Airtronic 2-4 TD TS Parts 12-2012 ESPAR

* / AIRTRONIC
* M
AIRTRONIC
Espar Heater Systems
Technical Description
Installation Instructions
Operating Instructions
Maintenance Instructions
Troubleshooting and Repair Instructions
Parts List
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AIRTRONIC D2
25 2069 05 - 12 Volt
25 2070 05 - 24 Volt
AIRTRONIC M D4
25 2113 05 - 12 Volt
25 2114 05 - 24 Volt
AIRTRONIC D2 Camper
25 2326 05 - 12 Volt
AIRTRONIC M D4S
25 2144 05 - 12 Volt
AIRTRONIC M D4 Camper Plus
25 2327 05 - 12 Volt
20 2900 81 01 03 0F
11.2010 Subject to Change
Espar Products, Inc.
(800) 387-4800
(905) 670-0960
www.espar.com
AIRTRONIC M B4
20 1812 05 - 12 Volt
Table of Contents
Page
Introduction
Heater Warnings
Introduction
Technical Data
Dimensions
Heater Components
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3
4
5
6
7
Installation Procedures
Heater Location
Heater Mounting
Heater Plate installation
Mounting Pattern
Heater Air Ducting
Ducting Components
Fuel System
Electrical Connections
Exhaust/Intake Connections
Operating Switches
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8
8
8
9
9
9
10
12
13
13
Heater Operation
Switch on
Start-Up
Temperature setting
Temperature Control
Switching Off
Controls & Safety Equipment
Operational Flow Chart
Function Diagrams
Schematic AIRTRONIC D2/D4
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14
14
15
16
16
16
16
17
18
Maintenance,
Troubleshooting &
Repairs
Periodic Maintenance
Basic Troubleshooting
Self Diagnostic Troubleshooting
Fault Codes
Fuel Quantity Test
Overheat/Flame sensor values
Control and Resistance values
Repair Steps
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21
21
22
23
29
29
30
31
Heater Parts
AIRTRONIC D2/D4
-Service Parts Diagram
-Service Parts List
-Parts List Diagram
-Parts List
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36
37
38
39
Special Notes
Note: Highlight areas requiring special attention or clarification.
Caution: Indicates that personal injury or damage to equipment may occur unless specific guidelines are followed.
Warning: Indicates that serious or fatal injury may result if specific guidelines are not followed.
This document aims to support service technicians and end users in North America. This does not replace documentation produced by J. Eberspächer.
The installation instructions and standards described in this document are NOT APPLICABLE TO MARINE INSTALLATIONS. Please consult a certified Espar Marine dealer for marine installation.
This publication was correct at the time of going to print. However, Espar Inc. has a policy of continuous improvement
and reserves the right to amend any specifications without prior notice.
2
Introduction
Heater Warnings
Warning To Installer:
Correct installation of this heater is necessary to ensure
safe and proper operation.
Read and understand this manual before attempting to
install a heater.
Warning - Explosion Hazard
1. Heater must be turned off while re-fueling.
2. Do not install heater in enclosed areas where combustible fumes may be present.
3. Do not install heaters in engine compartments of
marine vessels.
Warning - Fire Hazard
1. Install heater so it will maintain a minimum distance of
2” from any flammable or heat sensitive material.
2. Install the exhaust system so it will maintain a
minimum distance of 2” from any flammable or heat
sensitive material.
3. Ensure that the fuel system is intact and there are no
leaks.
Failure to follow these instructions could cause fire resulting
in serious or fatal injury.
Warning - Asphyxiation Hazard
1. Route the heater exhaust so that exhaust fumes can
not enter any passenger compartments.
ATTENTION
Operation with bio-diesel
AIRTRONIC D2
The diesel heater is not approved for 100% Bio-Diesel. Mixtures
up to 10% bio fuel (FAME) may be used.
Airtronic M (D4)
The diesel heater is approved for up to 100% Bio-Diesel according to the following conditions:
- Bio-Diesel (FAME) according to Standard CAS NO. 67784-809 (or similar) in free flowing state (reduced at tempera
tures below 0°C (32°F);
- Operation of heater with mixtures greater then 10% is restriced during periods of temperatures below 0°C (32°F)
- Maintenance schedule for Bio-Diesel mixtures greater then
10%
- Heater must be run for 30min on high heat with regular
diesel fuel once every 500h if mixtures above 20% are
used;
- Vent hole must be cleaned every 500h (twice a heating
season assuming 1000h of operation annually);
- Atomizing Screen must be replaced every 500h (twice a
heating season assuming 1000h of operation annually).
All maintenance procedures may be performed without removing heater from vehicle.
ATTENTION
Heating at high altitudes
Up to 1500 meters (4920’) - unrestricted heating operation is
possible.
2. Ensure an air tight seal is maintained between the heater
and mounting surface and at any exhaust connection
points.
Above 1500 meters (4920’) - heating operation is in principle
possible for short periods, e.g. when crossing a mountain pass
or during a brief stop. In cases of extended stays , the fuel
supply at the fuel metering pump has to be adapted to high
altitude conditions.
3. Ensure that heating air supply is taken from an area
where poisonous gases will not be present.
The following high altitude kits are available:
4. If running exhaust components through an enclosed
compartment, ensure that it is vented to the outside.
Failure to follow these instructions could cause oxygen
depletion resulting in serious or fatal injury.
P/N: 24 0222 00 00 00 - 12V only (Contains high altitude fuel pump)
or
P/N: 20 2900 70 00 07 - 12V or 24V (Contains high altitude compensator, no extra fuel pump needed)
or
P/N: 22 1000 33 22 00 - 12V or 24V (Only works with Airtronic
Heaters that have “H-Kit” on the factory label)
Direct questions to Espar Heater Systems
Note: Only one kit from the listed above is needed.
Canada & U.S.A. 1-800-387-4800
Marine conciderations:
· Follow marine manual for installation requirements (separete
document)
· Gasoline (B4) heaters must not be installed in ingene compartment.
· Diesel or Gasoline (petrol) heaters must not be installed in
engine compartment of gasoline (petrol) boats.
3
Introduction
Espar ‘s AIRTRONIC bunk heaters
The AIRTRONIC D2 is a compact diesel-fired 7,500 BTU/hr air heater,
quality engineered to provide a dependable means of space heating.
This heater is uniquely designed for inside mounting and ease of installation. The AIRTRONIC D4 is a 13,650 BTU/hr air heater for larger
bunks.
These heaters provide hot air to the interior of vehicles for passenger
comfort. Since the heater runs on diesel fuel and are available in
12 or 24 volt versions, it is able to provide space heat completely independently of the vehicle engine.
Various control options are available to operate the heater. It cycles
through four heat output modes (boost-high-medium-low) in order to
maintain the desired temperature.
In special cases where the heat output required is less then what the
"low" power mode provides the heater switches to "stand-by" mode.
Temperature and overheat sensors, and a specially designed heat
exchanger are among the safety features which make this heater a safe
and dependable unit.
For illustration purposes only
4
Product Information
Technical Data
Heater
Version
AIRTRONIC D2
D2
AIRTRONIC D4
D4
AIRTRONIC B4
B4
Heat Output (±10%)
7,500
6,150
4,100
2,900
13,650 BTU/hr Boost (4.0 kW)
10,200 BTU/hr High (3.0 kW)
6,800 BTU/hr Medium (2.0 kW)
3,500 BTU/hr Low (1.0 kW)
12,950 BTU/hr Boost (3.8 kW)
10,910 BTU/hr High (3.2 kW)
7,160 BTU/hr Medium (2.1 kW)
4,430 BTU/hr Boost (1.3 kW)
Current at 12v (±10%)
8.3
2.8
1.8
1.0
0.7
0.4
Start
Boost
High
Medium
Low
Stand by
8.3
3.3
2.0
1.1
0.6
0.4
amps
amps
amps
amps
amps
amps
-
Start
Boost
High
Medium
Low
Stand by
8.3
3.3
2.4
1.3
0.8
0.4
Current at 24v (±10%)
4.2 amps - Start
1.4 amps - Boost
0.92 amps - High
0.5 amps - Medium
0.3 amps - Low
0.2 amps - Stand by
4.2
1.7
1.0
0.5
0.3
0.2
amps
amps
amps
amps
amps
amps
-
Start
Boost
High
Medium
Low
Stand by
BTU/hr
BTU/hr
BTU/hr
BTU/hr
amps
amps
amps
amps
amps
amps
Fuel Consumption (±10%)
Boost
High
Medium
Low
-
Boost (2.2 kW)
High (1.8 kW)
Medium (1.2 kW)
Low (0.85 kW)
U.S.
Gal/hr
Litre/hr
0.07
0.06
0.04
0.03
0.28
0.23
0.15
0.10
Boost
High
Medium
Low
amps
amps
amps
amps
amps
amps
-
Start
Boost
High
Medium
Low
Stand by
(No 24V version available)
U.S.
Gal/hr
Litre/hr
0.13
0.10
0.07
0.03
0.51
0.38
0.25
0.11
Boost
High
Medium
Low
U.S.
Gal/hr
Litre/hr
0.14
0.12
0.08
0.05
0.54
0.46
0.29
0.18
Air Flow (±10%)
48 cfm Boost
40 cfm High
27 cfm Medium
19 cfm Low
6 cfm Stand by
85 cfm Boost
69 cfm High
50 cfm Medium
30 cfm Low
11 cfm Stand by
85 cfm Boost
74 cfm High
55 cfm Medium
43 cfm Low
11 cfm Stand by
Operating Voltage Range
10.5 - 16 vdc at 12 vdc
21 - 32 vdc at 24 vdc
10.5 - 16 vdc at 12 vdc
21 - 32 vdc at 24 vdc
10.5 - 16 vdc at 12 vdc
21 - 32 vdc at 24 vdc
Overheat Temperature
Shutdown (±10%)
240°F (115°C)
240°F (116°C)
240°F (116°C)
Ambient Operating
Temperature
-40°F to 158°F (-40°C to 70°C)
-40°F to 158°F (-40°C to 70°C)
-40°F to 122°F (-40°C
Weight
5.9 lbs. (2.7 kg)
9.9 lbs. (4.5 kg)
9.9 lbs. (4.5 kg)
Note: The heater control unit is equipped with a low
voltage cutout to prevent vehicle battery drain and a
high voltage cutout to protect heater electrical parts.
to
50°C)
Note: The terms "Boost" and "Power" are used interchangeably through out this manual. The terms refer to the
highest level of heat output.
5
Product Information
* All measurements in millimeters
25.4 mm = 1”
Minimum installation distance
(clearance) to open the lid and to
dismount the glow pin and the
control unit.
Principal Dimensions AIRTRONIC D2
Minimum installation distance
(clearance) to take in heating air.
(4.5 inches)
(4.8 inches)
(12.2 inches)
Principal Dimensions AIRTRONIC B / D4
(14.8 inches)
(5.9 inches)
(5.5 inches)
6
Product Information
Heater Components
12
11
8
9
Espar
23
10
Espar
2
1
0
3
4
1
2
3
4
6
5
7
21
H
F
14
13
15
16
17
19
20
18
C
22
E
24
1
2
3
4
5
6
7
8
9
10
11
12
13
Hot Air Blower Wheel
ECU
Combustion Air Blower Wheel
Glow Pin
Cover
Heat Exchanger
Overheat/Flame sensor
7 Day Timer with Thermostat (optional)
Operating Unit (Thermostat)
Operating Unit (Rheostat)
Mini Controller
Digi Controller
Blower Motor
14
15
16
17
18
19
20
21
22
23
Fuel Connection
Flange Seal
Combustion Chamber (Burner)
Hot Air Outlet Hood
Combustion Air Intake Hose
Fuel Metering Pump
Fuel Filter built into FMP
Hot Air Output Deflector
Flexible Exhaust Pipe
Main Fuse: AIRTRONIC 12 V - 20 A Fuse
AIRTRONIC 24 V - 10 A Fuse
23 Vent Hole
C = Combustion Air
D = Fuel Intake from
Tank
E = Exhaust
F = Fresh Air Intake
H = Hot Air Output
7
Installation
Heater Location
Heater Mounting Plate Installation
Depending on the type of vehicle, the best location for mounting
the heater will vary. Typically, air heaters are mounted inside tool
or luggage compartments. However, the heater may be mounted
anywhere inside the vehicle provided you adhere to the following
conditions:
• Combustion air intake, exhaust and fuel inlet must be located
outside of the vehicle.
• Heater must be mounted on flat horizontal surface
providing an air tight seal between heater and vehicle.
• Do not mount the heater outside the vehicle, unless care is
taken to protect the heater from the weather. When selecting
the location, consider the following:
• Combustion air and exhaust connections.
• Ducting.
• Fuel line connections.
• Electrical connections.
Silicon gasket (flange)
Stainless Steel Plate
Plate seal
Hex Head Tek Screw
Flat washer
Nut
Cab Floor
Spring Washer
Note: Tighten screws sufficiently to ensure positive seal
between mounting plate and mountingsurface.
Do not over tighten.
Heater Location
A mounting plate and hardware are provided with the truck heater
kit.
• Choose heater location.
• Cut a 4-1/2" hole or a rectangular opening 4"x 5" to accommodate mounting plate and seal. Secure mounting plate to vehicle with provided "Tek" screws.
Heater
Flange
Wiring Harness
Right or Left
• Mount heater on mounting plate with nuts and spring
washers provided.
Stainless Steel
Mounting Plate
and seal
• If the mounting plate will not be used, the heater flange can be
used as a template to mark where the individual components
openings should be made. (A diagram of the flange is on the
fallowing page.)
• For ease of installation make the exhaust, combustion air
intake and fuel connections at the base of the heater before
mounting the heater. See the fallowing pages for instructions
and restrictions on the exhaust, combustion air intake and fuel
connections.
Exhaust
Tubing
Combustion
Air intake
Fuel line
Wiring harness mounting
For convenient installation and maintenance purposes the wiring
harness can be mounted on the left or right side of the heater
housing. To do this the ECU must be removed from the heater.
The bottom of the ECU has is a plastic flap that holds the wiring
in place. Unlatch the plastic flap and position the harness in the
direction that you desire. Before relatching the plastic flap
ensure, that the wiring is laid neatly so that the latch can closed
without excessive force. When mounting the harness to the
housing remove the grommet from one side of the housing and
replace on the opposite side.
8
Allowable Mounting Angle
10mm
minimum
Note: The fallowing pages refer to a standard installation kit.
Components included with different kits may vary.
Installation
Mounting Pattern
Ø 7.5 (5 HOLES)
Ø 0.295 (5 HOLES)
Ø 26.0 (2 HOLES)
Ø 1.024 (2 HOLES)
millimeters
inches
12.0
0.472
44.0
1.732
0.709
2.165
Heater Air Ducting Installation
18.0
55.0
I
A 60mm flexible duct 40 inches long, hot air outlet and clamps
are provided with the heater kit. In routing and installing the
ducting the following criteria must be observed:
•
•
•
•
•
•
Route ducting with smooth bends. Avoid crushing duct.
Position hot air outlet so that it cannot be obstructed.
When not using return ducting. Use a protective air intake
grille on air inlet side of heater to prevent objects from
being sucked in.
Ensure provisions are made for proper air return ventilation.
Use return air ducting for best heating efficiency.
For exact ducting design specifications please refer to
Product Catalogue.
Return Ducting
For illustration
purposes only
No Return Ducting
For illustration
purposes only
Ducting Components
1.
2.
3.
4.
Protective Grill
Air Outlet Hood
Hose Clamp
Flex Duct
5. Air Outlet - Rotatable
6. Connection Piece
7. Protective Grill
Warning: Do not use existing vehicle ducting or outlets.
Ducts and outlets must be capable of
withstanding a minimum of 300°F operating
temperatures.
Note: For exact ducting design specifications please refer to
Product Catalogue.
Warning: Do not over tighten duct clamps. May
damage heater and result in a costly repair.
Caution: Do not position outlet so that it will blow hot air
directly at operator, at room thermostat, or return
air inlet.
9
Installation
Fuel System
The fuel metering pump is the heart of the system and must be
installed properly to ensure successful heater operation.
Fuel System Overview
7
6
Max. 20’
Max. 6’6”
8
6
7
2
5
3
Max. 6’6”
4
Max. 2’6”
2
5
Max. 2’
3
9
3
Fuel
Tank
1
3
Fuel
Tank
1
Optional
Note: Use butt joints and clamps on all connections.
1.
2.
3.
4.
Fuel Pick-Up Pipe
5.0mm Rubber Connector
11mm Clamp
2.0mm Black Plastic Fuel Line
5. Fuel Metering Pump
6. 9mm Clamp
7. 3.5mm Rubber Connector
8. 1.5mm or 2.0mm White
Plastic Fuel Line
9. 5mm Rubber Fuel Line
Fuel Pick-Up Pipe Installation (Drill Option)
•
Choose a protected mounting location close to the fuel
pump and heater. A spare fuel sender gauge plate provides
an ideal mounting location.
Drill the mounting holes as shown.
Tighten Ferrule nut to pick-up pipe at desired height.
Cut the fuel pick-up pipe to length.
Mount the fuel pick-up pipe as shown.
Lower the fuel pick-up pipe (with reinforcing washer) into
the tank using the slot created by the two 1/4” holes.
Lift the assembly into position through the 1” hole.
Assemble the rubber washer, fuel metering pump bracket,
metal cup washer and nut.
•
•
•
•
•
•
•
Note: Drill the two 1/4” holes first.
10
FMP Bracket
Optional
Installation
Fuel Line
Fuel Pick-up Pipe
Ferrule Nut (Tighten before installing)
FMP bracket
•
Route fuel lines from the fuel pick-up pipe to the fuel
metering pump then to the heater.
•
Use fuel lines provided.
•
Other sizes or types of fuel lines may inhibit proper fuel flow.
•
Make proper butt joints using clamps and connector pieces
as shown on previous page.
•
Use a sharp utility knife to cut plastic fuel lines to avoid burrs
and pinching fuel line shut.
Nut
Sheet Metal Washer
(raised center to top)
Fuel Tank
Reinforcing Washer
Holding Tabs
To Pin 5 (of 16 pin harness)
Green / Red
Allow 4" from Fuel
Pick-up to tank bottom.
Allow only 1" for flat
bottom tanks.
Brown
2.2
To Pin 5 (of 16 pin harness)
Normal FMP
Custom Pick-Up Pipe with 1/4” NPT fitting - option
Green / Red
Standard pick-up pipe can be installed as a drill type installation
or 1/4 NPT type installation.
• Remove an existing NPT plug from the top of the fuel tank.
• Cut the fuel pick-up pipe to length.
• Secure the fuel pick-up pipe into position using the combined
NPT compression fitting.
Brown
High Altitude FMP
2.2
Note: FMP bracket is not compatible with NPT pick up option.
Note: Refer to product catalogue for other pick-up pipe options.
Fuel Metering Pump
• Choose a protected mounting location close to the fuel pick- up
pipe and heater if not using standard assembly as shown on
right.
• Using the bracket and rubber mount provided, install fuel pump
as shown.
Note: Proper mounting angle of the fuel pump is
necessary to allow any air or vapor in the fuel lines
to pass through the pump rather than cause a
blockage.
Permissible
pre
fera
ble
not permissible
1 Installation position between 0° and 15° is not allowed.
2 Preferred installation position in range 15° to 35°.
3 Installation position in range 35° to 90° is allowed.
ble
fera
pre
not permissible
Typical standard
assembly, if not
using this format
please adhere to
specifications on
pg.10
11
Installation
Electrical Connections
Main Harness.......................................................................
16 pin connector with 10 terminated wires at 8 terminals.
(green/red, blue/white (2), red, grey/red, grey, brown, brown/white
and yellow (2)). Connect to the heater’s 16 pin connector. Main
harness branches off to sub harness's described below.
Power Harness.......................................
2 core harness (red and brown). Route power harness to batteries, cut to length and terminate. Install 20 amp fuse last (10
amp on 24V). Connect red wire to fuse holder near battery.
Connect fuse link wire directly to battery positive post using ring
terminal. Connect brown wire directly to battery negative post
using ring terminal.
Switch Harness.......................................
7 core harness (red, brown/white, yellow, grey, brown, grey/red and
blue/white). Route this harness to the control option mounted in
the cab. Do not cut this harness, wires have been soldered at ends
for convenience of terminating to terminals of the control option.
Coil up excess harness and secure in safe location.
Connect to control option (refer to switch connection section).
Fuel Metering Pump Harness...............
2 core harness (green/red and brown).
Route this harness from heater to fuel metering pump. Cut to
length and connect to fuel metering pump using single terminals
and connector provided with kit.
Note: Polarity does not matter for FMP connection.
Diagnostic Harness................................
8 pin connector (red, brown, yellow, blue/white). For diagnostic
purposes only.
Caution: Install power 20 amp fuse only after all electrical
connections are complete. (10 amp fuse on 24V.)
Note: All exposed electrical connections should be coated
with protective grease, (petroleum gel, Vaseline, etc.).
Main Harness
Digi Controller
Fuel Metering Pump Harness
Connector for Diagnostics
Fuse and holder
Mini Controller
Switch Harness
Power Harness
Thermostat
12
Installation / Operation and Function
Exhaust and Combustion Air Intake Connections
Operating Switches
A 24mm flexible stainless steel exhaust pipe (40” long) and a
25mm flexible plastic tube (40” long) for combustion air intake
are included with the heater kit. Exhaust clamps and holders are
also provided.
The heater can be controlled using a Mini Controller, Digi
Controller, Thermostat or Rheostat type switch. It can also be
controlled by a 7 day timer with thermostat. See schematic pg. 19.
Mini Controller
•
•
•
•
Attach the exhaust pipe to the exhaust outlet of the heat
exchanger.
Route exhaust pipe to an open area to the rear or side of the
vehicle so that fumes cannot build up and enter the cab or the
combustion air inlet to the heater.
Install protective cap.
Attach the combustion air intake tube to the combustion air
inlet of the heater.
Once secure to the heater inlet, the intake pipe must be
routed to the underside of the vehicle where it will pick up
clean, fresh, moisture free air.
•
•
•
•
•
•
Stick the drilling template to the required place of installation.
Drill 2.5mm and 7.5mm holes.
Remove the control knob from the mini controller.
Fit the mini controller with the foam base.
Screw in fixing screw up to the end stop.
Put the control knob on the mini controller. The arresting
device in the control knob must be inserted in the keyway in
the mini controller.
• Connect the mini controller in accordance with the circuit
diagram.
1 Drilling template
2 Elastic base for
uneven installation
area
Red
Yellow
Grey
White/red
Brown
Bue/White
Grey/Red
Brown/White
a)
B2
3
4
3
4
1
2
1
2
5
6
S2
a)
End Cap
Exhaust ( min. 8” - max. 6.5’ ).
B2
S2
6 5 4 3 2 1
•
Route exhaust and combustion air intakes so they
cannot be plugged by dirt, water or snow. Ensure the
outlets do not face into the vehicle slip stream.
Keep exhaust and combustion air intake a minimum
of 12” apart.
Drill 1/8” holes in exhaust pipe if necessary to allow
water drainage.
Combustion air intake and exhaust lengths can be
shortened to a minimum of 8”.
Red
Yellow
Brown
Grey
/
Yellow/Violet
Red
Blue
5
6
Caution:
Connection of
red
yellow
grey
brown
blue / white
grey / red
brown / white
control elements on the heater:
battery +
switch on signal
optional external sensor
battery diagnostics
set temperature value
sensor reference ground
Note: Insulate any cable ends not used.
The connectors and socket housing are shown from the
cable entry side.
Thermostat
Combustion Air Intake
( min. 8” - max. 6.5’ ).
End Cap
Note: Bends in both the intake and exhaust pipes should be
kept to a minimal. For every 90° bend it is recommended to shorten pipe by 16” (40cm).
Warning: The exhaust is hot, keep a minimum of 2”
clearance from any heat sensitive material.
Warning: Route exhaust so that the exhaust fumes
cannot enter the passenger compartment.
• Select a mounting location which will be representative of
the average temperature of the area being heated. Avoid
mounting near heater outlets, windows, doors, electrical
appliances or in areas receiving direct sunlight.
• Route the switch harness from the heater to the thermostat
mounting location.
• Mount the thermostat as shown using proper mounting
hardware and the slots provided on the thermostat base. Pull
the switch harness through the thermostat base access hole.
• Connect the six core switch harness to the thermostat as
shown.
13
Operation and Function
Mounting slots
Red
Yellow
5
6
Grey - not used
Blue/White - not used
9
4
3
10
2
Thermostat base
access hole
Brown/White
1
Grey/Red
Switch Harness
1
2
3
4
5 6
T
Blue/White - not used
Brown/White
Grey/Red
Brown
1
0
RED
GREEN
Heater Operation
Brown - not used
Red
Yellow
Warning - Fire Hazard
Grey
To prevent fire, the heater must be switched off while filling
fuel tanks. To prevent asphyxiation, the heater must not be
operated in enclosed areas unless heat exhaust is routed to the
outside.
This wire is “optional”
1 Switch On
Grey wire notes:
• It is recommended that when using return ducting, not to use
this wire. See illustration on pg. 9 for ducting.
• Not using the grey wire defaults the heater to use the temperature sensor on the control unit of the heater.
• Use of the grey wire defaults the heater to use the sensor on
the thermostat.
• The sensor on the control unit provides a more accurate
reading of the overall air temperature, the sensor in the
thermostat gives more of a spot reading of the air
surrounding the thermostat.
• Switch the heater on using the mini controller’s heat button or
the room thermostat’s, On/Off switch (1=On, 0=Off ) or the
rheostat switch.
2 Start Up
On start up the indicator light illuminates and the following
sequences take place:
• Control unit does a systems check of the glow pin, flame
sensor/temperature sensor, fuel metering pump and control
Temperature sensor on
AIRTRONIC control unit.
unit.
• Glow pin is energized and starts preheating the combustion
chamber.
Rheostat Switch
Note:
• Blower starts slowly and begins to accelerate.
When using Rheostat switch, the Return Ducting
method must be used as shown on page 9. This
allows the AIRTRONIC heater’s internal sensor to
properly monitor cab temperature.
The ventilation and blink code diagnostic features do
not work with Airtronic series heaters.
• After a delay (approx. 60 seconds) the fuel pump delivers fuel.
• Ignition will take place as the fuel/air mixture begins to burn.
• Blower speed and fuel delivery are slowly increased.
• Once flame sensor has detected a flame the glow pin will
switch off.
• The heater will regulate power output according to the
1
0
4
14
temperature and temperature set point.
2
3
• Mount the rheostat switch in a location
where it is easily accessible.
• Route the switch harness from the
heater to the Rheostat mounting
location.
• Connect the six core switch harness
as shown.
Operation and Function
3
Temperature Setting for Mini Controller
4
Temperature Setting for Thermostat and Rheostat
The mini controller enables you to set the heater to the temperature that you require.
Using the adjusting dial, set the desired temperature range.
You can control the desired temperature range by turning the
dial clockwise to increase temperature.
• Mid - Setting - approx. 20°C (68°F)
• Lowest Setting - approx. 47°F (8.5°C)
• Lowest Setting - approx. 10°C (50°F)
• Highest Setting - approx. 30°C (86°F)
5 Temperature
Control
• Highest Setting - approx. 97°F (36°C)
On/Off switch
Use the “Heater” button to start the heater in heating mode
(continuous operation). You can adjust the required temperature
with the temperature control knob. If the heater is in heating
mode, the red LED lights up as a check.
Use the “Fan” button to start the heater in fan mode (continuous
operation). This feature circulates the air through out the cabin
area. The temperature control knob has no function in fan
mode. If the heater is in fan mode, the blue LED lights up as a
check.
Red LED
operation check
for heater
Heater
Red operating light
On OEM installs the “red” & “green” indicator lights illuminate.
On aftermarket installs only the “red” light illuminates.
Operation indicating light
LOW
HIGH
2
1
0
3
Off switch
4
Blue LED
operation check for fan
5
Other Control Options
Digi Controller
Fan
Espar
Temperature control knob
• Counter-clockwise end stop
approx. 47°F (8.5°C) - small amount of heat
• Clockwise end stop
approx. 97°F (36°C) - large amount of heat
7 Day Timer
15
Operation and Function
6
Temperature Control
8
• The temperature is monitored constantly at the heater’s
process air inlet or external sensor.
• This temperature is compared to the set temperature on
the adjusting dial (Mini controller/Thermostat...)
• The heater cycles through Boost, High, Medium and Low
heat modes to maintain the desired temperature.
• If the desired temperature is exceeded while the heater is
operating in low heat mode the heater will switch into
“standby” mode.
• The heater will re-start once heat is required again.
7
Controls and Safety Equipment
• If the heater fails to ignite within two start attempts, a "no
start" shut down occurs.
• If a flame out occurs after the heater has started, the heater
will attempt one restart.
• If repeated flame outs occur within 10 minutes the heater will
not restart.
• Overheat shut down will occur if there is a restriction of the
heating air flow (i.e. blocked inlet or outlet).
The overheatsensor will automatically reset once the heater
has cooled down.
• Once the air flow restriction is removed, the heater can be
re-started by switching the heater off then back on.
• If the voltage drops below 10 volts or rises above 16 volts
the heater will shut down (21 volts and 32 volts for 24 volt
systems).
• If the glow pin circuit or fuel metering pump circuit are
interrupted the heater will not respond.
• The blower motor is checkeed continuously
during operation.
Shut down will occur if the blower does
not start or maintain proper speed.
Shut Down
Once switched off manually, the heater begins a controlled
cool down cycle.
• Indicating light(s) on switch will go off.
• Fuel pump stops delivering fuel.
• The glow pin is re-energized for a 40 second after-glow to
burn off any combustion residue.
• The blower continues to run for 4 minutes and automatically switches off.
Operational Chart*
Normal Operation
RUNNING PHASE
STARTING PHASE
Operating
Mode
SHUT DOWN
PHASE
System
Check
Pre-heat
Ignition
Attempt
Pre-heat
2nd. attempt
Ignition
Attempt
2nd. attempt
Boost
Controlled
Heating
After
Glow
Off a)
On
On
On
On
On
On
On c)
On
On
Off
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
On
Off
On
On
On
Off
Off
Off
Up to
90 sec.
120 sec.
Up to 90 sec.
Time
dependent
on heat
exchanger
temperature
Continual
Operation
until switched
off by operator
or temperature
control
40 sec.
Cool
Stand by
Down
Blower
Glow Pin
Fuel Pump
1- 3 sec. a)
60 sec.
d)
If Required
4 min.
* The timing shown is for the latest Airtronic D2 during normal operation. The timing does not account for ECU timing variances, or
special situations. Timing for other Airtronic heaters will vary. When timing is viewed on EDiTH software, timing will be different
because of communication delay between computer and the heater.
a) Blower is momentarily ON during System Check.
b) If desired heat level is exceeded, the heater will switch into Stand By. The heater will automatically restart once heat is required.
The restart from Stand By is similar to Pre-heat and Ignition attempt stages in Starting Phase.
c) The Blower is off during Stand By if an external temperature sensor is connected.
d) Time may vary if Glow Pin requires more or less energy to achieve required temperature.
e) If ECU detects that heat exchanger temperature is too high for start up, the start up is delayed to allow the heat exchanger to cool
down.
16
Operation and Function
Function diagram AIRTRONIC D2
*
Function diagram AIRTRONIC D4
*
* Timing may vary depending on version of ECU.
17
Operation and Function
Schematic AIRTRONIC D2 / AIRTRONIC D4
2
1
1
1
2
1
Black
White
2
Black
Blue
Blue
2
1.2
Brown
1
1.1
Brown
2
Overheat
sensor
Green
Green
Brown/White
1.5
Flame
sensor
2
2
1
1
Natural/Clear
1
2
Red
Blue/White
Yellow
Brown/White
Green/Red
Grey/Red
Blue/Yellow
Brown
Grey
Blue
Blue/Black
Pink
Black/Grey
2.1
S1
Red
B1
Yellow
Green/Red
Brown/White
Grey/Red
Blue/White
Brown
Grey
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Red
Yellow
Grey
Green/Red
Brown
Brown
Blue/White
a)
Grey/Red
2.2
Brown/White
Red
Yellow
6.1
Brown
Blue/White
2.7
5.1
1.1
1.2
1.5
2.1
2.2
2.7
5.1
6.1
6.2
18
Brown
Blower Motor
Glow Pin
Overheat and Flame sensor
Control Unit
Fuel Metering Pump
Main Fuse 12Volt - 20 amp / 24 volt - 10 amp (Fuse for heater)
Battery
Diagnostic Pigtail (for connection to Fault code retrieval device)
5 amp switch fuse - on certain models only (Fuse for mini)
6.2
Wire color key
for switches
red
yellow
brown
grey
Designation
=
=
=
=
power (+)
switch
ground (-)
temperature sensor
on thermostat
grey/red = temperature setting
blue = diagnostic
from heater
blue/white = diagnostic
from heater
brown/white = ground
black = to vehicle ignition
accessories for continuous
operation of heater on
7 day timer
Operation and Function
7 Day Timer
1 2 3 4 5 6 T
Yellow
Brown
Blue/White
Red
RED
GREEN
Yellow
Greyy
Yellow
Brown
Brown
Brown/White
Blue/White
Brown/White
Optional
y
Grey/Red
Brown/White
Red
Brown
Red
0
5
6
2
9
1
3
0
1
2
4
a)
B3
6
rt
9 10
Red
Yellow
Grey
White/red
Brown
Bue/White
Grey/Red
Brown/White
5
S2
B2
3
4
1
2
1
2
3
5
6
gn
4
Brown
Bue/White
y
Grey/Red
Brown/White
B2
3
4
Red
Yellow
Greyy
1
4
7
10
2
5
8
11
3
6
9
12
Mini Controller
3
10
DIAG
4
1
2
Rheostat
a)
Grey/Red
y
Grey/Red
a)
TRS
S2
6 5 4 3 2 1
0
Red
Yellow
Brown
Grey
/
Yellow/Violet
Red
Blue
5
6
1
12 11 10 9 8 7 6 5 4 3 2 1
Thermostat
Remote Starter - 7 Day Timer
Terminal
MINI.FE,AWG14-18
Espar Part Number
5670226
Red
R964
RECEIVER
Pin 11 on Timer
Green / Black
Espar Part Number
5670035
Pin 7 on Timer
Yellow / Black
Pin 12 on 7 day Timer
Black
ANTENNA
For best range, uncoil and place as high in vehicle as possible
and away from metal surfaces as much as possible
7 day timer
P/N: 22 1000 30 36 00 (coolant)
P/N: 22 1000 30 40 00 (air)
Remote A - green wire
pin 7 on timer
Remote B - yellow wire
Power - red wire pin 11 on timer
Ground - black wire pin 4 or pin 12 on timer
Remote Starter - Programmable Timer, Mini Timer, Thermostart & Rheostat
and Use remote Starter Kit 12 Volt: P/N 20 2900 70 01 56
Heater Harness
RECEIVER
Red
Red
Green / Black
Green
Yellow / Black
Yellow
Black / Brown
Brown
R
e
l
a
y
Red
Yellow
Brown
Mini
Timer
1. Remove fuses on heater’s harness or disconnect
from battery.
2. Connect four wires between relay and receiver as
shown.
3. Connect tree wires from relay to harness:
• Red wire to fused red wire on heater’s harness
going to control device.
• Brown wire to negative wire on heater’s harness
(do not ground to chassis if vehicle has switch on
battery “-”)
• Yellow wire of relay to yellow wire on heater’s
harness.
4. Replace fuses.
19
Operation and Function
External Temperature Sensor
Digi Controller
B2
6 5 4 3 2 1
a)
S2
B3
3
4
S3
Blue
Espar
1
2
B5
Green
3. .
B2
5
6
2.15.10
Red
Yellow
Brown/W
Grey Red
Grey
Blue/White
White
5
6
B3
3
4
S3
S2
Red
Yellow
Brown/White
Grey/Red
Grey
Blue/White
1
2
a)
Red
Yellow
Grey
White/Red
Brown
Blue/White
Grey/Red
Brown/White
High Altitude Compensator
Espar Heater
Control Unit.
High Altitude
Compensator.
Optional
Blue/White
The Espar Heater
Diagnostic Connector
Block may be used
when available
Yellow
Red
Brown
Orange
Green
1 2 3 4 5 6 7 8
4 3 2 1
1 2 3 4 5 6 7 8
4 3 2 1
Commonly a
Green Coloured
Wire
Cut
Wire
Espar Heater Systems
ALTITUDE COMPENSATOR
20 29 2900 70 00 06
Control device
Heater Enable
Power Source
(Yellow wire on
heater’s harness)
12 or 24 Volt
source
20
Commonly a Brown
Coloured Wire
Maintenance / Troubleshooting / Repair
Maintenance
Basic Troubleshooting
Recommended Periodic Maintenance
Check List:
• Remove the glow pin and inspect for carbon build up. Clean
What happens when the heater is switched on and...
or replace.
• Remove the glow pin screen and inspect for carbon build up.
Replace.
• Make sure vent hole is not clogged.
Heater does not ignite
1 Blower motor does not run
Check:
- Fuse in power harness.
- Power to control unit.
• Inspect the ducting, the air intake screen and air outlet for
- Power to and from switch.
restriction or blockage.
- Electrical connections.
• Inspect combustion air intake and exhaust for blockage.
• Operate your heater for a minimum of 20 minutes each month.
• Maintain your batteries and all electrical connections in good
condition. With insufficient power the heater will not start. Low
and high voltage cutouts will shut the heater down automati-
2 Blower motor runs approximately 20 seconds and then
shuts off
Check:
- Ensure voltage at control unit remains above
12V (or 24V) during start up with glow pin cir-
cally.
cuit on.
• Use fuel suitable for the climate (see fuel supplier
recomendations). Blending used engine oil with diesel fuel is
not permitted.
3 Blower motor runs/fuel metering pump starts and then
shuts down after two start up attempts
Check:
- Ventilation hole and glow pin screen.
- Fuel lines and fuel filter.
- Fuel quantity. Pg. 29
- Combustion air or exhaust tube blockage.
4 Blower motor runs/no fuel metering pump
Check:
- For electrical pulses at fuel metering pump.
- If pump is frozen.
- Blocked fuel line.
Heater ignites
1 Shuts down at random
Check:
- Possible overheat.
- Control unit input voltage.
2 Heater smokes and carbons up
Check:
- Exhaust pipe blocked.
- Combustion air intake blocked.
- Exhaust entering combustion air intake pipe.
- Short cycling, rapid on/off operation.
- Fuel system.
- Fuel metering pump position and quantity.
- Motor rpm.
21
Maintenance / Troubleshooting / Repair
Self Diagnostics
The heater is equipped with self diagnostic capabilities. The most
powerful diagnostic option is the ISO adapter along with EDiTH
software. The conventional "fault code retrieval devise" (P/N: 20
2900 70 5020) and the Digi Diagnostic (P/N: 20 2800 70 1002)
are more convenient options as they can be carried in your
pocket and a Personal computer is not needed.
Digi Diagnostic / Digi Controller
The diagnostic devises will be able to perform the functions
below.
1.
2.
3.
4.
5.
7 Day Timer
Access the current fault which is affecting the heater.
Access the five previous faults which affected the heater.
Clear the fault memory to erase previous fault history.
Unlock “lockout features” which exist for some control units.
Start heater.
Diagnostic Unit
Equipment Face and Controls
Symbols that are seen on the display face are as follows:
AF
Actual fault.
F1-F5
Up to five stored faults can be accessed.
The AF and F1 are the same.
ISO Adapter
This sign is displayed when the heater is in operation.
dIA
The word (dIA) ‘gnostic will come on when the unit is
connected.
000
Three digit diagnostic fault code number.
Note: A diagnostic connection is present in most
harnesses. If a connection is not present an
adapter must be connected in order to retrieve fault
codes (P/N: 22 1000 31 8600).
1.
2.
3.
4.
5.
6.
delete fault memory
delete fault memory
switch heater on / off, request diagnostic fault codes
backwards, fault F5 - F1, AF
forward AF, F1 - F5
display
• Switch the fault code retrieval device on and wait 10 seconds.
Note: If there are no heater faults, the heater will go
through a normal start cycle and regulate based
on thermostat setting.
• Press the "D" button.
• Wait 3-5 seconds for the current fault code to appear (AF).
• To review the previous faults use the arrow buttons
(F1= Most Recent, F5= Oldest).
• Consult the fault code chart for code number descriptions.
• To erase the faults that are in memory press both "L" keys at
the same time for 5 seconds. This will also unlock the control
unit in the case of an operational lockout.
22
See schematic
pg. 19
Maintenance / Troubleshooting / Repair
Fault Code
Fault Description Causes / Repair
---
Diagnosis not possible
• Check electrical connections.
• Diagnostic Devise defective.
• Test ECU and replace if necessary.
000
Normal Operation
004
Short circuit at external blower output
Function normally not used in North America
• Check for short circuit between pin 16 (B1) and appropriate relay.
• If there is no short, test ECU and replace if necessary.
005
Short circuit at security system output
Function normally not used in North America
• Check for short circuit between pin 15 (B1) and appropriate relay
or security system input.
• If there is no short, test ECU and replace if necessary.
006°
Altitude sensor fault
009
ADR – shutdown
Optional safety shutdown
Function normally not used in North America
• Signal at pin 13 (S1) changed from (+) to (-) or a (+) signal is
detected at pin 14 (S1).
• If above does not resolve problem test ECU and replace if
necessary.
010
Overvoltage
Overvoltage detected for at least 20 seconds without interruption.
• Check voltage between pin 1 (red wire) and 10 (brown wire) (B1).
Voltage here should be the same as the battery.
• Voltage must be less then 16 volts for 12 volt heater.
• Voltage must be less then 32 volts for 24 volt heater.
• Check if battery charger is connected. If so disconnect charger.
• Check vehicle charging system. If there is a problem correct as
necessary.
011
Undervoltage
Undervoltage detected for at least 20 seconds without interruption.
• Check voltage between pin 1 (red wire) and 10 (brown wire) (B1).
Voltage here should be the same as the battery.
• If voltage is lower check fuses and wiring for damage. Check battery connections for corrosion and proper contact.
• Voltage must be more then 10 volts for 12 volt heater.
• Voltage must be more then 21 volts for 24 volt heater.
• Check voltage before and after heater is started.
• Check if fuses, connections and wiring are in good condition.
• Check vehicle charging system. If there is a problem correct as
necessary.
012
Overheat at overheat sensor
• Check air ducting for excessive restriction or blockage.
• Check if ducting length is within specification. (Ref. to product
catalogue)
• Measure resistance of both the overheat sensor and flame sensor to
see if they are within specification. (pg. 29)
• Perform Fuel Quantity test (pg. 29)
013
Overheat at flame sensor
• Check air ducting for excessive restriction or blockage.
• Check if ducting length is within specification. (Ref. to product
catalogue)
• Measure resistance of both the flame sensor and overheat sensor to
see if they are within specification. (pg. 29)
• Perform fuel quantity test. (pg. 29)
• Check if sensor is connected properly. (Only applicable with “H-kit”
heaters°)
• Connect sensor to EDITH for further diagnosis.
23
Maintenance / Troubleshooting / Repair
Fault Code
Fault Description Causes / Repair
014
Excessive temperature difference between
overheat and flame sensor
015
ECU locked
017
Overheat sensor -Maximum temperature reached
018°
• Test glow pin as per fault code 20.
019*
Ignition energy too low
(only applicable with “H-Kit” heaters°)
Ignition energy too low
020
021
022*
Open circuit – Glow pin
Short circuit – Glow pin
Short circuit after battery voltage – Glow pin
•
•
•
•
025*
Diagnostic cable short circuit after battery voltage
•
•
•
•
•
031
032
Circuit interrupted – Blower motor
Short circuit – Blower motor
• Check wiring for short circuit.
• Apply appropriate voltage to blower and check current draw (8V for
12V heater 18V for 24V heater) Make sure power supply has at
least 20amp short circuit resistance.
If current is less then 6.5 amps test ECU and replace if necessary.
If current is more then 6.5 amps replace blower.
033
Speed differential, no rotation, short circuit after negative
034*
Short circuit – Blower motor
24
• Check if sensor is mounted properly.
• Measure resistance of flame sensor and overheat sensor to see if it
is within specification. (pg. 29)
• Perform fuel quantity test. (pg. 29)
• Measure resistance of both the flame sensor and overheat sensor
to see if they are within specification. (pg. 29)
Occurs after Airtronic is switched on after 017 has been registered.
• Unlock heater with an Espar diagnostic devise (EDITH, 7 day
timer…)
• Check troubleshooting suggestions for 012, 013 and 014.
• The ECU is locked because the temperature threshold has been
exceeded and the ECU did not register fault code 012 and / or 013.
• 015 will be displayed if unit is turned off after a 017.
• Test ECU and replace if necessary.
Check glow pin resistance at 20 deg C
12 volt heater: 0.42ohms - 0.7ohms
24 volt heater: 1.2 ohms - 2.0 ohms
Check glow pin harness for damage, if it is routed and connected
properly.
• Check harness for continuity.
• Test ECU and replace if necessary.
Fault Code(s) can not be displayed until fault has been corrected.
Check for damage to Diagnostic cable.
Heater is not compatible with diagnostic devise being used.
Check if diagnostic devise is working properly.
Check blower wiring and connections for proper routing and
damage.
• Check leads for continuity.
• Test ECU and replace if necessary.
Motor speed varies from specification by more then 10% for
longer then 30 seconds.
• Use non contact RPM meter to measure speed of blower (pg. 30)
• If RPM is too low, check for restrictions or blockage, if there are no
restrictions check remedies for fault code 032.
• If RPM is too high check if magnet in impeller is mounted properly,
if magnet is ok test RPM sensor if accurate. (Confirm RPM reading
using EDITH software.)
• Check for short circuit.
• Check blower wiring and connections for proper routing and damage.
• Check leads for continuity.
• Test ECU and replace if necessary.
Maintenance / Troubleshooting / Repair
Fault Code
Fault Description Causes / Repair
047
Short circuit – Fuel metering pump
• Disconnect connector from FMP, restart heater, if 048 is displayed,
FMP is defective.
• If 047 is still displayed disconnect harness from the heater and look
for short circuit from pin 5 (B1) to negative (pin 10)
• If there is no short circuit test ECU and replace if necessary.
048
Open circuit – Fuel metering pump
• Disconnect fuel pump wiring and check if resistance is within
specifications (pg. 30)
If good reconnect wiring and check resistance from connector (B1)
pin 5 and pin 10.
• If ok test ECU and replace if necessary.
049*
Short circuit after battery voltage - Metering pump
• Check wiring and connections for proper routing and damage.
• Check leads for continuity.
• Test ECU and replace if necessary.
050
Too many start attempts
051
Faulty flame recognition
• If temperature of flame sensor is greater then 70°C (158°F) when
starting up the heater, the start attempt is delayed and blower will
operate for a maximum of 15 minutes to cool down the flame
sensor.
• If temperature does not fall below 70°C (158°F) within 15 min 051
will occur.
• If temperature decreases to an acceptable level the heater will
attempt to start.
• Check resistance of Flame sensor. (pg. 29)
052
No flame detected – Start phase
• If there is actually a flame but it is not detected, check resistance of
the flame sensor. (pg. 29)
• If there is no flame:
• Check combustion air intake and exhaust lines for interference.
• Check glow pin screen (should be replaced yearly) and ventilation
hole (should be inspected when screen is replaced)
• Perform Fuel Quantity Test (pg. 29)
053
054
055
056
Flame cutout during:
Power/ Bust mode
High mode
Medium mode
Low mode
057°
Start phase (only applicable with “H-Kit” heaters°)
060
Circuit interrupted – external temperature sensor
061
Short circuit – external temperature sensor
ECU is locked after too many start attempts (max. 255)
• Check fault codes in memory before unlocking ECU.
• Fallow repair advice of codes in memory.
• Unlock ECU with a diagnostic devise.
Heater has started successfully but flame has extinguished.
• Check combustion air intake and exhaust.
• Check fuel supply perform fuel quantity test. (pg. 29)
• Inspect fuel lines for bubble formation.
• Check if appropriate grade of fuel is being used according to
temperature. (pg. 29)
• Check if flame sensor resistance is within specification and
mounted properly. (pg. 29)
• Test ECU and replace if necessary.
Sensor detects a temperature beyond it’s range.
• Measure resistance at pins 6 and 12. (B1)
• The circuit would be detected as open if the resistance is greater
then 3k ohms (7175 ohms•)
• Test ECU and replace if necessary.
• Measure resistance at pins 6 and 12. (B1)
• A short circuit will be detected if the resistance is less then 800
ohms (486 ohms•)
• Test ECU and replace if necessary.
25
Maintenance / Troubleshooting / Repair
Fault Code
Fault Description Causes / Repair
062
Circuit Interruption – Control switch
Temperature setting out of resistance range
Heater runs in High mode only
• Check resistance between pins 6 and 7 at B1. (Test will only work
with thermostat and rheostat. Resistance check will not work with
Mini controller or Digi controler) Resistance should be between
1740 – 2180 ohms.
• Mini controller or Digi controller should be tested while heater is con
nected to EDITH.
• If resistance is ok test ECU and replace if necessary.
063
Short circuit - Control switch
Short circuit is detected between pins 6 and 7 after heater has
started.
• If short occurred before heater is started heater will be in ventilation
mode.
• Check wiring connected to pins 6 and 7 for a short.
• If there is a switch connected to pins 6 and 7 test if switch is work
ing properly.
• Disconnect switch. If 063 still appears test ECU and replace if
necessary.
• Short will be registered between pins 6 and 7 less then 800 ohms
(486 ohms*).
• Normal value is 1740 – 2180 ohms.
064
Open circuit – flame sensor
• Disconnect flame sensor and check if resistance is within specification. (Green connector. Pg. 29)
• Open circuit detected at 3k ohms (7175 ohms*)
• If resistance is ok test ECU and replace if necessary.
065
Short circuit – flame sensor
• Disconnect flame sensor (green connector) and scan for fault codes
again.
• If 064 comes up replace combo sensor.
• If 065 comes up, test ECU and replace if necessary.
• Short circuit resistance is less then 500 ohms (486 ohms •)
071
Open circuit – overheat sensor
• Disconnect both the flame and overheat sensor from the ECU.
• Measure resistance between the blue and brown/white wire. (Pg. 29)
• The ECU will record an open circuit if the resistance is greater then
1600k ohms (223k ohms•)
072
Short circuit- overheat sensor
• Disconnect both the flame and overheat sensor from the ECU and
scan for fault codes again.
• If 071 comes up replace combo sensor.
• If fault 072 is still displayed test ECU and replace if necessary.
• Short circuit resistance is less then 95 ohms (183 ohms•)
074*
Overheat threshold not detected
• Test ECU and replace if necessary.
090
Control Unit defect
• Test ECU and replace if necessary.
091
External voltage interference
092
093*
094
095*
Internal Memory Error
26
Fault due to inconsistent voltage
• Inspect power system. (Battery, Battery charger, Alternator)
• Check the fuses, the supply cables, the negative connections and
the positive support point on the battery for corrosion and correct
contact.
• Disconnect power for 10 seconds. Reconnect and test gain.
• Test ECU and replace if necessary.
Maintenance / Troubleshooting / Repair
Fault Code
Fault Description Causes / Repair
096
Internal temperature sensor defect.
• Replace ECU or install an external temperature sensor.
097
Control Unit defect
• Replace Control Unit.
098*
099*
Short term Voltage drop.
Voltage less then 5 - 6 volt (for 12 volt) or less then 7 - 8 volt (for 24
volt).
• Check the fuses, the supply cables, the negative connections and
the positive support point on the battery for corrosion and correct
contact.
• Check if power supply can provide the appropriate amount of current
while heater is running. (At least 10 amp supply recommended.)
Transistor error in control box.
• Check lead harness of the external components for continuity, has
been correctly laid and check for damage.
• Test ECU and replace if necessary.
Transistor error in control box.
• Check lead harness of the external components for continuity, has
been correctly laid and check for damage.
• Test ECU and replace if necessary.
High Altitude Sensor Fault Code
Fault Description Causes / Repair
0
No faults.
11
Communication Lost.
• Check wiring and connections
12
No altitude adjustment.
• Use heater that is compatible with this high altitude sensor or use a
different high altitude devise (Pg. 3)
13
Air pressure sensor fault.
• Replace the air pressure sensor.
* Codes are only applicable for new style ECU’s.
To date new style ECU’s wiring is wrapped with tape.
Old style ECU’s are bundled in PVC.
° Codes and comments apply to ECU’s with integrated
high altitude compatibilities. (Ref. pg. 3)
• Resistance values apply to old style ECU’s. Ref. to *
for description of difference between old and new style ECU’s.
27
Maintenance / Troubleshooting / Repair
TROUBLESHOOTING FOR AIRTRONIC 2/4/ HEATERS
“No start” and “Heater Stops” conditions
Use these recommendations in conjunction with Fault Code List
#
1
Description of the problem
Absolutely nothing happens when the heater is turned on
Possible reason and method of repair*
1. Check voltage on heater’s harness on the heater’s side (pin # 1 and 10 on Airtronic
connector). Turn the heater ON and make sure that the voltage is still OK. Repair
harness and connections if necessary.
2. If the voltage is OK, than try to start the heater by connecting together red and
yellow wires on control branch of the heater’s harness. Make sure that you have
+12 or +24 volts on the red wire on the control branch.
3. If the voltage is OK but the heater still does not start even if red and yellow wires
are connected to each other, then the most likely ECU is locked, bad, or one of the
startup self tests failed.
Use one of diagnostic tools to retrieve fault codes from heater’s memory and unlock
ECU if it is locked. Follow heater’s manual for the fault codes description and repair
methods. Computerized diagnostic is advised for all kinds if troubleshooting of
Airtronic heaters.
4. If you troubleshoot your own heater and diagnostic tools are unavailable, the following information may help (please note that the features below are determined by
software in heater’s ECU and may be different in some revisions of heaters):
In the event that a heater is not locked out, but simply fails one of the start up tests.
The heater will not run in ‘Heat’ mode, but may however run in ‘Vent’ mode. If the
Mini-controller or Digi – controller is not available, vent mode can be accessed by
‘jumping’ the grey/red wire to the brown/white wire, then ‘jumping’ the red wire to
yellow wire (order is important). If blower starts up and runs, then ECU is not
locked. Otherwise it may or may not be locked.
If heater is able to start in ventilation mode, but can not run in heating mode:
-check FMP for open or short circuit;
heck roll-over or impact switch for open circuit (if installed);
-check Glow pin for open or short circuit;
-check overheat sensor for open circuit;
If heater does not work in either heat and vent modes:
-check flame sensor for open or short circuit;
-check overheat sensor for short circuit;
*Resistance values for the glow pin, sensors and fuel pump are listed in maintenance / Troubleshooting. Resistance of the fuel pump must be measured at the 16
pin connector with disconnected heater.
*Resistance values for the glow pin, sensors and fuel pump are listed in maintenance / Troubleshooting. Resistance of the fuel pump must be measured at the 16
pin connector with disconnected heater.
Being turned on, heater turns blower a few times, FMP
and ECU’s relay may click one time but heater would not
make an attempt to start.
1. Bad electrical connections. Check voltage like described in case #1.
3
Heater switches into shut-down phase 20-25 seconds
after being turned on (the most likely, fault code 11 found
in memory)
Check voltage on heater’s harness on the heater’s side (pins 1 and 10 on Airtronic
connector). Turn the heater ON and make sure that the voltage is still OK.
Repair harness and connections if necessary.
4
Being turned on, heater just blows cold air, never stops
and never performs a start attempt. No fault code record
ed.
1. Was “Ventilation” button pressed instead of “Heat”?
2. Replace combo Sensor.
3. Replace ECU if necessary.
5
Heater makes two attempts to start with no success and
then stops completely. No smoke comes from the exhaust
pipe, some smoke can be seen between the exhaust pipe
and heat exchanger.
1. Check if exhaust pipe is not plugged with ice. Reroute it if this is the case for not
having it to be U-shaped.
2
28
2. Start-up self test failed. Retrieve fault codes from heater’s memory using Diagnostic
tool or EDiTH, refer to the heater’s manual for the description and repair methods.
2. Check combustion air intake pipe. If the exhaust and combustion air intake pipes
are OK, see case #6 below.
Maintenance / Troubleshooting / Repair
6
Heater makes two attempts to start, may smoke for a
while and then it stops.
1. Do the fuel quantity check as described in manual, if the amount of fuel is insufficient, than check the fuel pick-up pipe, fuel lines and connections, fuel filter on the
pump, replace the filter or pump if necessary.
2. Check the glow pin, clean ventilation hole above the screen in the glow pin chamber and replace atomizing screen.
3. If necessary, take the heater apart, clean combustion tube (including it’s all air
ways) and the heat exchanger. If internal combustion chamber area is badly car
boned or has a ceramic-like build up behind the ring wall, replace the flame tube.
Refer to instructions for cleaning heater with kerosene, which sometimes helps to
avoid taking the heater apart for cleaning.
7
8
Heater makes two attempts to start, then stops. Both
times it sounds like the ignition takes place and then com
bustion process stops together with the fuel metering
pump. Usually no smoke comes from the exhaust pipe
just like when the heater starts normally.
1. The heater ignited but the flame was not detected. Check and replace combo sensor.
Heater ignites normally, goes into boost mode, then
switches to stand-by mode, blower is slowly spinning but
the heater never restarts. No fault code recorded.
1. Using EDiTH, check setpoint for temperature and current air temperature. Replace
part which works improperly. Swap minicontroller if do not have EDiTH;
2. Replace ECU if combo sensor was good.
2. If minicontroller OK, install external temperature sensor or replace ECU.
9
Heater ignites normally, but often stops (codes 52 - 56
found in memory)
1. Check fuel lines for gaps in connections inside connection pieces.
2. If the heater stops only when the vehicle is in motion, reroute combustion air intake
and exhaust pipes, or bend their ends toward to the rear of the vehicle.
*To avoid inefficient expenses, it is strongly recommended to have the heater diagnosed by specialist before replacing expensive
parts.
Warning: Do not skip trouble shooting steps replacing ECU before all other tests are done.
99% of repaired heaters do not need a new ECU.
29
Maintenance / Troubleshooting / Repair
Values for Overheat sensor
Fuel Quantity Test
Preparation
• Detach the fuel line from the AIRTRONIC.
• Insert the fuel line into a graduated cylinder 10ml.
• Switch the AIRTRONIC on. Once the FMP comes on allow the
fuel system to bleed air out for approximately 60 seconds.
• Switch the AIRTRONIC off and empty the graduated cylinder.
Measurement
• Switch the AIRTRONIC on.
• The fuel is pumped approx. 60 seconds after switching on.
• Hold the fuel line in the graduated cylinder level with the glow
pin while fuel is being delivered.
• The pump will stop automatically after delivering fuel for 90
seconds (110 seconds for AIRTRONIC 4).
• Once fuel pump stops, switch off the heater.
Evaluation
Temperature (°C)
Temperature °C (F°)
-40 (-40)
-20 (-4)
0 (32)
20 (68)
40 (104)
60 (140)
80 (176)
100 (212)
120 (248)
140 (284)
160 (320)
180 (356)
200 (392)
Resistance kΩ
min.
1597.0
458.80
154.70
59.30
25.02
11.56
5.782
3.095
1.757
1.050
0.6654
0.4253
0.2857
max.
1913.0
533.40
175.50
65.84
28.04
13.16
6.678
3.623
2.081
1.256
0.792
0.5187
0.3513
Values for Flame sensor
Resistance (Ohm)
• Read out the quantity of fuel in measuring glass.
• Fuel quantity should be between:
3.5 ml and 4.3 ml. on AIRTRONIC D2
5.0 ml and 6.0 ml. on AIRTRONIC D4
6.8 ml and 7.6 ml. on AIRTRONIC B4
• Replace the fuel metering pump if the fuel quantity is above
specified value.
If measured fuel quantity is insufficient:
– Check the filter in the fuel pump.
– Check that the fuel lines are correctly routed.
– Check that the fuel lines don’t leak.
– Check and tighten hose connections.
– Does fuel withdrawal comply with the data in the technical
description.
Resistance (kOhm)
The fuel quantity should be tested if the heater has difficulty
starting or maintaining a flame.
Connector blue
Connector green
1 = overheating sensor
2 = flame sensor
Note: The fuel quantity is not affected by voltage variances.
Espar part #: 552 00 04
Graduated Cylinder 10ml
30
Temperature (°C)
Temperature °C (F°)
— 40
— 20
0
20
40
60
80
100
120
140
160
Resistance Ω
842.7
921.6
1000.0
1077.9
1155.4
1232.4
1308.9
1385.1
1460.7
1535.8
1610.5
min.
825.9
803.2
980.0
1056.4
1132.3
1207.8
1282.8
1357.4
1431.5
1505.1
1578.3
max.
859.6
940.0
1020.0
1099.5
1178.5
1257.1
1335.1
1412.8
1489.9
1566.6
1642.8
Maintenance / Troubleshooting / Repair
Control values
Note: The terms "Boost" and "Power" are used interchangeably through out this manual. The terms refer to the
highest level of heat output of the heater.
Motor speed
Test speed for the blower heater
AIRTRONIC D2 / D2 Camper
12 volt heater
5000 rpm ±25 %
at U = 10.0 volt
AIRTRONIC D2
24 volt heater
5000 rpm ±25 %
at U = 18.0 volt
AIRTRONIC M B4 / D4 / D3 Camper / D4 Camper
12 volt heater
4400 rpm ±25 %
at U = 10.0 volt
AIRTRONIC M D4
24 volt heater
4400 rpm ±25 %
at U = 18.5 volt
AIRTRONIC M D4S / D4 Camper plus
12 volt heater
4400 rpm ±25 %
at U = 10.5 volt
AIRTRONIC M D4S
24 volt heater
4400 rpm ±25 %
at U = 19.0 volt
AIRTRONIC
Control stage
• Power
• Fast
• Medium
• Slow
• Adjustment
- in circulation mode with temperature sensor, internal
- In fresh air mode with temperature sensor, external
• Ventilation
AIRTRONIC
D2
4800
4000
2800
2000
U/min
U/min
U/min
U/min
D4
±
±
±
±
140 rpm
120 rpm
80 rpm
60 rpm
600 U/min ± 20 rpm
0 rpm
4800 U/min ± 140 rpm
4400
3500
2600
1600
U/min
U/min
U/min
U/min
±
±
±
±
130 rpm
100 rpm
80 rpm
50 rpm
600 U/min ± 20 rpm
0 rpm
4400 U/min ± 100 rpm
Resistance values
Component
AIRTRONIC - 12V
AIRTRONIC - 24V
Overheat ~60KOhm at room temp
Glow pin
0.42 - 0.7 Ω
1.2 - 2.0 Ω
Flame sensor ~1.0KOhm at room temp
Fuel metering pump
9.5 ± 0.5 Ω
36 ± 1.8 Ω
Operator control unit
set value potentiometer
1750 - 2180 ± 80 Ω
1750 - 2180 ± 80 Ω
Switching value
Component
AIRTRONIC D2 / D4
Overheating sensor
140°C - 170°C
(284°F - 338°F)
measured in the control
stage “power” and at a
clearance of 300 mm
from the hot air outlet
300 mm
Exhaust value
AIRTRONIC D2 / D4
2
CO in exhaust in control stage “high”
7.5 -12.5 Vol. %
Soot number as per Bacharach
<4
31
Maintenance / Troubleshooting / Repair
Repair Instructions
Removing the cover
Note: Remove power from the heater prior to any disassembly by unplugging main connection or removing
main fuse.
Removing and checking the control unit
Removing the glow pin
Removing the lining
If gasket was removed during disassembly, replace it
when reassembling.
Clean all parts before reassembly and check for any
signs of damage, replace where necessary.
Removing and checking the overheat and flame sensor
Installing the overheat and flame sensor
Dismantling the heat exchanger
Removing the combustion air blower
Removing the combustion chamber
Note: The cover must always be removed from the
AIRTRONIC for all repair stages. You may have to wait
for the device to cool down.
Removing the cover from the AIRTRONIC
Unlock both seal plates, lift cover and pull to the front.
1.
2.
The cable harness can exit from the left or right of heater shell.
Cover Seal Plates Removing the control unit
Remove the AIRTRONIC cover.
Unscrew fastening screw, press retaining brackets together, lift
out ECU. Unclip the lines from the holder of the control unit
(observe the positions of the lines). Remove the bushing (lower
part) from the outer case. Disconnect the control unit from the
controller. The ECU can now be removed.
Note: When reassembling the ECU, ensure that the lines are
correctly clipped in the holder of the ECU, and that the
connectors are plugged into the ECU (non-interchangeable).
Fastening screw
Retaining brackets
ECU
Bushing
32
Maintenance / Troubleshooting / Repair
Heater Casing Disassembly
• Remove the AIRTRONIC cover.
• Remove the ECU.
Disconnect the connector of the glow pin cable harness from
the ECU.
Remove the rubber grommet and use the special tool to unscrew
the glow pin.
The special tool is included with the glow pin.*
Tighten torque of the glow pin: 6 +0.5 Nm (50 in•lb)
Note: Please check Pg. 37, item 20 for more
information.
Note: When the glow pin has been removed, check the
screen of the support in installed state for any
contamination. The screen must be replaced if the
surface is covered with carbon.
Glow Pin Connector of glow pin cable harness Rubber bushing Removing the screen
Pull the screen out of the support with pointed pliers. Blow out
the support with compressed air.
If necessary, carefully pierce with a wire.
The special tool has to be used to install the screen. The special
tool is included with the screen. Push the screen onto the
special tool, watching the position of the recess. The recess
must be positioned at right angles (90°) to the axis of the heater.
1
90°
Newer screens do not have a recess.
Push the tool with the screen carefully as far as it will go,
ensuring that the bore (ø 2.7 mm) for the glow plug ventilation
is free. See illustration 1.
In case of the shorter, new style screen (see image B) the
position of the screen to the vent hole has no reference.
Ensure installation tool is completely seated when installing
screen.
Image A
illustration 1
Screen
Bore (Ø 2.7 mm) for glow pin ventilation
Vent Hole (Can be cleaned with wire)2
Allow riveted section to be placed in such a way as to not
block the vent more.
Image B
Screen 1
Bore (Ø 2.7 mm) for glow pin ventilation 2
Special tool
Position of recess
Special tool
Screen
33
Maintenance / Troubleshooting / Repair
Removing the overheat sensor / flame sensor
• Remove the AIRTRONIC cover.
• Remove the control unit.
Disconnect both connectors of the overheating / flame sensor
cable harness from the ECU.
Unlock clip from sensor.
Remove overheat /flame sensor.
2
1
Cable harness for overheat/flame sensor 1
clip 2
Overheat sensor
Check the overheat sensor with a digital multimeter. If the
resistance value is outside the set point indicated in the values,
on pg. 26 then the sensor must be replaced.
2
1
Flame Sensor
Check the flame sensor with a digital multimeter. If the resistance value is outside the set point indicated by the values table
on pg. 26, then the sensor must be replaced.
1 Special tool - only for AIRTRONIC D2
2 Overheat sensor / flame sensor
Installing the overheat / flame sensor
For AIRTRONIC D2 (Assembly using purpose made tool) mount
the special tool on the sensor.
Place the sensor on the heat exchanger using the special tool.
The special tool slides on the heat exchanger until the sensor
meets the collar (installation site of the sensor).
Lock the sensor in place and remove the purpose made tool.
It is then vital to check that the sensor sits flat on the heat
exchanger. If necessary use a mirror and lamp to aid correct
assembly.
Route the cable harness sensor along the clip eyelet to the
control unit and connect.
2
1
1 Special tool - only for AIRTRONIC D2
2 Overheat sensor / flame sensor
Connector blue
Connector green
1 = overheating sensor
2 = flame sensor
1
3
2
1 Clip
2 Overheat sensor / flame sensor
34
2
1
1 Clip
2 Cable harness - overheat/ flame sensor
3 Special tool - only necessary for the AIRTRONIC D2
Maintenance / Troubleshooting / Repair
Dismantling the heat exchanger
Removing the combustion air blower
•
•
Remove the AIRTRONIC cover.
Remove the ECU.
Remove the flange seal.
Take the AIRTRONIC out of the outer case (lower part).
Unscrew the 4 fastening screws from the combustion air
blower.
Remove the combustion air blower and the seal from the heat
exchanger.
2
1
Note: When reassembling the combustion air blower, a
new seal is always required.
Tighten the 4 fastening screws of the combustion air blower in
the series shown in the drawing, with a tightening torque of 4 +0.5
Nm. (35 in•lb)
1 Combustion Air blower
2 Heat Exchanger
3 Fastening screws
5
2
4
3
1
1-4
5
Tighten the fastening screws in this sequence with a
tightening torque of 4 +0.5 Nm (35in•lb)
Always replace the seal between combustion air
blower and heat exchanger.
35
Maintenance / Troubleshooting / Repair
Removing the combustion chamber
• Remove the AIRTRONIC cover.
2
Remove the flange seal.
Take the AIRTRONIC out of the outer case (lower part).
• Remove ECU (see previous pages).
• Remove glow pin (see previous pages).
• Remove combustion air blower (see previous pages).
1
Unscrew the fastening screws.
For AIRTRONIC D2 = 3 fastening screws
For AIRTRONIC D4 = 4 fastening screws
Pull the combustion burner out to the front and remove the
burner’s thermal insulator from the heat exchanger.
3
Note: When reassembling the combustion burner, the
thermal insulator, must always be replaced.
1 Combustion burner
2 Heat Exchanger
3 Fastening screws
AIRTRONIC D2 = 3 fastening screws
AIRTRONIC D4 = 4 fastening screws
Tighten the self tapping fastening screws of the combustion
chamber with a torque of 5 +0.5 Nm. (44 in•lb)
Note: If the heat exchanger is being replaced, the overheat / flame sensor must be dismantled and mounted to
the new heat exchanger (see previous pages).
3
2
1
4
1 Combustion burner
2 Thermal insulator between combustion burner and
heat exchanger, must always be replaced if burner is
removed from the heat exchanger. (Holes not threaded)
3 Heat exchanger
4 Self tapping fastening screws.
AIRTRONIC D2 = 3 fastening screws
AIRTRONIC D4 = 4 fastening screws
36
Note: Holes in heat exchanger that fasten the burner
tube are not tapped.
When fastening a burner to a new heat exchanger
it is recommended to use new screws.
Heater Parts
AIRTRONIC D2 / D3 / B / D4
Service Parts Diagram
17
20*
11
16
15
18
10
1
9
3
2
5
4
8
6
13
7
12
14
19
Note: Please check Pg. 37, item 20 for more information.
37
•
25 2069 10 01 00
•
•
3
4
5
6
Thermal insulator for burner
Grommet
•
25 2069 06 00 02
•
103 10 348
103 10 348
Blower motor
•
25 2113 06 00 01
Fillister head bolt, M 5 x 12 (3 required)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
12V 25 2069 99 20 00
•
24V 25 2070 99 20 00
12V 25 2113 99 20 00
•
•
25 2069 06 00 01
Fillister head bolt, M 5 x 12 (4 required)
•
•
25 2113 10 01 00
20 1812 10 01 00
25 2327 05 12V
Burner
•
25 2144 05 12V
2
•
•
25 2114 05 24V
25 2113 06 01 00
25 2113 05 12V
25 2069 06 01 00
25 2326 05 12V
Heat exchanger
Part Number
25 2070 05 24V
1
Description
25 2069 05 12V
Ref. No.
Model #
AIRTRONIC D2 / B / D4
20 1812 05 12V
Heater Parts
•
•
•
•
24V 25 2114 99 20 00
•
12V 25 2144 99 20 00
7
Fillister head bolt, M 5 x 25
8
Gasket, blower
Locally available hardware
25 2113 01 00 03
9
Control unit
•
25 2069 01 00 03
•
•
•
•
•
•
•
24V 22 5102 00 10 01
•
•
•
•
•
•
•
•
•
12V 22 5101 00 10 05
•
24V 22 5102 00 10 03
•
12V 22 5101 00 10 06
•
12V 22 5101 00 10 13
•
12V 22 5101 00 10 14
•
Hella 12V 22 5101 00 30 01
•
Hella 12V 22 5101 00 30 05
•
22 5101 00 30 15
•
103 10 349
•
10
Fillister head bolt, M 4 x 10
11
Upper casing
25 2069 01 06 00
12
Lower casing
25 2069 01 01 00
25 2113 01 01 00
•
13
Grommet
25 2069 01 00 01
•
25 2113 01 00 01
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
14
Flange seal
25 2069 01 00 02
•
•
•
•
•
•
•
•
15
Overheat sensor / Flame sensor with tool
25 2069 01 02 00
•
•
•
•
•
•
•
•
16
Clip
25 2069 01 02 02
•
•
•
•
•
17
Glow pin with socket wrench
18
Glow pin screen with tool
25 2113 01 02 02
•
12V 25 2069 01 13 00
•
•
25 2069 10 01 02
•
•
19
Mounting plate with hardware and seal
Glow pin wrench *
5540001
•
25 2069 01 03 03
•
*
This tool is designed for occasional usage. If heavy use is anticipated, more appropriate tools are available from tool manufacturers.
Recommended: Snap-On Flare nut socket 12mm Stock # FRXM12
38
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
24V 25 2070 01 11 00
20
•
•
•
•
•
Heater Parts
AIRTRONIC D2 / D3 / B / D4
Parts Diagram
4
3
5
2a
3
30
2
42
41
29
27
1
22
22
22
21
31
46
24
9
10
25
32
20
18
33
26
8
11
6
36
7
34
35
40
44
19
38a
18
43
10
37
18
28
38
45
12
16
23
13
17
17
15
14
17
39
47
17
16
39
5
6
Flexible air hose
Straight outlet hood
20 1609 80 09 00
ø75
22 1050 89 21 00
ø 50-70
5550004
ø 70-90
5550003
ø 60
10 2114 31 00 00
ø 90
10 2114 37 00 00
ø 75
10 2114 34 00 00
ø 60
22 1000 01 00 16
ø 90
22 1000 01 00 19
ø 75
22 1000 01 00 18
25 2326 05 12V
20 2800 50 02 00
ø 90
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
25 2327 05 12V
4
Clamp
ø 60
•
•
25 2144 05 12V
3
25 1688 80 06 00
25 1552 05 01 00
25 2114 05 24V
Warm air deflector
2a
ø 60
ø 75
25 2113 05 12V
2
Safety screen
Part Number
25 2070 05 24V
1
Description
25 2069 05 12V
Ref. No.
Model #
AIRTRONIC D2 / B / D4
20 1812 05 12V
Heater Parts
•
•
Main harness
20 2900 70 03 91
•
•
•
•
•
•
•
•
Short harness
20 2900 70 02 05
•
•
•
•
•
•
•
•
5590003
•
•
•
•
•
•
•
•
7
Cable ties (197mm)
8
Air intake (1 meter)
ø25 mm
360 00 006
•
•
•
•
•
•
•
•
9
Flexible exhaust (1 meter)
ø24 mm
25 1774 80 02 00
•
•
•
•
•
•
•
•
10
Fuel hose - rubber
3.5 mm
360 75 300
•
•
•
•
•
•
•
•
11
Plastic fuel line
1.5 mm
890 31 118
•
•
•
•
•
•
•
•
12
Fuel metering pump
12V
22 4519 01 00 00
•
•
•
•
•
•
24V
22 4518 01 00 00
13
Clamp for fuel metering pump
14
Plastic fuel line - black
15
Angle bracket
16
Fuel hose - rubber
5 mm
17
Clamp
18
Clamp
19
•
•
22 1000 50 03 00
•
•
•
•
•
•
•
•
890 31 125
•
•
•
•
•
•
•
•
20 2900 40 0104
•
•
•
•
•
•
•
•
360 75 350
•
•
•
•
•
•
•
•
11 mm
10 2068 01 10 98
•
•
•
•
•
•
•
•
9 mm
10 2068 00 90 98
•
•
•
•
•
•
•
•
End sleeve with cross bar - 25mm plastic
25 1729 89 00 02
•
•
•
•
•
•
•
•
20
Grommet
20 1280 09 01 03
•
•
•
•
•
•
•
•
21
Intake hose clamp
ø 20-32
10 2065 02 00 32
•
•
•
•
•
•
•
•
22
Clamp
26 mm
152 61 102
•
•
•
•
•
•
•
•
23
Fuel screen
20 1312 00 00 06
•
•
•
•
•
•
•
•
24
Blade fuse
20 amp
5670055
•
•
•
•
•
•
10 amp
5670056
25
2 mm
•
•
Plug connector - Kit
22 1000 31 80 00
•
•
•
•
•
•
•
•
26
Housing - Kit female
22 1000 31 81 00
•
•
•
•
•
•
•
•
*27
Muffler
25 1864 81 01 00
•
•
•
•
•
•
•
•
28
Connectors for fuel metering pump - Kit
22 1000 31 87 00
•
•
•
•
•
•
•
•
40
•
•
90° Bend
ø 60
25 1688 89 00 01
•
•
•
•
ø 75
25 1482 89 00 05
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
25 2326 05 12V
25 2327 05 12V
22 1000 01 00 20
22 1000 01 00 22
22 1000 01 00 23
25 2144 05 12V
*30
90° Air outlet hood
Part Number
25 2114 05 24V
*29
Description
Model #
Ref. No.
25 2113 05 12V
25 2069 05 12V
ø 60
ø 75
ø 90
AIRTRONIC D2 / B / D4
25 2070 05 24V
20 1812 05 12V
Heater Parts
•
31
Fuse holder with terminals
5670051
•
•
•
•
•
•
•
•
32
Terminals
5670199
•
•
•
•
•
•
•
•
33
3/8’ Ring terminals 10-12 G
5670178
•
•
•
•
•
•
•
•
*34
7 day timer
22 1000 30 40 00
•
•
•
•
•
•
35
*36
Thermostat
Operating switch (rotary)
12V
301 00 154
24V
301 00 153
12V
24V
2 mm
•
•
•
•
•
•
•
•
25 1895 71 00 00
25 1896 71 00 00
20 2900 20 20 56
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
* 38
Fuel pick up pipe (Compression fitting type)
20 2900 20 20 42
•
•
•
•
•
•
•
•
* 38a
Compression fittings
20 2900 20 20 44
5520002
5520006
152 00 139
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
37
Standard fuel pick up pipe
39
P-clamp w/Lining
1/4” NPT
3/8” NPT
1/2” NPT
10 mm
40
P-clamp
25 mm
152 10 048
•
•
•
•
•
•
•
•
41
P-clamp
28 mm
152 10 051
•
•
•
•
•
•
•
•
42
End-sleeve
24 mm
25 1482 80 00 01
•
•
•
•
•
•
•
•
43
Bezel kit for 7 day timer
25 1482 70 01 00
•
•
•
•
•
•
•
•
44
Mini Controller
22 1000 32 07 00
•
•
•
•
•
•
•
•
45
Digi Controller
20 2800 70 10 00
•
•
•
•
•
•
•
•
46
Ext Temp Sensor
25 1774 89 03 00
•
•
•
•
•
•
•
•
47
Fault code retrieval device
20 2900 70 50 20
•
•
•
•
•
•
•
•
*indicates optional features
41
Notes:
42
Notes:
43
Nov 2010
P/N: 20-2900-81-01-03-0F
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Espar Products, Inc.
(800) 387-4800
(905) 670-0960
www.espar.com
A member of the Worldwide Eberspächer Group of Companies
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