TECHNICAL DESCRIPTION, INSTALLATION, OPERATING ...

1 A WORLD OF COMFORTANTI-IDLING, EMISSION REDUCING EQUIPMENTE spar Heater SystemsVEHICLE HEATERS |T E C H N I C A L D O C U M E N TAT I O NTECHNICAL DESCRIPTION, installation , OPERATING , TROUBLESHOOTING, REPAIRAND MAINTENANCE INSTRUCTIONS - HYDRONIC II 5E, HYDRONIC INFORMATION IN THIS MANUAL IS ONLY VALID FOR THE FOLLOWING ENGINE-INDEPENDENT WATER HEATERSG asolineB 5 S 12 V 20 1904 05 00 00 DieselD 5 S 12 V 25 2526 05 00 00 CONTENTSCHAPTER TITLECONTENTPAGE1 Introduction Foreword4 Special text structure, presentation and picture symbols4 Special text formats and presentations 4 Picture symbols 4 Safety instructions for installation and repair4 Liability claim / Guarantee 4 Accident prevention 5 Initial start-up of the heater or functional test after a repair 5 Emergency shutdown EMERGENCY OFF 5 Diagnostic compatibility5 Heater warnings5 Disposal62 Product InformationCutaway view7 Main heater dimensions8 Main water pump dimensions83 TECHNICAL DataHydronic II D 5 S diesel heater (Metric values)9 Hydronic II D 5 S diesel heater (US values)

2 9 Hydronic II B 5 S diesel heater (Metric values)10 Hydronic II electrical consumption10 Water pump114 installation Procedures Principal dimensions - Boxed version12 Heater Location12- Box stud dimensions 12- Heater mounting 12- Permissible installation positions 13- installation Position with allowable swivel ranges 13- Water pump mounting 13 Water pump location and mounting 14- installation examples14 Heater bracket installation 15- installation steps15 Heater & Engine Plumbing 17 Fuel supply18- Preferred fuel extraction18- installation position of the metering pump19- Maximum suction and pressure head19- Fuel pick-up pipe

3 installation (Drill option)20- Fuel quality for diesel heaters21- Operation with biodiesel212 CONTENTSThis list of contents gives you precise information about thecontents of the Troubleshooting and Repair TITLECONTENTPAGE4 installation Procedures Exhaust connection22 Intake connections 23 Electrical connections245 Heater OperationOperating switches26 Heater wiring27 Parts list for heater circuit diagram27 Pin assignment for S1 connector 27 Heater circuit diagram 28 Pre-start procedures29 Start up / Safety factors29 Periodic maintenance306 Maintenance, Troubleshooting & Repairs Basic troubleshooting / Self Diagnostics31 Start the diagnosis query32 Fault diagnosis using the control unit 33 Fault code display / Description / Information34 Repair Instructions / Special tool40 Assembly drawing and parts list41 Repair Steps / Connector Assignment (S1, B2)

4 42 Measuring the fuel quantity without EDiTH52 Fuel quantity test with EDiTH 537 Parts ListHeater spare parts diagram 54 installation , water and c ombustion air system diagram59 Electrical and fuel system diagram 6131 INTRODUCTIONFOREWORD These Troubleshooting and Repair Instructions are applicable tothe heaters listed on the title page, to the exclusion of all liabili-ty on the version or revised status of the heater, theremay be differences between it and these trouble-shooting andrepair user must check this before carrying out the repair work and,if necessary, take the differences into TEXT STRUCTURE, PRESENTATION AND PICTURE SYMBOLSS pecial text formats and picture symbols are used in theseinstructions to emphasise different situations and refer to the following examples for their meanings andappropriate TEXT FORMATS AND PRESENTATIONS This dot ( ) indicates a list, which is started by a heading.

5 If an indented dash ( ) follows a "dot", this list is a subsec-tion of the black SYMBOLSDANGER!This information points out a potential serious or fatal this information can result in severe arrow indicates the appropriate precaution to take toavert the !This information points out a dangerous situation for a personand / or the product. Failure to comply with these instructions canresult in injuries to people and / or damage to arrow indicates the appropriate precaution to take toavert the NOTE!These remarks contain recommendations for use and useful tipsfor the operation, installation and repair of the INSTRUCTIONS FOR installation AND REPAIRCAUTION!

6 Improper installation or repair of Espar heaters can cause a fireor toxic exhaust entering the inside of the can cause serious and even fatal heater may only be installed according to the specifica-tions in the TECHNICAL documents or repaired using originalspare parts by authorised and trained and repairs by unauthorised and untrainedpersons, repairs using non-original spare parts and withoutthe TECHNICAL documents required for installation and repairare dangerous and therefore are not repair may only be carried out in connection with therespective unit-related TECHNICAL description, installationinstructions, OPERATING instructions and document must be carefully read through before / dur-ing installation and repair and followed throughout.

7 Particular attention is to be paid to the official regulations,the safety instructions and the general NOTE! The relevant rules of sound engineering practice and any infor-mation provided by the vehicle manufacturer are to be observedduring the installation and repair. When carrying out electric welding on the vehicle, the positivecable at the battery should be disconnected and placed atground to protect the CLAIM / GUARANTEEE spar does not accept any liability for defects and damage, whichare due to installation or repair by unauthorised and with the official regulations and the safety instruc-tions is prerequisite for liability to comply with the official regulations and safety instructionsleads to exclusion of any liability of the heater INTRODUCTIONACCIDENT PREVENTIONG eneral accident prevention regulations and the correspondingworkshop and OPERATING safety instructions are to be START-UP OF THE HEATER OR FUNCTIONAL TEST AFTER A REPAIR After installation or carrying out a repair on the heater.

8 Thecoolant circuit and the whole fuel supply system must bevented carefully. Comply with the instructions issued by the vehicle manufacturer. During the heater trial run, all water and fuel connections mustbe checked for leaks and secure, tight fit. If faults occur while the heater is running, use a diagnostic unitto correct the cause of the NOTE!DIAGNOSTIC COMPATIBILITYOnly EDiTH and EasyStart diagnostic products are compatiblewith Hydronic II heaters. Older diagnostic products like the 7daytimer, Digi Diagnostic and Fault code retrieval device are TO INSTALLER!

9 Correct installation of this heater is necessary to ensure safe andproper and understand this manual before attempting to install theheater. Failure to follow all these instructions could cause seriousor fatal injury. Disconnect the vehicle battery before starting any kind of work. Before working on the heater, switch the heater off and let allhot parts cool down. The heater must not be operated in closed areas, a garageor in a multi-storey heater must not be mounted in the passenger compartment ofvehicles. However, a heater in a hermetically sealed enclosurewhich also complies with the aforementioned conditions may appropriate precautions must be taken when arranging theheater to minimize the risk of injuries to people or damage related to the fuel system must not be located in the pas-senger - EXPLOSION HAZARD!

10 Heater must be turned off while re-fueling. Do not install heater in enclosed areas where combustiblefumes may be warning sign is to be fixed to the intake connection indicatingthat the heater must be switched off before - FIRE HAZARD! Install the exhaust system so it will maintain a minimumdistance of 50mm (2 ) from any flammable or heat sensitivematerial. Ensure that the fuel system is intact and there are no heater must not pose a fire hazard. This requirement isdeemed to be fulfilled if adequate clearance is ensured for allparts during installation , sufficient ventilation is provided andfireproof materials or heat shields are SHUTDOWN EMERGENCY OFFIf an emergency shutdown EMERGENCY OFF is necessary duringoperation, proceed as follows: Switch the heater off at the control element or remove the fuse or disconnect the heater from the INTRODUCTIONWARNING - ASPHYSIATION HAZARD!