DIAGNOSTIC PROTOCOL

(SAMPLE)

Date of test: 01.01.2022


Model: Eberspacher Airtronic D2

Voltage: 12V (DC)

SN: 1124368BA


Tested with controller: Easy Start Timer


FOLLOWING COMPONENTS SUPPLIED FOR DIAGNOSTIC TEST:

- Main Heating Unit

- Fuel Pump

- Wiring Loom


========================


PLASTIC CASING:

- integrity/visual check - FAIL

- top lid - FAIL (cracked clip)

- bottom housing - PASS

- air outlet hood - PASS

- thermal barriers - FAIL (2 pads missing)

- glue of thermal barriers - FAIL (unglued)


>> SUMMARY: FAIL

>> SOLUTION: REPLACEMENT OF TOP LID FOR NEW, 2 NEW THERMAL BARRIERS

>> NOTES: GLUING NEW PADS


========================


BOTTOM GASKET:

- integrity/visual check - FAIL

- thermal deformation - FAIL


>> SUMMARY: FAIL

>> SOLUTION: REPLACEMENT FOR NEW

>> NOTES:


========================


BLOWER MOTOR:

- integrity/visual check - PASS

- test of continuous run on 2000 RPM - PASS

- test of continuous run on 4800 RPM - PASS

- internal turbine gap - PASS (0.2-0.4mm = within allowed tolerance)

- acoustic level - FAIL (noisy during separate test)

- bearing - FAIL (excessive friction)

- vibrations/balancing - PASS

- sediments - FAIL (moderate sediment)

- surface for the gasket - FAIL (requires cleaning)


>> SUMMARY: FAIL

>> SOLUTION: REPLACEMENT FOR NEW

>> NOTES:


========================


GLOW PLUG:

- integrity/visual check - PASS

- peak consumption - PASS (104W)

- contamination - PASS (slight contamination)

- insulation of wires - PASS

- rubber gasket - FAIL (slight leak by incorrect placement)


>> SUMMARY: PASS

>> SOLUTION: KEEP ORIGINAL

>> NOTES: CHEMICAL CLEANING REQUIRED


========================

OVERHEATING SENSOR:

- integrity/visual check - PASS

- resistance test (room temperature) - PASS

- run test (high temperature) - PASS

- insulation of wires - PASS

- placement - FAIL (not installed correctly on the heat exchanger)


>> SUMMARY: FAIL

>> SOLUTION: KEEP ORIGINAL

>> NOTES: REFIT TO CORRECT POSITION


========================


OVERHEATING SENSOR CLIP:

- integrity/visual check - PASS


>> SUMMARY: PASS

>> SOLUTION: KEEP ORIGINAL

>> NOTES:


========================


FUEL PUMP:

- integrity/visual check - PASS

- flow capacity - PASS (21ml/1000p = within allowed tolerance)

- outisde contamination - FAIL (dust)


>> SUMMARY: PASS

>> SOLUTION: KEEP ORIGINAL

>> NOTES: CHEMICAL CLEANING REQUIRED


========================


HEAT EXCHANGER:

- integrity/visual check - PASS

- corosion by salt - PASS

- carbon deposition - FAIL (strong contamination)

- contamination outside - PASS (dust)

- surface for the burner gasket - PASS

- surface for the blower motor gasket - FAIL (gasket stuck to surface)


>> SUMMARY: FAIL

>> SOLUTION: KEEP ORIGINAL

>> NOTES: PRESSURE / CHEMICAL CLEANING REQUIRED


========================


GASKET - HEAT EXCHANGER / BURNER:

- integrity/visual check - FAIL (leaks, falling apart)


>> SUMMARY: FAIL

>> SOLUTION: REPLACE FOR NEW

>> NOTES:


========================


GASKET - HEAT EXCHANGER / BLOWER MOTOR:

- integrity/visual check - PASS


>> SUMMARY: PASS

>> SOLUTION: KEEP ORIGINAL

>> NOTES: CHEMICAL CLEANING REQUIRED


========================


BURNER:

- integrity/visual check - PASS

- glow plug hole - FAIL (slight contamination)

- carbon deposition - FAIL (strong contamination)


>> SUMMARY: FAIL

>> SOLUTION: REPLACE FOR NEW

>> NOTES:


========================


ATOMISING NET:

- integrity/visual check - PASS

- contamination - FAIL (strong contamination)


>> SUMMARY: FAIL

>> SOLUTION: REPLACE FOR NEW

>> NOTES:


========================


ECU:

- integrity/visual check - PASS

- fan speed regulation - PASS

- pump frequency regulation - PASS

- glow plug activation - PASS

- min RPM - PASS (2,000RPM)

- max RPM - PASS (4,800RPM)

- min pump frequency - PASS (1.33Hz)

- max pump frequency - PASS (3.72HZ)

- contamination - FAIL (dust)


>> SUMMARY: PASS

>> SOLUTION: KEEP ORIGINAL

>> NOTES: CHEMICAL CLEANING REQUIRED


========================


BLOWER MOTOR/BURNER BOLTS:

- integrity/visual check - PASS

- rust - PASS


>> SUMMARY: PASS

>> SOLUTION: KEEP ORIGINAL

>> NOTES: 


========================



WIRING LOOM:

- integrity/visual check - PASS

- resistance - FAIL (fuel pump wire damaged)

- run test - PASS


>> SUMMARY: FAIL

>> SOLUTION: KEEP ORIGINAL

>> NOTES: REPAIR OF CUT WIRE


========================


CONTROLLER:

- integrity/visual check - N/A

- operation - N/A

- buttons - N/A

- LCD - N/A


>> SUMMARY: N/A

>> SOLUTION: N/A

>> NOTES: NOT SUPPLIED