General Components WALRUS 5000C User manual

WALRUS 5000C
DIESEL COOLANT HEATER INSTRUCTION MANUAL
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WALRUS 5000C
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PREFACE
aims to answer all questions the user may have
about the product, however, if you have any
doubts or find anything incorrect in this manual,
please contact us directly. Check the heater for
any damage when unpacking and contact the dealer
immediately if any damage is found. If any
troubles arise during application, please
contact General Components or the company who
sold it to you. We shall do our best to provide
service to you.
Thank you for purchasing the
WALRUS 5000C coolant heater. This instruction
book describes the structures, working
principles, installation and operation of the
WALRUS 5000C. For correct use of the heater,
please read this instruction book carefully
before installation and operation. The
instruction book should be saved in a convenient
place for later reference. This instruction book
is subject to revision without notice, but will
conform to the purchased product. This manual
PREFACE ................................. 2
TABLE OF CONTENTS........................ 2
INTRODUCTION............................. 3
STRUCTURE ............................... 3
EXPLODED PARTS DIAGRAM ................... 4
DIMENSIONS, mm........................... 5
ALLOWABLE MOUNTING ANGLE ................. 5
FUEL PUMP ANGLE & SUCTION HEIGHT ......... 8
FUEL LINE CONNECTIONS .................... 9
FUEL STANDPIPE.......................... 10
WIRING DIAGRAM ......................... 13
CONNECTIONS ............................ 14
TIMER CONNECTIONS ...................... 14
OPERATING INSTRUCTIONS.................. 15
CHANGING LANGUAGE .................... 15
PRE-SETTING HEATING TIMES............. 16
MAINTENANCE .......................... 16
INSPECTION CHECKLIST.................. 16
ADDITIONAL PRECAUTIONS................ 17
TROUBLESHOOTING ........................ 18
TABLE OF CONTENTS

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INTRODUCTION
WALRUS 5000C is a 5kW modulating
diesel fired water heater, which is suitable for
providing hot water for heating purposes via
radiators or matrix heaters and also domestic
hot water via a calorifier. The WALRUS 5000C
is fully automatic in operation featuring low
energy glow pin ignition and microprocessor
control for full temperature regulation. It
has low servicing costs due to modular
construction and its simple wiring means
simple, 2wire system thermostats can be added
into the installation. It can be applied to
various heating purposes, whether its hot water
heating for easier living or engine pre-heating
and demisting. For both vehicle and marine
markets, WALRUS 5000C is a great way to
efficiently meet your heating needs. This
kit includes everything necessary for
installation excluding plumbing to the
radiators and calorifiers.
STRUCTURE
1. Heat Exchanger Assembly
2. Base Cover
3. External Water Pump
4. Fan Cover
5. Glow Pin Lining
6. Glow Pin
7. Glow Pin Housing
8. Flame Sensor
9. Holder
10. Temperature and Overheat Sensor
11. Temp sensor ‘O’ Rings
12. Leaf Spring
13. E.C.U.
14. Combustion Chamber
15. Combustion Chamber Seal
16. Air Motor
17. Fuel Pump
18. Timer Control
19. Main Wiring Harness

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EXPLODED PARTS DIAGRAM
1. Heater Cover
2. Heater Mounting Bracket
3. Combustion Air Intake Clamp
4. 22mm Combustion Air Intake
5. Combustion Air Fixing ‘P’ Clip
6. Exhaust Clamp
7. 24mm Exhaust - 1M (*)
8. Exhaust ‘P’ Clip
9. 24mm Exhaust Silencer*
10. Exhaust Mounting Bracket
11. Exhaust Silencer Clamp*
12. Fuel Standpipe
13. Inline Fuel Filter
14. Fuel Pump
15. Fuel Pump Bracket
16. Anti-Vibration Mount
17. Rubber Fuel Connector
18. Fuel Line Connector Clamp
19. Fuel Damper (Optional)
20. Rubber Coolant Pipe
21. Coolant Pipe Connectors
22. Bypass Valve (**)
23. Reducing Pipe Connectors
24. Coolant Pipe Clamps
25. Coolant Pipe Clamps
26. Fuel Pump Power Loom
27.Fuse Holder
28. Matrix Heater Relay
29. Main Wiring Harness
30. Heater body Loom and Plug
*Combined 2.3m stainless steel exhaust and silencer for marine applications
**Only supplied in vehicle applications

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Do not install the heater anywhere near
flammable sources, including the fuel tank, in
closed spaces without ventilation or exposed in
the proximity of people without a proper heat
shield.
DIMENSIONS, mm
The heater should ideally be installed in
the engine room, but with ease of access for
removal and servicing of the unit.
The main heater body is mounted onto a
suitable surface with a bracket. Ensure it is
lined up with all relevant holes in the correct
position. Once it is in place the unit can be
mounted to the bracket with the M6X10 bolt
supplied in the kit.
ALLOWABLE MOUNTING ANGLE
A. Combustion Air Inlet
B.
Exhaust Outlet
C.
Fuel Inlet
D.
Coolant Outlet
E.
Coolant Inlet

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1.Matrix Heater 2. The Heater 3. External Water Pump 4. Engine
The figure above shows the installation
of the coolant circulation system in a marine
application, not using a bypass valve. Figure
below shows the way to install the system in a
vehicle, using the bypass valve.
1. Matrix Heater 2. The Heater 3. Bypass Valve 4. External Water Pump 5. Engine
To bleed the system, simply loosen the
outlet hose from the heater and begin the system.
Any excess air should immediately circulate out
of the system and the hose can be re-tightened.
During installation, any existing coolant in the
system should be flushed out with clean water and
then re-filled with new coolant. Ensure you use
the right coolant specified for your vehicle.

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1. Heater
2. P-Clip
3. Air Silencer or End Cap
4. 20mm Combustion Air Intake
5. Exhaust P-Clip
6. Exhaust Silencer
7. 24mm Exhaust with End Cap
8. Exhaust Clamps (*)
Figure above shows the installation of the
air intake and exhaust. Make sure you only use
the appropriate pipes provided and use the clamps
to secure them in position.
The air inlet pipe is used to bring in
combustion supporting air into the furnace of the
heater from outside of the vehicle and in the
opposite direction of travel to ensure that the
air is clean and doesn’t clog up the pipe with
dirt and dust.
(*) Not necessary when the silencer is
built into the exhaust as part of a marine
application for example.
Make sure that the exhaust and any other
parts that become hot during the operation of the
heater are away from anything damaged by a high
heat like wires or plastics.
Also, please ensure that the exhaust does
not exit in such a way that the fumes are re-
circulated by the air inlet pipe or can be
inhaled by anyone.
The mounting bracket is supplied in the
installation kit, along with a 100mm M6 hex bolt, used
to secure the heater in place to the bracket using one
of the two M6 taps, located near the center of the
bracket.

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FUEL PUMP ANGLE & SUCTION HEIGHT
1. Heater Body
2. Max. Fuel Level
3. Min. Fuel Level
4. Fuel Pump
A. 3000mm
B. 500mm
C. 2000m
D. Not acceptable
E. Acceptable (between 15-
19°)
F. Not acceptable
Figure shows the ideal way to mount the fuel pump. The fuel pump’s outlet
should tilt upward at an angle between 15˚-35˚ (as shown above).
1. Fuel Tank
2. Fuel Standpipe
3. Fuel line Hose Clamp
4. Fuel Line
5. Rubber Fuel Connector
6. Fuel Filter
7. Fuel Pump
8. To Heater

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FUEL LINE CONNECTIONS
1. Fuel Connector Clamp 2. Fuel Pipe 3. Rubber Fuel Connector
Figures on this page show the correct way
to connect fuel lines to prevent the build-up of
air bubbles: Ensuring they are flush and
minimizing bends.
When the fuel is being sucked from the
vehicle tank, or an independent tank, a fuel
standpipe is required. Make sure all the openings
are appropriate for the installation and a tight
seal is maintained for the base of the standpipe
(see pages 10-11).
The bottom of the suction pipe should be
about 30-40mm from the bottom of the fuel tank,
to avoid sucking impurities or sediment from the
bottom.

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Only use the fuel line provided, ensure
the pipe is placed away from any possible debris
and avoid any sagging in the line. Make sure the
fuel line does not flow downward toward the fuel
pump. This will prevent correct fuel flow and
produce air bubbles in the line.
The fuel filter, fuel pipe and clamps should all be replaced after approximately 2 years of use.
This figure shows the allowable, installations angle of the fuel
filter, as well as the direction of fuel flow (arrow A). The filter
should be fitted between the vehicles tank and the fuel pump.
FUEL Pick-up Tubes
A Fuel pick-up tube will need to be
installed in the vehicle’s fuel tank or an
independent fuel tank depending on what the
installation calls for. Sealant is not required
to fit the pick-up tubes.
Depending on the pick-up tube provided in the
kit, you will need to install the pick-up tube
in one of two ways.
Usually supplied in Marine kits and supplied bent, this standpipe is installed like so:
•Drill a hole in the top of the vehicle’s fuel tank Φ22 ± 0.2mm in size. Ensure it is smooth
and clean of burrs
•Remove the top nut and washers and bend the standpipe straight
•Straighten the standpipe and cut it down to size if necessary

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•Fit the standpipe by tilting it into position into the newly drilled hole

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Supplied mainly in vehicle kits, this standpipe is installed like so:
•If possible, remove the sender unit from the vehicles fuel tank, this will make it easier to
attach the nut securely back onto the standpipe
•Drill a Φ6 ± 0.2mm hole into the sender unit
•Remove the nut from the standpipe and feed it through the hole ensuring the rubber ‘o’ ring
remains on the standpipe ‘head’ side
•Replace the nut on the standpipe to secure it safely to the sender unit.
•Replace the sender unit into the fuel tank.
The bottom of the fuel standpipe should be 30-40mm from the bottom of the fuel tank to allow
enough suction of fuel and at the same time not allow impurities and sediment to be drawn up the
standpipe.

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WIRING DIAGRAM

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CONNECTIONS
The connections on the main wiring harness
have all been pre-fitted so that only simple
connections to the corresponding plugs need to
be made.
The main connections on the heater are to
the main wiring harness, and to the water pump.
The connections on the wiring harness are for
the timer control, to the fuel pump, and to the
remote control (if one is installed, otherwise
it can be left unplugged), and to the main heater
itself. The remaining wires are installed as
follows:
Attach the positive line (4mm² red) to
the positive terminal of the vehicle’s battery
and the negative (2.5mm² brown) to the negative
terminal.
The black wire (4mm²) of the matrix
heater’s relay should be connected to the
vehicle’s fuse box, and the black/ purple wire
(4mm²) should be connected to the positive
terminal of the matrix heater.
All electrical components of the heater
should join to the main wiring harness according
to the corresponding connections. The only plug
that can be left unattached is the remote control
port (red, brown, and yellow) as it is an
optional extra.
Note: All terminals should be connected,
even if not in use to prevent short circuiting.
And when fitting the electrics, make sure
any exposed wiring outside of the vehicle are
well protected from damage or heat.
TIMER CONNECTIONS
All connections should be prepared for you
in your kit. However, if changes need to be made,
or terminals have become disconnected, use the
following diagrams to ensure the timer plugs are
wired correctly.

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OPERATING INSTRUCTIONS
CHANGING LANGUAGE
The language should be set to English. However, if it isn’t or the
control has been reset to default settings it will revert to Chinese. Please
follow these steps to convert the language to English.
1. Turn on the control with the power button. Wait for the symbols to
stop flashing, then press the power button again.
2. Navigate to the clock face symbol at the top of the control by using
the arrow keys. When it is flashing press both arrow keys
simultaneously.
3. P1 now appears.
4. Press ok and C1 will appear.
5. Keep pressing ok slowly until ‘02:oF’ appears.
6. Press any of the arrow keys until the screen reads ‘02:on’
7. Keep pressing ok until back to the P1 menu screen
8. Press power button to return. The language will now be set to
English.

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PRE-SETTING HEATING TIMES
The digital control can be used as a 7-Day timer, and is able to be
preset to switch on up to three times a day.
1. Navigate to the ‘P’ symbol, and press OK.
2. Using the arrow keys select the number 1 (flashing) at the top of the
screen, and press OK –Number 1 is the first heating time.
3. Using the arrow keys, select ‘ON’, as this will allow the heater to
switch on after the presetting is finished. Press OK to confirm.
4. Select the length of time you want the heater to run for by using the
arrow keys.
5. L800 represents 800 minutes. Run time can be selected from 50-990. Press
OK to confirm.
6. Select the hour you wish the heater to start at by using the arrow keys
and then pressing OK to confirm.
MAINTENANCE
Once the heater is installed, it should ideally be turned on a few times to remove any air trapped
in the fuel lines. Also ensure there is no leaks from the lines and that all electric terminals fit
securely together.
INSPECTION CHECKLIST
•Check the air inlet and outlet for any pollution or
•foreign matters
•Clean the externals of the heater
•Check for corrosion or loose connections of the
•circuits
•Check the combustion air inlet and exhaust pipe for
•damage and clogs
•Check the fuel line for leaks

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To ensure a long life of the heater it is
advised that you run it for at least 10 minutes
every month to prevent malfunction of mechanical
parts.
After 10 years the heat exchanger, overheat
sensor and exhaust should be replaced by a
professional.
If any welding is being attempted on the
vehicle, please remove the positive power supply
wire and earth it to protect the controller from
any damage.
ADDITIONAL PRECAUTIONS
1. A trial run is useful before continual use
of the heater to ensure all parts are working
correctly. If lasting dense smoke occurs,
irregular combustion noise, lingering fuel
smell, or overheating happens, the heater
should be switched off and allowed to cool.
The fuse should also be removed, rendering
the heater unusable. The installation should
then be looked over, paying close attention
to any loose connections of electrics, or
pipework. A voltage check may be required, as
well as checking fuel levels.
2. If the heater has not been allowed to cool
down before restarting, don’t be alarmed
when ignition does not occur straight away.
The heater will go into a self-check mode,
and will only start when the internal
temperature has cooled to appropriate levels.
3. If any problems persist, the heater and
installation should be looked at by a trained
professional.
4. Note: Once switched off, the water pump and
air motor will continue to run. This is the
cool down cycle, and is necessary to prevent
damage to internal parts.
5. Be sure to turn the heater off before filling
up the fuel tank.
6. Theheatershouldideallyberunfor10minutesever
ymonth to prevent the fuel pump, or any moving
parts from blocking.
7. The manufacturer will not be held responsible
for any damage to the heater caused by
anything That violates these instructions.

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TROUBLESHOOTING
Fault codes will be displayed on the timer.
Press the P key in the heating mode. The fault code
will be displayed as XEXX, where X is the breakdown
number and XX is the fault code (see next page).
Use the arrow keys to view the breakdown
information.
To eliminate the failure information; hold
down the P key and press the heating button. The
information will now be cleared. Press the heating
button again to display the current time.
Treatment of usual troubles If the heater
is switched on but does not work correctly, the
following methods can be used for treatment.
•Turn off and then restart the heater. Do not restart the heater
more than twice if the same problem persists.
•Ensure that the heater has cooled completely before attempting
a restart, paying close attention if the coolant temperature
has exceeded 70°C.
•Check the fuses
•Ensure that there is sufficient coolant in the system before
starting-up, and never start the heater if the coolant has
frozen.

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