Espar Products, Inc M8 Biodiesel Betriebsanleitung

Hydronic M-II (Water Heater)Espar Heater SystemsP/N 20 2900 81 0102 0A 04.2009 Subject to Change Printed in CanadaHYDRONIC M8Biodiesel25 2470 05 - 1

10IInnssttaallllaattiioonn PPrroocceedduurreessHeater Plumbing4231The heater is incorporated into the engine’s cooling system forengine preheating.Fol

11IInnssttaallllaattiioonn PPrroocceedduurreess• The exhaust outlet must end in the open air.• The exhaust pipe must not protrude beyond the lateral l

12IInnssttaallllaattiioonn PPrroocceedduurreessFuel SystemFUELTANKFuel System TolerancesFuel LineRight Wr ongBubbleCorrectWrongNote: Butt joints and c

13IInnssttaallllaattiioonn PPrroocceedduurreessFuel Metering Pump InstallationØ 2.5 cm (Ø 1.0”)1.5 cm 1.5 cm9 / 16” 9 / 16”Ø 0.625 cm (2 HOLES)(Ø 1

14IInnssttaallllaattiioonn PPrroocceedduurreessElectrical Connections• 2 core harness (red, brown).• Connect red wire to fuse link and terminal.• Atta

15IInnssttaallllaattiioonn PPrroocceedduurreessExhaust ConnectionThe exhaust is hot, keep a minimum of 5cm (2”) clearancefrom any heat sensitive mater

16IInnssttaallllaattiioonn PPrroocceedduurreessOperating SwitchesNote: If installing a remote starter, refer to remote starter instructions before ter

17IInnssttaallllaattiioonn PPrroocceedduurreessUsing the Heater Manually with the Vehicle Accesory “On”(Optional wire on pin 10 is connected to the ig

18IInnssttaallllaattiioonn PPrroocceedduurreessSetting the timePress and hold the CLOCK button.Press DAY button to select the correct day.Press HOUR b

19Notes:

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

20HHeeaatteerr OOppeerraattiioonnPre-Start ProceduresThe temperature can be lowered by connecting the positivecable (+) to connector S2, terminal C3 o

21HHeeaatteerr OOppeerraattiioonnHeater Wiring12-pin Connection Pin AssignmentCable harnessHYDRONIC MRewiring12-pin connectorConnectionCable colour HY

22HHeeaatteerr OOppeerraattiioonnParts list for wiring diagram,HydronicM-II - 12 Volt / 24 VoltPIN-No. Connectionpmup gnisoD1AB1 Solenoid valve, optio

23HHeeaatteerr OOppeerraattiioonnHydronicM-II,Wiring Diagram - 12 Volt / 24 Volt2.5.72.7.11.2.1 2.12 1.13 1.122.5.182.22.71.22.11.5 1.15.15.102.7.51 1

24HHeeaatteerr OOppeerraattiioonnHydronicM-II, Controler OptionsREDa4)a3)a5)YELLOWBROWN15 (K)00K (15)31Push/Pull switchYellow (Signal to Heater)a3)a5)

25Subtitle Right PageMMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssPeriodic Maintenance• Check coolant hoses, cl

26Maintenance, Troubleshooting & RepairsFault Code Fault Description Causes / Repair— — — Diagnosis not possible • Adapter cable not connected pr

27MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssFault Code Fault Description Causes / Repair020 Glow plug 1, inter

28Maintenance, Troubleshooting & RepairsFault Code Fault Description Causes / Repair047 Metering pump • Check the metering pump's connectio

29MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssFault Code Fault Description Causes / Repair071 Overheating sensor

3IInnttrroodduuccttiioonn• Correct installation of this heater is necessary to ensuresafe and proper operation.Read and understand this manual before

The permitted repair work on the heater is described in the"Repair Instructions" chapter. The heater must be removedfrom the vehicle for the

Note: Do not pull out the overheating (17) and temperature sensor (18) from the holder by pulling on the connec-tion cable, always use pliers to remov

Repair step 1Remove water pump connectorFigure 6• Disconnect the connector (24) at the water pump (26) and pullthe cable loom out of the holder.Remove

Note: When replacing the control box / blower unit, the Temp / Overheat sensor and water pump leadharnesses can be left in the 14-pin connector (2

34MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssNote: Remove combustion chamber seal (23) without leavingresidues

Note: Take care when installing the new combustion chamberseal (23) as there is a risk of breaking it.Note: Ensure the grommet is installed in the cor

Note: It is imperative to keep to the correct laying order for the sensor lead harness (19) and the glow plug leads.The glow plug leads may not be lai

37MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssRepair step 2Install flame sensorFigure 22• Screw the flame sensor

38MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssRepair step 2Connect the glow plug leadsFigure 24, 25 and Sketch 3•

39MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssRepair step 2Install electric motor coverFigure 26 and 27• Positio

4IInnttrroodduuccttiioonnTechnical dataHeater typeHYDRONIC M-IIHeater HYDRONIC M8 BiodieselVersion D 8 Wdiulf gnilooC ,retaWmuidem gnitaeHLowMediumHig

40MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssRepair step 2Lay water pump lead harnessFigure 29• Insert the wa

41MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssRepair step 2Install impeller coverFigure 32• Clamp the removed he

42MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssRepair step 3Remove / check glow pinFigure 33• Carry out repair ste

43MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssRepair step 4Remove glow pin socket liningFigure 35• Carry out repa

44MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssRepair step 5Figure 37 / Diagram 1• Removal of the overheating (17

45MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssRepair step 6Figure 38 / Diagram 2• Removal of the flame sensor (11

46MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssRepair step 7Figure 39• Disconnect the connector (24) at the water

47MMaaiinntteennaannccee,, TTrroouubblleesshhoooottiinngg && RReeppaaiirrssMeasuring the fuel quantity leuf fo ytitnauQretaeHDesired Maximum M

48HHeeaatteerr CCoommppoonneennttssHydronic M-II Parts Diagram

Model #25 2434 05 12V25 2471 05 24VRef. No. Description Part NumberHydronic M-II - 12 & 24 volt - Diesel & Gasoline versions1 Combustion a

5IntroductionTechnical dataHeater typeHYDRONIC M-IIHeater HYDRONIC M10Version D 10 Wdiulf gnilooC ,retaWmuidem gnitaeHwolf taeh eht fo lortnoC51181194

50Subtitle Left PageHHeeaatteerr CCoommppoonneennttssHydronic M Parts Diagram342e2d2c2b333132

Model #25 2434 05 12V25 2471 05 24VRef. No. Description Part NumberHydronic M-II - 12 & 24 volt - Diesel & Gasoline versions1 Fuel meteri

Model #Ref. No. Description Part NumberHydronic M-II - 12 & 24 volt - Diesel & Gasoline versions31 Fuse 25 A 204 00 089 • • • • • •1

A member of the Worldwide Eberspächer Group of Companies1st Printing - Apr 2008Printed in CanadaP/N: 20 2900 81 0102 0A EEssppaarr PPrroodduuccttss,,

6IntroductionTechnical dataHeater typeHYDRONIC M-IIHeater HYDRONIC M12Version D 12 Wdiulf gnilooC ,retaWmuidem gnitaeHLow3 muideM2 muideM1 muideMHighr

13F2 WOWIECA9875467IInnttrroodduuccttiioonnHeater Components1 Control box2 Burner motor3 Glow plug4 Flame pipe5 Overheating sensor6 Heat exchanger7 Wa

8IInnttrroodduuccttiioonnPrincipal DimensionsFWOWICA EM8 (x4)* All measurements in millimeters 25.4 mm = 1”Boxed Heaters Insure:Minimum installation d

9IInnssttaallllaattiioonn PPrroocceedduurreessPrincipal Dimensions - Boxed VersionAlways mount the heater in a protected area.Eg:storage com-partment,