Espar Products, Inc M12 Specifications

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Espar Products, Inc M12 Specifications | Manualzz

Warranty Manual

QSF-60

1

Espar Products, Inc.

Tel: 905.670.0960

800.387.4800

Fax: 905.670.0728 www.espar.com

02.2014

Rev. 7

Table of Contents

Policies

Warranty Policy Overview ............................................................................................................................. 3

Warranty Period ............................................................................................................................................ 4

What IS and IS NOT covered under Warranty? ............................................................................................ 5

Heater Identification Plate ............................................................................................................................. 6

Warranty Registration .................................................................................................................................... 8

Dealer Requirements to perform Warranty Repairs ...................................................................................... 9

Procedures

Procedure prior to starting Warranty work .................................................................................................. 10

Procedure for performing Warranty work .................................................................................................... 11

Procedure for submitting Warranty claims .................................................................................................. 12

Espar’s internal procedure for processing Warranty claims ........................................................................ 14

Warranty Notification Form .......................................................................................................................... 14

Warranty Authorization (WA) ....................................................................................................................... 14

Warranty Evaluation (WE) ........................................................................................................................... 15

“Always Repair Heater” Policy..................................................................................................................... 16

Procedure for submitting a heater to Espar for Repair (RR) ....................................................................... 16

New, Defective Parts or Heaters ................................................................................................................. 17

Procedure for Returning Defective Goods (RA) .......................................................................................... 17

Procedure for Warranty appeal ................................................................................................................... 18

Flat Rate Labor Guide

Flat Rate Labor Guide ................................................................................................................................. 19

AIRTRONIC 2/4 ........................................................................................................................................... 20

B1LC Compact ............................................................................................................................................ 22

B/D3LC Compact ........................................................................................................................................ 24

AIRTRONIC 5 .............................................................................................................................................. 26

D8LC ........................................................................................................................................................... 28

HYDRONIC 4/5 SC with integrated fuel metering pump ............................................................................. 30

HYDRONIC 4/5 SC with external fuel metering pump ................................................................................ 32

HYDRONIC 5 S ........................................................................................................................................... 34

HYDRONIC 5 Z ........................................................................................................................................... 36

HYDRONIC II (D5E) .................................................................................................................................... 38

HYDRONIC 10 ............................................................................................................................................ 40

HYDRONIC MII ........................................................................................................................................... 42

HYDRONIC 16/24/30/35 ............................................................................................................................. 44

HYDRONIC LII ............................................................................................................................................ 46

Tools and Equipment

Computer Diagnostic Tools ......................................................................................................................... 49

Appendices

Appendix A: The Espar Limited Warranty .................................................................................................. 50

Appendix B: Sample Warranty Tag ............................................................................................................ 51

Appendix C: Sample Shipping Label .......................................................................................................... 52

Appendix D: Warranty Notification Form .................................................................................................... 53

Append ix E: Technician’s Checklist ........................................................................................................... 54

Appendix F: Warranty Claim Appeal Form ................................................................................................. 55

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Warranty Policy Overview

The purpose of Espar warranty is to ensure that the end-user (customer) of Espar Products is satisfied with the quality of their purchase. In order to provide customer satisfaction, Espar stands behind its products as they leave Espar’s control.

This Espar Warranty Manual and all policies and procedures within it, supersedes all previous warranty manual revisions. It will remain valid until a new manual is released or until further notice. Any requests for dealer labour rate increases must be made in writing and forwarded to the Warranty Department. Approval or denial will be decided upon review with the decision communicated back to the dealer.

While the warranty is applicable to the end-user, it is administered and performed only through the Espar network of trained dealers and distributors.

To this end, Espar will follow the procedures outlined in this manual in the processing and administration of warranty claims.

For specific information please refer to the Espar Limited Warranty section as outlined in Appendix A of this manual.

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Warranty Period

The warranty period of a heater is specified in years or in heater operating hours, beginning from the date of installation, whichever is reached first. Refer to “What IS and IS NOT covered under Warranty” on Page 5 of this manual. If the installation date is not made known to Espar by registering the heater within thirty (30) days of installation, or by providing proof of installation date at time of warranty claim (i.e

. installation invoice or ‘in-service’ document), the warranty period will begin on the date of shipment from Espar’s North American warehouse.

IMPORTANT NOTE:

Heaters must be installed within one (1) year of purchase date to be eligible for warranty.

 Installation invoices or ‘in-service’ documents provided to Espar must include applicable model number(s) and serial number(s) of the heater(s) installed.

Heaters meant for truck applications should not be transferred / installed for marine applications.

Heater installation is recommended to be done by the service provider who have been trained and certified by Espar trainers.

Heater self installation by customer is recommended to be inspected and certified by trained service

provider to prevent denial of warranty due to installation issue.

Replacement Parts

All replacement parts are warranted to be free from defects in material and / or workmanship for ninety (90) days from the date of sale or the remainder of the original warranty period on the heater, whichever is greater.

Special Tools

Special tools (e.g. ISO Adapter, Fault Code Retrieval Device, EDiTH Adapters, etc.) are warranted to be free from defects in material and / or workmanship for twelve (12) months from the date of sale from Espar’s North

American warehouse.

Warranty periods by model:

Air Heaters

Heater Model

AIRTRONIC 2

AIRTRONIC 4

AIRTRONIC 5

B1LC Compact

B/D3LC Compact

B/D5LC

D8LC

Coolant Heaters

Standard Warranty Period

2 years or 2,000 hours*

2 years or 2,000 hours*

2 years or 2,000 hours*

2 years or 2,000 hours*

2 years or 2,000 hours*

1 year or 1,000 hours*

1 year or 1,000 hours*

Heater Model

B/D5W

HYDRONIC 4

HYDRONIC 5 (S/SC/E)

Standard Warranty Period

2 years or 2,000 hours*

2 years or 2,000 hours*

2 years or 2,000 hours*

HYDRONIC 10

HYDRONIC MII series (M8/M10/M12)

HYDRONIC 16/24/30/35 1 year or 1,000 hours*

HYDRONIC LII series (L16/L24/L30/L35) 1 year or 1,000 hours*

* which ever is reached first

1 year or 1,000 hours*

2 years or 1,500 hours*

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What IS and IS NOT Covered Under Warranty

The purpose of Espar Warranty is to provide the end user (customer) of Espar heaters with protection from defects in material and workmanship.

A. Items covered under warranty include:

PARTS

1. Timers, thermostats, mini-controllers or other electronic temperature control products provided by

Espar

2. Electronic control units (ECU’s)

3. Glow pins

4. Fuel metering pumps

5. Heat exchangers and / or combustion chambers (burner)

6. Air blowers

7. Coolant pumps

8. Flame, overheat and temperature sensors

9. O-rings, gaskets, seals (excluding HYDRONIC D5SC coolant pump and sensor O-rings)

10. Wire harnesses (only those provided by Espar are warranted) but prior authorization is required from

Espar’s Warranty Department

SERVICE

1. Shipping costs associated with the authorized return of warranted parts from the Espar Dealer /

Distributor to Espar (only for shipments that contain parts specifically requested by Espar).

2. To receive travel time to repair heaters installed on boats and / or off-highway heavy equipment, the travel section must be completed on the warranty claim for consideration of payment. Note that maximum limits do apply.

B. Items NOT covered under warranty include but are not limited to:

PARTS

1. Heaters no longer covered within terms of warranty

2. Wear and tear of parts, including: a) Glow plugs b) O-rings (HYDRONIC D5SC coolant pump and sensor O-rings) c) Clamps, clips, brackets d) Batteries e) Coolant f) Atomizer screens g) Fuel system components (e.g. fuel pick-up pipe, fuel line, filters, etc.) h) Fuses i) Connectors, terminals and screws j) Lamp bulbs k) Air ducting, intake and exhaust tubing

3. Parts that malfunction due to improper installation, which may result from: a) Inadequate air or coolant flow b) Inadequate or restricted fuel flow c) Inadequate voltage due to improper wiring upon installation d) Inadequate protection from shock or vibration e) Inadequate protection from road spray or weather conditions

4. Components that have been opened, tampered with or modified by parties other than Espar

5. Using non-standard parts or parts not approved by Espar, in the installation

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6. Diagnosis or repairs completed when cause of the problem or failure is due to electrical system problems outside the heater, excessive engine debris or empty fuel tanks or poor quality fuel.

7. Deterioration due to normal wear, corrosion, abuse, damage, accident, improper storage or operation.

8. Costs incurred through an incorrect diagnosis, poor performance of the repair. This also applies to corrections of installations that did not meet Espar specifications. In these cases the costs incurred are to be charged to original installer.

SERVICE

1. Travel time by dealers / distributors traveling within their assigned territories except as noted in

Service section A, above, item #2.

2. Shipping costs associated with the unauthorized return of warranted parts from the Espar Dealer /

Distributor to Espar Products.

3. Espar will not pay for return shipping costs to the Dealer / Distributor where parts are deemed acceptable after testing.

Normal periodic heater maintenance (as outlined in each heater manual) shall be the responsibility of the owner of the heater. As a general guideline, the heater should be run a minimum of once per month for fifteen (15) minutes all year round.

Heater Identification Plate

The heater identification plate provides all the heater information, which is required when filing a warranty claim, such as heater model type, part number and serial number. This information must be included on every warranty claim, so be sure to record it before any warranty repair work is completed. Claims without serial numbers are subject to rejection.

Model Name: AIRTRONIC, HYDRONIC or three or four digit heater model name (e.g. D5LC)

In a three or four digit name, the following explanation may be helpful in understanding the heater model name:

First digit indicates fuel type ....................................... Alpha (D = diesel, B = gasoline)

Second digit indicates kilowatt heat output ................ Numeric (5 = 5 kilowatt, etc.)

Third digit indicates type of heater ............................. Alpha (L = air heater, W = coolant heater)

Fourth digit provides further designation .................... Alpha (C = comfort, etc.)

.................. Heater model name

.................. Heater model name

.................. Heater model part number

.................. Heater serial number

.................. Fuel type

.................. Electrical power consumption

.................. Maximum heat output

.................. Operating pressure

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NOTE: It is strongly advised that during the heater installation the duplicate heater serial number label is affixed in a clearly visible and easily accessible location, such as on the driver door.

Duplicate heater identification plate or “serial number label”

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Warranty Registration

A blue warranty registration notification is shipped with every heater. Please note there are several important reasons why the warranty should be registered.

If a warranty registration is not received by Espar, the heater warranty period begins on the date the heater is shipped from Espar’s North American warehouse. When the warranty is properly registered, Espar can identify the date on which the heater was installed and / or put into service and therefore begin the heater warranty period on that date. This effectively extends the warranty period of the heater to the maximum time available.

Registering the warranty also serves the purpose of identifying the purchaser and original installation of the heater since the warranty is non-transferable.

It also identifies the installing dealer so, if required and if necessary, any installation related problems could be brought to the attention of the installer.

Espar recommends all dealers / distributors register their customers’ warranty within thirty (30) days of installation by completing and submitting registration form via the internet on Espar’s website, www.espar.com. Click on the

‘Warranty’ link, then on the ‘Warranty Registration Coupon’ link to access the warranty registration.

Again, it is in the customer’s best interest that the warranty be registered to receive the full warranty period allotted for their particular heater.

IMPORTANT NOTE:

If the warranty registration is not completed and received by Espar within thirty (30) days of installation the heater warranty period begins from the date the heater is shipped from Espar’s warehouse, unless other information is provided to Espar, upon request.

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Dealer Requirements to Perform Warranty Repairs

To conduct warranty repairs and submit warranty claims, the following criteria must be met:

1. Possess and maintain certified technician’s who have undergone Espar technical training (installation, diagnosing and troubleshooting) and warranty training.

2. Possess all tools required to inst all, maintain and service Espar products as outlined in the ‘Tools and

Equipment’ section of Espar manuals.

3. Possess at all times at least one copy of the current Espar Warranty Manual and all applicable heater service manuals. The latest Espar Warranty Ma nual is available by downloading directly from Espar’s website, www.espar.com.

4. Maintain sufficient inventory of parts, based on heater type serviced.

In order to access the Espar on-line Warranty Claim Form, at www.espar.com, and to submit a warranty claim,

Espar will provide a user name and password after all required information has been received. At that time, the hourly labor rate is agreed upon and it is frozen for one year. Espar’s Warranty Administrators must be notified in writing of a labor rate increase. Approval or denial will be decided upon review and a decision will be communicated back to the dealer by the Warranty Administrator in e-mail format.

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Procedure Prior to Starting Warranty Work

As a member of the Espar distribution organization, you are expected to stand behind your work. This includes properly specifying and installing heaters and instructing your customers on the proper operation and maintenance of the heater and all related components or accessories. All heater technical manuals are available for download at Espar’s website, www.espar.com.

Before starting any warranty repairs on the heater, please check, as appropriate and as suggested in the

‘Technician’s Checklist’, Appendix E:

1. Electrical System a) Are connections tight and free of corrosion? b) Has proper gauge wiring been used for the length and amperage requirements for that wiring? c) Have any fuses or circuit breakers been activated? d) Is power taken directly from the batteries and ground to the batteries?

2. Fuel System a) Have proper diameter fuel lines been used? b) Have proper length fuel lines been used? c) Has a proper connection to the fuel supply been made? d) Is the fuel flowing or has it gelled? e) Are there restrictions in the fuel line? f) Is the fuel metering pump properly aligned? g) Is the fuel filter clogged? h) Has an Espar fuel pick-up pipe been used and is it the proper length and diameter?

3. Coolant Flow or Air Flow System a) Are there any obstructions in the system? b) Is the heater system too large or small for the application? c) Has proper coolant hose size or ducting size been used?

4. Total operating hours to-date (with EDiTH diagnostics).

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Procedure for Performing Warranty Work

As a member of the Espar distribution organization you are trained in the installation, troubleshooting and repair of Espar heaters and systems and you have all of the necessary tools required to properly diagnose heater functions.

Technical publications such as Technical Descriptions, Troubleshooting Guides and Parts Manuals are available by downloading directly fro m Espar’s website, www.espar.com. Technical circulars are issued periodically from

Espar’s Technical Department. It is important to refer to current publications while working on a heater. Special tools and test equipment are available for some heaters. Refer to the Tools and Equipment section. If you have any questions, contact Espar’s Technical Department.

Once you have examined the heater for system or installation problems, as set forth in the preceding section and have determined that warranty work must be performed, follow the technical publications and use your training and experience to correct the cause of the problem.

IMPORTANT NOTE:

Always ensure that the root cause of the problem is corrected, rather than simply correcting the symptoms of the problem. For example: if a heater has overheated several consecutive times and has been locked out (F15), do not simply reset the heater with the diagnostic unit. Locate the source of the overheat problem and correct it.

Any part replaced under warranty must be tested as per the current heater manuals test procedures to confirm that it is defective before it is claimed. Parts that should be tested are, but not limited to: a) Glow pins b) Control units c) Fuel metering pumps d) Temperature, flame and overheat sensors e) Combustion air blowers f) Coolant pumps g) Thermostats and timers h) Mini-controllers i) Wire harnesses

Espar assumes that the technical repair is carried out without fault and economically, (i.e. replacement of only those parts that are defective, settlement of only those labor costs incurred) according to the Flat Rate Labor

Guide. Duplicate expenses, for example, two journeys because the spare part was not available, cannot be claimed.

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Procedure for Submitting Warranty Claims

IMPORTANT NOTE:

After the warranty work has been performed and the heater is operating properly and it has been determined that the problems were truly warranty problems and not due to improper application specification, installation or operation; the procedure is as follows:

1. Affix the Espar Warranty Tag to all claimed parts. Fill out all the information indicated on the tag:

Dealer Stamp, Dealer Claim Number, Espar Part Number, Part Description, Heater Name, Heater Part

Number, Serial Number, Description of Defect and WE#. Each part must be held for thirty (30) days after the claim has been filed. Espar reserves the right to inspect any or all parts, upon request. If any of these parts are not requested back by Espar after the thirty (30) day period, the part may be disposed of.

Supplies of Warranty Tags (Appendix B) are supplied by Espar upon request and are distributed through the main Espar authorized service branch.

IMPORTANT NOTE:

Should Espar request parts back, a WE# will be issued to the dealer. It is important to receive all requested parts back as warranty claims are reviewed either at Espar or its parent company,

Eberspaecher. It is imperative that defective parts are available for testing and evaluation.

2. A warranty claim must be submitted within thirty (30) days of the date of repair.

IMPORTANT NOTE:

If a new part is determined to be defective within ninety (90) days after installation, a warranty claim should be filed as usual and the description of the problem should clearly state ’90 day warranty’. This coverage will even apply should the heater be out of warranty however, no handling, labor or travel will apply in this case.

3. To file a warranty claim go to Espar’ website, www.espar.com and click the ‘Warranty’ link and then click on the ‘Warranty Claim’ link. Only authorized Espar dealers can submit warranty claims through the secured area of the Espar website.

4. Complete all information including: a) Claimant information b) Espar MSD or Direct Dealer claim number c) Warranty authorization number (WA#), refer to Page 14 of this manual d) Heater model number e) Heater model part number (e.g. 25 1976) f) Heater serial number (“Fabrik No.”) including all alpha-numeric digits (e.g. 123456AE) g) Voltage (12V or 24V) h) Repair date i) Application type j) Vehicle information (model, type and VIN) k) Installation date and registered owner information, including name and address

IMPORTANT NOTE:

Warranty claims that are inaccurate (information does not correspond to the information received for the warranty registration or sales record at Espar) will be on hold pending the information required for clarification. If required information is not received within ten (10) day the associated claim will be rejected.

5. Describe the problem and repair in detail in the ‘Description of Problem’ section; it is mandatory to include all fault codes, testing procedures and values. Note that the description of the troubleshooting should correspond to the relevant fault codes entered in the fields specified.

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6. Each claim automatically receives thirty (30) minutes of troubleshooting, Operation Code A and thirty (30) minutes for heater function testing, Operation Code D.

7. In ‘Parts Required for Repair’ section, indicate the quantity and choose Espar part number and description.

8. Choose the applicable operation code and labor times as per the applicable Flat Rate Labor Guide.

Example: The AIRTRONIC D2 appears to start normally but then it shuts down and attempts to restart. The diagnostic fault codes in memory are: AF 64; F1 64; F2 64 and F3 64. The flame sensor was removed, tested and found to be defective, an open circuit. The operations performed, according to the Flat

Rate Labor Guide were:

A ................ Troubleshoot ........................ 30 minutes

B230 .......... Replace flame sensor .......... 10 minutes

D ................ Function test ........................ 30 minutes

70 minutes Total Time

9. Indicate the total operating hours, to-date with EDiTH diagnostics.

10. To receive travel time for repair for heaters installed on boats and off-highway heavy equipment, the travel section must be completed on the warranty claim for consideration of payment. Note that maximum limits do apply.

IMPORTANT NOTE:

Espar must receive the warranty claim within thirty (30) days of the date of heater repair. Claims submitted 30-60 days from the date of repair will not include an additional 20% markup on parts for part handling. Claims submitted more than sixty (60) days from the date of repair will be rejected. There will

be no exceptions made.

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Espar’s Internal Procedure for Processing Warranty Claims

Espar will make every effort to process warranty claims promptly providing all information is provided as set out in this manual. Thus, Espar is committed to issuing credit for processed warranty claims within thirty (30) days of receiving back the requested parts.

Warranty Notification Form

It is the dealer’s responsibility to respond to the warranty notice (Appendix D) within ten (10) business days. If there is no response within this time period, Espar will permanently close and reject the claim. Espar will not reopen this claim once this process has been completed.

When a warranty claim is processed, according to Espar’s existing warranty policy, the Dealer submitting the claim and / or MSD or DD will receive notification based upon the following criteria:

1. Warranty claim is on-hold

Extra information is required by Espar to process the warranty claim.

2. Adjustments were made to the submitted warranty claim

Labor time / rate requested was incorrect, duplicate labor codes, authorization for excess time, labor or parts were not requested or installation date was incorrect.

3. Rejection of the warranty claim

The heater warranty period has expired; parts returned were tested and found to be not defective; parts claimed were not covered under warranty; inadequate parts return; duplicate warranty claim; vehicle owner is not the original registered owner; requested information not returned within ten (10) business days; or unauthorized WA# used for warranty claim that was not approved for a particular serial number, etc.

4. Acceptance of the warranty claim

The claim submitted meets all of the necessary criteria and is being processed.

See Appendix D for the notice form.

Warranty Authorization (WA)

A warranty authorization number (WA#) will be issued only for claims that are abnormal or outside the normal scope of the warranty manual. Please refer to the Flat Rate Labor Guide for the particular heater in question to see the additional parts that are allowable under certain conditions. These are identified by the shaded areas on the Flat Rate Labor Guide. Please request this WA# PRIOR to submitting any claim by sending an email to

Espar’s Warranty Administrator for authorization. The email must include the serial number of the heater, the end user (customer’s) name, a detailed description of the problem and tests performed and the main reason for the request. The WA request will be approved or rejected by the Warranty Department at their discretion based on the supplied information.

The warranty authorization number (WA#) issued by Espar pertains to one specific instance only and is to be used when submitting the claim on-line. It is not a generic number to be used liberally and if used as such will result in immediate warranty claim rejection.

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Warranty Evaluation (WE)

Every claimed part must be tagged and held for thirty (30) days following the submission of a warranty claim.

During this time frame Espar may request that a part or heater be returned to Espar for evaluation. In this case the following procedures will apply:

1. When requesting parts and / or heaters back for evaluation, associated with a warranty claim, the

Warranty Administrator will issue a Warranty Evaluation (WE) reference number and contact the customer of record (authorized Espar MSD / Direct Dealer) via email. It is the responsibility of the MSD /

DD to distribute this number to their sub-dealers. Upon receiving a WE# all parts corresponding to the given WE# must be returned within thirty (30) days.

IMPORTANT NOTE:

If the part is not received within this time frame the corresponding claim will receive no handling. If the part is still not received within the following thirty (30) days, the claim will be rejected and closed permanently.

2. All paperwork and packaging must reference the WE number to avoid rejection. When any product is returned without a WE number there will be a $50.00 administration charge to your account. No exceptions will be made.

3. Parts and heaters must be packaged securely to avoid damage in transit, as damaged parts / heaters are not covered under warranty.

4. Ship via UPS ground. Air shipments will not be paid for by Espar.

5. All parts and heaters must be marked clearly with a completed warranty tag (refer to Appendix B). Parts that are not tagged will not be tested, which will result in automatic claim rejection. Parts can be returned to the dealer at their cost. Proper documentation must accompany each shipment, which includes: shipping labels marked clearly with Espar reference numbers, affixed to the outside of the package (refer to Appendix C).

Canadian Customers ONLY

Ship to: Warranty Department

Espar Products, Inc.

6099A Vipond Drive

Mississauga, Ontario

L5T 2B2 CANADA

Espar Reference Number (WE# assigned to you)

U.S. Customers ONLY

Ship to: Warranty Department

Espar Products, Inc.

60 Industrial Parkway, Suite 730

Cheektowaga, New York 14227

USA

Espar Reference Number (WE# assigned to you)

NOTE: Tested parts found not to be defective can be returned to a dealer at their request and cost.

All parts are disposed by Espar thirty (30) days after the disposition of the claim has been sent to the dealer.

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“Always Repair Heater” Policy

Espar and Eberspaecher have an “Always Repair Heater” policy. In the case that a Main Service Distributor or Dealer has difficulty in diagnosing and rep airing a heater they should contact Espar’s Technical

Department for further assistance. After consulting with Espar and providing that it is within its warranty period and Espar has deemed it necessary to have the heater returned, Espar will issue an RR#. This will authorize the heater to be shipped to Espar for repair. A replacement heater should not be permanently issued to the customer prior to Espar assisting with the correct diagnosis of the heater in question.

Procedure for Submitting a Heater to Espar for Repair Purposes (RR)

1. A request must be made to Espar’s Warranty Supervisor or Technical Department.

2. Espar’s Warranty Supervisor or Tech Department will issue a “Repair / Rework” (RR) number.

3. The product may then be returned to Espar with the RR number clearly marked on the shipping label

(refer to Appendix C) and package(s). All costs associated with shipping the heater to Espar will be the responsibility of the dealer or heater owner. Parts and heaters must be packaged securely to avoid damage in transit. Parts damaged due to this will not be covered under warranty. Proper documentation must accompany each shipment, which includes: shipping labels marked clearly with

Espar reference numbers, where applicable and affixed to the outside of the package (Refer to

Appendix C).

4. Upon receipt, the heater will be tested and if possible, repaired. If the heater can not be repaired and it is still under warranty, it will be replaced at Espar’s expense. A replacement heater will be warranted for ninet y (90) days or the balance of previous heater’s warranty, which ever is longer.

5. The repaired heater, or new heater, when applicable, will be returned to the dealer or MSD. Shipping costs (UPS ground) of the return heater to the Dealer or MSD will be covered by Espar.

6. If a heater is returned without an RR number, there will be a $50.00 administration charge to your account. No exceptions will be made. In addition, heaters returned with proper authorization will receive the highest priority for repair.

Canadian Customers ONLY

Ship to: Warranty Department

Espar Products, Inc.

6099A Vipond Drive

Mississauga, Ontario

L5T 2B2 CANADA

Espar Reference Number (RR# assigned to you)

U.S. Customers ONLY

Ship to: Warranty Department

Espar Products, Inc.

60 Industrial Parkway, Suite 730

Cheektowaga, New York 14227

USA

Espar Reference Number (RR# assigned to you)

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New Defective Parts or Heaters (when they are NOT covered under warranty)

If a new part or heater is determined to be defective by visual inspection, or found to be functionally defective immediately, prior to installation, it should be returned to Espar using a Return Goods

Authorization Policy (RGA). New defective parts or heaters can not be claimed as warranty.

Procedure for Returning Defective Goods (RGA)

1. A faxed copy of the original invoice or packing slip (with the new, defective part or heater listed on it must be submitted to the attention of Espar’s Customer Service Department). Verbal requests will not be accepted or processed.

2. Espar’s Customer Service staff will then fax back a Return Goods Authorization (RGA) number.

3. The product may then be returned to Espar with a copy of the Return Goods Authorization (RGA) form enclosed.

4. Parts and heaters must be packaged securely to avoid damage in transit.

5. Ship via UPS ground. Air shipments will not be paid for by Espar.

6. Proper documentation must accompany each shipment, which includes: shipping labels marked clearly with Espar RGA, affixed to the outside of the package (refer to Appendix C).

Canadian Customers ONLY

Ship to: Customer Service Department

Espar Products, Inc.

6099A Vipond Drive

Mississauga, Ontario

L5T 2B2 CANADA

Espar Reference Number (RGA# assigned to you)

U.S. Customers ONLY

Ship to: Customer Service Department

Espar Products, Inc.

60 Industrial Parkway, Suite 730

Cheektowaga, New York 14227

USA

Espar Reference Number (RGA# assigned to you)

7. Upon receipt, the product will then be inspected and a credit will be processed to the customer of record, MSD or DD, or may be refused if testing concludes the product is functional. If the product has been found to be used (installed) the RGA will be rejected and no warranty claim will be accepted.

8. When any product is returned without an RGA number there will be a $50.00 administration charge to your account. No exceptions will be made.

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Procedure for Warranty Appeal

It is Espar’s intent to close all claims within thirty (30) days after parts are returned and claim process is completed.

The warranty appeal must be filed within thirty (30) days of claim rejection issue date in order to receive consideration for reversal.

IMPORTANT NOTE:

Appeals will not be considered for claims that have aged beyond thirty (30) days of final rejection issue date and closed permanently.

Warranty Appeal Process

1. The claim outcome is communicated to the MSD or Dealer with the appeal document (refer to Appendix

F).

2. The Dealer files an appeal to Espar through the Warranty Administrator. This must be within thirty (30) days from the claim outcome that was communicated.

3. The Warranty Technologist re-opens the claim for processing.

4. The Warranty Technologist re-evaluates the claim based on the new information from the appeal.

5. If there is a warranty returned part involved in the appeal, the Warranty Technician will re-test the part again and document the test results.

6. Based on the outcome of the report of the second test, the final disposition will be communicated to the

MSD or Dealer and the claim will be closed.

QSF-60

18 02.2014

Rev. 7

Espar Flat Rate Labor Guide

This Flat Rate Labor Guide has been developed and based on the worldwide experience of Espar and

Eberspaecher service centers. This guide is organized by heater model in order of heat output.

When submitting a warranty claim, it is mandatory to log a detailed description of the repair. The description you provide should correspond with the fault codes indicated. It is imperative to verify replaced parts as failed parts.

IMPORTANT NOTE:

Espar and Eberspaecher have an “Always Repair Heater” policy.

QSF-60

19 02.2014

Rev. 7

AIRTRONIC 2 / 4

For Heater Model Numbers:

12V

AIRTRONIC D2 25 2069

AIRTRONIC D4 25 2113

AIRTRONIC B4 20 1812

Diagram

Reference

Number

24V

25 2070

25 2114

Part Description

A. Troubleshoot

B. Components Replaced with Heater Installed

5

6

7

8

1

2

3

4

9

9

10

Electronic Control Unit (ECU)

Combi-Sensor (Overheat / Flame)

Glow Pin with Tool

Fuel Metering Pump

Mini-Controller

Thermostat

Rheostat

7-Day Timer

Digi-Max

Main Wire Harness

Main Wire Harness

Heat Exchanger / Burner

C. Components Replaced with Heater Removed

11

12

13

14

D. Heater Function Test

Blower Unit

Burner / Flame Tube

Gasket, Blower

Gasket, Burner

Operation

Flat

Rate

Labor

Code

A

Replace A-B180

Replace A-B230

Replace A-B310

Replace A-B480

Replace A-B540

Replace A-B545

Replace A-B550

Replace A-B565

Replace A-B572

Repair A-B580

Replace A-B520

Clean A-B010

A-C000

Replace A-C100

Replace A-C050

Replace A-C145

Replace A-C080

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number (WA#)

Required

10

10

10

10

15

15

10

15

10

30

30

15

60

10

20

15

10

30

QSF-60

20 02.2014

Rev. 7

AIRTRONIC 2 / 4

QSF-60

21 02.2014

Rev. 7

B/D1LC Compact

For Heater Model Numbers:

12V

B1LC Compact

D1LC Compact

20 1766

25 1976

Diagram

Reference

Number

Part Description

A. Troubleshoot

B. Components Replaced with Heater Installed

5

6

7

8

1

2

3

4

9

10

11

11

Electronic Control Unit (ECU)

Fuel Metering Pump

Mini-Controller

Thermostat

Rheostat

7-Day Timer

Seal, Glow Plug

Battery Wire Harness

Switch Wire Harness

Fuel Metering Pump Wire Harness

Main Wire Harness

Main Wire Harness

C. Components Replaced with Heater Removed

12

13

14

15

16

17

18

18

D. Heater Function Test

Blower Unit

Overheat Sensor

Flame Sensor

Seal Ring, burner

Gasket, blower

Gasket, burner

Heat Exchanger / Burner

Heat Exchanger / Burner

Operation

Flat

Rate

Labor

Code

A

Replace D1-B180

Replace D1-B480

Replace D1-B540

Replace D1-B545

Replace D1-B550

Replace D1-B565

Replace D1-B330

Replace D1-B525

Replace D1-B530

Replace D1-B535

Repair D1-B580

Replace D1-B520

D1-C000

Replace D1-C100

Replace D1-C255

Replace D1-C280

Replace D1-C085

Replace D1-C145

Replace D1-C080

Replace D1-C005

Clean D1-C010

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number (WA#)

Required

10

10

15

15

10

15

10

15

15

15

10

10

60

15

15

15

20

15

20

25

15

30

QSF-60

22 02.2014

Rev. 7

B/D1LC Compact

QSF-60

23 02.2014

Rev. 7

B/D3LC Compact

For Heater Model Numbers:

D3LC Compact

Diagram

Reference

Number

12V

25 1981

24V

Part Description

A. Troubleshoot

B. Components Replaced with Heater Installed

1

2

Electronic Control Unit (ECU)

Fuel Metering Pump

3

4

5

6

Mini-Controller

Thermostat

Rheostat

7-Day Timer

7

8

9

10

11

11

Seal, Glow Plug

Battery Wire Harness

Switch Wire Harness

Fuel Metering Pump Wire Harness

Main Wire Harness

Main Wire Harness

C. Components Replaced with Heater Removed

12

13

14

15

16

17

18

18

D. Heater Function Test

Blower Unit

Overheat Sensor

Flame Sensor

Seal Ring, burner

Gasket, blower

Gasket, burner

Heat Exchanger / Burner

Heat Exchanger / Burner

Operation

Flat

Rate

Labor

Code

A

Replace D3-B180

Replace D3-B480

Replace D3-B540

Replace D3-B545

Replace D3-B550

Replace D3-B565

Replace D3-B330

Replace D3-B525

Replace D3-B530

Replace D3-B535

Repair D3-B580

Replace D3-B520

D3-C000

Replace D3-C100

Replace D3-C255

Replace D3-C280

Replace D3-C085

Replace D3-C145

Replace D3-C080

Replace D3-C005

Clean D3-C010

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number (WA#)

Required

60

15

15

15

20

15

20

25

15

30

10

10

15

15

10

15

10

15

15

15

10

10 

QSF-60

24 02.2014

Rev. 7

B/D3LC Compact

QSF-60

25 02.2014

Rev. 7

AIRTRONIC 5

For Heater Model Numbers:

12V

AIRTRONIC B5 20 1859

24V

AIRTRONIC D5 25 2361 25 2362

Diagram

Reference

Number

Part Description

A. Troubleshoot

B. Components Replaced with Heater Installed

5

6

7

7

1

2

3

4

Remote Temperature Sensor

Fuel-Metering Pump

Mini-Controller

Thermostat

Rheostat

7 Day Timer

Digi-Max

Main Wire Harness

Main Wire Harness

C. Components Replaced with Heater Removed

8

9

10

11

12

13

14

15

Cable, Glow Plug

Combi-Sensor (Overheat / Flame)

Blower Unit

Seal Ring, burner

Cover, burner

Gasket, blower

Gasket, burner

Heat Exchanger / Burner

15 Heat Exchanger / Burner

D. Heater Function Test

Operation

Flat

Rate

Labor

Code

A

Replace A5-B180

Replace A5-B480

Replace A5-B540

Replace A5-B545

Replace A5-B550

Replace A5-B565

Replace A5-B572

Repair A5-B580

Replace A5-B520

A5-C000

Replace A5-C345

Replace A5-C230

Replace A5-C100

Replace A5-C085

Replace A5-C090

Replace A5-C145

Replace A5-C080

Replace A5-C005

Clean A5-C010

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number (WA#)

Required

10

10

15

10

15

15

10

30

30

60

15

20

20

25

25

15

20

30

15

30

QSF-60

26 02.2014

Rev. 7

AIRTRONIC 5

QSF-60

27 02.2014

Rev. 7

D8LC

For Heater Model Numbers:

D8LC

Diagram

Reference

Number

12V 24V

25 1890 25 1891

Part Description

A. Troubleshoot

B. Components Replaced with Heater Installed

9

10

11

11

12

13

14

15

5

6

7

8

1

2

3

4

Printed Circuit Board

Electronic Control Unit (ECU)

Overheat Switch

Temperature Sensor

Air-Solenoid Valve

Fuel Metering Pump

Thermostat

Rheostat

Remote Temperature Sensor

7-Day Timer

Digi-Max

Main Wire Harness

Main Wire Harness

Glow Plug Relay

Relay

Cover, Component Box Housing

Internal Main Wire Harness

C. Components Replaced with Heater Removed

16

17

18

19

20

21

22

22

D. Heater Function Test

Blower Unit

Flame Sensor

Gasket, Burner

Fan Wheel, Blower Unit

Housing, Blower Unit

Component Box housing with Seal

Heat Exchanger / Burner

Heat Exchanger / Burner

Operation

Flat

Rate

Labor

Code

A

Replace D8-B175

Replace D8-B180

Replace D8-B270

Replace D8-B305

Replace D8-B380

Replace D8-B480

Replace D8-B545

Replace D8-B550

Replace D8-B555

Replace D8-B565

Replace D8-B572

Repair D8-B580

Replace D8-B520

Replace D8-B355

Replace D8-B390

Replace D8-B435

Replace D8-B510

D8-C000

Replace D8-C100

Replace D8-C280

Replace D8-C080

Replace D8-C130

Replace D8-C135

Replace D8-C430

Replace D8-C005

Clean D8-C010

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number (WA#)

Required

15

15

10

30

30

5

5

5

15

10

10

10

10

10

10

15

10

60

35

30

15

15

35

20

45

20

30

QSF-60

28 02.2014

Rev. 7

D8LC

QSF-60

29 02.2014

Rev. 7

HYDRONIC 4 / 5 SC

(Integrated Coolant Pump, Integrated Fuel Metering Pump)

For Heater Model Numbers:

12V

HYDRONIC D5 25 2219

Diagram

Reference

Number

Part Description Operation

Flat

Rate

Labor

Code

A A. Troubleshoot

B. Components Replaced with Heater Installed

1

2

Electronic Control Unit (ECU)

Push / Pull Switch

3

4

5

5

7-Day Timer

Thermostat

Multi-Max

Main Wire Harness

Main Wire Harness

C. Components Replaced with Heater Removed

10

11

12

13

6

7

8

9

Blower Unit

Coolant Pump

Overheat Sensor with Cable Section

Flame Sensor

Glow Pin

Fuel Metering Pump

Burner / Flame Tube

O-Ring, Heat Exchanger

14

15

Seal Kit

Heat Exchanger

16 Fuel Connection, Glow Pin

D. Heater Function Test

Replace H1-B180

Replace H1-B560

Replace H1-B565

Replace H1-B545

Replace H1-B573

Repair H1-B580

Replace H1-B520

H1-C000

Replace H1-C100

Replace H1-C200

Replace H1-C240

Replace H1-C280

Replace H1-C310

Replace H1-C480

Replace H1-C050

Replace H1-C020

Replace H1-C081

Clean H1-C010

Replace H1-C315

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number (WA#)

Required

10

10

15

15

10

30

30

60

20

15

25

15

15

20

25

30

25

15

20

30

QSF-60

30 02.2014

Rev. 7

HYDRONIC 4 / 5 SC

(Integrated Coolant Pump, Integrated Fuel Metering Pump)

QSF-60

31 02.2014

Rev. 7

HYDRONIC 4 / 5 SC

(Integrated Coolant Pump, External Fuel Metering Pump)

For Heater Model Numbers:

12V 24V

HYDRONIC D4 20 1824

HYDRONIC B5 20 1820

HYDRONIC D5 25 2325 25 2147

Diagram

Reference

Number

Part Description Operation

Flat

Rate

Labor

Code

A A. Troubleshoot

B. Components Replaced with Heater Installed

1

2

Electronic Control Unit (ECU)

Fuel Metering Pump

3

4

5

6

6

Push / Pull Switch

7-Day Timer

Thermostat

Multi-Max

Main Wire Harness

Main Wire Harness

C. Components Replaced with Heater Removed

7

8

9

10

11

12

15

16

17

18

Blower Unit

Coolant Pump

Overheat Sensor with Cable Section

Flame Sensor

Glow Pin

Burner / Flame Tube

O-Ring, Heat Exchanger

Seal Kit

Heat Exchanger

Fuel Connection, Glow Pin

D. Heater Function Test

Replace H2-B180

Replace H2-B480

Replace H2-B560

Replace H2-B565

Replace H2-B545

Replace H2-B573

Repair H2-B580

Replace H2-B520

H2-C000

Replace H2-C100

Replace H2-C200

Replace H2-C240

Replace H2-C280

Replace H2-C310

Replace H2-C050

Replace H2-C020

Replace H2-C081

Clean H2-C010

Replace H2-C315

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number (WA#)

Required

10

10

10

15

15

10

30

30

60

20

15

25

15

15

25

30

25

15

20

30

QSF-60

32 02.2014

Rev. 7

HYDRONIC 4 / 5 SC

(Integrated Coolant Pump, External Fuel Metering Pump)

QSF-60

33 02.2014

Rev. 7

HYDRONIC 5 S

(External Coolant Pump, External Fuel Metering Pump)

For Heater Model Numbers:

HYDRONIC B5

12V

20 1819

24V 24V

HYDRONIC D5 25 2217 25 2146 25 2218

Diagram

Reference

Number

Part Description Operation

Flat

Rate

Labor

Code

A A. Troubleshoot

B. Components Replaced with Heater Installed

1

2

Electronic Control Unit (ECU)

Coolant Pump

3

4

5

6

Fuel Metering Pump

Push / Pull Switch

7-Day Timer

Thermostat

7

7

Multi-Max

Main Wire Harness

Main Wire Harness

C. Components Replaced with Heater Removed

8

9

10

11

12

13

14

15

Blower Unit

Overheat Sensor with Cable Section

Flame Sensor

Glow Pin

Burner / Flame Tube

O-Rings, Coolant Pump

O-Rings, Sensors

O-Ring, Heat Exchanger

16

17

Seal Kit

Heat Exchanger

18 Fuel Connection, Glow Pin

D. Heater Function Test

Replace H3-B180

Replace H3-B200

Replace H3-B480

Replace H3-B560

Replace H3-B565

Repair H3-B545

Replace H3-B573

Repair H3-B580

Replace H3-B520

H3-C000

Replace H3-C100

Replace H3-C240

Replace H3-C280

Replace H3-C310

Replace H3-C050

Replace H3-C205

Replace H3-C245

Replace H3-C020

Replace H3-C081

Clean H3-C010

Replace H3-C315

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number (WA#)

Required

10

10

10

10

15

15

10

30

30

60

20

25

15

15

25

15

15

30

25

15

20

30

QSF-60

34 02.2014

Rev. 7

HYDRONIC 5 S

(External Coolant Pump, External Fuel Metering Pump)

QSF-60

35 02.2014

Rev. 7

HYDRONIC 5 Z

(No Coolant Pump, External Fuel Metering Pump)

For Heater Model Numbers:

12V

HYDRONIC D5 25 2216

Diagram

Reference

Number

Part Description

A. Troubleshoot

B. Components Replaced with Heater Installed

1

2

Electronic Control Unit (ECU)

Fuel Metering Pump

3

4

5

6

6

Push / Pull Switch

7-Day Timer

Thermostat

Main Wire Harness

Main Wire Harness

C. Components Replaced with Heater Removed

7

8

9

10

11

12

13

14

Blower Unit

Overheat Sensor with Cable Section

Flame Sensor

Glow Pin

Burner / Flame Tube

O-Rings, Coolant Pump

O-Rings, Sensors

O-Ring, Heat Exchanger

15

16

Seal Kit

Heat Exchanger

17 Fuel Connection, Glow Pin

D. Heater Function Test

Operation

Flat

Rate

Labor

Code

A

Replace H4-B180

Replace H4-B480

Replace H4-B560

Replace H4-B565

Replace H4-B545

Repair H4-B580

Replace H4-B520

H4-C000

Replace H4-C100

Replace H4-C240

Replace H4-C280

Replace H4-C310

Replace H4-C050

Replace H4-C205

Replace H4-C245

Replace H4-C020

Replace H4-C081

Clean H4-C010

Replace H4-C315

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number (WA#)

Required

10

10

10

15

15

30

30

60

20

25

15

15

25

15

15

30

25

15

20

30

QSF-60

36 02.2014

Rev. 7

HYDRONIC 5 Z

(No Coolant Pump, External Fuel Metering Pump)

QSF-60

37 02.2014

Rev. 7

HYDRONIC II 5E

(External Coolant Pump, External Fuel-Metering Pump)

For Heater Model Numbers:

12V

HYDRONIC B5S 20 1904

HYDRONIC D5S 25 2526

Diagram

Reference

Number

Part Description Operation

Flat Rate

Labor

Code

A

Time

Allowance

(minutes)

30

Warranty

Authorization

Number (WA#)

Required

A. Troubleshoot

B. Components Replaced with Heater Installed

1

2

3

4

5

6

7

7

Coolant Pump

Fuel-Metering Pump

Push/Pull Switch

7-Day Timer

Programmable Timer

Easy start/Mini Timer

Multi-Max

Main Wire Harness

Main Wire Harness

C. Components Replaced with Heater Removed

8

9

10

11

12

13

14

15

16

Electronic Control Unit (ECU)

Blower Fan

Lead harness(temp & surface sensor)

Flame Sensor

Glow Pin

Combustion Chamber

O-Rings, Water pipe socket

Seal Kit

Heat Exchanger

D. Heater Function Test

Replace H5-B200

Replace H5-B480

Replace H5-B560

Replace H5-B565

Replace H5-B570

Replace H5-B571

Replace H5-B573

Repair H5-B580

Replace H5-B520

H5-C000

Replace H5-C180

Replace H5-C100

Replace H5-C240

Replace H5-C280

Replace H5-C310

Replace H5-C050

Replace H5-C205

Replace H5-C081

Clean H5-C010

D

10

10

10

15

15

15

10

30

30

60

30

20

25

15

15

25

15

25

15

30

QSF-60

38 02.2014

Rev. 7

QSF-60

39 02.2014

Rev. 7

HYDRONIC 10

For Heater Model Numbers:

HYDRONIC 10

Diagram

Reference

Number

12V 24V

25 2160 25 2227

Part Description

A. Troubleshoot

B. Components Replaced with Heater Installed

1

2

Electronic Control Unit (ECU)

Fuel Metering Pump

3

4

5

6

6

Push / Pull Switch

7-Day Timer

Thermostat

Multi-Max

Main Wire Harness

Main Wire Harness

C. Components Replaced with Heater Removed

7

8

9

10

11

12

13

14

Blower Unit

Coolant Pump

Overheat Sensor

Flame Sensor

Temperature Sensor

Glow Pin

O-Ring, Coolant Pump

O-Ring, Overheat Sensor

15

16

17

18

O-Ring, Temperature Sensor

O-Ring, Heat Exchanger

Burner / Flame Tube

Burner with Housing

19

20

Heat Exchanger

Wire Harness, Glow Pin

D. Heater Function Test

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Clean

Replace

Operation

Replace

Replace

Replace

Replace

Replace

Replace

Repair

Replace

Flat Rate

Labor

Code

A

H10-B180

H10-B480

H10-B560

H10-B565

H10-B545

H10-B573

H10-B580

H10-B520

H10-C000

H10-C100

H10-C200

H10-C255

H10-C280

H10-C305

H10-C310

H10-C205

H10-C265

H10-C295

H10-C020

H10-C050

H10-C055

H10-C010

H10-C911

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number

(WA#)

Required

10

10

10

15

15

10

30

30

60

15

15

15

20

15

10

10

15

15

25

35

35

15

15

30

QSF-60

40 02.2014

Rev. 7

HYDRONIC 10

QSF-60

41 02.2014

Rev. 7

HYDRONIC MII

For Heater Model Numbers:

12V 24V

HYDRONIC M8 25 2470 25 2471

HYDRONIC M10 25 2434 25 2435

HYDRONIC M12 25 2472 25 2473

HYDRONIC M12 25 2596

Diagram

Reference

Number

Part Description Operation

Flat Rate

Labor

Code

A. Troubleshoot

B. Components Replaced with Heater Installed

1

2

Coolant Pump

O-Ring, Coolant Pump

3

4

5

6

Relay Wire Harness

Fuel Metering Pump

Fuel Metering Pump Wire Harness

Push / Pull Switch

7

8

9

10

7-Day Timer

Programmable Timer

Multi-Max

Main Wire Harness

Main Wire Harness

C. Components Replaced with Heater Removed

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Repair

Replace

A

HM-B200

HM-B205

HM-B440

HM-B480

HM-B535

HM-B560

HM-B565

HM-B570

HM-B573

HM-B580

HM-B520

HM-C000

1

11

12

13

14

15

16

17

Coolant Pump (boxed heater)

Burner / Flame Tube

1

Seal, Burner

Blower / Control Unit

2

O-Ring, Blower

Overheat / Temperature Sensor

Flame Sensor

Glow Pins

3

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

HM-C201

HM-C050

HM-C080

HM-C150

HM-C185

HM-C241

HM-C280

HM-C310

18

19

Coolant Pump Wire Harness

Heat Exchanger / Water Jacket

20 Heat Exchanger / Water Jacket

D. Heater Function Test

Replace

Replace

Clean

HM-C450

HM-C006

HM-C010

1 – Burner tube replacement includes replacement of burner seal and blower O-ring

2

– Blower / control unit replacement includes replacement of blower O-ring and burner seal

3 – Glow pin replacement includes replacement of blower O-ring and burner seal

D

Time

Allowance

(minutes)

30

Warranty

Authorization

Number

(WA#)

Required

10

10

15

10

15

10

15

15

10

30

30

60

10

70

70

75

10

35

20

70

30

45

45

30

QSF-60

42 02.2014

Rev. 7

HYDRONIC MII

QSF-60

43 02.2014

Rev. 7

HYDRONIC 16 / 24 / 30 / 35

For Heater Model Numbers:

HYDRONIC 35

Diagram

Reference

Number

24V

25 1819

Part Description

A. Troubleshoot

B. Components Replaced with Heater Installed

1

2

Coolant Pump

Overheat Sensor

3

4

5

6

Temperature Sensor

Push / Pull Toggle Switch

7-Day Timer

Spare Part Kit, Coolant Pump

7

7

8

9

Multi-Max

Main Wire Harness

Main Wire Harness

Combustion Air Inlet Hood

Internal Main Wire Harness

C. Components Replaced with Heater Removed

10

11

12

13

14

15

16

17

Flame Tube

Burner Motor

Fuel Atomizer Nozzle

Heat Element Nozzle

Electronic Control Unit (ECU)

Ignition Spark Generator

Ignition Electrodes

Fuel Solenoid Coil

18

19

20

21

Hardware for Fuel Solenoid Coil

Baffle Plate / Heat Shield

Fuel Pump / Housing

Heat Exchanger / Water Jacket

21 Heat Exchanger / Water Jacket

D. Heater Function Test

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Clean

Operation

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Repair

Replace

Replace

Replace

A

LH-B200

LH-B255

LH-B305

LH-B560

LH-B565

LH-B225

LH-B573

LH-B580

LH-B520

LH-B450

LH-B510

LH-C000

LH-C050

LH-C105

LH-C165

LH-C170

LH-C180

LH-C195

LH-C335

LH-C500

LH-C505

LH-C155

LH-C495

LH-C006

LH-C010

D

Flat Rate

Labor

Code

Time

Allowance

(minutes)

30

Warranty

Authorization

Number

(WA#)

Required

10

10

10

10

15

20

10

30

30

10

5

60

15

5

20

20

20

30

5

10

10

10

10

10

10

15

QSF-60

44 02.2014

Rev. 7

HYDRONIC 16 / 24 / 30 / 35

QSF-60

45 02.2014

Rev. 7

HYDRONIC LII

For Heater Model Numbers:

HYDRONIC L16 25 2486

HYDRONIC L24 25 2487

HYDRONIC L30 25 2488 25 2599

HYDRONIC L35 25 2489

Diagram

Reference

Number

Part Description

A. Troubleshoot

B. Components Replaced with Heater Installed

1

2

Coolant Pump

Overheat Sensor

3

4

5

6

Temperature Sensor

Push / Pull Toggle Switch

7-Day Timer

Spare Part Kit, Coolant Pump

7

7

8

9

Multi-Max

Main Wire Harness

Main Wire Harness

Combustion Air Inlet Hood

Internal Main Wire Harness

C. Components Replaced with Heater Removed

10

11

12

13

Flame Tube

Burner Motor

Fuel Atomizer Nozzle

Heat Element Nozzle

14

15

16

17

18

19

20

20

Electronic Control Unit (ECU)

Ignition Spark Generator

Ignition Electrodes

Fuel Solenoid Coil

Baffle Plate / Heat Shield

Fuel Pump Kit

1

Heat Exchanger / Water Jacket

Heat Exchanger / Water Jacket

D. Heater Function Test

Operation

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Repair

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Replace

Clean

A

HL-B200

HL-B255

HL-B305

HL-B560

HL-B565

HL-B225

HL-B573

HL-B580

HL-B520

HL-B450

HL-B510

HL-C000

HL-C050

HL-C105

HL-C165

HL-C170

HL-C180

HL-C195

HL-C335

HL-C501

HL-C155

HL-C490

HL-C006

HL-C010

D

Flat Rate

Labor

Code

Time

Allowance

(minutes)

30

Warranty

Authorization

Number

(WA#)

Required

10

10

10

10

15

20

10

30

30

10

5

60

5

10

10

10

10

10

10

15

5

40

20

20

30

QSF-60

46 02.2014

Rev. 7

HYDRONIC LII

QSF-60

47 02.2014

Rev. 7

Tools and Equipment

Generally, standard shop tools are required for the installation and repair of Espar heaters. However, there are a few additional tools required for efficient troubleshooting and repair. All required tools are listed below.

Required Equipment for General Heater Repair

EDiTH diagnostic computer software and hardware

Diagnostic unit o Previously named “Fault Code Retrieval Device” o Appropriate diagnostic wire adaptors

 Electrician’s crimping tool for non-insulated terminals

Terminal removal tool, 1.6mm

Terminal removal tool, 2.8mm

Graduated cylinder, range of 0 to 50cm

3

or 0 to 50ml

Torx drivers

Metric Allen key wrenches

Metric wrenches and / or sockets (4mm through 27mm)

Fuel line cutter or knife

Multi-meter

For complete and thorough service of Espar heaters, the following special tools and equipment are recommended in addition to those listed above.

Special Tools

Graduated cylinder, range of 0 to 500cm

3

(for HYDRONIC 16 / 24 / 30 / 35)

Spark gapping gauge(s) for HYDRONIC 16 / 24 / 30 / 35

Tachometer (RPM meter), optical or digital readout preferred

Stop watch

Thermometer, minimum range of 0°C to 300°C (32°F to 572°F)

Carbon dioxide (CO

Smoke tester

2

) gas analyzer, minimum range of 0 to 20%

QSF-60

48 02.2014

Rev. 7

Computer Diagnostic Tool – EDiTH

The following overview is to help you understand the capability of different diagnostic hardware. Available are:

Diagnostic Unit, EDiTH Basic and EDiTH Expert.

PRODUCT / FUNCTIONS

Read out the current error and the latest five errors

Running diagnosis at installed heaters

Turn on the heater directly by PC or Notebook

Visualization of the sequence of operations of the heater / control unit with display of the operating state and measured data of each components – components test

DIAGNOSTIC

UNIT

EDiTH

BASIC

EDiTH

EXPERT

Individual test of components (independent of control unit) i.e. voltage of glow pin, voltage and speed of electric motor, fuel metering pump

Recognition if heater is high altitude adjustable

Display of general heater data

IPCU programming

Recognition if the control unit is high altitude adjustable

Running diagnosis on control unit

Test control unit under real performance conditions

In addition to EDiTH Basic and Expert hardware, additional adapter cables are required for each type of heater installation. Type of adapters will depend on heater model and installation. For list of adaptors and their part numbers please refer to the current Espar Product Catalogue.

EDiTH software is updated regularly and the most recent version should be downloaded and installed from www.espar.com/help.

QSF-60

49 02.2014

Rev. 7

APPENDIX A

The Espar Limited Warranty

Espar Products, Inc. (“Espar”) warrants its heaters (the “Products”) to be free from defects in materials and workmanship, subject to the terms below.

Espar will, at its option, repair or replace any Products or any parts of a Product which are subject to warranty according to

Espar’s Warranty Manual (the “Warranted Parts”) if such Products or Warranted Parts are proven defective in materials or workmanship during the relevant warranty period (the “Warranty Period”) described below. This is Espar’s sole obligation under this warranty.

This warranty extends only to the original owner (each an “Owner”). Unless Espar agrees in writing, this warranty cannot be transferred and it only applies to a Product in its original installation.

The Warranty Period is: (a) two (2) years or two thousand (2,000) operating hours (whichever comes first) for AIRTRONIC 2,

AIRTRONIC 4, AIRTRONIC 5, B1LC Compact, B/D3LC Compact, HYDRONIC 4, HYDRONIC 5 and B/D5W heaters; or (b) two (2) years or one thousand five hundred (1,500) operating hours (whichever comes first) for HYDRONIC MII heaters; or (c) one (1) year or one thousand (1,000) operating hours (whichever comes first) for all other Espar heaters.

The Warranty Period begins on: (a) the date of sale of equipment containing the Product by an Original Equipment

Manufacturer (“OEM”) to the Owner; or (b) the date of installation for the Owner or the date of shipment by Espar, whichever is later, for all Products not sold to an Owner by an OEM.

To obtain service of a Product under this warranty, present the nearest Espar authorized and trained dealer (each an “Espar

Dealer”) with proof of purchase and for Products not sold by an OEM, the date of installation. To establish the date of purchase and date of installation of a Product, Owners should register for the Espar Warranty on-line at www.espar.com within thirty (30) days of the installation or purchase of the Product. If the Owner has not registered online, the Owner can submit to the Espar Dealer other reasonable proof of the dates of purchase and for Products not sold by an OEM, of production installation. If the Owner cannot prove such dates, the Warranty Period will be deemed to have started when the Product was shipped by Espar.

The Espar Dealer will perform warranty service subject to this warranty and Espar’s Warranty Manual. The Espar Dealer will also complete and submit a Warranty Claim to Espar. Espar will pay only Espar Dealers or installers to remove and re-install

Products and Warranted Parts according to Espar’s Warranty Manual. Espar shall not pay for any other labor costs.

Depending on where and how the Product was installed, the Owner may be required to return the Product to the Espar Dealer who originally installed the Product for warranty service. The cost of this return will be paid by the Owner. When servicing according to this warranty, Espar or an Espar Dealer may replace parts with new parts and change part specifications without notice provided such replacements or changes do not adversely affect the Product’s performance.

This warranty does not cover damage or defects caused by: (a) installation; (b) service; (c) the use of replacement parts which are not genuine Espar parts; (d) use of a Product for other than its intended purpose; (e) use under other than normal conditions; (f) use contrary to Espar’s instructions; (g) accident; (h) neglect; or (i) normal wear and tear on parts such as glow plugs, atomizer screens, fuel filters, fuses, lamp bulbs, intake and exhaust tubing and ducting.

THIS WARRANTY IS IN LIEU OF ALL OTHER EXPRESSED OR IMPLIED WARRANTIES. ESPAR’S LIABILITY FOR

DAMAGES IS LIMITED TO THE COST OF REPLACING THE PRODUCT. ESPAR SHALL NOT BE LIABLE FOR SPECIAL,

INCIDENTAL, PUNITI

VE OR CONSEQUENTIAL DAMAGES. THIS IS ESPAR’S ENTIRE WARRANTY. IT CAN ONLY BE

CHANGED WITH THE EXPRESS WRITTEN CONSENT OF ESPAR.

THIS WARRANTY SHALL BE INTERPRETED AND GOVERNED BY THE LAWS OF THE PROVINCE OF ONTARIO,

CANADA REGARDLESS OF WHERE THE PRODUCT IS SOLD OR INSTALLED. ANY LEGAL ACTION REGARDING THIS

WARRANTY SHALL ONLY BE COMMENCED IN THE SUPERIOR COURT OF JUSTICE IN ONTARIO. THE PARTIES

EXPRESSLY WAIVE ANY RIGHT TO A TRIAL BY JURY.

If you have any questions about this warranty, contact Espar’s Warranty Manager at Espar Products, Inc., 6099A Vipond

Drive, Mississauga, ON L5T 2B2. For our Warranty Manual, visit our website www.espar.com.

QSF-60

50 02.2014

Rev. 7

APPENDIX B

Sample Warranty Tag

QSF-60

51 02.2014

Rev. 7

APPENDIX C

Sample Warranty Shipping Label

QSF-60

52 02.2014

Rev. 7

APPENDIX D

Warranty Notification Form

Warranty Claim # Date

Serial # Model #

Warranty Claim is ON HOLD: Additional information is required by Espar to process the warranty claim. Please submit the following information to Espar’s Warranty Department within 10 business days from the date on this form.

Installation documentation required to prove applicable warranty period (as warranty was not registered).

Further technical information required to support repair.

Other

Comments:

Adjustments were made to the submitted Warranty Claim:

Labor time requested is higher than the Flat Rate Labor Guide allows.

Duplicate labor codes.

Warranty authorization for excess time, labor or parts was not requested and/or authorized by Espar’s

Warranty Department.

Parts returned for inspection were tested and found to be free of defects.

Comments:

Rejection of the Warranty Claim:

Heater warranty period has expired.

Parts returned for inspection were tested and found to be not defective.

Parts claimed are not covered under warranty.

Inadequate parts return.

Duplicate warranty claim submitted.

Vehicle owner on Warranty Claim is not the original registered owner (warranty non-transferable).

Requested information to support warranty claim was not received within 10 business days.

Unauthorized WA# used for warranty claim that is not approved for this serial number.

Comments:

Acceptance of the Warranty Claim:

Warranty Claim has been approved.

QSF-60

53 02.2014

Rev. 7

APPENDIX E

Technician’s Checklist

Work Order:

Serial Number:

Heater Model:

Technician:

EDiTH Information

Installation position on vehicle

Fuel pump mounting position

ITEM CHECK

AF F1 F2 F3 F4 F5

Overall Heater Run Time: Number of Starts:

Fuel quantity test (before removal)

Unit is boxed?

CHECK PERFORMED

YES NO

FOUND

(YES / NO)

ACTION TAKEN

Are connections tight and free of corrosion?

ELECTRICAL SYSTEM

Has proper gauge wiring been used for the length and amperage requirements?

Have any fuses / circuit breakers been activated?

Is power taken directly from batteries and ground to the batteries?

COOLANT FLOW / AIR FLOW SYSTEM

Are there any obstructions in the system?

Is the heater system too large / small for the application?

Has proper coolant hose size or ducting been used?

FUEL SYSTEM

Have proper diameter fuel lines been used?

Have proper length fuel lines been used?

Has a proper connection to the fuel supply been made?

Is the fuel flowing freely (fuel is not gelled)?

Are there restrictions in the fuel line?

Is the fuel metering pump properly aligned?

Is the fuel filter clogged?

QSF-60

54 02.2014

Rev. 7

APPENDIX F

WARRANTY CLAIM APPEAL

Customer Information

Customer

Address, City

Province / State

Postal / Zip Code

Phone / Fax

Submitted by Information

Submitted by

Email

Date of Appeal MM

Claim Information

Claim #

Reason for Appeal

DD YY

WE # (if given)

Country

Comments:

NOTE: Warranty appeal should be done within 30 days after receiving the outcome of the warranty claim.

QSF-WD013 Rev. Rel

QSF-60

55 02.2014

Rev. 7

Espar Products, Inc.

800.387.4800

905.670.0960

905.670.0728 Fax www.espar.com

QSF-60

A member of the Worldwide Eberspaecher Group of Companies

56 02.2014

Rev. 7

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