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  5. Troubleshooting And Repair Instructions

Eberspächer Airtronic B5 Troubleshooting And Repair Instructions

Other manuals for Airtronic B5: Troubleshooting Manual, Operating Instructions Manual

Summary of Airtronic B5

  • Page 1

    Eberspächer j. Eberspächer gmbh & co. Kg eberspächerstr. 24 d-73730 esslingen phone (switchboard) (0711) 939-00 fax (0711) 939-0500 www.Eberspaecher.Com l 25 2361 95 16 95 04.2008 subject to changes printed in germany © j. Eberspächer gmbh & co. Kg troubleshooting and repair instructions the trouble...

  • Page 2

    2 4 3 1 1 introduction this list of contents gives you precise information about the contents of the troubleshooting and repair instructions. If you are looking for a term, technical term or you would like an abbreviation explained, please use the relevant index at the end of the instructions, from ...

  • Page 3

    3 8 1 introduction repair instructions circuit diagram service index 5 7 chapter title contents page list of contents 6 • repair instructions ........................................................................................ 25 • always observe the following safety instructions before working ...

  • Page 4

    4 introduction 1 these troubleshooting and repair instructions are applicable to the heaters listed on the title page, to the exclusion of all liability claims. Depending on the version or revised status of the heater, there may be differences between it and these troubleshooting and repair instruct...

  • Page 5

    5 function 2 cutaway view 1 module timer 2 changeover switch „heat / ventilate“ 3 fuse bracket – main fuse 25 a – fuse, „actuation“ 15 a 4 heater impeller 5 control box 6 intake hood 7 combustion air fan 8 glow plug 9 jacket shell, top 10 combination sensor (overheating and flame sensor) 11 outlet h...

  • Page 6

    6 function 2 description of functions switching on / starting the heater when the heater is switched on, the control lamp in the control unit lights up. The fan starts up in the fan stage "low". The glow plug starts with a 3 second delay. After approx. 45 seconds the fuel supply starts and the fuel ...

  • Page 7

    7 function 2 please note! Control and safety devices • if the heater does not ignite within 90 seconds after the fuel starts to pump, the start is repeated. If the heater still does not ignite after another 90 seconds of pumping fuel, the heater is switched off, i.E. The fuel supply is off and the f...

  • Page 8

    8 airtronic l – b5 airtronic l – d5 air air stage stage power high medium low power high medium low 5500 4800 2700 1200 5500 4800 2700 1500 280 275 180 125 280 275 180 125 10 10 0.75 0.65 0.37 0.27 0.66 0.58 0.34 0.19 85 80 30 15 85 80 30 15 12 12 / 24 approx. 10 volt and 20 volt respectively underv...

  • Page 9

    9 test speed for the blower heater 12 volt at 11.3 volt n = 4650 – 7000 u/min heater 24 volt at 23.6 volt n = 4650 – 6500 u/min resistance values 12 v 24 v glow plug (heat resistance) ca. 0.6 Ω ± 0.04 Ω ca. 2 Ω ± 0.2 Ω metering pump 9.5 Ω ± 0.50 Ω 36.0 Ω ± 1.8 Ω control device setpoint value potenti...

  • Page 10

    10 what to check first in case of faults • check – fuel in the tank? – fuel pipes leaking? (visual check) – summer diesel in the fuel pipe? – combustion air system or exhaust system damaged or blocked? • electrical components – cables, connections damaged? – contacts corroded? – fuses defective? – i...

  • Page 11

    11 troubleshooting 4 overview of the individual test equipment and control units the electronic control box can store up to 5 errors, which can be read out and displayed. The following test equipment can be used to query the fault memory in the control box and if necessary to delete the control box ...

  • Page 12

    12 troubleshooting 4 caution! Operating voltage safety information! Ensure you use the correct operating voltage, otherwise the connected components can be severely damaged. Check control unit order no. For the testing device – control unit – 22 1509 89 00 00 before the test connect the correct oper...

  • Page 13

    13 display of the fault memory f1 – f5 or f5 – f1 • the heater is switched on. • press the buttons e and f once or several times to display the individual fault memory positions, in ascending or descending order. Display is as follows: e.G. Fault memory 2 / fault code 10 only the fault memory positi...

  • Page 14

    14 troubleshooting 4 cancel the control box lock • delete the fault memory as described and switch off the heater using the d button. • the control box lock is cancelled and the diagnosis closed. Display is as follows: please note! Not only the defective component, but also a defective current circu...

  • Page 15

    15 troubleshooting 4 edith customer service program with iso adapter order no. 22 1524 89 00 00 an additional adapter cable is required to connect the iso adapter (order no.: 22 1000 31 86 00). • it is very important to always install in the given order. • not only the defective component, but also ...

  • Page 16

    16 troubleshooting 4 caution! Magnetic field! During the test operation a magnetic field develops at the adapter. Therefore, do not place any objects such as data media, credit cards, etc. On the adapter or in its immediate vicinity. 1 basic adapter 2 sub-d connection cable 3 mains connection 4 main...

  • Page 17

    17 troubleshooting 4 module timer (order no.: 22 1000 30 34 00) the current fault is displayed as “af” and is always written in memory position f1. Preceding faults are moved to the memory locations f2 – f5, if necessary the contents of memory position f5 is overwritten. • not only the defective com...

  • Page 18

    18 fault diagnosis using the radio remote control tp5 tp5 radio remote control order no. 22 1000 32 01 00 if faults occur while the heater is running, they are displayed with „err“ after the mobile unit is activated. In order to carry out the diagnosis, the diagnosis cable (blue / white) must be con...

  • Page 19

    19 4 the following actions are possible • call up fault memory. Call up the fault memory positions f1 – f5 with or . • call up fault memory again. Brieflypress and simultaneously..... • delete fault memory (display del) press . Press again. The diagnosis is completed. Switch off heater. Easystart r+...

  • Page 20

    Fault code fault description comments display • remedial action troubleshooting 20 –– • disconnect connector s1 / b1 at the heater and at the connector b1, pin 16 check the cable up to the fresh air fan relay for short circuit to negative, if ok –> replace control box, see page 28. • disconnect conn...

  • Page 21

    Fault code fault description comments display • remedial action troubleshooting 21 4 015 017 020 021 022 025 030 031 operating lock-out overheating glow plug – interruption glow plug output (–), overload or earth short circuit glow plug, output (+), short circuit after u b (battery voltage) diagnost...

  • Page 22

    Fault code fault description comments display • remedial action troubleshooting 22 4 032 034 047 048 049 050 051 052 053 054 055 056 blower motor – earth short circuit in the 12 volt heater, carry out the functional check with max. 11.3 volt. In the 24 volt heater, carry out the functional check wit...

  • Page 23

    Fault code fault description comments display • remedial action troubleshooting 23 • disconnect the plug-in connection of the external room temperature sensor and measure the resistance value, see page 9 for diagram and values table, if temperature sensor ok –> reconnect plug-in connection. • discon...

  • Page 24

    Fault code fault description comments display • remedial action troubleshooting 24 control box defective (internal fault) control box defective (rom error) control box defective control box defective (eeprom error) control box defective internal temperature sensor defective control box defective con...

  • Page 25

    25 repair instructions 5 repair instructions the permitted repair work to the heater is described in the „repair instructions“ chapter. If extensive repairs are necessary, it makes sense to dismantle the heater. The heater is assembled in the reverse order, if applicable not additional instructions....

  • Page 26

    26 repair instructions 5 assembly drawing.

  • Page 27

    27 repair instructions 5 parts list 1 heat exchanger, complete with combustion chamber 2 combustion chamber cover 3 seal combustion chamber 4 combustion air fan 5 seal 6 control box 7 glow plug 8 connection cable for glow plug 9 fixing nut m4 10 lining 11 intake hood 12 shell holder 13 upper jacket ...

  • Page 28

    28 repair instructions 5 햴 햳 햵 햶 햲 햲 햲 햲 repair step 1 dismantle / assemble glow plug (figure 1) • remove large angular rubber grommet. • unscrew m4 fixing nut of the connection cable and screw out the glow plug using a sw 19 socket spanner. • install in the reverse order. Glow plug torque 20 ±2 nm....

  • Page 29

    29 repair instructions 5 햲 b 햲 햲 햳 햲 햲 햳 repair step 4 dismantle / assembly combination sensor (overheating / flame sensor) (figure 4 – 6) • repair step 3, dismantle / assemble control box. • unscrew the 4 fixing screws of the outlet hood and remove outlet hood. • unscrew the 12 fixing screws of the...

  • Page 30

    30 repair instructions 5 table of overheating sensor values temperature °c resistance k Ω min. Max. –40 1597.00 1913.00 –20 458.80 533.40 0 154.70 175.50 20 59.30 65.84 40 25.02 28.04 60 11.56 13.16 80 5.782 6.678 100 3.095 3.623 120 1.757 2.081 140 1.050 1.256 160 0.6554 0.792 180 0.4253 0.5187 200...

  • Page 31

    31 repair instructions 5 햲 햲 햲 햲 햲 햳 햲 햲 햲 햲 repair step 5 dismantle / assemble combustion air fan (figure 7 – 11) • repair step 3, dismantle / assemble control box. • unscrew the 4 fixing screws of the outlet hood and remove outlet hood. • unscrew the 12 self-tapping screws of the upper jacket shel...

  • Page 32

    32 repair instructions 5 repair step 6 replace the combustion chamber cover seal (figure 12) • repair step 5, dismantle / assemble combustion air fan. • unscrew the 4 screws of the combustion chamber cover. • remove the combustion chamber cover. • remove seal, clean seal surfaces if necessary, insta...

  • Page 33

    33 repair instructions 5 check fuel supply before measuring the fuel quantity, check the following points in the fuel supply. • check the screen in the metering pump. • check the laying of the fuel pipes. • check fuel pipes for leaks. • check and tighten the hose connections. • is the fuel removal i...

  • Page 34

    34 circuit diagram 6 parts list circuit diagrams airtronic l / airtronic l – adr 1.1 burner motor 1.2 glow plug 1.5 overheating and flame sensor 2.1 control box 2.2 metering pump 2.7 main fuse 12 volt = 25 a 24 volt = 20 a 2.7.1 fuse, actuation (5 a) 5.1 battery 5.2.1 battery operating switch (opera...

  • Page 35

    35 circuit diagram 6 parts list page 34 25 2361 00 98 01 a airtronic l circuit diagram – 12 volt / 24 volt.

  • Page 36

    36 circuit diagram 6 parts list page 34 circuit diagram for control units 25 2069 00 97 01 c 25 2069 00 97 03 b.

  • Page 37

    37 circuit diagram 6 parts list page 34 circuit diagram for control units 25 2069 00 97 02 a.

  • Page 38

    38 circuit diagram 6 parts list page 34 circuit diagram for control units 25 2069 00 97 02 a.

  • Page 39

    39 circuit diagram 6 parts list page 34 circuit diagram for control units 25 2069 00 97 04 a.

  • Page 40

    40 circuit diagram 6 parts list page 34 circuit diagram for control units 25 2069 00 97 04 a.

  • Page 41

    41 parts list page 34 circuit diagram 6 circuit diagram airtronic l – adr – 12 volt / 24 volt 25 2361 00 96 01 a.

  • Page 42

    42 circuit diagram 6 circuit diagram control units – adr 25 2069 00 96 01 b parts list page 34.

  • Page 43

    43 circuit diagram 6 parts list circuit diagram control unit easystart r+ / r / t 2.15.1 temperature sensor (room temperature) (included in scope of supply for easystart r+, optional for easystart r / t) 2.15.9 outside temperature sensor (optional) 3.1.7 “off” button 3.1.9 “heat / ventilate” switch ...

  • Page 44

    44 circuit diagram 6 1 terminal 31 (negative) 2 – – 3 ventilate (switching signal –) 4 dat cable 5 pushbutton / led (negative) 6 temperature sensor (negative) 7 terminal 30 (positive) 8 s+ (switching on signal) 9 led (positive) 10 diagnosis cable (k line) 11 pushbutton (negative) 12 temperature sens...

  • Page 45

    45 circuit diagram 6 circuit diagram control units – easystart r+ this circuit diagram is for heaters with 2 diagnostics cable and whose control box cable loom is wound with cable tape. Parts list page 43 25 2361 00 97 01 c please note!.

  • Page 46

    46 circuit diagram 6 circuit diagram control units – easystart r 25 2361 00 97 05 b parts list page 43.

  • Page 47

    47 circuit diagram 6 circuit diagram control units – easystart r 25 2361 00 97 02 b this circuit diagram applies to control boxes with two diagnostic cables, see page 43. Parts list page 43 please note!.

  • Page 48

    48 circuit diagram 6 this circuit diagram is for heaters with 2 diagnostics cable and whose control box cable loom is wound with cable tape. 25 2361 00 97 03 a circuit diagram control units – easystart t parts list page 43 please note!.

  • Page 49

    49 circuit diagram 6 circuit diagram control units – easystart t – adr this circuit diagram is for heaters with 2 diagnostics cable and whose control box cable loom is wound with cable tape. 25 2361 00 97 04 a parts list page 43 please note!.

  • Page 50

    50 service 7 certifications the high quality of eberspächer’s products is the key to our success. To guarantee this quality, we have organised all work processes in the company along the lines of quality management (qm). Even so, we still pursue a large number of activities for continuous improvemen...

  • Page 51

    51 service 7 representatives abroad argentina agco argentinia s. A. Valentin gomez 577 1706 haedo ra - pcia. Buenos aires tel. 0054 / 1 - 483 32 01 fax. 0054 / 1 - 483 32 37 champion s. A. Av. Cordoba 2756 al 58 ra - 1187 buenos aires tel. 0054 / 1 - 962 16 21 fax. 0054 / 1 - 962 16 27 for boat heat...

  • Page 52

    52 service 7 representatives abroad sweden svenska eberspächer ab box 2103 s - 12823 skarpnäck tel. 0046 / 86 83 11 00 fax. 0046 / 87 24 90 40 switzerland technomag ag fischermättelistr. 6 ch - 3000 bern - 5 tel. 0041 - 31 379 81 21 fax. 0041 - 31 379 82 50 slovak republic molpir, spol.S.R.O. Hracho...

  • Page 53

    53 index 8 index keyword page keyword page a accident prevention ............................................................. 4 adapter cable ........................................................ 11, 12, 16 adr ..................................................... 7, 34, 41 – 43, 49, 54 assembly...

  • Page 54

    54 index 8 list of abbreviations adr european agreement about the international transport of dangerous goods on the road. Ec type-approval permit awarded by the federal vehicle office for the production of a heater for installation in motorised vehicles. Emc directive electromagnetic compatibility. ...