Espar Hydronic M8 Biodiesel, Hydronic M-II, Hydronic M10, Hydronic M12, D12W Installation & Operating Instructions Manual

Hydronic M-II (Water Heater)

*

Technical Description
Installation Instructions
Operating Instructions
Maintenance Instructions
Troubleshooting and Repair Instructions
Parts List

HYDRONIC M8Biodiesel

25 2470 05 - 12 Volt
25 2471 05 - 24 Volt

HYDRONIC

25 2434 05 - 12 Volt
25 2435 05 - 24 Volt

M10

Espar Products, Inc.
[phone]
[phone]
www.espar.com

HYDRONIC

25 2472 05 - 12 Volt
25 2473 05 - 24 Volt

M12

Espar Heater Systems

P/N 20 2900 81 0102 0A 04.2009 Subject to Change Printed in Canada

TTaabbllee ooff CCoonntteenntts

Introduction Heater Warnings .............................................. 3

Installation Procedures Heater Location / Mounting/ Fastening .............................................. 9

Heater Operation Pre-Start Procedures / Star t-Up .............................................. 20

s

Technical Data Hydronic M8 Biodiesel .............................................. 4

Technical Data Hydronic M10 ............................................. 5

Technical Data Hydronic M12 .............................................. 6

Heater Components .............................................. 7

Principal Dimensions .............................................. 8

Heater & Engine Plumbing

Fuel Quality .............................................. 11

Fuel System .............................................. 12

Electrical Connections .............................................. 14

Exhaust / Intake Connections .............................................. 15

Operating Switches: 7 Day Timer .............................................. 16

Push/Pull Switch, Programmable Timer .............................................. 18

Heating Mode /

Switching Off /Safety Equipment .............................................. 20

Heater Wiring .............................................. 21

Parts List for Wiring Diagram .............................................. 22

Heater Wiring Diagram .............................................. 23

Controler wireing diagrams .............................................. 24

Termperature Drop .............................................. 20

.............................................. 10

PPaagge

e

Maintenance, Periodic Maintenance .............................................. 25

Troubleshooting & Basic Troubleshooting / Self Diagnostics .............................................. 25

Repairs Fault codes / Description / Repair

Repair Instructions .............................................. 30

Repair Steps .............................................. 31

Fuel Quantity .............................................. 47

Heater Components Parts Diagram .............................................. 48

iption & Part #’s .............................................. 49

Descr

Parts Diagram - Boxed units .............................................. 50

Description & Part #’s .............................................. 51

Special Notes

Note: Highlight areas requiring special attention or clarification.

Caution:Indicates that personal injury or damage to equipment may occur unless specific guidelines are followed.

.............................................. 26

Warning: Indicates that serious or fatal injury may result if specific guidelines are not followed.

This publication was correct at the time of going to print. However, Espar Inc.has a policy of continuous improvement
and reserves the right to amend any specifications without prior notice.

IInnttrroodduuccttiioon

n

Heater Warnings

Warning T o Installer

• Correct installation of this heater is necessary to ensure
safe and proper operation.
Read and understand this manual before attempting to
install the heater. Failure to follow all these instructions
could cause serious or fatal injury.

Warning - Explosion Hazard

• Heater must be turned off while re-fueling.

• Do not install heater in enclosed areas where combustible
fumes may be present.

• Do not install heaters in engine compartments of marine
vessals.

Warning - Fire Hazard

• Install the exhaust system so it will maintain a minimum
distance of 50mm (2”) from an
tive material.

• Ensure that the fuel system is intact and there are no leaks.

y flammable or heat sensi-

Please note!

Installation of the heater is permitted in vehicles used
for the transport of dangerous goods as per ADR.

Caution

Note: All measurements contained in this manual contain

:

During electrical welding work on the vehicle discon­nect the power to the heater in order to protect the
control unit.

metric and approximate SAE equivalents in brack­ets eg 25mm (1”).

Safety instructions for application and
proper purpose

The heater must only be used and operated for the range of
application stated by the manufacturer in compliance with the
“Operating instructions” included with ever y heater.

Direct questions to Espar Heater Systems:

Warning - Asphyxiation Hazard

• Route the heater exhaust so that exhaust fumes cannot
enter any passenger compartments.

• If running exhaust components through an enclosed com­partment, ensure that it is vented to the outside.

Warning - Safety Hazard on Coolant Heaters
Used With Improper Antifreeze Mixtures

• The use of Espar coolant heaters requires that the coolant
in the system to be heated contains a proper mixture of
water and antifreeze to prevent coolant from freezing or
slushing.

• If the coolant becomes slushy or frozen, the heater’s
coolant pump cannot move the coolant causing a block­age of the circulating system. Once this occurs, pressure
will build up rapidly in the heater and the coolant hose will
either burst or blow off at the connection point to the
heater.

• This situation could cause engine damage and/or person­al injury. Extreme care should be taken to ensure a pro­per mixture of water and antifreeze is used in the coolant
system.

• Refer to the engine manufacturer’s or coolant manufactu­rer’s recommendations for your specific requirements.

Canada & U.S.A. 1-800-387-4800

This publication was correct at the time of print. However,
Espar has a policy of contin
reserves the right to amend any specifications without
prior notice.

uous improvement and

3

IInnttrroodduuccttiioon

Te chnical data

Heater type

HYDRONIC M-II

Heater HYDRONIC M8 Biodiesel

Version D 8 W

diulf gnilooC ,retaWmuidem gnitaeH

LowMediumHighPowerwolf taeh eht fo lortnoC

Heat flow (BTU) (Watt)

Figures for operation with diesel fuel. If operated with Biodiesel
the heat flow can reduce by up to 15 %.

27297 17061 11943 5118

8000

BTU
Watt50003500 1500

0.050.110.170.24

0.180.400.650.90

g/h
l/h

) (l/h)h/g( noitpmusnoc leuF

Electrical power (Watt) in operation 55 46 39 35

002Sec. 52 retfa – trats ta

23”FFO“ esahp lortnoc eht ni

tloV 42tloV 21egatlov detaR

Operating range

• Lower voltage limit: An undervoltage protection in
the controller switches the heater off on reaching the
voltage limit.

tloV 02tloV 01

• Upper voltage limit: An overvoltage protection in the
controller switches the heater off on reaching the
voltage limit.

tloV 03tloV 51

up to 200 kPa - 30 psierusserp gnitarepo elbareloT

1400 l/h

500 l/h

370 g/h

132 g/h

2 psi ta pmup retaw eht fo etar wolF

retaeh eht fo etar wolf retaw muminiM

gninnur toNnoitarepOerutarepmet gnitarepo elbareloT

Heater / Control box

Diesel

Biodiesel

Biodiesel

Dosing pump

Diesel

Weight with controller and water pump,
without dosing pump

approx. 6.2 kg - 13.7 lb

– 40 °F to +176 °F / –40 °C to +80 °C –40 °F to +185 °F / –40 °C to +85 °C

+17.6 °F to +176 °F / –8 °C to +80 °C –40 °F to +185 °F / –40 °C to +85 °C

– 40 °F to +122 °F / –40 °C to +50 °C –40 °F to +185 °F / –40 °C to +85 °C

+17.6 °F to +122 °F / –8 °C to +50 °C –40 °F to +185 °F / –40 °C to +85 °C

n

Caution:

Failure to comply with the technical data can
result in malfunctions.

4

Introduction

Te chnical data

Heater type

H

YDRONIC M-II

H

eater HYDRONIC M10

Version D 10 W

diulf gnilooC ,retaWmuidem gnitaeH

wolf taeh eht fo lortnoC

5118119432729732415BTU wolf taeH

0.050.110.240.32

0.180.40.91.2

(g/h) noitpmusnoc leuF

Electrical power (Watt)

021 52 retfa – trats ta

23”FFO“ esahp lortnoc eht ni

tloV 42tloV 21egatlov detaR

Operating range

• Lower voltage limit: An undervoltage protection in
the controller switches the heater off on reaching the
voltage limit.

tloV 02tloV 01

• Upper voltage limit: An overvoltage protection in the
controller switches the heater off on reaching the
voltage limit.

tloV 03tloV 51

up to 200 kPa - 30 psierusserp gnitarepo elbareloT

1400 l/h - 370 g/h2 psi ta pmup retaw eht fo etar wolF

500 l/h - 132 g/hretaeh eht fo etar wolf retaw muminiM

gninnur toNnoitarepOerutarepmet gnitarepo elbareloT

Heater / Control box

Dosing pump

Weight with controller and water pump,
without dosing pump

approx. 6.2 g/h - 13.7 lb

–40 °F to +176 °F / –40 °C to +80 °C –40 °F to +185 °F / –40 °C to +85 °C

–40 °F to +122 °F / –40 °C to +50 °C –40 °F to +185 °F / –40 °C to +85 °C

in operation 86 60 39 35

LowMediumHighPower

9500Watt80003500 1500

(l/h)

Sec.

Caution:

Failure to comply with the technical data can
result in malfunctions.

5

Introduction

Te chnical data

Heater type

H

YDRONIC M-II

H

eater HYDRONIC M12

Version D 12 W

diulf gnilooC ,retaWmuidem gnitaeH

Low3 muideM2 muideM1 muideMHighrewoPwolf taeh eht fo lortnoC

wolf taeH

noitpmusnoc leuF

in operation 132 86 46 39 35 34

02152 retfa – trats ta

23”FFO“ esahp lortnoc eht ni

tloV 42tloV 21egatlov detaR

Operating range

• Lower voltage limit: An undervoltage protection in
the controller switches the heater off on reaching the
voltage limit.

tloV 02tloV 01

• Upper voltage limit: An overvoltage protection in the
controller switches the heater off on reaching the
voltage limit.

tloV 03tloV 51

erusserp gnitarepo elbareloT

ta pmup retaw eht fo etar wolF

retaeh eht fo etar wolf retaw muminiM

gninnur toNnoitarepOerutarepmet gnitarepo elbareloT

Heater / Control box

Dosing pump

Weight with controller and water pump,
without dosing pump

409511943 5118170613241542000

.04.11.05.17.32.40

0.150.40 0.180.651.21.5

(g/h)
(l/h)

Electrical power (Watt)

2 psi

approx. 6.2 g/h - 13.7 lb.

Sec.

BTU

up to 200 kPa - 30 psi

1400 l/h - 370 g/h

500 l/h - 132 g/h

–40 °F to +176 °F / –40 °C to +80 °C –40 °F to +185 °F / –40 °C to +85 °C

–40 °F to +122 °F / –40 °C to +50 °C –40 °F to +185 °F / –40 °C to +85 °C

Caution:

6

Failure to comply with the technical data can
result in malfunctions

.

1

3

F

2 WO

WI

E

CA

987

54

6

IInnttrroodduuccttiioon

n

Heater Components

1 Control box
2 Burner motor
3 Glow plug
4 Flame pipe
5 Overheating sensor
6 Heat exchanger
7 Water pump
8 Combustion chamber
9 Flame sensor

WI = Water inlet
WO = Water outlet

= Combustion air

CA
F = Fuel
E = Exhaust

7

IInnttrroodduuccttiioon

FWO

WI

CA E

M8 (x4)

n

Principal Dimensions

E Exhaust
F Fuel
CA Combustion air
WO Water outlet
WI Water inlet

Permissible installation positions

* All measurements in millimeters 25.4 mm = 1”
Boxed Heaters Insure:

Minimum installation distance (clearance) to
open the lid and to dismount the glow pin and
the control unit.

Insure:
Minimum installation distance (clearance) to
take in combustion air.

1 Water outlet socket, heater
2 Water inlet socket, water pump

8

IInnssttaallllaattiioonn PPrroocceedduurrees

s

Principal Dimensions - Boxed Version

317 mm

(12.4”)

197 mm

(7.76”)

430 mm (16.9”)

Heater Location

Always mount the heater in a protected area.Eg: storage com­partment, engine compar tments, step box or battery box.
Espar recommends you use the boxed unit. Refer to fig. 1

When mounting the heater adhere to the following conditions:

• Situate the heater below the normal coolant level of the engine.

• Guard against excessive road spray.

• Keep coolant hoses, fuel lines and electrical wiring as short
as possible.

Arrangement of the heater

Parts of the structure and other components near the heater
must be protected from excess heat exposure and possible
contamination from fuel or oil.

The heater must not pose a fire hazard even when it
overheats.

– This requirement is deemed to be fulfilled when
adequate clearance to all parts is observed during
installation, sufficient ventilation is provided and fireproof

materials or heat plates are used.

The heater must not be located in the passenger compartment.
A unit may however be used in a hermetically sealed housing

which also corresponds to the conditions stated above.

The factory nameplate or duplicate must be affixed so that it
can still be easily read when the heater is installed in the
vehicle.

All appropriate precautions must be taken when
arranging the heater to minimise the risk of injuries
to persons or damage to other property.

Heater Mounting

Mount the heater using the four (4) shock mounts provided
with kit and one of the following mounting methods:

• Use the Side Mount Bracket to mount the heater on the

side of the fr

• Use a spare step box or battery box.

• Use the saddle bracket and hardware provided

Caution: Guard the heater against excessive road spray to

ame rail.

avoid internal corrosion.

Mounting and Fastening

Fix the unit holder from the installation kit to the heater
using 4 hexagon screws M8 and 4 spring washers.

Fix the heater and the mounted unit holder in a suitable
place in the vehicle using 5 hexagon screws M8, 5 spring
washers and 5 hexagon nuts M8

Fig. 1

Box Base

P/N 25 2800 40 10 02

Box Lid

P/N 25 2800 40 10 03

Intake Silencer

always needed
P/N 25 1786 80 02 00

1 Heater
2 Heater bracket

Side Mount Bracket

P/N 20 2900 40 00 75

9

IInnssttaallllaattiioonn PPrroocceedduurrees

42

3

1

s

Heater Plumbing

The heater is incorporated into the engine’s cooling system for
engine preheating.

Caution: It is possible for the coolant and components of the

coolant circuit to get very hot.

Engine Plumbing

Follow these guidelines and refer to the engine plumbing diag r am
shown below.

• Install hose fittings into the engine block for pick-up and return

lines.

• Use existing holes in the engine block (ie. remove

blanking plugs when possible).

• Use shut off valves to ensure the system can be isolated from

the engine when not in use. Alternatively “T” piece connectors
in existing coolant hoses can be used if no blanking plugs are
available.

• Provide 20mm (3/4” ) hose barbs for hose connections.

• Use 20mm (3/4” ) hoses to ensure adequate coolant flow.

• Keep the pick up and return points as far apart as possible to

ensure good heat distribution.

Water out

Water in

• Take the coolant from a low point on the engine to reduce

aeration in the system.

• Ensure proper direction of coolant flow by taking coolant from a

high pressure point in the engine and returning it to a low pres­sure point. (ie. pickup from back of block and retur n to the
suction side of the engine's water pump).

• Ensure adequate flow rate through the heater b y comparing the

incoming and outgoing coolant temperatures while the heater is
running. If the rise in temperature exceeds 10°C (18°F), coolant
flow must be increased by modifying the plumbing.

• Ensure the heater and water pump are installed as low as pos

sible to allow the purging of air.

• If a bunk heat exchanger is incor porated into the system,

proper plumbing layouts must be followed.

• Parts conveying water must be routed and fastened in such
a way that they pose no temperature risk to man, animals or
material sensitive to temperature from radiation / direct
contact.

• Before working on the coolant circuit, switch the heater off
and wait until all components have cooled down completely,
if necessary where safety gloves.

Caution:

• When installing the heater, please take note of the direction

w of the coolant circuit.

of flo

• Fill the heater and water hoses with coolant before con-

necting to the coolant circuit.

• Route the water hoses without any kinks, and in a rising

position if possible.

• When routing the water pipes, observe a sufficient clea-

rance to hot vehicle parts.

• Protect all water hoses / water pipes from chafing and from

extreme temperatures.

• Secure all hose connections with hose clips.

• After the vehicle has been operating for 2 hours or travelled

100 km, tighten the hose clips again.

• The minimum water flow rate is only guaranteed if the tem

perature difference of the heating medium does not exceed
15°C

(60°C)

between water inlet and water outlet during

heating.

• Only overpressure valves with an opening pressure of min.

6 psi – max. 30 psi bar may be used in the coolant circuit.

• The coolant liquid must contain at least 10 % antifreeze all

year round as corrosion protection.

• The cooling liquid must contain sufficient antifreeze for low

temperatures.

• Before commissioning the heater or after changing the

cooling liquid, the whole coolant circuit including heater must
be vented free of bubb les according to the instructions issued
by the vehicle manufacturer.

• Only top up with coolant approved by the vehicle manufac-

turer.

10

1 Heater
2 Non-retur n valve (Optional)
3 Heat exchanger
4 Vehicle engine

IInnssttaallllaattiioonn PPrroocceedduurrees

s

Caution: The coolant must contain a minimum of 10%

antifreeze at all times as protection against
corrosion.
Fresh water will corrode internal heater parts.

• The exhaust outlet must end in the open air.

• The exhaust pipe must not protrude beyond the lateral limits of
the vehicle.

• Install the exhaust pipe sloping slightly downwards.
If necessary, make a drain hole approx. Ø 5 mm at the lowest
point to drain off condensation.

• Important functional parts of the vehicle must not be impaired
(keep sufficient clearance).

• Mount the exhaust pipe with sufficient clearance to heat-sen­sitive parts. Pay particular attention to fuel pipes (plastic or
metal), electrical cables and brake hoses etc.!

• Exhaust pipes must be fastened safely (recommended clear­ance of 50 cm) to avoid damage from vibrations.

• Route the exhaust system so that the emitted fumes are not
sucked in with the combustion air.

• The mouth of the exhaust pipe must not get clogged by dirt
and snow.

• The mouth of the exhaust pipe must not point in the direction
of travel.

• Always fasten silencer to the vehicle.

• The e xhaust end pipe should be much shorter than the flexib le
exhaust pipe from the heater to the exhaust silencer.

Note:

The heater is approved for operation with biodiesel up to a temperature of – 8°C (17.5°F) (the flowability reduces at tempera­tures below 0 °C (35°F)).

• When using 100 % biodiesel, the heater should be run on diesel fuel twice a year (in the middle and at the end of a heating
period) to burn off possibly accumulated biodiesel deposits.To do so, let the vehicle tank run almost empty and fill with diesel fuel
without adding any biodiesel. While running on this tank filling, switch the heater on 2 to 3 times for 30 minutes at a time at the
highest temperature setting.

• If constantly operated with diesel / biodiesel mixtures of up to 50 % biodiesel, intermediate operation with pure diesel fuel is not
necessary.

Both heaters are not approved for operation with biodiesel. Up to 10 % biodiesel may be added.

HYDRONIC

HYDRONIC

M8 Biodiesel

M10 /

HYDRONIC

M12

Fuel Quality

This means that difficulties are only to be expected for extreme
drops in temperature, as also apply to the vehicle engine.Please
also refer to the vehicle manual.

If no special diesel fuel is available for low temperatures, then
kerosene or gasoline should be mixed with the fuel according to
the following table:

Temperature Winterdiesel Addition
0 °C to –25 °C 100 % –

(32 °F to –13 °F) 100 % –
–25 °C to –40 °C 50 %* 50 % paraffin or petrol
(32 °F to –13 °F) 50 %* –

* or 100 % special cold diesel fuel (Arctic diesel).

11

IInnssttaallllaattiioonn PPrroocceedduurrees

FUEL
TANK

Right Wrong

Bubble

Correct

Wrong

s

Fuel System

The Hydronic MII boxed unit is most commonly provided with the
fuel metering pump mounted inside the box. This is to reduce
installation time and to protect the pump from corrosion. If speci­fications cannot be met the pump must be mounted externally.
See illustration for connections and specifications. All par ts
necessary to do the installation are included in the kit as shown.

Note: Fuel line limits must not be exceeded.

Ensure that the following conditions are met.
Bottom of the fuel metering pump must be within a height

of 2’6” of the bottom of the fuel pick-up pipe.
Fuel metering pump must be within a total distance of

6’6” from the fuel pick-up pipe.
Pressure runs of less than 1.3 mtrs (50”) use only 3.5mm

rubber (360 75 300)

Control and Safety Devices

Emergency shutdown – EMERGENCY OFF

If an emergency shutdown – EMERGENCY OFF – is necessary
during operation, proceed as follows:

• Switch the heater off with the control

• pull the fuse out

• disconnect the heater from the battery.

Fuel Line

• Route fuel lines from the fuel pick-up pipe to the heater.

• Use Espar approved fuel lines.

• Other sizes or types of fuel lines may inhibit proper fuel flow.

• Make proper butt joints using clamps and connector pieces
as shown

• Use a sharp utility knife to cut plastic fuel lines to avoid burrs.

Note: Butt joints and clamps on all connections.

Fuel System Tolerances

Max. 6’6”

Max. 6’6”

Max. 2’6”

2

12

3

1

6

5

Max. 20”

6

7

1. Fuel Pick-Up Pipe

5

4

2

2. 11mm Clamp

3. 5.0mm Fuel Line

4. Fuel Metering Pump

5. 9mm Clamp

6. 3.5mm Rubber Connector

7. 2.0mm White Plastic Fuel Line
See notes if length is less than

1.3 mtr (50”)

IInnssttaallllaattiioonn PPrroocceedduurrees

Ø

2.5 cm (Ø 1.0”)

1.5 cm 1.5 cm
9 / 16” 9 / 16”

Ø

0.625 cm
(2 HOLES)
(

Ø

1 / 4”)

15° to
vertical

s

Fuel Metering Pump Installation

If the pump needs to be mounted externally follow these guide­lines:

• Choose a protected mounting location close to the fuel pick­up pipe and heater.

• Using the bracket and rubber mount provided, install pump as
shown.

Note: Proper mounting angle of the pump is necessary to

allow any air or vapor in the fuel lines to pass through
the pump rather than cause a blockage.

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

• Choose a protected mounting location close to the pump and
heater.A spare fuel sender gauge plate provides an
ideal mounting location.

• Drill the mounting holes as shown.

• Cut the fuel pick-up pipe to length.

• Mount the fuel pick-up pipe as shown

• Lower the fuel pick-up pipe (with reinforcing washer) into
the tank using the slot created by the two 0.6cm (1/4”) holes.

• Lift the assembly into position through the 2.5cm (1”) hole.

• Assemble the rubber washer, metal cup washer and nut.

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

Fuel Pick-Up Pipe
Nut
Sheet Metal Washer
Rubber Gasket
Steel Safety Washer
Holding Tabs
Allow 4” from fuel pick-up

to tank bottom. Allow
only 1” for flat bottom
tanks.

End tip of the fuel pick-up
pipe should have angle
so as to avoid picking up
dirt and
subsequent blockage

( Optional Pick-Up Pipe with NPT fitting )

• Remove an existing plug from the top of
the fuel tank.

•

Cut the fuel pick-up pipe to length.

• Secure the fuel pick-up pipe into position
using the combined NPT compression
fitting as shown

Note: NPT fittings are available in var ious sizes

(Refer to parts catalogue).

13

IInnssttaallllaattiioonn PPrroocceedduurrees

++

--

A

B

C

A

UT

O

M

A

N

U

A

L

R

E

S
E

T

C

L
O

C

K

T

I
M

E

R

D

A

Y

H

O

U

R

M

I
N

M
A

N

U

AL

Electrical Connections

s

Caution: To avoid potential short circuit damage during instal

lation, insert main fuse into the power harness after
all electrical connections are complete.

A) Power Harness...................................................................

Note: Wire must be inserted into fuse holder pr ior to

terminating.

B) Switch Harness..................................................................

C) Fuel Metering Pump Harness...........................................

7 Day Timer

Note: All harnesses should be cut to length.

All exposed electrical connections should be coated
with protective grease.

• 2 core harness (red, brown).

• Connect red wire to fuse link and terminal.

• Attach ring terminal to vehicle battery (+).

• Connect brown wire to vehicle battery (-) using ring
terminal provided.

• Insert fuse. (15A-24V, 20A-12V)

• 4 core harness (red, brown, yellow, blue/white)
Run to location of switch.Make terminal connections at

•
switch. Espar has different available switches.
See switch instructions for more information.

• 2 core harness (green, green).

•

Fuel Metering Pump Harness is pre-connected when
box is provided with pump pre-mounted.

• If mounted externally, connect wires to fuel meter ing
pump using connector and terminals supplied, with the
heater - (no polarity required).

Shown is a
Standard - Power, Switch, Fuel Metering Pump harnesses
and optional 7 day timer.

Other timers or switch options are available.
Easy Start Mini Timer

Hydronic

MII boxed version, 12 volt with

7 Day Timer

switch harness

Programable Push and
Timer Pull Switch

14

IInnssttaallllaattiioonn PPrroocceedduurrees

s

Exhaust Connection

A 30 mm flexible tube e xhaust pipe with a length of 1M long is sup­plied with the kit for the exhaust. An exhaust clamp is needed to
secure the exhaust to the the heater.The exhaust hose cannot be
any longer than 2 m. Connect the exhaust as follows:

• Connect the exhaust pipe to the exhaust port on the heater and
attach with clamp provided. Feed the exhaust pipe through the
silicone (white) grommet on the bottom of the box.

• Run exhaust to an open area to the rear or side of the vehicle so
that fumes can not build up and enter the passenger compart­ment or the heater combustion air intake.

• Install exhaust pipe with a slight slope or drill a small hole in the
lowest point to allow water to run off.Any restriction in exhaust
will cause operational problems.

• Route the exhaust pipe from the heater using holders provided.

Caution: Run exhaust so that it cannot be plugged by dirt, water

or snow. Ensure the outlet does not face into the vehi­cle slip stream.

Intake Connection

Combustion air must be drawn in from the outside of vehicle.
The combustion air opening must be kept free at all times.

• Connect the air intake pipe to the intake port on the heater
and secure with clamp provided.

Caution: Do not install the intake opening facing the vehi-

cle slipstream. Ensure that the opening cannot
become clogged with dirt or snow and that any
water entering the intake can drain away.

Note: 1. Exhaust hose cannot be any longer than 2m (80”)

2. Minimum length 0.2 m (8”)

3. Air intake silencer always needed.

Holding clamps

Flexible Exhaust

& Air intake hose

cannot be any

longer than

Max 2M (80”)

Exhaust & Intake

Clamps

P/N 25 1786 80 02 00

Air Intake silencer

Always needed

End Sleeve

Warning: Asphyxiation Hazard Warning: Fire Hazard

Route exhaust beyond the skirt of the cab and outside of the
frame area. Route exhaust so that the exhaust fumes cannot
enter the passenger compartment. Failure to comply with this
warning could result in Asphyxiation.

The exhaust is hot, keep a minimum of 5cm (2”) clearance
from any heat sensitive material. Failure to comply with this
warning could result in fire and serious injury.

15

IInnssttaallllaattiioonn PPrroocceedduurrees

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Option #1

Option #2

Yellow

Red
Brown

Blue

DIAG

TRS

Yellow

R

ed

Blue

Brown

12 11 10 9 8 7 6 5 4 3 2 1

P

a4)
a

3

)

a

5

)

a

2

)

s

Operating Switches

A 7 Day Timer , a Push/Pull switch or an easy start timer are
available for the heater.

7 Day Timer Instructions

The 7 Day Timer has been designed to provide a simple means
to control the operation of the heater system and to include the
capability for diagnostics. This timer connects to the diagnostic
circuit of the heater. The timer then displays any heater fault
codes in three digit number form automatically. The timer allows
for pre-selection of turn on time, up to 7 days in advance, as well
as an option for run times up to 2 hours before automatically turn­ing off.In addition, there is an on/off switch for manual operation.
By default the timer is pre-set by Espar to operate for two hours.
Refer to instructions provided with timer for setting options.

• Mount bezel into dash and insert timer or use Espar’s optional
mounting bracket and secure to dash.

• Use hardware supplied for connections.

• Connect the switch harness to the connector at the heater and
run harness to switch location. (Har ness should be neatly
routed and secured under dashboard).

• Cut harness to length and terminate wires. Attach using con­nectors provided.

• Refer to timer instructions for other wiring options.

Mounting Bracket & Bezel

P/N 25 1482 70 01 00

Option #2: Operate heater continuously - connect wire from

ignition circuit to terminal #10.

Note: An alternative to connecting pin 10 to the vehicle

ignition accessor

ies “On” circuit may also be con­sidered for some applications where extended run
times are desired. Connecting pin 10 with the red
wire will enable the heater to run continuously on
manual mode.

Operating Instructions

Setting Time and Weekday

Push button once 12:00 will begin to flash (this will occur
upon initial hook up to po
Using or set the present time of day (24 hour clock).
When the time stops flashing the time has been stored.
The weekday will now begin to flash.
Use or to set the present weekday.
When the weekday stops flashing the weekda y has been stored.

When the vehicle ignition is turned “on” the time display will
appear, if optional connection on pin 10 is insatlled.
When the vehicle ignition is turned “off” the timer display will go
off after 15 seconds.

Changing the Time or Day

Push and hold button until the time displa
Continue to set the time as listed in setting time and weekday.

wer).

y begins to flash.

Bezel

Mounting Bracket

Note: If installing a remote star ter, refer to remote starter

instructions before terminating wires.

Option #1: Dash lights to timer - connect wire between dash

Note: The timer display is automatically illuminated while the

16

lights circuit and timer at terminal #1.

heater is operating.
mer switch will allow the timer display to illuminate with
the vehicles dash lights.

Connecting pin 1 to the vehicle dim-

Using the Timer with the Vehicle Ignition “Off”

Push button.

will appear on the display as well as the operation countdown
timer.
The running time is factory set to maximum of 120 minutes.
This running time can be reset once or permanently as desired.

Adjusting Preheat Time Once

Press button.
The will appear in the display and the preselected run
time will appear in the display (maximum time of 120 min

utes).

Use the or to adjust the desired run time.

Adjusting the Heater Preheat Time Permanently

(Maximum Preheat Time of 120 min

utes)
Push and hold (about 3 seconds) until the display lights up
and flashes. Release button.
Use or to set the new fixed preheat time.
When the display goes off the new preheat time is set.

Note: At the end of a preheat cycle the timer will tur n the

heater off.The heater will complete a cool down cycle
and turn itself off.

IInnssttaallllaattiioonn PPrroocceedduurrees

s

Using the Heater Manually with the Vehicle Accesory “On”

(Optional wire on pin 10 is connected to the ignition lock)
Push buton.
The symbol will appear in the display next to the time of day.
The time of day will remain display ed during ignition on operation.
The heater will function continually as long as the vehicle ignition
is “On”.
When the vehicle ignition is turned “Off” the heater will continue
to operate for an additional 15 minutes.
The run time can be altered by pressing the or buttons.
The heater can be turned off by pressing button.

Set Preheat Times into Memory

Press b

utton until the desired memory location is shown in
the display (Three memory locations are available).
Using the or buttons set the desired preheat start time
of day.
When the time stops flashing the time of day is set.
Using the or buttons set the desired day of the week.
When the day of the week stops flashing the day is set.

To Use Preset Star t Times

Press the button until the desired memory location appears
in the displa

y.
The heater will start at the day and time displayed.
The display will go off in 15 seconds. The memory location
number will stay displayed (1, 2 or 3).

Note: When preset is chosen this symbol will flash red.

Control Unit Locking

The control unit may becomed locked due to one of the follow­ing conditions:

Overheat – If the heater overheats three times in succes-

1.

sion, fault message F15 is displayed and the
control unit is locked.

2.Too many failed start attempts - If the heater performs
many start attempts in succession (i.e. Fault 52), fault
messsage F50 is displayed and the control unit is locked.

king Control Units and Erasing Fault Memory

Unloc

Note: The electrical connection for the ignition / accessory

wire to the timer terminal #10 must be in place.

1. Tur n on the vehicle ignition to activate timer display.
Press the key.The current fault code (i.e.F15 or F50) is

2.
now displayed.

3. Press the key and hold it down and press the key
within two seconds.The timer is now in the retrieval mode.

4. Tur n off the ignition.

5. Press the key and hold it down and press the key
within two seconds and hold it down.

6. While holding down keys, turn ignition on and wait
until the following display appears:

To Turn Heater “Off” - All Modes

Press the button once.
The heat signal to the heater will be tur

ned “Off”.

The heater will do a normal cooldown and turn itself “Off”.

Note: · This timer is equipped to display fault code numbers if

the heater should shut down due to an operating fault.
The fault code will show in the timer display next to the
flashing heat wave symbol. This applies to all current
model heaters when the blue diagnostic wire is con­nected.

· If the timer is purchased without the harness kit, the
f

ollowing heaters will need a load relay intalled (D8Lc,
D7W, D12W, D24W and D30W), These heaters carry a
load on the switch wire.(i.e. fuel metering pump or noid
sole valve).

· An outside temperature sensor is available as an option.

Wiring Connections at Connector

Terminal 1 Power from vehicle dash lights.
Ter minal 2 Heater switch wire - Yellow wire.
Ter minal 4 Connect to vehicle ground.
Terminal 6 Temperature setting “+” (air only).
Ter minal 8 Heater diagnostic lead - blue wire.
Ter minal 9 Temperature setting “-” (air only).
Terminal 10 To vehicle “ACC” accessory for

Terminal 11 Positive power from heater - red “+”.
Ter minal 12 Ground lead from heater - brown “-”.
Ter minal 3,5,7 Left blank, not required.

continuous overnight use, and for
unlocking ECU.

7. Press the key to turn the heater off.

8. Press the key to turn the heater on.

9. Repeat step three. The following display appears:

10. The control unit lock is cancelled after three seconds
and the heater starts.

Retreaving the Stored Fault Codes

1. Press the key. The heater is switched on.
Press the key and hold it down and press the key

2.
within two seconds.The current fault code is now displayed
(Example: AF:64).

3. The stored fault codes (maximum of 5) can now be retrieved
using the arrow keys and (Example:F1:64).

Note: Consult the Troubleshooting and Repair manuals for

code definition and corrective action. If the heater is
not being operated using the 7-day timer, fault code
retrieval can be obtained using the “Fault Code
Retrieval Device”, part number: 20 2900 70 50 20.

17

IInnssttaallllaattiioonn PPrroocceedduurrees

14.5mm
9/16”

K (15)

15 (K)

31

Ø
Ø

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Yellow (Signal to Heater)

a

3

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a

5

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4

5670100 - 12 Volt
5670099 - 24 Volt

Programmable

Timer

3

2

1

Brown (-)

Red (+)

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Programmable Timer

Push/Pull Switch

s

• 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 har ness to length at the switch and install terminals

• Connect wiring as descr ibed below

Note: Switch light glows when pulled out and is off when

pushed in.

Brown- 31 Power from battery “-”
Red- K(15) Power from battery “+”
Yellow-15(K) Switch control to the heater
Blue/White Diagnostic from heater (disregard - tape end

and tie off to the side)

P/N 5670007 (12v)
P/N 5670008 (24v)

Setting the time

Press and hold the CLOCK button.
Press D

AY button to select the correct day.
Press HOUR button to select the correct hour.
Press MIN button to select the correct minutes.
When the MIN button is released the time will be set.

Holding down or repeatedly pressing the appropriate button will
advance the days, hours and minutes.

Programming of Switching Times

The Auto Time Switch has the capacity for 8 ON/OFF switches.
By using the b

locks of days available, you can save program

capacity. The block days are:
MO, TU, WE, TH, FR, SA, SU – Individual days of the week

MO, TU , WE, TH, FR
SA, SU
MO, TU , WE, TH, FR, SA
MO, WE, FR
TU, TH, SA
MO, TU , WE

Programmable Timer

P/N 5670100 (12v)
P/N 5670099 (24v)

IMPORTANT: This electronic timer has a maximum loading

printed on the rating label and under no circum­stances should this be exceeded.

Features:

• Up to 8 ON and OFF switches a day/56 ON and OFF
switches per week

• Option to program individual days or 8 different weekday
groups

• Minimum switching period of one minute

• Summer/Winter time changeover

• Manual Override button

• Easy to read LCD display

• Battery Back-up

Note: As soon as you have connected 12 volts you will

18

have to push down the RESET button to activate
the timer.

Programmable Timer Instructions

Each ON time and each OFF time, the da

ys, hours and minutes

must be set.
Press the TIMER button once to set the first ON time – you will

see “on” and the number “1” appears.
Enter the first ON time.
Press the DAY button to choose the required day or block of

days.
Set the hour and minutes using the HOUR and MIN buttons.
Press TIMER button to save first on time and are ready to set

first off time you will see “OFF” and the number “1” appear.
Use the DAY, HOUR and MIN buttons as above.
Press the TIMER button to save off time.
Repeat the same steps for the remaining 7 ON and OFF set-

tings as desired.
When you have set the required ON/OFF settings, press the

CLOCK button to return the display to the clock.
The timer is now ready to operate.

Note: You can check the settings you have programmed

by pressing the TIMER button repeatedly. Each set
ting will appear on the screen.

Notes:

19

HHeeaatteerr OOppeerraattiioon

n

Pre-Start Procedures

Upon completion of installation prepare the heater as follows:

• Check all fuel, electrical and plumbing connections.

• Refill the engine coolant.

• Bleed air from the coolant system by running the engine and
refilling the antifreeze as needed. Resecure heater hose.

• Run engine to further bleed the system

• Top up engine coolant.

Start Up

Once switched on, the following sequence occurs:

• Control unit does a systems check (flame sensor, tempera
ture, and various other control unit checks).

• Water pump starts circulating coolant fluid.

• Combustion air blower starts.

• Glow pin begins to preheat 20-30 secs.

• After about 20-30 seconds the Fuel Metering Pump starts deli­vering fuel and the combustion air blower ramps up gradually.

• Once ignition takes place the flame sensor alerts the control
unit and the control unit shuts off the glow pin (ignition time:

1.5 - 2 minutes).

Note: If the heater fails to star t the first time it will automa-

tically attempt a second start. If unsuccessful the heater
will shut down completely.

Note: On initial star t up the heater may require several

star

t attempts to self prime the fuel system.

Heating Mode

At the initial start the heater is operated with the “POWER” stage
until the water temperature exceeds the “POWER” / “HIGH”
changeover threshold.

HYDRONIC M8 / M10

Then, depending on the heat requirement, the heater switches to

“HIGH – MEDIUM – LOW – STAND BY” stages.

the
If the heating requirement in the “LOW”stage is so small that the

cooling water temperature reaches 85 °C, the heater switches
from “LOW” to “STAND BY”.

HYDRONC M12

Then, depending on the heat requirement, the heater switches to
the

“HIGH – MEDIUM 1 / MEDIUM 2 / MEDIUM 3 – LOW –

STAND BY” stages.
If the heating requirement in the “LOW”stage is so small that the

cooling water temperature reaches 85 °C, the heater switches
from “LOW” to “STAND BY”.

This is followed by the after-run with additional after glowing of the
glow plugs (like when heater is switched off).

After the cooling water has cooled to approx. 70 °C the
HYDRONIC M8 / M10 heater starts in the “MEDIUM” stage, the
HYDRONC M12 heater in the “MEDIUM 1” stage.

If the cooling water temperature reaches approx. 55 °C the
temperature sensor switches the vehicle fan on.

The temperature can be lowered by connecting the positive
cable (+) to connector S2, terminal C3 of the heater (see circuit
diagrams).

Switching Off

With the switching off the heater starts the after-run of
180 sec. During the after-run the first glow plug is switched
on after 90 seconds for a period of 45 seconds,
then the second glow plug is switched on until the end
of the after-run.

Safety Equipment

The heater is equipped with the following control and safety
devices.

• If the heater does not ignite within 74 seconds after the fuel
starts to pump, the start is repeated.
If the heater still does not ignite after another 65 seconds of
fuel being pumped, the heater is automatically shut down.
After an unacceptable number of failed start attempts, the
control box is locked.*

• If the flame goes off by itself during operation, the heater is
restarted.
If the heater does not ignite within 74 seconds after the fuel
starts to pump again, the heater is automatically shut down.
The shutdown on faults can be cancelled by briefly switching
off and on again.

• In the case of overheating (e.g.water shortage, poorly venti­lated cooling water circuit), the overheating sensor triggers,
the fuel feed is interrupted and the heater is automatically
shut down.
Once the cause of the overheating has been eliminated, the
heater can be re-started by switching it off and on again
(provided that the heater has cooled down sufficiently, cooling
water temperature < 70 °C).
After the heater has been shut down due to overheating an
unacceptable number of times, the control box is locked.*

* The ECU can be unlocked and the fault can be displayed

with:

• EasyStart.

• Diagnostics Unit.

• EDiTH diagnostics software.
For operation and fault list, please refer to the enclosed
operating instructions or these troubleshooting and repair
instructions.

• If the lower or upper voltage limit is reached, the heater
will shut down.

• The heater does not start up if the electric cable to the
metering pump is not connected.

• If one of the two glow plugs is defective, the start sequence
takes place with one glow plug only .

• The speed of the blower motor is continuously monitored.
If the blower motor does not start up, if it is blocked or if the
speed differs by > 12.5 % of the desired speed, the heater
will automatically shut down after 60 sec.

• The function of the water pump is continuously monitored.

Temperature Drop

Temperature drop only becomes active while the vehicle is runing
and if the heater is switched on.The control stages are reached
earlier and the heater‘s control action is adjusted to the lower heat
requirement.

20

Warning:

The heater must be switched off while any
fuel tank on the vehicle is being filled.

The heater must not be operated in
garages or enclosed areas.

HHeeaatteerr OOppeerraattiioon

Cable harness

H

YDRONIC M

Rewiring

1

2-pin connector

Connection

C

able colour HYDRONIC

M

PIN

H

YDRONIC M-II

PIN

M

etering pump

g

reen

4C A1

T

erminal (-)

brown

3C A2

Terminal ( +)

r

ed

2C A3

P

lus signal

m

ain battery switch

white / red

1C A4

Plus signal
Solenoid valve relay

–

4B B1

D

iagnosis

b

lue

3B B4

Plus signal
ADR auxiliary drive

violet

2B B3

Third party control
Water pump

– 1B

B2
remains
unused

Blower relay

red / yellow

4A C1

D+
for ADR operation

violet / green

3A C2

Te mperature drop –

2A C3

Heater ON

yellow

1A C4

Connector is shown
f

rom the lead entry

s

ide.

n

Heater Wiring

The heater is to be connected up electrically according to the
EMC directives.

Caution:

EMC can be affected if the heater is not connected up correctly.
For this reason, comply with the following instructions:

• Ensure that the insulation of electrical cables is not damaged.
Avoid:
chafing, kinking, jamming or exposure to heat.

• In water proof connectors, seal any connector chambers not
in use with filler plugs to ensure they are dirt-proof and water­proof.

• Electrical connections and ground connections must be free
of corrosion and firmly connected.

• Lubricate connections and ground connections outside the
heater interior with contact grease.

Note: Comply with the following when wiring the heater and the

control unit: fuses and controlers.

• Electrical leads, must be positioned in the vehicle so that they
can function perfectly under normal operating conditions with­out impairment (e.g. due to heat exposure, moisture, etc.).

12-pin Connection Pin Assignment

• The following wire gauge are to be used between the battery
and heater.

This ensures that the max. allowable voltage drop in the
cables does not exceed 0.5 V for 12 V or 1 V for 24 V rated
voltage.

Cable cross-sections for a cable length (plus cable + minus
cable) of:

– up to 5 m (plus cable + minus cable) = 10 AWG
– from 5 m up to 8 m (plus cable + minus cable) = 8 AWG

• If the ( + ) cable is to be connected to the fuse box, the
vehicle's cable from the battery to the fuse box must also be
included in the calculation for the total cable length and
re-dimensioned if necessary.

• Insulate unused cable ends.

If replacing the HYDRONIC 10 / M with the HYDRONIC M-II, the
cable harness installed in the vehicle is retained and continues to
be used, it is necessary to remove the 12-pin connector using the
terminal removal tool and to rewire it according to the following
table.

21

HHeeaatteerr OOppeerraattiioon

PIN-No. Connection

pmup gnisoD1A

B1 Solenoid valve, optional

rewolb ,yaleR1C

B2 Diagnosis cable (OEM)
B3 TRS signal (ADR)
C3 Temperature drop
B4 Diagnosis

NO retaeH4C

Battery ( - )

Battery ( + )3A

2A

n

Parts list for wiring diagram,

1.1 Blower motor

1.2 Glow pin I

1.2.1 Glow pin II (optional 12 kW)

1.5 Overheating sensor

1.12 Flame sensor

1.13 Temperature sensor

2.1 Control unit

2.2 Fuel metering pump

2.5.7 Relay, vehicle blower (fan)

2.5.18 Relay, changeover water circuit
(To be fitted by customer if required)

2.7 Main fuse 12 volt = 20A

24 volt = 15A

2.7.1 Fuse, control option 5A

2.7.5 Fuse, vehicle blower (fan) 25A

2.12 Water pump

5.1 Battery

5.10 Vehicle blower (fan)

a) Connection to 7 day timer, programmable timer, easy star t or

push pull switch

b) Water circuit change-over: Relay makes contact at 68°C and

breaks contact at 63 °C water temperature (with temperature

drop 58 °C / 45 °C)
c) Temperature drop
x) Disconnect cable

Hydronic

M-II - 12 Volt / 24 Volt

Diagnosis

a

2

a

Switch on signal

3

a

Power supply plus

4

a

Power supply minus

5

Connectors and bush holdings are shown from the cable
inlet side.

Connector pin assignment: 12-pin connector (external).

22

HHeeaatteerr OOppeerraattiioon

2.5.7

2.7.1

1.2.1 2.12 1.13 1.12

2.5.18

2.2

2.7

1.2

2.1

1.5 1.1

5.1

5.10

2.7.5

1

1 14 10 7 4 12 13 1 2 8 5 6 3 9

B1

x

)

a)

B2

S2

B1 B2 B3 S2 S3

B3

B3
S3

Circuit diagram HYDRONIC M-II – 12 Volt / 24 Volt

Brown / Green

Brown

Green

Brown

Red

White / Red

Blue / White

Red / Yellow

Yel low

Brown / Black

Brown

Brown

Brown

Pink

Green

Orange

Red

White

White

White / Red

Blue / White

Blue

Yel low

Black/Violet

Black

Red

Brown

Red / Yellow

Optional

b

)

Brown

Brown

Blue/White

White/Red

Brown

Red

Y

ellow

b

)

Red

Brown

Red

Red

Red

a1)
a

2

)

a

3

)

a

4

)

a

5

)

A1A2A3A4B1B4B3B2C1C2C3

C4

c)

n

Hydronic

M-II,Wiring Diagram - 12 Volt / 24 Volt

23

HHeeaatteerr OOppeerraattiioon

R

ED

a

4)

a

3)

a

5)

YELLOW
BROWN

15 (K)

0
0

K (15)

31

Push/Pull switch

Yellow (Signal to Heater)

a

3

)

a

5

)

a

4

)

5

4

5670100 - 12 Volt
5670099 - 24 Volt

Programmable

Timer

3

2

1

Brown (-)

Red (+)

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Programmable Timer

Easy Start T

LCD

White / Red
Blue / White

Brown

Grey

B1B1B1S1S1S1

a

1

)

Red

Brown / White
Grey
Grey / Black
Blue / White
Violet
Brown
Yellow
Red

a

2

)

a

5

)

a

4

)

1 2 3 4 5 6 7 8 9

O

ption #1

O

ption #2

Yellow

Red
Brown

Blue

D

IAG

TRS

Yellow

Red

Blue

Brown

12 11 10 9 8 7 6 5 4 3 2 1

P

a4)
a

3

)

a

5

)

a

2

)

n

Hydronic

M-II, Controler Options

Push / Pull Switch

7 Day Timer

24

Programmable Timer

Easy Start T

Optional On/Off Switch

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

LDL

Periodic Maintenance

Subtitle Right Page

Fault Code Retrieval Device

s

• Check coolant hoses, clamps, and make sure all valves
are open. Maintain the engine manufacturers recommended
coolant level and ensure that the heater is properly bled after
service on or involving the coolant system.

• Visual check of all fuel lines for leaks. Check and if necessary
replace fuel filter inserts.

• Visual check of electrical lines and connections for corrosion.

• Run your heater at least once a month during the year (for a
minimum of 15 minutes).

• Maintain your batteries and all electrical connections in good
condition.With insufficient power the heater will not start.
Low and high voltage cutouts will shut the heater down auto­matically.

• Use fuel suitable for the climate. Blending used engine oil
with diesel fuel is not permitted.

Troubleshooting

Basic Troubleshooting

In the event of failure there are several items which should be
checked first before any major troubleshooting is done.

Check:

Equipment Face and Controls

Symbols seen on the display
face are as follows:

AF Actual f
F1-F5 Up to five stored faults can be accessed.

The AF and F1 are the same.
This sign is displayed when the heater is in operation.

DIAG The word (Diagnostic) will come on when the

diagnostic n

000 Three digit diagnostic fault code number.

ault.

umber is requested.

Hook Up

•

Disconnect the main harness from heater and insert adapter
cable harness between them.

• Connect adapter cable to the cable loom of the Fault code
retrieval device.

• Star t diagnostic unit - switch heater on from switch.

Instructions:

• Fuses.

• Electrical lines and connections

• Interference in Combustion air and Exhaust pipes.

• Fuel in the tank.

• Batter y voltage on heater side of harness

• Coolant flow

Self Diagnostics

The heater is equipped with self diagnostic capability. You can
retrieve information on the heaters last 5 faults using the Espar 7
day timer , Espar’ s Fault Code Retrieval Device or ISO adapter and
computer.

Multifunction

Espar’s 7 day timer has a fault code
retrieval device built into the unit. This
function automatically activates if the
heater is experiencing problems.

• Fault codes appear on the LCD display screen.

• Codes can then be translated from the charts on the following
pages.

• Pg 10 - 17 for more detailed instructions.

• 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.

Diagnostic Adapter

P/N 25 2800 70 1004

Fault code

retrieval device

P/N 20 2900 70 5020

25

Maintenance, Troubleshooting & Repairs

Fault Code Fault Description Causes / Repair

— — — Diagnosis not possible • Adapter cable not connected properly.

• Diagnostic connection damaged.

• Internal control box fault, replace control box / blower unit.

000 No faults — —

005 Warning • Check connection and / or lead for continuity, shor t circuit and

Short circuit in "Burglar Alarm" output damage.

009 ADR / ADR99 shutdown • Switch the heater off and then on again –

The shutdown must be cancelled by D+ or HA / NA.

010 Overvoltage cutoff Overvoltage applied to control box for at least 6 seconds

–> heater not working.

• Disconnect heater / cable harness plug-in connector, start
the vehicle engine, measure the voltage. Connector B2, PIN
A2 and A3:
– If the voltage is >15 volt or >30 volt, check the generator

regulator and / or the battery.

011 Undervoltage cutoff Undervoltage applied to control box for at least 20 seconds

without interruption –> heater not working.

• Disconnect heater / cable harness plug-in connector, start the
vehicle engine, measure the voltage. Connector B2, PIN
A2 and A3:
– If the voltage is <10 volt or <20 volt, then check the fuses,

the supply cables, the negative connections and the positive
support point at the battery for voltage drop (corrosion).

012 Overheating Overheating sensor signals temperature greater than 120°C.

• Measure the resistive value of the overheating sensor,
connector B1, PIN 2 and 4, for measured values. See page 44.
– If overheating sensor ok, check connection leads for conti-

nuity, shor t circuit and damage.

014 Possible overheating dettected Difference between measured value in overheating sensor and

(Temperature difference evaluation) temperature sensor is too large.

• Measure the resistive value of the temperature sensor,
connector B1, PIN 2 and 4 and connector B1 PIN 1 and 2; for
measured values.See page 44.
– If temperature sensor ok, check connection leads for

continuity, shor t circuit and damage.

015 Too many overheats, Control box locked due to too frequent overheating (fault code

Control box is locked 012 or 014) in succession.

• Unlock the control box by deleting the fault memory, see
pages 16 and 25.

017 Overheating, Max. temperature exceeded at the overheating sensor (180°C).

Sensor threshold exceeded • Check overheating sensor —> fault code 012.

• Check control box.

019 Glow plug 1, Glow plug 1 energy input is too low (< 2000 Ws)

Ignition energy too low • Check glow plug for continuity, short circuit and damage

—> Fault code 020.

• Check control box.

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

s

Fault Code Fault Description Causes / Repair

020 Glow plug 1, interruption • Measure cold resistance of the glow plug at approx. 20°C

ambient temperature – connector B1, PIN 7 and 10.

021 Glow plug 1, over load / shor t circuit If the values are as follows the glow plug is ok, if the values

downstream of (–) differ – replace the glow plug.

022 Glow plug 1, short circuit downstream Measured value:

of (+) • 12 volt – glow plug = 0.42 – 0.6 ohm

• 24 volt – glow plug = 1.2 – 1.9 ohm
– If the glow plug is ok, check the lead harness of the glow plug

for continuity, short circuit and damage.

023 Glow plug 2, interruption • Measure cold resistance of the glow plug at approx. 20°C

ambient temperature – connector B1, PIN 11 and 14.

024 Glow plug 2, over load / shor t circuit If the values are as follows the glow plug is ok, if the values

downstream of ground differ – replace the glow plug.

Measured value:

• 12 volt – glow plug = 0.42 – 0.6 ohm

• 24 volt – glow plug = 1.2 – 1.9 ohm
– If the glow plug is ok, check the lead harness of the glow plug

for continuity, short circuit and damage.

025 Diagnostic line fault • Check diagnostics cable for continuity, short circuit and

Heater remains ready for operation damage – connector B2, PIN B4.

– if ok, check control box.

026 Glow plug 2, short circuit downstream see fault code 023 / 024

of (+)

029 Glow plug 2, Ignition energy too low Glow plug 2 energy input is too low (< 2000 W)

• Check glow plug for continuity, short circuit and damage.
—> Fault code 023.

• Check control box.

033 Burner motor, interr uption • Check the burner motor's connection leads for continuity, shor t

circuit and damage – connector B1, PIN 3, 6 and 9.

033 Burner motor, overload • Check burner motor for easy movement b y manually rotating the

impeller.
– if not smooth r unning, remove the blockage.

033 Burner motor, speed error / blocked – if ok, replace control box / blower unit.
034 Burner motor shor t circuit

downstream of (+) or (–)

037 Water pump not working • Check water pump.

Apply voltage to the water pump – connector B1, PIN 12 and 13
(power input = max. 4 A or 2 A)
– If water pump does not rotate, replace water pump.
– If water pump is ok –> replace control box / blower unit.

041 Water pump, interruption • Check the water pump's connection and lead harness for con-

tinuity, short circuit and damage – connector B1, PIN 12 and 13.

042 Water pump

Overload short circuit Water pump running dry.

043 Water pump • Vent heater (water shortage), open heater slide valve, check

Overload downstream of +Ub water flow rate

– If ok, check water pump —> fault code 037.

27

Maintenance, Troubleshooting & Repairs

Fault Code Fault Description Causes / Repair

047 Metering pump • Check the metering pump's connection and lead harness for

Overload short circuit continuity, short circuit and damage – connector B2, PIN A1.

If ok, check the resistance of metering pump – setpoint value

–

approx. 20 ohm.

048 Metering pump interruption
049 Metering pump

Overload downstream of +Ub

050 Too many attempted starts Control box locked due to repeated switching on in succession

Control box is locked without flame detection (fault code 052).

• Check fuel supply, exhaust and combustion air system.

• Check glow plug –> see fault code 019 to 024 / 026 / 029.

• Check flame sensor –> fault code 064 / 065.

• Unlock the control box by deleting the fault memor y.

052 Exceeding of safety time No flame detected within the start phase. Flame sensor value <

80°C,

therefore automatic shutdown because safety time exceeded.

• Check fuel supply, exhaust and combustion air system.

• Check glow plug –> see fault code 019 to 024 / 026 / 029.

• Check flame sensor –> fault code 064 / 065.

053 Flame cutout in Heater ignited (flame detected) and signals flame cutout during a

"POWER" control stage power stage.

• Check fuel quantity, blower speed, fuel supply, exhaust and com­bustion air system.

054 Flame cutout in "HIGH" control stage • Check flame sensor –> fault code 064 / 065.
055 Flame cutout in "Medium" control stage

(D 8 W / D 10 W) "Medium1" control stage
(D 12 W)

056 Flame cutout in

"Medium 2" control stage (D 12 W)

057 Flame cutout in

"Medium 3" control stage (D 12 W)

058 Flame cutout in "LOW" control stage

059 Too rapid r ise in water temperature • Vent air from system, open heater slide valve, check water flow

rate.

• Check temperature sensor –> fault code 060 / 061

060 Temperature sensor interruption Temperature sensor signals temperature value outside the

measuring range.

061 Temperature sensor short circuit • Measure the resistive value of the temperature sensor,

064 Flame sensor interruption Flame sensor signals temperature value outside the measuring

065 Flame sensor shor t circuit • Measure the resistive value of the flame sensor – connector B1,

28

Connector B1, PIN 1 and 2; for measured values. See page 44.
– If temperature sensor ok, check connection leads for continuity,

short circuit and damage.

range.

PIN 5 and 8; for measured values. See page 45.
– If flame sensor ok, check connection leads for continuity, short

circuit and damage.

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

s

Fault Code Fault Description Causes / Repair

071 Overheating sensor interruption Overheating sensor signals temperature value outside the mea-

suring range.

• Check overheating sensor –> fault code 012.
072 Overheating sensor short circuit
074 Overheating detection hardware is • Control box is defective.

defective, operating lock-out Replace control box / blower unit.

090 External reset • Control box reset by external interference voltage.

Check voltage supply, e.g. battery, leads, generator, fuses.
091 Internal reset • Internal control box fault, replace control box / blower unit.
092 ROM error
093 RAM error, at least one RAM cell is

not working

094 EEPROM error, checksum error within

the area of the operating data, diagnostic

parameters or calibration values
095 Invalid data record, checksum error
096 Internal temperature sensor is defective

/ ECU too hot
097 Internal device error
098 Main relay is faulty
099 Too many resets, operating lock-out

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Repair Instructions

s

The permitted repair work on the heater is described in the
"Repair Instructions" chapter. The heater must be removed
from the vehicle for the repair work to be carried out.
The heater is assembled in the reverse order, note and follow
any additional instructions.

Note: After completing all the work and installing the heater

in the vehicle, perform a functional check on the heater.

Always observe the following safety instructions before

orking on the heater

w

Warning - Risk of injury, burns and
poisoning

• Ensure power is disconnected from heater and that coolant is

cool bef

• The heater must not be operated in closed rooms such as

garages or workshops.
Exception:
Exhaust suction available directly at the entry to the exhaust

pipe on the heater.

ore dismantling the heater.

Terminal Removal Tools are used to release plug-in contacts
in a connector housing.

Terminal Removal Tool 1.6mm 206 00 205

Terminal Removal Tool 2.8mm 206 00 215

Caution: • The seals of dismantled components must be

renewed.

• During repair work, check all components for
damage and if necessary replace.

• Check connector contacts, plug-in connections
and cables for corrosion and damage and if
necessary repair.

• Only use Espar spare parts if replacements are
necessary.

• After working on the coolant circuit the level of the
coolant must be checked and if necessary topped
up according to the vehicle manufacturer's
instructions.
The coolant circuit must then be vented.

• Operation or the “after running” of the heater ma
only be stopped in an emergency (Turn off switch,
remove fuse or disconnect battery) by interrupting
the battery current (risk of heater over-heating).

Heater Components

1 Impeller cover
2 O-ring 117.07 x 3.53
3 Cover, side
4 Impeller
5 Glow plug 1
6 Glow plug 2
7 Spark plug socket lining
8 Combustion chamber
9 M5 x 16 TAPTITE / DIN 7500 TORX screw
10 Control box / blower unit
11 Flame sensor
12 Cable tie
13 Electric motor cover
14 M5 x 16 TAPTITE / DIN 7500 TORX screw
15 M4 x 12 TAPTITE / DIN 7985 TORX screw
16 Compression spring
17 Overheating sensor
18 Temperature sensor
19 Overheating / temperature sensor cable loom
20 Jacket with heat exchanger
21 M5 x 25 TAPTITE / DIN 7500 TORX screw
22 Grommet
23 Combustion chamber seal
24 Water pump cable loom connector
25 Hose clip
26 Water pump
27 O-ring 19.8 x 2.3
28 14-pin connector

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Preparatory work for all repairs

Figure 1 and 2

Clamp the removed heater in a retaining device (vice).

•

• Using 2 screwdrivers, always undo 2 snap connections
of the impeller cover at a time, starting at the control
box/blower unit. Keep to the order shown in the figure
(1.– 8.)

• Remove cover.

• Remove O-ring (2).

Note: The O-ring (2) must always be renewed.

s

Remove overheating sensor and temperature sensor

Figure 3 – 5

• Remove the (15) M4 x 12 screws of the compressive springs
(16) and use pliers to pull off the overheating (17) and
temperature sensor (18).

Note: Do not pull out the overheating (17) and temperature

sensor (18) from the holder by pulling on the connec­tion cable, always use pliers to remove them.

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Repair step 1

Dismantle control box/blower unit and jacket

Remove water pump connector

Figure 6

• Disconnect the connector (24) at the water pump (26) and pull
the cable loom out of the holder.

Remove side cover and dismantle jacket

Figure 7

• Pull out side cover (3) from abo

• Undo the 4 screws (21) M5 x 25 in the jacket (20) and remove
the jacket from the control box / blower unit.

ve.

s

Note: The control box / blower unit may not be placed on the

exposed impeller.

Remove electric motor cover

Figure 8

• Undo the 2 screws (14) M5 x 16 of the electric motor co
and remove the cover.

Note: The control box / blower unit may not be placed on the

exposed impeller.

ver (13)

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

A Long wire (brown, white)

Figure 11

B Short wire (brown, white)

A AMP release tool

Figure 10

29 14-pin connector

1

1 Flame sensor

Figure 9

1

2 Cable tie

1

2 14-pin connector

Sketch 1

Temperature sensor, Yellow

Sensor ground, Blue / White

Overheating sensor, Red

Motor, Phase 1, Pink

Motor, Phase 2, Green

Motor, Pha se 3, Orange

Flame sensor +, Blue

Flame sensor, Brown

Glow pl ug 1, long c able , Brown

Glow pl ug 1 +, long cable , White

Glow plug 2 +, short cable , White

Glow plug 2, short c able , Brown

Water pump, Black / Red

Water pump, Brown / Black

Repair step 1

Dismantle control box/blower unit and jacket

Disconnect 14-pin connector at control box and release cables

Figure 9 – 11 / Sketch 1

Use side cutters to open the cable tie (12).

•

• Disconnect the 14-pin connector (29).

• Use the terminal removal tool to remove pins in the 14-pin con­nector (29) for the electric motor, flame sensor (11), glow plug
1(5) and glow plug 2 (6).

• Expose the cables of the two glow plugs from above (cable duct).

Note: When replacing the control box / blower unit, the

Temp / Overheat sensor and water pump lead
harnesses can be left in the 14-pin connector (29).

s

33

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Repair step 1

Control box / blower unit and jacket

Remove flame sensor

Figure 12

• Unscrew the flame sensor (11) from the housing of the control
box / blower unit.

Dismantle combustion chamber

Figure 13 and 14

Undo the 3 screws (9) M5 x 16 of the combustion chamber (8).

•

• Lift the combustion chamber (8) with the fuel pipe until the
grommet (22) is exposed, then remove the combustion cham­ber.

• Remove combustion chamber seal (23).

s

Note: Remove combustion chamber seal (23) without leaving

residues. Always check the glow plugs during this repair
step, see repair step 3.

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Repair step 2

Assemble the control box/blower unit and jacket

Install combustion chamber seal

Figure 15 and 16

• Carefully guide the combustion chamber seal (23) over the
cables of the glow plugs and over the fuel pipes and position
on the combustion chamber (8).

Note: T ake care when installing the ne w combustion chamber

seal (23) as there is a risk of breaking it.

Install grommet

Figure 16 and 17

• Carefully position the g

chamber seal (23).

rommet (22) on the combustion

s

Note: Ensure the grommet is installed in the correct position,

see Figure 17.

Insert combustion chamber

Figure 18

First insert the combustion chamber (8) with the grommet

•
(22) into the control box / blower unit (10). If the grommet (22)
has been completely inserted, align the combustion chamber
and combustion chamber seal with the control box / blo wer unit
(10).

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Repair step 2

Assemble the control box/blower unit and jacket

Install combustion chamber

Figure 19

• Use 3 screws (9) M5 x 16 to fix the combustion chamber (8).

Tightening torque M5 x 16 screw.

s

Lay sensor lead harness and leads of the glo

Figure 20 and 21

• First lay the sensor lead harness (19) in the side cable duct,
then lay the 4 leads of glow plugs 1 (5) and 2 (6) in the cable
duct.
Lay the sensor lead harness (19) and the glow plug leads to
the 14-pin connector (29 - shown in page 33).

• Position the side cover (3) on the middle of the control box /
blower unit (10) and push into the cable duct guide.

Note: It is imperative to keep to the correct laying order for

the sensor lead harness (19) and the glow plug leads.
The glow plug leads may not be laid underneath the
sensor lead harness (19).
The sensor lead harness (19) must be laid in the area
of the fuel pipe as shown in Figure 20.
The side cover (3) is conical at the bottom to simplify
installation.

w plugs

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Sketch 2

Temperature sensor, Yellow

Sensor ground, Blue / White

Overheating sensor, Red

Motor, Phase 1, Pink

Motor, Phase 2, Green

Motor, Pha se 3, Orange

Flame sensor +, Blue

Flame sensor, Brown

Glow pl ug 1, long c able , Brown

Glow pl ug 1 +, long cable , White

Glow plug 2 +, short cable , White

Water pump Brown , Black

Glow plug 2, short cable , Brown

Water pump, Black / Red

Repair step 2

Assemble the control box/blower unit and jacket

Install flame sensor

Figure 22

• Screw the flame sensor (11) into the housing of the control
box / blower unit.
Flame sensor tightening torque.

Connect flame sensor lead harness and electric motor
leads

Figure 23 / Sketch 2

s

• Latch the flame sensor lead har

ness (11) and the three leads

of the electric motor into position in the 14-pin connector (29)

Note: • The leads may not lay against the housing.

• Always lay the Brown / White (long) leads of glow
plug 1 (5) last and latch into position in the 14-pin
connector (29).

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Temperature sensor, Yellow

Sensor ground, Blue / White

Overheating sensor, Red

Motor, Phase 1, Pink

Motor, Phase 2, Green

Motor, Phase 3, Orange

Water pump, Brown / Black

Flame sensor +, Blue

Flame sensor, Brown

Glow pl ug 1, long c able , Brown

Glow pl ug 1 +, long cable , White

Glow plug 2 +, short cable , White

Glow plug 2, short c able , Brown

Water pump, Black / Red

Sketch 3

Repair step 2

Assemble control box/blower unit and jacket

Connect the glow plug leads

Figure 24, 25 and Sketch 3

First, latch the leads of glow plug 2 (6 / short leads) into

•
position in the 14-pin connector (29).
Then wind the leads of glow plug 1 (5) 2 x around the leads
already latched into position in the 14-pin connector and then
latch into position in the 14-pin connector (29).
Use a cable tie (12) to bundle all leads above the winding.
Connect the 14-pin connector (29) to the control box / blower
unit.

s

38

Note: • The leads may not lay against the housing.

• Check the glow plugs before completely assembling
the heater.For check values, see fault code 020 / 021.

MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Repair step 2

Assemble control box/blower unit and jacket

Install electric motor cover

Figure 26 and 27

• Position the electric motor cover (13) on the housing of the
control box / blower unit, at the same time, inser t the water
pump lead harness in the groove provided in the cover.

• Use 2 screws (14) M5 x 16 to fasten the electric motor
cover (13) onto the housing of the control box / blower unit.

.

Assemble control box / blower unit and jacket

Figure 28

s

osition the heat exchanger on the control box / b lo wer unit and

P
fasten with 4 screws (21) M5 x 25.

Note: Tighten the 4 screws (21) M5 x 25 cross-wise (i.e.

tighten diagonally opposite screws).

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Repair step 2

Control box/blower unit and jacket

Lay water pump lead harness

Figure 29

• Inser t the water pump lead har ness into the holder on the
jacket, lay up to the water pump and connect.

Install overheating and temperature sensor

Figure 30 and 31

s

Insert the overheating (17) and temperature sensor (18)

•

into the holders on the jacket.

Insert the sensor cable loom (19) into the holders on the
jacket.
Use 2 screws (15) M4 x 12 to fasten both springs (16) on the

overheating (17) and temperature sensor (18). (See page

31)

Note: Insert the temperature sensor as shown in the figure

to avoid pinching the cable loom.

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Repair step 2

Control box/blower unit and jacket

Install impeller cover

Figure 32

• Clamp the removed heater in a retaining device (vice) and
position the new O-ring (2) on the control box / blower unit.

• Install the impeller cover; ensure that none of the leads of the
sensor lead harness (19) get jammed. (See page 40)

s

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Repair step 3

Control box/blower unit and jacket

Remove / check glow pin

Figure 33

•

Carry out repair step 1.

• Unscrew glow pins 1 (5) and 2 (6) from the combustion cham
ber housing (8) (See page 36), if necessary check the glow
plugs; for check values see fault code 020 / 021.

• Visually check the glow pin socket lining, if necessary renew
the glow pin lining.

Install glow pin

Figure 33

•

Screw glow pin 1 (5) with long connection leads into the left­hand spark plug socket (2 fuel lines).

• Screw glow pin 2 (6) with short connection leads into the right­hand spark plug socket (1 fuel line).

• Assemble the heater according to repair step 2.

s

Characteristics of the glow pins

Glow pin 1 (5) long leads

– brown lead in Chamber 7
–

white lead in Chamber 10

Glow pin 2 (6) short leads

– brown lead in Chamber 14
– wt lead in Chamber 11

12 volt glow pin

– green band around the brown and white leads

24 volt glow pin

– yellow band around the brown and white leads

Clean ignition air drillholes

Figure 34

•

Use a pointed object to clean the ignition air drillholes in the
left-hand and right-hand spark plug sockets.

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Repair step 4

Remove glow pin socket lining

Figure 35

•

Carry out repair step 1.

• Unscrew glow pin from the combustion chamber housing
(8).

• Use a pointed object to pull the glow pin socket lining out
of the glow pin socket.

Install glow pin socket lining

Figure 36, 36/1

s

• Insert the glow pin socket linings
facing upwards, into the spark plug sockets up to the limit
stop.

Note: Ensure the ignition air drillhole in the glow pin socket is

not concealed by the spark plug socket lining.

• Assemble the heater according to repair step 2.

, with the bevelled edge

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Resistance R

NTC

(kΩ)

Te mperature (°C)

Temp[°F]

Ta ble of values

Temp[°C] 0 25 40 60 80 100 120

R

NTC

[kΩ]32.55 10 5.33 2.49 1.26 0.677 0.389

32 77 104 140 176 212 248

Repair step 5

Check overheating and temperature sensor

Figure 37 / Diagram 1

• Removal of the overheating (17) and temperature sensor (18)
is described in repair step 1.

• Use the digital multimeter to check the overheating (17) and
temperature sensor (18).

If the resistance value lies outside the table of values or the
diagram, then replace the overheating (17) and temperature
sensor (18).

• Installation of the overheating (17) and temperature sensor
(18) is described in repair step 2.

s

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Te mperature (°C)

Resistance (

Ω)

Temp[°F]

Table of values

Temp[°C] -50 0 50 100 150 200 250 300 350 400

R [Ω] 803 1000 1194 1385 1573 1758 1941 2120 2297 2470

Diagram 2

-58 32 122 212 302 392 482 572 662 752

Repair step 6

Check flame sensor

Figure 38 / Diagram 2

• Removal of the flame sensor (11) is described in repair step 1.

• Use the digital multimeter to check the flame sensor (11). If the
resistance value lies outside the table of values or the diag ram,
then replace the flame sensor (11).

• Installation of the flame sensor (11) is described in repair step

2.

s

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

Repair step 7

Remove / attach water pump

Figure 39

• Disconnect the connector (24) at the water pump (26).

• Undo the hose clip (25)

• Remove the water pump.

• Check O-ring (See page 50 parts diagram #13), replace if
necessary

• Install in the reverse order.

Note: When assembling the O-ring coat it with lubricant.

s

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MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrs

leuf fo ytitnauQretaeH

Desired Maximum Minimum

HYDRONIC M8
Diesel / FAME

5

.7 ml/

68 sec

6

.27 ml/

68 sec

5

.13 ml/

68 sec

HYDRONIC M10
Diesel

7

.5 ml/

6

8 sec

8

.25 ml/

6

8 sec

6

.75 ml/

6

8 sec

HYDRONIC M12
Diesel

7.5 ml/
68 sec

8.25 ml/
68 sec

6.75 ml/
68 sec

Sketch 4

Measuring the fuel quantity

s

Preparing for the measurement

(Sketch 4)

• Disconnect the fuel pressure line at the heater and place the
end in a measuring cylinder (size 25 ml).

• Switch on the heater, if the fuel discharges uniformly and
free of bubbles, the fuel pipe is filled and vented.

• Switch off heater and empty measuring cylinder.

Measurement

• Switch on heater and wait until the metering pump stars pum­ping the fuel.

During the measurement, hold the measuring cylinder at the

•
level of the heater.

After 68 sec. the pumping of the fuel is automatically switched
off.

• Switch off heater, as otherwise it will start up again.

• Read off the quantity of fuel in the measuring cylinder.

Evaluation

Compare the measured quantity of fuel with the values in the

wing table.

follo
If the measured quantity of fuel is above the maximum value or

below the minimum value, the metering pump must be
replaced.

Note: Only carry out the fuel measurement if the batter y is

sufficiently charged. During the measurement the volt
age applied to the control box should be at least 11 volt
or 23 volt and max.
13 volt or 25 volt.

47

HHeeaatteerr CCoommppoonneenntts

s

Hydronic M-II Parts Diagram

48

HHeeaatteerr CCoommppoonneenntts

s

Hydronic M-II - 12 & 24 volt - Diesel & Gasoline versions

Description & Part #’s

Ref. No. Description Part Number

1 Combustion air blower/ECU 12 V 25 2470 99 15 00 •

24 V 25 2471 99 15 00 •
12 V 25 2434 99 15 00 •
24 V 25 2435 99 15 00 •
12 V 25 2472 99 15 00 •

24 V 25 2473 99 15 00 •
2 Bur ner assembly 25 2435 99 11 00 • • • • • •
3 Casing 25 2435 99 01 02 • • • • • •
4 Water pump 12 V 25 2434 99 25 01 • • •

24 V 25 2435 99 25 01 • • •
5 Flame sensor 25 1920 35 01 00 • • • • • •
6 Glow pin 12 V 25 2434 01 01 00 • • •

24 V 25 2435 01 01 00 • • •
7 Water pump harness 25 2435 25 02 00 • • • • • •
8 Temperature overheat sensor 25 2435 40 01 00 • • • • • •

Model #

25 2470 05 12V

25 2471 05 24V

25 2434 05 12V

25 2435 05 24V

25 2472 05 12V

25 2473 05 24V

9 Bottom cover blower housing 25 2435 01 00 02 • • • • • •
10 Cover 25 2435 99 01 03 • • • • • •
11 Cover blower housing channel 25 2435 01 00 04 • • • • • •
12 Seal for combustion chamber 25 2435 01 00 10 • • • • • •
13 Water pump O-Ring 19,8 x 2,3 22 1000 70 00 17 • • • • • •
14 Blower O-Ring 117,07 x 3,53 22 1000 70 00 15 • • • • • •
15 Fuel pipe grommet 25 2435 01 01 04 • • • • • •
16 Fuel pipe sleeve 20 1752 01 00 02 • • • • • •
17 Spring clip 25 2281 01 00 09 • • • • • •
18 Screen for glow pin 25 2069 10 01 02 • • • • • •
19 Hose clip 35 – 55 152 61 004 • • • • • •
20 Taptite screw M 5 x 25 109 10 152 • • • • • •
21 Taptite screw M 5 x 16 109 10 151 • • • • • •
22 Taptite screw M 4 x 12 5590010 • • • • • •
23 Cable tie 5590147 • • • • • •

49

HHeeaatteerr CCoommppoonneenntts

3

4

2e

2d

2c

2b

33

31

32

Subtitle Left Page

Hydronic M Parts Diagram

s

50

Heater Components

Hydronic M-II - 12 & 24 volt - Diesel & Gasoline versions

Description & Part #’s

Ref. No. Description Part Number

1 Fuel metering pump 12 V 22 4617 01 00 00 • • •

24 V 22 4618 01 00 00 • • •
2a Cable harness - (JE Harness) ADR 25 2435 80 07 00 • • • • • •

25 2435 80 06 00 • • •

2b Cable harness - Universal (No Relay) 12 V 25 2800 70 10 12 • • •

24 V 25 2800 70 10 24 • • •
2c Boxed Adapter har ness 25 2800 70 10 03 • • • • • •
2d Main box harness 12 V 25 2800 70 00 02 • • •

24 V 25 2800 70 00 04 • • •
2e Diagnostic adapter 25 2800 70 10 04 • • • • • •
3 Relay harness 22 1000 33 04 00 • • • • • •
4 Cable harness 22 1000 33 02 00 • • • • • •
5 Exhaust muffler 25 1806 80 01 00 • • • • • •
6 Intake silencer 25 1786 80 02 00 • • • • • •
7 Flex exhaust w/cap 25 1816 80 08 00 • • • • • •
8 20mm 90° bend coolant hose 20 1673 80 00 01 • • • • • •
9 20mm 180° bend coolant hose 20 1673 80 00 03 • • • • • •
10 Heater bracket 25 1816 80 00 01 • • • • • •
11 Cable tie 12” 5590147 • • • • • •
12 1.5 mm Plastic fuel line 890 31 118 • • • • • •
13 5mm Fuel hose (biodiesel compatible) 360 75 401 • • • • • •
14 Fuel hose 5x3mm 360 75 350 • • • • • •
15 Fuel line adaptor 3.5 - 5mm 25 1888 80 01 02 • •
16 Fuel hose 3,5 x 3 360 75 300 • • • • • •
17 9mm clamp 10 2068 00 90 98 • • • • • •
18 11mm clamp 10 2068 01 10 98 • • • • • •
19 Holder metering pump 22 1000 50 07 00 • • • • • •
20 FMP angle bracket 20 1348 03 00 04 • • • • • •
21 Metal r ubber buffer 20 1185 00 00 01 • • • • • •
22 Connection piece 20 1534 88 00 01 • • • • • •
23 Clamp 20 - 32mm 10 2066 02 00 32 • • • • • •
24 Flex exhaust clamp 152 09 003 • • • • • •
25 Clamp “C” type 152 10 060 • • • • • •
26 Hose connection piece 20 1623 45 00 02 ?????? • • • • • •
27 Integrated fuel filter 20 1312 00 00 06 • • • • • •
28 Socket housing 22 1000 31 93 00 • • • • •
29 Grommet 20 1280 09 01 03 • • • • • •
30 Fuse holder, receptacle housing kit 22 1000 31 06 00 • • • • • •

Model #

25 2470 05 12V

25 2471 05 24V

25 2434 05 12V

25 2435 05 24V

25 2472 05 12V

25 2473 05 24V

51

Heater Components

Hydronic M-II - 12 & 24 volt - Diesel & Gasoline versions

Description & Part #’s

Ref. No. Description Part Number

31 Fuse 25 A 204 00 089 • • • • • •

15 A 204 00 003 • • • • • •

5 A 204 00 079 • • • • • •

32 Relay 12 V 203 00 065 • • •

24 V 203 00 066 • • •

33 Convoluted tubing 1” X 17” 20 2900 70 90 16 • • • • • •

1/2” X 12” 20 2900 70 90 08 • • • • • •

3/8” 20 2900 70 90 13 • • • • • •
3/4” 5670380 • • • • • •

1” 20 2900 70 90 14 • • • • • •
34 Plastic fuel line 890 31 101 • •
35 Ring Terminal 5/16” 5670196 • • • • • •

Model #

25 2470 05 12V

25 2471 05 24V

25 2434 05 12V

25 2435 05 24V

25 2472 05 12V

25 2473 05 24V

52

1st Printing - Apr 2008
Printed in Canada
P/N: 20 2900 81 0102 0A

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