® Shop Manual Model Numbers HHE-200-07E - 12 VDC HHE-500-07M - 12 VDC
TABLE OF CONTENTS Contents Section 1 Section 2 General Heater Information 1.1 Component Overview .............................................. 1 1.2 Identification Plate ................................................... 2 Wiring Information 2.0 Section 3 Section 4 Wiring Information ................................................... 3 Switch Panel 3.1 Diesel Switch ........................................................... 4 3.2 Electric Switch ............................................
TABLE OF CONTENTS Contents Section 6 Diesel-Burner Wiring 6.1 Section 7 Troubleshooting 7.1 Section 8 Control Unit Wiring ................................................. 14 Troubleshooting ...................................................... 15 Diesel-Burner Service, Maintenance, and Repair Information 8.1 General Recommended Maintenance .................... 41 8.2 Detaching and Reattaching the Diesel-Burner ........ Head .......................................................................
Section 1: General Heater Information Component Overview 1.
Section 1: General Heater Information I.D. Plate 1.2 Identification Plate For Installation Only in Compartment Completely Closed Off from Living Quarters and Accessible Only from the Outdoors Exhaust system MUST NOT terminate beneath the vehicle or under an openable window or vent. HHE-500-07M 12 VDC / 170 Watts Model Number Diesel-Burner / DC Power Combustion Air MUST BE supplied from outside the vehicle. CAUTION: This appliance operates on both AC and DC Electrical Power.
") - Indicates "Polarity Sensitive" Connections - Indicates Interior Room / Fresh Water Tank Thermostats - Indicates Cozy III Heat Exchangers TSTAT Bathroom Heating Zone + oorraannggee - + bblluuee - + white - white + vviioolleett - + - + - brown - violet + orange - yellow + blue - blue + +brleadck - +brleadck - +brleadck - +brleadck - white - green + B3 INDIC B6 INDIC PREHEAT + PREHEAT - ELECTRIC + ELECTRIC - DIESEL + DIESEL - INDICATOR LIGHT - 12 Volt-DC Battery Connections B3
Section 3: General Heater Information Switch Panel 3.0 Switch Panel ��� � ����� �������� TM R By Vehicle Systems Diesel-Burner’s Indicator Light Diesel 3.1 Electric Diesel Switch Engine Preheat Figure 4 Function: The Diesel switch activates the indicator light on the switch and the Hydro-Hot's Diesel-Burner, reference Figure 4. This procedure allows the Diesel-Burner to operate and supply heat to the Hydro-Hot's Boiler Tank.
Section 4: General Heater Information Electronic Controller 4.0 Electronic Controller ��� � ����� �������� TM R Electronic Controller Emergency Cutoff Electric Heating Element Status Low Voltage Hydro-Hot Heating Status Reset Engine Preheat Pump #5 #4 Circulation Pump #1 Heating Zones Status #3 Circulation Pump #2 #2 #1 Stir Pump Low Battery Voltage Fault Diesel-Burner Status Low Temp Cutoff Status Overload Fault Figure 5 4.
Section 4: General Heater Information Electronic Controller, continued 4.3 Low Voltage Reset (Button) The Hydro-Hot's Electronic Controller must be manually reset whenever the Low Battery Voltage fault indicator light has been activated, reference Figure 5. To reset the Electronic Controller, simply depress the "Low Voltage Reset" button located on the Electronic Controller (use a thin straight object to access the reset button through the small hole in the faceplate). 4.
Section 4: General Heater Information Electronic Controller, continued 4.8 Circulation Pump #2 Indicator Light This indicator light will illuminate GREEN whenever Circulation Pump #2 is operating, reference Figures 1 and 5. Please note that this light will only be active if the Hydro-Hot is at normal operating temperature (i.e. between 160�� F and 190�� F) and if either Heating Zones #2, #3, or #4 are calling for heat, reference Figure 3.
Section 5: Diesel-Burner Component Overview 1. 2. 3. 4. 5. 6. 7. 8. 9. 5.1 Component Overview 10. 11. 12. 13. 14. 15. 16.
Section 5: Diesel-Burner Operational Flow-Chart 5.2 Operational Flow-Chart ~ Reference Figure 6 for all numbers indicated inside parenthesis. (e.g. #8). Operation sequence once the Hydro-Hot’s Diesel switch is turned ON. NOTE: The Diesel switch’s Indicator Light will illuminate (reference Figure 4), while the Hydro-Hot Heating Status and DieselBurner Status lights illuminate on the Electronic Controller, reference Figure 5.
Section 5: Diesel-Burner Operational Sequence 5.3 Operational Sequence The following sequence illustrates how the Hydro-Hot’s Diesel-Burner operates once it is activated. Also, if you are experiencing malfunctions with your Diesel-Burner, use this sequence of operating events as a diagnostic tool to determine at what point, in the Diesel-Burner’s operation, does the malfunction occur. Use the "KEY" provided below to understand each symbol shown.
Section 5: Diesel-Burner Operational Sequence, continued 5.3 Operational Sequence KEY Diesel Fuel Spray Combustion Air Exhaust Gases The particular component begins to operate. The component is currently operating. Diesel-Burner Operation, continued The Ignition Coil produces a high voltage spark, which is transferred across the Ignition Electrodes. The incoming air-fuel mixture is then ignited, creating combustion.
Section 5: Diesel-Burner Operational Sequence continued 5.3 Operational Sequence KEY Diesel Fuel Spray Combustion Air The particular component begins to operate. The component is currently operating. Diesel-Burner Operation, continued 5 6 The Diesel-Burner will continue to operate continuously in this manner (produce heat) until it is switched off manually, or by the VDC / VAC Control Thermostat once the coolant temperature in the Hydro-Hot’s Boiler Tank reaches 190 (+/- 5 deg.) farenheit.
Section 5: Diesel-Burner I.D. Plate 5.4 Identification Plate Fabrikschild-Duplikat gultig nur zusammen mit Original Thermosysteme GmbH To be shipped with Original Heater MADE IN GERMANY DBW 2010.75 HEIZGERAT Typ Spannung / El. Leistung 12 V / 60W 13,2 kW Warmestrom Brennstoff Diesel zul. Betriebsuberdruck 2 bar Prufzeichen Fabriknummer 1B230410 Inbetriebnahmejahr 2001 2002 2003 Model Type Voltage / Wattage Fuel Type Serial Number (230410) Year Manufactured Diesel-Burner I.D.
Section 6: Diesel Burner Wiring Control Unit Wiring 6.1 Control Unit Wiring NOTE: Reference Figure 3 for all "JP" Plug and Pin locations on the Electronic Conroller. C-1 ( + ) VDC / VAC Control Thermostat Circuit (Orange Wire) to JP-4 (Pin 5). C-2 ( + ) Motor Circuit (Black Wire) to Diesel-Burner. B-3 (+) Indicator Light Circuit (Blue Wire) to JP-4, (Pin 2). C-4 ( - ) VDC High-Limit Thermostat Circuit (Blue Wire) to Hydro-Hot’s Boiler Tank.
Section 7: Troubleshooting Troubleshooting This Troubleshooting Section has been separated into different Hydro-Hot Troubleshooting Scenario's, that may be experienced by the heater. Each section listed below begins with the most probable cause and remedy, to the least probable cause and remedy. This concept has been put in place to expedite the troubleshooting process and pinpoint the problem quickly.
Section 7: Troubleshooting Section 7.1, continued Section 7.1 After turning the Diesel switch ON: TS1: The Hydro-Hot's Diesel-Burner does not operate. NOTE: In order to perform the following checks, it is necessary to locate the Hydro-Hot's Electronic Controller and Switch Panel.
Section 7: Troubleshooting Section 7.1, continued Section 7.1, continued A: If YES: Check the JP-3 Plug for loose wire connections and/or harness damage. If NO: The Electronic Controller must be replaced. Please contact our Technical Department at 1-800-685-4298 for assistance. Q2: Is the Electronic Controller's Low Battery Voltage Fault light illuminated? A: If YES: Perform each of the following procedures as necessary until the problem is resolved. If NO: Proceed to Q3. a.
Section 7: Troubleshooting Section 7.1, continued Section 7.1, continued Department at 1-800-685-4298 for assistance. If NO: The Electronic Controller must be replaced. Please contact our Technical Department at 1-800-685-4298 for assistance. NOTE: If no problems were discovered up to this point, the problem most likely lies within the Diesel-Burner Head. However, prior to troubleshooting the Diesel-Burner Head, be sure to review the "Operational Flow-Chart" in Section 5.
Section 7: Troubleshooting Section 7.1, continued Section 7.2, continued NOTE: If the Hydro-Hot still does not operate after performing all of the listed checks, contact our Technical Department at 1-800-685-4298 for additional assistance. Section 7.2 After turning the Diesel switch ON: TS2: The Hydro-Hot's Diesel-Burner operates (3-minute prime cycle only), but does not ignite. NOTES: A. It is ideal to have the Hydro-Hot's Fuel Filter replaced yearly, reference Section 8.1.
Section 7: Troubleshooting Section 7.2, continued Section 7.2, continued Q3: Is the Diesel-Burner's Fuel Solenoid functioning properly? In order to determine if the Fuel Solenoid is functioning properly, reference Section 8.7 and perform the Fuel Solenoid's "Component Test". A: If the Fuel Solenoid is not functioning properly: The Fuel Solenoid must be replaced, reference Section 8.7 for replacement instructions. If the Fuel Solenoid is functioning properly: Continue Troubleshooting.
Section 7: Troubleshooting Section 7.2, continued Section 7.2, continued In order to determine if the Ignition Electrodes are in good condition and properly adjusted, reference Section 8.5. A: If the Ignition Electrodes are in poor condition: The Ignition Electrodes must be replaced, reference Section 8.5 for replacement instructions. If the Ignition Electrodes are not properly adjusted: Adjust the Ignition Electrodes, reference Section 8.5 for adjustment instructions.
Section 7: Troubleshooting Section 7.3, continued Section 7.3, continued Q2: Is the Diesel-Burner's Flame Sensor functioning properly? In order to determine if the Flame Sensor is functioning properly, reference Section 8.4 and perform the Flame Sensor's "Component Test". A: If the Flame Sensor is not functioning properly: The Flame Sensor must be replaced, reference Section 8.4 for replacement instructions. If the Flame Sensor is functioning properly: Continue Troubleshooting.
Section 7: Troubleshooting Section 7.3, continued Section 7.3, continued Continue Troubleshooting. Fuel Filter Q5: Is the Diesel-Burner's Fuel Supply System functioning properly? Quick Check - With the Diesel-Burner ignited, listen for constant sputtering from the HydroHot's exhaust system. A: If constant sputtering exists: Continue Troubleshooting. If constant sputtering does not exist: Proceed to Q6. NOTE: Inspect the clear bowl of the Fuel Filter for water.
Section 7: Troubleshooting Section 7.3, continued Section 7.3, continued NOTE: Be sure to check that each fitting at the Fuel Filter Head contains thread sealant. A fitting without thread sealant could result in an air leak. Be sure to clamp off both fuel lines at the filter head prior to any fitting removal. If fittings are removed and reinstalled, be sure to remove the fuel line clamps prior to attempting a heater restart.
Section 7: Troubleshooting Section 7.4 Section 7.4, continued After turning the Diesel switch ON: TS4: The Hydro-Hot's exhaust system sputters. Fuel Filter NOTE: Before proceeding to the following procedures, be sure to check that the vehicle's fuel tank has a sufficient level of fuel. Q1: Is the Diesel-Burner's Fuel Nozzle functioning properly? In order to determine if the Fuel Nozzle is functioning properly, reference Section 8.6 and perform the Fuel Nozzle's "Component Test".
Section 7: Troubleshooting Section 7.4, continued Section 7.4, continued If air bubbles are visible: You will need to inspect the fuel system (supply side) for air leaks. Therefore, be sure to perform the inspections listed below until the air leak has been detected: 1. Inspect the fuel system (supply side) from the vehicle's fuel tank to the Diesel-Burner. Inspect the fuel connections at the HydroHot, Diesel-Burner, and at the vehicle's fuel tank for looseness. Tighten if necessary.
Section 7: Troubleshooting Section 7.5 Section 7.5, continued After turning the Diesel switch ON: TS5: The Hydro-Hot's exhaust system produces white smoke after ignition. Q1: Is the Diesel-Burner's Fuel Nozzle functioning properly? In order to determine if the Fuel Nozzle is functioning properly, reference Section 8.6 and perform the Fuel Nozzle's "Component Test". A: If the Fuel Nozzle is not functioning properly: The Fuel Nozzle must be replaced, reference Section 8.6 for replacement instructions.
Section 7: Troubleshooting Section 7.5, continued Section 7.5, continued Fuel Filter NOTE: Inspect the clear bowl of the Fuel Filter for water. If water exists, be sure to purge the Hydro-Hot's entire fuel system prior to replacing the Fuel Filter. Attempt heater restart. a. Clamp off and remove the Hydro-Hot's Fuel Return Line, reference Figure 1. Now attach a short piece of fuel line to the Hydro-Hot's Fuel Return Port and place the other end in a container of diesel fuel.
Section 7: Troubleshooting Section 7.5, continued Section 7.6, continued 2. Once the potential air leak has been discovered and corrected, reattach the Hydro-Hot's Fuel Return Line and attempt heater restart. Does the Hydro-Hot's exhaust system still sputter? If the exhaust system is still sputtering: Perform the air leak inspections again, until all air leaks have been discovered and corrected.
Section 7: Troubleshooting Section 7.6, continued Section 7.6, continued b. Reset the Electronic Controller's Low Voltage Reset (button) on the Electronic Controller (this can be accomplished by using a thin straight object to access the reset button through the small hole in the faceplate). Continue to read the voltage level at the Electronic Controller's Battery Connections and then turn the Diesel switch ON. Under load, is the voltage level within 0.
Section 7: Troubleshooting Section 7.6, continued Section 7.6, continued If the Fuel Nozzle is functioning properly: Continue Troubleshooting. Q3: Is the Diesel-Burner's Motor operating at the proper RPM speed? In order to determine if the Motor is operating properly, reference Section 8.3 and perform the Motor's "RPM Test". A: If the Motor is not operating at the proper RPM: The Motor must be replaced, reference Section 8.3 for replacement instructions.
Section 7: Troubleshooting Section 7.6, continued Section 7.6, continued 3. Pump the rubber ball - 18 times. 4. Release the suction hose from the CO2 Analyzer's plunger. 5. Turn the CO2 Analyzer upside down so that the fluid runs to the top and then turn it right side up again. Perform this procedure twice. 6. Place the CO2 Analyzer on a flat surface and read the CO2 level. 7. The CO2 level should be between 10.5 and 11.5 percent (at a nominal 12 volts DC).
Section 7: Troubleshooting Section 7.7, continued Section 7.7 After turning the Diesel switch ON: TS7: The Hydro-Hot is at operating temperature, but an Interior and/or Fresh Water Tank Heating Zone is not producing heat. Q1: Is the particular Heating Loop's Circulation Pump operating? Quick Check - Remove the Hydro-Hot's Access Cover and determine if the problem Heat Exchanger(s) are plumbed with Circulation Pump #1 or Circulation Pump #2, reference Figure 1 and the illustration below.
Section 7: Troubleshooting Section 7.8, continued Section 7.8 After turning the Diesel switch ON: TS8: The Hydro-Hot is at operating temperature, but the fans of an Interior and/or Fresh Water Tank Heat Exchangers are not operating. Q1: Is the Electronic Controller's Low Temp Cutoff Status light illuminated? A: If YES: Perform each of the following procedures as necessary until the problem is resolved.
Section 7: Troubleshooting Section 7.9 Section 7.8, continued After turning the Diesel switch ON: voltage signal at the Electronic Controller? A: If YES: The interior Room Thermostat may need to be replaced. Please contact our Technical Department at 1-800685-4298 for assistance. If NO: The Electronic Controller must be replaced. Please contact our Technical Department at 1-800-685-4298 for assistance.
Section 7: Troubleshooting Section 7.9, continued The chart below, is a graphical representation of how the Hydro-Hot’s Domestic Hot Water System theoretically performs under varying domestic cold water temperatures. Because each Hydro-Hot has a performance tolerance, this graph should be used as a general guideline and not as actual domestic hot water performance data. F at e rc ur v e 70 dom e st ic h ot w 60 50 115 F Input (i.e.
Section 7: Troubleshooting Section 7.10 Section 7.10, continued After turning the Electric switch ON: TS10: The Hydro-Hot's 120 VAC Electric Heating Element does not operate (i.e. lack of hot water and/or interior heat). Q1: Is the Electronic Controller's Electric Heating Element Status light illuminated? (reference Figure 5) A: If YES: Perform each of the following procedures as necessary until the problem is resolved. 1. Locate the Electronic Controller and remove the Faceplate. 2.
Section 7: Troubleshooting Section 7.10, continued Section 7.10, continued a. Turn the Diesel and Electric switches ON and allow the Hydro-Hot to reach maximum operating temperature (i.e. until the DieselBurner cycles OFF). Locate both the VAC High-Limit Thermostat and the VAC / VDC Control Thermostat and check for continuity, reference Figure 1.
Section 7: Troubleshooting Section 7.10, continued Section 7.10, continued White wire connection at the 120 VAC Electric Heating Element. Is voltage present? A: If YES: Proceed to Q5. If NO: The VAC Element Relay must be replaced. Please contact out Technical Department at 1-800-685-4298 for assistance. Q5: Is 120 VAC Electric Heating Element functioning properly? WARNING: The following checks need to be performed with the motorhome connected to VAC power.
Section 7: Troubleshooting Section 7.11, continued If no voltage is present: Replace the Electronic Controller. If NO: Perform each of the following procedures as necessary until the problem is resolved. 1. Locate the Electronic Controller and remove the Faceplate. 2. Locate the Electronic Controller's JP-2 Plug. Use a jumper wire to make a connection from the Preheat (+) pin to the Preheat (-) pin, reference Figure 3.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information General Recommended Maintenance 8.1 General Recommended Maintenance Monthly Check the Hydro-Hot's water and antifreeze solution to ensure that it is at the proper level. Do this by visually checking the coolant level in the HydroHot's Expansion Tank, reference Figure 1. This should be checked only when the Hydro-Hot is at maximum operating temperature (i.e. when the Diesel-Burner cycles OFF), "HOT".
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Detaching and Reattaching the Diesel-Burner Head 8.2 Detaching and Reattaching the Diesel-Burner Head Grommets Eye-Bolts and Nuts Diesel-Burner Head Blower Casing Diesel Fuel Supply Diesel Fuel Return Figure 10 WARNING: Be sure to turn the Diesel switch OFF and disconnect the B-Plug Harness from the Diesel-Burner's Control Unit prior to detaching the Diesel-Burner Head, reference Figures 8 and 26.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Motor 8.3 Motor Function: The Motor drives the Combustion Air Blower and the Fuel Pump. NOTE: In order to perform the following procedures, it may be necessary to detach and reattach the Diesel-Burner Head. Be sure to reference Section 8.2, Page 42 for detaching and reattaching instructions.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Motor, continued Adjustment Procedure: N/A RPM Test: Disconnect the Ignition Cables from the Ignition Electrodes, reference Figure 16. Remove the four Ignition Coil Screws that secure the Ignition Coil to the Protection Cap, reference Figure 13. Lift the Ignition Coil and disconnect its wires from the C-Plug Harness wires prior to removing.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Motor, continued Replacement Procedure: 1. Remove the four Ignition Coil Screws that secure the Ignition Coil to the Protection Cap, reference Figure 13. Lift the Ignition Coil to disconnect its wires from the C-Plug Harness wires prior to removing. Remove the Protection Cap from the Diesel-Burner so that the Motor and Clutch Halves are exposed, reference Figures 13 and 14. 2.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Motor, continued secure to the Protection Cap with the four Ignition Coil Screws, reference Figure 13.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Flame Sensor 8.4 Flame Sensor Function: The Flame Sensor is a photoresistive device which supplies the Diesel-Burner's Control Unit with a DC voltage signal when it detects a flame (i.e. light source). NOTES: A: In order to perform the following procedures it is necessary to detach and reattach the Diesel-Burner Head. Be sure to review Section 8.2, Page 42 for detaching and reattaching instructions.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Flame Sensor, continued Flame Sensor Green Wire Photo Disc Green Wire (to Diesel-Burner) Blue Wire Figure 15 Ignition Electrodes 8.5 NOTE: This screw is used to fasten the Flame Sensor to the Photo Disc. Remove when replacing the Flame Sensor.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Ignition Electrodes, continued trodes into the appropriate notches of the Electrode Adjustment Gauge as illustrated in Figure 16. 3. Tighten the Retaining Clamp Bolt. NOTE: Be sure not to overtighten the Retaining Clamp Bolt when readjusting the Ignition Electrodes. Overtightening the Retaining Clamp Bolt will bend the Retaining Clamp and prevent the Photo Disc from floating freely (i.e. loose fit).
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Fuel Nozzle 8.6 Fuel Nozzle Function: The Fuel Nozzle is simply a fuel atomizer. It reduces the diesel fuel into a fine spray which is mixed with incoming combustion air and is ignited within the Combustion Chamber. NOTE: In order to perform the following procedures it is necessary to detach and reattach the Diesel-Burner Head. Be sure to review Section 8.2, Page 42 for detaching and reattaching instructions.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Fuel Nozzle, continued NOTE: An adjustment of the Ignition Electrodes may be necessary after replacing the Fuel Nozzle. Reference Section 8.5, Page 48 for the Ignition Electrode "Adjustment Procedure". 3. After replacing the Fuel Nozzle, reattach the Diesel-Burner Head. WARNING: Be sure to reattach the Diesel-Burner Head prior to switching the heater ON.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Fuel Solenoid 8.7 Fuel Solenoid Function: The Fuel Solenoid allows the flow of diesel fuel to the DieselBurner's Fuel Nozzle. NOTE: In order to perform the following procedures it is necessary to detach and reattach the Diesel-Burner Head. Be sure to review Section 8.2, Page 42 for detaching and reattaching instructions. Component Test: Locate and detach the C-Plug Harness' Violet (+) and Brown (-) wires from the Fuel Solenoid.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Fuel Solenoid, continued 8. Reinstall the Photo Disc and secure in place with the Retaining Clip. Connect the C-Plug Harness' Violet (+) and Brown (-) wires to the Fuel Solenoid's (+) and (-) Electrical Terminals, reference Figure 18. 9. Perform the "Ignition Electrodes Adjustment Procedure" in Section 8.5, Page 48 to complete the Fuel Solenoid installation.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Fuel Pump 8.8 Fuel Pump Function: The Fuel Pump draws diesel fuel from the vehicle's fuel tank and creates a preset pressure of 145 psi (required for proper fuel atomization). Reference the illustration below for a basic overview and understanding of how the Fuel Pump functions. FUEL PUMP OVERVIEW 1. 2. 3. 4. 5. 6.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Fuel Pump, continued Ignition Cable (1) Nozzle Stand Plate Screw (1) Retaining Clamp Retaining Clip Ignition Electrodes Photo Disc Flame Sensor Supply Banjo Bolt Fuel Pump Fuel Return Banjo Pipe Fuel Supply Banjo Pipe Nozzle Stand Plate Screw (2) Fuel Supply Line Ignition Cable (2) Nozzle Stand Plate Screw (4) Top Cover Plate Screws High Pressure Fuel Pipe Connections Pump Mounting Screw Nozzle Stand Plate Fuel Pressure Re
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Fuel Pump, continued Fuel Pressure Adjustment Check: NOTES: A: A Fuel Pressure Gauge (reference Section 11 for special tools information) is used to properly check the Fuel Pump's pressure setting, reference Figure 20. The Fuel Pump is preset to 145 psi (the pressure required for proper fuel atomization at the Fuel Nozzle). Perform the following procedures to check for a proper fuel pressure setting.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Fuel Pump, continued 60 80 100 120 140 40 160 20 psi 0 Fuel Pressure Gauge 180 200 ASHCROFT MADE IN U.S.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Fuel Pump, continued Replacement Procedure: 1. Locate and disconnect the C-Plug Harness wires that connect to the Flame Sensor and the Fuel Solenoid, reference Figures 3, 15, and 18. Also, disconnect the Ignition Cables from the Ignition Electrodes, reference Figures 16 and 19. 2. Remove the Retaining Clip that secures the Photo Disc in place, reference Figure 19.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Fuel Pump, continued and secure in place with the four Nozzle Stand Plate Screws. Install the new Grommets on the Fuel Return and Supply Banjo Pipes (with the fuel lines attached) and secure the pipes to the Fuel Pump with the new Banjo Bolts and Gasket Rings, reference Figure 22. NOTE: Reference Figure 22 for the correct order placement of the (4) Gasket Rings.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Bearings 8.9 Bearings Function: The Bearings support the Combustion Air Blower's shaft and allows the blower to turn smoothly. NOTE: In order to perform some of the following procedures it is necessary to detach and reattach the Diesel-Burner Head. Be sure to review Section 8.2, Page 42 for detaching and reattaching instructions. Function Test: Remove the Motor (reference Section 8.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Bearings, continued NOTE: Inspect the Clutch Halves' for cracks and also ensure that the flat portion in each shaft hole is free of wear and tear. Too much play on the shaft produces a loud clacking noise. If any cracks or wear are detected, the Clutch Half must be replaced. Reference the Hydro-Hot's "Parts Manual" for spare parts information. 6.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Bearings, continued through the Bearing Kit assembly until the threaded portion appears on Side-A of the Blower Casing, reference Figure 23. Place the new thick flat Washer and steel Drive Gear on the threaded end of the Combustion Air Blower's shaft. Thread the new Retaining Nut on the Combustion Air Blower's shaft until it is finger tight (DO NOT TIGHTEN). 11.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Bearings, continued Side-B Blower Casing Blower Housing Rubber Grommets Blower Casing O-Ring Combustion Air Blower w/shaft Blower Housing Screws Side-A Dished Surface Washer Dished Surface Washer Flat Washer Snap Ring Spacer Tube Wave Washer Bearing Flat Washer (Thick) Drive Gear (Steel) Retaining Nut Bearing Bearing Kit R Snap Ring Hydro-Hot Hydronic Heating System Shop Manual 07/03 Figure 23 Page 63
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Ignition Coil 8.10 Ignition Coil Function: The Ignition Coil produces a high voltage ignition spark (approx. 8000 volts), which is released across the metal tips of the Ignition Electrodes during the initial Diesel-Burner start-up. WARNING: Use extreme care when testing the Ignition Coil, as a High Voltage Shock may result.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Control Unit 8.11 Control Unit Function: The Control Unit operates all the components of the DieselBurner Head and safely shuts the heater OFF in the event of an overheat, flameout, and low voltage condition. It also receives Diesel-Burner operation status signals from the Flame Sensor, VDC Control Thermostat, and VDC High-Limit Thermostat.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Control Unit, continued B-2 ( - ) Battery Circuit (Brown Wire) to JP-4 (Pin 4) 12.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Control Unit, continued NOTE: If after performing the following circuit tests, the Control Unit is determined to be defective, and must be replaced, reference the Control Unit's "Replacement Procedure" on the following page. Reference Section 10 for spare parts information. Ground circuit test Locate the Control Unit's B-Plug and C-Plug, reference Figure 8.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Control Unit, continued NOTE: Be sure to reconnect the VDC High Limit Thermostat's 2-way male plug to the 6-way female plug. The Diesel-Burner will not ignite during normal operation if the VDC High-Limit Thermostat is left disconnected. CAUTION: Be sure to remove the jumper wire that was used to make the connection from the C-1 location to the C-7 location.
Section 8: Diesel-Burner Service, Maintenance, and Repair Information Control Unit, continued 7.
Section 9: Warranty Information WARRANTY INFORMATION - FOR ALL HYDRO-HOT MODELS Vehicle Systems Inc. warrants the HYDRO-HOT Heater to be free from defects in material and workmanship under normal use and service for a period of two (2) years on both parts and labor commencing upon the original date of registration of the vehicle. Replacement parts are warranted for the remainder of the Heater's standard warranty period or for six months (180 days), whichever is greater.
Section 10: Spare Parts List Control Unit 305 1 2 313 A 1 2 3 4 5 6 B 1 2 4 5 6 7 8 2455RM8589-6 L220 72 302 303 C 409 410 GEMS 2 59 411 2455RM8589-6 L220 62 412 61 50 5 56 27 51 2 WPX-287-962 Control Unit, 12 VDC, DBW 2010-300, AH/HH/WH 5 WPX-101-838 Coil, Ignition, 12 VDC, DBW 2010-300, AH/HH/WH 27 WPX-425-060 Motor, Combustion Air/Fuel Pump, 12 VDC, DBW-2010, AH/HH/WH 50 WPX-322-083 Assembly, Fuel Solenoid, 12 VDC, DBW 2010-300, AH/HH/WH 51 WPX-386-650 Valve, Kit, F
Section 11: Special Tools 60 80 100 120 140 40 160 20 psi 0 180 200 ASHCROFT MADE IN U.S.A 102 WPX-310-646 Gauge, Adjustment, Electrode, DBW 2010-300, AH/HH/WH 138 WPX-440-280 Control Box, Tester, DBW 2010-300, AH/HH/WH 139 WPE-600-190 Gauge Kit, Fuel Pressure, DBW 2010-300, AH/HH/WH 140 **************** Gas Analyzer, CO2, AH/HH/WH Order item #140 from a Grainger Industrial Supply Store near you or visit the Grainger website at www.grainger.com.
Motor Coach Heating Specialists • Manufacturers and Distributors 15549 East Highway 52 • Fort Lupton, Colorado 80621 • 1-800-685-4298 • Fax: 303-857-9000 © Copyright 2002 Vehicle Systems, Inc. All rights reserved www.vehiclesys.
