Diesel Heater - Error Codes

Troubleshooting for 5kW Diesel Heater

If you're experiencing issues with your 5kW Diesel Heater, it's important to address error codes promptly to ensure efficient operation. This troubleshooting guide will walk you through essential steps to resolve common problems, from checking battery voltage and fuel supply to ensuring proper installation. By following these guidelines, you can identify and fix many issues without the need for further assistance.

When your diesel heater is not working properly or displaying and error code, please always check first:

Battery voltage: Please check the voltage before and during start-up. Measure directly on the battery terminals. Low voltage can cause the glow plug to not work properly.
Fuel supply: Check the fuel level in the tank and look for any bubbles or blockages along the fuel line
Position of main unit: Check if your unit installed with the correct side up or sideways. Please make sure the glow plug is facing up.
Position of fuel pump: check the angle of installation of the fuel pump (please refer to manual)
Position of your fuel tank: Please refer to manual to position the fuel tank

After checking all the 5 points and the problem persists, please:

Check the next pages for common issues and troubleshooting
Provide us further details: please send a detailed video and photos of your installation so we can assist you further. Please show us:
- The position of your diesel heater, fuel pump, fuel tank, etc.
- The battery voltage measured at the terminals
- Any error code, smoke or unusual behavior

Please send the information above to info@ontrackoutdoor.com.au.

Error Code 1: Power Supply Undervoltage

A 12-volt deep cycle battery in good condition has a reading of between 12.4 and 12.7 volts

Check the voltage at the battery terminal before and during start up
If there is a high voltage drop, please check cabling size and distance from power supply to controller. Keep the cable short to reduce voltage drop.
Ensure the cable is properly dimensioned for up to 12A (startup draw)
Perform a battery and charging system testing to check if battery is holding charge and charging properly
Please charge or replace your battery if needed

Error Code 2: Power Supply Overvoltage

A 12-volt deep cycle battery in good condition has a reading of between 12.4 and 12.7 volts

Check the voltage at the battery terminal before and during start up
Make sure you are using a battery charge controller to not overcharge your battery from external sources
Please discharge or replace your battery if needed

Error Code 3: Ignition Plug Failure

Check if glow plug is open or short-circuited, if the connectors are loose or oxidized
Make sure your battery is fully charged are not dropping below 12V during start-up
Check your glow plug with an ohm meter, it should read 0.6 - 0.8ohms
Check if the voltage is slowly rising to 8-9V across the plug during start up
If you are running the system of a battery charger, please charge your battery first and run the diesel heater without the battery charger
Check the air inlet, outlet, and the exhaust pipe:
- Clean if any debris or dust
- Make sure you leave at least 10cm gap for the air-inlet

Error Code 4: Fuel Pump Failure

Check the fuel pump and connections for any leaks, damages or oxidation.

Error Code 5 and 6: Over-heat

Check fan magnet polarity, position of Holzer sensor or loose terminal
Check if the fan is spinning freely, with no scraping or rubbing noise
Make sure the distance between the fan and the mainboard is no more than 5mm
Verify if there is anything clogging the combustion air supply or exhaust system, such as dust around the vents
If the unit turns itself on (fan only):
- Check the temperature sensor for faulty cables
- Replace the temperature sensor if needed

If all above are checked and correct, it is possible that the mainboard has shifted, causing interference between the magnets (on the fan) and the sensor of the mainboard. If the mainboard isn't totally lined up with the magnets, then it won't run. Try to remove the mainboard, replace it nicely and try again. Make sure the unit has primed and please only run the heater with the cover on.

Error Code 7: Broken Line Fault

Check the LCD connectors harness, verify if the blue wiring is loose or short circuited

Error Code 8: Flame Failure

Check if the fuel circuit is blocked, resulting in poor fuel supply
Check if the fuel tank is clean and has enough fuel on it
Check if the fuel filter is clean

If still not working, please try to run on a higher setting (higher pump speed) and let me know if the problem still occurs.

If above has been checked and there is smoke: replace glow plug

Error Code 9: Sensor Failure

Check if sensor plug is loose, broken or short circuited

Error Code 10: Ignition Failure

Check if the fuel circuit is blocked
Check fuel quality
Check whether the fan is working properly, moving freely
Check glow plug for loose cables
Check if the filter at the glow plug is clean. Clear or replace as needed
Check if combustion intake and exhaust passages are clear
Check power cord connections for oxidation loose cables

For More Information

If your troubleshooting efforts haven't resolved the issue, please provide us with detailed photos and videos of your setup, including any error codes or unusual behavior. Our team is here to help—simply reach out via email at info@ontrackoutdoor.com.au, or use our Contact Us form on our website. We're committed to supporting you every step of the way, ensuring your diesel heater performs reliably throughout the colder months.

E-mail: info@ontrackoutdoor.com.au

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