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

3 July 2002
 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.
3 July 2002
 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.
3 July 2002
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.

3 July 2002