INSTALLATION AND SERVICE MANUAL PROHEAT X45 Rev.
CONTENTS A. SAFETY ...................................................................................... A-1 B. INTRODUCTION ......................................................................... B-1 C. MODEL DESCRIPTIONS ............................................................ C-1 1.0 TECHNICAL SPECIFICATIONS ................................................. 1-1 1.1 PHYSICAL – X45 ..................................................................... 1-2 1.2 ELECTRICAL – X45 ..................
5.0 TROUBLESHOOTING & REPAIR ............................................... 5-1 5.0.1 Troubleshooting a Problem ........................................ 5-1 5.0.2 Example Proheat Behavior Error – Code 01................. 5-2 5-1 OPERATION INDICATORS, FUNCTION & COMPONENT DIAGNOSTICS ................................................................... 5-3 5.1.1 Operation Indicators ................................................. 5-4 5.1.2 Function Diagnostics ...............................................
A. SAFETY Throughout this manual, you will see notes labeled DANGER, WARNING, CAUTION and NOTICE to alert you to special instructions or precautions concerning a particular procedure that would be hazardous if performed incorrectly or carelessly. Observe them carefully! These safety alerts alone cannot eliminate all hazards. Strict compliance with these special instructions and common sense are major accident prevention measures. DANGER Immediate hazards that will result in severe injury or death.
SAFETY CONSIDERATIONS WARNING Exhaust Inhalation of exhaust gas (containing carbon monoxide) may cause severe personal injury and/or death. Anyone suspected of suffering from CO inhalation should be removed from the hazardous area and given medical assistance immediately. WARNING Explosion Hazard Do not operate heater where combustible fumes or airborne particles, such as sawdust, are present. WARNING Fuel Exercise extreme caution when working near fuel or fuel-filled equipment.
B. INTRODUCTION PROHEAT Model X45 This manual is provided to assist an authorized PROHEAT dealer to install and service a PROHEAT heater. Although trucks have been used in the examples, applications for PROHEAT are by no means limited to trucks. PROHEAT heaters are designed to be used on any diesel equipped vehicle including: trucks, buses (school, transit and coach), construction equipment, off road equipment, military equipment and cargo.
B-2 PROHEAT INSTALLATION & SERVICE
C. MODEL DESCRIPTIONS Sleeper Fan Output or Auxiliary Input Identification. This manual covers all models of PROHEAT X45. Please refer to the X45 Parts Book at www.proheat.com for detailed part descriptions and part numbers. Included in the parts book are optional features such as a timer, sleeper fan control kit, impact switch (for school bus applications) and associated installation and maintenance tools.
C-2 PROHEAT INSTALLATION & SERVICE
1.0 TECHNICAL SPECIFICATIONS X45 12V 45,000 BTU (13 kW) SYSTEM VOLTAGE Nominal Voltage Range 10 –15 VDC 20 – 30 VDC CURRENT DRAW 7.5 Amps 3.75 Amps FUEL CONSUMPTION (Average to Maximum) 0.1 – 0.45 gal/hr. (0.4 – 1.7 L/hr.) COOLANT FLOW 8.0 gal/min. (30 L/min.) COOLANT TEMPERATURE (at Heater) 150°F to 185°F (65°C to 85°C) OPERATING TEMPERATURE RANGE -40°F to +122°F (-40°C to +50°C) IGNITION TYPE Electronic Spark Ignition HEAT EXCHANGER CAPACITY 1 quart (0.
10.1" [258] ON R T R AL E E , S OT I Ø1.5" [38] LEFT SIDE VIEW AUXILIARY MOUNTING PLATE SEE NOTE 1 CL EXHAUST PORT 4.4" [112] 11.2" [285] STANDARD EXHAUST PIPE SEE NOTE 1 1.5 I.D. 10.2" [259] 11.2" [284] THIS SPACE IS REQUIRED FOR COMBUSTION TUBE REMOVAL L 1-2 TIL Figure 1-1 L A ND 5.5" [140] 5.1" [129] C L EXHAUST PORT 9.4" [239] 5.5" [140] C L EXHAUST PORT SERIAL No: X-45 12V 9.0kW (KBTU) 2 BAR (29 PSI) OPERATING VOLTAGE:...10-16 VOLTS HEAT OUTPUT:.............
SECTION 1. TECHNICAL SPECIFICATIONS 10.5" [267] 10.5" [267] T R AL E E N R SO 12.0" [305] OT I L A ND THIS SPACE IS REQUIRED FOR COMBUSTION TUBE REMOVAL ENCLOSURE COVER LEFT SIDE VIEW LEFT SIDE VIEW ENCLOSURE LID REMOVED ASSEMBLED ENCLOSURE L TI L Figure 1-2 RE 10.5" [267] 12.0" [305] 3.6" [92] 3.6" [92] X-45 XXV 9.0kW (KBTU) 2 BAR (29 PSI) DIESEL FUEL ****** PROHEAT CONTROL MODULE G-III SOFT START 999100 12 VOLT POWER SWITCH INPUT SLEEPER FAN ENCLOSURE COVER FRONT VIEW 20.
D E F D E F SEE NOTE 1 FOR HARNESS PART NUMBERS SENSOR TEMPERATURE SENSOR FLAME COOLANT PUMP BLOWER ELECTRODE IGNITION (GROUND VIA COMBUSTION TUBE) FUEL PUMP COMPRESSOR 123 B A A B C (-) (+) 12V/24V 1A MAX.
Figure 1-4 PCM Electrical Connections – X45 SECTION 1.
1.3 TORQUE SPECIFICATIONS FAN END CASTING • Apply anti-seize to bolts (3) • Torque bolts (3) to 75±5 in/lbs (8.5±0.5 Nm) REGULATOR • Apply anti-seize to cap screw • Torque cap screw to 94±6 in/lbs (10.6±0.7 Nm) FLAME SENSOR • Torque sensor to 25±3 in/lbs (2.8±0.3 Nm) IGNITER • Apply anti-seize to igniter threads • Ensure gasket is present before installing • Torque igniter to 50±5 in/lbs (5.6±0.6 Nm) COMBUSTION TUBE • Apply anti-seize to cap screws • Torque cap screws (4) to 25±3 in/lbs (2.8±0.
OVERHEAT SENSOR • Lubricate o-ring with o-ring lubricant • Torque senor to 500±50 in/lbs (56±5.6 Nm) TEMPERATURE SENSOR • Lubricate o-ring with o-ring lubricant • Torque senor to 25±3 in/lbs (2.8±0.3 Nm) AIR FILTER • Torque cap screw to 50±5 in/lbs (5.6±0.6 Nm) BLOWER ASSEMBLY • Apply anti-seize to bolts (4) • Torque bolts (4) to 25±3 in/lbs (2.8±0.3 Nm) PROHEAT CONTROL MODULE (PCM) • Apply anti-seize to bolts (3) • Torque bolts (3) to 75±7 in/lbs (8.5±0.8 Nm) SECTION 1.
MAIN INTERNAL HARNESS • Torque bolt (1) to 10±2 in/lbs (1.1 +/- 0.2) NOZZLE TO FAN END • Lubricate o-ring on nozzle with diesel • Torque nozzle to 150±10 in/lbs (17±1.1 Nm) NOZZLE REASSEMBLY • Torque nozzle (1) to 30±3 in/lbs (3.4±0.3 Nm) BAND CLAMPS • Torque clamps (4) to 25±3 in/lbs (2.8±0.3 Nm) ENCLOSURE LID (Optional) • Anti-seize recommended on bolts • Torque clamps (2) to 30±3 in/lbs (3.4±3.
HARNESS GROUND LUG • Apply anti-seize to bolt • Torque bolt (1) to 75±5 in/lbs (8.5±0.5 Nm) B FUEL PUMP ASSEMBLY • • • • C • • A Apply Loctite 242 to threads Torque bolts (2) to 25±3 in/lbs (2.8±0.3 Nm). B Lubricate o-ring with diesel fuel Torque relief valve to 22±2 in/lbs (2.5±0.2 Nm). C Apply Loctite 59241 sealant to threads Torque elbow (1) to 55±5 in/lbs (6.2±0.
1-10 PROHEAT INSTALLATION & SERVICE
2.0 OPERATING YOUR PROHEAT HEATER NOTICE These instructions cover Standard Mode operation that are normally installed on trucks. To operate your heater in Preheat or Supplemental, refer to page 3-18 to page 3-20 and page 4-6 to page 4-7. NOTICE Regular use of your PROHEAT throughout the year will improve its reliability. Weekly operation is recommended. NOTICE The PROHEAT heater can be operated by either using a toggle switch or a 7 day timer. Refer to page 3-10 for WIRING & ELECTRICAL CONNECTIONS.
2-2 PROHEAT INSTALLATION & SERVICE
3.0 INSTALLATION NOTICE If additional installation information is required please contact your PROHEAT Dealer regarding your specific application. For more technical information, please contact PROHEAT Product Support at www.proheat.com The installation details described in this manual focuses on truck applications and does not cover all of the possible installations.
3.1 LOCATING THE HEATER 3.1.1 SELECT YOUR LOCATION The most suitable location for mounting the heater will vary depending on the type of vehicle. Recommended mounting locations are: • Behind the cab across the frame rails (1). • On either side of the frame rails (2). • In an existing enclosure on the vehicle (step or toolbox) (3). You Choose CAUTION Do not weld PROHEAT heater mounting brackets to the vehicle frame. If repairs to the vehicle require welding, disconnect the PROHEAT power cable at the PCM.
Heater must be mounted below the highest point in the cooling system. An expansion tank may be added to the coolant system above the heater if this is not possible. HIGHEST POINT IN COOLING SYSTEM HEATER MUST BE MOUNTED BELOW HIGHEST POINT PROHEAT Figure 3-5 3.1.3 ENGINE OR RADIATOR Height Requirement MOUNTING THE PROHEAT HEATER IN AN ENCLOSURE Do not locate the heater in an airtight enclosure.
3.2 MOUNTING THE HEATER Select Your Mounting Option 3.2.1 OPTION A – Heater With Enclosure 1. Remove the enclosure cover. 2. Drill the (4) mounting holes and exhaust pipe clearance hole. 3. Using the bolts supplied, fasten the enclosure to the mounting tray or brackets. 4. Ensure that the combustion tube can be removed for service. See Figure 1-2 on page 1-3 for service space requirements. Figure 3-8 Mounting Tray 20" (508 mm) 1 5/8" (45 mm) 3" (76 mm) Dia.
3.2.2 NOTICE Use anti-seize compound on fasteners to prevent galling and corrosion. OPTION B – Heater Without Enclosure Heater supplied without an enclosure (mount in an existing enclosure on the vehicle ie. tool box). Heater supplied with an auxiliary mounting plate. 1. Ensure that the proposed enclosure is big enough for the heater. 12 1 ⁄ 2W x 11H x 20 1 ⁄ 2L inches (318 x 280 x 521 mm) 2. Using the indicated dimensions, drill the (4) mounting holes and exhaust pipe clearance hole. 3.
3.3 EXHAUST PIPE CONNECTION 1. Push the exhaust pipe through the hole in the enclosure and onto the exhaust outlet port of the heater. Ensure that the pipe is pushed onto the spigot at least 11⁄2" (38 mm). NOTICE If additional information is required, please contact your PROHEAT Dealer regarding your specific application. Alternatively, please contact PROHEAT Product Support at www.proheat.com. 2. Route the exhaust pipe such that: • exhaust gasses do not enter the passenger compartment.
3.4 PLUMBING THE SYSTEM 3.4.1 GENERAL CONSIDERATIONS Coolant flow must be maintained throughout the coolant system under all conditions. MA XI MU M • Keep the engine inlet and outlet ports as far apart as possible to maximize cross-flow through engine. CR OS SFL OW • Coolant pump and engine water pump must flow in the same direction. • Ensure that no sharp kinks or bends exist in the hoses which may restrict coolant flow. • Avoid high points in the hose routing to prevent air traps.
Instructions for Options A and B 1. Remove the radiator cap to release the system pressure. WARNING Opening the radiator cap when the engine is hot may cause serious injury. 2. Drain the coolant system. 3. Plumb the system as per Figure 3-13 or Figure 3-15 4. Add engine coolant to the system as per the specific engine manufacturer’s recommendations and re-install the radiator cap. NOTE: Plumbing the PROHEAT through the dash fan is not recommended. 3.4.
3.4.3 For best results these vehicles should use an auxiliary heater. OPTION B – Engine and Sleeper Heat DASH HEATER OEM OR AUXILIARY SLEEPER HEATER International with single heater RETURN TO ENGINE SOLENOID VALVE OEM COMBO HEATERS ONLY (NORMALLY OPEN) SUPPLY TO PROHEAT Figure 3-15 ENGINE Engine and Sleeper Heat NOTE: Vehicles equipped with a combination heater/air-conditioner will have a solenoid operated shut-off valve in the heater unit.
3.5 WIRING & ELECTRICAL CONNECTIONS 3.5.1 GENERAL CONSIDERATIONS • Prior to installation of the PROHEAT Heater system, ensure that the vehicle batteries are in good condition. • Do not kink or abrade wires when routing them through the vehicle during installation. • Ensure wires are well supported and secured with tie-wraps. • Do not use acid core solder when making solder connections. Major Electrical Connections Required a) Power connection to batteries .................................................
3.5.2 CAUTION 12 Volt products should not use power split from a 24 Volt system. This will cause uneven charging of the batteries. NOTICE Systems providing heat to both engine and sleeper require four (4) batteries. POWER CONNECTION TO BATTERIES 1. Route wire harness from PCM to the battery. Cut the harness to length as required. 2. Strip outer wire jacket of harness back to expose the positive (red) and negative (black) leads.
3.5.3 TIMER CONNECTIONS (OPTIONAL) TIMER CAUTION 1 ON 2 3 TIMER The switch input circuit should only be used to supply power to the ON/OFF Switch, the Timer, or as a signal to trip a relay. Failure to follow this installation practice will result in damage to the PCM. NOTICE The PCM must be reset (power disconnected and reconnected) when changing from a Timer to an ON/OFF Switch or from an ON/OFF Switch to a Timer. Do not connect an ON/OFF Switch and a Timer in the same circuit.
3.5.4 ON/OFF SWITCH CONNECTIONS 1. Select a suitable location in the vehicle dash for the ON/OFF Switch. CAUTION The switch input circuit should only be used to supply power to the ON/OFF Switch, the Timer, or as a signal to trip a relay. Failure to follow this installation practice will result in damage to the PCM. NOTICE The PCM must be reset (power disconnected and reconnected) when changing from a Timer to an ON/OFF Switch or from an ON/OFF Switch to a Timer.
3.5.5 SLEEPER FAN MODEL HEATER WIRING DETAILS These installation options allow the operator to: NOTICE These instructions require a Sleeper Fan model. For more information see page 4-2. You Choose 1. Run the PROHEAT with the ignition key in the “OFF” position. 2. Return full control to the OEM system in normal operation mode. Select one of the following wiring options NOTICE Sleeper Fan output does not supply power during ignition (1 minute after switch ON). DO NOT use for controlling coolant valves.
3.5.7 OPTION B – OEM Heater & Thermostat 1. Make sure the vehicle ignition is switched “OFF.” 2. Locate the PROHEAT thermostat in a central area of the sleeper, approximately 12" above the bunk. Avoid direct air flow from sleeper fan ducts. (Figure 3-25) 3. Remove the adjusting knob and face cover. Mark and drill mounting holes. Mount thermostat using the screws provided. (Figure 3-27) 4. Install relay 1, always between OEM sleeper fan control and OEM thermostat.
3.5.8 OPTION C – Auxiliary Sleeper Heater 1. Make sure the vehicle ignition is switched “OFF.” 2. Locate the auxiliary heater in a suitable area of the vehicle. Install plumbing and air duct connections as per the manufacturer’s recommendations. 3. Locate the PROHEAT thermostat in a central area of the sleeper, approximately 12" above the bunk. Avoid direct air flow from sleeper fan ducts. (Figure 3-25) 4. Remove the adjusting knob and face cover. Mark and drill mounting holes.
3.5.9 OPTION D – Auxiliary Sleeper Heater Current Limited 1. Make sure the vehicle ignition is switched “OFF.” NOTICE Sleeper Fan output does not supply power during ignition (1 minutes after switch ON). DO NOT use for controlling coolant valves. DO NOT use for controlling coolant valves. See page 4-5 for operational sequence information. 2. Mount the isolator in the sleeper fan motor area to a solid metal surface with the screw provided. Cut OEM wire to sleeper fan motor and connect isolator in series.
3.5.10 NOTICE These instructions require a Auxiliary Input model. For more information see page 4-2. NOTICE The Preheat and Supplemental modes are generally used by transit and coach applications. AUXILIARY INPUT MODEL HEATER WIRING DETAILS These installation options allow the operator to: 1. Run the PROHEAT in Preheat Mode or Supplemental Mode alone. 2. Run the PROHEAT in the Preheat and Supplemental Mode. 3. Run the PROHEAT in Standard Mode (Proheat Timer option) and using the Supplemental Mode.
Note also that the Supplemental Heat Mode has priority over the Preheat Mode and will cause the Preheat Mode to drop out. NOTE: There is a thirty second delay in response to both an “ON” and “OFF” signal*. This is to allow time for the vehicle to start before the heater is activated in Supplemental Heat Mode. * There are special OEM versions for Supplemental Mode.
3.5.12 OPTION B – Preheat and Supplemental Mode The instructions below are general in nature. It is up to the installer to select appropriate switches and use proper electrical connection methods. If more information is required, contact your Authorized Proheat Dealer or Proheat Product Support at www.proheat.com WARNING When wiring for Supplemental Mode, ensure to install Mechanic’s Disable Switch in order to disable Supplement Mode for safety requirements. 3.5.
Figure 3-29 Preheat and Supplemental Wiring Diagram. SECTION 3.
3.6 FUEL SYSTEM 3.6.1 GENERAL CONSIDERATIONS • Use a dedicated 1/4" ID fuel line between the fuel tank and heater meeting SAE 30R9. (Fuel line length not to exceed 50' with a maximum rise of 10'.) CAUTION DO NOT use fuel lines and pick-up tubes less than 1/4" ID or greater than 3/8" ID. Failure to use the correct line size may result in heater malfunction. Ensure fuel lines are routed away from all heat sources, well secured and will not abrade. • Ensure clamps are secure at fuel pump and fuel pick-up.
3.6.2 OPTION A – 1/4" or 1/2" NPT Port Locate an existing pipe thread port in the vehicle fuel tank and select the 1⁄4" or 1⁄2" NPT portion of the fuel pick-up that fits into that port. Apply a pipe sealant paste to the fuel pick-up pipe threads prior to installation. CAUTION Do not use teflon tape as this will contaminate the heater and engine fuel system.
3.6.3 OPTION B – Existing Blank Fuel Sender Cover Plate Locate an existing, blank fuel sender port in the vehicle fuel tank. Remove the cover plate, drill a 1" diameter hole and install the fuel pick-up as shown. NUT WASHER GASKET COVER PLATE SUPPLIED WITH FUEL TANK (REQUIRES MODIFICATION) GASKET WASHER FUEL SENDER PORT IN TANK Figure 3-34 3.6.4 Blank Fuel Sender Port OPTION C – Hole Drilled into Fuel Tank This option requires a permanent modification to the fuel tank.
3.6.5 INSTALLATION 45˚±15˚ CUT BOTTOM OF FUEL PICK-UP AT AN ANGLE 3"-4" CLEAR 3-4" CLEAR OF BOTTOM OF TANK Figure 3-36 For some situations where the fuel pick-up is too far from the bottom of the tank, an extension from left over fuel line can be added. Figure 3-37 Fuel Pick-up Depth 1. Determine the depth of the fuel tank at the desired fuel pick-up location. Cut the fuel pick-up 3 to 4” shorter as shown in Figure 3-37. 2. Install the pick-up into the fuel tank as per selected option. 3.
3.7 FIRST TIME STARTUP 1. Inspect the entire installation for: a) b) c) d) e) f) loose bolts, loose hoses and hose clamps, loose wires and wire connections, kinked or pinched hoses or wires, battery connection for correct polarity, and coolant supply and return location on the engine. 2. Fill the vehicle cooling system with coolant as per owner’s manual or engine manufacturer’s recommendations. 3. Place dash heater control in the full “HOT” position. Turn air conditioning “OFF.
8. Once the heater is started it will continue to run until the coolant temperature reaches 185˚F (85˚C) at heater outlet, then it will shut off. NOTE: The vehicle dash temperature gauge may read significantly less depending on the location of the sender unit on the engine. Sequence of Events for Shutdown a) Fuel pump and compressor shut off. b) The blower will run for 3 minutes on Cool Down (Purge) cycle then shut “OFF.” c) The water pump will continue to run. 9.
3-28 PROHEAT INSTALLATION & SERVICE
4.0 PRINCIPLE OF OPERATION 4.1 GENERAL DESCRIPTION 17 3 2 1 4 6 Figure 4-1. Sleeper Fan model shown. 5 1. Fuel Pump 2. Fuel Regulator 3. Air Compressor 4. Ignition Coil 5. Coolant Pump A gear pump driven from the same motor as the compressor pulls fuel from the tank. The fuel is filtered at the fuel pump inlet. Reduces fuel to atmospheric pressure. Siphoning action from the nozzle draws fuel from the regulator. Without this siphoning there is no fuel flow.
6. PROHEAT Control Module (PCM) to the motors and sensors. It has powerful diagnostics to assist in troubleshooting. One of the key features is the diagnostic display on the front of the PCM which has a display LED to indicate function or component problems. The PCM comes in a "Sleeper Fan 12V" or "Aux Input 12V or 24V" model. The PCM model can be identified by looking at the lexan decal as shown in Figure 4-2.
12 10 13 11 9 8 7 14 2 Figure 4-3 7. Nozzle An air/fuel aspirating type spray nozzle (located inside housing). The compressed air flows through the nozzle at high speed creating a venturi effect. This siphons fuel from the regulator and combines it with the air, creating an extremely fine mist which is sprayed out of the nozzle into the combustion chamber. 8. Blower Uses an impeller-type fan to supply the combustion air at low pressure.
11. Ignition Electrode 12. Coolant Temperature Sensor 13. Overheat Breaker Sensor 14. Flame Sensor The electrode is located near the nozzle just out of the air/fuel mixture path. During the ignition sequence the spark jumps the gap between the electrode and the combustion tube, igniting the air/fuel mixture. Spark duration is 60 seconds. Measures coolant temperature at the outlet port of the heat exchanger. Protects the heater from damage should it be operated without coolant.
4.2 MODES OF OPERATION The PCM comes in a "Sleeper Fan" or "Aux Input" model. The PCM model can be identified by looking at the decal as shown on page 4-2. Depending on the model and installation (refer to electrical drawing), the X45 has only the Standard Mode of Operation or combination of Standard, Preheat and Supplemental Modes of operation.
6. Standby The coolant pump circulates the coolant through the system until the temperature drops to 150˚F (65˚C) at the heater outlet; then it will enter Precheck and repeat steps 2 to 6. The PROHEAT will continue to repeat steps 2 to 5 until it is switched “OFF.” 7. Switch “OFF” If PROHEAT is in Full Output, it will Cool Down (Purge) first, then shut “OFF”. If PROHEAT is in Standby, it will shut “OFF” immediately. When switched OFF, the sleeper fan output turns off (if equipped, see page 4-2).
4.2.3 1. Activate Supplemental Signal for 30 Seconds 2. Supplemental Standby SUPPLEMENTAL MODE – Aux Input Models Only The ‘ON” light and heater indicator will turn ON after 30 seconds of receiving the signal. In addition, the Hour Meter (Auxiliary Output) will be powered. The PROHEAT monitors coolant temperature until it drops below 150˚F (65°C). Once coolant temperature drops below 150˚F (65°C) the PROHEAT goes to “Pre-run”. 3.
4-8 PROHEAT INSTALLATION & SERVICE
5.0 TROUBLESHOOTING AND REPAIR Problems with the PROHEAT and its operation will be indicated in two ways: NOTICE Troubleshooting and repair is to be performed by Authorized Proheat Dealers. 5.0.1 1. PROHEAT Diagnostic Faults indicated by means of a flashing diagnostic code on an indicator light on the switch, Timer red manual light or OEM indicator light (installation options). See Example Proheat Behavior Error on page 5-2. 2.
5.0.2 EXAMPLE PROHEAT BEHAVIOR ERROR – CODE 01 The following is an example of an X45 PROHEAT behavior during an error. The following example shows the sequence of events when the PROHEAT is switch “ON” in the Standard Mode (similar for Preheat and Supplemental Modes). This sequence of events occurs for Codes 01 through 12. Codes 13 and 14 do not put the heater into Cool Down (Purge) mode or shut down the PROHEAT; rather, the PROHEAT reports the error and continues to run. 1.
5.1 OPERATION INDICATORS, FUNCTION AND COMPONENT DIAGNOSTICS Figure 5-2 Remote On/Off Switch. The microprocessor in the PCM continually monitors all the PROHEAT systems. If the internal diagnostics discover a problem, a diagnostic code will be displayed on the PCM function display. The remote ON/OFF Switch, Timer red manual light or OEM indicator light (installation options) will also flash the diagnostic code followed by a pause and then repeat.
5.1.1 OPERATION INDICATORS Operation States: 8.8. – Power Up • – On Pu – Cool Down (Purge) The operation indicators signal normal functioning of the PROHEAT. These two states do not indicate a fault. Power Up On The Power Up indicator communicates that the PROHEAT power has been supplied. All segments of the LED momentarily flash and then turn off. The ON indicator code communicates that the PROHEAT is operationally “ON” whenever the On LED is solid.
5.1.2 FUNCTION DIAGNOSTICS Function Errors: 1 – Start 2 – Flame Out 3 – Coolant Flow 4 – Overheat 5 – Voltage Errors displayed on the PCM diagnostic panel will cause the heater to shut down. These diagnostic codes are usually the result of a system problem. It is possible to have two or more diagnostic codes displayed at the same time. A function diagnostic code may be displayed in conjunction with a component diagnostic code. 1 Start A START diagnostic code.
AIR COMPRESSOR AIR FILTER FLAME SENSOR COMPRESSED AIR ELECTRODE NOZZLE FUEL PUMP FUEL SUCTION FUEL INLET FUEL SUCTION FUEL PICK-UP FUEL PRESSURE FUEL REGULATOR FUEL TANK Figure 5-3 Fuel System Schematic Fuel System – Step 1 Check: Fuel and fuel supply a) The PROHEAT operation when supplying fuel from a direct source. Test Procedure — Supplying fuel from a remote source: a) Remove the fuel supply line from the outlet of the fuel regulator.
PLACE THIS LINE IN A CONTAINER OF FUEL MAINTAIN FUEL LEVEL AT CENTRE OF THE REGULATOR REMOVE FUEL LINE FROM REGULATOR Figure 5-4 Eliminating Fuel Pump and Regulator from system. Fuel System – Step 2 Check: Regulator a) For damage, contamination and mechanical operation. Test Procedure — Vent Hole Regulator Style: a) Disconnect the fuel line at the nozzle fuel inlet fitting and place in a container. b) Inspect vent hole to ensure that it is not plugged. c) Start the heater.
Fuel System – Step 3 Check: Vehicle Fuel Supply, Fuel Pump a) Vehicle fuel level and/or for fuel gelling during cold weather. b) Air leaks and/or restrictions in the fuel supply lines to the PROHEAT. c) The PROHEAT operation when supplying fuel from a direct source. Test Procedure — Fuel Supply Inspection: a) Is there fuel in the tank? b) Check fuel lines, connections and routing back to the fuel tank for kinks, loose fittings, stiff lines or cuts. Replace any fuel lines that are cut, brittle or chaffed.
Fuel System – Step 4 Check: WARNING Shock hazard due to high secondary coil voltage. Air Compressor a) Air compressor pressure and operation Test Procedure — Air Compressor pressure: a) Run heater until warm to the touch. This ensures the heater components are up to normal operating temperature. b) Switch heater off. c) Install PK0037 Digital Manometer (or a calibrated PK0060 Analog Air pressure gauge) in-line as shown in Figure 5-6.
12V Proheat X45 Air Pressure Range vs. in Operation Coil Voltage for a Warm Compressor 7.6 7.4 7.2 GE N A R LE B TA P CE C A 7 Air Pressure (PSI) 6.8 6.6 6.4 6.2 Figure 5-7 6 5.8 10.5 11 11.5 12 12.5 13 13.5 14 Operational Coil Voltage (V) Figure 5-8 12V System Air Pressure Chart 24V Proheat X45 Air Pressure Range vs. in Operation Coil Voltage for a Warm Compressor 7.6 7.4 7.2 E G AN R LE B TA P CE C A 7 Air Pressure (PSI) 6.8 6.6 6.4 6.2 6 5.8 21 21.5 22 22.5 23 23.
Air Pressure Checks If Air Pressure is outside the range for the measured voltage please perform the following checks before adjusting the compressor: Low Pressure Reading – Check: i) Inspect air line from compressor outlet to fan end inlet for leaks, kinks or other restrictions. ii) Check condition of air compressor filter. Retest with the filter removed. High Pressure Reading – Check: i) Nozzle and cavity for blockage. Refer to Step 5 on page 5-12. ii) Compressor is out of adjustment.
Fuel System – Step 5 Check: NOTICE Fuel Nozzle parts are a matched set and not interchangeable. Nozzle a) For fuel nozzle and o-ring damage and/or contamination. Test Procedure — Fuel Nozzle Removal, Inspection & cleaning or replacement: a) Remove three (3) bolts from the fan end and open up heater. b) Remove nozzle from fan end. c) Disassemble, inspect, clean and reassemble Fuel Nozzle (Figure 5-12).
Ignition System Check: WARNING The PROHEAT chassis is grounded to the PCM as shown in Figure 5-14. Ensure that the ground is securely connected. Failure to ensure a proper ground may result in electrical shock. Ignition Coil and Electrode Gap a) Electrode cleanliness. b) Electrode positioning for proper gap. Test Procedure — Ignition System and Electrode Spark Inspection: a) Inspect high tension lead between the coil and the electrode.
Flame Sensor Check: Flame Sensor a) Flame sensor operation. NOTICE If the lens is dirty, the sensor does not properly “see” the flame. NOTICE DO NOT use an LED flashlight. Only an incandescent flashlight will check the sensor operation. Test Procedure — Flame Sensor Circuit: a) Check cleanliness of the flame sensor. b) To test flame sensor for operation: Spare Flame Sensor Available – Check: i) Ensure unit is powered off. Disconnect flame sensor. ii) Connect known good Flame Sensor to harness.
2 Flame Out Indicates that a flame was detected (started successfully for at least 60 seconds) but is unable to maintain a steady flame before reaching the cycle off temperature of 185°F (85°C). Flame Out sequence: a) A flame is detected during the Ignition period and during Full Output. b) The flame goes out or fails to be detected. c) The ignition is switched on for a maximum of 10 seconds to try and reestablish the flame.
3 Coolant Flow A COOLANT FLOW diagnostic code is displayed when the coolant temperature reaches 185˚F (85˚C) in less than one minute after ignition. This indicates that the coolant flow is severely restricted or blocked. This feature aids in detecting coolant flow problems that can degrade the PROHEAT performance. An in-line flow indicator is a valuable troubleshooting tool used to: (Figure 5-15) a) Check the coolant flow and direction. b) Check for air in the system.
4 Overheat An OVERHEAT diagnostic code is displayed when the overheat breaker has tripped, shutting the heater down. This occurs if the heater has been started with little or no coolant in the heat exchanger. Check: Coolant Flow a) Is there coolant in the system? b) Determine if there is a blockage or air in the plumbing. The compressor motor is wired in series with the overheat breaker. The breaker contains a normally closed thermo switch.
5 Voltage A VOLTAGE diagnostic code indicates that the supply voltage to the heater is out of the normal operating range. Voltage ranges: 12 Volt heater – 10.0 to 15.0 Volts 24 Volt heater – 20.0 to 30.0 Volts Check: NOTE: NOTE: Vehicle Voltage a) Heater voltage must be within the specified range. See following page for procedure to measure heater voltage. Bad connections may show good voltage under no load conditions but not under full load. With the heater “OFF,” measure the voltage.
Figure 5-17 5.1.3 Heater Voltage Measurement COMPONENT DIAGNOSTICS Component Faults: 6 – Flame Sensor 7 – Temp Sensor 8 – Fuel Pump NOTICE A SLEEPER FAN error (13) and HOUR METER error (14) will not shut the PROHEAT down and heat to the engine will be maintained. 6 Flame Sensor 12 – Blower 13 – Sleeper Fan 14 – Hour Meter This section covers the individual heater components. In many cases there is a corresponding indicator light on the PCM function display.
Flame Sensor Test Procedure Stop Stop Unit Unit Start Start Unit Unit Is there a Flame Sensor Code? Yes No Disconnect Disconnect Sensor/Start Sensor/Start Unit Unit Check Check Flame Flame Quality Quality Is there a Flame Sensor Code? No Replace Replace Sensor Sensor Yes Yes Is there a Flame? Yes No Sensor Sensor OK OK After 60 Seconds is there a Start Code? No 1 Is there a Spark? Check Check Main Main Harness Harness for a Short for a Short Circuit/ Circuit/ Replace Replace ifif necessary
7 Temp Sensor A TEMP SENSOR diagnostic code indicates a short or open circuit in the temperature sensor wiring or the coolant temperature is out of range—below -58˚F (-50˚C) or above 266˚F (130˚C). The resistance of the temperature sensor is proportional to temperature. Check: Temperature Sensor (CODE indicated) a) Inspect wiring for short or open circuits. b) Check resistance of sensor. Is it within range as shown in Figure 5-20.
Code 07 Code 07 150˚ 290˚ 140˚ 130˚ C (266˚ F) OUT OF RANGE (UPPER LIMIT) 2023 130˚ 260˚ 120˚ 110˚ 230˚ 100˚ 200˚ 90˚ 1541 85˚ C (185˚ F) UPPER SET POINT 80˚ 1354 60˚ 65˚ C (150˚ F) LOWER SET POINT 140˚ 50˚ 40˚ 110˚ 30˚ 80˚ 20˚ 10˚ VALID TEMPERATURE SENSOR RANGE Temperature Farenheit (°F) Temperature Centigrade (°C) 170˚ 70˚ 50˚ 0˚ -10˚ 20˚ -20˚ -10˚ -30˚ -40˚ 515 -50˚ -40˚ -50˚ C (-58˚ F) OUT OF RANGE (LOWER LIMIT) -60˚ -70˚ 400 600 800 1000 1200 1400 1600 1800 20
8 Fuel Pump The X45 fuel gear pump is driven by the same motor as the compressor. Therefore, there is NO fuel pump electrical diagnostic code. A FUEL PUMP diagnostic code would indicate a fault in the PCM only. A short or open circuit fault in the motor that drives the fuel pump will be indicated by a COMPRESSOR diagnostic code.
Compressor Mechanical And Electrical Troubleshooting (No code Indicated) The following material covers the air compressor mechanical or electrical problems that DO NOT indicate a Code 9. The compressor/fuel pump motor is ground side switched- there is always voltage at the positive terminal to the motor. Symptom: Air Compressor runs as soon as power is applied (No code indicated) Check: Internal Short in Motor a) Disconnect compressor/fuel pump motor from internal harness.
Symptom: Air Compressor running (No code indicated) Fuse blown in PCM Check: WARNING Air Compressor operation a) Harness for pinched or abraded wires. The positive wire must not short to ground. b) Motor for internal short. (See Figure 5-21 and Test Procedure) c) Check for seized motor or fuel pump. (See Figure 5-5 and Figure 5-22) Disconnect the PCM electrical power prior to trying to turn the compressor counterweight by hand.
Ignition Coil Electrical Troubleshooting (No code Indicated) The following material covers the ignition coil mechanical or electrical problems that do not indicate a Code 10. The ignition coil is ground side switched — there is always voltage at the positive terminal to the ignition coil. Symptom: No spark at the electrode (No code indicated) Check: High tension wires and electrode a) Inspect the high tension lead between the coil and the electrode.
11 Coolant Pump A COOLANT PUMP diagnostic code indicates an open circuit in the wire harness, a short in the wire harness between the positive and negative leads or an internal short in the motor. This component is ground side switched in the PCM. The coolant pump is not self-priming. Ensure that the coolant system has been purged of air by running the vehicle engine for at least ten minutes following installation or service. (DO NOT run dry.) Symptom: Pump not running (code indicated) SECTION 5.
Symptom: Coolant pump not running (code indicated) Check: Coolant Pump wiring & function a) That coolant pump is connected to harness correctly. (See PROHEAT Wiring Diagram page 1-4) b) The connector pins for damage or corrosion. c) Harness for pinched or abraded wires. d) Test pump. If it tests OK replace PCM. (See Figure 5-24 and Test Procedure.
Symptom: Coolant pump not running (no code indicated) Fuse blown in PCM Check: Coolant Pump function a) Harness for pinched or abraded wires. Positive lead must not short to ground. b) Check motor for internal short. (See Figure 5-24 and Test Procedure.) Symptom: Coolant pump not pumping (no code indicated) Check: Coolant Pump function a) If the impeller is turning freely. If not, replace pump. Symptom: Coolant pump leaking Check: SECTION 5. TROUBLESHOOTING & REPAIR Leak location a) Hose clamps.
12 Blower A BLOWER diagnostic code indicates an open circuit in the wire harness, a short in the wire harness between the positive and negative leads or an internal short in the motor. This component is ground side switched in the PCM. The PCM measures the RPM of the blower. This feature will give an error should it fall below the necessary RPM to maintain sufficient combustion air. CAUTION When a blower fails, the combustion chamber must be checked for carbon build up and cleaned as necessary.
iii) Inspect internal harness wires going to blower. Ensure that there is no chaffing or cuts that would provide a blower motor ground short. If internal harness is good condition, replace PCM Symptom: Blower not running (no code indicated) Fuse blown in PCM Check: Blower function a) Harness for pinched or abraded wires. Positive lead must not short to ground. b) Check motor for internal short.
13 Sleeper Fan A SLEEPER FAN diagnostic code indicates an electrical short in the sleeper fan wiring harness, electrical connections or fan motor. This error will not shut the heater down and heat to the engine will be maintained. An open circuit will not display a diagnostic code. NOTE: This error is only applicable to "Sleeper Fan" models. See page 4-2 for model identification. If the PCM model is an "Aux Input" model and this error is displayed, there is a fault with the PCM. Replace the PCM.
14 Hour Meter (Auxiliary Output) An HOUR METER (AUXILIARY OUTPUT) diagnostic code indicates an electrical short in the hour meter (auxiliary output) wiring harness, electrical connections or connected electrical load. The electrical load could be an hour meter, relay or any other low load (< 1 A) connection that depends on the installation. This error will not shut the heater down and heat to the engine will be maintained. An open circuit will not display a diagnostic code.
5.2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS 5.2.1 FUEL NOZZLE Go to page 5-12. 5.2.2 FUEL REGULATOR Go to page 5-7. 5.2.3 AIR COMPRESSOR Go to page 5-9 and page 5-23. 5.2.4 FUEL PUMP Go to page 5-8. 5.2.5 IGNITION ELECTRODE Go to page 5-13. 5.2.6 COOLANT PUMP Go to page 5-27. 5.2.7 BLOWER Go to page 5-30.
5.2.8 FUSE If, when the heater is switched “ON,” the heater does not run and the “ON” light does not light, check the fuse in the PCM. The fuse will blow if there is a short to ground in a positive lead or internally for the following components: • ON/OFF Switch • Air Compressor/Fuel Pump • Ignition Coil • Coolant Pump • Blower • Internal Wire Harness Reversing polarity at the battery will also cause the fuse to blow. This will not harm the PCM. Check: Heater wiring.
Fuse Blown Test Procedure with Power Connected and PROHEAT Switched “OFF” Check for correct battery polarity Remove Fuse NOTE: Ensure positive wire from the PCM to the ignition coil does not ground. Disconnect from PCM: • Internal Wire Harness (18 Pin Connector) • Switch Harness NOTE: A short circuit in the sleeper fan outlet and hour meter (auxiliary output) harness will not blow the fuse. An error will be indicated on the PCM. This will not shut the heater down.
5.3 OPERATIONAL PROBLEMS Heater Operational Problems that are not specifically described in the function or component diagnostic section. 5.3.1 COMPLAINT: Smoking exhaust/Smelly exhaust fumes These symptoms are usually an indication of an extremely rich air/fuel mixture. Check 5.3.
5-38 PROHEAT INSTALLATION & SERVICE
6.0 MAINTENANCE 6.1 WEEKLY MAINTENANCE Run the heater a minimum once a week to keep new fuel in the heater’s critical components. 6.2 ANNUAL MAINTENANCE Your PROHEAT has been designed to operate with a minimum of maintenance. To ensure the efficient operation of your heater an ANNUAL MAINTENANCE TUNEUP is strongly recommended to be performed each year. NOTICE A higher duty cycle may require a more frequent maintenance schedule. i.e. 2 or 3 times per year.
6.2.1 CLEAN HEATER, ENCLOSURE AND AIR INTAKE • Remove the heater enclosure cover. • Clean any accumulated debris or dust from the components. WARNING DO NOT pressure wash or steam clean. • Blow out the compartment with compressed air. • Check the combustion air inlet screen for restrictions. Clean as required. • Make sure the opening around the exhaust pipe is clear. • Visually inspect all the components for wear or damage. • Clean the X45 Heater using the following procedure.
6.2.2 CHECK EXHAUST SYSTEM • Make sure the exhaust pipe is vented safely away from the vehicle cab. • Check the pipe for dents, restrictions or severely corroded areas. • Replace the exhaust pipe and clamps if necessary. • Ensure the exhaust pipe clamp is tight. • Clean exhaust pipe if there is a significant accumulation of carbon build up. Figure 6-3 6.2.
6.2.4 CLEAN FLAME SENSOR • To maintain proper sensor readings, the flame sensor glass should be wiped clean. • With the fan end removed, clean the sensor glass with water and a rag. Glass should be clear. FLAME SENSOR Figure 6-5 6.2.5 Flame sensor CHECK COOLING SYSTEM • Check all heater hoses and connections for signs of leakage or damage. • Repair or replace as required. • NOTE: The coolant mix must be 50% Ethylene Glycol. 6.2.
6.2.7 CHECK FUEL SYSTEM • Check the fuel system for damaged fuel lines or leakage. • Make sure the clamps on the fuel lines are secure. • Ensure fuel lines are flexible. FUEL FILTER AIR FILTER FUEL PICK UP HOSE CLAMP FUEL TANK FUEL LINE GROMMET FUEL LINE HOSE CLAMP Figure 6-7 6.2.8 Fuel Line Clamp CHECK FUEL FILTER • Remove and inspect filter. Clean or replace as necessary. TORQUE TO 150±10 IN/LBS (17±1.1 Nm) FILTER O-RING O-RING Figure 6-8 SECTION 6.
6.2.9 CLEAN NOZZLE • Remove and install Nozzle as shown on page 5-12. Torque to 150±10 in/lbs (17±1.1 Nm). • To properly clean the nozzle use electrical contact cleaner or warm soapy water. This will wash any dirt out and leave no residue. When using compressed air, blow into the nozzle orifice from the head end. HOLD UPRIGHT TO ASSEMBLE TORQUE TO 30±3 IN/LBS (3.4±0.3 Nm) BLOW THIS DIRECTION WHEN USING COMPRESSED AIR. Figure 6-9 6.2.
6.2.11 CHECK ELECTRICAL SYSTEM • Check the internal and the external wire harnesses for damage. Replace if required. CAUTION Ensure that power is disconnected to the X-45 prior to servicing the Ignition Lead. • Service the X45 Ignition Lead and Ignition Coil by following the steps listed below. 1 Annually or better, inspect the ignition lead and the boots on both ends. Replace the entire lead with new lead (p/n 930523K) if the lead itself or boots are coated with oil, torn, cracked or brittle.
6.2.12 CHECK AIR PRESSURE • Refer to Air Compressor pressure test procedure on page 5-9. DIGITAL MANOMETER PK0037 HOSE TO NOZZLE AIR INLET HOSE FROM COMPRESSOR Figure 6-13 6.2.13 Air Compressor pressure test procedure CHECK MODES OF OPERATION – SWITCH, TIMER OR OEM SIGNALS • Check to see that the modes operate as described on page 4-5 to page 4-7. Operation Test • Run the system for at least 15 minutes or until the heater cycles “OFF” and then “ON” again.
7.0 APPENDICES CONTENTS COOLANT FLOW INDICATOR .......................................................... 951528K TEST LEADS ................................................................................ 967329K GROUND SIDE BATTERY DISCONNECT ............................................ SB0003 G-III PROHEAT CONTROL MODULE (PCM) FOR X45 AND XL SERIES HEATERS ................................................ PB0034 FUEL PUMP PRESSURE CHECK AND SERVICE ................................. SB0062 SECTION 7.
7-2 PROHEAT INSTALLATION & SERVICE
SERVICE BULLETIN Copy Part# 951528, Rev. A, 10/1993 Description: Coolant Flow Indicator FLOW INDICATOR TK9002 Page 1 of 1 FLOW Part: TK9002 Purpose: The Coolant Flow Indicator is a service tool used to troubleshoot and test for possible flow and air problems in the coolant flow path. Flow direction during heater operation or during engine operation can then be observed.
7-4 PROHEAT INSTALLATION & SERVICE
SERVICE BULLETIN Copy Part# 967329, Rev. A, 05/1994 Page 1 of 1 Description: The PROHEAT wiring system uses sealed connectors for resistance to corrosion and greater reliability. The following test leads are required for troubleshooting. USE SPADE CONNECTORS TO TEST VOLTAGE, RESISTANCE OR CONTINUITY A A B A B BLACK Parts: 967921K Test Lead RED 952925K Remote On/Off switch Instructions: 1.
7-6 PROHEAT INSTALLATION & SERVICE
SERVICE BULLETIN Copy Part# SB0003, Rev. A, 06/1995 Description: Purpose: Test Procedure: Page 1 of 2 Ground Side Battery Disconnect This service bulletin includes troubleshooting steps and protection recommendations from damage, that may occur when attempting an engine start while the ground side battery disconnect switch is in the "open" position.
SERVICE BULLETIN Copy Part# SB0003, Rev. A, 06/1995 Page 2 of 2 PIN C3 GROUND RING TERMINAL BLACK WITH GREEN STRIPE END VIEW FIGURE 1 SLEEPER FAN Pin C3 3-B 3-A 2-D 2-A 2-C 2-B 1-C 1-A PIN 1-B 3-A 3-B POWER +12V/+24V (3 AMP LIMIT) GROUND (-) 2-A 2-B 2-C 2-D POWER +12V/+24V (OUTPUT) GROUND (-) "ON" SIGNAL (TO HEATER) INDICATOR +12V/+24VOLTS 1-A 1-B 1-C POWER +12V/+24V (IMPUT) GROUND (-) NOT USED SWITCH OUTPUT POWER FIGURE 2 © 1995 Marine Canada Acquisition Inc.
PRODUCT UPDATE BULLETIN Copy Part# PB0034, Rev. B, 04/2009 Introducing: Part Numbers: G-III Proheat Control Module (PCM) for X45 and XL series Heaters.
PRODUCT UPDATE BULLETIN Copy Part# PB0034, Rev. B, 04/2009 Page 2 of 3 1 100 % Backward Compatible • G-III PCM works with existing heaters and wiring harnesses. 2 CANbus Communication and new Serial Port Location • The new communication port provides CANbus SAE J-1939 communication. • Relocated serial port allows Datalink connection without disconnecting the switch input. • New communication port requires the G-III controller Proheat Data Link Kit PK0053-3.
PRODUCT UPDATE BULLETIN Copy Part# PB0034, Rev. B, 04/2009 4 Page 3 of 3 Breather with Filter • A breather hole has been added to prevent moisture buildup inside the PCM by maintaining equal pressure inside the PCM enclosure. A wire mesh filter has been added to prevent any debris or excessive moisture from entering through the breather hole. NEW PCM DISPLAY – SAMPLE CODES ON PURGE STATE ERROR CODE 12 Figure3: New PCM display sample codes. © 2009 Marine Canada Acquisition Inc.
7-12 PROHEAT INSTALLATION & SERVICE
SERVICE BULLETIN Copy Part# SB0062, Rev. A, 09/2011 Page 1 of 6 X45 FUEL PUMP PRESSURE CHECK AND SERVICE Installation Instructions WARNING 1. Disconnect power to heater. 2. Remove air compressor hose to ensure heater will not run in full output during test. 3. Remove fuel outlet hose from fuel pump. To avoid the risk of shock, ensure to disconnect power to heater unit during disassembly/reassembly. 2 AIR COMPRESSOR HOSE WARNING Fire Hazard.
SERVICE BULLETIN Copy Part# SB0062, Rev. A, 09/2011 NOTICE Page 2 of 6 5. Install test gauge PK0060 on fuel pump outlet. TEST GUAGE PK0060K Calibrate gauge before each use see www.proheat.com/PDFs/990614.pdf for more information. 5 Figure C. 6. Switch the PROHEAT on and read the fuel pressure on test gauge. A reading of 5 – 10 PSI is normal and no further action is required. If reading is ABOVE 10 PSI 1. Locate the pressure relief valve cap and remove with a slot screwdriver.
SERVICE BULLETIN Copy Part# SB0062, Rev. A, 09/2011 Page 3 of 6 2. Remove the spring and brass ball guide from the cavity. 3. Carefully separate and discard the brass ball guide from the pressure relief valve spring. DO NOT stretch or damage the spring. 4. Remove the ball bearing from the cavity. 5. Inspect and clean all components. 6. Inspect and clean the cavity. Pay close attention to the center hole in the cavity for any debris or a damaged edge.
SERVICE BULLETIN Copy Part# SB0062, Rev. A, 09/2011 Page 4 of 6 3. Check fuel lines, connections and routing back to the fuel tank for kinks, loose fittings, stiff lines or cuts. FUEL PICK-UP FUEL LINE FUEL TANK FUEL LINE HOSE CLAMP GROMMET HOSE CLAMP Figure F. 4. Check pressure relief valve. Locate the pressure relief valve cap and remove with a slot screwdriver. Be careful not to lose any of the internal components that may fall out. 5. Remove the spring and brass ball guide from the cavity. 6.
SERVICE BULLETIN Copy Part# SB0062, Rev. A, 09/2011 Page 5 of 6 2. Inspect and clean all components. 8. Inspect and clean the cavity. Pay close attention to the center hole in the cavity for any debris or a damaged edge. The edge of the hole should be smooth with no nicks, do not use any tool that may damage the edge as this will cause loss of fuel pressure. 9. Place ball bearing back in cavity on the center hole. 10. Place spring back in hole with brass ball guide on top of ball bearing. 11.
SERVICE BULLETIN Copy Part# SB0062, Rev. A, 09/2011 Page 6 of 6 2. Reconnect fuel line to fuel pump outlet. 3. Reconnect air hose at compressor. 3 AIR COMPRESSOR HOSE 2 FUEL OUTLET HOSE Figure I. 4. Run heater for a full cycle and inspect for proper operation. © 1995 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS 3831 No. 6 Road, Richmond, B.C. Canada V6V 1P6 Tel: 604.270.6899 Web: www.proheat.
PROHEAT WARRANTY NOTICE This is a warranty summary. For the complete warranty manual, please go to www.proheat.com Proheat warrants the PROHEAT Heater to be free of defects in material and workmanship under design usage and service conditions for two (2) years on parts and labour from the date of first installation. Replacement parts are covered for the remainder of the heater’s warranty or ninety (90) days, which ever is greater.
Proheat Serial Number: Installation Date: Dealer: SeaStar Solutions 3831 No.6 Road Richmond, B.C. Canada V6V 1P6 Tel: 604-270-6899 Fax: 604-270-7172 www.proheat.com © 2009 Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS Proheat is a registered trademark of Marine Canada Acquisition Inc. and its subsidiary companies.
