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Eberspächer AIRTRONIC Troubleshooting and repair instructions

Manual is about: AIRTRONIC AIRTRONIC M

Summary of AIRTRONIC

  • Page 1

    Airtronic m orderno. Airtronicd3,12v 252317050000 airtronicb4,12v 201812050000 airtronicd4,12v 252113050000 airtronicd4,24v 252114050000 airtronicd4plus,12v 252484050000 airtronicd4plus,24v 252498050000 airtronicd4s,12v 252144050000 airtronicd4s,24v 252145050000 airtronicd3camper,12v (seeairtronicd3...

  • Page 2

    2 4 3 1 2 1 contents thislistofcontentsgivesyoupreciseinformationaboutthe contentsofthetroubleshootingandrepairinstructions. Introduction usetheindex,listofabbreviations,etc,tolookforaterm, technicalwordoranexplanationforanabbreviation. Chapter title contents page introduction • foreword...............

  • Page 3

    3 introduction 7 6 5 1 chapter title contents page repair instructions • repairinstructions.................................................................................................. 28 • alwaysobservethefollowingsafetyinstructionsbeforeworkingontheheater........ 28 • specialtool,ampreleaseto...

  • Page 4

    4 special text structure, presentation and picture symbols specialtextformatsandpicturesymbolsareusedinthese instructionstoemphasisedifferentsituationsandsubjects. Pleaserefertothefollowingexamplesfortheirmeaningsand appropriateaction. Special text formats and presentations • adot(•)indicatesalist,w...

  • Page 5

    5 cutaway view 1 heaterimpeller 2 controlbox 3 combustionairfanimpeller 4 glowplug 5 cover 6 heatexchanger 7 combinationsensor(overheating/flamesensor) 8 radioremotecontrol(mobileunit) 9 radioremotecontrol(stationaryunit) 10 button 11 temperaturesensor(roomtemperature) 12 fusebracketwithmainfuseand“...

  • Page 6

    6 description of functions switching on whentheheaterisswitchedon,thecontrollampinthecon- trolunitlightsup.Theglowplugisswitchedonandthefan startsatlowspeed. Fthereisstilltoomuchresidualheatintheheatexchanger fromwhentheheaterwaslastused,firstlyonlythefanstarts up(coldblowing). Oncetheresidualheatha...

  • Page 7

    7 forced shut-down for adr operation invehiclesforthetransportofdangerousgoods(e.G.Tanker trucks),theheatermustbeswitchedoffbeforethetruck drivesintoadangerarea(refinery,petrolstation,etc.). Failuretocomplyresultsintheheaterautomaticallyswitching offif: • thevehicleengineisswitchedoff, • anadditiona...

  • Page 8

    8 technichaldata 3 providednolimitvaluesaregiven,thetechnicaldatalisted issubjecttothetolerancesusuallyapplicabletoheatersof ±10%fornominalvoltage,ambienttemperature20°cand referencealtitudeesslingen. Caution! Safety instructions for technical data! Failuretocomplywiththetechnicaldatacanresultinmalf...

  • Page 9

    9 technichaldata 3 technichal data heatertype heater version heatingmedium controloftheheatflow heatflow(watt) heaterairflowratewithoutcounterpressure(kg/h) withhoodØ90mm fuelconsumption(l/h) elektr.Powerconsumption(watt) inoperation(12and24volt) atstart(12and24volt) ratedvoltage operatingrange lowe...

  • Page 10

    10 technichaldata 3 technichal data heatertype heater version heatingmedium controloftheheatflow heatflow(watt) d3 d4 d4plus heaterairflowratewithoutcounterpressure(kg/h) d3withhoodØ90mm d4withhoodØ90mm d4pluswithhoodØ75mm fuelconsumption(l/h) d3 d4 d4plus elektr.Powerconsumption(watt) d3 inoperatio...

  • Page 11

    11 technichaldata 3 technichal data heatertype heater version heatingmedium controloftheheatflow heatflow(watt) d4s d4camper/d4camperplus heaterairflowratewithoutcounterpressure(kg/h) d4s d4camper/d4camperplus fuelconsumption(l/h)) d4s d4camper/d4camperplus elektr.Powerconsumption(watt) d4s inoperat...

  • Page 12

    12 check values test speed for the blower airtronic d2 / d2 camper(12volt/24volt) • 12volt 5000rpm±25% atu=10,0volt • 24volt 5000rpm±25% atu=18,0volt airtronicb4 (12volt) airtronicd3 / d3 camper(12volt) airtronicd4(12volt/24volt) airtronicd4 camper(12volt) • 12volt 4400rpm±25% atu=10,0volt • 24volt ...

  • Page 13

    13 troubleshooting 4 what to check first in case of faults • check – fuelinthetank? – fuelpipesleaking?(visualcheck) – summerdieselinthefuelpipe? – combustionairsystemorexhaustsystemdamagedor blocked? – hotairsystemblocked? – airpressuresensorinstalled?Ifyes,referto„whattodo if…?“chapterofthe„altitu...

  • Page 14

    14 troubleshooting 4 overview of the test equipment and control units suitable for diagnosis theelectroniccontrolboxcanstoreupto5faults,whichcan bereadoutanddisplayed.Thefollowingtestequipmentand/ orcontrolunitscanbeusedtoquerythefaultmemoryin thecontrolboxandifnecessarytodeletethelockingofthe contr...

  • Page 15

    15 troubleshooting 4 testing device for the control device (orderno.:221509890000) prepare for test connectthecorrectoperatingvoltage(12or24volt)tothete- stingdevice,withplusattheredconnectorsocketandminus attheblueconnectorsocket. • disconnectsocketfromthecontrolunit. • connectcableloomfromtestingd...

  • Page 16

    16 connect diagnostic unit • disconnectthe8-pinconnectoroftheheater’scablehar- nessandconnecttheadaptercable. • connectthediagnosticunittotheadaptercable. Displayisasfollows: query fault memory • usethedkeytoswitchontheheater. Displayisasfollows: • after8secthefollowingisdisplayed: displayisasfollow...

  • Page 17

    17 troubleshooting 4 edith diagnostic tool with iso adapter (orderno.:221541890000) anadditionaladaptercableisrequiredtoconnecttheiso adapter(orderno.:221000318600). • itisveryimportanttoalwaysinstallinthegivenorder. • notonlythedefectivecomponent,butalsoadefectivecur- rentcircuitresultsinafaultbein...

  • Page 18

    18 troubleshooting 4 air pressure sensor diagnosis using edith diagnostics tool and iso adapter (orderno.221524890000) anadditionaladaptercableisrequiredtoconnectthe isoadapter(orderno.:221000333100). Theairpressuresensorconnectedtotheheatercanbediag- nosed.Iffaultsoccurduringthealtitudeadjustmentth...

  • Page 19

    19 caution! Magnetic field! Duringthetestoperationamagneticfielddevelopsatthe adapter.Therefore,donotplaceanyobjectssuchasdata media,creditcards,etc.Ontheadapterorinitsimmediate vicinity. Troubleshooting 4 (a) basicadapter (b) sub-dconnectioncable (c) mainsconnection (d) mainsswitch (e) usbtoserialr...

  • Page 20

    20 troubleshooting 4 module timer (orderno.:221000303400) thecurrentfaultisdisplayedas“af”andisalwayswrittenin memorypositionf1. Precedingfaultsaremovedtothememorylocationsf2–f5, ifnecessarythecontentsofmemorypositionf5isoverwrit- ten. • notonlythedefectivecomponent,butalsoadefectivecur- rentcircuit...

  • Page 21

    21 troubleshooting 4 tp5 radio remote control (orderno:221000320100) iffaultsoccurwhiletheheaterisrunning,theyaredisplayed with“err”afterthemobileunitisactivated. Afterthediagnosticscable(bl/ws)hasbeenconnectedand thefirstlogshavearrivedatthestationaryunit,thediagnose canbecarriedoutusingthemobileun...

  • Page 22

    22 the following actions are possible • callupfaultmemory. Callupthefaultmemorypositionsf1–f5with or . • callupfaultmemoryagain. Brieflypress and simultaneously. • deletefaultmemory (displaydel) press . Press again. The diagnosis is completed. Switch off heater. Enquire / delete fault memory activat...

  • Page 23

    23 troubleshooting 4 fault code display fault description comments • remedial action 000 nofaults —— 004 warning: shortcircuitincontrolbox, freshairoutput • disconnectconnectors1/b1attheheaterandattheconnectorb1,pin 16checkthecableuptothefreshairfanrelayforshortcircuittonegative, ifok—>replacecontro...

  • Page 24

    24 troubleshooting 4 fault code display fault description comments • remedial action 015 operatinglock-out thefaultcode015isdisplayed,iftheheaterwasswitchedbackonafterthe faultcodedisplay017. Thehardwarethresholdvaluefortheoverheatingsensorhasbeenexceeded —>thecontrolboxislocked. • replacecontrolbox...

  • Page 25

    25 troubleshooting 4 fault code display fault description comments • remedial action 034 * blowermotor,outlet(+)shortcircuit afteru b (batteryvoltage) • checkthattheleadharnessoftheblowermotorhasbeencorrectlylaid andcheckfordamage,ifok—>removeleadharnessatcontrolboxand checkforcontinuity,ifok—>repla...

  • Page 26

    26 troubleshooting 4 fault code display fault description comments • remedial action 061 externaltemperaturesensor– shortcircuit • disconnectconnectors4/b4oftheexternaltemperaturesensor,iffault code060isdisplayed—>checkexternaltemperaturesensor,diagramand tableofvalues,seepage32.Iftemperaturesensoro...

  • Page 27

    27 troubleshooting 4 fault code display fault description comments • remedial action 094 controlboxdefective (eeprom-fehler) • replacecontrolbox. 095 * controlboxdefective • replacecontrolbox. 096 internaltemperaturesensordefective • replacecontrolboxoruseanexternalroomtemperaturesensor.. 097 contro...

  • Page 28

    28 repair instructions thepermittedrepairworktotheheaterisdescribedinthe “repairinstructions”chapter. Ifextensiverepairsarenecessary,itmakessensetodismantle theheater. Theheaterisassembledinthereverseorder,ifapplicablenot additionalinstructions. Aftercompletingalltheworkontheheater,youmustcarryout a...

  • Page 29

    29 assembly drawing airtronic / airtronic m partslist 1 combustionairfan 2 seal–combustionairfan/heatexchanger 3 combustionchamber 4 seal–combustionchamber/heatexchanger 5 heatexchanger 6 controlbox 7 combinationsensor(overheating/flamesensor)with assemblytool 8 bracket 9 glowplug,withspecialtool(sw...

  • Page 30

    30 repair step 1 remove the heater’s cover (seefigure1) unlockbothfasteningclips,liftthecoverandremovefromthe front. Theheater’scovermustberemovedforallrepairsteps. Ifnecessary,waituntiltheunithascooleddown. Cableharnessoutletfromthehousingoptionallyonleftor right-handside. 1. 2. Figure1  cover  f...

  • Page 31

    31 repair step 3 dismantle glow plug (seefigure3) important! Safety instruction for installation of the rubber grommet topreventleaks,inserttherubbergrommetpreciselyinthe glowplugholeintheheatexchanger. Failuretocomplywiththisinstructioncanresultinpersonal injuriesaswellasmalfunctioningordamagetothe...

  • Page 32

    32 repair step 5 dismantle combination sensor (overheating / flame sen- sor) (seefigure5) • repairstep2. • removebothconnectorsfromthe“combinationsensor” cableloomatthecontrolbox. • unlockbracketfromcombinationsensor. • removethecombinationsensor. Figure5  “combinationsensor”cableloom  bracket,unl...

  • Page 33

    33 sketch2  specialtool–onlyrequiredforairtronic  combinationsensor figure6  specialtool–onlyrequiredforairtronic  combinationsensor repair step 6 install combination sensor (overheating / flame sensor) (seefigure6,7andsketch2–4) •repairstep2. • for airtronic(assemblywithspecialtool,seesketch2) ...

  • Page 34

    34 repair step 7 dismantle heat exchanger (seefigure8andsketch5) dismantle combustion air fan (seefigure8andsketch5) • repairstep2. • removeflangeseal.Removeheaterfromtheoutershell (bottomsection). Unscrewthe4fixingscrewsfromthecombustionairfan. Removethecombustionairfanandthesealfromtheheat exchang...

  • Page 35

    35 repair step 8 dismantle combustion chamber (seefigure9andsketch6) • repairstep3. • repairstep7. • unscrewthefixingscrews. Intheairtronic=3fixingscrews, intheairtronicm=4fixingscrews. • pulloutthecombustionchamberfromthefrontandremove theheatexchanger’sseal. Caution! Whenassemblingthecombustioncha...

  • Page 36

    36 measuring the fuel quantity 1. Preparation removethefuelpipeattheheaterandinsertameasuring cylinder(size10ml). Switchontheheater,ifthefuelisuniformlypumped(begins approx.60secafterbeingswitchedon),thefuelpipeisfull andvented. Switchoffheaterandemptymeasuringcylinder. Forprecisefuelmeasurementatle...

  • Page 37

    37 circuitdiagram 6 overview of the parts lists and circuit diagrams partslistcircuitdiagramairtronic/airtronicm................................................................................................................................ 38 circuitdiagramairtronic/airtronicm.........................

  • Page 38

    38 parts list circuit diagrams airtronic / airtronic m 1.1 burnerengine 1.2 glowplug 1.5 overheatingandflamesensor 2.1 controlbox 2.2 meteringpump 2.7 mainfuse 12volt=20a 24volt=10a 2.7.1fuse,actuation5a 5.1 battery a) connectionofcontrolunitandexternalsensoraccord- ingto“controlunits”circuitdiagram...

  • Page 39

    39 circuit diagram – airtronic / airtronic m 252069009801a partslistpage38 circuitdiagram 6 thiscircuitdiagramisforheaterswithadiagnosticscableandwhose controlboxcableloomwhichisfirmlyencapsulated. Please note!.

  • Page 40

    40 circuit diagram – airtronic / airtronic m circuitdiagram 6 thiscircuitdiagramisforheaterswith2diagnosticscableandwhose controlunitcableloomiswoundwithcabletape. 252069009801b partslistpage38 bitte beachten!.

  • Page 41

    41 circuitdiagram 6 parts list circuit diagrams, control units 2.15.1 temperaturesensor,external(roomtemperature) 2.15.9 temperaturesensor(externaltemperature) 3.1.9 changeoverswitch“heat/ventilate” 3.1.11 controlunit,round 3.1.16 radioremotecontrolbutton 3.1.17 minicontrollerairtronic 3.1.18 button...

  • Page 42

    42 circuit diagram, control units – part 1 252069009701c partslistpage41 circuitdiagram 6.

  • Page 43

    43 circuitdiagram 6 252069009701c partslistpage41 circuit diagram, control units – part 2.

  • Page 44

    44 circuit diagram, control units – part 3 252069009702a partslistpage41 circuitdiagram 6.

  • Page 45

    45 circuit diagram, control units – part 4 252069009702a partslistpage41 circuitdiagram 6.

  • Page 46

    46 circuit diagram, control units – part 5 252069009704a partslistpage41 circuitdiagram 6.

  • Page 47

    47 circuit diagram, control units – part 6 252069009704a partslistpage41 circuitdiagram 6.

  • Page 48

    48 circuit diagram, control units – part 7 partslistpage41 circuitdiagram 6 252069009703b.

  • Page 49

    49 circuitdiagram 6 parts list circuit diagram control units – easystart r+ / r / t 2.15.1 temperaturesensor(roomtemperature) (includedinscopeofsupplyforeasystartr+, optionalforeasystartr/t) 2.15.9 outsidetemperaturesensor(optional) 3.1.7 “off”button 3.1.9 “heat/ventilate”switch 3.1.11 “round”contro...

  • Page 50

    50 circuitdiagram 6 easystart r+ control unit circuit diagram (controlboxwithonediagnosticscable) partslistpage49 252069009706b.

  • Page 51

    51 circuitdiagram 6 partslistpage49 252069009706b easystart r+ control unit circuit diagram (controlboxwithonediagnosticscable).

  • Page 52

    52 circuitdiagram 6 easystart r+ control unit circuit diagram (controlboxwithtwodiagnosticscables) partslistpage49 252361009701b.

  • Page 53

    53 circuitdiagram 6 easystart r control unit circuit diagram (controlboxwithoneortwodiagnosticscables) partslistpage49 252361009705b.

  • Page 54

    54 circuitdiagram 6 easystart r control unit circuit diagram (controlboxwithtwodiagnosticscables) partslistpage49 252361009702b.

  • Page 55

    55 circuitdiagram 6 easystart r control unit circuit diagram (controlboxwithonediagnosticscable) partslistpage49 252069009707b.

  • Page 56

    56 circuitdiagram 6 easystart t control unit circuit diagram (controlboxwithonediagnosticscable) partslistpage49 252069009708.

  • Page 57

    57 circuitdiagram 6 easystart t control unit circuit diagram (controlboxwithtwodiagnosticscables) partslistpage49 252361009703.

  • Page 58

    58 circuitdiagram 6 parts list circuit diagrams airtronic / airtronic m – adr 1.1 burnerengine 1.2 glowplug 1.5 overheatingandflamesensor 2.1 controlbox 2.2 meteringpump 2.7 mainfuse 12volt=20a 24volt=10a 2.7.1fuse,actuation5a 5.1 battery 5.2.1operatingswitchbatteryd) (operationcontrollede.G.Viaigni...

  • Page 59

    59 circuit diagram – airtronic / airtronic m – adr 252069009601b partslistpage58 circuitdiagram 6 thiscircuitdiagramisforheaterswithonediagnosticscableand whosecontrolboxcableloomisfirmlyencapsulated. Bitte beachten!.

  • Page 60

    60 circuit diagram – airtronic / airtronic m – adr circuitdiagram 6 partslistpage58 252069009601c thiscircuitdiagramisforheaterswith2diagnosticscableandwhose controlboxcableloomiswoundwithcabletape. Bitte beachten!.

  • Page 61

    61 circuitdiagram 6 parts list circuit diagrams control unit easystart t – adr 3.1.7 “off”button 3.1.17 “minicontroller”controlunit 3.2.15 timereasystartt a) connectionofcontrolunitsattheheater g) connection“on/off”key (optionale.G.Orderno.:221000328400) x) adrjumper y) connectandinsulatecables • th...

  • Page 62

    62 252069009901b circuit diagram, control units – adr partslistpage61 circuitdiagram 6.

  • Page 63

    63 circuitdiagram 6 circuit diagram, control unit easystart t – adr (controlboxwithonediagnosticscable) 252069009709 partslistpage61.

  • Page 64

    64 circuitdiagram 6 circuit diagram, control unit easystart t – adr (controlboxwithtwodiagnosticscables) 252361009704 partslistpage61.

  • Page 65

    65 certification thehighqualityofeberspächer’sproductsisthekeytoour success. Toguaranteethisquality,wehaveorganisedallworkpro- cessesinthecompanyalongthelinesofqualitymanagement (qm). Evenso,westillpursuealargenumberofactivitiesforcon- tinuousimprovementofproductqualityinordertokeeppace withthesimil...

  • Page 66

    66 service 7 list of key words / a – z index a accidentprevention...............................................................4 adr..........................................................................7,59,69 alwaysobservethefollowingsafetyinstructionsbeforework- ingontheheater...................

  • Page 67

    67 service 7 list of abbreviations adr europeanagreementabouttheinternationaltransportofdan- gerousgoodsontheroad. Ec type-approval permitawardedbythefederalvehicleofficefortheproduc- tionofaheaterforinstallationinmotorisedvehicles. Emc directive electromagneticcompatibility. Je-partners j.Eberspäch...

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