion chamber
and combustion chamber seal with the control box / blower unit
(10).
35
Maintenance, Troubleshooting & Repairs
Repair step 2
Assemble the control box/blower unit and jacket
Install combustion chamber
Figure 19
• Use 3 screws (9) M5 x 16 to fix the combustion chamber (8).
Tightening torque M5 x 16 screw.
Lay sensor lead harness and leads of the glow plugs
Figure 20 and 21
• First lay the sensor lead harness (19) in the side cable duct,
then lay the 4 leads of glow plugs 1 (5) and 2 (6) in the cable
duct.
Lay the sensor lead harness (19) and the glow plug leads to
the 14-pin connector (29 - shown in page 33).
• Position the side cover (3) on the middle of the control box /
blower unit (10) and push into the cable duct guide.
Note: It is imperative to keep to the correct laying order for
the sensor lead harness (19) and the glow plug leads.
The glow plug leads may not be laid underneath the
sensor lead harness (19).
The sensor lead harness (19) must be laid in the area
of the fuel pipe as shown in Figure 20.
The side cover (3) is conical at the bottom to simplify
installation.
36
Maintenance, Troubleshooting & Repairs
Repair step 2
Assemble the control box/blower unit and jacket
Install flame sensor
Figure 22
• Screw the flame sensor (11) into the housing of the control
box / blower unit.
Flame sensor tightening torque.
Connect flame sensor lead harness and electric motor
leads
Figure 23 / Sketch 2
• Latch the flame sensor lead harness (11) and the three leads
of the electric motor into position in the 14-pin connector (29)
Temperature sensor, Yellow
Motor, Phase 2, Green
Flame sensor, Brown
Glow plug 1, long cable , Brown
Motor, Phase 3, Orange
Glow plug 2 +, short cable , White
Water pump Brown , Black
Note: • The leads may not lay against the housing.
• Always lay the Brown / White (long) leads of glow
plug 1 (5) last and latch into position in the 14-pin
connector (29).
Glow plug 2, short cable , Brown
Water pump, Black / Red
Glow plug 1 +, long cable , White
Flame sensor +, Blue
Motor, Phase 1, Pink
Overheating sensor, Red
Sensor ground, Blue / White
Sketch 2
37
Maintenance, Troubleshooting & Repairs
Repair step 2
Assemble control box/blower unit and jacket
Connect the glow plug leads
Figure 24, 25 and Sketch 3
• First, latch the leads of glow plug 2 (6 / short leads) into
position in the 14-pin connector (29).
Then wind the leads of glow plug 1 (5) 2 x around the leads
already latched into position in the 14-pin connector and then
latch into position in the 14-pin connector (29).
Use a cable tie (12) to bundle all leads above the winding.
Connect the 14-pin connector (29) to the control box / blower
unit.
Temperature sensor, Yellow
Motor, Phase 2, Green
Flame sensor, Brown
Glow plug 1, long cable , Brown
Motor, Phase 3, Orange
Glow plug 2 +, short cable , White
Water pump, Brown / Black
Glow plug 2, short cable , Brown
Water pump, Black / Red
Glow plug 1 +, long cable , White
Flame sensor +, Blue
Motor, Phase 1, Pink
Overheating sensor, Red
Sensor ground, Blue / White
Sketch 3
38
Note: • The leads may not lay against the housing.
• Check the glow plugs before completely assembling
the heater. For check values, see fault code 020 / 021.
Maintenance, Troubleshooting & Repairs
Repair step 2
Assemble control box/blower unit and jacket
Install electric motor cover
Figure 26 and 27
• Position the electric motor cover (13) on the housing of the
control box / blower unit, at the same time, insert the water
pump lead harness in the groove provided in the cover.
• Use 2 screws (14) M5 x 16 to fasten the electric motor
cover (13) onto the housing of the control box / blower unit.
.
Assemble control box / blower unit and jacket
Figure 28
Position the heat exchanger on the control box / blower unit and
fasten with 4 screws (21) M5 x 25.
Note: Tighten the 4 screws (21) M5 x 25 cross-wise (i.e.
tighten diagonally opposite screws).
39
Maintenance, Troubleshooting & Repairs
Repair step 2
Control box/blower unit and jacket
Lay water pump lead harness
Figure 29
• Insert the water pump lead harness into the holder on the
jacket, lay up to the water pump and connect.
Install overheating and temperature sensor
Figure 30 and 31
• Insert the overheating (17) and temperature sensor (18)
into the holders on the jacket.
Insert the sensor cable loom (19) into the holders on the
jacket.
Use 2 screws (15) M4 x 12 to fasten both springs (16) on the
overheating (17) and temperature sensor (18). (See page
31)
Note: Insert the temperature sensor as shown in the figure
to avoid pinching the cable loom.
40
Maintenance, Troubleshooting & Repairs
Repair step 2
Control box/blower unit and jacket
Install impeller cover
Figure 32
• Clamp the removed heater in a retaining device (vice) and
position the new O-ring (2) on the control box / blower unit.
• Install the impeller cover; ensure that none of the leads of the
sensor lead harness (19) get jammed. (See page 40)
41
Maintenance, Troubleshooting & Repairs
Repair step 3
Control box/blower unit and jacket
Remove / check glow pin
Figure 33
• Carry out repair step 1.
• Unscrew glow pins 1 (5) and 2 (6) from the combustion cham
ber housing (8) (See page 36), if necessary check the glow
plugs; for check values see fault code 020 / 021.
• Visually check the glow pin socket lining, if necessary renew
the glow pin lining.
Install glow pin
Figure 33
• Screw glow pin 1 (5) with long connection leads into the lefthand spark plug socket (2 fuel lines).
• Screw glow pin 2 (6) with short connection leads into the righthand spark plug socket (1 fuel line).
• Assemble the heater according to repair step 2.
Characteristics of the glow pins
Glow pin 1 (5) long leads
– brown lead in Chamber 7
– white lead in Chamber 10
Glow pin 2 (6) short leads
– brown lead in Chamber 14
– wt lead in Chamber 11
12 volt glow pin
– green band around the brown and white leads
24 volt glow pin
– yellow band around the brown and white leads
Clean ignition air drillholes
Figure 34
• Use a pointed object to clean the ignition air drillholes in the
left-hand and right-hand spark plug sockets.
42
Maintenance, Troubleshooting & Repairs
Repair step 4
Remove glow pin socket lining
Figure 35
• Carry out repair step 1.
• Unscrew glow pin from the combustion chamber housing
(8).
• Use a pointed object to pull the glow pin socket lining out
of the glow pin socket.
Install glow pin socket lining
Figure 36, 36/1
• Insert the glow pin socket linings, with the bevelled edge
facing upwards, into the spark plug sockets up to the limit
stop.
Note: Ensure the ignition air drillhole in the glow pin socket is
not concealed by the spark plug socket lining.
• Assemble the heater according to repair step 2.
43
Maintenance, Troubleshooting & Repairs
Repair step 5
Check overheating and temperature sensor
Figure 37 / Diagram 1
• Removal of the overheating (17) and temperature sensor (18)
is described in repair step 1.
• Use the digital multimeter to check the overheating (17) and
temperature sensor (18).
If the resistance value lies outside the table of values or the
diagram, then replace the overheating (17) and temperature
sensor (18).
• Installation of the overheating (17) and temperature sensor
(18) is described in repair step 2.
Table of values
0
25
40
Temp[°F]
32
77
104
140
176
212
RNTC [kΩ]
32.55
10
5.33
2.49
1.26
0.677
Resistance RNTC (kΩ)
Temp[°C]
Temperature (°C)
Diagram 1
44
60
80
100
120
248
0.389
Maintenance, Troubleshooting & Repairs
Repair step 6
Check flame sensor
Figure 38 / Diagram 2
• Removal of the flame sensor (11) is described in repair step 1.
• Use the digital multimeter to check the flame sensor (11). If the
resistance value lies outside the table of values or the diagram,
then replace the flame sensor (11).
• Installation of the flame sensor (11) is described in repair step
2.
Table of values
-50
0
50
100
150
200
250
300
350
400
Temp[°F]
-58
32
122
212
302
392
482
572
662
752
R [Ω]
803
1000
1194
1385
1573
1758
1941
2120
2297
2470
Resistance (Ω)
Temp[°C]
Temperature (°C)
Diagram 2
45
Maintenance, Troubleshooting & Repairs
Repair step 7
Remove / attach water pump
Figure 39
• Disconnect the connector (24) at the water pump (26).
• Undo the hose clip (25)
• Remove the water pump.
• Check O-ring (See page 50 parts diagram #13), replace if
necessary
• Install in the reverse order.
Note: When assembling the O-ring coat it with lubricant.
46
Maintenance, Troubleshooting & Repairs
Measuring the fuel quantity
Preparing for the measurement
Evaluation
(Sketch 4)
Compare the measured quantity of fuel with the values in the
following table.
• Disconnect the fuel pressure line at the heater and place the
end in a measuring cylinder (size 25 ml).
If the measured quantity of fuel is above the maximum value or
below the minimum value, the metering pump must be
replaced.
• Switch on the heater, if the fuel discharges uniformly and
free of bubbles, the fuel pipe is filled and vented.
Heater
• Switch off heater and empty measuring cylinder.
Quantity of fuel
Desired
Maximum
Minimum
Measurement
HYDRONIC M8
Diesel / FAME
5.7 ml/
68 sec
6.27 ml/
68 sec
5.13 ml/
68 sec
• Switch on heater and wait until the metering pump stars pumping the fuel.
HYDRONIC M10
Diesel
7.5 ml/
68 sec
8.25 ml/
68 sec
6.75 ml/
68 sec
• During the measurement, hold the measuring cylinder at the
level of the heater.
HYDRONIC M12
Diesel
7.5 ml/
68 sec
8.25 ml/
68 sec
6.75 ml/
68 sec
After 68 sec. the pumping of the fuel is automatically switched
off.
• Switch off heater, as otherwise it will start up again.
• Read off the quantity of fuel in the measuring cylinder.
Note: Only carry out the fuel measurement if the battery is
sufficiently charged. During the measurement the volt
age applied to the control box should be at least 11 volt
or 23 volt and max.
13 volt or 25 volt.
Sketch 4
47
Heater Components
Hydronic M-II Parts Diagram
48
1 Combustion air blower/ECU
12 V
25 2470 99 15 00
24 V
25 2471 99 15 00
12 V
25 2434 99 15 00
24 V
25 2435 99 15 00
12 V
25 2472 99 15 00
24 V
25 2473 99 15 00
24V
12V
24V
12V
24V
25 2434 05
25 2435 05
25 2472 05
25 2473 05
Part Number
25 2471 05
Ref. No. Description
12V
Description & Part #’s
Model #
Hydronic M-II - 12 & 24 volt - Diesel & Gasoline versions
25 2470 05
Heater Components
•
•
•
•
•
•
2
Burner assembly
25 2435 99 11 00
•
•
•
•
•
•
3
Casing
25 2435 99 01 02
•
•
•
•
•
•
4
Water pump
12 V
25 2434 99 25 01
•
24 V
25 2435 99 25 01
5
Flame sensor
6
Glow pin
•
•
25 1920 35 01 00
•
12 V
25 2434 01 01 00
•
24 V
25 2435 01 01 00
•
•
•
•
•
•
•
•
•
•
•
•
•
7
Water pump harness
25 2435 25 02 00
•
•
•
•
•
•
8
Temperature overheat sensor
25 2435 40 01 00
•
•
•
•
•
•
9
Bottom cover blower housing
25 2435 01 00 02
•
•
•
•
•
•
10
Cover
25 2435 99 01 03
•
•
•
•
•
•
11
Cover blower housing channel
25 2435 01 00 04
•
•
•
•
•
•
12
Seal for combustion chamber
25 2435 01 00 10
•
•
•
•
•
•
13
Water pump O-Ring
19,8 x 2,3
22 1000 70 00 17
•
•
•
•
•
•
14
Blower O-Ring
117,07 x 3,53
22 1000 70 00 15
•
•
•
•
•
•
15
Fuel pipe grommet
25 2435 01 01 04
•
•
•
•
•
•
16
Fuel pipe sleeve
20 1752 01 00 02
•
•
•
•
•
•
17
Spring clip
25 2281 01 00 09
•
•
•
•
•
•
18
Screen for glow pin
25 2069 10 01 02
•
•
•
•
•
•
19
Hose clip
35 – 55
152 61 004
•
•
•
•
•
•
20
Taptite screw
M 5 x 25
109 10 152
•
•
•
•
•
•
21
Taptite screw
M 5 x 16
109 10 151
•
•
•
•
•
•
22
Taptite screw
M 4 x 12
5590010
•
•
•
•
•
•
23
Cable tie
5590147
•
•
•
•
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49
Heater Components
Subtitle Left
Page Diagram
Hydronic
M Parts
34
2e
32
31
2c
2b
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2d
50
1
Fuel metering pump
24V
12V
24V
12V
24V
25 2434 05
25 2435 05
25 2472 05
25 2473 05
Part Number
25 2471 05
Ref. No. Description
12V
Description & Part #’s
Model #
Hydronic M-II - 12 & 24 volt - Diesel & Gasoline versions
25 2470 05
Heater Components
12 V
24 V
22 4617 01 00 00
22 4618 01 00 00
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2a
Cable harness - (JE Harness)
ADR
25 2435 80 07 00
25 2435 80 06 00
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2b
Cable harness - Universal (No Relay)
12 V
24 V
25 2800 70 10 12
25 2800 70 10 24
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25 2800 70 10 03
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25 2800 70 00 02
25 2800 70 00 04
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2c
Boxed Adapter harness
2d
Main box harness
12 V
24 V
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2e
Diagnostic adapter
25 2800 70 10 04
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3
Relay harness
22 1000 33 04 00
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4
Cable harness
22 1000 33 02 00
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5
Exhaust muffler
25 1806 80 01 00
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6
Intake silencer
25 1786 80 02 00
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7
Flex exhaust w/cap
25 1816 80 08 00
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8
20mm 90° bend coolant hose
20 1673 80 00 01
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9
20mm 180° bend coolant hose
20 1673 80 00 03
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10
Heater bracket
25 1816 80 00 01
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11
Cable tie 12”
5590147
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12
1.5 mm Plastic fuel line
890 31 118
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13
5mm Fuel hose (biodiesel compatible)
360 75 401
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14
Fuel hose 5x3mm
360 75 350
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15
Fuel line adaptor 3.5 - 5mm
25 1888 80 01 02
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16
Fuel hose 3,5 x 3
360 75 300
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17
9mm clamp
10 2068 00 90 98
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11mm clamp
10 2068 01 10 98
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19
Holder metering pump
22 1000 50 07 00
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20
FMP angle bracket
20 1348 03 00 04
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21
Metal rubber buffer
20 1185 00 00 01
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22
Connection piece
20 1534 88 00 01
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23
Clamp 20 - 32mm
10 2066 02 00 32
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24
Flex exhaust clamp
152 09 003
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25
Clamp “C” type
152 10 060
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26
Hose connection piece
20 1623 45 00 02 ??????
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27
Integrated fuel filter
20 1312 00 00 06
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28
Socket housing
22 1000 31 93 00
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Grommet
20 1280 09 01 03
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30
Fuse holder, receptacle housing kit
22 1000 31 06 00
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51
Heater Components
12V
24V
12V
24V
12V
24V
25 2471 05
25 2434 05
25 2435 05
25 2472 05
25 2473 05
31
Fuse
25 A
15 A
5A
204 00 089
204 00 003
204 00 079
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32
Relay
12 V
24 V
203 00 065
203 00 066
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20 2900 70 90 16
20 2900 70 90 08
20 2900 70 90 13
5670380
20 2900 70 90 14
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890 31 101
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5670196
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Description & Part #’s
Ref. No. Description
33
Convoluted tubing
34
Plastic fuel line
35
Ring Terminal
52
Part Number
1” X 17”
1/2” X 12”
3/8”
3/4”
1”
5/16”
Model #
25 2470 05
Hydronic M-II - 12 & 24 volt - Diesel & Gasoline versions
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1st Printing - Apr 2008
Printed in Canada
P/N: 20 2900 81 0102 0A
Espar Products, Inc.
(800) 387-4800
(905) 670-0960
www.espar.com
A member of the Worldwide Eberspächer Group of Companies