Retrofit air heater Eberspächer Airtronic D2

AZ83.70-W-0016BA

Retrofit air heater Eberspächer Airtronic D2

16.2.12

14.8.06

Work procedure completely revised.



Removing

 Danger!

Risk of explosion caused by fuel vapors igniting, risk of poisoning caused by inhaling combustible gases and risk of injury caused by burns during and after operation of heater unit

Do not operate a stationary heater, an auxiliary heater or an engine with heater booster in closed areas or when refueling. Allow heater unit to cool down after operation and wear protective gloves.

AS83.70-Z-0002-01A

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Unlock steering column and tilt backward

2

Disconnect ground lead from battery



Notes on battery

AH54.10-P-0001-01A

3

Remove grab bar from B-pillar

 The grab bar is inserted at the bottom into the paneling on the wheelhouse.



Remove/install support rod on B-pillar

AR68.70-W-0303C

4

Remove paneling from wheelhouse

 To do so, the plug of the level control operating device for ride-level control must be removed.

5

Remove footwell cover on the driver side



Remove/install footwell cover on driver side

AR68.30-W-1310D

6

Remove line cover in driver-side footwell

7

Remove paneling at side of instrument panel

 Remove only driver-side paneling



Remove/install side paneling on instrument panel

AR68.10-W-1503A

8

Remove center module



Remove/install center module

Vehicles with code (FN1) Distributor vehicle cockpit

AR68.10-W-1004A



Remove/install center module

Vehicles with code (FN2) Comfort cockpit

AR68.10-W-1004B



Remove/install center module

Vehicles with code (FN3) Long-distance haulage vehicle cockpit

AR68.10-W-1004C

9

Move driver seat towards the front

10

Remove footwell cover on the front passenger side



Remove/install footwell cover on passenger side

AR68.30-W-1300C

11

Remove bottom paneling for passenger-side instrument panel



Remove/install bottom paneling for instrument panel on passenger side

AR68.10-W-1502A

12

Fold up lower bunk and secure

13

Detach floor covering in installation area of hot air heater unit (A31) and place to one side

14

Remove fuel feed point

 Only on vehicles with fuel feed point without connection option for fuel metering pump (M16)



Remove/install fuel level sensor

AR47.10-W-7000A



Install

15

Make cutouts for exhaust gas, combustion air, fuel supply and fastening

Vehicles with code (F04) Cab L (long)

AZ83.70-W-0002-01L

Vehicles with code (F07) Cab S (short) or with code (F20) Cab with extended rear wall

AZ83.70-W-0002-01S

16

Install hot air heater unit (A31)

AZ83.70-W-0002-02J



Notes on installation of air heaters

AH83.70-N-0001-06A

17

Install heater air pipe

Vehicles with code (F04) Cab L (long)

AZ83.70-W-0002-08G

Vehicles with code (F07) S cab (short)

AZ83.70-W-0002-08J

Vehicles with code (F20) Cab with extended rear wall

AZ83.70-W-0002-08L

18

Route lines for exhaust, combustion air, and fuel supply

Vehicles with code (F04) Cab L (long)

AZ83.70-W-0002-03F

Vehicles with code (F07) Cab S (short) or with code (F20) Cab with extended rear wall

AZ83.70-W-0002-03S

19

Route wiring harness and connect

Vehicles with code (E06) Electrical system for hazardous goods vehicles (GGVS)

AZ83.70-W-0002-04MA

Vehicles without code (E06) Electrical system for hazardous goods vehicles (GGVS)

AZ83.70-W-0002-04M

20

Install timer (S61)

AZ83.70-W-0002-05G

21

Finish interior of vehicle

 Perform operation steps 3 to 13 in reverse order.

 Danger!

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut.

AS60.80-Z-0001-01A

22

Tilt cab



Notes on tilting the cab

AH60.80-N-0003-01A

23

Remove splash guard in left front fender

24

Remove noise encapsulation

25

Install fuel line

Route fuel line and wiring harness together in left longitudinal frame member.

AZ83.70-W-0008-01B

26

Install noise encapsulation

27

Install splash guard in left front fender

 Danger!

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure with the safety strut.

AS60.80-Z-0001-01A

28

Tilt cab back



Notes on tilting the cab

AH60.80-N-0003-01A

29.1

Prepare fuel remover for connecting fuel metering pump (M16)

On vehicles with fuel remover with a connection option for the fuel metering pump (M16)

AZ83.70-W-0002-06BA

On vehicles with fuel remover with preparation for connection of fuel metering pump (M16)

AZ83.70-W-0002-06B

29.2

Install fuel feed point

On vehicles with fuel remover without connection option for the fuel metering pump (M16)



Remove/install fuel level sensor

AR47.10-W-7000A

30

Install and connect fuel metering pump (M16)

AZ83.70-W-0002-07F



*000589122800

31

Connect ground lead to battery



Notes on battery

AH54.10-P-0001-01A

32

Unlock steering column and tip forward

33

Attach adhesive warning label for hot air heater unit (A31)

 Attach adhesive warning label in a conspicuous location on driver-side B-pillar.

34

Switch on hot air heater unit (A31) and perform function check

 Note operator's manual for auxiliary heater. Inspect fuel lines and connections for signs of leaks during function check.



Notes on retrofitting stationary heater with fuel combustion

AH83.70-N-0001-05A

Part no.

Designation

Quantity

B6 731 00 82

Installation kit Eberspächer D2 24 V

1

A 011 545 84 26

Contact spring 0.5 - 1.0 mm2 fuse holder

As required

A 004 545 52 26

Contact spring 1.0 - 2.5 mm2 fuse holder

As required

A 004 545 00 26

Contact spring 2.5 - 4.0 mm2 fuse holder

As required

N 072584 000304

10 A fuse

1

N 072584 000306

Fuse 20 A

1

A 940 680 01 34

Installation frame for timer (color number according to equipment code)

1

Fuel extraction point

As required

Also for code (F04) Cab L (long)

A 352 429 07 40

Bracket for air heater combustion air hose

1

A 973 830 07 15

Exhaust muffler

1

Also for code (F07) Cab S (short)

A 973 830 13 15

Exhaust pipe for LHD vehicles

1

A 973 830 06 15

Exhaust pipe for RHD vehicles

1

A 001 546 26 30

Insulating hose

1

N 000000 001022

Sheet metal screw

1

A 003 997 26 52

Preheating hose

1

A 973 836 00 65

Outlet grill

1

A 000 831 42 25

PIPE BEND

1

A 005 997 62 90

Cable tie

3

Also for code (F20) Cab with extended rear panel

A 973 830 13 15

Exhaust pipe for LHD vehicles

1

A 973 830 06 15

Exhaust pipe for RHD vehicles

1

A 001 546 26 30

Insulating hose

1

N 000000 001022

Sheet metal screw

1

A 003 997 65 52

Preheating hose

1

A 000 831 42 25

PIPE BEND

2

A 973 836 00 65

Outlet grill

1

A 973 832 01 08

Cover for LHD vehicles (color number according to equipment code)

1

A 973 832 02 08

Cover for RHD vehicles (color number according to equipment code)

1

A 641 990 01 92

Rivet (color number according to equipment code)

2

Also for code (E06) Electrical system for hazardous goods vehicles (GGVS)

A 655 548 00 18

Diode

1

A 011 545 84 26

Contact spring 0.5 - 1.0 mm2 fuse holder

As required

A 004 545 52 26

Contact spring 1.0 - 2.5 mm2 fuse holder

As required

A 004 545 00 26

Contact spring 2.5 - 4.0 mm2 fuse holder

As required