Airtronic 2/4 Diagnostic & Repair Manual
Contents
1. DUCTING RATING GUIDE FOR B1LC COMPACT Heater Rating 6 applies with a 60mm dia outlet hood Heater Rating 15 applies with a 75mm dia outlet hood The sketch shows how the most important air ducting parts that can be used They are not intended as examples of installation A l ES BE DEA 38 DUCTING RATING GUIDE REVISION LEVEL A 09 09 15 W DUCTING RATING GUIDE FOR BiLC COMPACT DESIGNATION 1 duct Heating air ducting with reduction hood 60 dia heater rating 6 Connecting socket plastic Flexible pipe 60 dia per m 90 pipe bend of flex pipe 60 dia Protective grille Slo ol COMPONENT RATING 2 duct 1 1 2 2 i 0 3 3 i 1 4 5 6 17 7 3 8 E 9 ia i 0 1 12 13 14 15 1 Position middle Heating air ducting vvith reduction hood 75 dia heater rating 15 16 1 Pipe bend 75 dia 2 Pipe bend 60 dia T piece 60 dia measurements in millimeters 0 25 17 Flexible pipe 75 dia per m 90 pipe bend of flex pipe 75 dia T pi ja 18 19 0 3 20 21 0 7 22 1 Position middle Position right left 23 24 25 26 Di 28 29 1 30 DIE Component is in front of the 2 duct system n the case of a combination of air ducting parts dia 60 at the intake side and dia 75 at the exhauster side the rating of the componenis at the exhauster side must be multiplied by 0 4 The heating rating 62. 1 Unit is seeing sensed heat prior to fuel pump engagement Often flooded chamber due to fuel supply issues 2 Check fuel supply measure fuel quantity a Disconnect the fuel line from heater b Turn the unit on remember 60 second delay prior to pump activation c Place the fuel line into the graduated cylinder and allow to run through a first start attempt d Once fuel pump stops running from first start attempt turn the unit off e Measured fuel must be between 3 5 to 4 3 milliliters Refer to page 19 f f the reading is high and the pump angle is verified correct replace the pump clear the codes and run the unit and restart troubleshooting g f the reading is low replace the fuel filter located on the inlet side of the pump and re run quantity test otherwise clear codes and restart troubleshooting h If results remain low after servicing the fuel filter replace the fuel pump and re run quantity test otherwise clear the codes and restart troubleshooting i If after steps G 8 H the results are still low check the fuel stand pipe for obstructions otherwise clear codes and restart troubleshooting 3 Check exhaust and combustion lines a Low spots b Crushed and kinked areas c At least a 45 degree downward angle in exhaust piping extended 1 5 to 2 5 past rear of cab Using shop air blow out the heat exchanger and airflow ducting including the intake Remove the sensor check connections wire and reinstall If the w
3. If it is sized too large or cycled off at too low of a coolant temperature could lead to premature burner chamber failures c Electrical connection issues If the signal wire is sporadic it will turn the heater on and off d Abrupt loss of main power Can cause burner chamber failure due to loss of its cool down cycle never use the Master Disconnect Switch to cut heater power Figure 40 31 7A FUEL FILTER FUEL PUMP ANGLE REVISION LEVEL A 09 09 15 FUEL PUMP MAINTENANCE PROPER MOUNTING Fuel pump inlet filter fi i 15 to ii vertical Figure 42 Fuel pump inlet filter clean or replace annually more frequently if fuel contamination is noticed Fuel pump should be mounted at a 15 35 degree angle harness connection outlet side facing up 32 DUCTING RATING GUIDE REVISION LEVEL A 09 09 15 W GENERAL TIPS ON HEATING AIR DUCTING AND COMPONENT RATINGS A heater has the biggest heating air throughput when it can operate with the air blowing freely Heating air ducting components reduce the throughput To enable you to check whether or not the installation you plan reduces the air throughput to an inadmissable degree we have calculated a heater rating for each heater and a component rating for each heating air ducting component 0 no temperature increase no component rating The sum of component ratings for the heating air ducting compo
4. 015 or 017 returns replace the sensor 12 Clear code and run unit 13 If code returns reinstall original sensor and replace control unit 14 Run unit ensuring issue is resolved DIM o 09 Y O 016 OVERHEAT WITH EXCESSIVE TEMPERATURE 1 This code is set when excess temperature is seen at the overheat sensor 2 See Code 015 019 GLOW PIN POWER CONSUMED BY GLOW PIN IS TOO LOW 1 Unplug the glow pin 2 Inspect the wire and plug condition if damaged replace the glow pin otherwise plug back in PLEASE NOTE Take care when working with the glow pin damaged wires or broken glow pins are not a warrantable failure Do not twist the wiring during removal See Basic Repair Analvsis Guide Non Genuine glow pins failing under warrantv must be returned 3 Clear codes and run unit 4 If code returns replace the glow pin 5 Clear codes and run unit 6 If code returns replace control unit and reinstalled the removed glow pin 020 OPEN CIRCUIT GLOW PIN BE CAREFUL NOT TO PULL WIRES OFF GLOW PIN DURING REMOVAL 1 Inspect glow pin leads for continuity replace if necessary 2 Check for corrosion in terminals maintenance 021 SHORT CIRCUIT GLOW PIN BE CAREFUL NOT TO PULL WIRES OFF GLOW PIN DURING REMOVAL 1 Inspect glow pin leads for continuity replace if necessary 2 Check for corrosion in terminals maintenance FAULT CODE TROUBLESHOOTING REVISION LEVEL A 09 09 15 025 DIAGNOSTICS CABLE BLUE
5. 36 TT Wa 4 3 1 4 Tighten the fastening screws in this sequence with a tightening torque of 4 05 Nm 35inelb 5 Alwavs replace the seal between combustion air blower and heat exchanger 24 Figure 35 Combustion Air blower Heat Exchanger Fastening screws SERV CE INFORMATION REVISION LEVEL A 09 09 15 REMOVING THE COMBUSTION GHAMBER Remove the AIRTRONIC cover Remove the flange seal Take the AIRTRONIC out of the outer case lower part e Remove ECU see previous pages e Remove glow pin see previous pages e 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 burner out to the front and remove the burner s thermal insulator from the heat exchanger PLEASE NOTE When reassembling the combustion burner the thermal insulator must alwavs be replaced Tighten the self tapping fastening screws of the combustion chamber with a torque of 5 05 Nm 44 inelb PLEASE 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 Figure 38 1 Combustion burner 2 Thermal insulator between combustion burner and heat exchanger must alwavs be replaced if burner is removed from the heat exchanger Holes not threaded 3 Heat ex
6. 8 Pos 4 if used as adapter 90 x 100 dia cut out the mesh 41 DUCTING RATING GUIDE REVISION LEVEL A 09 09 15 DUCTING RATING GUIDE FOR D8LC Heater Rating 8 The sketch shows how the most important air ducting parts that can be used They are not intended as examples of installation W DUCTING RATING GUIDE REVISION LEVEL A 09 09 15 DUCTING RATING GUIDE FOR D8LC DESIGNATION COMPONENT RATING measurements in millimeters 1 duct 2 duct uu heater rating 8 1 2 0 25 0 15 3 Connecting socket metal 1000 poa 0 4 0 1 0 1 5 0 25 6 Connector socket 100 dia 0 1 7 1 Outlet grill rotatable 100 dia DI 11 2 8 Grille 90x100 poa 3 9 Regulating valve 100x100x100 dias 2 6 10 0 8 11 Connecting socket metal 90 dia O o o 0 12 Outlet grill rotatable 90 dia 1 4 13 Y pipe 100x100x100 dia pp 0 4 14 15 Flexible pipe 75 dia perm 2 Pipe bend 90 of flex pipe 75 dia SS Y IB 16 Outlet grill rotatable 75 dia 17 Connector socket 75 dia 0 18 Connecting socket metal 75 dia 0 0v08hk0v0h81 e Pos 8 if used as adapter 90x100 dia cut out the mesh 99I 0U m abueyo 0 1 fqns 102 60 U01SJ9A ANVIN 4IVd34 Y SOILSONOVIO 10 20 9 v
7. WHITE SHORT CIRCUIT 1 Refer to No Communication 031 BLOWER MOTOR INTERRUPTED 1 2 3 4 5 Visually inspect air inlet for scratches on impeller If the fan has visable rub marks locate cause and correct thisis not a warrantable failure Run unit and listen for rubbing Turn blower by hand checking for hard spots If anv rubbing scratches or binding is found resolve the issue a Possible causes i Phvsical obstruction ii Ducting clamp over torqued iii Floor mat or debris under heater when mounted If a hard spot is noted and no intake issue are found remove blower motor and inspect the combustion fan and replace the whole assemble if necessary a A warped combustion fan is caused by short eycling and a power interruption while running 032 BLOWER MOTOR SHORT CIRCUIT 1 2 3 4 nstall test ECU Clear codes and run unit If problem is resolved leave new control unit in the Espar If problem is not resolved replace blower reinstall the previos control unit and restart the troubleshooting 033 Blower motor speed failure 1 Motor speed varies from specification by more than 1090 for longer than 30 seconds 2 Inspect the control unit ensuring it is secure 3 Fan speed is measured from a small magnet located on the fan wheel and the ECU itself 4 A loose ECU will cause inaccurate readings 5 If the ECU is loose tighten the screw 6 If the screw is stripped install a larger screw 7 Clear co
8. applies 39 DUCTING RATING GUIDE REVISION LEVEL A 09 09 15 DUCTING RATING GUIDE FOR AIRTRONIC 5 Heater Rating 10 The sketch shows how the most important air ducting parts that can be used They are not intended as examples of installation 1E 13815 12 5 gt 222 5 Ba W DUCTING RATING GUIDE REVISION LEVEL A 09 09 15 DUCTING RATING GUIDE FOR AIRTRONIC 5 DESIGNATION COMPONENT RATING measurements in millimeters 1 duct 2 duct prize heater rating 6 il NN a 1 N 0 2 2 Connecting socket metal 100 dia 0080808080 0 0 3 l Flexible pipe 100dia perm 06 0 2 Bend 90 of flexible pipe 100 dia 0080 6 E 4 Grille 90x100 dia pos 5 Connector piece 90 dia o 0 6 0 25 Bend 90 of flexible pipe 90 dia 0 2 7 1 Silencer 90 dia 0 8 8 Spherical reduction hood 90da 3078087877 4 9 0 1 10 lt 11 0 1 12 0 5 13 0 5 14 Y piece 100x100x100da 000800 k0 89894k5hhNhk1 82 0 5 15 100x100x100da 0k2727209075585451 00 05 16 Y piece 90x90x900da 082272222h8717 07701 0 6 Regulating valve 90x90x90 dias fr sf aac 2 FIJMoN si iH Position right left 18 19 Flexible pipe 75 dia per m 1 Bend 90 of flexible pipe 75 dia 0 5 20 Outlet grill rotatable 75 di 885 21 Connecting socket metal 75 0 22 Round outlet 75 dia closing o SSS o 23 Connector 90 dia 70200 0 24 0
9. condensation drain f Airflow intake Figure 13 and 14 and exhaust free of obstruction or damaged venting i Yes ii No ili If no repair as needed PLEASE NOTE If the unit is equipped with a Digi Controller and the display is showing H the interior temp of the unit is too high to allow the Espar unit to operate If the display is showing L the unit will work but the temp is too cold to show the correct temp on the display 2 Verifv operation if unit runs properly a Record any historic codes in the work performed section clear them and complete the job b If the unit does not operate properly continue below 3 Using either the Digi Controller Diagnostic Tool or Edith check for fault codes and utilize the troubleshooting steps listed VISUAL INSPECTION REVISION LEVEL A 09 09 15 PLEASE NOTE Return inlet air must be clear from obstructions Outlet air must be clear from obstructions Figure 14 Return inlet air must be clear from obstructions VISUAL INSPECTION REVISION LEVEL A 09 09 15 TYPICAL NON WARRANTABLE REPAIRS 1 FUEL FILTER a b 0 The fuel filter can be found on the inlet side of the fuel pump see page 32 If this filter is plugged or partially plugged it can cause a no start to your heater The filter can be serviced by using a backing wrench and turning the inlet cap off the pump Then use a small pick to pull the filter out to be replaced This fi
10. entered in order to charge the component to the work order MM VISUAL INSPECTION REVISION LEVEL A 09 09 15 VISUAL INSPECTION 1 Complete a visual inspection using the following instructions a Fuel Pump angle Figure 12 and 13 Between 15 and 35 degrees Inlet is low side outlet is high side i Yes ii No iii If no it will need to be reset to proper angle PLEASE NOTE It is very important that the pump angle is not reversed When checking angle ensure that the inlet side the fuel is drawn into the pump is the low side and the outlet side fuel exits the pump is the high side It is very important that the pump angle is not reversed see figure 12 for proper mounting Figure 12 90 Figure 13 De Permissible not permissible 0 not permissible 0 p L Fuel Metering Pump b Combustion Exhaust flexible pipe only 1 5 to 2 5 inch extension past rear of cab i Yes ii No iii lf no exhaust will need to be rerouted c Combustion Exhaust Flexible pipe only No Kinks and not crushed i Ves ii No iii f yes exhaust will require repair d Combustion Exhaust Flexible pipe only Bent facing the ground at least 45 degree angle I Ves Il No Ill If no exhaust will need to be adjusted e Combustion exhaust flexible pipe only Has low hanging areas i Ves ii No iii f yes eliminate the droop or drill a 1 8th inch
11. on only two methods EDITH PC diagnostics and the Digi Controller controller installed with the heater Digi Diagnostic Tool identical handheld tool 1 First turn the controller on by pressing and releasing the instant ON OFF key 2 To review fault codes press and hold the instant ON OFF until the display shows da a Codes will be displayed in the following manner 1 FO will display first followed by the code number 2 This is the active code and is the code that should be repaired first a Subsequent codes will be display with F1 F2 F3 etc followed by the code number 3 The F1 simply indicates this is the first or most recent historical code and they go in order 4 If there is not driver complaint no active code and the system is operating no repairs are needed codes should be cleared 5 To clear fault codes a While in diagnostic mode push and hold both arrow buttons until EE is displayed on the screen b To exit diagnostic mode hit the ON OFF button c To shut the unit down hit the ON OFF button again PLEASE NOTE ALWAYS document codes prior to clearing them EVEN if no repairs are made Figure 11 PLEASE NOTE Prior to making repairs ALWAYS complete a visual inspection operation inspection and note findings in the work performed section of your repair order PLEASE NOTE Any component replacement will require the serial number of the espar unit be
12. reading is low and the pump angle is verified correct replace inlet screen and retest h Inspect all fuel line connections to see if the lines have a crisp cut on the end Inspect fuel pick up pipe for anv obstructions Figure 17 Bubble Wrong Correct Wrong i If no fault is found on the inlet line or pick up pipe operate the fuel quantity test from an external fuel source j If results are still low replace pump 6 Replace atomizing screen clean starting air hole maintenance and inspect glow pin a If pin visibly deteriorated replace it clear codes and restart troubleshooting 7 Check flame sensor resistance see pages 19 23 8 Remove and inspect the burner chamber see pictures in the Basic Repair Analvsis guide a If burner chamber has carbon build up replace the burner chamber 1 Soft carbon non warrantv a 18 an indication of over fueling FMP angle b Restricted exhaust c Restricted intake d Plugged blower wheel 2 Hard carbon non warrantv a 18 an indication of too much additives b Heavv concentration of bio fuel Short eycle of heater recommended minimum runtime is 15 minutes d Road debris reposition combustion air intake to a location not to pick up debris e Clear codes and run unit 053 Flame cutout power boost mode 054 Flame cutout in high mode 055 Flame cutout in medium mode 056 Flame cutout in low mode 1 Heater has started successfully but the flame has exting
13. 0 10 1 FAULT CODE TROUBLESHOOTING REVISION LEVEL A 09 09 15 MM F THERE IS NO COMMUNICATION Fault reader displaying dash dash dash or non functional Espar unit without fault codes 1 Check units open circuit voltage at the batteries 2 If the voltage is below 12 6 Flooded cell or below 12 8 AGM charge the batteries to a minimum of 12 4 volts must be above the system LVD setting following your company s standard practices and restart troubleshooting a Otherwise continue below 3 Connect Diagnostic Interface adapter Figure 15 4 Using the Y adapter and multi meter a Perform a continuity test to verify ground on the brown wire of 0 ohms b Perform a voltage test to verify battery power between the red wire and the brown wire I If voltage is below 10 5 volts troubleshoot the tractor s wiring utilizing the manufacturer s documentation II Check for harness voltage drop to the heater c Perform a test to verifv continuitv to the diagnostic reader at blue wire white tracer at the white connector and blue wire vellow tracer on the Espar heater If wires are damaged repair wires ll Always use heat shrink solder or connectors with heat shrink tubing when making wiring repairs White diagnostic plug Connection to the heater n side of the harness Qe Connection to the truck side of the harness Figure 16 5 If the problem persists connect the test harness Figure
14. 15 and wire the Espar directly to the batteries a Plug the 8 pin adapter test harness in series with the Espar harness at the heater 6 Use a known good battery 12 volt min and supply external power using the white connector plug heavy red wire power heavy brown wire ground 7 If the problem persists replace the control unit ECU FAULT CODE TROUBLESHOOTING REVISION LEVEL A 09 09 15 FAULT CODE TROUBLESHOOT NG PLEASE NOTE EW13 Warranty Process requires an Edith extraction printout to record codes before proceeding Remember to carefully document the Complaint Cause and Correction 000 NORMAL OPERATION 1 No Repairs needed 010 OVER VOLTAGE 1 System maximum voltage is 16 volts 2 The possible causes of this code are non vvarranty a A battery charger in boost mode b Alternator overcharging 3 Clear the code repair as needed 011 UNDER VOLTAGE SHUT DOWN 1 Svstem minimum voltage is 10 5 volts 2 Verifv batterv voltage 3 Install the V interface adapter Connect the multi meter to the red and brown wires and set to volts DC 5 Record the voltage 6 If the voltage is less than 12 6 flooded cell 12 8 AGM connect the battery charger and log off the job until the batteries are fully charged otherwise continue below See note on page 11 7 Turn on the unit while watching the multi meter 8 If the voltage remains above 10 5 clear the code no repairs are needed otherwis
15. 2 D4 e Power e Fast e Medium e Slow e Adjustment in circulation mode with temperature sensor internal In fresh air mode with temperature sensor external e Ventilation AIRTRONIC D2 4800 U min 140 rpm 4000 U min 120 rpm 2800 U min 80 rpm 2000 U min 60 rpm 600 U min 20 rpm 0 rpm 4800 U min 140 rpm AIRTRONIC D4 4400 U min 130 rpm 3500 U min 100 rpm 2600 U min 80 rpm 1600 U min 50 rpm 600 U min 20 rpm 0 rpm 4400 U min 100 rpm RESISTANCE VALUES COMPONENT AIRTRONIC D2 12V AIRTRONIC D2 24V Overheat 60KOhm at room temp Glow pin 0 42 0 7 Q 12 200 Flame sensor 1 0KOhm at room temp Fuel metering pump 95 0 5 36 1 8 Operator control unit Set value potentiometer 1750 2180 80 Q 1750 2180 80 Q SWITCH VALUE AIRTRONIC D2 D4 140 C 170 C COMPONENT 284 F 338 F 300 mm measured in the control stage power and ata clearance of 300 mm from the hot air outlet Overheating sensor Figure 21 AIRTRONIC D2 D4 EXHAUST VALUE 7 5 12 5 Vol 90 CO in exhaust in control stage high lt 4 Soot number as per Bacharach 20 15 SERVICE INFORMATION ji REVISION LEVEL A 09 09 15 REPAIR INSTRUCTIONS Removing the cover Removing and checking the control unit Removing the glow pin Removing the lining Removing and checking the overheat and flame sensor Installing the overheat and flame sensor Dism
16. 2V 24V Glow pin screen with tool Mounting plate with hardware and seal Glow pin wrench x 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 25 2069 01 00 03 25 2113 01 00 03 22 5102 00 10 01 22 5101 00 10 05 22 5102 00 10 03 22 5101 00 10 06 22 5101 00 10 13 22 5101 00 10 14 22 5101 00 30 01 22 5101 00 30 05 22 5101 00 30 15 103 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 13 00 25 2070 01 11 00 25 2069 10 01 02 5540001 25 2069 01 03 03 VU Model ku 7 E uz EE AAA AE l 5 PARTS BREAKDOWN REVISION LEVEL A 09 09 15 AIRTRONIC D2 D3 B D4 SERVICE PARTS DIAGRAM PARTS BREAKDOWN AIRTRONIC DA B D4 DESCRIPTION amp PART 5 Ref No Description 1 2a 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 31 Safety screen Warm air deflector Clamp Flexible air hose Straight outlet hood Main harness Short harness Cable ties 197mm Air intake 1 meter Flexible exhaust 1 meter Fuel hose rubber 3 5 mm Plastic fuel line 1 5
17. AIRTRONIC D2 D4 DIAGNOSTIC AND REPAIR MANUAL Cu ANTI IDLING EMISSION REDUCING EQUIPMENT J TABLE OF CONTENTS REVISION LEVEL A 09 09 15 Chapter Content Page S LLLLUHMVU0401006066000 ER e ada 3 Diagnostie Devices nice e aa A m Sr oat 4 Visual INSpectioni cion a ia a ae 6 Maintenance Troubleshooting 8 Repair kanna 11 Service Information THT A 19 Pari3 Breakd yihn Ray ede a haa yaaa a nie dia 26 Fuel Filter Fuel Pump ANGE anrea er a s o a ed S ma ad die are cae one aS aa 32 Ducting Rating Guides canicas ai af 33 PLEASE NOTE The EW14 Warranty Process requires Edith extraction printouts to record codes before proceeding with repairs and after the repair steps listed in this manual are completed For your warrantv claim to be paid you must document the Complaint Cause and Correction steps in your warrantv claim write up A CAUTION Indicates that personal injurv or damage to equipment may occur unless specific guidelines are followed DANGER Indicates that serious or fatal injurv mav 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 4 Eberspacher The installation instructions and standards described in this document are NOT APPLICABLE TO MARINE INSTALLATIONS Please consult a certified Espar Marine dealer for m
18. N LEVEL A 09 09 15 RECOMMENDED PERIODIC MAINTENANCE e Remove the AIRTRONIC cover e Remove the ECU LO 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 05 Nm 50 inelb PLEASE NOTE Please check product catalogue for more information PLEASE NOTE When the glow pin has been removed check the screen of the support in installed state for anv contamination The screen must be replaced if the surface is covered with carbon Glow pin 1 Connector of glow pin cable harness 2 Rubber bushing 3 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 907 to the axis of the heater Newer screens do not have a recess Push the tool with the screen carefully as far as it will go ensuring that the bore 9 2 7 mm for the glow plug ventilation is free See illustration 1 In case of the shorter new stvle screen see image B the position of the screen to the vent hole has no reference Ensure installation t
19. TIME EXCEEDED 1 No flame detected on start attempt but unit diagnostics are unable to detect a fault 2 Check exhaust and combustion piping for restriction non warranty a Low spots b Crushes and kinks 3 Inspect and or replace fuel filter on inlet side of fuel pump see page 32 maintenance 4 Check fuel pump operation a Pump should tick if so continue to step 5 if not continue below b Install test pump clear codes and run unit PLEASE NOTE You cannot probe the fuel pump plug for voltage this sets a Code 48 and prevents the unit from running c If problem is resolved install pump clear codes run unit and restart troubles shooting Otherwise continue below d Troubleshoot wiring from pump to harness non warranty e If wiring is damaged repair as needed using heat shrink 8 solder butt connectors FAULT CODE TROUBLESHOOTING REVISION LEVEL A 09 09 15 5 Check fuel supplv measure fuel quantitv a Disconnect the fuel line from heater b Turn the unit on remember 60 second delav prior to pump activation c Place the fuel line into the graduated cvlinder and allow to run through a first start attempt d Once fuel pump stops running from first start attempt turn the unit off e The measured fuel must be between 3 5 to 4 3 milliliters Refer to page 19 f If the reading is high and the pump angle is verified correct replace the pump clear the codes run the unit and restart troubleshooting g If the
20. YSTEM OVERVIEW REVISION LEVEL A 09 09 15 SYSTEM OVERVIEW 4 Difference by controller operation a When operating in standby mode with a Mini Controller the fan will continue to run in order to maintain airflow across the return air temperature sensor b When operating in standbv mode with a Digi Digi Max Controller the fan will shut down as air flow is not required PLEASE NOTE Anv component replacement will require the serial number of the espar unit be entered in order to charge the component to the work order The selal number is located on the side of the Espar unit Figure 5 Figure DD Direction of air flow Ventilation hole Glow pin F 7 A li 2 Serial number 4 lame sensor Combustion chamber Fuel pump Figure 6 W DIAGNOSTIC DEVICES REVISION LEVEL A 09 09 15 MULTIPLE DIAGNOSTIC DEVICES ARE AVAILABLE AS OUTLINED BELOW 1 ED TH PC BASED DIAGNOSTICS PREFERRED This manual is designed to be used with the Airtronic D2 D4 Please reference The ability to print out an ECU extraction is only available using EDITH PC the data tag on your heater to verify which heater model you have The diagnostics and is a requirement for taking advantage of the EW14 express Airtronic D2 D4 can utilize any of the fault code readers listed here warranty protocols Full product testing capability including remote running of system components without removal of the heater c
21. al 7500 Joof oo 3 0 03 AAA OA AE 5 Intake silencer 75 dia 60008 081 1 7 me E 7 1 Spherical reduction hood 75 dia 0 8 8 T piece 75x75x75 dia 00000 k0v0 7001 l1 1 S Regulating valve 75x75x75 dia with flap 9 Position middle EE a Position right left 1 8 10 Branch piece 75x75x75 dia 0000 175 0 l l U 11 Outlet grill rotatable 75 dia 0 8 LI 0 2 12 1 Connector 75 dia 0 0 13 Outlet grill aii To 14 Connector 75 dia 6 0 Sd o 05 Tol 15 Ring 75x90 dia fos 16 Flexible pipe 90 dia perm 0 285 17 Connector socket 90 dia with grille nn Od e dof To 18 Reduction hood 90 dia IP 19 Spherical reduction hood 90 dia 60x87872797X X2 1 1 51 1 20 Round outlet 75 dia Ci l el 21 Outlet grill rotatable 100 dia i 0 5 22 Outlet grill rotatable 90 dia 2 2 0 5 23 Grille round 90x100 dia 000 fo PIU 24 Flexible pipe 1t0dia pemkkhkK 900 Toal Kaz II 26 Connector 90 dia with exhauster po 13 0 PP 0 Regulating valve 90x90x90 dia 27 Position middle 255 Position right left 1 4 XEL L SUR 0 20 Sianconl t daa uuu ji 30 Connector 100 ti oaf E SNE ANA Mo 32 Reduction piece 100 dia 78 dia L L L Jos Pos 23 if used as adapter 90x100 dia cut out the mesh 37 DUCTING RATING GUIDE REVISION LEVEL A 09 09 15
22. an be utilized for rapid fuel system priming EDITH BASIC EDITH PC DIAGNOSTICS PREFERRED EDITH Diagnostics When connected the green LED on the ISO adapter will indicate a 12 V power supply and the amber LED will indicate an active diagnostic link A constantly lit red LED may indicate a After the testing with EDITH DO NOT disconnect the Y shaped test adapter cable until the heater has been switched off and the cool down process has been Q ISO adapter kit EDITH basic adapter pin 22 1541 89 0000 The kit includes i ISO adapter ii Black spiral cable with 6 pin connector iti 9 pin to 9 pin serial port connector cabie iv USB 2 0 to 9 pin serial port adapter cable v CD with USB 2 0 to serial port software vi CD with EDITH diagnostics software Note install the EDITH software and the software for the USB 2 0 to 9 pin serial port adapter Q Test adapter cable suited to individual heater type Commoniy used test adapter cables pin 22 1000 31 8600 V shaped test adapter cable for Airtronic 02 D4 05 pin 20 2900 70 5028 Y shaped test adapter cable for Hydronic DS pin 20 2900 70 5046 This universal 6 pin to B pin connector adapter cable connects the ISO adaptor to any heater which has a diagnostic connector built into the main harness For a complete list of test adapter cables please refer to www espar convhelp EDITH Diagnostic Software EDITH is an acronym for Eberspaecher Diagnostic Tool Heater EDITH
23. antling the heat exchanger Removing the combustion air blower Removing the combustion chamber MM PLEASE NOTE Remove power from the heater prior to any disassembly by unplugging main connection or removing main fuse 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 PLEASE NOTE The cover must always be removed from the A RTRONIC for all repair stages You may have to wait for the device to cool down REMOVING THE COVER FROM THE A ATRONIC Unlock both seal plates lift cover and pull to the front The cable harness can exit from the left or right of heater shell Cover Seal Plates 2 REMOVING THE CONTROL UNIT Remove the A RTRONIC 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 Figure 22 PLEASE 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 1 Retaining brackets 2 ECU B Bushing 4 Figure 23 21 BI SERVICE INFORMATION REVISIO
24. arine 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 vvithout prior notice il SYSTEM OVERVIEW REVISION LEVEL A 09 09 15 SYSTEM OVERVIEW The Espar Airtronic D2 heater is designed to lower idling by providing an alternative in cab heat solution SYSTEM OPERATION 1 The operation tums on the device via either the Mini Digi or Digi Max Controller a The Mini Controller has a simple rheostat design for cab temperature control Figure 1 b The Digi Digi Max Controller are digital devices that controls the cab temperature and also acts as a diagnostic device Figure 2 amp 3 PLEASE NOTE If the unit is equipped with a Digi Controller and the display is showing H the interior temp of the unit is too high to allow the Espar unit to operate If the display is showing L the unit will work but the temp is too cold to show the correct temp on the display MM Figure 1 Figure 2 Figure 3 DIGI MAX D1000 2 When the heater is first started the following events take place a The unit runs through a 3 second diagnostic check b The fan and glow pin come on C After 60 seconds the fuel pump starts pumping fuel d If the unit doesn t fire within 2 1 2 minutes I The unit will then stop the fuel pump and pause for 60 seconds II The unit will then attempt a s
25. changer A Self tapping fastening screws AIRTRONIC D2 3 fastening screws AIRTRONIC D4 4 fastening screws Figure 37 Combustion burner Heat Exchanger Fastening screws AIRTRONIC D2 3 fastening screws AIRTRONIC D4 4 fastening screws PLEASE 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 25 3J PARTS BREAKDOWN REVISION LEVEL A 09 09 15 AIRTRONIC D2 D3 B 04 SERVICE PARTS DIAGRAM PARTS BREAKDOWN AIRTRONIC D2 B D4 DESCRIPTION amp PART 5 Ref No Description 1 10 11 13 14 15 16 18 19 20 Heat exchanger Burner Part Number 25 2069 06 01 00 25 2113 06 01 00 25 2069 10 01 00 25 2113 10 01 00 20 1812 10 01 00 Thermal insulator for burner 25 2069 06 00 01 25 2113 06 00 01 Grommet 25 2069 06 00 02 Fillister head bolt M 5 x 12 3 required 103 10 348 Fillister head bolt M 5 x 12 4 required 103 10 348 Blower motor 12V 25 2069 99 20 00 24V 25 2070 99 20 00 12 25 2113 99 20 00 24V 252114 99 20 00 12V 25 2144 99 20 00 Fillister head bolt M 5 x 25 Locally available hardware Gasket blower Control unit 24V 12V 24V 12V 12V 12V Hella 12V Hella 12V Fillister head bolt M 4 x 10 Upper casing Lovver casing Grommet Flange seal Overheat sensor Flame sensor with tool Clip Glow pin with socket wrench 1
26. ction hood 60mm straight 0 6 1x 90 bends of flex pipe 0 2 7 Swivel outlet 32 Total Component Rating 52 Rating sum 5 2 and does not exceed the heater rating of 6 The installation is permissable 33 DUCTING RATING GUIDE REVISION LEVEL A 09 09 15 DUCTING RATING GUIDE FOR AIRTONIC D2 Heater Rating 6 applies with a 60mm dia outlet hood Heater Rating 12 applies with a 75mm dia outlet hood The sketch shows how the most important air ducting parts that can be used They are not intended as examples of installation Sy SET amp ag da E 34 B iii D J d z 10 2 A 13 x 25 13 liliil L 3 EE y DH El Eb Eh 17 LTR 17 116 17 s 463 Se amp 6 23 13 Ii 17 a EE gg NE a AT 7 44 AID MM DUCTING RATING GUIDE REVISION LEVEL A 09 09 15 DUCTING RATING GUIDE FOR AIRTRONIC D2 DESIGNATION COMPONENT RATING measurements in millimeters 1 duct Heating air ducting with reduction hood 60 dia heater rating 6 Grille connecting socket plastic Flexible pipe 60 dia per m 00 pipe bend of Tlex pip 60 dia Protective grille Reduction hood 60 dia Spherical reduction hood 60 dia 90 pipe bend T piece Qutlet grill 60 dia rotatable Y piece 1 Regulating valve 60x60x60 dia with flap 11 Position middle Position right left Heating air ducting with reduction hood 75 dia E a d 12 13 13a 14 T piec
27. des and run unit 8 If code persists continue below otherwise clear historic codes and complete the job 9 Check heating air intake for obstructions ensuring the blower turns freely 10 See steps for Code 31 11 Clear codes and run unit 12 If problem persists install test control unit 13 Clear codes and run unit 14 If problem is resolved leave new control unit in the Espar 15 If problem is not resolved replace blower reinstall the previos control unit and restart the troubleshooting 034 Blower motor outlet short circuit after B battery voltage 1 Inspecting wiring from blower motor to control unit 2 If damaged replace blower otherwise continue below 3 Install test control unit 4 Clear codes and run unit 5 If problem is resolved leave new control unit in the Espar 6 If problem is not resolved replace blower reinstall the previos control unit and restart the troubleshooting 047 SHORT CIRCUIT OR OVERLOAD FUEL METERING PUMP FMP 14 1 2 NOAA Fuel pump positive wire green w red is shorted to chassis ground Inspect wiring for damage check continuity from 16 pin to fuel pump plug and repair using a heat shrink solder butt connector as needed If not damaged continue below Unplug the fuel pump and power up unit If fault Code 48 is displayed fuel pump is defective If fault Code 48 is not displayed recheck wiring If still not resolved install test ECU If problem is resolved lea
28. diagnostic software is available for free download from www espar com help EDITH is compatible with most versions of Windows OS including The current version of EDITH software is S3V11 F as on June 2011 Always uninstall the older version before installing the newer version of the software fil sudu sa m P a 95 te 1 Double click the EDITH shortcut on the desktop to launch the EDITH program 2 Click on the Select heater icon from the navigation menu displayed 4 Click and select the correct heater model number and the correct ECU version or click and run the Automatic detection 5 Select the diagnostic test to be activated in the far right column example Error memory General Data Functional check or Switch on component Functional check Activates the neater and displays live data on the heater operation a8 it unfolds This test disptays components as they are activated or deactivated the operational being measured like temperature speeds frequency voltages parameters heating modes etc To switch to a graphic view select the check boxes against the operational parameters and click on the graph tab Switch on component Enables independent activation and testing of the heater components including the blower fan fuel metering pump glow pin coolant pump etc Any component defect will be indicated by a fault code The fuel lines may be primed by independently activating the fuel meterin
29. e 75x75x75 dia 15 Grille 75 dia 16 Connecting socket metal 75 dia PO 17 Outlet grill rotatable tT Regulating valve 75x75x75 dia with flap 18 Position middle Position right left 19 Y piece 75x7575da OOOO O O O OOS o 20 21 Outlet grill mit E 22 Connecting socket plastic 75 880 23 Reduction hood 78 dla 24 Silencer 75 d a 25 26 Ring 0xZ da 80 CO CO N c l cl A 5 aIl lt a Cs 9 2 De eS lea a 2 duct 0 25 0 8 0 1 0 2 162 35 DUCTING RATING GUIDE REVISION LEVEL A 09 09 15 DUCTING RATING GUIDE FOR AIRTONIC D4 Heater Rating 3 applies with a 75mm dia outlet hood Heater Rating 10 applies with a 90mm dia outlet hood The sketch shows how the most important air ducting parts that can be used They are not intended as examples of installation 3 s Doo 207 11 TS 12 f LI T n lano MM DUCTING RATING GUIDE REVISION LEVEL A 09 09 15 DUCTING RATING GUIDE FOR AIRTRONIC D4 DESIGNATION COMPONENT RATING measurements in millimeters 1 duct 2 duct Heating air ducting with reduction hood 75 dia heater rating 3 Heating air ducting with reduction hood 90 dia heater rating 10 75 75 ter ratin 90 1 Flexible pipe 75 dia per m EEE KOM ta 907 pipe bend of flex pipe 75 dia gt gt Oz 2 Connecting socket met
30. e continue below 9 1 A Troubleshoot the tractors wiring harness utilizing the factory manuals check for voltage drop to the heater 0 Clear codes when repaired 012 OVERHEAT AT OVERHEATING SENSOR 1 Sensor has detected excessive temperatures 2 Using shop air blow out the heat exchanger and airflow ducting including the heating air intake 3 Check airflow ensuring the ducting is free from obstructions especially the bunk inlet and outlet 4 Check ducting rating of the installed heater See page 33 5 Remove the sensor check connections wiring and reinstall 6 If the wiring is damaged or connection is corroded replace the sensor otherwise continue below 7 Clear code and run unit 8 If code returns replace the sensor 9 Clear code and run unit ensuring issue is resolved 013 OVERHEAT AT FLAME SENSOR 12 1 Flame sensor detects excessive temperature at heat exchanger Using shop air blow out the heat exchanger and airflow ducting including the intake 2 Check airflow ensuring the ducting is free from obstructions especially the bunk inlet and outlet 3 Check ducting rating of the installed heater See page 33 4 Remove the sensor check connections wiring and reinstall 5 If the wiring is damaged or connection is corroded replace the sensor otherwise continue below 6 Check fuel pump angle and correct if needed A If correction was needed clear the fault and run unit 7 If fault code doesn t re
31. e 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 ca Connector blue A br ws Connector green gn GA 1 overheating sensor 2 flame sensor Figure 30 Clip Overheat sensor flame sensor Figure 31 Cable harness for overheat flame sensor clip Figure 32 Special tool only for A RTRONIC D2 Overheat sensor flame sensor Figure 33 Overheat sensor flame sensor Figure 34 O Clip 2 Cable harness overheat flame sensor Special tool only necessary for the A RTRONIC D2 23 2 SERVICE INFORMATION REVISION LEVEL A 09 09 15 DISMANTLING THE HEAT EXCHANGER REMOVING THE COMBUSTION AIR BLOWER e Remove the AIRTRONIC cover e Remove the ECU Remove the gasket 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 PLEASE NOTE When reassembling the combustion air blower a new gasket 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 05 Nm 35 inelb Figure
32. econd start e If the unit doesn t fire after the second attempt a code 52 will be set Refer to the fault code section of this document for proper troubleshooting PLEASE NOTE Times are approximate it is more important to understand there are 2 attempts and the process can takes some time After the second failed attempt the heater fan motor will remain on for up to three minutes which is normal and part of the logic of the heater The unit must be allowed time to run through its cvcle If there is an issue it will trip a code 3 Inside the unit a The fan provides air flow through the combustion chamber and the ventilation hole The glow pin heats the atomizer chamber to preheat in preparation for fuel Fuel first enters below the ventilation hole t is then atomized and ignites The flame burns through the combustion chamber The flame sensor recognizes a temperature rise and then shuts off the glow pin g The ECU measures the cab temperature via the return air temperature sensor in correlation with the set point Figure 4 h Units utilizing the Digi Digi Max Controller do not utilize the return air temp sensor but instead use the remote air temperature sensor on the Controller Figure 2 amp 3 page 3 i The unit switches between boost high medium low and standby I When it first ignites it is alwavs in boost Il Mode is controlled via fuel pump frequency and fan speed PRO LODO S
33. er 1 AIR FUEL MIXTURE a If the air fuel mixture is off it can cause a black soot in the burner chamber and can also be identified by looking though the heater exhaust exhaust port i Improper angle of fuel pump ii Wrong fuel pump used jii Fuel pump out of calibration perform fuel quantity test found on page 13 iv Low spots or restriction of intake tube or exhaust tube v Debris ingested into the combustion air intake fan impeller vi Improper length or too many bends of intake and exhaust tube Combined maximum of 6 5 and 270 of bends 2 NON FUEL RELATED BUILDUP a If all the steps have been covered under the section outlining code 52 and the chamber is clean looking the issue may be in the fuel or chemicals ingested by the intake tube i f the heater intake tube is in a location to pick up road debris like water and salt it can build up in the burner matting ii Additives are OK to use but if the concentration is in excess of the manufactures recommendations it can build up in the burner matting iii Oil related products like ATF or used oil will cause premature chamber failure This practice will not be tolerated by the heater If oil must be used it is ource FI id N Figure 39 MM 3 SHORT CYCLING OF HEATER a If the heater is allowed to short cycle it may cause a build up of Creosote Minimum runtime on a heater should be 15 minutes b Sizing of the heater is important
34. g pump NOTE The scope of information displayed in these tests will depend on the type of heater and the ECU version The fault codes can be cleared by clicking the Delete button Espar Products Inc www espar com 800 387 4800 2 Figure 8 Figure 9 P DIAGNOSTIC DEVICES REVISION LEVEL A 09 09 15 2 DIAGNOSTIC UNIT The diagnostic unit is solelv used to read out displav and delete faults stored in the heater s electronic control box The electronic control box can store up to 5 faults Please refer to user manual at www espar com help gt diagnostic tools gt Diagnostic unit 20 2900 70 50 60 backwards control button forwards control button activation button confirmation button Figure 10 PERFORM THE DIAGNOSIS Automatic detection Five seconds after the dia gnostic unit has been connected to the heater using the adapter cable the automatic detection starts to determine the tvpe of heater to which the dia gnostic unit is connected PLEASE NOTEI e If the automatic detection was successful if necessary the heater is briefly started and then s witches off again Displav until the automatic detection is completed TG POA m Display e If a water heater has been detected Airtronic M mn e f air heaters 11 3L 5 or Airtronic T Airtronic L air heaters control box cable loom fixed moulded were detected Confirm flashing symbol with possible dis
35. 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 PLEASE NOTE The fuel quantity is not affected by voltage variances Figure 18 Espar part f 552 00 04 Graduated Cylinder 10ml Temperature C F Resistance kQ 40 40 3 6 104 140 176 248 284 320 356 4 2 8 212 392 Resistance O Temperature C F 842 7 921 6 1000 0 1077 9 1155 4 1232 4 1308 9 1385 1 1460 7 1535 8 1610 5 SERVICE INFORMAT ON REVISION LEVEL A 09 09 15 CONTROL VALUES MOTOR SPEED Test speed for the blovver heater AIRTRONIC D2 D2 Camper 12 volt heater 5000 rpm 25 96 at U 10 0 volt AIRTRONIC D2 24 volt heater 5000 rpm 25 96 at U 18 0 volt AIRTRONIC M B4 7 D4 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 DAS D4 Camper plus 12 volt heater 4400 rpm 25 at U 10 5 volt AIRTRONIC M DAS 24 volt heater 4400 rpm 25 at U 19 0 volt CONTROL STAGE D
36. iring is damaged or connection is corroded replace the sensor otherwise continue below Install test sensor clear codes and run unit If problem is resolved leave sensor in and restart troubleshooting If problem persists install test control unit clear codes and run unit 0 If problem is resolved install old sensor leave in control unit clear codes and restart troubleshooting If problem persists contact tech support at 800 387 4800 PLEASE NOTE Before beginning any troubleshooting review pages 6 7 and ensure the visual checklist has been completed 0 JG E 060 Open circuit external temperature sensor Digi Digi Max Controllers only 1 Temperature sensor detects a value beyond its range 2 Replace Digi Controller 061 Short circuit external temperature Digi Digi Max Controllers only 1 Temperature sensor detects a value beyond its range 2 Replace Digi Controller 062 THERMOSTAT RHEOSTAT TIMER OPEN CIRCUIT 1 Fault reader connected prior to turning on temp controller or faultv temp controller 2 Clear code and run unit 3 If problem persists inspect control unit wire harness for damage or loose connection and repair if needed solder but connectors amp use heat shrink 4 If problem persists replace Digi Controller or Mini Controller 5 If problem persists install test ECU 6 If problem is resolved leave in test ECU clear codes and restart troubleshooting If problem persists co
37. lter mav cause the heater to smoke during start up and smoke during operation This filter can cause vour heater to over fuel due to repetitive start attempts Common codes associated with a fuel filter 50 56 2 ATOMIZER SCREEN a This screen surrounds the glow pin and is found when the glow pin is removed 3 OVERHEAT AND ASSOCIATED FAILURES Code 12 14 815 are normally non warrantable failures 4 PLUGGED OR RESTRICTED COMBUSTION INTAKE AND OR EXHAUST PIPING 5 CARBONED BURNER CHAMBER these are non warrantable unless caused bv a primarv failed part covered under a warrantable failure situation a b Caused by a restriction of intake or exhaust Caused bv improper angle of fuel pump pump must be 15 35 degree angle up with the outlet harness connection being on the high side c Fuel svstem that has had improper amount of additives injected into the tank d e Fuel svstem with anv kind of oil being used in the fuel Short cvcling caused bv improper application or electrical power connections 6 MODIFIED PARTS DURING REMOVAL OR REPAIR WHILE UNDER WARRANTV Any place where the integrity of the part has been compromised during the repair will not be covered under warranty If any part must be modified to remove or service cut wires broken housings damaged parts or a harness or a connector must be repaired in any way the Espar Warranty Department must be contacted and a WA first obtained 1 800 387 480
38. mm Fuel metering pump Clamp for fuel metering pump Plastic fuel line black Angle bracket Fuel hose rubber 5 mm Clamp Clamp End sleeve with cross bar 25mm plastic Grommet Intake hose clamp Clamp Fuel screen Blade fuse Plug connector Kit Housing Kit female Muffler Connectors for fuel metering pump Kit 90 Air outlet hood 90 Bend Fuse holder with terminals Part Number 0 60 25 1688 80 06 00 075 25 1552 05 01 00 0 60 20 2800 50 02 00 090 20 1609 80 09 00 075 22 1050 89 21 00 0 50 70 5550004 0 70 90 5550003 o 60 10 2114 31 00 00 090 10 2114 37 00 00 075 10 2114 34 00 00 o 60 22 1000 01 00 16 90 22 1000 01 00 19 075 22 1000 01 00 18 20 2900 70 03 91 20 2900 70 02 05 5590003 025 mm 360 00 006 024 mm 25 1774 80 02 00 360 75 300 890 31 125 12V 22 4519 01 00 00 24V 22 4518 01 00 00 22 1000 50 03 00 2mm 890 31 125 20 2900 40 0104 360 75 350 11mm 10 2068 01 10 98 9mm 10 2068 00 90 98 25 1729 89 00 02 20 1280 09 01 03 0 20 32 10 2065 02 00 32 26 mm 152 61 102 20 1312 00 00 06 20 amp 5670055 10 amp 5670056 22 1000 31 80 00 22 1000 31 81 00 25 1864 81 01 00 22 1000 31 87 00 0 60 22 1000 01 00 20 075 22 1000 01 00 22 90 22 1000 01 00 23 0 60 25 1688 89 00 01 075 25 1482 89 00 05 5670051 W Model az A feos a e pee ee eee ee ee ee ee ee 2118 08 a s oe OSSO SCONO OS OOO E PARTS BREAKDOWN AIRTRONIC DA B D4 DESCRIPTION amp PART 5 Ref No De
39. nents must not exceed the heater rating otherwise the outlet temperature will become too high and trigger the safety cutout switch If the sum of the component ratings exceeds the heater rating it can be reduced by selecting a larger diameter for the air ducting parts Rule of Thumb Double the cross section or two identical components running parallel 1 4 of the rating Example 50 diameter hose A 19 6 cm2 R rating 1 0 75 diameter hose The component rating of smooth welded pipes is only half that of flexible pipe of equal diameter A 44 2 cm2 R rating 0 25 e g double the pipe length MAIN LINE DRAWING FOR 1 DUCT AND 2 DUCT HEATING AIR SYSTEM 2 duct means i L The heating air line branches into two ducts after the heater Up to the branch the component ratings KON under 1 duct are valid after the branch they fall under 2 duct If an adiustable outlet is used in the 2 duct heating system one duct must be unclosable U PLEASE NOTEI L When determining the sum of the component ratings do not take the closable duct into consideration 1 duct 2 duct 1 duct means A heating duct leads to or from heater The component ratings under 1 duct are valid Example of Heating Air Ducting for AIRTRONIC D2 Heater Rating 6 ltem Designation Component Rating 1 Protective grille 0 5 2 Connection piece 60mm dia 0 3 Flex pipe 60mm dia 0 3m long 0 3 4 Flex pipe 60mm dia 1 0m long 1 0 5 Redu
40. nsor in and restart troubleshooting 3 If problem persists install test ECU clear codes and run unit 4 If problem is resolved install old sensor leave in ECU clear codes and restart troubleshooting If problem persists contact tech support at 800 387 4800 072 SHORT CIRCUIT OVERHEAT SENSOR 1 Open Airtronic shell and remove ECU from casing 2 Disconnect blue connector from control unit 3 If fault Code 071 displayed replace combination sensor flame temperature 4 If fault Code 072 is still displayed replace control unit 074 CONTROL BOX DEFECT 1 Overheating threshold value is not detected by ECU replace ECU 090 CONTROL UNIT DEFECTIVE 091 EXTERNAL VOLTAGE DISTURBANCE MAINTENANCE 1 Check vehicle charging system Poor battery battery charger eliminate fault 092 103 CONTROL UNIT DEFECTIVE Disconnect heater from power for 10 seconds by disconnecting the 14 pin connector at the heater or pull the 20 amp fuse Reconnect and test again If the problem persists test the heater using an external power source other than the vehicle known good battery only These faults are common to a bad power supply attached charger or dead cell in a battery If problem persists install test control unit clear codes and run unit Contact tech support at 1 800 387 4800 18 SERVICE INFORMATION REVISION LEVEL A 09 09 15 FUEL QUANTITV TEST The fuel quantitv should be tested if the heater has difficultv s
41. ntact tech support 800 387 4800 063 SWITCH CONTROL SHORT CIRCUIT 1 If a ventilating switch has been built in disconnect and check function If faulty replace switch 2 Disconnect wires from thermostat or switch If fault Code 062 is displayed replace switch 3 If switch is 0 K check connection of grey red wire and brown white wire for short circuit 4 If 0 K reconnect wires to thermostat control Disconnect connection B1 16 pin connector on vehicle of harness If fault Code 063 is still displayed replace control unit 17 FAULT CODE TROUBLESHOOTING REVISION LEVEL A 09 09 15 064 OPEN CIRCUIT FLAME SENSOR 1 Open Airtronic shell and remove ECU from casing Install test sensor clear codes and run unit 2 If problem is resolved leave sensor in and restart troubleshooting 3 If problem persists install test ECU clear codes and run unit 4 If problem is resolved install old sensor leave in ECU clear codes and restart troubleshooting If problem persists contact tech support at 800 387 4800 065 SHORT CIRCUIT FLAME SENSOR 1 Open Airtronic shell and remove ECU from casing 2 Disconnect green connector from ECU If fault Code 064 is displayed replace combination sensor flame temperature 3 If fault Code 065 is still displayed replace ECU 071 OPEN CIRCUIT OVERHEAT SENSOR 1 Open Airtronic shell and remove ECU from casing Install test sensor clear codes and run unit 2 If problem is resolved leave se
42. ool is completelv seated when installing screen Image A Special tool 2 Position of recess 22 Figure 24 Figure 26 Figure 27 Screen 2 Bore 2 7 mm for glow pin ventilation 3 Vent Hole Can be cleaned with wire Allow riveted section to be placed in such a wav as to not block the vent more Image B 2 Special tool 2 Screen SERV CE INFORMATION REVISION LEVEL A 09 09 15 REMOVING THE OVERHEAT SENSOR FLAME SENSOR e Remove the AIRTRONIC cover e 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 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 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 INSTALLING THE OVERHEAT SENSOR 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 th
43. plavs TC e if no errors faults exist P further action display fault memory E delete fault memory at ar I If errors faults exist ib further actions gt display current fault and ii fault memorv delete fault memorv Er m Display current fault in fault memory Simultaneously press B and E T ES Display e g AF 12 Display fault memory F1 F5 8 8 i press or Display e g F1 20 Delete the fault memory and as a result at the same time cancel the control box lock Current fault or fault F1 F5 confirm with El qora dEL Confirm display dEL again with 95 m fault memory is deleted and the control b box is unlocked QUIT DIAGNOSIS Switch off heater Press the heater is switched off PERFORM THE DIAGNOSIS AGAIN Press 9 the display is activated For further procedure see left hand column UNABLE TO PERFORM THE DIAGNOSIS b R SSA q Automatic detection vvas unsuccessful 25 Display if the automatic detection vvas not successfully completed Possible causes bl ws diagnostic cable not connected bl ws diagnostic cable is defective gt check for continuity short circuit and damage e Heater was not detected J DIAGNOSTIC DEVICES REVISION LEVEL A 09 09 15 3 DIGI DIAGNOSTIC TOOL CONTROLLER Inexpensive basic code viewing amp clearing functions While there are other fault code readers available in this manual we are going to focus
44. scription 37 x 38 x 38a 39 40 41 42 43 44 45 46 47 48 30 Terminals 3 8 Ring terminals 10 12 6 7 day timer Thermostat 12V 24V Operating svvitch rotary 12V 24V Standard fuel pick up pipe 2mm Fuel pick up pipe Compression fitting tvpe Compression fittings 1 4 NPT 3 8 NPT 1 2 NPT P clamp w Lining 10 mm P clamp 25 mm P clamp 28 mm End sleeve 24 mm Bezel kit for 7 day timer Mini Controller Digi Controller Ext Temp Sensor Fault code retrieval device Digi Max Controller x indicates optional features Part Number 5670199 5670178 22 1000 30 40 00 301 00 154 301 00 153 25 1895 71 00 00 25 1896 71 00 00 20 2900 20 20 56 20 2900 20 20 42 20 2900 20 20 44 5520002 5520006 152 00 139 152 10 048 152 10 051 25 1482 80 00 01 25 1482 70 01 00 22 1000 32 07 00 20 2800 70 10 00 25 1774 89 03 00 20 2900 70 50 20 20 2800 70 15 00 Model 6 0059999550 5 9 50 07 e JOGA ES RS sss s is s a O AAA 1111 2 12523770512V m 5205 RON Ze SH lg 2521140524V AS EE 5 CARBONING REVISION LEVEL A 09 09 15 EXAMPLES CAUSES OF CARBONING Carbon is a term used to classify debris in the burner chamber What you may visually see may not be carbon but still needs to be addressed properly to resolve the root cause of the issue This is just a guide to the more common things you may encount
45. t on remember 60 second delay prior to pump activation c Place the fuel line into the graduated cylinder and allow to run through a first start attempt d Once fuel pump stops running from first start attempt turn the unit off e Measured fuel must be between 3 5 to 4 3 milliliters 10 If the reading is high and the pump angle is verified correct replace the pump clear the codes and run the unit 11 1f the reading is low and the pump angle is verified correct replace the inlet filter and retest 12 If fault code doesn t return complete the job otherwise continue below 13 Replace the sensor Co O 1 Co 015 OVERHEAT WITH EXCESSIVE TEMPERATURES Sensor has detected excessive temperatures This code indicates that Code 017 was set and the unit was restarted This code indicates that the heaters has been overheated repeatediv consecutive times Unlock control unit by reviewing all codes a Document all codes b Clear codes once codes are cleared the lockout vill be cleared Using shop air blow out the heat exchanger and airflow ducting including the intake Check airflow ensuring the ducting is free from obstructions especially the bunk inlet and outlet Check ducting rating of the installed heater See page 33 Remove the sensor check connections wiring and reinstall If the wiring is damaged or connection is corroded replace the sensor otherwise continue below 10 Run unit 11 1f Code either
46. tarting or maintaining a flame PREPARATION e Detach the fuel line from the AIRTRONIC e Insert the fuel line into a graduated cylinder 10ml e Switch the AIRTRONIC on Once the FMP comes on allow the fuel system to bleed air out for approximately 60 seconds e Switch the AIRTRONIC off and empty the graduated cylinder MEASUREMENT e Switch the AIRTRONIC on e The fuel is pumped approx 60 seconds after switching on e Hold the fuel line in the graduated cylinder level with the glow pin while fuel is being delivered e The pump will stop automatically after delivering fuel for 90 seconds 110 seconds for AIRTRONIC 4 e Once fuel pump stops switch off the heater EVALUATION e Read out the quantity of fuel in measuring glass e 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 VALUES FOR OVERHEAT SENSOR 2000 1800 1600 1200 1000 Resistance kOhm co s B o 6 o o o T 20 40 60 80 100 120 140 200 Temperature C 40 20 0 Figure 19 VALUES FOR FLAME SENSOR 2400 2200 2000 gt 2 B 0 o o oc o Resistance kOhm 1200 1000 800 1 40 0 50 100 150 200 250 300 350 Temperature C Figure 20 MM e Replace the fuel metering pump
47. turn complete the job otherwise continue below 8 Measure fuel quantity a Disconnect the fuel line from heater b Turn the unit on remember 60 second delay prior to pump activation c Place the fuel line into the graduated cylinder and allow to run through a first start attempt d Once fuel pump stops running from first start attempt turn the unit off e Measured fuel must be between 3 5 to 4 3 milliliters If the reading is high and the pump angle is verified correct replace the pump clear the codes run the unit otherwise skip to step 16 9 If fault code doesn t return complete the job otherwise continue below 10 Replace the sensor FAULT CODE TROUBLESHOOTING REVISION LEVEL A 09 09 15 MM 014 TEMPERATURE DIFFERENCE BETWEEN FLAME SENSOR AND OVERHEAT SENSOR TO LARGE Using shop air blow out the heat exchanger and airflow ducting including the intake Check airflow ensuring the ducting is free from obstructions especially the bunk inlet and outlet Check ducting rating of the installed heater See page 33 Remove the sensor check connections wire and reinstall If the wiring is damaged or connection is corroded replace the sensor otherwise continue below Check fuel pump angle and correct if needed If correction was needed clear the fault and run unit If fault code doesn t return complete the job otherwise continue below Measure fuel quantity a Disconnect the fuel line from heater b Turn the uni
48. uished 2 Inspect and or replace fuel filter on inlet side of fuel pump see page 32 maintenance 3 Inspect for possible air entrv into the suction side of the fuel svstem 4 Check fuel supplv measure fuel quantitv a Disconnect the fuel line from the heater b Turn the unit on remember the 60 second delav prior to pump activation c Place the fuel line into the graduated cvlinder and allow to run through a first start attempt d Once the fuel pump stops running from the first start attempt turn the unit off e The measured fuel must be between 3 5 to 4 3 milliliters Refer to page 19 f If the reading is high and the pump angle is verified correct 15 35 replace the pump clear the codes run the unit and restart troubleshooting g If the reading is low and the pump angle is verified correct replace inlet screen and retest h Inspect all fuel line connections to see if the lines have a crisp cut on the end Figure 13 Inspect fuel pick up pipe for anv obstructions Figure 17 Correct Wrong i If not fault is found on the inlet line and pick up pipe operate the fuel quantity test from an external fuel source 16 FAULT CODE TROUBLESHOOTING REVISION LEVEL A 09 09 15 MM 5 Check exhaust and combustion air intake lines maintenance a Low spots b Crushed and kinked areas c At least a 45 degree downward angle in exhaust piping 6 Test flame detector see page 20 057 Flame cutout during start phase
49. ve test unit in clear codes and run unit 1 FAULT CODE TROUBLESHOOTING REVISION LEVEL A 09 09 15 MM 048 OPEN CIRCUIT FUEL METERING PUMP FMP Disconnect connector from fuel pump and measure resistance value of fuel pump see values pg 20 If resistance values are O K then reconnect cable harness to the fuel pump 1 Check fuel pump electrical connector a Pins of female plug end can become spread b Re crimp if needed C Clear code and run unit d If problem persists continue below 2 Inspect the wiring for damage check continuity from the 8 pin housing for an external FMP and 14 pin housing for an internal FMP 050 TOO MANY NO START ATTEMPTS LOCKOUT PLEASE NOTE This is normally not a warrantable failure 1 Document and clear fault codes 2 Restart troubleshooting i Reference Code 52 051 FAULTY FLAME RECOGNITION 1 Document codes clear codes and run unit PLEASE NOTE This code is cause from a hard shutdown power cut off which prevents a cool down If upon next start the sensed temperature is excessive the unit will run a cool down cycle If the sensed temperature doesn t fall enough a Code 051 is set This can be a loose power wire or using the master cutoff while the unit is running 2 If problem persists install test flame sensor 3 If problem is resolved leave sensor in clear codes and run unit Also refer to Code 52 for no start situations 052 NO START SAFETY
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