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' Eberspacher: Hydronic4 5 D4w D5w Description, Install, Maintenance, …'




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Hydronic 45 Coolant Parts Model 12 V Heater Model 24 V
D4 SC 25 1917 01 Hydronic D5 SC 25 2147 05
25 2096 05 Hydronic D5 S 25 2009 05
Hydronic B4 SC 20 1789 05
Hydronic D5 SC 25 1920 05
25 2098 05
Hydronic D5 S 25 2031 05
25 2100 05
Hydronic B5 SC 20 1791 05
Hydronic B5 S 20 1793 05
PN 6101210201 January 2001
Table of Contents
Heater Warnings 3
Introduction 4
Heater Components
Hydronic 45 SC 12 volt Diesel 5
Hydronic 5 SC 24 volt Diesel 6
Hydronic 45 SC 12 volt Gasoline 6
Hydronic 5 S 12 24 volt Diesel Gas 7
Principal Dimensions Heater Location 8
Procedures Heater Mounting 9
Heater Plumbing 10
Fuel System 11
Electrical Connections 13
Connections 14
Operating Switches 15
Heater Operation PreStart Procedures 16
StartUp 16
Running 16
Switching Off 17
Safety Equipment 17
Operational Flow Chart 18
Schematics
Hydronic D4 SC 12 volt diesel 25 1917 01 19
Hydronic D4 SC 12 volt diesel 25 2096 05 20
Hydronic D5 SC 12 volt diesel 25 1920 05 21
Hydronic D5 SC 12 volt diesel 25 2098 05 22
Hydronic D5 SC 24 volt diesel 22 2147 05 23
Hydronic B4 SC 12 volt gas 20 1789 05 23
Hydronic B5 SC 12 volt gas 20 1791 05 23
Hydronic D5 S 12 volt diesel 25 2031 05 24
Hydronic D5 S 12 volt diesel 25 2100 05 24
Hydronic B5 S 12 volt diesel 20 1793 05 24
Hydronic D5 S 24 volt diesel 25 2009 05 Periodic Maintenance
Basic 25
Repairs Self Diagnostic 25
Chart 26
Fuel Quantity Test 29
Heater Disassembly Repair Steps 30
Heater Components Parts Diagram Scope 32
Description Part s 33
Parts Accessories Diagram Scope 35
Description Part s 36
Special Notes
Note Highlight areas requiring special attention or 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
Heater Warnings
Warning To Installer
Correct installation of this heater is necessary to ensure Caution During electrical welding work on the vehicle
safe and proper operation disconnect the power to the heater in order
Read and understand this manual before attempting to to protect the control unit
install the heater Failure to follow all these instructions
could cause serious or fatal injury
Note All measurements contained in this manual
contain metric and approximate SAE equiva
lents in brackets eg 25mm 1
Warning Explosion Hazard
Direct questions to Espar Heater Systems
Heater must be turned off while refueling
Do not install heater in enclosed areas where com USA bustible fumes may be present
CANADA Do not install heaters in engine compartments of gaso
line powered boats
Warning Fire Hazard
Install the exhaust system so it will maintain a minimum
distance of 50mm 2 from any flammable or heat sensi
tive material
Ensure that the fuel system is intact and there are no leaks
Warning Asphyxiation Hazard
Route the heater exhaust so that exhaust fumes cannot
enter any passenger 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 contain a proper mix
ture of water and antifreeze to prevent coolant from
freezing or slushing
If the coolant becomes slushy or frozen the heaters
coolant pump cannot move the coolant causing a block
age 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 andor per
sonal injury Extreme care should be taken to ensure a
proper mixture of water and antifreeze is used in the This publication was correct at the time of print
coolant system However Espar has a policy of continuous improve
Refer to the engine manufacturer s or coolant manufac ment and reserves the right to amend any specifica
turers for your specific requirements tions without prior notice
Hydronic D4D5 engineered to provide a dependable means of heat
ing the Espar Hydronic 45 is a diesel fired coolant of 4 16 kW to 4 kWhr 5500 to 13700 5 24 kW to 5 kWhr 8200 to 17100 compact coolant heater
offers an affordable to many applications The Hydronic 45 is ideal the engines of trucks cars offroad trucks and boats It features automatic heat
being fuel and power efficient Since the heater runs on
fuel and 12 or 24 volt power it is able to perform this com
pletely independently of the vehicle engine The unit regu
lates the coolant temperature between a low of 65C 149F
and a high of 80C 176F by automatically cycling Hydronic 45 can be operated from the vehicle cab by an
onoff switch a preselect timer or a combination of both
A Flame sensor temperature regulating sensor and are among the safety features which makes the
Hydronic D4D5 a safe and dependable heating Hydronic 4 Hydronic 5
Heat output 10 4 kW 13700 BTUhr Boost
33 kW 11300 BTUhr High 5 kW 17000 BTUhr High
16 kW 5500 BTUhr Low 24 kW 8200 BTUhr Low
12 volt 24 volt
Current draw 10 43 amps Boost
30 amps High 416 amps High 208 amps High
20 amps Low 191 amps Low 095 amps Low
Fuel consumption 10 051 lhr 013 US galhr Boost
040 lhr 011 US galhr High 062 lhr 016 US galhr High
020 lhr 005 US galhr Low 027 lhr 008 US galhr Low
Operating Voltage Range
Minimum Voltage 10 V 10 V 204 V
Maximum Voltage 16 V 16 V 320 V
Working pressure 25 bar 36 psi 25 bar 36 psi
Ambient operating temperature 40C to 80C 40F to 176F 40C to 80C 40F to temperature shutdown 5 105C 221F
105C 25 kg 55 lbs 29kg available OnOff switch or 7day
timer OnOff switch or 7day timer
Note The heater is equipped with a highvoltage
cutout as well a lowvoltage cutout
Heater Components Hydronic 4 5 SC versions 12 Volt Diesel
25 1917 01
25 2096 05
25 1920 05
25 2098 05
A Combustion air
E Exhaust
F Fuel supply line
WO Water Outlet
17 18 WI Water Inlet
1 Combustion air blower wheel 10 Combustion air tube
2 Electric motor 11 Exhaust tube
3 Heat exchanger 12 Fuelmetering pump
4 Combustion chamber 13 Coolant pump
5 Glow pin 14 Main fuse
6 Flame sensor 15 connector
7 Temperature sensor 16 Bleed screw
8 Overheat temperature sensor 17 PushPull switch
9 Control unit 18 7day timer
Heater Components Hydronic 5 SC 24 volt version Diesel
25 2147 05
Heater Components Hydronic 4 5 SC 12 volt version Gasoline
20 1789 05
20 1791 05
Heater Components Hydronic 5 S 12 24 volt versions Diesel Gasoline versions
25 2031 05
25 2100 05
20 1793 05
25 2009 05
A Combustion air
E Exhaust
F Fuel supply line
WO Water Outlet
WI Water Inlet
17 18
1 Combustion air blower wheel 10 Combustion air tube
2 Electric motor 11 Exhaust tube
3 Heat exchanger 12 Fuelmetering pump
4 Combustion chamber 13 Coolant pump
5 Glow pin 14 Main fuse
6 Flame sensor 15 connector
7 Temperature sensor 16 Bleed screw
8 Overheat temperature sensor 17 PushPull switch
9 Control unit 18 7day timer
Principal Dimensions Hydronic D4D5 SC values in brackets D4SC
All measurements in millimeters
254mm 1
Heater the heater in a protected area if youre in extreme Caution Guard the heater against excessive where heavy salting is
experienced
spray to avoid internal corrosion
Eg storage compartment engine compartments step box or
battery box
Espar recommends you use the boxed unit Boxed heaters
can be mounted by utilizing one of the existing brackets See
following page
If mounting on frame rail use an optional Espar Inside frame
bracket to mount to inside of frame rails Heaters can also be
mounted on a cross tray behind the cab and on top of
the frame rails
When mounting the heater adhere to the
following 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
For Illustration purposes only
Heater heater in saddle bracket and secure with hardware Hydronic D4 SC boxed unit PN CA 2096 55
provided If heater is not a boxed unit mount bracket onto Hydronic D5 SC boxed unit PN CA 2098 55
inside frame rail bracket Boxed unit can also be secured to
the inside frame bracket or mounted to the Cross Tray
Cross Frame Mounting Tray
Hydronic 45 box
Inside frame mounting Heater
Spacer and screw
Saddle bracket
Saddle frame rail
For S and gasoline version heaters which have external
fuel metering pumps
Choose a protected mounting location close to the fuel
pickup pipe and heater
Using the bracket and rubber mount provided install fuel
pump as shown
Note Proper mounting angle of the fuel pump is nec
essary to allow any air or vapor in the fuel lines
to pass through the pump rather than cause a
blockage
Heater Plumbing
The heater is incorporated into the engines cooling system Engine Radiator
for engine these guidelines and refer to engine plumbing dia
gram shown below
Use existing holes in the engine block ie remove
blanking plugs when possible Install fittings into the block
for pickup and returns
If possible use shut off valves to ensure the system can
be isolated from the engine when not in use
Provide 20mm 34 hose barbs for hose connections Shutoff valves
Use 20mm 34 hoses to ensure adequate coolant flow
Keep the pick up and return points as far apart as Hydronic SC Heater
possible to ensure good heat 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 External Water Pump
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 engines water pump
Ensure adequate flow rate through the heater by compar
ing the incoming and outgoing coolant temperatures while
the heater is running If the rise in temperature exceeds
10C 18F coolant flow must be increased by modifying
the plumbing
Ensure the heater and water pump are installed as low as
possible to allow the purging of air Bleed system via radi Hydronic S version
ator or bleed screw located on heater
Bleed Screw
Caution The coolant must contain a minimum of 10
antifreeze at all times as a protection against
corrosion Fresh water will corrode internal
heater parts
Fuel System Fuel Line
The Hydronic water heaters typically have the fuel metering Route fuel lines from the fuel pickup pipe to the heater
pump mounted inside the unit This is to reduce installation
Use fuel lines and to protect the pump from corrosion Some versions
have an external fuel metering pump Refer to graphics for Other sizes or types of fuel lines may inhibit proper and
flow
All parts necessary to do the installation are included in the Make proper butt joints using clamps and connector
kit as shown pieces as shown
Use a sharp utility knife to cut plastic fuel lines to avoid
burrs
Note Butt joints and clamps on all Fuel line limits must not be exceeded
Ensure that the following conditions are met
Hydronic heater must be within a height of 76cm
26 from the bottom of the fuel pickup pipe
Fuelmetering pump must be within a total
distance of 200 cm 66 from the fuel pickup pipe
If the above conditions cannot be met a heater
with external fuel metering pump must be System Fuel PickUp Pipe
2 Fuel Pipe Reducer
3 9mm Clamp
4 35mm Rubber Connector
5 20mm White Plastic Fuel Line
6 Fuel Metering Pump Hydronic Heater
7 15m White Plastic Fuel Line
Max 2 M 66
Max 76cm 26 2 4
Max 6 M 198
Max 2 M 65 4
7 3
Max 2 M 66
Max 76cm 26 2 4
Fuel PickUp Pipe Installation Standard PickUp
Choose a protected mounting location close to the pump
and heater A spare fuel sender gauge plate provides an
ideal mounting location If one is not Drill mounting holes in tank to accommodate pickup pipe
as shown
Cut the fuel pickup pipe to length Allow 225 from bot
tom of tank
Mount the fuel pickup pipe as shown
Lower the fuel pickup pipe with reinforcing washer into the
tank using the slot created by the two 06cm 14 holes
Lift the assembly into position through the 25cm 1 hole
Assemble the rubber washer metal cup washer and nut
25cm 10
0625 cm 2 Holes
Double pick ups used with combo kits
Double NPT pipe
15 cm 15 cm
PN CA0 12 107
916 916
Note Drill the two 14 holes first
Fuel PickUp Pipe reducer
Fuel PickUp Pipe
Sheet Metal Washer
Optional PickUp Pipe with NPT fitting
Rubber Gasket
Steel Safety Washer Remove an existing plug from the top of
the fuel tank
Holding Tabs Cut the fuel pickup pipe to length
Secure the fuel pickup pipe into position
Allow 25 from fuel pick
using the combined NPT compression
up to tank bottom Allow
fitting as shown
only 1 for flat bottom
tanks
End tip of the fuel pickup
pipe should have angle to
avoid picking up dirt and Note NPT fittings are available in various sizes
subsequent blockage Refer to parts section
parts needed are included with the kit indicates external mounted fuel and or water pump versions of Main Heater Connects switch
and power harness to the heater harness
in some cases power to fuel metering pump
B Power 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 25 amp fuse
C Switch 4 core harness redyellow brown yellow bluewhite
Run to location of switch Make terminal connections at
switch Espar has 2 available switches see switch
instructions on following pages
D Fuel Metering Pump Harness 2 core harness green green
Connect to fuel metering pump using single terminals
and rubber protective boots no polarity required
E Water Pump Harness 2 core harness black brown
Connect to main harness at Heaters
Caution
To avoid potential short
circuit damage during
installation insert 25
amp fuse on power
harness after all
electrical connections
are complete
7 Day Timer
switch harness
Note All harnesses should be cut to length
All exposed electrical connections should be
coated with protective grease
Note Wire must be inserted into fuse holder prior 7 Day Timer
to terminating
Exhaust Connection Intake Connection
A 24mm flexible tube exhaust pipe with a length no more than Combustion air must be drawn in from the outside The com
2 m long is required for the exhaust A 2730mm exhaust bustion air opening must be kept free at all times
clamp is needed to secure the exhaust to the the the exhaust as follows
Connect the air intake pipe to the intake port on the
heater and secure with clamp provided
Connect the exhaust pipe to the exhaust port on the
heater and attach with clamp provided
Caution Do not install the intake opening facing the
Run exhaust to an open area to the rear or side of the vehicle slipstream Ensure that the opening
vehicle so that fumes can not build up and enter the cannot become clogged with dirt or snow
passenger compartment or the heater combustion air intake and that any water entering the intake can
Install exhaust pipe with a slight slope or drill a small hole drain away
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
Air Intake Hose
End Sleeve
Exhaust
Clamp
Flexible Exhaust
Max 2m 78
Fire Hazard Asphyxiation Hazard
Warning The exhaust is hot keep a minimum Warning Route exhaust beyond the skirt of the
of 5cm 2 clearance from any heat cab and outside of the frame area
sensitive material Route exhaust so Failure to comply with this warning
that the exhaust fumes cannot enter could result in the passenger
Switches
A PushPull switch or a 7 Day Timer are available
7 Day Timer
The 7 day timer is capable of setting 1 start time with in 7
days It also has other functions such as a current time dis
play and a heater numeric fault code Refer to with timer for setting options
Mount timer and bracket in a suitable location
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 switch harness to timer as shown below
Refer to timer instructions for other wiring options
a Power from battery
b Switch control to the heater Note The timer display is automatically illuminated
while the heater is operating Connecting the
c Power from battery grey wire to the vehicle dimmer switch will
d Diagnostic from heater allow the timer display to illuminate with the
e To the vehicle dimmer switch for light display vehicles dash lights
f To vehicle ignition accessories for continuos operation Note Connecting the black wire to the vehicle igni
of heater tion accessories On circuit may also be
considered for some applications where
extended run times are desired Powering
the black wire will enable the heater to run
continuously when the heater is switched on
manually
Switch
Mount switch in a location where it is easily accessible
Mount using hardware supplied
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 shown
Note Wired as above the switch light glows when
pulled out and is off when pushed 31 Power from battery
Red K15 Power from battery Switch control to the Diagnostic from heater disregard tape
end and tie off to the Procedures Note If the heater fails to start the first time it will
Upon completion of installation prepare the heater as follows automatically attempt a second start If unsuc
cessful the heater will shut down completely
Check all fuel electrical and plumbing connections
Refill the engine coolant Note On initial start up the heater may require sever
Bleed air from the coolant system by loosening the bleed al start attempts to self prime the fuel system
screw on top of the heater to allow air to escape
Loosen Rad cap and run engine to allow air to be purged
Top up engine coolant
Running
Once ignition is successful the following Up
take place
Once switched on the following sequence occurs
Control unit does a systems check flame sensor Heater runs in high heat mode and the temperature is
temperature sensor safety thermal sensor and various monitored at the heat exchanger
other control unit checks Once coolant reaches 80C 185F the heater
Water pump starts circulating coolant fluid automatically switches to low heat mode and continues
Combustion air blower comes on to run
Glow pin begins to preheat 2050 secs If coolant temperature drops to 75C 167F the heater
Metering pump starts and combustion air blower speeds will automatically switch back to high heat mode
up gradually If the coolant temperature continues to rise the heater
Once ignition takes place the flame sensor alerts the will automatically switch off once temperature reaches
control unit and the control unit shuts off the glow pin 86C 187F
ignition time 15 2 minutes The water pump will continue to circulate coolant to allow
the heater to monitor engine temperature
The heater will automatically restart once coolant
temperature reaches 75C 167F
The heater continues to run as described above until it is
switched off either manually automatically by a timer or
heater malfunction shutdown
Note If the heater should shut down due to flame
out while in running mode it will automatical
ly attempt one restart If successful it will
continue to run If not it will shut down com
pletely with a cooldown cycle
Note During operation the heater continually sens
es the input voltage from the batteries If the
input voltage drops to approximately 10 volts
or rises above 16 volts the heater will auto
matically shut down with a cooldown Off
When the heater is switched off manually or
it starts a controlled cool down cycle
The fuel metering pump stops delivering fuel and the
flame is The combustion air blower and water pump continue to
run for 130 seconds to cool down
The heater shuts off
Safety Equipment
The control unit temperature sensor overheat sensor and
flame sensor continually monitor heater functions and will
shut down the heater in case of a The control unit ensures electrical circuits fuel pump
combustion air blower etc are complete prior to starting
the heater
If the heater fails to ignite within 90 seconds of the fuel
pump being started the starting procedure will be
repeated If the heater again fails to ignite after 90
seconds of fuel being pumped a no start safety
shutdown follows
If the heater flames out during operation the heater
automatically attempts to restart If the heater fails to
ignite within 10 seconds of fuel delivery or ignites but
flames out again within 3 minutes flame out shutdown
follows After the problem the heater can
be started again by switching the heater off and then back
on again
Overheating due to lack of water a restriction or a poorly
bled coolant system results in the overheat shutdown
Fuel delivery will cease and an overheat shut down fol
lows If heater overheats 3 consecutive times a lockout
on the control unit will occur To unlock the control unit
you will need to use the Fault Code Retrieval Device See
following pages for self If at any time the voltage drops below 102V or rises
above 159V a highlow voltage shutdown follows after
a 20 second delay
Warning The heater must be switched off while
any fuel tank on the vehicle is being
filled The heater must not be operat
ed in garages or enclosed areas
Flow Chart
Hydronic D4 SC 12 Volt
Model 25 1917 01
Wiring Harness PN CA1 60 401
Hydronic D4 SC 12 Volt
Model 25 2096 05
Wiring Harness PN CA1 60 503
Hydronic D5 SC 12 Volt
Model 25 1920 05
Wiring Harness PN CA1 60 401
D5 SC 12 Volt
Model 25 2098 05
Wiring Harness PN CA1 60 503
Hydronic D5 SC 24 Volt
Model 25 2147 05
Wiring Harness PN CA1 60 502001
Also applicable to
Hydronic 4 5 SC 12 volt
Gasoline 20 1789 05
Model 20 1791 05
5 S 12 24 volt Gasoline 25 2031 05
Model 25 2100 05
Model 20 1793 05
Model 25 2009 05
Maintenance Self Diagnostics
Check coolant hoses clamps and make sure all valves The heater is equipped with self diagnostic capability You
are open Maintain the engine manufacturers recommend can retrieve information on the heaters last 5 faults using the
ed coolant level and ensure that the heater is properly Espar 7day timer or Espar s Fault Code Retrieval Device
bled after service on or involving the coolant system
Visual check of all fuel lines for leaks Check and if 7Day Timer
necessary replace fuel filter inserts
Espars 7day timer has a fault
Visual check of electrical lines and connections for
code retrieval device built into the
corrosion
unit This function Run your heater at least once a month during the year activates if the heater is experi
for a minimum of 15 minutes encing problems
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 Fault codes appear on the LCD display screen
heater down Codes can then be translated from the charts on the
following pages
Use fuel suitable for the climate see engine manufactur
ers Blending used engine oil with
diesel fuel is not permitted Fault Code Retrieval Device
Check the glow pin and replace if necessary
Equipment Face and Symbols seen on the display
Basic face are as follows
In the event of failure there are several items which
should be checked first before any major AF Actual fault
is done Check
F1F5 Up to five stored faults can be accessed
Circuit breakers and fuses The AF and F1 are the same number
Electrical lines and connections This sign is displayed when the heater is in
operation
For interference in Combustion air and Exhaust pipes
DIAG The word Diagnostic will come on when the
That there is fuel in the tank
diagnostic number is requested
Battery voltage
000 Three digit diagnostic fault code number
Connect as shown on following page
Switch the fault code retrieval device on and wait
10 seconds
Press the D button
Wait 35 seconds for the current fault code to appear
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 26
Fault code retrieval device harness
PN CA1 05 028
Hook Up
Disconnect the main harness from heater and insert
adapter cable harness between them
Fault code retrieval device
Connect adapter cable to the cable loom of the Fault
PN CA1 05 020
code retrieval pump approx 20
Glow Pin approx 09
Checking the sensors
To check the sensors measure the resistance at current see following diagrams
Temperature sensor
Overheating sensor Flame sensor
3000
30 2750
2500
2250
20 2000
1750
1500
1250
1000
0 500
0 20 40 60 80 100 120 50 0 50 100 150 200 250 300 350 400 450 500 550
Temperature C Temperature C
R 2 open circuit R 3400 open circuit
R 50 short circuit R 50 short circuit
Fault Code Fault Description Causes Repair
000 Normal Overvoltage Check voltage between terminals 1red and 2brown at connector
B1 This must be less than 16 volts
Check battery electrical leads and vehicle charging system
011 Under voltage shut down Check voltage between terminals 1red and 2brown at
connector B1 This must be greater than 102 volts
Check battery electrical leads and vehicle charging system
012 Overheating Check for possible causes of overheat water circuit Sensor
Check overheat switch resistance values Temperature at
temperature sensor or overheat sensor is greater than 125C
014 Possible overheating detected Difference of measured values at temperature sensor 15C
difference evaluation min 70C water temperature and metering pump in operation
Check temperature sensor and overheating sensor
replace if necessary Check values from previous page
015 Too many overheats Remove cause of over heat Reset control unit using 7 day
timer or fault code retrieval device to unlock control unit Permanent
overheating counter reading exceeded Heating enable only
possiblef by means of diagnostics system press both LL keys
Overheating detected Temperature at tempaerature or overheating sensor 130 C
emergency OFF if Fault Code 012 or 014 not applicable check water
circuit check temperature sensor and overheating sensor replace if
necessary See graph on previous page
020 Open circuit glow pin Check glow pin and electrical leads for continuity replace if
Short circuit glow pin Check glow pin and electrical leads for continuity replace if
Combustion air blower motor Blower impeller or electric motor may be jammed frozen solid dirty
etc Fix jam replace electric motor if Combustion air blower motor Check lead to combustion air motor for continuity
replace
motor if Combustion air blower motor shortcircuit Check combustion air blower motor electric motor replace if
necessary Check power supply chafed corroded etc
038 Vehicle fan relay control break Check electric lead to relay fix break replace relay if necessary
For wiring harness PN CA1 60 401 without relay replace harness
039 Vehicle fan relay control short circuit Check electric lead to relay fix break replace relay if necessary
For wiring harness PN CA1 60 401 without relay replace harness
041 Water pump break Check supply lead to water pump for continuity remedy break
replace water pump if necessary
Fault Code Fault Description Causes Repair
042 Water pump shortcircuit Check supply lead to water pump for short circuit check water
pump replace water pump if Short circuit fuel metering pump Check for wires for short to fuel metering pump Test fuel
metering
pump Replace if Open circuit fuel metering pump Check supply lead to metering pump for continuity remedy break
replace if Too many no start attempts Safety time counter reading exceeded Reset control unit using 7
day timer or fault code retrieval device to unlock control unit
051 Faulty flame recognition At start if flame sensor is a above 70C 240 seconds check
exhaust gas and combustion air supply check flame sensor replace
if necessary For flame sensor values see graph on previous page
052 No start safety time exceeded No flame detected on start attempt Check fuel delivery and fuel
supply Check exhaust gas and combustion air ducts
053 Flame cutout in boost mode Heater has started successfully the flame has
Check fuel supply Check combustion air and exhaust flow Check
flame sensor resistance value Replace flame sensor if Flame cutout in high mode Heater has started successfully the
flame has Check fuel supply Check combustion air and exhaust flow
056 Flame cutout in low mode Check flame sensor resistance value
060 Open circuit temperature sensor Temperature sensor detects a value beyond its range
Check connections Check sensor resistance values between
11 and 12 at connector B2 2 M if open circuit
061 Short circuit external temperature sensor Check connections Check sensor resistance values between
11 and 12 at connector B2 50 if short circuit
Temperature sensor values on previous pages
064 Open circuit flame sensor Sensor is sensing value outside of range Check connection leads
Resistance values between 13 and 14 at connector
B2 3040 if open circuit
065 Short circuit flame sensor Check connection leads Resistance values between 13 and 14 at
connector B2 780 if short circuit Flame sensor values on
page 17
071 Open circuit overheat sensor Check connection leads Resistance values between 9 and 10 at
connector B2 2 M if open circuit
072 Short circuit overheat sensor Check connection leads Resistance values between 9 and 10 at
connector B2 50 M if short circuit
090 Control unit defect internal fault Control unit malfunction due to interference voltage from
092 Control unit defectiveROM error vehicle electrical system possible causes low batteries charges
093 Control unit defectiveRAM error other sources of interference eliminate interference voltages
Internal faults detected in memory detected
Replace control unit
097 Control unit defective power failure Internal failure Replace control unit
Fuel Quantity Test
The fuel Quantity should be tested if the heater has or maintaining a flame
Note Measure the fuel quantity when the battery is
sufficiently charged At least 11V and at
most 13V should be applied at the control
unit during Remove metering pump cover in the cases of SC ver
sions
Pull the fuel line off the combustion chamber and insert
into a graduated measuring glass
Switch the heater on when fuel delivery is uniform
40 seconds after switching on the fuel
line is full and bled
Switch heater off
Empty measuring glass and Switch heater on
Fuel delivery stars automatically approximately 40
seconds after switching on
Hold the graduated measuring glass at the glow pin
height during measurement
After 90 seconds of fuel delivery it will shut off
Switch heater off
Read off quantity of fuel delivery in the graduated
measuring value Diesel D4W SC Hydronic D5W SC Hydronic B4W SC Hydronic B5W SC
77 cm3 90 seconds 86 cm3 90 seconds 107 cm3 90 seconds 120 cm3 90 seconds Max
67 cm3 90 seconds 75 cm3 90 seconds 93 cm3 90 seconds 105 cm3 90 seconds Min
If measured quantity of fuel is over or under the the metering pump must be replaced or fuel
Repair Steps covered are for the Hydronic 4 5 SC versions other models are Assembly
7 Flame sensor
1 Cover metering pump
8 Cable harness
2 Water pump assembly
9 Electric motor complete
3 Metering pump and bracket
10 Combustion chamber with flame tube
4 Cover blower
11 Heat exchanger and jacket
5 Control unit and cover
6 Glow pin
1 Cover metering pump 4 Cover blower
2 Water pump assembly When mounting place Orings
on connection on water pump housing 5 Control unit and cover
3 Metering pump and bracket 6 Glow pin
7 Flame sensor For removal of tab receptacles use
AMP extractor tool 10 Combustion chamber with flame tube
11 Heat exchanger and jacket Align slot on heat
8 Cable Harness exchanger arrow with lug in jacket
9 Electric motor complete
Parts Diagram Hydronic D4 D5 SC 12 24 volt Diesel Gasoline 25 1917 01 Model 25 2098 05
Model 25 2096 05 Model 20 1791 05
Model 25 20 1789 05 Model 22 2147 05
Model 25 1920 05
Model s
HYDRONIC 4 5 SC diesel gasoline Part s
Ref No Description Part Number
1 Outer casing 25 1917 01 01 01
25 1920 01 01 01
25 1922 01 01 01
2 Combustion air blower with cover 25 1917 99 15 00
20 1759 99 15 00
25 1922 99 15 00
25 2013 99 15 00
20 1774 99 15 00
25 2146 99 15 00
3 Cover 25 1917 01 00 02
25 2137 01 00 02
4 Burner 20 1752 10 00 00
20 1759 10 00 00
5 Burner 25 1917 19 00 00
25 1920 10 00 00
25 2146 10 00 00
6 Heat exchanger 25 1864 06 00 01
25 1922 06 00 01
7 Control unit 25 1917 51 00 04
25 1917 55 00 01
22 5201 00 20 01
22 5201 00 20 04
22 5201 00 10 01
22 5201 00 30 01
22 5202 00 10 03
8 Cover not available as a spare part 25 1752 99 01 03
9 Water pump 25 1917 99 25 00
25 1920 25 00 00
25 2096 25 00 00
25 2118 25 00 00
10 Fuel metering pump 25 1917 45 00 00
25 1920 45 00 00
25 1942 45 00 00
11 Strainer 20 1312 00 00 06
12 Holder for fuel metering pump 25 1917 01 00 07
13 Seal gasket 25 1864 99 00 21
20 1752 99 01 01
14 Oring 320 75 104
15 Glow pin 25 1864 01 10 00
25 2107 01 10 00
16 Glow pin connection 20 1752 01 10 00
17 Lining and 2 Orings 20 1752 99 01 02
18 Plug connection complete 25 2147 01 13 00
19 Holder 20 1752 01 00 04
20 Sleeve 20 1752 01 00 02
Model s
HYDRONIC 4 5 SC diesel gasoline Part s
Ref No Description Part Number
21 Flame sensor 25 1864 35 00 00
25 1920 35 00 00
22 Overheat and temperature sensors with cable section 25 1917 01 17 00
including glow plug connector and main connector 25 1920 01 17 00
22a 20 1753 01 17 00
25 2147 01 20 00
23 Control unit plug waterproof complete 22 1000 30 10 10
24 Cable section for glow plug 25 1922 01 18 00
25 1920 01 18 00
25 Cable section water pump 20 1752 01 18 00
20 1753 01 18 00
26 Spring leaf 25 1864 01 00 05
25 1922 01 00 05
27 Cover fuel metering pump 25 1917 01 00 03
20 1752 01 00 03
28 Oring for coolant barbs 14 x 26 320 75 119
29 Oring for sensors 75 x 2 320 75 111
30 Fuel hose 25 1917 01 00 11
31 Hose clip 209 31 071
32 Bleed screw 25 1917 25 00 12
33 Bleed screw washer Hardware
34 Tapite screw 109 10 104
35 Spring washer 171 22 112
36 Hexagon nut 110 10 024
37 Sleeve 25 1917 01 00 05
38 Grommet 20 1752 01 00 05
39 Hex bolt M5x35 109 10 027
40 Hex bolt M5x25 109 10 102
41 Bolt 100 10 300
42 Hex bolt M5x16 109 10 101
43 Tapite screw M4x10 109 10 100
44 Counter sunk screw 102 10 400
45 Rubber boots 320 31 120
46 Plastic protective dust cover CA0 00 073
47 Cable tie Hardware
Parts D4 D5 43
4 7 18
3 19
17 26
9 16
8 16
27 34
11 46
38 35
20 21 36
13 39
8 15
12 8
8 14 9
9 32
8 29
22 48
23 49 30
31 25
9 24
Model s
HYDRONIC 4 5 SC diesel gasoline Part s
Ref No Description Part Number
1 Tpiece 20mm 20 1673 80 11 00
2 Connecting pipe 20 1534 88 00 01
3 Clamp 20mm32mm 10 2065 02 00 32
4 Hose 25 1917 80 00 01
5 15m white plastic fuel line 090 31 118
6 Rubber mount 20 1185 00 00 01
7 Heater bracket 25 1864 80 00 01
8 Hose clamp 9mm 10 2063 00 90 98
9 Fuel hose 35mm 360 75 300
10 Bracket class 8 truck CA0 10 085
11 Fuel line 2mm 090 31 117
12 Pipe clamp 10mm 152 00 147
13 Fuel pipe reducer CA0 12 092
14 Fuel pick up pipe 2mm ID CA0 12 056
15 Main heater harness CA1 60 401
CA1 60 503
CA1 60 502001
25 1917 80 10 00
16 Exhaust clamp 2730mm ID 152 61 102
17 Intake hose clamp 10 2064 01 60 25
18 C clamp 28mm 152 10 051
19 End sleeve for exhaust 25 1729 80 06 00
20 Exhaust hose 360 61 299
21 Air intake hose 360 00 099
22 Compression fitting 14 NPT CA0 12 044
38 NPT CA0 00 031
12 NPT CA0 12 005
23 Custom straight pick up pipe 16 length CA0 00 030
24 length CA0 12 053
24 Replacement bulb 12V 207 00 005
24V 207 00 006
25 Pushpull switch 12V CA1 00 003
24V CA1 00 004
26 Muffler 25 1864 81 01 00
27 Muffler clamp 20 1533 88 00 07
28 Relay 12V 203 00 093
24V 203 00 092
29 Harness adapter for 7 day timer CA1 60 008001
30 7 day timer bezel 25 1482 70 01 00
Model s
HYDRONIC 4 5 SC diesel gasoline Part s
Ref No Description Part Number
31 7 day timer 22 1000 30 36 00
7 day timer with kit harness relay CA1 00 135
7 day timer with kit harness relay CA1 00 136
32 Bracket for 7 day timer CA0 10 061
33 Fault code retrieval device CA1 05 020
34 Main fuse holder CA1 07 001
35 Fuse blade 204 00 089
CA1 07 005
36 Wire awg 12 gage red CA1 61 908
37 Retrieval harness for fault code device CA1 05 028
38 Ring terminal 38 awg 1012 CA1 90 014
39 Fuse link power harness CA1 65 108
40 Double pickup used with combo kits CA0 12 057001
41 Spacer 25 1864 80 00 02
42 Screw CA3 00 103
43 Replacement hardware kit CA1 00 190
44 Cross frame mounting bracket CA0 10 028
45 Hydronic box Base CA0 10 101
Hydronic box Lid CA0 10 102
46 Plug Cables Complete 22 1000 30 10 21
47 Fuel metering pump 20 1645 45 00 00
25 1942 45 00 00
48 Boot sleeve 320 31 120
49 Fuel metering pump holder 22 1000 50 03 00
50 Fuel filter 22 4502 00 01 00
Parts Diagram Hydronic D4 D5 S 12 24 volt Diesel Gasoline 20 1793 05
Model 25 2009 05
Model 25 2031 05
Model 25 2100 05
Model s
HYDRONIC 4 5 SC diesel gasoline Part s
Ref No Description Part Number
1 Casing 25 1922 01 01 01
2 Combustion air blower with cover 25 1922 99 15 00
25 1922 99 16 00
25 1942 99 15 00
20 1759 99 15 00
3 Cover 20 1756 01 00 03
25 1864 01 00 04
4 Burner 20 1759 10 00 00
4a 25 1922 10 00 00
5 Heat exchanger 25 1922 06 00 01
6 Control unit 25 1917 55 00 08
25 1942 50 00 02
22 5201 00 30 02
22 5201 00 20 04
6a Water proof plug 22 1000 30 10 10
7 Cover 20 1756 99 01 02
8 Heater cover plate 25 1922 01 00 02
9 Seal 20 1752 99 01 01
25 1864 99 00 21
10 Oring 25 1864 99 00 23
11 Glow plug 12V 25 1864 01 10 00
24V 25 1816 01 01 00
12 Lining 2 orings 20 1752 99 01 02
13 Flame sensor 25 1920 35 00 00
14 Holder 20 1752 01 00 04
15 Nipple 25 1942 01 00 02
16 Cable section 25 1922 01 18 00
17 Cable section 25 1942 01 20 00
18 Cable section 25 2009 01 15 00
19 Spring 25 1922 01 00 05
20 Oring 7x2 25 1864 99 00 30
21 Sleeve 20 1756 01 00 04
22 Sleeve NA
23 Tapite Screw 25 1864 99 00 24
24 Spring washer 171 22 112
25 Hexagon nut 110 10 024
26 Tapite screw 25 1864 99 00 28
27 Cheese head screw 25 1864 99 00 26
28 Tapite screw 25 1864 99 00 29
29 Tapite screw 25 1864 99 00 27
30 Counter sunk screw 25 1864 99 00 25
31 Plug connection 20 1756 01 10 00
Parts D4 D5 accessories
Model s
HYDRONIC 4 5 SC diesel gasoline Part s
Ref No Description Part Number
1 Holder 25 1864 80 00 01
2 Washer 25 1864 80 00 02
3 Metal rubber buffer 20 1185 00 00 01
4 Flexible tubing 360 00 099
5 End sleeve 25 1688 80 12 01
6 Hose clip 10 2064 01 60 25
7 Hose 25 1774 80 02 00
8 Flexible spiral tubing 360 61 299
9 End sleeve 25 1729 80 06 00
10 Exhaust muffler 25 1864 81 01 00
11 Pipe clip 152 61 102
12 Pipe clip 152 10 051
13 Clamp 20 1533 88 00 07
14 Water pump 12V 330 00 012
14a 24V 25 2009 25 00 00
15 Coolant hose 25 1917 80 00 01
16 Connection piece 20 1534 88 00 01
17 Connection piece 20 1645 89 00 06
18 Hose clip 10 2064 02 00 32
19 Fastening clip 152 00 101
20 Bracket with holes 20 1568 88 00 02
21 Bottom section of fuse casing 204 31 004
22 Cover 204 31 005
23 Fuse 25 amp 204 00 089
24 Fuse 20 amp 204 00 087
25 Fuse 15 amp 204 00 081
26 Fuse 5 amp 204 00 079
27 Twin leafspring contact 206 73 058
28 Twin leafspring contact 206 00 199
29 Eyelet Hardware
30 Eyelet Hardware
31 Sleeve 320 31 120
32 Screw 108 10 318
33 Cable harness 25 2009 80 10 00
25 1917 80 10 00
34 Cable tie 25 1801 80 02 00
35 Cable 20 1668 80 05 00
36 Hose 360 75 300
37 Hose clip 10 2063 00 90 98
Model s
HYDRONIC 4 5 SC diesel gasoline Part s
Ref No Description Part Number
38 Fuel metering pump 12V 20 1645 45 00 00
24V 25 1942 45 00 00
39 Metering pump holder 22 1000 50 03 00
40 Relay 12V 203 00 065
24v 203 00 066
41 Fuel line 090 31 118
1st Printing July 1999
Printed in Canada
PN Espar Products Inc
6435 Kestrel Road
Mississauga Ontario
Canada L5T 1Z8
9675 Harrison Rd
Suite 102
Romulus Michigan
48174
Canada Tel 9056700960
8006685676
Fax US Tel a Member of the Eberspcher Group of Companies

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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.