Page 1
--------.------------------~-----
e
For
01
LC
Model:
2516880512V
2517670512V
2517740512V
2518300512V
D1L-C
INSTALLATION
TROUBLESHOOTING
&
PARTS
MANUAL
2516890524V
25
1768
05
24V
25
1775
05
24V
25
1831
05
24V
MARCH
1995
Page 2
TABLE
OF
CONTENTS
I.
INTRODUCTION
1)
Heater Warnings
2)
Heater Introduction
3)
General Specification
4)
D1
LC
Principal Dimensions
5)
Mounting Pattern
6)
Heater Components
II. INSTALLATION PROCEDURES
1)
Heater Location
2)
Heater Mounting
3)
Heating Air Ducting
4)
Fuel
System
5)
Electrical Connections
6)
Exhaust Connection
7)
Combustion Air Intake Connection
8)
Temperature Sensors
9)
Operating Switch
III.
HEATER
OPERATIONS .
1)
Switch On/Start-Up
2)
Running
3)
Switching Off
4)
Safety Equipment
5)
Operational Flow Chart
IV.
MAINTENANCE AND
1)
Recommended Periodic Maintenance
2)
D1
LC
Wiring Diagram
3)
Troubleshooting
4)
Diagnostic Codes
5)
Fuel
Quantity
Test
6)
Heater Repair Steps
V.
HEATER
PARTS
SECTION
1)
D1
LC
- Service Parts Diagram
2)
D1
LC
- Parts List
SPECIAL
NOTES
Note: Highlight areas requiring special attention or clarification.
Caution: Indicates that personal injury
or
damage to equipment
guidelines are
followed.
A.
Warning: Indicates that serious personal injury or death
.l11I1i~
lines are not followed.
-1-
1.
HEATER
WARNINGS
Warning
To
Installer:
Correct installation
of this heater is necessary to ensure safe and proper
operation. Read and understand this manual before attempting to
install a
heater.
A.
Warning
-.
Explosion Hazard
A Warning-
1.
Heater must be turned off while re-fueling.
2.
Do not install heater in enclosed areas where combustible fumes may be
present.
3.
Do not install heaters in engine compartments of gasoline powered boats.
Fire Hazard
1.
Install
heater
so
it
will
maintain a minimum
distance
of
2"
from
any
flammable
or
heat sensitive material.
2.
Install the exhaust system so it will maintain a minimum distance of
2"
from
any
flammable or heat sensitive material.
3.
Ensure that the fuel system is intact and there are no leaks.
Failure to follow these instructions could cause fire resulting in personal injury or death.
A Warning - Asphyxiation Hazard
1.
Route the heater exhaust so that exhaust fumes cannot enter any passenger
compartments.
2.
Ensure
an
air tight seal will be maintained between the heater and mounting
surface and at any exhaust connection points.
3.
Ensure that heating air supply is taken from
an
area where poisonous gases
will not be present.
4.
If running exhaust components through
an
enclosed compartment, ensure
that it is vented to the outside.·
Failure to
follow these instructions could cause oxygen depletion resulting in personal injury
or death.
Direct questions to Espar Heater Systems -
USA 1-800-387-4800
CDA 1-800-668-5676
Page 3
-
2-
ESPAR-D1
LC
AIR
HEATER
2.
INTRODUCTION
1.
Espar
D1
LC Air Heater - Heater Introduction
The
ESPAR
D1LC is a diesel-fired 6,150
BTU/HR
air heater, quality engineered to
provide a dependable means of space heating. This heater
is
uniquely designed for
inside mounting and ease of installation.
The heater provides
hot
air
to
the interior of vehicles for passenger comfort.
~in"".
heater runs on diesel fuel and 12 or 24 volt
power,
it is able to perform
independent of the vehicle engine.
The heater
is
operated by a rheostat switch for h"",tinln
ciapSlclt~(.;
through three temperature settings (high-medlum-Iowl
temperature.
If,
in
special cases, even less
supplies
in
the "Low" setting, it switches
tothe
limit switches, and a specially
de~)igrled
hecifEll<clla6
which make this heater a safe
anlcldepj~.nclal:ll~IJnjl;~'c:f
3.
GENERAL SPECIFICATIONS
Model 25 1830
05
12V
25
1831
05
24V
Heat
Output (+10%)
Current at 12v (+10%)
Current
at
24v (+10%)
Fuel
Consumption (+5%)
Air
Flow (+10%)
Operating Voltage Range
Overheat Temperature Shutdown
(+10%)
High
Med.
Low
U.S.
Gal/hr
. 06
.04
.03
54 cfm High
34 cfm Med/Low
10.5
to 15.0 vdc
at
12 vdc
21.0
to 30.0 vdc at 24 vdc
240°F (116°C)
Note: The heater control unit is equipped with a low
t()
battery drain and a high voltage cutout to protect heater electrical parts.
4.
D1
LC PRINCIPAL DIMENSIONS
..
..,
N
...
U.17
with
end
cap
11.42
o
Combustion air Exhaust
fO.n
fO.lIlS
4.114
Fuel
5.
MOUNTING
PATTERN
-
3-
Fr
••
apace
for
glow
plug
ace.
sa
--...
5.20
,---"'"
Me
Fastening
to
the vehicle
wall/floor
make penetrations in
accordance with the
hole pattern .
(*~~~.
<0
~'-~t
-I-
',\.,
.
.,.
\
N·
\~.::~~
.' . ,;I->-
18
55
Page 4
-
4-
6.
HEATER
COMPONENTS
18
14
1.
Hot air blower wheel
10.
Flange seal
2.
PCB with controller
11.
Fuel
line
temperature sensor
12.
Series resistor for glow
3.
Combustion air blower wheel
plug (for 24V only)
4.
Glow plug
5.
Safety thermal cutout switch
6.
Combustion chamber
7.
Flame monitor
8.
Heat exchanger
9.
Outer casing
13.
Blower motor
14.
Combustion air intake line
15.
Exhaust line
16.
Fuel
metering pump
17.
Fuel
strainer
F
= fresh air
V
= Combustion air
B
= fuel
W =
IIV
•.
",";.;
A
- 5 -
II.
INSTALLATION
PROCEDURES
1.
Heater
Location
Depending on the type of vehicle, the best location for mounting the heater will
vary.
Basically, the heater may be mounted anywhere inside the vehicle provided you adhere
to the following conditions:
A)
Combustion air intake, exhaust and fuel inlet must be located outside of vehicle.
B)
Heater must be mounted on flat horizontal surface providing
an
air tight seal
between heater and vehicle.
C) Do not mount the heater outside the vehicle, unless care is taken to protect the
heater
from
the weather.
When selecting the location, consider the following:
A)
Combustion air and exhaust connections
B)
Ducting
C)
Fuel
line connections
D)
Electrical connections
2.
Heater
Mounting
A mounting plate and hardware are provided with the heater
kit.
A)
Heater
• Choose heater location.
• Using template provided, drill and cut center hole (depending if you choose one
circular hole or one rectangular hole) and four plate mounting holes.
• Cut one
(1)
four and one half inch (4%") diameter hole or one rectangular hole
four
(4")
by
five (5") inches.
• Mount heater on mounting plate with nuts and spring washers provided.
• For ease of installation make
the
exhaust,
combustion
air
intake and fuel
connections at base of heater before mounting the heater into the vehicle.
• Position heater
in
vehicle and bolt down with hardware provided.
Note:
Tighten bolts sufficiently to ensure positive seal between mounting plate and
mounting surface. Do
not
over tighten bolts.
HEATER
MOUNTING
PLATE
INSTALLATION
HEX
HEAD TEK SCREW
FLAT
WASHER-
-...L-=~~~~====S~ILlCONE
GASKET
. '
L':"':":"~'
.:..
•.
'-'.;...:...:....:..~:P
NUT-G:.
~
SPRING
WASHER
/S.S.
PLATE
PLATE
SEAL
Page 5
-
6-
B)
Control Unit and Voltage Regulator
• Mount control unit using bracket provided
in
a convenient location near
heater.
• Mount voltage regulator beside control unit.
Note: Always mount control unit with pins pointing downwards to ensure that no moisture
or water can enter the unit.
•
It
is
possible to mount control unit at
is available. The
following diagram
ilh.Jstrcltel)t:lII()IJIIt:lblc;lJO~tc
Control unit allowable installation angles:
3.
HEATING AIR DUCTING
A) Installation
A two inch (2") flexible duct
(40
inches long),
with the heater
kit.
In
routing and installing the ducting the following criteria
must
- Do not use existing vehicle ducting
or
outlets. They. may not be rated
at
Espar
operating
temperature
standards.
Ducts
and
outlets
must
be
capable
of
withstanding a minimum of 300°F operating temperatures. Beware of vehicle
systems,
especially plastic ones.
-
Run
ducting with smooth bends. Avoid crushing duct.
Position hot air outlet so that it cannot be obstructed.
Use
protective air intake grille
on
air inlet side of heater to prevent objects from
being sucked
in.
Do not overtighten duct clamps.
Do not position outlet so that it will blow hot air directly at
nn"""t'lr
ri,;if'i~~,
thermostat.
---
------------------------------------------,
- 7 -
Caution:
Do
not
connect
too
many
components
it?
your ducting system. The sum
of
component ratings may
not
exceed the value
of
ten
(10).
*See the following ducting component rating for details.
Warning: Heating air inlet must be installed
in
an area where exhaust
from
the
vehicle's engine or
from
the heater cannot enter under normal operating
conditions.
B.)
Ducting Component Rating
To
make sure your ducting installation does not exceed allowable rating simply add
component ratings of
all components used including all bends made
in
the flexible
duct. This sum should not exceed ten
(Use
table below).
COMPONENT RATING DIAGRAM AND
TABLE
ITEM DESCRIPTION
1 Protective Grille
2 Air Outlet Hood
3 Hose
Clamp 2"-2%" (50-70mm)
4 Flex Duct
23fa"
(60mm)
5 Air Outlet - Rotatable
6 Connection
Piece
90°
Bend of Duct - 2
318"
(60mm)
COMPONENT
RATING
2.0
1.0
0.35/ft
1.0
0.4
1.0
PART
NUMBER
251688800600
251688800300
CA110047
10211431
0000
201577 89 06 00
201577890601
Page 6
!
!
-
8-
4.
FUEL
SYSTEM
The fuel metering pump is the heart
of
the system and must be installed properly to
insure a successful heater operation.
All parts necessary to do the installation are included
in
the kit as shown
in
Fig.
3.
Fig.
1:
Fuel System Overview
1
MAX.
6'6'
MAX
2
'6,1,2.,
__
"
•
.!:'""'~-J"
,.---~I-"""'"
3
I
I
I
1 :
I
I
•
I
I
FUEL
TANK
1.
Fuel
Pick-Up Pipe
2.
5.0
Rubber Connector
3.
10mm Clamp
4.
2.0mm
Black Plastic
Fuel
Line
A)
Fuel Pick-Up Pipe
HEATER
CONNECTION
NOTE:
BUTT JOINTS AND
CLAMPS
ON ALL
CONNECTIONS
Jlr~
~~
~
- Right
Wrong
5.
Fuel
Metering Pump
6.7mmClamp
7.
3.5mm
Rubber Connector
8.
1.5mm White Plastic
Fuel
Line
- Decide on location point for pipe
in
tank
(in
a protected
area).
- Drill a one inch
(1
") hole
in
tank or blanking plate.
-
Install a pick-up pipe as shown
in
Fig.
3A.
-
9-
Fig. 1A: Fuel Pick-Up Pipe Installations
FUEL
PICK-UP
PIPE
NUT
SHEET
METAL
WASHER-(raised center
to
top)
RUBBER
GASKET
~_;;;;;;;;::.......HOLDING
TABS
FUEL
TANK
B)
Fuel Metering Pump
- Decide on location for fuel pump.
- Must be
in
a protected
area.
- Near fuel tank.
ALLOW
4 IN. FROM FUEL
PICK-UP
TO
TANK
BOTTOM.
ALLOW
ONLY
1
INCH
FOR
FLAT
BOTTOM
TANKS.
Note: - The fuel metering pump maximum lengths are shown
in
Fig.
3 - do not exceed
these limits.
_.
Using the bracket and rubber mount provided install fuel pump as shown
in
Fig.
lB.
Note: - The mounting angle of the fuel pump, it is necessary to adhere to this angle to
allow any air or vapour
in
the fuel lines to pass through the pump rather than
cause a blockage.
Fig. 1
B:
Fuel Pump Installation
Note: - Always cut plastic fuel line to length.
~
I 15° to
Iii
vertical
D
\1
_
-j:J.J-
...
r15°1
I
-,~
-".
\
-
To
ensure clean unburred cuts always use a sharp utility knife
to
cut plastic fuel
line.
- Always use butt joints and clamps on all connections.
- Always use fuel line provided with heater - other sizes of fuel line
will reduce
fuel pump efficiency resulting
in
heater operating problems.
Page 7
-------
---
------'----,-'-----~-------~
-
10-
5.
ELECTRICAL CONNECTIONS
A)
Power Harness - 2 core harness
(red
& brown)
-
Red
wire with fuse direct to vehicle battery (positive)
- Brown wire to battery (Ground)
- Connect to 2 pin connector
block at heater harness
B)
Switch Harness
- 6 core harness
(red,
brown, yellow, black, blue and grey)
-
Run
to location of heater control
(ie.
rotary knob or thermostat)
- Connects to 6 pin connector
block at heater harness.
C) Fuel Pump Harness - 2 core harness (green and green)
0)
Wiring Harness
Hood to Heater
-
Run
to location of fuel pump
- Connects using two
(2)
single connector blocks at heater harness
- 14 pin connector and 2 pin connector
-
Gently press the 12 pin connector onto the printed circuit board
on
the top of the
heater.
- Join the 2 pin connector on harness to the 2 pin connector
leading to the glow plug.
- Install ring connectors onto glow plug - model 251830 and 251831
-
Carefully place the hood into position over the glow plug
and printed circuit board area and secure using a 6mm hex wrench.
All harnesses should enter vehicle through sealing grommets.
Electrical Connections
J'
c-
-~-.
jl,
--{...,.Y
Note: - All exposed electrical connections should be coated with profeotilifgre8Se,
(petroleum gel, vaseline,
etc.).
'
"'.'
•
•
-
11
-
6.
EXHAUST CONNECTION
A 24mm flexible stainless steel exhaust pipe (39", long), exhaust clamp and holder are
provided with the heater kit. The exhaust pipe can be shortened to a minimum of
8".
Attach the exhaust pipe to the exhaust outlet of the heat exchanger
(as
shown below).
Once
secured to the heater exhaust outlet, the exhaust pipe must
run
to
an
open area
to the rear or side of the vehicle so that fumes cannot
build up and enter the cab or
the combustion air
inlet to the
heater.
Install protective end cap.
Caution:
ALWAYS
slope
intake
and exhaust pipes
downwards to
allow
water produced by
condensation or
combustion to run out.
~~
?
---"
'''~
~
CUT
Exhaust
Min,8"
CUT
Min.
8'"
Combustion
Air
A WARNING: The exhaust
is
HOT
keep a minimum of
2"
clearance from any heat
sensitive
material.
A WARNING: Route exhaust so that exhaust fumes cannot enter the passenger
compartment or combustion air intake.
Note: -
Run
exhaust so that it cannot
be
plugged by dirt, snow or water and
allows water produced by combustion to run out.
-
Install exhaust pipe with a slight slope and drill a
1/8"
hole
in
the lowest
point to allow water to drain off.
- Any restriction
in
exhaust will cause operational problems.
7.
COMBUSTION AIR INTAKE CONNECTION
A 20mm flexible plastic tube (39" long) for combustion air intake, clamp and holder are
provided with the
kit.
'
Attach the combustion air intake tube to the combustion air inlet of the
heater.
Be
careful
to
keep intake pipe away from exhaust. Once secured to the heater inlet, the intake pipe
must run to the underside of the
vehicle where it will pick up clean, fresh, moisture free
air.
Note: - Please attempt to balance the exhaust pipe length with combustion air tube
lengths.
- The above MUST be adhered to ensure proper operation of the
heater.
Page 8
-
12
-
8.
AIR
TEMPERATURE
SENSORS
A)
Internal
Temperature
Sensor
(Universal
Models
Only)
A temperature sensor
is
provided
in
the heater
on
the heating air intake
side.
This
arrangement of the temperature sensor
is
only suitable
in
return ducted operation
with heaters that
have
blower circulation capability.
Note: -For
01L-C 12V
25176705,25177405,
24V25
176805
and
25
1775
05
when
less heating capacity
is
required than the heater supplies
in
the "Low" setting,·
it
cycles to the
"Off"
setting similar to previous models. Normal continued
operation
follows, and then a constant continued circulation at extremely low
blower
speed, until restart takes place. This allows the internal temperature sensor
to
accurately sense the average bunk temperature.
•.....
'.8
~>
-
13
-
9.
OPERATING
SWITCH
.
Note:
The
01
LC
truck kit
is
supplied with
an
electronic thermostat and a fifteen foot
(15')
switch harness.
The heater
may
be operated using one of the following switch options:
- Rotary control switch with
on
/ off control
-
Rotary control switch with timer for
on/off
control
-
Thermostat with built
in
on/off
switch
A)
Rotary
Control
Switch
and
Optional
Heater
Timer
Two
scales
are
supplied
as
follows:
1
Scale
disc
1 is fitted if operation is
exclusively with the operating unit. The
rotary
control switch then serves as
an
"ON/OFF"
switch
and temperature
controller.
2
Scale disc 2
is
fitted if a timer
is
used
for actuation. Switch
"ON"
is then
exclusively with the heater timer, and
the temperature is selected with the
rotary
control switch. See
wiring
diagram for connection.
Connect
the
six
pin
plug
of
the
switch
harness
to
the
corresponding
plug
on
the
heater
harness.
Connect
the
six
core
switch
loom
to
socket
housing
using
the
terminals
supplied
in
the
kit,
as
follows:
Brown/White wire to terminal No.1
Grey/Red wire to terminal No.2
Blue/White wire
to
terminal
No.3
Black/White wire to terminal NO.4
Red
wire to terminal NO.5
Yellow
wire
to
terminal
No.6
In
cases
where
the
optional
timer
is
used,
disconnect
the
red
wire
from
No. 5 on
the
rotary
control
switch
and
insure
that
the
bare
wire
is
not
exposed.
Note:
If
constant illumination of the switch
is
required, connect a wire
from
the vehicles
lighting circuit to terminal NO.9 of the rotary switch.
Page 9
-
14-
B)
Optional Thermostat with Built-In-Remote Sensor
, 0
o 0
RED
GREEN
0
_'\
C>
~
•
~
This operating device serves
as
an
"ON I
OFF"
switch, thermostat and external
temperature
sensor.
This thermostat option
requires a
special switch harness. Please
refer to parts section for
specific
part
numbers.
Connect the six pin
plug
and
the two pin plug of the switch harness to the corresponding
plugs
on
the main heater harness.
It
should be noted that the two
pin
plug with the single
blacklwhite
wire activates the external temperature sensor, already built into the
thermostat.
Simultaneously, it disengages the internal temperature sensor built into the
heaters
PCB.
Connect the six core switch harness to the thermostats terminal strip
as
follows:
Brown wire to terminal No.1
Grey wire to
terminal No.2
Blue wire to terminal
No.3
Red
wire to terminal
No.5
Yellow wire to terminal
No.6
Black wire to terminal
No.
T
•
-
15
-
III.
HEATER
OPERATION
1.
SWITCH
ON I START
UP
Heater always starts
in
HIGH
mode.
Once switched on the following sequence of events takes place:
A)
Green
pilot light
on
rotary switch
is
on.
Red
and green lights
on
thermostat are
"on" (Control unit does a systems check. Blower motor starts).
B)
Glow plug
begins
to preheat the combustion
chamber
(25-65
seconds
depending
on
the input voltage).
C)
Fuel
pump starts.
0)
Once ignition takes place the flame sensor will signal the control unit to turn
the
glow plug off (motor speed will increase slightly).
E) Heater begins heating interior.
Note: -
If
the heater fails to start the first time it will automatically attempt a second start
if
unsuccessful the heater will shut down completely.
If
input voltage to the control
unit
is
below
10.5
(21
v)
or above
15.0
(30v)
volts the unit will shut down after a
20
second
delay.
2.
RUNNING
A)
Heater runs
in
heat
mode.
B)
Once the air intake (or
room)
temperature set
on
the rheostat has
been
reached
(between
10°C
and 30°C), the heater switches to
"Low"
heating capacity
(reduced
blower noise).
If
the 850W heating capacity
is
insufficient
to
maintain
desired temperature, the heater switches to
"Medium"
(1200W)
with "Low" blower
speed.
In
most cases the Low-Medium-Low control sequence with low blower
speed will supply the heat requirement.
If
however the "Medium" stage
is
not
sufficient, the heater switches back to
"High". This again entails full blower
speed.
Note: - While in running mode if the heater flames out it will automatically attempt a
restart.
- During operation the heater
continually senses input voltage
from
the batteries
- if the input voltage drops to approx.
10.5v
or rises above
15.0v
(21.0v
or
30v
on
24
volts)
the heater will automatically shut down after a three
(3)
minute cool
down cycle.
Page 10
- 16 -
3.
SWITCHING OFF
After switch-off the green pilot light goes out. The blower continues to run for a three
(3)
minute cool down cycle then switches off completely.
4.
SAFETY EQUIPMENT
The flame
is
monitored
by
the flame
sensor.
The overheat termperature
is
monitored
by
the safety thermal cutout switch. Both influence the control unit which switches
off the heater in the event of
malfunction
(See
the following diagram
on
heater
components).
A)
If
the heater fails to ignite within three
(3)
minutes, malfunction shutdown follows.
B)
Overheating (due to restriction of heating air flow
by
blocking inlet or outlet with
blanket, rags, etc.) results in the safety thermal cutout switch popping, with
stoppage of
fuel supply followed by a cool down cycle and a malfunction
shutdown. Green light
on
operating switch will begin a steady flashing code.
C)
If
at
any time the voltage drops below
10.5v
or
21.0v
(as
the case
may
be),
or
rises above
15.0v
or
30.0v
automatic malfunction shutdown follows (after a
20
second
delay).
D)
The heater does not start if the blower motor
is
defective or the electrical cable
to the metering pump
is
broken.
Note: During electrical welding work
on
the vehicle, disconnect the power to the
heater,
in
order to protect the control unit.
A 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.
fit
- 17 -
5.
OPERATIONAL
FLOW
CHART
r{]
I
Os'
~
..
gg
t
t3~
."
L[J
.
~
~
~.
•
,
~.:
~~g
~!r
•
~
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Page 11
- 18 -
IV.
MAINTENANCE AND TROUBLESHOOTING
1.
RECOMMENDED PERIODIC MAINTENANCE
A) Remove the glow plug and inspect for carbon build
up.
Clean or replace.
B)
Remove the glow plug screen and inspect for carbon build
up.
Clean or replace.
If
cleaning
is
required, use brass brush (Espar part number
CAO
05
003).
C)
Make sure vent hole is open. Espar recommends the use of nondetergent 100%
volatile
carburetor cleaner and
an
air gun will also help. Remove loose carbon
from the
glow plug chamber.
D)
Inspect the dueling, the air intake screen and air outlet for restriction or blockage.
E)
Inspect combustion air intake and exhaust for blockage.
F)
Run
your heater and
check
for proper operation during regular Preventative
Maintenance throughout the
year.
G) 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.
H)
. Use fuel suitable for the climate (see engine manufacturers recommendations).
Blending used engine oil with diesel fuel is not permitted.
- 19 -
2.
D1
LC
WIRING DIAGRAM
D1LC - UNIVERSAL (12V/24V)
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speed change and plug distributor
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speed change and plug distributor
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Page 14
3.
TROUBLESHOOTING
BASIC
CHECK
LIST:
-
24-
What happens when the heater is switched on?
A) The heater does not ignite
1)
Blower motor does not run
Check: -
Fuse
in
power harness.
- Power
to
control
unit
- Power to switch.
- Electrical connections.
2)
Blower motor runs approximately 20 seconds and then shuts off
Check: - Ensure voltage at control unit remains above 10.5 volts during start up
with glow plug circuit
on.
3)
Blower motor runslfuel metering pump starts and then shuts down after two 90
second start up cycles
Check: -
Fuel
lines and fuel filter.
-
Fuel
quantity.
- Combustion air or exhaust tube blockage.
4)
Blower motor
runs/no
fuel metering pump
Check: - For electrical pulses at fuel metering pump.
-
If pump
is
frozen.
- Blocked fuel line.
B)
Heater ignites
1)
Shuts down at random
Check: -
Fuel
metering pump quantity.
-
Possible overheat.
- Control unit input
Voltage.
2)
Heater smokes and carbons
up
Check: - Exhaust pipe blocked.
- Combustion air intake blocked.
- Exhaust entering combustion air intake pipe.
- Short cycling, rapid
on/off
operation.
-
Fuel
system.
-
Fuel
metering pump quantity.
- Motor
rpm.
'-----.
1
•
-
25-
C)
SELF DIAGNOSTIC
The
D1
LC
is
equipped with a self diagnoses light
in
the center of the rotary control knob.
The green light
on
the thermostat face will produce fault codes.
In
the event of the component failure or a systems failure during operation the heater
will shut down. A failure code can
be
produced at the green light by jumping pins
#9
and
#11
at the control box for one
(1)
to
three
(3)
seconds. The code will be
in
the form
of a flashing green light. Refer to wiring diagrams.
To
assist the service technician to obtain heater fault
code
the diagnostic box as
illustrated
in
figure
1)
is
available. Espar part number 12V
CA1
05 003 and 24V
CA1
05
004.
Set Up:
- Unplug six pin switch harness connector
at
the
heater.
- Ensure diagnostic box switches are
in
the following positions:
on
/ off switch
in
"off" position.
high/low switch
in
"high" position.
-
Plug female six pin diagnostic box connector to the male connector from the heater
switch harness.
- Green indicator light should now light up indicating that there is
power.
Operation:
- Switch on / off switch to
"on" position to start the
heater.
- High/low heat switch can be switched to "low" position after heater start. When the
heater reaches operating temperature, switching to low heat mode will cause the heater
to
switch itself to run at low heat or
to
cool down and start
in
circulation mode.
-
If the heater does not operate when the
on/off
switch is switched
to
the "on" position,
the fault code can be obtained by pressing the momentary switch (labeled "activate
fault code") for approximately 3 seconds. The green indicator light will then flash a
code.
Fig.
1 : \Mjr
o
____
0
Page 15
~
y
Displaved: Green: Dark Field
Red:
Ught
Field
Operation
Warning
01
over-/undervollage
Overvollage
cutout
Undervollage
cutout
Glow
plug
break
Burner
motor
does
nollurn,
z
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speed
changeover
relay
does
not
function
Short-circuit
01
glow-plug
relay
contacls
.
Safety
lime
exceeded
no
start
Overheat
Short
circuit
of
luel
metering
pump
Temperature
sensor
defective
Flame
sensor
defective
Flame
goes
out
at
"Low"
or
"Medium"
stage
Heater
goes
oul
by
itself.
Flame
goes
out
al
"High"
stage
Heater
goes
out
by
itself
Control
unil
defective
Exlernal
disturbing
voltages
.
---
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controller,
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battery.
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Check
controller,
if
necessary
lest
charger.
Healer
must
be
connected
direclly
to Ihe
battery.
Charge
baUery.
check
controlier,
• • • • • • •
;!1;!1
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ao
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:::l
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o
A
G.heck
glow
plug,
glow
plug
series
resistor
(for 24
V),
repJace.
Check
connecting
lines
and
connection,
check
connection
to
glow
plug
relay.
~
Cil
"0
o
i
:i"
(0
S-
III
:::l
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3
!l?
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C
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(0
'"
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C
0:
g
a
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(l)
a
iB
0.
-
~
Check.
motor
speed
(test
adapter),
if
necessary
replace
blower.
Check
speed
change-
over
(test
adapter),
if
necessary
replace
PCB.
Rated speed:
high
=
4500
± 10%
rpm,
medium/low
==:
3000
±
10(1/(1
rpm
Replace
glow-plug
relay
Check
luel
supply,
test
glow
plug
(interrupted
coil,
yet
sooty
connection),
replace
if
necessary.
Check
heating
air lines,
inlet
and
outlet
for
clogging,
if
necessary
remove
clog.
Check
electrical
lines,
contacts
to
metering
pump.
Check
salety
thermal
cutout
switch
(test
adapter).
Check
metering
pump
and
supply
lines,
replace
iI
necessary.
Plug
connection
to
temperature
sensor
in
cable
harness
made
internally/externally?
Check
PCB,
internal
temperature
sensor
{lest
adapter).
II
necessary
test
the
external.
temperature
sensor
directly.
Check
connection
to
operating
device,
and
check
Ihe
laUer (test
equipment
lor
operating
device):
Check
flame
sensor
or
connection,
and
also
PCB (test
adapter).
Check
luel
Quantity
Check
btower
speed
Check
luel
Quantity
Check
blower
speed
Replace
·control
unit
Remove
cause
--I
:::;
(l)
8
0.
JJl
-
:::;
Q1.
~
3
al
:::l
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(0
III
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0.
-
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(l)
Cil
3
II
iJf
III
Cil
~
o
:::l
-
:::;
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~
:::l
n.
o·
:::l
III
:::l
0.
~
C
-;,
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:::;
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~
,..
~
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c
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c
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--J
Page 16
-
28-
MANUAL COMPONENT TESTING:
To
check the: - Room temperature sensor
(on
the
P.C.
Board)
-
Glow plug
- Overheat Switch
- Flame Sensor
an
OHM Meter is required.
The
glow plug cover must be removed by first removing the hood hold down screw.
Disconnect the
glow plug connector and remove the 12 pin connector
by:
Gently spreading the locking ears on the connector and pulling up.
Refer to the diagram showing the
P.C.
Board before using the OHM Meter to check the:
-
Flame sensor
- Overheat switch
FLAME
SENSOR: Place OHM Meter leads on pin
#1
and pin #8 being careful
NOT
to
touch other pins. A
stable reading of 900 - 1100 OHMs (0.9K -
1.1
K)
should be seen
for a
cool heat exchanger.
If
the flame sensor does not meet the specification it must be replaced.
CONTROL KNOB
CODE:
1--
-
HEATER-
Flame Senser
Test
OHM
METER
-----------------------------------------,
-
29-
INTERNAL TEMPERATURE SENSOR:
(on
P.C.
Board)
Place OHM Meter leads on pin #7 and pin
#1.
A steady reading of 1800 - 2200 OHMs
(1.8K -2.2K)
is
required.
If
these values are not
produced then the
P.C.
board must be replaced.
CONTROL KNOB CODE:
1--
-
HEATER-
1800-2200.iI
Page 17
-
30-
OVERHEAT SWITCH:
Place OHM
Meter leads on pin #9 and pin #10.
A steady reading
of
0.1
OHMs should be seen
If
this is not produced the overheat switch should be replaced.
CONTROL KNOB CODE:
~-------I
-
HEATER-
GLOW PLUG:
The
glow plug should produce a resistance
of
0.7
- 0.9 OHMs.
CONTROL KNOB CODE:
~
__
_
If all the above checks are OK the glow plug and the 12 pin connectors can be replaced
and the hood replaced and secured.
-.'.;'
..•...
'
....•
W
-
31
-
MOTOR TEST:
The heater is a two speed motor with speeds switched and
controlled by a relay and
a resistor on the
P.C.
board.
The
blower motor can be checked for proper high and low speeds by using an optical
or
strobe tachometer.
High Speed
Low
Speed
4500 = 10% RPM
3000 = 10% RPM
If low speed cannot be obtained it can be checked using a second method.
The
second
method requires
that
the
P.C.
board
be
removed from
the
heater.
Once
removed a OHM Meter is used
to
check
the low speed resistor.
Refer to the
following diagram for the proper test points.
Values required for the resistor are:
3.71 -4.1
ohms for 12 Volt OR
17.1
- 18.9 ohms for 24 Volt
If
the resistor is not within specification, replace the
P.C.
board.
If
the blower motor does not turn
to
specification in high
or
low speed, replace the blower
motor.
CONTROL KNOB CODE: f-I--
COMPONENT SPECIFICATION CHART:
PCB
COMPONENT
Flame Sensor
Temp
Sensor
Overheat Switch
Motor
Glow Plug
PINS
1,8
1,7
9, 10
See
Text
2 Pin Connector
RESPONSE
900-1100
1800-2200
0, 1
4500 + 10% RPM High
3000 + 10% RPM Low
0,7 -0,
9
Page 18
-
32-
5.
FUEL QUANTITY
TEST
Measuring Fuel Quantity
A) Preparation
- Disconnect the
electrical connection under the cover cap on the
heater.
- Connect a test lamp.
- Detach the fuel line from the heater and introduce it into a measuring glass
(size 10cc).
- Connect a voltmeter to terminals 3 (+) and 4 (-) of the control unit with the
4-pin plug.
- Switch on the
heater.
When the fuel is being pumped evenly (approx. 25-55 secs.
after switching
on),
the fuel line is now filled and bled.
- Switch off the
heater,
and empty the measuring glass.
B)
Measuement
- Switch on the
heater.
-
Fuel
is being pumped approx. 25-55 secs. after switching
on.
- Hold the measuring glass at the plug level during measurement.
Read
off the
electrical voltage at the voltmeter. Fuel pumping stops automatically after 90
seconds.
- Switch the heater back
off.
- Read off the fuel quantity
in
the measuring glass.
C)
Evaluation
- Transpose the values obtained to the graph.
- The
fuel consumption is okay when the intersection of the two lines is within the
limit curves.
-
If
the intersection
is
outside the limit curves, the metering pump must
be
replaced.
Note: Only measure the fuel quantity when the battery is sufficiently charged. At least
11/22
V and at most
13/26 V should
be applied at
the
control
unit
during
measurement.
"
li
Measuring glass,
lace
Control
unit
:J
o 0
Jl11
Voltmeter
(
~-.
"
'-
, '
90
seconds
...
Q
~;,;.
Testlamp
Connection
of
voltmeter to
control
unit
ml
---
90
seconds
7
6
5
4
11
22
12
24
13
26 Voltage
(V)
6.
HEATER
REPAIR
STEPS
1.
Removing/fitting the glow plug
2.
Removinglfitting the plug filter
Removing the cap
Remove the
glow plug connector.
Unscrew the
glow plug.
Remove the plug filter.
-
33-
When refitting the plug filter note the position of the nose.
-
~I~
--@)DEti=
~~~------------
Carefully slide
in
the plug
filter.
---------------------------------
Page 19
3.
Removing/fitting the
PCB.
Removing the plug from the
PCB.
Press down the nose.
Pull out the PCB.
PCB with changeover
relay for blower speed
and temperature sensor
(internal).
4.
Removing the air outlet section
-
34-
Temperature sensor for heating air (internal).
.,
•
5.
Removinglfitting the upper casing half.
Remove split rivet knock pin through using a
small drive, lever out rivet using a knife.
6.
Removing the safety thermal cutout switch .
-
35-
When assembling, use a new split rivet.
Removing the upper casing
half.
Page 20
Fit the safety thermal cutout switch, using
new clamping springs.
Fitting the flame sensor
1
1 - spacer clamps for the casing halves.
-
36-
7.
Removing.the
flame
sensor.
•
•
Removed
parts
1 -
PC.B
2 - safety thermal cutout switch
3
- glow plug
4 - plug filter
5 - flame sensor
6 - spacer clamps for casing halves
-
37-
8.
Changing
the
series
resistor
for
glow
plugs
in
the
24 V heaters
Note on removal: The series resistor has been fitted
with a clamping ring, there is no thread!
Please note when fitting:
Place fork-shaped section in slot of resistor. Fit the
pipe over this section and drive the series resistor
into its mounting by light hammer
blows.
Do not knock against the insulator
or
screw
connection.
Note:
When fitting the combustion air blower / heat exchanger
into the
lower casing half, care must be taken that the
fastening hooks of the
blower engage in the slots of the
casing
half, otherwise the blower wheel might catch.
1
,
"
,4.~
2
Removing the series resistor
Page 21
-
38-
9.
Unscrewing
the
blower
from
the
heat
exchanger
Change the seals on the heat exchanger.
Unscrew the
flange
(1)
from the heat exchanger.
Fit new
seals
(2)
and
(3)
as illustrated.
10.
Replace
the
seals
on
the
blower.
Remove/scrape the old seal from the blower
flange.
Affix new seal (self-adhesive).
Note:
When fitting the combustion air blower/heat exchanger
into the
lower casing half, care must be taken that the
fastening hooks of the
blower engage in the slots of the
casing
half, otherwise the blower wheel might catch.
-
39-
Removing the blower
NOTES
2
,
•
Page 22
-
40-
V.
HEATER
PARTS
1
SECTION
.
D1
LC -SERVICE
PARTS
DIAGRAM
~~3~~_
,,-~;:~"
~~.
(,
~
I
L...
-
41
-
-----
>
83
,//
Page 23
-
42-
- 43-
251830/251831
2.
D1
L-C
PARTS
LIST
251774/251775
25 1767 / 25
1768=]1
~!
251830/251831
No.
Description
. Part Number
251688/251689,
* Normally not available, Manufactured to order
251774/251
Ref.
No.
Description
Part Number
251767/251
Pot-shaped strainer
201312000006
•••
•
251688/251
.
Hose connection
201621450002
•••
•
1
Heat exchanger
251688990600
Relay
12V 20300082
•••
251774990600
24V
20300084
•
••
2
Combustion air
blower
12V
251688992000
Current regulator
12V
251830300100
•
24V
251689992000
24V
251769800600
•
3 Flame sensor
251774993600
Temperature
control switch complete
12V 25176771
0000
•••
•
24V
25176871
0000
•
••
•
4 Safety thermal cutout switch
25
1729 40
00 00
Ceramic holder
20600160
•••
5 Lower half of casing
25168801
01
00
Resistor
24V
251689300000
•••
6 Upper half of casing
25168801
0600
Protective plate
24V
25168901
0002
• ••
7 Printed circuit board
12V
25168801
0900
Double u-clip
24V
151
22052
24V
25168901
0300
•••
12V
25
1767
01 01
00
Cable harness
0.6m
long
251830800300
•
24V
25
1768
01 01
00
2.0m
long
221000302400
•
0.6m
long
25
1767
80
03
00
•••
8 Silicone Mounting
Seal
25168801
0002
2.0m
long
25176781
0300
•••
251774010002
Air outlet hood
60mm
251688800300
•
••
•
9*
Cable section
25168801
0700
Adjustable air outlet deflector
60mm
201577
89
06 00
•
••
•
10*
Cable
section 12V 25168801
0400
Cable section
(Fuel
metering pump)
201579800400
24V 25168901
0200
•
••
•
Temperature
control switch harness
251688800400
•
••
11
Retaining spring
251388010004
221000300200
•
251774010003
Power
Cable (unfused)
201575800300
12
Glow plug
12V
25
1830
01 01
00
•
••
•
24V
251831
01 01
00
Safety screen
251688800600
• • • •
13 Grub Screw
10610022
Hose connector
60mm
201577
89
06
01
•
••
•
14
Rivet
131
31
051
Combustion air intake hose
20mm
x 1mtr
36000099
•
••
•
15
Fillister head bolt M 5x20 10310461
Flexible
air hose
60mm
102114310000
•
••
•
16
Fuse
17142080
Fuel
hose
5mm
I.D.
360
75
350
(360
75
130)
•
••
•
17
U-Clip
25168801
0003
Plastic
fuel
line
1.5mm
1.0.
09031118
•
••
•
18
Gasket 25168801
00
06
Plastic
fuel
line
2mml.D. 09031
125
•
••
•
19 Removable glow plug screen
251688060400
Seal
ring
2516888001
02
•
••
20
Sealing washer
251688060003
Cable
harness
head
screw M 5x25
10010005
•
•
••
21
Sealing ring
251688060006
with
washer
22
Control Unit 12V
251688500006
Washer
N/A
•
•••
24V
251689500008
End
sleeve
22mm
201645800401
••
23
Mounting Bracket
251688650001
24mm
251482800001
••
24
.
Fuel
metering pump 12V
251688450000
Flexible Exhaust
22mm
36061 100
••
24mm
36061299
••
24V
251689450000
12V
251830450000
Bottom section,
Fuse
holder
20431004
• •
••
24V 251831
450000
Page 24
- 44-
Ref.
No.
Description
Part Number
50
Cover,
Fuse
holder
20431005
51
Fuse
25A
20400089
52
Terminal
for fuse holder
20673058
53
Plug and socket connector
20600040
54
Housing
20631282
55
Socket Housing
20631303
56
Socket connections
20636151
57
Flat-pin terminal
20673016
58
Flat-pin guide
20631
014
59
Cable band
CA1
00005
60
Holder
15622010
61
Angle piece
201348030002
62
Metal-rubber mount
201185000001
63
Metal-rubber mount
2016738001
01
64
Grommet
201280090103
65
Fuel
hose clamp
9mm
102063009098
66
Fuel
hose clamp
11mm
10206301
1098
10mm
10206301
0098
67
Fuel
hose clamp
12mm
10206301
2098
68
Hose clamp
CA110047
69
T -pipe section
26231153
70
T -pipe section 26231
152
71
T -pipe section 26231
151
72
Fuel
hose
7.5mm
360
31
070
73
Fuel
hose
9mm
360
31
095
74
Fuel
hose
11
mm
360
31
096
75
Fuel
pump clamp
15200144
76
Pipe clip
15200139
77
Pipe clip
25mm
15210048
28mm
15210051
78
Fuel
hose
3.5mm
1.0.
36075300
79
Hose clamp
102064106025
80
Exhaust clamp
22mm
251688801200
24mm
15261102
251830/251831
251774/251
251767/251
251688/251
No. Description
81
End
sleeve with crossbar
82
Heater timer
Timer/thermostat
7
day
timer
83
99
Hr.
timer
Screw taptite M
5x10
Temperature
sensor,
external
Cable
section
Temperature
sensor,
external
Cable
cover
Switch harness
Sealing ring
- 45-
12V
24V
12V
24V
251830/251831
251774/251775
Part Number
25
1767 / 25
1768~
251688/251689,
251688801201
•
••
•
221000300800
•
221000300900
•
221000301200
•
221000301300
•
CA1
00050
•••
10900043
•••
•
251482894500
•
••
•
251688890900
•
••
251482894000
•
251774890300
•
••
•
25177601
0400
•
201575800200
•
••
25
0999
00
01
22
•
••
25183001
01
01
•
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