Espar Airtronic D2 Installation Instructions Manual

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Espar Airtronic D2 Installation Instructions Manual | Manualzz

AIRTRONIC D2/D4

Installation, Troubleshooting & Parts Manual

AIRTRONIC

AIRTRONIC D2 - 12 volt

AIRTRONIC D2 - 24 volt

AIRTRONIC D4 - 12 volt

AIRTRONIC D4 - 24 volt

For Heater Models

25 2069 05 00 00

25 2070 05 00 00

25 2113 05 00 00

25 2114 05 00 00

Release period

November 2001

November 2001

November 2001

November 2001

Espar

P/N: 610-103-0901 November 2001

Table of Contents

Introduction

Installation Procedures

Heater Operation

Maintenance,

Troubleshooting &

Repairs

Heater Parts

Page

Heater Warnings

Introduction

Specifications

Principal Dimensions

Heater Components

Heater Location

Heater Mounting

Heater Plate installation

Mounting Pattern

Ducting Components

Heater Air Ducting

Fuel System

Electrical Connections

Exhaust/Intake Connections

Operating Switches

........................................................

3

........................................................

4

........................................................

5

........................................................

6

........................................................

7

........................................................

8

........................................................

8

........................................................

8

........................................................

9

........................................................

9

........................................................

9

........................................................

10

........................................................

12

........................................................

13

........................................................

13

Switch on

Start-Up

Temperature setting

Temperature Control

........................................................

14

........................................................

14

........................................................

14

........................................................

15

Switching Off ........................................................

15

Controls & Safety Equipment ........................................................

15

Operational Flow Chart

Function Diagrams

........................................................

........................................................

15

16

Schematic AIRTRONIC D2/D4 ........................................................

17

Periodic Maintenance ........................................................

18

Basic Troubleshooting ........................................................

18

Self Diagnostic Troubleshooting .......................................................

18

Fuel Quantity Test ........................................................

23

Overheat/Flame sensor values ........................................................

23

Control and Resistance values ........................................................

24

Repair Steps ........................................................

25

AIRTRONIC D2/D4

-Service Parts Diagram

AIRTRONIC D2/D4

-Parts List

........................................................

30/32

........................................................

31/33

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 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.

3

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 gasoline powered boats.

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.

2.

Ensure an air tight seal will be maintained between the heater and mounting surface and at any exhaust connection points.

3.

Ensure that heating air supply is taken from an area where poisonous gases will not be present.

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.

Direct questions to Espar Heater Systems

USA

CDA

1-800-387-4800

1-800-668-5676

ATTENTION

Operation with bio-diesel

AIRTRONIC D2

AIRTRONIC D2 is not certified for use with bio-diesel.

Admixtures of bio-diesel up to a magnitude of approx. 10%, as in some countries, are allowed.

AIRTRONIC D4

AIRTRONIC D4 is certified for operation with bio-diesel as per

DIN V 51606 in free-flowing state when installed in “normal horizontal position (exhaust pipe downwards)”; bio-diesel is not permitted for any other installation positions.

When using 100% bio-diesel, AIRTRONIC D4 should be oper ated with pure diesel fuel twice per year, preferably in the middle and at the end of a winter period, to burn off any possible

PME residues: For this purpose, drain your vehicle tank as far as possible (caution: do not forget to leave enough fuel in the tank to get to the next fuel station!) and then fill the tank with pure diesel fuel without bio-admixture.

While using this tank filling, let AIRTRONIC D4 run at the maxi mum temperatures pre-selection stage at least twice or three times for 30 minutes at a time. You can use this for example to pre-heat your vehicle before setting off. After this “diesel operation” of your AIRTRONIC D4, you can use bio-diesel again as required.

When using mixtures of diesel / bio-diesel with up to 50% bioshare, it is not necessary to use pure diesel fuel now and then.

ATTENTION

Heating at high altitudes

Up to 1500 meters - unrestricted heating operation is possible

Above 1500 meters - heating operation is in principle possible for short periods, e.g. when crossing a mountain pass of 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. Please call

USA 1-800-387-4800

CDA 1-800-668-5676 for special circumstances.

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

12,000 BTU/hr air heater for larger bunks.

These heater provide hot air to the interior of vehicles for passenger comfort. Since the heater runs on diesel fuel and 12 or 24 volt power, it is able to provide space heat completely independently of the vehicle engine.

The heater is operated by a rheostat switch or room thermostat. It cycles through four temperature settings (boost-highmedium-low) in order to maintain the desired temperature.

If, in special cases, less heating capacity is required than the heater supplies in the “Low” setting, the heater switches to a “stand-by” setting. Temperature and overheat sensors, and a specially designed heat exchanger are among the safety features which make this heater a safe and dependable unit.

4

For illustration purposes only

Specifications

Heat Output (±10%)

Current at 12v (±10%)

AIRTRONIC D2

7,500 BTU/hr Boost (2.2 kW)

6,150 BTU/hr High (1.8 kW)

4,100 BTU/hr Medium (1.2 kW)

2,900 BTU/hr Low (0.85 kW)

8.3 amps - Start

2.8 amps - Boost

1.9 amps - High

1.0 amps - Medium

0.7 amps - Low

Current at 24v (±10%)

Fuel Consumption (±10%)

Air Flow (±10%)

Operating Voltage Range

4.2 amps/hr - Start

1.4 amps/hr - Boost

1.0 amps/hr - High

0.5 amps/hr - Medium

0.3 amps/hr - Low

U.S.

Gal/hr

Litre/hr

Boost

High

Low

0.07

0.06

Medium 0.04

0.03

48 cfm Boost

40 cfm High

27 cfm Medium

19 cfm Low

0.28

0.23

0.14

0.10

10.5 - 16 vdc at 12 vdc

21 - 32 vdc at 24 vdc

240°F (115°C) Overheat Temperature

Shutdown (±10%)

Ambient Operating

Temperature

Weight

-40°F to 158°F (-40°C to 70°C)

6.0 lbs. (2.7 kg)

5

AIRTRONIC D4

13,650 BTU/hr Boost (4.0 kW)

10,200 BTU/hr High (3.0 kW)

6,800 BTU/hr Medium (2.0 kW)

3,400 BTU/hr Low (1.0 kW)

8.3 amps - Start

3.3 amps - Boost

2.0 amps - High

1.1 amps - Medium

0.6 amps - Low

4.2 amps/hr - Start

1.7 amps/hr - Boost

1.0 amps/hr - High

0.5 amps/hr - Medium

0.3 amps/hr - Low

U.S.

Gal/hr

Litre/hr

Boost

High

Low

0.13

0.10

Medium 0.07

0.03

85 cfm Boost

69 cfm High

50 cfm Medium

30 cfm Low

0.51

0.38

0.25

0.13

10.5 - 16 vdc at 12 vdc

21 - 32 vdc at 24 vdc

240°F (116°C)

-40°F to 158°F (-40°C to 70°C)

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.

Principal Dimensions AIRTRONIC D2

6

(12.2 inches)

* 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.

Minimum installation distance

(clearance) to take in heating air.

(4.5 inches)

Principal Dimensions AIRTRONIC D4

(14.8 inches)

(5.5 inches)

Heater Components

7

1 Hot Air Blower Wheel

2 Control Unit

3 Combustion Air Blower Wheel

4 Glow Pin

5 Cover

6 Heat Exchanger

7 Overheat/Flame sensor

8 7 Day Timer with thermostat (optional)

9 Operating Unit (Thermostat)

10 Operating Unit (Rheostat)

11 Blower Motor

12 Fuel Connection

13 Flange Seal

14 Combustion Chamber

15 Hot Air Outlet Hood

16 Combustion Air Intake Hose

17 Fuel Metering Pump

18 Fuel Filter built into FMP

19 Hot Air Output Deflector

20 Flexible Exhaust Pipe

21 Main Fuse: -

AIRTRONIC D2 - 20 A

AIRTRONIC D4 - 10 A

C = Combustion Air

D = Fuel Intake from tank

E = Exhaust

F = Fresh Air Intake

H = Hot Air Output

8

Installation Procedures

Heater Location

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.

Heater Mounting

A mounting plate and hardware are provided with the truck heater kit.

• Choose heater location.

• Using template provided, drill and cut center hole. Cut (1) four and one half inch (4 1/2”) diameter hole or one rectangular hole four (4”) by five (5”) inches to accommodate mounting plate and seal. Secure mounting plate to vehicle floor with “Tek” screws provided.

• Use Heater flange as a template if not using mounting plate and seal

• Mount heater on mounting plate with nuts and spring washers provided.

• For ease of installation make the exhaust, combustion air intake and fuel connections at base of heater before mounting the heater into the vehicle. See following pages for instructions and restrictions on exhaust, combustion and fuel hook-ups.

Wiring harness connection, right or left

Wiring harness can be converted to the opposite side of the heater if it makes the installation more practical. To do this you must remove the AIRTRONIC cover and then the control unit.

On the control unit (underneath) is a semicircular clip protecting the harness. This must be removed. The harness should be moved to the other side of the control unit then reassembled.

The grommet on the heater casing (side) must also be taken out and secured into the opposite lower side of heater casing.

Heater Mounting Plate Installation

Hex Head Tek Screw

Flat washer

Nut

Spring Washer

Silicon gasket (flange)

Stainless Steel Plate

Plate seal

Cab Floor

Note: Tighten screws sufficiently to ensure positive seal between mounting plate and mounting surface.

Do not over tighten.

Wiring Harness

Right or Left

Stainless Steel

Mounting Plate and seal

Combustion

Air intake

Fuel line

Heater

Flange

Exhaust

Tubing

9

Mounting Pattern inches

Heater Air Ducting Installation

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 illustration purposes only

For illustration purposes only

Ducting Components millimeters

Return Ducting

No Return Ducting

1. Protective Grill

2. Air Outlet Hood AIRTRONIC D2 - ø60 or75mm

AIRTRONIC D4 - ø75 or 90mm

3. Hose Clamp 2-2 3/4”

4. Flex Duct 2 3/8” (ø60 or 75mm) (ø90mm on D4)

Warning: Do not use existing vehicle ducting or outlets.

Ducts and outlets must be capable of withstanding a minimum of 300°F operating temperatures.

5. Air Outlet - Rotatable

6. Connection Piece

7. Protective Grill

8. 90° Bend Ducting 2 3/8”

Caution: Do not over tighten duct clamps.

Do not position outlet so that it will blow hot air directly at operator or at room thermostat.

10

Fuel System

The fuel metering pump is the heart of the system and must be installed properly to ensure a successful heater operation.

Fuel System Overview

Max. 2’6”

Fuel

Tank

1

7

6

2

3

Max. 6’6”

Max. 6’6”

4

Max. 20’

6

7

2

3

5

Max. 2’

9

3

3

5

Fuel

Tank

1

Optional

8

Note: Butt joints and clamps on all connections.

7. 3.5mm Rubber Connector

8. 1.5mm White Plastic Fuel Line

9. 5mm Rubber Fuel Line

1. Fuel Pick-Up Pipe

2. 5.0 Rubber Connector

3. 11mm Clamp

4. 2.0mm Black Plastic Fuel Line

5. Fuel Metering Pump

6. 9mm Clamp

Fuel Pick-Up Pipe Installation (Standard Pick-Up)

• 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

• 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, metal cup washer and nut.

Note: Drill the two 1/4” holes first.

Optional

11

Custom Pick-Up Pipe with NPT fitting - optional

• Remove an existing 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

Note: NPT fittings are available in various sizes (Refer to parts section).

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.

Fuel Line

• 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.

Typical standard assembly, if not using this format please adhere to specifications on pg.10

NPT fitting and pipe optional

12

Electrical Connections

Main Harness.......................................................................

Power Harness.....................................................................

Switch Harness....................................................................

Fuel Metering Pump Harness.............................................

Diagnostic 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

Connect other harnesses as described below

2 core harness (red and brown).

Route power harness to batteries, cut to length and terminate as described below. 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.

7 core harness (red, brown/white, yellow, grey, brown, grey/red and b l u e / w h i t e )

Route this harness the length required to reach thermostat installed in bunk compartment. Do not cut this harness, wires have been soldered at ends for convenience of terminating to terminals on thermostat. Coil up excess harness and secure in safe location.

Connect to thermostat or rheostat switch (refer to switch connection section).

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. (no polarity required).

4 pin on 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 on 24V.

Note: All exposed electrical connections should be coated with protective grease, (petroleum gel,

Vaseline, etc.).

Fuel Metering Pump Harness

Fuse and holder

Main Harness

Connector for Diagnostics

Switch Harness

Power Harness

Thermostat

13

Exhaust and Combustion Air Intake Connections

A 24mm flexible stainless steel exhaust pipe (39”long) and a

25mm flexible plastic tube (39” long) for combustion air intake are included with the heater kit. Exhaust clamps and holders are also provided.

Caution: 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”.

• 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.

Operating Switches

The heater can be controlled using a Thermostat or Rheostat type switch. It can also be controlled by a 7 day timer with thermostat. See schematic pg. 17.

Thermostat

• 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

Mounting slots

Thermostat base access hole

End Cap

Exhaust ( min. 8” - max. 6.5’).

Combustion Air Intake

( min. 8” - max. 6.5’).

Warning:

Warning:

End Cap

The exhaust is hot, keep a minimum of 2” clearance from any heat sensitive material

Route exhaust so that the exhaust fumes cannot enter the passenger compartment.

This wire is “optional”

• 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, whereas the sensor in the thermostat gives more of a spot reading of the air surrounding the thermostat.

Temperature sensor on

AIRTRONIC control unit.

Rheostat Switch

Note: 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.

• 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

Temperature sensor on

AIRTRONIC control unit.

14

Heater Operation

Warning: 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 outside of garage bay.

1 Switch On

• Switch the heater on using 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 con trol unit.

• Blower starts slowly and begins to accelerate.

• Glow pin is energized and starts preheating the combustion chamber.

• After a delay (approx. 60 seconds) the fuel pump delivers fuel.

• Ignition will take place as the fuel/air mixture contact the glow pin.

• Blower speed and fuel delivery are slowly increased.

• Once flame sensor has detected a flame the glow pin will switch off, after approx. 60 secs.

• After another 120 secs., heater will have reached maximum power.

3 Temperature Setting

Using the adjusting dial, set the desired temperature range.

Lowest Setting - approx. 10°C (50˚F)

Mid - Setting - approx. 20°C (68˚F)

Highest Setting - approx. 30°C (86˚F)

On OEM installs the ‘red” & “green” indicator lights illuminate.

On after market installs only the “Red” light illuminates.

Operation indicating light

High

Low

On/Off switch

Green diagnostic light

Red operating light

15

4.

Temperature Control

• The temperature is monitored constantly at the heater’s process air inlet or thermostat.

• This temperature is compared to the set temperature on the adjusting dial.

• 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. This is a comfort feature.

• The heater will re-start in once heat is again required.

5 Switch Off

Once switched off either manually or automatically, 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.

6 Controls and Safety Equipment

• If the heater fails to ignite within two 90 second start attempts, a "no start" shut down occurs.

• If a flame out occurs after the heater has started, the heater will attempt to restart.

• If repeated flame outs occur within 15 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 overheat sensor 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 10.5 volts or rises above 16 volts the heater will shut down (21 volts and 28 volts for 24 volt systems).

• If the glow pin circuit or fuel metering pump circuit are interrupted the heater will not start.

• The blower motor is checked on start up and continuously during operation.

Shut down will occur if the blower does not start or maintain proper speed.

Operational Flow Chart

Function diagram AIRTRONIC D2

16

Function diagram AIRTRONIC D4

Schematic AIRTRONIC D2 / AIRTRONIC D4

17

Wire color key for switches

Designation red = power (+) yellow = switch brown = ground (-) grey = temperature sensor on thermostat

* vehicle dimmer switch for light display on

7-day timer 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

1.1

1.2

1.5

2.1

Blower Motor

Glow Pin

Overheat and Flame sensor

Control Unit

2.2

2.7

Fuel Metering Pump

Main Fuse 12Volt - 20 amp / 24 volt - 10 amp

3.1.11 Rheostat

3.2.8

7 Day Timer

3.5

Thermostat

5.1

6.1

Battery

Diagnostic Pigtail (for connection to Fault code retrieval device)

18

Maintenance

Recommended Periodic Maintenance

• Remove the glow pin and inspect for carbon build up.

Clean or replace.

• Remove the glow pin screen and inspect for carbon build up. Clean or replace.

• Make sure vent hole is open. Espar recommends the use of non detergent 100% volatile carburetor cleaner, an air gun will also help. Remove loose carbon from the glow pin chamber.

• Inspect the ducting, the air intake screen and air outlet for restriction or blockage.

• 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 automatically.

• Use fuel suitable for the climate (see engine manufacturers recommendations). Blending used engine oil with diesel fuel is not permitted.

Basic Troubleshooting

Check LIst:

What happens when the heater is switched on and ....

Heater does not ignite

1 Blower motor does not run

Check: - Fuse in power harness.

- Power to control unit.

- Power to and from switch.

- Electrical connections.

2 Blower motor runs approximately 20 seconds and then shuts off

Check: - Ensure voltage at control unit remains above 10 volts during start up with glow plug circuit on.

3 Blower motor runs/fuel metering pump starts and then shuts down after two start up attempts

Check: - Fuel lines and fuel filter.

- Fuel quantity. Pg. 23

- 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: - Fuel metering pump quantity. Pg. 23

- 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 quantity.

- Motor rpm.

Self Diagnostics

The heater is equipped with self diagnostic capability. To retrieve information on the heater ’s last 5 faults, a retrieval device is required (part # CA1 05 020). There is a pig tail to accommodate the connector on the main harness from heater. If wire pigtail is not present, a wiring adapter (P/N: 22 1000 31 86 00) must be used.

Connect the fault code retrieval device as shown. This device enables these four functions to be performed.

1.

Access the current fault which is affecting the heater

2.

Access the four previous faults which affected the heater.

3.

Clear the fault memory to erase previous fault history

4.

Unlock “lockout features” which exist for some control units.

Equipment Face and Controls

Symbols that are seen on the display face are as follows:

AF

F1-F5

Actual fault.

Up to five stored faults can be accessed.

The AF and F1 are the same number.

DIAG

This sign is displayed when the heater is in operation.

The word (DIAG) nostic will come on when the diagnostic number is requested.

000 Three digit diagnostic fault code number.

On/Off switch

19

• Switch the fault code retrieval device on and wait 10 seconds.

• 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 a unlock the control unit.

On/Off

Retrieval Device

Note: If there are no heater faults, the heater will go through a normal start cycle and regulate based on thermostat setting.

Fault Code

000

004

Normal Operation

Warning - short circuit in controller, fresh air-outlet

005 Warning - short circuit at controller - anti-theft alarm output

009 TRS - shut down

010 Overvoltage

011 Undervoltage shut down

012 Overheat at overheating sensor

013 Overheat at flame sensor

014 Temperature difference between flame sensor and overheating sensor too large

015 Overheat with excessive temperatures

017 Overheat with excessive temperature

020 Open circuit - glow pin

021 Short circuit - glow pin

Caution!

For AIRTRONIC 12 volt, check functions with max. 8 volt

For AIRTRONIC 24 volt, check functions with max. 18 volt.

if voltage values are exceeded the component is destroyed.

Check sort-circuit resistance of mains unit: min. 20 Amp.

20

See schematic pg. 17

Fault Description Causes / Repair

Disconnect connection S1/B1 at AIRTRONIC . At connector B1, pin 16 check for short between pin and blower relay. If no short exists replace control unit.

Disconnect connection S1/B1 at AIRTRONIC . At connector B1, pin 16 check the line through to the relay isolating switch or theft warning in line for short circuit to chassis. If no short exists replace control unit.

Switch off due to signal change.Check for change of signal from (+) to

(-) at pin 13 (S1) or a (+) signal at pin 14 (S1).

Start vehicle motor. Check voltage at (B1) between terminals 1 and 10.

This must be less than 16 volts (15.2 volts with glow plug on). Check vehicle charging system.

AIRTRONIC 24 volt - voltage must be less than 32 volts

Start vehicle motor. Check voltage at connector (B1) between terminals

1 and 10. This must be more than 10 volts. Check vehicle charging system. Check batteries and connections.

AIRTRONIC 24 volt - voltage must be more than 21 volts .

Sensor has detected excessive temperatures. Check for clogged hot air ducting. Check that the the total number of ducting pieces in unison is not too large. Re-route if necessary. Check overheat sensor resistance values. (see component value chart pg 23). If O.K. Measure fuel quantity. See page 23.

Flame sensor detects excessive temperature at heat exchanger. Check for clogged hot air ducting. Check that the the total number of ducting pieces in unison is not too large. Re-route if necessary. Measure fuel quantity. See page 22. Check flame sensor resistance. (see component value chart pg 22)

Check for clogged hot air ducting. Check that the the total number of ducting pieces in unison is not too large. Check flame sensor, if O.K., check overheating sensor. If over-heating sensor defective replace combi-sensor. If over-heating sensor O.K. measure fuel quantity. See page 23. If fuel quantity O.K. replace control unit.

Fault code 015 is shown when the AIRTRONIC is switched on again after fault code 017. The hardware limit value for the overheating sensor, has been exceeded - control unit is damaged. Check sensor.

Replace control unit.

The hardware limit value for the overheating sensor, has been exceeded, because the control unit has not detected fault code 012, 013.The

control unit is locked. If AIRTRONIC is switched on again, fault code

015 is displayed. Replace control unit. Check sensor.

Check continuity of glow pin.

AIRTRONIC 12 volt - approx. 0.5

± 0.05

AIRTRONIC 24 volt - approx. 2

± 0.2

Check functions of glow pin in installed condition, to do so disconnect connector from controller.

AIRTRONIC 12 Volt and 24 Volt. Apply voltage of 8 / 18 volts to glow pin respectively, and measure current intensity after 40 seconds. Glow in is O.K. for the following values: glow pin 8 volt - current = 9 amps + 1.5 / - 1.2 amps glow pin 18 volt - current = 4 amps ± 0.5 amps

If the values differ, replace glow pin. If the values of the continuity test and function test are O.K., check glow pin cable harness for damage and continuity. If O.K., replace control unit.

Fault Code

031 Blower motor interrupted

032 Blower motor, short circuit

Caution!

For AIRTRONIC 12 volt, check functions with max. 8 volt

For AIRTRONIC 24 volt, check functions with max. 18 volt.

if voltage values are exceeded the component is destroyed.

Check sort-circuit resistance of mains unit: min. 20 Amp.

033 Blower motor does not turn

047 Short circuit - fuel metering pump

048 Open circuit - fuel metering pump

050 Too many no start attempts

051 Faulty flame recognition

052 No start safety time exceeded

053

054

055

056

Flame cutout in boost mode

Flame cutout in high mode

Flame cutout in medium mode

Flame cutout in low mode

060 Open circuit - external temperature

061 Short circuit - external temperature

21

Fault Description Causes / Repair

Check blower motor cable harness for correct routing and damage. If

O.K., disconnect cable harness from control unit and check for continuity, if O.K., replace control unit.

Check functions of blower motor, to so so, disconnect connector from control unit. Apply voltage of 8 volts or 18 volts ± 0.1 to blower motor and measure current intensity after 40 seconds.

Current < 6.5 amp - blower motor O.K., replace controller

Current > 6.5 amp, replace blower.

Motor speed varies from specification by more than 10% for longer than

30 seconds.

If too slow, check for restriction, and check for short in motor circuit or control unit. If none found, replace blower.

If too fast, check for damage or missing magnetic sensor on control unit. Replace blower motor if damaged.

Replace control unit otherwise.

Disconnect connector from fuel metering pump, if fault code 048 (interruption) is displayed then the fuel metering pump is defective, replace

FMP.

If fault code 047 is still displayed, then disconnect connection S1/B1. At connector B1, Pin 5, check line1(green/red) through to FMP for short circuit to (pin 10), if O.K. replace control unit

Disconnect connector from fuel pump and measure resistance value of fuel pump (see values, pg 22). If resistance values O.K., then reconnect cable harness to the fuel pump. Disconnect connection S1/B1, and measure the resistance value between pin 5 and pin 10. If O.K., replace control unit.

Control unit is locked after too many unsuccessful start attempts. Check fuel, glow plug, combustion air and exhaust flow. Use control unit tester or fault code retrieval device to unlock control unit. Maximum 255

If the resistance value of flame sensor is 1274

after switching on (>

70°C), then the blower of the AIRTRONIC runs for approx. 15 minutes to cool down. If resistance does not fall below the above value within

15 mins.., this is followed by fault shut down. Check flame sensor, diagrams and values, pg 23. If O.K., replace control unit.

No flame detected on start attempt.Check exhaust and combustion air lines. Check fuel supply/measure fuel quantity, see following pages.

Check glow pin (see fault code 020 and 021). Check flame sensor, diagram and values table on following pages, if O.K., replace control unit.

Heater has started successfully the flame has extinguished.

Check exhaust and combustion air lines. Check fuel supply/measure fuel quantity, see values, pg 23. Check flame sensor, diagram and values table on following pages, if O.K., replace control unit.

Temperature sensor detects a value beyond it's range sensor

Disconnect connection S1/B1 (main harness), measure resistance value at connector B1, pins 6 & 12. Refer to the values table on pg 23.

If there is an open circuit, the ohmic value between the pins is > 7175

. If the resistance value is O.K., then the control unit is defective.

Disconnect connection S1/B1 (main harness), measure resistance value at connector B1, between pins 6 & 12., see values on pg 23. If there is a short circuit, the ohmic value between the pins is < 486

. If fault 061 continues to be displayed, then the control unit is defective.

Fault Code

062 Thermostat/Rheostat/Timer, open circuit

063 Switch control - short circuit

Fault recognition only works in heating mode. However, if a short circuit already exists and the AIRTRONIC is subsequently switched on, ventilating mode will be active (no fault code).

064 Open circuit - flame sensor

065 Short circuit - flame sensor

071 Open circuit - overheat sensor

072 Short circuit - overheat sensor

090

091

Control unit defect

External voltage disturbance

092

094

096

097

Control unit defective (ROM fault)

Control unit defective (EEPROM fault)

Internal temperature sensor defect

Control unit defective (power failure)

22

Fault Description Causes / Repair

Potentiometer values outside of range on Thermostat (switch)

Check resistance between pins 6 and 7 at B1.

Resistance value for interruption between pins > 7175

Normal value: 1740

- 2180

(± 80

)

If resistance value is O.K., replace control unit. If not replace thermostat/(switch).

If a ventilating switch has been built in, disconnect and check function.

If faulty, replace switch. Disconnect wires from thermostat or switch. If fault code 062 is displayed, replace switch. If switch is O.K., check connection lines grey/red and brown/white for short-circuit. If O.K., reconnect wires to thermostat/switch. Disconnect connection B1. If fault 063 is still displayed, replace control unit. Resistance value for short circuit between pins 6 and 7 < 486

. Normal value: 1740

- 2180

(± 80

).

Sensor is sensing value outside of range. Open Airtronic shell and remove control unit from casing. Disconnect green connector from control unit. At green connector measure resistance value at green wire and brown/white wire. Check flame sensor, diagram and values on pg.

23. If flame sensor is O.K., replace control unit. Resistance value for interruption > 7175

Open Airtronic shell and remove control unit from casing. Disconnect green connector from control unit. If fault 064 is displayed, replace combination sensor (flame/temperature). If fault 065 is still displayed, replace control unit. Resistance value for shot circuit < 486

, see values on following pages.

Open Airtronic shell and remove control unit from casing. Disconnect blue and green connectors from control unit. Measure the resistance value at blue connector(pin 1- blue wire) and at green connector pin 2

(brown/white wire). See values on following pages. If O.K., replace control unit. Resistance value for interruption > 223

.

Open Airtronic shell and remove control unit from casing. Disconnect blue connector from control unit. If fault 071 displayed, replace combination sensor (flame/temperature). If fault 072 is still displayed, replace control unit. Resistance value for short circuit < 183

, see following pages for values.

Internal failure. Replace control unit.

Check vehicle charging system. Poor battery, battery charger, eliminate fault.

Internal failure. Replace control unit.

Replace control unit

Replace control unit or use external temperature sensor.

Internal failure. Replace control unit.

23

Fuel Quantity Test

The fuel quantity should be tested if the heater has difficulty starting or maintaining a flame. Check the following before measuring fuel quantity.

• 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.

Preparation

• Detach the fuel line from the AIRTRONIC .

• Insert the fuel line into a measuring glass (25 cm3).

• Switch the AIRTRONIC on and allow fuel system to bleed out air for approx. 60 seconds.

• Switch the AIRTRONIC off and drain the measuring glass.

Measurement

• Switch the AIRTRONIC on

• The fuel is pumped approx. 60 seconds after switching on.

• Hold the fuel line in the measuring glass 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

• Read out the quantity of fuel in measuring glass.

• Fuel quantity should be between

3.7 ml and 4.3 ml. on AIRTRONIC 2

5.4 ml and 6.3 ml. on AIRTRONIC 4

• If the fuel quantity is outside this range, check for and remove any restriction in fuel system or replace the fuel metering pump.

Note: The fuel quantity is not affected by voltage variances.

Values for Overheat sensor

60

80

100

120

140

160

180

200

Temperature °C

-40

-20

0

20

40

Temperature (°C)

Resistance k

Ω 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

Values for Flame sensor

160

200

240

280

320

360

400

Temperature °C

-40

0

40

80

120

Temperature (°C)

Resistance k

Ω min.

825.90

980.00

1132.30

1282.80

1431.50

1578.30

1723.40

1866.60

2008.10

2147.70

2285.50

2421.50

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

max.

859.60

1020.00

1178.50

1335.10

1489.90

1642.80

1793.70

1942.80

2090.00

2235.40

2378.80

2520.30

24

Control values

Motor speed

Control stage

• Power

• Fast

• Medium

• Slow

• Adjustment

- in circulation mode with temperature sensor, internal

- In fresh air mode with temperature sensor, external

• Ventilation

Resistance values

Component

Blower motor

Glow plug

Fuel metering pump

Operator control unit set value potentiometer

AIRTRONIC D2 -12V

0.6

± 0.1

0.5

± 0.05

10

± 0.5

1750 - 2080

± 80

AIRTRONIC

0 U/min

AIRTRONIC D2 -24V

2

± 0.4

2

± 0.2

36

± 1.8

1750 - 2080

± 80

D2

4800 U/min ± 140 U/min

4000 U/min ± 120 U/min

2800 U/min ± 80 U/min

2000 U/min ± 60 U/min

600 U/min ± 20 U/min

4800 U/min ± 140 U/min

AIRTRONIC D4 -12V

0.4

± 0.1

0.5

± 0.05

10

± 0.5

1750 - 2080

± 80

AIRTRONIC D4

4400 U/min ± 130 U/min

3600 U/min ± 100 U/min

2800 U/min ± 80 U/min

1600 U/min ± 50 U/min

600 U/min ± 20 U/min

0 U/min

3600 U/min ± 100 U/min

AIRTRONIC D4 -24V

1.5

± 0.3

2

± 0.2

36

± 1.8

1750 - 2080

± 80

Switching value

Component

Overheating sensor

AIRTRONIC D2 / D4

160°C - 170°C measured in the control stage “power”and at a clearance of 300 mm from the hot air outlet

300 mm

Exhaust value

CO2 in exhaust in control stage “fast”

Soot number as per Bacharach

AIRTRONIC D2 / D4

7.5 -12.5 Vol. %

<6

25

Repair Instructions

Removing the cover

Removing and checking the control unit

Removing the glow pin

Removing the lining

Removing and checking the overheating and flame sensor

Installing the overheating and flame sensor

Dismantling the heat exchanger

Removing the combustion air blower

Removing the combustion chamber

Caution: Remove power from the heater prior to any disassembly by unplugging main connection or removing main fuse.

Carefully check all seals and O-rings and replace where necessary

Clean all parts before reassembly and check for any signs of damage, replace where necessary

Removing the cover form the AIRTRONIC

Unlock both seal plates, lift cover and pull to the front.

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.

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 control unit. 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 control unit can now be removed.

Note:

When reassembling the control unit, ensure that the lines are correctly clipped in the holder of the control unit, and that the connectors are plugged into the control unit (non-interchangeable).

Fastening screw

Retaining brackets

Control unit

Bushing

Checking the control unit.

A test instrument is necessary to check the control unit in a dismantled state. The test instrument is connected up to the PC and with special software can display run times on certain parts and give a visual of heater in operation.

Part number 22 1524 89 00 00

Adapter P/N: 22 1000 3186 00

1.

2.

Heater Casing Disassembly

• remove the AIRTRONIC cover

• remove the control unit.

Disconnect the connector of the glow pin cable harness from the controller.

Remove the rubber bush and use the special tool (SW 12) to unscrew the glow pin.

The special tool is included with the glow pin.

Tighten torque of the glow pin : 6 +0.5

Nm

26

Note:

When the glow pin has been removed, check the lining of the support in installed state for any contamination. The lining must be replaced if the surface is covered with dirt.

Glow Pin

Connector of glow pin cable harness

Rubber bushing

Removing the lining

Pull the lining 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 new lining. The special tool is included with the lining. Push the lining onto the special tool, watching the position of the recess. The recess must be position at right angles (90°) to the axis of the heater

Push the tool with the lining 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

Special tool with lining

Position of recess

Lining

Bore (Ø 2.7 mm) for glow pin ventilation illustration 1

Removing the overheating sensor / flame sensor

Remove the AIRTRONIC cover

Remove the control unit

Disconnect both connectors of the overheating / flame sensor cable harness from the control unit.

Unlock clip from sensor.

Remove overheating/flame sensor.

Cable harness for overhear/flame sensor clip

Checking the overheating / flame sensor

Observe a maximum temperature of 320° C for checking the sensor

Overheating sensor

Check the overheating sensor with a digital multimeter. If the resistance value is outside the set point indicated in the values, on pg.22 then the sensor must be replaced

Flame Senor

Check the flame sensor with ta digital multimeter. If the resistance value is outside the set point indicated by the values table on pg 22, then the sensor must be replaced.

Installing the overheating / flame sensor

For AIRTRONIC D2 (Assembly without 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.

Connector blue

Connector green

NTC 50

= overheating sensor

PT=flame sensor

27

Special tool - only for AIRTRONIC D2

Overheating sensor / flame sensor

Special tool - only for AIRTRONIC D2

Overheating sensor / flame sensor

Clip

Overheat sensor / flame sensor

Clip

Cable harness -overheat/ flame sensor

Special tool - only necessary for the AIRTRONIC D2

Dismantling the heat exchanger

Removing the combustion air blower

• remove the AIRTRONIC cover

• remove the control unit.

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.

Important!

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.

28

Combustion Air blower

Heat Exchanger

Fastening screws

Tighten the fastening screws in this sequence with a tightening torque of 4 +0.5

Nm

Always replace the seal between combustion air blower and heat exchanger

Removing the combustion chamber

• remove the AIRTRONIC cover

Remove the flange seal.

Take the AIRTRONIC out of the outer case (lower part).

remove control unit ( see previous pages) remove glow pin ( see previous pages) remove combustion air blower ( see previous pages)

Unscrew the fastening screws.

For AIRTRONIC D2 = 3 fastening screws

For AIRTRONIC D4 = 4 fastening screws

Pull the combustion chamber out to the front and remove the seal from the heat exchanger.

Note!

When reassembling the combustion chamber, the seal, which has been enclosed with the spare part, must always be replaced.

Tighten the fastening screws of the combustion chamber with a torque of 5 +0.5

Nm.

Note:

If the heat exchanger is being replaced, the over heat sensor / flame sensor must be dismantled and mounted to the new heat exchanger. ( see previous pages)

29

Combustion chamber

Heat Exchanger

Fastening screws

AIRTRONIC D2 = 3 fastening screws

AIRTRONIC D4 = 4 fastening screws

Combustion chamber

Seal between combustion chamber and heat exchanger must always be replaced.

Heat exchanger

Fastening screws

AIRTRONIC D2 = 3 fastening screws

AIRTRONIC D4 = 4 fastening screws

AIRTRONIC D2/D4

Service Parts Diagram

12

8

30

18

17

16

11

10

9

7

14

6

3

4

5

1

13

19

2

15

20

Parts List AIRTRONIC D2/D4

Ref. No.

Description

3

4

5

6

7

1

2

Heat exchanger with burner (full assembly)

Heat exchanger

Burner

Gasket seal

Grommet

Fillister head bolt, M 5 x 12

Blower motor

8

9

10

Fillister head bolt, M 5 x 25

Gasket , blower

Control unit

11

12

13

14

15

16

17

18

19

20

Fillister head bolt, M 4 x 10q

Upper casing

Lower casing

Grommet

Flange seal

Overheating sensor / Flame sensor

Clip

Glow pin with socket wrench

Glow pin strainer

Mounting plate with hardware and seal

31

Part Number

25 2069 99 06 00

25 2113 99 06 00

25 2069 06 01 00

25 2113 06 01 00

25 2069 10 01 00

25 2113 10 01 00

25 2069 06 00 01

25 2113 06 00 01

25 2069 06 00 02

103 10 348

12V 25 2069 99 20 00

24V 25 2070 99 20 00

12V 25 2113 99 20 00

24V 25 2114 99 20 00

103 10 462

25 2069 01 00 03

25 2113 01 00 03

22 5101 00 10 01

22 5102 00 10 01

22 5101 00 10 05

22 5102 00 10 03

103 10 349

25 2069 01 06 00

25 2113 01 00 01

25 2069 01 01 00

25 2113 01 01 00

25 2069 01 00 01

25 2069 01 00 02

25 2069 01 02 00

25 2069 01 02 02

25 2113 01 02 02

25 2069 01 03 00

25 2070 01 03 00

25 2069 10 01 02

CA0 00 019

• •

• •

• •

• •

• •

• •

• •

• •

• • • •

• • • •

• • • •

• •

• •

• • • •

• •

• •

• •

• •

• • • •

• • • •

• • • •

• •

• •

• •

• • • •

• • • •

32

AIRTRONIC D2/D4

Service Parts Diagram

4

3

5

2 3

30

2a

42 43

1

6

22

22

21

9

10

25

26

11

8

7

13

28

41

18

10

18

12

23

17

15

16

44

19

39

17

14

29

27

34

40

20

16 17

22

35

37

24

32

31

38

38a

33

36

Parts List AIRTRONIC D2/D4

Ref. No.

Description

17

18

19

20

21

22

23

24

13

14

15

16

25

26

*27

28

*29

6

10

11

12

7

8

9

4

5

1

2

2a

3

Safety screen

Warm air deflector

Clamp

Flexible air hose

Straight outlet hood

Main harness

• short harness

Cable ties

Air intake

Flexible exhaust

Fuel hose

Plastic fuel line

Fuel metering pump

Clamp for fuel metering pump

Plastic fuel line

Angle bracket

Fuel hose

Clamp

Clamp

End sleeve with cross bar

Grommet

Intake hose clamp

Clamp

Fuel screen

Blade fuse

Plug connector

Housing

Muffler

Connectors for fuel metering pump

90° Air outlet hood

*30

31

32

33

*34

35

90° Bend

Fuse holder with terminals

Terminals

3/8’ Ring terminals 10-12 G

7 day timer with thermostat

Thermostat

ø25 mm

ø24 mm

3.5 mm

1.5 mm

12V

24V

2 mm

5 mm

11 mm

9 mm

ø 20-32

26 mm

20 amp

10 amp

33

Part Number

ø 60

ø 75

ø 60

ø 90

ø 50-70

ø 70-90

ø 60

ø 90

ø 60

ø 90

ø 60

ø 75

ø 90

ø 60

ø 75

12V

24V

12V

24V

25 1688 80 06 00

25 1552 05 01 00

20 1577 89 06 00

20 1609 80 09 00

10 2064 05 00 70

10 2064 07 00 90

10 2114 31 01 00

10 2114 37 00 50

22 1000 01 00 16

22 1000 01 00 19

CA1 60 201

CA1 60 205

CA1 00 005

360 00 006

25 1774 80 01 00

360 75 300

090 31 118

22 4519 01 00 00

22 4518 01 00 00

22 1000 50 03 00

090 31 125

CA0 10 105

360 75 350

10 2063 01 10 98

10 2063 00 90 98

25 1729 89 00 02

20 1280 09 01 03

10 2064 02 00 32

152 61 102

20 1280 09 01 03

CA1 07 005

CA1 07 006

22 1000 31 80 00

22 1000 31 81 00

25 1864 81 01 00

22 1000 31 87 00

22 1000 01 00 20

22 1000 01 00 22

22 1000 01 00 23

25 1688 89 00 01

25 1482 89 00 05

CA1 07 001

CA1 90 043

CA1 90 014

CA1 00 210

CA1 00 211

301 00 154

301 00 153

• •

• •

• •

• •

• •

• •

• •

• •

• •

• •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• • • •

• •

• • • •

• • • •

• • • •

• • • •

• •

• •

• •

• •

• •

• • • •

• • • •

• • • •

• •

• •

Parts List AIRTRONIC D2 / D4

Ref. No.

Description

34

Part Number

*39

40

41

42

43

*36

37

* 38

* 38a

*

44

Operating switch (rotary)

Standard fuel pick up pipe

Fuel pick up pipe (Compression fitting type)

12V

24V

2 mm

Compression fittings

Rubber hose

C-clamp

C-clamp

C-clamp

1/4” NPT

3/8” NPT

1/2” NPT

5 mm

10 mm

25 mm

28 mm

24 mm End-sleeve

Operators tape (not shown)

AIRTRONIC D2/D4 manual (not shown)

Operators guide (not shown)

Fault code retrieval device indicates optional features

Bezel kit for 7 day timer

25 1895 71 00 00

25 1896 71 00 00

CA0 12 056

CA0 12 042

CA0 12 044

CA0 00 031

CA0 12 005

CA3 00 103

152 00 139

152 10 048

152 10 051

25 1482 80 00 01

625 101 0102

610 103 0901

615 103 0901

CA1 05 020

25 1482 70 01 00

• •

• • • •

• • • •

• • • •

• • • •

• • • •

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1st. Printing - November 2001

Printed in Canada

P/N: 610-103-0901

Espar Products, Inc.

6435 Kestrel Road

Mississauga, Ontario

Canada L5T 1Z8

Canada (Tel):

Fax:

U.S. (Tel):

905-670-0960

800-668-5676

905-670-0728

800-387-4800

A member of the Worldwide Eberspächer Group of Companies

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