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Hydronic 10/ Hydronic M (Water Heater) Espar Heater Systems P/N 20 2900 81 01 24 0B 02.2007 Subject to Change Printed in Canada Hydronic 10 25 2081 05 - 12 Volt 25 2044 05 - 24 Volt Technical Description Installation Instructions Operating Instructions Maintenance Instructions Troubleshooting and Repair Instructions Parts List Espar Products, Inc. 6099A Vipond Drive Mississauga, Ontario Canada L5T 2B2 (905) 670-0960 (800) 387-4800 Canada & U.S.A. (905) 670-0728 Fax www.espar.com Hydronic M 25 2160 05 - 12 Volt 25 2161 05 - 24 Volt 25 2227 05 - 24 Volt * *

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  • Hydronic 10/ Hydronic M (Water Heater)Espar Heater Systems

    P/N 20 2900 81 01 24 0B 02.2007 Subject to Change Printed in Canada

    HHyyddrroonniicc 1100

    25 2081 05 - 12 Volt

    25 2044 05 - 24 Volt

    TTeecchhnniiccaall DDeessccrriippttiioonnIInnssttaallllaattiioonn IInnssttrruuccttiioonnssOOppeerraattiinngg IInnssttrruuccttiioonnssMMaaiinntteennaannccee IInnssttrruuccttiioonnssTTrroouubblleesshhoooottiinngg aanndd RReeppaaiirr IInnssttrruuccttiioonnssPPaarrttss LLiisstt

    Espar Products, Inc.6099A Vipond DriveMississauga, OntarioCanada L5T 2B2

    (905) 670-0960(800) 387-4800 Canada & U.S.A.(905) 670-0728 Fax

    www.espar.com

    HHyyddrroonniicc MM

    25 2160 05 - 12 Volt

    25 2161 05 - 24 Volt

    25 2227 05 - 24 Volt

    * *

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

    Table of Contents Page

    Introduction Heater Warnings ........................................................ 3Introduction ........................................................ 4Specifications ........................................................ 4Heater Components ........................................................ 5Principal Dimensions ........................................................ 6

    Installation Procedures Heater Location ........................................................ 7Heater Mounting ........................................................ 7Heater Plumbing ........................................................ 8Fuel System ........................................................ 9Electrical Connections ........................................................ 11Exhaust/Intake Connections ........................................................ 12Operating Switches ........................................................ 13

    Heater Operation Pre-Start Procedures ........................................................ 1771........................................................pU-tratS71........................................................gninnuR

    Switching Off ........................................................ 17Safety Equipment ........................................................ 17Operational Flow Chart ........................................................ 18Wiring Diagram (12V-24V boxed) ....................................................... 19Wiring Diagram (12V-24V boxed-Universal) ........................................................ 20Wiring Diagram (Engine heat only) ........................................................ 21Wiring Diagram Universal ........................................................ 22

    Maintenance, Periodic Maintenance ........................................................ 23Troubleshooting & Basic Troubleshooting ........................................................ 23Repairs Self Diagnostic Troubleshooting ....................................................... 23

    Fault codes/Description/Repair ........................................................ 24Fuel Quantity Test ........................................................ 28Repair Steps ........................................................ 28Resistance Values ........................................................ 28

    Heater Components Parts Diagram ........................................................ 32Description & Part #s ........................................................ 33Parts Diagram - Boxed units ........................................................ 36Description & Part #s ........................................................ 37Parts Diagram - Universal ........................................................ 40Description & Part #s ........................................................ 41Parts - Accesories ........................................................ 42Description & Part #s ........................................................ 43

    Special Notes

    Note: Highlight areas requiring special attention or clarification.

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

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

  • 3

    IInnttrroodduuccttiioonn

    Correct installation of this heater is necessary to ensuresafe and proper operation.Read and understand this manual before attempting toinstall the heater. Failure to follow all these instructionscould cause serious or fatal injury.

    Heater must be turned off while re-fueling.

    Do not install heater in enclosed areas where com-bustible fumes may be present.

    Do not install heaters in engine compartments of gaso-line powered boats.

    Install the exhaust system so it will maintain a minimumdistance of 50mm (2) from any flammable or heat sensi-tive material.

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

    Route the heater exhaust so that exhaust fumes cannotenter any passenger compartments.

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

    The use of Espar coolant heaters requires that thecoolant in the system to be heated contains a propermixture of water and antifreeze to prevent coolant fromfreezing or slushing.

    If the coolant becomes slushy or frozen, the heaterscoolant pump cannot move the coolant causing a block-age of the circulating system. Once this occurs, pressurewill build up rapidly in the heater and the coolant hosewill either burst or blow off at the connection point to theheater.

    This situation could cause engine damage and/or per-sonal injury. Extreme care should be taken to ensure aproper mixture of water and antifreeze is used in thecoolant system.

    Refer to the engine manufacturers or coolant manufac-turers recommendations for your specific requirements.

    WWaarrnniinngg TToo IInnssttaalllleerr

    WWaarrnniinngg -- EExxpplloossiioonn HHaazzaarrdd

    WWaarrnniinngg -- FFiirree HHaazzaarrdd

    WWaarrnniinngg -- AAsspphhyyxxiiaattiioonn HHaazzaarrdd

    WWaarrnniinngg -- SSaaffeettyy HHaazzaarrdd oonn CCoooollaanntt HHeeaatteerrssUUsseedd WWiitthh IImmpprrooppeerr AAnnttiiffrreeeezzee MMiixxttuurreess

    HHeeaatteerr WWaarrnniinnggss

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

    NNoottee:: All measurements contained in this manual con-tain metric and approximate SAE equivalents inbrackets eg 25mm (1).

    Direct questions to Espar Heater Systems:

    CCaannaaddaa && UU..SS..AA.. 11--880000--338877--44880000

    This publication was correct at the time of print.However, Espar has a policy of continuous improve-ment and reserves the right to amend any specifica-tions without prior notice.

  • 4

    IInnttrroodduuccttiioonnEEssppaarrss HHyyddrroonniicc 1100 CCoooollaanntt HHeeaatteerr

    Quality engineered to provide a dependable means of heating,the Espar Hydronic 10 is a diesel fired coolant heater capable ofbetween 1.5 kW to 9.5 kW/hr (5,100 to 32,400 BTU/hr). Theheater can be purchased either in a weather resistant box to pro-tect it from the elements and provide for ease of installation or inthe universal form.

    This light weight and compact coolant heater offers an affordableheating solution to many applications. The Hydronic 10 is idealfor pre-heating the engines of class 7 and 8 trucks, off-roadequipment, buses, boats and in Fuel + Hydraulics in conjunctionwith appropriate heat exchangers.

    The heater pumps coolant from the engine, heats it and returns itto the engine. It features automatic heat regulation while beingfuel and power efficient. Since the heater runs on diesel fuel and12 or 24 volt power, it is able to perform this completely indepen-dently of the vehicle engine. A temperature regulating switch inthe unit regulates the coolant temperature between a low of 68C(154F) and a high of 85C (185F) by automatically cycling theheater.

    The Hydronic 10 can be operated from the vehicle cab by anon/off switch, a pre-select timer or a combination of both.

    A flame sensor, temperature regulating sensor and overheat sensor are among the safety features which makes the Hydronic10 a safe and dependable heating system.

    HHyyddrroonniicc 1100 SSppeecciiffiiccaattiioonnss

    HHeeaatt oouuttppuutt ((1100%%)) 9.5 kW (32,400 BTU/hr) -- BBoooosstt7.5 kW (25,600 BTU/hr) -- HHiigghh3.2 kW (10,900 BTU/hr) -- MMeeddiiuumm1.5 kW (5,100 BTU/hr) -- LLooww

    CCuurrrreenntt ddrraaww ((1100%%)) 1122VVoolltt 2244VVoolltt10.4 - BBoooosstt -- 5.2 amps 6.3 - HHiigghh -- 3.2 amps 3.5 - MMeeddiiuumm -- 1.8 amps 2.9 - LLooww -- 1.5 amps

    FFuueell ccoonnssuummppttiioonn ((1100%%)) 1.2 l/hr (0.32 USgal/hr) BBoooosstt0.9 l/hr (0.24 USgal/hr) HHiigghh0.40 l/hr (0.11 USgal/hr) MMeeddiiuumm0.18 l/hr (0.05 USgal/hr) LLooww

    OOppeerraattiinngg VVoollttaaggee RRaannggeeMMiinniimmuumm VVoollttaaggee 10 V (20V on 24 volt systems)MMaaxxiimmuumm VVoollttaaggee 15 V (30 V on 24 volt systems)

    CCoooollaanntt ppuummpp ffllooww ((1100%%)) 1400 Litre/hr370 U.S. Gal/hr

    CCoooollaanntt TTeemmppeerraattuurree RRaannggee ((55%%)) 68-85C (154-185F)

    OOvveerrhheeaatt ccoooollaanntt tteemmppeerraattuurree sshhuuttddoowwnn ((55%%)) 115C (240F)

    WWeeiigghhtt 6.5 kg. (14.3 lbs.)

    CCoonnttrroollss aavvaaiillaabbllee On/Off switch, 99hr. timer or 7 day timer.

    NNoottee:: The heater is equipped with a high voltage cutout as well a low voltage cutout.

  • 1 2

    4 5

    6 7 9 8

    13

    10

    1211

    17 18 16

    14

    3

    15

    +

    we

    09:20

    P

    B

    WE

    AV

    V

    5

    IInnttrroodduuccttiioonnHHeeaatteerr CCoommppoonneennttss

    1 Combustion motor2 Flame sensor3 Combustion chamber4 Control unit5 Heater plug6 Temperature sensor7 Flame tube8 Heat exchanger9 Overheating switch

    10 Water pump11 Exhaust silencer12 Combustion air silencer13 Fuel feeder pump14 Fuel branch piece15 Cable tree16 Fuse bracket17 Relay for switching on the vehicles fan18 Automatic switch

    WWEE == WWaatteerr iinnlleettWWAA == WWaatteerr oouuttlleettVV == CCoommbbuussttiioonn aaiirrBB == FFuueellAA == FFuummeess

  • 6

    IInnttrroodduuccttiioonnPPrriinncciippaall DDiimmeennssiioonnss

    Espar

    HYDRONIC 10*

    * All measurements in millimeters25.4 mm = 1

    Minimum installation distance(clearance) to open the lid and todismount the glow pin and thecontrol unit.

    Minimum installation distance(clearance) to take in heating air.

    HYDRONIC 10

    Permissible installation positions

    20.2

    Combustion air Exhaust air Water Inlet

  • 7

    IInnssttaallllaattiioonn PPrroocceedduurreessPPrriinncciippaall DDiimmeennssiioonnss -- BBooxxeedd VVeerrssiioonn

    Always mount the heater in a protected area. Eg: storagecompartment, engine compartments, step box or battery box.Espar recommends you use the boxed unit. Boxed heaterscan be mounted by utilizing one of the existing brackets. Seefollowing page.

    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.

    Mount the heater using the four (4) shock mounts providedand one of the following mounting methods:

    Use the CCrroossss FFrraammee MMoouunnttiinngg TTrraayy to mount the heater behind the cab and on top of the frame rails.

    Use the SSiiddee MMoouunntt BBrraacckkeett to mount the heater on theside of the frame rail.

    Use a spare step box or battery box.

    Use the saddle bracket and hardware provided

    CCaauuttiioonn:: Guard the heater against excessive road spray to avoid internal corrosion.

    HHeeaatteerr LLooccaattiioonn

    HHeeaatteerr MMoouunnttiinngg

    E s p a r H e a t e r S y s t e m s

    CCrroossss FFrraammee MMoouunnttiinngg TTrraayyP/N CA0 10 028P/N CA0 10 022 with hardware

    SSiiddee MMoouunntt BBrraacckkeettP/N CA0 10 057

  • 8

    IInnssttaallllaattiioonn PPrroocceedduurreessHHeeaatteerr PPlluummbbiinngg

    HYDRONIC 10*

    Engine

    RadiatorShut-off valves

    (Optional)

    Hydronic 10WaterHeater

    The heater is incorporated into the engines cooling system forengine preheating

    Follow these guidelines and refer to the engine plumbing dia-gram shown below.

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

    Use existing holes in the engine block (ie. removeblanking 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.

    Take the coolant from a low point on the engine to reduceaeration 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 andreturn to the suction side of the engine's water pump).

    Ensure adequate flow rate through the heater bycomparing the incoming and outgoing coolanttemperatures while the heater is running. If the rise in temperature exceeds 10C (18F), coolant flow must be increased by modifying the plumbing.

    Ensure the heater and water pump are installed as low as possible to allow the purging of air.

    If a bunk heat exchanger is incorporated into the system, proper plumbing layouts must be followed.

    CCaauuttiioonn:: The coolant must contain a minimum of 10% antifreeze at all times as a protection againstcorrosion. Fresh water will corrode internal heater parts.

    Hydronic10water heater

    WWaatteerr iinn

    WWaatteerr oouutt

    EEnnggiinnee PPlluummbbiinngg

  • 9

    IInnssttaallllaattiioonn PPrroocceedduurreessFFuueell SSyysstteemm

    HYDRONIC 10*

    FUELTANK

    3

    6 7

    4

    5

    2

    2

    5

    6

    MAX. 66

    MAX. 26

    MAX. 20

    MAX. 66

    1

    FFuueell SSyysstteemm TToolleerraanncceess

    FFuueell LLiinnee

    Right Wrong

    Bubble

    Correct Wrong

    NNoottee:: Butt joints and clamps on all connections.

    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 piecesas shown

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

    NNoottee:: 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 26 of the bottom of the fuel pick-up pipe.

    Fuel metering pump must be within a total distance of 66 from the fuel pick-up pipe.

    Pressure Runs of less than 1.3 mtrs (50) use only 3.5mm rubber (360 75 300)

    The Hydronic 10 boxed unit is most commonly provided withthe fuel metering pump mounted inside the box. This is toreduce installation time and to protect the pump from corrosion.If specifications cannot be met the pump must be mountedexternally. See illustration for connections and specifications. Allparts necessary to do the installation are included in the kit asshown.

    1. Fuel Pick-Up Pipe

    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 LineSee notes if length is less than 1.3 mtr (50)

  • 10

    IInnssttaallllaattiioonn PPrroocceedduurreessFFuueell MMeetteerriinngg PPuummpp IInnssttaallllaattiioonn

    2.5 cm ( 1.0)

    1.5 cm 1.5 cm9 / 16 9 / 16

    0.625 cm (2 HOLES)( 1 / 4)

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

    (( OOppttiioonnaall PPiicckk--UUpp PPiippee wwiitthh NNPPTT ffiittttiinngg ))

    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 positionusing the combined NPT compressionfitting as shown

    NNoottee:: 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 4 from fuel pick-upto tank bottom. Allowonly 1 for flat bottomtanks.

    End tip of the fuel pick-uppipe should have angleso as to avoid picking updirt andsubsequent blockage

    FFuueell PPiicckk--UUpp PPiippee IInnssttaallllaattiioonn ((SSttaannddaarrdd PPiicckk--UUpp))

    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.

    NNoottee:: 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.

    If the pump needs to be mounted externally follow these guide-lines:

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

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

    FFuueell PPiicckk--UUpp PPiippee IInnssttaallllaattiioonn ((SSttaannddaarrdd PPiicckk--UUpp))

    15 tovertical

    15

  • 11

    IInnssttaallllaattiioonn PPrroocceedduurreessEElleeccttrriiccaall CCoonnnneeccttiioonnss

    NNoottee:: All harnesses should be cut to length.All exposed electrical connections should becoated 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 (-) usingring terminal provided.

    Insert fuse. (15A-24V, 20A-12V)

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

    Run to location of switch. Make terminal connections at switch. Espar has 3 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 metering pump using connector and terminals supplied, boots provided with the heater-(no polarity required ).

    77 DDaayy TTiimmeerr

    77 DDaayy

    TTiimmee

    rr

    sswwiittcc

    hh hhaarrnn

    eessss

    AA

    BB

    CCaauuttiioonn:: To avoid potential short circuit damage duringinstallation, insert 20 amp fuse into the powerharness after all electrical connections are complete.

    AA)) PPoowweerr HHaarrnneessss......................................................................................................................................

    BB)) SSwwiittcchh HHaarrnneessss....................................................................................................................................

    CC)) FFuueell MMeetteerriinngg PPuummpp HHaarrnneessss......................................................................................

    CC

    Shown is a Hydronic 10 boxed version,12 volt with Standard-Power, Switch, Fuel Metering Pump harnesses and optional 7 daytimer.

    Other timers or switch options are available.

    NNoottee:: Wire must be inserted into fuse holder prior toterminating.

  • 12

    IInnssttaallllaattiioonn PPrroocceedduurreessEExxhhaauusstt CCoonnnneeccttiioonn

    The exhaust is hot, keep a minimum of 5cm (2) clearancefrom any heat sensitive material. Failure to comply with thiswarning could result in serious injury.

    A 30 mm flexible tube exhaust pipe with a length of 1M long issupplied with the kit for the exhaust. An exhaust clamp is neededto secure the exhaust to the the heater. The exhaust hose cannotbe 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.

    CCaauuttiioonn:: Run exhaust so that it cannot be plugged by dirt, water or snow. Ensure the outlet does not face into the vehicle slip stream.

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

    Universal versions only:

    Combustion air must be drawn in from the outside. The com-bustion 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.

    CCaauuttiioonn:: 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.

    Flexible Exhaust& Air intake hose

    cannot be anylonger than

    Max 2M (80)

    Holding clamps

    Exhaust & IntakeClamps

    End Sleeve

    Air Intake Hose - oonnllyy uusseeddoonn uunniivveerrssaall vveerrssiioonnss

    IInnttaakkee CCoonnnneeccttiioonn

    WWaarrnniinngg:: AAsspphhyyxxiiaattiioonn HHaazzaarrdd WWaarrnniinngg:: FFiirree HHaazzaarrdd

    NNoottee:: 1. Exhaust hose cannot be any longer than 2m.2. Minimum lenght 14.3. AAvvooiidd eexxhhaauusstt lleennggtthhss ooff 33..55 ttoo 55 fftt lloonngg..

  • 13

    IInnssttaallllaattiioonn PPrroocceedduurreessOOppeerraattiinngg SSwwiittcchheess

    NNoottee:: If installing a remote starter, refer to remote starterinstructions before terminating wires.

    A Push/Pull switch, or a 7 Day Timer are available for theheater. Both are discussed on the following pages. Connect theoperating switch as follows.

    The 7 Day Timer has been designed to provide a simple meansto control the operation of the heater system and to include thecapability for diagnostics. This timer connects to the diagnosticcircuit of the heater. The timer then displays any heater faultcodes in three digit number form automatically. The timer allowsfor pre-selection of turn on time, up to 7 days in advance, aswell as an option for run times up to 2 hours before automati-cally turning off. In addition, there is an on/off switch for manualoperation. By default the timer is pre-set by Espar to operate fortwo hours. Refer to instructions provided with timer for settingoptions.

    Mount bezel into dash and insert timer or use Espars 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. (Harness 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.

    OOppttiioonn ##22:: Operate heater continuously - connect wire from ignition circuit to terminal #10. See also multifunction (7 day) timer in instructions.

    NNoottee:: An alternative to connecting the black wire tothe vehicle ignition accessories On circuitmay also be considered for some applica-tions where extended run times are desired.Connecting the black wire with the red wirewill enable the heater to run continuouslywhether the heater is switched on manuallyor through the preset function.

    YellowRed

    BrownBlue

    DIAG

    TRS

    Yellow

    Red

    Blue

    Brown

    1211

    109

    87

    65

    43

    21

    MO12318:00

    P

    43

    40

    40

    84

    43

    40

    40

    84

    aa)) Power from battery +

    bb)) Switch control to the heater

    cc)) Power from battery -

    dd)) Diagnostic from heater

    Mounting Bracket(optional)

    P/N CA0 10 061

    BezelP/N 25 1482 70 01 00

    CA1 00 135 (12v / 24v)

    MMuullttiiffuunnccttiioonn

    aa))

    bb))

    cc))

    dd))

    OOppttiioonn ##11:: Dash lights to timer - connect wire between dash lights circuit and timer at terminal #1.

    NNoottee:: 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.

  • The 7 Day Timer has beendesigned to provide a simplemeans to control the operationof the heater system and toinclude diagnostics capability.This timer connects to the diag-nostic circuit of the heater. Thetimer then displays any heaterfault codes in three digit numberform automatically. The timerallows for pre-selection of turnon time, up to 7 days inadvance, as well as an option forrun times up to 2 hours beforeautomatically turning off. In addi-tion, there is an on/off switch formanual operation. By default thetimer is pre-set by Espar to oper-ate for two hours.

    1 Mount bezel into dash andinsert timer or use Espar soptional mounting bracket andsecure to dash. 2 Use hardware supplied forconnections.3 Connect the switch harness tothe connector at the heater andrun harness to switch location.(Harness should be neatly rout-ed and secured under dash-board).4 Cut harness to length and ter-minate wires. Attach using con-nectors provided.

    1 Time set2 Preheat time set3 Heater On4 Backward scan5 Forward scan6 Memory location7 Time and day display8 Air temperature display (optional)9 Heater On symbol10 Temperature set (air heater only)

    Note: Upon connection to power theentire timer display will begin to flash.The heater will not function until thetime is programmed.

    Setting Time and Weekday

    Push button once. 12:00 will begin to flash (this will occur uponinitial hook up to power).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 weekday has been stored.When the vehicle ignition is turned on the time display will appear

    .When the vehicle ignition is turned off the timer display will go offafter 15 seconds.

    Coolant Heater

    Air Heater

    14

    IInnssttaallllaattiioonn PPrroocceedduurreessPPuusshh//PPuullll SSwwiittcchh

    MMoouunnttiinngg BBrraacckkeett && BBeezzeellP/N 25 1482 70 01 00

    Mounting Bracket

    Bezel

    77 DDaayy TTiimmeerr IInnssttrruuccttiioonnss OOppeerraattiinngg IInnssttrruuccttiioonnss

    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 described below

    14.5mm9/16

    K (15)

    15 (K)

    31

    NNoottee:: Wired described the 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 endand tie off to the side)

    P/N CA1 00 003 (12v)P/N CA1 00 004 (24v)

  • 15

    IInnssttaallllaattiioonn PPrroocceedduurreessSSuubbttiittllee RRiigghhtt PPaaggee

    Changing the Time or Day

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

    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 a maximum of 120 minutes. Thisrunning 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 willappear in the display (maximum time of 120 minutes).Use the or to adjust the desired run time.

    Adjusting the Heater Preheat Time Permanently(Maximum Preheat Time of 120 minutes)

    Push and hold (about 3 seconds) until the display lights up andflashes. 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 turn the heater off.The heater will complete a cool down cycle and turn itself off.

    Using the Heater Manually with the Vehicle Accessory On

    Push button.The symbol will appear in the display next to the time of day.The time of day will remain displayed 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 tooperate for an addtional 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 button until the desired memory location is shown in thedisplay (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 Start Times

    Press the button until the desired memory locationappears in the display.The heater will start at the day and time displayed.The display will go off in 15 seconds. The memory locationnumber will stay displayed (1, 2 or 3).Note: When preset is chosen this symbol will flash red.

    To Turn Heater Off - All Modes

    Press the button once.The heat signal to the heater will be turned off.The heater will do a normal cooldown and turn itself off.

    Note: When the vehicle ignition is turned on the time of day and day ofthe week will appear in the timer display. This will stay on as long as thevehicle ignition is on.

    Note: When the vehicle lights are turned on the timer backlight will comeon also.

    Note: An outside temperature sensor is available as an option

    Wiring Connections at connector

    Terminal 1 Power from vehicle dash lights - grey wireTerminal 2 Heater switch wire - yellow wireTerminal 4 Connect to vehicle ground - brown wireTerminal 6 Temperature setting + (air only) - grey/red wireTerminal 8 Heater diagnostic lead - blue wire or blue/white wire (air)Terminal 9 Temperature setting - (air only) - brown/whiteTerminal 10 To vehicle ACC accessory for continuous overnight useTerminal 11 Positive power from heater - red +Terminal 12 Ground lead from heater - brown -Terminal 3,5,7 Left blank, not required

    P

    P

    77 DDaayy TTiimmeerr IInnssttrruuccttiioonnss

  • 16

    NNootteess

  • NNoottee:: During operation the heater continually senses theinput voltage from the batteries, if the inputvoltage drops to approximately 10.5V (20V on a 24 volt system) or rises above 15V (30V on a 24 volt system) the heater will automatically shut down.

    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 runfor 130 seconds to cool down.

    The heater shuts off.

    The control unit, overheat sensor and flame sensor continuallymonitor heater functions and will shut down the heater in caseof 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 berepeated. If the heater again fails to ignite after 90 secondsof 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 90 seconds of fuel delivery, or ignites but flames out again within 10 minutes, flame out shutdown follows. After troubleshooting the problem, the heater can be started again by switching the heater off and then back on.

    Overheating due to lack of water, a restriction or a poorly bled coolant system results in an overheat shut down.

    If at any time the voltage drops below 10.5V (20V on a 24 volt system), or rises above 15V (30V on a 24 volt system),a high/low voltage shutdown follows (after a 20 second delay).

    17

    HHeeaatteerr OOppeerraattiioonn

    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.

    Once switched on, the following sequence occurs:

    Control unit does a systems check ( flame sensor, temperature, safety thermal sensor 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).

    NNoottee:: If the heater fails to start the first time it will automatically attempt a second start. Ifunsuccessful the heater will shut down completely.

    NNoottee:: On initial start up the heater may require several start attempts to self prime the fuel system.

    Once ignition is successful the following operations take place:

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

    Once the coolant reaches 72C (162F) the heater will start to cycle down between levels (High,Medium,Low).

    If the coolant temperature continues to rise, the heater will automatically switch off. This occurs when temperature reaches 85C (185F).

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

    The heater will automatically re-start once coolanttemperature reaches 68C (154F).

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

    NNoottee:: If the heater should flame out while in running mode, it will automatically attempt one restart. If successful it will continue to run, if not it will turn itself off.

    PPrree--SSttaarrtt PPrroocceedduurreess

    SSttaarrtt UUpp

    RRuunnnniinngg

    SSwwiittcchh OOffff

    SSaaffeettyy EEqquuiippmmeenntt

    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.

    WWaarrnniinngg::

  • 18

    HHeeaatteerr OOppeerraattiioonnOOppeerraattiioonnaall FFllooww CChhaarrtt

    OOppeerraattiioonn PPrrooffiillee

    SSttaarrtt uupp sseeqquueennccee

    Vehicle Blower 55COn Power - 7300 rpm

    Power - High 72C High - 5600 rpm

    High - Medium 78C Medium - 3000 rpm

    Medium - Low 79C Low - 1800 rpm

    Low - Off 85C

    Off - Medium 68C

    Medium - High 68C

    Low - Medium 73C

    High - Power 53C

    Speed of blower motor

    (rpm)

    Time (s)

    8

    6

    4

    2

    00 20 40 60 80 100 120 140 160 180 200

    8

    6

    4

    2

    0

    Glow plug

    Blower motor

    Metering pump

    Frecuency of

    metering pump (Hz)

    STARTING PHASE RUNNING PHASE SHUT DOWN PHASE

    OperatingMode

    Time

    FuelPump

    Glow Pin

    Blower

    Water Pump

    System Check

    Pre-heat Pre-heat2nd. attempt

    IgnitionAttempt

    IgnitionAttempt

    2nd. attempt

    ControlledHeating

    Off

    Off

    Off

    OffOn On

    Off On:

    if in stand byOnOnOnOnOn On

    OnOnOnOff

    OnOnOnOn

    On

    On

    On

    On OffOff Off

    Off Off Off Off OffOnOn On

    AfterGlow

    CoolDown

    Offor

    Stand by

    1- 3 sec. 80 sec. 20 sec.

    80 sec.Up to90 sec.

    Up to 90 sec.

    If Required High/Low Operation

    until switched off manually or automatically

    2.5 min.

    Note: During the controlled heating cycle, if the coolant temperature exceeds 85C(185F) the heater will cycle off.Heater will automatically restart in high mode once coolant temperature reaches 68C(154F)

    CCoonnttrrooll tteemmppeerraattuurreess SSppeeeedd ooff bblloowweerr mmoottoorr

    CCoooollaanntt TTeemmppeerraattuurree CCoonnttrrooll PPrrooffiillee

    90

    80

    70

    Power

    Power

    Power

    High

    High High

    Medium

    MittelMedium Medium

    Low

    Low

    Off

    Off

    68

    8579

    78

    72

    5355

    68

    73

    Power

    Power

    Power

    Max. Operation in Heat Levels

    Power = 2 h ( 15 min. High)

    High

    Medium

    Low = 20 h ( Off then On)

    Generally = 40 h (Off then On)

    Glow pin cycle for 40 sec.

    After 4 h if no heater off-on cycle

    High

    High High

    Medium

    MittelMedium Medium

    Time

    Low

    Low

    Off

    Off

    68

    8579

    78

    72

    5355

    68

    73

    60

    Tem

    pera

    ture

    in C

    50

    40

    30

    20

    10

    0

    -10

  • 19

    HHeeaatteerr OOppeerraattiioonnHHyyddrroonniicc 1100 WWiirriinngg DDiiaaggrraamm -- 1122 VVoolltt ++ 2244 VVoolltt

    2255 22008811 0055 -- 1122VV2255 22004444 0055 -- 2244VV

    1.1 Blower motor1.2 Glow pin1.5 Overheat sensor1.12 Flame sensor1.13 Temperature sensor2.1 Control unit2.12 Water Pump2.2 Fuel metering pump2.7 20 amp main fuse2.7.1 5 amp switch fuse3.2.9 7 day timer, push/pull switch

    or 99hr. timer5.1 Battery

    a) Optional - supply for vehicle blowerb) Powerc) Diagnosticsd) Switche) Groundh) Optional - LED for flashing code

    B1

    B5

    B1

    b

    RED

    BROWNGR

    EE

    N

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    13

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    1112

    1314

    1516

    1718

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    2.7.1

    3.1.1

    3.2.9

    2.1

    2.75.1

    2.2

    1.2 1.5 2.12 1.121.13 1.1

    1 2 3 4 5 6 7 8 9 10 11 12 13 14

    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

    h)YELLOW

    BLUE

    LED

    RED

    YELLOW

    BROWN

    15 (K)

    00

    K (15) 31

    Push/Pull switch

    Diagnostic

    7 Day timer

    Optional

    YellowRed

    BrownBlue

    DIAG

    TRS

    Bro

    wn

    1211

    109

    87

    65

    43

    21

    Grey

    Black

    BROWNYELLOW

    BLUE/WHITE

    RED/YELLOW

  • 20

    HHeeaatteerr OOppeerraattiioonnHHyyddrroonniicc 1100 WWiirriinngg DDiiaaggrraamm -- 1122 VVoolltt ++ 2244 VVoolltt -- UUnniivveerrssaall HHaarrnneessss

    2255 22008811 0055 -- 1122VV2255 22004444 0055 -- 2244VV

    B1

    B5

    B1

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    RE

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    12

    13

    3

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    32

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    72

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    1112

    1314

    1516

    1718

    14

    87

    3.1.13.2.9

    2.5.7

    2.1

    2.7

    2.7.1

    2.7.2

    5.1

    2.2

    1.2 1.5 2.12 1.121.13 1.1

    1 2 3 4 5 6 7 8 9 10 11 12 13 14

    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

    h)YELLOW

    BLUE

    LED

    RED

    YELLOW

    BROWN

    15 (K)

    00

    K (15) 31

    Push/Pull switch

    7 Day timer

    Optional

    YellowRed

    BrownBlue

    DIAG

    TRS

    Bro

    wn

    1211

    109

    87

    65

    43

    21

    Grey

    Black

    BROWNYELLOW

    BLUE/WHITE

    RED/YELLOW

    Diagnostic

    1.1 Blower motor1.2 Glow pin1.5 Overheat sensor1.12 Flame sensor1.13 Temperature sensor2.1 Control unit2.12 Water Pump2.2 Fuel metering pump2.5.7 Vehicle blower relay2.7 20 amp main fuse (12V)2.7.1 5 amp switch fuse2.7.5 15 amp blower fuse3.2.9 7 day timer, push/pull switch

    or 99hr. timer5.1 Battery

    a) vehicle blower step switchb) vehicle ignition terminalc) external control (water pump)d) diagnosticse) switchf) powerg) groundh) LED for flashing code

  • 1211

    109

    87

    65

    43

    21

    B1

    B3B5B1

    B1

    BA

    C

    D

    B5

    2.12.7

    5.1

    2.2

    1.2 1.5 2.12 1.121.13 1.1

    l)

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    a6)

    a2)

    a3)

    a4)

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    WH

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    W

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    4

    C3

    C2

    C1

    B4

    B3

    B2

    B1

    A4

    A3

    A2

    A1

    g)

    b)

    8 9 2 7 11 17 3 6 14 18 15 16 10 13 5 4 1 12

    BR

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    BROWN

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    3.1.1

    h)YELLOW

    BLUE

    LED

    Push/Pull switch

    7 Day timer

    RED

    YELLOW

    BROWN

    15 (K)

    00

    31

    Optional

    YellowRed

    BrownBlue

    DIAG

    TRS

    Bro

    wn

    Grey

    Black

    K (15)

    Diagnostic

    25 2227 05 only

    21

    HHeeaatteerr OOppeerraattiioonnHHyyddrroonniicc MM WWiirriinngg DDiiaaggrraamm -- 1122 VVoolltt aanndd 2244 VVoolltt -- EEnnggiinnee HHeeaatt OOnnllyy

    1.1 Blower motor1.2 Glow pin1.5 Overheat sensor1.12 Flame sensor1.13 Temperature sensor2.1 Control unit2.12 Water Pump2.2 Fuel metering pump2.7 20 amp main fuse (12V)2.7.1 5 amp switch fuse3.2.9 7 day timer, push/pull switch

    or 99hr. timer5.1 Battery

    a) vehicle blower step switchb) vehicle ignition terminalc) external control (water pump)d) diagnosticse) switchf) powerg) groundh) LED for flashing code

    LED

    2255 22116600 0055 -- 1122VV2255 22222277 0055 -- 2244VV

  • B1

    B3B5B1

    B1

    BA

    C

    D

    B5

    2.1 2.7

    5.1

    2.2

    1.2 1.5 2.12 1.121.13 1.1

    l)

    k)

    a6)

    a2)

    a3)

    a4)

    a5)

    2.7.12.7.1

    2.5.7

    5.10

    2.5.18

    WH

    ITE

    BR

    OW

    N

    BLU

    E

    BLU

    E

    BLA

    CK

    /RE

    D

    BR

    OW

    N/B

    LAC

    K

    YE

    LLO

    W

    YE

    LLO

    W

    GR

    EY

    GR

    EY

    RE

    D

    VIO

    LET

    GR

    EE

    N

    OR

    AN

    GE

    BLA

    CK

    RED

    BROWN

    GR

    EE

    NC

    4

    C3

    C2

    C1

    B4

    B3

    B2

    B1

    A4

    A3

    A2

    A1

    g)

    b)

    c) c)

    8 9 2 7 11 17 3 6 14 18 15 16 10 13 5 4 1 12

    BR

    OW

    N

    BR

    OW

    N

    RE

    D

    RE

    D

    BLA

    CK

    BK

    /VT

    RE

    D/Y

    ELL

    OW

    BLU

    E

    YE

    LLO

    W

    WH

    ITE

    RED

    BR

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    N

    RED

    BROWN

    BROWN

    Optional

    YellowRed

    BrownBlue

    Grey

    Black

    3.1.1

    h)YELLOW

    BLUE

    LED

    RED

    YELLOW

    BROWN

    15 (K)

    00

    K (15) 31

    Push/Pull switch

    25 2227 05 Only

    7 Day timer

    Optional

    DIAG

    TRS

    Bro

    wn

    1211

    109

    87

    65

    43

    21

    Diagnostic

    22

    HHeeaatteerr OOppeerraattiioonnHHyyddrroonniicc MM WWiirriinngg DDiiaaggrraamm -- 1122 VVoolltt aanndd 2244 VVoolltt -- UUnniivveerrssaall HHaarrnneessss

    2255 22116600 0055 -- 1122VV2255 22222277 0055 -- 2244VV

    1.1 Blower motor1.2 Glow pin1.5 Overheat sensor1.12 Flame sensor1.13 Temperature sensor2.1 Control unit2.12 Water Pump2.2 Fuel metering pump2.5.7 Vehicle blower relay2.5.18 Relay, changeover water circuit.2.7 20 amp main fuse (12V)2.7.1 5 amp switch fuse2.7.5 15 amp blower fuse3.2.9 7 day timer, push/pull switch

    or 99hr. timer5.1 Battery5.10 Vehicle fan

    a) vehicle blower step switchb) vehicle ignition terminalc) external control (water pump)d) diagnosticse) switchf) powerg) groundh) LED for flashing code

  • 23

    SSuubbttiittllee RRiigghhtt PPaaggee

    MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssPPeerriiooddiicc MMaaiinntteennaannccee

    Check coolant hoses, clamps, and make sure all valves are open. Maintain the engine manufacturers recommend-ed coolant level and ensure that the heater is properly bledafter 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 manufacturersrecommendations). Blending used engine oil with dieselfuel is not permitted.

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

    Fuses.

    Electrical lines and connections

    Interference in Combustion air and Exhaust pipes.

    Fuel in the tank.

    Battery voltage

    Coolant flow

    The heater is equipped with self diagnostic capability. You canretrieve information on the heaters last 5 faults using the Espar7 day timer or Espars Fault Code Retrieval Device.

    Espars 7 day timer has a fault coderetrieval device built into the unit. Thisfunction automatically activates if theheater is experiencing problems.

    Fault codes appear on the LCD display screen

    Codes can then be translated from the charts on thefollowing pages.

    See instruction sheet that comes with the timer

    Symbols seen on the displayface are as follows:

    AAFF Actual fault.

    FF11--FF55 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.

    DDIIAAGG The word (Diagnostic) will come on when the diagnostic number is requested.

    000000 Three digit diagnostic fault code number.

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

    Connect adapter cable to the cable loom of the Fault coderetrieval device

    Start diagnostic unit - switch heater on from switch

    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.

    LD L

    22 5302 00

    10 05HYDR

    ONIC10

    24 V Made in

    Gemany NICH

    T WERFEN

    FFaauulltt ccooddee rreettrriieevvaall ddeevviicceeP/N CA1 05 020

    FFaauulltt ccooddeerreettrriieevvaall

    ddeevviicceehhaarrnneessss

    P/N CA1 05 030Rounded end

    or CA1 05 044Squared end

    TTrroouubblleesshhoooottiinngg

    BBaassiicc TTrroouubblleesshhoooottiinngg

    SSeellff DDiiaaggnnoossttiiccss

    MMuullttiiffuunnccttiioonn

    FFaauulltt CCooddee RReettrriieevvaall DDeevviiccee

    EEqquuiippmmeenntt FFaaccee aanndd CCoonnttrroollss

    HHooookk UUpp

    IInnssttrruuccttiioonnss::

  • 24

    MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssFF

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    pins

    13

    and

    14 o

    f co

    ntro

    l

    unit(

    exte

    rnal

    plu

    g) is

    less

    tha

    n 10

    V o

    r 20

    V

    010

    Ove

    rvol

    tage

    shu

    tdow

    nC

    heck

    vol

    tage

    bet

    wee

    n pi

    ns 1

    3 an

    d 14

    at

    the

    cont

    rol u

    nit

    (ext

    erna

    l plu

    g) is

    gre

    ater

    tha

    n 15

    V o

    r 30

    V.C

    heck

    veh

    icle

    char

    ging

    sys

    tem

    .

    011

    Und

    er v

    olta

    ge s

    hut

    dow

    nC

    heck

    vol

    tage

    bet

    wee

    n pi

    ns 1

    3 an

    d 14

    at

    the

    cont

    rol u

    nit

    (ext

    erna

    l plu

    g) is

    less

    tha

    n 10

    V o

    r 20

    V.C

    heck

    bat

    terie

    s

    and

    conn

    ectio

    ns.

    012

    Ove

    rhea

    ting

    Che

    ck fo

    r po

    ssib

    le c

    ause

    s of

    ove

    rhea

    t, ch

    eck

    wat

    er

    thro

    ugh

    flow

    (w

    ater

    circ

    uit)

    , se

    nsor

    .Tem

    pera

    ture

    at

    tem

    pera

    ture

    sen

    sor

    is g

    reat

    er t

    han

    115

    C.I

    mpe

    danc

    e at

    tem

    pera

    ture

    sen

    sor

    < 4

    00

    .Che

    ck d

    iffer

    ence

    at

    the

    cont

    rol u

    nit,

    dism

    antle

    the

    con

    trol

    uni

    t, di

    scon

    nect

    the

    inte

    rnal

    plu

    g fr

    om t

    he c

    ontr

    ol u

    nit

    and

    mea

    sure

    the

    diffe

    renc

    e be

    twee

    n pi

    ns 5

    and

    8.

    Ove

    rhea

    t se

    nsor

    val

    ues:

    150

    kohm

    s at

    -25

    C

    10 k

    ohm

    s at

    +25

    C.

    013

    Exc

    essi

    ve t

    empe

    ratu

    re a

    t fla

    me

    sens

    orF

    lam

    e se

    nsor

    sig

    nals

    tem

    pera

    ture

    of

    grea

    ter

    than

    700

    C.

    Diff

    eren

    ce a

    t fla

    me

    sens

    or >

    340

    0 oh

    ms.

    Che

    ck t

    he

    impe

    danc

    e at

    the

    con

    trol

    uni

    t (in

    tern

    al p

    lug)

    , di

    sman

    tle

    the

    cont

    rol u

    nit,

    disc

    onne

    ct t

    he in

    tern

    al p

    lug

    from

    the

    cont

    rol u

    nit

    and

    mea

    sure

    the

    impe

    danc

    e be

    twee

    n pi

    ns 1

    0

    and

    12.F

    lam

    e se

    nsor

    val

    ues:

    900

    ohm

    s at

    -25

    C

    1100

    ohm

    s at

    +25

    C.

    014

    Pos

    sibl

    e ov

    erhe

    atin

    g de

    tect

    edD

    iffer

    ence

    of

    mea

    sure

    d va

    lues

    at

    tem

    pera

    ture

    sen

    sor

    >70

    C (

    diffe

    renc

    e ev

    alua

    tion)

    Che

    ck t

    empe

    ratu

    re s

    enso

    r

    and

    over

    heat

    ing

    sens

    or,

    open

    hea

    ter

    slid

    e va

    lve

    and

    chec

    k w

    ater

    thr

    ough

    flow

    .Che

    ck t

    he im

    peda

    nce

    betw

    een

    5 an

    d 8

    at t

    he c

    ontr

    ol u

    nit

    (inte

    rnal

    plu

    g).O

    ver

    tem

    pera

    ture

    sen

    sor

    valu

    es:1

    50 k

    ohm

    s at

    -25

    C

    10 k

    ohm

    s at

    +25

    C.

    88 ss

    eeccoo

    nndd

    ss

  • 25

    MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssFF

    aauu

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    5To

    o m

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    heat

    sT

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    nit

    is in

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    afte

    r th

    ree

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    essi

    ve

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    heat

    s (e

    rror

    cod

    es 0

    12,

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    and

    014)

    .Elim

    inat

    e th

    e

    case

    of

    the

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    heat

    .Can

    cel t

    he in

    terlo

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    g th

    e

    erro

    r m

    emor

    y w

    ith t

    he d

    iagn

    ostic

    uni

    t/PC

    .

    020

    Ope

    n ci

    rcui

    t -

    glow

    pin

    Che

    ck g

    low

    pin

    (no

    min

    al v

    alue

    :2 o

    hms)

    , re

    plac

    e if

    nece

    ssar

    y.C

    heck

    pin

    4(w

    hite

    ) on

    the

    con

    trol

    uni

    t

    021

    Sho

    rt c

    ircui

    t -

    glow

    plu

    g(in

    tern

    al p

    lug)

    lead

    ing

    to g

    low

    plu

    g to

    ter

    min

    al 3

    (br

    own)

    for

    cont

    inui

    ty/s

    hort

    -circ

    uit.

    If O

    .K.-

    > r

    epla

    ce c

    ontr

    ol u

    nit.

    033

    Com

    bust

    ion

    air

    blow

    er m

    otor

    S

    peed

    dev

    iatio

    n fo

    r lo

    nger

    tha

    n 60

    sec

    onds

    .Nom

    inal

    valu

    es:5

    600

    rpm

    (fu

    ll-lo

    ad),

    185

    0 rp

    m (

    part

    load

    )

    * C

    heck

    bur

    ner

    mot

    or:

    appl

    y su

    pply

    vol

    tage

    to

    mot

    or.

    Con

    nect

    + t

    o 1.

    5 bl

    ack

    and

    - to

    1.5

    ora

    nge.

    Mot

    or d

    oes

    not

    turn

    >

    rep

    lace

    bur

    ner

    mot

    or w

    ith in

    tegr

    ated

    sen

    sor.

    * C

    heck

    sen

    sor

    supp

    ly.S

    witc

    h on

    hea

    ter

    and

    mea

    sure

    volta

    ge b

    etw

    een

    outp

    ut 1

    3 (0

    .25

    red)

    and

    14

    (0.2

    5 gr

    een)

    at t

    he c

    ontr

    ol u

    nit

    (inte

    rnal

    plu

    g).N

    omin

    al v

    alue

    :8

    V.If

    devi

    atio

    n

    > r

    epla

    ce c

    ontr

    ol u

    nit.

    * C

    heck

    sen

    sor:

    Mea

    sure

    vol

    tage

    bet

    wee

    n te

    rmin

    al 1

    5

    (0.2

    5 vi

    olet

    ) an

    d 14

    (0.

    25 g

    reen

    ) w

    ith a

    n an

    alog

    vol

    tmet

    er

    whe

    n th

    e bl

    ower

    is r

    unni

    ng.N

    omin

    al v

    alue

    :4

    V (

    + 0

    .3 V

    )

    aver

    age

    valu

    e (8

    V s

    quar

    e-w

    ave

    sign

    al).

    If de

    viat

    ion

    >

    repl

    ace

    mot

    or w

    ith in

    tegr

    ated

    sen

    sor.

    If se

    nsor

    sig

    nal i

    s

    O.K

    ., th

    en t

    he s

    peed

    con

    trol

    ler

    is d

    efec

    tive

    >

    Cha

    nge

    cont

    rol u

    nit.

    037

    Wat

    er p

    ump

    is n

    ot w

    orki

    ngC

    heck

    wat

    er p

    ump

    (driv

    en e

    xter

    nally

    ).

    042

    Wat

    er p

    ump

    shor

    t-ci

    rcui

    tC

    heck

    wat

    er p

    ump

    and

    lead

    s.

    043

    Sho

    rt c

    ircui

    t at

    ext

    erna

    l com

    pone

    nts

    Che

    ck t

    erm

    inal

    2 (

    1 gr

    een)

    of

    cont

    rol u

    nit

    (ext

    erna

    l plu

    g)

    for

    shor

    t-ci

    rcui

    t.C

    heck

    con

    nect

    ed c

    ompo

    nent

    s (m

    ax.

    curr

    ent

    6A),

    rep

    lace

    the

    m if

    nec

    essa

    ry.

    047

    Sho

    rt c

    ircui

    t -

    fuel

    met

    erin

    g pu

    mp

    Che

    ck t

    erm

    inal

    1 (

    1 bl

    ue)

    of c

    ontr

    ol u

    nit

    (ext

    erna

    l plu

    g)

    and

    lead

    s up

    to

    met

    erin

    g pu

    mp

    for

    shor

    t-ci

    rcui

    t/

    inte

    rrup

    tion.

    Che

    ck t

    he m

    eter

    ing

    pum

    p.N

    omin

    al v

    alue

    :

    048

    Ope

    n ci

    rcui

    t -

    fuel

    met

    erin

    g pu

    mp

    appr

    ox.2

    0 oh

    ms.

    Rep

    lace

    if n

    eces

    sary

    .88

    ssee

    ccoonn

    ddss

  • 26

    MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssFF

    aauu

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    oodd

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    aauu

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    aauussee

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    sshhiinn

    gg CC

    oodd

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    0To

    o m

    any

    no s

    tart

    atte

    mpt

    sT

    he c

    ontr

    ol u

    nit

    is in

    terlo

    cked

    afte

    r it

    has

    been

    sw

    itche

    d

    on 1

    0 tim

    es in

    suc

    cess

    ion

    (=20

    faile

    d st

    arts

    ) w

    ithou

    t

    flam

    e de

    tect

    ion

    (fau

    lt co

    de 0

    52).

    Che

    ck t

    he f

    uel s

    uppl

    y,

    glow

    plu

    g, e

    xhau

    st p

    ipin

    g, c

    ombu

    stio

    n ai

    r pi

    ping

    and

    flam

    e se

    nsor

    .C

    ance

    l the

    inte

    rlock

    by

    clea

    ring

    the

    erro

    r

    mem

    ory

    with

    the

    dia

    gnos

    tic u

    nit/P

    C.

    051

    Faul

    ty f

    lam

    e re

    cogn

    ition

    Fla

    me

    sens

    or s

    igna

    ls a

    tem

    pera

    ture

    of

    grea

    ter

    than

    80C

    des

    pite

    4 m

    inut

    es o

    f co

    olin

    g w

    ith c

    old

    air.

    Impe

    danc

    e at

    fla

    me

    sens

    or >

    130

    0 oh

    m.I

    f no

    com

    bust

    ion

    take

    s pl

    ace

    >

    che

    ck t

    he f

    lam

    e se

    nsor

    ,

    repl

    ace

    it if

    nece

    ssar

    y.F

    lam

    e se

    nsor

    val

    ues:

    900

    ohm

    s

    at -

    25C

    , 11

    00 o

    hms

    at +

    25C

    .

    052

    No

    star

    t sa

    fety

    tim

    e ex

    ceed

    edN

    o fla

    me

    was

    det

    ecte

    d du

    ring

    the

    star

    t-up

    pha

    se.

    Fla

    me

    sens

    or v

    alue

    of

    less

    tha

    n 90

    C (

    1350

    ohm

    s).

    Che

    ck t

    he f

    uel s

    uppl

    y, g

    low

    plu

    g, e

    xhau

    st p

    ipin

    g, c

    om

    bust

    ion

    air

    pipi

    ng a

    nd f

    lam

    e se

    nsor

    .Fla

    me

    sens

    or

    valu

    es:9

    00 o

    hms

    at -

    25C

    , 11

    00 o

    hms

    at +

    25C

    .

    053

    Fla

    me

    cuto

    ut in

    boo

    st m

    ode

    Hea

    ter

    has

    star

    ted

    (fla

    me

    dete

    cted

    ) an

    d in

    dica

    tes

    flam

    e

    loss

    in a

    pow

    er s

    ettin

    g.C

    heck

    fue

    l flo

    w r

    ate,

    blo

    wer

    054

    Fla

    me

    cuto

    ut in

    hig

    h m

    ode

    spee

    d, f

    uel s

    uppl

    y, e

    xhau

    st p

    ipe

    and

    com

    bust

    ion

    air

    056

    Fla

    me

    cuto

    ut in

    med

    ium

    mod

    epi

    ping

    .If

    com

    bust

    ion

    is O

    .K.,

    chec

    k fla

    me

    sens

    or,

    056

    Fla

    me

    cuto

    ut in

    low

    mod

    ere

    plac

    e if

    nec

    essa

    ry.F

    lam

    e se

    nsor

    val

    ues:

    900

    ohm

    s

    at -

    25C

    , 11

    00 o

    hms

    at +

    25C

    .

    059

    Wat

    er t

    empe

    ratu

    re r

    ises

    to

    quic

    kly

    Che

    ck w

    ater

    circ

    ulat

    ion

    (012

    ) an

    d te

    mpe

    ratu

    re c

    ontr

    ol

    sens

    or (

    060/

    061)

    .

    060

    Tem

    pera

    ture

    con

    trol

    sen

    sor

    inte

    rrup

    tion

    Con

    trol

    sen

    sor

    sign

    als

    tem

    pera

    ture

    val

    ue o

    utsi

    de

    mea

    sure

    men

    t ra

    nge.

    Che

    ck t

    he c

    onne

    ctin

    g le

    ads

    (0.3

    5

    yello

    w).

    For

    th

    is p

    urpo

    se,

    dism

    antle

    the

    con

    trol

    uni

    t,

    061

    Sho

    rt c

    ircui

    t -

    tem

    pera

    ture

    con

    trol

    disc

    onne

    ct t

    he in

    tern

    al p

    lug

    from

    the

    con

    trol

    uni

    t an

    d

    mea

    sure

    the

    impe

    danc

    e be

    twee

    n 9

    and

    11.I

    mpe

    danc

    e

    betw

    een

    term

    inal

    s 9

    and

    11 o

    f th

    e co

    ntro

    l uni

    t (in

    tern

    al

    plug

    ):gr

    eate

    r th

    an 1

    0 ko

    hms

    (in t

    he e

    vent

    of

    inte

    rrup

    tion)

    less

    tha

    n 10

    0 oh

    ms

    (in t

    he e

    vent

    of

    shor

    t

    circ

    uit)

    .Tem

    pera

    ture

    sen

    sor

    valu

    es:6

    50 o

    hms

    at -

    25C

    ,

    1000

    ohm

    s at

    +25

    C.

    88 ss

    eeccoo

    nndd

    ss

  • 27

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    aauu

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    uit

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    pera

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    val

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    mea

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    men

    t ra

    nge.

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    ck t

    he c

    onne

    ctin

    g le

    ads

    (0.3

    5

    gree

    n).

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    danc

    e be

    twee

    n te

    rmin

    als

    10 a

    nd 1

    2 of

    the

    065

    Sho

    rt c

    ircui

    t -

    flam

    e se

    nsor

    cont

    rol u

    nit

    (inte

    rnal

    plu

    g):g

    reat

    er t

    han

    50 k

    ohm

    s (in

    the

    even

    t of

    inte

    rrup

    tion)

    less

    tha

    n 10

    0 oh

    ms

    (in t

    he e

    vent

    of s

    hort

    -circ

    uit)

    .Fla

    me

    sens

    or v

    alue

    s:

    900

    ohm

    s at

    -25

    C,

    1100

    ohm

    s at

    +25

    C.

    071

    Ope

    n ci

    rcui

    t -

    over

    heat

    sen

    sor

    Ove

    rhea

    t se

    nsor

    sig

    nals

    tem

    pera

    ture

    val

    ue o

    utsi

    de

    mea

    sure

    men

    t ra

    nge.

    Che

    ck t

    he c

    onne

    ctin

    g le

    ads

    (0.3

    5

    072

    Sho

    rt c

    ircui

    t -

    over

    heat

    sen

    sor

    blue

    ).Im

    peda

    nce

    betw

    een

    term

    inal

    s 5

    and

    8 of

    the

    cont

    rol u

    nit

    (inte

    rnal

    plu

    g):g

    reat

    er t

    han

    700

    kohm

    s

    (in t

    he e

    vent

    of

    inte

    rrup

    tion)

    less

    tha

    n 10

    0 oh

    ms

    (in t

    he

    even

    t of

    sho

    rt-c

    ircui

    t).O

    verh

    eat

    sens

    or v

    alue

    s:

    150

    kohm

    s at

    -25

    C,

    10 k

    ohm

    s at

    +25

    C.

    090

    Con

    trol

    uni

    t de

    fect

    (in

    tern

    al fa

    ult)

    Inte

    rnal

    con

    trol

    uni

    t er

    ror

    in m

    icro

    proc

    esso

    r/m

    emor

    y

    dete

    cted

    .Rep

    lace

    con

    trol

    uni

    t.

    093

    Con

    trol

    uni

    t de

    fect

    ive(

    RA

    M e

    rror

    )

    094

    Con

    trol

    uni

    t de

    fect

    ive(

    EP

    RO

    M fa

    ult)

    097

    Con

    trol

    uni

    t de

    fect

    ive

    (pow

    er fa

    ilure

    )

    88 ss

    eeccoo

    nndd

    ss

  • 28

    MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssFFuueell QQuuaannttiittyy TTeesstt

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

    NNoottee:: Measure the fuel quantity when the battery issufficiently charged. At least 11V/22V and at most 13V/26V should be applied at the controlunit during measurement.

    Pull the fuel line from the heater and insert into a

    graduated measuring glass (size: 25cm3).

    Espar # 5520005.

    Switch the heater on, when fuel delivery is uniform (approximately 63 seconds after switching on), the fuel line is full and bled.

    Switch the heater off and empty the measuring glass.

    Switch heater on.

    Fuel delivery stars automatically approximately 63seconds after switching on.

    After 105 seconds of fuel delivery, it will shut offautomatically.

    Wait for restart.

    Fuel pump is automatically switched offafter another 75 seconds.

    Switch off the heater.

    Measure the fuel in the measuring glass.

    NNoommiinnaall vvaalluuee:: 1188 mmll 1100%%

    If the quantity is less than the tolerance, replace the fuelmetering pump.

    11 Control unit HYDRONIC 10 (on installation of controlunit, grease the gasket with sealing paste).

    11 Control unit HYDRONIC 10 (on installation of controlunit, grease the gasket with sealing paste).

    PPrreeppaarraattiioonn

    RReeppaaiirr SStteeppss

    DDiissaasssseemmbbllyy // AAsssseemmbbllyy

    MMeeaassuurreemmeenntt

    EEvvaalluuaattiioonn

    TTeemmppeerraattuurree sseennssoorr --2255CC 665500 oohhmmss2255CC 11000000 oohhmmss

    FFllaammee sseennssoorr --2255CC 990000 oohhmmss2255CC 11110000 oohhmmss

    OOvveerrhheeaatt sseennssoorr --2255CC 115500 KKoohhmmss2255CC 1100 KKoohhmmss

    GGllooww PPiinn ~~22 oohhmmss

    FFuueell MMeetteerriinngg PPuummpp ~~2200oohhmmss

    CCoooollaanntt PPuummpp vvaarriieess wwiitthh mmoottoorr ssppeeeedd

    CCoommbbuussttiioonn AAiirr BBlloowweerr vvaarriieess wwiitthh mmoottoorr ssppeeeedd

    RReessiissttaannccee VVaalluueess11 Control unit

    22 Glow pin cable

    33 Glow pin

    44 Overheat sensor / temperature sensor

    55 Cover Blower

    66 Flame sensor/heat exchanger fastening screws

    77 Housing including heat exchanger, dismantled

    88 Burner

    99 Burner dismantled

    1100 Heat exchanger

    1111 Heat exchanger dismantled

  • 29

    MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrss

    44 Overheat sensor / temperature. 55 Cover Blower (on installation of the cover, clean the seal-ing surface and apply liquid seal).

    22 Glow plug cable HYDRONIC 10. 22 Glow plug cable HYDRONIC M.

    33 Glow plug HYDRONIC 10. 33 Glow plug HYDRONIC M.

  • 30

    MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrss66 Flame sensor / heat exchanger fastening screws. 77 Housing including heat exchanger, dismantled.

    99 Burner dismantled.88 Burner.

    1100 Heat exchanger. 1111 Heat exchanger dismantled.

  • 31

    NNootteess

  • 32

    HHeeaatteerr CCoommppoonneennttssHHyyddrroonniicc 1100 aanndd HHyyddrroonniicc MM PPaarrttss DDiiaaggrraamm

    22 5302 00

    10 05HYDR

    ONIC10

    24 V Made in

    Gemany NICH

    T WERFEN

    32

    25

    13

    21

    27

    20

    29

    28

    14

    11

    15

    2

    18

    12

    10

    15

    32

    26

    17

    930

    7

    22

    8

    22

    6

    23

    31

    31

    33(FCRD Adapter)

    1

    19

    4

    5

    28

    3

    24

    24

    16

    HYDRONIC 1025 2081 05 - 12 volt25 2044 05 - 24 volt

    HYDRONIC M25 2160 05 - 12 volt25 2161 05 - 24 volt25 2227 05 - 24 volt

  • Mod

    el #

    RReeff.. NNoo.. DDeessccrriippttiioonn PPaarrtt NNuummbbeerr

    HHyyddrroonniicc 1100 // MM -- 1122 && 2244 vvoolltt -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

    DDeessccrriippttiioonn && PPaarrtt ##ss

    33

    HHeeaatteerr CCoommppoonneennttss

    25 2

    044

    05 2

    4V

    25 2

    081

    05 1

    2V

    1 Outer casing 25 1997 01 00 02

    2 Combustion air blower with cover 25 1815 99 15 00 25 1816 99 15 00 25 2160 99 15 00 25 2161 99 15 00

    3 Burner assembly 25 2044 99 11 00 25 2161 99 11 00

    4 Flame tube and burner 25 2044 11 01 00

    5 Seal 25 1816 99 11 07

    6 Water pump 25 1815 25 01 00 25 1816 25 01 00

    7 Temperature Sensor 25 1816 99 01 11 25 1816 99 01 11

    8 Overheat sensor 25 1997 99 41 00

    9 Flame sensor 25 1816 01 03 00

    10 Glow pin 12V 25 1996 99 01 01 24V 25 1997 99 01 01

    11 Seal 25 2044 01 00 12

    12 Glow plug cable 25 2044 01 04 00

    13 Heat exchanger 25 1816 06 00 01

    14 Cover 25 2044 01 00 11

    15 Screw 100 61 317

    16 Washer 171 22 118

    17 Seal 25 1816 01 00 04

    18 Seal 25 1816 01 13 00

    19 Sleeve 25 1816 01 00 12

    20 Clamp 10 2065 05 00 70

    21 O-ring 22 1000 70 00 01

    22 O-ring 22 1000 70 00 09

    23 O-ring 22 1000 70 00 03

    24 Fillister head bolt 109 10 107

    25 Spring washer 171 22 101

    26 Taptite screw 109 10 153 109 10 104

    27 Taptite screw 109 10 106

    28 Taptite screw 109 10 107

    29 Clip 156 22 021

    30 Indented Hexagon nut 171 19 254

    25 2

    160

    05 1

    2V

    25 2

    227

    05 2

    4V

    25 2

    161

    05 2

    4V

  • Mod

    el #

    RReeff.. NNoo.. DDeessccrriippttiioonn PPaarrtt NNuummbbeerr

    HHyyddrroonniicc 1100 // MM -- 1122 && 2244 vvoolltt -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

    DDeessccrriippttiioonn && PPaarrtt ##ss

    34

    HHeeaatteerr CCoommppoonneennttss

    31 Control unit 12V 25 2081 99 50 03 24V 25 2044 99 50 07 12V 22 5301 00 10 01 24V 22 5302 00 10 01 24V 22 5302 00 10 04

    32 Twist tie 209 31 080

    33 Retrieval harness for fault code device (FCRD Adapter) CA1 05 030 CA1 05 044

    25 2

    044

    05 2

    4V

    25 2

    081

    05 1

    2V

    25 2

    160

    05 1

    2V

    25 2

    227

    05 2

    4V

    25 2

    161

    05 2

    4V

  • 35

    NNootteess

  • 36

    HHeeaatteerr CCoommppoonneennttssHHyyddrroonniicc 1100 aanndd HHyyddrroonniicc MM PPaarrttss DDiiaaggrraamm ffoorr BBooxxeedd UUnniittss

    1

    2

    5

    717

    8

    53

    52

    25

    25

    25

    26

    25

    28

    14

    9

    10

    11

    12

    50

    13

    23

    242424 18

    20

    21

    21

    42

    44

    51

    45

    43

    222222

    1924

    27

    27

    31

    12

    12

    131313

    3233

    34

    35

    41

    38

    39

    36

    373737

    16

    6

    6

    293

    4

    4

    4

    4

    46

    47

    48

    49

    303030

    40

  • Mod

    el #

    25 2

    044

    05 2

    4V

    25 2

    081

    05 1

    2V

    RReeff.. NNoo.. DDeessccrriippttiioonn PPaarrtt NNuummbbeerr

    HHyyddrroonniicc 1100 // MM BBooxxeedd -- 1122 && 2244 vvoolltt -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

    1 Hydronic 10 heater 12V 24V

    2 Heater mounting bracket 25 1816 80 00 01

    3 Molded hose 20 2900 60 10 23 (CA0 11 023)

    4 Spring loaded clamp 17-32mm 556 00 13 (CA1 10 046)

    5 Flexible Exhaust w/ end cap 25 1816 80 08 00

    6 Bolts 5/16x1/2 #18 stainless 559 00 07 (CA3 00 102-001)

    7 Box Base 20 2900 40 90 01 (CA0 10 069-001)

    8 Fuel metering pump 25 1894 45 00 00 25 1963 46 00 00

    9 FPM rubber ring 20 1449 00 10 01

    10 Fuel metering pump holder 20 1156 20 00 11

    11 Clamp 11mm 10 2063 08 10 98

    12 Bulk head hose connector 3/4 20 2900 60 10 11 (CA0 11 011)

    13 Washer Bulkhead 559 00 86 (CA3 00 311)

    14 Connector 206 31 290

    15 Dust Cap - bulkhead fitting 556 00 03 (CA0 11 016)

    16 Grommet 20 2900 60 10 61 (CA0 11 061)

    17 Silicon Seal - exhaust 25 1216 88 03 01

    18 Blower relay block 203 00 085

    19 Relay 203 00 065 203 00 066

    20 Fuse holder 204 31 004

    21 Fuse Inserts 5 amp 204 00 079 15 amp 567 00 53 (CA1 07 002) 20 amp 567 00 55 (CA1 07 005)

    22 Fuse holder cover 204 31 005

    23 Fuel hose 360 75 350

    24 Hex bolt M6x12 559 00 08 (CA3 00 103)

    25 Clamp 9mm 10 2068 00 90 98

    26 Fuel hose 3.5mm 360 75 300

    27 Hex nut 559 00 64 (CA3 00 208)

    28 Plastic fuel line 2mm 090 31 117

    29 Grommet 20 1280 09 01 03

    30 Washer 6mm 559 00 84 (CA3 00 308)

    31 Screw M3x30 559 00 25 (CA3 00 115-001)

    32 Bolt M8x16 559 00 37 (CA3 00 137)

    DDeessccrriippttiioonn && PPaarrtt ##ss

    25 2

    160

    05 1

    2V

    25 2

    227

    05 2

    4V

    25 2

    161

    05 2

    4V

    37

    HHeeaatteerr CCoommppoonneennttss

  • Mod

    el #

    25 2

    044

    05 2

    4V

    25 2

    081

    05 1

    2V

    RReeff.. NNoo.. DDeessccrriippttiioonn PPaarrtt NNuummbbeerr

    HHyyddrroonniicc 1100 // MM BBooxxeedd -- 1122 && 2244 vvoolltt -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

    33 Washer 8mm 559 00 85 (CA3 00 309)

    34 Nut hex 8mm 559 00 65 (CA3 00 209)

    35 Bolt M8x50 559 00 31 (CA3 00 128)

    36 Washer fender 5/16x1.25 559 00 80 (CA3 00 305)

    37 Shock mount 8mm CA0 00 061-001

    38 Washer for Shock CA3 00 333-001

    39 Threaded washer 559 00 99 (CA3 00 333)

    40 Spring washer 8mm 559 00 78 (CA3 00 302)

    41 Hex nut 8mm 559 00 65 (CA3 00 209)

    42 Fuse holder cover 20 2900 60 70 09 (CA1 07 009)

    43 Fuse holder base 567 00 55 (CA1 07 005)

    44 Ring terminal 3/8 awg 10-12 267 01 78 (CA1 90 014)

    45 Box cover 20 2900 40 00 70 (CA0 10 070)

    46 Exhaust clamp 30-33mm 152 10 061

    47 Coolant hose for boxed unit 20 2900 60 10 23 (CA0 11 023)

    48 Clamp P 34mm 152 10 043

    49 End sleeve 25 1785 80 02 00

    50 Harness boxed 12V FMP in 20 2900 70 09 10 (CA1 60 910) 24V FMP in (CA1 60 912)

    12V FMP out 25 1801 80 02 00 (CA1 60 911) 24V FMP out 25 1864 80 00 02 (CA1 60 913) 24V FMP out 20 2900 70 10 02 (CA1 60 1002) 12V FMP in 20 2900 70 10 06 (CA1 60 1006)

    12V FMP out 20 2900 70 10 07 (CA1 60 1007) 24V FMP in 20 2900 70 10 08 (CA1 60 1008)

    51 Power pig tail 12V 20 2900 70 09 20 (CA1 60 901-002) 24V 20 2900 70 10 01 (CA1 60 901-001)

    52 Cup sieve 20 1312 00 00 06

    53 Fuel connection piece 20 1621 45 00 02

    DDeessccrriippttiioonn && PPaarrtt ##ss

    25 2

    160

    05 1

    2V

    25 2

    227

    05 2

    4V

    25 2

    161

    05 2

    4V

    38

    HHeeaatteerr CCoommppoonneennttss

  • 39

    NNootteess

  • 40

    HHeeaatteerr CCoommppoonneennttssHHyyddrroonniicc 1100 // MM PPaarrttss DDiiaaggrraamm -- UUnniivveerrssaall VVeerrssiioonn -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

    12/12a

    32

    32

    32

    30

    32

    3334

    24

    34

    33

    33 28 6

    74

    5

    8

    2

    3

    27

    25

    26

    19

    18

    18

    16

    19

    19

    19

    15

    14

    13

    17

    23

    21

    910

    11

    22

    20

    20

    31

    35

    35a

    11a

    29

  • Mod

    el #

    RReeff.. NNoo.. DDeessccrriippttiioonn PPaarrtt NNuummbbeerr

    HHyyddrroonniicc 1100 // MM -- UUnniivveerrssaall VVeerrssiioonn -- DDiieesseell && GGaassoolliinnee vveerrssiioonnss

    DDeessccrriippttiioonn && PPaarrtt ##ss

    41

    HHeeaatteerr CCoommppoonneennttss

    25 2

    044

    05 2

    4V

    25 2

    081

    05 1

    2V

    1 Universal harness 25 1816 80 07 00 25 1816 80 06 00

    1a Universal harness 25 2160 80 07 00

    2 Cable 20 1668 80 05 00

    3 Fuse holder bottom 204 31 004

    4 Fuse holder cover 204 31 005

    5 Fuse inserts 5 amp 204 00 079 15 amp 567 00 53 (CA1 07 002) 20 amp 567 00 55 (CA1 07 005) 25 amp 204 00 089

    6 Relay 203 00 065 203 00 066

    7 Ring terminal 3/8 awg 10-12 567 01 78 (CA1 90 014)

    8 Twin leaf spring contact awg 12 206 73 033 206 73 058

    9 Socket housing 206 31 290

    10 Female terminals 206 00 182

    11 Seal 206 75 022

    12 Tie cables 5 x 200 559 00 03 (CA1 00 005) 12a Tie cables 5 x 360 25 1816 80 02 00

    13 Fuel metering pump 25 1894 45 00 00 25 1963 46 00 00

    14 Fuel connection piece 20 1621 45 00 02

    15 Cup sieve 20 1312 00 00 06

    16 Fuel line 090 31 108

    17 Fuel hose 360 75 350

    18 Fuel hose-pressure side 360 75 300

    19 Clamps 10 2063 00 90 98

    20 Clamp (suction side) 10 2063 01 10 98

    21 P clamp 152 10 040

    22 Metal rubber buffer 20 1185 00 00 01

    23 Angle 20 1348 03 00 04

    24 Intake silencer 25 1786 80 02 00

    25 Exhaust (flexible) 25 1816 80 08 00

    26 Flexible spiral tubing 360 61 580

    27 End sleeve 25 1785 80 02 00

    28 Muffler 25 1806 80 01 00

    29 Coolant hose 20 1673 80 00 01

    30 Coolant hose 20 1673 80 00 03

    31 Connection piece 25 1534 88 00 01

    32 Clamps 10 2065 02 00 32

    33 Hose clamps 152 10 061

    34 Muffler clamps 152 10 049

    35 Round Socket housing 25 1766 65 02 00 35a Square Socket housing 22 1000 31 93 00

    25 2

    160

    05 1

    2V

    25 2

    227

    05 2

    4V

    25 2

    161

    05 2

    4V

  • 42

    HHeeaatteerr CCoommppoonneennttssHHyyddrroonniicc 1100 AAcccceessoorriieess

    3

    2

    7

    30305

    6

    19

    2931

    32

    33

    20

    12

    13

    1415

    1716

    2425

    2623

    22

    28

    27

    21

    30

    18

    11

    9(FCRD Adapter)

    10

    8(FCRD Adapter)

    4

    1

  • Mod

    el #

    RReeff.. NNoo.. DDeessccrriippttiioonn PPaarrtt NNuummbbeerr

    HHyyddrroonniicc 1100 // MM AAcccceessssoorriieess

    DDeessccrriippttiioonn && PPaarrtt ##ss

    43

    HHeeaatteerr CCoommppoonneennttss

    25 2

    044

    05 2

    4V

    25 2

    081

    05 1

    2V

    1 7 day timer bezel 25 1482 70 01 00

    2 Bracket for 7 day timer 20 2900 40 01 58

    3 Complete 7 day timer bracket kit with bezel and bracket 25 1482 70 01 00

    4 7 day timer 25 2900 70 02 30

    5 Fuse link power harness 12V (CA1 60 901-002) 20 2900 70 09 20 24V (CA1 60 901-001) 20 2900 70 10 01

    6 Push / Pull switch 12V (CA100 003) 567 00 07 24V (CA100 004) 567 00 08

    7 Bulb (push/pull switch) 12V 207 00 005 24V 207 00 006

    8 Fault code harness adapter (CA1 05 030) 20 2900 70 50 30

    9 Fault code harness adapter (CA1 05 044) 20 2900 70 50 44

    10 Fault code retrieval device (CA1 05 020) 20 2900 70 50 20

    11 Bolt M8x50 (CA3 00 128) 559 0031

    12 Fender Washer 5/16 CA0 00 305

    13 Shock (CA0 00 061-001) 554 0007

    14 Special Washer for Shock (CA3 00 333-001) 559 0100

    15 Threaded nut / washer (CA3 00 333) 559 0099

    16 Lock washer 8mm (CA3 00 302) 559 0078

    17 Nut 8mm (CA3 00 209) 559 0065

    18 Side mount bracket (CA0 10 057) 20 2900 40 00 57

    19 Cross frame mounting tray (CA0 10 022) 20 2900 40 00 28

    20 90 bulkhead hose connector (CA0 11 037) 20 2900 60 10 37

    21 Washer - bulkhead (CA3 00 086) 559 00 86