e For 01 LC Model: V V V V D1L-C INSTALLATION TROUBLESHOOTING & PARTS MANUAL

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1 Visit fr mre technical infrmatin and dwnlads. D1L-C NSTALLATON TROUBLESHOOTNG & PARTS MANUAL e Fr 1 LC Mdel: V V V V V V V V MARCH

2 Visit fr mre technical infrmatin and dwnlads.. NTRODUCTON 1) Heater Warnings 2) Heater ntrductin 3) General Specificatin 4) D1 LC Principal Dimensins 5) Munting Pattern 6) Heater Cmpnents. NSTALLATON PROCEDURES 1) Heater Lcatin 2) Heater Munting 3) Heating Air Ducting 4) Fuel System 5) Electrical Cnnectins 6) Exhaust Cnnectin 7) Cmbustin Air ntake Cnnectin 8) Temperature Sensrs 9) Operating Switch. HEATER OPERATONS. 1) Switch On/Start-Up 2) Running 3) Switching Off 4) Safety Equipment 5) Operatinal Flw Chart V. MANTENANCE AND 1) Recmmended Peridic Maintenance 2) D1 LC Wiring Diagram 3) Trubleshting 4) Diagnstic Cdes 5) Fuel Quantity Test 6) Heater Repair Steps TABLE OF CONTENTS 1. HEATER WARNNGS Warning T nstaller: A. Warning -. Explsin Hazard A Warning- -1- Crrect installatin f this heater is necessary t ensure safe and prper peratin. Read and understand this manual befre attempting t install a heater. 1. Heater must be turned ff while re-fueling. 2. D nt install heater in enclsed areas where cmbustible fumes may be present. 3. D nt install heaters in engine cmpartments f gasline pwered bats. Fire Hazard 1. nstall heater s it will maintain a minimum distance f 2" frm any flammable r heat sensitive material. 2. nstall the exhaust system s it will maintain a minimum distance f 2" frm any flammable r heat sensitive material. 3. Ensure that the fuel system is intact and there are n leaks. Failure t fllw these instructins culd cause fire resulting in persnal injury r death. A Warning - Asphyxiatin Hazard 1. Rute the heater exhaust s that exhaust fumes cannt enter any passenger cmpartments. 2. Ensure an air tight seal will be maintained between the heater and munting surface and at any exhaust cnnectin pints. 3. Ensure that heating air supply is taken frm an area where pisnus gases will nt be present. 4. f running exhaust cmpnents thrugh an enclsed cmpartment, ensure that it is vented t the utside. Failure t fllw these instructins culd cause xygen depletin resulting in persnal injury r death. Direct questins t Espar Heater Systems - USA CDA V. HEATER PARTS SECTON 1) D1 LC - Service Parts Diagram 2) D1 LC - Parts List SPECAL NOTES Nte: Highlight areas requiring special attentin r clarificatin. Cautin: ndicates that persnal injury r damage t equipment guidelines are fllwed. A. Warning: ndicates that serius persnal injury r death.l111i lines are nt fllwed.

3 Visit fr mre technical infrmatin and dwnlads. 2. NTRODUCTON - 2- ESPAR-D1 LC AR HEATER 4. D1 LC PRNCPAL DMENSONS Espar D1 LC Air Heater - Heater ntrductin The ESPAR D1LC is a diesel-fired 6,15 BTU/HR air heater, quality engineered t prvide a dependable means f space heating. This heater is uniquely designed fr inside munting and ease f installatin. U.17 with end cap Fr apace fr glw plug ace. sa ,---"'" The heater prvides ht air t the interir f vehicles fr passenger cmfrt. in"". heater runs n diesel fuel and 12 r 24 vlt pwer, it is able t perfrm independent f the vehicle engine. The heater is perated by a rhestat switch fr h"",tinln ciapslclt(.; thrugh three temperature settings (high-medlum-wl temperature. f, in special cases, even less supplies in the "Lw" setting, it switches tthe limit switches, and a specially de)igrled hecifell<clla6 which make this heater a safe anlcldepj.nclal:lljnjl;'c:f 3. GENERAL SPECFCATONS Mdel V V.., N... Cmbustin air fo.n Fuel Exhaust fo.lls Me Heat Output (+1%) Current at 12v (+1%) Current at 24v (+1%) Fuel Cnsumptin (+5%) High Med. Lw U.S. Gal/hr MOUNTNG PATTERN Fastening t the vehicle wall/flr make penetratins in accrdance with the hle pattern. Air Flw (+1%) Operating Vltage Range Overheat Temperature Shutdwn (+1%) 54 cfm High 34 cfm Med/Lw 1.5 t 15. vdc at 12 vdc 21. t 3. vdc at 24 vdc 24 F (116 C) (*. < '-t -- ',\.,..,. \ N \.::.'.,;-> Nte: The heater cntrl unit is equipped with a lw t() battery drain and a high vltage cutut t prtect heater electrical parts.

4 Visit fr mre technical infrmatin and dwnlads HEATER COMPONENTS. NSTALLATON PROCEDURES Heater Lcatin Depending n the type f vehicle, the best lcatin fr munting the heater will vary. Basically, the heater may be munted anywhere inside the vehicle prvided yu adhere t the fllwing cnditins: A) Cmbustin air intake, exhaust and fuel inlet must be lcated utside f vehicle. B) Heater must be munted n flat hrizntal surface prviding an air tight seal between heater and vehicle. C) D nt munt the heater utside the vehicle, unless care is taken t prtect the heater frm the weather. When selecting the lcatin, cnsider the fllwing: A) Cmbustin air and exhaust cnnectins B) Ducting C) Fuel line cnnectins D) Electrical cnnectins 2. Heater Munting A munting plate and hardware are prvided with the heater kit. A) Heater Chse heater lcatin. Using template prvided, drill and cut center hle (depending if yu chse ne circular hle r ne rectangular hle) and fur plate munting hles. Cut ne (1) fur and ne half inch (4%") diameter hle r ne rectangular hle fur (4") by five (5") inches. Munt heater n munting plate with nuts and spring washers prvided. Fr ease f installatin make the exhaust, cmbustin air intake and fuel cnnectins at base f heater befre munting the heater int the vehicle. Psitin heater in vehicle and blt dwn with hardware prvided. 1. Ht air blwer wheel 1. Flange seal 2. PCB with cntrller 11. Fuel line temperature sensr 12. Series resistr fr glw 3. Cmbustin air blwer wheel plug (fr 24V nly) 4. Glw plug 13. Blwer mtr 5. Safety thermal cutut switch 14. Cmbustin air intake line 6. Cmbustin chamber 15. Exhaust line 7. Flame mnitr 16. Fuel metering pump 8. Heat exchanger 17. Fuel strainer 9. Outer casing F = fresh air V = Cmbustin air B = fuel W = V. ",";.; A Nte: Tighten blts sufficiently t ensure psitive seal between munting plate and munting surface. D nt ver tighten blts. HEATER MOUNTNG PLATE NSTALLATON HEX HEAD TEK SCREW FLAT WASHER- -...L-=====SLlCONE. GASKET /S.S. PLATE PLATE SEAL ' L':"':":"'.:...'-'.;...:...:...:..:P NUT-G:. SPRNG WASHER

5 Visit fr mre technical infrmatin and dwnlads B) Cntrl Unit and Vltage Regulatr Munt cntrl unit using bracket prvided in a cnvenient lcatin near heater. Munt vltage regulatr beside cntrl unit Cautin: D nt cnnect t many cmpnents it? yur ducting system. The sum f cmpnent ratings may nt exceed the value f ten (1). *See the fllwing ducting cmpnent rating fr details. Nte: Always munt cntrl unit with pins pinting dwnwards t ensure that n misture r water can enter the unit. t is pssible t munt cntrl unit at is available. The fllwing diagram ilh.jstrcltel)t:l()jt:lblc;ljotc Cntrl unit allwable installatin angles: Warning: Heating air inlet must be installed in an area where exhaust frm the vehicle's engine r frm the heater cannt enter under nrmal perating cnditins. B.) Ducting Cmpnent Rating T make sure yur ducting installatin des nt exceed allwable rating simply add cmpnent ratings f all cmpnents used including all bends made in the flexible duct. This sum shuld nt exceed ten (Use table belw). COMPONENT RATNG DAGRAM AND TABLE 3. HEATNG AR DUCTNG A) nstallatin A tw inch (2") flexible duct (4 inches lng), with the heater kit. n ruting and installing the ducting the fllwing criteria must TEM DESCRPTON COMPONENT RATNG PART NUMBER - D nt use existing vehicle ducting r utlets. They. may nt be rated at Espar perating temperature standards. Ducts and utlets must be capable f withstanding a minimum f 3 F perating temperatures. Beware f vehicle systems, especially plastic nes. - Run ducting with smth bends. Avid crushing duct. Psitin ht air utlet s that it cannt be bstructed. Use prtective air intake grille n air inlet side f heater t prevent bjects frm being sucked in. D nt vertighten duct clamps. D nt psitin utlet s that it will blw ht air directly at nn"""t'lr ri,;if'i, thermstat. 1 Prtective Grille 2 Air Outlet Hd 3 Hse Clamp 2"-2%" (5-7mm) 4 Flex Duct 23fa" (6mm) 5 Air Outlet - Rtatable 6 Cnnectin Piece 9 Bend f Duct " (6mm) /ft CA

6 Visit fr mre technical infrmatin and dwnlads. 4. FUEL SYSTEM - 8- The fuel metering pump is the heart f the system and must be installed prperly t insure a successful heater peratin. All parts necessary t d the installatin are included in the kit as shwn in Fig. 3. Fig. 1A: Fuel Pick-Up Pipe nstallatins - 9- FUEL PCK-UP PPE NUT SHEET METAL WASHER-(raised center t tp) RUBBER GASKET _;;;;;;;;::...HOLDNG TABS Fig. 1: Fuel System Overview 1 MAX. 6'6' HEATER CONNECTON FUEL TANK B) Fuel Metering Pump - Decide n lcatin fr fuel pump. - Must be in a prtected area. - Near fuel tank. ALLOW 4 N. FROM FUEL PCK-UP TO TANK BOTTOM. ALLOW ONLY 1 NCH FOR FLAT BOTTOM TANKS. Nte: - The fuel metering pump maximum lengths are shwn in Fig. 3 - d nt exceed these limits. _. Using the bracket and rubber munt prvided install fuel pump as shwn in Fig. lb. MAX 2 '6,1,2., ".!:'""'-J",.----"""'" 3 1 : FUEL TANK NOTE: BUTT JONTS AND CLAMPS ON ALL CONNECTONS Jlr - Right Wrng Nte: - The munting angle f the fuel pump, it is necessary t adhere t this angle t allw any air r vapur in the fuel lines t pass thrugh the pump rather than cause a blckage. Fig. 1 B: Fuel Pump nstallatin ii 15 t vertical D \1 : 1. Fuel Pick-Up Pipe Rubber Cnnectr 3. 1mm Clamp 4. 2.mm Black Plastic Fuel Line 5. Fuel Metering Pump 6.7mmClamp mm Rubber Cnnectr mm White Plastic Fuel Line r15 1 _ -j:j.j-... -, -". \ Nte: - Always cut plastic fuel line t length. 1! A) Fuel Pick-Up Pipe - Decide n lcatin pint fr pipe in tank (in a prtected area). - Drill a ne inch (1 ") hle in tank r blanking plate. - nstall a pick-up pipe as shwn in Fig. 3A. - T ensure clean unburred cuts always use a sharp utility knife t cut plastic fuel line. - Always use butt jints and clamps n all cnnectins. - Always use fuel line prvided with heater - ther sizes f fuel line will reduce fuel pump efficiency resulting in heater perating prblems.,! 1 [

7 ------'----,-' Visit fr mre technical infrmatin and dwnlads. 5. ELECTRCAL CONNECTONS - 1- A) Pwer Harness - 2 cre harness (red & brwn) - Red wire with fuse direct t vehicle battery (psitive) - Brwn wire t battery (Grund) - Cnnect t 2 pin cnnectr blck at heater harness B) Switch Harness - 6 cre harness (red, brwn, yellw, black, blue and grey) - Run t lcatin f heater cntrl (ie. rtary knb r thermstat) - Cnnects t 6 pin cnnectr blck at heater harness. C) Fuel Pump Harness - 2 cre harness (green and green) ) Wiring Harness Hd t Heater - Run t lcatin f fuel pump - Cnnects using tw (2) single cnnectr blcks at heater harness - 14 pin cnnectr and 2 pin cnnectr - Gently press the 12 pin cnnectr nt the printed circuit bard n the tp f the heater. - Jin the 2 pin cnnectr n harness t the 2 pin cnnectr leading t the glw plug. - nstall ring cnnectrs nt glw plug - mdel and Carefully place the hd int psitin ver the glw plug and printed circuit bard area and secure using a 6mm hex wrench. All harnesses shuld enter vehicle thrugh sealing grmmets. Electrical Cnnectins 6. EXHAUST CONNECTON CUT Min. 8'" A 24mm flexible stainless steel exhaust pipe (39", lng), exhaust clamp and hlder are prvided with the heater kit. The exhaust pipe can be shrtened t a minimum f 8". Attach the exhaust pipe t the exhaust utlet f the heat exchanger (as shwn belw). Once secured t the heater exhaust utlet, the exhaust pipe must run t an pen area t the rear r side f the vehicle s that fumes cannt build up and enter the cab r the cmbustin air inlet t the heater. nstall prtective end cap. A WARNNG: A WARNNG: Cmbustin Air ---" '''? Cautin: CUT Exhaust Min,8" ALWAYS slpe intake and exhaust pipes dwnwards t allw water prduced by cndensatin r cmbustin t run ut. The exhaust is HOT keep a minimum f 2" clearance frm any heat sensitive material. Rute exhaust s that exhaust fumes cannt enter the passenger cmpartment r cmbustin air intake. Nte: - Run exhaust s that it cannt be plugged by dirt, snw r water and allws water prduced by cmbustin t run ut. - nstall exhaust pipe with a slight slpe and drill a 1/8" hle in the lwest pint t allw water t drain ff. - Any restrictin in exhaust will cause peratinal prblems. J' c --. jl, --{...,.Y 7. COMBUSTON AR NTAKE CONNECTON A 2mm flexible plastic tube (39" lng) fr cmbustin air intake, clamp and hlder are prvided with the kit. ' Attach the cmbustin air intake tube t the cmbustin air inlet f the heater. Be careful t keep intake pipe away frm exhaust. Once secured t the heater inlet, the intake pipe must run t the underside f the vehicle where it will pick up clean, fresh, misture free air. Nte: - All expsed electrical cnnectins shuld be cated with prfetilifgre8se, (petrleum gel, vaseline, etc.). ' "'.' Nte: - Please attempt t balance the exhaust pipe length with cmbustin air tube lengths. - The abve MUST be adhered t ensure prper peratin f the heater.

8 Visit fr mre technical infrmatin and dwnlads. 8. AR TEMPERATURE SENSORS A) nternal Temperature Sensr (Universal Mdels Only) A temperature sensr is prvided in the heater n the heating air intake side. This arrangement f the temperature sensr is nly suitable in return ducted peratin with heaters that have blwer circulatin capability. Nte: - Fr 1L-C 12V , , 24V and when less heating capacity is required than the heater supplies in the "Lw" setting, it cycles t the "Off" setting similar t previus mdels. Nrmal cntinued peratin fllws, and then a cnstant cntinued circulatin at extremely lw blwer speed, until restart takes place. This allws the internal temperature sensr t accurately sense the average bunk temperature.... > '.8 9. OPERATNG SWTCH Nte: The 1 LC truck kit is supplied with an electrnic thermstat and a fifteen ft (15') switch harness. The heater may be perated using ne f the fllwing switch ptins: - Rtary cntrl switch with n / ff cntrl - Rtary cntrl switch with timer fr n/ff cntrl - Thermstat with built in n/ff switch A) Rtary Cntrl Switch and Optinal Heater Timer Tw scales are supplied as fllws:. 1 Scale disc 1 is fitted if peratin is exclusively with the perating unit. The rtary cntrl switch then serves as an "ON/OFF" switch and temperature cntrller. 2 Scale disc 2 is fitted if a timer is used fr actuatin. Switch "ON" is then exclusively with the heater timer, and the temperature is selected with the rtary cntrl switch. See wiring diagram fr cnnectin. Cnnect the six pin plug f the switch harness t the crrespnding plug n the heater harness. Cnnect the six cre switch lm t scket husing using the terminals supplied in the kit, as fllws: Brwn/White wire t terminal N.1 Grey/Red wire t terminal N.2 Blue/White wire t terminal N.3 Black/White wire t terminal NO.4 Red wire t terminal NO.5 Yellw wire t terminal N.6 n cases where the ptinal timer is used, discnnect the red wire frm N. 5 n the rtary cntrl switch and insure that the bare wire is nt expsed. Nte: f cnstant illuminatin f the switch is required, cnnect a wire frm the vehicles lighting circuit t terminal NO.9 f the rtary switch.

9 Visit fr mre technical infrmatin and dwnlads B) Optinal Thermstat with Built-n-Remte Sensr, RED GREEN _'\ C> This perating device serves as an "ON OFF" switch, thermstat and external temperature sensr. This thermstat ptin requires a special switch harness. Please refer t parts sectin fr specific part numbers. Cnnect the six pin plug and the tw pin plug f the switch harness t the crrespnding plugs n the main heater harness. t shuld be nted that the tw pin plug with the single blacklwhite wire activates the external temperature sensr, already built int the thermstat. Simultaneusly, it disengages the internal temperature sensr built int the heaters PCB. Cnnect the six cre switch harness t the thermstats terminal strip as fllws: Brwn wire t terminal N.1 Grey wire t terminal N.2 Blue wire t terminal N.3 Red wire t terminal N.5 Yellw wire t terminal N.6 Black wire t terminal N. T. HEATER OPERATON 2. RUNNNG SWTCH ON START UP Heater always starts in HGH mde. Once switched n the fllwing sequence f events takes place: A) Green pilt light n rtary switch is n. Red and green lights n thermstat are "n" (Cntrl unit des a systems check. Blwer mtr starts). B) Glw plug begins t preheat the cmbustin chamber (25-65 secnds depending n the input vltage). C) Fuel pump starts. ) Once ignitin takes place the flame sensr will signal the cntrl unit t turn the glw plug ff (mtr speed will increase slightly). E) Heater begins heating interir. Nte: - f the heater fails t start the first time it will autmatically attempt a secnd start if unsuccessful the heater will shut dwn cmpletely. f input vltage t the cntrl unit is belw 1.5 (21 v) r abve 15. (3v) vlts the unit will shut dwn after a 2 secnd delay. A) Heater runs in heat mde. B) Once the air intake (r rm) temperature set n the rhestat has been reached (between 1 C and 3 C), the heater switches t "Lw" heating capacity (reduced blwer nise). f the 85W heating capacity is insufficient t maintain desired temperature, the heater switches t "Medium" (12W) with "Lw" blwer speed. n mst cases the Lw-Medium-Lw cntrl sequence with lw blwer speed will supply the heat requirement. f hwever the "Medium" stage is nt sufficient, the heater switches back t "High". This again entails full blwer speed. Nte: - While in running mde if the heater flames ut it will autmatically attempt a restart. - During peratin the heater cntinually senses input vltage frm the batteries - if the input vltage drps t apprx. 1.5v r rises abve 15.v (21.v r 3v n 24 vlts) the heater will autmatically shut dwn after a three (3) minute cl dwn cycle.

10 Visit fr mre technical infrmatin and dwnlads SWTCHNG OFF After switch-ff the green pilt light ges ut. The blwer cntinues t run fr a three (3) minute cl dwn cycle then switches ff cmpletely. 4. SAFETY EQUPMENT Nte: The flame is mnitred by the flame sensr. The verheat termperature is mnitred by the safety thermal cutut switch. Bth influence the cntrl unit which switches ff the heater in the event f malfunctin (See the fllwing diagram n heater cmpnents). A) f the heater fails t ignite within three (3) minutes, malfunctin shutdwn fllws. B) Overheating (due t restrictin f heating air flw by blcking inlet r utlet with blanket, rags, etc.) results in the safety thermal cutut switch ppping, with stppage f fuel supply fllwed by a cl dwn cycle and a malfunctin shutdwn. Green light n perating switch will begin a steady flashing cde. C) f at any time the vltage drps belw 1.5v r 21.v (as the case may be), r rises abve 15.v r 3.v autmatic malfunctin shutdwn fllws (after a 2 secnd delay). D) The heater des nt start if the blwer mtr is defective r the electrical cable t the metering pump is brken. During electrical welding wrk n the vehicle, discnnect the pwer t the heater, in rder t prtect the cntrl unit. A WARNNG: - The heater must be switched ff while any fuel tank n the vehicle is being filled. The heater must nt be perated in garages r enclsed areas. fit,.: g!r -f- 5 ::'1' nj i g 5. OPERATONAL FLOW CHART! t gg r{] Os'.. t t3." L[J.. h gg 1.. +, i t! <....i.. 2 : g : '. e: r. - - J_, - ; -.._ : - i

11 r '< -.i: ",R L-1tj tj i LL-L J.. it. e <" ( "'- ::3 NjJ8'j -- ( ::3 --.D>b T""" '" T"""'- ('\J,-C\llOr--':':C\i NNNNC'i("j("j r:,,!c\jl!:!1'-:,- r- T""" T""" T""" V. MANTENANCE AND TROUBLESHOOTNG 1. RECOMMENDED PERODC MANTENANCE A) Remve the glw plug and inspect fr carbn build up. Clean r replace. B) Remve the glw plug screen and inspect fr carbn build up. Clean r replace. f cleaning is required, use brass brush (Espar part number CAO 5 3). 2. D1 LC WRNG DAGRAM D1LC - UNVERSAL (12V/24V) /----z".. 8)- We < \ , C) Make sure vent hle is pen. Espar recmmends the use f nndetergent 1% vlatile carburetr cleaner and an air gun will als help. Remve lse carbn frm the glw plug chamber. (! ';\ '. W! i t+---- \.,-..f:( l.. J:-,-) D) nspect the dueling, the air intake screen and air utlet fr restrictin r blckage. Visit fr mre technical infrmatin and dwnlads. E) nspect cmbustin air intake and exhaust fr blckage. F) Run yur heater and check fr prper peratin during regular Preventative Maintenance thrughut the year. G) Maintain yur batteries and all electrical cnnectins in gd cnditin. With insufficient pwer the heater will nt start. Lw and high vltage cututs will shut the heater dwn autmatically. H). Use fuel suitable fr the climate (see engine manufacturers recmmendatins). Blending used engine il with diesel fuel is nt permitted., , _..J ( e,/ A (r-g id ' iir ;\-:::f:-::ll:-g!=j ' _---- _ ;;:l': g r "l L, ': : t [ 2, ::=-:7:: r:::::=-: =:. =:: j -. tji' : :., '- - J ' ! ' ,,,,,,,,,, e

12 r.. -/ - ;t / =!......, Ci3) \ i,r' \ =, j!,-m'- c_.." - i :,-, " _' _w 1 ' \\!.=i!"'. ".. u t :=:,-! j.- / " j t; Z 5 "! _ -...! >,"v : :: : r::;:!'r>t!:':-'l';"'j': 'i"1fu "lilt" ) ". RCD./ E '. R!:D spar "'- : : '.!CV ""'" :',=-:-" ' '11 1--=,<c.. [J].:::: :!i "c" SET \ -l!: r '1 r -i:<j l::::i ","" \ MAN.--i-'-.,'.,,"W"'" '-..! 1 lj CTJ '- / =Jf=t==tftaf"::"V;2 r-l-l '-"r 'l _L-. i il'-' ', ' "'-:;:"-',, 'EO '"''W"''' \ r "l,, L.._... J <EEl ) :! ',,'mldv' /, "" CREEN, 1 _.... "! 1 (UJ irh1 }:ri r l ii tg-j Gl R.LN tllov<! Visit fr mre technical infrmatin and dwnlads. mr-j RlCL-llUb,ev",V"'".ev",V"'",.L.:",_.,=.. BRO'l\VH1( "i "'Hire (,RO\RrL "'H e " V";; ",DV"''''iR..... "i' ,,. - ;-9 -'-'-< : :.;,.-,....Li...L..-'-'-LLl. : L.. _.. _...J i L.. n).._.._.. '_.._.._.._...J em i..'..j.. u.l C!j 'i Uil 1 A "i- 11, L. lln..l,j'e""""""' LL...J... c r-... < - :c c: " C1... '" C) " C1... C1... " "" C) C1 \) Blwer mtr Glw plug Safety thermal cutut switch Flame mnitr Cntrl unit Fuel metering pump Pushbuttn fr diagnstic display Timer, 99hr cuntdwn Thermstat PCB with cntriler temperature sensr Glw plug relay 5.1 Battery speed change and plug distributr 2.7 Main fuse, 25A e) Cnnectin f external temperature _ensr.. 6'., ,r' ;' " : em P : i ' i i = r.. J :-.. _... " : i ri-n=±±- Ci3) r", tc;:j",.,- : '.... = """\ ' ",... "",',""."' L '''lk : :: : H :11Al LJ <EEl = +=1 i=i l t 1\ -r=="" e)(,' z; \... "] L.. _....J (ill) i <ill) p-rjlj!->-;ii! L.. J / Re," Espar '-" / r-tl:j r--...! ""'- --Lk!!tl/ VHl(.!"-... '. YellO" \ ( '1'12 HllOV SET ':.ev" :::,: \ OOM LJ BROliN AN' L.J,"": /...,,/ r:qij? n :: -f ---:r'-l \ " TEllO... TellO'"!' -, TellO" : '[(!' ',. d)'" t (U), t----t--t-t--+--tt-+,-++t----'''',-"., !'<!,.,! cp H \\! d'>! i \\\: '", ), :--,...:.. :..L. :t3j BOVN ROliN r 7:=' 9LA(n... HE i i 9l"CK\VHf(ici i t., ft ""'''''-''''w''"'"''-'-,-----i-<: : BLU(\V"TC : (: : Re '1:, " n n ". : BROWWK TC '-.:: :, : G:lD BROVNWHJ[!_! 9RO... NWH[f(!(! _! GREeN i i """ 1 1 :: GR[Y\R(il " 'GR(r\!CO ".;" -j _.",- c''''. V"'" 1 :.. v"''' Li...i Li-L J d::-.. r:: ::-.:-:=-::.;::.:-:.-::b r-j; t, 2 ) 4, ' , ill lq.: r L- -L.-LLL...L.-'---...L...L.1_...L.J---L,, "J 1",A C B.. : i {, ) "'" i'" ill i L.. _.. _.. :'? 1 : ad L._.... _.. _.... _.. _.J <7D " c),,.. Gl 1.1 Blwer mtr 2.1 Cntrl unit Ptentimeter with switch 1.2 Glw plug 2.2 Fuel metering pump 3.4 Switch-n pilt light 1.5 Safety thermal cutut switch Glw plug relay Lighting 1.7 PCB with cntriler temperature sensr 2.7 Main fuse, 25A Diagnstic light speed change and plug distributr Operating unit 5.1 Battery 1.12 Flame mnitr Pushbuttn fr diagnstic display d) Break line here t cnnect timer 1.13 Temperature sensr, external Timer, 99hr cuntdwn e) Cnnectin f external temperature sensr O l", \ -, ---' ',,- :t:.j... c h... c: z <: m :c r-... C1 "'" C) C1... C1... ". "" C1 \)...

13 /r"-"--:"'-"-"-""-"=' 1\ : em n.....! r"-"!.. '-,j" c f=l:=::::=:'::": i = i, --: L..: "'" --!." "\.... "" i " ern r",!=.siif!!j L.._.. J -J(uE> : \L'tfifV'"" ', m ltl r - jj mt j----::-"'j (ill) r:=afil L'.. "':.. J " '"'' "" 3 f ;pj = 1=tt==-W= / e'( U.. _ <T<l 11(./ '-. '" kl q!,.. Esper', mc" : ",, v"''' " =- '.,e",! '!;-,- "ce'" SET \. t:::i '"" \ lqqj hi AN J '-,... Tn,/ """,------'---t+-l _ Hl-+- -Hl+- --'l::,,---:co" lsw: :::""t'i: i-l\\l..,'.,... BLACKWi!J( '" """ 9LACK\VH)f( 1(1"-l 3.-1 eux:\\,hllt ".'alu(wh("" (',(!) l/- r--. ii lt- : 9ROVN k : :: / : BROVN\VH( 1!- er!jv\vhc!.(!_. W 'OO"' )1 v",,,. GR(Y\1ED ' :'" 'GRCn1ED '(:",' "<T( \,T ", "'"'+-- ::: '"'""'''"<'' c.i.. J c.i.. {._.. _.. _"-._.. j r-l- 1: + -,... ::1..._. c :-:"c--....,. l, rm irh1 L.. _.. ii..j t3- J (ill Visit fr mre technical infrmatin and dwnlads. t::j}::::lnct-c;'db:nl' BROVHWHtT( ::. ntj i!hh H i L._.. _ : : L.. _.... _.. _.. _.. _.. _.. _.. _.. _ <Tl ;'... c r- N... < c: z <: m :EJ (f) l> r- N C Q) ) C1... N C C1 C1 \) \) 1.1 Blwer mtr 1.13 Temperature sensr, external 1.2 Glw plug 2.1 Cntrl unit Resistr fr glw plug (24V nly) 2.2 Fuel metering pump 1.5 Safety thermal cutut switch Glw plug relay 1.7 PCB with cntrller temperature sensr speed change and plug distributr 1.12 Flame mnitr Mai n fuse, 25A Operating unit Pushbuttn fr diagnstic display e Timer, 99hr cuntdwn d) e) Ptentimeter with switch Switch-n pilt light Lighting Diagnstic light Battery Break line here t cnnect timer Cnnectin f external temperature sensr Q r. : --_\@... '-,",, 1- \,.., Z'-=J \..J/ -.. ij1.._.._...-._.., r,'-'il \-"l,",.. : i! L..J L.. _...J@) i! i =! i! i = lit ":,,: i l,l: "'"""' ::l&f Jh r.j ", "-" L,..'1-.. n=f :""' OJ). /.' \Lbl-j::::::-::y:?p=,._.._.._. ::._.._.._.._.. j ", e _, x Z ::l 1;;.,... :t :<l '#1i!5<lg r;r i;' i lstj l-..=f==t=============================t==t=t::,,:;,vni't C1]) r h--::""""':::-::'"":.:".ti.::-, ;;, 21 2 i :_. -_.-: L t ;=::=t----t---t-+-t--""='1',: ' _ BLACK i --""is' t \ 1\ LLJ r-1 <:l:rn,._. : -J.. ", lied " rr;---' lit» :,+---1H-t---"""",:u.OV"'--t' ="";<.!!. YELLD\ : RED.,.-,::: OREEH, 'LC L -..:.J y:;..., --;:::::J;::::=1=======:::;----t-tl-i-r=+==j,,± RtD ;", 1 L/CK\''i.tt 13..., '/;{, i+-i 1\ ' "r :::: """"..1 i, "" L.... _.. _.. L.. J' BRO... N '5 - r BRD... N 8.lf.:\''i.TE, BLU : " /" [ [[ [ H: v,'" l'''' -'"'''''''----- r -.,1 1 - '::O.,.,=, c r :EJ c: " 3: c m r- N C1... ) W C1 \) W r' -- --l., '""1'.1.,-,.1. --L.L..L..l...L..J-LLL.L...-L,t-- "! :',! 1.!!. -A... C,81 H i r"":t'1j L.._... J j i!hh ph : BRO... N '" Blwer mtr Glw plug Safety thermal cutut switch PCB with cntrller temperature sensr speed change and plug distributr' Flame mnitr Cntrl unit L.._.._.._.._.._.._.._.._.._.._.._ ill) L.._.. _ Fuel metering pump Temperature sensr Current regulatr Main fuse, 25A Pushbuttn fr diagnstic display Thermstat Battery '

14 Visit fr mre ' technical infrmatin and dwnlads TROUBLESHOOTNG BASC CHECK LST: What happens when the heater is switched n? A) The heater des nt ignite 1) Blwer mtr des nt run Check: - Fuse in pwer harness. - Pwer t cntrl unit - Pwer t switch. - Electrical cnnectins. 2) Blwer mtr runs apprximately 2 secnds and then shuts ff Check: - Ensure vltage at cntrl unit remains abve 1.5 vlts during start up with glw plug circuit n. 3) Blwer mtr runslfuel metering pump starts and then shuts dwn after tw 9 secnd start up cycles Check: - Fuel lines and fuel filter. - Fuel quantity. - Cmbustin air r exhaust tube blckage. 4) Blwer mtr runs/n fuel metering pump Check: - Fr electrical pulses at fuel metering pump. - f pump is frzen. - Blcked fuel line. B) Heater ignites 1) Shuts dwn at randm Check: - Fuel metering pump quantity. - Pssible verheat. - Cntrl unit input Vltage. 2) Heater smkes and carbns up Check: - Exhaust pipe blcked. - Cmbustin air intake blcked. - Exhaust entering cmbustin air intake pipe. - Shrt cycling, rapid n/ff peratin. - Fuel system. - Fuel metering pump quantity. - Mtr rpm. Operatin: C) SELF DAGNOSTC The D1 LC is equipped with a self diagnses light in the center f the rtary cntrl knb. The green light n the thermstat face will prduce fault cdes. n the event f the cmpnent failure r a systems failure during peratin the heater will shut dwn. A failure cde can be prduced at the green light by jumping pins #9 and #11 at the cntrl bx fr ne (1) t three (3) secnds. The cde will be in the frm f a flashing green light. Refer t wiring diagrams. T assist the service technician t btain heater fault cde the diagnstic bx as illustrated in figure 1) is available. Espar part number 12V CA1 5 3 and 24V CA Set Up: - Unplug six pin switch harness cnnectr at the heater. - Ensure diagnstic bx switches are in the fllwing psitins: n / ff switch in "ff" psitin. high/lw switch in "high" psitin. - Plug female six pin diagnstic bx cnnectr t the male cnnectr frm the heater switch harness. - Green indicatr light shuld nw light up indicating that there is pwer. - Switch n / ff switch t "n" psitin t start the heater. - High/lw heat switch can be switched t "lw" psitin after heater start. When the heater reaches perating temperature, switching t lw heat mde will cause the heater t switch itself t run at lw heat r t cl dwn and start in circulatin mde. - f the heater des nt perate when the n/ff switch is switched t the "n" psitin, the fault cde can be btained by pressing the mmentary switch (labeled "activate fault cde") fr apprximately 3 secnds. The green indicatr light will then flash a cde. Fig. 1 : \Mjr

15 y Displaved: Green: Dark Field Red: Ught Field Operatin Warning 1 ver-/undervllage Overvllage cutut Undervllage cutut Glw plug break z r(j) :::; (O "'. W. W W", W '" a a.. '" _. '" :i" - (O_ (:::; -:::; 361 _ - a c 2 ll<_ - :::; n> g. CD ia -c. :::;_ ::: _. _", c. O-. - "O '" :::T -. '" 6' :"" g.». ::J = "":' (Cm. '" a 3 _."O _ :::;. _ -ll c ;::;; "2. a. _ 3 -- :::; ":::; a Cil 3. c. Cil,< '" a C 3 C - "" S' ::J _.:::; a -:::; _. :::;ll "',.. '6;1 C a Cil. al!jl. - ll tbci3 -:::;Cil "O "O a el. ". a CiS. \D'< OJ. Yl -:::; Cil * 8.!Jl S- '" C Cil z C ( ;:r () G) $ Cl " C "(ji. : 8 sees. -- :::; a.!jl. g. ::;. 3 al 5 ( '" Cil '" :::; g. n.. C -;, () :::; ;::l- _. ::J (") ::::;:: ( ::r......"q)... :::T ::::::!. ::;; _. _ a. 3 = - _"""'cc' iil3s- :::T '" g, -g. a. g a _, -.lllcila '". :!.::J a C (O'" (. """' ::J - 8l. -- :::;:::; ::: ( :::;a"o _. --" ::J a () -- :::;,,_. C a 3 -" CJ),-" """'li<o -" g. c g. (').ll 55""'" C ( :::; :::J CD 3!e.... _. Cf)... a_:::; c-eacd '" S- a _ ur - - :::; - C" - X _. '" :::; :::; 6.1ll'" a , 'filii a OCD. ( Ci3 _. _( «5. :::;" - (i)" a =:-. -:::; «5. ;:r. iii " -:::; a " - iii ( $? :;- g. g. 3 i -:::; -i c,... m :J: Z G) c en Z G) i! m Fn c en z -i :J: m 8 z -i,... m ::a i! m ::a 3: it "" l> G) C C m Check cntrller, char.ge battery. :::; :::;; _!!l.:::; '" - S- :i" a :::;. -- :Tilt _. S- ::;; _. Cil < ( "- _ (:::; Yl"O - r 3 " a [ S- 2' -:::; - C -!Jl :::; ( -:::; Check cntrller, if necessary lest charger. Healer must be cnnected direclly t he battery. Charge bauery. check cntrlier, G);!1()G)m ;!1;!1 ", Q1.. C 3 ::;; n. _. ::J :" :::!. (") ::J.Oc_a_ se,c:d.l::jm _ A ( - al :::J 5' -!!l. ai a g A <:!". _. '"..." "Q> ::J '".'. :::; c!e. ' al ts :::; -'" c n. $.. A G.heck glw plug, glw plug series resistr (fr 24 V), repjace. Check cnnecting lines and cnnectin, check cnnectin t glw plug relay. a A!. '" A Cil " i :i" ( S- '< 3!l? - C -!Jl :::; g. ( g. ' :i" ( :::; '" C : g a :::; a ib :::; 8. JJl -:::; Q1. 3 al (. -:::; Cil 3 ijf Cil -:::; n.. C -;, () :::;,..! f' c z 8 c rn Visit fr mre technical infrmatin and dwnlads. Burner mtr des nllurn, speed changever relay des nt functin Shrt-circuit 1 glw-plug relay cntacls Safety lime exceeded n start Overheat Shrt circuit f luel metering pump Temperature sensr defective Flame sensr defective Flame ges ut at "Lw" r "Medium" stage Heater ges ul by itself. Flame ges ut al "High" stage Heater ges ut by itself Cntrl unil defective Exlernal disturbing vltages Check. mtr speed (test adapter), if necessary replace blwer. Check speed changever (test adapter), if necessary replace PCB. Rated speed: high = 45 ± 1% rpm, medium/lw ==: 3 ± 1(1/(1 rpm Replace glw-plug relay Check luel supply, test glw plug (interrupted cil, yet sty cnnectin), replace if necessary. Check heating air lines, inlet and utlet fr clgging, if necessary remve clg. Check electrical lines, cntacts t metering pump. Check salety thermal cutut switch (test adapter). Check metering pump and supply lines, replace i necessary. Plug cnnectin t temperature sensr in cable harness made internally/externally? Check PCB, internal temperature sensr {lest adapter). necessary test the external. temperature sensr directly. Check cnnectin t perating device, and check he lauer (test equipment lr perating device): Check flame sensr r cnnectin, and als PCB (test adapter). Check luel Quantity Check btwer speed Check luel Quantity Check blwer speed Replace cntrl unit Remve cause \:) --J

16 Visit fr mre technical infrmatin and dwnlads NTERNAL TEMPERATURE SENSOR: (n P.C. Bard) MANUAL COMPONENT TESTNG: T check the: an OHM Meter is required. - Rm temperature sensr (n the P.C. Bard) - Glw plug - Overheat Switch - Flame Sensr Place OHM Meter leads n pin #7 and pin #1. A steady reading f OHMs (1.8K - 2.2K) is required. f these values are nt prduced then the P.C. bard must be replaced. CONTROL KNOB CODE: 1-- The glw plug cver must be remved by first remving the hd hld dwn screw. Discnnect the glw plug cnnectr and remve the 12 pin cnnectr by: Gently spreading the lcking ears n the cnnectr and pulling up. Refer t the diagram shwing the P.C. Bard befre using the OHM Meter t check the: - Flame sensr - Overheat switch FLAME SENSOR: Place OHM Meter leads n pin #1 and pin #8 being careful NOT t tuch ther pins. A stable reading f 9-11 OHMs (.9K K) shuld be seen fr a cl heat exchanger. - HEATER- f the flame sensr des nt meet the specificatin it must be replaced. CONTROL KNOB CODE: HEATER i Flame Senser Test OHM METER

17 Visit fr mre technical infrmatin and dwnlads OVERHEAT SWTCH: Place OHM Meter leads n pin #9 and pin #1. A steady reading f.1 OHMs shuld be seen f this is nt prduced the verheat switch shuld be replaced. MOTOR TEST: The heater is a tw speed mtr with speeds switched and cntrlled by a relay and a resistr n the P.C. bard. The blwer mtr can be checked fr prper high and lw speeds by using an ptical r strbe tachmeter. CONTROL KNOB CODE: HEATER- High Speed Lw Speed 45 = 1% RPM 3 = 1% RPM f lw speed cannt be btained it can be checked using a secnd methd. The secnd methd requires that the P.C. bard be remved frm the heater. Once remved a OHM Meter is used t check the lw speed resistr. Refer t the fllwing diagram fr the prper test pints. Values required fr the resistr are: hms fr 12 Vlt OR hms fr 24 Vlt f the resistr is nt within specificatin, replace the P.C. bard. f the blwer mtr des nt turn t specificatin in high r lw speed, replace the blwer mtr. CONTROL KNOB CODE: f--- COMPONENT SPECFCATON CHART: PCB COMPONENT Flame Sensr Temp Sensr Overheat Switch Mtr Glw Plug PNS 1,8 1,7 9, 1 See Text 2 Pin Cnnectr RESPONSE , % RPM High 3 + 1% RPM Lw,7 -, 9 GLOW PLUG: The glw plug shuld prduce a resistance f OHMs. CONTROL KNOB CODE: -.'.;'... '... W f all the abve checks are OK the glw plug and the 12 pin cnnectrs can be replaced and the hd replaced and secured.

18 Visit fr mre technical infrmatin and dwnlads. 5. FUEL QUANTTY TEST Measuring Fuel Quantity A) Preparatin - Discnnect the electrical cnnectin under the cver cap n the heater. - Cnnect a test lamp. - Detach the fuel line frm the heater and intrduce it int a measuring glass (size 1cc). - Cnnect a vltmeter t terminals 3 (+) and 4 (-) f the cntrl unit with the 4-pin plug. - Switch n the heater. When the fuel is being pumped evenly (apprx secs. after switching n), the fuel line is nw filled and bled. - Switch ff the heater, and empty the measuring glass. B) Measuement - Switch n the heater. - Fuel is being pumped apprx secs. after switching n. - Hld the measuring glass at the plug level during measurement. Read ff the electrical vltage at the vltmeter. Fuel pumping stps autmatically after 9 secnds. - Switch the heater back ff. - Read ff the fuel quantity in the measuring glass. C) Evaluatin - Transpse the values btained t the graph. - The fuel cnsumptin is kay when the intersectin f the tw lines is within the limit curves. - f the intersectin is utside the limit curves, the metering pump must be replaced. Nte: Only measure the fuel quantity when the battery is sufficiently charged. At least 11/22 V and at mst 13/26 V shuld be applied at the cntrl unit during measurement. Cntrl unit ml secnds 6. HEATER REPAR STEPS 1. Remving/fitting the glw plug 2. Remvinglfitting the plug filter Remving the cap Remve the glw plug cnnectr. Unscrew the glw plug. Remve the plug filter When refitting the plug filter nte the psitin f the nse. :J Jl11 Vltmeter @)DEti= Carefully slide in the plug filter. ( Vltage (V) -. " li Measuring glass, lace " '-, ' 9 secnds... Q ;,;. Testlamp Cnnectin f vltmeter t cntrl unit

19 Visit fr mre technical infrmatin and dwnlads. 3. Remving/fitting the PCB , 5. Remvinglfitting the upper casing half Remving the plug frm the PCB. Press dwn the nse. Remve split rivet knck pin thrugh using a small drive, lever ut rivet using a knife. When assembling, use a new split rivet. Pull ut the PCB. PCB with changever relay fr blwer speed and temperature sensr (internal). Remving the upper casing half. 6. Remving the safety thermal cutut switch. Temperature sensr fr heating air (internal). 4. Remving the air utlet sectin

20 Visit fr mre technical infrmatin and dwnlads. Fit the safety thermal cutut switch, using new clamping springs Remving.the flame sensr. Remved parts 1 - PC.B 2 - safety thermal cutut switch 3 - glw plug 4 - plug filter 5 - flame sensr 6 - spacer clamps fr casing halves Changing the series resistr fr glw plugs in the 24 V heaters Nte n remval: The series resistr has been fitted with a clamping ring, there is n thread! 1, ",4. 2 Remving the series resistr Fitting the flame sensr Please nte when fitting: Place frk-shaped sectin in slt f resistr. Fit the pipe ver this sectin and drive the series resistr int its munting by light hammer blws. D nt knck against the insulatr r screw cnnectin spacer clamps fr the casing halves. Nte: When fitting the cmbustin air blwer / heat exchanger int the lwer casing half, care must be taken that the fastening hks f the blwer engage in the slts f the casing half, therwise the blwer wheel might catch.

21 Visit fr mre technical infrmatin and dwnlads Unscrewing the blwer frm the heat exchanger Remving the blwer NOTES Change the seals n the heat exchanger. Unscrew the flange (1) frm the heat exchanger. Fit new seals (2) and (3) as illustrated. 2, 1. Replace the seals n the blwer. Remve/scrape the ld seal frm the blwer flange. Affix new seal (self-adhesive). Nte: When fitting the cmbustin air blwer/heat exchanger int the lwer casing half, care must be taken that the fastening hks f the blwer engage in the slts f the casing half, therwise the blwer wheel might catch.

22 Visit fr mre technical infrmatin and dwnlads V. HEATER PARTS 1 SECTON. D1 LC - SERVCE PARTS DAGRAM 3_,,-;:". (, L ,// > 83

23 Visit fr mre technical infrmatin and dwnlads. 2. D1 L-C PARTS LST! 25183/ * Nrmally nt available, Manufactured t rder /251 Ref. N. Descriptin Part Number / / N. Descriptin. Part Number / =] /251689, /251 Pt-shaped strainer /251 Hse cnnectin Heat exchanger Relay 12V V 2384 Current regulatr 12V Cmbustin air blwer 12V V V Temperature cntrl switch cmplete 12V Flame sensr V Safety thermal cutut switch Ceramic hlder Lwer half f casing Resistr 24V Upper half f casing Prtective plate 24V Printed circuit bard 12V Duble u-clip 24V V V Cable harness.6m lng V m lng m lng Silicne Munting Seal m lng Air utlet hd 6mm * Cable sectin Adjustable air utlet deflectr 6mm Cable sectin (Fuel metering pump) 24V * Cable sectin 12V Temperature cntrl switch harness Retaining spring Pwer Cable (unfused) Glw plug 12V V Safety screen Grub Screw Hse cnnectr 6mm Rivet Cmbustin air intake hse 2mm x 1mtr Fillister head blt M 5x Flexible air hse 6mm Fuse Fuel hse 5mm.D ( ) 17 U-Clip Plastic fuel line 1.5mm Gasket Plastic fuel line 2mml.D Remvable glw plug screen Seal ring Sealing washer Cable harness head screw M 5x Sealing ring Cntrl Unit 12V V End sleeve 22mm mm Munting Bracket Flexible Exhaust 22mm Fuel metering pump 12V mm V with washer Washer N/A 12V Bttm sectin, Fuse hlder V

24 Visit fr mre technical infrmatin and dwnlads Ref. N. Descriptin Part Number 5 Cver, Fuse hlder Fuse 25A Terminal fr fuse hlder Plug and scket cnnectr Husing Scket Husing Scket cnnectins Flat-pin terminal Flat-pin guide Cable band CA1 5 6 Hlder Angle piece Metal-rubber munt Metal-rubber munt Grmmet Fuel hse clamp 9mm Fuel hse clamp 11mm mm Fuel hse clamp 12mm Hse clamp CA T -pipe sectin T -pipe sectin T -pipe sectin Fuel hse 7.5mm Fuel hse 9mm Fuel hse 11 mm Fuel pump clamp / / / /251 N. Descriptin 81 End sleeve with crssbar 82 Heater timer Timer/thermstat 7 day timer Hr. timer Screw taptite M 5x1 Temperature sensr, external Cable sectin Temperature sensr, external Cable cver Switch harness Sealing ring V 24V 12V 24V Part Number 25183/ / / /251689, CA Pipe clip Pipe clip 25mm mm Fuel hse 3.5mm Hse clamp Exhaust clamp 22mm mm