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INSTALLATION AND SERVICE MANUAL PROHEAT X45

1. Figure 3 1 Other Applications SECTION 3 INSTALLATION 3 1 3 1 3 1 1 You Choose 25 A 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 This will prevent damage to the PROHEAT electronics 3 1 2 WARNING Never locate the heater inside the vehicle cab See Figure 3 3 3 2 Figure 3 3 LOCATING THE HEATER SELECT YOUR LOCATION The most suitable location for mounting the heater will vary depending on the type of vehicle Recommended mounting locations are e Behind the cab across the frame rails 1 e On either side of the frame rails 2 e n an existing enclosure on the vehicle step or toolbox 3 42 PUB ae Figure 3 2 Recommended Mounting Positions GENERAL CONSIDERATIONS e Never mount the heater to two separate parts of the vehicle e Avoid mounting the heater in areas of excessive vibration e Do not mount the heater directly to the engine e Do not mount the heater beneath a wood floor without a proper fire wall above the heater e Avoid mounting the heater in areas of excessive dust dirt and moisture accumulation e The heater must be easily accessed for service COOLANT OUT V 6 amp AA fa up v d pum IN b
2. 1 4 weyuarey neadus pf ssa 50 58 F OUT OF RANGE LOWER LIMIT 1 60 400 600 800 1000 1200 1400 1600 1800 2000 2200 Resistance Ohms Q Figure 5 20 Coolant Temperature Sensor Graph NOTE Room temperature 20 C Resistance 950Q Boiling water 212 F 100 C Resistance 1700Q PROHEAT INSTALLATION amp SERVICE 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 8 Fuel Pump A COMPRESSOR 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 71 short the motor This component is ground side switched the PCM fe 9 Compressor Symptom Air Compressor not running code indicated Check Air Compressor wiring amp function a That compressor 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 compressor If it tests OK replace PCM See Figures 5 7 amp 5 8 and Test Procedure Test Procedure a Conne
3. HailVa3H JION 335 8343315 YSL 3504 Nid 1915 1405 111 9 LAdNI AYVITIXNV IOYLNOD ees 3L1ON 33S LAdLNO H3d33 l Ed V SI 3514 31ON 335 NOILVOISILNACI XAY HO 9343315 SNOILdO 1HVd HOS SLON 338 INGON 1OH LNOO 1V3HOHd LNO Nid HOLO3NNOO td LNO HOLO3NNOO Sd TIVL3Q LNO HOLO3NNOO 1 1 139 5911 NOILWLNAIHO ALON SYOLVNDISAG HOLO3NNOO NOLLVOIJILN3GI 0 0615 MOO OL YASS L SALON PCM Electrical Connections X45 Figure 1 4 1 5 SECTION 1 TECHNICAL SPECIFICATIONS TORQUE SPECIFICATIONS FAN END CASTING e Apply anti seize to bolts 3 e Torque bolts 3 to 75 5 in Ibs 8 5 0 5 Nm REGULATOR e Apply anti seize to cap screw e Torque cap screw to 94 6 5 10 6 0 7 Nm FLAME SENSOR e Torque sensor to 2533 in lbs 2 8 0 3 Nm IGNITER e Apply anti seize to igniter threads e Ensure gasket is present before installing e Torque igniter to 50 5 5 5 6 0 6 Nm COMBUSTION TUBE e Apply anti seize to cap screws e Torque cap screws 4 to 25 3 in lbs 2 8 0 3 Nm PROHEAT INSTALLATION amp SERVICE Speer OVERHEAT SENSOR e Lubricate o ring with o ring lubricant e Torque senor to 5
4. ILON 33S 67 ISOH QI 8v 91 er 6 L hue ea NOLLOANNOO 1SNYHXI 5 AlddNs 1305 1HOd ISNVHX4 I m Lv 9 I ezz 18 ILON LOL 0 K ISOH Z L3SOH 64 ENOILLOANNOO 1HOd 131 10 LNV1OOO SNOISN3MWIG J 1OH LNNOW dOL 31ON 335 31V Id 160 92 XZ 912 10678 S3 ONILNNOW Ort S S OLX 91 9 LNOHLIM 39NVHO OL LOArANS ANY AINO SASOduNd 3ON3H3HHH SNOISN3INIG NOIJVOIALLN3GI H38INTN LuVd 0206715 MOO SPX OL dada SALON 0 41 9 01 1J1NI 1 LNV 1OOO vel 5 9 p E Mn 6 d CR 1 vs 18VIS 1405 5 ON 7 eZ xL 1v3HOHd sm Y De T Ig lovt TWAOWSY 1 NOILSNENOD SI SIH L A E 4 2 LDN T SN dOL m leez p6 lovt 1HOd IsnvHxa M a 692 sec L ALON 33S 3dld 5 15 peel esc 0 NOILSNANOO SI Heater Dimensions X45
5. 512 AIR COMPRESSOR HOSE Soa LE CS EE CONTROL MODULE Teleflex SLEEPER Fay SWITCH INPUT 999100 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 V6V1P6 Tel 604 270 6899 Web www proheat com PROFEAT This is a warranty summary For the complete warranty manual please go to www proheat com PROHEAT WARRANTY 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 This warranty does not apply to damage or failure of the PROHEAT Heater or the vehicle into which it was installed due to improper installation assembly maintenance abuse neglect accident or the use of parts not supplied by Proheat Accessories supplied but not manufactured by Proheat shall be covered by the manufacturer s warranty only and not subject to this warranty Non standard installations that is those requiring a departure from published installation instructions should not be undertaken without first having consulted Proheat Coverage for warrantable parts at the discretion of Proheat will
6. 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 1 5 8 VENERE ARR A 20 508 mm 45 mm 3 76 mm Dia C 5 127 mm E 5 127 mm 306 mm 5 3 4 146 mm 8 13 16 223 mm 3 4 20 mm MOUNTING HOLES 4 REQUIRED 5 127 mm gt n 16 11 16 427 mm 1 5 8 45 mm AES Figure 3 9 X45 Enclosure Base Dimensions 3 4 PROHEAT INSTALLATION amp SERVICE 3 2 2 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 Use anti seize compound on fasteners 1 Ensure that the proposed enclosure is big enough for the heater to prevent galling and corrosion 12 YW x 11H x 20 ZL inches 318 x 280 x 521 mm 2 Using the indicated dimensions drill the 4 mounting holes and exhaust pipe clearance hole 3 Ensure that the combustion tube can be removed for service See Figure 1 2 on page 1 3 for service space requirements ww 4 X 38 10MM C MOUNTING HOLES 1 0 25 mm 3 76 mm Dia Di 1 5 5 140 mm 6 4 163mm 5 127 mm _ gt 2 02 51 mm 7 5 191 mm Figure 3 10 X45 Mounting Plate Dimensions
7. D 1 iiij Pg SWITCH POWER 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 A diaphragm type compressor supplies air to the fuel nozzle An automotive type ignition coil supplies high voltage to the ignition electrode sparking to the combustion tube Circulates the engine coolant An impeller style pump is used because of its low current draw and free flow during engine operation IT IS NOT SELF PRIMING The pump must be flooded and the system must be purged of all air for it to operate DO NOT run dry Utilizes a microprocessor to monitor operating conditions and control outputs 4 1 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 e The Sleeper Fan model has an output with a special current limiting feature which if used limits the current draw of the sleeper heater fan to 3 Amps This is done to cont
8. MINIMUM CLEARANCE 6 Figure 3 4 Allow minimum 6 clearance for hose connections PROHEAT INSTALLATION amp SERVICE 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 15 not possible HIGHEST POINT IN COOLING SYSTEM HEATER MUST BE MOUNTED BELOW HIGHEST POINT Co PROHEAT ENGINE OR RADIATOR Figure 3 5 Height Requirement 3 1 3 MOUNTING THE PROHEAT HEATER IN AN ENCLOSURE Do not locate the heater in an airtight enclosure If the heater is to be mounted in an enclosure other than the PROHEAT enclosure adequate air flow must be provided to ensure proper combustion The enclosure must also be adequately ventilated so that the ambient temperature inside the enclosure does not exceed 185 F 85 The openings must be positioned to prevent moisture dirt and snow from accumulating in the enclosure The heater enclosure must be easily accessed for servicing of the heater Figure 3 6 Adequate Air Flow Heater must be mounted within 5 of horizontal as shown Figure 3 7 Mounting Angle SECTION 3 INSTALLATION 3 3 3 2 MOUNTING THE HEATER Select Your Mounting Option 3 2 1 OPTION A Heater With Enclosure Remove the enclosure cover 2 Drill the 4 mounting holes and exhaust pipe clearance hole 2 Q 3 Using the bolts supplied fasten the enclosure to the mounting tray or brackets
9. If the resistance is in the mega ohm range go to Step iii iii Inspect internal harness wires going to coolant pump Ensure that there is no chaffing or cuts that would provide a motor ground short If internal harness is good condition replace PCM PROHEAT INSTALLATION amp SERVICE SECTION 5 TROUBLESHOOTING amp REPAIR 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 Leak location a Hose clamps Tighten if necessary b Pump housing seal Replace pump if required 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 A CAUTION Symptom Blower not running code indicated When a blower fails the combustion Check chamber must be checked for carbon build up and cleaned as necessary Blow
10. PRODUCT UPDATE BULLETIN Copy Part PBOO34 Rev B 04 2009 4 Breather with Filter e 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 PURGE STATE ERROR CODE 12 Figure3 New PCM display sample codes 2009 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 6 Road Richmond B C Canada V6V1P6 Tel 604 270 6899 Web www proheat com 7 12 PROHEAT INSTALLATION amp SERVICE SERVICE BULLETIN Copy Part SBOO62 Rev A 09 2011 X45 FUEL PUMP PRESSURE CHECK AND SERVICE Installation Instructions 1 Disconnect power to heater 2 Remove air compressor hose to ensure heater will not run in full output during test A WARNING 3 Remove fuel outlet hose from fuel pump To avoid the risk of shock ensure to disconnect power to heater unit during disassembly reassembly A WARNING Fire Hazard Do not place any flammable items around the heater oo D and exhaust pipe AIR COMPRESSOR HOSE OPERATI states COMp S sll i E 899105 9 OUTLET HOSE Figure A 4 Remove T fitting from test gauge PKOOGO TEST GUAGE a 0060 T FITTING Figure 19
11. 1 1 1 HOLIMS LNdNI 90 jenuey 205 41 1UBIOOD 60 Jamojg Zi Z0 LL 15 10 01 SOILSONDVIG 60 jen4 80 4osues 0 2 Josuag 90 SOILSONDVIG 531715 1N3NOdWO2 LYVLS 1305 1 9 FTINGOW TOYULNOD LVAHOdd JHL 3AVH LSA NOILLYSININWOD squawaiinbay sng WMHS 1 siu Figure 3 29 Preheat and Supplemental Wiring Diagram 3 21 SECTION 3 INSTALLATION 3 6 3 6 1 A 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 Figure 3 30 Do not kink or pinch fuel line when routing lines You Choose 25 FUEL SYSIEM GENERAL CONSIDERATIONS e Use a dedicated 1 4 ID fuel line between the fuel tank and heater meeting SAE Fuel line length not to exceed 50 with a maximum rise of 10 Ensure fuel lines are routed away from all heat sources well secured and will not abrade e Ensure clamps are secure at fuel pump and fuel pick up e Ensure the proper fuel line clamps with uniform 360 compress
12. INSTALLATION AND SERVICE MANUAL PROHEAT X45 Rev H CONTENTS 2 0 3 0 4 0 SAFET eet A 1 INTRODUCTION eee eee eed 1 MODEL DESCRIPTIONS C 1 TECHNICAL SPECIFICATIONS 1 1 BEPHYSICAL XAB emm 1 2 TZ EEG TRIGA Ke rna uberi 1 4 1 3 TORQUE SFECIFICATION Sraa 1 6 OPERATING YOUR PROHEAT 2 1 INSTALLATION 3 1 LEOCATING THE HEA WER fienda 3 2 1 Select LOCION 3 2 3 1 2 General 3 2 3 1 3 Mounting the Proheat Heater in an Enclosure 3 3 3 2 MOUNTING IHE HEATER ire o ar Lia Ux wd tibl i aUud 3 4 3 2 1 Option A Heater With Enclosure 3 4 3 2 1 Option B Heater Without Enclosure 3 5 SOS EXHAUST PIPE CONNECTION A aus 3 6 3 4 PLUMBING THE SYSTEM hoax bx 3 7 3 4 1 General Considerations 3 7 3 4 2 Option Engine Heat or Supplemental Heat 3 8 3 4 3 Option B Engine and S
13. 020 3 25 Sd FIRST TIME STARTUR 3 26 PRINCIPLES OF OPERATION 4 1 Al GENERAL DESCRIP TIO IN eae to cuta remit 4 1 4 2 MODES OF OPERATION estu tumidi de pe Codi us ds 4 5 4 2 1 Standard Mode All Models 4 5 4 2 2 Preheat Mode Aux Input Models Only 4 6 4 2 3 Supplemental Mode Aux Input Models Only 4 7 5 0 TROUBLESHOOTING amp 5 1 5 0 1 Troubleshooting a 5 1 5 0 2 Example Proheat Behavior Error Code O41 5 2 5 1 OPERATION INDICATORS FUNCTION amp COMPONENT DIAGNOSTICS Lb Cdi m Gd Vierte 5 3 5 1 1 Operation Indicators 5 4 01 2 FUNCTION Diagnostics 152250259 5 5 Ody RESTE 5 5 OZ 5 15 OS GOOlAIE FOW 5 16 MERDA 5 17 OD VOILAS m 5 18 5 1 3 Component 51 5 2 5 lt 5 19 06 lame Ur ot
14. 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 L 31 1 1 1 2 6 8 6 6 154 94155914 6 4 6 2 5 8 21 219 22 225 23 235 24 245 2 25 26 265 0 Operational Coil Voltage V Figure 5 9 24V System Air Pressure Chart 5 10 PROHEAT INSTALLATION amp SERVICE 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 Inspect air line from compressor outlet to fan end inlet for leaks kinks 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 Compressor Adjustment After performing the above checks and the Air Pressure is still outside the range for the measured voltage Adjust the air pressure by turning the screw as shown in Figure 5 10 Altitude Correction is needed above 3000 Feet see inset on charts DO NOT adjust air pressure when above 6000 Feet END VIEW OF ADJUSTMENT SCREW COMPRESSOR DECREASE PRESSURE
15. 185 F 85 C at heater outlet then it will shut off NOTE The vehicle dash temperature gauge may read significantly less 10 11 12 13 14 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 The heater will restart when the coolant temperature falls below 150 F 65 C at heater outlet as long as the ON OFF switch is left ON If the vehicle has been equipped with the sleeper heat option then a Adjust the PROHEAT sleeper thermostat to highest heat position b The sleeper heat exchanger fan will start blowing warm air Switch the ON OFF switch to OFF The red light will go out and the heater will Cool Down Purge for three minutes Inspect the installation again for leaks Install the enclosure cover TO ENSURE FULL WARRANTY COVERAGE COMPLETE THE WARRANTY CARD AND MAIL TO PROHEAT 3 28 PROHEAT INSTALLATION amp SERVICE 4 0 PRINCIPLE OF OPERATION 4 1 GENERAL DESCRIPTION Figure 4 1 Sleeper Fan model shown 1 Fuel Pump 2 Fuel Regulator 3 Air Compressor 4 Ignition Coil 5 Coolant Pump SECTION 4 PRINCIPLE OF OPERATION yy 54 Yok Se 2 PROHEAT G I SOFT CONTROL MODULE Fi SLEEPER Fay M m NM an
16. 20 PROHEAT INSTALLATION amp SERVICE 401 1 abed dO1VOIGNI TVNH3LNI ANY HOLIMS 1V3HOUd NOILdO 3d0IN QHVONVIS HO9LIMSA33 01 LH9I DIOVG TWNOILdO AVG lt gt d3lNIL 1 140 QHVONVIS LOVLNOD AHVLN3INOW HOLIMS 1HVIS o HOLIMS dOLS LYVLS NO LLR8 HSNd 340 ATIVINHON 75 L9YLNO9 AHVLN3INOW 5771 HOLIMS 4018 9 1 NOILdO 1 NO 1V3H38d 1V3HOUd H91IMS AHVLN3INOIN 1 318000 q3831N39 9 45 440 1V3H3Hd 1V3HOUd NOILdO SCOW 1 TWNOIS 3NI9N3 Ave el HOLIMS 3189590 S 9INVHO3IN 3Q0IN TVLN3IN3 19905 eee AlddN 01 IN30 431v3d 1 1 0 Av2 AZL HOLVOIGNI 3LIHM Ave Acl 300IN Qd VQNVIS TVNOIS NO N33H9 aNn089 t INdLNO HAMOd 1 9 dOLVOICNI INdLNO Avc AcL d3MOd 3H Avc AcL 300111 1V3H3Hd 1 9 5 9 L3 AGOW TWLNAWATddNS 1 915 V INdLNO dINV 1 HOIVOIQNI 3LIHM Ave Acl 300IN QHVQNVIS 1VN9IS NO N33 9v 18 KlddfiS 01 WINIA _ HOLIMS 00 666 IIOA VE 1 j
17. 4 Eliminating Fuel Pump and Regulator from system Fuel System Step 2 Check Regulator a Fordamage 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 Start the heater No fuel should be exiting the outlet of the regulator If fuel is leaking from the outlet replace fuel regulator Test Procedure Capped Style a Remove fuel line that goes from the outlet of the regulator to the nozzle b Start the heater No fuel should be exiting the outlet of the regulator If fuel is leaking from the outlet replace the fuel regulator Install clear plastic hose that replaces the hose removed d Start the heater Fuel should start to flow out of the regulator and up to the nozzle If the regulator does not operate as described in d replace the regulator 9 7 A e Apply Loctite 242 to threads Torque bolts 2 to 25 3 in lbs 2 8 0 3 Nm B e Lubricate o ring with diesel fuel e Torque relief valve to 22 2 in lbs 2 5 0 2 Nm C e Apply Loctite 59241 sealant to threads e Torque elbow 1 to 55 5 in lbs 6 2 0 5 Nm minimum or until elbow is at correct orientation 9 0 Fuel System Step 3 Check Vehicle Fuel Supply Fuel Pump a Vehicle fuel level and or for fuel gelling during cold weather b Air leak
18. 5 TROUBLESHOOTING amp REPAIR Symptom Air Compressor running No code indicated Fuse blown in PCM Check 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 Check for seized motor or fuel pump See Figure 5 5 and Figure 5 22 REMOVE FOUR BOLTS AND COVER FOR ACCESS TO THE COMPRESSOR COUNTER WEIGHT BY HAND TO CHECK FOR SEIZED MOTOR OR FUEL PUMP Figure 5 22 Compressor Access Cover An IGNITION COIL 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 coil The fuse will blow if there is a short to ground in the positive lead or the coil The ignition coil is the easiest place to measure the voltage on the heater This component is ground side switched in the PCM Symptom No spark at the electrode code indicated Check Coil wiring a Inspect the wiring harness to ensure the ring terminals are secured to the coil Make sure the polarity is correct b Inspect for broken or abraded wires in the wire harness b Test coil Figure 5 23 c If an IGNITION COIL diagnostic code occurs and no fault is found in the coil and wiring then the PCM must be checked Ignition Coil Electrical Troubleshooting No code Indicated The following material covers the ignition coil mechanic
19. 5 19 Of Temp SellSOl 5 21 OS Fuel EEUU TT 5 23 SS ON bosses petet dua usa us es 5 23 TO TETREIOD COM 5 25 11 600l ant PULTID vs esit ia des Putent Cua oa Ora ded 5 27 T BOW CY 5 30 T3 SleeDer alls 5 32 14 Hour Meter Auxiliary Output 5 33 5 2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS 5 34 5 2 Fuel INOZZIG c E Mss 5 34 22222 Fuel RESUIALO esu do usu m doux Uode into its 5 34 0 23 COMPRIS SOM Sessa scans ote ascen duis 5 34 5 24 EUueb PU Tb E 5 34 22229 5 34 5 2 BO COOlANU PUlTID s 5 34 9 2 xf gt 5 34 5 35 53 OPERATIONAL PROBLEEM 5 37 9 9 1 5moking CXNGUSh sc le ee 5 37 9 9 2 LOW TS aU aes eh aed st 5 37 5 3 3 Engine temperature gauge reads low 5 37 9 3 us teo a i ese ver EOM ate ue 5 37 6 0 MAINTENANCE 6 1 WEEKLY MAINT
20. 5 2 2 Operational problems may not be identified with a flashing diagnostic code e g blown fuse smoking exhaust backfiring or low heat output Go to page 5 34 to page 5 37 TROUBLESHOOTING A PROBLEM Locate the PROHEAT remove the enclosure lid if equipped and visually check for any problems with wiring harnesses fuel leaks coolant leaks exhaust pipe damage and environmental conditions Inspect Proheat Control Module PCM display for error code If PCM display is difficult to view determine the blink code on the switch Timer red manual light or OEM indicator light installation options If no code is indicated turn the PROHEAT off and then on again using the existing operational switches timer or a PROHEAT remote start switch PROHEAT P N 952925 Let the PROHEAT attempt to start and or operate Observe the operation NOTE The PROHEAT will always attempt to start twice as long as the coolant temperature is below 150 F 65 C If a fault is detected it will shut down go through a Cool Down Purge and attempt a second start After both attempts to start or operate the PCM will display a code and the switch Timer red manual light or OEM indicator installation options will blink the same code e After two consecutive start attempts the PROHEAT will not attempt to start again and goes into a hold state In the hold state the switch Timer red manual light or OEM indicator light installation options will blink
21. PCM The Air Compressor and Fuel Pump shut off immediately The Blower and Coolant Pump continue to run After 3 minutes the Blower and Coolant Pump stop and the PROHEAT goes to Supplemental Standby and repeats steps 2 to 7 The ON light and the Heater Indicator turn off after 30 seconds of the signal being removed If the PROHEAT is in the Supplemental Standby or Pre run sequence the PROHEAT will turn off immediately If the PROHEAT is in any other function it will complete a Cool Down Purge function before turning off When switched OFF the Hour Meter Auxiliary Output will shut off NOTE The PROHEAT will Cool Down Purge for 3 reasons e the coolant reaches 185 F 85 C e there is a function or component problem See Troubleshooting amp Repair on page 5 1 e the PROHEAT is operating at Full Output when it is shut off 4 7 4 8 PROHEAT INSTALLATION amp SERVICE 5 0 Troubleshooting and repair is to be performed by Authorized Proheat Dealers 5 0 1 STEP 1 STEP 2 Figure 5 1 Troubleshooting Tools SECTION 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING AND REPAIR Problems with the PROHEAT and its operation will be indicated in two ways 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
22. Timer or ON OFF switch 5 page 3 12 c Sleeper fan model heater connections optional page 3 14 d Auxiliary Input model heater connections optional page 3 18 TO SLEEPER FAN OR AUX INPUT DEPENDING ON MODEL d TO ON OFF SWITCH AND OR TIMER TO BATTERIES Figure 3 18 Major Electrical Connections PROHEAT INSTALLATION amp SERVICE 3 5 2 POWER CONNECTION TO BATTERIES 1 Route wire harness from PCM to the battery Cut the harness to length A CAUTION as required 12 Volt products should not use 2 Strip outer wire jacket of harness back to expose the positive red and power split from a 24 Volt system negative black leads Strip the leads as shown and crimp the ring This will cause uneven charging of tongue terminals supplied to the wires Connect the leads to the battery the batteries terminals See Figure 3 19 3 Leave power harness disconnected See Figure 3 19 Do not install until mn coolant pump system has been purged of air See First Time Systems providing heat to both engine Startup page 3 26 and sleeper require four 4 batteries NOTE When power is connected to the PCM all segments of the LED will flash on the PCM This indicates that power has been supplied See page 5 4 for more information NOTE Ensure the battery terminals are clean and free of corrosion Remo
23. at the heater outlet The PROHEAT shuts the flame off and goes to Cool Down Purge The air compressor and fuel pump shut off immediately The blower and coolant pump continue to run After 3 minutes the blower stops and the PROHEAT goes to Standby The coolant pump circulates the coolant through the system until the temperature drops to 150 F 65 C at the heater outlet The Proheat returns to Precheck and repeats steps 2 to 6 The PROHEAT will continue to repeat this cycle until it is switched off or will switch OFF automatically after 90 minutes If PROHEAT is in Full Output it will Cool Down Purge first then shuts off If PROHEAT is in Standby it shuts off immediately When switched OFF the Hour Meter Auxiliary Output will shut off NOTE The PROHEAT will Cool Down Purge for 3 reasons e the coolant reaches 185 F 85 C e there is a function or component problem See Troubleshooting amp Repair on page 5 1 e the PROHEAT is operating at Full Output when it is shut OFF PROHEAT INSTALLATION amp SERVICE 4 2 3 1 Activate Supplemental Signal for 30 Seconds 2 Supplemental Standby 3 Pre run 4 Pre check 5 Ignition 6 Full Output 7 Purge 8 Remove Supplemental Signal for 30 Seconds There are special OEM versions for Supplemental Mode For example temperature thresholds may have a low threshold of 160 F 71 C rather than 150 F 65 C and a reduced
24. be made to the claimant in the form of repair replacement or credit Warranty labour payments will be made only to Registered PROHEAT Service Centres in accordance with the Standard Repair Times SRT s as published by Proheat Marine Installations The purchaser and installer are advised that specific rules and regulations are in effect with respect to the installation of heaters in marine applications These rules and regulations are enforced by regional and federal agencies and or other agencies having jurisdiction It is the installer s responsibility to review and comply with all such rules and regulations In addition each marine installation must be inspected and approved by an Authorized PROHEAT Dealer Only those installations which are approved and so registered will be eligible for warranty coverage of one 1 year on parts and labour THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY PROHEAT IN REGARD TO THE PROHEAT HEATER SYSTEM PROHEAT MAKES NO OTHER WARRANTIES EXPRESSED OR IMPLIED OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OWNER RESPONSIBILITIES Before the expiration of the warranty Owner must give notice to a Registered PROHEAT Dealer of failures if any considered to be warrantable and deliver the defective heater system to such dealer Owner is responsible for the cost of all repairs made to the engine or equipment in which it is installed other than the PROHEAT Heater system Owner is responsib
25. 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 For example temperature thresholds may have a low threshold of 160 F 71 rather than 1509F 65 C and a reduced coolant pump Pre run time of 30 seconds rather than three minutes Please contact Proheat Technical Support for more information Preheat Mode For those fleets with outdoor parking preheating is often essential in order to start the engine in cold weather Since much of an engine s wear occurs during start up preheating Preheating reduces this wear and contributes to longer engine life and reduced operating costs The Preheat Mode is activated by use of a momentary contact switch This will typically be activated each morning by the maintenance personnel an hour or 50 prior to pull out The Proheat then runs in a mode similar to Standard Heat Mode heating the coolant which is circulated through the engine block The advantage of this system is the manner in which it is switched off No operator input is required The Proheat has a built in time out feature to prevent the heater from running indefinitely If the bus is not needed for pull out the Proheat will switch itself off after 90 minutes of operation Starting the engine will also cause the preheat mode to end if Supplemental mode is wired To manually end preheat mode
26. coolant pump Pre run time of 30 seconds rather than three minutes SECTION 4 PRINCIPLE OF OPERATION 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 The coolant pump operates for 3 minutes to circulate coolant through the system If the coolant temperature rises above 150 F 65 C the pump shuts off and the PROHEAT returns to Supplemental Standby If the coolant temperature remains below 150 F 65 C the PROHEAT goes to Pre check The PCM performs a short diagnostic cycle This takes a few seconds to check components for proper ranges checking for the presence of a flame short circuits and open circuits If there are no errors indicated the PROHEAT goes to Ignition The blower starts first followed by the coolant pump ignition spark air compressor and fuel pump The ignition electrode sparks for 60 seconds Once the flame sensor detects a good flame the PROHEAT goes to Full Output PROHEAT runs at Full Output until the coolant temperature reaches 185 F 85 C at the heater outlet The PROHEAT shuts the flame off and goes to Cool Down Purge Pu is displayed on the Proheat Control Module
27. electrode provides the spark to ignite the fuel and the flame sensor is an optical device which sees the flame 9 9 AIR FILTER gt AIR FLAME SENSOR 1 COMPRESSOR COMPRESSED AIR FUEL PUMP FUEL SUCTION FUEL SUCTION FUEL PICK UP FUEL PRESSURE d 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 b Put this end of fuel into a small container of CLEAN fuel that is about the same level as the regulator centre similarly to Figure 5 4 This will remove the vehicle fuel supply fuel pump and regulator from the fuel delivery b Switch the PROHEAT on and operate for at least 90 seconds Observe the operation If the PROHEAT functions correctly the fault is with the regulator fuel supply or fuel pump Check fuel lines connections and routing back to fuel tank Proceed to Step 2 If a Start diagnostic code is indicated the problem is with the nozzle or compressor fuel system Proceed to Step 4 5 6 PROHEAT INSTALLATION amp SERVICE SECTION 5 TROUBLESHOOTING amp REPAIR PLACE THIS LINE INA CONTAINER OF FUEL MAINTAIN FUEL LEVEL AT CENTRE OF THE REGULATOR REMOVE FUEL LINE FROM REGULATOR Figure 5
28. lt INCREASE PRESSURE ADJUSTMENT ELECTRICAL gt amp SCREW MOTOR FUEL PUMP Figure 5 10 Compressor Fuel Pump Assembly If the air compressor pressure cannot be adjusted back into normal range replace air compressor SECTION 5 TROUBLESHOOTING amp REPAIR 5 11 Fuel Nozzle parts are a matched set and not interchangeable Figure 5 11 Nozzle Number Location DO NOT use cleaner in the fuel orifice Fuel System Step 5 Nozzle a For fuel nozzle and o ring damage and or contamination Check Test Procedure Fuel Nozzle Removal Inspection amp cleaning or replacement a Remove three 3 bolts from the fan end and open up heater b Remove nozzle from fan end Disassemble inspect clean and reassemble Fuel Nozzle Figure 5 12 Fuel Nozzle disassembly inspection cleaning amp reassembly e Hold the Fuel Nozzle stem lightly but firmly in a vise using soft jaws take care not to cause damage Disassembles in three pieces e Inspect Fuel Nozzle stem and O ring for contamination and or damage Inspect and clean distributor fuel orifice a soft bristled brush may be used air passages head and stem with electrical contact cleaner or warm soapy water e Re clamp the Fuel Nozzle stem lightly but firmly in a vise using soft jaws take care not to cause damage Reinstall the distributor and Fuel Nozzle head Ensure that the distributor is seated correctly The Fuel Noz
29. no chaffing or cuts that would provide a compressor motor ground short If internal harness is in good condition replace PCM Spare Compressor Motor is not Available Check Plug connector that normally goes to compressor motor into the blower If the blower does not spin when power is applied this indicates that there is a short in the compressor motor or short in the internal harness Verify root cause by checking Steps and If the blower spins this indicates that there is a fault with the PCM or there is a short in the internal harness Verify root cause by checking Step ii Measure resistance between either pin on the connector going to the motor and the body of the heater If the resistance is not in the mega ohm range replace the compressor fuel pump motor If the resistance is in the mega ohm range go to Step iii iii Inspect internal harness wires going to compressor Ensure that there is no chaffing or cuts that would provide a motor ground short If internal harness is good condition replace PCM 5 24 PROHEAT INSTALLATION amp SERVICE WARNING Disconnect the PCM electrical power prior to trying to turn the compressor counterweight by hand 10 Ignition Coil A WARNING The PROHEAT chassis is grounded from the PCM as shown in Figure 5 14 Ensure the ground is securely connected Failure to ensure a proper ground may result in electrical shock SECTION
30. of the ignition coil and peel it back to expose the positive and negative terminals b Select the DC Volts range of a multimeter and connect as per Figure 5 17 The positive lead of the multimeter should be attached to the positive coil lead The negative lead of the multimeter should be attached to the heater chassis at the PROHEAT ground boss Figure 5 1 7 C Read the voltage with the heater running or trying to run Normal Voltage Ranges 12 Volt heater 10 0 to 15 0 Volts 24 Volt heater 20 0 to 30 0 Volts PROHEAT INSTALLATION amp SERVICE 5 1 3 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 SECTION 5 TROUBLESHOOTING amp REPAIR wy t Figure 5 17 gt Heater Voltage Measurement COMPONENT DIAGNOSTICS Component Faults 6 Flame Sensor 9 Compressor 12 Blower 7 Temp Sensor 10 Ignition Coil 13 Sleeper Fan 8 Fuel Pump 11 Coolant Pump 14 Hour Meter This section covers the individual heater components In many cases there is a corresponding indicator light on the PCM function display The indicator light only indicates an electrical problem NOT a mechanical failure Component problems can also cause Function diagnostic codes A FLAME SENSOR diagnostic code indicates an electrical short circuit in the flame sensor wiring or a flame sensor failure In ad
31. of water Anti freeze will damage painted surfaces Never top up with salt water Even when travelling in territories where the water supply contains salt always ensure you carry a supply of fresh rain or distilled water California Proposition 65 Warning Do not operate heater in garages or in other closed or unventilated areas Diesel exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Electrical components in this product may contain lead a chemical known to the State of California to cause cancer and birth defects and other reproductive harm PROHEAT INSTALLATION amp SERVICE B INTRODUCTION PROHEAT Model X45 EJ PROHEaT ae DO POWER WASH H STARTING This Product Pu Purge Me FHWA Bus Heater Power On Lighy Requirements 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 PROHEAT heaters are used in the following applications 1 Engine Block Heat PROHEAT will preheat an engine block to ensure reliable starting in cold weather At the sam
32. rich air fuel mixture Check a Is the PROHEAT connected to the correct voltage page 5 18 b Is the blower functioning Is the air inlet restricted d Is it a new heater New heaters may smoke for 15 minutes as oil is burned off the exhaust pipe This is normal 15 the compressor functioning page 5 23 Is the exhaust restricted 5 3 2 COMPLAINT Low heat output If the heater appears to be functioning properly but the driver complains of low heat this is often indicative of a coolant flow restriction See section on Coolant Flow page 5 16 5 3 3 COMPLAINT Engine temperature gauge reads low Depending on its location the engine temperature sensor may not be directly in the path of coolant flow from the heater In these cases the gauge may read significantly lower than actual coolant temperature 5 3 4 COMPLAINT Backfiring Backfiring occurs when there is air in the fuel supply lines Check a Fuel level in tank is the pick up submerged b Air leaks are all the fuel line clamps tight c For severely restricted combustion air blockage at the blower inlet in the combustion chamber or in the exhaust system SECTION 5 TROUBLESHOOTING amp REPAIR 5 37 5 38 PROHEAT INSTALLATION amp SERVICE 6 0 6 1 6 2 A higher duty cycle may require a more frequent maintenance schedule i e 2 or 3 times per year SECTION 6 MAINTENANCE MAINTENANCE WEEKLY MAINTENANC
33. simply depress the momentary contact switch Please refer to the wiring diagrams on page 1 4 and page 3 21 Select one of the following wiring options NOTE PROHEAT IS NOT RESPONSIBLE FOR CHANGES IN ELECTRICAL SYSTEMS BY ORIGINAL EQUIPMENT MANUFACTURING COMPANIES Option A Run the PROHEAT in Preheat Mode or Supplemental Mode alone Option B Run the PROHEAT in the Preheat and Supplemental Mode Option C Run the PROHEAT in Standard Mode Proheat Timer optional and using the Supplemental Mode OPTION A Preheat Mode or Supplemental Mode Operation 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 1 Select the operation mode of choice Note that Preheat may be wired as Preheat Option 1 or Preheat Option 2 as shown in Figure 3 29 In addition note to that the engine run signal may be off the alternator multiplex or others Wire the Preheat Mode or Supplemental Mode as shown in Figure 3 29 Install hardware as required on the vehicle 3 Install an Indicator Light near the vehicle operator 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 i
34. states do not indicate a fault 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 This indicates a Mode of Operation see page 4 5 is active A WARNING The ON LED indicates that the heater can start at any time Refer to page 4 5 to page 4 7 The PROHEAT will be in the Cool Down Purge state as defined in the Modes of Operation see page 4 5 when Pu is displayed PROHEAT INSTALLATION amp SERVICE 5 1 2 1 Start SECTION 5 TROUBLESHOOTING amp REPAIR FUNCTION DIAGNOSTICS Function Errors 1 Start 4 Overheat 2 Flame Out 5 Voltage 3 Coolant Flow 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 A START diagnostic code Indicates that the flame sensor did not see a flame during the FULL 60 second ignition period the START diagnostic code is displayed switch the heater OFF and then ON to restart Observe the exhaust and the heater operation through the inspection window Troubleshoot the Flame Out
35. switch or Timer lamp and the PCM ON LED will light In addition the Hour Meter Auxiliary Output will be powered The PROHEAT goes to The PCM performs a short diagnostic cycle This takes few seconds to check components for proper ranges checking for the presence of a flame short circuits and open circuits If there are no errors indicated the PROHEAT goes to Ignition The blower starts first followed by the coolant pump ignition spark air compressor and fuel pump The ignition electrode sparks for 60 seconds Once the flame sensor detects a good flame the PROHEAT goes to Full Output At 60 seconds the sleeper fan output turns on if equipped See page 4 2 for more information The PROHEAT runs at Full Output until the coolant temperature reaches 185 F 85 C at the heater outlet The PROHEAT shuts the flame off and goes to Cool Down Purge Pu is displayed on the Proheat Control Module PCM The air compressor and fuel pump shut off immediately The blower and coolant pump continue to run After 3 minutes the blower stops and the PROHEAT goes to Standby 4 5 6 Standby 7 Switch OFF 4 2 2 1 Activate Preheat Signal 2 Precheck 3 Ignition 4 Full Output 5 Purge 6 Standby 7 After 90 minutes or Switched off 4 6 The coolant pump circulates the coolant through the system until the temperature drops 150 F 65 a
36. 0 TECHNICAL SPECIFICATIONS 0 usaw Nominal Voltage Range FUEL CONSUMPTION Average to Maximum 0 1 0 45 gal hr 0 4 1 7 L hr COOLANT TEMPERATURE at Heater 150 F 185 F 65 C 85 C DIMENSIONS HEATER L x W x H 18 9 x 11 2 x 10 6 inches 520 x 320 x 280 mm DIMENSIONS ENCLOSURE Lx W xH 20 2 x 12 3 x 10 5 inches 513 x 313 x 267 mm WARRANTY Two years parts and labor FUEL TYPES DO NOT Diesel ULSD 1 2 Arctic JP8 Jet A1 use gasoline Bio Fuels Contact Proheat www proheat com 4 DANGER SYSTEM OUTPUTS HOUR METER Same as System Voltage AUXILIARY OUTPUT Maximum 1 Amp draw over load shut off protection High side switched SWITCH TIMER Same as System Voltage POWER Maximum 1 Amp draw over load shut off protection High side switched SLEEPER FAN Same as System Voltage Certain Models Only Maximum 3 Amp draw over load shut off protection High side switched INDICATOR LIGHT Same as System Voltage Maximum 1 Amp draw over load shut off protection High side switched SYSTEM INPUTS SWITCH 10 15 VDC 12V X45 20 VDC 24V X45 Standard Run Mode Preheat Run Mode Certain Models Only Supplemental Certain Models Only SECTION 1 TECHNICAL SPECIFICATIONS 1 1 1 1 PHYSICAL X45 1 X45 HEATER 1 1 LNOHJ mE 3966 1331 3SOH 61 v e MJA 3GIS LHOIH ei 62 6 84 SON 33S 31v1d ONILNNOW
37. 00 50 in lbs 5645 6 Nm TEMPERATURE SENSOR e Lubricate o ring with o ring lubricant e Torque senor 25 3 in Ibs 2 8 0 3 Nm AIR FILTER e Torque cap screw to 50 5 in Ibs 5 6 0 6 Nm BLOWER ASSEMBLY e Apply anti seize to bolts 4 e Torque bolts 4 to 25 3 in Ibs 2 8 0 3 Nm PROHEAT CONTROL MODULE PCM e Apply anti seize to bolts 3 e Torque bolts 3 to 75 7 in Ibs 8 5 0 8 Nm SECTION 1 TECHNICAL SPECIFICATIONS 1 7 Wyo uec Hoe x ON E in 9 MAIN INTERNAL HARNESS e Torque bolt 1 to 10 2 in lbs 1 1 0 2 e Lubricate o ring on nozzle with diesel 5 Torque nozzle to 150 10 in Ibs 1741 1 Nm NOZZLE REASSEMBLY Torque nozzle 1 to 3023 in lbs 3 4 0 3 Nm lt e NOZZLE TO END BAND CLAMPS e Torque clamps 4 to 25 3 in lbs 2 8 0 3 Nm ENCLOSURE LID Optional e Anti seize recommended on bolts e Torque clamps 2 to 30 3 in lbs 3 43 4 Nm 1 8 PROHEAT INSTALLATION amp SERVICE SECTION 1 TECHNICAL SPECIFICATIONS HARNESS GROUND LUG e Apply anti seize to bolt e Torque bolt 1 to 75 5 in lbs 8 5 0 5 Nm FUEL PUMP ASSEMBLY A e Apply Loctite 242 to threads e Torque bolts 2 to 25 3 in Ibs 2 8 0 3 Nm B e Lubricate o ring with diesel fuel e Torque relief valve to 22 2 in lbs 2 5 0 2 Nm C e Apply Loctite 59241 sealant to threads e Torque elbow
38. 1 to 55 5 in lbs 6 2 0 5 Nm minimum or until elbow is at correct orientation FUEL FILTER e Lubricate o ring with diesel fuel e Torque nut 1 to 15010 in lbs 17 1 1 Nm 1 9 1 10 PROHEAT INSTALLATION amp SERVICE 2 0 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 Regular use of your PROHEAT throughout the year will improve its reliability Weekly operation is recommended The PROHEAT heater can be operated by either using a toggle switch or a 7 day timer Refer to page 3 10 for WIRING amp ELECTRICAL CONNECTIONS SECTION 2 OPERATING YOUR PROHEAT HEATER OPERATING YOUR PROHEAT HEATER ENGINE HEAT ONLY 1 Switch the ON OFF switch located in the vehicle dash to ON The switch will light and the heater will cycle on It will continue to operate until the coolant reaches 185 85 C at the heater outlet and then cycle OFF When the coolant temperature falls below 150 65 at the heater outlet it will refire and repeat the cycle It will continue to cycle until a the heater is switched OFF the heater runs out of fuel the vehicle battery voltage drops below 10 0 Volts or an error occurs and the switch light flashes See Troubleshooting amp Repair Section 5 NOTE The PROHEAT may be operated if the engine is running or
39. 95 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 No 6 Road Richmond B C CanadaV6V1P6 Tel 604 270 6899 Web www proheat com SERVICE BULLETIN Copy Part 5 0062 Rev A 09 2011 5 Install test gauge on fuel pump outlet Calibrate gauge before each use see www proheat com PDFs 990614 pdf for more information 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 Be careful lose any of the internal components that may fall out RELIEF VALVE ASSEMBLY BALL BEARING BRASS BALL CAP GUIDE O RING SPRING Figure D 1995 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 No 6 Road Richmond B C Canada V6V1P6 Tel 604 270 6899 Web www proheat com SERVICE BULLETIN Copy Part SBOO62 Rev A 09 2011 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 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 The edge of the hole should be smooth
40. ALLATION amp SERVICE Sleeper Fan Output or Auxiliary Input Identification BLAIS S fA V AF A oo d FN 1 SECTION MODEL DESCRIPTIONS MODEL DESCRIPTIONS 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 The following information describes the three general characteristics of X45 models covered in this manual voltage enclosure and Proheat Control Module PCM options PROHEAT CONTROL MODULE PCM SLEEPER FAN OUTPUT OR AUXILIARY INPUT The PCM comes in either a sleeper fan output or auxiliary input model The sleeper fan model is limited to a 3 amp output and is generally installed on trucks that require sleeper fan power it is only available on 12 V models The Auxiliary Input model uses two special input pins that allow for a Preheat Mode and Supplemental Mode This operation is typically used for transit and coach installation Refer to page 4 2 for more information VOLTAGE CONFIGURATION 12 V OR 24 V The X45 is available in either a 12 V or 24 V models ENCLOSURE An optional enclosure provides environmental protection C 1 C 2 PROHEAT INSTALLATION amp SERVICE 1
41. E Run the heater a minimum once a week to keep new fuel in the heater s critical components 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 TUNE UP is strongly recommended to be performed each year Proper maintenance will result in the following benefits Maximum heat transfer to the coolant e Minimum battery power draw e Long term cost savings e Increased reliability Check the system annually before each heating season There are several maintenance procedures you can perform to keep your heater in service Read this section of the manual carefully Always return to your Authorized PROHEAT Dealer for major maintenance Your PROHEAT Dealer has the specialized equipment necessary to keep your PROHEAT in new condition Figure 6 1 PROHEAT X45 Heater 6 1 6 2 1 CLEAN HEATER ENCLOSURE AND AIR INTAKE e Remove the heater enclosure cover e Clean any accumulated debris or dust from the components e Blow out the compartment with compressed air A WARNING met eee MN Check the combustion air inlet screen for restrictions Clean as required DO NOT pressure wash or steam clean e Make sure the opening around the exhaust pipe is clear e Visually inspect all the components for wear or damage e Clean the X45 Heater using the following procedure 1 Protect yourself from burns a
42. ENANCE 6 1 6 2 ANNUAL MAINTENANCE to c n 6 1 6 2 1 Clean Heater Enclosure and Air Intake 6 2 0 2 2 Check Exhaust SYSTEM 6 3 6 2 3 Check 6 3 6 24 Clean Flame Sensi sever aise ded ed ERE 6 4 6 2 5 Check Cooling 6 4 6 2 6 Check a a 6 4 2 Check 6 5 6 2 9 Fuel FIET 6 5 6 2 9 Clean NOZZE ds duree usen ated 6 6 6 2 10 Replace Compressor Air Filter 6 6 6 2 11 Check Electrical System 6 7 6 2312 CheckK AIF PIeSSUTG i oues e Co 6 8 6 2 13 Check Modes of Operation Switch Timer or OEM Signals 6 8 2 0 APPENDICES 7 1 Bulletins 951528 967329 5 4 5 0062 5 0 WARRANTY 8 1 PROHEAT INSTALLATION amp SERVICE SECTION A SAFETY 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 ca
43. ER SET 4 TIME gt DAY BUTTON CD CO mt CLOCK TIMER ID LIGHT GREEN CLOCK Day Timer PROHEAT INSTALLATION amp SERVICE 4 2 4 2 1 1 Switch ON Standard Mode Signal 2 Precheck 3 Ignition 4 Full Output 5 Purge SECTION 4 PRINCIPLE OF OPERATION 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 The following table defines the applicability Operational Mode Sleeper Fan Model Aux Input Model Standard Yes Yes Preheat no Yes Supplemental no Yes Aux Input Operation Mode Summary See page 3 18 for background information Standard Heat Mode Supplemental Heat Mode Preheat Mode normal operation of the e similar to standard mode similar to standard Proheat except coolant pump mode Except 90 minute e over rides and drops out does not run when time out preheat mode Proheat is not firing activated via momentary overrides supplemental overrides and drops out contact push button mode preheat mode switch with latching e 30 second signal required internal to the PCM before mode enabled e 30 second signal removal before mode shut off STANDARD MODE All Models The ON OFF
44. FF instantly shutting the heater down It cannot be restarted until the breaker is manually reset To reset the breaker remove the rubber cap covering the top of the overheat breaker and press the red reset button on top If the breaker will not reset allow the heater to cool Test Procedure a Connect a multimeter adjusted to measure resistance to the overheat breaker connector Figure 5 16 The sensor should be normally closed If the sensor has tripped the circuit should be open POLARITY NOT IMPORTANT A CAUTION RED RESET BUTTON PLUNGER Do not reset the Overheat breaker SPRING until the cause of the overheat condition has been determined Figure 5 16 Overheat Sensor Test SECTION 5 TROUBLESHOOTING amp REPAIR 5 17 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 Vehicle Voltage a Heater voltage must be within the specified range See following page for procedure to measure heater voltage NOTE Bad connections may show good voltage under no load conditions but not under full load With the heater OFF measure the voltage Then switch the heater ON and measure the voltage again If the voltage drop is more than one Volt check the vehicle battery connections harness and the power connection at the PCM b If the measured v
45. FF Switch to a Timer Connecting an ON OFF Switch and a Timer in the same circuit will cause the indicator light to flash incorrectly 3 5 5 These instructions require a Sleeper Fan model For more information see page 4 2 You Choose 25 Sleeper Fan output does not supply power during ignition 1 minute after switch ON DO NOT use for controlling coolant valves See page 4 5 for operational sequence information The Hour Meter Auxiliary Output may be used to control supplemental relays to turn on coolant valves If additional installation information is required please contact your PROHEAT Dealer or Product Support at www proheat com 3 5 6 SLEEPER FAN MODEL HEATER WIRING DETAILS These installation options allow the operator to 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 NOTE PROHEAT IS NOT RESPONSIBLE FOR CHANGES IN SLEEPER FAN SYSTEMS BY ORIGINAL EQUIPMENT MANUFACTURING COMPANIES Due to the wide variety of wiring schematics that exist we emphasize that if you are in any doubt you should contact your dealer or PROHEAT Product Support at www proheat com Option A Used when climate control systems in sleepers require one or more of the following features to be controlled 1 Normal OEM fan speed selection 2 A separate thermostat is required to turn the sleeper f
46. Figure 1 1 PROHEAT INSTALLATION amp SERVICE 1 2 1 1 22 X45 WITH ENCLOSURE MJA MAIA LNOHH 1331 H3AOO H3JAOO AYNSOTONA SYNSOTONS 292 9 01 MEN ELE EZL ers 202 GSAOWSY Q3AON3H MIA SLON 33S ACIS LH9IH 3916 1431 NOLLO3NNOO Q3AON3H AlddNs Tana LNOHJ soe 061 021 Xe 98 XZ 46 912 9 8 usc 01 z92 3SOH 64 v SIRE NOLSHENOD E NOILSNENOD 61 v e Q3AOIN3H HO SI NOLLO3NNOO 131160 1 3OvdS SIHL Qa laWassv 908 O Z 39ILON LNOHLIM 39NVHO OL ANV AINO S3SOdufid 3ON3H3HHH SNOISN3INIG NOIIVOIAILLN3GI H38INCQN 070618 MOO SVX OL Y34434 1 SALON 80s 0 02 Heater Dimensions including Enclosure X45 Figure 1 2 1 3 SECTION 1 TECHNICAL SPECIFICATIONS 1 2 ELECTRICAL X45 LON 9 AH3aLIVa MOVE AN LISOd LHYd INdLNO AvZ AcE HOLVOIGNI SLIHM SS3NHVH HOJ 1 Q
47. HYONVLS IVNDIS NO N33H9 1 33S C INdLNO H3MOd LNdLNO Ave Acl H3MOd Qaa GQNNOWD t V TIVL3G 335 4 ZEZSH SNENVO NOILVOINRININOO Gd V LJ 4 2 9 ev V V eg SS3NHVH TVNH3LNI ev H31V3H Gd O uoiMs V V lt 15 ig a u3da1s lv V ed eee 10 336 NMOHS WOd H3d331S 310N 338 NOLLdO LAdNI AAIBOAY 1 NVO SHAEWAN LHYd LINSNVUL SS3NHVH HOS 5 NYO H NVO ty ee ee 3 3uHWN33HO 01 VE AYVITIXNV H3 L3IN NMOHE 8 HOSN3S AVHD v NMOHS V SEHE IPIS 3L1IHWMOv1aC HOSN3S SLIHM Y SLIHM 1 1002 3019 v i d v v 105 3aoulog 3 NOLLINDI NOL
48. LSnHINOO Ndu5pOViO VIA L a GNNOYD sISVHO H31V3H vol 44 3LON 33S 3snd 9 8 8 xNIdC V SS3NHVH SLON 335 SOM HOLO3NNOO 40 NOLIVLN3IHO ALON HOS 020615 MOO LYVd SVX OL H333U SALON LINdNI SGOW IV3H3Hd IVNOIS NO AYVITIXNV Av Acl SGOW IWLNSAWSIddNsS 5 NO MC J MNid V HOSN3S 1V3HH3AO 31ON 338 HOLIMS TWNOILdO LNO HOLO3NNOO 81 C LLI LL mo SS3NHVH IWNYALNI H311V3H SYOLVNOISAG TVNIINH3 L HOLO3NNOO Wiring Diagram X45 Figure 1 3 PROHEAT INSTALLATION amp SERVICE 14 SLON 335 NOILLVOIAILLN3GI H38IAFN LH Vd H3TIOH LNOO 9 5 QNV 001666 N Id ZL q MOd NOLIVOINIWWOD 90 0 eas pL 0 0 v n Pooma Nid 81 HOLIMS HOLM sno SSSNHYVH dung jon4 80 Pede imanoanes
49. ND ON HEAT EXCHANGER PIN LOCATIONS MOLDED INTO CONNECTOR HARNESS TO F COMPONENTS E COOLANT PUMP Figure 5 27 Internal Wire Harness Test Check for correct battery polarity Fuse Blown Test Procedure with Power Connected and PROHEAT Switched OFF NOTE Ensure positive wire from the PCM to the ignition coil does not ground Disconnect from PCM e Internal Wire Harness 18 Pin Connector e Switch Harness A short circuit in the sleeper fan outlet and hour meter Replace Fuse auxiliary output harness 15 amp only will not blow the fuse An error will be indicated on Yes Replace PCM the PCM This will not shut the heater down No Reconnect Internal Wire Harness 18 Pin Connector Disconnect all components from Reconnect Switch Harness Internal Wire Harness 10 Connections See NOTE Check Switch Harness and Connections for Short Circuit Replace Internal Harness OK Wire Harness Reconnect Components One atatime Check Component as per Component OK Troubleshooting Guide Figure 5 28 Blown Fuse Test Procedure Flow Chart 5 36 PROHEAT INSTALLATION amp SERVICE 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
50. O53 2 download cable and software will not work with the 1 controller 3 New 2x7 Segment LED e he 2x segment LED provides improved communication of operational states and error messages e Figure 2 Original G II PCM display with single LED lamps and new 111 PCM display with 2x segment LEDs OLD PCM DISPLAY NEW PCM DISPLAY ON START FLAME OUT COOLANT FLOW OVERHEAT VOLTAGE FUNCTION DIAGNOSTICS FLAME SENSOR TEMP SENSOR COMPONENT FUEL PUMP DIAGNOSTICS COMPRESSOR IGNITION COIL COOLANT PUMP BLOWER SLEEPER FAN Figure 2 Comparison of the original G Il PCM to the new 6 11 PCM display e Figure 3 Original G II PCM code numbers still apply For example Diagnostic Code LED associated with 12 Blower on the original PCM display will light up as the number 12 on the new display In addition the G II controller indicator switch lamp will blink 12 times like the G II controller does e Figure 3 Also illustrated is the ON indicator meaning the heater is powered in the normal or standby state and Pu indicator showing the heater is in the Cool Down Purge state e X45 ONLY A new error code 14 has been added to indicate a short circuit on the hour meter auxiliary output harness For this error code the indicator switch lamp will blink 14 times as well 2009 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 No 6 Road Richmond B C Canada V6V 1 6 Tel 604 270 6899 Web www proheat com
51. SLEEPER HEATER gt FAN OEM SLEEPER ASSEMBLY HEATER ASSEMBLY Figure 3 26 Isolator Detail HEATER PROHEAT PROHEAT THERMOSTAT SEE WIRE BLACK WIRE CONNECTION NOT USED DETAIL SLEEPER FAN FAN MOTOR HARNESS SINGLE WINDING TYPE Figure 3 27 Thermostat Detail Figure 3 28 Option D SECTION 3 INSTALLATION 3 17 3 5 10 These instructions require a Auxiliary Input model For more information see page 4 2 The Preheat and Supplemental modes are generally used by transit and coach applications Supplemental operation will not override the Standard Mode operation Proheat Timer runs in Standard Mode The PROHEAT must have coolant flowing through it when it is monitoring temperature 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 In addition to the Standard Operating Mode there are two other operating modes Preheat and Supplemental One operating mode is for one button preheating the engine and the second is for supplemental heat while the vehicle is being operated The benefits include easier operation for the driver simplified installation eliminates need for extra control relays and increases reliability by reducing unnecessary hea
52. The PROHEAT PCM sleeper fan circuit has one minute delay during ignition gt Power to open a sleeper fan coolant valve must be taken from another SUPPLY TO PROHEAT ENGINE source such as the wire for the hour meter auxiliary output See PROHEAT Wiring Diagram on page 1 4 gt 3 gt 3 lt 8 pag Figure 3 16 Engine and Sleeper Heat SECTION 3 INSTALLATION 3 9 KO 3 5 1 Figure 3 17 Test Battery A WARNING Do not use on positive ground vehicles A CAUTION If repairs to the vehicle require welding disconnect the PROHEAT power cable at the PCM This will prevent damage to the PROHEAT electronics A CAUTION Vehicles using ground side battery disconnect switches must install an in line 10 Amp fuse on the internal harness Proheat part PK0310 This will prevent damage to the harness and PCM refer to Service Bulletin 58000 in Appendix 3 10 WIRING amp ELECTRICAL CONNECTIONS GENERAL CONSIDERATIONS e Prior to installation of the PROHEAT Heater system ensure that the vehicle batteries are in good condition e Do not kink or abrade wires when routing them through the vehicle during installation e Ensure wires are well supported and secured with tie wraps e Do not use acid core solder when making solder connections Major Electrical Connections Required a Power connection to batteries page 3 11 b
53. ain coolant supply line from the radiator to engine pump the return line must be moved to avoid loss of heat through the radiator ENGINE ENGINE RETURN TO ENGINE RETURN TO ENGINE PROFEAT PROFEAT SUPPLY TO PROHEAT SUPPLY TO PROHEAT Figure 3 14 Correct Return Line Plumbing 3 8 PROHEAT INSTALLATION amp SERVICE 3 4 3 OPTION B Engine and Sleeper Heat For best results these vehicles s OEM OR AUXILIARY should use an auxiliary heater SLEEPER HEATER International with single heater 1 SOLENOID VALVE 7 Ly FEURN TO Enone O OEM COMBO HEATERS ONLY NORMALLY OPEN SUPPLY PROHEAT ENGINE Figure 3 15 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 Typically this valve is normally open with the truck engine turned off and the key removed See Figure 3 16 for plumbing Due to the many options available in vehicle heating and air conditioning systems the installer should be looking for any restrictions that may affect coolant flow with vehicle ignition in the OFF position For vehicles with solenoid valves SLEEPER HEATER DASH HEATER in the normally closed position SOLENOID VALVE NORMALLY CLOSED Western Star I ae E E RETURN TO ENGINE l SS
54. al 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 b Inspect the ground lead between the second electrode and the heater chassis c Is the electrode gap adjusted correctly See page 5 13 for Electrode Gap Detail Test Procedure a Measure ignition coil resistance Use a multimeter to measure the resistance across the positive and negative terminals The resistance should be less than 1 ohm If resistance is open circuit or O ohms short circuit then replace the ignition coil NOTE Remove positive and negative wires from the coil when testing ION f 2E X G9 2245 23 Q 95s SO Figure 5 23 Ignition Coil Test PROHEAT INSTALLATION amp SERVICE 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 follo
55. amaged replace o Remove three 3 bolts from the fan end and open up heater Check the electrode for carbon buildup and clean as required Check electrode gap as per Figure 5 13 Reinstall fan end and torque three 3 bolts to 75 5 in Ibs 8 5 0 5 Nm Qa COMBUSTOR TUBE N gt 1 4 9 32 Figure 5 13 Electrode Gap Detail 3 S GROUND WIRE FROM PCM Ss i 5 GEI SERDUNDEDSS P abis Figure 5 14 PROHEAT Ground Boss Flame Sensor Check Flame Sensor a Flame sensor operation Test Procedure Flame Sensor Circuit TES a Check cleanliness of the flame sensor If the lens is dirty the sensor does not properly see the flame 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 iii Hold up known good Flame Sensor to Inspection Port iv Start heater with the known good flame sensor held to Inspection Port If heater runs for at least 90 seconds with the known good flame sensor replace flame sensor as it is faulty Spare Flame Sensor Not Available Check i Ensure unit is powered off Disconnect flame sensor ii Shine incandescent flashlight directly at sensor iii Start heater with a flashlight shined directly at the sensor iv Code 6 should be displayed immediately on st
56. amp Exhaust Hole SECTION 3 INSTALLATION 3 5 22 If additional information is required please contact your PROHEAT Dealer regarding your specific application Alternatively please contact PROHEAT Product Support at www proheat com A WARNING Exhaust gases must not enter the vehicle interior Direct exhaust pipe away from vehicle Use of muffler or other restrictions in the exhaust system is not recommended 3 6 EXHAUST PIPE CONNECTION 4 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 14 38 mm Route the exhaust pipe such that e exhaust gasses do not enter the passenger compartment e exhaust gasses do not enter the heater s combustion air inlet e exhaust system does not rest against or be directed toward any parts of the vehicle that may be damaged by heat i e brake lines seals wires rubber hoses or bumpers The exhaust pipe may be have to be insulated if it s within 6 of combustible materials or composite body parts e the exhaust outlet does not face the same direction as vehicle travel e debris and snow will not plug the outlet e the exhaust pipe is protected from curb damage e the exhaust system should have a downwards slope for condensation to drain If needed a 3 8 hole should be drilled into the exhaust pipe at the lowest point so that the condensation will drain Disassemble the ex
57. an motor ON and OFF because the OEM system uses a constant running fan 3 A valve in the sleeper heater coolant line regulates the flow and must be fully opened when the PROHEAT is running 4 Prevent possible back feeding on ground side switched systems Option B Used in larger sleepers requiring greater fan speed to provide sufficient air movement to the sleeper This allows the driver to select the fan speed Option C Used when a dedicated auxiliary heater is required Option D Limits the power provided to the sleeper fan motor to 3 Amps With this system the total electrical draw is controlled by PROHEAT NOTE For larger systems in the latest model trucks this may not provide enough fan speed and therefore Option A B or C should be used OPTION A OEM Heater amp Proheat Thermostat Please go to www proheat com for equipment specific installation instructions PROHEAT INSTALLATION amp SERVICE 3 5 7 OPTION B OEM Heater amp Thermostat SECTION 3 INSTALLATION 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 NOTE The c
58. arness Next check the controller by measuring for continuity between pin C3 on the controller 18 pin connector and pin B at the power harness connector See Figure 2 If the fuel pump did not run in step 2 refer to Fuel Pump Start error and Flame Out error in the troubleshooting section of the Service Manual Install a 10 amp in line fuse on the ground wire black with green stripe of the Proheat harness Proheat Part PKO310 Ensure that the Proheat exhaust pipe does not contact vehicle chassis If possible rewire the disconnect switch to the positive side of the battery 1995 Marine Canada Acquisition Inc SEASTAR SOLUTIONS 3831 No 6 Road Richmond B C Canada V6V 1 6 Tel 604 270 6899 Web www proheat com SERVICE BULLETIN Copy Part SBOOOS Rev A 06 1995 GROUND RING TERMINAL BLACK WITH GREEN STRIPE END VIEW FIGURE 1 SLEEPER FAN POWER 12V 24V 3 AMP LIMIT GROUND SWITCH OUTPUT POWER 12V 24V OUTPUT GROUND ON SIGNAL TO HEATER INDICATOR 12V 24VOLTS POWER POWER 12V 24V IMPUT GROUND NOT USED FIGURE 2 1995 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 No 6 Road Richmond B C Canada V6V1P6 Tel 604 270 6899 Web www proheat com PRODUCT UPDATE BULLETIN Part PBOO34 Rev B 04 2009 Introducing Control Module PCM for X45 and XL series Heaters Part Numbers Application Discontinued Replacemen
59. art up DO NOT use an LED flashlight Only an incandescent flashlight will check the sensor operation If Code 6 does not display immediately on start up replace flame sensor as it is faulty 5 14 PROHEAT INSTALLATION amp SERVICE 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 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 d If the flame is not detected within 10 seconds the Flame Out diagnostic code is displayed e The PROHEAT goes into Cool Down Purge mode and attempts to restart after Cool Down Purge is complete A Flame Out diagnostic code distinguishes that a A flame was detected therefore there was a spark and the Ignition system works b The flame was detected therefore the Flame Sensor works c The fault is in the fuel supply system d The Flame Sensor could be dirty Troubleshoot the Flame Out diagnostic code based on 1 Fuel supply to the PROHEAT Go to page 5 6 and perform Fuel Systems Steps 1 to 5 e Fuel tank pick up e Fuel fittings e Fuel lines e OEM supplied filters and check valves 2 PROHEAT fuel and flame detection system G
60. at at 604 270 6899 8 1 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 N o cs e ios Designed and Manufactured 4 in North Ameri 50 9001 Printed in Canada 07 13 PID 925830H QMI SAI Global
61. at 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 Symptom Hour Meter Auxiliary Output Electrical Load not Operating code indicated Check Hour Meter Auxiliary Output Electrical Load a The wiring connections and polarity b For an electrical short from the positive wire to the negative wire For an electrical short from the positive wire to the chassis Test electrical load See Test Procedure Hour Meter Troubleshooting No code Indicated The following material covers the Hour Meter Auxiliary Output electrical problems that do not indicate a Code 14 Note that the Hour Meter Auxiliary Output is high side switched Symptom Hour Meter Auxiliary Output Electrical Load not Operating no code indicated Check Hour Meter Auxiliary Output Electrical Load a The wiring connections and polarity b Test electrical load See Test Procedure Test Procedure a Disconnect load circuit to hour meter auxiliary output harness and start heater If error goes away check for short circuits in the load circuit b Restart the PROHEAT If there is still an error disconnect the 18 pin internal harness and restart the PROHEAT again If code 14 is still present replace PCM Check for correct voltage 12 V 9 14 V 24 V 19 30 V the hour meter auxiliary output harness d Reconnect h
62. ce TORQUE TO as necessary 150210 IN LBS 1721 1 Nm Figure 6 8 Fuel Filter Components SECTION 6 MAINTENANCE 6 5 6 2 9 CLEAN NOZZLE e Remove and install Nozzle as shown on page 5 12 Torque to 150 10 in lbs 1741 1 Nm e To properly clean the nozzle use electrical E contact cleaner or warm soapy water UPRIGHT TO This will wash any dirt out and leave ASSEMBLE 7 residue When using compressed air blow into the nozzle orifice qv from the head end TORQUE TO 6 30 3 IN LBS 3 4 0 3 Nm BLOW THIS DIRECTION WHEN USING COMPRESSED AIR Figure 6 9 Nozzle Components 6 2 10 REPLACE COMPRESSOR AIR FILTER a 8 6 6 e Replace inlet air filter annually or more often if dusty conditions are encountered TORQUE TO 50 5 IN LBS 5 60 7 Nm Figure 6 10 Compressor Air Filter PROHEAT INSTALLATION amp SERVICE 6 2 11 CHECK ELECTRICAL SYSTEM e Check the internal and the external wire harnesses for damage Replace if required e Service the X45 Ignition Lead and Ignition Coil by following the steps listed 4 CAUTION Sin Ensure that power is disconnected 1 Annually or better inspect the ignition lead and the boots on both ends to the X 45 prior to servicing the Replace the entire lead with new lead p n 930523 if the lead itself or Ignition Lead boots are coated with oil torn cracked or brittle 2 Ensure that the electrical connections are clean and tight 3 Ensu
63. crews provided Figure 3 27 5 Route sleeper fan harness from PCM to PROHEAT thermostat Cut to length Connect white wire to terminal 1 of the thermostat using the fork terminal provided Black wire is not used 6 Route a wire from terminal 2 of the thermostat to an appropriate wire on the sleeper fan motor Make a splice connection and seal the splice with tape or heat shrink NOTE The electrical power and operation in this option is controlled by the PROHEAT See Option B should a relay be required to provide more electrical power A WARNING Thermostat Wire Connection Detail Systems using a ground side Screw Wire Colour battery disconnect must install White from PCM a 10 Amp fuse to protect the White to sleeper heater sleeper fan harness Not used Not used SLEEPER FAN HARNESS THERMOSTAT AUXILIARY 10 AMP EN SLEEPER HEATER N FUSE ug SPLICE WIRES GROUND FAN MOTOR MULTIPLE WINDING TYPE ber RED NOT USED Figure 3 24 Option 3 16 PROHEAT INSTALLATION amp SERVICE 3 5 9 OPTION D Auxiliary Sleeper Heater Current Limited 1 Make sure the vehicle ignition is switched OFF 2 Mount the isolator in the sleeper fan motor area to a solid metal surface Sleeper Fan output does not supply with the screw provided Cut OEM wire to sleeper fan motor and connect power during ignition 1 minutes after switch ON DO NOT use for controlling isolator in
64. ct air compressor directly to a power source of the rated voltage 12 24 Volts and see if the motor runs If not replace the compressor b Measure air compressor motor resistance Use a multimeter to measure the resistance across the compressor connector pins If resistance shows an open or short circuit replace the compressor assembly C Measure air compressor current Use test lead part 967921K as described on Service Bulletin 967329 in the Appendix PRESSURE ADJUSTING SCREW Figure 5 21 Compressor Test CURRENT DRAW Amps 3 50 5 00 12 Volts 1 50 3 00 24 Volts SECTION 5 TROUBLESHOOTING amp REPAIR 5 23 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 b To check motor condition Spare Compressor Motor is Available Check Connect spare motor to internal harness and apply power to heater If spare motor does not run replace compressor fuel pump motor If the spare motor still runs ii Inspect internal harness wires going to compressor Ensure that there is
65. diagnostic code based on 1 Fuel System Go to page 5 6 to page 5 12 Steps 1 to 5 e There is no fuel fuel odor or atomized fuel coming from the exhaust pipe e There is no hot exhaust coming from the exhaust pipe e There is no flame visible through the inspection window 2 Ignition System e There is raw fuel and or atomized fuel and a raw fuel odor coming from the exhaust pipe Go to page 5 13 e There is no hot exhaust coming from the exhaust pipe e There is no flame visible through the inspection window 3 Flame Sensor Go to page 5 14 e There is a flame and the combustion sounds good the PROHEAT appears to be operating normally No smoke raw fuel odor or atomized fuel is coming from the exhaust pipe Fuel System Schematic The PROHEAT X45 fuel system operates on a venturi style atomizing nozzle technology It operates similarly to a compressed air paint sprayer As shown in Figure 5 3 when the compressor fuel pump motor is on fuel is drawn from the tank through the fuel pump and pressurizes the high pressure side of the fuel regulator The fuel regulator reduces the fuel pressure supplied by the fuel pump to atmospheric pressure Compressed air flowing through the nozzle creates a venturi or suction effect which siphons fuel from the regulator If the compressed air flow through the nozzle stops the regulator closes shutting off the fuel flow Also shown in Figure 5 3 is the electrode and the flame sensor The
66. dition it can also indicate in rare cases the flame sensor detected a flame during pre check see Modes of Operation Section It will not indicate an open circuit The flame sensor is an optical device which sees the flame If the sensor lens is dirty or has an open circuit it can not see the flame and results in either a START or a FLAME OUT diagnostic code to display Check Flame Sensor a Inspect the flame sensor wiring for a short circuit b Inspect the flame sensor lens for cleanliness C Test the flame sensor See following page for flowchart Figure 5 18 Flame Sensor Test Procedure Yes Stop Unit Disconnect Sensor Start Unit Is there a Flame Sensor Code Yes Check Main Harness for a Short Circuit Replace if necessary Try with New Replace if necessary Sensor Figure 5 18 Flame Sensor Test Procedure Flow Chart 9 20 Start Unit Check Flame Quality Yes cil Yes Is there a Flame Sensor Code NO Is there a Flame After 60 Seconds is there a Start Code NO Is there a Spark Disconnect Old Sensor Connect Test Sensor Hold up to Inspection Port Restart Check Fuel System page 5 6 Check Ignition System page 5 13 1 Check main Harness Yes for Open Circuit Replace if necessary After 60 Seconds is there a Start Code 2 Try with New PCM Replace if nece
67. ds are required for troubleshooting Parts 96 921K Test Lead 952925K Remote On Off switch Instructions 1 Test Lead 96 7921K is used for measuring voltage resistance continuity or amperage and can be used on all components except for the blower Direct voltage can be applied to the compressor and water pump by wiring from a remote power source to the spade connections 2 he 952925K Remote On Off switch allows the service technician to plug into the heater at the switch input of the PCM This allows the heater to be turned On Off at the unit Copy Part 967329 Rev A 05 1994 USE SPADE CONNECTORS TO TEST VOLTAGE RESISTANCE OR CONTINUITY USED IN SERIES TO READ AMP 1994 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 No 6 Road Richmond B C Canada V6V 1P6 SERVICE BULLETIN Page 1 of 1 FIGURE 1 REMOTE ON OFF SWITCH 952925K Tel 604 270 6899 Web www proheat com 7 6 PROHEAT INSTALLATION amp SERVICE SERVICE BULLETIN Copy Part SBOOOS Rev A 06 1995 Description Ground Side Battery Disconnect Purpose 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 A Proheat is typically connected directly to the batteries so that it can be used to preheat the coolant when the ground side battery d
68. e Code O1 errors the PROHEAT goes into a hold state No further start attempts will be made Code O1 will be displayed continuously and the PCM LED ON light will turn OFF In addition the Hour Meter Auxiliary Output will shut off The switch timer red manual light or OEM indicator light will continue to flash once pause flash and repeat NOTE In order to restart the heater turn the switch OFF and back ON PROHEAT INSTALLATION amp SERVICE 5 1 y f gt Figure 5 2 Remote On Off Switch BH The X45 fuel pump is a gear pump driven directly by the compressor motor The fuel pump is NOT being monitored electrically Should this component diagnostic code appear there will be a fault in the main wire harness connector See page 5 35 Figure 5 27 or in the PCM mechanical problems with the fuel pump will be indicated as either a START 1 or a FLAME OUT 2 diagnostic code Code 13 Sleeper Fan is only applicable to Sleeper Fan models Should this diagnostic code appear on Aux Input models there will be a fault with the PCM SECTION 5 TROUBLESHOOTING amp REPAIR OPERATION INDICATORS FUNCTION AND COMPONENT DIAGNOSTICS 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 o
69. e a Code 13 Note that the sleeper fan is high side switched Symptom Sleeper Heater fan not turning no code indicated Check Sleeper Heater system a The wiring connections and polarity b Test sleeper heater fan See Test Procedure Symptom Sleeper Heater system has low air flow no code indicated Check Sleeper Heater system a Air ducting b Use Test Procedure items e and f to determine if PROHEAT iS Supplying enough power to drive the sleeper fan Test Procedure a Disconnect sleeper fan harness b Restart the PROHEAT If there is still an error replace the PCM c Check for correct voltage at the sleeper fan output on the PCM See wiring diagram on page 1 4 and page 1 5 d Reconnect sleeper fan harness Start the PROHEAT e Check for voltage at the thermostat isolator if used and the sleeper fan motor The power to the sleeper heater fan is regulated by voltage in the PCM It will read low when trying to drive the sleeper fan f Connect sleeper heater fan motor directly to a remote power source of the rated voltage 12 24 Volts Does the motor run PROHEAT INSTALLATION amp SERVICE 14 Hour An HOUR METER AUXILIARY OUTPUT diagnostic code indicates an electrical Meter short in the hour meter auxiliary output wiring harness electrical connections Auxiliary or connected electrical load The electrical load could be an hour meter relay Output or any other low load lt 1 A connection th
70. e cavity 6 Remove the ball bearing from the cavity RELIEF VALVE ASSEMBLY SEARING i BRASS BALL CAP GUIDE O RING SPRING FUEL PUMP Figure G 1995 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 No 6 Road Richmond B C Canada V6V1P6 Tel 604 270 6899 Web www proheat com SERVICE BULLETIN Copy Part SBOO62 Rev A 09 2011 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 Lubricate O ring with diesel fuel 12 Install pressure relief valve cap and torque relief valve to 22 2 in lbs 2 5 0 2 Nm 13 Re test the fuel pressure 14 If fuel pressure is still below 5 PSI replace relief valve or fuel pump assembly Reassembly 1 Remove test gauge PKOOGOK TEST GUAGE PK0060K 1995 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 6 Road Richmond B C CanadaV6V1P6 Tel 604 270 6899 Web www proheat com SERVICE BULLETIN Copy Part 5 0062 Rev A 09 2011 2 Reconnect fuel line to fuel pump outlet 3 Reconnect air hose at compressor
71. e or shut down the PROHEAT rather the PROHEAT reports the error and continues to run The ON OFF switch or Timer lamp and the PCM ON LED will light In addition the Hour Meter Auxiliary Output will be powered The PROHEAT goes to PCM performs short diagnostic cycle This takes several seconds checking components for proper ranges checking for the presence of a flame short circuits and open circuits If there are no errors indicated the PROHEAT goes to Ignition The blower starts first followed by the coolant pump ignition spark air compressor and fuel pump The ignition electrode sparks for 60 seconds If the flame sensor did not see a flame in 60 seconds after entering ignition the air compressor and fuel pump shut off immediately The blower and coolant pump continue to run Code 01 will be displayed alternating with Pu There will be one flash pause and then one flash repeating on the switch timer red manual light or OEM indicator light After 3 minutes the blower stops and the PROHEAT attempts to start again NOTE Codes 13 and 14 will not cause the heater to shut down The PROHEAT reports the error and continues to run The PROHEAT always restarts after one error detection except for Codes 13 and 14 After the 3 minute Cool Down Purge the PROHEAT will go through Precheck Ignition and the Error Detection Cool Down Purge cycle one more time After two consecutiv
72. e time it may be used throughout the year to reduce the wear associated with cold starts 2 Cab or Sleeper Heat engine off PROHEAT will supply heat to the cab or sleeper Drivers can sleep in comfort not only in the cold of winter but also in the spring and fall when the weather is miserable Substantial savings through reduced fuel consumption and engine wear can be obtained by not idling the engine SECTION B INTRODUCTION El PROHEAT SORT Sm TROL MODULE Xe 3 5 SLEEPER Fay Wr a 7 SWITCH INPUT 12 voi v 999100 Supplemental Heat engine running as the efficiency of modern diesel engines are improved there is no longer adequate reject heat available to heat the vehicle s interior This is particularly true for buses PROHEAT can be used while the vehicle is operating to provide supplemental heat for the interior Cargo Heat PROHEAT can be used to provide heat to protect valuable cargo such as produce or beverages from damage due to freezing Marine Marine applications typically involve the engineering and installation of a complete hot water heating system of which PROHEAT is only one component Proheat recommends that only an expert in marine hot water heating systems install a PROHEAT on a boat It is the installer s responsibility to ensure that the installation complies with all applicable regulations B 1 B 2 PROHEAT INST
73. er current Use test lead part 967921 as described on Service Bulletin 967329 in Appendix Figure 5 25 Blower Test CURRENT DRAW Amps 15 1 5 12 Volts 5 1 0 24 Volts 13 Sleeper Fan The PROHEAT PCM sleeper fan circuit has a one minute delay during ignition Power to open a Sleeper fan coolant valve must be taken from another source such as the wire for the Hour Meter Auxiliary Output See PROHEAT Wiring Diagram page 1 4 5 32 SECTION 5 TROUBLESHOOTING amp REPAIR 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 Symptom Sleeper Heater fan not turning code indicated Check Sleeper Heater system a The wiring connections and polarity b For an electrical short from the positive wire to the negative wire For an electrical short from the positive wire to the chassis Test sleeper heater fan See Test Procedure Sleeper Fan Troubleshooting No code Indicated The following material covers the sleeper fan mechanical or electrical problems that do not indicat
74. er wiring amp function a That blower 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 blower If it tests OK replace PCM See Figure 5 25 and Test Procedure Blower Mechanical and Electrical Troubleshooting No code Indicated This section covers the blower mechanical or electrical problems that do not indicate a Code 12 The blower motor is ground side switched there is always voltage at the positive terminal to the motor Symptom Blower runs as soon as power is applied No code indicated Check Internal Short in Motor a Disconnect blower motor from internal harness b To check motor condition Spare Blower is Available Check Connect spare blower to internal harness and apply power to heater If spare blower does not run replace the blower pump If the spare blower still runs ii Inspect internal harness wires Ensure that there is no chaffing or cuts that would provide a blower motor ground short If internal harness is in good condition replace PCM Spare Blower is not Available Check Plug connector that normally goes to blower motor into the coolant pump If the coolant pump does not spin when power is applied this indicates that there is a short in the blower motor or short in the internal harness Verify root cause by checking Steps ii and iii If the co
75. g 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 id v E SWITCH 5 ON OFF SWITCH oe Figure 3 21 ON OFF Switch Assembly SECTION 3 INSTALLATION ON OFF SWITCH CONNECTIONS 1 Select a suitable location in the vehicle dash for the ON OFF Switch NOTE Many dash panels have switches which are not utilized It may be convenient to remove one and replace it with the PROHEAT switch 2 Drill a gt diameter hole through the dash for the switch Make sure you have clearance behind the dash for the switch wires and connections Install the switch as per the diagram Figure 3 21 3 Route the switch wire harness from the PCM to the dash panel You will have to pass the wire harness through the vehicle firewall If possible use an existing hole Use a grommet to prevent the wire from being damaged when it is passed through the hole Cut the harness to length Strip outer wire jacket of harness back to expose the 4 wires Strip the wires as shown and crimp the supplied spade terminals NOTE Use fully insulated disconnects when connecting Switch GROUND ON POWER OFF ON SIGNAL INDICATOR Figure 3 22 ON OFF Switch Connections 6 Connect the terminals to the switch as shown Figure 3 22 NOTE Ihe PCM must be reset power disconnected and reconnected when changing from a Timer to an ON OFF Switch or from an ON O
76. haust pipe clamp and apply anti seize compound to the threads Assemble the exhaust clamp over the exhaust pipe clamp goes inside the enclosure and tighten the nuts NOTE 17 exhaust pipe should not exceed 5 ft and have no more than 180 degrees of bends The bends must be formed for best results Do not use 90 degree welded pipe to turn corners 0695 p A Use formed elbows X Do not use welded 90 elbows EXHAUST CLAMP U BOLT APPLY ANTI SEIZE COMPOUND TO THREADS DIRECTION OF VEHICLE TRAVEL ENSURE THERE ARE NO AIR LEAKS AROUND THE CONNECTION Figure 3 11 Exhaust Pipe PROHEAT INSTALLATION amp SERVICE 3 4 PLUMBING THE SYSTEM 3 4 1 GENERAL CONSIDERATIONS Coolant flow must be maintained throughout the coolant system under all conditions e Keep the engine inlet and outlet ports as far apart as possible to maximize cross flow through engine e Coolant pump and engine water pump must flow in the same direction e Ensure that no sharp kinks or bends exist in the hoses which may restrict coolant flow Avoid high points the hose routing to prevent air traps e For systems requiring more than 50 feet of coolant line contact Proheat Product Support at www proheat com for coolant pump recommendations For plumbing the system use NPT pipe fittings or bigger ID heater hose Figure 3 12 Maximum cross flow NOTE Use of silicone hose requires spec
77. he temperature reaches 286 F 141 C the breaker trips out This shuts off the power to the air compressor extinguishing the flame The breaker can be reset by pushing down on the red button located under the rubber cap Photo electrically measures the intensity of the flame It is the flame sensor that signals to the PCM that the air fuel mixture is burning properly Is used to switch the heater ON and OFF It has an indicator lamp that displays a red light when switched ON A flashing red light indicates a heater diagnostic code and one of the LEDs on the PCM diagnostic display will be lit See page 5 3 for details Is used to switch the heater ON and OFF This can be done manually or by a preset time and day It has an indicator lamp that displays a red light when switched or timed ON A flashing red light indicates a heater diagnostic code and one of the LEDs on the PCM diagnostic display will be lit See page 5 3 for details On Sleeper Fan 12 V models see page 4 2 the Proheat Control Module is equipped with a 3 A limited output It is used to drive fans or other equipment as determined by the installation see page 3 1 The output is ON 60 seconds after switch ON In addition it is also ON when there is a functional error see page 5 1 for details Indicator Light Located in the Toggle ON OFF Switch INDICATOR LIGHT RED MANUAL SA MANUAL BUTTON TIM
78. ial hose clamps Shut off valves are not required at the engine inlet and outlet connections but may be used if desired They should be left open at all times so that the heater can be operated throughout the year Select Your Plumbing Option You Choose 25 Option A Engine heat or supplemental heat The PROHEAT heats the engine block only NOTE When the engine block is preheated you will have nearly instant heat from the dash heat exchanger Option B Engine and sleeper heat The PROHEAT heats the engine block and the sleeper NOTE Plumbing the PROHEAT through the dash fan is not recommended SECTION 3 INSTALLATION 3 7 Instructions for Options A and B Remove the radiator cap to release the system pressure WARNING Opening the radiator cap when Drain the coolant system the engine is hot may cause serious injury Plumb the system as per Figure 3 13 or Figure 3 15 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 2 OPTION A Engine Heat or Supplemental Heat 3 Em RETURN TO ENGINE e PAOFHEAT L SUPPLY TO PROHEAT ENGINE Figure 3 13 Engine Heat or Supplemental Heat NOTE On coolant systems where the return from the PROHEAT is plumbed to the bottom of the m
79. ion Lead 1 x Air Filter 1 x Fuel Filter 2 x O Ring 6 8 PROHEAT INSTALLATION amp SERVICE 880035K 1 Fuel Filter X45 SECTION 7 APPENDICES 7 0 APPENDICES CONTENTS COOLANT INDICATOR E redo Dade ES EBAD eet dev pete GROUND SIDE BATTERY DISCONNECT 5 PROHEAT CONTROL MODULE PCM FOR X45 AND XL SERIES HEATERS FUEL PUMP PRESSURE CHECK AND SERVICE 951528K 967329K 580003 PB0034 580062 1 1 1 2 PROHEAT INSTALLATION amp SERVICE SERVICE BULLETIN Copy Part 951528 Rev A 10 1993 Description FLOW INDICATOR Coolant Flow Indicator TK9002 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 FIGURE 1 FLOW INDICATOR SLEEPER FAN TK9002 OTHER POSSIBLE LOCATIONS FLOW INDICATOR FIGURE 2 1994 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 No 6 Road Richmond B C Canada V6V 1 6 Tel 604 270 6899 Web www proheat com 7 4 PROHEAT INSTALLATION amp SERVICE Description The PROHEAT wiring system uses sealed connectors for resistance to corrosion and greater reliability The following test lea
80. ion are used e Use of a fuel filter is not recommended All models have a built in fuel filter at the fuel inlet fitting on the heater 90 MAXIMUM LENGTH OF FUEL LINE WoW oW WOW W WoW OW WoW 2 7 2 7 SEAS 22 0 0 10 MAXIMUM RISE Figure 3 31 Fuel Supply Height Requirement Select Your Fuel Pick up Installation Option Option A Fuel pick up to be installed in an existing 1 2 NPT port in fuel tank Option B Fuel pick up to be installed in an existing blank fuel sender cover plate Option C Fuel pick up to be installed in a hole drilled into the fuel tank PROHEAT INSTALLATION amp SERVICE 3 6 2 CAUTION Do not use teflon tape as this will contaminate the heater and engine fuel system SECTION 3 INSTALLATION OPTION 1 4 or 1 2 NPT Port Locate an existing pipe thread port in the vehicle fuel tank and select the or 4 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 FUEL PICK UP EXISTING PORT IN FUEL TANK 1 4 NPT Figure 3 32 NPT Port EXISTING PORT u IN FUEL TANK gt 1 2 FUEL TANK Figure 3 33 NPT Port 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 sho
81. ion tube to access the inside of the heat exchanger e Ensure exhaust pipe is clean and free from restriction e Use a wire brush to loosen the deposits and a vacuum to suck them out e Torque securing screws to 25 3 in Ibs 2 8 0 3 Nm COMBUSTION TUBE SECURING SCREWS EXHAUST PIPE Figure 64 Exchanger SECTION 6 MAINTENANCE 6 3 6 2 4 6 2 5 6 2 6 CLEAN FLAME SENSOR To maintain proper sensor readings the flame sensor glass should be wiped clean e With the fan end removed clean the sensor glass with water and a rag Glass should be clear FLAME SENSOR Figure 6 5 Flame sensor CHECK COOLING SYSTEM e Check all heater hoses and connections for signs of leakage or damage e Repair or replace as required e NOTE The coolant mix must be 50 Ethylene Glycol CHECK BATTERIES e Check the condition of batteries and the power connections The heater will not function properly with weak batteries or corroded connections Figure 6 6 Test Battery PROHEAT INSTALLATION amp SERVICE 6 2 7 CHECK FUEL SYSTEM e Check the fuel system for damaged fuel lines or leakage e Make sure the clamps on the fuel lines are secure e Ensure fuel lines are flexible FUEL FILTER FUEL PICK UP FUEL TANK GROMMET FUEL LINE a HOSE CLAMP Figure 6 7 Fuel Line Clamp A 6 2 8 CHECK FUEL FILTER e Remove and inspect filter Clean or repla
82. isconnect switch is open If the operator driver attempts to start the engine with this switch open the entire electrical current from the starter motor attempts to pass through the proheat internal wiring harness Without adequate fuse protection the Proheat ground circuit in the internal harness and or controller will be damaged Test Procedure The symptoms may include a START error or FLAME OUT error The fuel pump will not operate if the Proheat ground circuit has been damaged resulting in intermittent operation of the Proheat 1 Recommended Method of Protection 1 Start the Proheat Check that the fuel pump is running Approximately 20 to 40 pulses per minute can be felt or heard Check for voltage at the fuel pump power terminal If the fuel pump does not operate ground the body of the fuel pump directly to the battery negative post using a wire Restart the Proheat If the fuel pump runs and the Proheat starts then the problem is in the ground wire Note lt is possible to get a partial ground for the fuel pump if the exhaust pipe is contacting the machine frame and the ground side battery disconnect switch is closed To locate the fault in the ground circuit first check the internal harness The ground wire is black with a green stripe Remove the 18 pin connector from the controller and check for continuity between the ground pin Pin C3 and the ring terminal See Figure 1 over If a fault is found replace the h
83. le for lodging meals and incidental costs incurred by the Owner as a result of a warrantable failure Owner is responsible for down time expenses and all business costs and losses resulting from a warrantable failure Proheat is not responsible for incidental or consequential damages Items Covered Under This Warranty 1 Basic Heater including combustion chamber components fuel system components air compressor ignition components coolant pump air blower 2 Electrical controls provided by PROHEAT including cab mounted controls and PCM 3 PROHEAT supplied accessories and mounting hardware Items Not Covered Under This Warranty 1 Proheats no longer within the warranty period 2 Normal wear and maintenance parts including fuel filter air filter nozzle and clamps 3 Parts which malfunction due to improper installation causing inadequacies in air fuel or coolant flow voltage due to wiring shock or vibration protection Any progressive damage to the engine or vehicle arising out of failure of the PROHEAT Proheats which have been modified or use of non standard parts not approved by Proheat Proheats that have been abused or damaged Travel time by a PROHEAT Dealer Diagnosis or repairs when caused by problems not directly related to the heater or due to empty fuel tanks or poor fuel quality If you have any questions or concerns about the PROHEAT Warranty contact your nearest PROHEAT Distributor or Prohe
84. leeper Heat 3 9 3 5 WIRING amp ELECTRICAL 3 10 3 5 1 General Considerations 3 10 3 5 2 Power Connection to Batteries 3 11 3 5 3 Timer Connections Optional 3 12 3 5 4 On Off Switch Confhectloris n resur owe a ne pe 3 13 3 5 5 Sleeper Fan Model Heater Wiring Details 3 14 3 5 6 Option A OEM Heater 8 Proheat Thermostat 3 14 3 5 7 Option B OEM Heater amp Thermostat 3 15 3 5 8 Option C Auxiliary Sleeper 3 16 3 5 9 Option D Auxiliary Sleeper Heater Current Limited 3 17 3 5 10 Auxiliary Input Model Heater Wiring Details 3 18 3 5 11 Option A Preheat Mode Supplemental Mode Operation 3 19 3 5 12 Option B Preheat and Supplemental Mode 3 20 3 5 13 Option C Standard Mode amp Supplemental Mode 3 20 310 TUE tem 3 22 3 6 1 General Considerations 3 22 346 2 Option A 174 0r 172 NPT 3 23 3 6 3 Option B Existing Blank Fuel Sender Cover Plate 3 24 3 6 4 Option C Hole Drilled into Fuel Tank 3 24
85. nd only touch a heater after it has cooled to room temperature 2 Clean the X45 Heater by hand with dry or damp cloth or with compressed air DO NOT use chemical agents as this may damage surfaces gaskets boots cabling and or hoses 3 DO NOT use a pressure washer or hose down the heater This may result in damage to the PCM or damage to the electrical system 4 Water should not come into contact with any part of the heater when it is hot Water can cause rapid cooling which may damage components 5 Ensure that the rubber boots on the ignition lead are clean and free from debris Remove debris with compressed air or by wiping with a clean towel DO NOT use chemical agents on the rubber boots AIR INLET SCREEN X45 HEATER flex MN ENCLOSURE Figure 6 2 X45 Heater and Enclosure 6 2 PROHEAT INSTALLATION amp SERVICE 6 2 2 CHECK EXHAUST SYSTEM e Make sure the exhaust pipe i is vented safely away from the vehicle cab Check the pipe for dents restrictions or severely corroded areas e Replace the exhaust pipe and clamps if necessary i ee e Ensure the exhaust pipe clamp is tight e Clean exhaust pipe if there is a significant accumulation of carbon build up Figure 6 3 Exhaust Pipe 6 2 3 CHECK HEAT EXCHANGER e To maintain optimum heat output clean any combustion deposits that may have accumulated on the heat exchanger fins e Remove the fan end assembly and combust
86. not running 2 When engine preheat is no longer required switch the PROHEAT heater OFF ENGINE AND SLEEPER HEAT 1 Switch the ON OFF switch located in the vehicle dash to ON The switch will light and the heater will cycle on It will continue to operate until the coolant reaches 185 F 85 C at the heater outlet and then cycle OFF When the coolant temperature falls below 150 65 at the heater outlet it will refire and repeat the cycle It will continue to cycle until a the heater is switched OFF b the heater runs out of fuel the vehicle battery voltage drops below 10 0 Volts or d an error occurs and the switch light flashes See Troubleshooting amp Repair Section 5 NOTE The PROHEAT may be operated if the engine is running or not running 2 For sleeper heat set the thermostat in the sleeper to the desired temperature If the set temperature is higher than the temperature in the Sleeper the fan will cycle ON When the air reaches the set temperature the fan will cycle OFF The fan will cycle ON and OFF to maintain the set temperature 3 When engine and or sleeper preheat is no longer required switch the PROHEAT heater OFF 2 1 2 2 PROHEAT INSTALLATION amp SERVICE 3 0 INSTALLATION The installation details described in this manual focuses on truck applications and does not cover all of the possible installations As seen in the figures If addi
87. o to page 5 7 through page 5 14 and perform Fuel Systems Steps 2 to 5 Ignition System and Flame Sensor checks e Fuel Supply Pump e Air Compressor pressure Fuel Regulator dirty or clogged e Nozzle dirty or clogged e Flame Sensor dirty 3 Operational symptoms that may occur in conjunction with a Flame Out code Go to page 5 37 e Combustion hesitation or coughing e Backfiring e Smoke e Strong diesel fuel odor SECTION 5 TROUBLESHOOTING amp REPAIR 5 15 3 Coolant A COOLANT FLOW diagnostic code is displayed when the coolant temperature Flow reaches 185 85 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 c Check for restrictions caused by the truck systems ie Shuttle valves manual valves air operated valves Check Coolant Flow a Coolant Lines For restrictions and blockages Are clamps tight b Shut off Valves Ensure that shut off valves are open and functioning properly c Fittings Fittings must be at least gt NPT or larger Avoid using 90 fittings where possible d Coolant Flow Direction The PROHEAT must be plumbed so that the coolant pump is pumping the coolant in the
88. olant pump spins this indicates that there is a fault with the PCM or there is a short in the internal harness Verify root cause by checking Step iii ii Measure resistance between either pin on the connector going to the blower motor and the body of the heater If the resistance is not in the mega ohm range replace the blower If the resistance is in the mega ohm range go to Step iii 5 30 PROHEAT INSTALLATION amp SERVICE SECTION 5 TROUBLESHOOTING amp REPAIR 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 Check Blower not running no code indicated Fuse blown in PCM Blower function a Harness for pinched or abraded wires Positive lead must not short to ground b Check motor for internal short See Figure 5 25 and Test Procedure Symptom Check Blower turning slowly no code indicated Blower function a For fan blade rubbing on housing b For fan blade slipping on motor shaft Test Procedure a Connect the blower to a power supply of the rated voltage Does it turn If not replace the blower b Measure the blower motor resistance Using a multimeter measure the resistance across the blower connector pins If resistance shows an open circuit or an internal short circuit then replace the blower assembly Measure blow
89. oltage is higher than the specified range then check the voltage regulator on the vehicle NOTE If the vehicle batteries are marginal starting the vehicle while the heater is running may a Drop voltage enough to cause a voltage error b Cause random component errors brown out To reset the PCM switch the heater OFF and then back ON at the dash ON OFF Switch If the problem continues load test the batteries to confirm their condition Each battery should be independently tested Current Checking current draw is done at the power harness connections on the batteries 1 Check current draw on the red POSITIVE wire with the heater NOT running Should read 50 to 100 mA 2 Check current draw on the red POSITIVE wire with the heater running in full output ignition OFF For 12 V models the current should be 6 5 to 9 0 A varies with input voltage For 24 V models the current should be 2 0 to 6 0 A varies with input voltage 3 Check current draw on the black NEGATIVE wire with the heater NOT running and the red POSITIVE wire disconnected Should read O mA This test is to confirm whether or not there is a power leakage from the vehicle through the heater Heater Voltage Measurement The positive terminal of the ignition coil is always hot relative to the heater chassis ground as long as power is connected to the heater This is the supply voltage to the heater Test Procedure a Locate the rubber boot on the end
90. onstant power supply wire must be of sufficient size to handle sleeper fan motor electrical current draw 5 Route sleeper fan harness from PCM to PROHEAT thermostat Cut to length Connect white wire to terminal 1 of the thermostat 6 Route a wire from terminal 2 of the thermostat to relay 1 can be cut from left over wire harness Ground the relay using PROHEAT sleeper fan ground wire black OEM THERMOSTAT VEHICLE CONSTANT POWER SOURCE i e CIGARETTE LIGHTER ee RELAY 1 STANDARD i 12 OR 24 30 30 187 lt PROHEAT KY 86 85 THERMOSTAT OEM FAN MOTOR 2 CONTROL 1 WHITE BLACK 2 OR 3 SPEED RESISTOR ASSEMBLY NOTE MAY OR MAY NOT BE LOCATED INSIDE SLEEPER HEATER ASSEMBLY SLEEPER FAN d HARNESS SLEEPER pus ASSEMBLY T Rm d FAN MOTOR SINGLE WINDING TYPE Figure 3 23 Option B 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 Mount thermostat using the s
91. oolant as necessary Shut the engine OFF Connect the power harness All segments of the LED will flash on the PCM This indicates that power has been supplied See page 5 4 for more information 7 Start the PROHEAT heater using the ON OFF switch The indicator lamp should be lit with a solid red light Go to the heater and observe its operation Test Preheat and Supplemental Mode operation if equipped Refer to page 3 18 and page 4 5 for proper information Sequence of Events a Coolant temperature must be less than 150 65 C b ON light on PCM should be lit c You should hear the coolant pump blower and compressor start Looking through the inspection port you should see a spark and a flame d The spark will stop after 60 seconds and the heater will continue to run NOTE If the indicator lamp in the ON OFF Switch flashes upon initial Startup WAIT The heater will attempt a restart in 3 minutes In some cases it takes longer for the fuel pump to prime the empty fuel lines during the initial start This is usually the case if the fuel lines are long it may take a few restarts If the light continues to flash after the restart then there is a problem The Troubleshooting amp Repair section of this manual will assist you in correcting the problem PROHEAT INSTALLATION amp SERVICE SECTION 3 INSTALLATION 8 Once the heater is started it will continue to run until the coolant temperature reaches
92. our meter auxiliary output harness Start the PROHEAT e Connect electrical load directly to a remote power source of the rated voltage 12 24 Volts Does the electrical load run Figure 5 26 Hour Meter Auxiliary Output Test SECTION 5 TROUBLESHOOTING amp REPAIR 5 33 2 4 5 2 1 5 2 2 5 2 3 5 2 4 5 2 5 5 2 6 5 2 7 9 34 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS FUEL NOZZLE Go to page 5 12 FUEL REGULATOR Go to page 5 7 AIR COMPRESSOR Go to page 5 9 and page 5 23 FUEL PUMP Go to page 5 8 IGNITION ELECTRODE Go to page 5 13 COOLANT PUMP Go to page 5 27 BLOWER Go to page 5 30 PROHEAT INSTALLATION amp SERVICE 5 2 8 4 CAUTION Repeated replacement of the fuse or using incorrectly rated fuses without correcting the problem can damage the PCM SECTION 5 TROUBLESHOOTING amp REPAIR 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 e ON OFF Switch e Coolant Pump e Air Compressor Fuel Pump e Blower Ignition Coil e nternal Wire Harness Reversing polarity at the battery will also cause the fuse to blow This will not harm the PCM Check Heater wiring See flow chart Figure 5 28 on next page GROU
93. p 3 to 4 shorter as shown in Figure 3 37 Install the pick up into the fuel tank as per selected option Route the fuel line from the heater to the fuel pick up Ensure the fuel line is well secured and will not abrade 4 Attach the fuel line to the heater fuel pump fitting and the fuel pick up with hose clamps Lubricating the fittings with fuel may ease the installation effort GROMMET HOSE CLAMP Ce eee FUEL TANK D E FUEL HOSE CLAMP 7 5 FUEL PICK UP FUEL LINE Figure 3 38 Fuel Line Connection Detail SECTION 3 INSTALLATION 3 25 3 FIRST TIME STARTUP 1 Inspect the entire installation for 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 AD Eo m gt 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 NOTE If shut off valves are installed make sure they are fully OPEN 4 Start the vehicle engine and run it at a fast idle for 5 to 10 minutes to purge air from the heater and coolant system While the engine is running a make sure the coolant is flowing freely b inspect hoses and fittings for leaks c check the coolant level in the radiator and add c
94. r OEM indicator light installation options will also flash the diagnostic code followed by a pause and then repeat The number of flashes correspond to the numbered diagnostic code For example 5 flashes indicates a VOLTAGE ERROR See diagram below for a complete list of operation states and error flash codes If multiple errors occur multiple codes will be displayed For example if a 5 and 9 error occurs together the PCM LED will flash 5 and then 9 Similarly the remote ON OFF Switch Timer red manual light or OEM indicator light installation options will flash 5 times pause and then 9 times CODE No Description of Operating State No of and Diagnostic Codes Flashes Operation Indicators 8 8 Power Up No Indicator Switch On Standard Preheat Solid Indicator or Supplemental Mode Pu Cool Down Purge Solid Indicator Function Diagnostics 01 Start 1 02 Flame Out 2 03 Coolant Flow 3 04 Overheat 4 5 Voltage 5 Component Diagnostics 06 Flame Sensor 6 07 Temp Sensor 7 08 Fuel Pump See Note 8 09 9 10 Ignition Coil 10 11 Coolant Pump 11 12 Blower 12 13 Sleeper Fan 13 14 Hour Meter Auxiliary Output 14 Figure 5 3 Function Display Panel Detail amp Error Flash Codes 9 3 5 1 1 Purge OPERATION INDICATORS Operation States 8 8 Power Up e Pu Cool Down Purge The operation indicators signal normal functioning of the PROHEAT These two
95. r pressure d gauge calibrate gauge before each use refer to e www proheat com PDFs 990614 pdf Remove Pressure Gauge when finished f with measuring amp setting procedure Altitude Correction is needed above 3000 Feet see inset on charts DO NOT adjust air pressure when above 6000 Feet SECTION 5 TROUBLESHOOTING amp REPAIR 2 components up to normal operating temperature Switch heater off Install 7 Digital Manometer or a calibrated PKOOGO Analog Air pressure gauge in line as shown in Figure 5 6 lee x y D lt 7 HOSE FROM COMPRESSOR Locate the rubber boot on the positive end of the ignition coil and peel it back to expose the positive terminal Select the DC Volts range of a multimeter and connect as per Figure B The positive lead of the multimeter should be attached to the positive coil lead The negative lead of the multimeter should be attached to the heater chassis at the PROHEAT ground boss With the heater running in full output flame on and ignition is off read the voltage and refer to the 12 or 24 volt chart Figure 5 8 and Figure 5 9 for the correct Air Pressure Reading The reading must be within the range of the shaded area as shown in Figure 5 8 and Figure 5 9 9 9 12V Proheat X45 Air Pressure Range vs in Operation Coil Voltage for a Warm Compressor 154 e1nsseJg Figure 5 7
96. re that all boots are clean and free from debris Remove debris by wiping with a clean towel Do not use water or chemical agents 4 Ensure that all boots are properly reseated is recommended that the ignition lead is replaced every five years or better with a new lead p n 930523 Figure 6 11 Wire Harnesses IGNITION LEAD IGNITION COIL Figure 6 12 Ignition Coil SECTION 6 MAINTENANCE 6 7 6 2 12 CHECK AIR PRESSURE e Refer to Air Compressor pressure test procedure on page 5 9 QN T m P d 8 DIGITAL MANOMETER PK0037 D 5 N er j 5 2 it TS EN NOZZLE AIR INLET HOSE FROM COMPRESSOR Figure 6 13 Air Compressor pressure test procedure CHECK MODES OF OPERATION SWITCH TIMER OR 6 2 13 OEM SIGNALS e Check to see that the modes operate as described on page 4 5 to page 4 7 Operation Test e Run the system for at least 15 minutes or until the heater cycles OFF and then ON again e Alternate the thermostat for the sleeper heater if connected between the lowest and highest settings to ensure that the sleeper heater fan cycles ON and OFF Replacement Parts PART DESCRIPTION PKOO94 1 X45 Fall Service Kit includes 1 x Air Filter 1 x Fuel Filter 2 x O Ring PKOO69 1 X45 Major Service Kit 1 x Electrode 1 x Nozzle 1 x Regulator 1 x Flame Sensor 1 x Ignit
97. refully These safety alerts alone cannot eliminate all hazards Strict compliance with these special instructions and common sense are major accident prevention measures 4 DANGER Immediate hazards that will result in severe injury or death A WARNING Hazards or unsafe practices that could result in severe personal Injury or death CAUTION Hazards or unsafe practices that could result in minor injury or product or property damage Information that is important to proper installation or maintenance but is not hazard related A 1 gt WARNING A WARNING WARNING A WARNING A WARNING A WARNING A WARNING WARNING A WARNING 4 DANGER SAFETY CONSIDERATIONS 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 Explosion Hazard Do not operate heater where combustible fumes or airborne particles such as saw dust are present Fuel Exercise extreme caution when working near fuel or fuel filled equipment Do not operate heater during fueling operations In addition do not smoke or handle open flame equipment such as a blowtorch around fuel Fire Hazard Do not place any flammable items around the heater and exhaust pipe Batteries Wear hand and eye protection when working near bat
98. ri 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 It is also used to cool and Cool Down Purge the combustion chamber during the 3 minute shut down sequence 9 Inspection Port Allows visual inspection of the combustion process and is invaluable for reducing time spent on troubleshooting and servicing the heater 10 Heat Exchanger A two part cast aluminum housing Coolant will typically rise 10 to 15 F 6 to 8 C in temperature as it passes through the heat exchanger depending on the flow rate SECTION 4 PRINCIPLE OF OPERATION 4 3 11 Ignition Electrode 12 Coolant Temperature Sensor 13 Overheat Breaker Sensor 14 Flame Sensor 15 On Off Switch 16 7 Day Timer 17 Sleeper Fan only output connector shown 4 4 Figure 4 4 Figure 4 5 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 The overheat breaker monitors the surface temperature of the heat exchanger casting When t
99. rol the total current draw on the vehicles batteries This operation is typically used for truck installations e The Aux Input model uses two special input pins see Electrical Drawing on page 1 4 that allow for a Preheat Mode and Supplemental Mode operation This operation is typically used for transit and coach installation NOTE See Modes of Operation Section for a description of the operating modes used for both the Sleeper Fan and Aux Input Models NOTE The PROHEAT PCM Sleeper Fan circuit has a one minute delay during ignition NOTE The PROHEAT PCM is unique in that it uses ground side switching for the blower compressor coolant pump and ignition coil The positive wire to the motors and ignition coil will show voltage even when the heater is switched OFF PCM MODEL IDENTIFICATION SLEEPER FAN MODEL SHOWN S x A FAN 0 Mitoy NEU Wen la VO Lr lt Figure 4 2 LED will light to indicate a problem Switch or Timer indicator light will flash to indicate the diagnostic code page 5 3 PROHEAT INSTALLATION amp SERVICE S FUSE 15A ee Eee po NOT poWER WASH This Product Meets FHWA Bus Heater Requirements COMMUNICATION 852328 Bus 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 ventu
100. s 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 Test Procedure Fuel Pump Inspection a Disconnect the fuel line at the inlet to the regulator and place into a cup b Start PROHEAT Ensure that fuel flows out of the fuel line in a steady uninterrupted and clear stream of fuel If fuel does not flow check filter and relief valve for contamination as per Service Bulletin 5 0062 See appendices page 7 1 2 55 COMPRESSOR RELIEF VALVE ADJUSTING SCREW oD 0 RING OUTLET 5 FUEL PUMP FITTING Co D SY INLET dd FITTING FILTER BOLTS X2 ADAPTER tt Figure 5 5 Compressor Fuel Pump Assembly PROHEAT INSTALLATION amp SERVICE Fuel System Step 4 Check Air Compressor a Air compressor pressure and operation Test Procedure Air Compressor pressure A WARNING a heater until warm to the touch This ensures the heater Shock hazard due to high secondary coil voltage b DIGITAL MANOMETER PK0037 HOSE TO NOZZLE AIR INLET Figure 5 6 If using PKOOGO Analog Ai
101. s required contact your Authorized Proheat Dealer or Proheat Product Support at www proheat com 1 Identify engine run signal This may be off the alternator multiplex or others A WARNING fy eng y Install hardware as required on the vehicle as shown in Figure 3 29 When wiring for Supplemental Mode ensure to install Mechanic s Disable Switch in order to disable Supplement Mode for 4 Install an Indicator Light near the vehicle operator safety requirements 3 Choose either Preheat Option 1 or Preheat Option 2 Install hardware as required on the vehicle as shown in Figure 3 29 OPTION C Standard Mode Proheat Timer Optional 3 5 13 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 Supplemental operation will not Product Support at www proheat com override the Standard Mode operation Proheat Timer runs in Standard Mode 1 Install the timer as per Section 3 5 3 or the switch as per Section 3 5 4 See Figure 3 29 2 Identify engine run signal This may be off the alternator multiplex or others A WARNING 3 Route and connect engine run signal to wire A on the auxiliary input DO NOT connect an ON OFF Switch connector Install hardware as required on the vehicle and a Timer in the same circuit 3
102. same direction as the engine coolant pump The PROHEAT can be used when the engine is running e Coolant Pump Does the pump function properly page 5 27 f Coolant System Capacity The coolant system must contain at least 3 gallons 11 litres of coolant If the system contains less the coolant may reach 185 F in less than 1 minute causing a COOLANT FLOW diagnostic code g Sleeper Heater Many OEM sleeper heaters are combined with an air conditioning system The solenoid shut off valve used to cut off coolant flow during the air conditioning mode must be open when using the PROHEAT Refer to page 3 9 SLEEPER FAN If the coolant system is contaminated with magnetic material it may cause 1 the impeller to stop turning OTHER POSSIBLE LOCATIONS FLOW INDICATOR NM Figure 5 15 Indicator TK9002 5 16 PROHEAT INSTALLATION amp SERVICE 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 When the thermostat reaches the preset temperature of 286 F 141 C the contacts OPEN shutting the compressor and fuel pump O
103. series Connect using 14 spade connectors provided Figure coolant valves DO NOT use for 3 26 Wire end from resistor pack connected to isolator terminal marked controlling coolant valves See page IGNITION Wire end from sleeper fan motor connected to isolator 4 5 for operational sequence terminal marked FAN information 3 Locate PROHEAT thermostat in central area of sleeper approximately 12 above the bunk Avoid direct air flow from sleeper fan ducts See Figure 3 25 4 Remove the adjusting knob and face cover Mark and drill mounting holes Mount thermostat using the screws provided Figure 3 27 5 Route sleeper fan harness from PCM to PROHEAT thermostat Cut to length Connect white wire to terminal 1 of the thermostat Use fork terminal provided Black wire not used 6 Route a wire from terminal 2 of the thermostat to the isolator terminal marked HEATER Connect using fork and spade terminal provided Can be cut from left over wire harness NOTE For large sleepers this MAY NOT provide enough fan speed and emasta Location therefore option A B or C should be considered VEHICLE FUSE PANEL Thermostat Wire Connection Detail MUST BE BOLTED TO A METAL SURFACE FOR Screw Wire Colour HEAT SINKING White from PCM White to isolator Not used Not used OEM FAN RESISTOR ASSEMBLY ISOLATOR IGNITION yb NOTE MAY OR MAY NOT BE LOCATED INSIDE
104. ssary After 60 Seconds if there is a Start Error go to Fuel System PROHEAT INSTALLATION amp SERVICE 7 Temp A TEMP SENSOR diagnostic code indicates a short or open circuit in the Sensor temperature sensor wiring or the coolant temperature is out of range below 58 F 50 C or above 266 130 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 If it is within valid range and the PCM still displays code on start up replace PCM C Test the sensor See test procedure below Test Procedure a Connect a multimeter adjusted to measure resistance to the temperature sensor as per Figure 5 19 The polarity of the sensor connections to the multimeter is not important b Measure the sensor resistance versus temperature under the following conditions e at room temperature e in a freezer in boiling water c Compare the measured values against the graph Figure 5 20 If values do not approximately match then the sensor is defective and must be replaced Figure 5 19 Temperature Sensor Test SECTION 5 TROUBLESHOOTING amp REPAIR 5 21 pi Code 290 260 230 o 154190 85 185 UPPER SET POINT o 170 13540 65 C 150 LOWER SET POINT 9
105. t PCM PID PCM PID X45 12 V Trucks with or without Sleeper Kit 903100K 999100K and on Heavy Equipment X45 12 V Transit or Coach 904200K 999200K X45 12 V School Bus 904300K 999300K X45 24 V Transit or Coach Heavy Equipment 905300K 999400K and School Bus XL Bravo 24 V External Compressor 917526 1 999600K Transit or Coach XL Bravo 24 V Internal Compressor 906300K 999700K Transit or Coach X45 24 V Coach MCI Custom 906400K 999800K Updates 1 100 backward compatible no adapter required 2 CANbus communication and new serial port location 3 New 2x7 Segment LED 4 Vent with filter 2x7 Seqment LED 100 Backward Compatible CANbus and RS232 Communication Port Figure 1 Example photo of new PCM PID 999100 shown 2009 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 6 Road Richmond B C Canada 1 6 Tel 604 270 6899 Web www proheat com PRODUCT UPDATE BULLETIN Part PBOO34 Rev B 04 2009 1 100 Backward Compatible e 0 11 PCM works with existing heaters and wiring harnesses 2 CANbus Communication and new Serial Port Location e The new communication port provides CANbus SAE J 1939 communication e Relocated serial port allows Datalink connection without disconnecting the switch input e New communication port requires the controller Proheat Data Link Kit PKOO53 3 The G I download cable kit PKO
106. t 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 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 When switched OFF the Hour Meter Auxiliary Output will shut off NOTE The PROHEAT will Cool Down Purge for 3 reasons ethe coolant reaches 185 F 85 C ethere is a function or component problem See Troubleshooting amp Repair on page 5 1 ethe PROHEAT is operating at Full Output when it is shut OFF PREHEAT MODE Aux Input Models Only Push the Preheat button and the PCM ON LED will light will turn on In addition the Hour Meter Auxiliary Output will be powered The PROHEAT goes to Pre check The PCM performs a short diagnostic cycle This takes a few seconds to check components for proper ranges checking for the presence of a flame short circuits and open circuits If there are no errors indicated the PROHEAT goes to Ignition The blower starts first followed by the coolant pump ignition spark air compressor and fuel pump The ignition electrode sparks for 60 seconds Once the flame sensor detects a good flame the PROHEAT goes to Full Output The PROHEAT runs at Full Output until the coolant temperature reaches 185 F 85
107. ter operation The feature that makes this Auxiliary Input Model unique is that the PCM Proheat Control Module has three inputs to turn the heater on one for each operating mode The following is a description of the three operating modes Standard Heat Mode Coolant temperature is monitored via a built in sensor When the temperature at the Proheat is below 150 65 the Proheat operates heating the coolant to 185 F 85 C at which point it stops burning fuel and goes into Standby with only the coolant pump running Standard Heat Mode is typically activated by use of a toggle switch which must be manually switched off If the switch is not turned off the heater will continue to run overnight Since the coolant pump runs continuously in this mode It is possible to accumulate a high number of coolant pump operating hours vs heater run hours Use of supplemental mode is recommended in conjuction with standard mode in many cases Supplemental Heat Mode The amount of heat required varies depending on engine load outside temperature frequency of door opening etc Recognizing this varying demand for heat the Proheat monitors the conditions and supplies heat only when required When heat is not required the Proheat puts itself into supplemental standby shutting off the coolant pump thereby avoiding additional run hours on the pump This is ideal for transit and coach applications In order to simplify operation this function is f
108. teries Do not smoke or use open flames near batteries Electrical Electric shock can cause severe personal injury burns and death Before working on any unit disconnect the batteries Use only approved materials and methods when working on the electrical system and follow local electrical codes Never work with electricity in wet conditions or when you are feeling fatigued Poisons Toxins Fuel and coolant are toxic and in some cases carcinogenic Wear eye and hand protection at all times Remove contaminated clothing immediately and wash contaminated skin Do not breathe in vapors Moving Hot Parts Moving hot parts can cause severe injury and or death Before working on any unit shut it off Do not operate any unit until protective covers have been replaced Always ensure bolts and clamps are correctly torqued and secured Inspect mechanical com ponents periodically for damage and corrosion Coolant Never remove the filler cap when the engine is hot escaping steam or scalding water could cause serious personal injury The coolant level in the expansion tank should be checked at least weekly more frequently in high mileage or arduous conditions Always check the level when the system is cold Unscrew the filler cap slowly allowing the pressure to escape before removing completely Never run the engine without coolant Prevent anti freeze coming in contact with the skin or eyes If this occurs rinse immediately with plenty
109. that do not indicate a Code 11 The coolant pump motor is ground side switched there is always voltage at the positive terminal to the motor Symptom Coolant pump runs as soon as power is applied No code indicated Check Internal Short in Motor a Disconnect coolant pump motor from internal harness b To check motor condition Spare Coolant Pump is Available Check i Connect spare coolant pump motor to internal harness and apply power to heater If spare coolant pump does not run replace the coolant pump If the spare coolant pump still runs ii Inspect internal harness wires going to coolant pump Ensure that there is no chaffing or cuts that would provide a coolant pump motor ground short If internal harness is in good condition replace PCM Spare Coolant Pump is not Available Check Plug connector that normally goes to coolant pump motor into the blower If the blower does not spin when power is applied this indicates that there is a short in the coolant pump motor or short in the internal harness Verify root cause by checking Steps and If the blower spins this indicates that there is a fault with the PCM or there is a short in the internal harness Verify root cause by checking Step ii Measure resistance between either pin on the connector going to the coolant pump motor and the body of the heater If the resistance is not in the mega ohm range replace the coolant pump
110. the error code s continuously The PROHEAT will try again once the switch is turned OFF and then ON again e f the indicator light flashes count the number of flashes and refer to the troubleshooting diagnostic code description for that number on the following pages e f the PROHEAT runs but is not performing or operating correctly consult the Operational Problems Section 5 3 on page 5 37 Troubleshooting and Repair Tools Required e Remote Start Switch PROHEAT P N 952925K Allows the service technician to work at the PROHEAT Isolates the PROHEAT from the existing vehicle system controls and comes with a built in indicator light e Digital Air Compressor Test Gauge PROHEAT P N PKOO37 Allows the service technician to check compressor pressure in order to ensure for correct fuel delivery Note The analog Air pressure gauge PKOOGO can also be used 9 1 9 2 5 0 2 1 Switch ON Standard Mode Signal 2 Pre check 3 Ignition 4 Error Detection Purge 5 Steps 1 to 4 are Repeated 6 Hold State 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 mod
111. tional installation information is below the PROHEAT X45 is installed on a variety of equipment including required please contact your PROHEAT trucks school buses coaches drill rigs mine dump trucks and excavators Dealer regarding your specific In these cases the manual should be used as a guideline only application There are seven major steps that must be completed to successfully install For more technical information the PROHEAT heater please contact PROHEAT Product 3 1 LOCATING THE page 3 2 Support at www proheat com 3 2 MOUNTING THE HEATER page 3 4 3 3 EXHAUST PIPE CONNEC TION page 3 6 3 4 PLUMBING THE 5 page 3 7 3 5 WIRING ELECTRICAL CONNECTIONS page 3 10 229 FUEL SYSTEM een page 3 22 eet eee asit die page 3 26 Prior to the installation of your PROHEAT consult your engine owner s manual or engine manufacturer for any restrictions or changes that may apply to plumbing into the engine coolant system
112. ully automatic and invisible to the operator The Proheat picks up a signal that the engine is running and then monitors the coolant temperature via a built in sensor If the coolant temperature at the Proheat is below 150 F 65 C the coolant pump is activated for three minutes This causes coolant in the engine to be circulated through the Proheat If after three minutes the coolant temperature is above 150 65 the Proheat will turn off the coolant pump and return to supplemental standby If the coolant temperature remains below 150 65 C the Proheat will operate and continue to supply heat to the system until the coolant temperature reaches 185 F 85 C The Proheat then shuts itself off returns to supplemental standby deactivates the coolant pump and waits for the coolant temperature to fall below 150 F 65 and the cycle is repeated The Proheat switches off when the engine stops thus avoiding the problem of the driver forgetting to switch the unit off and leaving it running overnight PROHEAT INSTALLATION amp SERVICE You Choose 35 3 5 11 WARNING When wiring for Supplemental Mode ensure to install Mechanic s Disable Switch in order to disable Supplement Mode for safety requirements SECTION 3 INSTALLATION 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
113. ve and clean Prior to re connecting grease terminals with electrically conductive grease STRIP WIRE AS SHOWN AND CRIMP TO TERMINAL 227 I 3 16 POWER SUPPLY HARNESS BLACK NEGATIVE RED POSITIVE Figure 3 19 Power Connection to Battery SECTION 3 INSTALLATION 3 11 3 5 3 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 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 TIMER CONNECTIONS OPTIONAL TIMER BLACK Em BLACK RED 2 EC NEST E us GREY TO KEYSWITCH OPTIONAL Ground Power Operational signal from heater ON Signal to heater Keyswitch backlighting optional Black wire Red wire White wire Green wire Grey wire Figure 3 20 Timer Connections PROHEAT INSTALLATION amp SERVICE 3 5 4 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 The PCM must be reset power disconnected and reconnected when changin
114. wing installation or service DO NOT run dry Symptom Pump not running code indicated Check Pump Motor a Connect coolant pump directly to the rated voltage 12 24 Volts and see if it runs If not replace the pump b Measure coolant pump motor resistance Using a multimeter measure the resistance across the coolant pump connector pins If resistance shows an open circuit or internal short circuit replace the coolant pump Measure coolant pump current Use test lead part 967921 as described on Service Bulletin 967329 in Appendix nan we i FUSE 24 3 7 is SLEEPER FAN POWER lt lt wee STATES lt lt eee J 5 FHWA FI Vl Ficu Sleeser Orerhgat Mana Figure 5 24 Coolant Pump Test CURRENT DRAW Amps 1 50 4 00 12 Volts 0 75 2 00 24 Volts SECTION 5 TROUBLESHOOTING amp REPAIR 5 27 Symptom Coolant pump not running code indicated Check Coolant Pump wiring amp 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 Coolant Pump Mechanical amp Electrical Troubleshooting No code Indicated The following material covers the coolant pump mechanical or electrical problems
115. with no nicks do not use any tool that may damage the edge as this will cause loss of fuel pressure Place ball bearing back in cavity on the center hole Place spring back in hole on top of ball bearing Lubricate O ring with diesel fuel 10 Install pressure relief valve cap and torque relief valve to 22 2 in lbs 2 5 0 2 Nm 11 Re test the fuel pressure 12 If fuel pressure is still above 10 PSI replace relief valve assembly or fuel pump assembly ON If reading is BELOW 5 PSI 1 Check that there is fuel in the fuel tank 2 Check the fuel filter for contamination COMPRESSOR LUBRICATE O RING WITH DIESEL FUEL ADAPTER FUEL PUMP INLET FITTING BN FUEL FILTER TORQUE ADAPTER O RING NUT TO 15 10 IN LBS 17 1 1 NM Figure E 1995 Marine Canada Acquisition Inc DBA SEASTAR SOLUTIONS 3831 6 Road Richmond B C CanadaV6V1P6 Tel 604 270 6899 Web www proheat com SERVICE BULLETIN Copy Part 5 0062 Rev A 09 2011 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 JS 24 FUEL TANK HOSE CLAMP FUEL LINE Figure F 4 Check pressure relief valve Locate the pressure relief valve 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 th
116. wn NUT WASHER 4 m SEA o GASKET COVER PLATE SUPPLIED SI e WITH FUEL TANK CL REQUIRES MODIFICATION od WASHER FUEL SENDER PORT IN TANK Figure 3 34 Blank Fuel Sender Port 3 6 4 OPTION C Hole Drilled into Fuel Tank This option requires a permanent modification to the fuel tank Select the location for the fuel pick up in the vehicle fuel tank Ensure sufficient clearance above the tank to get the fuel pick up into the tank Drill a 1 diameter CAUTION hole in the tank To prevent fuel system contamination do not allow drill chips to fall into the fuel tank NUT WASHER when drilling the hole GASKET E ae A WARNING 5121 lt GASKET Drilling the fuel tank may not be acceptable in some jurisdictions Do not drill the fuel tank on passenger carrying vehicles such as school buses X WASHER DRILL 1 DIA HOLE IN FUEL TANK 2 CS Figure 3 35 Drill Hole in Tank 3 24 PROHEAT INSTALLATION amp SERVICE 3 6 5 INSTALLATION N KD OF FUEL PICK UP AT AN ANGLE 77 a 3 4 CLEAR 3 4 CLEAR OF BOTTOM OF TANK Figure 3 36 For some situations where Figure 3 37 Fuel Pick up Depth the fuel pick up is too far from the bottom of the tank an extension from left over fuel line can be added 1 Determine the depth of the fuel tank at the desired fuel pick up location Cut the fuel pick u
117. zle assembly is self aligning Torque to 30 3 in Ibs 3 4 0 3 Nm d Inspect the Fuel Nozzle cavity and clean as necessary using electrical contact cleaner or warm soapy water e Reinstall Fuel Nozzle into the fan end using diesel fuel to lubricate the o ring Torque to 150 10 in Ibs 1731 1 Nm f Reinstall fan end and torque three 3 bolts to 75 5 in lbs 8 5 0 5 Nm FUEL AND AIR OUTLET ORIFICE ARROWS SHOW HOW TO HEAD LOOSEN THE NOZZLE NOZZLE m NUMBER HOLD UPRIGHT TO ASSEMBLE D FUEL NOZZLE 3 ORIFICE DISTRIBUTOR AIR PASSAGES AS TORQUE SEE e lt gt 1 3 C AIR PASSAGES 5 STEM LUBRICATE n O RING WITH E DIESEL FUEL O RING Figure 5 12 Fuel Nozzle Assembly PROHEAT INSTALLATION amp SERVICE A WARNING The PROHEAT chassis 15 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 SECTION 5 TROUBLESHOOTING amp REPAIR Ignition System Check 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 Ensure that there is a proper connection at both the coil positive and negative terminals and at the electrode If the high tension lead is cut or d

INSTALLATION AND SERVICE MANUAL PROHEAT X45

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