Espar AIRTRONIC D2, AIRTRONIC D4 Installation Instructions Manual

AIRTRONIC D2/D4

Installation, Troubleshooting & Parts Manual

AIRTRONIC

For Heater Models Release period

AIRTRONIC D2 - 12 volt 25 2069 05 00 00 November 2001
AIRTRONIC D2 - 24 volt 25 2070 05 00 00 November 2001
AIRTRONIC D4 - 12 volt 25 2113 05 00 00 November 2001
AIRTRONIC D4 - 24 volt 25 2114 05 00 00 November 2001

Espar

P/N: 610-103-0901 November 2001

Table of Contents Page

Introduction Heater Warnings ........................................................ 3

Introduction ........................................................ 4

Specifications ........................................................ 5

Principal Dimensions ........................................................ 6

Heater Components ........................................................ 7

Installation Procedures Heater Location ........................................................ 8

Heater Mounting ........................................................ 8

Heater Plate installation ........................................................ 8

Mounting Pattern ........................................................ 9

Ducting Components ........................................................ 9

Heater Air Ducting ........................................................ 9

Fuel System ........................................................ 10

Electrical Connections ........................................................ 12

Exhaust/Intake Connections ........................................................ 13

Operating Switches ........................................................ 13

Heater Operation Switch on ........................................................ 14

Start-Up ........................................................ 14

Temperature setting ........................................................ 14

Temperature Control ........................................................ 15

Switching Off ........................................................ 15

Controls & Safety Equipment ........................................................ 15

Operational Flow Chart ........................................................ 15

Function Diagrams ........................................................ 16

Schematic AIRTRONIC D2/D4 ........................................................ 17

Maintenance, Periodic Maintenance ........................................................ 18

Troubleshooting & Basic Troubleshooting ........................................................ 18

Repairs Self Diagnostic Troubleshooting ....................................................... 18

Fuel Quantity Test ........................................................ 23

Overheat/Flame sensor values ........................................................ 23

Control and Resistance values ........................................................ 24

Repair Steps ........................................................ 25

Heater Parts AIRTRONIC D2/D4 ........................................................ 30/32

-Service Parts Diagram

AIRTRONIC D2/D4

-Parts List ........................................................ 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.

Heater Warnings

3

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.

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 oper­ated 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

Failure to follow these instructions could cause oxygen
depletion resulting in serious or fatal injury.

Direct questions to Espar Heater Systems

USA 1-800-387-4800
CDA 1-800-668-5676

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 thermo-
stat. It cycles through four temperature settings (boost-high-
medium-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

5

Specifications

AIRTRONIC D2 AIRTRONIC D4

Heat Output (±10%) 7,500 BTU/hr Boost (2.2 kW) 13,650 BTU/hr Boost (4.0 kW)

6,150 BTU/hr High (1.8 kW) 10,200 BTU/hr High (3.0 kW)
4,100 BTU/hr Medium (1.2 kW) 6,800 BTU/hr Medium (2.0 kW)
2,900 BTU/hr Low (0.85 kW) 3,400 BTU/hr Low (1.0 kW)

Current at 12v (±10%) 8.3 amps - Start 8.3 amps - Start

2.8 amps - Boost 3.3 amps - Boost

1.9 amps - High 2.0 amps - High

1.0 amps - Medium 1.1 amps - Medium

0.7 amps - Low 0.6 amps - Low

Current at 24v (±10%) 4.2 amps/hr - Start 4.2 amps/hr - Start

1.4 amps/hr - Boost 1.7 amps/hr - Boost

1.0 amps/hr - High 1.0 amps/hr - High

0.5 amps/hr - Medium 0.5 amps/hr - Medium

0.3 amps/hr - Low 0.3 amps/hr - Low

Fuel Consumption (±10%) U.S. Litre/hr U.S. Litre/hr

Gal/hr Gal/hr

Boost 0.07 0.28 Boost 0.13 0.51
High 0.06 0.23 High 0.10 0.38
Medium 0.04 0.14 Medium 0.07 0.25
Low 0.03 0.10 Low 0.03 0.13

Air Flow (±10%) 48 cfm Boost 85 cfm Boost

40 cfm High 69 cfm High
27 cfm Medium 50 cfm Medium
19 cfm Low 30 cfm Low

Operating Voltage Range 10.5 - 16 vdc at 12 vdc 10.5 - 16 vdc at 12 vdc

21 - 32 vdc at 24 vdc 21 - 32 vdc at 24 vdc

Overheat Temperature 240°F (115°C) 240°F (116°C)
Shutdown (±10%)

Ambient Operating -40°F to 158°F (-40°C to 70°C) -40°F to 158°F (-40°C to 70°C)
Temperature

Weight 6.0 lbs. (2.7 kg) 9.9 lbs. (4.5 kg)

Note: The heater control unit is equipped with a low

voltage cutout to prevent vehicle battery drain and
a high voltage cutout to protect heater electrical
parts.

Principal Dimensions AIRTRONIC D2

6

* 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.

Principal Dimensions AIRTRONIC D4

(12.2 inches)

(4.5 inches)

(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

Heater Mounting Plate Installation

Hex Head Tek Screw

Flat washer

Nut

Spring Washer

Cab Floor

Note: Tighten screws sufficiently to ensure positive seal

between mounting plate and mounting surface.
Do not over tighten.

Silicon gasket (flange)
Stainless Steel Plate
Plate seal

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.

Wiring Harness
Right or Left

Stainless Steel
Mounting Plate
and seal

Combustion
Air intake

Fuel line

Heater
Flange

Exhaust
Tubing

Mounting Pattern

inches millimeters

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:

9

• 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.

Ducting Components

Return Ducting

For illustration
purposes only

No Return Ducting

For illustration
purposes only

1. Protective Grill 5. Air Outlet - Rotatable

2. Air Outlet Hood AIRTRONIC D2 - ø60 or75mm 6. Connection Piece
AIRTRONIC D4 - ø75 or 90mm 7. Protective Grill

3. Hose Clamp 2-2 3/4” 8. 90° Bend Ducting 2 3/8”

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.

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.

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

10

7

6

Max. 2’6”

Fuel

Tank

1

1. Fuel Pick-Up Pipe

2. 5.0 Rubber Connector

3. 11mm Clamp

2

3

Max. 6’6”

Fuel
Tank

Optional

Max. 6’6”

4

2

3

Max. 2’

Max. 20’

6

5

3

9

3

1

4. 2.0mm Black Plastic Fuel Line

5. Fuel Metering Pump

6. 9mm Clamp

8

7

5

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

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

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

11

NPT fitting and pipe

optional

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

12

Electrical Connections

Main Harness....................................................................... 16 pin connector with 10 terminated wires at 8 terminals.

(green/red, blue/white (2), red, grey/red, grey, brown,
brown/white and yellow (2)).
Connect to the heater’s 16 pin connector
Connect other harnesses as described below

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

Switch Harness.................................................................... 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).

Fuel Metering Pump Harness............................................. 2 core harness (green/red and brown).

Route this harness from heater to fuel metering pump. Cut to
length and connect to fuel metering pump using single termi­nals and connector provided with kit. (no polarity required).

Diagnostic Harness............................................................. 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 coat-

ed with protective grease, (petroleum gel,
Vaseline, etc.).

Fuel Metering Pump Harness

Fuse and holder

Main Harness

Connector for Diagnostics

Switch Harness

Thermostat

Power Harness

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

End Cap

Exhaust ( min. 8” - max. 6.5’).

Combustion Air Intake
( min. 8” - max. 6.5’).

End Cap

Warning: The exhaust is hot, keep a minimum of 2”

clearance from any heat sensitive material

Thermostat base
access hole

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.

Warning: Route exhaust so that the exhaust fumes

cannot enter the passenger compartment.

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 con­trol 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/Off switch

Green diagnostic light

Red operating light

On OEM installs the ‘red” & “green” indicator lights illuminate.
On after market installs only the “Red” light illuminates.

Operation indicating light

Low

High

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 Designation

for switches

red = power (+)
yellow = switch
brown = ground (-)

grey = temperature sensor

on thermostat

*vehicle dimmer switch

for light display on

grey/red = temperature setting

blue/white = diagnostic

brown/white = ground

7-day timer

blue = diagnostic

from heater

from heater

black = to vehicle ignition

accessories for continuous

operation of heater

1.1 Blower Motor

1.2 Glow Pin

1.5 Overheat and Flame sensor

2.1 Control Unit

2.2 Fuel Metering Pump

2.7 Main Fuse

12Volt - 20 amp / 24 volt - 10 amp

3.1.11 Rheostat

3.2.8 7 Day Timer

3.5 Thermostat

5.1 Battery

6.1 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:

19

AF Actual fault.
F1-F5 Up to five stored faults can be accessed.

The AF and F1 are the same number.
This sign is displayed when the heater is in

operation.

DIAG The word (DIAG) nostic will come on when

the diagnostic number is requested.

000 Three digit diagnostic fault code number.

On/Off switch

• 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

20

Note: If there are no heater faults, the heater will go through

a normal start cycle and regulate based on thermostat

See schematic

pg. 17

setting.

Fault Code Fault Description Causes / Repair

000 Normal Operation

004 Warning - short circuit in controller, fresh air-outlet 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.

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

009 TRS - shut down Switch off due to signal change.Check for change of signal from (+) to

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

010 Overvoltage 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

011 Undervoltage shut down 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.

012 Overheat at overheating sensor 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.

013 Overheat at flame sensor 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)

014 Temperature difference between flame sensor and Check for clogged hot air ducting. Check that the the total number of

overheating sensor too large 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.

015 Overheat with excessive temperatures 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.

017 Overheat with excessive temperature The hardware limit value for the overheating sensor, has been exceed-

ed, 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.

020 Open circuit - glow pin Check continuity of glow pin.

AIRTRONIC 12 volt - approx. 0.5 Ω ± 0.05 Ω
AIRTRONIC 24 volt - approx. 2 Ω ± 0.2 Ω

021 Short circuit - glow pin Check functions of glow pin in installed condition, to do so disconnect

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.

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.

21

Fault Code Fault Description Causes / Repair

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

032 Blower motor, short circuit Check functions of blower motor, to so so, disconnect connector from

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

047 Short circuit - fuel metering pump Disconnect connector from fuel metering pump, if fault code 048 (inter-

048 Open circuit - fuel metering pump Disconnect connector from fuel pump and measure resistance value of

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

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.

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.

ruption) 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

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.

050 Too many no start attempts Control unit is locked after too many unsuccessful start attempts. Check

051 Faulty flame recognition If the resistance value of flame sensor is 1274 Ω after switching on (>

052 No start safety time exceeded No flame detected on start attempt.Check exhaust and combustion air

053 Flame cutout in boost mode Heater has started successfully the flame has extinguished.

054 Flame cutout in high mode Check exhaust and combustion air lines. Check fuel
055 Flame cutout in medium mode supply/measure fuel quantity, see values, pg 23. Check flame
056 Flame cutout in low mode sensor, diagram and values table on following pages, if O.K., replace

060 Open circuit - external temperature Temperature sensor detects a value beyond it's range sensor

061 Short circuit - external temperature Disconnect connection S1/B1 (main harness), measure resistance

fuel, glow plug, combustion air and exhaust flow. Use control unit
tester or fault code retrieval device to unlock control unit. Maximum 255

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.

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.

control unit.

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

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

22

Fault Code Fault Description Causes / Repair

062 Thermostat/Rheostat/Timer, open circuit Potentiometer values outside of range on Thermostat (switch)

063 Switch control - short circuit If a ventilating switch has been built in, disconnect and check function.

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 Sensor is sensing value outside of range. Open Airtronic shell and

065 Short circuit - flame sensor Open Airtronic shell and remove control unit from casing. Disconnect

Check resistance between pins 6 and 7 at B1.
Resistance value for interruption between pins > 7175 Ω
Normal value: 1740 Ω - 2180 Ω (± 80 Ω )
If resistance value is O.K., replace control unit. If not replace thermo­stat/(switch).

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 Ω. Normal value: 1740 Ω - 2180 Ω (± 80
Ω).

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 Ω

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 Ω, see val-
ues on following pages.

071 Open circuit - overheat sensor Open Airtronic shell and remove control unit from casing. Disconnect

072 Short circuit - overheat sensor Open Airtronic shell and remove control unit from casing. Disconnect

090 Control unit defect Internal failure. Replace control unit.

091 External voltage disturbance Check vehicle charging system. Poor battery, battery charger, eliminate

092 Control unit defective (ROM fault) Internal failure. Replace control unit.

094 Control unit defective (EEPROM fault) Replace control unit

096 Internal temperature sensor defect Replace control unit or use external temperature sensor.
097 Control unit defective (power failure) Internal failure. Replace control unit.

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 Ω.

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 Ω, see following
pages for values.

fault.

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.

Values for Overheat sensor

Temperature (°C)

Temperature °C Resistance kΩ min. max.

-40 1597.0 1913.0

-20 458.80 533.40
0 154.70 175.50
20 59.30 65.84
40 25.02 28.04
60 11.56 13.16
80 5.782 6.678
100 3.095 3.623
120 1.757 2.081
140 1.050 1.256
160 0.6654 0.792
180 0.4253 0.5187
200 0.2857 0.3513

Values for Flame sensor

Note: The fuel quantity is not affected by voltage vari-

ances.

Temperature (°C)

Temperature °C Resistance kΩ min. max.

-40 825.90 859.60
0 980.00 1020.00
40 1132.30 1178.50
80 1282.80 1335.10
120 1431.50 1489.90
160 1578.30 1642.80
200 1723.40 1793.70
240 1866.60 1942.80
280 2008.10 2090.00
320 2147.70 2235.40
360 2285.50 2378.80
400 2421.50 2520.30

24

Control values

Motor speed

Control stage AIRTRONIC D2 AIRTRONIC D4

• Power 4800 U/min ± 140 U/min 4400 U/min ± 130 U/min

• Fast 4000 U/min ± 120 U/min 3600 U/min ± 100 U/min

• Medium 2800 U/min ± 80 U/min 2800 U/min ± 80 U/min

• Slow 2000 U/min ± 60 U/min 1600 U/min ± 50 U/min

• Adjustment

- in circulation mode with temperature sensor, internal 600 U/min ± 20 U/min 600 U/min ± 20 U/min

- In fresh air mode with temperature sensor, external 0 U/min 0 U/min

• Ventilation 4800 U/min ± 140 U/min 3600 U/min ± 100 U/min

Resistance values

Component AIRTRONIC D2 -12V AIRTRONIC D2 -24V AIRTRONIC D4 -12V AIRTRONIC D4 -24V

Blower motor 0.6 Ω ± 0.1 Ω 2 Ω ± 0.4 Ω 0.4 Ω ± 0.1 Ω 1.5 Ω ± 0.3 Ω
Glow plug 0.5 Ω ± 0.05 Ω 2 Ω ± 0.2 Ω 0.5 Ω ± 0.05 Ω 2 Ω ± 0.2 Ω
Fuel metering pump 10 Ω ± 0.5 Ω 36 Ω ± 1.8 Ω 10 Ω ± 0.5 Ω 36 Ω ± 1.8 Ω
Operator control unit

set value potentiometer 1750 - 2080 Ω ± 80 Ω 1750 - 2080 Ω ± 80 Ω 1750 - 2080 Ω ± 80 Ω 1750 - 2080 Ω ± 80 Ω

Switching value

Component AIRTRONIC D2 / D4

Overheating sensor 160°C - 170°C

measured in the control
stage “power”and at a
clearance of 300 mm
from the hot air outlet

Exhaust value

AIRTRONIC D2 / D4

CO2 in exhaust in control stage “fast” 7.5 -12.5 Vol. %
Soot number as per Bacharach <6

300 mm

Repair Instructions

25

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

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.

Caution: Remove power from the heater prior to any disas-

sembly 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

1.

2.

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 dis-

mantled 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

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

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.

26

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

Bore (Ø 2.7 mm) for glow pin ventilation

Lining

Special tool with lining
Position of recess

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

27

Flame Senor

Check the flame sensor with ta digital multimeter. If the resis-

tance 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 50Ω = overheating sensor

PT=flame sensor

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

30

18

17

16

19

11

2

10

4

3

6

1

5

9

7

14

8

13

15

20

31

Parts List AIRTRONIC D2/D4

Ref. No. Description Part Number

1 Heat exchanger with burner (full assembly) 25 2069 99 06 00 • •

25 2113 99 06 00 • •

2 Heat exchanger 25 2069 06 01 00 • •

25 2113 06 01 00 • •

3 Burner 25 2069 10 01 00 • •

25 2113 10 01 00 • •

4 Gasket seal 25 2069 06 00 01 • •

25 2113 06 00 01 • •
5 Grommet 25 2069 06 00 02 • • • •
6 Fillister head bolt, M 5 x 12 103 10 348 • • • •
7 Blower motor 12V 25 2069 99 20 00 •

24V 25 2070 99 20 00 •

12V 25 2113 99 20 00 •

24V 25 2114 99 20 00 •
8 Fillister head bolt, M 5 x 25 103 10 462 • • • •
9 Gasket , blower 25 2069 01 00 03 • •

25 2113 01 00 03 • •

10 Control unit 22 5101 00 10 01 •

22 5102 00 10 01 •
22 5101 00 10 05 •

22 5102 00 10 03 •
11 Fillister head bolt, M 4 x 10q 103 10 349 • • • •
12 Upper casing 25 2069 01 06 00 • •

25 2113 01 00 01 • •
13 Lower casing 25 2069 01 01 00 • •

25 2113 01 01 00 • •
14 Grommet 25 2069 01 00 01 • • • •
15 Flange seal 25 2069 01 00 02 • • • •
16 Overheating sensor / Flame sensor 25 2069 01 02 00 • • • •
17 Clip 25 2069 01 02 02 • •

25 2113 01 02 02 • •
18 Glow pin with socket wrench 25 2069 01 03 00 • •

25 2070 01 03 00 • •
19 Glow pin strainer 25 2069 10 01 02 • • • •
20 Mounting plate with hardware and seal CA0 00 019 • • • •

AIRTRONIC D2/D4
Service Parts Diagram

32

4

5

2

3

3

30

2a

42

43

29

1

22

21

22

27

22

31

24

9

10

25

20

32

26

11

6

7

8

34

41

35

19

13

28

10

18

18

12

17

23

44

16

39

37

38

17

33

36

38a

40

14

15

17

16

33

Parts List AIRTRONIC D2/D4

Ref. No. Description Part Number

1 Safety screen ø 60 25 1688 80 06 00 • •

ø 75 25 1552 05 01 00 • •

2 Warm air deflector ø 60 20 1577 89 06 00 • •
2a ø 90 20 1609 80 09 00 • •

3 Clamp ø 50-70 10 2064 05 00 70 • •

ø 70-90 10 2064 07 00 90 • •

4 Flexible air hose ø 60 10 2114 31 01 00 • •

ø 90 10 2114 37 00 50 • •

5 Straight outlet hood ø 60 22 1000 01 00 16 • •

ø 90 22 1000 01 00 19 • •

6 Main harness CA1 60 201 • • • •

• short harness CA1 60 205 • • • •
7 Cable ties CA1 00 005 • • • •
8 Air intake ø25 mm 360 00 006 • • • •
9 Flexible exhaust ø24 mm 25 1774 80 01 00 • • • •
10 Fuel hose 3.5 mm 360 75 300 • • • •
11 Plastic fuel line 1.5 mm 090 31 118 • • • •
12 Fuel metering pump 12V 22 4519 01 00 00 • •

24V 22 4518 01 00 00 • •
13 Clamp for fuel metering pump 22 1000 50 03 00 • • • •
14 Plastic fuel line 2 mm 090 31 125 • • • •
15 Angle bracket CA0 10 105 • • • •
16 Fuel hose 5 mm 360 75 350 • • • •
17 Clamp 11 mm 10 2063 01 10 98 • • • •
18 Clamp 9 mm 10 2063 00 90 98 • • • •
19 End sleeve with cross bar 25 1729 89 00 02 • • • •
20 Grommet 20 1280 09 01 03 • • • •
21 Intake hose clamp ø 20-32 10 2064 02 00 32 • • • •
22 Clamp 26 mm 152 61 102 • • • •
23 Fuel screen 20 1280 09 01 03 • • • •
24 Blade fuse 20 amp CA1 07 005 • •

10 amp CA1 07 006 • •
25 Plug connector 22 1000 31 80 00 • • • •
26 Housing 22 1000 31 81 00 • • • •
*27 Muffler 25 1864 81 01 00 • • • •
28 Connectors for fuel metering pump 22 1000 31 87 00 • • • •
*29 90° Air outlet hood ø 60 22 1000 01 00 20 • •

ø 75 22 1000 01 00 22 • •

ø 90 22 1000 01 00 23 • •
*30 90° Bend ø 60 25 1688 89 00 01 • •

ø 75 25 1482 89 00 05 • •
31 Fuse holder with terminals CA1 07 001 • • • •
32 Terminals CA1 90 043 • • • •
33 3/8’ Ring terminals 10-12 G CA1 90 014 • • • •
*34 7 day timer with thermostat 12V CA1 00 210 • •

24V CA1 00 211 • •
35 Thermostat 12V 301 00 154 • •

24V 301 00 153 • •

34

Parts List AIRTRONIC D2 / D4

Ref. No. Description Part Number

*36 Operating switch (rotary) 12V 25 1895 71 00 00 • •

24V 25 1896 71 00 00 • •

37 Standard fuel pick up pipe 2 mm CA0 12 056 • • • •

* 38 Fuel pick up pipe (Compression fitting type) CA0 12 042 • • • •

* 38a Compression fittings 1/4” NPT CA0 12 044 • • • •

3/8” NPT CA0 00 031 • • • •

1/2” NPT CA0 12 005 • • • •
*39 Rubber hose 5 mm CA3 00 103 • • • •
40 C-clamp 10 mm 152 00 139 • • • •
41 C-clamp 25 mm 152 10 048 • • • •
42 C-clamp 28 mm 152 10 051 • • • •
43 End-sleeve 24 mm 25 1482 80 00 01 • • • •

Operators tape (not shown) 625 101 0102 • • • •
AIRTRONIC D2/D4 manual (not shown) 610 103 0901 • • • •
Operators guide (not shown) 615 103 0901 • • • •

Fault code retrieval device CA1 05 020 • • • •
* indicates optional features
44 Bezel kit for 7 day timer 25 1482 70 01 00 • • • •

1st. Printing - November 2001
Printed in Canada
P/N: 610-103-0901

A member of the Worldwide Eberspächer Group of Companies

Espar Products, Inc.

6435 Kestrel Road

Mississauga, Ontario

Canada L5T 1Z8

Canada (Tel): 905-670-0960

800-668-5676

Fax: [phone]

U.S. (Tel): 800-387-4800