Proheat x45 Plus

INSTALLATION AND SERVICE MANUAL
PROHEAT X45 PLUS
Rev. A
CONTENTS
A. SAFETY....................................................................................... A-1
B. INTRODUCTION.......................................................................... B-1
B.1 HEATER APPLICATIONS.............................................................B-1
1.0 TECHNICAL SPECIFICATIONS ................................................. 1-1
1.1 PHYSICAL – X45 PLUS............................................................. 1-2
1.2 ELECTRICAL – X45 PLUS.......................................................... 1-4
1.3 TORQUE SPECIFICATIONS......................................................... 1-6
2.0 INSTALLATION .......................................................................... 2-1
2.1 LOCATING THE HEATER............................................................ 2-2
2.1.1 Select Your Location....................................................... 2-2
2.1.2 General considerations................................................... 2-2
2.1.3 Mounting the PROHEAT Heater in an Enclosure................. 2-3
2.2 MOUNTING THE HEATER........................................................... 2-4
2.2.1 Option A – Heater With Enclosure..................................... 2-4
2.2.2 Option B – Heater Without Enclosure................................ 2-5
2.3 EXHAUST PIPE CONNECTION.................................................... 2-6
2.4 COMBUSTION AIR SUPPLY........................................................ 2-7
2.4.1 General Considerations................................................... 2-7
2.4.2 Air Inlet Snorkel Hose Option.......................................... 2-7
2.5 PLUMBING THE SYSTEM.......................................................... 2-8
2.5.1 General Considerations................................................... 2-8
2.5.2 Option A – Engine Heat or Supplemental Heat................... 2-9
2.5.3 Option B – Engine and Sleeper Heat............................... 2-10
2.6 WIRING & ELECTRICAL CONNECTIONS..................................... 2-11
2.6.1 General Considerations................................................. 2-11
2.6.2 Power Connection to Batteries....................................... 2-12
2.6.3 Heater Modes.............................................................. 2-13
2.6.4 On/Off Switch Connections............................................ 2-15
2.6.5 Timer Connections (Optional)......................................... 2-16
2.6.6 Optional Modes and Features Wiring.............................. 2-17
2.6.7 Optional Auxiliary Sleeper Heater Installation.................. 2-19
2.7 FUEL SYSTEM........................................................................ 2-22
2.7.1 General Considerations................................................. 2-22
2.7.2 Option A – 1/4” or 1/2” NPT Port.................................. 2-23
2.7.3 Option B – Existing Blank Fuel Sender Cover Plate........... 2-24
2.7.4 Option C – Hole Drilled into Fuel Tank............................. 2-24
2.7.5 Installation................................................................... 2-25
2.8 FIRST TIME STARTUP............................................................. 2-26
2.8.1 Programing a Replacement PCM/Changing the
PCM Configuration........................................................ 2-27
3.0 PRINCIPLES OF OPERATION.................................................... 3-1
3.1 COMPONENT DESCRIPTION...................................................... 3-1
3.2 THEORY OF OPERATION............................................................ 3-5
3.3 MODES OF OPERATION............................................................ 3-7
3.3.1 Standard Mode............................................................... 3-7
3.3.2 Optional Supplemental Mode........................................... 3-8
3.3.3 Optional Preheat Mode.................................................... 3-9
3.3.4 Optional Anti-Freeze Mode............................................. 3-10
i
4.0 TROUBLESHOOTING AND REPAIR........................................... 4-1
4.0.1 Troubleshooting a Problem.............................................. 4-1
4.1 OPERATION INDICATORS, FUNCTION AND COMPONENT
DIAGNOSTICS.......................................................................... 4-3
4.1.1 Operation Indicators........................................................ 4-3
4.1.2 Example PROHEAT Behavior Error – Code 01.................... 4-5
4.1.3 Function Diagnostics....................................................... 4-6
01 Start......................................................................... 4-7
02 Flame Out............................................................... 4-23
03 Coolant Flow........................................................... 4-24
04 Overheat................................................................. 4-25
05 Voltage................................................................... 4-26
4.1.4 Component Diagnostics................................................ 4-28
06 Flame Sensor.......................................................... 4-28
07 Temp Sensor........................................................... 4-30
08 Fuel Pump............................................................... 4-32
09 Compressor............................................................ 4-32
10 Ignition Coil............................................................. 4-35
11 Coolant Pump......................................................... 4-36
12 Blower.................................................................... 4-39
13 Sleeper Fan............................................................ 4-41
14 Hour Meter (Auxiliary Output).................................... 4-42
16 System Current....................................................... 4-43
18 CANbus Error.......................................................... 4-43
19 High Ambient PCM Temperature............................... 4-43
21 to 29 Outputs 1–9 Fault........................................... 4-43
4.2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS........... 4-44
4.2.1 Fuel Nozzle................................................................... 4-44
4.2.2 Fuel Regulator.............................................................. 4-44
4.2.3 Air Compressor............................................................. 4-44
4.2.4 Fuel Pump.................................................................... 4-44
4.2.5 Ignition Electrode.......................................................... 4-44
4.2.6 Coolant Pump............................................................... 4-44
4.2.7 Blower......................................................................... 4-44
4.3 OPERATIONAL PROBLEMS...................................................... 4-45
4.3.1 Smoking exhaust/smelly exhaust fumes......................... 4-45
4.3.2 Low heat output............................................................ 4-45
4.3.3 Engine temperature gauge reads low.............................. 4-46
4.3.4 Backfiring..................................................................... 4-46
5.0 MAINTENANCE........................................................................... 5-1
5.1 WEEKLY MAINTENANCE............................................................ 5-1
5.2 ANNUAL MAINTENANCE............................................................ 5-1
5.2.1 Clean Heater Enclosure and Air Intake.............................. 5-2
5.2.2 Check Exhaust System.................................................... 5-3
5.2.3 Check Heat Exchanger.................................................... 5-3
5.2.4 Clean Flame Sensor........................................................ 5-4
5.2.5 Check Cooling System..................................................... 5-4
5.2.6 Check Batteries.............................................................. 5-4
5.2.7 Check Fuel System......................................................... 5-5
5.2.8 Check Fuel Filter............................................................. 5-5
5.2.9 Clean Nozzle.................................................................. 5-6
5.2.10 Replace Compressor Air Filter........................................ 5-6
5.2.11 Check Electrical System................................................ 5-7
5.2.12 Check Air Pressure........................................................ 5-8
5.2.13 Check Modes of Operation – Switch, Timer or OEM Signals... 5-8
6.0 WARRANTY ............................................................................... 6-1
ii PROHEAT INSTALLATION & SERVICE

A. SAFETY
Throughout this manual, you will see notes labeled DANGER, WARNING,
CAUTION and NOTICE to alert you to special instructions or precautions
concerning a particular procedure that would be hazardous if performed
incorrectly or carelessly.
Observe them carefully!
These safety alerts alone cannot eliminate all hazards. Strict compliance
with these special instructions and common sense are major accident
prevention measures.
DANGER
Immediate hazards that will result
in severe injury or death.
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.
NOTICE
Information that is important to
proper installation or maintenance,
but is not hazard-related.
SECTION A. SAFETY A-1

SAFETY CONSIDERATIONS
WARNING Exhaust
Inhalation of exhaust gas (containing carbon monoxide) may cause severe personal
injury and/or death. Anyone suspected of suffering from CO inhalation should be
removed from the hazardous area and given medical assistance immediately.
WARNING Explosion Hazard

Do not operate heater where combustible fumes or airborne particles, such as
sawdust, are present.
WARNING Fuel
Exercise extreme caution when working near fuel or fuel-filled equipment. Do
not operate heater during fueling operations. In addition, do not smoke or
handle open flame equipment, such as a blowtorch, around fuel.
WARNING Fire Hazard

Do not place any flammable items around the heater and exhaust pipe.
WARNING Batteries
Wear hand and eye protection when working near batteries. Do not smoke or
use open flames near batteries.
WARNING 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.
WARNING 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.
WARNING 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 components periodically for damage and corrosion.
WARNING 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 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.
DANGER 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.
A-2 PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

B. INTRODUCTION
PROHEAT Model X45 Plus
This manual is provided to assist authorized PROHEAT dealers install and

service PROHEAT X45 Plus heaters. The X45 Plus features a new PROHEAT
Control Module (PCM) and other significant improvements and replaces all
earlier versions of the X45 heater. The X45 Plus can be configured for a variety
of applications and for either 12V or 24V power supply.
Please refer to the X45 Plus Parts Book at www.proheat.com for detailed part
descriptions and part numbers. The parts book also provides information on
optional equipment, such as timers, sleeper fan control kit, impact switch (for
school bus applications), and associated installation and maintenance tools.
B.1 HEATER APPLICATIONS

Although trucks have been used in the examples, 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 carriers.
PROHEAT heaters can be used in a variety of applications including:
Engine block heat – PROHEAT will preheat an engine block to ensure reliable
starting in cold weather. When used throughout the year, it helps to reduce
the wear associated with cold starts.
SECTION B. INTRODUCTION B-1

Cab or sleeper heat (with the engine off) – PROHEAT will supply heat to a
vehicle cab or sleeper so drivers can sleep in comfort during cold weather
without idling the engine, which reduces fuel consumption.
Supplemental heat (with the engine running) – as the efficiency of modern
diesel engines improves, there is less reject heat available to heat the vehicle’s
interior, particularly for buses. PROHEAT can be used while the vehicle is
operating to provide supplemental heat for the vehicle 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 applications – Marine applications typically involve the engineering and
installation of a complete hot-water heating system of which PROHEAT is one
component. PROHEAT recommends that only an expert in marine hot-water
heating systems install a PROHEAT on a boat. The installer is responsible for
ensuring that the installation complies with all applicable regulations.
B-2 PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

1.0 TECHNICAL
SPECIFICATIONS
X45 Plus 12V X45 Plus 24V
RATING 45,000 BTU (13 kW)
SYSTEM VOLTAGE 10 –15 VDC 20 – 30 VDC
Nominal voltage range
CURRENT DRAW 7.5 Amps 3.75 Amps
FUEL CONSUMPTION
(Average to maximum) 0.1 – 0.45 gal/hr. (0.4 – 1.7 L/hr.)
COOLANT FLOW 8.0 gal/min. (30 L/min.)
COOLANT TEMPERATURE (at heater) 150°F to 185°F (65°C to 85°C)
OPERATING TEMPERATURE RANGE -40°F to +122°F (-40°C to +50°C)
IGNITION TYPE Electronic spark ignition
HEAT EXCHANGER CAPACITY 1 quart (0.95 L)
WEIGHT Heater ONLY 40 lbs (18 Kg)
WEIGHT Heater with enclosure 55 lbs (25 Kg)
DIMENSIONS – HEATER (L x W x H) 18.9 x 11.2 x 10.6 inches
(520 x 320 x 280 mm)
DIMENSIONS – ENCLOSURE (L x W x H) 20.2 x 12.3 x 10.5 inches
(513 x 313 x 267 mm)
WARRANTY Two years parts and labor
DANGER FUEL TYPES

COMPATIBLE Diesel (ULSD, #1, #2, Arctic), JP8, Jet A1
DO NOT use gasoline. Bio fuels – Contact PROHEAT www.proheat.com
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
Maximum 3 Amp draw (over-load shut-off protection)
High-side switched
INDICATOR LIGHT Same as system voltage
High-side switched
AUTOSTART Same as system voltage
High-side switched
SYSTEM INPUTS
SWITCH 10 – 15 VDC (12V X45 Plus) | 20 – 30 VDC (24V X45 Plus)
Standard mode
Preheat mode (momentary)
Supplemental mode
Anti-freeze mode
Supplemental Priority, Supplemental Max Heat,
Global Low Temperature
POWER 12 VDC or 24 VDC
CANBus Meets SAE J1939-11
SECTION 1. TECHNICAL SPECIFICATIONS 1-1

1-2
NOTES:
1/ REFER TO X45 PLUS PARTS BOOK SL9170 FOR PART
NUMBER IDENTIFICATION
THIS SPACE
Figure 1-1.
IS REQUIRED FOR 2/ DIMENSIONS ARE FOR REFERENCE PURPOSES ONLY
COMBUSTION TUBE REMOVAL AND SUBJECT TO CHANGE WITHOUT NOTICE
1.3" [34] COOLANT OUTLET
C
L EXHAUST
PORT
1.5 I.D.
6.40" [163]
4X 0.38" [10]
2X 5.5" [140] MOUNTING HOLES
11.2" [284]
10.1" [258]
8.50" [216] 2X 7.5" [191]

1.1.1
Heater Dimensions – X45 Plus

STANDARD EXHAUST PIPE COOLANT INLET
5.5" [140]
SEE NOTE 1
9.4" [239]
AUXILIARY MOUNTING PLATE - SEE NOTE 1
TOP VIEW TOP VIEW
MOUNT HOLE DIMENSIONS
THIS SPACE IS REQUIRED FOR

11.2" [285] COMBUSTION TUBE REMOVAL
CL EXHAUST COOLANT OUTLET
PORT CONNECTION 3/4" [19]
4.4" [112]
5.5" [140] ID HOSE 1/2" NPT
HOSE FITTING
4.0" [101] SEE NOTE 1
X45 PLUS HEATER
10.2" [259] 10.6" [270]

8.7" [222]
N R
SO
OT
L
TI L
L A ND
RE
I
T R AL E E ,
1.6" [41] 1.3" [33]
C
L EXHAUST
Ø1.5" [38] PORT
FUEL SUPPLY
CL EXHAUST
5.1" [129] 2.0" [50] CONNECTION
PORT 1.9" [49] 1/4" [6.3] ID HOSE
4.9" [125] SEE NOTE 1
1.1 PHYSICAL – X45 PLUS
AUXILIARY MOUNTING PLATE

SEE NOTE 1
COOLANT INLET
18.9" [479] CONNECTION RIGHT SIDE VIEW
3/4" [19] ID HOSE
LEFT SIDE VIEW
FRONT VIEW
PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

Figure 1-2.
20.0" [508] NOTES:
1/ REFER TO X45 PARTS BOOK SL9170 FOR PART
2/ DIMENSIONS ARE FOR REFERENCE PURPOSES ONLY
AND SUBJECT TO CHANGE WITHOUT NOTICE
12.0" [305]
SECTION 1. TECHNICAL SPECIFICATIONS

1.1.2
3.6" [92]
THIS SPACE TOP VIEW COOLANT OUTLET CONNECTION
ASSEMBLED IS REQUIRED FOR
ENCLOSURE LID REMOVED 3/4" [19] ID HOSE
ENCLOSURE COMBUSTION COOLANT INLET 1/2" NPT HOSE FITTING
TUBE REMOVAL CONNECTION SEE NOTE 1
3/4" [19] ID HOSE
9.9" [252]
3.6" [92]
Heater Dimensions including Enclosure – X45 Plus

10.5" [267] 10.5" [267]
8.5" [216]
N R
SO
OT
L
TI L
L A ND
RE
I
T R AL E E ,
3.8" [97]
2X 1.4" [36]
2X 1.20" [30]
12.0" [305] FRONT VIEW FUEL SUPPLY 7.1" [181]
ENCLOSURE LID REMOVED CONNECTION
1/4" [48] ID HOSE
LEFT SIDE VIEW SEE NOTE 1 RIGHT SIDE VIEW
ENCLOSURE LID REMOVED ENCLOSURE LID REMOVED
20.2" [513] 12.3" [313]

X45 PLUS WITH ENCLOSURE
10.5" [267]
ENCLOSURE COVER ENCLOSURE COVER ENCLOSURE COVER

LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW
1-3
1-4
CONNECTOR TERMINAL NOTICE
DESIGNATORS
All control signal input voltages must
Figure 1-3.
123
A A match heater supply voltage.
B B
C C All heater output signals will match
NOTE ORIENTATION
OF CONNECTOR LUGS
D D
heater supply voltage.
E E
F F
HEATER INTERNAL HARNESS

18 PIN CONNECTOR PIN OUT DETAIL
NOTES:
1/ REFER TO X45 PLUS PART BOOK SL9170 FOR PART
OPTIONAL IMPACT SWITCH
HEATER INTERNAL HARNESS PCM
SEE NOTE 1
SEE NOTES SEE NOTES
Wiring Diagram – X45 Plus

A B C
OVERHEAT SENSOR
A (+)PINK A (+)PINK C2 C2
B A
B A
B (-)PINK B (-)PINK D3 D3
COMPRESSOR A (+)ORANGE A (+)ORANGE A1 A1
B A
B (-)BLACK/ORANGE B (-)BLACK/ORANGE B1 B1 AUTOSTART OUTPUT – (HIGH SIDE SWITCHED)( 1 AMP MAX)
1 1
ANTI-FREEZE SWITCH INPUT – ACTIVE HIGH
2 2
FUEL PUMP
OPTIONAL GROUND FUSE PREHEAT MONTARY SWITCH INPUT – ACTIVE HIGH
3 3
SEE NOTE 1
SUPPLEMENTAL SWITCH INPUT – ACTIVE HIGH
4 4
10 A PLUGGED
HEATER CHASIS GROUND LUG C1 C1 GREEN – MAIN SWITCH INPUT (STANDARD "ON" SIGNAL OR
5 5 PREHEAT UNLATCH) – ACTIVE HIGH
C3 C3 P2 6 6
SUPPLEMENTAL MAX HEAT SWITCH INPUT – ACTIVE HIGH
(GROUND VIA (-)BLACK/GREEN SWITCH/ 7
7 AUXILIARY OUTPUT GROUND (1 AMP MAX)
COMBUSTION TUBE) CONTROL
8 8
(+) (+)RED UNUSED
9 9
RED – POWER OUTPUT (CONSTANT POWER. TIMER/SWITCH
IGNITION IGNITION D2 D2 REMOTE PANEL) (1 AMP MAX)
10 10
ELECTRODE COIL D1 D1
11 11 CANBUS HIGH SEE NOTES
(-) (-)BLACK CANBUS LOW
P4 12 12
HEATER CANBUS SHIELD
13 13
A (+)PURPLE A (+)PURPLE A3 A3 INTERNAL
HARNESS 14 BLACK – GROUND (INDICATOR GROUND) (1 AMP MAX)
A B
BLOWER 14
B (-)BLACK/PURPLE B (-)BLACK/PURPLE B2 B2
WHITE – INDICATOR OUTPUT (HIGH SIDE SWITCHED. DASH OR
PROHEAT TOGGLE SWITCH LIGHT) (1 AMP MAX)
A (+)BLUE A (+)BLUE
COOLANT A2 A2
B A
PUMP B (-)BLACK/BLUE B (-)BLACK/BLUE B3 B3
A (+)WHITE A (+)WHITE F2 F2 BLACK – BATTERY NEGATIVE (GROUND)

FLAME 1 1
B A
SENSOR B (-)BLACK/WHITE B (-)BLACK/WHITE E2 E2 P1 RED – BATTERY POSITIVE (FUSE/BREAKER 15 AMP)
2 2
POWER/ WHITE – SLEEPER FAN OUTPUT (HIGH SIDE SWITCHED)
SLPR FAN 3 3 (3 AMPS MAX)
A (+)BROWN A (+)GRAY F3 F3 4 4
TEMPERATURE BLACK – SLEEPER FAN OUTPUT GROUND (3 AMPS MAX)
B A
SENSOR B (-)BROWN B (-)BROWN E3 E3
HOUR METER (AUXILIARY OUTPUT) A (+)RED/WHITE E1 E1

12V/24V 1A MAX. B (-)GREEN/WHITE F1 F1
1.2 ELECTRICAL – X45 PLUS
P3 USB
DATALINK
PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

1
10
Figure 1-4.
6 P2 NOTES:
1/ REFER TO X45 PART BOOK SL9070 FOR PART
CONNECTOR
TERMINAL
DESIGNATORS
1 2 3
SECTION 1. TECHNICAL SPECIFICATIONS

3 1
F
E
D
P4 P1
NOTE ORIENTATION
OF CONNECTOR LUGS
C
B
A 4 2
PCM Electrical Connections – X45 Plus

DETAIL A DETAIL B
P4 CONNECTOR PIN OUT DETAIL P1 - P2 CONNECTOR PIN OUT DETAIL
PROHEAT CONTROL MODULE (PCM)
DETAIL B
DETAIL A
P2 - SWITCH/ CONTROL
14 PIN
P4 - HEATER
INTERNAL
HARNESS
18 PIN
P1 - POWER/SLEEPER
P3 - USB DATALINK FAN 4 PIN
(STANDARD B) PORT
CONTROLLER VOLTAGE AND PART NUMBER

IDENTIFICATION SEE NOTE 1
1-5
1.3 TORQUE SPECIFICATIONS
FAN END CASTING

• Apply anti-seize to bolts (3)
• Torque bolts (3) to 75±5 in/lbs (8.5±0.5 Nm)
REGULATOR
• Apply anti-seize to cap screw
• Torque cap screw to 94±6 in/lbs (10.6±0.7 Nm)
FLAME SENSOR
• Torque sensor to 25±3 in/lbs (2.8±0.3 Nm)
IGNITER
• Apply anti-seize to igniter threads
• Ensure gasket is present before installing
• Torque igniter to 50±5 in/lbs (5.6±0.6 Nm)
COMBUSTION TUBE
• Apply anti-seize to cap screws
• Torque cap screws (4) to 25±3 in/lbs (2.8±0.3 Nm)
1-6 PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

OVERHEAT SENSOR
• Lubricate O-ring with O-ring lubricant
• Torque senor to 500±50 in/lbs (56±5.6 Nm)
TEMPERATURE SENSOR
• Lubricate O-ring with O-ring lubricant
• Torque senor to 25±3 in/lbs (2.8±0.3 Nm)
AIR FILTER
• Torque cap screw to 50±5 in/lbs (5.6±0.6 Nm)
BLOWER ASSEMBLY
X45 PLUS PROHEAT CONTROL MODULE (PCM)


MAIN INTERNAL HARNESS
• Torque bolt (1) to 10±2 in/lbs (1.1 +/- 0.2)
NOZZLE TO FAN END

• Lubricate O-ring on nozzle with diesel
• Torque nozzle to 150±10 in/lbs (17±1.1 Nm)
NOZZLE REASSEMBLY
• Torque nozzle (1) to 30±3 in/lbs (3.4±0.3 Nm)
BAND CLAMPS
• Torque clamps (4) to 25±3 in/lbs (2.8±0.3 Nm)
ENCLOSURE LID (Optional)

• Anti-seize recommended on bolts
• Torque clamps (2) to 30±3 in/lbs (3.4±3.4 Nm)

HARNESS GROUND LUG
• Apply anti-seize to bolt
• Torque bolt (1) to 75±5 in/lbs (8.5±0.5 Nm)
B
FUEL PUMP ASSEMBLY
A
• Apply Loctite 242 to threads
B
• Lubricate O-ring with diesel fuel
C • Torque relief valve to 22±2 in/lbs (2.5±0.2 Nm)
C
• Apply Loctite 59241 sealant to threads
• Torque elbow (1) to 55±5 in/lbs (6.2±0.5 Nm) minimum or until
elbow is at correct orientation
FUEL FILTER
• Lubricate O-ring with diesel fuel
• Torque nut (1) to 150±10 in/lbs (17±1.1 Nm)

2.0 INSTALLATION
The installation details described in this manual focus on truck applications

NOTICE and do not cover all of the possible installations. As seen in the figures
If additional installation information is below, the PROHEAT X45 Plus can be installed on a variety of equipment
required, please contact your PROHEAT including trucks, school buses, coaches, drill rigs, mine dump trucks, and
dealer regarding your specific application. excavators. In these cases, the manual should be used as a guideline only.
For more technical information, There are eight major steps that must be completed to successfully install the
please contact PROHEAT Product PROHEAT heater:
Support at www.proheat.com
2.1 LOCATING THE HEATER......................................................... page 2-2
2.2 MOUNTING THE HEATER....................................................... page 2-4
2.3 EXHAUST PIPE CONNECTION................................................. page 2-6
2.4 COMBUSTION AIR SUPPLY................................................... page 2-7
2.5 PLUMBING THE SYSTEM....................................................... page 2-8
2.6 WIRING & ELECTRICAL CONNECTIONS................................. page 2-11
2.7 FUEL SYSTEM.................................................................... page 2-22
2.8 FIRST TIME STARTUP.......................................................... page 2-26
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.
Figure 2-1. Other Applications
SECTION 2. INSTALLATION 2-1

2.1 LOCATING THE HEATER
2.1.1 SELECT YOUR LOCATION
The most suitable location for mounting the heater will vary depending
on the type of vehicle. Recommended mounting locations are:
You Choose + • Behind the cab across the frame rails (1).
• On either side of the frame rails (2).
• In an existing enclosure on the vehicle (step or toolbox) (3).
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 1
prevent damage to the PROHEAT 2
electronics.
3
Figure 2-2. Recommended Mounting Positions
2.1.2 GENERAL CONSIDERATIONS

• Never mount the heater to two separate parts of the vehicle.
• Avoid mounting the heater in areas of excessive vibration.
• Do not mount the heater directly to the engine.
• Do not mount the heater beneath a wood floor without a proper fire wall
above the heater.
• Avoid mounting the heater in areas of excessive dust, dirt, and moisture
accumulation.
• The heater must be easily accessed for service.
WARNING COOLANT OUT

Never locate the heater inside
the vehicle cab. (See figure 2-3)
FUEL IN
MINIMUM COOLANT IN
CLEARANCE 6”
Figure 2-3. Figure 2-4. Allow minimum 6” clearance

for hose connections.

Heater must be mounted below the highest point in the cooling system. An
expansion tank may be added to the coolant system above the heater if this
is not possible.
HIGHEST POINT IN
COOLING SYSTEM
HEATER MUST
BE MOUNTED
BELOW
HIGHEST POINT
PROHEAT OR RADIATOR
Figure 2-5. Height Requirement
2.1.3 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 Figure 2-6. Adequate Air Flow
does not exceed 185°F (85°C).
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.
Heater must be mounted within 5˚ of horizontal, as shown.
5˚ 5˚
5˚ 5˚
Figure 2-7. Mounting Angle

2.2 MOUNTING THE HEATER
Select Your Mounting Option
2.2.1 OPTION A – Heater With Enclosure

1. Remove the enclosure cover.
2. Drill the (4) mounting holes and exhaust pipe clearance hole.
3. Using the bolts supplied, fasten the enclosure to the mounting tray
or brackets.
NOTE: Ensure that the combustion tube can be removed for service.
See figure 1-2 on page 1-3 for service space requirements.
Figure 2-8. Mounting Tray
20” (508 mm)
1 5/8”
(45 mm)
3” (76 mm) Dia.

5” (127 mm)
5” (127 mm)
CENTERLINE OF ENCLOSURE
12”
(306 mm)
5 3/4” (146 mm)

8 13/16”
(223 mm)
3/4” (20 mm) MOUNTING HOLES
(4 REQUIRED) 5” (127 mm)
16 11/16” (427 mm)

1 5/8” (45 mm)
Figure 2-9. X45 Plus Enclosure Base Dimensions

2.2.2 OPTION B – Heater Without Enclosure
Heaters supplied without an enclosure need to be mounted in an existing
NOTICE enclosure on the vehicle, such as a tool box. Heater supplied with an auxiliary
mounting plate.
Use anti-seize compound on fasteners
to prevent galling and corrosion. 1. Ensure that the proposed enclosure is big enough for the heater.
12.5”W x 11”H x 20.5”L (318 x 280 x 521 mm).
2. Using the indicated dimensions, drill the (4) mounting holes
and exhaust pipe clearance hole.
NOTE: Ensure that the combustion tube can be removed for service.
See figure 1-2 on page 1-3 for service space requirements.
8.5” (216 mm)

4 X .38” (10 mm)
1.0” (25 mm) MOUNTING HOLES
3” (76 mm) Dia.
5”
(127 mm)
5.5”
(140 mm)
6.4”
(163 mm)
5” (127 mm)
2.02”
(51 mm) 7.5” (191 mm)
Figure 2-10. X45 Plus Mounting Plate Dimensions & Exhaust Hole

2.3 EXHAUST PIPE CONNECTION
1. Push the exhaust pipe through the hole in the enclosure and onto the
exhaust outlet port of the heater. Ensure that the pipe is pushed onto
the spigot at least 11⁄2” (38 mm).
2. Route the exhaust pipe such that:
• exhaust gasses do not enter the passenger compartment
• exhaust gasses do not enter the heater’s combustion air inlet
• exhaust system does not rest against or be directed toward any parts of
the vehicle that may be damaged by heat (such as brake lines, seals,
wires, rubber hoses, or bumpers). The exhaust pipe may have to be insulated
if it’s within 6” of combustible materials or composite body parts
• the exhaust outlet does not face the same direction as vehicle travel
• debris and snow will not plug the outlet
NOTICE • the exhaust pipe is protected from curb damage
If additional information is required, • the exhaust system should have a downwards slope for condensation
please contact your PROHEAT dealer to drain. If needed a 3/8” hole should be drilled into the exhaust pipe
regarding your specific application. at the lowest point so that the condensation will drain
Alternatively, please contact PROHEAT 3. Disassemble the exhaust pipe clamp and apply anti-seize compound to
Product Support at www.proheat.com. the threads.
4. Assemble the exhaust clamp over the exhaust pipe (clamp goes inside
the enclosure) and tighten the nuts.
NOTE: 11⁄2” 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.
WARNING
Exhaust gases must not enter the
vehicle interior. Direct exhaust pipe
away from vehicle.
NOTICE Use formed elbows.
Use of muffler or other restrictions in the

exhaust system is not recommended.
EXHAUST CLAMP Do not use welded

U BOLT (APPLY 90˚ elbows.
DIRECTION ANTI-SEIZE
OF VEHICLE COMPOUND
TRAVEL TO THREADS)
ENSURE THERE ARE

NO AIR LEAKS AROUND
THE CONNECTION
Figure 2-11. Exhaust Pipe

2.4 COMBUSTION AIR SUPPLY
The heater’s combustion air intake must be in an area of calm, clean and dry
air. If this is not possible, a snorkel hose may be used to draw combustion air
from a remote source.
An air intake snorkel hose may be required to prevent the Proheat from drawing
dust, dirt and moisture into the combustion chamber.

• Must not be taken from the passenger compartment.
• Snorkel hose or pipe must be smooth on the ID to prevent any disruption in
air flow.
• The hose length should not exceed 7 ft.
• No more than 270° of total bends.
• The center line bend radius must be 3.5” or greater to prevent kinking of
the hose.
• Route to an area of calm, clean and dry air.
• Clamps must be sized so they do not kink or crimp snorkel hose.
• The use of an air filter is not recommended.
2.4.2 AIR INLET SNORKEL HOSE OPTION
2’ AIR INLET
SNORKEL HOSE
PK0320
Figure 2-12. Air Inlet Snorkel Hose (Optional)

2.5 PLUMBING THE SYSTEM
Coolant flow must be maintained throughout the coolant system
under all conditions.
MA • Keep the engine inlet and outlet ports as far apart as possible to maximize
XI
MU cross-flow through engine.
M
CR • Coolant pump and engine water pump must flow in the same direction.
OS
S-
FL • Ensure that no sharp kinks or bends exist in the hoses which may restrict
OW
coolant flow.
• Avoid high points in the hose routing to prevent air traps.
• 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:
⁄2” NPT pipe fittings or bigger
1
Figure 2-13. Maximum Cross-flow ⁄4” ID heater hose

3
NOTE: Use of silicone hose requires special 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 + 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, using
auxiliary heater core and fan kit PK0360 or similar.
NOTE: Plumbing the PROHEAT through the dash fan is not
recommended.

Instructions for Options A and B
1. Remove the radiator cap to release the system pressure.

WARNING
Opening the radiator cap when the 2. Drain the coolant system.
engine is hot may cause serious injury. 3. Plumb the system as per figure 2-14 or figure 2-16.
4. Add engine coolant to the system as per the specific engine manufacturer’s
recommendations and re-install the radiator cap.
NOTE: Plumbing the PROHEAT through the dash fan is not recommended.
2.5.2 OPTION A – Engine Heat or Supplemental Heat
DASH HEATER
RETURN TO ENGINE
SUPPLY TO PROHEAT ENGINE
Figure 2-14. Engine Heat or Supplemental Heat
NOTE: On coolant systems where the return from the PROHEAT is plumbed to
the bottom of the main 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
® ®
SUPPLY TO PROHEAT SUPPLY TO PROHEAT
Figure 2-15. Correct Return Line Plumbing

2.5.3 OPTION B – Engine and Sleeper Heat
AUXILIARY SLEEPER DASH HEATER

HEATER PK0360
RETURN TO ENGINE
SUPPLY TO PROHEAT ENGINE
Figure 2-16. Engine and Sleeper Heat

2.6 WIRING & ELECTRICAL
CONNECTIONS

• Prior to installation of the PROHEAT heater system, ensure that the vehicle
batteries are in good condition.
• Do not kink or abrade wires when routing them through the vehicle during
installation.
• Ensure wires are well supported and secured with tie-wraps.
• Do not use acid core solder when making solder connections.
Major Electrical Connections Required

• Power connection to batteries.................................................. page 2-12
Figure 2-17. Test Battery • Timer or ON/OFF switch connections........................................ page 2-15
• Optional add in harness.......................................................... page 2-17
• Optional add in Sleeper fan harness......................................... page 2-19
WARNING
Do not use on positive ground
vehicles.
SWITCH I/O HARNESS

CAUTION
If repairs to the vehicle require
welding, disconnect the PROHEAT
power cable at the PCM. This will
prevent damage to the PROHEAT
electronics.
CAUTION
Vehicles using ground side battery
disconnect switches must install an
in-line 10 Amp fuse on the internal
harness (PROHEAT part # PK0310). POWER HARNESS
This will prevent damage to the TO ON/OFF SWITCH
harness and PCM. (Refer to page AND/OR TIMER
2-12).
Figure 2-18. Major Electrical Connections

2.6.2 POWER CONNECTION TO BATTERIES
The new X45 Plus Proheat Control Module (PCM) requires a fuse to be installed
on the positive power supply cable at the battery or power source.
Figure 2-19. Fuse kit.
Installation Instructions
1. The fuse kit comes with a 15 amp ATO fuse and a pre wired fuse holder, one
NOTICE crimp and heat shrink ring terminal and one crimp and heat shrink butt splice.
If batteries are equipped with a ground 2. Inspect the power harness from the Proheat to the batteries for corrosion,
side disconnect, a second fuse kit kinks, cuts or damage. Replace existing harness with a new X45 Plus power
must be installed on the power harness harness 305531K if needed and continue with fuse installation in step 3.
negative wire.
3. Strip outer wire jacket of the power harness back to expose the positive (red)
lead (figure 2-21). Strip the lead as shown in figure 2-20, using the provided
crimp and heat shrink butt splice connect the fuse to the end of the red
NOTICE wire, then crimp and heat shrink as per instructions on page 2-13. On the
Remove and clean battery terminals. other side of the fuse connect the provided crimp and heat shrink ring
Prior to re-connecting, grease terminals terminal, then crimp and heat shrink as per instructions on page 2-13.
with electrically conductive grease. Connect the leads to the battery terminals. (See figure 2-21.)
STRIP WIRE AS SHOWN AND

CRIMP TO TERMINAL
0.3" (7.6 mm) HEAT SHRINK
Figure 2-20.
OPTIONAL GROUND SIDE FUSE
X45 PLUS POWER

HARNESS
BLACK (-) NEGATIVE
REQUIRED POSITIVE
SIDE FUSE
RED (+) POSITIVE
Figure 2-21. Power Connection to Battery.

Crimping & Heat Shrinking Instructions
1.
Strip the wires 0.3” (7.6 mm) from the end and insert into the crimp barrel.
WARNING 2.
BATTERIES. Wear hand and eye Making sure the wire end is properly seated, make the crimp connection
protection when working near using a tool designed for insulated splices.
batteries. Do not smoke or use
open flames near batteries.
3.
Apply heat directly to

the splice working from
the center out to the edges,
using a hot air gun, until the
tubing shrinks and the
adhesive flows. Allow to cool
before inspecting splice and
checking integrity.
2.6.3 HEATER MODES

The X45 Plus has four basic modes of operation:
Standard Mode
(Engine OFF or RUNNING) (Pre wired for included switch or optional T-II Timer)
Coolant temperature is monitored via a built-in sensor. When the temperature at
the PROHEAT is below 150°F (65°C)* 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 or optional timer. Since the coolant pump runs continuously
in this mode, it’s possible to accumulate a high number of coolant pump
operating hours vs. heater run hours when used with the engine running. Use of
supplemental mode is recommended if the heater is going to be used with the
engine running). Please refer to the wiring diagrams on page 1-4 and page 2-16.
Supplemental Mode
(Engine RUNNING) (Optional add in harness needed)
This mode is generally used in buses (school, transit, and coach) to help heat
the engine and passenger compartment all year round. This mode is typically
automatically enabled any time the engine is running.
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.
To simplify heater operation, this function is fully 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 30
seconds*. This causes coolant in the engine to be circulated through the PROHEAT.
If after 30 seconds* the coolant temperature is above 150° F (65° C)*, the

PROHEAT will turn off the coolant pump and return to supplemental standby. If
the coolant temperature remains below 150° F (65° C)*, the PROHEAT will
NOTICE operate and continue to supply heat to the system until the coolant temperature
There is a 30-second delay in response reaches 185° F (85° C). The PROHEAT then shuts itself off, returns to
to an “ON” and 5-second “OFF” signal* supplemental standby, deactivates the coolant pump and waits for the coolant
to allow time for the vehicle to start temperature to fall below 150° F (65° C)*, and the cycle is repeated.
before the heater is activated in The PROHEAT switches off when the engine stops so that the heater can’t be
supplemental heat mode. accidentally left running overnight.
Supplemental heat mode has priority over the preheat mode and will cause
the preheat mode to drop out.
Please refer to the wiring diagrams on page 1-4 and page 2-18.
Supplemental Max Heat Feature (Optional add in harness needed)

• To use this feature supplemental mode must also be enabled, the cycle on/
off temperature range shifts up to between 170–190°F (77 –88°C) to push
the average coolant temperature higher.
• This mode is useful for Tier 4 engines to help maintain higher engine
temperatures to reduce emissions and resulting regens, or when more heat
is needed such as high HVAC demands.
Please refer to the wiring diagram on page 1-4.
Supplemental Priority Feature (Optional add in harness needed)

To use this feature supplemental mode must also be enabled, when active this
gives priority to supplemental mode over standard mode. When both standard
and supplemental modes are active, the heater will run in supplemental mode.
Preheat Mode (Engine off) (Optional add in harness needed)

Preheating the engine coolant is often essential to start engines in cold weather.
And since much of an engine’s wear occurs during cold start-ups, preheating
also reduces the wear and contributes to longer engine life and reduced
operating costs.
The preheat mode is usually activated an hour or so before starting the engine
using a momentary contact switch. 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 mode is it’s switched off automatically.
No operator input is required. The PROHEAT has a built-in time-out feature to
prevent the heater from running indefinitely. 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,
simply press the momentary contact switch again.
Please refer to the wiring diagrams on page 1-4 and page 2-18.
Anti-freeze Heating Mode (Battery Save Mode) (Optional add in harness needed)
The anti-freeze heating mode is designed to minimize battery consumption
and keep the coolant system warm or from freezing over a longer period of
time such as a weekend. Anti-freeze mode is generally activated by a toggle
switch. This mode is similar to the supplemental mode and only runs the
coolant pump while heating and checking the temperature during the pre-run
cycle. The difference is that when the heater is in standby (coolant pump off)
the coolant pump is run every 20 minutes to sample the system coolant
temperature to ensure the coolant temperature is maintained throughout the
system. In Anti-freeze mode the coolant temperature will be maintained between
41°F and 60°F (5°C and 20°C)*.
When Anti- freeze mode is enabled and another heating mode becomes active
it will override Anti-freeze heating mode but will not cancel it. Once the other
heating mode is turned off the heater will return to Anti-freeze heating mode.

Global Low Temperature Feature (Optional add in harness needed)
To use this feature a heating mode needs to be enabled. This feature shifts
all the cycle on/off temperature of all operating modes (Preheat, Standard
and Supplemental) down to between 73–108°F (40–60°C)* so the overall
average coolant temperature is lower.
* There are special OEM versions for supplemental This shift can prevent short cycling especially with smaller engines and small-
heat mode. For example, temperature thresholds er coolant circuits which saves fuel and battery power over a longer period of
may have a low threshold of 160°F (71°C) rather time as well as reducing heater maintenance due to sooting up.
than 150°F (65°C) and a reduced coolant pump
pre-run time of 30 seconds rather than three The X45 Plus Switch / Control harness comes pre wired to run the heater in
minutes. Please contact PROHEAT Technical Standard mode with the included toggle switch or the optional T-II Timer.
Support for more information. Please refer to the wiring diagram on page 1-4.
For additional features or operating modes an add in harness kit is needed.

See section 2.6.6 for optional connections.
2.6.4 ON/OFF SWITCH CONNECTIONS

1. Select a suitable location in the vehicle dash for the ON/OFF switch.
Switch is for dry locations only.
CAUTION
The switch input circuit should only NOTE: Many dash panels have switches that are not used. It may be
be used to supply power to the convenient to remove one and replace it with the PROHEAT switch.
ON/OFF switch, the timer, or as 2. Drill a 1⁄2” diameter hole through the dash for the switch. Make sure you
a signal to trip a relay. Failure to have clearance behind the dash for the switch wires and connections.
follow this installation practice will Install the switch as per the diagram. (Figure 2-22.)
result in damage to the PCM.
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
CAUTION when it is passed through the hole.
The switch is not waterproof and must
be mounted in a dry location only. 4. Cut the harness to length.
5. Strip outer wire jacket of harness back to expose the 4 wires. Strip the
wires as shown and crimp the supplied 1/4” spade terminals.
NOTICE NOTE: Use fully insulated disconnects when connecting switch.
Do not connect an ON/OFF switch

and a timer in the same circuit. 3/16"
(5 mm)
DASH
1/2” DIA.
HOLE
GROUND
2" (51 mm)
SWITCH
LABEL BLACK
ON POWER
RED
OFF WHITE
ON SIGNAL
ON/OFF GREEN
SWITCH INDICATOR
NUT
Figure 2-22. ON/OFF Switch Assembly Figure 2-23. ON/OFF Switch Connections
6. Connect the terminals to the switch as shown. (Figure 2-23.)

NOTE: Connecting an ON/OFF switch and a timer in the same circuit will
cause the indicator light to flash incorrectly.

2.6.5 TIMER CONNECTIONS (OPTIONAL)
TIMER
CAUTION
The switch power circuit should
ON
1
2
3
only be used to supply power to the
TIMER
ON/OFF switch, the timer, or as
a signal to trip a relay. Failure to
follow this installation practice will
result in damage to the PCM.
NOTICE
Do not connect an ON/OFF switch
and a timer in the same circuit. BLACK BLACK
RED RED
SWITCH/CONTROL
WHITE WHITE HARNESS
GREEN GREEN
GREY
TO KEYSWITCH (OPTIONAL
BACK LIGHTING)
Black wire Ground

Red wire Power
White wire Operational signal from heater
Green wire “ON” signal to heater
Grey wire Keyswitch backlighting (optional)
Figure 2-24. Timer Connections
PRE WIRED SWITCH / CONTROL HARNESS STANDARD MODE OPTION 1
PROHEAT TIMER
9 (+) RED POWER 12V/24V OUTPUT RED
13 (-) BLACK - GROUND BLACK MANUAL
5 GREEN - ON SIGNAL STANDARD MODE 12V/24V GREEN

14 (+) WHITE - INDICATOR LAMP 12V/24V OUTPUT WHITE
CLOCK TIME DAY
TIMER
GREY
OPTIONAL
BACKLIGHT TO KEYSWITCH
STANDARD MODE OPTION 2
PROHEAT SWITCH AND

INTERNAL INDICATOR
LIGHT
Figure 2-25. Pre wired switch/control harness

2.6.6 OPTIONAL MODES AND FEATURES WIRING
To enable optional modes and features the add in harness must be added to the
corresponding pin on the switch/control harness.
1. Carefully prying between the black edge of the connecter and one of the
PIN# DESCRIPTION corners of the red wedge lock until it is released from (but not completely
1. Autostart output – (high side out of) the connector body. Repeat if necessary on the opposite corner.
switched) ( 1 amp max). The red wedge lock is now in the open position.
2. Anti-freeze switch input –
active high.
3. Preheat momentary switch
input – active high.
4. Supplemental switch input –
active high.
5. Green – main switch input
(standard “ON” signal or pre-
heat unlatch) – active high.
6. Supplemental max heat switch
input – active high.
7. Auxiliary output ground
(1 amp max).
8. Not used.
9. Red – power output (constant
power. Timer/switch remote
panel) (1 amp max). Figure 2-26.
10. Yellow – CANbus high.
11. Green – CANbus low. 2. From the wire side of the connector, remove the cavity plug from the
12. Black – CANbus shield. corresponding terminals and discard.
13. Black – ground (indicator
ground) (1 amp max).
14. White – indicator output (high
side switched. Dash or Proheat
toggle switch light) (1 amp max).
NOTE: Pins 5, 9, 13 & 14 are pre populated from
the factory.
Figure 2-27.
NOTICE 3. Next align the wire with the cavity. Insert until there is an audible and tactile
click. DO NOT force the wires. If difficulty inserting the wires, ensure the
DO NOT attempt to insert any contacts red wedge lock is in the open position. Repeat steps 2 & 3 for each
with the red wedge lock in the closed option you selected.
position.
4
3
Figure 2-28.

4. Push the red wedge lock in all the way until it’s in the locked position.
NOTICE Then pull slightly on wires to ensure they are fully seated and locked.
All unpopulated cavities must have
plugs installed (wide end first).
ADD ZIP TIE
NOTICE Figure 2-29.

If the wire needs to be removed, put the
red wedge lock into the open position, 5. Add a loop of tape or zip tie to tie the harnesses together.
then from the wire side gently pull the
wire from the cavity while rotating (a The harness is now ready to be connected.
quarter turn each direction) back and
forth until the contact and wire is
removed from the connector. Ensure
all open cavities are plugged.
DEALER/OEM. TO SUPPLY
SUPPLEMENTAL MODE
MECHANIC'S DISABLE
SWITCH
12/24V
ENGINE SIGNAL
4 ON SIGNAL SUPPLEMENTAL MODE
12V/24V INPUT
3 ON SIGNAL PREHEAT MODE

12V/24V INPUT PROHEAT PREHEAT MODE OPTION 1
PREHEAT
SWITCH / CONTROL OFF
HARNESS A
9 (+) RED POWER 12V/24V OUTPUT B SPRING CENTERED
DOUBLE THROW
12 (-) BLACK – GROUND MOMENTARY SWITCH.
5 GREEN – ON SIGNAL STANDARD C
MODE 12V/24V PROHEAT
PREHEAT
14 (+) WHITE – INDICATOR LAMP ON
12V/24V OUTPUT
PREHEAT MODE OPTION 2

A
STOP SWITCH
(MOMENTARY CONTACT,
C NORMALLY OPEN)
(-)
INDICATOR LIGHT
PUSH BUTTON
START/STOP SWITCH
(+) START SWITCH

(MOMENTARY CONTACT,
F NORMALLY OPEN)
DEALER/OEM. TO SUPPLY
See page 2-15 for wiring
Figure 2-30. Preheat and Supplemental Wiring Diagram Examples

2.6.7 OPTIONAL AUXILIARY SLEEPER HEATER INSTALLATION
To enable the sleeper fan output feature, the sleeper fan add in harness must
be installed. Follow the instructions below to install.
PIN# DESCRIPTION
1. Black – battery negative
(ground).
2. Red – battery positive
(fuse/breaker 15 amp).
3. White – sleeper fan output Figure 2-31. X45 Plus Sleeper Fan Add In harness.
(high side switched)
(3 amps max).
4. Black – sleeper fan output 1. Carefully insert a standard screwdriver into the slot on top of white
ground (3 amps max). wedge lock.
NOTE: Pins 1 & 2 are pre populated from
the factory.
2. Carefully pry the white wedge lock forward and listen for audible click. The
white wedge lock is now in the open position.
3. Continue to pry the white wedge lock forward until its free from the
connector body.
Figure 2-32.
4. Remove the two cavity seal plugs by gently prying up on the lock tab and
pull the cavity plug out the back (wire side) of the connector.
Figure 2-33.

5. Replace the white wedge lock and push it all the way until it’s in the
locked position.
6. Next move the white wedge lock back to the open position as per steps 1
and 2.
Figure 2-34.
7. Align the tab on the terminal with the keyway on the connector and insert
the white wire into cavity 3 and the black wire into cavity 4. Push in until
the terminal is seated and cannot be pulled out.
NOTICE
DO NOT attempt to insert any contacts
with the white wedge lock in the
closed position.
ADD ZIP TIE
KEYWAY
TAB
Figure 2-35.
8. Push the white wedge lock in all the way until it’s in the locked position.
Then pull slightly on wires to ensure they are fully seated and locked.
9. Add a loop of tape or zip tie to tie the harnesses together.
The harness is now ready to be used with the sleeper fan.

1. Make sure the vehicle ignition is switched “OFF.”
2. Locate the auxiliary heater in a suitable area of the vehicle.
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 2-37)
4. Remove the adjusting knob and face cover. Mark and drill mounting holes.
Mount thermostat using the screws provided. (Figure 2-38)
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.
K
AC
BL
1
PCM ITE 1
WARNING WH 2 2
SLEEPER FAN
Systems using a ground side battery HARNESS ITE 3
WH
disconnect must install a 10 amp fuse 4
to protect the sleeper fan harness. THERMOSTAT
AUXILIARY
SLEEPER HEATER
Thermostat Wire Connection Detail

Screw # Wire Colour SPLICE WIRES OPTIONAL
1 White (from PCM) GROUND
ORANGE
2 White (to sleeper heater) (LOW SPEED)
3 Not used
4 Not used
RED
(NOT USED)
FAN MOTOR
(MULTIPLE WINDING TYPE)
Figure 2-36. Auxiliary Sleeper Heater Installation
MOUNTING SCREW
BASE
FACE
Figure 2-37. Thermostat Location Figure 2-38. Thermostat Detail

2.7 FUEL SYSTEM
• Use a dedicated 1/4” ID fuel line between the fuel tank and heater meeting
SAE 30R9. (Fuel line length is not to exceed 50’ with a maximum rise of 10’.)
• Ensure fuel lines are routed away from all heat sources, well secured and
CAUTION will not abrade.
DO NOT use fuel lines and pick-up
tubes less than 1/4” ID or greater • Ensure clamps are secure at fuel pump and fuel pick-up.
than 3/8” ID. Failure to use the
• Ensure the proper fuel line clamps with uniform 360° compression are used.
correct line size may result in
heater malfunction. • Use of a fuel filter is not recommended. All models have a built in fuel filter
at the fuel inlet fitting on the heater.
50’ MAXIMUM LENGTH OF FUEL LINE
Figure 2-39. Do not kink or pinch fuel

line when routing lines
10’ MAXIMUM RISE
Figure 2-40. Fuel Supply Height Requirement
You Choose + Select Your Fuel Pick-up Installation Option
Option A: Fuel pick-up to be installed in an existing 1/4”or 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.

2.7.2 OPTION A – 1/4” or 1/2” NPT Port
Locate an existing pipe thread port in the vehicle fuel tank and select the
1/4” or 1/2” NPT portion of the fuel pick-up that fits into that port. Apply a
pipe sealant paste to the fuel pick-up pipe threads prior to installation.
CAUTION
Do not use teflon tape as this will
contaminate the heater and engine
fuel system. FUEL PICK-UP
EXISTING PORT
IN FUEL TANK 1/4” NPT
FUEL TANK
Figure 2-41. 1/4” NPT Port
FUEL PICK-UP
EXISTING PORT
IN FUEL TANK 1/2” NPT
FUEL TANK
Figure 2-42. 1/2” NPT Port

2.7.3 OPTION B – Existing Blank Fuel Sender Cover Plate
Locate an existing, blank fuel sender port in the vehicle fuel tank. Remove the
cover plate, drill a 1” diameter hole and install the fuel pick-up as shown.
NUT
WASHER
GASKET
COVER PLATE SUPPLIED

WITH FUEL TANK
(REQUIRES MODIFICATION)
GASKET
WASHER
FUEL SENDER PORT IN TANK
Figure 2-43. Blank Fuel Sender Port
2.7.4 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 when drilling the hole. NUT
WASHER
GASKET
WARNING
GASKET
Drilling the fuel tank may not be
acceptable in some jurisdictions. Do
not drill the fuel tank on passenger
WASHER
carrying vehicles such as school buses.
DRILL 1” DIA. HOLE

IN FUEL TANK
Figure 2-44. Drill Hole in Tank

2.7.5 INSTALLATION
45˚±15˚
CUT BOTTOM
OF FUEL PICK-UP
AT AN ANGLE
3”-4” CLEAR
3-4” CLEAR OF BOTTOM OF TANK
Figure 2-45. For some situations where Figure 2-46. 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-up 3 to 4” shorter as shown in figure 2-46.
2. Install the pick-up into the fuel tank as per selected option.
3. 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
FUEL TANK
FUEL LINE
FUEL HOSE CLAMP
FUEL LINE FUEL PICK-UP
Figure 2-47. Fuel Line Connection Detail

2.8 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
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:
• make sure the coolant is flowing freely
• inspect hoses and fittings for leaks
• check the coolant level in the radiator and add coolant as necessary
5. Shut the engine “OFF.”

6. Connect the power harness. All segments of the LED will flash on the
PCM. This indicates that power has been supplied. See page 4-3 for
more information.
7. Load the configuration file if needed. See Section 2.8.1 on page 2-27.
8. 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
3-8 and page 3-9 for more information.
Sequence of Events:
• Coolant temperature must be less than 150˚F (65˚C).
• “ON” light on PCM should be lit.
• You should hear the coolant pump, blower, and compressor start.
Looking through the inspection port you should see a spark and
a flame.
• 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. See Troubleshooting & Repair Manual.

9. Once the heater is started it will continue to run until the coolant
temperature reaches 185˚F (85˚C) at heater outlet, then it will shut off.
NOTE: The vehicle dash temperature gauge may read significantly less
depending on the location of the sender unit on the engine.
Sequence of Events for Cycle Off
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.
10. The heater will cycle on when the coolant temperature falls below 150˚F
(65˚C) at heater outlet, as long as the ON/OFF switch is left “ON.”
11. 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.
12. Switch the ON/OFF switch to “OFF.” The red light will go out and the
NOTICE heater will Cool Down (Purge) for three minutes.
To ensure full warranty coverage,
13. Inspect the installation again for leaks.
complete the warranty card and mail
to PROHEAT. 14. Install the enclosure cover.
2.8.1 PROGRAMING A REPLACEMENT PCM/CHANGING

THE PCM CONFIGURATION
PCM Kits: First time power up
When the replacement X45 Plus PCM is powered up for the first time the display
will be flashing “CC” and requires a configuration number to be selected before
the PCM will function.
OLD NEW
G-I PCM G-II PCM G-III PCM X45 Plus 2 digit
Config file code
X45 12V ~ 903100 999100 999110 10 All 12 Volt models
Sleeper Fan Standard Voltage and Temperature Range
X45 12V ~ 904200 999100
Aux Input
X45 12V ~ 904300 904300 999130 30 All 12 Volt School Buses
School Bus Standard Voltage and Temperature Range
X45 12V ~ ~ 999350 999135 35 12 Volt School Bus Special
School Bus • Voltage range 11.2–16VDC
Special • Temperature range 160–185°F (71–85°C)

Config file code
X45 24V 985628 905300 999400 999140 40 All 24 Volt models
Aux Input Standard Voltage and Temperature Range

1. Use the (right) SELECT button to toggle up through the configuration
numbers, configuration display should continue to flash during setting (10,
30, 35, and 40) until the desired configuration number is displayed.
2. Press the (left) ENTER button and hold for 2 seconds to lock in configuration.
The configuration number will flash 4 times to indicate confirmation and
then go ON solid for 2 seconds before the display is turned off.
3. Once the configuration number has been set, apply the correct
identification decal.
- Red for all 12 volt models
- Yellow for all School Bus models
- Green for all 24 volt models
4. PCM is now in the off state and is ready to use.
ENTER
BUTTON
SELECT
BUTTON
DECAL
Figure 2-48. X45 Plus PCM
Identifying the saved PCM configuration number.

To identify the current saved configuration number, the power to the PCM
must be disconnected for 20 seconds.
When the power is reconnected, all of the LED’s flash twice “88” on power
up, Followed by a 2 second display of the configuration code.
PCM configuration change

• If the wrong configuration is saved in the PCM or if change is desired.
• Press and hold both SELECT and ENTER buttons for 5 seconds until the
configuration change indicator “CC” is flashing.
Use the (right) SELECT button and set the correct configuration as per steps
1 and 2 above.

3.0 PRINCIPLES
OF OPERATION
3.1 COMPONENT DESCRIPTION
3
6 17
Figure 3-1. PROHEAT Heater
5
1. Fuel Pump A gear pump driven from the same motor as the compressor pulls fuel from
the tank. The fuel is filtered at the fuel pump inlet.
2. Fuel Regulator Reduces fuel to atmospheric pressure. Siphoning action from the nozzle
draws fuel from the regulator. Without this siphoning there is no fuel flow.
3. Air Compressor A diaphragm type compressor supplies air to the fuel nozzle.
4. Ignition Coil An automotive type ignition coil supplies high voltage to the ignition electrode,
sparking to the combustion tube.
5. Coolant Pump 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.)
SECTION 3. PRINCIPLES OF OPERATION 3-1

6. PROHEAT Control The PCM utilizes a microprocessor to monitor operating conditions and
Module (PCM) control outputs 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.
NOTE: See “Modes of Operation Section” for a description of the operating
modes used.
NOTE: The PROHEAT PCM “Sleeper Fan” will be turned off during ignition.
Figure 3-2. LED will light to indicate a problem. Switch or timer indicator light will
flash to indicate the diagnostic code (page 4-3)
7. Nozzle An air/fuel aspirating-type spray nozzle located inside housing. The compressed
air flows through the nozzle at high speed creating a venturi effect. This siphons
fuel from the regulator and combines it with the air, creating an extremely fine
mist that 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) as it passes through the heat exchanger, depending on the
flow rate.
11. Ignition Electrode 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.

12 10 13
11
8
7
14
Figure 3-3. PROHEAT Heater Detail
12. Coolant Temperature Measures coolant temperature at the outlet port of the heat exchanger.
Sensor
13. Overheat Breaker Protects the heater from damage should it be operated without coolant. The
Sensor overheat breaker monitors the surface temperature of the heat exchanger casting.
When the 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.
14. Flame Sensor Photo-electrically measures the intensity of the flame. The flame sensor
signals to the PCM that the air/fuel mixture is burning properly.
15. On/Off Switch Used to switch the heater “ON”

and “OFF.” It has an indicator
lamp that displays a red light Indicator Light
when switched “ON.” A flashing Located in the Toggle
red light indicates a heater
diagnostic code and one of the
LEDs on the PCM diagnostic
display will be lit. (See page
4-3 for details.)
Figure 3-4. ON/OFF Switch

16. Optional 7-Day Used to switch the heater “ON” and “OFF.” This can be done manually or by a
Timer 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 4-3
for details.)
T-II
MANUAL
INDICATOR LIGHT
(RED)
MANUAL BUTTON
TIMER SET BUTTON
CLOCK TIMER
BUTTON INDICATOR LIGHT
(GREEN)
Figure 3-5. 7-Day Timer
17. Optional Add In Sleeper The PROHEAT X45 Plus Control Module is equipped with a 3 amp limited
Fan Harness output. It is used to drive fans or other equipment as determined by the
installation (see page 2-1). The output is ON 60 seconds after switch ON.
In addition, it is also ON when there is a functional error (see page 4-1 for
details).

3.2 THEORY OF OPERATION
There are four basic systems within the PROHEAT.
1. Air Compressor The purpose of the air compressor is to deliver a metered amount of clean
compressed air to the nozzle.
As the motor turns it drives a diaphragm type compressor. The compressor draws
fresh air through an air filter located on the front of the compressor. It’s then
compressed and delivered to the nozzle in the fan end casting via a hose.
2. Fuel Supply System The purpose of the fuel supply system is to deliver clean, air-free fuel to the
fuel regulator.
As the compressor motor turns, it directly drives a positive displacement type
gear pump. The fuel pump draws (under a vacuum) fuel from the fuel tank
through the fuel line. The fuel then enters the sintered fuel filter located
behind the fuel inlet fitting on the front of the pump. The fuel then enters the
fuel pump gears. The fuel pump then pressurizes the fuel to 5–10 psi. This
pressure is controlled via the fuel pump relief valve. The fuel then enters the
fuel regulator via a hose. The fuel regulator then reduces the fuel pressure to
0 PSI. The fuel is now drawn from the regulator by the low pressure created
by the nozzle (like a carburetor float bowl).
3. Nozzle The purpose of the nozzle is to atomize the fuel and set the fuel/air ratio.
The compressed air travels over the body of the nozzle. As it reaches the end
of the nozzle, it passes through a restriction. This creates a negative
pressure or venturi effect (like a carburetor). This negative pressure extends
back through the centre of the nozzle all the way to the fuel regulator. This
negative pressure causes fuel to be siphoned from the fuel regulator (like a
carburetor float bowl). The compressed air and fuel are then mixed at the end
of the nozzle into a very fine mist of fuel/air that is sprayed into the
combustion chamber in the shape of a cone.
4. Combustion Air The purpose of the combustion system is to deliver a metered amount of air
System to the combustion tube. This provides the majority of the air needed to
combust the atomized fuel/air mist created by the nozzle, and to cool the
combustion chamber when the heater cycles off.
As the blower motor turns, it directly drives the combustion air blower blade.
The combustion air is not filtered so it needs to come from a clean area. A
snorkel hose is sometimes used to draw air from a clean source. The air is
then directed into the combustion tube. The fan end casting is shaped in such
a way that it causes the air to swirl into the combustion tube. The swirling air
then mixes with the atomized fuel/air cone from the nozzle. Once lit this
creates an intense flame in the combustion tube. The hot gases then reach
the end of the combustion tube and make a 180 degree turn to enter the
heat exchanger. The heat exchanger has fins that transfer the heat to the
coolant that flows around the heat exchanger. The gases then enter the
exhaust system and are directed away from the vehicle.

All four systems must work together to produce safe, smoke-free operation of
the PROHEAT. It is important for the service technician to understand the four
systems and how a change in one system can result in improper combustion.
Examples: An increase in the compressor air pressure over the nozzle will add more
atomized fuel into the combustion tube. However, the combustion air provided
by the combustion air blower remains constant resulting in a rich air/fuel
mixture and possibly black smoke from the exhaust.
A restriction in the amount of air through the combustion chamber (restricted air
intake, dirty heat exchanger plugged exhaust) will also result in a rich air/fuel
mixture as the compressor air pressure (and atomized fuel flow) remains constant.
A restriction in the fuel line, filter, or nozzle fuel passage will reduce the
atomized fuel/air flow into the combustion tube. However, the combustion air
provided by the combustion air blower remains constant resulting in a lean
air/fuel mixture and possibly gray/white smoke from the exhaust.
A decrease in the compressor air pressure over the nozzle will reduce the
amount of atomized fuel/air into the combustion tube. However, the combustion
air provided by the combustion air blower remains constant resulting in a lean
air/fuel mixture and possibly gray/white smoke from the exhaust.
AIR
FILTER AIR
COMPRESSOR
AIR IN
AIR PRESSURE 6.4/6.8 psi

VOLTAGE DEPENDENT AIR
FUEL
BLOWER
MOTOR M FUEL
FILTER REGULATOR
NOZZLE
FUEL IN
FUEL/AIR
MIXTURE
FUEL ATMOSPHERIC
PUMP PRESSURE
FUEL 0 PRESSURE
FUEL TANK
5 –10 psi
Figure 3-6. Fuel Delivery Theory of Operation

3.3 MODES OF OPERATION
The PROHEAT X45 Plus has four modes of operation: standard, preheat,
supplemental, and anti-freeze. For a general description of the modes, see
Heater Modes starting on page 2-13.
STANDARD MODE SUPPLEMENTAL MODE PREHEAT MODE GLOBAL LOW FEATURE

• normal operation of the (engine running) (engine off) • Shifts all the cycle
Proheat • similar to Standard • similar to Standard Mode on/off temperature
• overrides Supplemental Mode except: coolant except: 90 minute time out of operating modes
Mode pump does not run when • overrides Anti-Freeze Mode (Preheat, Standard
Proheat is not firing and Supplemental)
• overrides and cancels • activated via momentary down to between
Preheat Mode • overrides and cancels contact push button
Preheat Mode 73–108°F (40–60°C)
• overrides Anti-Freeze switch with latching
Mode • overrides Anti-Freeze internal to the G-II PCM SUPPLEMENTAL MAX
Mode HEAT FEATURE
• Optional Global Low • Optional Global Low
• 30 second signal required temperature feature • Changes the supple-
temperature feature before mode enabled mental mode cycle
• 5 second delay required ANTI-FREEZE MODE on/off temperature
for mode switch off (engine off) range to 170–190°F
• similar to Supplemental (77–88°C)
• Optional Supplemental
Max Heat feature Mode except: coolant
SUPPLEMENTAL
pump runs at set
• Optional Global Low PRIORITY FEATURE
intervals when Proheat is
temperature feature not firing to check actual • Overrides Standard
• Optional Supplemental system temperature Mode but does not
Priority feature cancel Standard Mode
• Optional Global Low
temperature feature
3.3.1 STANDARD MODE
1. Switch “ON” The ON/OFF switch lamp, timer or OEM indicator (installation options) will light.
Standard In addition, the X45 Plus PCM ON Indicator will light. If the coolant temperature is
Mode Signal below 150°F (65°C) the PROHEAT enters Pre-check. If the coolant temperature is
above 150°F (65°C) the PROHEAT enters Standby.
2. Pre-check The PCM performs self diagnosis checking sensors for correct range, electrical
components for over-load and for a flame presence. If there are no errors
indicated, the PROHEAT goes to Ignition.
3. Ignition The blower starts first, followed by the coolant pump, ignition spark, air compressor,
and fuel pump. The ignition electrode can spark for up to 60 seconds. Once the
flame sensor detects a good flame, the PROHEAT goes to full output and turns
the Ignition off. Once the heater enters full output the sleeper fan output turns
on if equipped. See page 3-4 for more information.
4. Full Output 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).
5. 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
6. Standby drops to 150˚F (65˚C) at the heater outlet. Then it will enter precheck and
repeat steps 2 to 6. The PROHEAT will continue to repeat steps 2 to 5 until it
is switched “OFF.”
If PROHEAT is in full output, it will Cool Down (Purge) first, then shut “OFF.”
7. Switch “OFF” If PROHEAT is in standby, it will shut “OFF” immediately.
When switched “OFF,” the sleeper fan output turns off (if equipped, see page
3-2).
When switched “OFF,” the hour meter (auxiliary output) will shut off.
NOTE: The PROHEAT will Cool Down (Purge) for 3 reasons:

• the coolant reaches 185˚F (85˚C)
• there is a function or component problem
(See Troubleshooting & Repair Manual)
• the PROHEAT is operating at full output when it is shut “OFF”
3.3.2 OPTIONAL SUPPLEMENTAL MODE
1. Activate The “ON” light and heater indicator will turn “ON” after 30 seconds of receiving
Supplemental the signal. In addition, the hour meter (auxiliary output) will be powered.
Signal for
30 Seconds
2. Supplemental The PROHEAT monitors coolant temperature until it drops below 150˚F (65°C),
Standby and then goes to pre-run.
3. 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.
4. 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.
and fuel pump. The ignition electrode can spark for up to 60 seconds. Once
the flame sensor detects a good flame, the PROHEAT goes to full output and
turns the Ignition off. Once the flame sensor detects a good flame, the
PROHEAT goes to full output.
6. Full Output 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).
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.
NOTICE
If supplemental priority is selected,
supplemental mode will have priority
over other modes.

8. Remove The “ON” light and the heater indicator turn off after 5 seconds of the signal
Supplemental being removed. If the PROHEAT is in the supplemental standby or pre-run
Signal for sequence, the PROHEAT will turn off immediately. If the PROHEAT is in any other
5 Seconds function, it will complete a Cool Down (Purge) function before turning off.
When switched “OFF,” the sleeper fan output turns off if connected and the
hour meter (auxiliary output) will shut off.
NOTICE NOTE: The PROHEAT will Cool Down (Purge) for 3 reasons:
There are special OEM versions for • the coolant reaches 185˚F (85˚C)
Supplemental Mode. For example, • there is a function or component problem
temperature thresholds may have a (See Troubleshooting & Repair Manual)
low threshold of 160°F (71°C) rather • the PROHEAT is operating at full output when it is shut off
than 150°F (65°C) and a reduced
coolant pump Pre-run time of 30
seconds rather than three minutes.
3.3.3 OPTIONAL PREHEAT MODE
1. Activate Push the preheat button and the PCM “ON” LED light will turn on. In addition, the
Preheat Signal hour meter (auxiliary output) will be powered. The PROHEAT goes to pre-check.
2. Precheck 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.
and fuel pump. The ignition electrode can spark for up to 60 seconds. Once the
flame sensor detects a good flame, the PROHEAT goes to full output and turns
the Ignition off. Once the flame sensor detects a good flame, the PROHEAT
goes to full output.
4. Full Output 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).
pump continue to run. After 3 minutes, the blower stops and the PROHEAT
goes to standby.
6. 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.
7. After 90 If PROHEAT is in full output, it will Cool Down (Purge) first, then shut off.
Minutes or If PROHEAT is in standby, it shuts off immediately.
Switched Off When switched “OFF,” the sleeper fan output turns off if connected and the
hour meter (auxiliary output) will shut off.


3.3.4 OPTIONAL ANTI-FREEZE MODE
1. Switch “ON” The “ON” light and heater indicator will turn “ON” after receiving the signal. In
Anti-freeze addition, the hour meter (auxiliary output) will be powered.
Mode Signal
2. Anti-Freeze The PROHEAT monitors coolant temperature until it drops below 41˚ (5°C),
Standby and then goes to pre-run temperature, or every 20 minuets the heater goes
to Pre run interval
3. Pre-Run The coolant pump operates for 30 seconds to circulate coolant through the
Temperature system. If the coolant temperature rises above 41˚ (5°C), the pump shuts off
and the PROHEAT returns to anti-freeze standby. If the coolant temperature
remains below 41˚ (5°C), the PROHEAT goes to pre-check.
4. Pre-Run Every 20 minutes the coolant pump is operated for 30 seconds to circulate
Interval coolant through the system and the temperature is again checked. If the
coolant temperature rises above 41˚ (5°C), the pump shuts off and the
PROHEAT returns to supplemental standby. If the coolant temperature
remains below 41˚ (5°C), the PROHEAT goes to pre-check.
5. Precheck 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.
6. Ignition The blower starts first, followed by the coolant pump, ignition spark, air
compressor, and fuel pump. The ignition electrode can spark for up to 60
seconds. Once the flame sensor detects a good flame, the PROHEAT goes to
full output and turns the Ignition off.
7. Full Output The PROHEAT runs at full output until the coolant temperature reaches 68˚
(20°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).
8. Cool Down The air compressor and fuel pump shut off immediately. The blower and
Purge coolant pump continue to run. After 3 minutes the blower and coolant pump
stop and the PROHEAT goes to anti-freeze standby and repeats steps 2 to 8
until switched off.
9. Switch “OFF” The “ON” light and the heater indicator turn off once the “ON” signal is removed.
If the PROHEAT is in the anti-freeze standby or any 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 sleeper fan output turns off if connected and the hour meter
(auxiliary output) will shut off.


4.0 TROUBLESHOOTING
AND REPAIR
NOTICE 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
Troubleshooting and repair is to be
on an indicator light on the switch, timer red manual light or OEM indicator
performed by authorized PROHEAT
light (installation options). See Example PROHEAT Behavior Error on page 4-5.
dealers.
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 4-44 to page 4-45.)
4.0.1 TROUBLESHOOTING A PROBLEM

1. 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.
2. 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).
3. If no code is indicated, turn the PROHEAT off and then on again using the
existing operational switches or timer.
4. 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.
• 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 the error
code(s) continuously. The PROHEAT will try again once the switch is turned
“OFF” and then “ON” again.
• If the indicator light flashes, count the number of flashes and refer to
the troubleshooting diagnostic code description for that number on the
following pages.
• If the PROHEAT runs but is not performing or operating correctly, consult
the Operational Problems, Section 4.3 on page 4-45.
Mechanics Mode
• Heater can be to be turned on in a special “Mechanics mode” by holding
the (left) Enter button for 1 second and pressing the (right) Select button
momentarily (.25s) to turn the heater on. The heater will run for 5 minutes
and then automatically turn off.
• Cycle on temperatures is 160°F (71°C) and cycle off temperature at 185°F
(85°C) during this special “Mechanics mode”
SECTION 4. TROUBLESHOOTING AND REPAIR 4-1

ENTER BUTTON
SELECT BUTTON
Figure 4-1. PCM – Mechanics Mode
Mechanics mode can be turned off by holding the (left) Enter button for 1
second and pressing the (right) Select button momentarily (.25sec)
Secondary function of Mechanics mode

If heater is activated via any analog or CAN input it can be temporary turned
off from any ON mode by pressing and holding the (left) Enter button for 1sec
and momentarily pressing the (right) Select button (.25sec). This will leave the
heater off until the current ON request has been removed or any new on
command is received.
Troubleshooting and Repair Tools Required

• Digital Air Compressor Test Gauge (PROHEAT P/N PK0037)
Allows the service technician to check compressor pressure in order to ensure
correct fuel delivery. (NOTE: The analog air pressure gauge PK0060 can
also be used.)
Figure 4-2. Troubleshooting Tools

4.1 OPERATION INDICATORS,
FUNCTION AND COMPONENT
DIAGNOSTICS
4.1.1 OPERATION INDICATORS
Operation States:
8.8. – Power Up
Right (•) – On
Left (•) – Cool Down (Purge)
The operation indicators signal normal functioning of the PROHEAT. These
three states do not indicate a fault.
Power Up The power up indicator communicates that the PROHEAT power has been
supplied. All segments of the LED momentarily flash “88” twice, followed by
a 2 second display of the configuration code number (if configuration is set)
or “CC” (if configuration is not set).
On The ON indicator code communicates:

On solid – Heater is switched on via analog switch inputs and is operating
normally.
Off then two flashes then off again – Heater is connected to CANBus network
and is communicating on the network but is not switched on.
On solid with two flashes then on solid again – Heater is switched on Via
Analog or CANBus switch inputs and is communicating on the network.
WARNING
The “ON” LED indicates that the heater can start at any time. Refer to
page 3-7 to page 3-10 .
Cool Down The PROHEAT will be in the Cool Down (Purge) state as defined in Modes of
Operation (see page 3-7) when “Pu” is displayed.

The microprocessor in the PCM continually monitors all the PROHEAT systems.
If the internal diagnostics discover a problem, a diagnostic code will be displayed
on the PCM function display. The remote ON/OFF switch, timer red manual light,
or OEM indicator light (installation options) will also flash the diagnostic code
followed by a pause and then repeat. The number of flashes correspond to the
Figure 4-3. Remote On/Off Switch. 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.
NOTICE CODE No. Description of Operating State No. of

and Diagnostic Codes Flashes
The X45 Plus fuel pump is a gear pump Operation Indicators
driven directly by the compressor
CC Configuration Not Selected No indicator
motor. The fuel pump is NOT being
monitored electrically. Should this Function Diagnostics
component diagnostic code appear, 01 Start (Lockout mode after 10 1
the wrong PCM configuration was consecutive start faults)
selected. All mechanical problems 02 Flame Out 2
with the fuel pump will be indicated 03 Coolant Flow 3
as either a Start (1) or a Flame Out 04 Overheat 4
(2) diagnostic code.
05 Voltage 5
Component Diagnostics
06 Flame Sensor (Lockout mode after two 6
consecutive Cool Down (Purge) attempts
07 Temp Sensor 7
NOTICE 08 Fuel Pump (See Note) 8

09 Compressor 9
LOCKOUT MODE
10 Ignition Coil 10
After 10 consecutive start faults
(Code 01) or after two Cool Down 11 Coolant Pump 11
(Purge) attempts (Code 06) the X45 12 Blower 12
Plus PCM will go into Lockout mode, 13 Sleeper Fan 13
Power to the X45 Plus PCM must be 14 Hour Meter (Auxiliary Output) 14
removed and reapplied to exit
15 Not Used -
Lockout mode.
16 System Current 16
17 Not Used -
18 CANbus 18
19 High Ambient PCM Temperature 19
20 Not Used -
21–29 Outputs 1–9 Fault
Figure 4-4. Function Display Panel Detail & Error Flash Codes

4.1.2 EXAMPLE PROHEAT BEHAVIOR ERROR – CODE 01
The following is an example of an X45 Plus PROHEAT behavior during an error.
The following example shows the sequence of events when the PROHEAT is
switched “ON” in the standard mode (similar for preheat and supplemental
Modes). This sequence of events occurs for Codes 01 through 12. Codes 13,
14, 19 and 21 to 29 do not put the heater into Cool Down (Purge) mode or shut
down the PROHEAT. Rather, the PROHEAT reports the error and continues to run.
1. Switch “ON” The ON/OFF switch (or timer) lamp and the PCM “ON” LED will light. In addition,
Standard the hour meter (auxiliary output) will be powered. The PROHEAT goes to
Mode Signal precheck.
2. Pre-check The PCM performs a 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.
3. Ignition The blower starts first, followed by the coolant pump, ignition spark, air
compressor, and fuel pump. The ignition electrode sparks for 60 seconds.
4. Error If the flame sensor does not see a flame in 60 seconds after entering
Detection – ignition, the air compressor and fuel pump shut off immediately. The blower
Purge and coolant pump continue to run.
Code 01 will be displayed. 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, 14, 19 and 21 to 29 will not cause the heater to shut down.
The PROHEAT reports the error and continues to run.
5. Steps 1 to 4 The PROHEAT always restarts after one error detection (except for Codes 13,
are Repeated 14, 19 and 21 to 29). 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.
6. Hold State After two consecutive Code 01 errors, the PROHEAT goes into a hold state.
No further start attempts will be made. Code 01 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: To restart the heater, turn the switch “OFF” and back “ON.”

4.1.3 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.
Configuration A conflagration code is displayed if the PCM is powered up and no configuration

number is set.
• No heater operation will occur until heater has been configured
• No response to CAN commands
• No analog outputs will occur
First Time Power Up
When the replacement X45 Plus PCM is powered up for the first time the display
will be flashing “CC” and requires a configuration number to be selected before
the PCM will function.
OLD NEW
Config file code
X45 12V ~ 903100 999100 999110 10 All 12 Volt models
Sleeper Fan Standard Voltage and Temperature Range
X45 12V ~ 904200 999100
Aux Input
X45 12V ~ 904300 904300 999130 30 All 12 Volt School Buses
School Bus Standard Voltage and Temperature Range
X45 12V ~ ~ 999350 999135 35 12 Volt School Bus Special
School Bus • Voltage range 11.2–16VDC
Special • Temperature range 160–185°F (71–85°C)

Config file code
X45 24V 985628 905300 999400 999140 40 All 24 Volt models
Aux Input Standard Voltage and Temperature Range
1. Use the (right) SELECT button to toggle up through the configuration

numbers, configuration display should continue to flash during setting (10,
30, 35, and 40) until the desired configuration number is displayed.
2. Press the (left) ENTER button and hold for 2 seconds to lock in configuration.
The configuration number will flash 4 times to indicate confirmation and
then go ON solid for 2 seconds before the display is turned off.
3. Once the configuration number has been set, apply the correct
ENTER identification decal.
BUTTON
- Red for all 12 volt models
- Yellow for all School Bus models
SELECT
BUTTON - Green for all 24 volt models
4. PCM is now in the off state and is ready to use.
Figure 4-5. X45 Plus PCM

1 Start A START diagnostic code indicates that the flame sensor did not detect a
flame or the flame was too weak to be detected during the FULL 60 second
ignition period.
If 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.
NOTICE
After 10 consecutive start faults Troubleshoot the Start diagnostic code based on:
the X45 Plus PCM will go into
1. Fuel System
Lockout Mode.
Go to page 4-8.
Power to the X45 Plus PCM must
be removed and reapplied to exit • There is no fuel, fuel odor, or atomized fuel coming from the exhaust pipe.
Lockout mode. • There is no hot exhaust coming from the exhaust pipe.
• There is no flame visible through the inspection window.
2. Ignition System
• There is raw fuel and/or atomized fuel, and a raw fuel odor coming from
the exhaust pipe. Go to page 4-21.
• There is no hot exhaust coming from the exhaust pipe.
• There is no flame visible through the inspection window.
3. Flame Sensor
Go to page 4-22.
• 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 Plus fuel system operates on a venturi-style atomizing nozzle
technology. It operates similarly to a compressed air paint sprayer.
As shown in figure 4-6, 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 that 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 4-6 is the electrode and the flame sensor. The electrode
provides the spark to ignite the fuel and the flame sensor is an optical device
which “sees” the flame.
AIR FILTER AIR

COMPRESSOR
FLAME SENSOR
COMPRESSED AIR
ELECTRODE
NOZZLE FUEL PUMP
FUEL INLET FUEL SUCTION
FUEL SUCTION FUEL PICK-UP
FUEL PRESSURE
FUEL REGULATOR
FUEL TANK
Figure 4-6. Fuel System Schematic
Check Fuel System
Test Procedure — Supplying fuel from a remote source:

1. Remove the fuel supply line from the outlet of the fuel
regulator.
2. Put this end of fuel into a small container of clean fuel that
is about the same level as the regulator center as shown in
figure 4-7. This will remove the vehicle fuel supply, fuel pump
and regulator from the fuel delivery.
3. 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.
If a Start diagnostic code is indicated, the problem is with the
nozzle or compressor fuel system.
PLACE THIS LINE IN A

CONTAINER OF FUEL
MAINTAIN FUEL LEVEL

AT CENTER OF THE
REGULATOR
REMOVE FUEL LINE

FROM REGULATOR
Figure 4-7. Eliminating Fuel Pump and Regulator from System
Check Regulator
Check regulator for damage, contamination, and mechanical
operation.
Test Procedure:
1. Remove fuel line that goes from the outlet of the regulator to
the nozzle.
2. Start the heater. No fuel should be exiting the outlet of the
regulator.
If fuel is leaking from the outlet, replace the fuel regulator.
3. Install clear plastic hose that replaces the hose removed.

4. 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 Step 4, replace
the regulator.

Check Vehicle Fuel Supply and Fuel Pump
1. Vehicle fuel level and/or for fuel gelling during cold weather.
2. Air leaks and/or restrictions in the fuel supply lines to the
PROHEAT.
3. The PROHEAT operation when supplying fuel from a direct
source.
Test Procedure — Fuel Supply Inspection:

1. Is there fuel in the tank?
2. 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:

1. Disconnect the fuel line at the inlet to the regulator and place
into a cup.
2. Start PROHEAT. Ensure that fuel flows out of the fuel line in a
steady, uninterrupted, and clear stream of fuel.
3. If fuel does not flow, check filter and relief valve for contamination.
NOTICE
A
• Apply Loctite 242 to threads COMPRESSOR
• Torque bolts (2) to 25±3 in/lbs
(2.8±0.3 Nm) RELIEF VALVE
B B
• Lubricate O-ring with diesel fuel PRESSURE
ADJUSTING SCREW
• Torque relief valve to 22±2 in/lbs
(2.5±0.2 Nm)
C
• Apply Loctite 59241 sealant to DRIVE COUPLING X 2
threads
• Torque elbow (1) to 55±5 in/lbs
(6.2±0.5 Nm) minimum or until “O” RING
elbow is at correct orientation
C
OUTLET FUEL PUMP
FITTING
INLET
FITTING
FILTER
BOLTS X 2
ADAPTER
Figure 4-8. Compressor / Fuel Pump Assembly

Check Fuel Pump Pressure and Service
1. Disconnect power to heater.
2. Remove air compressor hose to ensure heater will not run in
full output during test.
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.
AIR COMPRESSOR HOSE
2
WARNING
Fire Hazard. DO NOT place any
flammable items around the heater
and exhaust pipe.
3
FUEL OUTLET HOSE
Figure 4-9. X45 Plus Heater
4. Remove ‘T’ fitting from test gauge PK0060.
TEST GAUGE
PK0060K
‘T’ FITTING
Figure 4-10. Test Gauge

5. Install test gauge PK0060 on fuel pump outlet.
NOTICE
Calibrate gauge before each use. TEST GAUGE
PK0060K
See installation instructions # 990614
available at www.proheat.com for
more information.
NOTICE
It is normal to get a start error code 1
or a flame out Code 2 during the test.
The compressor/fuel pump motor
will only run for the first 60 seconds
during this test. See Service Manual
for operating sequence. 5
Figure 4-11. Installation of Test Gauge
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 not to lose any of the internal
components that may fall out.
RELIEF
VALVE
ASSEMBLY
COMPRESSOR
BALL
BEARING
BRASS
BALL
CAP GUIDE
O-RING SPRING
FUEL PUMP
Figure 4-12. Pressure Relief Valve

2. Remove the spring and brass ball guide from the cavity.
3. Carefully separate and discard the brass ball guide from the
pressure relief valve spring. DO NOT stretch or damage
the spring.
4. Remove the ball bearing from the cavity.
5. Inspect and clean all components.
6. Inspect and clean the cavity. Pay close attention to the center
hole in the cavity for any debris or a damaged edge. 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.
7. Place ball bearing back in cavity on the center hole.
8. Place spring back in hole on top of ball bearing.
9. 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.
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
FUEL FILTER
TORQUE ADAPTER O-RING

NUT TO 15 ±10 IN-LBS
(17 ±1.1 NM)
Figure 4-13. Check Valve Filter

3. Check fuel lines, connections and routing back to the fuel
tank for kinks, loose fittings, stiff lines or cuts.
FUEL
PICK-UP
FUEL LINE
FUEL LINE FUEL TANK
HOSE CLAMP
GROMMET HOSE
CLAMP
Figure 4-14. Check Fuel Lines, Connections and Routing
4. Check pressure relief valve. Locate the pressure relief valve

cap and remove with a slot screwdriver. Be careful not to lose
any of the internal components that may fall out.
5. Remove the spring and brass ball guide from the cavity.
6. Remove the ball bearing from the cavity.
RELIEF
VALVE
ASSEMBLY
COMPRESSOR
BALL
BEARING
BRASS
BALL
CAP GUIDE
O-RING SPRING
FUEL PUMP
Figure 4-15. Pressure Relief Valve

7. 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 PK0060K.
TEST GAUGE
PK0060K
Figure 4-16. Remove Test Gauge

2. Reconnect fuel line to fuel pump outlet.
3. Reconnect air hose at compressor.
AIR COMPRESSOR HOSE

3
2
FUEL OUTLET HOSE
Figure 4-17. Reconnect Fuel Lines and Air Hose
4. Run heater for a full cycle and inspect for proper operation.

Check Air Compressor Pressure and Operation
Test Procedure — Air Compressor pressure:

1. Run heater until warm to the touch. This ensures the heater
WARNING components are up to normal operating temperature.
Shock hazard due to high secondary
2. Switch heater “OFF”.
coil voltage.
3. Connect Digital Manometer PK0037 (or analog gauge
PK0060) in-line as shown in figure 4-18.
DIGITAL
MANOMETER
PK0037
HOSE TO
NOZZLE AIR
INLET
HOSE FROM COMPRESSOR
NOTICE Figure 4-18.
If using PK0060, Analog Air pressure

4. Locate the rubber boot on the positive end of the ignition coil
gauge, calibrate gauge before each
and peel it back to expose the positive terminal.
use. Refer to: installation instructions
# 990614 available at www.proheat.com 5. Select the DC Volts range of a multimeter and connect as per
figure 4-19. The positive lead of the multimeter should be
attached to the positive coil lead. The negative lead of the
NOTICE multimeter should be attached to the heater chassis.
Remove pressure gauge when finished 6. With the heater running in full output (flame on and ignition is
with measuring & setting procedure. off) read the voltage at the coil to ensure voltage is nominally
12 +/- 1V for 12 V models and 24+/- 1V for 24 V models.
NOTICE Check air pressure reading using the correct altitude for your
location.
For sustained operation above 7000 7. The reading must be within the range of the shaded area as
feet (2134 m) the compressor must shown in figure 4-20.
be adjusted in order to maintain
proper combustion.

Figure 4-19. Check Coil Voltage
X45 Plus Compressor Pressure Altitude Setpoint

7.0
(48.3)
6.5
(44.8) NOTICE
For sustained operation above 7000 feet
6.0 ACC (2134 m) the compressor must be adjusted
EPT in order to maintain proper combustion.
(41.4) ABL
E RA
Air Pressure PSI (kPa)
NGE
5.5
(37.9)
5.0
(34.5)
4.5
(31.0)
4.0
(27.6)
3.5
(24.1)
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000
(305) (610) (914) (1219) (1524) (1829) (2134) (2438) (2743) (3048) (3353) (3678) (3962) (4267) (4572)
Altitude Feet (m)
Figure 4-20. System Air Pressure Chart

Air Pressure Checks
If air pressure is outside the recommended setting for your location please
perform the following checks before adjusting the compressor:
Low Pressure Reading – Check:

Ensure the coil voltage is nominally 12 ±1V for 12V models and 24 ±1V for 24V
models. If voltage is low, charge batteries and check compressor reading again.
1. Inspect air line from compressor outlet to fan end inlet for leaks, kinks or
other restrictions..
2. Check condition of air compressor filter. Retest with the filter removed.
High Pressure Reading – Check:

Ensure the coil voltage is nominally 12 ±1V for 12V models and 24 ±1V for 24V
models. If voltage is high, stop charging batteries (turn engine off) and check
compressor reading again.
1. Nozzle and cavity for blockage. Refer to Step 5 on page 5-10 of the X45
service manual.
NOTICE Compressor Adjustment

Altitude correction is needed above If after performing the above checks and the air pressure is still outside the
7,000 feet (2134 m) (see figure 4-20). recommended setting for your location, adjust the air pressure by turning the
screw as shown in figure 4-21.
END VIEW OF
ADJUSTMENT SCREW:
COMPRESSOR
DECREASE
PRESSURE
NOTICE
INCREASE
If the air compressor pressure cannot PRESSURE
be adjusted back into normal range,
repair or replace air compressor.
Refer to parts manual.
ADJUSTMENT
ELECTRICAL SCREW
MOTOR
FUEL PUMP
Figure 4-21. Compressor / Fuel Pump Assembly

Check Fuel Nozzle and O-ring
Check for fuel nozzle and O-ring damage and/or contamination.
Test Procedure — Fuel nozzle removal, inspection & cleaning or replacement:

1. Remove three (3) bolts from the fan end and open up heater.
2. Remove nozzle from fan end.
3. Disassemble, inspect, clean, and reassemble fuel nozzle
(Figure 4-23).
Fuel nozzle disassembly, inspection, cleaning & reassembly:
NOTICE • Hold the fuel nozzle stem lightly but firmly in a vise using
soft jaws, taking care not to cause damage. Disassembles
Fuel nozzle parts are a matched set in three pieces.
and not interchangeable. • 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.
• 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 nozzle assembly is
self-aligning. Torque to 30±3 in/lbs (3.3±0.3 Nm).
4. Inspect the fuel nozzle cavity and clean as necessary using
electrical contact cleaner or warm soapy water
5. Reinstall fuel nozzle into the fan end using diesel fuel to
lubricate the O-ring. Torque to 150±10 in/lbs (17±1.1 Nm).
6. Reinstall fan end and torque three (3) bolts to 75±5 in/lbs
(8.5±0.5 Nm)
Figure 4-22. Nozzle Number Location FUEL AND AIR OUTLET ORIFICE
ARROWS
SHOW HOW TO
LOOSEN THE HEAD NOZZLE
NOZZLE NUMBER
NOTICE HOLD UPRIGHT

TO ASSEMBLE
DO NOT use a tip cleaner in the fuel FUEL NOZZLE
ORIFICE
orifice. DISTRIBUTOR
AIR PASSAGES
TORQUE = SEE
SECTION 1.3
STEM
AIR PASSAGES
LUBRICATE
O-RING WITH
DIESEL FUEL O-RING
Figure 4-23. Fuel Nozzle Assembly

Check Ignition Coil and Electrode Gap
1. Electrode cleanliness.
2. Electrode positioning for proper gap.
Test Procedure — Ignition system and electrode spark inspection:

1. Inspect high tension lead between the coil and the electrode.
WARNING Ensure that there is a proper connection at both the coil
The PROHEAT chassis is grounded to (positive and negative terminals) and at the electrode.
the PCM as shown in figure 4-25. If the high tension lead is cut or damaged, replace.
Ensure that the ground is securely
connected. Failure to ensure a 2. Remove three (3) bolts from the fan end and open up heater.
proper ground may result in
3. Check the electrode for carbon buildup and clean as required.
electrical shock.
4. Check electrode gap as per figure 4-24.
5. Reinstall fan end and torque three (3) bolts to 75±5 in/lbs
(8.5±0.5 Nm).
ELECTRODE
COMBUSTOR
TUBE
1/4” - 9/32”
Figure 4-24. Electrode Gap Detail
GROUND WIRE
FROM PCM
FUSE
(24V MODEL)
CHASSIS GROUND BOSS
Figure 4-25. PROHEAT Ground Boss

Check Flame Sensor
Test Procedure — Flame Sensor Circuit:

NOTICE
Check cleanliness of the flame sensor. To test flame sensor
If the lens is dirty, the sensor does for operation:
not properly “see” the flame.
Spare Flame Sensor Available – Check:
1. Ensure unit is powered off. Disconnect flame sensor.
2. Connect known good flame sensor to harness.
3. Hold up known good flame sensor to inspection port.
4. 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:

1. Ensure unit is powered off. Disconnect and remove
flame sensor from fan end casting.
NOTICE
2. Shine incandescent flashlight directly at sensor.
DO NOT use an LED flashlight. Only 3. Start heater with a flashlight shined directly at the sensor.
an incandescent flashlight will check
4. Code 6 should be displayed immediately on start up.
the sensor operation.
If Code 6 does not display immediately on start up, replace flame
sensor as it is faulty.

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:

1. A flame is detected during the ignition period and during full output.
2. The flame goes out or fails to be detected.
3. The ignition is switched on for a maximum of 10 seconds to try and
reestablish the flame.
4. If the flame is not detected within 10 seconds, the flame out diagnostic
code is displayed.
5. The PROHEAT goes into Cool Down (Purge) mode and attempts to restart
after Cool Down (Purge) is complete.
A flame out diagnostic code indicates that:

• A flame was detected therefore there was a spark and the ignition
system works.
• The flame was detected therefore the flame sensor works.
• The fault is in the fuel supply system.
• The flame sensor could be dirty.
Troubleshoot the flame out diagnostic code based on:

1. Fuel supply to the PROHEAT.
Go to page 4-8 and perform fuel system check.
• Fuel tank pick-up
• Fuel fittings
• Fuel lines
• OEM supplied filters and check valves
2. PROHEAT fuel and flame detection system.
Go to page 4-8 through page 4-22 and perform Regulator, Ignition
System and Flame Sensor checks.
• Fuel Supply Pump
• Air Compressor – pressure
• Fuel Regulator – dirty or clogged
• Nozzle – dirty or clogged
• Flame Sensor – dirty
3. Operational symptoms that may occur in conjunction with a flame out code.
Go to page 4-45.
• Combustion hesitation or coughing
• Backfiring
• Smoke
• Strong diesel fuel odor

3 Coolant A COOLANT FLOW diagnostic code is displayed when the coolant temperature
Flow reaches 185˚F (85˚C) in less than one minute after ignition. This indicates
that the coolant flow is severely restricted or blocked. This feature aids in
detecting coolant flow problems that can degrade the PROHEAT performance.
An in-line flow indicator (see figure 4-27) is a valuable troubleshooting tool used to:
1. Check the coolant flow and direction.
2. Check for air in the system.
FLOW
3. Check for restrictions caused by the truck systems such as
shuttle valves, manual valves, air operated valves.
The coolant flow indicator shown in figure 4-26 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 4-26. Flow Indicator – TK9002 Check: Coolant Flow

1. Coolant Lines: For restrictions and blockages
Are clamps tight?
2. Shut-off Valves: Ensure that shut-off valves are open and
functioning properly.
3. Fittings: Recommend 1/2” NPT x 3/4” Hose Barb. Minimum
size is 1/2” NPT x 5/8” Hose Barb.
Avoid using 90˚ fittings where possible.
4. Coolant Flow Direction: The PROHEAT must be plumbed so
that the coolant pump is pumping the coolant in the same
direction as the engine coolant pump. The PROHEAT can be
used when the engine is running.
5. Coolant Pump: Does the pump function properly? (page 4-36)
6. 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 (85°C) in less than one
minute causing a COOLANT FLOW diagnostic code.
SLEEPER FAN
NOTICE
If the coolant system is contaminated
with magnetic material, it may cause
the impeller to stop turning.
OTHER POSSIBLE
LOCATIONS
FLOW
INDICATOR
Figure 4-27. Flow Indicator – TK9002

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 and the heat exchanger temperature reaches 280°F
+/- 12°F (138°C +/- 11°C).
If the heater is equipped with an Impact Switch, and it is triggered by
mechanical shock the PCM will also display code 04 Overheat. Ensure the
impact switch (if equipped) is reset by depressing the red button on top
of the impact switch.
Check: Coolant Flow

1. Is there coolant in the system?
2. 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 “OFF,” instantly shutting the heater down. It cannot be restarted
until the breaker is manually reset.
Figure 4-28. Impact Switch
To reset the breaker, carefully 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:
1. Connect a multimeter (adjusted to measure resistance) to the
overheat breaker connector. (Figure 4-29.)
The sensor should be normally closed. If the sensor has
tripped, the circuit should be open.
POLARITY
NOT IMPORTANT
CAUTION RED RESET BUTTON PLUNGER
Do not reset the overheat breaker SPRING
until the cause of the overheat
condition has been determined.
Figure 4-29. Overheat Sensor Test

5 Voltage A VOLTAGE diagnostic code indicates that the supply voltage to the heater is
out of the normal operating range for more then 10 seconds.
Normal voltage ranges:
12 Volt heater – 9.5 to 16.0 Volts
Check: Vehicle Voltage

1. 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.
2. If the measured voltage 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:
• Drop the voltage enough to cause a voltage error.
• 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 0 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:
1. Locate the rubber boot on the end of the ignition coil and
peel it back to expose the positive and negative terminals.
2. Select the DC Volts range of a multimeter and connect as
per figure 4-30. 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 4-30)
3. Read the voltage with the heater running or trying to run.
Normal Voltage Ranges


Figure 4-30. Heater Voltage Measurement

4.1.4 COMPONENT DIAGNOSTICS
Component Faults:
6 – Flame Sensor 11 – Coolant Pump 19 – High Ambient PCM
7 – Temp Sensor 12 – Blower Temperature
8 – Fuel Pump 13 – Sleeper Fan 21–26 – Outputs 1–9 Faults
9 – Compressor 16 – System Current
NOTICE 10 – Ignition Coil 18 – CANbus Error
A sleeper fan error (13) and hour meter This section covers the individual heater components. In many cases there is
error (14) will not shut the PROHEAT a corresponding indicator light on the PCM function display. The indicator light
down and heat to the engine will be only indicates an electrical problem, NOT a mechanical failure. Component
maintained. problems can also cause Function diagnostic codes.
6 Flame A FLAME SENSOR diagnostic code indicates an electrical short circuit in the
Sensor flame sensor wiring, a flame sensor failure or a flame in Cool Down (Purge).
The PROHEAT was switched on and a flame (signal) was detected in Pre-check.
It will not indicate an open circuit. The flame sensor is an optical device that “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
NOTICE This code may also be displayed if the sensor “sees” a flame when there should
A flame fault in Cool Down (Purge) not be a flame in Cool Down (Purge). After 180 seconds in Cool Down (Purge) a
will cause the heater to preform a flame was still detected, and heater went into another 180 second Cool Down
second Cool Down (Purge) and then (Purge). At the end of the second Cool Down (Purge) the heater will shut down
go into Lockout mode. (Requires and enter Lockout mode.
power to be removed and reapplied
to clear the code). Check: Flame Sensor
• Inspect the flame sensor wiring for a short circuit.
• Inspect the flame sensor lens for damage.
• Test the flame sensor. (See following page for flowchart,
Figure 4-31.)

Flame Sensor Test Procedure
Start
Start unit
Unit
Is there
Stop
Stop unit
Unit Yes a flame No
sensor code?
Disconnect
Disconnect sensor/
Sensor/
start
Start unit
Unit
Is there
Check
Check flame
Flame quality
Quality Yes a flame?
Is there
a flame Replace
Replace No
No
sensor code? sensor
Sensor Sensor
Sensor
OK
OK
After 60
Yes seconds is there No
Yes a start code?
1 Is there
a spark? Yes
Check
Check main
Main harness
Harness
for
for aa short
Short circuit/
Circuit/
replace
Replaceififnecessary
necessary
1 CleanClean sensor if
Sensor if necessary
2 necessary and restart
and Restart
No
Try
Try with
with new
New PCM/
PCM/
replace 2
Replaceififnecessary
necessary Disconnect
Disconnect old Old sensor/
Sensor/
connect test
Connect Test sensor/hold
Sensor/Hold Check
Check ignition
Ignition Check
Check fuel
Fuel
up
up to
to inspection
Inspection port/
Port/ system system
System System
restart
Restart page
Page 4-21
5-15 page 5-27
Page 4-8
1 Check
After 60 Check main
main harness
Harness
Replace
Replace for
No seconds is there Yes for open
Open circuit/
Circuit/
sensor
Sensor replace
a start code? Replaceififnecessary
necessary
2 Try
Try with
with new
New PCM/
PCM/
replace
Replace ifnecessary/
if necessary/
After
After 60
60 seconds
Seconds ifif
there
there is a start
is a Start error
Error
Figure 4-31. Flame Sensor Test Procedure Flow Chart
go
go to Fuel system
to fuel System

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˚F (130˚C). The resistance of the temperature
sensor is proportional to temperature.
Check: Temperature Sensor (CODE indicated)

1. Inspect wiring for short or open circuits.
2. Check resistance of sensor. Is it within range as shown
in figure 4-33? If it is within valid range and the PCM still
displays code on start up, replace PCM.
3. Test the sensor. (See test procedure below.)
Test Procedure:
1. Connect a multimeter (adjusted to measure resistance) to
the temperature sensor as per figure 4-32. The polarity of the
sensor connections to the multimeter is not important.
2. Measure the sensor resistance versus temperature under the
following conditions:
• at room temperature
• in a freezer
• in boiling water
3. Compare the measured values against the graph (Figure 4-33).
If values do not approximately match, then the sensor is
defective and must be replaced.
Figure 4-32. Temperature Sensor Test

Code Code
07 07
150˚
140˚ 290˚
130˚ 2023 130˚ C (266˚ F) OUT OF RANGE (UPPER LIMIT)

260˚
120˚
110˚ 230˚
100˚
90˚ 200˚
1541 85˚ C (185˚ F) UPPER SET POINT
80˚
170˚
Temperature Centigrade (°C)
Temperature Farenheit (°F)

70˚
1354 65˚ C (150˚ F) LOWER SET POINT
60˚
140˚
50˚
40˚ 110˚
30˚
20˚ 80˚
10˚ VALID TEMPERATURE SENSOR RANGE

50˚
0˚
-10˚ 20˚
-20˚
-30˚ -10˚
-40˚
-40˚
-50˚ 515 -50˚ C (-58˚ F) OUT OF RANGE (LOWER LIMIT)
-60˚ -70˚
400 600 800 1000 1200 1400 1600 1800 2000 2200
Resistance Ohms ( )
Figure 4-33. Coolant Temperature Sensor Graph
NOTE: Room temperature 70˚F (20˚C) Resistance 950Ω

Boiling water 212˚F (100˚C) Resistance 1700Ω

8 Fuel Pump The FUEL PUMP diagnostics code is not used on the X45 Plus and indicates
that the wrong configuration number was installed. See “CC” on page 4-6.
9 Compressor The COMPRESSOR diagnostic code is activated when the PCM detects that the
compressor motor is electrically shorted, open, overloaded (software breaker
hasn’t tripped), or is damaged (compressor is running when it shouldn’t be “ON”).
Symptom: Air Compressor not running (code indicated)
Check: Air Compressor wiring & function

1. That compressor is connected to harness correctly.
(See PROHEAT Wiring Diagram page 1-4)
2. The connector pins for damage or corrosion.
3. Harness for pinched or abraded wires.
4. Test compressor. If it tests OK replace PCM.
(See page 4-17, figure 4-18, figure 4-19 and Test
Procedure.)
Test Procedure:
1. Connect 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.
2. 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.
3. Measure air compressor current. Use test lead part # 967921K.
PRESSURE
ADJUSTING
SCREW
Figure 4-34. Compressor Test
MODEL CURRENT DRAW (Amps)

X45-12 3.50 - 5.00 @ 12 Volts
X45-24 1.50 - 3.00 @ 24 Volts

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.
Symptom: Air compressor runs as soon as power is applied (No code indicated)
Check: Internal Short in Motor

Disconnect compressor/fuel pump motor from internal harness.
To check motor condition:
Spare Compressor Motor is Available – Check:
1. Connect spare motor to internal harness and apply power
to heater.
If spare motor does not run, replace the compressor/fuel
pump motor. If the spare motor still runs:
2. Inspect internal harness wires going to compressor.
Ensure that there is 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:

1. 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 2 and 3.
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 3.
2. 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 3.
3. Inspect internal harness wires going to compressor.
a motor ground short.

Symptom: Air Compressor running (No code indicated)
Fuse blown in PCM
Check: Air Compressor operation

1. Harness for pinched or abraded wires. The positive wire must
not short to ground.
2. Motor for internal short. (See figure 4-34 and Test Procedure.)
3. Check for seized motor or fuel pump. (See page 4-10, figure
WARNING 4-8 and figure 4-35 below.)
Disconnect the PCM electrical
power prior to trying to turn the
compressor counterweight by
hand.
REMOVE FOUR BOLTS AND
COVER FOR ACCESS TO THE
COMPRESSOR COUNTER
WEIGHT BY HAND TO
CHECK FOR SEIZED MOTOR
OR FUEL PUMP.
Figure 4-35. Compressor Access Cover

10 Ignition An IGNITION COIL diagnostic code indicates an open circuit in the wire harness,
Coil 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)

WARNING
The PROHEAT chassis is grounded Check: Coil wiring
from the PCM as shown in figure 1. Inspect the wiring harness to ensure the ring terminals are
4-25. Ensure the ground is securely secured to the coil. Make sure the polarity is correct.
connected. Failure to ensure 2. Inspect for broken or abraded wires in the wire harness.
a proper ground may result in 3. Test coil. (Figure 4-36.)
electrical shock. 4. 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 mechanical or electrical problems
that do not indicate a Code 10. The ignition coil is ground side switched —
there is always voltage at the positive terminal to the ignition coil.
Symptom: No spark at the electrode (No code indicated)

Check: High tension wires and electrode
1. Inspect the high tension lead between the coil and the electrode.
2. Inspect the ground lead between the second electrode and the
heater chassis.
3. Is the electrode gap adjusted correctly? (See page 4-21 for
Electrode Gap Detail)
Test Procedure:
1. 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 0 ohms (short circuit), then replace the ignition coil.
NOTE: Remove positive and negative wires from the coil when testing.
Figure 4-36. Ignition Coil Test

11 Coolant A COOLANT PUMP diagnostic code indicates an open circuit in the wire
Pump harness, a short in the wire harness between the positive and negative leads,
an internal short in the motor, or an overload fault detected.
The coolant pump is not self-priming. Ensure that the coolant system has
been purged of air by running the vehicle engine for at least ten minutes
following installation or service. (DO NOT run dry.)
Symptom: Pump not running (code indicated)
Check: Pump Motor

1. Connect coolant pump directly to the rated voltage
(12/24 Volts) and see if it runs. If not, replace the pump.
2. Measure coolant pump motor resistance. Using a multimeter,
measure the resistance across the coolant pump connector
pins. If resistance shows an open circuit or an internal short
circuit, replace the coolant pump.
3. Measure coolant pump current. Use test lead part # 967921K.
Figure 4-37. Coolant Pump Test

X45-12 1.50 - 4.00 @ 12 Volts
X45-24 0.75 - 2.00 @ 24 Volts

Symptom: Coolant pump not running (code indicated)
Check: Coolant pump wiring & function

1. That coolant pump is connected to harness correctly.
4. Test pump. If it tests OK replace PCM.
(See figure 4-37 and Test Procedure.)
Coolant Pump Mechanical & Electrical Troubleshooting (no code indicated)

The following material covers the coolant pump mechanical or electrical problems
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

Disconnect coolant pump motor from internal harness.
Spare Coolant Pump is Available – Check:
1. 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:
2. Inspect internal harness wires going to coolant pump.
a coolant pump motor ground short.
Spare Coolant Pump is not Available – Check:

1. 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 2 and 3.
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 3.
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.
3. Inspect internal harness wires going to coolant pump.
a motor ground short.
If internal harness is good condition, replace PCM.


Symptom: Coolant pump not running (no code indicated)
Fuse blown in PCM
Check: Coolant Pump function

1. Harness for pinched or abraded wires. Positive lead
must not short to ground.
2. Check motor for internal short.
(See figure 4-37 and Test Procedure.)
Symptom: Coolant pump not pumping (no code indicated)
Check: Coolant Pump function

1. If the impeller is turning freely. If not, replace pump.
Symptom: Coolant pump leaking
Check: Leak location

1. Hose clamps. Tighten if necessary.
2. 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.
The PCM measures the RPM of the blower. This feature will give an error should
it fall below the necessary RPM to maintain sufficient combustion air.
CAUTION Symptom: Blower not running (code indicated)

When a blower fails, the combustion
Check: Blower wiring & function
chamber must be checked for carbon
build up and cleaned as necessary. 1. That blower is connected to harness correctly.
4. Test blower. If it tests OK replace PCM.
(See figure 4-38 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.
Symptom: Blower runs as soon as power is applied (no code indicated)
Check: Internal short in motor

Disconnect blower motor from internal harness.
Spare blower is available – check:
1. 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:
2. Inspect internal harness wires. Ensure that there is no chaffing
or cuts that would provide a blower motor ground short.
Spare Blower is not Available – Check:

1. 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 2
and 3.
If the coolant 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 3.
going to the blower motor and the body of the heater
If the resistance is not in the mega-ohm range, replace the blower.

3. Inspect internal harness wires going to blower. Ensure
that there is no chaffing or cuts that would provide a
blower motor ground short.
If internal harness is good condition, replace PCM
Symptom: Blower not running (no code indicated)

Fuse blown in PCM
Check: Blower function

Positive lead must not short to ground.
2. Check motor for internal short.
(See figure 4-38 and Test Procedure)
Symptom: Blower turning slowly (no code indicated)
Check: Blower function

1. For fan blade rubbing on housing.
2. For fan blade slipping on motor shaft.
Test Procedure:
1. Connect the blower to a power supply of the rated voltage.
Does it turn? If not, replace the blower.
2. 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.
3. Measure blower current. Use test lead part #967921K as
described on Service Bulletin #967329 in Appendix.
Figure 4-38. Blower Test

X45-12 .75 - 1.5 @ 12 Volts
X45-24 .5 - 1.0 @ 24 Volts

13 Sleeper A SLEEPER FAN diagnostic code indicates an electrical short in the sleeper
Fan fan wiring harness, electrical connections, or fan motor. This is a non-critical
fault and will not cause the heater to shut down, heat to the engine will be
maintained. An open circuit will not display a diagnostic code.
Symptom: Sleeper heater fan not turning (code indicated)
Check: Sleeper Heater system

1. The wiring connections and polarity.
2. 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 indicate 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

2. Test sleeper heater fan. (See Test Procedure)
Symptom: Sleeper heater system has low air flow (no code indicated)
Check: Sleeper heater system

1. Air ducting.
2. Use Test Procedure items 5 and 6 to determine if PROHEAT is
supplying enough power to drive the sleeper fan.
Test Procedure:
1. Disconnect sleeper fan harness.
2. Restart the PROHEAT, If there is still an error, replace the PCM.
3. Check for correct voltage at the sleeper fan output on the
NOTICE PCM. (See wiring diagram on page 1-4 and page 1-5.)
4. Reconnect sleeper fan harness. Start the PROHEAT.
The PROHEAT PCM sleeper fan
circuit has a one-minute delay 5. Check for voltage at the thermostat, isolator (if used) and
during ignition. Power to open a the sleeper fan motor. The power to the sleeper heater fan is
sleeper fan coolant valve must be regulated by voltage in the PCM. It will read low when trying to
taken from another source such as drive the sleeper fan.
the wire for the Hour Meter (Auxiliary 6. Connect sleeper heater fan motor directly to a remote power
Output). (See PROHEAT Wiring source of the rated voltage (12/24 Volts). Does the motor run?
Diagram page 1-4.)

14 Hour An HOUR METER (AUXILIARY OUTPUT) diagnostic code Indicates a short circuit
Meter fault in the harness or the device being operated by the Hour Meter (Auxiliary
(Auxiliary Output). This is a non-critical fault and will not cause the heater to shut down,
Output) 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
2. 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
2. Test electrical load. (See Test Procedure)
Test Procedure:
1. Disconnect load/circuit to hour meter (auxiliary output) harness
and start heater. If error goes away, check for short circuits in
the load/circuit.
2. 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.
3. Check for correct voltage (12 V: 9–14 V, 24 V: 19–30 V) at
the hour meter (auxiliary output) harness.
4. Reconnect hour meter (auxiliary output) harness. Start the
PROHEAT.
5. Connect electrical load directly to a remote power source of
the rated voltage (12/24 Volts). Does the electrical load run?
Figure 4-39. Hour Meter (Auxiliary Output) Test

16 System Indicates that the total system current limit of 15 amps was reached as
Current measured by the PCM.
Troubleshoot the system current diagnostic code based on voltage.
See page 4-26.
18 CANbus Indicates the heater was switched on via a CANbus input and then lost the
Error CANbus heartbeat message for longer than 2 seconds.
The heater will go to the Cool Down (Purge) mode then turn off until valid CAN
communication is restored.
If this diagnostic code displays, contact PROHEAT for more information.
19 High Indicates that the PCM’s onboard temperature reaches 203°F (95°C).
Ambient This is a non-critical fault and will not cause the heater to shut down.
PCM
Temperature
21–29 Activated when the PCM detects that any of the configurable output circuits is
Outputs 1–9 electrically shorted. This will only be detected whenever the output is powered.
Fault This is a non-critical fault and will not cause the heater to shut down. The output
fault code refers to a specific hardware pin on the switch/control connector.
(See wiring diagram on page 1-4.)
PIN# DESCRIPTION
21 Autostart Output shorted (Pin 1).
22 Not used.
23 Not used.
24 Not used.
25 Not used.
26 Not used.
27 Accessory Output Shored (Pin 9).
28 Indicator Output Shorted (Pin 14).
29 Not used.

4.2 COMPONENT MECHANICAL OR
ELECTRICAL PROBLEMS
4.2.1 FUEL NOZZLE
Go to page 4-20.
4.2.2 FUEL REGULATOR

Go to page 4-9.
4.2.3 AIR COMPRESSOR

Go to page 4-17 and page 4-32.
4.2.4 FUEL PUMP

Go to page 5-8.
4.2.5 IGNITION ELECTRODE

Go to page 4-21.
4.2.6 COOLANT PUMP

Go to page 4-36.
4.2.7 BLOWER
Go to page 4-39.

4.3 OPERATIONAL PROBLEMS
This section describes heater operational problems that are not specifically
described in the function or component diagnostic section.
4.3.1 COMPLAINT: Smoking exhaust/smelly exhaust fumes

NOTICE Black Smoke = Too much fuel for the amount of combustion air.
The heater may puff smoke on start • An increase in the compressor air pressure over the nozzle will add more
up/shut down for a few seconds. atomized fuel into the combustion tube; however the combustion air provided
by the combustion air blower remains constant resulting in a rich air/fuel
Normal combustion in full output mixture and possibly black smoke from the exhaust.
(ignition off) should be smoke free.
• A restriction in the amount of air through the combustion chamber (restricted
air intake, dirty heat exchanger plugged exhaust) will also result in a rich
air/fuel mixture as the compressor air pressure (and atomized fuel flow)
remains constant.
Check • Is the Combustion air restricted?

• Do you have the correct nozzle?
• Is the compressor air pressure correct?
• Is the fuel regulator faulty (leaking internally)?
Gray/White Smoke = incomplete combustion of the fuel (bad atomization).

• A restriction in the fuel line, filter, screens, or nozzle fuel passage will reduce
the atomized fuel/air flow into the combustion tube: however the combustion
air provided by the combustion air blower remains constant resulting in a
lean air/fuel mixture and possibly gray/white smoke from the exhaust.
• A decrease in the compressor air pressure over the nozzle will reduce the
amount of atomized fuel/air into the combustion tube; however the combustion
air provided by the combustion air blower remains constant resulting in a
lean air/fuel mixture and possibly gray/white smoke from the exhaust.
• Heater flooded with raw fuel will smoke heavily as it vaporize away. Heater
can take up to 10 minutes of running to clear a flood and stop smoking.
Check • Is it actually smoke or steam?

• Is there air in the fuel?
• Is the heat exchanger and exhaust flooded?
• Do you have the correct nozzle?
• Is the compressor air pressure correct?
• Is the fuel regulator faulty (not opening fully)?
4.3.2 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 4-24).

4.3.3 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.
4.3.3 COMPLAINT: Backfiring

Backfiring occurs when there is air in the fuel supply lines.
Check • Fuel level in tank – is the pick-up submerged?

• Air leaks – are all the fuel line clamps tight?
• For severely restricted combustion air blockage at the blower inlet, in the
combustion chamber, or in the exhaust system.

5.0 MAINTENANCE
5.1 WEEKLY MAINTENANCE

Run the heater a minimum of once a week to keep new fuel in the heater’s
critical components.
5.2 ANNUAL MAINTENANCE

Your PROHEAT has been designed to operate with a minimum of maintenance. To
ensure the efficient operation of your heater an annual maintenance tune-up
is strongly recommended to be performed each year.
Proper maintenance will result in the following benefits:
NOTICE • Maximum heat transfer to the coolant
A higher duty cycle may require a • Minimum battery power draw
more frequent maintenance schedule,
such as 2 or 3 times per year. • Long-term cost savings
• 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 5-1. PROHEAT X45 Plus Heater
SECTION 5. MAINTENANCE 5-1

5.2.1 CLEAN HEATER, ENCLOSURE AND AIR INTAKE
To clean the heater, enclosure, and air intake:
1. Remove the heater enclosure cover.
2. Clean any accumulated debris or dust from the components.
WARNING
3. Blow out the compartment with compressed air.
DO NOT pressure wash or steam clean.
4. Check the combustion air inlet screen for restrictions. Clean as required.
5. Make sure the opening around the exhaust pipe is clear.
6. Visually inspect all the components for wear or damage.
Clean the X45 Plus using the following procedure:

1. Protect yourself from burns and only touch a heater after it has cooled to
room temperature.
2. Clean the X45 Plus 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 PLUS HEATER
ENCLOSURE
Figure 5-2. X45 Plus Heater and Enclosure

5.2.2 CHECK EXHAUST SYSTEM
• Make sure the exhaust pipe
is vented safely away from
the vehicle cab.
• Check the pipe for dents,
restrictions, or severely
corroded areas.
• Replace the exhaust pipe
and clamps if necessary.
• Ensure the exhaust pipe
clamp is tight.
• Clean exhaust pipe if there is
a significant accumulation
of carbon build up.
Figure 5-3. Exhaust Pipe
5.2.3 CHECK HEAT EXCHANGER

• To maintain optimum heat output, clean any combustion deposits that may
have accumulated on the heat exchanger fins.
• Remove the fan end assembly and combustion tube to access the inside of
the heat exchanger.
• Ensure exhaust pipe is clean and free from restriction.
• Use a wire brush to loosen the deposits and a vacuum to suck them out.
• Torque securing screws to 25±3 in/lbs (2.8±0.3 Nm).
COMBUSTION TUBE
SECURING
SCREWS
HEAT EXCHANGER FINS
EXHAUST PIPE
Figure 5-4. Heat Exchanger

5.2.4 CLEAN FLAME SENSOR
• To maintain proper sensor readings, the flame sensor glass should be
wiped clean.
• With the fan end removed, clean the sensor glass with water and a rag.
Glass should be clear.
FLAME SENSOR
Figure 5-5. Flame sensor
5.2.5 CHECK COOLING SYSTEM

• Check all heater hoses and connections for signs of leakage or damage.
• Repair or replace as required.
• NOTE: The coolant mix must be 50% Ethylene Glycol.
5.2.6 CHECK BATTERIES

• Check the condition of batteries and
the power connections. The heater will
not function properly with weak
batteries or corroded
connections.
Figure 5-6. Test Battery

5.2.7 CHECK FUEL SYSTEM
• Check the fuel system for damaged fuel lines or leakage.
• Make sure the clamps on the fuel lines are secure.
• Ensure fuel lines are flexible.
FUEL FILTER
AIR FILTER
FUEL PICK UP
HOSE CLAMP
FUEL TANK
FUEL LINE
GROMMET
FUEL LINE HOSE CLAMP
Figure 5-7. Fuel Line Clamp
5.2.8 CHECK FUEL FILTER

• Remove and inspect
filter. Clean or replace
as necessary.
TORQUE TO
150±10 IN/LBS
(17±1.1 Nm)
FILTER
O-RING
O-RING
Figure 5-8. Fuel Filter Components

5.2.9 CLEAN NOZZLE
• Remove and install Nozzle as shown on page 4-20.
Torque to 150±10 in/lbs (17±1.1 Nm).
• To properly clean the nozzle use electrical
HOLD
contact cleaner or warm soapy water. UPRIGHT TO
This will wash any dirt out and leave ASSEMBLE
no residue. When using compressed
air, blow into the nozzle orifice
from the head end. TORQUE TO
30±3 IN/LBS
(3.4±0.3 Nm)
BLOW THIS DIRECTION
WHEN USING
COMPRESSED AIR
Figure 5-9. Nozzle Components
5.2.10 REPLACE COMPRESSOR AIR FILTER

• Replace inlet air filter annually or more often
if dusty conditions are encountered.
TORQUE TO 50±5 IN/LBS (5.6±0.7 Nm)
Figure 5-10. Compressor Air Filter

5.2.11 CHECK ELECTRICAL SYSTEM
To check the electrical system:
• Check the internal and the external wire harnesses for damage. Replace if
required.
CAUTION
• Service the X45 Plus ignition lead and Ignition coil by following the steps
Ensure that power is disconnected listed below.
to the X-45 prior to servicing the
1 Annually or better, inspect the ignition lead and the boots on both ends.
ignition lead.
Replace the entire lead with new lead (p/n 930523K) if the lead itself or
boots are coated with oil, torn, cracked or brittle.
2 Ensure that the electrical connections are clean and tight.
3 Ensure 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.
• Replace the ignition lead every five years or sooner (p/n 930523K).
Figure 5-11. Wire Harnesses
IGNITION LEAD IGNITION COIL
Figure 5-12. Ignition Coil

5.2.12 CHECK AIR PRESSURE
• To check the air pressure, refer to the air compressor pressure test
procedure on page 4-17.
DIGITAL
MANOMETER
PK0037
HOSE TO
NOZZLE AIR
INLET
HOSE FROM COMPRESSOR
Figure 5-13. Air Compressor Pressure Test Procedure
CHECK MODES OF OPERATION – SWITCH, TIMER OR

5.2.13 OEM SIGNALS
Check to see that the modes operate as described on page 3-7 to page 3-10.
Operation Test 1. Run the system for at least 15 minutes or until the heater cycles “OFF” and
then “ON” again.
2. 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 # QTY DESCRIPTION PART # QTY DESCRIPTION
825730K 1 Air Filter, X45. PK0094 1 X45 Plus Fall Service Kit
includes:
1 x Air Filter
1 x Fuel Filter
2 x O-Ring
PK0069 1 X45 Plus Major

Service Kit includes:
1 x Electrode
880035K 1 Fuel Filter, X45. 1 x Nozzle
1 x Regulator
1 x Flame Sensor
1 x Ignition Lead
1 x Air Filter
1 x Fuel Filter
2 x O-Ring

6.0 PROHEAT WARRANTY
PROHEAT warrants the PROHEAT heater to be free of defects in material and workmanship under
NOTICE design usage and service conditions for two (2) years on parts and labour from the date of first
This is a warranty summary. For the installation. Replacement parts are covered for the remainder of the heater’s warranty or ninety
(90) days, which ever is greater.
complete warranty manual, please
go to www.proheat.com 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 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 responsible 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. PROHEAT heaters 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.
4. Any progressive damage to the engine or vehicle arising out of failure of the PROHEAT.
5. PROHEAT heaters which have been modified or use of non-standard parts not approved
by PROHEAT.
6. PROHEAT heaters that have been abused or damaged.
7. Travel time by a PROHEAT dealer.
8. 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 PROHEAT at (604) 270-6899.
SECTION 6. PROHEAT WARRANTY 6-1

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
© 2015 Marine Canada Acquisition Inc.

DBA SEASTAR SOLUTIONS
Proheat is a registered trademark of

Marine Canada Acquisition Inc. and its
subsidiary companies.
PID# 925860 REV. A Designed and Manufactured Printed in Canada 11–15

in North America

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INSTALLATION AND SERVICE MANUAL

PROHEAT X45 PLUS

6.0 WARRANTY ............................................................................... 6-1

ii PROHEAT INSTALLATION & SERVICE

SECTION A. SAFETY A-1

WARNING Explosion Hazard

WARNING Fire Hazard

WARNING Moving/Hot Parts

DANGER California Proposition 65 Warning

A-2 PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

This manual is provided to assist authorized PROHEAT dealers install and

B.1 HEATER APPLICATIONS

SECTION B. INTRODUCTION B-1

B-2 PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

DANGER FUEL TYPES

SECTION 1. TECHNICAL SPECIFICATIONS 1-1

8.50" [216] 2X 7.5" [191]

Heater Dimensions – X45 Plus

THIS SPACE IS REQUIRED FOR

10.2" [259] 10.6" [270]

1.6" [41] 1.3" [33]

AUXILIARY MOUNTING PLATE

PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

SECTION 1. TECHNICAL SPECIFICATIONS

Heater Dimensions including Enclosure – X45 Plus

20.2" [513] 12.3" [313]

ENCLOSURE COVER ENCLOSURE COVER ENCLOSURE COVER

All control signal input voltages must

HEATER INTERNAL HARNESS

Wiring Diagram – X45 Plus

COMPRESSOR A (+)ORANGE A (+)ORANGE A1 A1

A (+)WHITE A (+)WHITE F2 F2 BLACK – BATTERY NEGATIVE (GROUND)

HOUR METER (AUXILIARY OUTPUT) A (+)RED/WHITE E1 E1

PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

SECTION 1. TECHNICAL SPECIFICATIONS

PCM Electrical Connections – X45 Plus

PROHEAT CONTROL MODULE (PCM)

CONTROLLER VOLTAGE AND PART NUMBER

FAN END CASTING

1-6 PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

X45 PLUS PROHEAT CONTROL MODULE (PCM)

SECTION 1. TECHNICAL SPECIFICATIONS 1-7

NOZZLE TO FAN END

ENCLOSURE LID (Optional)

1-8 PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

SECTION 1. TECHNICAL SPECIFICATIONS 1-9

The installation details described in this manual focus on truck applications

Figure 2-1. Other Applications

SECTION 2. INSTALLATION 2-1

If repairs to the vehicle require

Figure 2-2. Recommended Mounting Positions

2.1.2 GENERAL CONSIDERATIONS

WARNING COOLANT OUT

Figure 2-3. Figure 2-4. Allow minimum 6” clearance

2-2 PROHEAT X45 PLUS INSTALLATION & SERVICE MANUAL

Figure 2-5. Height Requirement

2.1.3 MOUNTING THE PROHEAT HEATER IN AN ENCLOSURE

Heater must be mounted within 5˚ of horizontal, as shown.

Figure 2-7. Mounting Angle