Espar Hydronic 4, Hydronic D4 SC, Hydronic 5, Hydronic B5 SC, Hydronic D5 SC Installation, Troubleshooting, Parts Manual

Hydronic 4/5 (Coolant Heaters)

Installation • Troubleshooting • Parts Manual

Heater Model 12 V

Hydronic D4 SC 25 1917 01

25 2096 05

Hydronic B4 SC 20 1789 05
Hydronic D5 SC 25 1920 05

25 2098 05

Hydronic D5 S 25 2031 05

25 2100 05
Hydronic B5 SC 20 1791 05
Hydronic B5 S 20 1793 05

Heater Model 24 V

Hydronic D5 SC 25 2147 05
Hydronic D5 S 25 2009 05

Espar

P/N 610-121-0201

January 2001

Table of Contents Page

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

Introduction ........................................................ 4

Specifications ........................................................ 4

Heater Components

Hydronic 4/5 SC, 12 volt, Diesel ........................................................ 5

Hydronic 5 SC, 24 volt, Diesel ........................................................ 6

Hydronic 4/5 SC, 12 volt, Gasoline ........................................................ 6

Hydronic 5 S, 12 + 24 volt, Diesel + Gas ........................................................ 7

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

Installation Heater Location ........................................................ 8

Procedures Heater Mounting ........................................................ 9

Heater Plumbing ........................................................ 10

Fuel System ........................................................ 11

Electrical Connections ........................................................ 13

Exhaust/Intake Connections ........................................................ 14

Operating Switches ........................................................ 15

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

Start-Up ........................................................ 16

Running ........................................................ 16

Switching Off ........................................................ 17

Safety Equipment ........................................................ 17

Operational Flow Chart ........................................................ 18

Schematics

Hydronic D4 SC 12 volt, diesel - 25 1917 01 ........................................................ 19

Hydronic D4 SC 12 volt, diesel - 25 2096 05 ........................................................ 20

Hydronic D5 SC 12 volt, diesel - 25 1920 05 ........................................................ 21

Hydronic D5 SC 12 volt, diesel - 25 2098 05 ........................................................ 22

Hydronic D5 SC 24 volt, diesel - 22 2147 05 ........................................................ 23

Hydronic B4 SC 12 volt, gas - 20 1789 05 ........................................................ 23

Hydronic B5 SC 12 volt, gas - 20 1791 05 ........................................................ 23

Hydronic D5 S 12 volt, diesel - 25 2031 05 ........................................................ 24

Hydronic D5 S 12 volt, diesel - 25 2100 05 ........................................................ 24

Hydronic B5 S 12 volt, diesel - 20 1793 05 ........................................................ 24

Hydronic D5 S 24 volt, diesel - 25 2009 05 ........................................................ 24

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

Troubleshooting & Basic Troubleshooting ........................................................ 25

Repairs Self Diagnostic Troubleshooting ....................................................... 25

Troubleshooting Chart ....................................................... 26

Fuel Quantity Test ........................................................ 29

Heater Disassembly / Repair Steps ........................................................ 30

Heater Components Parts Diagram / Scope ........................................................ 32

Description & Part #’s ........................................................ 33

Parts & Accessories Diagram / Scope ....................................................... 35

Description & Part #’s ....................................................... 36

Special Notes

Note: Highlight areas requiring special attention or clarification.

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

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

Heater Warnings

Warning To Installer

3

• 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 gaso­line powered boats.

Warning - Fire Hazard

• Install the exhaust system so it will maintain a minimum
distance of 50mm (2”) from any flammable or heat sensi­tive material.

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

Warning - Asphyxiation Hazard

Caution: During electrical welding work on the vehicle

disconnect the power to the heater in order
to protect the control unit.

Note: All measurements contained in this manual

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

Direct questions to Espar Heater Systems

USA 1-800-387-4800
CANADA 1-800-668-5676

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

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

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

• The use of Espar coolant heaters requires that the
coolant in the system to be heated contain a proper 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.

This publication was correct at the time of print.

However, Espar has a policy of continuous improve­ment and reserves the right to amend any specifica­tions without prior notice.

4

Introduction

Espar’s Hydronic D4/D5 Heater

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

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

This compact coolant heater offers an affordable heating
solution to many applications. The Hydronic 4/5 is ideal for
pre-heating the engines of trucks, cars, off-road equipment,
small trucks and boats. It features automatic heat regulation
while being fuel and power efficient. Since the heater runs on
fuel and 12 or 24 volt power, it is able to perform this com­pletely independently of the vehicle engine. The unit regu­lates the coolant temperature between a low of 65°C (149°F)
and a high of 80°C (176°F) by automatically cycling the
heater.

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

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

Specifications Hydronic 4 Hydronic 5

Heat output (±10%) 4 kW (13,700 BTU/hr) - Boost

3.3 kW (11,300 BTU/hr - High 5 kW (17,000 BTU/hr) - High

1.6 kW (5,500 BTU/hr - Low 2.4 kW (8,200 BTU/hr) - Low

12 volt 24 volt

Current draw (±10%) 4.3 amps Boost

3.0 amps High 4.16 amps High 2.08 amps High

2.0 amps Low 1.91 amps Low 0.95 amps Low

Fuel consumption (±10%) 0.51 l/hr (0.13 US gal/hr) Boost

0.40 l/hr (0.11 US gal/hr) High 0.62 l/hr (0.16 US gal/hr) High

0.20 l/hr (0.05 US gal/hr) Low 0.27 l/hr (0.08 US gal/hr) Low

Operating Voltage Range

Minimum Voltage 10 V 10 V 20.4 V

Maximum Voltage 16 V 16 V 32.0 V
Working pressure 2.5 bar (36 psi) 2.5 bar (36 psi)
Ambient operating temperature -40°C to +80°C (-40°F to 176°F) -40°C to +80°C (-40°F to 176°F)
Overheat temperature shutdown (±5%) 105°C (221°F) 105°C (221°F)
Weight 2.5 kg. (5.5 lbs.) 2.9kg. (6.4lbs)
Controls available On/Off switch or 7-day timer On/Off switch or 7-day timer

Note: The heater is equipped with a high-voltage

cutout as well a low-voltage cutout.

5

Heater Components - Hydronic 4 & 5 SC versions - 12 Volt - Diesel

25 1917 01
25 2096 05
25 1920 05
25 2098 05

17

1 Combustion air blower wheel
2 Electric motor
3 Heat exchanger
4 Combustion chamber
5 Glow pin
6 Flame sensor
7 Temperature sensor
8 Overheat temperature sensor
9 Control unit

18

A = Combustion air
E = Exhaust
F = Fuel supply line
WO = Water Outlet
WI = Water Inlet

10 Combustion air tube
11 Exhaust tube
12 Fuel-metering pump
13 Coolant pump
14 Main fuse
15 Interface/8-pin connector
16 Bleed screw
17 Push/Pull switch
18 7-day timer

6

Heater Components - Hydronic 5 SC - 24 volt version - Diesel

Heater Components - Hydronic 4 & 5 SC - 12 volt version - Gasoline

25 2147 05

20 1789 05
20 1791 05

7

Heater Components - Hydronic 5 S - 12 & 24 volt versions - Diesel & Gasoline versions

25 2031 05
25 2100 05
20 1793 05
25 2009 05

17

18

1 Combustion air blower wheel
2 Electric motor
3 Heat exchanger
4 Combustion chamber
5 Glow pin
6 Flame sensor
7 Temperature sensor
8 Overheat temperature sensor
9 Control unit

A = Combustion air
E = Exhaust
F = Fuel supply line
WO = Water Outlet
WI = Water Inlet

10 Combustion air tube

11 Exhaust tube
12 Fuel-metering pump
13 Coolant pump
14 Main fuse
15 Interface/8-pin connector
16 Bleed screw
17 Push/Pull switch
18 7-day timer

8

Heater Location

Mount the heater in a protected area if you’re in extreme
conditions where heavy salting is experienced.
Eg: storage compartment, engine compartments, step box or
battery box.
Espar recommends you use the boxed unit. Boxed heaters
can be mounted by utilizing one of the existing brackets. See
following page.
If mounting on frame rail use an optional Espar Inside frame
bracket to mount to inside of frame rails. Heaters can also be
mounted on a cross tray behind the cab and on top of
the frame rails.

When mounting the heater adhere to the
following conditions.

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

• Guard against excessive road spray.

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

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

* All measurements in millimeters

25.4mm = 1”

Caution: Guard the heater against excessive road

spray to avoid internal corrosion

For Illustration purposes only

Heater Mounting

9

Mount heater in saddle bracket and secure with hardware
provided. If heater is not a boxed unit, mount bracket onto
inside frame rail bracket. Boxed unit can also be secured to
the inside frame bracket or mounted to the Cross frame
Mounting Tray

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

Inside frame
mounting bracket

Hydronic D4 SC boxed unit P/N CA 2096 55
Hydronic D5 SC boxed unit P/N CA 2098 55

Hydronic
Water Heater

Spacer and screw

Saddle bracket

Inside frame rail

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

• Choose a protected mounting location close to the fuel
pick-up pipe and heater.

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

Note: Proper mounting angle of the fuel pump is nec-

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

blockage.

Saddle bracket

10

Heater Plumbing

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

Engine Plumbing

Follow these guidelines and refer to engine plumbing dia­gram shown below.

• Use existing holes in the engine block (ie. remove
blanking plugs when possible). Install fittings into the block
for pick-up and returns.

• If possible, use shut off valves to ensure the system can
be isolated from the engine when not in use.

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

• 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.

• 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
return to the suction side of the engine's water pump).

• Ensure adequate flow rate through the heater by 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
possible to allow the purging of air. Bleed system via radi­ator or bleed screw located on heater.

Caution: The coolant must contain a minimum of 10%

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

Engine

Radiator

External Water Pump

Shut-off valves

Hydronic SC Heater

Bleed Screw

Hydronic “S” version

11

Fuel System

The Hydronic water heaters typically have the fuel metering
pump mounted inside the unit. This is to reduce installation
time and to protect the pump from corrosion. Some versions
have an external fuel metering pump. Refer to graphics for
connections and specifications.
All parts 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.
Hydronic heater must be within a height of 76cm
(2’6”) from the bottom of the fuel pick-up pipe.
Fuel-metering pump must be within a total
distance of 200 cm (6’6”) from the fuel pick-up pipe.
If the above conditions cannot be met, a heater
with external fuel metering pump must be used.

Fuel System Tolerances

Fuel Line

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

• Use fuel lines provided.

• 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.

1. Fuel Pick-Up Pipe

2. Fuel Pipe Reducer

3. 9mm Clamp

4. 3.5mm Rubber Connector

5. 2.0mm White Plastic Fuel Line

6. Fuel Metering Pump

7. 1.5m White Plastic Fuel Line

Max. 76cm (2’6”)

1

Max. 76cm (2’6”)

Max. 2 M (6’6”)

4

2

3

Max. 2 M (6’6”)

2

4
3

5

5

Max. 2 M (6.5’)

4

3

Hydronic Heater

6

4

3

Max. 6 M (19.8’)

4

7

3

6

4

3

1

12

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

( 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

Double pick ups (used with combo kits)

• Double NPT pipe.
P/N: CA0 12 107

Note: NPT fittings are available in various sizes

(Refer to parts section).

Fuel Pick-Up Pipe

Nut
Sheet Metal Washer
Rubber Gasket
Steel Safety Washer
Holding Tabs
Allow 2.5” 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 to
avoid picking up dirt and

subsequent 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. If one is not available.....

• Drill mounting holes in tank to accommodate pick-up pipe
as shown.

• Cut the fuel pick-up pipe to length. Allow 2-2.5” from bot­tom of tank.

• Mount the fuel pick-up pipe as shown

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

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

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

ø 2.5cm (ø1.0”)

ø 0.625 cm (2 Holes)
(ø 1/4”)

1.5 cm
(9/16”)

1.5 cm
(9/16”)

Fuel Pick-Up Pipe reducer

13

Electrical Connections

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

A. Main Heater Harness...................................................

B. Power Harness............................................................

C. Switch Harness............................................................

D.*Fuel Metering Pump Harness........................................

E.*Water Pump Harness......................................................

Hydronic Heaters

• Connects switch and power harness to the heater harness.
( * in some cases power to fuel metering pump )

• 2 core harness (red, brown).

• Connect red wire to fuse link and terminal.

• Attach ring terminal to vehicle battery (+).

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

• Insert 25 amp fuse

• 4 core harness (red/yellow, brown, yellow, blue/white)

• Run to location of switch. Make terminal connections at
switch. Espar has 2 available switches see switch
instructions on following pages.

• 2 core harness (green, green)

• Connect to fuel metering pump using single terminals
and rubber protective boots (no polarity required).

• 2 core harness (black, brown)

• Connect to main harness at heater.

Caution:

To avoid potential short

circuit damage during

installation, insert 25

amp fuse on power

harness after all

electrical connections

are complete.

E

Note: All harnesses should be cut to length.

All exposed electrical connections should be
coated with protective grease.

Note: Wire must be inserted into fuse holder prior

to terminating

A

D

B

C

7 Day Timer

switch harness

7 Day Timer

14

Fire Hazard

Warning: The exhaust is hot, keep a minimum

of 5cm (2”) clearance from any heat
sensitive material. Route exhaust so
that the exhaust fumes cannot enter
the passenger compartment.

Exhaust Connection

A 24mm flexible tube exhaust pipe with a length no more than
2 m. long is required for the exhaust. A27-30mm exhaust
clamp is needed to secure the exhaust to the the heater.
Connect the exhaust as follows:

• Connect the exhaust pipe to the exhaust port on the
heater and attach with clamp provided.

• 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.

Asphyxiation Hazard

Warning: Route exhaust beyond the skirt of the

cab and outside of the frame area.
Failure to comply with this warning
could result in Asphyxiation.

Intake Connection

Combustion air must be drawn in from the outside. 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

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

Max 2m (78”)

Flexible Exhaust

Exhaust

Clamp

End Sleeve

Air Intake Hose

Operating Switches

A Push/Pull switch or a 7 Day Timer are available.

7 Day Timer

The 7 day timer is capable of setting 1 start time with in 7
days. It also has other functions such as a current time dis­play and a heater numeric fault code. Refer to instructions
provided with timer for setting options.

• Mount timer and bracket in a suitable location.

• Connect the switch harness to the connector at the
heater and run the harness to the switch location.

• Cut harness to length at the switch and install terminals.

• Connect switch harness to timer as shown below

• Refer to timer instructions for other wiring options.

15

a) Power from battery “+”
b) Switch control to the heater
c) Power from battery “-”
d) Diagnostic from heater
e) To the vehicle dimmer switch for light display
f) To vehicle ignition accessories for continuos operation

of heater

Note: The timer display is automatically illuminated

while the heater is operating. Connecting the
grey wire to the vehicle dimmer switch will
allow the timer display to illuminate with the
vehicles dash lights.

Note: Connecting the black wire to the vehicle igni-

tion accessories “On” circuit may also be
considered for some applications where
extended run times are desired. Powering
the black wire will enable the heater to run
continuously when the heater is switched on
manually.

16

Heater Operation

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 loosening the bleed
screw on top of the heater to allow air to escape.

• Loosen Rad cap and run engine to allow air to be purged.

• Top up engine coolant.

Start Up

Once switched on the following sequence occurs:

• Control unit does a systems check ( flame sensor,
temperature sensor, safety thermal sensor and various
other control unit checks).

• Water pump starts circulating coolant fluid.

• Combustion air blower comes on.

• Glow pin begins to preheat 20-50 secs.

• Metering pump starts and combustion air blower speeds
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)

Push/Pull Switch

• Mount switch in a location where it is easily accessible

• Mount using hardware supplied

• Connect the switch harness to the connector at the heater
and run the harness to the switch location

• Cut harness to length at the switch and install terminals

• Connect wiring as shown

Note: Wired as above the switch light glows when

pulled out and is off when pushed in.

Control Wiring
Push/Pull Switch

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

end and tie off to the side)

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.

Note: On initial start up the heater may require sever-

al start attempts to self prime the fuel system.

Running

Once ignition is successful the following operations
take place:

• Heater runs in high heat mode and the temperature is
monitored at the heat exchanger.

• Once coolant reaches 80°C (185°F) the heater
automatically switches to low heat mode and continues
to run.

• If coolant temperature drops to 75°C (167°F) the heater
will automatically switch back to high heat mode

• If the coolant temperature continues to rise, the heater
will automatically switch off once temperature reaches
86°C (187°F)

• The water pump will continue to circulate coolant to allow
the heater to monitor engine temperature

• The heater will automatically re-start once coolant
temperature reaches 75°C (167°F)

• The heater continues to run as described above until it is
switched off, either manually, automatically by a timer or
heater malfunction shutdown.

Note: If the heater should shut down due to flame

out while in running mode, it will automatical­ly attempt one restart. If successful, it will
continue to run. If not, it will shut down com­pletely with a cool-down cycle.

Note: During operation the heater continually sens-

es the input voltage from the batteries. If the
input voltage drops to approximately 10 volts
or rises above 16 volts the heater will auto­matically shut down with a cool-down cycle.

Switching Off

• When the heater is switched off, manually or
automatically, it starts a controlled cool down cycle

• The fuel metering pump stops delivering fuel and the
flame is extinguished

• The combustion air blower and water pump continue to
run for 130 seconds to cool down

• The heater shuts off.

17

Safety Equipment

The control unit, temperature sensor, overheat sensor and
flame sensor continually monitor heater functions and will
shut down the heater in case of a malfunction.

• The control unit ensures electrical circuits (fuel pump,
combustion air blower etc.) are complete prior to starting
the heater.

• If the heater fails to ignite within 90 seconds of the fuel
pump being started, the starting procedure will be
repeated. If the heater again fails to ignite after 90
seconds of fuel being pumped, a “no start safety
shutdown” follows

• If the heater flames out during operation, the heater
automatically attempts to restart. If the heater fails to
ignite within 10 seconds of fuel delivery, or ignites but
flames out again within 3 minutes, “flame out” shutdown
follows. After troubleshooting the problem the heater can
be started again by switching the heater off and then back
on again

• Overheating due to lack of water, a restriction or a poorly
bled coolant system results in the overheat shutdown.
Fuel delivery will cease and an “overheat shut down” fol­lows. If heater overheats 3 consecutive times, a lockout
on the control unit will occur. To unlock the control unit
you will need to use the Fault Code Retrieval Device. See
following pages for self diagnostics.

• If at any time the voltage drops below 10.2V, or rises
above 15.9V, a “high/low voltage” shutdown follows (after
a 20 second delay).

Warning: The heater must be switched off while

any fuel tank on the vehicle is being
filled. The heater must not be operat­ed in garages or enclosed areas

18

Operational Flow Chart

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

19

20

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

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

21

22

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

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

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

23

24

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

Maintenance Troubleshooting & Repairs
Periodic Maintenance

• 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 (see engine manufactur­ers recommendations). Blending used engine oil with
diesel fuel is not permitted.

• Check the glow pin and replace if necessary

Troubleshooting

25

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 or Espar’s Fault Code Retrieval Device.

7-Day Timer

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.

Fault Code Retrieval Device

Equipment Face and Controls

Basic Troubleshooting

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

• Circuit breakers and fuses.

• Electrical lines and connections

• For interference in Combustion air and Exhaust pipes.

• That there is fuel in the tank.

• Battery voltage

Symbols seen on the display
face are as follows:

AF Actual fault.

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

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

operation.

DIAG The word (Diagnostic) will come on when the

diagnostic number is requested.

000 Three digit diagnostic fault code number.

Instructions:

• Connect as shown on following page

• Switch the fault code retrieval device on and wait
10 seconds.

• Press the "D" button.

• Wait 3-5 seconds for the current fault code to appear
(AF).

• To review the previous faults use the arrow buttons
(F1= Most Recent, F5= Oldest).

• To erase the faults that are in memory press both "L"
keys at the same time.

• See the fault code chart on following pages for code
number descriptions.

26

Fault code retrieval device

P/N CA1 05 020

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

Fault code retrieval device harness

P/N CA1 05 028

Test Values

Resistance

Metering pump approx. 20 Ω
Glow Pin approx. 0.9 Ω

Checking the sensors

To check the sensors, measure the resistance at current tem­perature, see following diagrams

0

0

5

10

15

20

25

30

35

Temperature sensor
Overheating sensor

Flame sensor

Temperature (°C)

Temperature (°C)

20 40 60 80 100 120

-50 0

500

750

1000

1250

1500

1750

2000

2250

2500

2750

3000

50 100 150 200 250 300 350 400 450 500 550

R> 2 Ω = open circuit
R< 50 Ω = short circuit

R> 3400 Ω = open circuit
R< 50 Ω = short circuit

27

Fault Code Fault Description Causes / Repair

000 Normal Operation

010 Overvoltage Check voltage between terminals 1(red) and 2(brown) at connector.

(B1). This must be less than 16 volts.
Check battery, electrical leads and vehicle charging system.

011 Under voltage shut down Check voltage between terminals 1(red) and 2(brown) at

connector (B1). This must be greater than 10.2 volts
Check battery, electrical leads and vehicle charging system.

012 Overheating Check for possible causes of overheat (water circuit), Sensor.

Check overheat switch resistance values. Temperature at
temperature sensor or overheat sensor is greater than 125°C

014 Possible overheating detected Difference of measured values at temperature sensor >15°C

(difference evaluation) (min. 70°C water temperature and metering pump in operation);

Check temperature sensor and overheating sensor,
replace if necessary. Check values from previous page.

015 Too many overheats Remove cause of over heat. Reset control unit using 7 day

timer or fault code retrieval device to unlock control unit. Permanent
overheating counter reading exceeded. Heating enable only
possiblef by means of diagnostics system (press both “LL” keys
simultaneously)

017 Overheating detected Temperature at tempaerature or overheating sensor > 130 °C,

emergency OFF if Fault Code 012 or 014 not applicable; check water
circuit, check temperature sensor and overheating sensor; replace if
necessary. See graph on previous page.

020 Open circuit - glow pin Check glow pin and electrical leads for continuity, replace if

necessary

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

necessary

030 Combustion air blower motor Blower impeller or electric motor may be jammed (frozen solid, dirty,

etc.) Fix jam, replace electric motor if necessary

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

motor if necessary

032 Combustion air blower motor short-circuit Check combustion air blower motor (electric motor); replace if

necessary. Check power supply (chafed, corroded etc.)

038 Vehicle fan relay control break Check electric lead to relay, fix break, replace relay if necessary

For wiring harness (P/N CA1 60 401) without relay, replace harness

039 Vehicle fan relay control short circuit Check electric lead to relay, fix break, replace relay if necessary

For wiring harness (P/N CA1 60 401) without relay, replace harness

041 Water pump break Check supply lead to water pump for continuity, remedy break,

replace water pump if necessary

28

Fault Code Fault Description Causes / Repair

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

pump, replace water pump if necessary

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

pump. Replace if necessary

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

replace if necessary

050 Too many no start attempts Safety time counter reading exceeded. Reset control unit using 7

day timer or fault code retrieval device to unlock control unit

051 Faulty flame recognition At start, if flame sensor is a above 70°C > 240 seconds; check

exhaust gas and combustion air supply, check flame sensor, replace
if necessary. For flame sensor values see graph on previous page

052 No start safety time exceeded No flame detected on start attempt. Check fuel delivery and fuel

supply, Check exhaust gas and combustion air ducts

053 Flame cutout in boost mode Heater has started successfully the flame has extinguished.

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

054 Flame cutout in high mode Heater has started successfully the flame has extinguished.

Check fuel supply. Check combustion air and exhaust flow.

056 Flame cutout in low mode Check flame sensor resistance value.

060 Open circuit - temperature sensor Temperature sensor detects a value beyond it's range.

Check connections. Check sensor resistance values between
11 and 12 at connector B2 > 2 M Ω (if open circuit)

061 Short circuit - external temperature sensor Check connections. Check sensor resistance values between

11 and 12 at connector B2 < 50 Ω (if short circuit)
Temperature sensor values on previous pages

064 Open circuit - flame sensor Sensor is sensing value outside of range. Check connection leads.

Resistance values between 13 and 14 at connector
B2 > 3040 Ω (if open circuit)

065 Short circuit - flame sensor Check connection leads. Resistance values between 13 and 14 at

connector B2 > 780 Ω (if short circuit). Flame sensor values on
page 17

071 Open circuit - overheat sensor Check connection leads. Resistance values between 9 and 10 at

connector B2 > 2 M Ω (if open circuit)

072 Short circuit - overheat sensor Check connection leads. Resistance values between 9 and 10 at

connector B2 < 50 M Ω (if short circuit)

090 Control unit defect (internal fault) Control unit malfunction due to interference voltage from
092 Control unit defective(ROM error) vehicle electrical system; possible causes low batteries, charges,
093 Control unit defective(RAM error) other sources of interference, eliminate interference voltages.

Internal faults detected in microprocessor/ memory detected.
Replace control unit

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

Fuel Quantity Test

The fuel Quantity should be tested if the heater has difficulty
starting or maintaining a flame.

Note: Measure the fuel quantity when the battery is

sufficiently charged. At least 11V and at
most 13V should be applied at the control
unit during measurement.

Preparation

• Remove metering pump cover in the cases of SC ver-

sions.

• Pull the fuel line off the combustion chamber and insert

into a graduated measuring glass

• Switch the heater on, when fuel delivery is uniform

(approximately 40 seconds after switching on), the fuel
line is full and bled.

• Switch heater off

• Empty measuring glass and replace

29

Measurement

• Switch heater on

• Fuel delivery stars automatically approximately 40

seconds after switching on

• Hold the graduated measuring glass at the glow pin

height during measurement

• After 90 seconds of fuel delivery, it will shut off

automatically

• Switch heater off.

• Read off quantity of fuel delivery in the graduated

measuring glass

Evaluation

Nominal value

Diesel Gasoline

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

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

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

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

30

1 Cover, metering pump

2 Water pump assembly. When mounting, place O-rings

on connection on water pump housing

3 Metering pump and bracket

4 Cover, blower

5 Control unit and cover

6 Glow pin

Disassembly / Assembly

1 Cover, metering pump
2 Water pump, assembly
3 Metering pump and bracket
4 Cover, blower
5 Control unit and cover
6 Glow pin

7 Flame sensor

8 Cable harness
9 Electric motor, complete
10 Combustion chamber with flame tube
11 Heat exchanger and jacket

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

7 Flame sensor, For removal of tab receptacles, use

AMP extractor tool

31

10 Combustion chamber with flame tube

8 Cable Harness

9 Electric motor, complete

11 Heat exchanger and jacket, Align slot on heat

exchanger (arrow) with lug in jacket

32

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

Model 25 1917 01
Model 25 2096 05

Model 25 20 1789 05
Model 25 1920 05

Model 25 2098 05
Model 20 1791 05
Model 22 2147 05

33

Model #’s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & Part #’s

Ref. No. Description Part Number

1 Outer casing 25 1917 01 01 01 • • •

25 1920 01 01 01 • • •
25 1922 01 01 01 •

2 Combustion air blower with cover 25 1917 99 15 00 •

20 1759 99 15 00 •

25 1922 99 15 00 • •
25 2013 99 15 00 •
20 1774 99 15 00 •

25 2146 99 15 00 •

3 Cover 25 1917 01 00 02 • • • • • •

25 2137 01 00 02 •

4 Burner 20 1752 10 00 00 •

20 1759 10 00 00 •

5 Burner 25 1917 19 00 00 • •

25 1920 10 00 00 • •
25 2146 10 00 00 •

6 Heat exchanger 25 1864 06 00 01 • • •

25 1922 06 00 01 • • • •

7 Control unit 25 1917 51 00 04 •

25 1917 55 00 01 •
22 5201 00 20 01 •

22 5201 00 20 04 •

22 5201 00 10 01 •

22 5201 00 30 01 •

22 5202 00 10 03 •

8 Cover (not available as a spare part) 25 1752 99 01 03 • • • • • • •
9 Water pump 25 1917 99 25 00 •

25 1920 25 00 00 • • •
25 2096 25 00 00 • •

25 2118 25 00 00 •

10 Fuel metering pump 25 1917 45 00 00 • •

25 1920 45 00 00 • •

25 1942 45 00 00 •

11 Strainer 20 1312 00 00 06 • • • •
12 Holder for fuel metering pump 25 1917 01 00 07 • • • •
13 Seal & gasket 25 1864 99 00 21 • • • • •

20 1752 99 01 01 • •

14 O-ring 320 75 104 • • • • • • •
15 Glow pin 25 1864 01 10 00 • • • • • •

16 Glow pin connection 20 1752 01 10 00 • •
17 Lining and 2 O-rings 20 1752 99 01 02 • •
18 Plug connection complete 25 2147 01 13 00 •
19 Holder 20 1752 01 00 04 • • •
20 Sleeve 20 1752 01 00 02 • • •

25 2107 01 10 00 •

34

Ref. No. Description Part Number

HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & Part #’s

Model #’s

21 Flame sensor 25 1864 35 00 00 •

25 1920 35 00 00 • • • • • •

22 Overheat and temperature sensors with cable section 25 1917 01 17 00 •

including glow plug connector and main connector 25 1920 01 17 00 • • •

22a 20 1753 01 17 00 • •

25 2147 01 20 00 •
23 Control unit plug waterproof, complete 22 1000 30 10 10 • • • • • •
24 Cable section for glow plug 25 1922 01 18 00 •

25 1920 01 18 00 • • • • • •
25 Cable section water pump 20 1752 01 18 00 •

20 1753 01 18 00 • • • • • •
26 Spring leaf 25 1864 01 00 05 • • •

25 1922 01 00 05 • • • •
27 Cover fuel metering pump 25 1917 01 00 03 • • • • •

20 1752 01 00 03 • •
28 O-ring for coolant barbs 14 x 2,6 320 75 119 • • • • • • •
29 O-ring for sensors 7.5 x 2 320 75 111 • • • • • • •
30 Fuel hose 25 1917 01 00 11 • • • • •
31 Hose clip 209 31 071 • • • • •
32 Bleed screw 25 1917 25 00 12 • • • • • • •
33 Bleed screw washer Hardware • • • • • • •
34 Tapite screw 109 10 104 • • • • • • •
35 Spring washer 171 22 112 • • • • • • •
36 Hexagon nut 110 10 024 • • • • • • •
37 Sleeve 25 1917 01 00 05 • • • • •
38 Grommet 20 1752 01 00 05 • •
39 Hex bolt M5x35 109 10 027 • • • • • • •
40 Hex bolt, M5x25 109 10 102 • • • • • • •
41 Bolt 100 10 300 • • • • • • •
42 Hex bolt, M5x16 109 10 101 • • • • • • •
43 Tapite screw M4x10 109 10 100 • • • • • • •
44 Counter sunk screw 102 10 400 • • • • • • •
45 Rubber boots 320 31 120 • • • •
46 Plastic protective dust cover CA0 00 073 • • • • • • •
47 Cable tie Hardware • •

Parts Diagram
HYDRONIC D4 / D5 accessories

43

35

1

42

2

41

3

4

3

7

6

18

19

6

8

21

16

26

28

27

16

38

36

34

35

39

32

9

11

8

5

46

16

17

20

12

13

8

8

14

9

8

15

9

23

22

40

10

49

44

8

48

29

47

50

30

31

25

8

9

8

37

24

11

33

45

36

Ref. No. Description Part Number

HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & Part #’s

Model #’s

1 T-piece, 20mm 20 1673 80 11 00 • • • • • • •
2 Connecting pipe 20 1534 88 00 01 • • • • • • •
3 Clamp 20mm-32mm 10 2065 02 00 32 • • • • • • •
4 Hose 25 1917 80 00 01 • • • • • • •
5 1.5m white plastic fuel line 090 31 118 • • •
6 Rubber mount 20 1185 00 00 01 • • • • • • •
7 Heater bracket 25 1864 80 00 01 • • • • • • •
8 Hose clamp 9mm 10 2063 00 90 98 • • • • • • •
9 Fuel hose 3.5mm 360 75 300 • • • • • • •

10 Bracket - class 8 truck CA0 10 085 • • • • • • •

11 Fuel line 2mm 090 31 117 • • • • • • •
12 Pipe clamp 10mm 152 00 147 • • • • • • •
13 Fuel pipe reducer CA0 12 092 • • • • • • •
14 Fuel pick up pipe 2mm ID CA0 12 056 • • • • • • •
15 Main heater harness CA1 60 401 • •

CA1 60 503 • •

CA1 60 502-001 •

25 1917 80 10 00 • •
16 Exhaust clamp 27-30mm ID 152 61 102 • • • • • • •
17 Intake hose clamp 10 2064 01 60 25 • • • • • • •
18 C clamp 28mm 152 10 051 • • • • • • •
19 End sleeve for exhaust 25 1729 80 06 00 • • • • • • •
20 Exhaust hose 360 61 299 • • • • • • •
21 Air intake hose 360 00 099 • • • • • • •
22 Compression fitting 1/4” NPT CA0 12 044 • • • • • • •

3/8” NPT CA0 00 031 • • • • • • •
1/2” NPT CA0 12 005 • • • • • • •

23 Custom straight pick up pipe 16” length CA0 00 030 • • • • • • •

24” length CA0 12 053 • • • • • • •

24 Replacement bulb 12V 207 00 005 • • • • • •

24V 207 00 006 •

25 Push/pull switch 12V CA1 00 003 • • • • • •

24V CA1 00 004 •
26 Muffler 25 1864 81 01 00 • • • • • • •
27 Muffler clamp 20 1533 88 00 07 • • • • • • •
28 Relay 12V 203 00 093 • • • • • •

24V 203 00 092 •
29 Harness adapter for 7 day timer CA1 60 008-001 • • • • • • •
30 7 day timer bezel 25 1482 70 01 00 • • • • • • •

37

Model #’s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & Part #’s

Ref. No. Description Part Number

31 7 day timer 22 1000 30 36 00 • • • • • • •

7 day timer with kit (harness & relay) CA1 00 135 • • • • • •

7 day timer with kit (harness & relay) CA1 00 136 •
32 Bracket for 7 day timer CA0 10 061 • • • • • • •
33 Fault code retrieval device CA1 05 020 • • • • • • •
34 Main fuse holder CA1 07 001 • • • • •
35 Fuse blade 204 00 089 • • • •

CA1 07 005 •
36 Wire awg 12 gage red CA1 61 908 • • • • •
37 Retrieval harness for fault code device CA1 05 028 • • • • • • •
38 Ring terminal 3/8” awg 10-12 CA1 90 014 • • • • • • •
39 Fuse link power harness CA1 65 108 • • • •
40 Double pick-up (used with combo kits) CA0 12 057-001 • • • • • • •
41 Spacer 25 1864 80 00 02 • • • • • • •
42 Screw CA3 00 103 • • • • • • •
43 Replacement hardware kit CA1 00 190 • • • •
44 Cross frame mounting bracket CA0 10 028 • • • • • • •
45 Hydronic box Base CA0 10 101 • • • • • • •

Hydronic box Lid CA0 10 102 • • • • • • •
46 Plug Cables Complete 22 1000 30 10 21 • • • • • • •
47 Fuel metering pump 20 1645 45 00 00 • •

25 1942 45 00 00 •
48 Boot sleeve 320 31 120 • • •
49 Fuel metering pump holder 22 1000 50 03 00 • • •
50 Fuel filter 22 4502 00 01 00 • • • • • • •

38

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

Model 20 1793 05
Model 25 2009 05

Model 25 2031 05
Model 25 2100 05

39

Model #’s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & Part #’s

Ref. No. Description Part Number

1 Casing 25 1922 01 01 01 • • • •
2 Combustion air blower with cover 25 1922 99 15 00 •

25 1922 99 16 00 •
25 1942 99 15 00 •
20 1759 99 15 00 •

3 Cover 20 1756 01 00 03 •

25 1864 01 00 04 • • •

4 Burner 20 1759 10 00 00 •

4a 25 1922 10 00 00 • • •

5 Heat exchanger 25 1922 06 00 01 • • • •
6 Control unit 25 1917 55 00 08 •

25 1942 50 00 02 •
22 5201 00 30 02 •
22 5201 00 20 04 •

6a Water proof plug 22 1000 30 10 10 • • • •

7 Cover 20 1756 99 01 02 • • • •
8 Heater cover plate 25 1922 01 00 02 • • • •
9 Seal 20 1752 99 01 01 •

25 1864 99 00 21 • • •

10 O-ring 25 1864 99 00 23 • • • •

11 Glow plug 12V 25 1864 01 10 00 • • •

24V 25 1816 01 01 00 •
12 Lining & 2 o-rings 20 1752 99 01 02 •
13 Flame sensor 25 1920 35 00 00 • • • •
14 Holder 20 1752 01 00 04 •
15 Nipple 25 1942 01 00 02 •
16 Cable section 25 1922 01 18 00 • • • •
17 Cable section 25 1942 01 20 00 • • • •
18 Cable section 25 2009 01 15 00 • • • •
19 Spring 25 1922 01 00 05 • • • •
20 O-ring, 7x2 25 1864 99 00 30 • • • •
21 Sleeve 20 1756 01 00 04 •
22 Sleeve N/A
23 Tapite Screw 25 1864 99 00 24 • • • •
24 Spring washer 171 22 112 • • • •
25 Hexagon nut 110 10 024 • • • •
26 Tapite screw 25 1864 99 00 28 • • • •
27 Cheese head screw 25 1864 99 00 26 • • • •
28 Tapite screw 25 1864 99 00 29 • • • •
29 Tapite screw 25 1864 99 00 27 • • • •
30 Counter sunk screw 25 1864 99 00 25 • • • •
31 Plug connection 20 1756 01 10 00 •

40

Parts Diagram
HYDRONIC D4 / D5 accessories

41

Model #’s
HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & Part #’s

Ref. No. Description Part Number

1 Holder 25 1864 80 00 01 • • • •
2 Washer 25 1864 80 00 02 • • • •
3 Metal rubber buffer 20 1185 00 00 01 • • • •
4 Flexible tubing 360 00 099 • • • •
5 End sleeve 25 1688 80 12 01 • • • •
6 Hose clip 10 2064 01 60 25 • • • •
7 Hose 25 1774 80 02 00 • • • •
8 Flexible spiral tubing 360 61 299 • • • •
9 End sleeve 25 1729 80 06 00 • • • •

10 Exhaust muffler 25 1864 81 01 00 • • • •

11 Pipe clip 152 61 102 • • • •
12 Pipe clip 152 10 051 • • • •
13 Clamp 20 1533 88 00 07 • • • •
14 Water pump 12V 330 00 012 • • •

14a 24V 25 2009 25 00 00 •

15 Coolant hose 25 1917 80 00 01 • • • •
16 Connection piece 20 1534 88 00 01 • • • •
17 Connection piece 20 1645 89 00 06 • • • •
18 Hose clip 10 2064 02 00 32 • • •
19 Fastening clip 152 00 101 •
20 Bracket with holes 20 1568 88 00 02 • • • •
21 Bottom section of fuse casing 204 31 004 • • • •
22 Cover 204 31 005 • • • •
23 Fuse 25 amp 204 00 089 • • • •
24 Fuse 20 amp 204 00 087 • • •
25 Fuse 15 amp 204 00 081 •
26 Fuse 5 amp 204 00 079 • • • •
27 Twin leaf-spring contact 206 73 058 • • • •
28 Twin leaf-spring contact 206 00 199 • • • •
29 Eyelet Hardware • • • •
30 Eyelet Hardware • • • •
31 Sleeve 320 31 120 • • • •
32 Screw 108 10 318 • • • •
33 Cable harness 25 2009 80 10 00 •

25 1917 80 10 00 • • •
34 Cable tie 25 1801 80 02 00 • • • •
35 Cable 20 1668 80 05 00 • • • •
36 Hose 360 75 300 • • • •
37 Hose clip 10 2063 00 90 98 • • • •

42

Ref. No. Description Part Number

HYDRONIC 4 / 5 SC diesel & gasoline versions
Description & Part #’s

Model #’s

38 Fuel metering pump 12V 20 1645 45 00 00 • • •

24V 25 1942 45 00 00 •

39 Metering pump holder 22 1000 50 03 00 • • • •
40 Relay 12V 203 00 065 • • •

24v 203 00 066 •

41 Fuel line 090 31 118 • • • •

1st. Printing - July 1999
Printed in Canada
P/N: 610-121-0201

Espar Products, Inc.

6435 Kestrel Road

Mississauga, Ontario

Canada L5T 1Z8

9675 Harrison Rd.

Suite 102

Romulus, Michigan

48174

U.S.A.

Canada (Tel): 905-670-0960

800-668-5676

Fax: [phone]

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

a Member of the Eberspächer Group of Companies