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



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Hydronic 45 Coolant Parts ManualHeater Model 12 V Heater Model 24 V EsparHydronic D4 SC 25 1917 01 Hydronic D5 SC 25 2147 05 25 2096 05 Hydronic D5 S 25 2009 05Hydronic B4 SC 20 1789 05Hydronic D5 SC 25 1920 05 25 2098 05Hydronic D5 S 25 2031 05 25 2100 05Hydronic B5 SC 20 1791 05Hydronic B5 S 20 1793 05 PN 6101210201 January 2001Table of Contents Heater Warnings 3 Introduction 4 Specifications 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 8Installation Heater Location 8Procedures Heater Mounting 9 Heater Plumbing 10 Fuel System 11 Electrical Connections 13 ExhaustIntake Connections 14 Operating Switches 15Heater 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 24Maintenance Periodic Maintenance Basic 25Repairs Self Diagnostic 25 Chart 26 Fuel Quantity Test 29 Heater Disassembly Repair Steps 30Heater Components Parts Diagram Scope 32 Description Part s 33 Parts Accessories Diagram Scope 35 Description Part s 36Special Notes Note Highlight areas requiring special attention or clarification Caution Indicates that personal injury or damage to equipment may occur unless specific guidelines are followed Warning Indicates that serious or fatal injury may result if specific guidelines are not followed 3Heater 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 18003874800 bustible fumes may be present CANADA 18006685676 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 compartments If running exhaust components through an enclosed compartment ensure that it is vented to the outside Warning Safety Hazard on Coolant Heaters Used With Improper Antifreeze Mixtures The use of Espar coolant heaters requires that the coolant in the system to be heated 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 HeaterQuality engineered to provide a dependable means of heating the Espar Hydronic 45 is a diesel fired coolant heatercapable of 4 16 kW to 4 kWhr 5500 to 13700 BTUhrHydronic 5 24 kW to 5 kWhr 8200 to 17100 BTUhrThis compact coolant heater offers an affordable to many applications The Hydronic 45 is ideal forpreheating the engines of trucks cars offroad equipmentsmall trucks and boats It features automatic heat being fuel and power efficient Since the heater runs onfuel and 12 or 24 volt power it is able to perform this completely independently of the vehicle engine The unit regulates the coolant temperature between a low of 65C 149Fand a high of 80C 176F by automatically cycling theheaterThe Hydronic 45 can be operated from the vehicle cab by anonoff switch a preselect timer or a combination of bothA Flame sensor temperature regulating sensor and overheatsensor are among the safety features which makes theHydronic D4D5 a safe and dependable heating Hydronic 4 Hydronic 5Heat 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 voltCurrent draw 10 43 amps Boost 30 amps High 416 amps High 208 amps High 20 amps Low 191 amps Low 095 amps LowFuel 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 LowOperating Voltage Range Minimum Voltage 10 V 10 V 204 V Maximum Voltage 16 V 16 V 320 VWorking pressure 25 bar 36 psi 25 bar 36 psiAmbient operating temperature 40C to 80C 40F to 176F 40C to 80C 40F to 176FOverheat temperature shutdown 5 105C 221F 105C 221FWeight 25 kg 55 lbs 29kg 64lbsControls 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 5Heater 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 Interface8pin connector 7 Temperature sensor 16 Bleed screw 8 Overheat temperature sensor 17 PushPull switch 9 Control unit 18 7day timer 6Heater Components Hydronic 5 SC 24 volt version Diesel 25 2147 05Heater Components Hydronic 4 5 SC 12 volt version Gasoline 20 1789 05 20 1791 05 7Heater 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 Interface8pin connector 7 Temperature sensor 16 Bleed screw 8 Overheat temperature sensor 17 PushPull switch 9 Control unit 18 7day timer 8 Principal Dimensions Hydronic D4D5 SC values in brackets D4SC All measurements in millimeters 254mm 1Heater LocationMount the heater in a protected area if youre in extreme Caution Guard the heater against excessive roadconditions where heavy salting is experienced spray to avoid internal corrosionEg storage compartment engine compartments step box orbattery boxEspar recommends you use the boxed unit Boxed heaterscan be mounted by utilizing one of the existing brackets Seefollowing pageIf mounting on frame rail use an optional Espar Inside framebracket to mount to inside of frame rails Heaters can also bemounted on a cross tray behind the cab and on top ofthe frame railsWhen mounting the heater adhere to thefollowing conditions Situate the heater below the normal coolant level of the engine Guard against excessive road spray Keep coolant hoses fuel lines and electrical wiring as short as possible For Illustration purposes only 9Heater MountingMount heater in saddle bracket and secure with hardware Hydronic D4 SC boxed unit PN CA 2096 55provided If heater is not a boxed unit mount bracket onto Hydronic D5 SC boxed unit PN CA 2098 55inside frame rail bracket Boxed unit can also be secured tothe inside frame bracket or mounted to the Cross frameMounting Tray Cross Frame Mounting Tray Hydronic 45 box Inside frame mounting bracketInside framemounting Heater Spacer and screwSaddle bracket Saddle bracketInside frame railFor S and gasoline version heaters which have externalfuel 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 10Heater PlumbingThe heater is incorporated into the engines cooling system Engine Radiatorfor engine PlumbingFollow these guidelines and refer to engine plumbing diagram 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 distribution 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 11Fuel System Fuel LineThe Hydronic water heaters typically have the fuel metering Route fuel lines from the fuel pickup pipe to the heaterpump mounted inside the unit This is to reduce installation Use fuel lines providedtime and to protect the pump from corrosion Some versionshave an external fuel metering pump Refer to graphics for Other sizes or types of fuel lines may inhibit proper and specifications flowAll parts necessary to do the installation are included in the Make proper butt joints using clamps and connectorkit 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 usedFuel System Tolerances1 Fuel PickUp Pipe2 Fuel Pipe Reducer3 9mm Clamp4 35mm Rubber Connector5 20mm White Plastic Fuel Line6 Fuel Metering Pump Hydronic Heater7 15m White Plastic Fuel Line 6 4 3 Max 2 M 66 5 Max 76cm 26 2 4 3 1 Max 6 M 198 4 Max 2 M 65 4 7 3 4 3 6 3 Max 2 M 66 5 Max 76cm 26 2 4 3 1 12Fuel 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 available 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 14 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 Nut 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 13Electrical ConnectionsAll parts needed are included with the kit indicates external mounted fuel and or water pump versions of HydronicsA Main Heater Harness Connects switch and power harness to the heater harness in some cases power to fuel metering pump B Power Harness 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 fuseC Switch Harness 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 pagesD Fuel Metering Pump Harness 2 core harness green green Connect to fuel metering pump using single terminals and rubber protective boots no polarity requiredE Water Pump Harness 2 core harness black brown Connect to main harness at heaterHydronic Heaters Caution To avoid potential short circuit damage during installation insert 25 amp fuse on power harness after all electrical connections are complete E A D C B 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 14Exhaust Connection Intake ConnectionA 24mm flexible tube exhaust pipe with a length no more than Combustion air must be drawn in from the outside The com2 m long is required for the exhaust A 2730mm exhaust bustion air opening must be kept free at all timesclamp is needed to secure the exhaust to the the heaterConnect 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 Asphyxiation the passenger compartment 15Operating SwitchesA PushPull switch or a 7 Day Timer are available7 Day TimerThe 7 day timer is capable of setting 1 start time with in 7days It also has other functions such as a current time display 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 16PushPull 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 inControl WiringPushPull SwitchBrown 31 Power from battery Red K15 Power from battery Yellow15K Switch control to the Diagnostic from heater disregard tape end and tie off to the sideHeater Procedures Note If the heater fails to start the first time it willUpon 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 placeOnce 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 17 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 cycleSwitching Off When the heater is switched off manually or automatically it starts a controlled cool down cycle The fuel metering pump stops delivering fuel and the flame is extinguished The combustion air blower and water pump continue to run for 130 seconds to cool down The heater shuts offSafety EquipmentThe control unit temperature sensor overheat sensor andflame sensor continually monitor heater functions and willshut down the heater in case of a malfunction 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 diagnostics 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 18Operational Flow Chart 19Hydronic D4 SC 12 VoltModel 25 1917 01Wiring Harness PN CA1 60 401 20Hydronic D4 SC 12 VoltModel 25 2096 05Wiring Harness PN CA1 60 503 21Hydronic D5 SC 12 VoltModel 25 1920 05Wiring Harness PN CA1 60 401 22Hydronic D5 SC 12 VoltModel 25 2098 05Wiring Harness PN CA1 60 503 23Hydronic D5 SC 24 VoltModel 25 2147 05Wiring Harness PN CA1 60 502001Also applicable toHydronic 4 5 SC 12 voltGasoline versionsModel 20 1789 05Model 20 1791 05 24Hydronic 5 S 12 24 volt versionsDiesel Gasoline versionsModel 25 2031 05Model 25 2100 05Model 20 1793 05Model 25 2009 05 25Maintenance 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 automatically 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 automatically 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 displayBasic face are as followsIn the event of failure there are several items whichshould be checked first before any major AF Actual faultis 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 Instructions 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 AF To review the previous faults use the arrow buttons F1 Most Recent F5 Oldest To erase the faults that are in memory press both L keys at the same time See the fault code chart on following pages for code number descriptions 26 Fault code retrieval device harness PN CA1 05 028Hook 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 deviceTest pump approx 20 Glow Pin approx 09 Checking the sensorsTo check the sensors measure the resistance at current temperature see following diagrams Temperature sensor Overheating sensor Flame sensor 35 3000 30 2750 2500 25 2250 20 2000 1750 15 1500 1250 10 1000 5 750 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 27Fault Code Fault Description Causes Repair000 Normal Operation010 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 system011 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 system012 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 125C014 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 page015 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 page020 Open circuit glow pin Check glow pin and electrical leads for continuity replace if necessary021 Short circuit glow pin Check glow pin and electrical leads for continuity replace if necessary030 Combustion air blower motor Blower impeller or electric motor may be jammed frozen solid dirty etc Fix jam replace electric motor if necessary031 Combustion air blower motor Check lead to combustion air motor for continuity replace motor if necessary032 Combustion air blower motor shortcircuit Check combustion air blower motor electric motor replace if necessary Check power supply chafed corroded etc038 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 harness039 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 harness041 Water pump break Check supply lead to water pump for continuity remedy break replace water pump if necessary 28Fault Code Fault Description Causes Repair042 Water pump shortcircuit Check supply lead to water pump for short circuit check water pump replace water pump if necessary047 Short circuit fuel metering pump Check for wires for short to fuel metering pump Test fuel metering pump Replace if necessary048 Open circuit fuel metering pump Check supply lead to metering pump for continuity remedy break replace if necessary050 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 unit051 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 page052 No start safety time exceeded No flame detected on start attempt Check fuel delivery and fuel supply Check exhaust gas and combustion air ducts053 Flame cutout in boost mode Heater has started successfully the flame has extinguished Check fuel supply Check combustion air and exhaust flow Check flame sensor resistance value Replace flame sensor if necessary054 Flame cutout in high mode Heater has started successfully the flame has extinguished Check fuel supply Check combustion air and exhaust flow056 Flame cutout in low mode Check flame sensor resistance value060 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 circuit061 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 pages064 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 circuit065 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 17071 Open circuit overheat sensor Check connection leads Resistance values between 9 and 10 at connector B2 2 M if open circuit072 Short circuit overheat sensor Check connection leads Resistance values between 9 and 10 at connector B2 50 M if short circuit090 Control unit defect internal fault Control unit malfunction due to interference voltage from092 Control unit defectiveROM error vehicle electrical system possible causes low batteries charges093 Control unit defectiveRAM error other sources of interference eliminate interference voltages Internal faults detected in microprocessor memory detected Replace control unit097 Control unit defective power failure Internal failure Replace control unit 29Fuel Quantity TestThe 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 approximately 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 automatically 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 SC77 cm3 90 seconds 86 cm3 90 seconds 107 cm3 90 seconds 120 cm3 90 seconds Max67 cm3 90 seconds 75 cm3 90 seconds 93 cm3 90 seconds 105 cm3 90 seconds MinIf measured quantity of fuel is over or under the nominalvalue the metering pump must be replaced or fuel 30Repair Steps covered are for the Hydronic 4 5 SC versions other models are Assembly 7 Flame sensor1 Cover metering pump 8 Cable harness2 Water pump assembly 9 Electric motor complete3 Metering pump and bracket 10 Combustion chamber with flame tube4 Cover blower 11 Heat exchanger and jacket5 Control unit and cover6 Glow pin1 Cover metering pump 4 Cover blower2 Water pump assembly When mounting place Orings on connection on water pump housing 5 Control unit and cover3 Metering pump and bracket 6 Glow pin 317 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 heat8 Cable Harness exchanger arrow with lug in jacket9 Electric motor complete 32Parts Diagram Hydronic D4 D5 SC 12 24 volt Diesel Gasoline versionsModel 25 1917 01 Model 25 2098 05Model 25 2096 05 Model 20 1791 05Model 25 20 1789 05 Model 22 2147 05Model 25 1920 05 33 Model sHYDRONIC 4 5 SC diesel gasoline Part sRef 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 34 Model sHYDRONIC 4 5 SC diesel gasoline Part sRef No Description Part Number21 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 35Parts D4 D5 accessories 43 1 42 2 41 3 6 4 7 18 3 19 6 8 17 26 9 16 5 8 16 27 34 16 11 46 38 35 20 21 36 13 39 8 15 12 8 28 8 14 9 9 32 8 29 22 48 47 23 49 30 31 25 50 40 8 9 24 8 37 11 10 33 45 44 36 Model sHYDRONIC 4 5 SC diesel gasoline Part sRef 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 37 Model sHYDRONIC 4 5 SC diesel gasoline Part sRef No Description Part Number31 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 38Parts Diagram Hydronic D4 D5 S 12 24 volt Diesel Gasoline versionsModel 20 1793 05Model 25 2009 05Model 25 2031 05Model 25 2100 05 39 Model sHYDRONIC 4 5 SC diesel gasoline Part sRef 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 NA23 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 40Parts D4 D5 accessories 41 Model sHYDRONIC 4 5 SC diesel gasoline Part sRef 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 42 Model sHYDRONIC 4 5 SC diesel gasoline Part sRef No Description Part Number38 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 1999Printed in CanadaPN 6101210201 Espar Products Inc 6435 Kestrel Road Mississauga Ontario Canada L5T 1Z8 9675 Harrison Rd Suite 102 Romulus Michigan 48174 USA Canada Tel 9056700960 8006685676 Fax 9056700728 US Tel 8003874800 a Member of the Eberspcher Group of Companies

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