IK1900172 - Espar Airtronic Heater Diagnostic Guide

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Document
IK1900172
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Availability: ISIS, FleetISIS, Body Builder, IsSIR

Revision: 22

Major
System:

ACCESSORIES

Created:

Current
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English

Last
7/17/2018
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11/4/2011

Bobby
Christopher

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23424
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Title : Espar Airtronic Heater Diagnostic Guide
Applies To : Airtronic Heater, Feature code 16VTV

CHANGE LOG
07/17/2018 Updated Hyper link to Espar manual
05/10/2018 - Author updated for Feedback Purposes.
12/15/15 - Removed all information about Hydronic D5 unit since a seperate iKnow exists for it (IK1900245). Improved robustness of Airtronic
diagnostic and repair procedures. Added pre season maintenance section.
9/8/2015 - Made minor grammatical corrections, added actual table for service parts instead of clickable PDF link, added the special warranty

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DESCRIPTION
The Espar diesel-fired heating system provides heat for the cab area without the use of the vehicle engine. When the Espar
system is on, the front cab blower will also operate to prevent condensation buildup. The heater may have a short run time if the
the vehicle has sat for an extended period of time with battery low state of charge. This document will guide the user through pre
season maintenance and diagnosing the Espar Airtronic system on Navistar equipped vehicles. You may refer to the
manufacturer's website for additional literature as indicated in diagnostic steps below.

PRE SEASON MAINTENANCE
It is recommended that the Airtronic heaters receive a pre-season check-up to make sure that the heaters are ready for a trouble-free cold weather
season. Please use the recommended tools and follow the procedures as outlined in the heater manual while removing and reinstalling the different
heater components. It should be noted that periodic heater maintenance is the responsibility of the owner of the heater and is not covered under
Espar’s warranty.
The heaters should be inspected and repaired by an Espar trained mechanic, as follows:
1. Before initial operation ensure that the heater is not being subjected to external loads by heavy objects being placed over it. This may cause
damage to the heater parts and affect its normal operation. Ensure that sufficient clearances, as recommended in the heater manual, are being
maintained around the heater, even while the vehicle is in operation.
2. Check the return air inlet port and hot air outlet port for any blockages. Inspect the length of ducting for any damage and replace as necessary.
Ensure all ducting connections are secure. Discourage heat sensitive materials from being placed too close to the heater, ducting components, or hot
air outlet ports.
3. Check all electrical connections from the heater to the batteries. Check for wear and abrasion along the length of the harnesses. Repair or replace
the harness whenever the harness insulation is broken or damaged. Check the battery connections. Clean any corrosion at the terminals. Replace the
battery terminals if the corrosion is severe. Check the fuse for corrosion and the correct rating.
4. Remove the glow pin and if necessary, clean it. If the glow pin shows signs of dissimilar color or distortions, replace it. Inspect the glow pin wires for
damage and if necessary, replace it. Remember to clean the glow pin chamber and ensure glow pin ventilation hole is clear of any obstructions, then
replace the glow pin.

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IK1900172 - Espar Airtronic Heater Diagnostic Guide

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5. Regardless of its condition, remove and replace the glow pin screen every pre-season. Make sure that the new screen is installed correctly. Install
the new screen.
6. Check the condition of the exhaust pipe. Look for any holes or breaks in the exhaust piping. Replace if necessary. Ensure the exhaust pipe is
securely located and correctly routed.
7. Check the condition of the combustion air intake tube. Clear any blockages. If damaged, replace it. Ensure that the combustion air intake tube is
securely located and correctly routed.
8. Ensure mounting angle of the fuel pump is in between 15-35 degrees. An incorrectly mounted fuel pump may lead to excessive carbon issues.
Check the fuel lines for possible leaks, loosened clamps, etc. inspect the filter on the suction side fuel pump filter - clean or replace as necessary.
Once the entire fuel system has been checked and any issues corrected, it is advisable to do a fuel quantity check.
9. If the fuel quantity result is above specification, then it will be a cause for excessive carbon issues and the fuel pump should be replaced. If the fuel
quantity result is within specifications, but on the higher side, then any possible excessive carbon issues may be corrected by increasing the mounting
angle of the fuel pump to the near vertical position. If fuel quantity result is below specification, then it is recommended that the fuel pump may be
replaced only if the heater repeatedly flames out during operation.
10. If there are complaints about the heater smoking excessively during operation then remove and check the condition of the burner. The burner
should be light brown in color. Clean any carbon build up inside the burner tube. Check the inside of the heat exchanger and scrape out any loose
carbon.
When reassembling the burner and the heat exchanger, use a new thermal insulator. Likewise, when reassembling the blower motor assembly use a
new blower gasket.
Re-assemble the heater and test operation. The heater should be bench tested for 15-20 minutes before returning the heater to the vehicle.
Regardless of the season, run the heater every month for a minimum period of 15 minutes. This will help the heater to burn away any combustion
residue in the burner chamber. It will ensure that the fuel in the lines to the heater does not gel and solidify and that the heater will start reliably when
heating season arrives.

SYMPTOMS
Diagnostic Trouble Codes:
DTC/Light
N/A

Description
N/A

Customer Observations or Concerns:
Performance:
No heat in cab
Espar not working all the time
Espar intermittent operation
Espar stops working after a period of time
Noise:
Abnormal Noise

SPECIAL TOOLS / SOFTWARE

Figure 1: ISO Adaptor ESP2215418900000Z (Used for all Espar Heaters)

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IK1900172 - Espar Airtronic Heater Diagnostic Guide

Tool Description

Tool Number

Comments

EDiTH Diagnostic Software

Part of EZ Tech
software

Manufacturer Tool

ISO Adaptor

ESP2215418900000Z Manufacturer Tool

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To download diagnostic software, go to espar.com and click on "Download Center" and then "Technical Manuals". Click on the
link to log in and then create a free account. You will need to activate your account with the link provided in the confirmation
email. Once you are logged in, click on "Dealer Area" at the top and then "Downloads". Click on "Diagnostic Tools" under
"Downloads" to the left and then click on "EDiTH". There will be a link to download the software.

SERVICE PARTS INFORMATION
Click here for parts. Full unit part numbers can be found on the first page. Individual service parts can be found on page 40 of
the manual.

Circuit Diagrams
Diagram

Link

Airtronic with key off operation

PDF

Airtronic with key on or in accessory position

PDF

DIAGNOSTIC AND REPAIR STEP(s)
Click here to view the full Espar Airtronic Manual. It contains detailed information on technical data, installation
procedures, heater operation, maintenance, troubleshooting & repair, and heater parts.

Addtional information:
Step Action
Operational Checks:

Decision
Yes. Educate operator with
manufacturer operating intentions

Review operational cards to determine if Espar control equipment is operating
as intended

1

Operation Cards
Multi Max
Digi Max (under voltage shutdown must be set to 11.4 V)

No Step 2

Does the heater controller and unit operate as the manufacture intended?

Step Action
2

Diagnostics:

Decision
Yes. Educate operator with
manufacturer's operating intentions
No

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IK1900172 - Espar Airtronic Heater Diagnostic Guide

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Review manufacturer provided troubleshooting manuals posted below to
diagnose and repair controller or heater as required (additional resources may 1. Visit Espar.com
be found at Espar.com)
2. Click Download Center
3. Click Technical Manuals
Multi Max Controller
4. Create free username and password
5. Follow additional technical manuals
Digi Max Controller
Airtronic Flame Tube Carbon Removal
Diagnostic Overview
Does the controller and heater operate as manufacture intended?

WARRANTY INFORMATION
Special Requirements:

The following information is necessary for the warranty claim to be processed:
a. Serial Number needs to be listed
b. Hours on Espar System
c. Fault Code Found
Complete Espar system replacement not warrantable, individual system parts need to be replaced.
Warranty Claim Coding:
Group:

19030 - Auxiliary No-Idle HVAC

Noun:

633 - Auxiliary Fuel-Fired Heater

Standard Repair Times:
Description

Chassis

Engine

SRT

Hours

Airtronic/Hydronic Diagnostics

Prostar

All

R19-8013A

Link to Hours

Combustion Air Blower

Prostar

All

R19-7633A-20

Link to Hours

ESPAR Airtronic Heater (Replace)

Prostar

All

T-time

Overheat Sensor

Prostar

All

R19-7633A-22

Flame Sensor

Prostar

All

R19-7633A-23

Glow Pin

Prostar

All

R19-7633A-24

Fuel Metering Pump

Prostar

All

R19-7633A-25

Burner Flame Tube

Prostar

All

R19-7633A-26

O-Ring Sensor

Prostar

All

R19-7633A-28

O-Ring Heat Exchanger

Prostar

All

R19-7633A-29

Seal Kit

Prostar

All

R19-7633A-30

0.5

Link to Hours

OTHER RESOURCES
Master Service Information Site

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Copyright © 2018 Navistar, Inc.

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