D1LC compact Air Heater

Installation Troubleshooting & Parts Manual

Espar

D1LC compact For Heater Models 25 1976 05 - 12Volt 25 1977 05 - 24Volt 25 1965 05 - 12Volt 25 1966 05 - 24Volt 25 1895 05 - 12Volt 25 1896 05 - 24Volt Release period October/97-present Feburary/98-present April/97-October/97 August/96-Feburary/98 August/96-April/97 August/96-Limited

April 1998

Table of Contents

Page

Introduction

Heater Warnings Introduction Specifications Principal Dimensions Mounting Pattern Heater Components Heater Location Heater Mounting Heater Air Ducting Heater Plumbing Ducting Components Fuel System Electrical Connections Exhaust/Intake Connections Operating Switches Switch on Start-Up Temperature setting Temperature Control Switching Off Controls & Safety Equipment Operational Flow Chart Schematic 25 1976/1977 Schematic 25 1965/1966 Schematic 25 1895/1896 Periodic Maintenance Basic Troubleshooting Self Diagnostic Troubleshooting Fuel Quantity Test Component Spec chart Repair Steps

........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ........................................................ ....................................................... ........................................................ ........................................................ ........................................................

2 3 4 5 5 6 7 7 7 7 8 8 11 12 12 13 13 13 13 13 13 14 15 16 17 18 18 19 22 22 23 26 29

Installation Procedures

Heater Operation

Maintenance, Troubleshooting & Repairs

Heater Parts

D1LC Compact-Parts Diagram ........................................................ D1LC Compact-Parts List ........................................................

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.

2 Heater Warnings Warning To Installer: Correct installation of this heater is necessary to ensure safe and proper operation. Read and understand this manual before attempting to install a heater. Warning - Explosion Hazard 1. 2. 3. Heater must be turned off while re-fueling. Do not install heater in enclosed areas where combustible fumes may be present. Do not install heaters in engine compartments of gasoline powered boats.

Warning - Fire Hazard 1. 2. Install heater so it will maintain a minimum distance of 2 from any flammable or heat sensitive material. Install the exhaust system so it will maintain a minimum distance of 2 from any flammable or heat sensitive material. Ensure that the fuel system is intact and there are no leaks.

3.

Failure to follow these instructions could cause fire resulting in serious or fatal injur y. Warning - Asphyxiation Hazard 1. 2. Route the heater exhaust so that exhaust fumes can not enter any passenger compartments. Ensure an air tight seal will be maintained between the heater and mounting surface and at any exhaust connection points. Ensure that heating air supply is taken from an area where poisonous gases will not be present. If running exhaust components through an enclosed compartment, ensure that it is vented to the outside.

3. 4.

Failure to follow these instructions could cause oxygen depletion resulting in serious or fatal injury. Direct questions to Espar Heater Systems USA CDA 1-800-387-4800 1-800-668-5676

Introduction Espar D1LC Compact Air Heater The Espar D1LC compact is a diesel-fired 7,500 BTU/HR air heater, quality engineered to provide a dependable means of space heating.This heater is uniquely designed for inside mounting and ease of installation. The heater provides hot air to the interior of vehicles for passenger comfort. Since the heater runs on diesel fuel and 12 or 24 volt po wer, it is able to provide space heat completely independently of the vehicle engine. The heater is operated by a rheostat switch or room thermostat. It cycles through four temperature settings (boost-high-medium-low) in order to maintain the desired temperature. If, in special cases, less heating capacity is required than the heater supplies in the Low setting, the heater switches to the Off setting. Temperature and overheat limit switches, and a specially designed heat exchanger are among the safety features which make this heater a safe and dependable unit.

4 Specifications

Heat Output (10%)

7,500 BTU/hr Boost 6,150 BTU/hr High 4,100 BTU/hr Medium 2,900 BTU/hr Low 20.8 amps/hr - Star t 2.5 amps/hr - Boost 1.8 amps/hr - High 0.8 amps/hr - Medium 0.8 amps/hr - Low 11.25 amps/hr - Star t 1.25 amps/hr - Boost 0.9 amps/hr - High 0.4 amps/hr - Medium 0.4 amps/hr - Low U.S. Gal/hr .07 .06 .04 .03 Litre/hr .27 .21 .14 .10

Current at 12v (10%)

Current at 24v (10%)

Fuel Consumption (10%) Boost High Medium Low Air Flow (10%) 50 cfm Boost 43 cfm High 30 cfm Medium 30 cfm Low

Operating Voltage Range

10.5 to 15.9 vdc at 12 vdc 21.0 to 31.8 vdc at 24 vdc 240F (116C)

Overheat Temperature Shutdown (10%) Ambient Operating Temperature Weight

-40F to 122F (-40C to 50C)

7.7 lbs. (3.5kg)

Note: The heater control unit is equipped with a low voltage cutout to prevent vehicle battery drain and a high voltage cutout to protect heater electrical parts.

Principal Dimensions

* All measurements in inches 1= 2.5 cm

Mounting Pattern If fastening to the vehicle wall/floor, make penetrations in accordance with the hole pattern shown below. A prepunched mounting kit is also available as shown beside.

Heater Components

1 Hot Air Blower Wheel 2 Blower Motor 3 Combustion Air Blower Wheel 4 Glow Plug 5 Control Unit 6 Safety Thermal Sensor 7 Combustion Chamber 8 Flame Monitor 9 Heat Exchanger 10 Operating Unit (Thermostat)

11 12 13 14 15 16 17 18 19

Operating Unit (Rheostat) Outer Casing Exhaust Line Flange Seal Fuel Line Main Fuse, 25 A Combustion Air Intake Line Fuel Metering Pump Fuel Strainer

C = Combustion Air D = Fuel E = Exhaust F = Fresh Air H = Hot Air

Installation Procedures Heater Location Depending on the type of vehicle, the best location for mounting the heater will var y. Typically, heaters are mounted inside tool or luggage compartments. However, the heater may be mounted anywhere inside the vehicle provided you adhere to the following conditions: Combustion air intake, exhaust and fuel inlet must be located outside of the vehicle. Heater must be mounted on flat horizontal surface providing an air tight seal between heater and vehicle. Do not mount the heater outside the vehicle, unless care is taken to protect the heater from the weather. When selecting the location, consider the following: Combustion air and exhaust connections. Ducting. Fuel line connections. Electrical connections. Heater Mounting A mounting plate and hardware are provided with the truck heater kit. Choose heater location. Using template provided, drill and cut center hole. Cut one (1) four and one half inch (4 1/2) diameter hole or one rectangular hole four (4) by five (5) inches. Mount heater on mounting plate with nuts and spring washers provided. For ease of installation make the exhaust, combustion air intake and fuel connections at base of heater before mounting the heater into the vehicle . Position heater in vehicle and secure with Tek screws provided. Heater Mounting Plate Installation Figure IIA
Return Ducting

Note: Tighten screws sufficiently to ensure positive seal between mounting plate and mounting surface. Do not over tighten.

Heater Air Ducting Installation A 60mm flexible duct 40 inches long, hot air outlet and clamps are provided with the heater kit. In routing and installing the ducting the following criteria must be observed: Run ducting with smooth bends . Avoid crushing duct. Position hot air outlet so that it cannot be obstructed. Use protective air intake grille on air inlet side of heater to prevent objects from being sucked in. Ensure provisions are made for proper air return ventilation. Use return air ducting for best heating efficiency (see below).

HEX HEAD TEK SCREW FLAT WASHER

SILICONE GASKET S.S. PLATE PLATE SEAL

NUT SPRING WASHER

CAB FLOOR

8 Ducting Components

1. Protective Grill 2. Air Outlet Hood

3. Hose Clamp 2-2 3/4 4. Flex Duct 2 3/8

5. Air Outlet - Rotatable 6. Connection Piece

7. 90 Bend Ducting 2 3/8

Warning: Do not use existing vehicle ducting or outlets. Ducts and outlets must be capable of withstanding a minimum of 300F operating temperatures. To avoid exhaust leakage, the heater must always be operated with an end cap installed.

Caution:

Do not over tighten duct clamps. Do not position outlet so that it will blow hot air directly at operator or at room thermostat.

Fuel System The fuel metering pump is the heart of the system and must be installed properly to ensure a successful heater operation. Fuel System Overview 7 6

Max. 66

Max. 20 6 7 2 5

Max. 66 Max. 26 2 3 Fuel Tank 1 3 Fuel Tank 1 4

3 5

Max. 2 9

Optional

Note: Butt joints and clamps on all connections.

1. Fuel Pick-Up Pipe 2. 5.0 Rubber Connector 3. 11mm Clamp

4. 2.0mm Black Plastic Fuel Line 5. Fuel Metering Pump 6. 9mm Clamp

7. 3.5mm Rubber Connector 8. 1.5mm White Plastic Fuel Line 9. 5mm Rubber Fuel Line

Fuel Pick-Up Pipe Installation (Standard Pick-Up) Choose a protected mounting location close to the fuel 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 1/4 holes. Lift the assembly into position through the 1 hole. Assemble the rubber washer, metal cup washer and nut. Note: Drill the two 1/4 holes first.

NPT fitting and pipe

( Custom Pick-Up Pipe with NPT fitting ) Remove an existing plug from the top of the fuel tank. Cut the fuel pick-up pipe to length. Secure the fuel pick-up pipe into position using the combined NPT compression fitting

Note: NPT fittings are available in various sizes (Refer to parts section).

10 Fuel Metering Pump Choose a protected mounting location close to the fuel pick-up pipe and heater. Using the bracket and rubber mount provided, install fuel pump as shown

Note: Proper mounting angle of the fuel pump is necessary to allow any air or vapor in the fuel lines to pass through the pump rather than cause a blockage.

Fuel Line Route fuel lines from the fuel pick-up pipe to the fuel metering pump then to the heater. Use fuel lines provided. Other sizes or types of fuel lines may inhibit proper fuel flow. Make proper butt joints using clamps and connector pieces as shown on page 8 Use a sharp utility knife to cut plastic fuel lines to avoid burrs.

11

Electrical Connections Caution: Install power fuse only after all electrical connections are complete. 11 core harness (red/white, green/red, blue/white, red, white, grey/red, grey, brown, brown, brown/white and yellow). Connect to heater control unit (mounted in heater) using the 14 pin connector then connect glow plug connector. Place protective hood over glow plug and control unit & secure. Connect to other harnesses as described for each harness. 2 core harness (red and brown). Connect red wire to fuse holder near battery. Connect red fuse link wire to other side of fuse holder. Connect other end of fuse link wire directly to battery positive post using ring terminal provided. Connect brown wire directly to battery negative post using ring terminal provided. Run power harness to main harness - connect 2 pin connec-

Main Harness.......................................................................

Power Harness.....................................................................

tors Switch Harness.................................................................... 7 core harness (red, brown/white, yello w, grey, blue/white, brown and grey/red ). Connect to rheostat switch or thermostat (refer to switch connection section). Connect switch harness to main harness using 8 pin connector. 2 core harness (green/red and brown). Connect to fuel metering pump using single terminals and rubber protective boots (no polarity required). Connect fuel metering pump harness to main harness using two single connectors.

Fuel Metering Pump Harness.............................................

Note: All exposed electrical connections should be coated with protective grease, (petroleum gel, Vaseline, etc.).

Fuel Metering Pump Harness

Main Harness

Fuse and holder

Switch Harness Thermostat

Power Harness

12 Exhaust and Combustion Air Intake Connections A 24mm flexible stainless steel exhaust pipe (39long) and a 20mm flexible plastic tube (39 long) for combustion air intake are included with the heater kit. Exhaust clamps and holders are also provided. Caution: Run exhaust and combustion air intakes so they cannot be plugged by dirt, water or snow. Ensure the outlets do not face into the vehicle slip stream. Keep exhaust and combustion air intake a minimum of 12 apart. Drill 1/8 holes where necessary to allow water drainage. Balance the exhaust pipe length with the combustion air intake length. Combustion air intake and exhaust lengths can be shortened to a minimum of 8. Operating Switches The heater can be controlled using a Thermostat or Rheostat type switch. It can also be accessed by a 7 day timer with thermostat. Thermostat Mount the thermostat in a location where it is easily accessible and its temperature sensor is representative of the area being heated. Mount using the mounting slots in its base. Connect the six core switch harness to the thermostat as shown

Attach the exhaust pipe to the exhaust outlet of the heat exchanger Run to an open area to the rear or side of the vehicle so that fumes cannot build up and enter the cab or the combustion air inlet to the heater. Install protective cap. Attach the combustion air intake tube to the combustion air inlet of the heater Once secure to the heater inlet, the intake pipe must run to the underside of the vehicle where it will pick up clean, fresh, moisture free air.

Rheostat Switch

Note: When using Rheostat switch, the Return Ducting method must be used as shown on page 7.This allows the heaters internal sensor to properly monitor cab temperature.

Combustion Air Intake (min.of 8).

Mount the rheostat switch in a location where it is easily accessible. Connect the six core switch har ness as shown

Exhaust (min.8).

Warning:

The exhaust is hot, keep a minimum of 2 clearance from any heat sensitive material Route exhaust so that the exhaust fumes cannot enter the passenger compartment.

Warning:

13

Heater Operation

Warning:

To prevent fire, the heater must be switched off while filling fuel tanks. To prevent asphyxiation, the heater must not be operated in enclosed areas.

4.

Temperature Control The temperature is monitored constantly at the heater intake or thermostat. This temperature is compared to the set temperature on the adjusting dial. The heater cycles through Boost, High, Medium and Low heat modes to maintain the desired temperature. If the desired temperature is exceeded while the heater is operating in low heat mode the heater will switch off. This is a comfort feature. The heater will re-start in medium heat mode once heat is again required.

Switch On Switch the heater on using the room thermostats, On/Off switch (1=On, 0=Off ) or the rheostat switch.

Start Up On start up the indicator light illuminates and the following sequences take place: Control unit does a systems check (glow plug, flame sensor, temperature sensor, safety thermal sensor). Blower starts slowly and begins to accelerate. Glow plug is energized and starts preheating the combustion chamber. After a short delay (approximately 15 seconds) the fuel pump delivers fuel. Ignition will take place as the fuel/air mixture contact the glow plug. Blower speed and fuel delivery are slowly increased. Once flame is established the glow plug will switch off. Heater will begin heating. 6

Switch Off Once switched off either manually or automatically, the heater begins a controlled cool down cycle. The fuel pump stops delivering fuel. The glow plug is re-energized for a 15 second after-glow. The blower continues to run for 3 minutes and automatically switches off. Controls and Safety Equipment If the heater fails to ignite within two 90 second start attempts, a "no start" shut down occurs. If a flame out occurs after the heater has started, the heater will attempt to restart. If repeated flame outs occur within 10 minutes the heater will not restart. Overheat shut down will occur if there is a restriction of the heating air flow (i.e. blocked inlet or outlet). The overheat switch will automatically reset once the heater has cooled down. Once the air flow restriction is removed, the heater can be re-started by switching the heater off then back on. If the voltage drops below 10.5 volts or rises above 15.9 volts the heater will shut down (21volts and 30 volts for 24 volt systems). If the glow plug circuit or fuel metering pump circuit are interrupted the heater will not start.

Temperature Setting Using the adjusting dial, set the desired temperature range. From 1-4 Lowest Setting - approx. 10C (50F) Mid - Setting - approx. 18C (65F) Highest Setting - approx. 30C (85F) Operation indicating light

Low

High

The blower motor is checked on start up and every 4 minutes. Shut down will occur if the blower does not start or maintain proper speed.

14 Operational Flow Chart

15

Wiring Diagram D1LCcompact Models: 25 1976 05 (12v) 25 1977 05 (24v)

16 Wiring Diagram D1LCcompact Models: 25 1965 05 (12v) 25 1966 05 (24v)

17

Wiring Diagram D1LCcompact Models: 25 1895 05 (12v) 25 1896 05 (24v)

18 Maintenance, Troubleshooting and Repairs Recommended Periodic Maintenance Remove the glow plug and inspect for carbon build up. Clean or replace. Remove the glow plug screen and inspect for carbon build up. Clean or replace. If cleaning is required, use brass brush (Espar part number CA0 05 003). Make sure vent hole is open. Espar recommends the use of non detergent 100% volatile carburetor cleaner and an air gun will also help. Remove loose carbon from the glow plug chamber. Inspect the ducting, the air intake screen and air outlet for restriction or blockage. Inspect combustion air intake and exhaust for blockage. Run your heater and check for proper operation during regular preventative maintenance throughout the year. Maintain your batteries and all electrical connections in good condition. With insufficient power the heater will not start. Low and high voltage cutouts will shut the heater down automatically. Use fuel suitable for the climate (see engine manufacturers recommendations). Blending used engine oil with diesel fuel is not permitted. Basic Troubleshooting Check LIst: What happens when the heater is switched on and .... Heater does not ignite 1 Blower motor does not run Check: - Fuse in power harness. - Power to control unit. - Power to switch. - Electrical connections. 2 Blower motor runs approximately 20 seconds and then shuts off Check: - Ensure voltage at control unit remains above 9.5 volts during start up with glow plug circuit on.

3 Blower motor runs/fuel metering pump starts and then shuts down after two 90 second start up cycles Check: - Fuel lines and fuel filter. - Fuel quantity. - Combustion air or exhaust tube blockage. 4 Blower motor runs/no fuel metering pump Check: - For electrical pulses at fuel metering pump. - If pump is frozen. - Blocked fuel line. Heater ignites 1 Shuts down at random Check: - Fuel metering pump quantity. - Possible overheat. - Control unit input voltage. 2 Heater smokes and carbons up Check: - Exhaust pipe blocked. - Combustion air intake blocked. - Exhaust entering combustion air intake pipe. - Short cycling, rapid on/off operation. - Fuel system. - Fuel metering pump quantity. - Motor rpm.

19

Self Diagnostics The heater is equipped with self diagnostic capability. To retrieve information on the heaters last 5 faults, a retrieval device is required (part # CA1 05 020). Connect the fault code retrieval device as shown Equipment Face and Controls Symbols that are seen on the display face are as follows: AF F1-F5 Actual fault. Up to five stored faults can be accessed. The AF and F1 are the same number. This sign is displayed when the heater is in operation. DIAG The word (Diagnostic) will come on when the diagnostic number is requested. On/Off 000 Three digit diagnostic fault code number.

Retrieval Device

Switch the fault code retrieval device on and wait 10 sec onds. 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. Consult the fault code chart for code number descriptions.

20 Note: If there are no heater faults, the heater will go through a normal start cycle and regulate based on thermostat setting. Fault Code 000 001 002 004 Fault Description Normal Operation Warning - overvoltage Warning - under voltage Warning - short in blower signal Check vehicle charging system. Check batteries and connections. Check for short between pin 1 to blower relay. If no shor t exists replace control unit. Check for short between pin 2 and alarm relay. Causes / Repair

005

Warning - short circuit in anti-theft alarm output TRS - shut down

009

Check for change of signal from (+) to (-) at pin 10 or a (+) signal at pin 12. Check voltage between terminals 9 and 11. This must be less than 15.9 volts (15.2 volts with glow plug on). Check vehicle charging system. Check voltage between control unit pins 9 and 11. This must be greater than 10.5 volts (9.5 volts with glow plug on). Check batteries and connections. Check for possible causes of overheat. Check overheat switch resistance values. (see component value chart). Flame sensor senses temperature above 340C (resistance value above 2270 ). Check flame sensor resistance values and overheat switch resistance values (see component value chart). Control unit limits heater to 3 consecutive overheats (fault code12,13). Remove cause of over heat. Reset control unit using control unit tester or fault code retrieval device to unlock control unit. Check glow plug for break in coils. Check resistance across glow plug leads (1-2 ). Check for continuity between pins 6 and 9. If afore mentioned checks okay, replace control unit. Check glow plug for short across coils. Check pin 6 to glow plug for short. If glow plug short detected, replace glow plug. If afore mentioned checks okay replace control unit Check for short between pin 4 and diagnostics and output connection. Motor speed varies from specification by more than 10% for longer than 30 seconds . If too slow, check for restriction, and check for shor t in motor circuit or control unit. If none found, replace blower. If too fast, check for damage to magnetic sensor control on control unit. Replace blower motor if damaged. Replace control unit otherwise.

010

Overvoltage

011

Undervoltage shut down

012

Overheat

013

Overheat at flame sensor

015

Too many overheats

020

Open circuit - glow plug

021

Short circuit - glow plug

025

Diagnostics ouput shor t

033

Burner motor speed deviation

21

Fault Code 047

Fault Description Short circuit - fuel metering pump

Causes / Repair Check for short between pin 3 and fuel metering pump. Test fuel metering pump. Check for open circuit between pins 3 and fuel metering pump. Control unit restricts heater to 10 start attempts (20 starts if no flame is detected during start attempts). Check fuel, glow plug, combustion air and exhaust flow. Use control unit tester or fault code retrieval device to unlock control unit. Allow heater to cool 15 minutes then try restart. Check flame sensor resistance value. No flame detected on start attempt. Temperature at flame sensor <100C (1380 ). Check flame sensor resistance values. Check fuel, glow plug, combustion air and exhaust flows . Heater has started successfully the flame has extinguished. Check fuel supply. Check combustion air and exhaust flow. Check flame sensor resistance value. Heater has started successfully the flame has extinguished. Check fuel supply. Check combustion air and exhaust flow. Check flame sensor resistance value. Temperature sensor detects a value beyond it's range Check connections. Check sensor resistance between pins 8 and 13 > 2800 - open < 280 - short Potentiometer values outside of range Check resistance between pins 7 and 13. > 2800 - open < 280 - short Normal range 1750 - 2080 (+/- 80). Sensor is sensing value outside of range > 3200 - open < 200 - shor t Internal failure. Replace control unit. Check vehicle charging system. Internal failure. Replace control unit.

048

Open circuit - fuel metering pump

050

Too many no start attempts

051

Faulty flame recognition

052

No start safety time exceeded

053

Flame cutout in boost mode

054 055 056

Flame cutout in high mode Flame cutout in medium mode Flame cutout in low mode

060 061

Open circuit - external temperature sensor Short circuit - external temperature sensor

062 063

Open circuit - set point poteniometer (control switch) Short circuit - set point poteniometer (control switch)

064 065 071 090 091 092 093 094 096

Open circuit - flame sensor Short circuit - flame sensor Open circuit - overheat sensor Control unit defect External voltage disturbance Control unit defective

Control unit defective (internal temperature sensor) Control unit defective (power failure)

Internal failure. Replace control unit or use external sensor. Internal failure. Replace control unit.

097

22 Fuel Quantity Test The fuel quantity should be tested if the heater has difficulty starting or maintaining a flame: Preparation Detach the fuel line from the heater. Insert the fuel line into a measuring glass (10 cc). Switch the heater on and allow fuel system to bleed out air for approx. 20 seconds. Switch the heater off and empty the measuring glass. Measurement Switch heater on. Hold the fuel line in the measuring glass while fuel is being delivered. The pump will stop automatically after delivering fuel for 90 seconds. Once fuel pump stops, switch heater off. Evaluation Read the amount of fuel delivered. Fuel quantity should be between 3.4ml and 4.65ml. If the fuel quantity is outside this range, check for and remove any restriction in fuel system or replace the fuel metering pump. (Check screen in suction side of pump) Note: The fuel quantity is not affected by voltage variances.

Component Specification Chart Component values given are reference numbers only (at room temperature). Actual component values may vary 10%. Resistance Values Component Glow Plug Motor Flame Sensor Overheat Sensor Fuel Pump Rheostat (Range) Temperature Sensor (Range) Resistance 1 .5 1.1 K 1.1 K 10.0 1.8-2.2 K 1.8-2.2 K Location Glow Plug From Control Unit From Control Unit From Control Unit Fuel Metering Pump Thermostat Pins 1,2 Thermostat Pins 1,T Wire Colors White, Brown Black, Brown Blue, Blue Blue, Blue Grn/Brn,Grn Brn/Wt,Gr/Rd Brn/Wt ,Grey

Motor Speeds Boost High Medium Low Recirculation 5,000 RPM 4,400 RPM 3,000 RPM 3,000 RPM 1,000 RPM (when using internal temperature sensor)

Exhaust Gas CO2 concentration in exhaust gas when heater is running in High heat mode 6-10%. Smoke test value from exhaust gas when heater is running in High heat mode <4.

23 Repair Steps

Inspection, Removal and Replacement of the:..Glow Plug ..Atomizer Screen ..Control Unit ..Heater Casing Disassembly ..Overheat Sensor ..Flame Sensor ..Blower Removal and Replacement ..Heat Exchanger Cleaning

Caution:

Remove power from the heater prior to any disassembly by unplugging main connection or removing main fuse.

Disconnect

Glow Plug Removal, Inspection and Replacement Remove glow plug connector. Remove glow plug. Inspect coils for carbon build up, breaks or metal fatigue. Clean or replace if necessar y. Re-install in reverse order using a new gasket. Atomizer Screen Removal, Inspection and Replacement Remove atomizing screen using the metal tab and a pair of pliers. Clean screen using varsol, brass wire brush and compressed air. Inspect screen for deterioration and replace if necessary. Clean the glow plug chamber to remo ve carbon build up. Ensure air vent hole and fuel port are clear. Re-install fuel screen. Note: Ensure seam of screen and tab do not block the air vent hole or fuel port.
1.Glow Plug 2.Atomizer Screen 3.Glow Plug Connector

Fuel port & Air vent hole

Control Unit Removal and Replacement Unplug main harness and motor connectors. (1) To remove Control Unit, unlock and slide out. (2) Unplug overheat switch and flame sensor connectors. 3 Re-install in reverse order.

Control Unit

24 Heater Casing Disassembly Remove internal hex screw and cap. Pry off air outlet hood using a flat screw driver. Remove rivets by punching center pin through and prying out base. Remove rubber seal at base of heat exchanger. Separate outer casing. Re-assemble in reverse order using new rivets.
1.Outer Casing 2.Air Outlet Hood 3.Cap with Internal Hex Screw

Overheat Sensor Replacement Using a small flat screw driver, pry off holding clips. Lift sensor from mounting studs . Install replacement sensor using new holding clips. Ensure the sensor is securely mounted against heat exchanger. Flame Sensor Replacement Using a small flat screw driver, pry off holding spring. Remove spring and flame sensor. Install replacement sensor using a new mounting spring. Ensure the sensor is securely mounted against heat exchanger

Overheat Sensor

Flame Sensor

25

Blower Removal and Replacement Remove four mounting screws. Separate blower from heat exchanger. Re-assemble using new gasket. Heat Exchanger

Blower

Gasket

Heat Exchanger Cleaning and Inspection Remove two mounting screws and baffle plate Remove and replace gasket. Clean excessive carbon from inside heat exchanger using a brass wire brush, varsol and compressed air. Inspect felt ring and replace if damaged. Re-assemble in reverse order using new gaskets.
1

1 Baffle Plate 2 Gasket 3 Felt Ring

26 D1LCcompact Service Parts Diagram

27

28

Parts continued.

29 Parts List D1LC compact

Ref. No.

Description

Part Number

1 2 3 4 5 6 7

Heat exchanger Combustion air blower Flame sensor Safety thermal sensor Lower half of casing Upper half of casing Control unit

25 1774 99 06 00 12 Volt 25 1895 99 20 00 24 Volt 25 1896 99 20 00 25 1895 99 35 00 25 1895 41 00 00 25 1895 01 01 00 25 1895 01 06 00 12 Volt 25 1895 50 00 13 12 Volt 25 1976 99 51 01 24 Volt 25 1977 99 51 01 25 1774 01 00 02 25 1895 01 02 00 12 Volt 25 1830 01 01 00 24 Volt 25 1831 01 01 00 25 1830 01 01 01 25 1688 06 04 00 25 1688 01 00 06 25 1688 06 00 03 25 1688 06 00 06 25 1895 01 00 03 171 42 080 171 19 254 106 10 022 103 10 461 25 1688 01 00 03 131 31 051 12 Volt 25 1830 45 00 00 24 Volt 25 1831 45 00 00 20 1312 00 00 06 20 1621 45 00 00 20 1348 03 00 02 152 00 144 20 1185 00 00 01 20 1673 80 01 01 360 75 300 090 31 118 360 75 350 090 31 125 25 1688 80 03 00 10 2114 31 00 00 20 1577 89 06 00 25 1688 80 06 00 CA1 10 047 360 00 099 25 1688 80 12 01

8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Flange seal Cable cover Glow plug Seal ring Glow plug screen Gasket, blower Gasket, heat exchanger Seal ring, heat exchanger Spring, flame sensor Clip, safety switch Serrated ring Grub screw M6x20 DIN 835 Fillister head bolt M5x20 U-Clip Rivet, black plastic Fuel metering pump Fuel screen Hose connection Angle bracket Clamp for fuel metering pump Rubber mount 6mm Rubber mount Fuel hose 3.5mm ID Plastic fuel line 1.5mm ID Fuel hose 5mm ID Plastic fuel line 2mm ID Straight outlet hood 60mm Flexible air hose 60mm ID Deflector 60mm Safety screen Clamp 46mm-70mm Air intake hose 20mm ID End sleeve with crossbar

30 Ref. No. Description Part Number

41 42 43 44 45 46 47 48 49 50

Flexible exhaust tube 24mm ID End sleeve 24mm Clamp 16mm-25mm Clamp 26mm "C" Clamp 28mm "C" Clamp 25mm Clamp 9mm Clamp 11mm "C" Clamp 10mm Main harness

360 61 299 25 1482 80 00 01 10 2064 01 60 25 152 61 102 152 10 051 152 10 048 10 2063 00 90 98 10 2063 01 10 98 152 00 139 CA1 60 105 CA1 60 107 CA1 60 120 CA1 90 060 320 31 120 CA1 00 005 CA0 00 019 20 1577 89 06 01 22 1000 01 00 01 25 1688 89 01 01 25 1688 89 00 01 CA0 12 056 CA0 12 042 CA0 12 044 CA0 00 031 CA0 12 005 CA1 70 111 CA1 70 120 CA1 65 106 CA1 75 015 12 Volt 301 00 154 24 Volt 301 00 153 12 Volt 25 1895 71 00 00 24 Volt 25 1896 71 00 00 204 00 089 CA1 07 001 CA1 90 014 206 00 040 CA1 90 043 22 1000 30 40 00 CA1 900 21 CA1 90 060 12 Volt 25 1830 30 01 00 24 Volt 25 1966 30 01 00 615 101 0296 610 101 0396 625 101 0893 CA1 05 020

51 52 53 54 55 56 * 57 * 58 59 * 60 * 61

Terminal 18 AWG Rubber boot Cable ties 197mm Mounting plate with hardware & seal Flange for outlet grill Plastic Screen 60mm 90 Air outlet hood 90 Bend Standard fuel pick up pipe 2mm Fuel pick up pipe (Compression fitting type) Compression fittings 1/4 NPT 3/8 NPT 1/2 NPT Switch/Thermostat harness (15) Power harness (13) Fuel metering pump harness (20) Thermostat Operating switch (rotary) Blade fuse (25A) Fuse holder with terminals 3/8 Ring terminal 10-12G Plug & socket connector Terminals 7 day timer Terminals Terminals for fuel metering pump 18 AWG Glow plug regulator Operators guide (not shown) D1LCc North American manual (not shown) Operators tape (not shown) Fault code retrieval device (shown pg. 21)

62 63 64 65 * 66 67 68 69 70 71 *72 73 74 75

indicates optional features

1st. Printing - October 1996 Printed in Canada P/N: 610 - 101- 0498

Espar Products, Inc.

A member of the Worldwide Eberspcher Group of Companies