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AIRTRONIC D2/D4DIAGNOSTIC AND REPAIR MANUALA WORLD OF COMFORT

3Visual Inspection10TYPICAL NON-WARRANTABLE REPAIRS1. FUEL FILTERa. The fuel lter can be found on the inlet side of the fuel pump, see page 32.

Connection to the heater side of the harnessConnection to the truck side of the harnessWhite diagnostic plugIF THERE IS NO COMMUNICATION -Fault reader

4Fault Code / Troubleshooting12FAULT CODE / TROUBLESHOOTINGEW13 Warranty Process requires an Edith extraction printout to record codes before proceedi

REVISION LEVEL A - 12/09/13134Fault Code / Troubleshooting014 - TEMPERATURE DIFFERENCE BETWEEN FLAME SENSOR AND OVERHEAT SENSOR TO LARGE1. Using sho

4Fault Code / Troubleshooting14025 - DIAGNOSTICS CABLE BLUE/WHITE - SHORT CIRCUIT 1. Refer to “No Communication”031 - BLOWER MOTOR INTERRUPTED 1. V

REVISION LEVEL A - 12/09/13154Fault Code / Troubleshooting048 - OPEN CIRCUIT - FUEL METERING PUMP (FMP)Disconnect connector from fuel pump and measure

Right WrongBubbleCorrectWrongRight WrongBubbleCorrectWrong4Fault Code / Troubleshooting165. Check fuel supply/measure fuel quantity. a. Disconne

REVISION LEVEL A - 12/09/13174Fault Code / Troubleshooting17 5. Check exhaust and combustion air intake lines (maintenance) a. Low spots b

REVISION LEVEL A - 12/09/134Fault Code / Troubleshooting18064 - OPEN CIRCUIT - FLAME SENSOR 1. Open Airtronic shell and remove ECU from casing. Inst

1234200018001600120010008006004002000-40 -20 020406080 100 140120 200Temperature (°C)Resistance (kOhm)24002200200018001600140012001000800-40 050 100 1

REVISION LEVEL A - 12/09/13Table of ContentsChapter Content Page System Overview ...

300 mm5Service Information20REVISION LEVEL A - 12/09/13CONTROL VALUESMOTOR SPEEDTest speed for the blower heaterAIRTRONIC D2 / D2 Camper12 volt heater

1ba 2b a cb5Service Information21REPAIR INSTRUCTIONSRemoving the coverRemoving and checking the control unitRemoving the glow pinRemoving the liningRe

90°ba cacbbabaREVISION LEVEL A - 12/09/135Service Information22RECOMMENDED PERIODIC MAINTENANCE• Remove the AIRTRONIC cover.• Remove the ECU.Disconnec

ababblbr / wsgnbabca5Service Information23REMOVING THE OVERHEAT SENSOR / FLAME SENSOR • Remove the AIRTRONIC cover.• Remove the control unit.Disco

52431abcREVISION LEVEL A - 12/09/135Service Information24DISMANTLING THE HEAT EXCHANGERREMOVING THE COMBUSTION AIR BLOWER• Remove the AIRTRONIC cove

4123abc5Service Information25REMOVING THE COMBUSTION CHAMBER • Remove the AIRTRONIC cover.Remove the ange seal.Take the AIRTRONIC out of the outer c

AIRTRONIC D2 / /D3 / B /D4SERVICE PARTS DIAGRAM1711161518110971314191235*862420*REVISION LEVEL A - 12/09/136Parts Breakdown26

6Parts Breakdown27DESCRIPTION & PART #’SRef. No. Description Part NumberModel #AIRTRONIC D2 / B / D41 Heat exchanger 25 2069 06 01 00

6Parts Breakdown28REVISION LEVEL A - 12/09/13464842293041243233344544473537 38311739172319434016142a32345223627229820221211818101810182526117620281315

6Parts Breakdown29DESCRIPTION & PART #’SRef. No. Description Part NumberModel #AIRTRONIC D2 / B / D41 Safety screen ø 60 25 1688 80 06 00

SYSTEM OVERVIEWThe Espar Airtronic D2 heater is designed to lower idling by providing an alternative in cab heat solutionSYSTEM OPERATION1.

6Parts Breakdown30DESCRIPTION & PART #’SRef. No. Description Part NumberModel #AIRTRONIC D2 / B / D432 Terminals 5670199 • • • •

7CarboningREVISION LEVEL A - 12/09/13EXAMPLES / CAUSES OF CARBONINGCarbon is a term used to classify debris in the burner chamber. What you may visual

7Fuel Filter / Fuel Pump angle32FUEL PUMP MAINTENANCE / PROPER MOUNTINGFigure 41Fuel pump inlet lterFMP and bracket assemblyFigure 42Fuel pump inle

www.espar.comEspar Products, Inc.(800) 387-4800(905) 670-0960www.espar.comAIRTRONIC D2/D4 DIAGNOSTICS & REPAIR MANUAL Version 12/2013 Subject t

Direction of air flowFuel pumpGlow pinVentilation holeFlame sensorCombustion chamberSerial number1System Overview4REVISION LEVEL A - 12/09/13Figure 6SY

REVISION LEVEL A - 12/09/1352Diagnostic DevicesMULTIPLE DIAGNOSTIC DEVICES ARE AVAILABLE AS OUTLINED BELOW:This manual is designed to be used with the

REVISION LEVEL A - 12/09/132Diagnostic Devices6EDITH PC DIAGNOSTICS “PREFERRED” Figure 9

REVISION LEVEL A - 12/09/1372Diagnostic Devices2. DIGI-DIAGNOSTIC TOOL/CONTROLLER 1. First turn the controller on by pressing and releasing the inst

PermissibleFuel Metering Pumpnot permissiblenot permissiblepreferablepreferable3Visual Inspection8REVISION LEVEL A - 12/09/13PLEASE NOTE!VISUAL INSPEC

Return/inlet air must be clear from obstructionsOutlet air must be clear from obstructionsReturn/inlet air must be clear from obstructionsREVISION LEV