Monday, June17, 2019 L-36.com

' Eberspacher: Diagnosticinstruction Ca1 05 020 Diagnostic Unit'



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Diagnostic Unit
CA1 05 020


The Diagnostic Unit is used for reading, displaying and deleting fault codes saved in the
electronic control unit of the heater. The electronic control unit can save up to 5 fault codes,
labeled F1 to F5. The most recent fault code is in memory location F1.
The current or actual fault code is shown as "AF" and is always written into the F1 memory
location. Previous fault codes are transferred to memory locations F2 to F5.


                                       1. Button      : delete fault memory
                                       2. Button      : delete fault memory
                                       3. Button      : switch heater on/off,
                                                        request diagnostic fault codes
                                       4. Button      : backwards, fault F5 ­ F1, AF
                                       5. Button      : forward AF, F1 ­ F5
                                       6. Display


Connection

1. When available, connect the unit to the diagnostic pigtail (8-pin black connector) on the
   heater's main wiring harness, located at the heater main connection.
2. If the diagnostic pigtail is not present, connect the unit as outlined in the appropriate
   heater technical manual. A wiring adaptor may be required.
                                                    Wiring Adaptor Part
                            Heater
                                                          Number
                    D8LC                                CA1 05 031
                    HYDRONIC 4/5                        CA1 05 028
                    D7WB (boxed)                        CA1 05 025
                    D7WB (Freightliner)                 CA1 05 029
                    D9W / HYDRONIC 10                   CA1 05 030
                    HYDRONIC 16/24/30/35                CA1 05 036
3. Once correctly connected, the Diagnostic Unit display shows:




Fault Code Retrieval

4. Press the button     on the diagnostic unit to switch on the heater. The display shows:



5. After 8 seconds, the display shows one of the following:


                 No error
                   Current fault (i.e. fault code 64)


                   Fault diagnosis not possible
                   Possible causes:
                   o Adapter cable not connected properly.
                   o Control unit defect or incapable of diagnosis
                      (i.e. control unit not equipped with self-diagnostics)

Display of the Fault Memory F1 ­ F5 or F5 ­ F1

6. Press the buttons or once or several times to show the individual fault code
   memories in decreasing or increasing order. The display shows:


                   i.e. fault memory 2 / fault code 10

   Only those fault memories occupied by a fault are shown.

Delete Fault Memory

7. Eliminate the cause of the fault. Be sure to correct the root cause, not just the symptom.

8. Press both buttons       at the same time until the display shows:




9. Once the fault memories are deleted, the last current fault is shown. The current fault is
   not reset to 00 until the next restart of the heater, providing no other current fault has
   occurred. The display shows:


                   Heater no faults

End Diagnosis

10. Press button     on the diagnosis unit to switch the heater off. The display shows:




11. Wait for the end of the heater cool down period.

12. Remove the adapter cable from the cable harness and restore the connection.
 Diagnostic Fault Codes


 Note: Consult the appropriate Troubleshooting and Repair Manual for heater-specific
       diagnosis and repair procedures.

Fault
                       Fault Description                                           Comments
Code
 00     Normal operation
 01     Warning ­ over voltage
                                                           Check batteries and charging system.
 02     Warning ­ under voltage
 04     Warning ­ output short circuit
                                                           Refer to heater technical manual.
 05     Warning ­ output short circuit, anti-theft alarm
 09     TRS ­ shut down                                    Replace control unit.
 10     Over-voltage shutdown
                                                           Check batteries and charging system.
 11     Under-voltage shutdown
                                                           Check air duct or coolant hose for blockage.
 12     Overheat at overheat sensor
                                                           Test overheat sensor.
                                                           Check air duct or coolant hose for blockage.
 13     Overheat at flame sensor
                                                           Test flame sensor.
                                                           Excessive temperature rise through the heater.
 14     Potential overheat detected
                                                           Check air duct or coolant hose for blockage.
                                                           Check air duct or coolant hose for blockage.
        Too many overheat shutdowns
 15                                                        Test overheat sensor.
        Overheat with excessive temperature (AIRTRONIC)
                                                           Reset control unit using Diagnostic Unit or 7-Day Timer.
                                                           Check air duct for coolant hose for blockage.
 17     Overheat with excessive temperature                Test overheat sensor.
                                                           Replace control unit.
 20     Open circuit ­ glow pin / glow plug
                                                           Test glow pin / plug and wire harness.
 21     Short circuit ­ glow pin / glow plug
 22     Short circuit ­ glow plug relay contacts           Test glow plug relay and replace (only D2H control unit).
 23     Open circuit ­ glow plug relay
                                                           Test relay and wire harness.
 24     Short circuit ­ glow plug relay
 25     Short circuit ­ diagnostic output                  Test diagnostic wire harness for short circuit
                                                           Relieve cause of jam
 30     Blower motor will not turn
                                                           Replace blower if necessary
 31     Open circuit ­ blower motor
                                                           Test blower motor and wire harness.
 32     Short circuit ­ blower motor
                                                           Measure blower speed using no-contact instrument.
 33     Blower motor speed deviation (>10%)
                                                           (Air heater only)
 34     Open circuit ­ water valve relay                   Test wiring and relay connections.
 35     Open circuit ­ partial load resistor relay
                                                           Test resistor and wire harness.
 36     Short circuit ­ partial load resistor relay
 37     Coolant pump does not rotate                       Test coolant pump.
 38     Open circuit ­ vehicle blower relay                Test relay and wire harness.
 39     Short circuit ­ vehicle blower relay               Replace relay.
                                                           Test water valve relay and wire harness for short circuit.
 40     Short circuit ­ water valve relay
                                                           Replace relay.
Fault
                     Fault Description                                           Comments
Code
 41     Open circuit ­ coolant pump
                                                            Test coolant pump and wire harness.
 42     Short circuit ­ coolant pump
 43     Short circuit ­ external components                 Test external components for short circuit.
 47     Short circuit ­ fuel-metering pump                  Test fuel-metering pump and wire harness for short
 48     Open circuit ­ fuel-metering pump                   circuit.
                                                            Perform fuel-quantity test.
                                                            Check combustion air and exhaust hose for blockage.
 50     Too many start attempts                             Test glow pin / glow plug.
                                                            Test flame sensor.
                                                            Reset control unit using Diagnostic Unit or 7-Day Timer.
 51     Faulty flame recognition                            Test flame sensor.
                                                            Perform fuel-quantity test.
        No start                                            Check combustion air and exhaust hose for blockage.
 52
        Safety time exceeded                                Test glow pin / glow plug.
                                                            Test flame sensor.
 53     Flame cutout in boost mode                          Flame was established, but was extinguished.
 54     Flame cutout in high mode                           Perform fuel-quantity test.
 55     Flame cutout in medium mode                         Check combustion air and exhaust hose for blockage.
                                                            Test glow pin / glow plug.
 56     Flame cutout in low mode                            Test flame sensor.
 57     Flame sensor defect                                 Test connection at flame sensor.
 58     Flame detected on cool down                         Test flame sensor.
 59     Coolant excessive temperature rise                  Check coolant flow.
 60     Open circuit ­temperature control sensor            Test external temp sensor and wire harness (air heater).
 61     Short circuit ­temperature control sensor           Test water temperature sensors (coolant heater).
 62     Open circuit ­ potentiometer
                                                            Test controller and wire harness.
 63     Short circuit ­ potentiometer
 64     Open circuit ­ flame sensor
                                                            Test flame sensor and wire harness.
 65     Short circuit ­ flame sensor
 71     Open circuit ­ overheat sensor
                                                            Test overheat sensor and wire harness.
 72     Short circuit ­ overheat sensor
                                                            Check air duct or coolant hose for blockage.
 73     Overheat sensor ­ excessive temperature rise
                                                            Test overheat sensor.
 90     Control unit defect ­ internal fault
 91     External voltage disturbance                        Malfunction due to interference voltage from vehicle
                                                            electrical system (i.e. poor battery or charger).
 92     Control unit defect ­ ROM error
                                                            Remove interference voltage.
 93     Control unit defect ­ RAM error                     Replace control unit.
 94     Control unit defect ­ EEPROM error
                                                            Replace control unit or use external air temperature
 96     Control unit defect ­ internal temperature sensor
                                                            sensor (air heater).
 97     Control unit defect                                 Replace control unit.


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