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Hydronic 4/5 (Coolant Heaters)
Installation  Troubleshooting  Parts Manual




Heater Model 12 V                  Heater Model 24 V
                                                                    Espar
Hydronic 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




  P/N 610-121-0201                                                  January 2001
Table of Contents                                                                                                                              Page



Introduction              Heater Warnings                                           ........................................................     3
                          Introduction                                              ........................................................     4
                          Specifications                                            ........................................................     4
                          Heater Components
                          Hydronic 4/5 SC, 12 volt, Diesel                          ........................................................     5
                          Hydronic 5 SC, 24 volt, Diesel                            ........................................................     6
                          Hydronic 4/5 SC, 12 volt, Gasoline                        ........................................................     6
                          Hydronic 5 S, 12 + 24 volt, Diesel + Gas                  ........................................................     7
                          Principal Dimensions                                      ........................................................     8


Installation              Heater Location                                           ........................................................     8
Procedures                Heater Mounting                                           ........................................................     9
                          Heater Plumbing                                           ........................................................     10
                          Fuel System                                               ........................................................     11
                          Electrical Connections                                    ........................................................     13
                          Exhaust/Intake Connections                                ........................................................     14
                          Operating Switches                                        ........................................................     15


Heater Operation          Pre-Start Procedures                                      ........................................................     16
                          Start-Up                                                  ........................................................     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                ........................................................     24


Maintenance,              Periodic Maintenance                                      ........................................................     25
Troubleshooting &         Basic Troubleshooting                                     ........................................................     25
Repairs                   Self Diagnostic Troubleshooting                           .......................................................      25
                          Troubleshooting 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 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.
                                                                    3


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 re-fueling.
   Do not install heater in enclosed areas where com-                  USA              1-800-387-4800
    bustible fumes may be present.                                      CANADA           1-800-668-5676
   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 heater's
    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 and/or 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-
    turer's recommendations for your specific requirements.                tions without prior notice.
                                                                    4


Introduction

Espar's Hydronic D4/D5 Heater

Quality engineered to provide a dependable means of heat-
ing, the Espar Hydronic 4/5 is a diesel fired coolant heater
capable of between

Hydronic 4 - 1.6 kW to 4 kW/hr (5,500 to 13,700 BTU/hr).
Hydronic 5 - 2.4 kW to 5 kW/hr (8,200 to 17,100 BTU/hr).

This compact coolant heater offers an affordable heating
solution to many applications. The Hydronic 4/5 is ideal for
pre-heating the engines of trucks, cars, off-road equipment,
small trucks and boats. It features automatic heat regulation
while 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 the
heater.

The Hydronic 4/5 can be operated from the vehicle cab by an
on/off switch, a preselect timer or a combination of both.

A Flame sensor, temperature regulating sensor and overheat
sensor are among the safety features which makes the
Hydronic D4/D5 a safe and dependable heating system.




Specifications                                 Hydronic 4                         Hydronic 5


Heat output (10%)                             4 kW (13,700 BTU/hr) - Boost
                                               3.3 kW (11,300 BTU/hr - High       5 kW (17,000 BTU/hr) - High
                                               1.6 kW (5,500 BTU/hr - Low         2.4 kW (8,200 BTU/hr) - Low
                                                                                  12 volt            24 volt
Current draw (10%)                            4.3 amps Boost
                                               3.0 amps High                      4.16 amps High 2.08 amps High
                                               2.0 amps Low                       1.91 amps Low 0.95 amps Low
Fuel consumption (10%)                        0.51 l/hr (0.13 US gal/hr) Boost
                                               0.40 l/hr (0.11 US gal/hr) High    0.62 l/hr (0.16 US gal/hr) High
                                               0.20 l/hr (0.05 US gal/hr) Low     0.27 l/hr (0.08 US gal/hr) Low
Operating Voltage Range
   Minimum Voltage                             10 V                               10 V               20.4 V
   Maximum Voltage                             16 V                               16 V               32.0 V
Working pressure                               2.5 bar (36 psi)                   2.5 bar (36 psi)
Ambient operating temperature                  -40C to +80C (-40F to 176F)    -40C to +80C (-40F to 176F)
Overheat temperature shutdown (5%)            105C (221F)                      105C (221F)
Weight                                         2.5 kg. (5.5 lbs.)                 2.9kg. (6.4lbs)
Controls available                             On/Off switch or 7-day timer       On/Off switch or 7-day timer




   Note:    The heater is equipped with a high-voltage
             cutout as well a low-voltage cutout.
                                                             5



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   Fuel-metering pump
                 4     Combustion chamber                         13   Coolant pump
                 5     Glow pin                                   14   Main fuse
                 6     Flame sensor                               15   Interface/8-pin connector
                 7     Temperature sensor                         16   Bleed screw
                 8     Overheat temperature sensor                17   Push/Pull switch
                 9     Control unit                               18   7-day timer
                                                          6



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
                                                         7



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   Fuel-metering pump
                   4   Combustion chamber                    13   Coolant pump
                   5   Glow pin                              14   Main fuse
                   6   Flame sensor                          15   Interface/8-pin connector
                   7   Temperature sensor                    16   Bleed screw
                   8   Overheat temperature sensor           17   Push/Pull switch
                   9   Control unit                          18   7-day timer
                                                                     8



      Principal Dimensions - Hydronic D4/D5 SC (values in brackets* = D4SC)




                                                                          * All measurements in millimeters
                                                                            25.4mm = 1"




Heater Location

Mount the heater in a protected area if you're in extreme                Caution:      Guard the heater against excessive road
conditions 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 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
                                                                9


Heater Mounting


Mount heater in saddle bracket and secure with hardware             Hydronic D4 SC boxed unit P/N CA 2096 55
provided. If heater is not a boxed unit, mount bracket onto         Hydronic D5 SC boxed unit P/N CA 2098 55
inside frame rail bracket. Boxed unit can also be secured to
the inside frame bracket or mounted to the Cross frame
Mounting Tray

     Cross Frame Mounting Tray
     Hydronic 4/5 box
      Inside frame mounting bracket




Inside frame
mounting bracket

Hydronic
Water Heater

                                            Spacer and screw

Saddle bracket

                                                                    Saddle bracket
Inside frame rail




For "S" and gasoline version heaters which have external
fuel metering pumps

   Choose a protected mounting location close to the fuel
    pick-up 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.
                                                                   10


Heater Plumbing

The heater is incorporated into the engine's cooling system                                Engine                         Radiator
for engine preheating

Engine Plumbing
Follow 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 pick-up and returns.
 If possible, use shut off valves to ensure the system can
  be isolated from the engine when not in use.
 Provide 20mm (3/4") hose barbs for hose connections.                                                      Shut-off valves
 Use 20mm (3/4") 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 engine's 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.
                                                                     11


Fuel System                                                                   Fuel Line

The Hydronic water heaters typically have the fuel metering                    Route fuel lines from the fuel pick-up pipe to the heater.
pump mounted inside the unit. This is to reduce installation
                                                                               Use fuel lines provided.
time 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 fuel
connections and specifications.                                                 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 connections.

Note:     Fuel line limits must not be exceeded.
          Ensure that the following conditions are met.
          Hydronic heater must be within a height of 76cm
          (2'6") from the bottom of the fuel pick-up pipe.
          Fuel-metering pump must be within a total
          distance of 200 cm (6'6") from the fuel pick-up pipe.
          If the above conditions cannot be met, a heater
          with external fuel metering pump must be used.




Fuel System Tolerances

1.   Fuel Pick-Up Pipe
2.   Fuel Pipe Reducer
3.   9mm Clamp
4.   3.5mm Rubber Connector
5.   2.0mm White Plastic Fuel Line
6.   Fuel Metering Pump                                                                                     Hydronic Heater
7.   1.5m White Plastic Fuel Line
                                                                                                                         6

                                                                                      4

                                                                                      3
                                         Max. 2 M (6'6")
                                                                5
             Max. 76cm (2'6")        2        4

                                              3


                              1
                                                                                                  Max. 6 M (19.8')
                                                                                                                     4
                                                                 Max. 2 M (6.5')             4
                                                                                                       7      3
                                                                          4
                                                                                              3
                                                                                      6
                                                                          3
                                          Max. 2 M (6'6")
                                                            5
                  Max. 76cm (2'6")   2    4

                                          3


                               1
                                                                     12


Fuel Pick-Up Pipe Installation (Standard Pick-Up)

 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 pick-up pipe
  as shown.
 Cut the fuel pick-up pipe to length. Allow 2-2.5" from bot-
  tom of tank.
 Mount the fuel pick-up pipe as shown
 Lower the fuel pick-up pipe (with reinforcing washer) into the
  tank using the slot created by the two 0.6cm (1/4") holes.
 Lift the assembly into position through the 2.5cm (1") hole.
 Assemble the rubber washer, metal cup washer and nut.




                                    2.5cm (1.0")



                                    0.625 cm (2 Holes)
                                   ( 1/4")



                                                                          Double pick ups (used with combo kits)


                                                                           Double NPT pipe.
        1.5 cm    1.5 cm
                                                                            P/N: CA0 12 107
        (9/16")   (9/16")

   Note:    Drill the two (1/4") holes first.




                                       Fuel Pick-Up Pipe reducer

                                       Fuel Pick-Up Pipe

                                       Nut

                                       Sheet Metal Washer
                                                                          ( Optional Pick-Up 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 pick-up pipe to length.
                                                                           Secure the fuel pick-up pipe into position
                                       Allow 2.5" 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 pick-up
                                       pipe should have angle to
                                       avoid picking up dirt and             Note:    NPT fittings are available in various sizes
                                       subsequent blockage                            (Refer to parts section).
                                                                                 13



Electrical Connections


All parts needed are included with the kit. ( * ) indicates external mounted fuel and or water pump versions of Hydronics.


A. 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 fuse
C. Switch Harness............................................................            4 core harness (red/yellow, brown, yellow, blue/white)
                                                                                         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 heater.


Hydronic 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
                                                                   14


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 27-30mm exhaust                bustion air opening must be kept free at all times.
clamp is needed to secure the exhaust to the the heater.
Connect 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.
                                                                15


Operating Switches

A Push/Pull 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 instructions
provided 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.
                                                                 16



Push/Pull 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 in.



Control Wiring
Push/Pull Switch

Brown- 31         Power from battery "-"
Red- K(15)        Power from battery "+"
Yellow-15(K)      Switch control to the heater
Blue/White        Diagnostic from heater (disregard- tape
                  end and tie off to the side)




Heater Operation


Pre-Start 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 operations
Start 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 20-50 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: 1.5 - 2 minutes)                                     The water pump will continue to circulate coolant to allow
                                                                        the heater to monitor engine temperature
                                                                       The heater will automatically re-start 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 cool-down 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 cool-down cycle.



Switching 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 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 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 troubleshooting 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 10.2V, or rises
  above 15.9V, a "high/low 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
                         18



Operational Flow Chart
                                 19


Hydronic D4 SC 12 Volt
Model 25 1917 01
Wiring Harness P/N: CA1 60 401
                                 20


Hydronic D4 SC 12 Volt
Model 25 2096 05
Wiring Harness P/N: CA1 60 503
                                 21


Hydronic D5 SC 12 Volt
Model 25 1920 05
Wiring Harness P/N: CA1 60 401
                                 22



Hydronic D5 SC 12 Volt
Model 25 2098 05
Wiring Harness P/N: CA1 60 503
                                     23


Hydronic D5 SC 24 Volt
Model 25 2147 05
Wiring Harness P/N: CA1 60 502-001

Also applicable to
Hydronic 4 & 5 SC 12 volt
Gasoline versions
Model 20 1789 05
Model 20 1791 05
                                       24



Hydronic 5 S - 12 & 24 volt versions
Diesel & Gasoline versions
Model 25 2031 05
Model 25 2100 05
Model 20 1793 05
Model 25 2009 05
                                                              25


Maintenance Troubleshooting & Repairs
Periodic 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 7-day 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           7-Day Timer
  necessary replace fuel filter inserts.
                                                                   Espar's 7-day 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 recommendations). 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 Controls
Troubleshooting

                                                                   Symbols seen on the display
Basic Troubleshooting
                                                                   face are as follows:
In the event of failure there are several items which
should be checked first before any major troubleshooting
                                                                   AF       Actual fault.
is done. Check:
                                                                   F1-F5    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 3-5 seconds for the current fault code to appear
                                                                     (AF).
                                                                    To review the previous faults use the arrow buttons
                                                                     (F1= Most Recent, F5= Oldest).
                                                                    To erase the faults that are in memory press both "L"
                                                                     keys at the same time.
                                                                    See the fault code chart on following pages for code
                                                                     number descriptions.
                                                                26




                                                                             Fault code retrieval device harness
                                                                                                  P/N 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
                                                                                                                          P/N CA1 05 020
  code retrieval device




Test Values


Resistance
Metering pump                    approx. 20 
Glow Pin                        approx. 0.9 


Checking the sensors
To check the sensors, measure the resistance at current tem-
perature, 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
                                                         27


Fault Code   Fault Description                                Causes / Repair

000          Normal Operation

010          Overvoltage                                      Check voltage between terminals 1(red) and 2(brown) 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 1(red) and 2(brown) at
                                                              connector (B1). This must be greater than 10.2 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
                                                              simultaneously)

017          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
                                                              necessary

021          Short circuit - glow pin                         Check glow pin and electrical leads for continuity, replace if
                                                              necessary

030          Combustion air blower motor                      Blower impeller or electric motor may be jammed (frozen solid, dirty,
                                                              etc.) Fix jam, replace electric motor if necessary

031          Combustion air blower motor                      Check lead to combustion air motor for continuity, replace
                                                              motor if necessary

032          Combustion air blower motor short-circuit        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 (P/N 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 (P/N 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
                                                           28


Fault Code   Fault Description                                  Causes / Repair

042          Water pump short-circuit                           Check supply lead to water pump for short circuit, check water
                                                                pump, replace water pump if necessary

047          Short circuit - fuel metering pump                 Check for wires for short to fuel metering pump. Test fuel metering
                                                                pump. Replace if necessary

048          Open circuit - fuel metering pump                  Check supply lead to metering pump for continuity, remedy break,
                                                                replace if necessary

050          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 extinguished.
                                                                Check fuel supply. Check combustion air and exhaust flow. Check
                                                                flame sensor resistance value. Replace flame sensor if necessary

054          Flame cutout in high mode                          Heater has started successfully the flame has extinguished.
                                                                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 it's 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 defective(ROM error)                  vehicle electrical system; possible causes low batteries, charges,
093          Control unit defective(RAM error)                  other sources of interference, eliminate interference voltages.
                                                                Internal faults detected in microprocessor/ memory detected.
                                                                Replace control unit

097          Control unit defective (power failure)             Internal failure. Replace control unit
                                                                  29


Fuel Quantity Test

The fuel Quantity should be tested if the heater has difficulty
starting 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 measurement.



Preparation
 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 replace


Measurement
 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 glass
Evaluation
Nominal value                               Diesel     Gasoline

Hydronic D4W SC            Hydronic D5W SC              Hydronic B4W SC         Hydronic B5W SC

7.7 cm3 / 90 seconds       8.6 cm3 / 90 seconds         10.7 cm3 / 90 seconds   12.0 cm3 / 90 seconds   Max

6.7 cm3 / 90 seconds       7.5 cm3 / 90 seconds         9.3 cm3 / 90 seconds    10.5 cm3 / 90 seconds   Min



If measured quantity of fuel is over or under the nominal
value, the metering pump must be replaced or fuel restriction
eliminated
                                                          30



Repair Steps covered are for the Hydronic 4 & 5 SC versions - other models are similar

Disassembly / 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 O-rings
    on connection on water pump housing                        5   Control unit and cover




3   Metering pump and bracket                                  6   Glow pin
                                                        31




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
                                                         32


Parts Diagram - Hydronic D4 / D5 SC - 12 & 24 volt - Diesel & Gasoline versions

Model 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
                                                33



                                                                        Model #'s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & 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      O-ring                                            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 O-rings                         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 #'s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & 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      O-ring for coolant barbs 14 x 2,6                                320 75 119                                 

29      O-ring for sensors 7.5 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                               
                                                                                            35


Parts Diagram
HYDRONIC 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 #'s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & Part #'s
Ref. No. Description                                           Part Number

 1      T-piece, 20mm                                        20 1673 80 11 00                                 

 2      Connecting pipe                                      20 1534 88 00 01                                 

 3      Clamp 20mm-32mm                                      10 2065 02 00 32                                 

 4      Hose                                                 25 1917 80 00 01                                 

 5      1.5m 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 3.5mm                                           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 60 502-001                                        
                                                             25 1917 80 10 00                          

16      Exhaust clamp 27-30mm 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                1/4" NPT               CA0 12 044                                  
                                           3/8" NPT               CA0 00 031                                  
                                           1/2" 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      Push/pull 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 60 008-001                                  
30      7 day timer bezel                                    25 1482 70 01 00                                 
                                                  37



                                                                          Model #'s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & 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 3/8" awg 10-12                        CA1 90 014                                  

39      Fuse link power harness                             CA1 65 108                                 

40      Double pick-up (used with combo kits)           CA0 12 057-001                                  

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                                 
                                                         38


Parts Diagram - Hydronic D4 / D5 S - 12 & 24 volt - Diesel & Gasoline versions

Model 20 1793 05
Model 25 2009 05
Model 25 2031 05
Model 25 2100 05
                                                     39



                                                                Model #'s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & 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      O-ring                                            25 1864 99 00 23            
11      Glow plug                              12V        25 1864 01 10 00             
                                               24V        25 1816 01 01 00       
12      Lining & 2 o-rings                                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      O-ring, 7x2                                       25 1864 99 00 30            
21      Sleeve                                            20 1756 01 00 04   
22      Sleeve                                                        N/A
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   
                               40


Parts Diagram
HYDRONIC D4 / D5 accessories
                                                        41



                                                                   Model #'s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & 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 leaf-spring contact                                  206 73 058             
28      Twin leaf-spring 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 #'s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & 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
P/N: 610-121-0201




                                            Espar Products, Inc.

                                             6435 Kestrel Road
                                            Mississauga, Ontario
                                              Canada L5T 1Z8

                                             9675 Harrison Rd.
                                                 Suite 102
                                             Romulus, Michigan
                                                  48174
                                                  U.S.A.

                                 Canada (Tel):             905-670-0960
                                                           800-668-5676
                                         Fax:              905-670-0728

                                    U.S. (Tel):            800-387-4800




                            a Member of the Eberspcher Group of Companies


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Disclaimer:
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.