HHE 07E MHydro HotShopManual07 03

®
Shop Manual
Model Numbers
HHE-200-07E - 12 VDC
HHE-500-07M - 12 VDC
TABLE OF CONTENTS
Contents
Section 1 General Heater Information
1.1 Component Overview .............................................. 1

1.2 Identification Plate ................................................... 2
Section 2 Wiring Information
2.0 Wiring Information ................................................... 3
Section 3 Switch Panel
3.1 Diesel Switch ........................................................... 4

3.2 Electric Switch ......................................................... 4
3.3 Engine Preheat Switch ............................................. 4
Section 4 Electronic Controller
4.1 Electric Heating Element Status Indicator Light ....... 5

4.2 Heating Zones Status Indicator Light ....................... 5
4.3 Low Voltage Reset Button ........................................ 6
4.4 Emergency Cutoff Indicator Light ............................. 6
4.5 Heating Status Indicator Light .................................. 6
4.6 Engine Preheat Pump Indicator Light ...................... 6
4.7 Circulation Pump #1 Indicator Light ......................... 6
4.8 Circulation Pump #2 Indicator Light ......................... 7
4.9 Stir Pump Indicator Light .......................................... 7
4.10 Low Battery Voltage Fault Indicator Light ................. 7
4.11 Low Temp Cutoff Status Indicator Light .................... 7
4.12 Diesel-Burner Status Indicator Light ......................... 7
4.13 Overload Fault Indicator Light .................................. 7
Section 5 Diesel-Burner
5.1 Component Overview. ............................................. 8

5.2 Operational Flow-Chart ............................................ 9
5.3 Operational Sequence ............................................ 10
5.4 Identification Plate .................................................. 13
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Hydro-Hot Hydronic Heating System Shop Manual 07/03
TABLE OF CONTENTS
Contents
Section 6 Diesel-Burner Wiring
6.1 Control Unit Wiring ................................................. 14
Section 7 Troubleshooting
7.1 Troubleshooting ...................................................... 15
Section 8 Diesel-Burner Service, Maintenance, and Repair

Information
8.1 General Recommended Maintenance .................... 41
8.2 Detaching and Reattaching the Diesel-Burner ........
Head ....................................................................... 42
8.3 Motor ...................................................................... 43
8.4 Flame Sensor ......................................................... 47
8.5 Ignition Electrodes .................................................. 48
8.6 Fuel Nozzle ............................................................. 50
8.7 Fuel Solenoid .......................................................... 52
8.8 Fuel Pump .............................................................. 54
8.9 Bearings ................................................................. 60
8.10 Ignition Coil ............................................................. 64
8.11 Control Unit ............................................................. 65
Section 9 Warranty Information
9.0 Warranty Information .............................................. 70
Section 10 Spare Parts List
10.0 Spare Parts List ...................................................... 71
Section 11 Special Tools
11.0 Special Tools ........................................................... 72
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Section 1: General Heater Information
Component 1.1 Component Overview

Overview
Figure 1
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Page 1
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.
Combustion Air MUST BE supplied

from outside the vehicle.
HHE-500-07M 12 VDC / 170 Watts CAUTION: This appliance operates on
both AC and DC Electrical Power.
Model Number Diesel-Burner / DC Power The AC Powered Electrical Heating Element can be
wired using flexible nonmetallic cable (ROMEX).
USE COPPER CONDUCTORS ONLY
HM02-224 120 VAC, 60 Hz / 1.65 kW CAUTION: The Mixing / Anti-Scald Valve

must be installed with this product.
Serial Number Electric Heating Use 25 Amp fuse for over current protection
for DC Power supply.
Element / AC Power
Use 20 Amp Circuit Breaker for over current
protection for AC Power supply.
06-02 DIESEL / 50,000 BTU Mount Heater near a Bay / Storage Door so
Acess Cover can be easily removed.
Manufactured Date Fuel Type / Firing Rate Minimum Heater clearances

Front - Open Acess
Back - 8 inches
Testing Complies with the requirements Top - 9 inches
Sides - 0 inches
Engineers of UL 307A
Install in strict compliance with local codes, NFPA
International Made in U.S.A. 501c and manufacturer’s instructions.
Manufactured
Date Box
Serial Number Reference Figure 1 for

Box I.D. Plate locations.
Model Number
Box
Figure 2
Page 2 R
Section 2: Wiring Information
K ey
R
- Indicates Cozy III Heat Exchangers Hydro-Hot Components
Electronic Controller
lectronic Controller
GEMS
T-
STAT - Indicates Interior Room / Fresh Water Tank Float Switch
Thermostats VEHICLE
SYSTEMS
VDC / VAC
(" ") - Indicates "Polarity Sensitive" Connections INC. Control Thermostat
ZETTLER
AZ2280-1A-12D
LWCO SW - JP 3 16-red
HYDRO-HOT LWCO SW + 15-red Black 120 VAC Power Supply
Note: All wire colors shown, for "Field Wiring Connections", CONTROLLER TSTAT SW - 14-black
Black
2455RM8589-6 L220
and "Switch Panel Connections" may vary from actual OEM TSTAT SW + 13-black VAC Element Relay Black
AC REL SW - 12-orange
/ Converter wiring colors. JP 1 # 5 FAN + AC REL SW +
VAC High-Limit
11-orange
# 5 FAN - Thermostat
Accessory / Optional LTCO SW - 10-yellow
# 5 THERM +
Heating Zone LTCO SW + 9-yellow 120 VAC/1650 Watt Common
# 5 THERM -
Component Wiring 8-brown Electric Heating Element
# 4 FAN + PHPUMP -
7-red White
+brleadck Connections PHPUMP +
# 4 FAN -
R
Fresh Water Tank T- - 6-white
# 4 THERM + ZPUMP1 -
Heating Zone STAT
# 4 THERM - ZPUMP1 +
+ vviioolleett 5-violet
-
+brleadck # 3 FAN + ZPUMP2 -
4-green Low Temperature
# 3 FAN - ZPUMP2 + 3-brown Thermostat
Bedroom Heating T-
- Field Wiring
white # 3 THERM +
Zone STAT Connections STPUMP - 2-black
# 3 THERM -
+ white
- STPUMP + 1-red
# 2 FAN +
# 2 FAN -
+brleadck
Bathroom Heating T-
- Engine Preheat Pump
# 2 THERM +
Zone STAT
# 2 THERM -
+ bblluuee
-
# 1 FAN +
# 1 FAN -
+brleadck
Living Room / T- - ON/OFF SWITCH B1
Kitchen # 1 THERM + JP 4 7-yellow
STAT + oorraannggee # 1 THERM - THERM. WHITE C7
Heating Zone - 6-white Circulation Pump #1
THERM. ORANGE C1 5-orange
GROUND - B2
Diesel-Burner 4-brown
Control Unit BATTERY + B4 3-red
Wiring INDICATOR LIGHT + B3 2-blue
Switch Panel, INDICATOR LIGHT - B6 1-green Circulation Pump #2
Backside View blue + JP 2 DIESEL +
DIESEL -
blue - Switch Panel
"ENGINE yellow + ELECTRIC + Connections
PREHEAT" "ELECTRIC" "DIESEL" ELECTRIC -
orange -
Stir Pump
violet + PREHEAT +
brown - PREHEAT - GND +12V 12 Volt-DC

Battery Diesel-Burner Components
green + B3 INDIC
+ -
-
+ + + Connections
white - B6 INDIC
B-PLUG C-PLUG black C-2
- - -
+
blue Burner Motor
C-4
2455RM8589-6 L220
brown
green VDC High-Limit

Thermostat
yellow
12 VDC + (Positive) 12 VDC - (Ground) C-5
Screw Terminal / Screw Terminal /
A B C Fuel Solenoid
Red wire Black wire
Diesel-Burner C-6
Control Unit
Flame Sensor
NOTE:
The two-way plug connector is used C -8
ONLY when replacing older Ignition coil
CAUTION: Reversed polarity to the
12 Volt-DC Battery Connections will Hydro-Hot Electronic Controllers. Wiring
iring Diagram
Diagram
seriously damage the Electronic
Controller. For Technical Support call 1-800-685-4298 Figure 3
Page 3
Switch Panel 3.0 Switch Panel
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By Vehicle Systems
Diesel-Burner’s
Indicator
Light
Diesel Electric Engine

Preheat
Figure 4
3.1 Diesel Switch
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. The Diesel-Burner will heat the Hydro-Hot System to maximum
operating temperature (190�F {+/- 5 deg.}) in approximately 10-20 min-
utes. Please note that the Diesel-Burner is the Hydro-Hot's primary heat
source for heating both the interior and/or the domestic hot water (such
as when cool ambient temperatures exist and/or when there is a high
demand for domestic hot water).
3.2 Electric Switch

Function: The Electric switch activates the indicator light on the switch
and the Hydro-Hot's 120 VAC Electric Heating Element, reference Figure
4. This procedure allows the 120 VAC Electric Heating Element to supply
heat to the Hydro-Hot's Boiler Tank. The 120 VAC Electric Heating
Element will heat the Hydro-Hot System to maixmum operating tempera-
ture (190�F {+/- 5 deg.}) in approximately 1-2 hours. Please note the 120
VAC Electric Heating Element is the Hydro-Hot's secondary heat source
for heating both the interior and/or the domestic hot water during low
heating demand situations (such as when moderate ambient tempera-
tures exist and/or when there is a low demand for domestic hot water).
This feature is only operational whenever the motorhome is connected to
VAC power or when the generator is operating.
3.3 Engine Preheat Switch

Function: The Engine Preheat switch activates the indicator light on the
switch and the Hydro-Hot's Engine Preheat Circulation Pump, reference
Figure 4. This procedure allows the Engine Preheat Circulation Pump to
circulate the engine's coolant through a separate double wall copper loop
in the Hydro-Hot's Boiler Tank, resulting in a warm engine for easy start-
ups on cool mornings. Please note that this feature will be effective only if
the Engine Preheat switch is ON in conjunction with either the Diesel and/
or Electric switch. This feature is available on HHE-200 Model Hydro-
Hot's, ONLY.
Page 4 R
Electronic 4.0 Electronic Controller
Controller
� ��
��
TM R
Electronic
Controller
Emergency
Cutoff
Electric Heating Low Voltage Hydro-Hot

Element Status
Heating Status
Reset
#5 Engine Preheat
Pump
#4
Circulation
Pump #1
Heating Zones #3
Status
Circulation
#2 Pump #2
#1
Stir Pump
Low Battery
Voltage Fault Diesel-Burner
Status
Low Temp
Cutoff Status
Overload Fault
Figure 5
4.1 Electric Heating Element Status Indicator Light
This indicator light will illuminate GREEN whenever the Hydro-Hot's 120
VAC Electric Heating Element is operating and providing heat to the Hydro-
Hot's Boiler Tank, reference Figure 5. Please note that this light will only be
active if the Electric switch is in the ON position, reference Figure 4. If this
indicator light illuminates RED, it indicates an electrical overload condition
(i.e. short) has occurred in the Electric Heating Element's VDC powered
circuitry.
4.2 Heating Zones Status Indicator Lights

These five indicator lights (separately) will illuminate GREEN whenever a
Zone Thermostat, for each particular zone, is calling for heat, reference
Figure 5. The GREEN indicator lights also indicate that VDC power is being
supplied to the particular interior heating zone's Heat Exchangers (i.e. fan
motors). If any of the five indicator lights illuminate RED, it indicates that an
electrical overload condition (i.e. short) has occurred in a particular heating
zone's circuitry.
NOTE: A short in either a heating zone's Thermostat or a heating zone's
Heat Exchanger circuit, will cause the indicator light to illuminate RED.
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Page 5
Electronic 4.3 Low Voltage Reset (Button)

Controller, The Hydro-Hot's Electronic Controller must be manually reset whenever the
continued 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).
4.4 Emergency Cutoff Indicator Light

This indicator light will illuminate RED when either the 120 VAC Electric
Heating Element and/or the Diesel-Burner have automatically shutdown
due to a low water and antifreeze solution level inside the Hydro-Hot's
Boiler Tank, reference Figure 5. This fault will automatically reset when the
low level condition is corrected.
4.5 Heating Status Indicator Light

This indicator light will illuminate GREEN whenever the Hydro-Hot's VDC /
VAC Control Thermostat is calling for heat, allowing the water and
antifreeze solution in the Hydro-Hot's Boiler Tank to be heated by either the
Diesel-Burner and/or the 120 VAC Electric Heating Element, reference
Figure 5. When this indicator light is off, no heat is being supplied to the
Hydro-Hot's Boiler Tank. Please note that this light will only be active if
either the Diesel and/or the Electric switch are turned ON, reference Figure
4.
NOTE: The Hydro-Hot's VDC / VAC Control Thermostat will automat-
ically activate the Diesel-Burner and/or the 120 VAC Electric Heating
Element, only if the Diesel and/or Electric switch is in the ON position.
So to heat the motorhome / domestic hot water, simply choose the
desired heat source(s) and leave the switch(s) (i.e. Diesel and/or
Electric) ON.
4.6 Engine Preheat Pump Indicator Light

This indicator light will illuminate GREEN whenever the Engine Preheat
Pump is operating, reference Figures 1 and 5. Please note that this light
will only be active if the Engine Preheat switch is ON in conjunction with
either the Diesel and/or the Electric switch, reference Figure 4. If this
indicator light illuminates RED, it indicates an electrical overload condition
(i.e. short) has occurred in this particular component's circuitry.
4.7 Circulation Pump #1 Indicator Light

This indicator light will illuminate GREEN whenever Circulation Pump #1 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 Zone #1 or #5 are calling for heat,
reference Figure 3. If this light illuminates RED, it indicates an electrical
overload condition (i.e. short) has occurred in this particular component's
circuitry.
Page 6 R
Electronic 4.8 Circulation Pump #2 Indicator Light
Controller, 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
continued 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. If this light illuminates RED, it indicates an
electrical overload condition (i.e. short) has occurred in this particular
component's circuitry.
4.9 Stir Pump Indicator Light

This indicator light will illuminate GREEN whenever there is a continuous
demand for domestic hot water (i.e. during a shower), reference Figures 1
and 5. Please note that this light will be active only when the Diesel switch
is turned ON, reference Figure 4.
4.10 Low Battery Voltage Fault Indicator Light

This indicator light will illuminate RED whenever the VDC voltage level is
too low for the Hydro-Hot to operate properly, reference Figure 5. This fault
must be manually reset after the voltage level has been restored to the VDC
battery system, reference Section 4.3 for reset instructions.
4.11 Low Temp Cutoff Status Indicator Light

This indicator light will illuminate GREEN whenever the Hydro-Hot is able to
provide heat for both the Interior and Fresh Water Tank Heating Zones,
reference Figure 5. Whenever this indicator light is OFF, it indicates that
domestic hot water is being used on a continuous basis (i.e. during a
shower).
NOTE: The Hydro-Hot will not provide both interior zone heating and a
continuous supply of domestic hot water simultaneously; Domestic Hot
Water will take priority over Interior Heating. This is referred to as the
"Domestic Water Priority System".
4.12 Diesel-Burner Status Indicator Light

This indicator light will illuminate GREEN whenever the Hydro-Hot's Diesel-
Burner is operating and supplying heat to the Hydro-Hot's Boiler Tank,
reference Figures 1 and 5. Please note that this light will only be active if
the Diesel switch is turned ON, reference Figure 4.
4.13 Overload Fault Indicator Light

This indicator light will illuminate RED (reference Figure 5) whenever one of
the following conditions have occurred:
1. The Hydro-Hot is off due to an electrical overload (i.e. short) in the
main VDC power supply circuitry.
2. The Hydro-Hot is off due to a combination of high electrical VDC
power loads and a high surface temperature of the Electronic
Controller.
The Hydro-Hot will automatically restart once the electrical overload (i.e.
short) and/or high heat condition is corrected.
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Page 7
Section 5: Diesel-Burner
Component 5.1 Component Overview

Overview
1. Control Unit 10. Heat Exchanger

2. Motor 11. Combustion Chamber
3. Ignition Coil 12. Exhaust Port
4. Clutch 13. Flame Sensor
5. Combustion Air Blower 14. Fuel Pump
6. Fuel Solenoid 15. Fuel Ports (Supply / Return)
7. Electrode Holder 16. Combustion Air Intake Port,
8. Ignition Electrodes with Adjustable Shutter
9. Fuel Nozzle
Figure 6
Page 8 R
Operational 5.2 Operational Flow-Chart

Flow-Chart ~ Reference Figure 6 for all numbers indicated inside parenthesis. (e.g. #8).
Operation sequence once the Simultaneously the Ignition Once the heater switches OFF,
Hydro-Hot’s Diesel switch is Coil (#3) produces a high thermostatically or manually,
turned ON. voltage spark across the the Fuel Solenoid (#6) closes,
Ignition Electrodes (#8), which interrupts the supply of
NOTE: diesel fuel to the Fuel Nozzle
The Diesel switch’s Indicator which ignites the incoming
air-fuel mixture. (#9).
Light will illuminate (reference
Figure 4), while the Hydro-Hot
Heating Status and Diesel-
Burner Status lights illuminate
on the Electronic Controller, Once the ignited air-fuel The Motor (#2) will continue
reference Figure 5. mixture (FLAME) is observed to run for approximately three
by the Flame Sensor (#13), (3) additional minutes. This
the Ignition Coil (#3) will process is refered to as the
automatically switch OFF. The purge-cycle, which cools
combustion process now down the heater’s internal
continues to operate components and purges the
unassisted. Combustion Chamber (#11)
of any residual exhaust
gases.
The Motor (#2), which turns NOTE:
The combustion process will When the Hydro-Hot’s Diesel-
the Combustion Air Blower
continue to operate in this Burner is switched OFF, by the
(#5) and drives the Fuel Pump
manner until one of the following VDC / VAC Control Thermostat
(#14), will begin to operate.
take’s place: (see Figure 3), the following
NOTE: process will take place:
If the Hydro-Hot’s coolant A.) The VDC / VAC Control
temperature is approximately Thermostat (see Figure 3), 1.) The Motor (#2) will shut-off
190 (+/- 5 deg.) degrees which senses coolant once the three (3) minute purge-
fahrenheit, or higher, the Motor temperature, reaches the preset cycle has expired.
(#2) will not operate. Only temperature of approximately -THEN-
when the coolant temperature 190 (+/-5 deg.) degrees 2.) The Hydro-Hot’s Diesel-
has dropped below 160 (+/- 5 fahrenheit. Burner will automatically turn
deg.) degrees fahrenheit, and back ON once the coolant
the VDC / VAC Control
NOTE: temperature reaches the preset
If process "A" occurs, the Low temperature of approximately
Thermostat (see Figure 3) is
Temp Cutoff Status, Hydro-Hot 160 (+/- 5 deg.) degrees
calling for heat, will the Motor
Heating Status, and Diesel- fahrenheit.
(#2) begin to operate.
Burner Status lights on the
Electronic Controller will go
OFF, reference Figure 5.
B.) The Hydro-Hot’s Diesel SUMMARY:

switch is turned OFF. The Hydro-Hot’s Diesel-Burner
NOTE: is operational anytime the
If process "B" occurs, the Diesel operator activates the Diesel
switch’s Indicator Light, on the switch (reference Figure 4) to
After approximately 10 - 25 Switch Panel (reference Figure the ON position. The Diesel-
seconds, the Fuel Solenoid 4), will go OFF along with the Burner will then automatically
(#6) opens and fuel is Hydro-Hot Heating Status, maintain the coolant
sprayed into the Diesel-Burner Status, and Stir temperature in the Hydro-Hot’s
Combustion Chamber (#11) Pump lights on the Electronic Boiler Tank without additional
through the Fuel Nozzle (#9). Controller, reference Figure 5. involvement from the operator.
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Page 9
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.
KEY
Diesel Fuel Spray
Combustion Air Exhaust Gases
The particular component begins to operate.
The component is currently operating.
Diesel-Burner Operation
When the Diesel switch is turned ON, the Motor
Combustion
1
and Combustion Air Blower begin to operate. This
process is referred to as the prime-cycle. Air Blower
Motor
NOTE: The Motor and Combustion

Air Blower will begin to operate
only if the VDC / VAC Control
Thermostat is closed and calling
for heat, reference Figure 3. Combustion
Air
The Fuel Pump builds up pressure
against the Fuel Solenoid. After
2
approximately 10 - 25 seconds, the Fuel
Solenoid opens and fuel is released into
the Fuel Nozzle and then sprayed into the
Combustion Chamber.
Fuel Nozzle Fuel Solenoid
Combustion Diesel Fuel

Chamber Fuel Pump (Supply and Return)
Page 10 R
Operational
Sequence,
continued
KEY
Diesel Fuel Spray
Combustion Air Exhaust Gases
Diesel-Burner Operation, continued

The Ignition Coil produces a high voltage spark, which is transferred
3
across the Ignition Electrodes. The incoming air-fuel mixture is then
ignited, creating combustion.
Ignition Coil
Ignition
Electrodes
Combustion
The combustion’s flame is detected by the
4
Flame Sensor and the Ignition Coil is then
automatically switched off (no more spark
across the Ignition Electrodes).
Flame
Hot Exhaust Sensor
Gases
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Page 11
Operational
Sequence
continued
KEY
Diesel Fuel Spray
Combustion Air
Diesel-Burner Operation, continued

The Diesel-Burner will continue to operate continuously in this manner
5
(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.
Once the Diesel-Burner has switched
6
OFF, the Motor and Combustion Air
Blower will continue to operate for approx.
2-3 minutes. This process is referred to
as the purge-cycle.
Cool Exhaust
Gases
NOTE: If the Diesel-Burner is switched off by the VDC / VAC

Control Thermostat, it will automatically reactivate the Diesel-
Burner whenever the Hydro-Hot Boiler Tank’s coolant temperature
has dropped below 160 (+/- 5 deg.) degrees fahrenheit.
Page 12 R
I.D. Plate 5.4 Identification Plate
Fabrikschild-Duplikat To be shipped with

gultig nur zusammen mit Original Original Heater
Thermosysteme GmbH
MADE IN GERMANY
HEIZGERAT Typ DBW 2010.75 Model Type

Spannung / El. Leistung 12 V / 60W Voltage / Wattage
Warmestrom 13,2 kW
Brennstoff Diesel Fuel Type
zul. Betriebsuberdruck 2 bar
Prufzeichen
Fabriknummer 1B230410 Serial Number (230410)
Inbetriebnahmejahr 2001 2002 2003 Year Manufactured
Diesel-Burner
I.D. Plate
Diesel-Burner
Head
Figure 7
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Page 13
Section 6: Diesel Burner Wiring
Control 6.1 Control Unit Wiring

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 C-4 ( - ) VDC High-Limit Thermostat
Wire) to JP-4, (Pin 2). Circuit (Blue Wire) to Hydro-Hot’s
Boiler Tank.
B-2 ( - ) Battery Circuit (Brown Wire)
to JP-4 (Pin 4)
B-1 ( + ) On / Off Switch

Circuit, with Low Voltage
Protection (Yellow Wire) to
JP-4 (Pin 7).
B-Plug B-1 B-2 B-3 C-1 C-2 C-4 C-Plug

B-4 B-6 C-5 C-6 C-7 C-8
C-8 ( + ) Ignition Coil Circuit (Yellow Wire)

to Diesel-Burner.
B-4 ( + ) Battery Circuit (Red Wire)
to JP-4 (Pin 3) C-7 ( + ) VDC / VAC Control Thermostat Circuit
(White Wire) to JP-4 (Pin 6).
B-6 ( - ) Indicator Light Circuit
(Green Wire) to JP-4 (Pin 1).
C-6 ( + ) Flame Sensor Circuit (Green Wire)
to Diesel-Burner.
C-5 ( - ) Ground Circuit (Brown Wire), for

Diesel-Burner components, to Diesel-Burner.
Figure 8
Page 14 R
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. However, if you need additional assistance,
please feel free to contact our Technical Department at 1-800-685-4298 or e-mail them by going to
www.vehiclesys.com and clicking on the Technical Support button. Also, please review the following
"KEY", prior to troubleshooting, as it may be helpful in understanding each nomenclature.
KEY:
TS#: (i.e. TS1, TS2, ....) = Troubleshooting Scenario 1, Troubleshooting Scenario 2, ....
Q#: (i.e. Q1, Q2,....) = Question 1, Question 2, ....
A: = Answer
After turning the Diesel switch ON: Section

TS1 - The Hydro-Hot's Diesel-Burner does not operate. ................................................................. 7.1
TS2 - The Hydro-Hot's Diesel-Burner operates (3-minute prime cycle only), ...................................
but does not ignite. ................................................................................................................ 7.2
TS3 - The Hydro-Hot's Diesel-Burner ignites after several starting attempts. .................................. 7.3
TS4 - The Hydro-Hot's exhaust system sputters. ............................................................................ 7.4
TS5 - The Hydro-Hot's exhaust system produces white smoke after ignition. ................................. 7.5
TS6 - The Hydro-Hot's exhaust system produces black smoke after ignition. ................................. 7.6
Other troubleshooting issues:
TS7 - The Hydro-Hot is at operating temperature, but an Interior and/or Fresh ...............................
Water Tank Heating Zone is not producing heat. .................................................................. 7.7
TS8 - The Hydro-Hot is at operating temperature, but the fans of an Interior ..................................
and/or Fresh Water Heat Exchangers are not operating. ....................................................... 7.8
TS9 - The Hydro-Hot is at operating temperature, but the domestic hot water
system is not producing hot water. ........................................................................................ 7.9
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). ............................................................................. 7.10
After turning the Engine Preheat switch ON:

TS11 - The Hydro-Hot's Engine Preheat System does not preheat the engine. ................................ 7.11
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Page 15
Section 7.1 Section 7.1,

continued
After turning the Diesel switch ON:
TS1: The Hydro-Hot's Diesel-Burner does not

operate.
� ��
��
TM R
Electronic
Controller
NOTE: In order to perform the following checks, Emergency

Cutoff
it is necessary to locate the Hydro-Hot's Elec- Electric Heating Low Voltage
tronic Controller and Switch Panel.
Hydro-Hot
Element Status
Heating Status
Reset
Q1: Is the Electronic Controller's Emergency #5 Engine Preheat

Pump
Cutoff light Illuminated? #4
A: If YES: Circulation
Pump #1
Perform each of the following Heating Zones
Status
#3
procedures as necessary until the Circulation
problem is resolved.
#2 Pump #2
If NO: #1
Proceed to Q2. Stir Pump
Low Battery
WARNING: DO NOT remove the Voltage Fault Diesel-Burner

Status
Hydro-Hot's Radiator Cap when the

Low Temp
Cutoff Status
heater is at maximum operating Overload Fault
temperature, reference Figure 1.

Hot coolant can be present and
serious personal injury may result.
a. Check the coolant level in the Hydro-Hot's
Faceplate
Expansion Tank, and then the Boiler Tank if
necessary.
A: If coolant level is okay:
Continue troubleshooting.
If coolant level is low:
Add coolant and attempt heater
restart.
b. Check for continuity at the Float Switch, � ��
��
TM R
By Vehicle Systems
reference Figures 1 and 3.
A: If continuity exists: Diesel-Burner’s
Continue troubleshooting. Indicator
Light
If continuity does not exist:
The Float Switch must be replaced.
Please contact our Technical Depart- Diesel Electric Engine
Preheat
ment at 1-800-685-4298 for assis-
tance.
c. Remove the Electronic Controller's Faceplate Switch Panel
and use a jumper wire to make a connection
from Pin 15 to Pin 16 on the JP-3 Plug,
reference Figure 3. Does the Emergency
Cutoff light go off?
Page 16 R
Section 7.1, Section 7.1,

continued continued
A: If YES: and/or loose connections, and

Check the JP-3 Plug for loose wire ensure that all of the Hydro-Hot's
connections and/or harness damage. electrical motors are operating
If NO: normally when under load.
The Electronic Controller must be
replaced. Please contact our Techni- NOTE: If after testing and correcting the battery
cal Department at 1-800-685-4298 for system, the Low Battery Voltage Fault indicator
assistance. light continues to illuminate, and/or if the Low
Voltage Reset (button) will not reset, the Elec-
Q2: Is the Electronic Controller's Low Battery tronic Controller must be replaced. Please
Voltage Fault light illuminated? contact our Technical Department at 1-800-
A: If YES: 685-4298 for assistance.
Perform each of the following
procedures as necessary until the Q3: Is the Electronic Controller's Diesel-
problem is resolved. Burner Status light illuminated?
If NO: A: If NO:
Proceed to Q3. Perform each of the following
procedures as necessary until the
a. Remove the Electronic Controller's Faceplate. problem is resolved.
Check the DC battery voltage level at the If YES:
supply batteries and at the Electronic Proceed to Q5.
Controller's Battery Connections, reference
Figure 3. Both voltage readings should be a. Remove the Electronic Controller's Faceplate.
between 11.5 and 14.0 volts. Use a jumper wire to make a connection from
A: If the voltage level is within specs: the Diesel (+) to the Diesel (-) on the JP-2
Continue troubleshooting. Plug, reference Figure 3. Does the Diesel-
If the voltage level is out of specs: Burner Status light illuminate?
Recharge and/or replace batteries, if A: If YES:
necessary. The Diesel switch must be replaced.
b. Reset the Low Voltage Reset (button) on the Please contact our Technical Depart-
Electronic Controller (this can be accom- ment at 1-800-685-4298 for assis-
plished by using a thin straight object to tance. Attempt heater restart.
access the reset button through the small If NO:
hole in the Faceplate). Continue to read the Continue troubleshooting.
voltage level at the Electronic Controller's b. Turn the Diesel switch OFF (also, make sure
Battery Connections and then turn the Diesel the Electric switch is OFF ). Use a jumper
switch ON. Under load, is the voltage level wire to make a connection from Pin 13 to Pin
within 0.5 volts of the supply battery's volt- 14 on the JP-3 Plug, reference Figure 3. With
age? the jumper wire in place, turn the Diesel
A: If YES: switch ON. Does the Diesel-Burner ignite and
See the "NOTE" at the top right of the Diesel-Burner Status light illuminate?
this page. A: If YES:
If NO: The VDC / VAC Control Thermostat
Load-test the supply batteries, must be replaced, reference Figure
inspect battery wiring for damage 3. Please contact our Technical
R
Page 17

continued continued
Department at 1-800-685-4298 for

assistance.
If NO:
The Electronic Controller must be
replaced. Please contact our Techni-
cal 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 5.2, the "Operational Sequence" Diesel-Burner
Control
in Section 5.3, and the "Function" section for Unit
each of the Diesel-Burner Components, Diesel-Burner
reference Sections 8.3 thru 8.11. This informa- Head
tion may help determine at what point the
Diesel-Burner fails to operate.
Ignition Coil
Q4: Is the Diesel-Burner's Motor operating?
Quick Check - Listen at the heater for the
Diesel-Burner's Motor to operate, or check for Ignition
Photo Disc
Electrodes
output air at the heater's exhaust pipe.
A: If the Motor does not seem to be operating: Fuel Solenoid
Flame Sensor
Reference Section 8.3 and perform
the Motor's "Component Test".
If the Motor is operating: Fuel Pump
Q5: Is the Diesel-Burner's Control Unit func-

tioning properly?
In order to determine if the Control Unit is
functioning properly, reference Section 8.11
and perform the Control Unit's "Component Control
Fuel
Unit
Test". Nozzle
A: If the Control Unit is not functioning prop-
erly:
The Control Unit must be replaced,
reference Section 8.11 for replace-
ment instructions.
If the Control Unit is functioning properly:
See the "NOTE" on the top left-hand
side of the following page.
Page 18 R

continued continued
a. Turn the Diesel switch ON and allow the

NOTE: If the Hydro-Hot still does not operate
after performing all of the listed checks, contact Hydro-Hot to reach operating temperature
our Technical Department at 1-800-685-4298 for (i.e. until the Diesel-Burner cycles OFF).
additional assistance. Locate both the VDC High-Limit Thermostat
and the VAC / VDC Control Thermostat and
check them for continuity, reference Figure 1.
A: If there is no continuity at the VDC High-
Section 7.2 Limit Thermostat, but there is continuity at
After turning the Diesel switch ON: the VAC / VDC Control Thermostat:
The VAC / VDC Control Thermostat
TS2: The Hydro-Hot's Diesel-Burner operates must be replaced. Please contact
(3-minute prime cycle only), but does our Technical Department at 1-800-
not ignite. 685-4298 for assistance.
If there is continuity at the VDC High-Limit
NOTES: Thermostat, but none at the VAC / VDC
A. It is ideal to have the Hydro-Hot's Fuel Filter Control Thermostat:
replaced yearly, reference Section 8.1. A The overheat condition may have
plugged Fuel Filter will not allow the Diesel- been caused by another faulty
Burner to operate properly. Also, before component and no further trouble-
proceeding on to the following procedures, shooting is necessary, see the
be sure to check that the vehicle's fuel "NOTE" below and please contact
tank has a sufficient level of fuel. our Technical Department at 1-800-
685-4298 for additional assistance.
B. In order to perform some of the following
procedures it may be necessary to detach NOTE: If the VDC High-Limit Thermostat
the Diesel-Burner Head from the Hydro-Hot. continues to trip, and no overheating problems
Therefore, be sure to reference Section 8.2 were discovered (i.e. faulty VAC / VDC Control
for detaching and reattaching instructions. Thermostat or Control Unit), it may be that the
VDC High-Limit Thermostat is not operating
Q1: Has the Hydro-Hot's VDC High-Limit Ther- properly and it may need to be replaced.
mostat tripped?
Locate the VDC High-Limit Thermostat and Q2: Is the Diesel-Burner's Fuel Nozzle func-
check for continuity, reference Figure 1. Is tioning properly?
continuity present? In order to determine if the Fuel Nozzle is
A: If YES: functioning properly, reference Section 8.6
Proceed to Q2. and perform the Fuel Nozzle's "Component
If NO: Test".
Press the red reset button located on A: If the Fuel Nozzle is not functioning
the VDC High-Limit Thermostat and properly:
attempt heater restart. The Fuel Nozzle must be replaced,
NOTE: Although the Diesel-Burner is now ment instructions.
functioning, be sure to perform the following If the Fuel Nozzle is functioning properly:
steps until the cause for overheating has been Continue Troubleshooting.
discovered and corrected. Failure to do so
could result in another overheating condition.
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Page 19

continued continued
Q3: Is the Diesel-Burner's Fuel Solenoid

functioning properly?
In order to determine if the Fuel Solenoid is
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.
Diesel-Burner
Q4: Is the Diesel-Burner's Control Unit func- Control
tioning properly? Unit
In order to determine if the Control Unit is Diesel-Burner

Head
and perform the Control Unit's "Component
Test".
A: If the Control Unit is not functioning prop- Ignition Coil
erly:
The Control Unit must be replaced, Ignition
Photo Disc
reference Section 8.11 for replace- Electrodes
ment instructions.
Fuel Solenoid
If the Control Unit is functioning properly: Flame Sensor
Fuel Pump
Q5: Is the Diesel-Burner's Ignition Coil func-
tioning properly?
In order to determine if the Ignition Coil is
and perform the Ignition Coil's "Component
Test".
A: If the Ignition Coil is not functioning
Control
properly: Unit Fuel
Nozzle
The Ignition Coil must be replaced,
ment instructions.
If the Ignition Coil is functioning properly:
Q6: Are the Diesel-Burner's Ignition Electrodes

in good condition and properly adjusted?
Page 20 R

continued continued
In order to determine if the Ignition Electrodes NOTE: If the Hydro-Hot still does not ignite after
are in good condition and properly adjusted, performing all of the listed checks, contact our
reference Section 8.5. Technical Department at 1-800-685-4298 for
A: If the Ignition Electrodes are in poor additional assistance.
condition:
The Ignition Electrodes must be
replaced, reference Section 8.5 for
replacement instructions.
If the Ignition Electrodes are not properly
Section 7.3
adjusted:
Adjust the Ignition Electrodes,
reference Section 8.5 for adjustment After turning the Diesel switch ON:
instructions.
If the Ignition Electrodes are both in good
condition and properly adjusted: TS3: The Hydro-Hot's Diesel-Burner ignites
Continue Troubleshooting. after several starting attempts.
NOTES:
Q7: Is the Diesel-Burner's Flame Sensor A. It is ideal to have the Hydro-Hot's Fuel Filter
functioning properly? replaced yearly, reference Section 8.1. A
In order to determine if the Flame Sensor is plugged Fuel Filter will not allow the Diesel-
functioning properly, reference Section 8.4 Burner to operate properly. Also, before
and perform the Flame Sensor's "Component proceeding to the following procedures,
Test". be sure to check that the vehicle's fuel
A: If the Flame Sensor is not functioning tank has a sufficient level of fuel.
properly:
The Flame Sensor must be replaced, B. In order to perform the following procedures,
reference Section 8.4 for replace- it is necessary to detach the Diesel-Burner
ment instructions. Head from the Hydro-Hot. Be sure to
If the Flame Sensor is functioning prop- reference Section 8.2 for detaching and
erly: reattaching instructions.
Q1: Is the Diesel-Burner's Fuel Nozzle function-
Q8: Is the Diesel-Burner's Fuel Pump functioning properly?
ing properly? In order to determine if the Fuel Nozzle is
In order to determine if the Fuel Pump is functioning properly, reference Section 8.6
functioning properly, reference Section 8.8 and perform the Fuel Nozzle's "Component
and perform the Fuel Pump's "Component Test".
Test". A: If the Fuel Nozzle is not functioning
A: If the Fuel Pump is not functioning prop- properly:
erly: The Fuel Nozzle must be replaced,
The Fuel Pump must be replaced, reference Section 8.6 for replacement
reference Section 8.8 for replace- instructions.
ment instructions. If the Fuel Nozzle is functioning properly:
If the Fuel Pump is functioning properly: Continue Troubleshooting.
See the "NOTE" below.
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Page 21

continued continued
Q2: Is the Diesel-Burner's Flame Sensor func-

tioning properly?
In order to determine if the Flame Sensor is
and perform the Flame Sensor's "Component
Test".
A: If the Flame Sensor is not functioning
properly:
The Flame Sensor must be replaced,
ment instructions.
If the Flame Sensor is functioning properly:
Diesel-Burner
Control
Q3: Are the Diesel-Burner's Ignition Electrodes Unit
in good condition and properly adjusted? Diesel-Burner
In order to determine if the Ignition Electrodes Head
are in good condition and properly adjusted,
reference Section 8.5.
A: If the Ignition Electrodes are in poor
Ignition Coil
condition:
The Ignition Electrodes must be
replaced, reference Section 8.5 for Ignition
Photo Disc
Electrodes
replacement instructions.
If the Ignition Electrodes are not properly Fuel Solenoid
Flame Sensor
adjusted:
Adjust the Ignition Electrodes,
reference Section 8.5 for adjustment Fuel Pump
instructions.
If the Ignition Electrodes are both in good
condition and properly adjusted:
Q4: Is the Diesel-Burner's Fuel Pump function-

ing properly? Control
Fuel
Unit
In order to determine if the Fuel Pump is Nozzle
and perform the Fuel Pump's "Component
Test".
A: If the Fuel Pump is not functioning
properly:
The Fuel Pump must be replaced,
ment instructions.
If the Fuel Pump is functioning properly:
Page 22 R

continued continued
Fuel Filter Continue Troubleshooting.
Q5: Is the Diesel-Burner's Fuel Supply System

Quick Check - With the Diesel-Burner ignited,
listen for constant sputtering from the Hydro-
Hot's exhaust system.
A: If constant sputtering exists:
If constant sputtering does not exist:
Proceed to Q6.
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
TOP VIEW: the Fuel Filter. Attempt heater restart.
of Fuel Filter Head
Plug a. Clamp off and remove the Hydro-Hot's Fuel
Return Line, reference Figure 1. Now attach
2 4 output to
Hydro-Hot’s Fuel
a short piece of fuel line to the Hydro-Hot's
"Supply" Port Fuel Return Port and place the other end in a
input 1 3
from Fuel Tank /
container of diesel fuel. Remove the clamp
fuel pick-up Plug
and ensure that the fuel line is completely
submersed in the fuel and then turn the Diesel
switch ON. Are air bubbles visible in the
container of fuel when the Diesel-Burner is
operating?
A: If air bubbles are not visible:
SUPPLY PORT: RETURN PORT: Proceed to Q6.
to Hydro-Hot’s from Hydro-Hot’s
If air bubbles are visible:
Fuel Filter "Return" Port
You will need to inspect the fuel
dedicated system (supply side) for air leaks.
fuel pick-up
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 Hydro-Hot,
Diesel-Burner, and at the vehicle's
fuel tank for looseness. Tighten if
necessary. Also, check that all
Fuel Pick-up Pipe Illustration Fuel Filter Head fittings are se-
curely tightened; see the "NOTE"
at the top left-hand side of the
following page.
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Page 23

continued continued

NOTE: Be sure to check that each fitting at the
ment instructions.
Fuel Filter Head contains thread sealant. A
If the Ignition Coil is functioning properly:
fitting without thread sealant could result in an
See the "NOTE" below.
air leak. Be sure to clamp off both fuel lines at
the filter head prior to any fitting removal. If
NOTE: If the Hydro-Hot still does not ignite
fittings are removed and reinstalled, be sure to
after several starting attempts and all of the
remove the fuel line clamps prior to attempting a
listed checks were performed, contact our
heater restart. Failure to do so could result in
Technical Department at 1-800-685-4298 for
serious damage to the Diesel-Burner's Fuel
additional assistance.
Pump.
2. Once the potential air leak has
been discovered and corrected, Ignition Coil
reattach the Hydro-Hot's Fuel
Return Line and attempt heater
restart. Does the Hydro-Hot's ex- Ignition
Electrodes
Photo Disc
haust system still sputter?
If the exhaust system is still sputtering: Flame Sensor
Fuel Solenoid
Perform the air leak inspections
again, until all air leaks have been
discovered and corrected. Fuel Pump
Q6: Is the Diesel-Burner's Control Unit func-

tioning properly?
In order to determine if the Control Unit is
and perform the Control Unit's "Component
Test". Control
Fuel
Unit
A: If the Control Unit is not functioning Nozzle
properly:
The Control Unit must be replaced,
ment instructions.
If the Control Unit is functioning properly:
Q7: Is the Diesel-Burner's Ignition Coil func-

tioning properly?
In order to determine if the Ignition Coil is
and perform the Ignition Coil's "Component
Test".
A: If the Ignition Coil is not functioning prop-
erly:
The Ignition Coil must be replaced,
Page 24 R

continued
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 func-

tioning properly?
In order to determine if the Fuel Nozzle is
and perform the Fuel Nozzle's "Component
Test".
A: If the Fuel Nozzle is not functioning
properly:
The Fuel Nozzle must be replaced,
ment instructions. TOP VIEW:
If the Fuel Nozzle is functioning properly: of Fuel Filter Head
Continue Troubleshooting. Plug
2 4 output to
Q2: Is the Diesel-Burner's Fuel Supply System Hydro-Hot’s Fuel
functioning properly? "Supply" Port
input 3
Quick Check - With the Diesel-Burner 1
from Fuel Tank /
ignited, listen for constant sputtering from the fuel pick-up Plug
Hydro-Hot's exhaust system.
A: If constant sputtering exists:

for water. If water exists, be sure to purge the SUPPLY PORT: RETURN PORT:
Hydro-Hot's entire fuel system prior to replacing to Hydro-Hot’s from Hydro-Hot’s
Fuel Filter "Return" Port
the Fuel Filter. Attempt heater restart.
dedicated
fuel pick-up
a. Clamp off and remove the Hydro-Hot's Fuel
Fuel Return Port and place the other end in a
submersed in the fuel and then turn the
Diesel switch ON. Are air bubbles visible in
the container of fuel when the Diesel-Burner
is operating?
A: If air bubbles are not visible: Fuel Pick-up Pipe Illustration
See the last "NOTE" in this section
(Section 7.4).
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Page 25

continued continued
If air bubbles are visible: Fuel Filter

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:
fuel connections at the Hydro-
Hot, Diesel-Burner, and at the
vehicle's fuel tank for looseness.
Tighten if necessary. Also, check
that all Fuel Filter Head fittings
are securely tightened, see the
"NOTE" below. TOP VIEW:
of Fuel Filter Head
NOTE: Be sure to check that each fitting at the Plug
fitting without thread sealant could result in an 2 4 output to
air leak. Be sure to clamp off both fuel lines at Hydro-Hot’s Fuel
"Supply" Port
the filter head prior to any fitting removal. If input 1 3
fittings are removed and reinstalled, be sure to from Fuel Tank /

remove both clamps prior to attempting a fuel pick-up Plug
serious damage to the Diesel-Burner's Fuel
Pump.
been discovered and corrected, SUPPLY PORT: RETURN PORT:
to Hydro-Hot’s from Hydro-Hot’s
reattach the Hydro-Hot's Fuel Fuel Filter "Return" Port
Return Line and attempt heater
dedicated
restart. Does the Hydro-Hot's ex- fuel pick-up
haust 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.
NOTE: If the Hydro-Hot's exhaust system still

sputters after performing all of the listed checks,
contact our Technical Department at 1-800-685-
4298 for additional assistance.
Fuel Pick-up Pipe Illustration
Page 26 R

continued
TS5: The Hydro-Hot's exhaust system pro-

duces white smoke after ignition.
Q1: Is the Diesel-Burner's Fuel Nozzle func-
tioning properly?
Test".
properly:
reference Section 8.6 for replacement
instructions.
If the Fuel Nozzle is functioning properly: Diesel-Burner
Control
Continue Troubleshooting. Unit
Diesel-Burner
Q2: Is the Diesel-Burner's Fuel Pump produc- Head
ing the proper pressure?
In order to determine if the Fuel Pump is
producing the proper pressure, reference
Ignition Coil
Section 8.8 and perform the Fuel Pump's
"Fuel Pressure Adjustment Check".
A: If the Fuel Pump is not producing the Ignition
Photo Disc
Electrodes
correct pressure:
Adjust the fuel pressure to 145 psi. Fuel Solenoid
Flame Sensor
If the Fuel Pump is producing the correct
pressure:
Continue Troubleshooting. Fuel Pump
NOTE: Be sure to check that the Ignition

Electrode's Retaining Clamp Bolt has not been
overtightened, reference Figure 16. Overtighten-
ing can result in a bound-up (i.e. rigid) Photo
Disc. Not allowing the Photo Disc to float freely
(i.e. a loose fit) will cause poor combustion and Control
Unit Fuel
result in a smoky exhaust. If a tight Photo Disc Nozzle
exists, reference Section 8.5 and perform the
"Ignition Electrode Adjustment Procedure".
Q3: Is the Diesel-Burner's Fuel Supply System
Quick Check - With the Diesel-Burner
ignited, look for constant white smoke from
the Hydro-Hot's exhaust system.
A: If constant white smoke exists:
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Page 27

continued continued
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

Fuel Return Port and place the other end in a
submersed in the fuel and then turn the
Diesel switch ON. Are air bubbles visible in
the container of fuel when the Diesel-Burner
is operating?
TOP VIEW:
A: If air bubbles are not visible:
of Fuel Filter Head
Proceed to Q6.
Plug
If air bubbles are visible:
You will need to inspect the fuel 2 4 output to
system (supply side) for air leaks. Hydro-Hot’s Fuel
Therefore, be sure to perform the "Supply" Port
input 1 3
inspections listed below until the air from Fuel Tank /
leak has been detected: fuel pick-up Plug
fuel connections at the Hydro-
Hot, Diesel-Burner, and at the SUPPLY PORT: RETURN PORT:
vehicle's fuel tank for looseness. to Hydro-Hot’s from Hydro-Hot’s
Tighten if necessary. Also, check Fuel Filter "Return" Port
that all Fuel Filter Head fittings dedicated
are securely tightened, see the fuel pick-up
"NOTE" below.
NOTE: Be sure to check that each fitting at the
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 both clamps prior to attempting a
serious damage to the Diesel-Burner's Fuel Fuel Pick-up Pipe Illustration
Pump.
Page 28 R

continued continued

� ��
��
TM R
been discovered and corrected, Electronic

Controller
reattach the Hydro-Hot's Fuel
Return Line and attempt heater Emergency
Cutoff
restart. Does the Hydro-Hot's ex- Electric Heating Low Voltage Hydro-Hot
Element Status
haust system still sputter? Reset
Heating Status
If the exhaust system is still sputtering:

Perform the air leak inspections #5 Engine Preheat
Pump
again, until all air leaks have been #4
discovered and corrected. Circulation

Pump #1
Heating Zones #3
Status
NOTE: If the Hydro-Hot's exhaust system still Circulation
produces white smoke after performing all of the

#2 Pump #2
listed checks, contact our Technical Department #1
at 1-800-685-4298 for additional assistance. Stir Pump
Low Battery
Status
Low Temp
Section 7.6 Cutoff Status
Overload Fault

TS6: The Hydro-Hot's exhaust system pro- Faceplate
duces black smoke after ignition.
Q1: Is the Electronic Controller's Low Battery
Voltage Fault light illuminated?
A: If YES:
problem is resolved. � ��
��
TM R
By Vehicle Systems
If NO:
Proceed to Q2. Diesel-Burner’s
Indicator
Light
a. Remove the Electronic Controller's Faceplate.
Check the DC battery voltage level at the
Diesel
supply batteries and at the Electronic Electric Engine
Preheat
Controller's Battery Connections, reference
Figure 3. Both voltage readings should be
between 11.5 and 14.0 volts.
A: If the voltage level is within specs:
If the voltage level is out of specs:
Recharge and/or replace batteries, if
necessary.
R
Page 29

continued 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 Connec-
tions and then turn the Diesel switch ON.
Under load, is the voltage level within 0.5
volts of the supply batteries voltage?
A: If YES:
See the first "NOTE" below.
If NO:
Load-test the supply batteries, Diesel-Burner
Control
inspect battery wiring for damage Unit
and/or loose connections, and Diesel-Burner
ensure that all of the Hydro-Hot's Head
electrical motors are operating

normally when under load.
Ignition Coil
NOTE: If after testing and correcting the battery
system, the Low Battery Voltage Fault indicator
Ignition
light continues to illuminate, and/or if the Low Electrodes
Photo Disc
Voltage Reset (button) will not reset, the

Electronic Controller must be replaced. Flame Sensor
Fuel Solenoid
Please contact our Technical Department at 1-

800-685-4298 for assistance.
Fuel Pump
NOTE: In order to perform some of the follow-

ing procedures it may be necessary to detach
the Diesel-Burner Head from the Hydro-Hot.
Therefore, be sure to reference Section 8.2 for
detaching and reattaching instructions.
Q2: Is the Diesel-Burner's Fuel Nozzle func- Control

Unit Fuel
tioning properly? Nozzle

Test".
properly:
ment instructions.
Page 30 R

continued continued
If the Fuel Nozzle is functioning properly:

Q3: Is the Diesel-Burner's Motor operating at

#3 - Plunger
the proper RPM speed? #4 - Rubber Ball
CO2 Gas
In order to determine if the Motor is operating Analyzer
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, refer-
ence Section 8.3 for replacement
instructions.
If the Motor is operating at the proper
RPM:
Q4: Is the Diesel-Burner's Combustion Air

Intake adjusted properly?
A: See the "NOTE" below.
NOTE: Inorder to determine if the Diesel-

Burner's Combustion Air Intake is adjusted
properly, a CO2 Gas-Analyzer will be required, CO2 - + CO2
reference the illustration on this page. Also,

reference Section 11 for the Bacharach Fyrite
CO2 Analyzer's part number information, if
necessary.
Combustion Air Intake
a. When using the Bacharach Fyrite CO2 Ana- Adjustment
lyzer, turn the Diesel switch ON and allow the
Diesel-Burner to ignite. Then perform the Vol %
following procedures:
1. Place the small end of the CO2 13
Analyzer's suction hose into the 12
Hydro-Hot's Exhaust Pipe. 11

2. Place the round plunger connec- 10
tion of the suction hose on the CO2
9
Percentage
CO2 Analyzer's "Plunger". Press 8
down on the suction hose, with
7
the palm of your hand, so that the
CO2 Analyzer's Plunger" is fully 20 22 24 26 28
V-
10 12 14
compressed. This will allow a DC Voltage Level
sample of the Hydro-Hot's ex-
CO2 - Value Chart
haust to enter the CO2 Analyzer.
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Page 31

continued continued
3. Pump the rubber ball - 18 times. Fuel Pump is producing the proper
4. Release the suction hose from the pressure. In order to determine if the
CO2 Analyzer's plunger. Fuel Pump is producing the proper
5. Turn the CO2 Analyzer upside pressure, reference Section 8.8 and
down so that the fluid runs to the perform the Fuel Pump's "Fuel Pressure
top and then turn it right side up Adjustment Check".
again. Perform this procedure D. Check and reset the Combustion Air
twice. Blower gap, if applicable. In order to
6. Place the CO2 Analyzer on a flat determine if the Combustion Air Blower's
surface and read the CO2 level. gap is set properly, reference Section 8.9
7. The CO2 level should be between and perform Steps 1-6 and 11-17 of the
10.5 and 11.5 percent (at a nomi- Bearings "Replacement Procedure".
nal 12 volts DC). If the CO2 level is E. See the "NOTE" below.
not within specs, an adjustment of
the Diesel-Burner's Combustion NOTE: If the Hydro-Hot's exhaust system still
Air Intake will be necessary, produces black smoke after performing all of
reference the illustration on the the listed checks, contact our Technical Depart-
previous page. Once the proper ment at 1-800-685-4298 for additional assis-
CO2 adjustment has been made, tance.
be sure to tighten the adjustment
screw.
NOTE: For temporary high altitude situations

(less available oxygen) the CO2 will rise by
0.3% CO2 per 1,000 feet of elevation. (e.g. a
Diesel-Burner adjusted at sea level should
register approximately a 1.5% higher CO2
reading when in Denver, Colorado {5,000
above sea level}). If permanently residing in a
high altitude area, be sure to properly adjust
the Diesel-Burner so that it operates within the
10.5% - 11.5% CO2 range.
NOTES: If the proper CO2 - value cannot be

obtained, perform each of the following inspec-
tions as necessary until the cause has been
detected:
A. Check the rubber Grommets on the top
and bottom of the Diesel-Burner Head's
cast-aluminum Blower Casing to ensure
they are securely in place.
B. Check the Diesel-Burner Head for proper
alignment. (torque specification = approx.
20-40 in. lbs.), reference Section 8.2.
C. Check to ensure that the Diesel-Burner's
Page 32 R

continued
TS7: The Hydro-Hot is at operating tempera-

2. Locate the Electronic Controller's
ture, but an Interior and/or Fresh Water
JP-3 Plug and then insert the
Tank Heating Zone is not producing heat.
probes of a DC voltmeter into
Q1: Is the particular Heating Loop's Circula- Pin locations 5 (+) and 6 (-) for
tion Pump operating? Circulation Pump #1, and/or into
Quick Check - Remove the Hydro-Hot's Pin locations 3 (+) and 4 (-) for
Access Cover and determine if the problem Circulation Pump #2, reference
Heat Exchanger(s) are plumbed with Circula- Figure 3. Observe the DC voltage
tion Pump #1 or Circulation Pump #2, refer- level on the voltmeter. Does a
ence Figure 1 and the illustration below. Once nominal voltage reading register
the correct Circulation Pump has been deter- on the voltmeter?
mined, locate and activate the Room Thermo- A: If YES:
stat for the particular heating zone. This The Circulation Pump must be
should activate that particular Circulation replaced. Please contact our
Pump. Is the Circulation Pump operating? Technical Department at 1-800-
A: If YES: 685-4298 for assistance.
Check the particular Heating Loops If NO:
plumbing system for kinks and/or The Electronic Controller must
any other types of flow restrictions. be replaced. Please contact
If NO: our Technical Department at 1-
Perform each of the following proce- 800-685-4298 for assistance.
dures as necessary until the problem
is resolved.
1. Locate the Electronic Controller
and remove the Faceplate.
Living Room Heating Heating Fresh Water

Cozy III Heat Loop 2 Tank Zone
Loop 1
Exchanger Cozy III Heat
Exchanger
Living Room Bathroom

Living Room / Cozy III Heat Zone
Kitchen Zone Exchanger Cozy III Heat
Exchanger
Typical Heat Exchanger
Locations
Kitchen Bedroom
Cozy III Heat Zone
Exchanger Cozy III Heat
Exchanger
R
Page 33

continued

ture, but the fans of an Interior and/or � ��
��
TM R
Electronic
Controller
Fresh Water Tank Heat Exchangers are
not operating. Emergency
Cutoff
Electric Heating Low Voltage Hydro-Hot
Q1: Is the Electronic Controller's Low Temp

Element Status
Heating Status
Reset
Cutoff Status light illuminated? #5 Engine Preheat
A: If YES: Pump
Perform each of the following #4

Circulation
procedures as necessary until the Heating Zones

Status
#3
Pump #1
problem is resolved. Circulation
If NO:
#2 Pump #2
Inspect the Heat Exchanger fans #1

Stir Pump
and interior Room Thermostat wiring

for loose connections at JP-1 Plug of Low Battery
Status
the Electronic Controller, reference Low Temp

Cutoff Status
Figure 3. Overload Fault
a. Activate the interior Room Thermostat and

then turn the Diesel switch ON. Remove the
Hydro-Hot's Access Cover and locate the two Electronic Controller
yellow colored wires, which connect to the two Faceplate
black wires, reference the illustration on this
page. Disconnect the wires and then connect
the two yellow wires together by utilizing an
ATO type automotive fuse, again reference
the illustration. Do the Heat Exchanger fans Black wires
now operate?
A: If YES: Yellow wire
The Low Temp Cutoff Thermostat ATO

may need to be replaced. Please Fuse Yellow wire
contact our Technical Department at Black wires
1-800-685-4298 for assistance.

If NO: Yellow wires

problem is resolved.
JP-1 Plug and read the DC voltage
signal output, and input, at the
particular interior Room
Thermostat's circuit, reference
Figure 3. Is there an output DC
Page 34 R
Section 7.8, Section 7.9

continued

voltage signal at the Electronic ture, but the domestic hot water system is
Controller? not producing hot water.
A: If YES:
The interior Room Thermostat may Q1: Is the Electronic Controller's Stir Pump
need to be replaced. Please contact Status light illuminated? (reference Figure
our Technical Department at 1-800- 5)
685-4298 for assistance. A: If YES:
If NO: Perform each of the following
The Electronic Controller must be procedures as necessary until the
replaced. Please contact our Techni- problem is resolved.
cal Department at 1-800-685-4298 for 1. Seal all openings that may allow
assistance. cool air to enter the open area at
the backside of the Hydro-Hot.
2. Locate the Low-Temp Cutoff Ther-
mostat, reference Figure 1. Make
sure that the thermostat has not
been dislodged from the copper
line, reference Figure 1.
3. Turn the Diesel switch ON and
allow the Hydro-Hot to reach it's
maximum operating temperature.
Once the Diesel-Burner has
cycled OFF, check the Low-Temp
Cutoff Thermostat for continuity,
reference Figures 1 and 3. If no
continuity is present, the Low
Temp Cutoff Thermostat must be
replaced. Please contact our
Technical Department at 1-800-
685-4298 for assistance.
If NO:
Check the Hydro-Hot's heating
solution for the proper antifreeze to
water mixture (should be 33% anti-
freeze and 67% water). A high
concentration of antifreeze will cause
a poor domestic hot water perfor-
mance.
NOTE: If there is still a lack of hot water after

performing all of the listed checks, contact our
Technical Department at 1-800-685-4298 for
additional assistance. Also, be sure to refer-
ence the chart on the following page regarding
the Hydro-Hot's Domestic Hot Water System.
R
Page 35
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.
80
Input (i.e. incoming) Temperature of Domestic
70
Cold Water to the Hydro-Hot
e
ur v
rc
at e
60
ot w
ic h
e st
50
dom
F
115
40
GPM
0.5 1.0 1.5 2.0 2.5 3.0
(GPM - Gallons per Minute)
Estimated flow rate, of domestic cold water, required to maintain an

approximate 115 F output temperature of domestic hot water.
Notes of interest:
When water is heated to.....

156 degrees - Hot water causes a third-degree burn in one second
149 degrees - Hot water causes a third-degree burn in two seconds
133 degrees - Hot water causes a third-degree burn quickly
115-120 degrees - General purpose temperatures
107-109 degrees - Average "Hot-Tub" temperatures
105 degrees - Average "Shower" temperature
Page 36

continued
After turning the Electric switch ON:
TS10: The Hydro-Hot's 120 VAC Electric Heat-

Plug's Electric (+) and Electric (-)
ing Element does not operate (i.e. lack of
pins. If connections are in good
hot water and/or interior heat).
condition, replace the Electric
Q1: Is the Electronic Controller's Electric switch.
Heating Element Status light illuminated? If the Electric Heating Element
(reference Figure 5) Status light did not illuminate:
A: If YES: Locate the Electronic Controller's
Perform each of the following proce- JP-2 Plug and check for DC
dures as necessary until the problem voltage at the Electric (+) and
is resolved. Electric (-) pins, reference Figure
1. Locate the Electronic Controller 3.
and remove the Faceplate. If no voltage is present:
2. Locate the Electronic Controller's Replace the Electronic Controller.
JP-3 Plug and check for DC Please contact our Technical
voltage at Pin 11 (+) and Pin 12 (-), Department at 1-800-685-4298 for
reference Figure 3. assistance.
A: If voltage is present:
Check for loose wire connections Q2: Has the Hydro-Hot's VAC High-Limit Ther-
at Pin 11 (+) and Pin 12 (-) of the mostat tripped?
JP-3 Plug. If the wire connec-
tions are in good condition, WARNING: Turn the VAC breaker
proceed to Q2. OFF prior to performing the follow-
If no voltage is present: ing checks. Failure to do so may
Replace the Electronic Controller. result in serious bodily injury (i.e.
Please contact our Technical electrical shock).
assistance. Remove the 4 in. x 4 in. Electric Heating
If NO: Element Access Panel and locate the VAC
Perform each of the following proce- High-Limit Thermostat, reference Figure 1.
dures as necessary until the problem Check for continuity at the VAC High-Limit
is resolved. Thermostat. Is continuity present?
1. Locate the Electronic Controller A: If YES:
and remove the Faceplate. Proceed to Q3.
2. Locate the Electronic Controller's If NO:
JP-2 Plug. Use a jumper wire to Press the red reset button located on
make a connection from the the VAC High-Limit Thermostat.
Electric (+) pin to the Electric (-) Reset the VAC breaker and then turn
pin, reference Figure 3. Does the Electric switch ON.
Electronic Controller's Electric
Heating Element Status light NOTE: Although the 120 VAC Electric Heating
illuminate? Element is now functioning, be sure to perform
A: If the Electric Heating Element Status the following steps until the cause for over-
light illuminates: heating has been discovered and corrected.
Check for loose wire connections Failure to do so could result in another over-
at Electric switch and at the JP-2 heating condition.
Page 37

continued continued
a. Turn the Diesel and Electric switches ON and Turn the Electric switch ON. Locate the VAC
allow the Hydro-Hot to reach maximum Element Relay in the 4 in. x 4 in. junction box,
operating temperature (i.e. until the Diesel- reference Figure 1. Check for AC voltage at
Burner cycles OFF). Locate both the VAC the Black (+) wire ("120 VAC Power Supply")
High-Limit Thermostat and the VAC / VDC connection at the AC Element Relay, refer-
Control Thermostat and check for continuity, ence Figure 3. For a common ground, use
reference Figure 1. the White wire connection at the 120 VAC
A: If there is no continuity at the VAC High- Electric Heating Element. Is voltage present?
Limit Thermostat, but there is continuity at A: If YES:
the VAC / VDC Control Thermostat: Proceed to Q4.
The VAC / VDC Control Thermostat If NO:
must be replaced. Please contact Check for loose wire connections
our Technical Department at 1-800- at the motorhome's VAC junction
685-4298 for assistance. box. If the wire connections are in
If there is continuity at the VAC High-Limit good condition, please contact our
Thermostat, but none at the VAC / VDC Technical Department at 1-800-685-
Control Thermostat: 4298 for additional assistance.
The overheat condition may have
been caused by another faulty Q4: Is VAC Element Relay functioning prop-
component and no further trouble- erly?
shooting is necessary, see the
"NOTE" below. Please contact our WARNING: The following checks
Technical Department at 1-800-685- need to be performed with the
4298 for additional assistance. motorhome connected to VAC
power. Be sure to use extreme
NOTE: If the VDC High-Limit Thermostat caution when performing each
continues to trip, and no overheating problems check, as 120 VAC power will be
were discovered (i.e. faulty VAC / VDC Control present at each of the electrical
Thermostat), it may be that the VDC High-Limit components. Also, be sure to
Thermostat is not operating properly and it may disconnect VAC power prior to
need to be replaced. replacing any electrical compo-
nents. Failure to do so may result
Q3: Is VAC power being supplied to the VAC in serious bodily injury (i.e. electri-
Element Relay? cal shock).
WARNING: The following checks NOTE: Inspect the VAC Element Relay for
need to be performed with the damage. If visual signs of damage exist, the
motorhome connected to VAC relay must be replaced.
caution when performing each Turn the Electric switch ON. Locate the VAC
check, as 120 VAC power will be Element Relay in the 4 in. x 4 in. junction box.
present at each of the electrical Check for AC voltage at the Black (+) wire
components. Failure to do so may (from the VAC High-Limit Thermostat) con-
result in serious bodily injury (i.e. nection at the AC Element Relay, reference
electrical shock). Figure 3. For a common ground, use the
Page 38 R

continued continued
White wire connection at the 120 VAC Electric NOTE: If the 120 VAC Electric Heating Element
Heating Element. Is voltage present? still does not seem to operate after performing
A: If YES: all of the listed checks, contact our Technical
Proceed to Q5. Department at 1-800-685-4298 for additional
If NO: assistance.
The VAC Element Relay must be
replaced. Please contact out Techni-
cal Department at 1-800-685-4298 for
assistance. Section 7.11
Q5: Is 120 VAC Electric Heating Element
After turning the Engine Preheat switch ON:
WARNING: The following checks
need to be performed with the TS11: The Hydro-Hot's Engine Preheat System
motorhome connected to VAC does not preheat the engine.
caution when performing each NOTE: The Diesel or Electric switch must be
check, as 120 VAC power will be activated, along with the Engine Preheat
present at each of the electrical switch, prior to performing the following checks.
components. Also, be sure to
disconnect VAC power prior to Q1: Is the Electronic Controller's Engine
replacing any electrical compo- Preheat Pump light illuminated? (reference
nents. Failure to do so may result Figure 5)
in serious bodily injury (i.e. electri- A: If YES:
cal shock). Perform each of the following proce-
dures as necessary until the prob-
Disconnect the motorhome from VAC shore lem is resolved.
power. Locate the 120 VAC Electric Heating 1. Locate the Electronic Controller
Element in the 4 in. x 4 in. junction box. and remove the Faceplate.
Remove the White (common) wire from the 2. Locate the Electronic Controller's
120 VAC Electric Heating Element. Check for JP-3 Plug and check for DC
continuity at the Black (+) wire and at the voltage at Pin 7 (+) and Pin 8 (-),
terminal where the White (common) wire was reference Figure 3.
removed. Is continuity present? A: If voltage is present:
A: If YES: Check for loose wire connections
See the "NOTE" on the top right- at Pin 7 (+) and Pin 8 (-) of the JP-
hand side of this page. 3 Plug. Also, check the wire con-
If NO: nections at the Engine Preheat
The 120 VAC Electric Heating Ele- Pump. If all connections are in
ment must be replaced. Please good condition, listen and feel the
contact out Technical Department at Engine Preheat Pump to ensure
1-800-685-4298 for assistance. that it is operating, reference
Figure 1. If the Engine Preheat
Pump is not operating, it must be
replaced.
R
Page 39
Section 7.11,
continued
If no voltage is present:
Replace the Electronic Controller.
If NO:
Perform each of the following proce-
dures as necessary until the problem
is resolved.
JP-2 Plug. Use a jumper wire to
make a connection from the
Preheat (+) pin to the Preheat (-)
pin, reference Figure 3. Does
Electronic Controller's Engine
Preheat Pump light illuminate?
A: If the Engine Preheat Pump light
illuminates:
Check for loose wire connections
at Engine Preheat switch and at
the JP-2 Plug's Preheat (+) and
Preheat (-) pins, reference Figure
3. If connections are in good
condition, replace the Engine
Preheat switch.
If the Engine Preheat Pump light did
not illuminate:
Locate the Electronic Controller's
JP-2 Plug and check for DC
voltage at the Preheat (+) and
Preheat (-) pins, reference Figure
3.
If no voltage is present:
Replace the Electronic Controller.
Please contact our Technical
assistance.
If voltage is present:
See "NOTE" below.
NOTE: If the Engine Preheat Pump still does

not seem to operate after performing all of the
listed checks, contact our Technical Department
at 1-800-685-4298 for additional assistance.
Page 40 R
Section 8: Diesel-Burner Service, Maintenance, and Repair Information
General 8.1 General Recommended Maintenance

Recommended
Monthly
Maintenance
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 Hydro-
Hot'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".
WARNING: When the Hydro-Hot is at maximum operating temperature
(HOT), DO NOT loosen the Radiator Cap. If removed, scalding by hot
vapor or coolant could result.
If the coolant needs replenishing, fill the Hydro-Hot's Expansion Tank to the
FULL HOT level mark. Be sure to reference the Hydro-Hot "Owner's
Manual" for the proper antifreeze type and mixture. If coolant frequently
needs replenishing, please contact our Technical Department at 1-800-685-
4298 for assistance.
Annually
WARNING: Before cleaning or servicing, disconnect all power sup-
plies.
To keep your Hydro-Hot running smoothly, it is ideal to have the Diesel-
Burner tuned-up annually. A tune-up should consist of a new Fuel Nozzle
and Fuel Filter, along with a thorough cleaning of the Combustion Chamber,
if necessary (reference Figure 9). To ensure maximum Diesel-Burner
performance, always use the recommended Fuel Nozzle and Fuel Filter
(i.e. 10 Micron) when replacing these parts. Reference Section 10 for
spare parts information.
NOTE: Be sure to use care when handling the Fuel Nozzle. Oils and/or
small dust or dirt particles from your hands may plug the nozzle's small
orifice. A partially plugged orifice will restrict fuel flow, which will affect
the combustion process of the Diesel-Burner (i.e. excessive smoking).
CAUTION: Operating the Hydro-Hot's Diesel-Burner or the 120 VAC
Electric Heating Element, without the water and antifreeze solution, will
cause serious damage to the heater.
Fuel Nozzle
(0.35 GPH)
Combustion
Chamber
Fuel Filter
(10 Micron)
small orifice
Figure 9
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Page 41
Detaching and 8.2 Detaching and Reattaching the Diesel-Burner Head

Reattaching the
Diesel-Burner Grommets
Head
Eye-Bolts
Diesel-Burner
and Nuts
Head
Blower
Casing
Diesel Diesel
Fuel Supply 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. Failure to do so
may result in the ignition of the Diesel-Burner and serious bodily injury.
1. Loosen the two Eye-Bolt Nuts and swing the Eye-Bolts out of the
way, reference Figure 10.
2. With both hands, carefully pull the Diesel-Burner Head away from
the Hydro-Hot (approximately 4-5 inches). Please note that you
may have to lift the Diesel-Burner Head slightly while pulling it away
from the Hydro-Hot.
3. Rotate the Diesel-Burner Head upward until all the internal compo-
nents are visible.
CAUTION: When reattaching the Diesel-Burner Head, be sure to
properly align the Diesel-Burner Head before tightening the Eye Bolt
Nuts. Also, visually inspect all of the rubber Grommets on the top and
bottom of the Diesel-Burner Head's cast-aluminum Blower Casing to
ensure they are in place. DO NOT over tighten the Eye-Bolt Nuts
(torque specification = approx. 20-40 in. lbs.). An improper alignment
and/or an over tightening of the Eye-Bolt Nuts can cause damage to
the Diesel-Burner Head's cast-aluminum Blower Casing, reference
Figure 10.
Page 42
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 neces-
sary to detach and reattach the Diesel-Burner Head. Be sure to refer-
ence Section 8.2, Page 42 for detaching and reattaching instructions.
Component Test: Locate the Control Unit's C-Plug and insert the probes
of a DC voltmeter into the C-2 (+) and C-5 (-) locations, reference Figure
11. Turn the Diesel switch ON and observe the voltage level. If a nominal
voltage registers on the voltmeter and the Motor is not operating, inspect
the C-Plug Harness for loose or damaged wire connections. If the C-Plug
Harness and connections are in good condition, the Motor must be re-
placed, reference the Motor's "Replacement Procedure" on Page 45.
Cleaning Tips / Maintenance: N/A
C-2 ( + ) Motor Circuit (Black Wire)

to Diesel-Burner.
12.5 V
COM (-)
(+)
C-1 C-2 C-4 C-Plug

C-5 C-6 C-7 C-8
C-5 ( - ) Ground Circuit (Brown Wire), for

Diesel-Burner components, to Diesel-Burner.
Figure 11
Page 43
Adjustment Procedure: N/A

Motor,
continued 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.
Remove the Protection Cap from the Diesel-Burner so that the Motor and
Clutch Halves are exposed, reference Figures 12 and 13. Place a few
wraps of black electrical tape around the Clutch Halves and then place a
small piece of reflective tape over the black tape, as illustrated in Figure 12.
Disconnect the Motor's Black (+) and Brown (-) wires from the C-Plug
Harnesses Black (+) and Brown (-) wires, reference Figures 12 and 13.
Connect the Motor's wires directly to a 12 volt DC power supply, reference
Figure 12. Turn the power supply ON and use a photo-tachometer to test
for a proper RPM reading, reference Figure 12. At approximately 12.5 volts
DC, the RPM reading should be 4500 RPM's (+/- 300 RPM's). If the
Motor's RPM reading is not within the above specs, the Motor must be
replaced, reference the Motor's "Replacement Procedure" on Page 45.
Reference Section 10 for spare part number information.
NOTE: If the Motor's RPM reading is out of specs, or even if within
specs, be sure to test the Diesel-Burner's Bearings prior to reattaching
the Diesel-Burner Head or replacing the Motor, if applicable. Worn
Bearings can cause lower than normal RPM readings and premature
Motor wear. To properly test for worn Bearings, reference Section 8.9,
Page 60 for the Bearings "Function Test".
Photo
Tachometer
M
0 RP
450
Reflective
Tape
Motor
Black
Wire (+) Brown
Figure 12
Wire (-)
Black Electrical
Tape on Clutch Halves
Page 44 R
Motor, Replacement Procedure:
continued 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 remov-
ing. Remove the Protection Cap from the Diesel-Burner so that the
Motor and Clutch Halves are exposed, reference Figures 13 and 14.
2. Remove the three Hex Head Screws that secure the Motor and
flange assembly to the Blower Housing, reference Figure 13.
Remove the Motor and flange assembly along with the Clutch
Halves, reference Figures 13 and 14. Disconnect the Motor's Black
(+) and Brown (-) wires from the C-Plug Harness' wires, reference
Figure 13.
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.
3. Detach the Motor from the Motor Flange by removing the two
Phillips Head Screws that fasten the two parts together, reference
Figure 13.
NOTES:
A: Be sure to test the Diesel-Burner's Bearings prior to reinstalling the
Motor. Worn Bearings can cause lower than normal RPM readings
and premature Motor wear. To properly test for worn Bearings,
reference Section 8.9, Page 60 for the Bearings "Function Test"..
B: The Motor must be mounted to the flange with the wires and drain
hole pointing downward and the recessed edge of the Motor Flange
pointing upward, reference Figure 14. This will ensure a proper
Protection Cap fit.
4. Reinstall a Clutch Half on both the new Motor's shaft and the
Combustion Air Blower's shaft. Attach the Motor and flange assem-
bly, with the recessed edge of the Motor Flange in-line with the
wiring access slot of the Blower Casing, to the Blower Housing with
the three Hex Head Screws, reference Figure 14.
NOTE: Inspect the Blower Casing's O-Ring for damage or wear prior to
reinstalling the Diesel-Burner Head's Protection Cap, reference Figure
14. If damage or wear exists, replace the O-Ring. Reference the Hydro-
Hot's "Parts Manual" for spare parts information.
5. Connect the Black (+) and Brown (-) wires of the new Motor to the
C-Plug Harness' Black (+) and Brown (-) wires, reference Figure 13.
Feed the C-Plug Harness' Yellow and Brown wires back through the
wiring access hole in the Protection Cap, reference Figure 14.
6. Reinstall the Protection Cap. Reconnect the Black (+) and Brown (-)
wires of the Ignition Coil to the C-Plug Harness' Yellow (+) and
Brown (-) wires, reference Figure 24. Reinstall the Ignition Coil and
R
Page 45
Motor, secure to the Protection Cap with the four Ignition Coil Screws,
reference Figure 13.
continued
Figure 13
Figure 14
Page 46 R
Flame 8.4 Flame Sensor

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.
B: Be sure to calibrate your ohmmeter prior to checking the Flame
Sensor for proper resistance values.
Component Test: Locate and detach the Flame Sensor's Green and Blue
wires from the C-Plug Harness wires, reference Figure 15. Connect the
Flame Sensor's Green and Blue wires to an ohmmeter, reference Figure
15. Check resistance by placing a shop rag over the Flame Sensor's glass
surface, to simulate a no flame condition, and then remove the rag (and
expose to a light source) to simulate a flame condition. If the Flame
Sensor is operating properly, the ohmmeter should register high resistance
(i.e. 100K ��when the glass surface is covered, and less than 300 �
when exposed to a light source. If these resistance numbers cannot be
obtained, the Flame Sensor must be replaced, reference the Flame
Sensor's "Replacement Procedure" below. Reference Section 10 for spare
parts information.
Cleaning Tips / Maintenance: For light dirt, dust, and/or carbon deposits,
simply wipe off the Flame Sensor with a soft cloth. Should heavy carbon
deposits be present, completely remove the Flame Sensor from the Photo
Disc and clean with brake cleaner, reference Figure 15.
Replacement Procedure:
1. Remove the Screw that fastens the Flame Sensor to the Photo Disc
and detach the sensor's Green and Blue wires from the C-Plug
Harness' Green and Violet wires, reference Figure 15.
2. Slide the tab of the new Flame Sensor into the provided slot in the
Photo Disc and secure in place with the screw, reference Figure 15.
Connect the Flame Sensor's Green wire to the Green C-Plug
Harness wire and the Blue wire to the C-Plug Harness' Violet
wire, reference Figure 15.
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Page 47
Flame
Sensor,
Flame
continued Sensor
Green
Wire
Photo
Disc
Green Wire
(to Diesel-Burner)
NOTE: This screw is used to
fasten the Flame Sensor to
Blue the Photo Disc. Remove
Wire when replacing the Flame
Sensor.
Violet Wire
Figure 15 (to Diesel-Burner)
Ignition 8.5 Ignition Electrodes
Electrodes
Function: The Diesel-Burner's Ignition Coil (reference Figure 24) pro-
duces a high voltage ignition spark across the Ignition Electrodes, which
ignites the incoming air / fuel mixture.
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: N/A
Cleaning Tips / Maintenance: Polish away any carbon deposits that may
have baked onto the metal tips of the Ignition Electrodes with a scotch
brite pad (or similar), reference Figure 16. If the Ignition Electrode's
R
electrical insulator (reference Figure 16) is cracked and/or damaged, the

Ignition Electrode must be replaced, reference the Ignition Electrode
"Replacement Procedure" on Page 49. Reference Section 10 for spare
parts information.
NOTE: The Electrode Adjustment Gauge is to used to set the gap
between the Ignition Electrodes. The Electrode Adjustment Gauge is
located on the outside surface of the Diesel-Burner Head on the lefthand
side.
Ignition Electrode Adjustment Procedure: An adjustment of the Ignition
Electrodes can be accomplished by performing the following procedures:
1. Slightly loosen the Retaining Clamp Bolt, reference Figure 16.
2. Place the Electrode Adjustment Gauge on the Nozzle Stand Hex
(reference Figure 17) and insert the metal tips of the Ignition Elec-
Page 48
Ignition trodes into the appropriate notches of the Electrode Adjustment

Gauge as illustrated in Figure 16.
Electrodes,
3. Tighten the Retaining Clamp Bolt.
continued
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). Not allowing the Photo Disc to float freely
will cause poor combustion and result in a smoky exhaust. A bent
Retaining Clamp can be restraightened with a punch and hammer. Lay
the clamp's beveled side down on a solid flat surface and align the thick
end of the punch at dead center. Tap the punch lightly until the Retaining
Clamp returns to proper form (i.e. flat).
4. Remove the Electrode Adjustment Gauge and reattach to the
Diesel-Burner Head.
1. Disconnect the Ignition Cables from the Ignition Electrodes and
slightly loosen the Retaining Clamp Bolt just enough to allow the
Ignition Electrodes to be removed, reference Figure 16.
2. Slide the new Ignition Electrodes up through the Retaining Clamp
and Photo Disc. Do not tighten the Retaining Clamp Bolt yet.
3. Perform Steps 2 thru 4, of this section's "Adjustment Procedure", to
complete the Ignition Electrode installation. Once Steps 2 thru 4
have been performed, connect the Ignition Cables to the Ignition
Electrodes, reference Figure 16.
Electrode Adjustment
Gauge
Igniton
Electrodes
(metal tips) Retaining

Clamp Bolt
Ignition
Cables
Ignition
Photo Disc Electrodes
Retaining Electrode
Clamp Adjustment Gauge
(Properly Positioned)
Figure 16
Fuel
Electrical Insulators Nozzle
Nozzle Stand
Page 49
Fuel 8.6 Fuel Nozzle
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.
Component Test: Remove both Ignition Cables from the Ignition Electrodes
(reference Figure 16), or connect a jumper wire (with alligator clips) across
the metal tips of the electrodes.
WARNING: Failure to connect a jumper wire across the Ignition Elec-
trodes, or to remove the Ignition Cables from the Ignition Electrodes
(reference Figure 16), will result in a HIGH VOLTAGE shock and/or a fire.
If the Ignition Cables are removed, be sure to place a piece of electrical
tape to the end of each cable.
Remove the B-Plug from the Diesel-Burner Head's Control Unit, reference
Figure 8. Turn the Diesel switch ON (reference Figure 4) and then plug the
B-Plug back into the Control Unit to activate the Diesel-Burner. After approx.
20 seconds, the Fuel Solenoid will "click" and a fine mist of fuel should
appear from the Fuel Nozzle in a cone shaped spray pattern. Remove the
B-Plug from the Control Unit. If the cone shaped spray pattern did not
appear, the Fuel Nozzle must be replaced, reference the Fuel Nozzle's
"Replacement Procedure" below. Reference Section 10 for spare parts
information.
Cleaning Tips / Maintenance: The Fuel Nozzle is a precision calibrated
part and cannot be cleaned or serviced. A replacement of the Fuel Nozzle
is recommended annually. Reference Section 8.1, Page 41 for maintenance
information.
1. Use a 3/4 in. wrench to hold the Fuel Nozzle Stand Hex while loosen-
ing the Fuel Nozzle with a 5/8 in. wrench, reference Figure 17.
NOTE: Be sure to use care when handling the new Fuel Nozzle. Oils
and/or small dust or dirt particles from your hands may plug the nozzle's
small orifice. A partially plugged orifice will restrict fuel flow, which will
affect the combustion process of the Diesel-Burner (i.e. excessive
smoking).
2. When replacing the Fuel Nozzle, be sure to tighten the nozzle, loosen
it a 1/4 turn, and then firmly retighten. This will establish a seated fit
and avoid any leaks.
Page 50 R
Fuel NOTE: An adjustment of the Ignition Electrodes may be necessary after

Nozzle, replacing the Fuel Nozzle. Reference Section 8.5, Page 48 for the
Ignition Electrode "Adjustment Procedure".
continued
3. After replacing the Fuel Nozzle, reattach the Diesel-Burner Head.
WARNING: Be sure to reattach the Diesel-Burner Head prior to switch-
ing the heater ON. Failure to do so may result in ignition of the Diesel-
Burner and serious bodily injury.
4. Turn ON the Diesel switch (reference Figure 4) for 5 seconds, then
turn it OFF. This will activate the Diesel-Burner's prime-cycle and
flush the fuel system of any potential contaminants.
Ignition Electrodes
Fuel Nozzle
Diesel-Burner Fuel Nozzle

Head
Fuel Nozzle
Nozzle Stand Hex
5/8 in.
Wrench
Figure 17
3/4 in.
Wrench
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Page 51
Fuel 8.7 Fuel Solenoid

Solenoid
Function: The Fuel Solenoid allows the flow of diesel fuel to the Diesel-
Burner's Fuel Nozzle.
Component Test: Locate and detach the C-Plug Harness' Violet (+) and
Brown (-) wires from the Fuel Solenoid. Connect the (-) lead of a 12 volt
DC power supply to the Fuel Solenoid's (-) Electrical Terminal, reference
Figure 18. Now, intermittently apply the (+) lead of the power supply to the
Fuel Solenoid's (+) Electrical Terminal and listen for the Fuel Solenoid to
click (i.e. open and close). If the Fuel Solenoid does not click, it must be
replaced, reference the Fuel Solenoid's "Replacement Procedure" below.
Reference Section 10 for spare parts information.
1. Disconnect the Ignition Cables from the Ignition Electrodes and
loosen the Retaining Clamp Bolt, reference Figure 16.
2. Remove the Retaining Clip that secures the Photo Disc in place.
Gently lift the Photo Disc (with Flame Sensor attached) so that it
releases from the Nozzle Stand and the Ignition Electrodes, refer-
ence Figures 16 and 19.
3. Disconnect the C-Plug Harness' Violet (+) and Brown (-) wires from
the Fuel Solenoid, reference Figure 18.
4. Remove the four Nozzle Stand Plate Screws that secure the Nozzle
Stand Plate in place, reference Figure 19. Remove the Nozzle
Stand Plate by pulling on the Nozzle Stand until the plate releases
from the cast-aluminum Blower Casing, reference Figures 13 and
19.
5. Remove the Lock Nut and Flat Washer from the end of the Fuel
Solenoid Shaft and then remove the Fuel Solenoid. With the
appropriate wrench, remove the Fuel Solenoid Shaft from the
Nozzle Stand. Discard the shaft and valve kit, as replacements are
provided with the new Fuel Solenoid Assembly.
6. Insert the contents of the new Fuel Solenoid Valve Kit into the new
Fuel Solenoid Shaft, as illustrated in Figure 18. Thread the new Fuel
Solenoid Shaft to the Fuel Nozzle Stand and tighten. Slide the new
Fuel Solenoid onto the Fuel Solenoid Shaft and secure in place with
the new Flat Washer and Lock Nut.
7. Fit the Nozzle Stand Plate inside the cast-aluminum Blower Casing
and secure in place with the four Nozzle Stand Plate Screws.
Page 52 R
Fuel 8. Reinstall the Photo Disc and secure in place with the Retaining Clip.
Connect the C-Plug Harness' Violet (+) and Brown (-) wires to the
Solenoid, Fuel Solenoid's (+) and (-) Electrical Terminals, reference Figure 18.
continued 9. Perform the "Ignition Electrodes Adjustment Procedure" in Section
8.5, Page 48 to complete the Fuel Solenoid installation.
NOTE: If a long after-smoking condition exists during the Diesel-
Burner's purge-cycle (reference Page 12, Step 6), the Fuel Solenoid
Valve Kit may need to be replaced, reference Figure 18. Please contact
our Technical Department at 1-800-685-4298 for assistance. Reference
Section 10 for spare parts information.
Retaining Clamp
Ignition Cable
Violet wire
Brown wire
Photo Disc
Retaining Clip
Fuel Solenoid Lock Nut
Electrical Terminals
(+) (-)
Fuel
Solenoid Shaft
Fuel Solenoid
Valve Kit
Fuel
Solenoid
Fuel Solenoid
Assembly
Figure 18
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Page 53
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 atomi-
zation). Reference the illustration below for a basic overview and under-
standing of how the Fuel Pump functions.
FUEL PUMP
OVERVIEW
1. Fuel Nozzle
2. Air Relief Bore
3. Fuel Supply Line
4. Fuel Return Line
5. Fuel Pressure Regulator
6. Fuel Solenoid
NOTE: In order to perform some of 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 instruc-
tions.
Component Test:
Clamp off and remove the Hydro-Hot's Fuel Return and Fuel Supply Lines,
reference Figure 1. Attach a short piece of fuel line to both the Hydro-Hot's
Fuel Return and Fuel Supply ports, reference Figure 1. Submerse the
opposite end of the temporary fuel supply line in a container of diesel fuel.
Place the opposite end of the temporary fuel return line in an empty
container. Turn the Diesel switch ON to activate the Diesel-Burner, refer-
ence Figure 4. If fuel does not flow out of the return line into the empty
container, the Fuel Pump must be replaced, reference the Fuel Pump's
"Replacement Procedure" on Page 58. Reference Section 10 for spare
parts information.
NOTE: Prior to replacing the Fuel Pump, be sure to inspect the Screen
Filter in the supply inlet of the Fuel Pump, for dirt particles (reference
Figure 19). Clean and/or replace, if necessary. A plugged Screen Filter
will restrict fuel from entering the Fuel Pump. Reference the Hydro-Hot's
Cleaning Tips / Maintenance:
1. Check all Fuel Connections for tightness (i.e. Banjo Bolts, High
Pressure Fuel Pipe Connections, reference Figure 19.
2. Check the Screen Filter, located in the fuel supply inlet of the Fuel
Pump, for dirt particles. Clean and/or replace, if necessary (refer-
ence Figure 19).
Page 54 R
Fuel Pump, Ignition Cable (1)

continued Retaining Nozzle Stand
Clamp Plate Screw (1)
Retaining Clip
Ignition
Electrodes
Photo Disc
Flame Sensor
Supply
Banjo Bolt
Fuel Pump
Fuel Supply
Fuel Return Line
Banjo Pipe Nozzle Stand
Plate Screw (2)
Fuel Supply
Banjo Pipe
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
Regulator
Nozzle Stand
Plate Screw (3) Screen
Filter
Fuel Return
Line
Return
Banjo Bolt
Figure 19
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Page 55
Fuel Pump, Fuel Pressure Adjustment Check:

continued 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.
B: Be sure to use care when handling the Fuel Nozzle. Oils and/or
small dust or dirt particles from your hands may plug the nozzle's
small orifice, reference Figure 9. A partially plugged orifice will
restrict fuel flow, which will affect the combustion process of the
Diesel-Burner (i.e. excessive smoking from the exhaust pipe).
1. Remove the Fuel Nozzle (reference Figure 17) and replace it with
the Fuel Pressure Gauge, reference Figure 20.
WARNING: A spark will appear across the Ignition Electrodes (refer-
ence Figure 16) for a brief moment after the Diesel-Burner has been
activated. DO NOT attempt to make any fuel pressure adjustments until
the spark has disappeared. Failure to do so may result in serious bodily
injury (i.e. electrical shock).
2. Turn the Diesel switch ON, reference Figure 4. A pressure will
register on the Fuel Pressure Gauge once the Fuel Solenoid opens
(after approx. 10-25 seconds).
3. If the Fuel Pressure Gauge registers a 145 psi pressure reading, no
pressure adjustment is necessary. Turn the Diesel switch OFF and
wait until the motor stops running. Remove the Fuel Pressure
Gauge and reinstall the Fuel Nozzle (reference Section 8.6, Page 50
for the Fuel Nozzle's "Replacement Procedure"). Reattach the
Diesel-Burner Head.
NOTE: If the Fuel Pressure Gauge registers below or above 145 psi,
perform the adjustment procedures listed below.
Fuel Pressure Adjustment Procedure:
1. Turn the Diesel switch ON and simply turn the Pressure Regulator
Adjustment Screw clockwise to increase fuel pressure or counter
clockwise to decrease fuel pressure, reference Figure 21.
NOTE: If the fuel pressure will not maintain a 145 psi setting, the Fuel
Pump must be replaced, reference the Fuel Pump's "Replacement
Procedure" on Page 58. Also, reference Section 10 for spare parts
information.
2. Once the pressure adjustment has been made, turn the Diesel
switch OFF and wait until the motor stops running. Remove the Fuel
Pressure Gauge and reinstall the Fuel Nozzle (reference Section
8.6, Page 50 for the Fuel Nozzle's "Replacement Procedure").
Reattach the Diesel-Burner Head.
Page 56 R
Fuel Pump,
continued
80 100 120
60 140
40 160
20 psi 180 Fuel Pressure
0 200 Gauge
ASHCROFT
MADE IN U.S.A
Figure 20
increase
Fuel Pump
Pressure decrease
Regulator
(Adjustment)
Figure 21
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Page 57
Fuel Pump, Replacement Procedure:

continued 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 Elec-
trodes, reference Figures 16 and 19.
2. Remove the Retaining Clip that secures the Photo Disc in place,
reference Figure 19. Gently lift the Photo Disc (with Flame Sensor
attached) so that it releases from the Nozzle Stand and the Ignition
Electrodes, reference Figures 16 and 19.
3. Clamp off both the Fuel Supply and Return Lines from the Diesel-
Burner Head, reference Figures 19 and 22. Loosen the Supply and
Return Banjo Bolts to remove the Fuel Supply and Return Pipes
(with the fuel lines attached) from the Fuel Pump, reference Figures
19 and 22. Also, disconnect the High Pressure Fuel Pipe from both
the Fuel Pump and the Nozzle Stand, reference Figures 19 and 22.
Discard the High Pressure Fuel Pipe, Gasket Rings, Banjo Bolts,
and Grommets, as replacements are provided in the new Fuel Pump
Kit (Part No. WPX-502-05A).
19.
5. Remove the two Pump Mounting Screws that secure the Fuel Pump
in place, reference item 70 of Figure 22. Turn the Nozzle Stand
Plate over and remove the Snap Ring from the Fuel Pump shaft,
using snap ring pliers, reference item 89 of Figure 22. Remove the
nylon Drive Gear and then the Fuel Pump, reference items 88 and
72 of Figure 22.
6. Attach the new Fuel Pump to the Nozzle Stand Plate with the two
Pump Mounting Screws. Turn the Nozzle Stand Plate over to
install the nylon Drive Gear on the Fuel Pump's shaft and secure in
place with the Snap Ring. Dab the teeth of the nylon Drive Gear
with white lithium grease (Isoflex LDS-18 is recommended).
NOTES:
A: Do not adjust the Fuel Pressure Regulator of the new Fuel Pump, as
it has been factory preset.
B: Inspect the nylon Drive Gear's cavity inside the cast aluminum
Blower Casing for fuel stains. If fuel stains are present, a replace-
ment of the Bearings and/or the entire Bower Casing may be
necessary (leaking fuel could cause Bearing seizure, resulting in
potential damage to the internal bore / bearing cavity of the Blower
Casing). Reference Section 8.9, Page 60 for the Bearing "Replace-
ment Procedure" and contact our Technical Department at 1-800-
685-4298 for additional assistance.
Page 58 R
Fuel Pump, and secure in place with the four Nozzle Stand Plate Screws.
Install the new Grommets on the Fuel Return and Supply Banjo
continued 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. Failure to use the new Gasket Rings, and/or the correct
order placement, could result in a fuel leak.
8. Reconnect the C-Plug Harness' Violet (+) and Brown (-) wires to the
Fuel Solenoid's (+) and (-) Electrical Terminals, reference Figure 18.
Insert both Ignition Cables into the new rubber Grommet and slide
into the appropriate notch on the Blower Casing, reference Figure
19. Reconnect the Ignition Cables to the Ignition Electrodes and
remove the fuel line clamps from the Fuel Return and Supply Lines.
9. Reinstall the Photo Disc and secure it in place with the Retaining
Clip, reference Figure 19. Reconnect the Flame Sensor's Green
wire to the Green C-Plug Harness wire and the Blue wire to the C-
Plug Harness' Violet wire, reference Figure 15.
NOTE: Check the Ignition Electrodes for proper adjustment, reference
Steps 2 thru 4, of the Adjustment Procedure in Section 8.5, Page 48 to
ensure proper Ignition Electrode adjustment.
Figure 22
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Page 59
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 neces-
sary to detach and reattach the Diesel-Burner Head. Be sure to review
Function Test: Remove the Motor (reference Section 8.3, Page 45 for the
Motor's "Replacement Procedure") and spin the Combustion Air Blower by
hand (place one of the Clutch Halves to the end of the shaft to assist with
this spinning exercise). If the Combustion Air Blower rotates smoothly
without any friction or noise, the Bearings are in proper working condition.
However, if the Combustion Air Blower does not rotate smoothly and/or
produces noise, the Bearings are worn and must be replaced, reference
the Bearings "Replacement Procedure" below.
Component Test: N/A
1. Clamp off and remove the Fuel Supply and Return Lines from the
Diesel-Burner Head, reference Figures 19 and 22.
2. Locate and disconnect the C-Plug Harness wires that connect to the
Flame Sensor and Fuel Solenoid, reference Figures 3, 15 and 18.
Also, disconnect the Ignition Cables from the Ignition Electrodes,
reference Figures 16 and 19.
19.
4. 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 Black (+) and Brown (-) wires from the C-Plug Har-
ness wires, prior to removing (reference Figures 3 and 24). Re-
move the Protection Cap from the Diesel-Burner so that the Motor
and Clutch Halves are exposed, reference Figures 12 and 14.
5. Remove the three Hex Head Screws that secure the Motor and
Motor Flange to the Blower Housing, reference Figure 13. Remove
the Motor and flange assembly along with the Clutch Halves,
reference Figures 13 and 14. Disconnect the Motor's Black (+) and
Brown (-) wires from the C-Plug Harness' wires, reference Figure
13.
Page 60 R
Bearings, NOTE: Inspect the Clutch Halves' for cracks and also ensure that the
continued 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
6. Remove the four Blower Housing Screws that secure the Blower
Housing to the Blower Casing, reference Figure 23. Remove the
Blower Housing so that the Combustion Air Blower is exposed,
NOTE: Be sure to observe the placement of the three Washers of the
Bearing Kit illustrated in Figure 23. To ensure proper tension, the same
order and direction of the dished surfaces of the Washers must be
followed when reassembling.
7. Hold Side-B of the Blower Casing and loosen the Retaining Nut
located in Side-A of the Blower Casing. Remove the Retaining Nut,
steel Drive Gear, and thick Flat Washer from the Combustion Air
Blower's shaft. Lightly tap the threaded end of the shaft so that the
Combustion Air Blower can be easily removed from the Blower
Casing.
8. With a pair of snap-ring pliers, remove the Snap Rings from both
Side-A and Side-B of the Blower Casing, reference Figure 23. Push
all the contents of the Bearing Kit out of the Blower Casing's bore /
bearing cavity. Discard the Retaining Nut, steel Drive Gear, Snap
Rings, Bearings, Spacer Tube, and Washers, as replacements are
provided in the new Bearing Kit.
NOTE: Be sure to inspect the Blower Casing's bore / bearing cavity for
signs of damage due to potentially seized Bearings. If damage is
present, the Blower Casing must be replaced. Reference the Hydro-
Hot's "Parts Manual" for spare parts information.
9. Install a new Snap Ring into Side-A of the Blower Casing, refer-
ence Figure 23. Once the Snap Ring is in place, insert the remain-
ing contents of the new Bearing Kit into Side-B of the Blower
Casing, starting with the Wave Washer, as illustrated in Figure 23.
Secure the Bearing Kit assembly in place with the remaining Snap
Ring (Side-B).
NOTES:
A: Reference Figure 23 for exact placement of the three Washers that
slide over the threaded end of the Combustion Air Blower's shaft
prior to installation. Failure to follow the correct order and direction
of the dished surfaces on the Washers will result in a restricted
rotation of the Combustion Air Blower.
B: Inspect the Combustion Air Blower for warpage and/or damage. If
warpage or damage is visible, the Combustion Air Blower must be
replaced. Reference the Hydro-Hot's "Parts Manual" for spare parts
information.
10. Slide the Combustion Air Blower's shaft (with the three washers) up
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Page 61
Bearings, through the Bearing Kit assembly until the threaded portion appears
on Side-A of the Blower Casing, reference Figure 23. Place the new
continued 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. Place a feeler gauge between the Combustion Air Blower and the
flat surface of the Blower Casing. Slowly tighten (or loosen) the
Retaining Nut, holding the Combustion Air Blower, until a .003 - .005
gap is achieved.
12. Spin the Combustion Air Blower to ensure a friction free rotation.
NOTE: If the Combustion Air Blower is rubbing, loosen the Retaining
Nut slightly and lightly tap on the Combustion Air Blower's shaft (oppo-
site side {i.e. Side-B}), then readjust the gap (repeat Steps 11 and 12).
13. Reattach the Blower Housing to the Blower Casing using the four
Blower Housing Screws. Reinstall a Clutch Half on both the Motor's
shaft and the Combustion Air Blower's shaft. Attach the Motor and
flange assembly, with the recessed edge of the Motor Flange in-line
with the wiring access slot of the Blower Casing, to the Blower
Housing with the three Hex Head Screws, reference Figure 14.
Reconnect the Black (+) and Brown (-) wires of the Motor to the C-
Plug Harness' Black (+) and Brown (-) wires, reference Figure 13.
Feed the C-Plug Harness' Yellow and Brown wires back through the
wiring access hole in the Protection Cap, reference Figure 14.
15. Reinstall the Protection Cap. Reconnect the Black (+) and Brown (-)
wires of the Ignition Coil to the C-Plug Harness' Yellow (+) and
Brown (-) wires, reference Figure 24. Reinstall the Ignition Coil and
secure to the Protection Cap with the four Ignition Coil Screws,
reference Figure 13. Reconnect the Ignition Cables to the Ignition
Electrodes, reference Figure 16.
and secure in place with the four Nozzle Stand Plate Screws.
Reattach the Fuel Supply and Return Lines to the Diesel-Burner
Head.
17. Reconnect the Blue (+) and Brown (-) wires to the Fuel Solenoid's
(+) and (-) Electrical Terminals, reference Figure 18. Also, recon-
nect the Flame Sensor's Green wire to the Green C-Plug Harness
wire and the Blue wire to the C-Plug Harness' Violet wire, reference
Figure 15.
Page 62 R
Bearings,
continued
Side-B Side-A
Blower Casing
Blower Housing Rubber
Grommets
Blower Housing Combustion Air Blower Casing
Screws Blower w/shaft O-Ring
Dished
Surface
Washer
Dished
Wave
Surface Snap Retaining
Washer
Washer Ring Flat Drive Nut
Bearing
Flat Washer Gear
Spacer (Thick)
Washer (Steel)
Tube
Snap
Ring Bearing
Bearing Kit Figure 23
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Page 63
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.
NOTE: In order to perform some of the following procedures it is neces-
sary to detach and reattach the Diesel-Burner Head. Be sure to review
Component Test: Remove the four Ignition Coil Screws that secure the
Ignition Coil in place, reference Figure 13. Disconnect the Ignition Coil's
Black (+) and Brown (-) wires from the C-Plug Harness' Yellow (+) and
Brown (-) wires. Connect the Ignition Coil wires directly to a 12 volt DC
power supply (i.e. Black (+) wire to (+) lead and Brown (-) wire to (-) lead).
Turn the power supply ON and watch for a spark to appear across the
metal tips of the Ignition Electrodes, reference Figure 16. If a spark does
not appear, the Ignition Coil must be replaced, reference the Ignition Coil's
"Replacement Procedure" below. Reference Section 10 for spare parts
information.
1. Disconnect the Ignition Cables from the Ignition Electrodes, refer-
ence Figures 16 and 19. 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 (reference Figures 3 and 24).
2. Connect the new Ignition Coil's Black (+) and Brown (-) wires to the
C-Plug Harness' Yellow (+) and Brown (-) wires, reference Figure
24. Attach the Ignition Coil to the Protection Cap with the four
Ignition Coil Screws, then reconnect the Ignition Cables to the
Ignition Electrodes.
Ignition
Coil
Ignition
Cable
Brown
Wire (-) Black
Wire (+)
Brown Wire (-)

Figure 24 (to Diesel-Burner)
Yellow Wire (+)
(to Diesel-Burner)
Page 64 R
Control Unit 8.11 Control Unit
Function: The Control Unit operates all the components of the Diesel-
Burner 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.
Component Test: The following conditions must exist prior to performing
the Control Unit circuit tests on the following page. If one of the conditions
below does not exist, please contact our Technical Support Department at
1-800-685-4298 for additional assistance.
Condition #1
A battery voltage level of between 11.5 to 14.0 volts DC must be
present at the Control Unit during all testing, reference Figure 25. It
may be necessary to perform a voltage check to ensure that this
condition exists. To perform the voltage check, locate the Control
Unit's B-Plug, and insert the probes of a DC voltmeter into the B-4
(+) and B-2 (-) locations, reference Figure 26.
Condition #2
A voltage level of between 11.5 to 14.0 volts must be present at the
Diesel ON/OFF switch circuit of the Control Unit during all testing. It
may be necessary to perform a voltage check to ensure that this
condition exists. To perform the voltage check, locate the Control
Unit's B-Plug, and insert the probes of a DC voltmeter into the B-1
(+) and B-2 (-) locations, reference Figure 8. Turn the Diesel switch
ON and observe the voltage level, reference Figure 4.
Diesel-Burner
Control Unit
Diesel-Burner
Head
Figure 25
R
Page 65
Control Unit,
continued
B-2 ( - ) Battery Circuit (Brown Wire)

to JP-4 (Pin 4)
12.5 V
COM (-)
(+)
B-Plug B-1 B-2 B-3

B-4 B-6
B-4 ( + ) Battery Circuit (Red Wire)

to JP-4 (Pin 3)
Figure 26
Page 66 R
Control Unit, NOTE: If after performing the following circuit tests, the Control Unit is
continued 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. Insert the
probes of a DC voltmeter into the B-4 (+) and C-5 (-) locations and turn the
Diesel switch ON, reference Figures 4 and 8. If a voltage reading does not
register on the voltmeter, the Control Unit must be replaced. If voltage is
present, proceed to the next circuit test.
VDC / VAC Control Thermostat circuit test

probes of a DC voltmeter into the C-1 (+) and B-2 (-) locations and turn the
VDC High-Limit Thermostat circuit test

probes of a DC voltmeter into the C-4 (+) and B-2 (-) locations and turn the
Motor circuit test

Locate the Control Unit's C-Plug, reference Figure 8. Use a jumper wire to
make a connection from the C-1 location to the C-7 location, reference
Figure 8. Turn the Diesel switch ON and insert the probes of a DC voltme-
ter into the C-2 (+) and C-5 (-) locations, reference Figures 4 and 8. If no
voltage reading registers on the voltmeter, the Control Unit must be re-
placed. If voltage is present, proceed to the next circuit test.
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. A failure to do
so will result in an overheating condition during normal operation.
Ignition Coil circuit test

Turn the Diesel switch OFF and locate the Control Unit's C-Plug, reference
Figures 4 and 8. Use a jumper wire to make a connection from the C-1
location to the C-7 location, reference Figure 8. Also, locate the VDC High-
Limit Thermostat and disconnect it's 2-way male plug from the (white
plastic) 6-way female connector, reference Figure 1. Insert the probes of a
DC voltmeter into the C-8 (+) and C-5 (-) locations and turn the Diesel
switch ON, reference Figures 4 and 8. If a voltage reading does not
register on the voltmeter, 18-25 seconds after the initial start-up, the
Control Unit must be replaced.
R
Page 67
Control Unit, NOTE: Be sure to reconnect the VDC High Limit Thermostat's 2-way
continued 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 discon-
nected.
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. A failure to do
so will result in an overheating condition during normal operation.

1. Remove both the B-Plug and C-Plug from the Control Unit, refer-
ence Figure 8. Gently pry away each side of the Control Unit
Bracket from the Control Unit's locking posts with a flat-head screw
driver. Once the locking posts have been released, pull on the
Control Unit to remove it from the Diesel-Burner Head.
2. Slide the new Control Unit into the Control Unit Bracket, reference
Figure 27. Push down on the Control Unit until the locking posts
snap into the bracket slots. Reinstall both the B-Plug and C-Plug.
NOTE: Be sure to install the Control Unit with it's C-Plug and B-Plug
ports facing downward. Failure to do so, will result in moisture collecting
in the ports and potential damage to the Control Unit's internal circuitry,
Page 68 R
Control Unit, 7.11 Control Unit

continued
Bracket Slots
Locking Posts
Control Unit
Control Unit
Bracket Figure 27
R
Page 69
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 war-
ranted for the remainder of the Heater's standard warranty period or for six months (180 days),
whichever is greater.
This warranty is conditional upon proper use of the Heater by the end-user. This war-
ranty does not apply to damage or failure of the HYDRO-HOT Heater, or the vehicle into
which it was installed, due to improper installation, assembly, maintenance, abuse,
neglect, accident, or the use of parts not supplied by Vehicle Systems Inc. Vehicle Sys-
tems is not responsible for incidental or consequential damages.
The intent of this warranty is to protect the end-user of the heating system from such defects,
which would occur in the manufacture of the product. The warranty is not intended to protect
the end-user from problems, which are outside the ability of Vehicle Systems’ control.
To obtain warranty repair authorization or for additional product information, please contact our
Technical Department at 1-800-685-4298 (8 AM to 5 PM Mountain Standard Time).
Page 70 R
Section 10: Spare Parts List
Control Unit
305
1 1 2 3 1 2 4
302
2 4 5 6 5 6 7 8
303
313 A B C
409
2455RM8589-6 L220
72 2 410
GEMS
59
411
412
2455RM8589-6 L220
62
61
50
56 5 51
27
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, Fuel Solenoid, DBW 2010-300, AH/HH/WH
56 WPX-274-313 Electrode, Ignition, DBW-2010, AH/HH/WH
59 WPX-638-78A Sensor, Flame, DBW 2010-300, AH/HH/WH
61 WPX-887-71A Photo Disc, DBW-2010, AH/HH/WH
62 WPX-886-41A Nozzle, Fuel, 0.35 GPH, DBW-2010, AH/HH/WH
72 WPX-502-05A Pump, Fuel, 10 Bar, DBW 2010-300, AH/HH/WH
302 FLX-120-VS1 Filter, Fuel, System, 10 Micron, AH/HH
303 FLX-R12-TRA Filter, Fuel, Spin-On Element, 10 Micron, AH/HH
305 WPE-905-83H Burner-Head, Diesel, Modified, VSI DBW-2010, 12 VDC, HH
313 WPX-265-53A Combustion Chamber, DBW-2010, AH/HH/WH
409 ELE-ASY-001 Thermostat Assembly, VAC High-Limit, 220�F, HH
410 ELX-01G-ML7 Switch, Float, HH
411 ELE-C14-001 Thermostat, VDC / VAC Control, 200�F, HH
412 ELE-HLT-222 Thermostat, VAC High-Limit, 220�F, HH
R
Page 71
Section 11: Special Tools
80 100 120
60 140
40 160
20 psi 180
0 200
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.
(Grainger Part# 6T153)
Page 72 R
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.com
LTE-VHS-220

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1.1 Component Overview .............................................. 1

Section 2 Wiring Information

2.0 Wiring Information ................................................... 3

Section 3 Switch Panel

3.1 Diesel Switch ........................................................... 4

Section 4 Electronic Controller

4.1 Electric Heating Element Status Indicator Light ....... 5

5.1 Component Overview. ............................................. 8

6.1 Control Unit Wiring ................................................. 14

7.1 Troubleshooting ...................................................... 15

Section 8 Diesel-Burner Service, Maintenance, and Repair

Section 9 Warranty Information

9.0 Warranty Information .............................................. 70

Section 10 Spare Parts List

10.0 Spare Parts List ...................................................... 71

Section 11 Special Tools

11.0 Special Tools ........................................................... 72

Component 1.1 Component Overview

I.D. Plate 1.2 Identification Plate

For Installation Only in Compartment Completely

Exhaust system MUST NOT terminate beneath

Combustion Air MUST BE supplied

USE COPPER CONDUCTORS ONLY

HM02-224 120 VAC, 60 Hz / 1.65 kW CAUTION: The Mixing / Anti-Scald Valve

Manufactured Date Fuel Type / Firing Rate Minimum Heater clearances

Serial Number Reference Figure 1 for

Hydro-Hot Hydronic Heating System Shop Manual 07/03

green VDC High-Limit

Switch Panel 3.0 Switch Panel

Diesel Electric Engine

3.2 Electric Switch

3.3 Engine Preheat Switch

Electric Heating Low Voltage Hydro-Hot

4.2 Heating Zones Status Indicator Lights

Electronic 4.3 Low Voltage Reset (Button)

4.4 Emergency Cutoff Indicator Light

4.5 Heating Status Indicator Light

4.6 Engine Preheat Pump Indicator Light

4.7 Circulation Pump #1 Indicator Light

Electronic 4.8 Circulation Pump #2 Indicator Light

4.9 Stir Pump Indicator Light

4.10 Low Battery Voltage Fault Indicator Light

4.11 Low Temp Cutoff Status Indicator Light

4.12 Diesel-Burner Status Indicator Light

4.13 Overload Fault Indicator Light

Component 5.1 Component Overview

1. Control Unit 10. Heat Exchanger

Operational 5.2 Operational Flow-Chart

B.) The Hydro-Hot’s Diesel SUMMARY:

5.3 Operational Sequence

Combustion Air Exhaust Gases

The particular component begins to operate.

The component is currently operating.

NOTE: The Motor and Combustion

Combustion Diesel Fuel

5.3 Operational Sequence

Combustion Air Exhaust Gases

The particular component begins to operate.

The component is currently operating.

Diesel-Burner Operation, continued

The combustion’s flame is detected by the

5.3 Operational Sequence