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Diagnostic UnitCA1 05 020The Diagnostic Unit is used for reading displaying and deleting fault codes saved in theelectronic control unit of the heater The electronic control unit can save up to 5 fault codeslabeled F1 to F5 The most recent fault code is in memory location F1The current or actual fault code is shown as AF and is always written into the F1 memorylocation 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 onoff request diagnostic fault codes 4 Button backwards fault F5 F1 AF 5 Button forward AF F1 F5 6 When available connect the unit to the diagnostic pigtail 8pin black connector on the heaters main wiring harness located at the heater main connection2 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 45 CA1 05 028 D7WB boxed CA1 05 025 D7WB Freightliner CA1 05 029 D9W HYDRONIC 10 CA1 05 030 HYDRONIC 16243035 CA1 05 0363 Once correctly connected the Diagnostic Unit display showsFault Code Retrieval4 Press the button on the diagnostic unit to switch on the heater The display shows5 After 8 seconds the display shows one of the following No error Current fault ie fault code 64 Fault diagnosis not possible Possible causes o Adapter cable not connected properly o Control unit defect or incapable of diagnosis ie control unit not equipped with of the Fault Memory F1 F5 or F5 F16 Press the buttons or once or several times to show the individual fault code memories in decreasing or increasing order The display shows ie fault memory 2 fault code 10 Only those fault memories occupied by a fault are shownDelete Fault Memory7 Eliminate the cause of the fault Be sure to correct the root cause not just the symptom8 Press both buttons at the same time until the display shows9 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 faultsEnd Diagnosis10 Press button on the diagnosis unit to switch the heater off The display shows11 Wait for the end of the heater cool down period12 Remove the adapter cable from the cable harness and restore the connection Diagnostic Fault Codes Note Consult the appropriate and Repair Manual for heaterspecific diagnosis and repair Fault Description CommentsCode 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 antitheft alarm 09 TRS shut down Replace control unit 10 Overvoltage shutdown Check batteries and charging system 11 Undervoltage 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 7Day 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 nocontact 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 relayFault Fault Description CommentsCode 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 fuelmetering pump Test fuelmetering pump and wire harness for short 48 Open circuit fuelmetering pump circuit Perform fuelquantity 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 7Day Timer 51 Faulty flame recognition Test flame sensor Perform fuelquantity 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 fuelquantity 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 ie 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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