Owner`s Manual

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Owner`s Manual
TABLE OF CONTENTS
Manufacturer Warranty……………………………………………………………………………………..1
Utility Trailer Owner’s Manual……………………………………………………………………….…..6
Tire Safety Information…………………………………………………………………………………….57
Wiring………………………………………………………………………………………………………………68
Propane Safety…………………………………………………………………………………………………70
ProWatt SW Sine Wave Inverter………………………………………………………………………71
Atwood Water Heater…………………………………………………………………………………….105
Atwood Cooktops…………………………………………………………………………………………..120
Water Pump…………………………………………………………………………………………………..133
Max Coupler…………………………………………………………………………………………………..137
Solar Charge Controller……………………………………………………….…………………………140
Page 2 of 145
Turtleback Trailers LLC
855-732-2383
1424 E. Broadway Rd Phoenix AZ 85040
[email protected] —
www.turtlebacktrailers.com
Manufacturer Warranty
THE WARRANTY BEGINS
The warranty period begins on the date the vehicle is delivered to the first retail buyer or put into use,
whichever is earlier.
FOR HOW LONG AND WHAT IS COVERED
BASIC COVERAGE
The basic coverage period is 12 months.
This warranty covers any repairs needed to correct defects in materials or workmanship of all parts and
components of each new Turtleback Trailers LLC (Turtleback Trailers) vehicle supplied by Turtleback Trailers
subject to the exclusions listed under the heading “WHAT IS NOT COVERED”
WHAT IS COVERED - NO CHARGE
Warranty repairs will be made at no charge for parts and/or labor except for tires. Any needed parts
replacement will be made using Genuine Turtleback Trailers or Turtleback Trailers approved new or
remanufactured parts. Turtleback Trailers reserves the right to make changes at any time, without notice, to
production and service parts in their specifications, colors, and materials, including those used in connection
with warranty repairs. For this reason, when approved by Turtleback Trailers and at Turtleback Trailers ’s
discretion, functionally equivalent replacement parts may be used that do not exactly match the original
production part.
OBTAINING WARRANTY SERVICE
You must take the vehicle to the authorized Turtleback Trailers dealer in Phoenix Arizona during regular
business hours at your expense in order to obtain warranty service.
If you require warranty service in another location other than Turtleback Trailers Phoenix location contact
Turtleback Trailers for authorization prior to repairs.
Page 3 of 145
MAINTENANCE, DATA ACCESS, AND RECORDS
As a condition of this warranty, you are responsible for properly using, maintaining and caring for your vehicle
as outlined in your OWNER’S MANUAL and your Turtleback Trailers SERVICE & MAINTENANCE GUIDE, and
maintaining copies of all maintenance records & receipts for review by Turtleback Trailers . Evidence of the
performance of the required maintenance should be kept and presented as proof of such maintenance in
connection with related warranty repairs. To assist you in maintaining appropriate records, the maintenance log
located in your Turtleback Trailers SERVICE & MAINTENANCE GUIDE can be used along with supporting
repair invoices, receipts and other such records.
WHAT IS NOT COVERED - GENERAL EXCLUSIONS
This warranty does not cover damage, failures or corrosion resulting from or caused by:
Failure to operate the vehicle in accordance with the OWNER’S MANUAL.
Misuse
Failure of a component not covered by warranty
Racing and competitive driving
Theft, vandalism, fire, or flooding (including engine water ingestion)
Accident, collision, abuse
Repairs performed by anyone other than an authorized Turtleback Trailers Commercial Vehicle certified dealer
Normal wear and tear, including dings, dents, chips, or scratches
Damage caused by any automated or manually operated car wash or by using a pressure washer
DAMAGE OR FAILURES DUE TO ALTERATION OR MODIFICATION
This warranty does not cover damage, failures or corrosion resulting from or caused by:
Alteration, tampering, or improper repair.
Installation of non-Turtleback Trailers approved accessories or components.
Improper installation of any Turtleback Trailers approved aftermarket accessory or component.
Page 4 of 145
SALVAGE TITLE
This limited warranty does not apply to any vehicle, and is rendered VOID if the vehicle is (or ever has been)
issued a “salvage” or similar title including, but not limited to junk, scrap, rebuilt, or flood titles under any state’s
law; or has ever been determined to be a “total loss” or equivalent by any insurance company, such as by
payment of a cash payment of claim in lieu of repairs because of a determination that the cost of repairs
exceeded the actual cash value of the vehicle.
DAMAGE, FAILURES OR CORROSION FROM ENVIRONMENTAL CONDITIONS
This warranty does not cover damage, failures or corrosion resulting from or caused by: Stone chipping,
chemical fallout (acid rain), tree sap, salt,hail,windstorm,lightning, flood or other environmental conditions.
MAINTENANCE SERVICE EXPENSE
This warranty does not cover normal maintenance services as specified in your Turtleback Trailers SERVICE &
MAINTENANCE GUIDE such as cleaning and polishing; wheel alignment; lubricants, worn brake shoes, drums.
Page 5 of 145
Utility Trailer
Owner’s Manual
^ WARNING
This Owner’s Manual contains safety
information and instructions for your
trailer.
You must read this manual before loading
or towing your trailer.
You must follow all safety precautions and
instructions.
Turtleback Trailers, LLC
1424 E Broadway Road
Phoenix, AZ 85040
Bumper Pull Trailers
November 2013
1
Page 6 of 145
Contents
1. INTRODUCTION ............................................................................................ 5
2. SAFETY .................................................................................................... 6
2.1 Safety Alert Symbols And Signal Words .......................................................6
2.2 Major Hazards ...................................................................................................6
2.2.1 IMPROPER SIZING OF TRAILER TO TOW VEHICLE..................................................................... 6
2.2.2 DRIVING TOO FAST ............................................................................................................. 6
2.2.3 ADJUST DRIVING WHEN TOWING TRAILER .............................................................................. 7
2.2.4 TRAILER NOT PROPERLY COUPLED TO HITCH ......................................................................... 7
2.2.5 PROPER USE OF SAFETY CHAINS ......................................................................................... 8
2.2.6 PROPER CONNECTION OF BREAKAWAY BRAKE ........................................................................ 8
2.2.7 MATCHING TRAILER AND HITCH ............................................................................................ 8
2.2.8 WORN TIRES, LOOSE WHEELS AND LUG NUTS ....................................................................... 8
2.2.9 IMPROPER LOADING ............................................................................................................ 9
2.2.10 UNSAFE LOAD DISTRIBUTION ............................................................................................ 10
2.2.11 SHIFTING CARGO ............................................................................................................ 10
2.2.12 INAPPROPRIATE CARGO ................................................................................................... 10
2.2.13 INOPERABLE BRAKES OR LIGHTS .......................................................................................11
2.2.14 TRAILER MODIFICATIONS ...................................................................................................11
2.2.15 TRAILER TOWING GUIDE ...................................................................................................11
2.2.16 SAFE TRAILER TOWING GUIDELINES .................................................................................. 12
2.2.17 SAFETY WARNING LABELS ON YOUR TRAILER .................................................................... 13
2.2.18 REPORTING SAFETY DEFECTS ........................................................................................... 16
3. TIRE SAFETY INFORMATION......................................................................... 17
3.1 Trailer Tire Information ..................................................................................17
3.2 Steps For Determining Correct Load Limit - Trailer ...................................18
3.2.1 TRAILERS 10,000 POUNDS GVWR OR LESS ...................................................................... 18
3.2.2 TRAILERS OVER 10,000 POUNDS GVWR .......................................................................... 18
3.3 Steps For Determining Correct Load Limit - Tow Vehicle ..........................19
3.4 Glossary Of Tire Terminology.......................................................................19
3.5 Tire Safety - Everything Rides On It .............................................................21
3.5.1 SAFETY FIRST- BASIC TIRE MAINTENANCE ........................................................................... 22
3.5.2 FINDING YOUR VEHICLE’S RECOMMENDED TIRE PRESSURE AND LOAD LIMITS............................ 22
3.5.3 UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS .............................................................. 22
3.5.4 SAFETY FIRST- BASIC TIRE MAINTENANCE ........................................................................... 22
3.5.5 STEPS FOR MAINTAINING PROPER TIRE PRESSURE ................................................................ 22
3.5.6 TIRE SIZE ........................................................................................................................ 23
3.5.7 TIRE TREAD ..................................................................................................................... 23
3.5.8 TIRE BALANCE AND WHEEL ALIGNMENT .............................................................................. 23
3.5.9 TIRE REPAIR .................................................................................................................... 23
3.5.10 TIRE FUNDAMENTALS ....................................................................................................... 23
3.5.10.1 INFORMATION ON PASSENGER VEHICLE TIRES ............................................................. 23
3.5.10.2 UTQGS Information ...................................................................................................... 24
3.5.10.3 Additional Information On Light Truck Tires ............................................................. 24
3.5.10.4 Tire Safety Tips ............................................................................................................. 25
Page 7 of 145
Contents
4. COUPLING TO TOW VEHICLE ...................................................................... 26
4.1 Tow Vehicle And Hitch ...................................................................................26
4.1.1 TRAILER INFORMATION ....................................................................................................... 26
4.1.2 TOW VEHICLE................................................................................................................... 26
4.2 Coupling And Uncoupling The Trailer .........................................................26
4.3 Couple Trailer To Tow Vehicle ......................................................................27
4.3.1 BALL HITCH COUPLER ....................................................................................................... 27
4.3.1.1 BEFORE COUPLING TRAILER TO TOW VEHICLE ............................................................. 28
4.3.1.2 PREPARE COUPLER AND HITCH .................................................................................. 28
4.3.1.3 COUPLE TRAILER TO TOW VEHICLE ............................................................................ 28
4.3.2 TRAILER WITH RING AND PINTLE COUPLER ......................................................................... 29
4.3.2.1 BEFORE COUPLING TRAILER TO TOW VEHICLE ............................................................. 29
4.3.2.2 PREPARE RING AND PINTLE ....................................................................................... 29
4.3.2.3 COUPLE TRAILER TO TOW VEHICLE ............................................................................ 30
4.3.3 CONNECT SAFETY CHAINS ................................................................................................. 30
4.3.4 CONNECT ELECTRICAL CABLE ............................................................................................ 31
4.3.5 ATTACH BREAKAWAY BRAKE LANYARD................................................................................. 31
4.3.5.1 TEST ELECTRIC BRAKES ........................................................................................... 31
4.3.5.2 TEST ELECTRIC BREAKAWAY BRAKES.......................................................................... 31
4.3.5.3 TEST SURGE BRAKES (IF EQUIPPED) .......................................................................... 32
4.3.5.4 TEST SURGE BREAKAWAY SYSTEM.............................................................................. 33
4.4 Uncouple Trailer .............................................................................................33
4.5 Tongue Weight ...............................................................................................33
4.5.1 CHECKING TONGUE WEIGHT ............................................................................................... 34
4.6 Adjust Hitch Height (If Equipped) .................................................................34
5. LOADING AND UNLOADING ......................................................................... 36
5.1 Loading Trailer ...............................................................................................36
5.1.1 PREPARING TRAILER FOR LOADING ...................................................................................... 36
5.1.2 LOADING A RIGID DECK TRAILER ........................................................................................ 36
5.1.3 LOADING A TILT DECK TRAILER .......................................................................................... 37
5.1.3.1 MANUAL TILT TRAILER .............................................................................................. 37
5.1.3.2 HYDRAULIC TILT TRAILER .......................................................................................... 38
5.2 Unload Trailer .................................................................................................38
5.2.1 UNLOAD MANUAL TILT TRAILER .......................................................................................... 38
5.2.2 UNLOAD HYDRAULIC TILT TRAILER ...................................................................................... 38
5.3 Hydraulic Components .................................................................................39
5.4 Securing Cargo ..............................................................................................39
6. PRE-TOW CHECKLIST ................................................................................ 40
6.1 Pre-Tow Checklist ..........................................................................................40
6.2 Make Regular Stops ......................................................................................40
Page 8 of 145
7. BREAKING IN A NEW TRAILER .................................................................... 41
7.1 Retighten Lugs At First 10, 25 & 50 Miles....................................................41
7.2 Adjust Brake At First 200 Miles ....................................................................41
7.3 Synchronizing Brake Systems .....................................................................41
8. ACCESSORIES........................................................................................... 42
8.1 Accessory Battery .........................................................................................42
9. INSPECTION, SERVICE AND MAINTENANCE .................................................... 43
9.1 Inspection, Service & Maintenance Summary Charts ................................43
9.2 Inspection And Service Instructions............................................................46
9.2.1 TRAILER STRUCTURE ......................................................................................................... 46
9.2.1.1 FASTENERS AND FRAME MEMBERS ............................................................................. 46
9.2.1.2 WELDS ................................................................................................................... 46
9.2.2 TRAILER BRAKES - ELECTRIC ............................................................................................. 46
9.2.2.1 BRAKE DISCS, SHOES AND DRUMS ............................................................................ 46
9.2.2.2 MANUALLY ADJUSTING BRAKE SHOES ......................................................................... 47
9.2.2.3 ELECTRIC BRAKES.................................................................................................... 47
9.2.2.4 TOW VEHICLE OPERATED ELECTRIC BRAKES ................................................................ 47
9.2.2.5 ELECTRIC BRAKE MAGNETS ....................................................................................... 47
9.2.3 TRAILER BRAKES - SURGE (IF EQUIPPED) ............................................................................ 47
9.2.3.1 SURGE BRAKE MASTER CYLINDER .............................................................................. 47
9.2.3.2 HYDRAULIC SURGE BRAKE ........................................................................................ 48
9.2.3.3 MASTER CYLINDER BLEEDING .................................................................................... 48
9.2.4 TRAILER CONNECTION TO TOW VEHICLE .............................................................................. 48
9.2.4.1 COUPLER AND BALL................................................................................................. 48
9.2.4.2 RING AND PINTLE .................................................................................................... 49
9.2.5 LANDING LEG OR JACK ..................................................................................................... 49
9.2.6 LIGHTS AND SIGNALS ........................................................................................................ 49
9.2.7 WHEEL RIMS.................................................................................................................... 49
9.2.8 TIRES .............................................................................................................................. 49
9.2.9 WHEEL BEARINGS............................................................................................................. 50
9.2.10 LUBRICATION .................................................................................................................. 50
9.2.11 HYDRAULIC RESERVOIR .................................................................................................... 50
9.2.12 LUG NUTS OR BOLTS ..................................................................................................... 50
Page 9 of 145
Introduction
1. INTRODUCTION
Congratulations on the purchase of your trailer. We
believe you will be happy and completely satisfied with
your purchase. Our goal is to provide a valued customer
a quality trailer at a reasonable price.
For your safety, read and understand this manual
before operating your trailer. If there are any questions
about information in this manual, please consult your
dealer.
When calling about your trailer, please have the VIN
number available for the dealer. The VIN number is
normally on the front left side of the trailer.
For future reference, please write your VIN number in
the space below:
___________________________________________
This manual covers the basic trailer. You must read,
understand and follow the instructions given by the
trailer manufacturer, tow vehicle and trailer hitch
manufacturers. Keep all manuals provided with your
trailer in a safe place at all times.
Inserts providing information on axles and tire warranty
are provided with this manual. Please keep these
inserts for future reference.
Page 10 of 145
Safety
2. SAFETY
NOTICE
2.1 SAFETY ALERT SYMBOLS AND SIGNAL
WORDS
An Owner’s Manual that provides general trailer
information cannot cover all of the specific details
necessary for the proper combination of every trailer,
tow vehicle and hitch. You must read, understand and
follow the instructions given by the tow vehicle and
trailer hitch manufacturers, as well as the instructions
in this manual.
Our trailers are built with components produced by
various manufacturers. Some of these items have
separate instruction manuals. Where this manual
indicates that you should read another manual, and
you do not have that manual, contact your dealer for
assistance.
The safety information in this manual is denoted by the
safety alert symbol:
^
This symbol means ATTENTION! BECOME ALERT!
YOUR SAFETY IS INVOLVED!
The level of risk is indicated by the following signal
words:
^ DANGER
DANGER - Indicates a hazardous situation,
which, if not avoided, WILL result in death
or serious injury.
^ WARNING
WARNING - Indicates a hazardous
situation, which, if not avoided, could
result in death or serious injury.
^ CAUTION
CAUTION - Indicates a hazardous situation,
which, if not avoided, could result in minor
or moderate injury.
NOTICE - Indicates a situation that could
result in damage to the equipment or other
property.
2.2 MAJOR HAZARDS
Loss of control of the trailer or trailer/tow vehicle
combination can result in death or serious injury. The
most common causes for loss of control of the trailer
are:
• Improper sizing the trailer for the tow vehicle, or
vice versa.
• Excessive Speed: Driving too fast for the
conditions.
• Improper braking
and steering under sway
conditions
• Overloading and/or improper weight distribution.
• Not keeping lug nuts tight.
• Failure to adjust driving behavior when towing a
trailer.
• Not maintaining proper tire pressure
• Improper or mis-coupling of the trailer to the hitch.
2.2.1 IMPROPER SIZING OF TRAILER TO TOW VEHICLE
Trailers that weigh too much for the tow vehicle can
cause stability problems, which can lead to death or
serious injury. The additional strain put on the engine
and drive-train may lead to serious tow vehicle
maintenance problems.
Do not exceed the maximum towing capacity of your
tow vehicle. The towing capacity of your tow vehicle,
in terms of maximum Gross Trailer Weight (GTW) and
maximum Gross Combined Weight Rating (GCWR)
can be found in the tow vehicle Owner’s Manual.
^ DANGER
Use of an under-rated hitch, ball or tow
vehicle can result in loss of control leading
to death or serious injury.
Make certain your hitch and tow vehicle
are rated for your trailer.
2.2.2 DRIVING TOO FAST
With ideal road conditions, the maximum recommended
speed for safely towing a trailer is 55 mph. Driving
too fast can cause the trailer to sway, thus increasing
Page 11 of 145
Safety
the possibility for loss of control. Also your tires may
overheat, increasing the possibility of a blowout.
^ WARNING
Driving too fast for conditions can result in
loss of control and cause death or serious
injury.
Adjust speed down when towing trailer.
2.2.4 TRAILER NOT PROPERLY COUPLED TO HITCH
It is critical that the trailer be securely coupled to
the hitch, and that the safety chains and emergency
breakaway brake lanyard are correctly attached.
Uncoupling may result in death or serious injury to you
and to others.
^ WARNING
2.2.3 ADJUST DRIVING WHEN TOWING TRAILER
Proper selection and condition of the
coupler and hitch are essential to safely
towing a trailer.
When towing a trailer, you will have decreased
acceleration, increased stopping distance, and
increased turning radius.
A loss of coupling may result in death or
serious injury.
The trailer will change the handling characteristics of
the tow vehicle, making it more sensitive to steering
inputs and more likely to be pushed around in windy
conditions or when being passed by large vehicles. In
addition, you will need a longer distance to pass, due
to slower acceleration and increased length. With this
in mind:
• When encountering trailer sway, take your foot
off the accelerator, and steer as little as possible
in order to stay on the road. Use small “trim-like”
steering adjustments. Do not attempt to steer out
of the sway; you’ll only make it worse. Also do
not apply the tow vehicle brakes to correct trailer
swaying. On the other hand, application of the
trailer brakes alone will tend to straighten out the
combination, especially when going downhill.
• Check rearview mirrors frequently to observe trailer
and traffic.
• Be aware of trailer height, especially when
approaching bridges, roofed areas and trees.
• Be alert for slippery conditions. You are more likely
to be affected by slippery road surfaces when
driving a tow vehicle with a trailer, than driving a
tow vehicle without a trailer.
• Anticipate the trailer “swaying.” Swaying can be
caused by excessive steering, wind gusts, roadway
edges, or by the trailer reaction to the pressure
wave created by passing trucks and busses.
• Use lower gear when driving down steep or long
grades. Use the engine and transmission as a
brake. Do not ride the brakes, as they can overheat
and become ineffective.
Hitch size must match coupler size.
Be sure hitch load rating is equal to or
greater than load rating of the coupler.
Be sure hitch components are tight before
coupling trailer to tow vehicle.
Observe hitch for wear, corrosion and
cracks before coupling. Replace worn,
corroded or cracked hitch components
before coupling trailer to tow vehicle.
^ WARNING
An improperly coupled trailer can result in
death or serious injury. Do not move the
trailer until:
•
•
•
•
•
•
•
•
Coupler is secured and locked to hitch.
Safety chains are secured to tow
vehicle.
Trailer jack(s) are fully retracted.
Trailer brakes are checked.
Tires and wheels are checked.
Breakaway switch is connected to tow
vehicle;
The trailer lights are connected and
checked.
Load is secured to trailer.
Page 12 of 145
Safety
2.2.5 PROPER USE OF SAFETY CHAINS
Safety chains are provided so that control of the trailer
can be maintained if your trailer comes loose from the
hitch.
^ WARNING
2.2.7 MATCHING TRAILER AND HITCH
^ DANGER
Be sure hitch and tow vehicle are rated for
the Gross Vehicle Weight Rating (GVWR)
of your trailer.
Improper rigging of the safety chains can
result in loss of control of the trailer and
tow vehicle, leading to death or serious
injury, if the trailer uncouples from the tow
vehicle.
Use of a hitch with a load rating less than
the load rating of the trailer can result in
loss of control and may lead to death or
serious injury.
Cross chains underneath hitch and coupler
with enough slack to permit turning and to
hold tongue up, if the trailer comes loose.
Use of a tow vehicle with a towing capacity
less than the load rating of the trailer can
result in loss of control, and may lead to
death or serious injury.
Fasten chains to frame of tow vehicle.
2.2.8 WORN TIRES, LOOSE WHEELS AND LUG NUTS
Do not fasten chains to any part of the
hitch unless the hitch has holes or loops
specifically for that purpose.
Inspect all trailer tires before each tow. If a tire has a
bald spot, bulge, cut, cracks, or is showing any cords,
replace the tire before towing.
2.2.6 PROPER CONNECTION OF BREAKAWAY BRAKE
If equipped with brakes, your trailer will be equipped
with a breakaway brake system that can apply the
brakes on your trailer if your trailer comes loose from
the hitch. You may have a separate set of instructions
for the breakaway brake if the trailer is so equipped. The
breakaway brake system, including battery, must be in
good condition and properly rigged to be effective.
^ WARNING
An ineffective or inoperative breakaway
brake system can result in a runaway
trailer, leading to death or serious injury if
the coupler or hitch fails.
Breakaway lanyard must be connected
to the tow vehicle, NOT to any part of the
hitch.
If a tire has uneven tread wear, take the trailer to a
trailer service center for diagnosis. Uneven tread wear
can be caused by tire imbalance, axle misalignment or
incorrect inflation.
Tires with too little tread will not provide adequate
frictional forces on wet roadways and can result in loss
of control, leading to death or serious injury.
Improper tire pressure causes increased tire wear and
may reduce trailer stability, which can result in a tire
blowout or possible loss of control. Therefore, before
each tow you must also check the tire pressure.
The proper tire pressure is listed on the Certification
/ VIN label, normally mounted on the front left side of
the trailer, and should be checked when tires are cold.
Allow 3 hours cool-down after driving as much as 1
mile at 40 mph before checking tire pressure.
Before towing trailer, test the function
of the breakaway brake system. If the
breakaway brake system is not working,
do not tow the trailer. Have it serviced or
repaired.
Page 13 of 145
Safety
^ WARNING
Inflate tires to pressure stated on the
Certification / VIN label.
Improper tire pressure may cause unstable
trailer. Blowout and loss of control may
occur. Death or serious injury can result.
Make sure of proper tire pressure before
towing trailer.
The tightness of the wheel nuts or bolts is very
important in keeping the wheels properly seated to the
hub. Before each tow, check to make sure they are
tight.
^ WARNING
Metal creep between the wheel rim and
wheel nuts or bolts may cause rim to
loosen.
Death or injury can occur if wheel comes
off.
Tighten lug nuts or bolts before each tow.
The proper tightness (torque) for wheel nuts or bolts
and tightening sequence is listed in the Inspection,
Service and Maintenance section of this manual. Use
a torque wrench to tighten the lug nuts and use the
crisscross star pattern sequence. Improper tightening
of the lug nuts voids the axle warranty.
Wheel nuts or bolts are also prone to loosen after
first being assembled. When driving a new trailer (or
after wheels have been remounted), check to make
sure they are tight after the first 10, 25 and 50 miles of
driving and before each tow thereafter.
Failure to perform this check can result in a wheel
separating from the trailer and a crash, leading to
death or serious injury.
^ WARNING
Wheel nuts or bolts are prone to loosen
after being first assembled. Death or
serious injury can result.
Check wheel nuts or bolts for tightness
on a new trailer, and after re-mounting a
wheel at 10, 25 and 50 miles.
^ WARNING
Inadequate wheel nut or bolt torque can
cause a wheel to separate from the trailer,
leading to death or serious injury.
Verify wheel nuts or bolts are tight before
each tow.
2.2.9 IMPROPER LOADING
The total weight of the load you put on the trailer, plus
the empty weight of the trailer itself, must not exceed
the trailer’s Gross Vehicle Weight Rating (GVWR).
If you do not know the empty weight of the trailer plus
the cargo weight, you must weigh the loaded trailer at
a commercial scale. In addition, you must distribute the
load in the trailer such that the load on any axle does
not exceed the Gross Axle Weight Rating (GAWR).
If your trailer is equipped with a Tire & Loading
Information Placard, mounted next to the Certification
/ VIN label, the cargo capacity weight stated on that
placard is only a close estimate. The GVWR and GAWR
are listed on the Certification / VIN label normally
located on the front left side of the trailer.
^ WARNING
An overloaded trailer can result in failure
or loss of control of the trailer, leading to
death or serious injury.
Never load a trailer so that the weight on
any tire exceeds its rating.
Never exceed the trailer Gross Vehicle
Weight Rating (GVWR) or axle Gross Axle
Weight Rating (GAWR).
Page 14 of 145
Safety
2.2.10 UNSAFE LOAD DISTRIBUTION
Improper front / rear load distribution can lead to an
unstable trailer or poor tow vehicle handling. Poor
trailer stability results from tongue weights that are too
low, and poor tow vehicle stability results from tongue
weights that are too high.
Refer to the “Loading And Unloading” section for more
information.
In the following table, the second column shows the
rule of thumb percentage of total weight of the trailer
plus its cargo (Gross Trailer Weight, or “GTW”) that
should appear on the tongue of the trailer. For example,
a large trailer with a loaded weight of 6,000 pounds,
should have 10-15% of 6,000 pounds (600-900 lbs.)
on the hitch.
Tongue Weight as a Percentage of Loaded Trailer
Weight
Type of Hitch
Percentage
Ball Hitch or 10-15% for large trailers
Ring & Pintle
6-10% for small trailers
The numbers quoted are for example purposes only
and should be tailored to the specific trailer.
For questions regarding the actual percent of tongue
weight for the trailer, check with the manufacturer
for specifics.
After loading, be sure to check that none of the axles
are overloaded.
Uneven left / right load distribution can cause tire,
wheel, axle or structural failure.
Be sure your trailer is evenly loaded left / right. Towing
stability also depends on keeping the center of gravity
as low as possible.
^ WARNING
Improper tongue weight (load distribution)
can result in loss of control of the trailer,
leading to death or serious injury.
Make certain that tongue weight is within
the allowable range.
Be sure to:
• Distribute the load evenly, right and left.
• Keep the center of gravity low.
• Distribute the load front-to-rear to provide
proper tongue weight (see chart).
2.2.11 SHIFTING CARGO
Since the trailer “ride” can be bumpy and rough, you
must secure the cargo so that it does not shift while the
trailer is being towed.
^ WARNING
A shifting load can result in failure, or to
loss of control of the trailer, and can lead
to death or serious injury.
You must tie down all loads with proper
sized fasteners, chains, straps, etc. to
prevent the load from shifting while
towing.
2.2.12 INAPPROPRIATE CARGO
The trailer may be designed for specific cargo. If your
trailer is designed for specific cargo, only carry that
cargo in the trailer. A trailer must not be used to carry
certain items, such as people, containers of hazardous
substances or containers of flammable substances.
^ WARNING
Do not transport people on your trailer.
Besides putting their lives at risk, the
transport of people on a trailer is illegal.
Page 15 of 145
Safety
^ WARNING
2.2.14 TRAILER MODIFICATIONS
Do not transport flammable, explosive,
poisonous or other dangerous materials
on your trailer.
Modification of the trailer structure or alteration of your
trailer can make the trailer unsafe and will void all
warranty options. Before making any alteration to the
trailer, contact your dealer or the manufacturer and
describe the alteration you are contemplating.
The exception is fuel in the tank of a
vehicle or equipment being hauled.
2.2.15 TRAILER TOWING GUIDE
If your trailer has electric brakes, your tow vehicle will
have an electric brake controller that sends power to
the trailer brakes.
Driving a vehicle with a trailer in tow is vastly different
from driving the same vehicle without a trailer in tow.
Acceleration, maneuverability and braking are all
diminished with a trailer in tow. It takes longer to get up
to speed; you need more room to turn and pass, and
more distance to stop when towing a trailer.
Before towing the trailer, you must operate the brake
controller while trying to pull the trailer in order to
confirm that the electric brakes operate. While towing
the trailer at less than 5 mph, manually operate the
electric brake controller in the tow vehicle cab. You
should feel the operation of the trailer brakes.
You will need to spend time adjusting to the different
feel and maneuverability of the tow vehicle with a
loaded trailer. Because of the significant differences in
all aspects of maneuverability when towing a trailer,
the hazards and risks of injury are also much greater
than when driving without a trailer.
If your trailer has hydraulic “surge” brakes, pull the
emergency breakaway brake lanyard to check the
operation of the surge mechanism.
You are responsible for keeping your vehicle and trailer
in control, and for all the damage that is caused if you
lose control of your vehicle and trailer.
Be sure that the electric brakes and all of the lights
on your trailer are functioning properly before towing
the trailer. Electric brakes and lights on a trailer are
controlled via a connection to the tow vehicle, generally
a multi-pin electrical connector.
Find an open area with little or no traffic for your first
practice. Before you start towing the trailer, you must
follow all of the instructions for inspection, testing,
loading and coupling. Also, before you start towing,
adjust the mirrors so you can see the trailer as well as
the area to the rear of it.
2.2.13 INOPERABLE BRAKES OR LIGHTS
^ WARNING
Improper electrical connection between
the tow vehicle and the trailer will result in
inoperable lights and electric brakes, and
can lead to collision.
Before each tow:
• Check that the electric brakes work by
operating the brake controller inside the
tow vehicle.
• Check that all lights and turn signals
work.
You must provide mirrors that allow you to safely
observe approaching traffic. Standard mirrors usually
do not provide adequate visibility for viewing traffic to
the sides and rear a towed trailer.
Drive slowly at first, 5 mph or so, and turn the wheel
to get the feel of how the tow vehicle and trailer
combination responds. Next, make some right and
left hand turns. Watch in your side mirrors to see how
the trailer follows the tow vehicle. Turning with a trailer
attached requires more room.
Stop the rig a few times from speeds no greater than
10 mph. If your trailer is equipped with brakes, try using
different combinations of trailer/electric brake and tow
vehicle brake. Note the effect that the trailer brakes
have when they are the only brakes used. When
properly adjusted, the trailer brakes will come on just
before the tow vehicle brakes.
It will take practice to learn how to back up a tow vehicle
with a trailer attached. Take it slow. Before backing up,
get out of the tow vehicle and look behind the trailer to
make sure that there are no obstacles.
Page 16 of 145
Safety
Some drivers place their hands at the bottom of the
steering wheel, and while the tow vehicle is in reverse,
“think” of the hands as being on the top of the wheel.
When the hands move to the right (counter-clockwise,
as you would do to turn the tow vehicle to the left when
moving forward), the rear of the trailer moves to the
right.
Conversely, rotating the steering wheel clockwise with
your hands at the bottom of the wheel will move the rear
of the trailer to the left, while backing up. Be careful not
to allow the trailer to turn too much, because it will hit
the rear of the tow vehicle. To straighten the rig, either
pull forward, or turn the steering wheel in the opposite
direction.
•
•
The tires are not visibly low on pressure.
The cargo is secure and in good condition.
Slow down for bumps in the road.
Do not brake while in a curve unless absolutely
necessary. Instead, slow down before you enter the
curve.
Do not drive so fast that the trailer begins to sway due
to speed. Generally never drive faster than 55 m.p.h.
Allow plenty of room for passing. A rule of thumb is
that the passing distance with a trailer is 4 times the
passing distance without a trailer.
2.2.16 SAFE TRAILER TOWING GUIDELINES
Before towing, check coupling, safety chain, brakes,
tires, wheels and lights.
Check the lug nuts or bolts for tightness.
Recheck the load tie downs to make sure the load will
not shift during towing.
Check coupler tightness after towing 50 miles.
Adjust the brake controller to engage the trailer brakes
before the tow vehicle brakes. Follow the brake
controller manufacturer’s literature.
Use your mirrors to verify that you have room to change
lanes or pull into traffic.
Use your turn signals well in advance.
Allow plenty of stopping space for your trailer and tow
vehicle.
Use lower gears for climbing and descending grades.
Do not ride the brakes while descending grades; they
may get so hot that they stop working. Then you will
potentially have a runaway tow vehicle and trailer.
Do not apply the tow vehicle brakes to correct extreme
trailer swaying. Instead, lightly apply the trailer brakes
with the hand controller.
Make regular stops, about once each hour. Confirm
that:
• The coupler is secure to the hitch and is locked.
• Electrical connectors are made.
• There is appropriate slack in safety chains.
• There is appropriate slack in breakaway lanyard.
Page 17 of 145
Safety
2.2.17 SAFETY WARNING LABELS ON YOUR TRAILER
Depending on trailer configuration, your trailer may not be equipped with all safety labels shown.
Page 18 of 145
Safety
Page 19 of 145
Safety
^ WARNING
To protect you and others against death or
serious injury, all applicable labels shown
must be on the trailer and must be legible.
If any of these labels are missing or
cannot be read, contact your dealer for
replacement labels.
Page 20 of 145
Safety
2.2.18 REPORTING SAFETY DEFECTS
If you believe that your vehicle has a defect that could
cause a crash or could cause injury or death, you should
immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying
Turtleback Trailers, LLC
1424 E Broadway Road
Phoenix, AZ 85040
If NHTSA receives similar complaints, it may open an
investigation, and if it finds that a safety defect exists
in a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved
in individual problems between you, your dealer, or
Turtleback Trailers, LLC
1424 E Broadway Road
Phoenix, AZ 85040
To contact NHTSA, you may call the Vehicle Safety
Hotline toll-free at 1-888-327-4236 (TTY: 1-800-4249153); or go to http://www.safercar.gov; or write to:
Administrator, NHTSA,
1200 New Jersey SE,
Washington, DC 20590.
You can also obtain other information about motor
vehicle safety from http://www.safercar.gov.
Page 21 of 145
Tire Safety
3. TIRE SAFETY INFORMATION
3.1 TRAILER TIRE INFORMATION
This portion of the User’s Manual contains tire safety
information as required by 49 CFR 575.6.
Trailer tires may be worn out even though they still
have plenty of tread left. This is because trailer tires
have to carry a lot of weight all the time, even when
not in use.
Section 3.1 contains “Trailer Tire Information”.
Section 3.2 contains “Steps for Determining Correct
Load Limit - Trailer”.
Section 3.3 contains “Steps for Determining Correct
Load Limit – Tow Vehicle”.
Section 3.4 contains a Glossary of Tire Terminology,
including “cold inflation pressure”, “maximum inflation
pressure”, “recommended inflation pressure”, and
other non-technical terms.
Section 3.5 contains information from the NHTSA
brochure entitled “Tire Safety – Everything Rides On
It”.
This brochure, as well as preceding subsections,
describes the following items;
• Tire labeling, including a description and explanation
of each marking on the tires, and information about
the DOT Tire Identification Number (TIN).
• Recommended tire inflation pressure, including a
description and explanation of:
A. Cold inflation pressure.
B. Vehicle Placard and location on the vehicle.
C. Adverse safety consequences of under inflation
(including tire failure).
D. Measuring and adjusting air pressure for proper
inflation.
• Tire Care, including maintenance and safety
practices.
• Vehicle load limits, including a description and
explanation of the following items:
A. Locating and understanding the load limit
information, total load capacity, and cargo
capacity.
B. Calculating total and cargo capacities with varying
seating configurations including quantitative
examples showing / illustrating how the vehicles
cargo and luggage capacity decreases as
combined number and size of occupants’
increases. This item is also discussed in Section
3.
C. Determining compatibility of tire and vehicle load
capabilities.
D. Adverse safety consequences of overloading on
handling and stopping on tires.
It is actually better for the tire to be rolling down the road
than to be idle. During use, the tire releases lubricants
that are beneficial to tire life. Using the trailer tires often
also helps prevent flat spots from developing.
The main cause of tire failure is improper inflation. Check
the cold tire inflation pressures at least once a week for
proper inflation levels. “Cold” means that the tires are
at the same temperature as the surrounding air, such
as when the vehicle has been parked overnight. Wheel
and tire manufacturers recommend adjusting the air
pressure to the trailer manufacturer’s recommended
cold inflation pressure, in pounds per square inch (PSI)
stated on the vehicle’s Federal Certification Label or
Tire Placard when the trailer is loaded to its gross
vehicle weight rating (GVWR).
If the tires are inflated to less than the recommended
inflation level or the GVWR of the trailer is exceeded, the
load carrying capacity of the tire could be dramatically
affected. If the tires are inflated more than the
recommended inflation level, handling characteristics
of the tow vehicle/trailer combination could be affected.
Refer to the owner’s manual or talk to your dealer
or vehicle manufacturer if you have any questions
regarding proper inflation practices.
Tires can lose air over a period of time. In fact, tires can
lose 1 to 3 PSI per month. This is because molecules of
air, under pressure, weave their way from the inside of
the tire, through the rubber, to the outside. A drop in tire
pressure could cause the tire to become overloaded,
leading to excessive heat build up. If a trailer tire is
under-inflated, even for a short period of time, the tire
could suffer internal damage.
High speed towing in hot conditions degrades trailer tires
significantly. As heat builds up during driving, the tire’s
internal structure starts to breakdown, compromising
the strength of the tire. It is recommended to drive at
moderate speeds.
Statistics indicate the average life of a trailer tire is
about five years under normal use and maintenance
conditions. After three years, replacing the trailer tires
with new ones should be considered, even if the tires
have adequate tread depth. Some experts claim that
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Tire Safety
after five years, trailer tires are considered worn out
and should be replaced, even if they have had minimal
or no use. This is such a general statement that it
may not apply in all cases. It is best to have your tires
inspected by a tire supplier to determine if your tires
need to be replaced.
If you are storing your trailer for an extended period,
make sure the tires are fully inflated to the maximum
rated pressure and that you store them in a cool, dry
place, such as a garage. Use tire covers to protect the
trailer tires from the harsh effects of the sun.
overloading and, as a result, abnormal tire flexing
occurs. This situation can generate an excessive
amount of heat within the tire. Excessive heat may lead
to tire failure. It is the air pressure that enables a tire
to support the load, so proper inflation is critical. The
proper air pressure may be found on the Certification /
VIN label and/or on the Tire Placard. This value should
never exceed the maximum cold inflation pressure
stamped on the tire.
3.2.1 TRAILERS 10,000 POUNDS GVWR OR LESS
3.2 STEPS FOR DETERMINING CORRECT LOAD
LIMIT - TRAILER
Determining the load limits of a trailer includes more
than understanding the load limits of the tires alone.
On all trailers there is a Federal Certification / VIN label
that is located on the forward half of the left (road) side
of the unit. This certification/VIN label will indicate the
trailer’s Gross Vehicle Weight Rating (GVWR). This is
the most weight the fully loaded trailer can weigh. It will
also provide the Gross Axle Weight Rating (GAWR).
This is the most a particular axle can weigh. If there
are multiple axles, the GAWR of each axle will be
provided.
If your trailer has a GVWR of 10,000 pounds or less,
there is a vehicle placard located in the same location
as the certification label described above. This placard
provides tire and loading information. In addition, this
placard will show a statement regarding maximum
cargo capacity.
Cargo can be added to the trailer, up to the maximum
weight specified on the placard. The combined weight
of the cargo is provided as a single number. In any
case, remember: the total weight of a fully loaded trailer
can not exceed the stated GVWR.
When loading your cargo, be sure it is distributed
evenly to prevent overloading front to back and side to
side. Heavy items should be placed low and as close
to the axle positions as reasonable. Too many items
on one side may overload a tire. The best way to know
the actual weight of the vehicle is to weigh it at a public
scale. Talk to your dealer to discuss the weighing
methods needed to capture the various weights related
to the trailer. This would include the weight empty or
unloaded, weights per axle, wheel, hitch or king-pin,
and total weight.
1. Locate the statement, “The weight of cargo should
never exceed XXX kg or XXX lbs.,” on your vehicle’s
placard.
2. This figure equals the available amount of cargo
and luggage load capacity.
3. Determine the combined weight of luggage and
cargo being loaded on the vehicle. That weight may
not safely exceed the available cargo and luggage
load capacity.
4. The trailer’s placard refers to the Tire Information
Placard attached adjacent to or near the trailer’s
VIN (Certification) label at the left front of the
trailer.
3.2.2 TRAILERS OVER 10,000 POUNDS GVWR
(Note: These trailers are not required to have a tire
information placard on the trailer and may not have
one installed)
1. Determine the empty weight of your trailer by
weighing the trailer using a public scale or other
means.
2. Locate the GVWR (Gross Vehicle Weight Rating) of
the trailer on your trailer’s VIN (Certification) label.
3. Subtract the empty weight of your trailer from the
GVWR stated on the VIN label. That weight is the
maximum available cargo capacity of the trailer
and may not be safely exceeded. National Highway
Transportation Safety Administration (NHTSA) in
addition to notifying us.
Excessive loads and/or under inflation cause tire
Page 23 of 145
Tire Safety
3.3 STEPS FOR DETERMINING CORRECT LOAD
LIMIT - TOW VEHICLE
Cold inflation pressure: The pressure in the tire
before you drive.
Cord: The strands forming the plies in the tire.
1. Locate the statement, “The combined weight of
2.
3.
4.
5.
6.
occupants and cargo should never exceed XXX
lbs.,” on your vehicle’s placard.
Determine the combined weight of the driver and
passengers who will be riding in your vehicle.
Subtract the combined weight of the driver and
passengers from XXX kilograms or XXX pounds.
The resulting figure equals the available amount
of cargo and luggage capacity. For example, if the
“XXX” amount equals 1400 lbs. and there will be
five 150 lb. passengers in your vehicle, the amount
of available cargo and luggage capacity is 650 lbs.
(1400-750 (5 x 150) = 650 lbs.).
Determine the combined weight of luggage and
cargo being loaded on the vehicle. That weight may
not safely exceed the available cargo and luggage
capacity calculated in previous step.
If your vehicle will be towing a trailer, load from your
trailer will be transferred to your vehicle. Consult
the tow vehicle’s manual to determine how this
weight transfer reduces the available cargo and
luggage capacity of your vehicle.
Cord separation: The parting of cords from adjacent
rubber compounds.
Cracking Any parting within the tread, sidewall, or
inner liner of the tire extending to cord material.
CT: A pneumatic tire with an inverted flange tire and rim
system in which the rim is designed with rim flanges
pointed radially inward and the tire is designed to fit on
the underside of the rim in a manner that encloses the
rim flanges inside the air cavity of the tire.
Curb weight: The weight of a motor vehicle with
standard equipment including the maximum capacity
of fuel, oil, and coolant, and, if so equipped, air
conditioning and additional weight optional engine.
Extra load tire: A tire designed to operate at higher
loads and at higher inflation pressures than the
corresponding standard tire.
Groove: The space between two adjacent tread ribs.
3.4 GLOSSARY OF TIRE TERMINOLOGY
Accessory weight: The combined weight (in excess
of those standard items which may be replaced) of
automatic transmission, power steering, power brakes,
power windows, power seats, radio and heater, to
the extent that these items are available as factoryinstalled equipment (whether installed or not).
Gross Axle Weight Rating: The maximum weight that
any axle can support, as published on the Certification
/ VIN label on the front left side of the trailer. Actual
weight determined by weighing each axle on a public
scale, with the trailer attached to the towing vehicle.
Bead: The part of the tire that is made of steel wires,
wrapped or reinforced by ply cords and that is shaped
to fit the rim.
Gross Vehicle Weight Rating: The maximum weight of
the fully loaded trailer, as published on the Certification
/ VIN label. Actual weight determined by weighing
trailer on a public scale, without being attached to the
towing vehicle.
Bead separation: This is the breakdown of the bond
between components in the bead.
Hitch Weight: The downward force exerted on the
hitch ball by the trailer coupler.
Bias ply tire: A pneumatic tire in which the ply cords
that extend to the beads are laid at alternate angles
substantially less than 90 degrees to the centerline of
the tread.
Innerliner: The layer(s) forming the inside surface of a
tubeless tire that contains the inflating medium within
the tire.
Carcass: The tire structure, except tread and sidewall
rubber which, when inflated, bears the load.
Chunking: The breaking away of pieces of the tread
or sidewall.
Innerliner separation: The parting of the innerliner
from cord material in the carcass.
Intended outboard sidewall: The sidewall that
contains a white-wall, bears white lettering or bears
manufacturer, brand, and/or model name molding that
Page 24 of 145
Tire Safety
is higher or deeper than the same molding on the other
sidewall of the tire or the outward facing sidewall of an
asymmetrical tire that has a particular side that must
always face outward when mounted on a vehicle.
Light truck (LT) tire: A tire designated by its
manufacturer as primarily intended for use on
lightweight trucks or multipurpose passenger vehicles.
May be used on trailers.
Load rating: The maximum load that a tire is rated to
carry for a given inflation pressure.
Occupant distribution: The distribution of occupants
in a vehicle as specified in the third column of Table I
of 49 CFR 571.110.
Open splice: Any parting at any junction of tread,
sidewall, or innerliner that extends to cord material.
Outer diameter: The overall diameter of an inflated
new tire.
Maximum load rating: The load rating for a tire at the
maximum permissible inflation pressure for that tire.
Overall width: The linear distance between the
exteriors of the sidewalls of an inflated tire, including
elevations due to labeling, decorations, or protective
bands or ribs.
Maximum permissible inflation pressure: The
maximum cold inflation pressure to which a tire may
be inflated.
Pin Weight: The downward force applied to the 5th
wheel or gooseneck ball, by the trailer kingpin or
gooseneck coupler.
Maximum loaded vehicle weight: The sum of curb
weight, accessory weight, vehicle capacity weight, and
production options weight.
Ply: A layer of rubber-coated parallel cords.
Measuring rim: The rim on which a tire is fitted for
physical dimension requirements.
Non-pneumatic rim: A mechanical device which,
when a non-pneumatic tire assembly incorporates a
wheel, supports the tire, and attaches, either integrally
or separably, to the wheel center member and upon
which the tire is attached.
Non-pneumatic spare tire assembly: A nonpneumatic tire assembly intended for temporary use
in place of one of the pneumatic tires and rims that
are fitted to a passenger car in compliance with the
requirements of this standard.
Non-pneumatic tire: A mechanical device which
transmits, either directly or through a wheel or wheel
center member, the vertical load and tractive forces
from the roadway to the vehicle, generates the tractive
forces that provide the directional control of the vehicle
and does not rely on the containment of any gas or
fluid for providing those functions.
Non-pneumatic tire assembly: A non-pneumatic tire,
alone or in combination with a wheel or wheel center
member, which can be mounted on a vehicle.
Normal occupant weight: This means 68 kilograms
(150 lbs.) times the number of occupants specified in
the second column of Table I of 49 CFR 571.110.
Ply separation: A parting of rubber compound between
adjacent plies.
Pneumatic tire: A mechanical device made of rubber,
chemicals, fabric and steel or other materials, that,
when mounted on an automotive wheel, provides the
traction and contains the gas or fluid that sustains the
load.
Production options weight: The combined weight
of those installed regular production options weighing
over 2.3 kilograms (5 lbs.) in excess of those standard
items which they replace, not previously considered in
curb weight or accessory weight, including heavy duty
brakes, ride levelers, roof rack, heavy duty battery, and
special trim.
Radial ply tire: A pneumatic tire in which the ply cords
that extend to the beads are laid at substantially 90
degrees to the centerline of the tread.
Recommended inflation pressure: This is the
inflation pressure provided by the vehicle manufacturer
on the Tire Information label and on the Certification /
VIN tag.
Reinforced tire: A tire designed to operate at higher
loads and at higher inflation pressures than the
corresponding standard tire.
Rim: A metal support for a tire or a tire and tube
assembly upon which the tire beads are seated.
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Tire Safety
Rim diameter: This means the nominal diameter of
the bead seat.
Rim size designation: This means the rim diameter
and width.
Rim type designation: This means the industry of
manufacturer’s designation for a rim by style or code.
Rim width: This means the nominal distance between
rim flanges.
Section width: The linear distance between the
exteriors of the sidewalls of an inflated tire, excluding
elevations due to labeling, decoration, or protective
bands.
Sidewall: That portion of a tire between the tread and
bead.
Sidewall separation: The parting of the rubber
compound from the cord material in the sidewall.
Special Trailer (ST) tire: The “ST” is an indication the
tire is for trailer use only.
individual tire that is determined by distributing to each
axle its share of the curb weight, accessory weight,
and normal occupant weight (distributed in accordance
with Table I of CRF 49 571.110) and dividing by 2.
Weather side: The surface area of the rim not covered
by the inflated tire.
Wheel center member: In the case of a non-pneumatic
tire assembly incorporating a wheel, a mechanical
device which attaches, either integrally or separably,
to the non-pneumatic rim and provides the connection
between the nonpneumatic rim and the vehicle; or,
in the case of a non-pneumatic tire assembly not
incorporating a wheel, a mechanical device which
attaches, either integrally or separably, to the nonpneumatic tire and provides the connection between
tire and the vehicle.
Wheel-holding fixture: The fixture used to hold the
wheel and tire assembly securely during testing.
3.5 TIRE SAFETY - EVERYTHING RIDES ON IT
Test rim: The rim on which a tire is fitted for testing,
and may be any rim listed as appropriate for use with
that tire.
The National Traffic Safety Administration (NHTSA)
has published a brochure (DOT HS 809 361) that
discusses all aspects of Tire Safety, as required by
CFR 575.6. This brochure is reproduced in part below.
It can be obtained and downloaded from NHTSA, free
of charge, from the following web site:
Tread: That portion of a tire that comes into contact
with the road.
http://www.nhtsa.dot.gov/cars/rules/TireSafety/
ridesonit/tires_index.html
Tread rib: A tread section running circumferentially
around a tire.
Studies of tire safety show that maintaining proper tire
pressure, observing tire and vehicle load limits (not
carrying more weight in your vehicle than your tires
or vehicle can safely handle), avoiding road hazards,
and inspecting tires for cuts, slashes, and other
irregularities are the most important things you can do
to avoid tire failure, such as tread separation or blowout
and flat tires. These actions, along with other care and
maintenance activities, can also:
Tread separation: Pulling away of the tread from the
tire carcass.
Treadwear indicators (TWI): The projections within the
principal grooves designed to give a visual indication
of the degrees of wear of the tread.
Vehicle capacity weight: The rated cargo and luggage
load plus 68 kilograms (150 lbs.) times the vehicle’s
designated seating capacity.
Vehicle maximum load on the tire: The load on an
individual tire that is determined by distributing to each
axle its share of the maximum loaded vehicle weight
and dividing by two.
Vehicle normal load on the tire: The load on an
•
•
•
•
Improve vehicle handling
Help protect you and others from avoidable
breakdowns and accidents
Improve fuel economy
Increase the life of your tires.
This booklet presents a comprehensive overview of tire
safety, including information on the following topics:
•
Basic tire maintenance
Page 26 of 145
Tire Safety
•
•
•
Uniform Tire Quality Grading System
Fundamental characteristics of tires
Tire safety tips.
Use this information to make tire safety a regular part
of your vehicle maintenance routine. Recognize that
the time you spend is minimal compared with the
inconvenience and safety consequences of a flat tire
or other tire failure.
3.5.1 SAFETY FIRST- BASIC TIRE MAINTENANCE
Properly maintained tires improve the steering,
stopping, traction, and load-carrying capability of your
vehicle. Underinflated tires and overloaded vehicles are
a major cause of tire failure. Therefore, as mentioned
above, to avoid flat tires and other types of tire failure,
you should maintain proper tire pressure, observe
tire and vehicle load limits, avoid road hazards, and
regularly inspect your tires.
3.5.2 FINDING YOUR VEHICLE’S RECOMMENDED TIRE
PRESSURE AND LOAD LIMITS
Tire information placards and vehicle certification labels
contain information on tires and load limits. These
labels indicate the vehicle manufacturer’s information
including:
•
•
•
•
•
Recommended tire size
Recommended tire inflation pressure
Vehicle capacity weight (VCW–the maximum
occupant and cargo weight a vehicle is designed
to carry)
Front and rear gross axle weight ratings (GAWR–
the maximum weight the axle systems are designed
to carry).
Both placards and certification labels are
permanently attached to the trailer near the left
front.
determine this number based on the vehicle’s design
load limit, that is, the greatest amount of weight a
vehicle can safely carry and the vehicle’s tire size. The
proper tire pressure for your vehicle is referred to as
the “recommended cold inflation pressure.” (As you will
read below, it is difficult to obtain the recommended tire
pressure if your tires are not cold.)
Because tires are designed to be used on more than one
type of vehicle, tire manufacturers list the “maximum
permissible inflation pressure” on the tire sidewall.
This number is the greatest amount of air pressure
that should ever be put in the tire under normal driving
conditions.
3.5.4 SAFETY FIRST- BASIC TIRE MAINTENANCE
It is important to check your vehicle’s tire pressure at
least once a month for the following reasons:
•
•
•
Most tires may naturally lose air over time.
Tires can lose air suddenly if you drive over a
pothole or other object or if you strike the curb
when parking.
With radial tires, it is usually not possible to
determine under inflation by visual inspection.
For convenience, purchase a tire pressure gauge to
keep in your vehicle. Gauges can be purchased at
tire dealerships, auto supply stores, and other retail
outlets. The recommended tire inflation pressure that
vehicle manufacturers provide reflects the proper psi
when a tire is cold. The term cold does not relate to the
outside temperature. Rather, a cold tire is one that has
not been driven on for at least three hours. When you
drive, your tires get warmer, causing the air pressure
within them to increase. Therefore, to get an accurate
tire pressure reading, you must measure tire pressure
when the tires are cold or compensate for the extra
pressure in warm tires.
3.5.3 UNDERSTANDING TIRE PRESSURE AND LOAD
LIMITS
3.5.5 STEPS FOR MAINTAINING PROPER TIRE
PRESSURE
Tire inflation pressure is the level of air in the tire that
provides it with load-carrying capacity and affects the
overall performance of the vehicle. The tire inflation
pressure is a number that indicates the amount of
air pressure– measured in pounds per square inch
(psi)–a tire requires to be properly inflated. (You will
also find this number on the vehicle information placard
expressed in kilopascals (kPa), which is the metric
measure used internationally.)
1. Locate the recommended tire pressure on the
Manufacturers of passenger vehicles and light trucks
vehicle’s tire information placard, certification label,
or in the owner’s manual.
2. Record the tire pressure of all tires.
3. If the tire pressure is too high in any of the tires,
slowly release air by gently pressing on the tire
valve stem with the edge of your tire gauge until
you get to the correct pressure.
4. If the tire pressure is too low, note the difference
between the measured tire pressure and the correct
tire pressure. These “missing” pounds of pressure
Page 27 of 145
Tire Safety
are what you will need to add.
5. At a service station, add the missing pounds of air
pressure to each tire that is under inflated.
6. Check all the tires to make sure they have the same
air pressure except in cases in which the front and
rear tires are supposed to have different amounts
of pressure).
If you have been driving your vehicle and think that a
tire is under inflated, fill it to the recommended cold
inflation pressure indicated on your vehicle’s tire
information placard or certification label. While your
tire may still be slightly under inflated due to the extra
pounds of pressure in the warm tire, it is safer to drive
with air pressure that is slightly lower than the vehicle
manufacturer’s recommended cold inflation pressure
than to drive with a significantly under inflated tire.
Since this is a temporary fix, don’t forget to recheck
and adjust the tire’s pressure when you can obtain a
cold reading.
3.5.6 TIRE SIZE
To maintain tire safety, purchase new tires that are the
same size as the vehicle’s original tires or another size
recommended by the manufacturer. Look at the tire
information placard, the owner’s manual, or the sidewall
of the tire you are replacing to find this information. If
you have any doubt about the correct size to choose,
consult with the tire dealer.
wheels so that they are positioned correctly relative to
the vehicle’s frame. This adjustment maximizes the
life of your tires. These adjustments require special
equipment and should be performed by a qualified
technician.
3.5.9 TIRE REPAIR
The proper repair of a punctured tire requires a plug
for the hole and a patch for the area inside the tire
that surrounds the puncture hole. Punctures through
the tread can be repaired if they are not too large, but
punctures to the sidewall should not be repaired. Tires
must be removed from the rim to be properly inspected
before being plugged and patched.
3.5.10 TIRE FUNDAMENTALS
Federal law requires tire manufacturers to place
standardized information on the sidewall of all tires. This
information identifies and describes the fundamental
characteristics of the tire and also provides a tire
identification number for safety standard certification
and in case of a recall.
3.5.10.1 INFORMATION ON PASSENGER VEHICLE TIRES
3.5.7 TIRE TREAD
The tire tread provides the gripping action and traction
that prevent your vehicle from slipping or sliding,
especially when the road is wet or icy. In general, tires
are not safe and should be replaced when the tread is
worn down to 2/32 of an inch. Tires have built-in tread
wear indicators that let you know when it is time to
replace your tires. These indicators are raised sections
spaced intermittently in the bottom of the tread grooves.
When they appear “even” with the outside of the tread,
it is time to replace your tires. Another method for
checking tread depth is to place a penny in the tread
with Lincoln’s head upside down and facing you. If you
can see the top of Lincoln’s head, you are ready for
new tires.
3.5.8 TIRE BALANCE AND WHEEL ALIGNMENT
To avoid vibration or shaking of the vehicle when a
tire rotates, the tire must be properly balanced. This
balance is achieved by positioning weights on the wheel
to counterbalance heavy spots on the wheel-and-tire
assembly. A wheel alignment adjusts the angles of the
P: The “P” indicates the tire is for passenger vehicles.
Next number: This three-digit number gives the width
in millimeters of the tire from sidewall edge to sidewall
edge. In general, the larger the number, the wider the
tire.
Next number: This two-digit number, known as the
aspect ratio, gives the tire’s ratio of height to width.
Page 28 of 145
Tire Safety
Numbers of 70 or lower indicate a short sidewall
for improved steering response and better overall
handling on dry pavement.
R: The “R” stands for radial. Radial ply construction
of tires has been the industry standard for the past 20
years.
Maximum Permissible Inflation Pressure: This
number is the greatest amount of air pressure that
should ever be put in the tire under normal driving
conditions.
3.5.10.2 UTQGS Information
Next number: This two-digit number is the wheel or
rim diameter in inches. If you change your wheel size,
you will have to purchase new tires to match the new
wheel diameter.
Treadwear Number: This number indicates the tire’s
wear rate. The higher the treadwear number is, the
longer it should take for the tread to wear down. For
example, a tire graded 400 should last twice as long as
a tire graded 200.
Next number: This two- or three-digit number is the
tire’s load index. It is a measurement of how much
weight each tire can support. You may find this
information in your owner’s manual. If not, contact a
local tire dealer. Note: You may not find this information
on all tires because it is not required by law.
Traction Letter: This letter indicates a tire’s ability to
stop on wet pavement. A higher graded tire should allow
you to stop your car on wet roads in a shorter distance
than a tire with a lower grade. Traction is graded from
highest to lowest as “AA”,”A”, “B”, and “C”.
M+S: The “M+S” or “M/S” indicates that the tire has
some mud and snow capability. Most radial tires have
these markings; hence, they have some mud and
snow capability.
Speed Rating: The speed rating denotes the speed
at which a tire is designed to be driven for extended
periods of time.
Note: You may not find this information on all tires
because it is not required by law.
Temperature Letter: This letter indicates a tire’s
resistance to heat. The temperature grade is for a tire
that is inflated properly and not overloaded. Excessive
speed, under inflation or excessive loading, either
separately or in combination, can cause heat build-up
and possible tire failure. From highest to lowest, a tire’s
resistance to heat is graded as “A”, “B”, or “C”.
3.5.10.3 Additional Information On Light Truck
Tires
U.S. DOT Tire Identification Number: This begins
with the letters “DOT” and indicates that the tire meets
all federal standards. The next two numbers or letters
are the plant code where it was manufactured, and the
last four numbers represent the week and year the tire
was built. For example, the numbers 3197 means the
31st week of 1997. The other numbers are marketing
codes used at the manufacturer’s discretion. This
information is used to contact consumers if a tire
defect requires a recall.
Tire Ply Composition and Materials Used: The
number of plies indicates the number of layers of
rubber-coated fabric in the tire. In general, the greater
the number of plies, the more weight a tire can support.
Tire manufacturers also must indicate the materials
in the tire, which include steel, nylon, polyester, and
others.
Maximum Load Rating: This number indicates the
maximum load in kilograms and pounds that can be
carried by the tire.
Tires for light trucks have other markings besides those
found on the sidewalls of passenger tires.
LT: The “LT” indicates the tire is for light trucks or
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Tire Safety
trailers.
ST: An “ST” is an indication the tire is for trailer use
only.
Max. Load Dual kg (lbs) at kPa (psi) Cold: This
information indicates the maximum load and tire
pressure when the tire is used as a dual, that is, when
four tires are put on each rear axle (a total of six or
more tires on the vehicle).
Max. Load Single kg (lbs) at kPa (psi) Cold: This
information indicates the maximum load and tire
pressure when the tire is used as a single.
Load Range: This information identifies the tire’s loadcarrying capabilities and its inflation limits.
3.5.10.4 Tire Safety Tips
Preventing Tire Damage
Slow down if you have to go over a pothole or other
object in the road.
• Do not run over curbs or other foreign objects in
the roadway, and try not to strike the curb when
parking.
•
Tire Safety Checklist
Check tire pressure regularly (at least once a
month), including the spare.
• Inspect tires for uneven wear patterns on the tread,
cracks, foreign objects, or other signs of wear or
trauma.
• Remove bits of glass and foreign objects wedged
in the tread.
• Make sure your tire valves have valve caps.
• Check tire pressure before going on a long trip.
• Do not overload your vehicle. Check the Tire
Information Placard or Owner’s Manual for the
maximum recommended load for the vehicle.
•
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Coupling To Tow Vehicle
4. COUPLING TO TOW VEHICLE
Follow all of the safety precautions and instructions in
this manual to ensure safety of persons, cargo, and
satisfactory life of the trailer.
4.1 TOW VEHICLE AND HITCH
If the vehicle and hitch are not properly selected and
matched to the Gross Vehicle Weight Rating (GVWR)
of your trailer, you can cause an accident that could
lead to death or serious injury. If you already have a
tow vehicle, know your vehicle tow rating and make
certain the trailer’s rated capacity is less than or equal
to the tow vehicle’s rated towing capacity.
^ DANGER
Use of a tow vehicle with a towing capacity
less than the load rating of the trailer can
result in loss of control, and may lead to
death or serious injury.
Use of a hitch with a load rating less than
the load rating of the trailer can result in
loss of control and may lead to death or
serious injury.
Verify hitch and tow vehicle are rated for
the Gross Vehicle Weight Rating of your
trailer.
4.1.1 TRAILER INFORMATION
The Certification / Vehicle Identification Number (VIN)
tag is located on the front left side of the trailer.
The trailer Certification / VIN tag contains the following
critical safety information for the use of your trailer:
MANUFACTURER: Name of trailer manufacturer.
DATE OF MANUFACTURE: Month and year the trailer
was manufactured.
GVWR: The Gross Vehicle Weight Rating is the
maximum allowable gross weight of the trailer and its
contents. The gross weight of the trailer includes the
weight of the trailer and all of the items within it (such
as cargo and other supplies).
GAWR: The Gross Axle Weight Rating is the maximum
gross weight that an axle can support. It is the lowest of
axle, wheel, or tire rating. Sometimes the tire or wheel
rating is lower than the axle manufacturers rating, and
will then determine GAWR.
The sum total of the GAWR for all trailer axles may be
less than the GVWR for the trailer, because some of
the trailer load is carried by the tow vehicle, rather than
by the trailer axle(s). The total weight of the cargo and
trailer must not exceed the GVWR, and the load on an
axle must not exceed its GAWR.
TIRE SIZE: The tire size and load range for your
trailer.
RIM SIZE: The rim size and load range for your trailer.
PSI: The tire air pressure (kPa / PSI) measured with
tires cold.
VIN: The Vehicle Identification Number.
VEHICLE TYPE: Model or style of trailer.
CERTIFICATION STATEMENT: “This trailer meets all
the Federal Motor Vehicle Safety Standards in effect
on the date of manufacture shown above”.
4.1.2 TOW VEHICLE
When equipping a new vehicle or an older vehicle to
tow a trailer, ask the vehicle dealer for advice on how
to outfit the tow vehicle.
Vehicle manufacturers will provide you with the
maximum towing capacities of their various models, as
well as the GCWR. No amount of reinforcement will
give a 100 horsepower, 2,500 pound truck the towing
capacity that a 300 horsepower, 5,000 pound truck
has.
4.2 COUPLING AND UNCOUPLING THE TRAILER
A secure coupling (or fastening) of the trailer to the tow
vehicle is essential. A loss of coupling may result in
death or serious injury. Therefore, you must understand
and follow all of the instructions for coupling.
The following parts are involved in making a secure
coupling between the trailer and tow vehicle:
Coupling: The trailer connecting mechanism by which
the connection is actually made to the trailer hitch. This
does not include any structural member, extension of
the trailer frame, or brake controller.
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Coupling To Tow Vehicle
Hitch: The connecting mechanism including the ball
support platform and ball and those components that
extend and are attached to the towing vehicle, including
bumpers intended to serve as hitches.
Safety chains: Chains permanently attached to the
trailer such that if the coupler connection comes loose,
the safety chains can keep the trailer attached to the
tow vehicle. With properly rigged safety chains, it is
possible to keep the tongue of the trailer from digging
into the road pavement, even if the coupler-to-hitch
connection comes apart.
Trailer lighting (and braking) connector: A device
that connects electrical power from the tow vehicle
to the trailer. In addition, if your trailer has a separate
braking system, the electrical connector will also supply
power to the trailer brakes from the tow vehicle.
Breakaway switch: If the trailer becomes uncoupled
from the tow vehicle, the breakaway switch lanyard,
attached independently to the tow vehicle hitch, will
pull a pin in the emergency electrical breakaway switch
on the trailer. The breakaway switch is activated by
a battery on the trailer to energize the trailer brakes
independently of the towing vehicle.
^ WARNING
An improperly coupled trailer can result in
death or serious injury. Do not move the
trailer until:
•
•
•
•
•
•
•
•
Coupler is secured and locked to hitch.
Safety chains are secured to tow
vehicle.
Trailer jack(s) are fully retracted.
Trailer brakes are checked.
Tires and wheels are checked.
Breakaway switch is connected to tow
vehicle;
The trailer lights are connected and
checked.
Load is secured to trailer.
4.3 COUPLE TRAILER TO TOW VEHICLE
The trailer may be equipped with a ball hitch coupler or
a ring & pintle coupler. See the appropriate section for
the coupler on your trailer.
4.3.1 BALL HITCH COUPLER
It is important to check the state of charge of the
emergency breakaway battery before each trip. Simply
pull the pin out of the switch by hand and then try to
pull the trailer. If you feel a significant drag force the
brakes are activated. Be sure to re-insert the pin in
the breakaway switch. Also be sure to allow enough
slack in the breakaway brake lanyard such that the
switch will only activate (pin pulls out) if the coupler
connection comes loose.
Jack: A device on the trailer that is used to raise and
lower the trailer tongue.
A ball hitch coupler connects to a ball that is located on
or under the rear bumper of tow vehicle.
We have utilized a ball hitch coupler that is suitable for
the size and weight of the trailer. The load rating of the
coupler and the necessary ball size are listed on the
trailer tongue.
You must provide a hitch and ball for your tow vehicle,
that meets or exceeds the GVWR of the trailer.
The ball size must be the same as the coupler size. If
the hitch ball is too small, too large, is underrated, is
loose or is worn, the trailer can come loose from the
tow vehicle, and may cause death or serious injury.
The tow vehicle, hitch and ball must have a rated
towing capacity equal to or greater than the trailer
gross vehicle weight rating (GVWR).
It is essential that the hitch ball be the same size
as the coupler.
The ball size and load rating (capacity) are marked on
the ball; hitch capacity is marked on the hitch.
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Coupling To Tow Vehicle
4.3.1.1 BEFORE COUPLING TRAILER TO TOW VEHICLE
1. Be sure the size and rating of hitch ball match
the size and rating of the coupler. Hitch balls and
couplers are marked with their size and rating.
6. Raise the bottom surface of the coupler to be above
the top of the hitch ball.
4.3.1.2 PREPARE COUPLER AND HITCH
1. Lubricate hitch ball and inside of coupler with a thin
^ WARNING
Coupler-to-hitch mismatch can result in
uncoupling, leading to death or serious
injury.
Be sure the LOAD RATING of the hitch ball
is equal or greater than the load rating of
the coupler.
layer of automotive bearing grease.
2. Remove safety latch pin and open coupler locking
mechanism. In the open position, coupler is
able to drop fully onto hitch ball. See the coupler
instructions for details of placing the coupler in the
“open” position.
3. Slowly back up tow vehicle so that hitch ball is near
or aligned under coupler.
Be sure the SIZE of the hitch ball matches
the size of the coupler.
2. Wipe the hitch ball clean and inspect it visually and
by feel for flat spots, cracks and pits.
^ WARNING
A worn, cracked or corroded hitch ball can
fail while towing, and may result in death
or serious injury.
Your trailer may be equipped with a different style
coupler. If so, see the coupler manufacturers operating
instructions.
4.3.1.3 COUPLE TRAILER TO TOW VEHICLE
1. Lower the trailer tongue until the coupler fully
and visually check that the hitch ball nut is solid
against the lock washer and hitch frame.
4. Wipe the inside and outside of the coupler clean
and inspect it visually for cracks and deformations;
feel the inside of the coupler for worn spots and
pits.
5. Be sure the coupler is tight to the tongue of the
trailer. All coupler fasteners must be visibly solid
against the trailer frame.
engages the hitch ball. If the coupler does not line
up with the hitch ball, adjust the position of the tow
vehicle.
2. Close latch and engage the coupler locking
mechanism. In the engaged position, the locking
mechanism securely holds the coupler to the hitch
ball.
3. Insert the safety lock pin through the hole in the
locking mechanism.
4. Be sure the coupler is all the way on the hitch ball
and the locking mechanism is engaged. A properly
engaged locking mechanism will allow the coupler
to raise the rear of the tow vehicle. Using the trailer
jack, test to see that you can raise the rear of the
tow vehicle by 1 inch, after the coupler is locked to
the hitch.
^ WARNING
NOTICE
Before coupling trailer, inspect the hitch
ball for wear, corrosion and cracks.
Replace worn or damaged hitch ball.
3. Rock the ball to make sure it is tight to the hitch,
A loose hitch ball nut can result in
uncoupling, leading to death or serious
injury.
Make sure the hitch ball is tight to the hitch
before coupling the trailer.
The tongue jack can be damaged by
overloading. Do not use the tongue jack to
raise the tow vehicle more than 1 inch.
5. If the coupler cannot be secured to the hitch ball,
do not tow the trailer. Contact your dealer for
assistance.
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Coupling To Tow Vehicle
6. Lower the trailer so that its entire tongue weight is
held by the hitch, and continue retracting the jack to
its fully retraced position.
^ CAUTION
^ WARNING
Ring-to-pintle mismatch can result in
uncoupling, leading to death or serious
injury.
Drop leg jacks may be spring loaded and
may rapidly return to the raise position
when released.
Be sure the LOAD RATING of the pintle is
equal or greater than the load rating of the
ring.
Keep clear when releasing drop legs.
Be sure the SIZE of the pintle matches the
size of the ring.
7. Fully retract jack drop leg if equipped.
2. Wipe the pintle clean and inspect it visually and by
Go to Section 4.3.3 “Connect Safety Chains” to
continue connecting trailer to tow vehicle.
4.3.2 TRAILER WITH RING AND PINTLE COUPLER
A ring on the trailer connects to the pintle that is located
on or under the rear bumper of tow vehicle.
We have utilized a ring that is suitable for the size and
weight of the trailer. The load rating of the ring and the
necessary pintle size are listed on the trailer tongue.
You must provide a pintle for your tow vehicle, where
the load rating of the hitch and pintle is equal to or
greater than that of your trailer. The pintle size must be
the same as the ring size. If the pintle is too small, too
large, is underrated, is loose or is worn, the trailer can
come loose from the tow vehicle, and may cause death
or serious injury.
The tow vehicle, hitch and pintle must have a rated
towing capacity equal to or greater than the trailer
gross vehicle weight rating (GVWR).
It is essential that the pintle be the same size as the
coupler.
The pintle size and load rating (capacity) are marked
on the pintle; ring capacity is marked on the ring.
feel for flat spots, cracks and pits.
^ WARNING
A worn, cracked or corroded pintle can fail
while towing, and may result in death or
serious injury.
Before coupling trailer, inspect the pintle
for wear, corrosion and cracks.
Replace worn or damaged pintle.
3. Rock the pintle to make sure it is tight to the hitch,
and visually check that the pintle fasteners are
solid against the hitch frame.
4. Wipe the inside and outside of the ring clean and
inspect it visually for cracks and deformations; feel
the inside of the ring for worn spots and pits.
5. Be sure the ring is tight to the tongue of the trailer.
All ring fasteners must be visibly solid against the
trailer frame.
^ WARNING
A loose pintle can result in uncoupling,
leading to death or serious injury.
Make sure the pintle is tight to the hitch
before coupling the trailer.
4.3.2.1 BEFORE COUPLING TRAILER TO TOW VEHICLE
1. Be sure the size and rating of pintle match the size
and rating of the ring. Hitch ring and pintles are
marked with their size and rating.
6. Raise the bottom surface of the ring to be above
the top of the open pintle.
4.3.2.2 PREPARE RING AND PINTLE
1. Lubricate the inside of the pintle with a thin layer of
automotive bearing grease.
2. Remove the safety latch pin and open the pintle
locking mechanism.
Page 34 of 145
Coupling To Tow Vehicle
3. In the open position, the ring is able to drop fully
7. Fully retract jack drop leg if equipped.
onto the pintle.
Go to Section 4.3.3 “Connect Safety Chains” to
continue connecting trailer to tow vehicle.
4.3.3 CONNECT SAFETY CHAINS
1. Visually inspect the safety chains and hooks for
4. See the coupler instructions for details of placing
the pintle in the “open” position.
5. Slowly back up the tow vehicle so that the pintle is
aligned under the ring.
4.3.2.3 COUPLE TRAILER TO TOW VEHICLE
1. Lower the trailer tongue until the ring fully engages
wear or damage. Replace worn or damaged safety
chains and hooks before towing.
2. Safety chains must crisscross under the coupler so
if the trailer uncouples, the safety chains can hold
the tongue up above the road. Loop around a frame
member of the tow vehicle or to holes provided
in the hitch system, but do not attach them to an
interchangeable part of the hitch assembly.
3. Attach hooks up from underneath the hole. Do not
just drop into hole.
4. Provide enough slack in chains to permit tight turns,
but not be close to the road surface to drag.
the pintle. If the ring does not line up with the pintle,
adjust the position of the tow vehicle.
2. Close pintle and engage the pintle locking
mechanism. In the engaged position, the locking
mechanism securely holds the ring to the pintle.
3. Insert the safety lock pin through the hole in the
locking mechanism.
4. Be sure the ring is all the way on the pintle and the
locking mechanism is engaged. A properly engaged
locking mechanism will allow the pintle to raise the
rear of the tow vehicle. Using the trailer jack, test to
see that you can raise the rear of the tow vehicle by
1 inch, after the pintle is closed and locked.
NOTICE
The tongue jack can be damaged by
overloading. Do not use the tongue jack to
raise the tow vehicle more than 1 inch.
5. If the ring cannot be secured to the pintle, do not
tow the trailer. Contact your dealer for assistance.
6. Lower the trailer so that its entire tongue weight is
held by the hitch, and continue retracting the jack
to its fully retraced position.
^ CAUTION
Drop leg jacks may be spring loaded and
may rapidly return to the raise position
when released.
Keep clear when releasing drop legs.
Page 35 of 145
Coupling To Tow Vehicle
^ WARNING
Improper rigging of the safety chains can
result in loss of control of the trailer and
tow vehicle, leading to death or serious
injury, if the trailer uncouples from the tow
vehicle.
hydraulic actuator will engage or the electric brake
pullpin will be pulled out before all of the slack in the
safety chains is taken up. Do not connect the lanyard
to a safety chain, hitch ball or hitch ball assembly.
This would keep the breakaway brake system from
operating when it is needed.
Cross chains underneath hitch and coupler
with enough slack to permit turning and to
hold tongue up, if the trailer comes loose.
Fasten chains to frame of tow vehicle.
Do not fasten chains to any part of the
hitch unless the hitch has holes or loops
specifically for that purpose.
4.3.4 CONNECT ELECTRICAL CABLE
1. Connect the trailer lights to the tow vehicle’s
electrical system using trailer electrical cable.
2. Check all lights for proper operation. Repair or
replace non-working lights before towing trailer.
3. Check electric brakes for proper operation using
brake controller mounted in the cab.
^ WARNING
Improper electrical connection between
the tow vehicle and the trailer will result in
inoperable lights and electric brakes, and
can lead to collision.
Before each tow:
• Check that the electric brakes work by
operating the brake controller inside the
tow vehicle.
• Check that all lights and turn signals
work.
4.3.5 ATTACH BREAKAWAY BRAKE LANYARD
If the coupler or hitch fails, a properly connected and
working breakaway brake system will apply the trailer
brakes. The safety chains will keep the tow vehicle
attached and as the trailer brakes are applied, the
trailer/tow vehicle combination will come to a controlled
stop.
Connect the lanyard to the tow vehicle so that the
4.3.5.1 TEST ELECTRIC BRAKES
If your trailer has electric brakes, your tow vehicle will
have an electric brake controller that sends power to
the trailer brakes. Before towing the trailer on the road,
you must operate the brake controller while trying
to pull the trailer in order to confirm that the electric
brakes operate.
While towing the trailer at less than 5 mph, manually
operate the electric brake controller in the tow vehicle.
You should feel the operation of the trailer brakes. If
the trailer brakes are not functioning, the brake system
MUST be evaluated to determine the cause of the
problem and corrective action MUST be taken before
the trailer is used. Take the unit to your dealer or a
qualified brake specialist.
Use this procedure each time you tow the trailer to
check brake system operation.
4.3.5.2 TEST ELECTRIC BREAKAWAY BRAKES
The breakaway brake system includes a battery, a
switch with a pullpin and lanyard, and a breakaway
brake controller. Read and follow the instructions here
as well as the instructions that have been prepared by
the breakaway brake manufacturer. If you do not have
these instructions, contact your dealer for assistance.
Hydraulic tilt trailers may use the hoist battery to
provide power to the breakaway brakes. If your trailer
is not setup this way, there will be a small breakaway
battery mounted near the breakaway switch.
Most trailers are setup to charge the battery from
Page 36 of 145
Coupling To Tow Vehicle
the tow vehicle. If the electrical system on your tow
vehicle does not provide power to the battery, you
must periodically charge the battery with a commercial
battery charger to keep the battery charged.
^ CAUTION
Extreme cold weather can degrade battery
performance and cause brakes to not
operate properly.
Check battery charge level before towing.
Do not tow trailer if the battery requires recharging. A
discharged brake battery will not activate the brakes if
the trailer uncouples from the tow vehicle. The battery
must be fully charged before towing trailer.
To test the breakaway brake battery, remove the pullpin
from the switch and attempt to pull the trailer forward.
You should feel the trailer resisting being towed, but
the wheels will not necessarily be locked. If the brakes
do not function, do not tow the trailer until brakes, or
battery, are repaired.
Immediately replace the pullpin. The breakaway
brake battery discharges rapidly when the pullpin is
removed.
^ WARNING
An ineffective breakaway brake system can
result in a runaway trailer, leading to death
or serious injury if the coupler fails.
Test the function of the breakaway brake
system before towing trailer. Do not tow
trailer if breakaway brake system is not
working; have it serviced or repaired.
Connect breakaway lanyard to the tow
vehicle, NOT to the safety chain, ball,
pintle, hitch, or support.
Do not tow the trailer with the breakaway brake system
ON because the brakes will overheat which can result
in permanent brake failure.
^ WARNING
Failure to replace the pullpin can result
in ineffective brakes, leading to loss of
control, serious injury or death.
If you do not use your trailer for three or more months,
or during winter months:
• Store the battery indoors; and
• Charge the battery every three months.
Replace the breakaway brake battery according to the
intervals specified by battery manufacturer.
4.3.5.3 TEST SURGE BRAKES (IF EQUIPPED)
Hydraulic surge actuator systems provide automatic
and smooth trailer braking without special application
by the tow vehicle driver. While this is extremely
convenient it can sometimes be difficult to determine
if the surge setup is functioning properly. The following
steps provide a quick field-test to confirm that the trailer
brake system is operational.
^ WARNING
The field-test procedure indicates only if
the trailer brake system is functional, but
DOES NOT provide information on how
efficiently it will operate.
Regular inspection, maintenance,
and adjustment of all brake system
components (including the surge actuator,
tubing, hoses, brake clusters, drums, and
associated hardware/support structure)
are still required to ensure maximum brake
performance and smooth, even brake
operation.
Move the trailer to flat, level ground, pulling FORWARD
several feet before parking. This forward motion will
ensure trailers equipped with free-backing brakes are
in their normal operating mode. Disconnect the trailer
from the tow vehicle and jack up the trailer’s tongue
until it is horizontal. Hook the trailer’s safety chains
(NOT the actuator’s breakaway cable) together to form
a loop, which is centered below the actuator’s coupler.
Place wheel chock blocks two feet behind the trailer to
prevent a runaway trailer.
Place a sturdy board, such as a 2 inch by 4 inch piece
of lumber, into the chain loop below the coupler. The
Page 37 of 145
Coupling To Tow Vehicle
board should be 4 feet or longer so it will extend several
feet above the actuator. Keep the end of the board
a few inches off the ground, and position it to press
against the front end of the actuator’s coupler. Press
the board towards the rear of the trailer.
Keep pressing the top of the board to stroke the
actuator and its internal master cylinder. If the trailer
brake system is operational, the brakes will apply and
keep the trailer from rolling away from you. Properly
adjusted uni-servo or duo-servo type brakes will
prevent you from moving the trailer back more than
a few inches. Free-backing type brakes will initially
provide rolling resistance, but continued force on the
board will switch them into free-backing mode, and
you’ll be able to move the trailer backwards.
If you have uni-servo or duo-servo brakes, and stroking
the actuator (as described above) causes the trailer to
roll away from you freely or with only minimal resistance,
the brakes are NOT applying properly. If you have freebacking brakes and stroking the actuator (as described
above) causes the trailer to roll away without initial
resistance, then the brakes are NOT applying properly.
The brake system MUST be evaluated to determine
the cause of the problem and corrective action MUST
be taken before the trailer is used. Use this procedure
each time you tow your trailer to check your surge
brake system operation.
4.3.5.4 TEST SURGE BREAKAWAY SYSTEM
1. Park the trailer on a firm level surface and block
trailer tires.
Disconnect electrical connector.
Disconnect breakaway brake switch lanyard.
Disconnect safety chains from tow vehicle.
Unlock the coupler and open it.
Before extending jack, make certain the ground
surface below the jack pad will support the tongue
load.
7. Rotate jack handle to extend the jack and transfer
the weight of the trailer tongue to the jack.
8. Raise the trailer coupler above the tow vehicle
hitch.
9. Drive tow vehicle forward.
2.
3.
4.
5.
6.
4.5 TONGUE WEIGHT
It is critical to have a portion of the trailer load carried
by the tow vehicle. That is, the trailer tongue must exert
a downward force on the hitch. This is necessary for
two reasons. First, the proper amount of tongue weight
is necessary for the tow vehicle to be able to maintain
control of the tow vehicle/trailer system. If, for example,
the tongue exerts an upward pull on the hitch, instead
of pushing down on it (because the trailer is overloaded
behind its axle(s)), the rear wheel of the tow vehicle
can lose traction or grip and cause loss of control. Also,
even if there is some weight on the tongue, but not
enough weight on the tongue, the trailer can become
unstable at high speeds. Remember, the faster you go
the more likely the trailer is to sway.
Before towing, check that the breakaway lever and
lanyard are properly positioned. If the breakaway lever
and lanyard are not located correctly due to either the
lanyard being pulled during use or by accident, it MUST
be reset prior to the trailer being moved.
If there is too much tongue weight, the tow vehicle is
prone to jack-knife. The front wheels of the tow vehicle
can be too lightly loaded and cause loss of steering
control and traction, if the front wheels are driving.
See the Surge Brake Actuator manual for the correct
resetting and testing procedure.
In addition to tow vehicle control, tongue weight
is necessary to insure that the trailer axle(s) do not
exceed their Gross Axle Weight Rating (GAWR).
^ WARNING
The breakaway system is designed to
operate if the trailer separates from the tow
vehicle.
DO NOT use the breakaway system as a
parking brake.
4.4 UNCOUPLE TRAILER
Follow these steps to uncouple trailer from the tow
vehicle:
In the following table, the second column shows the
rule of thumb percentage of total weight of the trailer
plus its cargo (Gross Trailer Weight, or “GTW”) that
should appear on the tongue of the trailer. For example,
a large trailer with a loaded weight of 6,000 pounds,
should have 10-15% of 6,000 pounds (600-900 lbs.)
on the hitch.
Tongue Weight as a Percentage of Loaded Trailer
Weight
Type of Hitch
Percentage
Ball Hitch or 10-15% for large trailers
Ring & Pintle
6-10% for small trailers
Page 38 of 145
Coupling To Tow Vehicle
The numbers quoted are for example purposes only
and should be tailored to the specific trailer.
For questions regarding the actual percent of tongue
weight for the trailer, check with the manufacturer
for specifics.
^ WARNING
Improper tongue weight (load distribution)
can result in loss of control of the trailer,
leading to death or serious injury.
4.6 ADJUST HITCH HEIGHT (IF EQUIPPED)
The height of the hitch on the trailer must be adjusted
so that the trailer, when loaded to rated capacity, is
level while connected to the tow vehicle. A level trailer
allows equal weight distribution on the axles.
Your dealer or a trailer service center can perform this
adjustment or you can use the following steps to adjust
the hitch height yourself.
If the trailer is not equipped with an adjustable hitch,
an offset ball mount may be available from your hitch
manufacturer.
Make certain that tongue weight is within
the allowable range.
^ WARNING
Be sure to:
• Distribute the load evenly, right and left.
• Keep the center of gravity low.
• Distribute the load front-to-rear to provide
proper tongue weight (see chart).
Improper hitch height adjustment can
result in overloaded tires, blowout and
loss of control, leading to death or serious
injury.
Adjust the hitch height so that the loaded
trailer is level.
4.5.1 CHECKING TONGUE WEIGHT
To check the tongue weight, the tow vehicle and trailer
must be on level ground, as they will be when the trailer
is being towed.
Take the trailer to a truck stop or grain elevator where
there is a “certified” scale. Place the tow vehicle only
onto the scale and get the weight. This weight must be
less than your tow vehicle’s GVWR.
Pull the trailer onto the scale and uncouple it from the
tow vehicle, leaving just the trailer on the scale. Get a
ticket which lists the total trailer weight. Re-connect the
trailer to your tow vehicle and the drive the tow vehicle
wheels off the scale, just leaving the trailer axles on
the scale. Get a “ticket”, which lists the trailer’s axle
weight. Simply subtract the axle weight from the total
weight to determine the hitch weight.
1. Connect trailer to tow vehicle and load the trailer to
2.
3.
4.
5.
rated capacity. See Loading And Unloading.
Park the tow vehicle and trailer on a firm level
surface.
Stand away from the trailer and visually verify if the
trailer is level front-to-rear. If the front of the trailer
is higher than the rear, the hitch must be raised.
If the front of the trailer is lower than the rear, the
hitch must be lowered.
Uncouple trailer from tow vehicle. See Coupling
And Uncoupling.
Remove the lock nuts and bolts (1) on hitch. Discard
lock nuts. Inspect bolts for damage and replace if
necessary. Contact your dealer for the correct size
and grade of bolts.
While you are at the scale, you should weigh the entire
combination vehicle. This result should be less than
the Gross Combined Weight Rating (GCWR) for your
towing vehicle. Some scales allow you to get individual
axle weights also. If this is possible, get the tow vehicles
front and rear axle weights to make sure they are in the
same proportion as the tow vehicle alone, and that the
rear axle is not overloaded.
Page 39 of 145
Coupling To Tow Vehicle
^ WARNING
Used lock nuts are prone to loosen,
resulting in the hitch separating from the
trailer, which can lead to death or serious
injury.
NEVER re-use a lock nut.
Use new lock nuts each time the hitch
height is adjusted.
Contact your dealer for the proper grade
and size of lock nut.
6. Raise or lower the hitch as necessary.
7. Install bolts and new lock nuts.
8. Tighten lock nuts to torque specified by your
dealer.
9. Couple the trailer to the tow vehicle and verify that
the trailer is level front to rear. Adjust if necessary.
10. Unload trailer. See Loading And Unloading.
Page 40 of 145
Loading And Unloading
5. LOADING AND UNLOADING
Improper trailer loading causes many accidents and
deaths. To safely load a trailer, you must consider:
• Overall load weight.
• Load weight distribution.
• Proper tongue weight.
• Securing the load properly.
To determine that you have loaded the trailer within its
rating, you must consider the distribution of weight, as
well as the total weight of the trailer and its contents.
The trailer axles carry most of the total weight of the
trailer and its contents (Gross Vehicle Weight, or
“GVW”). The remainder of the total weight is carried by
the tow vehicle hitch.
^ WARNING
Do not transport people on your trailer.
Besides putting their lives at risk, the
transport of people on a trailer is illegal.
5.1 LOADING TRAILER
5.1.1 PREPARING TRAILER FOR LOADING
1. Inspect the floor of the trailer.
2. Inspect the tie down rings and track system for
damage, looseness or signs of bending before
loading the trailer.
^ WARNING
It is essential for safe towing that the trailer tongue and
tow vehicle hitch carry the proper amount of the loaded
trailer weight, otherwise the trailer can develop an
undesirable sway at towing speeds, or the rear of the
towing vehicle can be overloaded. Read the “Tongue
Weight” information in Section 4.
Damaged or loose tie down rings or track
can break, allowing cargo to become
loose.
The load distribution must be such that no component
part of the trailer is loaded beyond its rating. You must
consider the rating of the tires, wheels and axles. For
tandem and triple axle trailers, you must make sure
that the front-to-rear load distribution does not result in
overloading any axle.
Inspect and test tie downs and track before
loading cargo.
Towing stability also depends on keeping the center
of gravity as low as possible. Load heavy items on
the floor and over the axles. When loading additional
items, be sure to maintain even side-to-side weight
distribution and proper tongue weight. The total weight
of the trailer and its contents must never exceed the
total weight rating of the trailer (Gross Vehicle Weight
Rating, or “GVWR”).
Do not transport people, containers of hazardous
substances, or flammable liquids. The exception is fuel
in the tank of vehicles or equipment being hauled.
^ WARNING
Do not transport flammable, explosive,
poisonous or other dangerous materials
on your trailer.
Loose cargo can shift the center of gravity,
and result in loss of control of the trailer.
Do not use a damaged or loose tie downs
or track to secure cargo.
3. Park the tow vehicle and trailer on a firm and level
surface.
4. Clear the area around the trailer.
5.1.2 LOADING A RIGID DECK TRAILER
1. Couple the trailer to the tow vehicle.
^ WARNING
Trailer must be coupled to tow vehicle
before loading trailer.
2. Lower rear stabilizers (if equipped) or place
blocking under rear of trailer so the weight of the
cargo does not raise the front of the trailer during
loading.
The exception is fuel in the tank of a
vehicle or equipment being hauled.
Page 41 of 145
Loading And Unloading
^ CAUTION
^ WARNING
Use a safe lifting procedure to avoid injury
when handling ramps.
Loading a pivoting-deck trailer before
retracting the deck catch pin can crack the
catch pin, which can cause loss of cargo
or loss of control of the trailer. Death or
serious injury may result.
3. Remove ramps from storage position and secure
to rear of trailer. Adjust ramp position to align with
equipment tires or tracks.
^ WARNING
Load can suddenly move or topple, which
can result in death or serious injury.
Do not load or unload trailer unless
coupled to tow vehicle and is on a firm and
level surface.
NOTICE
Ramps are not rated for load bearing
capacity. They will NOT support the load
bearing capacity of the trailer.
Do not overload ramps.
4. Load the cargo on trailer with approximately 60%
5.
6.
7.
8.
of the cargo in the front half of the trailer.
Secure the load to the trailer using appropriate
straps, chains and tensioning devices. Refer to
www.fmcsa.dot.gov for regulations regarding cargo
securement rules.
Remove ramps and place in storage position.
Secure ramps to trailer.
Raise rear stabilizers (if equipped) or remove
blocking under rear of trailer.
5.1.3 LOADING A TILT DECK TRAILER
A tilt deck trailer may be equipped with a manual or a
hydraulic tilt deck.
5.1.3.1 MANUAL TILT TRAILER
1. Couple the trailer to the tow vehicle.
^ WARNING
Trailer must be coupled to tow vehicle
before loading trailer.
Before loading the trailer, retract the deck
catch pin.
If the deck catch pin becomes bent, do not
straighten it. Replace the deck catch pin
before towing the load.
3. Load the cargo on trailer with approximately 60%
of the cargo in the front half of the trailer. Deck will
pivot down into the driving position as the cargo is
moved forward on the deck.
4. Extend the deck catch pin into the deck to lock
the deck into the driving position. Verify the catch
engages the hole in the pivoting deck.
^ WARNING
An unlocked pivoting deck can result
in loss of cargo or loss of control of the
trailer, which can result in death or serious
injury.
Before towing the trailer:
• Lock the pivoting deck in the driving
position.
• Verify that the catch engages the hole in
the pivoting deck.
5. Secure the load to the trailer using appropriate
straps, chains and tensioning devices. Refer to
www.fmcsa.dot.gov for regulations regarding cargo
securement rules.
^ WARNING
Shifting cargo can result in loss of control
of the trailer, and can lead to death or
serious injury.
Tie down all loads with proper sized
fasteners, chains, straps, etc.
2. Release deck latch pin to pivot trailer deck for
loading.
Page 42 of 145
Loading And Unloading
5.1.3.2 HYDRAULIC TILT TRAILER
1. Couple the trailer to the tow vehicle.
^ WARNING
Trailer must be coupled to tow vehicle
before loading trailer.
2. Read and understand the hoist operating procedure
before operating the tilt deck.
3. Locate the tilt deck controller. Position yourself in a
4.
5.
6.
7.
8.
9.
safe location clear of the tilt deck.
Press and hold button to raise the tilt deck. Release
the button when the rear of the tilt deck touches the
ground.
Load the cargo on trailer with approximately 60%
of the cargo in the front half of the trailer.
Secure cargo to prevent movement.
Press and hold button to lower the tilt deck.
Release the button when the tilt deck is in the
driving position.
Secure the load to the trailer using appropriate
straps, chains and tensioning devices. Refer to
www.fmcsa.dot.gov for regulations regarding cargo
securement rules.
Stow controller.
^ WARNING
Shifting cargo can result in loss of control
of the trailer, and can lead to death or
serious injury.
Tie down all loads with proper sized
fasteners, chains, straps, etc.
5.2 UNLOAD TRAILER
5. Release deck latch pin to pivot trailer deck for
unloading.
^ WARNING
Unloading a pivoting-deck trailer before
retracting the deck catch pin can crack the
catch pin, which can cause loss of cargo
or loss of control of the trailer. Death or
serious injury may result.
Before unloading the trailer, retract the
deck catch pin.
If the deck catch pin becomes bent, do not
straighten it. Replace the deck catch pin
before towing the load.
6. Carefully move cargo toward rear of trailer. Deck
will pivot down into the unload position as the cargo
is moved rearward on the deck.
7. Pivot deck back to the driving position and extend
the deck catch pin to lock the deck. Verify the catch
engages the hole in the pivoting deck.
^ WARNING
An unlocked pivoting deck can result
in loss of cargo or loss of control of the
trailer, which can result in death or serious
injury.
Before towing the trailer:
• Lock the pivoting deck in the driving
position.
• Verify that the catch engages the hole in
the pivoting deck.
5.2.1 UNLOAD MANUAL TILT TRAILER
1. Couple the trailer to the tow vehicle.
5.2.2 UNLOAD HYDRAULIC TILT TRAILER
1. Couple the trailer to the tow vehicle.
^ WARNING
Trailer must be coupled to tow vehicle
before unloading trailer.
^ WARNING
Trailer must be coupled to tow vehicle
before unloading trailer.
2. Park the tow vehicle and trailer on a firm and level
surface.
3. Clear the area around the trailer.
4. Remove chains, straps and tensioning devices.
2. Park the tow vehicle and trailer on a firm and level
surface.
3. Clear the area around the trailer.
4. Remove chains, straps and tensioning devices.
5. Read and understand the hoist operating procedure
Page 43 of 145
Loading And Unloading
before operating the tilt deck.
6. Locate the tilt deck controller. Position yourself in a
safe location clear of the tilt deck.
7. Press and hold button to raise the tilt deck. Release
the button when the rear of the tilt deck touches the
ground.
8. Unload the cargo from trailer.
9. Press and hold button to lower the tilt deck.
Release the button when the tilt deck is in the
driving position.
10. Stow controller.
5.3 HYDRAULIC COMPONENTS
Do not alter or substitute and hydraulic components
on the trailer. The hydraulic system is designed with
each component being compatible with the safe and
reliable operation of the hydraulic system. Under
no circumstances should you alter the hydraulic
pressure or flow rate in the hydraulic system.
^ DANGER
Crushing hazard.
An altered or component substituted
hydraulic system may malfunction,
resulting in the tilt deck falling without
warning.
NEVER alter or substitute any hydraulic
system component.
Always have the hydraulic system repaired or
maintained by a qualified technician.
5.4 SECURING CARGO
^ WARNING
Shifting cargo can result loss of control of
the trailer, and can lead to death or serious
injury.
Tie down all loads with proper sized
fasteners, chains, straps, etc.
Refer to www.fmcsa.dot.gov for regulations regarding
cargo securement rules.
Page 44 of 145
Pre-Tow Checklist
6. PRE-TOW CHECKLIST
6.1 PRE-TOW CHECKLIST
Before towing, double-check all of these items:
• Tires, wheels and lug nuts. See “Breaking In A New
Trailer” section of this manual.
• Tire Pressure. Inflate tires on trailer and tow vehicle
to the pressure stated on the Certification / VIN
label.
• Coupler secured and locked. See “Coupling To Tow
Vehicle” section of this manual.
• Safety chains properly rigged to tow vehicle, not to
hitch or ball. See “Coupling To Tow Vehicle” section
of this manual.
• Test Tail, Stop, and Turn Lights.
• Test trailer brakes.
• Safety breakaway lanyard fastened to tow vehicle,
not to safety chains. See “Coupling To Tow Vehicle”
section of this manual.
• Cargo properly loaded, balanced and tied down.
See the appropriate “Loading And Unloading”
section of this manual.
• Tongue weight and weight distribution set-up.
• Ramps secured for travel.
• Fire extinguisher.
• Flares and reflectors.
6.2 MAKE REGULAR STOPS
After each 50 miles, or one hour of towing, stop and
check the following items:
• Coupler secured.
• Safety chains are fastened and not dragging.
• Cargo secured.
Page 45 of 145
Breaking In A New Trailer
7. BREAKING IN A NEW TRAILER
^ WARNING
7.1 RETIGHTEN LUGS AT FIRST 10, 25 & 50
MILES
Wheel lugs can shift and settle quickly after being first
assembled, and must be checked after the first 10, 25
and 50 miles of driving. Failure to perform this check
may result in a wheel coming loose from the trailer,
causing a crash leading to death or serious injury.
Improper tightening of the lug nuts or bolts voids the
axle warranty.
If trailer and tow vehicle brakes do not
work properly together, death or serious
injury can occur.
Road test the brakes in a safe area at no
more than 30 m.p.h. before each tow.
To insure safe brake performance and synchronization,
read and follow the axle/brake and the brake controller
manufacturers’ instructions. If you do not have these
instructions, contact your dealer for assistance.
Refer to the Inspection, Service and Maintenance
section of this manual.
^ WARNING
Lug nuts or bolts are prone to loosen after
being first assembled. Death or serious
injury can result.
Check lug nuts or bolts for tightness on a
new trailer, and after re-mounting a wheel
at 10, 25 and 50 miles.
7.2 ADJUST BRAKE AT FIRST 200 MILES
Brake shoes and drums experience a rapid initial wear.
The brakes must be adjusted after the first 200 miles of
use, and each 3,000 miles thereafter. Some axles are
fitted with a mechanism that will automatically adjust
the brake shoes.
Read your axle and brake manual to see if your brakes
adjust automatically. If you do not have the axle and
brake manual, contact your dealer for assistance.
If your trailer is not fitted with automatically adjusting
brakes, the brakes will need to be manually adjusted.
See section 9 for instructions.
7.3 SYNCHRONIZING BRAKE SYSTEMS
Trailer brakes are designed to work in synchronization
with the brakes on the tow vehicle. When the tow
vehicle and trailer braking systems are synchronized,
both braking systems contribute to slowing, and the
tongue of the trailer will neither dive nor rise sharply.
Page 46 of 145
Accessories
8. ACCESSORIES
This section provides some basic information for the
safe operation of accessories.
You must read and follow these instructions before
using the accessory. If you are uncertain whether you
have all of the instructions, contact your dealer before
operating the accessory.
8.1 ACCESSORY BATTERY
Your trailer may be equipped with an accessory battery
that operates the tilt deck.
The battery may be kept charged either by the tow
vehicle, by an auxiliary charger or by using an onboard battery maintainer/charger (if equipped). If the
trailer is used daily, it is recommended that the battery
charger be plugged in after each days use. The battery
may be located in a tongue mounted battery box or a
side mounted box.
The accessory battery must be kept in a charged
condition during storage. The battery could freeze and
break if it becomes discharged.
If the battery is not fully charged, the hydraulic pump
will lose pressure which may cause hydraulic fluid to
flow back into the hydraulic reservoir, overfilling the
reservoir and ejecting fluid into the battery box.
^ WARNING
Risk of battery exploding.
Battery box prop rod may contact battery
terminals, which may result in the battery
exploding.
Place battery box lid prop rod in retaining
clip.
Page 47 of 145
Inspection, Service And Maintenance
9. INSPECTION, SERVICE AND MAINTENANCE
9.1 INSPECTION, SERVICE & MAINTENANCE SUMMARY CHARTS
You must inspect, maintain and service your trailer regularly to insure safe and reliable operation. If you cannot
or are unsure how to perform the items listed here, have your dealer do them. Note: In addition to this manual,
also check the relevant component manufacturer’s manual.
Item
Breakaway Brakes
• Electric
• Hydraulic
Breakaway Battery
Brakes
• Electric
• Surge
Inspection And Service Before Each Tow
Inspection/Service
Manual Section Reference
Shoes And Drums
Safety Chains And Hooks
Coupler And Hitch Ball
Check operation.
Check operation.
Fully charged, connections clean.
Section 4.
Section 4.
Section 4 and 9.
Check operation.
Check operation.
Check master cylinder level.
Adjust
Check for wear, damage.
Check for cracks, pits, and flats.
Replace w/ ball and coupler having
trailer GVW Rating.
Section 4 and 9.
Grease.
Ring And Pintle
Wheels - Lug Nuts Or Bolts & Hub
Section 4 and 9.
Check locking device & replace
Section 4 and 9.
when worn.
Check for cracks, pits, and flats. Section 4 and 9.
Replace w/ ring and pintle having
trailer GVW Rating.
Grease.
Tires
Section 9.
Section 4.
Section 4 and 9.
Section 4 and 9.
Check locking device & replace Section 4 and 9.
when worn.
Check tire pressure when cold. Section 6 and 9
Inflate as needed.
Section 6 and 9
Check for damage.
Check for tightness.
Section 6.
Tighten. For new and remounted Section 7 and 9.
wheels, check torque after first 10,
25 & 50 miles of driving and after
any impact.
Page 48 of 145
Inspection, Service And Maintenance
Inspection And Service Every Month
Inspection / Service
Manual Section Reference
Lubricate tilt deck pivot points (if Section 9.
equipped).
Item
Lubrication
Lubricate hydraulic cylinder ends (if Section 9.
equipped).
Item
Brakes, electric
• Magnet
•
Inspection and Service Every 6 Months or 6,000 Miles
Inspection/Service
Manual Section Reference
Controller (in tow vehicle)
Tires
Check wear and current draw.
Section 9.
Check power output (amperage) Section 9.
and modulation.
See Controller Mfr’s Manual
Inspect tread
thoroughly.
and
sidewalls Section 9.
Replace tire when treads are worn, Section 9.
when sidewall has a bulge, or
sidewall is worn.
Brakes
• Electric
• Surge
Brake Shoes And Drums
Safety Chains & Hooks
Coupler And Hitch Ball
Rotate every 5,000 Miles.
Section 9.
Check Operation.
Check Operation.
Check Master Cylinder Level.
Adjust
Check for wear, damage.
Check for cracks, pits, and flats.
Replace w/ ball and coupler having
trailer GVW Rating.
Section 4.
Grease.
Ring And Pintle
Section 7 and 9.
Section 4.
Section 4.
Section 4 and 9.
Check locking device and replace Section 4 and 9.
when worn.
Check for cracks, pits, and flats. Section 4.
Replace w/ ring and pintle having
trailer GVW Rating.
Grease.
Section 4 and 9.
Check locking device & replace Section 4 and 9.
when worn.
Page 49 of 145
Inspection, Service And Maintenance
Item
Brakes, all types
• Shoes and Drums
Inspection And Service Every Year or 12,000 Miles
Inspection/Service
Manual Section Reference
Check for scoring and wear. Replace Section 9.
per manufacturer’s specifications.
See Brake Mfr’s Manual
Jack, Drop-leg (if equipped)
Structure
• Frame Members
•
Welds
Wheels
• Wheel Bearings
•
Grease gears at top.
See Jack Mfr’s Manual
Inspect all frame members, bolts & Section 9.
rivets. Repair or replace damaged,
worn or broken parts.
Inspect all
needed.
welds.
Repair
as Section 9.
Disassemble / inspect / assemble Section 9 & See Axle Mfr’s Manual
and repack. Replace promptly if
immersed in water.
Rims
Inspect for cracks & dents. Replace
as needed.
Structure
• Axle Attachment Bolts
Check BY DEALER
Section 9.
Page 50 of 145
Inspection, Service And Maintenance
9.2 INSPECTION AND SERVICE INSTRUCTIONS
^ WARNING
Worn or broken suspension parts can
cause loss of control and injury may result.
Have trailer professionally inspected
annually and after any impact.
To perform many of the inspection and maintenance
activities, you must jack up the trailer.
When jacking and using jack stands, place them so
as to clear wiring, brake lines, and suspension parts
(springs, torsion bars, etc.). Place jacks and jack
stands under the outer frame rail to which the axles
are attached.
^ WARNING
Never go under trailer unless it is on firm
and level ground and resting on properly
placed and secured jack stands.
^ WARNING
^ WARNING
Broken or damaged fasteners can cause
injury or damage to trailer and contents.
Inspect for, and repair all damaged parts at
least once a year.
9.2.1.2 WELDS
All welds can crack or fail when subjected to heavy
loads or movement of cargo that was not properly
secured. Any time that you know or suspect that the
trailer has been subjected to heavy loads or movement
of cargo, immediately inspect the welds and fasteners
for damage. To prevent severe damage to your trailer,
inspect all of the welds for cracks or failure at least
once a year. If a weld failure is detected, contact your
dealer.
^ WARNING
Do not attempt to repair a cracked or
broken weld unless you have the skills and
equipment to make the repair.
Crushing hazard.
Improper weld repair will lead to early
failure of the trailer structure and serious
injury or death.
The tow vehicle and trailer could be
inadvertently moved while a person is
under the trailer.
See your dealer for weld repairs.
The tow vehicle engine must be off,
ignition key removed and parking brakes
set before entering the area under the
trailer.
9.2.1 TRAILER STRUCTURE
Wash the trailer as needed with a power washer and a
detergent solution.
^ WARNING
Broken or damaged welds can cause injury
or damage to trailer and contents.
Inspect for, and repair all damaged parts at
least once a year.
9.2.2 TRAILER BRAKES - ELECTRIC
9.2.2.1 BRAKE DISCS, SHOES AND DRUMS
9.2.1.1 FASTENERS AND FRAME MEMBERS
Inspect all fasteners and structural frame members for
bending and other damage, cracks, or failure. Repair
or replace any damaged fastener and repair the frame
member. If you have any questions about the condition
or method of repair of fasteners or frame members,
get the recommendation of, or have the repair done by
your dealer.
Properly functioning brake shoes and drums are
essential to ensure safety. You must have your dealer
inspect these components at least once per year, or
each 12,000 miles. Brake adjustment is not covered
under the axle warranty.
The brake shoes must be adjusted after the first 200
miles of use, and each 3,000 miles thereafter. Most
axles are fitted with a brake mechanism that will
automatically adjust the brake shoes when the trailer
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Inspection, Service And Maintenance
is “hard braked” from a rearward direction. Trailer
disc brakes are self-adjusting and do not need to be
periodically adjusted. Using pads or shoes without
enough brake lining material can result in brake
damage, create excessive heat and potentially cause
the loss of braking capacity. Read your axle and brake
manual to see how to adjust your brakes. If you do not
have this manual, contact your dealer for assistance.
9.2.2.2 MANUALLY ADJUSTING BRAKE SHOES
Some braking systems are not automatically adjusted.
These brakes require manual adjustment. The following
steps apply to adjust most manually adjustable
brakes.
Read your axle and brake manual to see how to adjust
your brakes. If you do not have this manual, contact
your dealer for assistance.
1. Jack up the trailer and secure it on adequate
capacity jack stands.
2. Be sure the wheel and brake drum rotate freely.
3. Remove the adjusting-hole cover from the adjusting
4.
5.
6.
7.
8.
slot on the bottom of the brake backing plate.
With a screwdriver or standard adjusting tool, rotate
the starwheel of the adjuster assembly to expand
the brake shoes. Adjust the brake shoes out until
the pressure of the linings against the drum makes
the wheel very difficult to turn. Note: Your trailer
maybe equipped with drop spindle axles. See axle
manual for your axle type. You will need a modified
adjusting tool for adjusting the brakes in these
axles.
Rotate the starwheel in the opposite direction until
the wheel turns freely with a slight drag.
Replace the adjusting-hole cover.
Repeat the above procedure on all brakes.
Lower the trailer to the ground.
9.2.2.3 ELECTRIC BRAKES
Two different types of electric brakes may be present on
the trailer: an emergency electric breakaway system,
which acts only if the trailer comes loose from the hitch
and the breakaway pin is pulled. The other brake is an
electric braking system that acts whenever the brakes
of the tow vehicle are applied.
Breakaway Battery - This battery supplies the power
to operate the trailer brakes if the trailer uncouples from
the tow vehicle. Be sure to check, maintain and replace
the battery according to the battery manufacturer’s
instructions. Your trailer may use the hydraulic system
battery to operate the breakaway brakes.
^ CAUTION
Extreme cold weather can degrade battery
performance and cause brakes to not
operate properly.
Check battery charge level before towing.
Breakaway Switch - This switch engages the electric
brakes if the trailer uncouples from the tow vehicle.
To check for proper functioning of the switch, battery
and brakes, you must pull the pin from the switch and
confirm that the brakes apply to each wheel. You can
do this by trying to pull the trailer with the tow vehicle,
after pulling the pin. The trailer brakes may not lock,
but you will notice that a greater force is needed to pull
the trailer.
^ WARNING
If electric breakaway brakes do not operate
when trailer is uncoupled from the tow
vehicle, death or serious injury can occur.
Check emergency breakaway brake system
before each tow.
9.2.2.4 TOW VEHICLE OPERATED ELECTRIC BRAKES
The electric brakes that operate in conjunction with
the tow vehicle brakes must be “synchronized” so
that braking is properly distributed to the tow vehicle
brakes and the trailer brakes. For proper operation and
synchronization, read and follow the axle/brake and
the brake controller manufacturers’ instructions. If you
do not have these instructions, contact your dealer for
assistance.
9.2.2.5 ELECTRIC BRAKE MAGNETS
To make certain an electrically-operated braking system
will function properly, you must have your dealer inspect
the magnets at least once a year, or each 12,000 miles.
See the brake manual for wear and current inspection
instructions.
9.2.3 TRAILER BRAKES - SURGE (IF EQUIPPED)
9.2.3.1 SURGE BRAKE MASTER CYLINDER
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Inspection, Service And Maintenance
Check fluid level prior to using the trailer. The master
cylinder is normally located on the tongue of the
trailer. The fluid level must maintained at full mark on
reservoir. Check with your dealer for the type of brake
fluid used in the brake system.
9.2.3.2 HYDRAULIC SURGE BRAKE
Before each tow, perform the following steps:
1. Check that the brake master cylinder level as
instructed above. Check for leaks and repair as
required.
2. Examine the actuator for wear, bent parts, corroded/
seized parts, or other damage. Have the affected
components replaced with genuine service parts.
3. Check to determine that the actuator mounting bolts
are tightened to the manufacturer’s specification.
4. Test the actuator and brake function as described
in the Coupling To Tow Vehicle section of this
manual. Actuator travel over one inch indicates
that the brakes need adjustment (or that the
actuator has been structurally damaged). Actuator
travel is the distance the coupler case assembly
moves to the outer case during braking. Adjust the
brakes following the instructions given in the brake
installation manual. Failure to adjust brakes will
result in loss of braking.
5. Before storage or after extended use, apply motor
oil to the coupler components and the internal
rollers to keep them moving freely and to prevent
corrosion.
6. See the surge brake manufacturer’s manual for
other inspection and maintenance activities. If you
do not have this manual, contact your dealer for
assistance.
2. Fill the master cylinder with correct fluid.
3. Install a bleeder hose on the bleeder screw of the
farthest wheel cylinder from the actuator. If the
trailer has multiple axles, bleed the rear axle first.
Submerse the other end of the hose in a glass
container of brake fluid, so that air bubbles can be
observed.
4. Open the bleeder screw and have an assistant
stroke (but not release) the actuator. Brake fluid
and/or air bubbles will flow into the jar. Close the
bleeder screw. The helper can then allow the
actuator to return to its rest position.
5. Repeat the process until no more bubbles are
released with the stroke. Air trapped in the brake
lines will greatly reduce your braking efficiency. Be
sure to close the bleeder screw securely when the
cylinder is fully bled. Repeat the bleeding operation
at each wheel cylinder. During the bleeding process,
replenish the master cylinder reservoir with fresh
brake fluid so that the level does not fall below half
full. This will ensure that no air is drawn into the
system.
6. After all brakes have been bled, refill the master
cylinder before operating. Be sure to install the
master cylinder filler cap.
^ WARNING
Use only fresh brake fluid from a sealed
container. DO NOT reuse fluid. After filling
and bleeding, refill the actuator.
Failure to maintain an adequate fluid level
may cause brake failure.
9.2.3.3 MASTER CYLINDER BLEEDING
9.2.4 TRAILER CONNECTION TO TOW VEHICLE
Remove the master cylinder’s cap and fill the reservoir
to three quarters full with DOT-3 or DOT 4 brake fluid.
DO NOT allow brake fluid to contact painted surfaces
since it will damage the finish. Wipe up any spills
immediately and wash the area with water.
9.2.4.1 COUPLER AND BALL
Bleed the brake system manually or with a pressure
bleeder. Pressure bleeding equipment simplifies the
process, and is available at most automotive supply
stores. Use the instructions provided with the pressure
bleeder. If you chose to manually bleed the system,
an assistant is required. Use the following steps to
manually bleed the brake system:
1. Disconnect the trailer from the tow vehicle and jack
the trailer’s tongue until it is horizontal. Make sure
that the wheels are blocked so that the trailer will
not roll away.
Before each tow, coat the ball with a thin layer of
automotive bearing grease to reduce wear and ensure
proper operation; and check the locking device that
secures the coupler to the ball for proper operation.
See the coupler manufacturer’s manual for other
inspection and maintenance procedures. If you do not
have this manual, contact your dealer for assistance.
If you see or feel evidence of wear, such as flat spots,
deformations, pitting or corrosion, on the ball or coupler,
immediately have your dealer inspect them to determine
the proper action to prevent possible failure of the ball
and coupler system. All bent or broken coupler parts
must be replaced before towing the trailer.
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Inspection, Service And Maintenance
The coupler latch lever must be able to rotate freely
and automatically snap into the latched position. Oil
the pivot points, sliding surfaces, and spring ends with
SAE 30W motor oil. Keep the ball pocket and latch
mechanism clean. Dirt or contamination can prevent
proper operation of the latching mechanism.
To avoid risk of collisions, all lights must
work.
9.2.7 WHEEL RIMS
When replacing a ball, the load rating must match or
exceed the GVWR of the trailer.
If the trailer has been struck, or impacted, on or near
the wheels, or if the trailer has struck a curb, inspect
the rims for damage. Replace any damaged wheel.
Inspect the wheels for damage every year, even if no
obvious impact has occurred.
9.2.4.2 RING AND PINTLE
9.2.8 TIRES
Before each tow, coat the ring with a thin layer of
automotive bearing grease to reduce wear and ensure
proper operation; and check the locking device that
secures the pintle to the ring for proper operation.
Before each tow, check the tire pressure to make sure
it is at the level indicated on the tire sidewall or VIN
label. Tire pressure must be checked while the tire
is cold. Do not check tire pressure immediately after
towing the trailer. Allow at least three hours for the tires
to cool, if the trailer has been towed for as much as one
mile. Tires can lose air over a period of time.
See the pintle manufacturer’s manual for other
inspection and maintenance activities. If you do not
have this manual, contact your dealer for assistance.
If you see or feel evidence of wear, such as flat spots,
deformations, pitting or corrosion, on the ring or
pintle, immediately have your dealer inspect them to
determine the proper action to prevent possible failure
of the ring and pintle system. All bent or broken coupler
parts must be replaced before towing the trailer.
The pintle handle lever must be able to rotate freely
and automatically snap into the latched position. Oil
the pivot points, sliding surfaces, and spring ends with
SAE 30W motor oil. Keep the ring pocket and latch
mechanism clean. Dirt or contamination can prevent
proper operation of the latching mechanism.
Replace the tire before towing the trailer if the tire
treads have less than 2/32 inch depth or the telltale
bands are visible.
A bubble, cut or bulge in a side wall can result in a
tire blowout. Inspect both side walls of each tire for
any bubble, cut or bulge; and replace a damaged tire
before towing the trailer.
If you are storing your trailer for an extended period,
make sure the tires are inflated to the maximum rated
pressure indicated on the sidewall or VIN label and that
you store them in a cool, dry place such as a garage.
Use tire covers to protect the tires from the harsh
effects of the sun.
When replacing a ring, the load rating must match or
exceed the GVWR of the trailer.
9.2.5 LANDING LEG OR JACK
If a grease fitting is present, use a grease gun to
lubricate the jack mechanism. Grease the gears in the
top of hand-cranked jacks once a year, by removing the
top of the jack and pumping or hand packing grease
into the gears.
9.2.6 LIGHTS AND SIGNALS
Before each tow, check all trailer lights for proper
operation.
^ WARNING
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Inspection, Service And Maintenance
Never go under trailer unless it is on firm
and level ground and resting on properly
placed and secured jack stands.
If your axle(s) are equipped with a grease zerk on the
ends of the axle(s), the bearings must be greased
every 6 months or 6,000 miles to ensure reliable and
safe operation of your trailer.
1. Remove the rubber plug from the axle end.
2. Place grease gun on zerk.
3. Pump grease until new grease begins to appear.
Use a different color grease each time so you will
know when the new grease begins to appear.
4. Install rubber plug and cap. Repeat for remaining
wheel bearings.
If your trailer axle(s) are not equipped with grease
zerks, refer to the axle manufacturer’s manual for
service and maintenance information.
9.2.10 LUBRICATION
Lubricate tilt deck pivots and hydraulic cylinder ends
every month (if equipped).
9.2.11 HYDRAULIC RESERVOIR
Check fluid level prior to towing the trailer. The reservoir
is normally located inside the battery box.
Tire Inspection Chart
^ WARNING
Worn, damaged or under-inflated tires can
cause loss of control, injury and damage.
Check tires before each tow.
9.2.9 WHEEL BEARINGS
A loose, worn or damaged wheel bearing is the most
common cause of brakes that grab.
To check your bearings, jack up the trailer and secure
it on adequate capacity jack stands. Check wheels for
side-to-side looseness.
The tilt deck must be fully lowered before checking fluid
level. The reservoir should be filled to the full mark on
the side of the reservoir.
Use a quality hydraulic fluid with anti-wear properties,
rust and oxidation inhibitors. Fluid ejecting from the
reservoir could indicate a low battery.
9.2.12 LUG NUTS OR BOLTS
Lug nuts or bolts are prone to loosen right after a wheel
is mounted to a hub. When driving on a remounted
wheel, check to see if the lug nuts or bolts are tight
after the first 10, 25 and 50 miles of driving, and before
each tow thereafter.
^ WARNING
If the wheels are loose, or spin with a wobble, the
bearings must be serviced or replaced.
^ WARNING
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Inspection, Service And Maintenance
Lug nuts or bolts are prone to loosen after
being first assembled. Death or serious
injury can result.
Check lug nuts or bolts for tightness on a
new trailer, and after re-mounting a wheel
at 10, 25 and 50 miles.
^ WARNING
Metal creep between the wheel rim and lug
nuts or bolts can cause rim to loosen.
Death or injury can occur if wheel comes
off.
Tighten lug nuts or bolts before each tow.
Tighten the lug nuts or bolts in three stages to the
final torque for the axle size on your trailer, to prevent
wheels from coming loose. Tighten each lug nut or bolt
in the order shown in the following figure.
Use a calibrated torque wrench to tighten the fasteners.
Verify that wheel studs are free of contaminates such
as paint or grease, which may result in inaccurate
torque readings. Over-tightening will result in breaking
the studs or permanently deforming the mounting stud
holes in the wheels, and will void the axle warranty.
See your axle manufacturers manual or your dealer for
wheel nut or bolt torque specifications.
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Tire Safety Information
1. TIRE SAFETY INFORMATION
This portion of the User’s Manual contains tire safety information as required by 49 CFR 575.6.
Section 2.1 contains “Steps for Determining Correct Load Limit - Trailer”.
Section 2.2 contains “Steps for Determining Correct Load Limit – Tow Vehicle”.
Section 2.3 contains a Glossary of Tire Terminology, including “cold inflation pressure”, “maximum inflation
pressure”, “recommended inflation pressure”, and other non-technical terms.
Section 2.4 contains information from the NHTSA brochure entitled “Tire Safety – Everything Rides On It”.
This brochure This brochure, as well as the preceding subsections, describes the following items;
Tire labeling, including a description and explanation of each marking on the tires, and information
about the DOT Tire Identification Number (TIN).
Recommended tire inflation pressure, including a description and explanation of:
A. Cold inflation pressure.
B. Vehicle Placard and location on the vehicle.
C. Adverse safety consequences of under inflation (including tire failure).
D. Measuring and adjusting air pressure for proper inflation.
Tire Care, including maintenance and safety practices.
Vehicle load limits, including a description and explanation of the following items:
A. Locating and understanding the load limit information, total load capacity, and cargo capacity.
B. Calculating total and cargo capacities with varying seating configurations including quantitative examples
showing / illustrating how the vehicles cargo and luggage capacity decreases as combined number and size
of occupants’ increases. This item is also discussed in Section 3.
C. Determining compatibility of tire and vehicle load capabilities.
D. Adverse safety consequences of overloading on handling and stopping on tires.
1.1. STEPS FOR DETERMINING CORRECT LOAD LIMIT – TRAILER
Determining the load limits of a trailer includes more than understanding the load limits of the tires alone. On all trailers
there is a Federal certification/VIN label that is located on the forward half of the left (road) side of the unit. This
certification/VIN label will indicate the trailer’s Gross Vehicle Weight Rating (GVWR). This is the most weight the fully
loaded trailer can weigh. It will also provide the Gross Axle Weight Rating (GAWR). This is the most a particular axle
can weigh. If there are multiple axles, the GAWR of each axle will be provided.
If your trailer has a GVWR of 10,000 pounds or less, there is a vehicle placard located in the same location as the
certification label described above. This placard provides tire and loading information. In addition, this placard will show
a statement regarding maximum cargo capacity. Cargo can be added to the trailer, up to the maximum weight specified on
the placard. The combined weight of the cargo is provided as a single number. In any case, remember: the total weight of
a fully loaded trailer can not exceed the stated GVWR.
For trailers with living quarters installed, the weight of water and propane also need to be considered. The weight of fully
filled propane containers is considered part of the weight of the trailer before it is loaded with cargo, and is not considered
part of the disposable cargo load. Water however, is a disposable cargo weight and is treated as such. If there is a fresh
water storage tank of 100 gallons, this tank when filled would weigh about 800 pounds. If more cargo is being
transported, water can be off-loaded to keep the total amount of cargo added to the vehicle within the limits of the GVWR
so as not to overload the vehicle. Understanding this flexibility will allow you, the owner, to make choices that fit your
travel needs.
When loading your cargo, be sure it is distributed evenly to prevent overloading front to back and side to side. Heavy
items should be placed low and as close to the axle positions as reasonable. Too many items on one side may overload a
tire. The best way to know the actual weight of the vehicle is to weigh it at a public scale. Talk to your dealer to discuss
the weighing methods needed to capture the various weights related to the trailer. This would include the weight empty or
unloaded, weights per axle, wheel, hitch or king-pin, and total weight.
Page 57 of 145
Excessive loads and/or underinflation cause tire overloading and, as a result, abnormal tire flexing occurs. This situation
can generate an excessive amount of heat within the tire. Excessive heat may lead to tire failure. It is the air pressure that
enables a tire to support the load, so proper inflation is critical. The proper air pressure may be found on the
certification/VIN label and/or on the Tire Placard. This value should never exceed the maximum cold inflation pressure
stamped on the tire.
1.1.1. TRAILERS 10,000 POUNDS GVWR OR LESS
Tire and Loading Information Placard – Figure 1-1
1. Locate the statement, “The weight of cargo should never exceed XXX kg or XXX lbs.,” on your vehicle’s
placard. See figure 1-1.
2. This figure equals the available amount of cargo and luggage load capacity.
3. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not
safely exceed the available cargo and luggage load capacity.
The trailer’s placard refers to the Tire Information Placard attached adjacent to or near the trailer’s VIN
(Certification) label at the left front of the trailer.
1.1.2. TRAILERS OVER 10,000 POUNDS GVWR (NOTE: THESE TRAILERS ARE NOT REQUIRED TO HAVE A TIRE
INFORMATION PLACARD ON THE VEHICLE)
1. Determine the empty weight of your trailer by weighing the trailer using a public scale or other means.
This step does not have to be repeated.
2. Locate the GVWR (Gross Vehicle Weight Rating) of the trailer on your trailer’s VIN (Certification) label.
3. Subtract the empty weight of your trailer from the GVWR stated on the VIN label. That weight is the
maximum available cargo capacity of the trailer and may not be safely exceeded.
1.2. STEPS FOR DETERMINING CORRECT LOAD LIMIT – TOW VEHICLE
1. Locate the statement, “The combined weight of occupants and cargo should never exceed XXX lbs.,” on
your vehicle’s placard.
2. Determine the combined weight of the driver and passengers who will be riding in your vehicle.
3. Subtract the combined weight of the driver and passengers from XXX kilograms or XXX pounds.
4. The resulting figure equals the available amount of cargo and luggage capacity. For example, if the “XXX”
amount equals 1400 lbs. and there will be five 150 lb. passengers in your vehicle, the amount of available
cargo and luggage capacity is 650 lbs. (1400-750 (5 x 150) = 650 lbs.).
5. Determine the combined weight of luggage and cargo being loaded on the vehicle. That weight may not
safely exceed the available cargo and luggage capacity calculated in Step # 4.
6. If your vehicle will be towing a trailer, load from your trailer will be transferred to your vehicle. Consult the
tow vehicle’s manual to determine how this weight transfer reduces the available cargo and luggage
capacity of your vehicle.
1.3. GLOSSARY OF TIRE TERMINOLOGY
Accessory weight
The combined weight (in excess of those standard items which may be replaced) of automatic transmission,
power steering, power brakes, power windows, power seats, radio and heater, to the extent that these items
are available as factory-installed equipment (whether installed or not).
Page 58 of 145
Bead
The part of the tire that is made of steel wires, wrapped or reinforced by ply cords and that is shaped to fit the
rim.
Bead separation
This is the breakdown of the bond between components in the bead.
Bias ply tire
A pneumatic tire in which the ply cords that extend to the beads are laid at alternate angles substantially less
than 90 degrees to the centerline of the tread.
Carcass
The tire structure, except tread and sidewall rubber which, when inflated, bears the load.
Chunking
The breaking away of pieces of the tread or sidewall.
Cold inflation pressure
The pressure in the tire before you drive.
Cord
The strands forming the plies in the tire.
Cord separation
The parting of cords from adjacent rubber compounds.
Cracking
Any parting within the tread, sidewall, or inner liner of the tire extending to cord material.
CT
A pneumatic tire with an inverted flange tire and rim system in which the rim is designed with rim flanges
pointed radially inward and the tire is designed to fit on the underside of the rim in a manner that encloses the
rim flanges inside the air cavity of the tire.
Curb weight
The weight of a motor vehicle with standard equipment including the maximum capacity of fuel, oil, and
coolant, and, if so equipped, air conditioning and additional weight optional engine.
Extra load tire
A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard
tire.
Groove
The space between two adjacent tread ribs.
Gross Axle Weight Rating
The maximum weight that any axle can support, as published on the Certification / VIN label on the front left
side of the trailer. Actual weight determined by weighing each axle on a public scale, with the trailer attached
to the towing vehicle.
Gross Vehicle Weight Rating
The maximum weight of the fully loaded trailer, as published on the Certification / VIN label. Actual weight
determined by weighing trailer on a public scale, without being attached to the towing vehicle.
Hitch Weight
The downward force exerted on the hitch ball by the trailer coupler.
Innerliner
The layer(s) forming the inside surface of a tubeless tire that contains the inflating medium within the tire.
Innerliner separation
The parting of the innerliner from cord material in the carcass.
Page 59 of 145
Intended outboard sidewall
The sidewall that contains a white-wall, bears white lettering or bears manufacturer, brand, and/or model name
molding that is higher or deeper than the same molding on the other sidewall of the tire or the outward facing
sidewall of an asymmetrical tire that has a particular side that must always face outward when mounted on a
vehicle.
Light truck (LT) tire
A tire designated by its manufacturer as primarily intended for use on lightweight trucks or multipurpose
passenger vehicles.
Load rating
The maximum load that a tire is rated to carry for a given inflation pressure.
Maximum load rating
The load rating for a tire at the maximum permissible inflation pressure for that tire.
Maximum permissible inflation pressure
The maximum cold inflation pressure to which a tire may be inflated.
Maximum loaded vehicle weight
The sum of curb weight, accessory weight, vehicle capacity weight, and production options weight.
Measuring rim
The rim on which a tire is fitted for physical dimension requirements.
Pin Weight
th
The downward force applied to the 5 wheel or gooseneck ball, by the trailer kingpin or gooseneck coupler.
Non-pneumatic rim
A mechanical device which, when a non-pneumatic tire assembly incorporates a wheel, supports the tire, and
attaches, either integrally or separably, to the wheel center member and upon which the tire is attached.
Non-pneumatic spare tire assembly
A non-pneumatic tire assembly intended for temporary use in place of one of the pneumatic tires and rims that
are fitted to a passenger car in compliance with the requirements of this standard.
Non-pneumatic tire
A mechanical device which transmits, either directly or through a wheel or wheel center member, the vertical
load and tractive forces from the roadway to the vehicle, generates the tractive forces that provide the
directional control of the vehicle and does not rely on the containment of any gas or fluid for providing those
functions.
Non-pneumatic tire assembly
A non-pneumatic tire, alone or in combination with a wheel or wheel center member, which can be mounted on
a vehicle.
Normal occupant weight
This means 68 kilograms (150 lbs.) times the number of occupants specified in the second column of Table I
of 49 CFR 571.110.
Occupant distribution
The distribution of occupants in a vehicle as specified in the third column of Table I of 49 CFR 571.110.
Open splice
Any parting at any junction of tread, sidewall, or innerliner that extends to cord material.
Outer diameter
The overall diameter of an inflated new tire.
Overall width
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The linear distance between the exteriors of the sidewalls of an inflated tire, including elevations due to
labeling, decorations, or protective bands or ribs.
Ply
A layer of rubber-coated parallel cords.
Ply separation
A parting of rubber compound between adjacent plies.
Pneumatic tire
A mechanical device made of rubber, chemicals, fabric and steel or other materials, that, when mounted on an
automotive wheel, provides the traction and contains the gas or fluid that sustains the load.
Production options weight
The combined weight of those installed regular production options weighing over 2.3 kilograms (5 lbs.) in
excess of those standard items which they replace, not previously considered in curb weight or accessory
weight, including heavy duty brakes, ride levelers, roof rack, heavy duty battery, and special trim.
Radial ply tire
A pneumatic tire in which the ply cords that extend to the beads are laid at substantially 90 degrees to the
centerline of the tread.
Recommended inflation pressure
This is the inflation pressure provided by the vehicle manufacturer on the Tire Information label and on the
Certification / VIN tag.
Reinforced tire
A tire designed to operate at higher loads and at higher inflation pressures than the corresponding standard
tire.
Rim
A metal support for a tire or a tire and tube assembly upon which the tire beads are seated.
Rim diameter
This means the nominal diameter of the bead seat.
Rim size designation
This means the rim diameter and width.
Rim type designation
This means the industry of manufacturer’s designation for a rim by style or code.
Rim width
This means the nominal distance between rim flanges.
Section width
The linear distance between the exteriors of the sidewalls of an inflated tire, excluding elevations due to
labeling, decoration, or protective bands.
Sidewall
That portion of a tire between the tread and bead.
Sidewall separation
The parting of the rubber compound from the cord material in the sidewall.
Special Trailer (ST) tire
The "ST" is an indication the tire is for trailer use only.
Test rim
The rim on which a tire is fitted for testing, and may be any rim listed as appropriate for use with that tire.
Tread
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That portion of a tire that comes into contact with the road.
Tread rib
A tread section running circumferentially around a tire.
Tread separation
Pulling away of the tread from the tire carcass.
Treadwear indicators (TWI)
The projections within the principal grooves designed to give a visual indication of the degrees of wear of the
tread.
Vehicle capacity weight
The rated cargo and luggage load plus 68 kilograms (150 lbs.) times the vehicle’s designated seating capacity.
Vehicle maximum load on the tire
The load on an individual tire that is determined by distributing to each axle its share of the maximum loaded
vehicle weight and dividing by two.
Vehicle normal load on the tire
The load on an individual tire that is determined by distributing to each axle its share of the curb weight,
accessory weight, and normal occupant weight (distributed in accordance with Table I of CRF 49 571.110) and
dividing by 2.
Weather side
The surface area of the rim not covered by the inflated tire.
Wheel center member
In the case of a non-pneumatic tire assembly incorporating a wheel, a mechanical device which attaches,
either integrally or separably, to the non-pneumatic rim and provides the connection between the nonpneumatic rim and the vehicle; or, in the case of a non-pneumatic tire assembly not incorporating a wheel, a
mechanical device which attaches, either integrally or separably, to the non-pneumatic tire and provides the
connection between tire and the vehicle.
Wheel-holding fixture
The fixture used to hold the wheel and tire assembly securely during testing.
1.4. TIRE SAFETY - E VERYTHING RIDES ON IT
The National Traffic Safety Administration (NHTSA) has published a brochure (DOT HS 809 361) that
discusses all aspects of Tire Safety, as required by CFR 575.6. This brochure is reproduced in part below. It
can be obtained and downloaded from NHTSA, free of charge, from the following web site:
http://www.nhtsa.dot.gov/cars/rules/TireSafety/ridesonit/tires_index.html
Studies of tire safety show that maintaining proper tire pressure, observing tire and vehicle load limits (not
carrying more weight in your vehicle than your tires or vehicle can safely handle), avoiding road hazards, and
inspecting tires for cuts, slashes, and other irregularities are the most important things you can do to avoid tire
failure, such as tread separation or blowout and flat tires. These actions, along with other care and
maintenance activities, can also:
Improve vehicle handling
Help protect you and others from avoidable breakdowns and accidents
Improve fuel economy
Increase the life of your tires.
This booklet presents a comprehensive overview of tire safety, including information on the following topics:
Basic tire maintenance
Uniform Tire Quality Grading System
Fundamental characteristics of tires
Page 62 of 145
Tire safety tips.
Use this information to make tire safety a regular part of your vehicle maintenance routine. Recognize that the
time you spend is minimal compared with the inconvenience and safety consequences of a flat tire or other tire
failure.
1.5. SAFETY FIRST–BASIC TIRE M AINTENANCE
Properly maintained tires improve the steering, stopping, traction, and load-carrying capability of your vehicle.
Underinflated tires and overloaded vehicles are a major cause of tire failure. Therefore, as mentioned above,
to avoid flat tires and other types of tire failure, you should maintain proper tire pressure, observe tire and
vehicle load limits, avoid road hazards, and regularly inspect your tires.
1.5.1. FINDING YOUR VEHICLE 'S RECOMMENDED TIRE PRESSURE AND L OAD LIMITS
Tire information placards and vehicle certification labels contain information on tires and load limits. These
labels indicate the vehicle manufacturer's information including:
Recommended tire size
Recommended tire inflation pressure
Vehicle capacity weight (VCW–the maximum occupant and cargo weight a vehicle is designed to carry)
Front and rear gross axle weight ratings (GAWR– the maximum weight the axle systems are designed to
carry).
Both placards and certification labels are permanently attached to the trailer near the left front.
1.5.2. UNDERSTANDING TIRE PRESSURE AND LOAD LIMITS
Tire inflation pressure is the level of air in the tire that provides it with load-carrying capacity and affects the
overall performance of the vehicle. The tire inflation pressure is a number that indicates the amount of air
pressure– measured in pounds per square inch (psi)–a tire requires to be properly inflated. (You will also find
this number on the vehicle information placard expressed in kilopascals (kpa), which is the metric measure
used internationally.)
Manufacturers of passenger vehicles and light trucks determine this number based on the vehicle's design
load limit, that is, the greatest amount of weight a vehicle can safely carry and the vehicle's tire size. The
proper tire pressure for your vehicle is referred to as the "recommended cold inflation pressure." (As you will
read below, it is difficult to obtain the recommended tire pressure if your tires are not cold.)
Because tires are designed to be used on more than one type of vehicle, tire manufacturers list the "maximum
permissible inflation pressure" on the tire sidewall. This number is the greatest amount of air pressure that
should ever be put in the tire under normal driving conditions.
1.5.3. CHECKING TIRE PRESSURE
It is important to check your vehicle's tire pressure at least once a month for the following reasons:
Most tires may naturally lose air over time.
Tires can lose air suddenly if you drive over a pothole or other object or if you strike the curb when
parking.
With radial tires, it is usually not possible to determine underinflation by visual inspection.
For convenience, purchase a tire pressure gauge to keep in your vehicle. Gauges can be purchased at tire
dealerships, auto supply stores, and other retail outlets.
The recommended tire inflation pressure that vehicle manufacturers provide reflects the proper psi when a tire
is cold. The term cold does not relate to the outside temperature. Rather, a cold tire is one that has not been
driven on for at least three hours. When you drive, your tires get warmer, causing the air pressure within them
to increase. Therefore, to get an accurate tire pressure reading, you must measure tire pressure when the tires
are cold or compensate for the extra pressure in warm tires.
Page 63 of 145
1.5.4. STEPS FOR MAINTAINING PROPER TIRE PRESSURE
Step 1: Locate the recommended tire pressure on the vehicle's tire information placard, certification
label, or in the owner's manual.
Step 2: Record the tire pressure of all tires.
Step 3: If the tire pressure is too high in any of the tires, slowly release air by gently pressing on the
tire valve stem with the edge of your tire gauge until you get to the correct pressure.
Step 4: If the tire pressure is too low, note the difference between the measured tire pressure and the
correct tire pressure. These "missing" pounds of pressure are what you will need to add.
Step 5: At a service station, add the missing pounds of air pressure to each tire that is underinflated.
Step 6: Check all the tires to make sure they have the same air pressure (except in cases in which the
front and rear tires are supposed to have different amounts of pressure).
If you have been driving your vehicle and think that a tire is underinflated, fill it to the recommended cold
inflation pressure indicated on your vehicle's tire information placard or certification label. While your tire may
still be slightly underinflated due to the extra pounds of pressure in the warm tire, it is safer to drive with air
pressure that is slightly lower than the vehicle manufacturer's recommended cold inflation pressure than to
drive with a significantly underinflated tire. Since this is a temporary fix, don't forget to recheck and adjust the
tire's pressure when you can obtain a cold reading.
1.5.5. TIRE SIZE
To maintain tire safety, purchase new tires that are the same size as the vehicle's original tires or another size
recommended by the manufacturer. Look at the tire information placard, the owner's manual, or the sidewall of
the tire you are replacing to find this information. If you have any doubt about the correct size to choose,
consult with the tire dealer.
1.5.6. TIRE TREAD
The tire tread provides the gripping action and traction that prevent your vehicle from slipping or sliding,
especially when the road is wet or icy. In general, tires are not safe and should be replaced when the tread is
worn down to 1/16 of an inch. Tires have built-in treadwear indicators that let you know when it is time to
replace your tires. These indicators are raised sections spaced intermittently in the bottom of the tread
grooves. When they appear "even" with the outside of the tread, it is time to replace your tires. Another method
for checking tread depth is to place a penny in the tread with Lincoln's head upside down and facing you. If
you can see the top of Lincoln's head, you are ready for new tires.
1.5.7. TIRE BALANCE AND WHEEL ALIGNMENT
To avoid vibration or shaking of the vehicle when a tire rotates, the tire must be properly balanced. This
balance is achieved by positioning weights on the wheel to counterbalance heavy spots on the wheel-and-tire
assembly. A wheel alignment adjusts the angles of the wheels so that they are positioned correctly relative to
the vehicle's frame. This adjustment maximizes the life of your tires. These adjustments require special
equipment and should be performed by a qualified technician.
1.5.8. TIRE REPAIR
The proper repair of a punctured tire requires a plug for the hole and a patch for the area inside the tire that
surrounds the puncture hole. Punctures through the tread can be repaired if they are not too large, but
punctures to the sidewall should not be repaired. Tires must be removed from the rim to be properly inspected
before being plugged and patched.
1.5.9. TIRE FUNDAMENTALS
Federal law requires tire manufacturers to place standardized information on the sidewall of all tires. This
information identifies and describes the fundamental characteristics of the tire and also provides a tire
identification number for safety standard certification and in case of a recall.
Page 64 of 145
1.5.9.1. Information on Passenger Vehicle Tires
Please refer to the diagram below.
P
The "P" indicates the tire is for passenger vehicles.
Next number
This three-digit number gives the width in millimeters of the tire from sidewall edge to sidewall edge. In
general, the larger the number, the wider the tire.
Next number
This two-digit number, known as the aspect ratio, gives the tire's ratio of height to width. Numbers of 70 or
lower indicate a short sidewall for improved steering response and better overall handling on dry pavement.
R
The "R" stands for radial. Radial ply construction of tires has been the industry standard for the past 20 years.
Next number
This two-digit number is the wheel or rim diameter in inches. If you change your wheel size, you will have to
purchase new tires to match the new wheel diameter.
Next number
This two- or three-digit number is the tire's load index. It is a measurement of how much weight each tire can
support. You may find this information in your owner's manual. If not, contact a local tire dealer. Note: You may
not find this information on all tires because it is not required by law.
M+S
The "M+S" or "M/S" indicates that the tire has some mud and snow capability. Most radial tires have these
markings; hence, they have some mud and snow capability.
Speed Rating
The speed rating denotes the speed at which a tire is designed to be driven for extended periods of time. The
ratings range from 99 miles per hour (mph) to 186 mph. These ratings are listed below. Note: You may not find
this information on all tires because it is not required by law.
Page 65 of 145
Tire Safety Information
Letter Rating
Q
R
S
T
U
H
V
W
Y
Speed Rating
99 mph
106 mph
112 mph
118 mph
124 mph
130 mph
149 mph
168* mph
186* mph
* For tires with a maximum speed capability over 149 mph, tire manufacturers sometimes use the letters ZR.
For those with a maximum speed capability over 186 mph, tire manufacturers always use the letters ZR.
U.S. DOT Tire Identification Number
This begins with the letters "DOT" and indicates that the tire meets all federal standards. The next two
numbers or letters are the plant code where it was manufactured, and the last four numbers represent the
week and year the tire was built. For example, the numbers 3197 means the 31st week of 1997. The other
numbers are marketing codes used at the manufacturer's discretion. This information is used to contact
consumers if a tire defect requires a recall.
Tire Ply Composition and Materials Used
The number of plies indicates the number of layers of rubber-coated fabric in the tire. In general, the greater
the number of plies, the more weight a tire can support. Tire manufacturers also must indicate the materials in
the tire, which include steel, nylon, polyester, and others.
Maximum Load Rating
This number indicates the maximum load in kilograms and pounds that can be carried by the tire.
Maximum Permissible Inflation Pressure
This number is the greatest amount of air pressure that should ever be put in the tire under normal driving
conditions.
1.5.9.2. UTQGS Information
Treadwear Number
This number indicates the tire's wear rate. The higher the treadwear number is, the longer it should take for the
tread to wear down. For example, a tire graded 400 should last twice as long as a tire graded 200.
Traction Letter
This letter indicates a tire's ability to stop on wet pavement. A higher graded tire should allow you to stop your
car on wet roads in a shorter distance than a tire with a lower grade. Traction is graded from highest to lowest
as "AA","A", "B", and "C".
Temperature Letter
This letter indicates a tire's resistance to heat. The temperature grade is for a tire that is inflated properly and
not overloaded. Excessive speed, underinflation or excessive loading, either separately or in combination, can
cause heat build-up and possible tire failure. From highest to lowest, a tire's resistance to heat is graded as
"A", "B", or "C".
Page 66 of 145
1.5.9.3. Additional Information on Light Truck Tires
Please refer to the following diagram.
Tires for light trucks have other markings besides those found on the sidewalls of passenger tires.
LT
The "LT" indicates the tire is for light trucks or trailers.
ST
An "ST" is an indication the tire is for trailer use only.
Max. Load Dual kg (lbs) at kPa (psi) Cold
This information indicates the maximum load and tire pressure when the tire is used as a dual, that is,
when four tires are put on each rear axle (a total of six or more tires on the vehicle).
Max. Load Single kg (lbs) at kPa (psi) Cold
This information indicates the maximum load and tire pressure when the tire is used as a single.
Load Range
This information identifies the tire's load-carrying capabilities and its inflation limits.
1.6. TIRE SAFETY TIPS
Preventing Tire Damage
Slow down if you have to go over a pothole or other object in the road.
Do not run over curbs or other foreign objects in the roadway, and try not to strike the curb when
parking.
Tire Safety Checklist
Check tire pressure regularly (at least once a month), including the spare.
Inspect tires for uneven wear patterns on the tread, cracks, foreign objects, or other signs of wear or
trauma.
Remove bits of glass and foreign objects wedged in the tread.
Make sure your tire valves have valve caps.
Check tire pressure before going on a long trip.
Do not overload your vehicle. Check the Tire Information and Loading Placard or User’s Manual for the
maximum recommended load for the vehicle.
Page 67 of 145
Page 68 of 145
5
B
J
M
J
H
I
U
5
B
J
M
*
H
I
U
Turtle
Light
Red Running Light
Back-Up
Light
Licence
Plate
Light
Red Running Light
Electric Brake
Electric Brake
Turtle
Light
Turtle
Light
Amber Running Light
Amber Running Light
TOP VIEW
4
J
E
F
5
3
B
J
M
F
S
Grey - Turtle Lights
Blue - Brake Control
Green - Right Turn/Brake
Brown - Running Lights
Red - Battery
Yellow - Left Turn/Brake
Orange - Backup
White - Ground
Junction Box Wiring
7
F
I
J
D
M
F
4
J
E
F
5
P
X
0
Q
U
J
P
O
B
M
O
E
#
B
U
U
F
S
Z
Exterior Light
Page 69 of 145
Water Pump
Battery Switch
Water Heater
Optional 110v Inverter
Hella
Socket
4 Gauge
Welding
Cable
Water Heater
Exterior Light
USB
Charger
Stove Switch
Water Pump
Kitchen Light
Shore Power Input
To Battery(S)
Solar Panel
Circuits inside Main Box
Shore Power Battery Charger
Solar Controller
Circuits in Nose Box
Charge Circuit
16ga Grey/Red Stripe
16ga Brown
Exterior Light
DSI Water Heater Switched
16ga Green
Kitchen Light
DSI Switch 12v Power
DSI Water Heater Ground
16ga Blue
Stove Switch to Excite Relay
16ga Black
Switched Water Pump
LED Lighting 12v
Switched LED at Kitchen
16ga Grey
16ga Yellow
Propane Lock-Off Circuit
Ground
Kitchen Light Power
Water Pump Power
DSI Switch Power
Kitchen Circuit
16ga Purple
12ga White
12ga Blue
USB and Hella Plug at Kitchen
Relay Power at Stove Switch
Optional Additional Charge Port
12ga Red
Wire Color Code
Page 70 of 145
Page 71 of 145
PROwatt SW 600 shown.
TM
PO
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FA
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MO
TE
Sine Wave Inverter
PROwatt SW 600
PROwatt SW 1000
PROwatt SW 2000
Owner’s Guide
TM
Page 72 of 145
August 2009 Rev B
Product Numbers
PROwatt SW 600: 806-1206
PROwatt SW 1000: 806-1210
PROwatt SW 2000: 806-1220
Xantrex Technology Inc. (www.xantrex.com), a subsidiary of Schneider Electric, is a
world leader in the development, manufacturing and marketing of advanced power
electronic products and systems for the renewable and mobile power markets. The
company's products convert and control raw electrical power from any central,
distributed, renewable, or backup power source into high-quality power required by
electronic equipment and the electricity grid. Xantrex is headquartered in Vancouver,
Canada, with facilities in the United States, Germany, Spain, and a joint venture in
China.
Trademarks
975-0529-01-01
TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION;
(B) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES,
WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE
OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY
AT THE USER ’S RISK; AND
(C) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH,
ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE
ACCURACY CANNOT BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE
ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.
UNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX TECHNOLOGY INC. (“XANTREX”)
(A) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY
Exclusion for Documentation
[email protected]
www.xantrex.com
Web:
1 800 994 7828 (toll free North America)
1 800 670 0707 (toll free North America)
1 408 987 6030 (direct)
Email:
Fax:
Notice of Copyright
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide © August 2009 Xantrex
Technology Inc. All rights reserved. No part of this document may be reproduced in
any form or disclosed to third parties without the express written consent of: Xantrex
Technology Inc., 161-G South Vasco Road, Livermore, California, USA 94551.
Xantrex Technology Inc. reserves the right to revise this document and to
periodically make changes to the content hereof without obligation or organization of
such revisions or changes unless required to do so by prior arrangement.
Telephone:
Contact Information
Xantrex, PROwatt, and Smart choice for power are trademarks of Schneider
Electric, registered in the U.S. and other countries. Other trademarks, registered
trademarks, and product names are the property of their respective owners and are
used herein for identification purposes only.
975-0529-01-01
Document Part Number
Date and Revision
About Xantrex
i
Page 73 of 145
ii
Warnings identify conditions that could result in personal injury
or loss of life.
WARNING
The following conventions are used in this guide.
Conventions Used
The Guide is intended for users and operators of the PROwatt™ SW Sine
Wave Inverter.
Audience
The Guide provides safety guidelines, as well as information about
operating, installing, and troubleshooting the inverter. It does not provide
details about particular brands of batteries. You need to consult individual
battery manufacturers for this information.
Xantrex recommends that installation should be handled by qualified
installers including licensed technicians and electricians. Qualified
installers have knowledge and experience in installing electrical equipment,
knowledge of the applicable installation codes, and awareness of the
hazards involved in performing electrical work and how to reduce those
hazards.
Scope
The purpose of this Owner’s Guide is to provide explanations and
procedures for operating, installing, maintaining, and troubleshooting the
PROwatt™ SW Sine Wave Inverter.
Purpose
About This Guide
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
The product marking on the left (yellow background, black
exclamation point) when found imprinted on electrical and
electronic units and appliances means that you are to refer to
this guide for cautions and warnings.
You can find more information about Xantrex Technology Inc. as well as
its products and services at www.xantrex.com.
Related Information
Important: These notes describe things which are important for you to
know, however, they are not as serious as a caution or warning.
Cautions identify conditions or practices that could result in
damage to the unit or other equipment.
CAUTION
Page 74 of 145
Do not expose the PROwatt™ SW Sine Wave Inverter to rain, snow,
spray, or bilge water. To reduce risk of fire hazard, do not cover or
obstruct the ventilation openings. Overheating may result.
To avoid a risk of fire and electric shock, make sure that wiring is in
good condition, adequately rated, and not undersized. Do not operate
the PROwatt™ SW Sine Wave Inverter with damaged or substandard
wiring.
975-0529-01-01
2.
1.
WARNING: Shock, fire, and heat hazard. Risk of
injury to persons.
This chapter contains important safety instructions for the PROwatt™ SW
Sine Wave Inverter.
Before using the PROwatt™ SW Sine Wave Inverter, READ ALL
instructions and cautionary markings on or provided with the PROwatt™
SW Sine Wave Inverter, the batteries, and all appropriate sections of this
guide.
IMPORTANT: READ AND SAVE THIS OWNER’S GUIDE FOR FUTURE
REFERENCE.
Important Safety Instructions
Do not operate the PROwatt™ SW Sine Wave Inverter if it has
received a sharp blow, been dropped, or otherwise damaged in any
way. If the PROwatt™ SW Sine Wave Inverter is damaged, see the
Warranty section.
Do not disassemble the PROwatt™ SW Sine Wave Inverter. It
contains no user-serviceable parts. See Warranty for instructions on
obtaining service. Attempting to service the PROwatt™ SW Sine
Wave Inverter yourself may result in a risk of electrical shock or fire.
Internal capacitors remain charged after all power is disconnected.
To reduce the risk of electrical shock, disconnect DC power from the
PROwatt™ SW Sine Wave Inverter before attempting any
maintenance or cleaning or working on any circuits connected to the
PROwatt™ SW Sine Wave Inverter. Turning off controls will not
reduce this risk.
1.
iii
Follow all instructions published by the battery manufacturer and the
manufacturer of the equipment in which the battery is installed to
reduce the risk of battery explosion.
WARNING: Explosion or fire hazard.
Precautions When Working With Batteries
5.
4.
3.
Page 75 of 145
iv
8.
7.
4.
5.
6.
3.
2.
Remove all metal items, like rings, bracelets, and watches when
working with lead-acid batteries. Lead-acid batteries produce a short
circuit current high enough to weld metal to skin, causing a severe
burn.
WARNING: Risk of personal injury due to burns
or battery acid.
Working in the vicinity of lead-acid batteries is dangerous. Batteries
generate explosive gases during normal operation. Therefore, you
must read this guide and follow the instructions exactly before
installing or using your PROwatt™ SW Sine Wave Inverter.
This equipment contains components which tend to produce arcs or
sparks. To prevent fire or explosion, do not operate the PROwatt™
SW Sine Wave Inverter in compartments containing batteries or
flammable materials, or in locations that require ignition-protected
equipment. This includes any space containing gasoline-powered
machinery, fuel tanks, as well as joints, fittings, or other connections
between components of the fuel system.
Make sure the area around the battery is well ventilated.
Never smoke or allow a spark or flame near the engine or batteries.
Use caution to reduce the risk or dropping a metal tool on the battery.
It could spark or short circuit the battery or other electrical parts and
could cause an explosion.
If you need to remove a battery, always remove the ground terminal
from the battery first. Make sure all accessories are off so you don’t
cause a spark.
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
Have someone within range of your voice or close enough to come to
your aid when you work near a lead-acid battery.
10. Have plenty of fresh water and soap nearby in case battery acid
contacts skin, clothing, or eyes.
11. Wear complete eye protection and clothing protection. Avoid touching
your eyes while working near batteries.
12. If battery acid contacts skin or clothing, wash immediately with soap
and water. If acid enters your eye, immediately flood it with running
cold water for at least twenty minutes and get medical attention
immediately.
9.
Page 76 of 145
975-0529-01-01
This device complies with Part 15 of the FCC rules. Operation
is subject to the following two conditions:
(1) This device may not cause harmful interference and
(2) this device must accept any interference received, including
interference that might cause undesired operation.
NOTE: This equipment has been tested and found to comply
with the limits for a Class A digital device, pursuant to part 15
of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the
equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own
expense.
WARNING
FCC Statement
v
Page 77 of 145
Warranty and Return Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
Contents
Page 78 of 145
975-0529-01-01
This Guide contains information about all three models. Unless
specified by the model name, all features, functions, and instructions will pertain to all models. All the models of the inverter will be
referred to collectively as PROwatt SW Inverter.
There are three PROwatt SW Inverter models in the series namely:
• PROwatt SW 600,
• PROwatt SW 1000, and
• PROwatt SW 2000.
PROwatt SW Inverter Series
Thank you for purchasing the PROwatt™ SW Sine Wave Inverter.
The PROwatt SW Inverter is a high quality, true sine wave output
inverter. It is designed to operate AC loads as if these loads were
operating from grid/utility supplied power in household AC outlets.
To get the most out of your PROwatt™ SW Sine Wave Inverter,
carefully read and follow the instructions in this guide.
Introduction
•
540 watts
900 watts
1800 watts
PROwatt SW 600
PROwatt SW 1000
PROwatt SW 2000
3000 watts
2000 watts
1200 watts
Surge Power
1
The unit’s low standby battery demand means you don’t have
to worry about excessive drain on your battery if you leave the
inverter on for a few days. When the inverter is on but no power
is being supplied to a load, the inverter draws less than 800 mA
from the battery.
Continuous
Model
The PROwatt SW Inverter is a professional-quality, mid-range
inverter designed to handle a variety of applications including
compact microwaves, TVs, VCRs, coffee makers, and small power
tools.
• The PROwatt SW Inverter provides optimal continuous power,
making it ideal for large single loads, intermittent loads, or
multiple smaller loads.
• The inverter’s high surge capability lets you handle many hardto-start loads, including large TVs, refrigerators, and freezers.
Quality Power
Page 79 of 145
Alerts you if the battery has become discharged
to 11 V or lower.
Low battery voltage
alarm
2
De-energizes the AC circuits and thereby
protects the user from electric shock if a ground
fault occurs.
GFCI protection
The PROwatt SW Inverter is equipped with the following protection
features:
Comprehensive Protection
Superior features and rugged durability have been combined with
ease of use:
• The unit is compact, light weight, and easy to install.
• You can power loads directly from the dual GFCI-protected
AC receptacles on the front panel.
• Easy-to-read digital display on the front panel lets you monitor
system performance at a glance.
• The optional PROwatt Remote Panel lets you control the
inverter from a convenient location—up to 25 feet (7.6 m)
away—while the inverter itself is mounted out of sight and
close to the batteries.
• A convenient USB port powers most modern electronic
products.
Ease of Use
Introduction
Shuts the inverter down automatically if the
input voltage rises to more than 15.5 V. Within
five minutes after shutdown, the unit recovers
automatically once the battery voltage falls
below 15.5 Vdc. After five minutes, the unit
turns itself off.
Shuts the unit down automatically if a short
circuit occurs or if the loads attached to the
inverter exceed the operating limits.
Turns the inverter off if its temperature rises
above an acceptable level. Within five minutes
after shutdown, the unit recovers automatically
once the temperature of the unit cools down.
After five minutes of operating in high
temperature, the unit turns itself off.
High battery voltage
shutdown
AC output overload
shutdown
Over temperature
shutdown
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
Automatically shuts the inverter down if the
battery voltage drops below 10.5 V. This feature
protects the battery from being completely
discharged. Within five minutes after
shutdown, the unit recovers automatically once
the battery voltage reaches above 11.5 Vdc.
After five minutes, the unit turns itself off.
Low battery voltage
shutdown
Page 80 of 145
975-0529-01-01
The PROwatt SW Inverter can also be installed with the PROwatt
Remote Panel that comes with a 25-foot (7.6 m) communications
cable (part number 808-9001).
For ordering information, please contact Customer Service (see
“Contact Information” on page i of this guide). Please reference the
part number above when ordering.
Optional Accessory
Your PROwatt SW Inverter package includes these items:
• PROwatt SW Inverter unit,
• Owner’s Guide.
If any of these materials are missing or are unsatisfactory in any
way, please contact Customer Service (see “Contact Information”
on page i of this guide).
Materials List
The following information describes the main features of the
PROwatt SW Inverter. We recommend that you familiarize yourself
with these features before installing and operating the unit.
Features
Mounting flanges
E
OT
REM
LT
FAU
Digital Display
R
WE
PO
AC Outlets
(GFCI-protected)
ventilation openings
Figure 1 PROwatt SW Inverter (PROwatt SW 600 shown)
Optional PROwatt Remote Panel (not shown)
DC Input
Owner’s Guide
3
Page 81 of 145
POWER
REMOTE
FAULT
4
5
6
7
Indicator LEDs
Green LED indicates that the unit is on and receiving
power. When a shutdown occurs due to an error
condition the Green LED remains on.
Red LED indicates an error or alarm condition.
Digital Display
Shows input voltage (in volts), output power (in
kilowatts), and error code information.
1
2
4
Description
Feature
Figure 2 PROwatt SW Inverter Front Panel (PROwatt SW 600 shown)
3
2
1
Front Panel Details
Features
GFCI-protected AC Outlets
Equipped with two AC outlets that are protected by a
standard Ground Fault Circuit Interruptor (GFCI)
device with reset and test buttons.
Ventilation Holes
Allows internal heat to escape.
6
7
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
USB Port
Powers and charges USB-enabled devices.
5
Remote Switch Port
Use to connect the optional PROwatt Remote Panel
via a communications cable.
Power Switch Button
Turns the inverter ON or OFF.
3
4
Description
Feature
Page 82 of 145
2
3
4
Positive (+) DC Terminal
Accepts lug or ring connectors appropriate to the
cable size being used. See Table 1 : Voltage Drop
Per Foot of DC Cable on page 10 for
recommendations.
Cooling Fan
Automatically turns on when internal temperature
reaches more than 122 °F (50 °C). It turns off when
the internal temperature falls below 122 °F (50 °C).
1
2
975-0529-01-01
Description
Feature
Figure 3 PROwatt SW Inverter Back Panel (PROwatt SW 600 shown)
1
Back Panel Details
Serial No.
Description
Chassis Ground (GND) Terminal
Negative (–) DC Terminal
Accepts lug or ring connectors appropriate to the
cable size being used. See Table 1 : Voltage Drop
Per Foot of DC Cable on page 10 for
recommendations.
Feature
3
4
5
Features
Page 83 of 145
6
If you do not have some electrical knowledge and
knowledge of local electrical codes or are not comfortable
installing cables yourself, use a qualified installer
including a licensed technician and electrician. Qualified
installers have knowledge and experience in installing
electrical equipment, knowledge of the applicable
installation codes, and awareness of the hazards involved
in performing electrical work and how to reduce those
hazards.
WARNING
Determine a charging system.
Choose a location.
Mount the inverter.
Connect the chassis ground.
Connect the battery cables.
2.
3.
4.
5.
6.
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
Determine battery capacity.
1.
Basic Installation Steps
•
•
•
•
•
•
Follow all instructions from this guide and instructions including
safety guidelines from the battery manufacturer. Installing battery
cables require some electrical knowledge and local electrical codes.
Adjustable wrench for fastening DC terminal bolts,
Two battery cables (copper, appropriately sized according to
application) with connectors already crimped by the company
or store where you purchased the cables,
Ground cable (copper, appropriately sized) for attaching to the
ground chassis,
DC-rated fuses (and fuse holders),
Screwdriver (flathead and Philips), power screwdriver, or
power drill for use in mounting the inverter,
Mounting screws (4) size #10.
Tools and Materials
Guidelines
Installation
Page 84 of 145
975-0529-01-01
The charging system must be appropriate for your particular
installation. A well-designed charging system will ensure that
power is available when you need it and that your batteries remain
in top condition. Inadequate charging will degrade system
performance and the wrong type of charger will reduce battery life.
For a list of Xantrex Battery Chargers, go to www.xantrex.com or
contact Customer Service (see “Contact Information” on page i of
this guide).
Determine A Charging System
The PROwatt SW Inverter must only be connected to a
battery that has a nominal output of 12 volts. The PROwatt
SW Inverter will:
• Not operate if connected to a 6 volt battery and
• Be damaged if connected to a 24 volt battery.
CAUTION: Risk of inverter damage.
Battery type and battery size strongly affect the performance of the
PROwatt SW Inverter. Therefore, you need to identify the type of
loads your inverter will be powering and how much you will be
using them between charges. Once you know how much power you
will be using, you can determine how much battery capacity you
need. Xantrex recommends that you purchase as much battery
capacity as possible.
Determine Battery Capacity
To reduce the risk of fire, do not cover or obstruct the
ventilation openings. Do not install the PROwatt SW
Inverter in a zero-clearance compartment. Overheating
may result.
WARNING
Do not install the PROwatt SW Inverter in a wet
environment or in any other environment where moisture
can occur and enter the inverter enclosure through the
ventilation openings. This unit is not intended for marine
applications.
WARNING: Risk of electrical shock.
7
The PROwatt SW Inverter contains components that tend
to produce arcs or sparks. To prevent fire or explosion, do
not install the inverter in compartments containing
batteries or flammable materials or in locations that
require ignition-protected equipment.
CAUTION: Risk of inverter damage.
Choose A Location
Installation
Ambient air temperature should be between
32 ºF and 104 º F (0 ºC and 40 º C)—the cooler
the better within this range.
Allow at least 2 inches (5 cm) of clearance
around the inverter for air flow. Ensure that
ventilation openings on the DC end and the
bottom of the unit are not obstructed.
Do not install the inverter in the same
compartment as batteries or in any
compartment capable of storing flammable
liquids like gasoline.
Cool
Ventilated
Safe
8
Protected from
battery gases
Do not mount the inverter where it will be
exposed to gases produced by the batteries.
These gases are very corrosive and prolonged
exposure will damage the inverter.
Close to battery Do not use excessive DC cable lengths: they
increase wire resistance and reduce input
power.
Do not allow water or other liquids to drop or
splash on the inverter.
Dry
Fasten the inverter to the mounting surface using corrosionresistant hardware sized #10.
4.
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
Pilot-drill the four mounting holes.
REMOTE
FAULT
3.
POWER
On or under a horizontal surface.
DC connections should NOT
point up or down.
Horizontally on a vertical surface or
Hold the inverter against the mounting surface and mark the
positions using the mounting flanges as guide.
•
•
Select an appropriate mounting location and orientation. The
unit can be oriented in any way, such as:
2.
1.
Mount The Inverter
REMOTE
FAULT
Installation
POWER
Page 85 of 145
Page 86 of 145
975-0529-01-01
Recreational
Vehicle
Connect the CHASSIS GND screw to the
vehicle’s chassis using a minimum 8 AWG
copper wirea (preferably with green/yellow
insulation).
The chassis ground terminal must be connected to a grounding
point. The grounding point varies depending on where you install
the PROwatt SW Inverter. Follow the guidelines that correspond to
your type of installation.
The PROwatt SW Inverter has a screw terminal labeled CHASSIS
GND on the outside of the rear panel as shown in Figure 3,
“PROwatt SW Inverter Back Panel (PROwatt SW 600 shown)” on
page 5.
Follow the guidelines below to connect the inverter’s chassis to the
ground.
Grounding Locations
Never operate the PROwatt SW Inverter without
connecting it to the ground. Electrical shock hazard could
result.
WARNING: Risk of electrical shock.
Connect the Chassis Ground
Connect the CHASSIS GND screw to your
system’s DC grounding point using a minimum
6 AWG wirea. The system’s grounding point is
usually the AC service entrance grounding
point or a separate ground rod. For a solar PV
(photovoltaic) installation, this is usually the
same rod used to ground the PV array.
9
To operate safely and effectively, the PROwatt SW Inverter needs
proper DC cables and DC-rated fuse(s). Because the PROwatt SW
Inverter has low-voltage and high-current input, low-resistance
wiring between the battery and the inverter is essential to deliver the
maximum amount of usable energy to your load.
Important: Use of a qualified installer strongly recommended.
Connect The Battery Cables
a.Xantrex recommends that the grounding conductor (grounding wire) should be the same wire
size as the DC cables.
Fixed Location
Installation
Page 87 of 145
10
Follow these guidelines and refer to Table 1 : Voltage Drop Per
Foot of DC Cable on page 10 to determine battery cable lengths.
• Use 4 AWG copper (90 ºC insulation rating) as the smallest
battery cable size. This will minimize the voltage drop between
the battery and the inverter. If the cables cause an excessive
voltage drop, the inverter may shut down when drawing higher
currents because the voltage at the inverter input drops below
10.5 volts.
• Keep all cables as short as possible, and ensure that each cable
between the inverter and the battery is no longer than 6 feet
(1.8 m).
• Have all wires and cables terminated with correct and
appropriately-sized connectors and have the connectors
crimped at the place of purchase.
• Do not use aluminum. It has about 1/3 more resistance than
copper cable of the same size, and it is difficult to make good,
low-resistance connections to aluminum wire.
Cabling Guidelines
Installation
0.000253
0.000201
0.000159
0.000126
0.000100
0.000079
0.000063
0.000050
4
3
2
1
0
2/0
3/0
4/0
0.0030
0.0038
0.0048
0.0060
0.0076
0.0096
0.0121
0.0152
150
1500
0.0050
0.0063
0.0079
0.0100
0.0126
0.0159
0.0201
0.0253
0.0075
0.0095
0.0119
0.0150
0.0189
0.0239
0.0302
0.0380
Voltage Drop per Foot
100
1000
0.0150
0.0189
0.0237
0.0300
0.0378
0.0477
0.0603
0.0759
300
3000
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
Note: Voltage Drop per foot = Current value × Resistance value
So for a 600 W inverter output with a DC cable of size 0, multiply
the maximum current of 60 A with 0.000100. The result is 0.00600
voltage drop per feet. If the cable is 6 feet long, the total voltage
drop is 0.00600 × 6 ( × 2) = 0.072. (Cable length multiplied by 2.)
So for a battery operating at 12.6 V at battery terminal the voltage at
the inverter terminal drops to 12.53 V.
Note: Xantrex recommends a size 0 cable with a maximum cable
length of 6 feet (1.8 m).
For example:
Resistance
(ohms/ft)
@ 25 °C
60
Current (A)
Wire
Size
(AWG)
600
Inverter
Output (W)
Table 1 : Voltage Drop Per Foot of DC Cable
Page 88 of 145
Once you have determined the total cold cranking amp rating of
your batteries, identify the corresponding Ampere Interrupting
Capacity (AIC) of the fuse or breaker required for your system
by referring to Table 2.
For example:
• If you are using one battery to power your inverter and its
rating is 500, the total cold cranking amp rating is 500.
• If you are powering your inverter with two batteries in
parallel, and each has a rating of 500, the total cold
cranking amp rating is 1000.
Note: The cold cranking amp rating of each battery is displayed
on the battery case. If it is not, contact the battery manufacturer
to find out.
Determine the total cold cranking amp rating for your
battery(s).
975-0529-01-01
2.
1.
To select the correct fuse type and size:
Because batteries can produce thousands of amps, you are required
to install DC-rated fuses (or circuit breakers) that can safely
withstand the short-circuit current batteries can produce.
Fuse/Circuit Breaker Sizing Guidelines
3000
5000
651–1100
over 1100
ANL Fuse
80 A
150 A
250 A
Model
PROwatt SW 600
PROwatt SW 1000
PROwatt SW 2000
250 A
150 A
80 A
Class T
1500
650 or less
Table 3 Fuse Ratings
Ampere Interrupting Capacity
(AIC)
Total Cold Cranking
Amps
Table 2 Cold Cranking Amps / AIC
11
Installation
Note: The AIC is the amount of battery short-circuit amperage
that the fuse can safely withstand.
• If the Total Cold Cranking Amps indicate that the AIC is
2,700 amps or less, see Table 3 for the correct ANL fuse.
• If the Total Cold Cranking Amps indicate that the AIC is
up to 200,000 amps or if you require a “code fuse”, see
Table 3 for the correct Class T fuse.
Page 89 of 145
FUSE OR
CIRCUIT
BREAKER
FUSE OR
CIRCUIT
BREAKER
DEEP-CYCLE
AUXILIARY
BATTERY
GROUND TO
VEHICLE
CHASSIS
12
Figure 4 Configuration for Normal Loads
TO OTHER
DC LOADS
GROUND TO
VEHICLE
CHASSIS
ISOLATOR
GROUND TO
VEHICLE
CHASSIS
TO VEHICLE
VEHICLE
STARTING
BATTERY
FROM ALTERNATOR
OR CHARGER
Consult the following configurations and determine a match
specific to your installation and follow the installation procedure
“To connect the battery cables:” that comes next.
Cabling Procedure
Installation
1
2
ALL
OFF
BATTERY
SELECTOR
SWITCH
FUSE OR
CIRCUIT
BREAKER
1
2
ALL
OFF
DEEP-CYCLE
BATTERY
DEEP-CYCLE
BATTERY
ISOLATOR
Line up the connectors that will join the cables to the battery,
battery selector switch, and fuse (or circuit breaker).
2.
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
Make sure the inverter is off and assemble the terminated
cables (cables with connectors) that you bought.
1.
To connect the battery cables:
FUSE OR
CIRCUIT
BREAKER
DEEP-CYCLE
BATTERY
GROUND TO
VEHICLE
CHASSIS
GROUND TO
VEHICLE
CHASSIS
TO VEHICLE
DEEP-CYCLE
BATTERY
VEHICLE
STARTING
BATTERY
GROUND TO
VEHICLE
CHASSIS
FUSE OR
CIRCUIT
BREAKER
Figure 5 Configuration for Heavy Loads
TO OTHER
DC LOADS
BATTERY
SELECTOR
SWITCH
FUSE OR
CIRCUIT
BREAKER
FROM ALTERNATOR
OR CHARGER
Page 90 of 145
On the inverter side, attach the connectors of the positive and
negative cables into the cabling terminals of the inverter.
5.
975-0529-01-01
Note: Make a secure connection. Loose connectors cause
excessive voltage drop and may cause overheated wires and
melted insulation.
Note: The red terminal is positive (+) and the black terminal is
negative (–). Power connections to the PROwatt SW Inverter
must be positive to positive and negative to negative.
When configuring for heavy loads (see Figure 5), install a
battery selector switch and connect it to the DC-rated fuse (or
circuit breaker).
Alternatively, install a DC-rated circuit breaker that connects to
the positive battery terminal.
The fuse (or circuit breaker must have an Ampere Interrupting
Capacity (AIC) that exceeds the short-circuit current available
from the battery. For guidance, see “Cold Cranking Amps /
AIC” on page 11.
Install a DC-rated fuse on the positive battery terminal.
4.
3.
The PROwatt SW Inverter does not come with a DC-rated
fuse (or circuit breaker) to safely withstand the shortcircuit current batteries can produce. To avoid the risk of
electrical shock or fire, install a DC-rated fuse (and fuse
holder) on the positive battery terminal.
WARNING: Risk of electrical shock or fire.
6.
13
Do not complete the next step if flammable fumes are
present. Explosion or fire may result. Thoroughly ventilate
the battery compartment before making this connection.
WARNING: Risk of explosion or fire.
When configuring for heavy loads (see Figure 5), attach the
connector on the positive cable to the battery selector switch
that is already connected to the DC-rated fuse (or circuit
breaker).
Note: Make a secure connection. Loose connectors cause
excessive voltage drop and may cause overheated wires and
melted insulation.
Attach the connector on the positive cable to the DC-rated fuse
(or circuit breaker) which is connected to the positive terminal
of the battery.
A reverse polarity connection (positive to negative) will
blow a fuse in the inverter and may permanently damage
the unit. Damage caused by a reverse polarity connection
is not covered by your warranty.
CAUTION: Risk of inverter damage due to
reverse polarity.
Installation
Page 91 of 145
Turn on the inverter.
9.
14
The other indicators should be off.
10. Check the front panel of the inverter. The digital display should
show 12–13 volts, depending on the voltage of the battery. If it
does not, check your battery and the connection to the inverter.
If you have installed a battery selector switch, use it to select
one of the batteries or battery banks.
Note: This is the last cable connection. You may observe a
spark when making this last connection.
Note: Make a secure connection. Loose connectors cause
excessive voltage drop and may cause overheated wires and
melted insulation.
Attach the connector on the negative cable to the negative
battery terminal.
8.
7.
Installation
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
Page 92 of 145
Press the inverter’s power switch button (for one second) to
turn Off the inverter (from On).
2.
975-0529-01-01
If you are going to operate several loads from the PROwatt SW
Inverter, turn them on separately after you have turned the inverter
on.
This will ensure that the inverter does not have to deliver the
starting current for all the loads at once.
Operating Several Loads at Once
The unit’s power switch when turned off does not
disconnect power from the PROwatt SW Inverter.
WARNING: Risk of electrical shock.
Note: When the inverter’s power switch button is Off, the
inverter draws no current from the battery.
Press the inverter’s power switch button (for half a second) to
turn On the inverter (from Off).
15
Important: Test the GFCI periodically to make sure it is operating
correctly.
The AC outlets are Ground Fault Circuit Interrupter (GFCI) outlets.
This protects you against hazardous electrical shocks that could be
caused by dampness, faulty mechanism in the appliance, worn
insulation, etc. GFCI-protected outlets cut off hazardous electrical
shocks quickly enough so an adult in normal health is not seriously
injured (infants and small children may still be affected).
GFCI-Protected AC Outlets
When the power switch is on but no power is being supplied to a
load, the inverter draws less than 800 mA from the battery. This is a
low current draw. It would take a week to discharge a 150 Ah
battery at this current, so you don’t have to worry about excessive
drain on your battery if you leave the inverter switched on for a few
days.
If you are not planning to recharge your battery within a week or so,
switch the inverter off.
The power switch on the inverter’s front panel turns the control
circuit in the PROwatt SW Inverter on and off.
To toggle the inverter on and off from its front panel:
1.
Turning the Inverter Off Between Charges
Turning the Inverter On and Off
Operation
Page 93 of 145
Plug a test lamp into the AC outlet.
Push the TEST button.
2.
3.
If the Green LED is On, it indicates that the unit is On. Under
normal operating conditions, the AC outlets and USB port have
power. However, even under an error condition such as a
shutdown, the Green LED may still remain On.
If the Red LED is on, it indicates an error or alarm condition
and an error code is displayed on the digital display underneath
the LED.
16
•
•
Under normal operating conditions, the digital display shows
the input voltage (in volts) and the output power (in kilowatts).
Under error or alarm conditions, the digital display shows an
error code and the Red LED turns on.
Digital Display
•
•
Indicator LEDs
Reading the Front Panel Indicators
Note: The RESET button should pop out and the power should
turn Off (the lamp should go out). If the lamp remains lit, or if
the RESET button does not pop out, the GFCI may not be
functioning.
If the GFCI trips by itself at any time, reset it and perform the
preceding test.
Press the unit’s power switch to turn the inverter On.
1.
To test (or reset) the GFCI protection:
Operation
Under voltage alarm and/or
Under voltage shutdown
Over voltage shutdown
Over load shutdown
Over temperature shutdown
(...
(...
(...
(...
Red
Red
Red
Red
Remove all AC loads or let the unit cool down for 15 minutes.
Press and hold the unit’s power switch to turn it On.
2.
3.
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
Press and hold the unit’s power switch to turn it Off.
1.
Restarting After an AC Output Shutdown
Note: The audio alarm will sound for five minutes. After five
minutes, the unit will turn off.
Short circuit or output circuit
overheat
Example: 0.25 Kw (250 watts)
...
Green
(...
Example: 13.5 volts
...
Green
Red
Description
Digital Display
LED
Description of LED and Digital Display Codes
Page 94 of 145
540 W
900 W
1800 W
PROwatt SW 600
PROwatt SW 1000
PROwatt SW 2000
15 A
7.5 A
4.5 A
13 Vdc
Ambient
25 °C
(77 °F)
Tempera
ture
10.5–15.5 V
Normal
975-0529-01-01
Voltage Range
Operating
Condition
n/a
Comment
The input voltage limits are shown in the following table.
Input Voltage
a.Applies to resistive loads such as incandescent lights.
b.Applies to reactive loads such as motors.
Power
Model
a
Output Input
Currentb Voltage
The PROwatt SW Inverter will deliver the following power
continuously, depending on input voltage and ambient temperature.
The inverter will deliver more than 10% of its continuous power
rating for approximately five minutes. The inverter must cool down
for 15 minutes before it can resume operation above its continuous
power rating.
Power Output
Operating Limits
Voltage is
The unit shuts down to
15.5 V or more. protect itself from
excessive input voltage.
Note: Although the
PROwatt SW Inverter
incorporates overvoltage protection, it can
still be damaged if input
voltage exceeds 16 V.
11.5 V
High Voltage
Shutdown
Unit restarts after
low voltage
shutdown
17
The unit will not restart
unless the battery
voltage is acceptable for
running the load.
The unit shuts down to
protect the battery from
being over-discharged.
Voltage is
10.5 V or less.
Low Voltage
Shutdown
Comment
The audible low battery
alarm sounds.
Voltage Range
Voltage is
11.0 V or less
Low Voltage Alarm
n/a
Operating
Condition
13–14.5 V
Peak Performance
Operation
Page 95 of 145
When possible, recharge your batteries when they are about 50%
discharged or earlier. This gives them a much longer life cycle than
recharging when they are almost completely discharged. For
information about battery chargers, see our web site at
www.xantrex.com.
USB Loads
A lot of USB-powered devices such as portable music (MP3)
players, mobile phones, and video game players can be charged and
powered safely via the standard USB port. However, some devices
such as portable GPS receivers and certain cameras may not work
and even cause damage even if you use the USB cable that came
with the product. Be sure that the device only accepts 5 volts and
can be charged or powered using other sources of power. See the
device’s owner’s guide under specifications for information.
18
Some induction motors used in freezers, pumps, and other motoroperated equipment need high surge currents to start. The PROwatt
SW Inverter may not be able to start some of these motors even
though their rated current draw is within the inverter’s limits.
If a motor refuses to start, observe the VOLTS indicator while you
are trying to start the motor. If the indicator drops below 11 volts
while the PROwatt SW Inverter is trying to start the motor, this may
explain why the motor won’t start. Make sure the length and
Exceptional Loads
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
Routine maintenance is required to keep your PROwatt SW Inverter
operating properly. Periodically you should:
• Clean the exterior of the unit with a damp cloth to prevent the
accumulation of dust and dirt.
• Tighten the screws on the DC input terminals.
Maintenance
Battery Charging Frequency
The PROwatt SW Inverter will operate many AC loads within its
power rating. However, some appliances and equipment may be
difficult to operate. Please see “Exceptional Loads” below carefully.
Inverter Loads
diameter of the battery cables are appropriate. Check that the battery
connections are good and that the battery is fully charged. If the
cables are sized correctly, the connections are good, and the battery
is charged, but the voltage still drops below 11 volts, you may need
to use a larger battery.
Operation
Page 96 of 145
Under Voltage (low
input) shutdown
Poor DC wiring
and/or poor battery
condition
Over Voltage (high
input) shutdown
(...
(...
with persistent low
battery alarm.
(...
975-0529-01-01
Possible Cause
Condition
Troubleshooting Reference
Make sure the
inverter is connected
to a 12 V battery.
Use proper cable and
make secure
connections.
Charge the battery or
install a new battery.
Recharge the battery.
Check cables and
connection if secure.
Solution
Do not dismantle the PROwatt SW Inverter. It does not
contain any user-serviceable parts. Attempting to service
the unit yourself could result in an electrical shock or burn.
WARNING: Electrical shock and burn hazard.
Troubleshooting
(...
Normal load is
connected then AC
output becomes
unavailable.
(...
Heavy load is
connected then AC
output becomes
unavailable.
(...
Condition
Over temperature
shutdown
Over temperature
shutdown
Overload shutdown
Possible Cause
19
Improve ventilation
and make sure the
inverter’s ventilation
openings are not
obstructed.
Reduce the ambient
temperature, if
possible.
Allow the inverter to
cool off and reduce
the load if
continuous operation
is required.
Reduce the load
within the inverter’s
continuous power
rating.
Solution
Page 97 of 145
Remove the load.
Turn the unit off.
Let the unit cool
down, check the fan
for any obstructions
and clear it, or
reduce the load.
Turn the unit back
on.
Very heavy load
Output circuit
overheat
20
Check the AC
wiring for a short
circuit.
Short circuit
(...
No output voltage.
Solution
Possible Cause
Condition
Troubleshooting
Turn the inverter on.
Check wiring to the
inverter.
Have a qualified
service technician
check and replace
the fuse if necessary.
Have a qualified
service technician
check and replace
the fuse, making
sure to observe
correct polarity.
Reset the GFCI. See
page 16 for
instructions.
The GFCI device
tripped.
Solution
The unit is off.
No power to the
inverter.
Inverter fuse open.
Reverse DC polarity.
Possible Cause
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
The unit is on and
running but there is
no AC output.
No output voltage;
no voltage
indication.
Condition
Page 98 of 145
540 W
Continuous power
975-0529-01-01
600 W
Peak power (5 minutes)
600
900 W
1000 W
1000
10.5 V
Low battery cutout
AC / USB Output
Audible, 11 V
Low battery alarm
93 A
10.5–15.5 Vdc
60 A
Input current
(max at full load)
1200 VA
Input voltage range
720 VA
Input power (max at full load)
1000
1800 W
2000 W
2000
200 A
2400 VA
2000
32–104 °F (0–40 °C)
Operating temperature
600
6.5 lbs. (3.0 kg)
7.2 lbs. (3.3 kg)
10.6 lbs. (4.8 kg)
Weight
•
PROwatt SW 600
•
PROwatt SW 1000
•
PROwatt SW 2000
DC Input
12.2×8.7×3.5 inch. (31×22×8.9 cm)
14×9×3.5 inch. (35×22×8.5 cm)
13.8×11.8×3.9 inch. (35×30×10 cm)
Length × Width × Height
•
PROwatt SW 600
•
PROwatt SW 1000
•
PROwatt SW 2000
Physical and Environmental Specifications
Note: Specifications are subject to change without prior notice.
Specifications
5.8 A
< 600 mA
Output current (max)
No load current draw
General Use Power Supplies
Electromagnetic Compatibility (EMC)
FCC Part 15, Class A
21
Power Converters/Inverters and Power Converter/
Inverter Systems for Land Vehicles and Marine
Crafts
CSA 107.1-01
UL 458 5th edition
Regulatory Approvals
5 Vdc, 500 mA
USB Output
60 Hz ±0.5Hz
Output frequency
Approximately 85–90%
True sine wave
Output waveform
< 800 mA
19.2 A
15 A
3000 W
2000
Efficiency
104–127 Vac
120 Vac RMS ±5%
< 600 mA
9.6 A
7.5 A
2000 W
1000
Output voltage range
Output voltage (nominal)
4.6 A
1200 W
600
Output current (continuous)
Surge power
AC / USB Output
Page 99 of 145
22
What does this warranty cover and how long does it last? This
Limited Warranty is provided by Xantrex Technology Inc.
("Xantrex") and covers defects in workmanship and materials in
your PROwatt™ SW Sine Wave Inverter. This warranty period
lasts for 24 Months from the date of purchase at the point of sale to
you, the original end user customer, unless otherwise agreed in
writing (the “Warranty Period”). You will be required to
demonstrate proof of purchase to make warranty claims.
This Limited Warranty is transferable to subsequent owners but
only for the unexpired portion of the Warranty Period. Subsequent
owners also require original proof of purchase as described in
"What proof of purchase is required?"
What will Xantrex do? During the Warranty Period Xantrex will,
at its option, repair the product (if economically feasible) or replace
the defective product free of charge, provided that you notify
Xantrex of the product defect within the Warranty Period, and
provided that Xantrex through inspection establishes the existence
of such a defect and that it is covered by this Limited Warranty.
Xantrex will, at its option, use new and/or reconditioned parts in
performing warranty repair and building replacement products.
Xantrex reserves the right to use parts or products of original or
improved design in the repair or replacement. If Xantrex repairs or
replaces a product, its warranty continues for the remaining portion
of the original Warranty Period or 90 days from the date of the
Warranty
Warranty and Return Information
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
Direct returns may be performed according to the Xantrex Return
Material Authorization Policy described in your product manual.
For some products, Xantrex maintains a network of regional
Authorized Service Centers. Call Xantrex or check our website to
see if your product can be repaired at one of these facilities.
Telephone: 1 800 670 0707 (toll free North America)
1 408 987 6030 (direct)
Fax:
1 800 994 7828 (toll free North America)
Email:
[email protected]
Website:
www.xantrex.com
return shipment to the customer, whichever is greater. All replaced
products and all parts removed from repaired products become the
property of Xantrex.
Xantrex covers both parts and labor necessary to repair the product,
and return shipment to the customer via a Xantrex-selected nonexpedited surface freight within the contiguous United States and
Canada. Alaska, Hawaii and outside of the United States and
Canada are excluded. Contact Xantrex Customer Service for details
on freight policy for return shipments from excluded areas.
How do you get service? If your product requires troubleshooting
or warranty service, contact your merchant. If you are unable to
contact your merchant, or the merchant is unable to provide service,
contact Xantrex directly at:
Page 100 of 145
975-0529-01-01
What does this warranty not cover? Claims are limited to repair
and replacement, or if in Xantrex's discretion that is not possible,
reimbursement up to the purchase price paid for the product.
Xantrex will be liable to you only for direct damages suffered by
you and only up to a maximum amount equal to the purchase price
of the product.
This Limited Warranty does not warrant uninterrupted or error-free
operation of the product or cover normal wear and tear of the
product or costs related to the removal, installation, or
troubleshooting of the customer's electrical systems. This warranty
does not apply to and Xantrex will not be responsible for any defect
in or damage to:
a) the product if it has been misused, neglected, improperly
installed, physically damaged or altered, either internally or
externally, or damaged from improper use or use in an
unsuitable environment;
b) the product if it has been subjected to fire, water, generalized
corrosion, biological infestations, or input voltage that creates
What proof of purchase is required? In any warranty claim,
dated proof of purchase must accompany the product and the
product must not have been disassembled or modified without prior
written authorization by Xantrex.
Proof of purchase may be in any one of the following forms:
• The dated purchase receipt from the original purchase of the
product at point of sale to the end user; or
• The dated dealer invoice or purchase receipt showing
original equipment manufacturer (OEM) status; or
• The dated invoice or purchase receipt showing the product
exchanged under warranty.
23
Warranty and Return Information
operating conditions beyond the maximum or minimum limits
listed in the Xantrex product specifications including but not
limited to high input voltage from generators and lightning
strikes;
c) the product if repairs have been done to it other than by Xantrex
or its authorized service centers (hereafter "ASCs");
d) the product if it is used as a component part of a product
expressly warranted by another manufacturer;
e) component parts or monitoring systems supplied by you or
purchased by Xantrex at your direction for incorporation into
the product;
f) the product if its original identification (trade-mark, serial
number) markings have been defaced, altered, or removed;
g) the product if it is located outside of the country where it was
purchased; and
h) any consequential losses that are attributable to the product
losing power whether by product malfunction, installation error
or misuse.
Page 101 of 145
24
IN NO EVENT WILL XANTREX BE LIABLE FOR: (a) ANY SPECIAL,
INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, INCLUDING
LOST PROFITS, LOST REVENUES, FAILURE TO REALIZE EXPECTED
SAVINGS, OR OTHER COMMERCIAL OR ECONOMIC LOSSES OF ANY
KIND, EVEN IF XANTREX HAS BEEN ADVISED, OR HAD REASON TO
KNOW, OF THE POSSIBILITY OF SUCH DAMAGE; (b) ANY LIABILITY
ARISING IN TORT, WHETHER OR NOT ARISING OUT OF XANTREX'S
NEGLIGENCE, AND ALL LOSSES OR DAMAGES TO ANY PROPERTY OR
FOR ANY PERSONAL INJURY OR ECONOMIC LOSS OR DAMAGE CAUSED
BY THE CONNECTION OF A PRODUCT TO ANY OTHER DEVICE OR
SYSTEM; AND (c) ANY DAMAGE OR INJURY ARISING FROM OR AS A
RESULT OF MISUSE OR ABUSE, OR THE INCORRECT INSTALLATION,
INTEGRATION OR OPERATION OF THE PRODUCT BY PERSONS NOT
AUTHORIZED BY XANTREX.
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
If this product is a consumer product, federal law does not allow an
exclusion of implied warranties. To the extent you are entitled to
implied warranties under federal law, to the extent permitted by
applicable law they are limited to the duration of this Limited
Warranty. Some states, provinces and jurisdictions do not allow
limitations or exclusions on implied warranties or on the duration of
an implied warranty or on the limitation or exclusion of incidental
or consequential damages, so the above limitation(s) or exclusion(s)
may not apply to you. This Limited Warranty gives you specific
legal rights. You may have other rights which may vary from state
to state, province to province or jurisdiction to jurisdiction.
Product
THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY
PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX
PRODUCT AND IS, WHERE PERMITTED BY LAW, IN LIEU OF ALL OTHER
WARRANTIES, CONDITIONS, GUARANTEES, REPRESENTATIONS,
OBLIGATIONS AND LIABILITIES, EXPRESS OR IMPLIED, STATUTORY OR
OTHERWISE IN CONNECTION WITH THE PRODUCT, HOWEVER ARISING
(WHETHER BY CONTRACT, TORT, NEGLIGENCE, PRINCIPLES OF
MANUFACTURER'S LIABILITY, OPERATION OF LAW, CONDUCT,
STATEMENT OR OTHERWISE), INCLUDING WITHOUT RESTRICTION ANY
IMPLIED WARRANTY OR CONDITION OF QUALITY, MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE. ANY IMPLIED WARRANTY
OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO
THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE
PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD
STIPULATED UNDER THIS LIMITED WARRANTY.
Exclusions
Disclaimer
Warranty and Return Information
Page 102 of 145
25
Package the unit safely, preferably using the original box and
packing materials. Please ensure that your product is shipped fully
insured in the original packaging or equivalent. This warranty will
not apply where the product is damaged due to improper packaging.
Include the following:
• The RMA number supplied by Xantrex Technology Inc.
clearly marked on the outside of the box.
• A return address where the unit can be shipped. Post office
boxes are not acceptable.
• A contact telephone number where you can be reached
during work hours.
• A brief description of the problem.
Ship the unit prepaid to the address provided by your Xantrex
customer service representative.
If you are returning a product from outside of the USA or
Canada In addition to the above, you MUST include return freight
funds and are fully responsible for all documents, duties, tariffs, and
deposits.
If you are returning a product to a Xantrex Authorized Service
Center (ASC) A Xantrex return material authorization (RMA)
number is not required. However, you must contact the ASC prior to
returning the product or presenting the unit to verify any return
procedures that may apply to that particular facility and that the
ASC repairs this particular Xantrex product.
For those products that are not being repaired in the field and are
being returned to Xantrex, before returning a product directly to
Xantrex you must obtain a Return Material Authorization (RMA)
number and the correct factory "Ship To" address. Products must
also be shipped prepaid. Product shipments will be refused and
returned at your expense if they are unauthorized, returned without
an RMA number clearly marked on the outside of the shipping box,
if they are shipped collect, or if they are shipped to the wrong
location.
When you contact Xantrex to obtain service, please have your
instruction manual ready for reference and be prepared to supply:
• The serial number of your product
• Information about the installation and use of the unit
• Information about the failure and/or reason for the return
• A copy of your dated proof of purchase
Record these details on page 26.
975-0529-01-01
Return Procedure
Return Material Authorization Policy
Warranty and Return Information
Page 103 of 145
806-1206
806-1210
806-1220
______________________
______________________
❐ Product Number/s
❐ Purchased From
❐ Purchase Date
26
❐ Battery/battery bank size
has been installed
❐ Length of time inverter
RV, truck)
❐ Type of installation (e.g.
______________________
______________________
______________________
If you need to contact Customer Service, please record the
following details before calling. This information will help our
representatives give you better service.
______________________
❐ Serial Number
As soon as you open your PROwatt™ SW Sine Wave Inverter
package, record the following information and be sure to keep your
proof of purchase.
Information About Your System
Warranty and Return Information
______________________
______________________
Xantrex PROwatt™ SW Sine Wave Inverter Owner’s Guide
________________________________________________
________________________________________________
❐ Description of problem
when problem occurred
❐ Appliances operating
on front panel
______________________
______________________
❐ Alarm sounding?
❐ Description of indicators
______________________
______________________
❐ DC wiring size and length
sealed gel cell, AGM)
❐ Battery type (e.g. flooded,
Page 104 of 145
975-0529-01-01
1 800 670 0707 Tel toll free NA
1 408 987 6030 Tel direct
1 800 994 7828 Fax toll free NA
[email protected]
www.xantrex.com
Xantrex Technology Inc.
Printed in China
Page 105 of 145
Atwood Mobile Products garantit ce produit à l'acheteur initial, suivant les
termes stipulés ci-dessous, contre tout défaut de matériel ou de fabrication,
pendant une période de deux ans à compter de la date d'achat d’origine.
La responsabilité d'Atwood décrite ci-dessous se limite au remplacement, à
la réparation ou au remplacement du produit par un produit reconditionné, à
la discrétion du fabricant. La présente garantie est annulée si le produit est
endommagé du fait d’un accident, d’une utilisation non raisonnable, d’une
négligence, d’une modification du produit ou de toute autre cause non liée
au matériau ou à un vice de fabrication. La présente garantie ne s'applique
qu'à l'acheteur initial et elle est soumise aux conditions suivantes :
1. Pendant une période de deux ans, à compter de la date d'achat, Atwood
remplacera tout le chauffe-eau si le réservoir interne fuit pour des raisons
de corrosion. La présente garantie couvre les frais raisonnables de maind’œuvre nécessaires au remplacement du chauffe-eau.
2. Pendant deux ans, à compter de la date d'achat, Atwood réparera ou
remplacera toute pièce trouvée défectueuse en raison du matériau ou d'un
vice de fabrication. La présente garantie couvre les frais raisonnables de
main-d’œuvre nécessaires au retrait et au remplacement de la pièce. Les
visites pour l’entretien chez le client ne sont pas prises en charge et
restent donc la responsabilité du client.
3. La présente garantie ne couvre pas les articles suivants, qui sont
considérés comme faisant partie de l’entretien régulier :
a. réglage de la pression du gaz
b. nettoyage ou remplacement de l’orifice du brûleur
c. nettoyage ou réglage du tube du brûleur
d. nettoyage ou réglage du conduit
e. nettoyage ou réglage de la veilleuse et du thermocouple
f. réglage de la soupape de décharge de type pression-température
g. remplacement du dispositif de coupure thermique
4. Dans l'éventualité d'une réclamation de garantie, l’acheteur doit
contacter, à l'avance, soit un Centre de service Atwood agréé, soit le
Service à la clientèle Atwood. La réclamation de garantie doit être
exécutée dans un Centre de service Atwood agréé (une liste vous
sera fournie gratuitement) ou selon les procédures reconnues par le
Service clientèle Atwood (Consumer Service Department) Atwood
Mobile Products, 1120 North Main St., Elkhart IN 46514 États-Unis.
Téléphone : (574) 264-2131.
GARANTIE LIMITÉE POUR
CHAUFFE-EAU ATWOOD
Atwood Mobile Products warrants to the original owner and subject to the
below mentioned conditions, that this product will be free of defects in
material or workmanship for a period of two years from the original date of
purchase. Atwood’s liability hereunder is limited to the replacement of the
product, repair of the product, or replacement of the product with a
reconditioned product at the discretion of the manufacturer. This warranty
is void if the product has been damaged by accident, unreasonable use,
neglect, tampering or other causes not arising from defects in material
workmanship. This warranty extends to the original owner of the product
only and is subject to the following conditions:
1. For a period of two years from the date of purchase, Atwood will
replace the complete water heater if the inner tank leaks due to
corrosion. This warranty includes reasonable labor charges required to
replace the complete water heater.
2. For two years from the date of purchase, Atwood will repair or replace
any part defective in material or workmanship. This warranty includes
reasonable labor charges, required to remove and replace the part.
Service calls to customer’s location are not considered part of these
charges and are, therefore, the responsibility of the owner.
3. This warranty does not cover the following items classified as normal
maintenance:
a. adjustment of gas pressure
b. cleaning or replacement of burner orifice
c. cleaning or adjustment of burner tube
d. cleaning or adjustment of flue
e. cleaning or adjustment of pilot and thermocouple
f. adjustment of pressure-temperature relief valve
g. replacement of thermal cut-off device.
4. In the event of a warranty claim, the owner must contact, in
advance, either an authorized Atwood Service Center or the
Atwood Service Department. Warranty claim service must be
ATWOOD WATER HEATER
LIMITED WARRANTY
16
5. Les pièces retournées (ou le chauffe-eau) doivent être expédiées à
Atwood, tout port payé. Un avoir pour les frais d'expédition sera compris
avec la réclamation de garantie. Les pièces défectueuses (ou le chauffeeau) deviennent la propriété d’Atwood Mobile Products et doivent être
retournées à Consumer Service Department, Atwood Mobile Products,
6320 Kelly Willis Road, Greenbrier, TN 37073 États-Unis.
6. La présente garantie est valide uniquement si l'unité est installée selon les
consignes d'installation fournies, en conformité avec les codes locaux et
nationaux.
7. La période de garantie pour les pièces de remplacement (ou le chauffeeau) est la période inutilisée de la période de garantie initiale ou quatrevingt-dix (90) jours, selon ce qui est le plus long.
8. Tout dommage ou toute déficience résultant d'une mauvaise utilisation (y
compris le manquement à faire effectuer les réparations nécessaires),
d'une mauvaise mise en application, de modifications, de dommages
causés par l'eau ou par le gel relèvent de la responsabilité de l’acheteur.
9. Atwood n’est aucunement responsable de l’impossibilité d’utiliser le
véhicule, de toute perte de temps, de tout dérangement et de tous frais
d'essence, de téléphone, de déplacement, de logement, de perte ou de
dommages aux biens personnels ou de perte de revenus. Certains États
ne permettent pas l’exclusion ou la limitation des dommages accessoires
ou indirects ; il est donc possible que les limitations ou exclusions cidessus ne s'appliquent pas à votre cas.
10. Toute garantie implicite est limitée à une période de deux (2) ans.
Certains États ne permettent pas de limiter la période d'une garantie
implicite, donc il est possible que la limite ci-dessus ne vous concerne
pas. La présente garantie vous accorde des droits légaux particuliers
mais il est également possible que vous ayiez certains droits
supplémentaires, selon les États.
11. Les pièces de remplacement (composantes ou réservoirs) achetées en
dehors de la garantie initiale du chauffe-eau sont couvertes par une
garantie de 90 jours ; ceci comprend la pièce sans frais et les frais
raisonnables de main-d'œuvre découlant du remplacement.
Ce chauffe-eau Atwood est conçu pour utilisation en véhicule de plaisance et
dans le but de chauffer l'eau comme le stipule la plaque signalétique fixée au
chauffe-eau. Toute autre utilisation, à moins d’une autorisation écrite du
Service technique Atwood, annule la présente garantie.
performed at an authorized Atwood Service Center (a list will be
provided at no charge) or as approved by the Consumer Service
Department, Atwood Mobile Products, 1120 North Main St., Elkhart,
IN 46514 USA. Phone: (574-264-2131).
5. Return parts (or water heater) must be shipped to Atwood “Prepaid”.
Credit for shipping costs will be included with the warranty claim. The
defective parts (or water heater) become the property of Atwood Mobile
Products and must be returned to the Consumer Service Department,
Atwood Mobile Products, 6320 Kelly Willis Road, Greenbrier, TN
37073 USA.
6. This warranty applies only if the unit is installed according to the installation instructions provided and complies with local and state codes.
7. The warranty period on replacement parts (or water heater) is the
unused portion of the original warranty period or ninety (90) days,
whichever is greater.
8. Damage or failure resulting from misuse (including failure to seek proper
repair service), misapplication, alterations, water damage, or freezing
are the owner’s responsibility.
9. Atwood does not assume responsibility for any loss of use of vehicle,
loss of time, inconvenience, expense for gasoline, telephone, travel,
lodging, loss or damage to personal property or revenues. Some states
do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitations or exclusions may not apply to you.
10. Any implied warranties are limited to two (2) years. Some states do not
allow limitations on how long an implied warranty lasts, so the above
limitation may not apply to you. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state.
11. Replacement parts (components or tanks) purchased outside of the
original water heater warranty carry a 90 day warranty. This includes
the part at no charge and reasonable labor charges to replace it.
This Atwood heater is designed for use in recreational vehicles for the purpose
of heating water as stated in the “data plate” attached to the water heater. Any
other use, unless authorized in writing by the Atwood Engineering Department,
voids this warranty.
(et Canada)
CAUTION
avoid possible
injury and/or property damage
16˝
16˝
WIDTH
HEIGHT
DEPTH
18.5˝
21.8˝
WARNING
FIRE OR EXPLOSION
12.5˝
15.5˝
25 lbs
32 lbs
SHIPPING WT.
6 GALLON
10 GALLON
WHAT TO DO IF YOU SMELL GAS
• Evacuate ALL persons from vehicle.
• Shut off gas supply at gas container or source.
• DO NOT touch any electrical switch, or use any phone or
radio in vehicle.
• DO NOT start vehicle’s engine or electric generator.
• Contact nearest gas supplier or qualified Service Technician
for repairs.
• If you cannot reach a gas supplier or qualified Service
Technician, contact the nearest fire department.
• DO NOT turn on gas supply until gas leak(s) has been
repaired.
Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
U If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
6 GALLON
10 GALLON
ALL MODEL
DIMENSIONS
Installation and service must be performed by a qualified Service
Technician, Service Center, OEM or Gas Supplier.
avoid possible
injury or death
WARNING
Safety Symbols alerting you to potential personal safety hazards.
Obey all safety messages following these symbols.
SAFETY ALERT SYMBOLS
SERVICE CALLS & QUESTIONS
Location and phone numbers of qualified Service Centers can
be found at our website http:/www.atwoodmobile.com or call
574-262-2655 to have a Service Center List mailed.
This water heater design has been certified by the Canadian
Standards Association for installation in recreation vehicles. This
water heater is not for use in marine applications.
ENGLISH, FRANCAIS
1
MPD 93050
WEIGHT ................................................................ 1
DIMENSIONS .......................................................... 1
MODEL IDENTIFICATION ............................................1
....................................................4
....................................................5
E
H
I6
-
EXT®
Effective Capacity**
Engine Heat Exchanger
Electric
Gas
Electronic XT*
calculated gallons of 130˚F moderated water is 9 gallons and 16 gallons.
* EXT® indicates Electronic Exothermal (XT) technology.
** Water heater actual capacity is 6 and10 gallon respectively. Effective capacity,
G
EXPLANATION OF MODEL NUMBER
PART IDENTIFICATION
FIGURES
................................................................................6-7
....................................................................8
Water Heater WARRANTY ..............................................................16
Flushing to Remove Unpleasant Odor ..................................................5
Pressure-Temperature Relief Valve
Preventative Maintenance ................................................................4
Winterizing (Flushing) Instructions ....................................................5
Maintenance and Care Instructions
Consumer Safety Warnings ..............................................................2
How to Operate Your Water Heater ..................................................3-4
Wiring
Cutout Chart
Pressure - Temperature Relief Valve
Water Heater GENERAL INSTALLATION
SAFETY INFORMATION
WATER HEATER
Effective 10/13/09
s)NSTALLATION s/PERATION s-AINTENANCE
PATENT # 7,020,386
G16EXT, GE16EXT, GEH16EXT
XT® Models: G9EXT, GE9EXT, GEH9EXT
6 & 10 GALLON
L.P. GAS
WATER HEATER
LITERATURE NUMBER
Page 106 of 145
- FOLLOW ALL APPLICABLE STATE AND LOCAL CODES -
®
• When using Romex with a bare earth ground, take care to position
ground wire so it does not contact the heating element terminals.
PRODUCT DAMAGE
CAUTION
COMBINATION GAS/ELECTRIC MODELS are designed to operate with gas,
electricity, or a combination of both.
• Use electrical metallic tubing, flexible metal conduit, metal clad
cable, or nonmetallic-sheathed cable with grounding conductor. Wire
must have a capacity of 1400 watts or greater. The wiring method
must conform to applicable sections of article 551 of National
Electrical Code ANSI/NFPA 70.
1. Refer to Wiring Diagram (FIG 12). Make 120 VAC electrical
connections from junction box on back of unit.
a. Connect hot lead to (1) Black.
b. Connect common lead to (2) White.
c. Connect ground wire from electrical service to (3) green ground
lead in junction box 3.
All wiring must comply with applicable electrical codes.
WIRING
1. Locate water heater on floor of coach before erecting side walls.
The water heater tank must be permanently supported at the same
level as the bottom of sidewall cutout (by the floor or a raised floor)
FIG 2. Provide adequate clearance at rear of unit for service of water
connections.
2. To install water heater on carpeting, you must install appliance on a
metal or wood panel that extends at least three inches beyond the
full width and depth of appliance.
3. If the appliance is installed where connection or tank leakage will
damage adjacent area, install a drain pan (which can be drained to
out side of coach) under water heater.
This is a common installation for water heaters. There are other
approved methods such as Flush Mount (MPD 93948) installations.
Consult with your Field Auditor, Account Manager, or the Atwood
Service Department if you have additional questions.
GENERAL INSTALLATION
• Recreation Vehicles ANSI A119.2/NFPA 501C.
• National Fuel Gas Code ANSI Z223.1 and/or CAN/CGA B149 Installation Codes
• Federal Mobile Home Construction & Safety Standard, Title 24 CFR, part
3280, or when this Standard is not applicable, the Standard for Manufactured
Home Installations (Manufactured Home Sites, Communities and Set-Ups),
ANSI A255.1 and/or CAN/CSA-Z240 MH Series, Mobile Homes.
• National Electrical Code ANSI/NFPA No. 70 and/or CSA C22.1
• Park Trailers A119.5
• CSA standard Z240 RV Series, Recreational Vehicle.
• ASSE Standard 1017 (Mixing Value).
• NSF Standard ANSI/NSF 14-2003 (All Hoses and Plastic Fittings).
IN THE ABSENCE OF LOCAL CODES OR REGULATIONS, REFER TO CURRENT STANDARDS OF:
USA AND CANADA
• Install in recreation vehicles only. RV’s are recreation vehicles
designed as temporary living quarters for recreation, camping, or
travel use having their own power or towed by another vehicle.
• All combustion air must be supplied from outside the RV, and all
products of combustion must be vented to outside the RV.
• DO NOT vent water heater with venting system serving another
appliance.
• DO NOT vent water heater to an outside enclosed porch area.
• Protect building materials from flue gas exhaust.
• Install water heater on an exterior wall, with access door opening to
outdoors.
• DO NOT modify water heater in any way.
• DO NOT alter water heater for a positive grounding system.
• DO NOT HI-POT water heater unless electronic ignition system
(circuit board) has been disconnected.
• DO NOT use battery charger to supply power to water heater even
when testing.
CRITICAL INSTALLATION WARNINGS
2
CUT OUT DIMENSION
1-A
1-B
12-5/8˝
16-1/4˝
15-3/4˝
16-1/4˝
FIG
1.
DEPTH
2-C
18.5˝
21.75˝
6. Bend all flanges 90˚ along scored lines (FIG 3-A).
7. To prevent water leaks caulk thoroughly around opening, including
bend slots. Butyl Tape (1-1/3˝x1/8˝) may be substituted for caulking
material.
8. Push unit against caulking, secure 4-corner brackets (FIG 3-B) to
coach with No. 8 - 3/4˝ round head screws (not furnished) or equivalent.
Complete the installation by inserting the same type of #8 screws in the
holes provided around the flange of the water heater housing. Check all
gaskets, they must adhere to the pan creating an air tight seal.
MINIMUM CLEARANCE FROM COMBUSTIBLE CONSTRUCTION
Sides:
0˝
Top:
0˝
Back:
0˝
Bottom:
0˝
CAPACITY
Gallon
6
10
CUTOUT (FIG 1 & 2)
5. Erect side walls and cut opening. See chart and
Frame with 2x2 lumber (or equivalent).
• Do not lift, pull, push or misalign the main burner tube (FIG 3-F).
PRODUCT DAMAGE
CAUTION
CONTINUE GENERAL INSTALLATION
4. Connect both 1/2˝ NPT water lines (FIG 2) hot water outlet female
and cold water inlet female and 3/8˝ flared LP gas line to the water
heater (FIG 9).
a. Allow flexibility in water and gas lines so you can pull unit
forward through wall one inch past skin.
b. Seal gas line entrance opening (FIG 9) by sliding grommet (9-B)
onto 3/8˝ tubing (9-D) before flaring tubing (9-E). Pull gas line and
grommet through opening in housing (9-A). Connect flare fitting
(9-C) and press grommet into opening. If gas line tubing is
already flared, cut grommet on one side. Place split grommet
over gas line and press it into opening.
c. Always use pipe lubricant on threads when connecting hot and
cold water couplings. A suitable plastic fitting is recommended.
HEAT EXCHANGE MODELS - FIG 5
1. Push a 5/8˝ diameter coolant system hose (5-A) [with SAE 053 A
Type “E”clamp attached] onto heat exchanger tube (5-B) making a
tight connection.
2. Spread hose clamp and slide toward heat exchange unit past
annular groove (5-C) and release.
3. Continue to HOW TO OPERATE YOUR WATER HEATER and/or Electronic
Ignition OPERATION.
1. Refer to Wiring Diagram (FIG 12). Install remote switch in a
convenient location. Position wall plate with letters up. Before
making connections turn switch OFF.
2. Install wires see FIG 10 & 11.
ELECTRONIC IGNITION
NOTE: It is recommended unit be connected directly to a 12V DC
battery or to filtered side of an AC/DC converter. Avoid connections to
unfiltered side of an AC/DC converter whenever possible. Use a
minimum of 18 gauge wire, UL and CSA listed.
• Label all wires before disconnecting when servicing controls.
• Verify proper operation after servicing.
ELECTRICAL DAMAGE
CAUTION
• When a cord and plug connection to the power supply are used on
water heater, power cord must be UL listed as suitable for damp
locations, hard or extra hard usage. It must be a flexible cord such
as type S, SO, ST, STO, SJ, SJT, SJTO, HS or HSO cord as described
in National Electrical Code, ANSI/NFPA 70. The length of external
cord to water heater, measured to face of attachment plug, shall be
no less than 2 feet nor more than 6 feet. Supply cord must be a
minimum of 14 AWG and attachment plug must be rated at 15 amps.
15
INTENTIONALLY LEFT BLANK
Page 107 of 145
Tank Maintenance
ELECTRONIC MODEL—Check electrode for cracks and gap (Spark probe and Ground gap should be 1/8”)
PILOT MODEL—Check orifice for contamination. Clean if flame is low, replace assembly if cleaning fails.
Check Alignment of Burner tube and Orifice—Must be straight
Periodically clean Burner Tube with small brush
Check air adjustment of Burner by positioning the air shutter 1/4 open (blue flame with small trace of yellow).
Periodically clear all obstructions in Burner Orifice and pilot Assembly (dirt, spider webs, etc.)
Winterizing
Turn off the main water supply (pump or water hook-up source).
Drain the water heater by removing the drain plug. If the water flows sporadically or trickles instead of a steady stream, we recommend the following
action: First, open the Pressure/Temperature relief Valve to allow air into the tank and Second, using a small gauge wire or coat hanger, poke through
the drain coupling to dislodge any obstructions.
With the tank drained, approximately two quarts of water remain in the bottom (note drain plug position in illustration above). This water contains
most of the harmful corrosive particles. To remove these materials, Atwood recommends use of a commercially available “RV Water Heater Flushing
Tool”. Simply running water through the inlet does not stir up and flush out all sediment. The wand of a flushing tool allows you to move around at
different angles inside the tank with a higher pressure water jet, suspending and flushing the materials back out of the drain coupling. Continue flushing
until the water being flushed from the drain coupling runs clear.
Replace the drain Plug.
14
90091 07/10/2009
Use of Aftermarket Heating Element Devices (Hot Rods) can lead to an out-of-control heating of water in the tank and catastrophic wet side explosion.
These devices lack critical safety controls. Personal injury and product damage may result. Replacing the Atwood drain plug with an Anode Rod will damage the coupling with cathodic action and product damage will result. Atwood water heater tanks are constructed of a high strength aluminum. The interior
of the tank consists of a .0015 thick, type 7072 clad aluminum (pure aluminum and zinc) fused to the core in the rolling process. This material protects the
tank from the affects of heavy metals and salts found throughout North America. It is anodic to these heavy metals and acts much like an anode in a steel
glass-lined tank, except it lasts much longer.
Use of Aftermarket Heating Elements or Anode Devices are not compatible with Atwood Water Heaters and will void the warranty!
If the water heater has been altered the Warranty will be Void
Altering Atwood Water Heaters
If you experience low flow from the hot water faucet or notice the water is not as hot coming from the water heater, you may have to have the Mixing Valve
serviced by a Certified Service Technician. Low flow or cold flow from the XT water heater is a result of corrosion on the seats and/or debris blocking the
inlet screen (if equipped) of the mixing valve. When the technician removes the mixing valve, cleans the screen (if equipped) and soaks the valve in a hot
white vinegar bath, he will also complete the “Flushing the Tank” procedure as corrosion and sediment from improper “Tank Maintenance” is the cause of
this condition.
XT Models—Special Requirements
A Pressure Temperature Relief Valve, dripping while the water heater is in use, DOES NOT mean it is defective. During normal use, water expands as it is
heated in the closed water system. The Atwood water heater is designed with an internal air gap at the top of the tank to absorb the expansion and reduce
the dripping. In time, this air gap will be absorbed and need to be restored. To restore the Air Gap:
1. Turn off the main water supply (pump or water hook-up source) and allow water to cool.
2. Open the nearest hot water faucet to the water heater.
3. Pull the handle on the Pressure Temperature Relief Valve straight out and allow water to flow until it stops flowing.
4. Trip the handle on the relief valve allowing it to snap shut, shut off the hot water faucet, turn on the water supply, and turn the water heater on. Test.
Dripping Pressure Temperature Relief Valve
A “rotten egg odor” (hydrogen sulfide) may be produced when the electro galvanic action of the cladding material releases hydrogen from the water. If
sulfur is present in the water supply the two will combine and produce an unpleasant smell. To remedy the problem, first complete the (4) steps in “Flushing
the Tank” above. When the tank is flushed, perform the following:
1. Remove the Pressure/Temperature relief Valve. Mix a solution of (4) parts white vinegar to (2) parts water. (For a 6 gallon tank, use (4) gallons of vine
gar to (2) gallons of water.) With a funnel, carefully pour the solution into the tank through the P&T coupling. Re-install the P&T Relief Valve.
2. Turn on the water heater and allow the water to heat up through a full cycle (this may take up to 45 minutes.) It is recommended you allow the water
heater to operate through 3 or 4 additional heat maintenance cycles.
3. Turn off and allow to cool. When cool, remove the drain plug and drain. Then repeat Steps 3 and 4 of “Flushing the Tank” above.
4. Refill the tank with fresh water that contains no sulfur.
Unpleasant Odors
Prior to storing your RV, Follow Steps 1-4 of “Flushing the Tank” above. Note: The approximately (2) quarts of water that remains in the bottom of the
tank will not cause freeze damage to the tank. Caution!: An un-drained tank, (water level above the drain plug level), will crack the tank in freezing conditions.
4.
3.
1.
2.
Flushing the Tank
sediment deposits that shorten the life of the tank, element, relief valve, and Mixing Valve (XT Models). (Lack of proper maintenance of the tank will cause
Mixing Valves on XT Models to malfunction, requiring costly service procedures to clean and/or replace at the owner’s expense.)
Failure to follow these instructions May result in Denial of Your Warranty Coverage!
Caution! Always turn off the main water supply (pump or water supply hook-up), allow the water to cool, then drain the tank by removing drain plug.
Frequency: Full-Time RV’er, Every (60) days (Southwest US, every (30) days). Part-Time RV’er, Minimum of 2X annually (Southwest, every (90) days).
Reason: The Life of the tank and performance of the water heater are directly affected by water quality! High mineral content will cause corrosion and
•
•
•
•
•
•
General—Burner Maintenance
Preventative Maintenance Requirements—Preservation of Warranty and Water Heater Life Extension
DO NOT use matches, candles or other sources of ignition when
checking for gas leaks.
WARNING
Valve is not serviceable, it must be replaced.
Replacement by a Certified Service Technician only.
Tampering with valve will result in scalding injury.
Tampering with valve will void warranty.
SCALDING INJURY
temperature and pressure relief valve that complies with the standard
for Relief Valves and Automatic Gas Shutoff Devices for Hot Water
Systems, ANSI Z21.22.
If you use a discharge line, do not use a reducing coupling or other
restriction smaller than outlet of relief valve. Allow complete drainage
of both valve and line.
THIS VALVE IS A SAFETY COMPONENT AND MUST NOT BE REMOVED FOR ANY REASON
OTHER THAN REPLACEMENT. This water heater is equipped with a
pressure-temperature relief valve.
s DO NOT place a valve, plug or reducing coupling on outlet part of
EXPLOSION
WARNING
s Tampering with valve will void warranty.
s Valve is not serviceable, it must be replaced.
s Tampering with valve will result in scalding injury.
SCALDING INJURY
WARNING
PRESSURE-TEMPERATURE RELIEF VALVE - (FIG 3-G)
(moderating) valve which mixes cold water with higher temperature
water to moderate outlet water to approximately 130˚F. It is also
equipped with a higher temperature thermostat, raising the storage
water temperature.
THIS VALVE IS A SAFETY COMPONENT AND MUST NOT BE REMOVED FOR ANY REASON
OTHER THAN REPLACEMENT. REMOVAL FOR REPLACEMENT BY A CERTIFIED SERVICE
TECHNICIAN ONLY. The water heater is equipped with a mixing
s
s
s
s
MIXING VALVE - (FIG 9)
11. Turn on gas and check water heater and all connections for gas
leaks with leak detecting solution.
12. Fill water heater tank, check all connections for water leaks.
s
FIRE AND/OR EXPLOSION
WARNING
9. Attach access door.
a. Snap hinge pin (FIG 3-C) into clip (FIG 3-D).
b. Slide cover (FIG 3-E) onto hinge pin.
c. Slide hinge pin into cover, snapping into clip at same time (FIG 3-D).
NOTE: To remove hinge pin, support access cover and apply force to
corner of hinge pin.
10. Disconnect unit and its individual shut-off valve from gas supply
line during any pressure testing of system in excess of 1/2 PSIG
(3.4 kPa, 14˝ water column [W.C.]). DO NOT set inlet pressure higher
than maximum indicated on rating plate of gas valve (13˝ W.C.).
Isolate unit from gas supply line by closing its individual manual
shutoff valve during any pressure testing b 1/2 psig.
3
Do not smoke or have any flame near an open faucet.
FIRE
CAUTION
HOW TO OPERATE YOUR WATER HEATER
s Do not operate without water in tank.
PRODUCT FAILURE
CAUTION
s Do not tamper with orifice or mixing valve.
SCALDING INJURY
WARNING
If hydrogen gas is present, you will probably hear sounds like air
escaping through the pipe as water begins to flow.
If water heater has not been used for more than two weeks, hydrogen
gas may form in water line. Under these conditions to reduce the risk
of injury, open hot water faucet for several minutes at kitchen sink
before you use any electrical appliance connected to hot water system.
s
s
store or use gasoline or other flammable vapors and liquids in
the vicinity of this or any other appliance.
Should overheating occur, or gas supply fail to shut off, turn gas
OFF at the LP tank. On ELECTRONIC IGNITION MODEL turn operating
switch to OFF position and remove red wire from left hand terminal
of ECO switch or turn gas OFF at the LP tank.
s Use with LP gas only.
s Shut off gas appliances when refueling.
s Turn gas OFF at the LP tank when vehicle is in motion. This disables
all gas appliances. Gas appliances must never be operated while
vehicle is in motion. Unpredictable wind currents may be created
which could cause flame reversal in the burner tube, which could
result in fire damage. The thermal cut off fuse could also be
unnecessarily activated resulting in a complete shutdown of the
water heater requiring replacement of the thermal cut off. See
maintenance of electronic ignition water heaters for further
explanation of the thermal cut off.
s LP tanks must be filled by a qualified gas supplier only.
s DO NOT
EXPLOSION OR FIRE
WARNING
CONSUMER SAFETY WARNINGS
Your ATWOOD WATER HEATER is now ready for operation. Continue to
HOW TO OPERATE YOUR WATER HEATER.
FOR REPLACEMENT PARTS:
s DO NOT install anything less than a combination temperature-pressure
relief valve certified by a nationally recognized testing laboratory that
maintains periodic inspection of product of listed equipment or
materials, as meeting requirements for Relief Valves and Automatic
Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22.
Valve must have a maximum set pressure not to exceed 150 psi.
s Install valve into opening provided and marked for this purpose on
water heater.
s Installation must conform with local codes or in the absence of local
codes, American National Standard for Recreational Vehicles, ANSI
A119.2/NFPA 50IC.
s For an external electrical source, ground this unit in accordance with
National Electrical Code ANSI/NFPA70.
Page 108 of 145
The use of any aftermarket heating element devices may also result in
damage to components or water heater. Atwood’s written warranty
states - “failure or damage resulting from any alteration to our water
heater is the owner’s responsibility”. Any alteration, like the addition of
an aftermarket heating element device, will void the warranty.
heating of water tank and a catastrophic wet side explosion.
s Use of Aftermarket heating elements can lead to an out of control
controls.
s DO NOT USE Aftermarket heating elements, they can lack critical safety
s DO NOT alter water heater, it will void warranty.
EXPLOSION / BURN INJURY
WARNING
AFTERMARKET WATER HEATING ELEMENT DEVICES
material, and flammable liquids and vapors.
s Keep control compartment clean and free of gasoline, combustible
s Shut off gas supply at LP container before disconnecting a gas line.
FIRE OR EXPLOSION
WARNING
Location and phone numbers of qualified Service Centers can be found
at our website http:/www.atwoodmobile.com or call 574-262-2655 to
have a Service Center List mailed.
SERVICE CALLS & QUESTIONS
MAINTENANCE AND CARE INSTRUCTIONS
Read MAINTENANCE AND CARE INSTRUCTIONS .
The unit can be run in both gas and electric
modes simultaneously for quick recovery. note: if the gas fails to
ignite, the gas mode will lockout, but the lockout lamp will not
illuminate since the electric mode is still operational. Should you notice
slow recovery, indicating the gas is not working, turn the electric
switch off. The lamp will then illuminate indicating a lockout has
occurred on the gas side. Correct the problem and turn the switches
back on.
GAS/ELECTRIC OPERATION.
ELECTRIC OPERATION. When the electric switch is turned on, the relay at the
rear of the unit will close and pass 110vac to the element. If the
thermostat were to fail, the ECO will open and lockout the system. To
correct, check the thermostat to assure good contact with the tank
and reset the control by turning the electric switch off, then on.
When the gas switch is turned on, the unit will make three
attempts to light. If for any reason there is no ignition, the unit will
lockout and the red lockout lamp will illuminate. If the thermostat fails,
the ECO will also lockout the unit, requiring resetting. Determine the
reason for no ignition, correct it, and reset the gas ignition sequence
by turning the switch off, then on.
4
ELECTRONIC IGNITION MAINTENANCE
GAS/ELECTRIC COMBINATION FUNCTION
removing drain plug to flush tank.
s Turn off water heater and allow time for water to cool before
WARNING
SCALDING INJURY
WATER HEATER TANK CARE
HOW TO CLEAN ELECTRONIC IGNITION MODEL
1. Check main burner orifice.
2. Clean and adjust main burner.
3. Main burner and valve manifold must align with each other
4. Check electrode for cracked porcelain (FIG 4-E).
5. Check electrode for proper gap - 1/8” between electrode and
ground.
6. If module board functions intermittently, remove board and clean
terminal block with pencil eraser ( FIG 3-H).
Spiders, mud wasps, and other insects can build nests in the burner
tube. This will cause poor combustion, delayed ignition or ignition
outside combustion tube. Listen for a change in burner sounds or in
flame appearance from a hard blue flame to a soft lazy flame or one
that is very yellow. These are indications of an obstruction in burner
tube (FIG 4-C). Inspect and clean on a regular basis.
a. Remove air shutter screw (FIG 4-A) and slide air shutter (FIG 4-B)
down burner tube.
b. Run a flexible wire brush down burner tube ( FIG 4-D) until it is
visible at end of burner tube.
c. Vacuum burner where it enters combustion tube.
d. Return air shutter to original position and replace screw.
e. The orifice, burner tube and shutter must be aligned so that the shutter is not
binding on the air tube.
PREVENTATIVE MAINTENANCE
s The water heater comes factory-equipped with a fused circuit board,
which will protect the circuit board from wiring shorts. If the fuse
should activate, the water heater will not operate. Before replacing
the fuse, check for a short external to the board. Once the short is
corrected, replace the 2 amp fuse with a mini ATO style fuse. Do not
install a fuse larger than 3 amps.
s If the fuse is good and the unit is inoperative, check for excessively
high voltage to the unit (more than 14 volts).
s If the previous two steps did not solve the problem, check the
thermal cut-off (FIG 3-I). The thermal cutoff is a device installed in the
power supply line. This device will shut off electrical power and stop
heater operation when activated. For example, if an obstruction
within the flue tube should occur, as described in the Preventative
Maintenance section, the burner flame/heat may contact the cutoff,
resulting in a melting of the fuse element incorporated in the
thermal cutoff. In order to restore power and proper operation of the
water heater, the obstruction must be removed and the thermal
cutoff must be replaced.
s LP and Water system must be turned on.
s Have gas pressure tested periodically. Should be set at 11 inches of
water column with three appliances running.
s Drain water heater at regular intervals (at least one time during the
year).
s Drain water heater before storing RV for the winter or when the
possibility of freezing exists.
s Keep vent and combustion air grill clear of any obstructions.
s Periodically, compare flame of main burners with FIG 4 and main
burner adjustments in HOW TO OPERATE YOUR WATER HEATER.
s Presence of soot indicates the need to adjust flame.
1. Refer to WIRING DIAGRAM FIG12. Place remote switch in ON position.
2. For complete shut-down and before servicing:
a. Place remote switch in OFF position.
b. Remove red wire from left hand terminal of ECO switch (ECO to
valve).
3. If heater fails to operate due to high water temperature, a lockout
condition occurs (indicator light on). After water cools, reset switch
in OFF position for at least 30 seconds, then turn to ON position.
4. If a lockout condition persists contact an Atwood Service Center.
Read MAINTENANCE AND CARE INSTRUCTIONS & ELECTRONIC IGNITION
MAINTENANCE
GAS OPERATION.
GENERAL INFORMATION
ELECTRONIC IGNITION OPERATION
pression-température et de rétablir l’intervalle d'air. L'eau contenue dans
le réservoir doit être froide.
s Couper le chauffe-eau avant d'ouvrir la soupape de décharge de type
BRÛLURES
AVERTISSEMENT
Lorsqu’une soupape de décharge de type pression-température goutte
pendant le fonctionnement du chauffe-eau, cela NE SIGNIFIE PAS
qu’elle est défectueuse. La soupape de décharge goutte parfois, du
fait d'une expansion naturelle de l'eau, lorsque celle-ci est chauffée à
l'intérieur du réseau d’alimentation en eau d'un véhicule de plaisance.
Le réservoir du chauffe-eau Atwood comporte un intervalle d'air
interne en haut du réservoir, permettant de réduire les risques
d’égouttement. Au fil du temps, l'expansion de l'eau absorbe cet air et
l’intervalle doit être rétabli.
sur la sortie de la soupape de décharge de type pression-température.
s Ne pas placer de robinet, de bouchon ou de raccord de réduction
EXPLOSION
AVERTISSEMENT
s Toucher à la soupape annulera la garantie.
s La soupape ne se prête pas aux réparations, elle devra être remplacée.
s Toucher à la soupape risque de provoquer des brûlures.
BRÛLURES
AVERTISSEMENT
SOUPAPE DE DÉCHARGE DE TYPE PRESSION-TEMPÉRATURE
Pour assurer le meilleur rendement de votre chauffe-eau et prolonger
la vie du réservoir, évacuer et rincer régulièrement le réservoir du
chauffe-eau. Avant le rangement à long terme ou avant l’arrivée du
gel, évacuer et rincer le réservoir.
1. Couper l'alimentation principale en eau (la pompe ou la source
d'apport en eau).
2. Évacuer l'eau du réservoir du chauffe-eau en retirant le bouchon de
vidange. Si l'eau coule de façon irrégulière ou goutte au lieu de
couler à jet normal, nous vous conseillons tout d’abord d’ouvrir la
soupape de décharge de type pression-température, pour permettre
à l'air d’entrer dans le réservoir. Ensuite, à l'aide d'un fil de fer de
petit diamètre ou d'un porte-manteau, piquer à l’intérieur de l’orifice
d'évacuation, de façon à éliminer toute obstruction.
3. Une fois le réservoir vide, étant donné l'emplacement du bouchon de
vidange, il restera environ 2 litres d'eau dans le réservoir. Cette eau
contient la plus grande partie des particules corrosives dangereuses.
Pour retirer ces particules corrosives dangereuses, rincer le réservoir
soit avec de l’air, soit avec de l’eau. Que vous utilisiez de l'air ou de
l’eau sous pression, l’application peut se faire soit par l'entrée, soit
par la sortie située à l'arrière du réservoir ou de la soupape de
décharge de type pression-température. (En cas d’utilisation de la
soupape de décharge de type pression-température, il faudra d'abord
retirer le rebord de sécurité). La pression force l’eau et les particules
corrosives restantes à s’évacuer.
En cas d’utilisation d’eau sous pression, pomper de l'eau fraîche
dans le réservoir à l'aide d'une pompe transportée ou utiliser de l'eau
externe pendant 90 secondes, de façon à permettre à l'eau fraîche de
remuer l'eau stagnante se trouvant au fond du réservoir et de
propulser les dépôts par l’orifice d’évacuation. Continuer à rajouter de
l’eau et à évacuer, jusqu'à ce que l’eau restant dans le réservoir ne
comporte plus aucune particule.
4. Replacer le bouchon de vidange et fermer la soupape de décharge
de type pression-température. La quantité d’eau (environ 2 litres)
restant au fond du réservoir suite à la vidange ne causera pas de
dommage au réservoir en cas de gel.
INSTRUCTIONS POUR L'HIVERNAGE (RINÇAGE)
13
Il faudra pomper de l’eau claire dans le réservoir, soit avec la pompe
transportée à bord, soit avec de l’eau sous pression externe.
Continuer le processus de rinçage pendant environ cinq minutes ;
ceci permet à l’eau claire de remuer l'eau stagnante du fond du
réservoir et de pousser les dépôts par l’orifice d’évacuation.
4. Replacer le bouchon de vidange et la soupape de décharge de
type pression-température.
5. Remplir le réservoir avec de l’eau claire ne contenant pas de
souffre.
Le chauffe-eau Atwood est conçu pour être utilisé dans les véhicules
de plaisance. Si vous utilisez votre véhicule fréquemment ou pour des
périodes prolongées, rincer le chauffe-eau plusieurs fois par an
permettra de prolonger la vie du réservoir d’approvisionnement.
POUR RINCER LE RÉSERVOIR AVEC DE L’EAU SOUS PRESSION :
L’air sous pression devra passer par le raccord de la soupape de
décharge de type pression-température. Le robinet de vidange ouvert,
l’air sous pression forcera l’eau restante à s’écouler de l’unité.
POUR RINCER LE RÉSERVOIR AVEC DE L’AIR SOUS PRESSION :
Une odeur d’œuf pourri (sulfure d’hydrogène) pourra se dégager du
fait de l’action électrogalvanique du matériau de gainage qui dégage
de l’hydrogène de l’eau. En cas de présence de souffre dans
l’alimentation en eau, l’eau et le souffre se mélangent pour donner une
odeur désagréable.
1. Couper l’alimentation principale en eau. Évacuer l’eau du réservoir
du chauffe-eau et réinstaller le bouchon de vidange. Retirer la
soupape de décharge de type pression-température. Préparer une
solution de 4 parts de vinaigre blanc pour 2 parts d’eau. (Pour un
réservoir de 10 gallons, utiliser 6 gallons de vinaigre et 3 gallons
d’eau.) Au moyen d’un entonnoir, verser la solution à l’intérieur du
réservoir, avec précaution.
2. Effectuer 4 à 5 cycles du chauffe-eau avec la solution indiquée cidessus en laissant fonctionner normalement.
3. Retirer le bouchon de vidange et évacuer toute l’eau du réservoir.
Rincer le chauffe-eau pour en éliminer tout sédiment. Il est
possible de rincer le réservoir avec de l’air sous pression ou avec
de l’eau claire. Appliquer la pression soit sur les clapets d’arrivée
ou de sortie à l’arrière du réservoir, soit au raccord de la soupape
de décharge de type pression-température se trouvant à l’avant
de l’unité.
RINCER POUR ÉLIMINER LES MAUVAISES ODEURS
s Installer une soupape de décharge de type pression-température
dans la conduite d’arrivée d'eau froide du chauffe-eau et fixer une
conduite d’évacuation sur la vanne extérieure du véhicule. Régler la
limite sur 100 à 125 psi.
s Installer un réservoir d’expansion de type membrane dans la conduite
d’arrivée d'eau froide. Le réservoir devra permettre une dilatation
d’environ 15 oz d'eau et une mise sous pression égale à la pression
de l'alimentation en eau. Ces dispositifs sont disponibles chez un
plombier ou dans un Centre de service.
Lorsque la soupape de décharge de type pression-température
s’écoule à nouveau, répéter la procédure ci-dessus. Pour une
solution permanente, nous vous conseillons l'une des choses
suivantes :
s Faire fonctionner manuellement la soupape de décharge de type
pression-température au moins une fois par an (FIG 3-G).
POUR RÉTABLIR L'INTERVALLE D'AIR, SUIVRE LES ÉTAPES SUIVANTES :
1. Couper l'alimentation principale en eau (la pompe ou la source
d'apport en eau).
2. Laisser l’eau refroidir ou la laisser couler jusqu’à ce qu’elle soit froide.
3. Ouvrir le robinet d’eau chaude le plus proche du chauffe-eau.
4. Tirer la poignée de la soupape de décharge de type pressiontempérature vers soi et laisser l'eau couler, jusqu'à ce qu'elle s'arrête.
5. Laisser la soupape de décharge de type pression-température
revenir brusquement en position fermée ; fermer le robinet ; ouvrir
l'alimentation en eau.
6. Allumer le chauffe-eau et le tester.
Page 109 of 145
L'utilisation d'éléments de chauffe provenant de fabricants de marché
secondaire pourra également entraîner des endommagements des
composantes ou du chauffe-eau. La garantie écrite Atwood stipule
que « la responsabilité d'un mauvais fonctionnement ou de
dommages causés par une modification au chauffe-eau revient à
le risque de perte de contrôle du chauffage du réservoir à eau et
d’explosion d'eau catastrophique.
s L'utilisation d'éléments de chauffe de marché secondaire comporte
risquent de ne pas avoir fait l’objet de certains contrôles de sécurité
importants.
s NE PAS modifier le chauffe-eau, sous peine d’annuler la garantie.
s NE PAS utiliser d'éléments de chauffe de marché secondaire, car ils
EXPLOSION / BRÛLURES
AVERTISSEMENT
ÉLÉMENTS DE CHAUFFE D'EAU DE MARCHÉ SECONDAIRE
comporte pas de carburant, de matériaux combustibles ou de
liquides ou vapeurs inflammables.
s S’assurer que le compartiment de commande est propre et ne
avant de débrancher la conduite de gaz.
s Fermer l'alimentation en gaz au niveau du réservoir de propane liquide
INCENDIE OU EXPLOSION
AVERTISSEMENT
Les adresses et les numéros de téléphone des centres de service
agréés se trouvent sur notre site Internet http:/www.atwoodmobile.com
ou composer le 574-262-2655 pour recevoir la liste par courrier.
APPELS ET QUESTIONS D’ENTRETIEN
INSTRUCTIONS POUR L'ENTRETIEN
Lire les INSTRUCTIONS POUR L’ENTRETIEN.
FONCTIONNEMENT GAZ-ÉLECTRICITÉ. L’unité peut fonctionner à la fois en mode
gaz et en mode électrique simultanément, ce qui permet d’éviter les
interruptions prolongées. Remarque : si le gaz ne s’allume pas, le
mode de fonctionnement au gaz se verrouille, mais le voyant lumineux
de verrouillage ne s’allume pas pour autant, étant donné que le mode
électrique est encore en marche. Si vous remarquez une interruption
prolongée indiquant que le gaz ne fonctionne pas, mettre l’interrupteur
électrique sur la position éteinte (OFF). Le voyant s’allume alors,
indiquant qu’un verrouillage vient de se produire du côté gaz. Rectifier
le problème et remettre les interrupteurs sur la position allumée (ON).
FONCTIONNEMENT ÉLECTRIQUE.
Lorsque l’interrupteur à électricité est ouvert, le
relais situé à l’arrière de l’unité se ferme, envoyant un courant de 110
VCA vers l’élément. Si le thermostat ne fonctionne pas, l’ECO s’ouvre
et verrouille le système. Pour remédier à ce problème, vérifier le
thermostat et s’assurer qu’il existe un contact stable avec le réservoir,
puis réinitialiser la commande en mettant l’interrupteur électrique en
position éteinte (OFF), puis allumée (ON).
FONCTIONNEMENT AU GAZ.
Lorsque l’interrupteur à gaz est ouvert, l’unité
tentera de s’allumer trois fois. Dans le cas où, pour une raison
quelconque, l’allumage ne se produit pas, l’unité se verrouille et le
voyant lumineux de verrouillage s’allume au rouge. Dans le cas où le
thermostat ne fonctionne pas, l’ECO verrouille également l’unité et la
remise à zéro est alors obligatoire. Identifier la raison pour laquelle
l’allumage ne s’effectue pas, rectifier l’erreur et réinitialiser le
processus d’allumage en éteignant, puis en rallumant l’interrupteur.
FONCTION COMBINÉE GAZ-ÉLECTRICITÉ
Lire les INSTRUCTIONS POUR L’ENTRETIEN et L'ENTRETIEN DE L'ALLUMAGE
ÉLECTRONIQUE.
1. Consulter le SCHÉMA DE CÂBLAGE FIG 12. Mettre la commande à distance
en position allumée (ON).
2. Pour éteindre complètement l'unité et avant d’effectuer des réparations :
a. Mettre la commande à distance en position éteinte (OFF).
b. Enlever le fil rouge de la borne gauche de l'interrupteur ECO
(ECO au robinet).
3. Si le chauffe-eau ne fonctionne pas car la température de l’eau est
trop élevée, il se verrouille (voyant lumineux allumé). Une fois l'eau
refroidie, remettre l'interrupteur en position éteinte (OFF) pendant au
moins 30 secondes, puis repasser à la position allumée (ON).
4. Si le verrouillage persiste, contacter un centre de service Atwood.
FONCTIONNEMENT DE L'ALLUMAGE ÉLECTRONIQUE
12
d'enlever le bouchon de vidange et de rincer le réservoir.
s Éteindre le chauffe-eau et attendre que l'eau refroidisse avant
AVERTISSEMENT
BRÛLURES
ENTRETIEN DU RÉSERVOIR DU CHAUFFE-EAU
COMMENT NETTOYER LES MODÈLES À ALLUMAGE ÉLECTRONIQUE
1. Vérifier l'orifice du brûleur principal.
2. Nettoyer et régler le brûleur principal.
3. Le brûleur principal et les voies de la soupape doivent être alignés.
4. Vérifier que la porcelaine de l'électrode ne comporte pas de
fissures (FIG 4-E).
5. Vérifier que l’écart entre l’électrode et le sol est bien de 1/8 po.
6. Lorsque la carte des modules fonctionne en alternance, enlever la
carte et nettoyer la plaque à bornes avec une gomme pour crayon
(FIG 3-H).
Araignées, guêpes et autres insectes font parfois leur nid dans le tube
du brûleur. Cela risque de causer une mauvaise combustion, un retard
dans l’allumage ou un allumage à l'extérieur du tube de combustion.
Prêter attention à tout changement du son produit par le brûleur et de
l'apparence de la flamme (molle, calme et jaune vif plutôt que drue et
bleue). Cela indique que le tube du brûleur est obstrué (FIG 4-C).
Inspecter et nettoyer régulièrement.
a. Retirer la vis de l’obturateur d'air (FIG 4-A) et glisser l’obturateur
d'air (FIG 4-B) le long du tube du brûleur.
b. Introduire une brosse métallique flexible à l’intérieur du tube du brûleur
(FIG 4-D), jusqu'à ce qu'elle ressorte par l'autre extrémité du tube.
c. Nettoyer le brûleur à l’aide d'un aspirateur, à l'endroit où il s’insère
dans le tube de combustion.
d. Remettre l’obturateur d'air dans sa position d'origine et replacer la vis.
e. The orifice, burner tube and shutter nmust be aligned so that the shutter is not
binding on the air tube.
ENTRETIEN PRÉVENTIF
s A l’usine, votre chauffe-eau a été équipé d’une carte imprimée à
fusible. Ce fusible protège la carte imprimée des courts-circuits
pouvant survenir dans les câblages. Si le fusible venait à s’activer, le
chauffe-eau ne pourrait pas fonctionner. Avant de remplacer le
fusible, vérifier que le court-circuit n’est pas externe à la carte
imprimée. Une fois le court-circuit réparé, remplacer le fusible de 2
ampères par un fusible mini de type ATO. Ne pas installer de fusible
de plus de 3 ampères.
s Si le fusible est bon mais que l’unité ne fonctionne pas, vérifier que la
tension du courant alimentant l’unité n’est pas trop élevée (plus de 14 volts).
s Si les deux étapes précédentes ne résolvent pas le problème, vérifier le
système de coupure thermique (FIG 3-I). Le système de coupure
thermique est installé dans le tuyau d’alimentation. Ce dispositif, une
fois déclenché, coupe l’arrivée du courant électrique et le
fonctionnement du chauffe-eau. Par exemple, en cas d’obstruction
dans le tube d’évacuation, comme le décrit la section d’Entretien
préventif, la flamme et la chaleur du brûleur risquent d’entrer en
contact avec le système de coupure, ce qui fera fondre l’élément du
fusible incorporé dans le système de coupure thermique. Pour rétablir
l’électricité et le bon fonctionnement du chauffe-eau, l’obstruction doit
être éliminée et le système de coupure thermique doit être remplacé.
ENTRETIEN DE L'ALLUMAGE ÉLECTRONIQUE
s Le système de propane liquide et le système à eau doivent être allumés.
s Faire tester la pression du gaz régulièrement. La pression doit être
réglée sur 11 po. de colonne d'eau, lorsque 3 appareils fonctionnent.
s La pression d’admission minimale ne doit pas dépasser 14 po. de
colonne d’eau.
s Évacuer l'eau contenue dans le chauffe-eau à intervalles réguliers
(au moins une fois par an).
s Évacuer l'eau contenue dans le chauffe-eau avant de garer votre
véhicule de plaisance pour l'hiver ou lorsqu’il existe un risque de gel.
s S’assurer que l'évacuation et la grille d'air de combustion ne
comportent aucune obstruction.
s Comparer régulièrement la flamme des brûleurs principaux à la
FIG 4 et aux réglages du brûleur principal dans la section COMMENT
UTILISER VOTRE CHAUFFE-EAU.
INFORMATIONS GÉNÉRALES
l’acheteur ». Toute modification, telle que, par exemple, le rajout d'un
élément de chauffe de marché secondaire, annule la garantie.
TO REPLACE THE AIR GAP FOLLOW THESE STEPS:
1. Turn off main water supply (the pump or water hook up source).
2. Let water cool or let run until cool.
3. Open the hot water faucet closest to the water heater.
4. Pull handle of pressure temperature relief valve straight out and
allow water to flow until it stops.
5. Allow pressure temperature relief valve to snap shut; close faucet;
turn on water supply.
6. Turn on water heater and test.
valve to establish air space. Storage water must be cool.
s Turn off water heater before opening pressure-temperature relief
SCALDING INJURY
WARNING
A Pressure Temperature Relief Valve, dripping while the water heater is
running, DOES NOT mean it is defective. During normal expansion of
water, as it is heated in the closed water system of a recreation
vehicle, the Pressure Temperature Relief Valve will sometimes drip. The
Atwood water heater tank is designed with an internal air gap at the
top of the tank to reduce the possibility of dripping. In time, the
expanding water will absorb this air and it must be restored.
pressure-temperature relief valve.
s Do not place a valve, plug or reducing coupling on outlet part of
EXPLOSION
WARNING
s Tampering with valve will void warranty.
s Valve is not serviceable, it must be replaced.
s Tampering with valve will result in scalding injury.
SCALDING INJURY
WARNING
PRESSURE-TEMPERATURE RELIEF VALVE
To insure the best performance of your water heater and add to the life
of the tank, periodically drain and flush the water heater tank. Before
long term storage or freezing weather drain and flush the tank.
1. Turn off main water supply (the pump or water supply (the pump or
water hook up source).
2. Drain Water Heater Tank by removing the drain plug. If the water
flows sporadically or trickles instead of a steady stream of water, we
recommend the following action; first open the Pressure
Temperature Relief Valve to allow air into the tank and secondly,
take a small gauge wire or coat hanger and poke through the drain
opening to eliminate any obstructions.
3. After draining the tank, because of the placement of the Drain Plug,
approximately two quarts of water will remain in the tank. This water
contains most of the harmful corrosive particles. To remove these
harmful corrosive particles flush the tank with either air or water.
Whether using air or water pressure, it may be applied through the
inlet or outlet on the rear of the tank or the Pressure Temperature
Relief Valve. (If using the Pressure Temperature Relief Valve the
Support Flange must be removed). The pressure will force out the
remaining water and the corrosive particles.
If you use water pressure, pump fresh water into the tank with the
assistance of the on-board pump or use external water for 90
seconds to allow the fresh water to agitate the stagnant water on
the bottom of the tank and force deposits through the drain
opening. Continue repeating adding water and draining until the
particles have been cleared from the water remaining in the tank.
4. Replace the Drain Plug and close the Pressure Temperature Relieve
Valve. The approximately two quarts of water remining in the tank
after draining will not cause damage to the tank should freezing occur.
WINTERIZING (FLUSHING) INSTRUCTIONS
5
A rotten egg odor (hydrogen sulfide) may be produced when the
electro galvanic action of the cladding material releases hydrogen from
the water. If sulfur is present in the water supply the two will combine
and produce an unpleasant smell.
1. Turn off main water supply. Drain the water heater tank and
reinstall drain plug. Remove the pressure-temperature relief valve.
Mix solution of 4 parts white vinegar to two parts water. (For a 10
gallon tank, use 6 gallons vinegar to 3 gallons water). With a
funnel, carefully pour solution into tank.
2. Cycle water heater with the above solution, letting it run under
normal operation 4-5 times.
3. Remove the drain plug and thoroughly drain all water from the
tank. Flush the water heater to remove any sediment. you may
flush the tank with air pressure or fresh water. Pressure may be
applied through either the inlet or outlet valve on the rear of the
tank or through the pressure-temperature relief valve coupling
located on the front of the unit.
TO FLUSH TANK WITH AIR PRESSURE:
Insert your air pressure through the pressure-temperature relief valve
coupling. With the drain valve open, the air pressure will force the
remaining water out of the unit.
TO FLUSH TANK WITH WATER PRESSURE:
Fresh water should be pumped into the tank with either the onboard
pump or external water pressure. Continue this flushing process for
approximately five minutes, allowing the fresh water to agitate the
stagnant water on the bottom of the tank and forcing the deposits
through the drain opening.
4. Replace drain plug and pressure-temperature relief valve.
5. Refill tank with fresh water that contains no sulphur.
The Atwood water heater is designed for use in a recreation vehicle. If
you use your vehicle frequently or for long periods of time, flushing the
water heater several times a year will prolong the life of the storage
tank.
FLUSHING TO REMOVE UNPLEASANT ODOR
s At least once a year manually operate pressure-temperature relief
valve (FIG 3-G).
When pressure-temperature relief valve discharges again, repeat above
procedure. For a permanent solution, we recommend one of the following:
s Install a pressure relief valve in cold water inlet line to water heater
and attach a drain line from valve to outside of coach. Set to relieve
at 100-125 PSI.
s Install a diaphragm-type expansion tank in cold water inlet line. Tank
should be sized to allow for expansion of approximately 15 oz. of
water and pre-charged to a pressure equal to water supply pressure.
These devices can be obtained from a plumbing contractor or
Service Center.
5
Page 110 of 145
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Cold Water
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Hot Water
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Ne pas fumer ou tenir de flamme à proximité d'un robinet ouvert.
L’hydrogène est hautement inflammable.
INCENDIE
ATTENTION
COMMENT UTILISER VOTRE CHAUFFE-EAU
BRÛLURES
AVERTISSEMENT
Si le chauffe-eau n'a pas été utilisé pendant plus de deux semaines, il
est possible que de l'hydrogène se soit formé dans la conduite d'eau.
Dans ces conditions, avant d'utiliser tout appareil électrique branché
sur le système d'eau chaude, faire couler l'eau du robinet d'eau
chaude de l’évier de la cuisine pendant plusieurs minutes pour réduire
le risque de blessures.
En cas de présence d’hydrogène, vous entendrez probablement l'air
s'échapper du tuyau, lorsque l'eau commence à couler.
s
s
s
NE PAS entreposer ou utiliser de carburant ou tout autre liquide ou
toute vapeur inflammables à proximité de cet appareil ou de tout
autre appareil.
s En cas de surchauffe ou si l'alimentation en gaz ne s'arrête pas
convenablement, fermer le gaz au niveau du réservoir de propane
liquide. Sur le MODÈLE À ALLUMAGE ÉLECTRONIQUE, mettre
l'interrupteur de commande en position arrêt (OFF) et retirer le fil
rouge de la borne gauche de l'interrupteur ECO ou fermer le gaz au
niveau du réservoir de propane liquide (OFF).
s Utiliser uniquement avec du gaz de propane liquide.
s Lors du ré-approvisionnement en carburant, éteindre les appareils à gaz.
s Éteindre le gaz au niveau du réservoir à propane liquide, lorsque le
véhicule est en déplacement. Cela permet de désactiver tous les
appareils à gaz. Les appareils à gaz ne doivent jamais fonctionner
lorsque le véhicule se déplace. Des mouvements d'air imprévisibles
risqueraient d’entraîner un retour de flamme dans le tube du brûleur,
ce qui pourra causer des endommagements par le feu. Le fusible de
coupure thermique pourra également être activé accidentellement et
éteindre complètement le chauffe-eau. Le système de coupure
thermique devra alors être remplacé. Consulter l'entretien des
chauffes-eau à allumage électronique pour plus de détails sur la
coupure thermique.
s Les réservoirs à propane liquide devront être remplis uniquement
par un fournisseur en gaz qualifié.
EXPLOSION OU INCENDIE
AVERTISSEMENT
CONSIGNES DE SÉCURITÉ DESTINÉES AU CONSOMMATEUR
Votre CHAUFFE-EAU ATWOOD est maintenant prêt à fonctionner. Passer
à COMMENT UTILISER VOTRE CHAUFFE-EAU.
PIÈCES DE RECHANGE :
s Installer AU MINIMUM une soupape de décharge combinée de type
température-pression, homologuée par un laboratoire de test reconnu
au niveau national, qui inspecte régulièrement les produits
d’équipement ou de matériaux concernés, selon les normes pour les
soupapes de décharge et les mécanismes de coupure automatique de
l’alimentation en gaz pour systèmes à eau chaude ANSI Z21.22. Le
réglage de la pression de la soupape ne doit pas dépasser 150 psi.
s Installer la soupape dans l'ouverture prévue et marquée à cet effet
sur le chauffe-eau.
s L'installation doit être conforme aux codes locaux ou, faute de
codes locaux, à la norme américaine nationale pour véhicules de
plaisance ANSI A119.2/NFPA 50IC.
s En cas de source électrique externe, cet appareil doit être mis à la
terre selon le Code électrique national ANSI/NFPA70.
s Ne pas toucher l'orifice ou le robinet mélangeur.
décharge de type pression-température en conformité avec la norme
sur les soupapes de décharge et les mécanismes de coupure
automatique de l'alimentation en gaz pour systèmes à eau chaude
ANSI Z21.22.
ATTENTION
En cas d’utilisation d’un tuyau d'écoulement, ne pas utiliser de
PANNE DE L'APPAREIL
raccord réducteur ou toute autre restriction qui soit inférieure en
s Ne pas faire fonctionner sans eau dans le réservoir.
diamètre à la sortie de la soupape de décharge. Laisser la soupape et
11
la conduite s'écouler complètement.
LA SOUPAPE EST UN ÉLÉMENT DE SÉCURITÉ ET NE DOIT PAS ÊTRE RETIRÉE SAUF EN
CAS DE REMPLACEMENT. Ce chauffe-eau est équipé d'une soupape de
sur la sortie ou l’admission de la soupape de décharge.
s NE PAS placer de robinet, de bouchon ou de raccord de réduction
EXPLOSION
AVERTISSEMENT
s Toucher à la soupape annulera la garantie.
s La soupape ne se prête pas aux réparations, elle devra être remplacée.
s Toucher à la soupape risque de provoquer des brûlures.
BRÛLURES
AVERTISSEMENT
SOUPAPE DE DÉCHARGE DE TYPE PRESSION-TEMPÉRATURE - (FIG 3-G)
chauffe-eau est équipé d'un robinet mélangeur (régulateur) qui
mélange l’eau froide avec de l’eau à plus haute température, de façon
à obtenir une température de l’eau de sortie de 130ºF environ. Il est
également équipé d’un thermostat à plus haute température qui
permet d’augmenter la température de l’eau d’approvisionnement.
CETTE SOUPAPE EST UN ÉLÉMENT DE SÉCURITÉ QUI DEVRA ÊTRE RETIRÉ UNIQUEMENT
EN CAS DE REMPLACEMENT. LE RETRAIT, À DES FINS DE REMPLACEMENT, DOIT
UNIQUEMENT ÊTRE EFFECTUÉ PAR UN TECHNICIEN D’ENTRETIEN QUALIFIÉ. Ce
s Toucher à la soupape risque de provoquer des brûlures.
s Toucher à la soupape annulera la garantie.
qualifié.
s La soupape ne se prête pas aux réparations ; elle devra être remplacée.
s Le remplacement doit uniquement être fait par un technicien d’entretien
BRÛLURES
AVERTISSEMENT
ROBINET DE MÉLANGE - (FIG 9)
11. Ouvrir l'alimentation en gaz et s’assurer que le chauffe-eau et les
différents raccords de gaz ne comportent pas de fuites, à l'aide
d'une solution de détection de fuites.
12. Remplir le réservoir du chauffe-eau ; vérifier que les différents
raccords ne comportent pas de fuites d’eau.
s NE PAS utiliser d'allumettes, de bougies ou toute autre source
d'allumage pour contrôler la présence éventuelle de fuites de gaz.
INCENDIE ET/OU EXPLOSION
AVERTISSEMENT
8. Pousser l'unité contre le mastic, fixer les 4 équerres de fixation (FIG
3-B) au véhicule à l'aide de vis à tête ronde No. 8, de 3/4 po. (nonfournies) ou l’équivalent. Terminer l'installation en insérant le même
type de vis No. 8 dans les orifices situés sur le bord du logement du
chauffe-eau. Check all gaskets, they must adher to the pan creating an
air tight seal.
9. Fixer la trappe d'accès.
a. Enfoncer l'axe de la charnière (FIG 3-C) dans le logement de la
charnière (FIG 3-D).
b. Faire glisser le couvercle (FIG 3-E) sur l'axe de la charnière.
c. Glisser l’axe de la charnière dans le couvercle, tout en l'enfonçant
dans le logement de la charnière (FIG 3-D).
REMARQUE : pour retirer l'axe de la charnière, soutenir le couvercle
d'accès et appuyer sur le coin de l'axe de la charnière.
10. Débrancher l'unité et son robinet d'arrêt individuel de la conduite
d’alimentation en gaz lors de tout test de pression du système audelà de 3,4 kPa (12 psi), 14 po. de colonne d'eau (C.E.). NE PAS
régler la pression d’admission au-delà du maximum indiqué sur la
plaque signalétique du clapet à gaz (13 po. C.E.). Isoler l'unité de
la conduite d'alimentation en gaz en fermant le robinet d'arrêt
manuel individuel lors de tout test de pression supérieur ou égal à
3,4 kPa (12 psi).
Page 111 of 145
s Lorsqu'on utilise Romex® avec une mise à la terre nue, faire
attention de placer le fil de mise à la terre de manière à ce qu’il
n’entre pas en contact avec les bornes de l’élément de chauffe.
ENDOMMAGEMENT DU PRODUIT
ATTENTION
électriques en vigueur.
LES MODÈLES COMBINÉS GAZ-ÉLECTRICITÉ sont conçus pour fonctionner
au gaz, à l'électricité ou aux deux.
s Utiliser un conduit électrique métallique, un conduit métallique
souple, un câble à blindage métallique ou un câble blindé nonmétallique avec fil de masse. Le fil doit avoir une capacité
supérieure ou égale à 1400 watts. La méthode de câblage doit être
conforme aux sections en vigueur de l'article 551 du Code
électrique national ANSI/NFPA 70.
1. Consulter le Schéma électrique (FIG 12). Effectuer les branchements de
120 VCA à partir du boîtier de dérivation situé au dos de l'appareil.
a. Brancher le fil de phase sur le noir (1).
b. Brancher le fil neutre sur le blanc (2).
c. Brancher le fil de masse de l'alimentation électrique sur le fil de
masse vert (3) du boîtier de dérivation 3.
CÂBLAGE - Tous les câblages doivent être conformes aux codes
Cette méthode d’installation est l’une des plus répandues pour les
chauffe-eau. Il existe d’autres méthodes homologuées telles que les
installations d’encastrements (MPD 93948). Consulter votre inspecteur
sur le terrain, votre responsable de compte ou le service à la clientèle
Atwood pour toute question supplémentaire.
1. Poser le chauffe-eau sur le sol du véhicule, avant de construire les
parois latérales. Le réservoir du chauffe-eau doit toujours être
positionné au même niveau que le bas de la découpe de la paroi
latérale (au sol ou sur un support surélevé) FIG 2. Laisser
suffisamment d’espace à l'arrière de l’unité pour permettre les
réparations des raccordements d’eau.
2. L’ installation du chauffe-eau sur de la moquette doit se faire avec
un panneau en métal ou en bois de 7 ou 8 cm plus large et plus
profond que la taille totale de l'appareil.
3. Si l’appareil est installé dans un lieu où le branchement et les fuites
du réservoir risquent d’endommager les zones environnantes,
installer sous le chauffe-eau un système d'écoulement (permettant
l’évacuation vers l'extérieur du véhicule).
INSTALLATION GÉNÉRALE
USA ET CANADA - SUIVRE LES CODES NATIONAUX ET LOCAUX EN VIGUEUR - À DÉFAUT
DE CODES OU RÉGLEMENTATIONS LOCAUX, SE REPORTER AUX NORMES ACTUELLES DE :
U Véhicules de plaisance ANSI A119.2/NFPA 501C.
U Code national de carburant et de gaz ANSI Z223.1 et/ou codes d'installation CAN/CGA
B149.
U Norme fédérale de sécurité et de construction de maisons mobiles, titre 24 CFR, partie
3280 ; lorsque cette norme n’est pas applicable, utiliser la norme d’installation de
maisons préfabriquées (Sites de maisons préfabriquées, collectivités et installation),
ANSI A255.1 et/ou la série CAN/CSA-Z240 MH, maisons mobiles.
U Code électrique national ANSI/NFPA No. 70 et/ou CSA C22.1.
U Caravanes de parc A119.5.
U Norme CSA de série Z240 RV, véhicules de plaisance.
U Norme ASSE 1017 (valeur de mélange).
U Norme NSF ANSI/NSF 14-2003 (tous les tuyaux et raccords en plastique).
s Installer dans les véhicules de plaisance uniquement. Les véhicules
de plaisance sont conçus comme résidences temporaires pour les
vacances, le camping ou les voyages ; ils fonctionnent de façon
autonome ou sont parfois remorqués par un autre véhicule.
s Tout l'air de combustion doit provenir de l'extérieur du véhicule de
plaisance et tous les produits de la combustion doivent être
évacués vers l'extérieur.
s NE PAS évacuer l'air du chauffe-eau par un système d'évacuation
servant à un autre appareil.
s NE PAS évacuer l'air du chauffe-eau vers un espace extérieur couvert.
s Protéger les matériaux de construction des gaz de carneau.
s Installer le chauffe-eau sur un mur extérieur, avec une trappe
d'accès donnant vers l'extérieur.
s NE modifier le chauffe-eau en AUCUNE façon.
s NE PAS modifier le chauffe-eau pour une mise à la terre positive.
s NE PAS faire d’essai diélectrique du chauffe-eau sans avoir
débranché l'allumage électronique (carte de circuit imprimé).
s NE PAS utiliser de chargeur de batterie pour alimenter le chauffeeau, même lors des essais.
AVERTISSEMENTS IMPORTANTS POUR L'INSTALLATION
NE PAS
soulever, tirer ou pousser le tube du brûleur principal (FIG 3-F).
1-B
16-1/4po.
16-1/4PO.
DIMENSION DE LA DÉCOUPE
1-A
12-5/8po.
15-3/4PO.
(FIG 1 & 2)
2-C
18,5po.
21,75PO.
PROFONDEUR
Haut :
Bas :
0 po.
0 po.
6. Suivre les marques et plier tous les rebords à 90º (FIG 3-A).
7. Pour éviter les fuites d'eau, appliquer du mastic tout autour de
l'ouverture, y compris dans les fentes de pliage. Il est possible de
substituer une bande adhésive de butyle au mastic (1-1/3 po. x 1/8
10
po.).
Côtés : 0 po.
Arrière : 0 po.
DISTANCE MINIMALE PAR RAPPORT À TOUT MATÉRIAU DE CONSTRUCTION COMBUSTIBLE
Gallons
6
10
CAPACITÉ
DÉCOUPE
5. Construire les parois latérales et découper l'ouverture. Cf. tableau et
FIG 1. Utiliser des montants de 2x2 (ou équivalent) pour l'encadrement.
s
ENDOMMAGEMENT DU PRODUIT
ATTENTION
CONTINUER L'INSTALLATION GÉNÉRALE
4. Brancher les deux conduites d'eau de 1/2 po. NPT (FIG 2), sortie
femelle d'eau chaude et entrée femelle d'eau froide, et la conduite
de gaz PL évasée de 3/8 po. au chauffe-eau (FIG 9).
a. Permettre une flexibilité suffisante des conduites d'eau et de gaz,
de façon à pouvoir tirer l’unité en avant par le mur, à deux ou
trois centimètres de l’enveloppe extérieure.
b. Étanchéiser le passage de la conduite de gaz (FIG 9) en glissant
l'œillet (9-B) sur le tube de 3/8 po. (9-D) avant de l’évaser (9-E).
Tirer la conduite de gaz et l’œillet par l'ouverture du logement (9A). Brancher le raccord conique (9-C) et enfoncer l’œillet dans
l'ouverture. Si la conduite de gaz est déjà évasée, couper l’œillet
d'un côté. Placer l’œillet fendu sur la conduite de gaz et
l'enfoncer dans l'ouverture.
c. Toujours appliquer du lubrifiant de tuyau sur le filet lorsqu’on
raccorde les accouplements d'eau chaude et d’eau froide. Un
raccord en plastique adapté est préconisé.
MODÈLES D’ÉCHANGE DE CHALEUR - FIG 5
1. Pousser un tuyau de système de refroidissement (glycol) d’un
diamètre de 5/8 po. (5-A) [avec un collier SAE 053 A type « E » ] sur
le tube de l'échangeur de chaleur (5-B) et effectuer un
raccordement serré.
2. Ouvrir le collier et le faire glisser vers l'échangeur de chaleur, audelà de la rainure annulaire (5-C), puis relâcher.
3. Passer à COMMENT UTILISER VOTRE CHAUFFE-EAU et/ou
FONCTIONNEMENT de l’allumage électronique.
1. Consulter le Schéma électrique (FIG 12). Installer l'interrupteur de
commande à distance, dans un lieu accessible. Positionner la
plaque murale, les lettres debout. Avant d’effectuer les
branchements, mettre l'interrupteur en position d’arrêt (OFF).
2. Brancher les fils Cf. FIG 10 & 11.
ALLUMAGE ÉLECTRONIQUE
REMARQUE : il est recommandé de brancher l'unité directement sur une
batterie de 12 VCC ou en aval du filtre du convertisseur électrique CACC. Éviter à tout prix les branchements en amont du convertisseur
CA-CC. Utiliser un fil d’un calibre minimal de 18, homologué UL et CSA.
sAprès toute réparation, vérifier le bon fonctionnement de l'unité.
les déconnecter.
sLors de la réparation des commandes, étiqueter tous les fils avant de
ENDOMMAGEMENTS ÉLECTRIQUES
ATTENTION
s Lorsqu’on utilise une connexion avec fil et fiche pour alimenter le
chauffe-eau, le fil doit être homologué UL et convenir aux lieux humides
et aux usages intenses et super intenses. Le fil doit être souple, de type
S, SO, ST, STO, SJ, SJT, SJTO, HS ou HSO, en conformité avec le
Code électrique national, ANSI/NFPA 70. La longueur du fil externe
menant au chauffe-eau ne doit pas dépasser 6 pieds et ne doit pas
être inférieure à 2 pieds, lorsqu’elle est mesurée à partir de la fiche. Le
calibre minimum du fil d'alimentation électrique doit être de 14 AWG et
la fiche doit posséder une capacité nominale de 15 ampères.
6
O
F
F
O
N
4
5
6
BALL VALVE
MIXING VALVE
7
3
IN USE
WINTERIZED
+
BALL VALVE
–
MIXING VALVE
Page 112 of 145
1
NS
NS
18
19
20
21A
21B
22
1
12
13
15
16
17
1
2
3
4A
4B
9
11
REFERENCE
ITEM
90034
92249
93849
90029
90030
90031
90032
90960
91857
91604
90028
93844
91959
91859
91226
93191
93866
93868
91547
6 GALLON
22 LITRES
90033
90034
92690
92249
93849
90029
90030
90031
90960
91857
91604
90028
93844
91959
91859
91226
93191
93866
93868
91547
10 GALLON
38 LITRES
ÉCHANGE DE CHALEUR
Réservoir
HEAT EXCHANGE
Tank
8
GAZ – ÉLECTRICITÉ COMBINÉS
Réservoir
Élément de chauffe et joint
Relais
Robinet mélangeur
Robinet à bille
Raccord en T
Tuyau 9 po. (6 gallons)
Tuyau 12 po. (10 gallons)
Raccord en coude
Kit de vanne de remplacement 10 gallons
ALLUMAGE PAR ÉTINCELLE
Réservoir
Boîtier du conduit
Bouchon de vidange
Soupape pression-température !/2po. NPT
Soupape pression-température 3/4po. NPT
Électrovanne
Interrupteur Marche/Arrêt noir
Interrupteur Marche/Arrêt blanc
Circuit imprimé
Faisceau électrique
Coupure thermique
Détecteur d'étincelle
Thermostat ECO (kit)
22
19
20
21B
18
21A
20
19
22
SPARK IGNITION
Tank
Flue Box Assembly
Drain Plug
Pressure-Temperature Relief Valve !/2” NPT
Pressure-Temperature Relief Valve 3/4” NPT
Solenoid Valve
Black on-Off Switch
White On-Off Switch
Circuit Board
Wiring Harness
Thermal Cut Off
Spark Probe
ECO/T-STAT (kit)
16
17
15
12
13
GAZ-ÉLECTRICITÉ COMBINÉS
ALLUMAGE PAR ÉTINCELLES
ÉCHANGE DE CHALEUR
IDENTIFICATION DES PIÈCES
COMBINATION GAS/ELECTRIC
Tank
Heating Element & Gasket
Relay
Mixing Valve
Ball Valve
Tee
9” Hose (6 gallon)
12” Hose (10 gallon)
Elbow
10 Gal Replacement Valve Kit
All tanks includes styrofoam jacket =
Tous les réservoirs comprennent une chemise de polystyrène.
Order by model
Commander selon le modèle
order by color
Commander selon la couleur
11
9
3
2
4
1
8
SPARK IGNITION
HEAT EXCHANGE
COMBINATION GAS/ELECTRIC
PART IDENTIFICATION
(et Canada)
16po.
16PO.
AVERTISSEMENT
18,5po.
21,8PO.
6 GALLON
10 GALLONS
INCENDIE OU EXPLOSION
12,5po.
15,5PO.
25 lbs
32 LBS
POIDS À L'ENVOI
QUE FAIRE SI VOUS SENTEZ DU GAZ ?
• Évacuer TOUS les passagers du véhicule.
• Couper l'alimentation en gaz au niveau du réservoir ou à
la source.
• NE toucher AUCUN interrupteur électrique, n’utiliser ni le
téléphone, ni la radio à l'intérieur du véhicule.
• NE PAS démarrer le véhicule ou le générateur électrique.
• Contacter le fournisseur en gaz ou le technicien d’entretien
qualifié le plus proche pour effectuer toute réparation.
• S’il est impossible de joindre un fournisseur en gaz ou un
technicien d’entretien qualifié, contacter la caserne de
pompiers la plus proche.
• NE PAS ouvrir l'alimentation en gaz avant que la ou les
fuites soient réparées.
Ne pas entreposer ni utiliser de carburant ou autres liquides
et vapeurs inflammables à proximité de cet appareil ou de
tout autre appareil.
ce manuel risque d’entraîner un incendie ou une
explosion et des dégâts matériels, des blessures, voire
la perte de vie humaine.
UÊNe pas suivre à la lettre les instructions contenues dans
10 GALLONS
6 GALLONS
TOUS MODÈLES /LARGEUR /HAUTEUR /PROFONDEUR
DIMENSIONS
L'installation et l'entretien doivent être effectués par un technicien
d’entretien qualifié, un centre de service, un équipementier ou un
fournisseur de gaz.
ou les accidents mortels
ATTENTION
Évite les blessures potentielles
et/ou les dommages matériels
Évite les blessures potentielles
AVERTISSEMENT
Les symboles d'alerte de sécurité vous avertissent des dangers possibles.
Respecter tous les messages de sécurité qui font suite à ces symboles.
SYMBOLES D'ALERTE DE SÉCURITÉ
APPELS ET QUESTIONS D’ENTRETIEN
Les adresses et les numéros de téléphone des Centres de service
agréés se trouvent sur notre site Internet à www.atwoodmobile.com
ou composer le 574-262-2655 pour recevoir la liste par courrier.
La conception de ce chauffe-eau a été homologuée par
l’Association canadienne de normalisation pour installation à
l'intérieur de véhicules de plaisance. Ce chauffe-eau n'a pas été
conçu pour usage sur bateaux.
ENGLISH, FRANÇAIS
9
MPD 93050
POIDS .................................................................. 1
IDENTIFICATION DU MODÈLE ..................................1
DIMENSIONS ........................................................ 1
............................................................4
................................5
E
H
I6
-
EXT®
Capacité utile**
Échangeur de chaleur du moteur
Électrique
Gaz
T* Électronique
sur la base des gallons d’eau à 130º F, est de 9 et 16 gallons.
* EXT® se rapporte à la technologie électronique exothermique (XT).
** La capacité réelle du chauffe-eau est de 6 ou 10 gallons. La capacité utile, calculée
G
EXPLICATION DU NUMÉRO DE MODÈLE
GARANTIE du chauffe-eau
IDENTIFICATION DES PIÈCES
..........................................................8
............................................................16
Rinçage pour éliminer les mauvaises odeurs ........................................5
FIGURES ..................................................................................6-7
Soupape de sécurité de type pression-température
Entretien préventif ........................................................................4
Instructions pour l’hivernage (rinçage) ................................................5
Instructions pour l’entretien
Consignes de sécurité destinées au consommateur ................................2
Comment utiliser votre chauffe-eau ................................................3-4
Câblage
Tableau de découpe
Soupape de sécurité de type pression-température
INSTALLATION GÉNÉRALE du chauffe-eau
INFORMATIONS SUR LA SÉCURITÉ
CHAUFFE EAU
En vigueur à partir du 13/10/09
s)NSTALLATION s&ONCTIONNEMENT s%NTrETIEN
PATENT # 7,020,386
G16EXT, GE16EXT, GEH16EXT
Modèles XT® G9EXT, GE9EXT, GEH9EXT
6 et 10 GALLONS
CHAUFFE EAU AU
PROPANE LIQUIDE (PL)
NUMÉRO DE BROCHURE
Page 113 of 145
16
2. Pendant deux ans, à compter de la date d'achat, Atwood réparera ou
remplacera toute pièce trouvée défectueuse en raison du matériau ou
d'un vice de fabrication. La présente garantie couvre les frais
raisonnables de main-d’œuvre nécessaires au retrait et au
remplacement de la pièce. Les visites pour l’entretien chez le client ne
sont pas prises en charge et restent donc la responsabilité du client.
4. Dans l'éventualité d'une réclamation de garantie, l’acheteur doit
contacter, à l'avance, soit un centre de service Atwood agréé, soit le
Service à la clientèle Atwood. La réclamation de garantie doit être
exécutée dans un centre de service Atwood agréé (une liste vous sera
fournie gratuitement) ou selon les procédures reconnues par le Service
clientèle Atwood (Consumer Service Department) Atwood Mobile
Ce chauffe-eau Atwood est conçu pour utilisation en véhicule de plaisance
et dans le but de chauffer l'eau comme le stipule la plaque signalétique
fixée au chauffe-eau. Toute autre utilisation, à moins d’une autorisation
écrite du Service technique Atwood, annule la présente garantie.
11. Les pièces de remplacement (composantes ou réservoirs) achetées
en dehors de la garantie initiale du chauffe-eau sont couvertes par
une garantie de 90 jours ; ceci comprend la pièce sans frais et les
frais raisonnables de main-d'œuvre découlant du remplacement.
10. Toute garantie implicite est limitée à une période de deux (2) ans.
Certains États ne permettent pas de limiter la période d'une garantie
implicite, donc il est possible que la limite ci-dessus ne vous concerne
pas. La présente garantie vous accorde des droits légaux particuliers
mais il est également possible que vous ayiez certains droits
supplémentaires, selon les États.
9. Atwood n’est aucunement responsable de l’impossibilité d’utiliser le
véhicule, de toute perte de temps, de tout dérangement et de tous frais
d'essence, de téléphone, de déplacement, de logement, de perte ou de
dommages aux biens personnels ou de perte de revenus. Certains États
ne permettent pas l’exclusion ou la limitation des dommages
accessoires ou indirects ; il est donc possible que les limitations ou
exclusions ci-dessus ne s'appliquent pas à votre cas.
3. La présente garantie ne couvre pas les articles suivants, qui sont
considérés comme faisant partie de l’entretien régulier :
a. réglage de la pression du gaz
b. nettoyage ou remplacement de l’orifice du brûleur.
c. nettoyage ou réglage du tube du brûleur
d. nettoyage ou réglage du conduit
e. nettoyage ou réglage de la veilleuse et du thermocouple
f. réglage de la soupape de décharge de type pression-température
g. remplacement du dispositif de coupure thermique
8. Tout dommage ou toute déficience résultant d'une mauvaise utilisation
(y compris le manquement à faire effectuer les réparations nécessaires),
d'une mauvaise mise en application, de modifications, de dommages
causés par l'eau ou par le gel relèvent de la responsabilité de l’acheteur.
7. La période de garantie pour les pièces de remplacement (ou le chauffeeau) est la période inutilisée de la période de garantie initiale.
6. La présente garantie s'applique uniquement si l'unité est installée selon
les consignes d'installation fournies, en conformité avec les codes
locaux et nationaux.
5. Les pièces retournées (ou le chauffe-eau) doivent être expédiées à
Atwood, tout port payé. Un avoir pour les frais d'expédition sera
compris avec la réclamation de garantie. Les pièces défectueuses (ou le
chauffe-eau) deviennent la propriété d’Atwood Mobile Products et
doivent être retournées à Consumer Service Department, Atwood
Mobile Products, 6320 Kelly Willis Road, Greenbrier, TN 37073 ÉtatsUnis.
Products, 1120 North Main, Elkhart IN États-Unis.
Téléphone : (574) 264-2131.
performed at an authorized Atwood Service Center (a list will be
provided at no charge) or as approved by the Consumer Service
Department, Atwood Mobile Products, 1120 North Main St., Elkhart,
IN 46514 USA. Phone: (574-264-2131).
5. Return parts (or water heater) must be shipped to Atwood “Prepaid”.
Credit for shipping costs will be included with the warranty claim. The
defective parts (or water heater) become the property of Atwood Mobile
Products and must be returned to the Consumer Service Department,
Atwood Mobile Products, 6320 Kelly Willis Road, Greenbrier, TN
37073 USA.
6. This warranty applies only if the unit is installed according to the installation instructions provided and complies with local and state codes.
7. The warranty period on replacement parts (or water heater) is the
unused portion of the original warranty period or ninety (90) days,
whichever is greater.
8. Damage or failure resulting from misuse (including failure to seek proper
repair service), misapplication, alterations, water damage, or freezing
are the owner’s responsibility.
9. Atwood does not assume responsibility for any loss of use of vehicle,
loss of time, inconvenience, expense for gasoline, telephone, travel,
lodging, loss or damage to personal property or revenues. Some states
do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitations or exclusions may not apply to you.
10. Any implied warranties are limited to two (2) years. Some states do not
allow limitations on how long an implied warranty lasts, so the above
limitation may not apply to you. This warranty gives you specific legal
rights and you may also have other rights which vary from state to state.
11. Replacement parts (components or tanks) purchased outside of the
original water heater warranty carry a 90 day warranty. This includes
the part at no charge and reasonable labor charges to replace it.
This Atwood heater is designed for use in recreational vehicles for the purpose
of heating water as stated in the “data plate” attached to the water heater. Any
other use, unless authorized in writing by the Atwood Engineering Department,
voids this warranty.
1. Pendant une période de deux ans, à compter de la date d'achat,
Atwood remplacera tout le chauffe-eau si le réservoir interne fuit pour
des raisons de corrosion. La présente garantie couvre les frais
raisonnables de main-d’œuvre nécessaires au remplacement du
chauffe-eau.
La responsabilité d'Atwood décrite ci-dessous se limite au remplacement
ou à la réparation du produit par un produit reconditionné, à la discrétion
du fabricant. La présente garantie est annulée si le produit est
endommagé du fait d’un accident, d’une utilisation non raisonnable, d’une
négligence, d’une modification du produit ou de tout autre cause non liée
au matériau ou à un vice de fabrication. La présente garantie ne s'applique
qu'à l'acheteur initial et elle est soumise aux conditions suivantes :
Atwood Mobile Products garantit ce produit à l'acheteur initial, suivant les
termes stipulés ci-dessous, contre tout défaut de matériel ou de
fabrication, pendant une période de deux ans à compter de la date
d'achat.
GARANTIE LIMITÉE POUR
CHAUFFE-EAU ATWOOD
Atwood Mobile Products warrants to the original owner and subject to the
below mentioned conditions, that this product will be free of defects in
material or workmanship for a period of two years from the original date of
purchase. Atwood’s liability hereunder is limited to the replacement of the
product, repair of the product, or replacement of the product with a
reconditioned product at the discretion of the manufacturer. This warranty
is void if the product has been damaged by accident, unreasonable use,
neglect, tampering or other causes not arising from defects in material
workmanship. This warranty extends to the original owner of the product
only and is subject to the following conditions:
1. For a period of two years from the date of purchase, Atwood will
replace the complete water heater if the inner tank leaks due to
corrosion. This warranty includes reasonable labor charges required to
replace the complete water heater.
2. For two years from the date of purchase, Atwood will repair or replace
any part defective in material or workmanship. This warranty includes
reasonable labor charges, required to remove and replace the part.
Service calls to customer’s location are not considered part of these
charges and are, therefore, the responsibility of the owner.
3. This warranty does not cover the following items classified as normal
maintenance:
a. adjustment of gas pressure
b. cleaning or replacement of burner orifice
c. cleaning or adjustment of burner tube
d. cleaning or adjustment of flue
e. cleaning or adjustment of pilot and thermocouple
f. adjustment of pressure-temperature relief valve
g. replacement of thermal cut-off device.
4. In the event of a warranty claim, the owner must contact, in
advance, either an authorized Atwood Service Center or the
Atwood Service Department. Warranty claim service must be
ATWOOD WATER HEATER
LIMITED WARRANTY
(et Canada)
avoid possible
injury and/or property damage
CAUTION
WHAT TO DO IF YOU SMELL GAS
• Evacuate ALL persons from vehicle.
• Shut off gas supply at gas container or source.
• DO NOT touch any electrical switch, or use any phone or
radio in vehicle.
• DO NOT start vehicle’s engine or electric generator.
• Contact nearest gas supplier or qualified Service Technician
for repairs.
• If you cannot reach a gas supplier or qualified Service
Technician, contact the nearest fire department.
• DO NOT turn on gas supply until gas leak(s) has been
repaired.
➤ Do not store or use gasoline or other flammable vapors and
liquids in the vicinity of this or any other appliance.
• If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
WARNING
FIRE OR EXPLOSION
Installation and service must be performed by a qualified Service
Technician, Service Center, OEM or Gas Supplier.
avoid possible
injury or death
WARNING
Safety Symbols alerting you to potential personal safety hazards.
Obey all safety messages following these symbols.
SAFETY ALERT SYMBOLS
SERVICE CALLS & QUESTIONS
Location and phone numbers of qualified Service Centers can
be found at our website http:/www.atwoodmobile.com or call
574-264-2131 to have a Service Center List mailed.
This water heater design has been certified by the Canadian
Standards Association for installation in recreation vehicles. This
water heater is not for use in marine applications.
ENGLISH, FRANCAIS
9
1
MPD 93756
Effective 11/19/07
..........................................................4-5
H
6
AA - 8
E/P
Electronic Ignition or Pilot Relight
Revision (NUMBER)
Heating Element (SCREW-IN OR BOLT-ON)
4 - 6 - 10 gallon capacity
Engine Heat Exchange
Combination Gas and AC Electric
Gas (PROPANE)
- IF YOUR MODEL NUMBER IS NOT LISTEDOlder revision numbers may be 3, 4, 6, 7, 8 or 9 (_ _ _ _ _ - X _)
C
4 GAL
G4-7
6 GALLON
10 GALLON
ALL MODEL
16˝
16˝
WIDTH
DIMENSIONS
12.5˝
15.5˝
HEIGHT
Pilot Relight
Heat Exchange
Electronic Ignition
Combination Gas/Electric
Electronic Ignition
Pilot Ignition
TYPE
10 GAL
6 GALLON
10 GALLON
25 lbs
32 lbs
SHIPPING WT.
G6A-7
GC6AA-8P
G10-2
GC10A-2
GC6AA-8
GH6-7
G10-2P
GC10A-2P
G6A-8E
GCH6A-9E
G10-3E GCH10A-3E
GC6AA-9E
GH6-8E
GC10A-3E
GH10-3E
P IN MODEL # - SEE MODEL CLARIFICATION ABOVE
H IN MODEL # - SEE MODEL CLARIFICATION ABOVE
E IN MODEL # - SEE MODEL CLARIFICATION ABOVE
C IN MODEL # - SEE MODEL CLARIFICATION ABOVE
6 GAL
MODEL NUMBER CLARIFICATION
Regardless of your revision number the current instructions are still generally
applicable to your unit. If you have questions contact your dealer, an Atwood
Service Center or the Atwood Service Department.
G
EXPLANATION OF MODEL NUMBER (EXAMPLE)
WIRING DIAGRAMS
FIGURES
1-11 ............................................................................6
........................................................................7
PART IDENTIFICATION ..................................................................8-9
Water Heater WARRANTY ..............................................................16
Electronic Ignition
Electric
Water Heater MAINTENANCE
Electronic Ignition
Pilot Relight
Combination Gas/Electric
Water Heater PILOT OPERATION ......................................................3-4
Electronic Ignition wiring installation
Pilot Relight wiring installation
Heat Exchanger
Combination Gas/Electric
MODEL IDENTIFICATION
............................................1
DIMENSIONS ..........................................................1
WEIGHT ................................................................1
SAFETY INFORMATION ..................................................................2-4
Water Heater GENERAL INSTALLATION ..............................................2-3
WATER HEATER
•Installation •Operation •Maintenance
4 - 6 - 10 GALLON
L.P. GAS
WATER HEATER
LITERATURE NUMBER
Page 114 of 145
DO NOT
vent water heater to an outside enclosed porch area.
DO NOT vent water heater with venting system serving another
appliance.
DO NOT HI-POT water heater unless electronic ignition system
(circuit board) has been disconnected.
use battery charger to supply power to water heater even
when testing.
•
•
5. Erect side walls and cut opening. See chart and
Frame with 2x2 lumber (or equivalent).
FIG
• Do not lift, pull or push main burner tube (FIG 9-C).
PRODUCT DAMAGE
CAUTION
2-A & B.
1. Locate water heater on floor of coach before erecting side walls.
The water heater tank must be permanently supported at the same
level as the bottom of sidewall cutout (by the floor or a raised floor).
2. To install water heater on carpeting, you must install appliance on a
metal or wood panel that extends at least three inches beyond the
full width and depth of appliance.
3. If water heater is installed where leakage of connections or tank will
damage adjacent area, install a drain pan which can be drained to
out side of coach, under water heater.
4. Connect both 1/2˝ NPT water lines - hot water outlet female
(FIG 1-A) and cold water inlet female (FIG 1-B) and 3/8˝ flared LP gas
lines (FIG 1-C).
a. Allow flexibility in water and gas lines so you can pull unit
forward through wall one inch past skin (FIG 2.
b. Seal gas line entrance opening by sliding grommet (FIG 1-D) onto
3/8˝ tubing (FIG 1-F) before flaring tubing (FIG 1-F). Pull gas line
and grommet through opening in housing (FIG 1-C). Connect flare
fitting (FIG 1-E) and press grommet into opening. If gas line tubing
is already flared, cut grommet on one side. Place split grommet
over gas line and press it into opening.
c. Always use pipe lubricant on threads when connecting hot and
cold water couplings. A suitable plastic fitting is recommended.
Below is the most common type of installation for the water heater.
However, there are other approved methods such as baggage
compartment (refer to MPD 90093) and flush mounting installations
(refer to MPD 93948). Consult your Field Auditor, Account Manager, or
the Atwood Service Department if you have additional questions.
GENERAL INSTALLATION
• Recreation Vehicles ANSI A119.2/NFPA 501C.
• National Fuel Gas Code ANSI Z223.1 and/or CAN/CGA B149 Installation
Codes
• Federal Mobile Home Construction & Safety Standard, Title 24 CFR, part
3280, or when this Standard is not applicable, the Standard for Manufactured
Home Installations (Manufactured Home Sites, Communities and Set-Ups),
ANSI A255.1 and/or CAN/CSA-Z240 MH Series, Mobile Homes.
• National Electrical Code ANSI/NFPA No. 70 and/or CSA C22.1
• Park Trailers A119.5
• CSA standard Z240 RV Series, Recreational Vehicle.
USA AND CANADA
- FOLLOW ALL APPLICABLE STATE AND LOCAL CODES IN THE ABSENCE OF LOCAL CODES OR REGULATIONS, REFER TO CURRENT STANDARDS OF:
DO NOT
DO NOT
•
alter water heater for a positive grounding system.
DO NOT
•
modify water heater in any way.
• Install water heater on an exterior wall, with access door opening to
outdoors.
• Protect building materials from flue gas exhaust.
•
•
• All combustion air must be supplied from outside the RV, and all
products of combustion must be vented to outside the RV.
• Install in recreation vehicles only. RV’s are recreation vehicles
designed as temporary living quarters for recreation, camping, or
travel use having their own power or towed by another vehicle.
CRITICAL INSTALLATION WARNINGS
2
CUT OUT DIMENSION
DEPTH
WARNING
FIRE AND/OR EXPLOSION
use matches, candles or other sources of ignition when
checking for gas leaks.
DO NOT
FOR REPLACEMENT PARTS:
• DO NOT install anything less than a combination temperature-pressure
relief valve certified by a nationally recognized testing laboratory that
maintains periodic inspection of product of listed equipment or
materials, as meeting requirements for Relief Valves and Automatic
Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22.
Valve must have a maximum set pressure not to exceed 150 psi.
• Install valve into opening provided and marked for this purpose on
water heater.
• Installation must conform with local codes or in the absence of local
codes, American National Standard for Recreational Vehicles, ANSI
A119.2/NFPA 50IC.
temperature and pressure relief valve that complies with standard for
Relief Valves and Automatic Gas Shutoff Devices for Hot Water
Systems, ANSI Z21.22.
If you use a discharge line, do not use a reducing coupling or other
restriction smaller than outlet of relief valve. Allow complete drainage
of both valve and line.
THIS VALVE IS A SAFETY COMPONENT AND MUST NOT BE REMOVED FOR ANY REASON
OTHER THAN REPLACEMENT. This water heater is equipped with a
pressure temperature relief valve.
• DO NOT place a valve, plug or reducing coupling on outlet part of
EXPLOSION
WARNING
• Valve is not serviceable, it must be replaced.
• Tampering with valve will result in scalding injury.
• Tampering with valve will void warranty.
SCALDING INJURY
WARNING
PRESSURE-TEMPERATURE RELIEF VALVE - (FIG 10)
11. Turn on gas and check water heater and all connections for gas
leaks with leak detecting solution.
12. Fill water heater tank, check all connections for water leaks (FIG 1A & B).
•
6. Bend all flanges 90˚ along scored lines (FIG 3).
7. To prevent water leaks caulk thoroughly around opening, including
bend slots (FIG 3-A). Butyl Tape (1˝x1/8˝) may be substituted for
caulking material.
8. Push unit against caulking, secure 4-corner brackets FIG 4-A to
coach with No.8 - 3/4˝ round head screws (not furnished) or equivalent.
Complete the installation by inserting the same type of #8 screws in the
holes provided around the flange of the water heater housing. Check all
gaskets, they must adhere to the pan creating an air tight seal.
9. Attach access door (FIG 5).
a. Snap hinge pin (FIG 5-A) into clip (FIG 5-B).
b. Slide cover (FIG 5-C) onto hinge pin.
c. Slide hinge pin into cover, snapping into clip at same time (FIG 5-D).
NOTE: To remove hinge pin, support access cover and apply force to
corner of hinge pin as shown FIG 5-E.
10. Disconnect unit and its individual shut-off valve from gas supply
line during any pressure testing of system in excess of 1/2 PSIG
(3.4 kPa, 14˝ water column [W.C.]). DO NOT set inlet pressure higher
than maximum indicated on rating plate of gas valve (13˝ W.C.).
Isolate unit from gas supply line by closing its individual manual
shutoff valve during any pressure testing ) 1/2 psig.
Gallon
A
B
C
4-6
12-5/8˝
16-1/4˝
17-5/8˝
10
15-3/4˝
16-1/4˝
20-5/8˝
MINIMUM CLEARANCE FROM COMBUSTIBLE CONSTRUCTION
Sides:
0˝
Top:
0˝
Back:
0˝
Bottom:
0˝
CAPACITY
CUTOUT
BRÛLURES
• Installer une soupape de décharge de type pression-température
dans la conduite d’arrivée d'eau froide du chauffe-eau et fixer une
conduite d’évacuation sur la vanne extérieure du véhicule. Régler la
limite sur 680 à 850 kPa.
• Installer un réservoir d’expansion de type membrane dans la
conduite d’arrivée d'eau froide. Le réservoir devrait permettre une
dilatation d’environ 426 ml d'eau et une mise sous pression égale à
la pression de l'alimentation en eau. Ces dispositifs sont disponibles
chez un plombier ou dans un centre de service.
Lorsque la soupape de décharge de type pression-température
s’écoule à nouveau, répéter la procédure ci-dessus. Pour une solution
permanente, nous vous conseillons l'une des choses suivantes :
• Faire fonctionner manuellement la soupape de décharge de type
pression-température au moins une fois par an (FIG 10).
1. Couper l'alimentation principale en eau (la pompe ou la source
d'apport en eau).
2. Laisser l’eau refroidir ou la laisser couler jusqu’à ce qu’elle soit
froide.
3. Ouvrir le robinet d’eau chaude le plus proche du chauffe-eau.
4. Tirer la poignée de la soupape de décharge de type pressiontempérature vers soi et laisser l'eau couler, jusqu'à ce qu'elle
s'arrête.
5. Laisser la soupape de décharge de type pression-température
revenir brusquement en position fermée ; fermer le robinet ; ouvrir
l'alimentation en eau.
6. Allumer le chauffe-eau et le tester.
POUR RÉTABLIR L'INTERVALLE D'AIR, SUIVRE LES ÉTAPES SUIVANTES :
type pression-température et rétablir l’intervalle d'air. L'eau
contenue dans le réservoir doit être froide.
• Couper le chauffe-eau avant d'ouvrir la soupape de décharge de
AVERTISSEMENT
Lorsqu’une soupape de décharge de type pression-température goutte
pendant le fonctionnement du chauffe-eau, cela NE SIGNIFIE PAS
qu’elle est défectueuse. La soupape de décharge goutte parfois, du
fait d'une expansion naturelle de l'eau lorsque celle-ci est chauffée à
l'intérieur du réseau d’alimentation en eau d'un véhicule de plaisance.
Le réservoir du chauffe-eau Atwood comporte un intervalle d'air
interne en haut du réservoir, permettant de réduire les risques
d’égouttement. Au fil du temps, l'expansion de l'eau absorbe cet air et
l’intervalle doit être rétabli.
sur la sortie de la soupape de décharge de type pression-température.
• Ne pas placer de robinet, de bouchon ou de raccord de réduction
EXPLOSION
AVERTISSEMENT
SOUPAPE DE DÉCHARGE DE TYPE PRESSION-TEMPÉRATURE
15
POUR RINCER LE RÉSERVOIR AVEC DE L’EAU SOUS PRESSION :
Il faudra pomper de l’eau fraîche dans le réservoir, soit avec la
pompe transportée à bord, soit avec de l’eau sous pression externe.
Continuer le processus de rinçage pendant environ 5 minutes ; ceci
permet à l’eau fraîche de remuer l'eau stagnante du fond du réservoir
et de pousser les dépôts par l’orifice d’évacuation.
4. Replacer le bouchon de vidange et la soupape de décharge de type
pression-température.
5. Remplir le réservoir avec de l’eau fraîche ne contenant pas de
souffre.
Le chauffe-eau Atwood est conçu pour être utilisé dans les véhicules
de plaisance. Si vous utilisez votre véhicule fréquemment ou pour des
périodes prolongées, rincer le chauffe-eau plusieurs fois par an
permettra de prolonger la vie du réservoir d’approvisionnement.
L’air sous pression devra passer par le raccord de la soupape de
décharge de type pression-température. Le robinet de vidange
ouvert, l’air sous pression forcera l’eau restante à s’écouler de
l’unité.
POUR RINCER LE RÉSERVOIR AVEC DE L’AIR SOUS PRESSION :
Une odeur d’œuf pourri (sulfure d’hydrogène) pourra se dégager du fait
de l’action électrogalvanique du matériau de gainage qui dégage de
l’hydrogène de l’eau. En cas de présence de souffre dans l’alimentation
en eau, l’eau et le souffre se mélangent pour donner une odeur
désagréable.
1. Couper l’alimentation principale en eau. Évacuer l’eau du réservoir
du chauffe-eau et réinstaller le bouchon de vidange. Retirer la
soupape de décharge de type pression-température. Préparer une
solution de 4 parts de vinaigre blanc pour 2 parts d’eau. Au moyen
d’un entonnoir, verser la solution à l’intérieur du réservoir, avec
précaution.
2. Effectuer 4 à 5 cycles du chauffe-eau avec la solution indiquée cidessus en le laisser fonctionner normalement.
3. Retirer le bouchon de vidange et évacuer toute l’eau du réservoir.
Rincer le chauffe-eau pour en éliminer tout sédiment. Il est possible
de rincer le réservoir avec de l’air sous pression ou avec de l’eau
fraîche. Appliquer la pression soit sur les clapets d’arrivée ou de
sortie à l’arrière du réservoir, soit au raccord de la soupape de
décharge de type pression-température se trouvant à l’avant de
l’unité.
RINCER POUR ÉLIMINER LES MAUVAISES ODEURS
Page 115 of 145
Araignées, guêpes et autres insectes font parfois leur nid dans le tube
du brûleur. Cela risque de causer une mauvaise combustion, un retard
dans l’allumage ou un allumage à l'extérieur du tube de combustion.
Prêter attention à tout changement du son produit par le brûleur et de
l'apparence de la flamme (molle, calme et jaune vif plutôt que drue et
bleue). Cela indique que le tube du brûleur est obstrué (FIG 9-C).
Inspecter et nettoyer régulièrement.
a. Retirer la vis de l’obturateur d'air (FIG 9-A) et glisser l’obturateur
d'air (FIG 9-B) le long du tube du brûleur.
b. Introduire une brosse métallique flexible à l’intérieur du tube du
brûleur (FIG 9-C), jusqu'à ce qu'elle ressorte par l'autre extrémité
du tube.
ENTRETIEN PRÉVENTIF
• A l’usine, votre chauffe-eau a été équipé d’une carte imprimée à
fusible. Ce fusible protège la carte imprimée des courts-circuits
pouvant survenir dans les câblages. Si le fusible venait à s’activer, le
chauffe-eau ne pourrait pas fonctionner. Avant de remplacer le
fusible, vérifier que le court-circuit n’est pas externe à la carte
imprimée. Une fois le court-circuit réparé, remplacer le fusible de 2
ampères par un fusible mini de type ATO. Ne pas installer de fusible
de plus de 3 ampères.
• Si le fusible est bon mais que l’unité ne fonctionne pas, vérifier que la
tension du courant alimentant l’unité n’est pas trop élevé (plus de 14
volts).
• Si les deux étapes précédentes ne résolvent pas le problème, vérifier
le système de coupure thermique. Le système de coupure thermique
est installé dans le tuyau d’alimentation. Ce dispositif, une fois
déclenché, coupe l’arrivée du courant électrique et le fonctionnement
du chauffe-eau. Par exemple, en cas d’obstruction dans le tube
d’évacuation, comme le décrit la section d’Entretien préventif, la
flamme et la chaleur du brûleur risquent d’entrer en contact avec le
système de coupure ce qui fera fondre l’élément du fusible incorporé
dans le système de coupure thermique. Pour rétablir l’électricité et le
bon fonctionnement du chauffe-eau, l’obstruction doit être éliminée
et le système de coupure thermique doit être remplacé.
ENTRETIEN DE L'ALLUMAGE ÉLECTRONIQUE
• Le système de propane liquide et le système à eau doivent être allumés.
• Faire tester la pression du gaz régulièrement. La pression doit être
réglée à 279 mm de colonne d'eau, lorsque 3 appareils fonctionnent.
• Évacuer l'eau contenue dans le chauffe-eau à intervalles réguliers
(au moins une fois par an).
• Évacuer l'eau contenue dans le chauffe-eau avant de garer votre
véhicule de plaisance pour l'hiver ou lorsqu’il existe un risque de gel.
• S’assurer que l'évacuation et la grille d'air de combustion ne
comportent aucune obstruction.
• Comparer régulièrement la flamme du brûleur principal et les
flammes des veilleuses à la FIG 9 et les réglages du brûleur
principal avec la section COMMENT UTILISER VOTRE CHAUFFE-EAU.
• Lorsque vous n'utilisez pas le chauffe-eau, régler le levier (White
Rogers) ou le cadran (Robertshaw) du thermostat à la position la
plus basse possible. Cela réduira les effets de la température
extérieure sur le calibrage du mécanisme de commande de la
température.
INFORMATIONS GÉNÉRALES
L'utilisation d'éléments de chauffe provenant de fabricants de marché
secondaire pourra également entraîner des endommagements des
composantes ou du chauffe-eau. La garantie écrite Atwood stipule
que « la responsabilité d'un mauvais fonctionnement ou de dommages
causés par une modification au chauffe-eau revient à l’acheteur ».
Toute modification, telle que, par exemple, le rajout d'un élément de
chauffe de marché secondaire, annule la garantie.
• L'utilisation d'éléments de chauffe de marché secondaire comporte le risque
de perte de contrôle du chauffage du réservoir à eau et d’explosion d'eau
catastrophique.
risquent de ne pas avoir fait l’objet de certains contrôles de sécurité
importants.
• NE PAS modifier le chauffe-eau, sous peine d’annuler la garantie.
• NE PAS utiliser d'éléments de chauffe de marché secondaire, car ils
EXPLOSION / BRÛLURES
AVERTISSEMENT
ÉLÉMENTS DE CHAUFFE D'EAU DE MARCHÉ SECONDAIRE
14
Pour assurer le meilleur rendement de votre chauffe-eau et prolonger
la vie du réservoir, évacuer et rincer régulièrement le réservoir du
chauffe-eau. Avant le rangement à long terme ou avant l’arrivée du
gel, évacuer et rincer le réservoir.
1. Couper l'alimentation principale en eau (la pompe ou la source
d'apport en eau).
2. Évacuer l'eau du réservoir du chauffe-eau en retirant le bouchon de
vidange. Si l'eau coule de façon irrégulière ou goutte au lieu de
couler à jet normal, nous vous conseillons tout d’abord d’ouvrir la
soupape de décharge de type pression-température, pour permettre
à l'air d’entrer dans le réservoir. Ensuite, à l'aide d'un fil de fer de
petit diamètre ou d'un porte-manteau, piquer à l’intérieur de l’orifice
d'évacuation, de façon à éliminer toute obstruction.
3. Une fois le réservoir vide, étant donné l'emplacement du bouchon
de vidange, il restera environ 2 litres d'eau dans le réservoir. Cette
eau contient la plus grande partie des particules corrosives
dangereuses. Pour retirer ces particules corrosives dangereuses,
rincer le réservoir soit avec de l’air, soit avec de l’eau. Que vous
utilisiez de l'air ou de l’eau sous pression, l’application peut se faire
soit par l'entrée, soit par la sortie située à l'arrière du réservoir ou
de la soupape de décharge de type pression-température. (En cas
d’utilisation de la soupape de décharge de type pressiontempérature, il faudra d'abord retirer le rebord de sécurité). La
pression force l’eau et les particules corrosives restantes à
s’évacuer.
En cas d’utilisation d’eau sous pression, pomper de l'eau fraîche
dans le réservoir à l'aide d'une pompe transportée ou utiliser de
l'eau externe pendant 90 secondes, de façon à permettre à l'eau
fraîche de remuer l'eau stagnante se trouvant au fond du réservoir
et de propulser les dépôts par l’orifice d’évacuation. Continuer à
rajouter de l’eau et à évacuer, jusqu'à ce que l’eau restant dans le
réservoir ne comporte plus aucune particule.
4. Replacer le bouchon de vidange et fermer la soupape de décharge
de type pression-température. La quantité d’eau (environ 2 litres)
restant au fond du réservoir suite à la vidange ne causera pas de
dommage au réservoir en cas de gel.
INSTRUCTIONS POUR L'HIVERNAGE (RINÇAGE)
d'enlever le bouchon de vidange et de rincer le réservoir.
• Éteindre le chauffe-eau et attendre que l'eau refroidisse avant
BRÛLURES
AVERTISSEMENT
ENTRETIEN DU RÉSERVOIR DU CHAUFFE-EAU
Vérifier l'orifice du brûleur principal.
Nettoyer et régler le brûleur principal.
Le brûleur principal et les voies du clapet doivent être alignés.
Vérifier que la porcelaine de l'électrode ne comporte pas de
fissures.
5. Vérifier que l’écart entre l’électrode et le sol est bien de 3,1 mm.
6. Lorsque la carte des modules fonctionne en alternance, enlever la
carte et nettoyer la plaque à bornes avec une gomme pour crayon.
1.
2.
3.
4.
COMMENT NETTOYER LES MODÈLES À ALLUMAGE ÉLECTRONIQUE
1. Vérifier que l'orifice du brûleur principal et l'assemblage de la
veilleuse ne comportent aucune contamination (saleté, toiles
d'araignées, etc.).
2. Nettoyer le tube du brûleur principal avec une petite brosse.
3. Réglage du brûleur principal – ouvrir l’obturateur d'air à un quart.
4. Flamme de la veilleuse basse. Vérifier qu’il n’y ait pas de
contamination – si elle est propre, remplacer l'orifice de la
veilleuse.
COMMENT NETTOYER LES MODÈLES À VEILLEUSE
c. Nettoyer le brûleur à l’aide d'un aspirateur, à l'endroit où il
s’insère dans le tube de combustion.
d. Remettre l’obturateur d'air dans sa position d'origine et replacer la vis.
e. The orifice, burner tube and shutter nmust be aligned so that the shutter is not
binding on the air tube.
ELECTRONIC IGNITION - WIRING INSTRUCTIONS
1. Install unit according to GENERAL INSTALLATION instructions.
NOTE: It is recommended unit be connected directly to a 12V DC battery
or to filtered side of an AC/DC converter. Avoid connections to
unfiltered side of an AC/DC converter whenever possible. Use a
minimum of 18 gauge wire, UL and CSA listed.
Refer to WIRING DIAGRAM. Install remote switch in a convenient
location. Position wall plate with letters up. Before making
connections turn switch OFF. The switch is off when the button is
depressed towards terminal see wiring diagram.
Operation using gas continue to HOW TO OPERATE YOUR WATER HEATER,
electrically continue to COMBINATION Gas/Electric OPERATION.
• Label all wires before disconnecting when servicing controls.
• Verify proper operation after servicing.
ELECTRICAL DAMAGE
CAUTION
• Use electrical metallic tubing, flexible metal conduit, metal clad cable,
or nonmetallic-sheathed cable with grounding conductor. Wire must
have a capacity of 1500 watts or greater. The wiring method must
conform to applicable sections of article 551 of National Electrical
Code ANSI/NFPA 70.
2. Refer to Wiring Diagram. Make 120 VAC electrical connections from
junction box on back of unit.
a. Connect hot lead to (1) Black.
b. Connect common lead to (2) White.
c. Connect ground wire from electrical service to (3) green ground
lead in junction box 3. Place switch in “OFF” position.
• When a cord and plug connection to the power supply are used on
water heater, power cord must be UL listed as suitable for damp
locations, hard or extra hard usage. It must be a flexible cord such as
type S, SO, ST, STO, SJ, SJT, SJTO, HS or HSO cord as described in
National Electrical Code, ANSI/NFPA 70. The length of external cord to
water heater, measured to face of attachment plug, shall be no less
than 2 feet nor more than 6 feet. Supply cord must be a minimum of
14 AWG and attachment plug must be rated at 15 amps.
• When using Romex® with a bare earth ground, take care to position
ground wire so it does not contact the heating element terminals.
CAUTION
PRODUCT DAMAGE
For COMBINATION GAS/ELECTRIC MODELS continue —
This water heater is designed to operate with gas, electricity, or a
combination of both.
Provide adequate clearance at rear of unit for service of water
connections and operation of manually re-setable high temperature limit
switch on combination gas/electric units.
1. Follow GENERAL INSTALLATION instructions.
NOTE: All wiring must comply with applicable electrical codes.
For HEAT EXCHANGE continue —
1. Push 5/8˝ dia. 2 or 3 coolant system hose with SAE 053 A Type
“E”clamp attached (FIG 6-E) onto heat exchange tube as far as
possible (FIG 6-B).
2. Spread hose clamp and slide toward heat exchange unit past annular
groove (FIG 6-C) and release.
3. Continue to HOW TO OPERATE YOUR WATER HEATER and/or Electronic
Ignition OPERATION.
• For an external electrical source, ground this unit in accordance with
National Electrical Code ANSI/NFPA70.
Your Atwood gas water heater is now ready for operation. Continue to
HOW TO OPERATE YOUR WATER HEATER.
Electronic Ignition continue to Electronic Ignition WIRING INSTRUCTIONS.
Pilot Relight continue to Pilot Relight WIRING INSTRUCTIONS.
3
FIRE
Do not smoke or have any flame near an open faucet.
1. Turn gas control valve knob (FIG 7-B or FIG 8-B) to OFF position.
2. Wait at least five minutes to allow accumulated gas in burner
compartment to escape.
3. Water heater may be equipped with a White Rodgers® or
Robertshaw Unitrol® Control.
PILOT OPERATION
• Do not operate without water in tank.
CAUTION
PRODUCT FAILURE
• Do not tamper with pilot orifice.
WARNING
SCALDING INJURY
If hydrogen gas is present, you will probably hear sounds like air
escaping through the pipe as water begins to flow.
If water heater has not been used for more than two weeks, hydrogen
gas may form in water line. Under these conditions to reduce the risk
of injury, open hot water faucet for several minutes at kitchen sink
before you use any electrical appliance connected to hot water system.
•
CAUTION
HOW TO OPERATE YOUR WATER HEATER
store or use gasoline or other flammable vapors and liquids in
the vicinity of this or any other appliance.
• Should overheating occur, or gas supply fail to shut off, turn OFF
manual gas control valve to appliance, or turn gas OFF at the LP
tank. On ELECTRONIC IGNITION MODEL turn operating switch to OFF
position and remove red wire from left hand terminal of ECO switch
or turn gas OFF at the LP tank.
• Use with LP gas only.
• Shut off gas appliances and pilot lights when refueling.
• On PILOT RELIGHT MODELS, turn off the ignition module when
refueling gasoline tanks or LP tanks.
• Turn gas OFF at the LP tank when vehicle is in motion. This disables
all gas appliances and pilot lights. Gas appliances must never be
operated while vehicle is in motion. Unpredictable wind currents
may be created which could cause flame reversal in the burner
tube, which could result in fire damage. The thermal cut off fuse
could also be unnecessarily activated resulting in a complete
shutdown of the water heater requiring replacement of the thermal
cut off. See maintenance of electronic ignition water heaters for
further explanation of the thermal cut off.
• LP tanks must be filled by a qualified gas supplier only.
• DO NOT
WARNING
EXPLOSION OR FIRE
CONSUMER SAFETY WARNINGS
1. Install unit according to GENERAL INSTALLATION instructions.
2. Refer to Wiring Diagram. Use 18 gauge wire, UL/CSA listed.
3. Read PILOT & PILOT RELIGHT OPERATIONS.
PILOT RELIGHT - WIRING INSTRUCTION
2. Installing wires:
a. blue lead to switch terminal (6) on indicator light of switch
b. terminal (4) on indicator light of switch to negative battery terminal
c. green lead to negative battery terminal
d. brown lead on water heater to terminal (3) on switch
e. terminal 2 on switch to positive battery terminal.
3. Read ELECTRONIC IGNITION OPERATION.
Page 116 of 145
1. For gas operation refer to Pilot, Pilot Relight or Electronic Ignition
OPERATION section (as applicable).
2. For electrical operation use switch at the rear of water heater.
3. Completely fill tank with water.
COMBO gas/electric ELECTRIC OPERATION
1. Turn the switch located on the spark module to the ON position.
2. Read PILOT OPERATION instructions.
3. For complete shut down, turn lighting control knob on thermostat
and spark module switch to the OFF position.
Read MAINTENANCE AND CARE INSTRUCTIONS
PILOT RELIGHT OPERATION
1. Refer to WIRING DIAGRAM. Place remote switch in ON position.
2. If remote switch light stays on longer than 15 seconds, place
remote switch in OFF position and wait 5 minutes.
3. Repeat step one.
4. For complete shut-down and before servicing:
a. Place remote switch in OFF position.
b. Remove red wire from left hand terminal of ECO switch (ECO to
valve).
5. If heater fails to operate due to high water temperature, a lockout
condition occurs (indicator light on). After water cools, reset switch
in OFF position for at least 30 seconds, then turn to ON position.
6. If a lockout condition persists contact an Atwood Service Center.
Read MAINTENANCE AND CARE INSTRUCTIONS & ELECTRONIC IGNITION
MAINTENANCE
ELECTRONIC IGNITION OPERATION
Read MAINTENANCE AND CARE INSTRUCTIONS
5. To Adjust Main Burner (FIG 9):
a. Loosen air shutter screw (FIG 9-A).
b. Slide air shutter (FIG 9-B) to right until some yellow appears in
main burner flame.
c. Move air shutter (FIG 9-B) to left until yellow disappears.
d. Retighten air shutter screw (FIG 9-A).
The temperature knob or lever is factory adjusted to its lowest dial
setting. We recommended the mid-point position between warm and
hot, as noted above. This will provide for energy efficient operation
and sufficient hot water. Valves for reducing point of use temperature
by mixing cold and hot water are available. Consult a licensed plumber
or local plumbing authority.
excessively hot water.
• Setting temperature control dial at a higher position will produce
SCALDING INJURY
WARNING
4. For complete shut down and before servicing, turn gas control knob
(FIG 7-B or FIG 8-B) to OFF position. When water heater is not in use
set temperature control lever (White Rogers®) or dial (Robertshaw®)
to lowest possible position.
FOR A ROBERTSHAW UNITROL® (FIG 8)
a. Turn lighting control dial (FIG 8-B) to PILOT position.
b. Depress and hold reset push button (FIG 8-A) while lighting pilot
burner (FIG 9-D).
c. Allow pilot to burn 30 seconds before releasing reset push button.
d. If pilot does not remain lit, repeat operation allowing longer
period before releasing reset push button.
e. Turn lighting control dial (FIG 8-B) to ON position.
f. Set temperature control dial (FIG 8-C) at mid-point position
between warm and hot.
g. Close access door.
FOR WHITE RODGERS® CONTROL (FIG 7)
a. Turn lighting control knob (FIG 7-B) to PILOT position and hold
against stop while lighting pilot burner (FIG 9-D).
b. Allow pilot to burn 30 seconds then release lighting control knob.
c. Turn lighting control knob (FIG 7-B) to ON position.
d. If pilot does not remain lit, repeat operation allowing longer
period before releasing lighting control knob.
e. Set temperature selection lever (FIG 7-A) at mark between warm
and hot position.
f. Close access door.
4
• The water heater comes factory-equipped with a fused circuit board,
which will protect the circuit board from wiring shorts. If the fuse
should activate, the water heater will not operate. Before replacing
the fuse, check for a short external to the board. Once the short is
corrected, replace the 2 amp fuse with a mini ATO style fuse. Do not
install a fuse larger than 3 amps.
• If the fuse is good and the unit is inoperative, check for excessively
high voltage to the unit (more than 14 volts).
• If the previous two steps did not solve the problem, check the
thermal cut-off. The thermal cutoff is a device installed in the power
supply line. This device will shut off electrical power and stop
heater operation when activated. For example, if an obstruction
within the flue tube should occur, such as described above in the
Preventative maintenance section, the burner flame/heat may
contact the cutoff, resulting in a melting of the fuse element
incorporated in the thermal cutoff. In order to restore power and
proper operation of the water heater, the obstruction must be
removed and the thermal cutoff must be replaced.
ELECTRONIC IGNITION MAINTENANCE
• LP and Water system must be turned on.
• Have gas pressure tested periodically. Should be set at 11 inches of
water column with three appliances running.
• Drain water heater at regular intervals (at least one time during the
year).
• Drain water heater before storing RV for the winter or when the
possibility of freezing exists.
• Keep vent and combustion air grill clear of any obstructions.
• Periodically, compare flame of main and pilot burners with FIG ➈
and main burner adjustments in HOW TO OPERATE YOUR WATER HEATER.
• When water heater is not in use set temperature control lever (White
Rogers) or dial (Robertshaw) to lowest possible position. This will
reduce the effects of low outdoor temperatures on calibration of
temperature control mechanism.
• Presence of soot indicates the need to adjust flue.
GENERAL INFORMATION
The use of any aftermarket heating element devices may also result in
damage to components or water heater. Atwood’s written warranty
states - “failure or damage resulting from any alteration to our water
heater is the owner’s responsibility”. Any alteration, like the addition of
an aftermarket heating element device, will void the warranty.
heating of water tank and a catastrophic wet side explosion.
• Use of Aftermarket heating elements can lead to an out of control
controls.
• DO NOT alter water heater, it will void warranty.
• DO NOT USE Aftermarket heating elements, they can lack critical safety
EXPLOSION / BURN INJURY
WARNING
AFTERMARKET WATER HEATING ELEMENT DEVICES
material, and flammable liquids and vapors.
• Shut off gas supply at LP container before disconnecting a gas line.
• Keep control compartment clean and free of gasoline, combustible
FIRE OR EXPLOSION
WARNING
Location and phone numbers of qualified Service Centers can be found
at our website http:/www.atwoodmobile.com or call 574-264-2131 to
have a Service Center List mailed.
SERVICE CALLS & QUESTIONS
MAINTENANCE AND CARE INSTRUCTIONS
4. Turn switch ON (FIG 11-B) (located at rear of water heater).
NOTE: Turning power on to heater without water covering heating
element may burn out element and void warranty.
5. Check for proper operation. Water temperature is set at 140°F (60°C).
6. If the manual reset high temperature limit switch should operate,
reset switch (FIG 11-A) by depressing with pencil or other
nonmetallic object. If still experiencing problems contact an
authorized Atwood Service Center or Atwood Service Department.
Read MAINTENANCE AND CARE INSTRUCTIONS.
5. Réglage du brûleur principal (FIG 9) :
1. Desserrer la vis de l’obturateur d'air (FIG 9-A).
2. Faire glisser l’obturateur d'air (FIG 9-B) vers la droite, jusqu'à ce
que du jaune apparaisse dans la flamme du brûleur principal.
Le bouton ou le levier de commande de la température est réglé au
plus bas à l'usine. Comme indiqué ci-dessus, nous vous conseillons
d’utiliser un réglage moyen, entre chaud et très chaud. Cela permet un
fonctionnement éconergétique, tout en garantissant que l’eau est
suffisamment chaude. Il est possible d'installer des robinets
mélangeurs, permettant de régler la température de l'eau au point
d'utilisation. S’adresser à un plombier agréé ou aux autorités locales
de plomberie.
l'eau brûlante.
• Régler le cadran à une température plus élevée aura pour résultat de
BRÛLURES
AVERTISSEMENT
4. Pour éteindre complètement l'unité ou pour toute réparation, placer
le robinet de commande du gaz (FIG 7-B ou FIG 8-B) sur la position
éteinte (OFF). Lors des périodes de non-utilisation du chauffe-eau,
régler le levier (White Rogers®) ou le cadran (Robertshaw®) du
thermostat sur la position la plus basse possible.
POUR LES COMMANDES ROBERTSHAW UNITROL® (FIG 8)
a. Tourner le cadran de réglage de l'allumage (FIG 8-B) sur la
position VEILLEUSE (PILOT).
b. Appuyer sur le bouton-poussoir de réarmement (FIG 8-A) et le
maintenir appuyé, tout en allumant le brûleur de la veilleuse (FIG 9-D).
c. Laisser la veilleuse brûler pendant 30 secondes avant de relâcher
le bouton-poussoir de réarmement.
d. Si la veilleuse ne reste pas allumée, répéter l'opération en gardant
le bouton-poussoir de réarmement appuyé plus longtemps.
e. Mettre le cadran de réglage de l'allumage (FIG 8-B) en position
allumée (ON).
f. Régler le cadran du thermostat (FIG 8-C) à une température
moyenne, entre chaud (warm) et très chaud (hot).
g. Fermer la trappe d'accès.
POUR LES COMMANDES WHITE RODGERS® (FIG 7)
a. Tourner le bouton de commande de l’allumage (FIG 7-B) en
position VEILLEUSE (PILOT) et le maintenir contre la butée
pendant l'allumage de la veilleuse (FIG 9-D).
b. Laisser la veilleuse brûler pendant 30 secondes puis relâcher le
bouton de commande de l'allumage.
c. Mettre le bouton de commande de l’allumage (FIG 7-B) en
position allumée (ON).
d. Si la veilleuse ne reste pas allumée, répéter l'opération en
gardant le bouton de commande de l’allumage appuyé plus
longtemps.
e. Positionner le levier du thermostat (FIG 7-A) sur le repère situé
entre la position chaude (WARM) et très chaude (HOT).
f. Fermer la trappe d'accès.
1. Mettre le robinet de commande du gaz (FIG 7-B ou FIG 8-B) en
position arrêt (OFF).
2. Attendre au moins 5 minutes pour permettre au gaz accumulé dans
le compartiment du brûleur de s'échapper.
3. Le chauffe-eau pourra comporter une commande White Rodgers®‚
ou une commande Robertshaw Unitrol® FIG 7.
FONCTIONNEMENT DE LA VEILLEUSE
• Ne pas faire fonctionner sans eau dans le réservoir.
PANNE DE L'APPAREIL
ATTENTION
• Ne pas toucher l'orifice de la veilleuse.
BRÛLURES
AVERTISSEMENT
En cas de présence d’hydrogène dans les conduites, vous entendrez
probablement l'air s'échapper du tuyau, lorsque l'eau commence à
couler.
13
comporte pas de carburant, de matériaux combustibles ou de
liquides ou vapeurs inflammables.
• S’assurer que le compartiment de commande est propre et ne
avant de débrancher la conduite de gaz.
• Fermer l'alimentation en gaz au niveau du réservoir de propane liquide
AVERTISSEMENT
INCENDIE OU EXPLOSION
Les adresses et les numéros de téléphone des centres de service
agréés se trouvent sur notre site Internet http:/www.atwoodmobile.com
ou composer le 574-264-2131 pour recevoir la liste par courrier.
APPELS ET QUESTIONS D’ENTRETIEN
INSTRUCTIONS POUR L'ENTRETIEN
Lire LES INSTRUCTIONS POUR L’ENTRENTIEN.
1. Pour le fonctionnement au gaz, se reporter à la section FONCTIONNEMENT
de la veilleuse, FONCTIONNEMENT du rallumage de la veilleuse ou
FONCTIONNEMENT de l’allumage électronique (le cas échéant).
2. Pour le fonctionnement électrique, utiliser l'interrupteur situé à
l'arrière du chauffe-eau
3. Remplir complètement le réservoir avec de l'eau.
4. Mettre l'interrupteur situé à l'arrière du chauffe-eau en position
allumée (ON) (FIG 11-B).
REMARQUE : allumer l’élément chauffant sans l’immerger dans l'eau
risque de brûler l'élément et donc d’annuler la garantie.
5. Vérifier le bon fonctionnement de l'unité. La température de l'eau
est réglée sur 60°C.
6. Si l'interrupteur limiteur de haute température à réarmement manuel
se déclenche, réarmer l'interrupteur (FIG 11-A) en appuyant dessus
à l'aide d'un crayon ou de tout autre objet non métallique. Si les
problèmes persistent, contacter un centre de service agréé Atwood
ou le centre de service à la clientèle Atwood.
FONCTION COMBINÉE gaz-électricité
Lire LES INSTRUCTIONS POUR L'ENTRETIEN
1. Mettre l'interrupteur situé sur le module d'allumage en position
allumée (ON).
2. Lire les instructions FONCTIONNEMENT DE LA VEILLEUSE.
3. Pour éteindre complètement l'unité, mettre le bouton de commande
de l'allumage situé sur le thermostat et sur le module d'allumage en
position éteinte (OFF).
FONCTIONNEMENT DU RALLUMAGE DE LA VEILLEUSE
1. Consulter le SCHÉMA DE CÂBLAGE. Mettre la commande à distance en
position allumée (ON).
2. Si la commande à distance reste allumée pendant plus de 15
secondes, la placer en position éteinte (OFF) et attendre 5 minutes.
3. Répéter la première étape.
4. Pour éteindre complètement l'unité et avant d’effectuer des
réparations :
a. Mettre la commande à distance en position éteinte (OFF).
b. Enlever le fil rouge de la borne gauche de l'interrupteur ECO
(ECO au robinet).
5. Si le chauffe-eau ne fonctionne pas car la température de l’eau est
trop élevée, il se verrouille (voyant lumineux allumé). Une fois l'eau
refroidie, remettre l'interrupteur en position éteinte (OFF) pendant au
moins 30 secondes, puis repasser à la position allumée (ON).
6. Si le verrouillage persiste, contacter un centre de service Atwood.
Lire les INSTRUCTIONS POUR L’ENTRETIEN et L'ENTRETIEN DE L'ALLUMAGE
ÉLECTRONIQUE.
FONCTIONNEMENT DE L'ALLUMAGE ÉLECTRONIQUE
LIRE LES INSTRUCTIONS POUR L'ENTRETIEN
3. Glisser l’obturateur d'air (FIG 9-B) vers la gauche jusqu'à ce que
le jaune disparaisse.
4. Resserrer la vis de l’obturateur d'air (FIG 9-A).
Page 117 of 145
• Après toute réparation, vérifier le bon fonctionnement de l'unité.
les déconnecter.
• Lors de la réparation des commandes, étiqueter tous les fils avant de
ENDOMMAGEMENTS ÉLECTRIQUES
ATTENTION
• Utiliser un conduit électrique métallique, un conduit métallique souple,
un câble à blindage métallique ou un câble blindé non-métallique avec
fil de masse. Le fil doit avoir une capacité supérieure ou égale à 1500
watts. La méthode de câblage doit être conforme aux sections
applicables de l'article 551 du Code électrique national ANSI/NFPA 70.
2. Consulter le schéma électrique. Faire les branchements de 120 VCA à
partir du boîtier de dérivation au dos de l'appareil.
a. Brancher le fil de phase sur le noir (1).
b. Brancher le fil neutre sur le blanc (2).
c. Brancher le fil de masse de l'alimentation électrique sur le fil de
masse vert (3) à l'intérieur du boîtier de dérivation 3. Mettre
l’interrupteur en position arrêt (OFF).
• Lorsque vous effectuez une connexion avec un fil et une fiche, pour
alimenter le chauffe-eau, le fil doit être homologué UL et convenir aux
lieux humides et aux usages intenses et super intenses. Le fil doit être
souple, de type S, SO, ST, STO, SJ, SJT, SJTO, HS ou HSO, selon les
normes du Code électrique national, ANSI/NFPA 70. La longueur du fil
menant au chauffe-eau, mesurée à partir de la fiche, ne doit pas
dépasser 1,8 m, ni être inférieure à 0,6 m. Le fil d'alimentation
électrique doit avoir une taille minimale de 14 AWG et la fiche doit
posséder une capacité nominale de 15 ampères.
• Lorsque vous utilisez du Romex® avec une mise à la terre nue, faire
attention de placer le fil de mise à la terre de manière à ce qu’il
n’entre pas en contact avec les bornes de l’élément chauffant.
ENDOMMAGEMENTS DU PRODUIT
ATTENTION
Suite pour les MODÈLES COMBINÉS GAZ-ÉLECTRICITÉ — Ce chauffe-eau a
été conçu pour fonctionner au gaz, à l'électricité ou aux deux. Laisser
suffisamment d’espace à l’arrière de l'unité pour réparer les raccordements
de l'eau et pour régler l'interrupteur limiteur de haute température à
réarmement manuel, pour les unités combinées gaz-électricité.
1. Suivre les instructions d'INSTALLATION GÉNÉRALE.
REMARQUE : tout le câblage doit être conforme aux codes électriques en
vigueur.
Continuer pour l'ÉCHANGE DE CHALEUR —
1. Pousser un tuyau de système de refroidissement 2 ou 3 d’un
diamètre de 1,6 cm avec un collier SAE 053 Type E attaché aussi loin
que possible (FIG 6-E) sur le tube de l'échangeur (FIG 6-B).
2. Ouvrir le collier, le faire glisser vers l'échangeur de chaleur, au-delà de
la rainure annulaire (FIG 6-C), puis le relâcher.
3. Passer à COMMENT UTILISER VOTRE CHAUFFE-EAU et/ou
FONCTIONNEMENT de l’allumage électronique.
Pour le rallumage de la veilleuse, passer à INSTRUCTIONS DE CÂBLAGE
pour le rallumage de la veilleuse.
Pour l’allumage électronique, passer à INSTRUCTIONS DE CÂBLAGE pour l’allumage
électronique.
Votre chauffe-eau à gaz Atwood est maintenant prêt à fonctionner.
Passer à COMMENT UTILISER VOTRE CHAUFFE-EAU.
PIÈCES DE RECHANGE :
• Installer AU MINIMUM une soupape de décharge combinée de type
température-pression homologuée par un laboratoire de test reconnu
au niveau national, qui inspecte régulièrement les produits
d’équipement ou de matériaux concernés, selon les normes pour les
soupapes de décharge et les mécanismes de coupure automatique de
l’alimentation en gaz pour systèmes à eau chaude ANSI Z21.22. Le
réglage de la pression de la soupape ne doit pas dépasser 1034 kPa.
• Installer la soupape dans l'ouverture prévue et marquée à cet effet sur
le chauffe-eau.
• L'installation doit être conforme aux codes locaux ou, faute de
codes locaux, à la norme américaine nationale pour véhicules de
plaisance ANSI A119.2/NFPA 50IC.
• En cas de source électrique externe, cet appareil doit être mis à la
terre selon le Code électrique national ANSI/NFPA70.
En cas d’utilisation d’un tuyau d'écoulement, ne pas utiliser de
raccord réducteur ou toute autre restriction qui soit inférieure en
diamètre à la sortie de la soupape de décharge. Laisser la soupape et
la conduite s'écouler complètement.
12
Ne pas fumer ou tenir de flamme à proximité d'un robinet ouvert.
INCENDIE
ATTENTION
COMMENT UTILISER VOTRE CHAUFFE-EAU
Si le chauffe-eau n'a pas été utilisé pendant plus de deux semaines, il
est possible que de l'hydrogène se soit formé dans la conduite d'eau.
Dans ces conditions, avant d'utiliser tout appareil électrique branché
sur le système d'eau chaude, faire couler l'eau du robinet d'eau
chaude de l’évier de la cuisine pendant plusieurs minutes pour réduire
le risque de blessures.
•
•
NE PAS entreposer ou utiliser de carburant ou tout autre liquide ou
vapeurs inflammables à proximité de cet appareil ou de tout autre
appareil.
• En cas de surchauffe ou si l'alimentation en gaz ne s'arrête pas
convenablement, mettre le robinet d'alimentation en gaz de l’unité
en position arrêt (OFF) ou fermer le gaz au niveau du réservoir de
propane liquide. Sur le MODÈLE À ALLUMAGE ÉLECTRONIQUE, mettre
l'interrupteur de commande en position arrêt (OFF) et retirer le fil
rouge de la borne gauche de l'interrupteur ECO ou fermer le gaz au
niveau du réservoir de propane liquide.
• Utiliser uniquement avec du gaz de propane liquide.
• Lors du ré-approvisionnement en carburant, éteindre les appareils à
gaz et les veilleuses.
• Sur les MODÈLES AVEC RALLUMAGE DE LA VEILLEUSE, éteindre le
module d'allumage lors du ré-approvisionnement en carburant dans
les réservoirs à carburant ou à propane liquide.
• Éteindre le gaz au niveau du réservoir à propane liquide, lorsque le
véhicule est en déplacement. Cela permet de désactiver tous les
appareils et toutes les veilleuses. Les appareils à gaz ne doivent
jamais fonctionner lorsque le véhicule se déplace. Des mouvements
d'air imprévisibles risqueraient d’entraîner un retour de flamme dans
le tube du brûleur, ce qui pourra causer des endommagements par
le feu. Le fusible de coupure thermique pourra également être activé
accidentellement et éteindre complètement le chauffe-eau. Le
système de coupure thermique devra alors être remplacé. Consulter
l'entretien des chauffes-eau à allumage électronique pour plus de
détails sur la coupure thermique.
• Les réservoirs à propane liquide devront être remplis uniquement
par un fournisseur en gaz qualifié.
EXPLOSION OU INCENDIE
AVERTISSEMENT
CONSIGNES DE SÉCURITÉ DESTINÉES AU CONSOMMATEUR
1. Installer l'unité selon les instructions d'INSTALLATION GÉNÉRALE.
2. Consulter le schéma électrique. Utiliser du fil de taille 18 homologué UL et
CSA.
3. Lire FONCTIONNEMENT DE LA VEILLEUSE et FONCTIONNEMENT DU RALLUMAGE
DE LA VEILLEUSE.
INSTRUCTIONS DE CÂBLAGE POUR LE RALLUMAGE DE LA VEILLEUSE
INSTRUCTIONS DE CÂBLAGE POUR L'ALLUMAGE ÉLECTRONIQUE
1. IInstaller l'unité selon les instructions d'INSTALLATION GÉNÉRALE.
REMARQUE : il est recommandé de brancher l'unité directement sur une
batterie de 12 VCC ou en aval du filtre du convertisseur électrique CACC. Éviter, autant que possible, tout branchement en amont du
convertisseur CA-CC. Utiliser un fil de taille 18 homologué UL et CSA.
Consulter le SCHÉMA ÉLECTRIQUE. Installer l'interrupteur de commande à
distance dans un endroit pratique. Positionner la plaque murale, les
lettres debout. Avant d’effectuer le branchement, mettre l'interrupteur en
position arrêt (OFF). L'interrupteur est en arrêt (OFF) lorsque le bouton
est enfoncé vers la broche (3).
2. Branchement des fils :
a. Le fil bleu sur la broche de l'interrupteur (6), sur le voyant lumineux
de l'interrupteur.
b. La broche (4) du voyant de l'interrupteur sur la borne négative de
la batterie.
c. Le fil vert sur la borne négative de la batterie.
d. Le fil marron du chauffe-eau sur la broche (3) de l'interrupteur.
e. La broche (2) de l'interrupteur sur la borne positive de la batterie.
3. Lire FONCTIONNEMENT DE L'ALLUMAGE ÉLECTRONIQUE.
Pour le fonctionnement au gaz, passer à COMMENT UTILISER VOTRE
CHAUFFE-EAU, et pour le fonctionnement électrique, passer à
FONCTIONNEMENT COMBINÉ gaz-électricité.
To insure the best performance of your water heater and add to the life
of the tank, periodically drain and flush the water heater tank. Before
long term storage or freezing weather drain and flush the tank.
1. Turn off main water supply (the pump or water supply (the pump or
water hook up source).
2. Drain Water Heater Tank by removing the drain plug. If the water
flows sporadically or trickles instead of a steady stream of water, we
recommend the following action; first open the Pressure
Temperature Relief Valve to allow air into the tank and secondly,
take a small gauge wire or coat hanger and poke through the drain
opening to eliminate any obstructions.
3. After draining the tank, because of the placement of the Drain Plug,
approximately two quarts of water will remain in the tank. This water
contains most of the harmful corrosive particles. To remove these
harmful corrosive particles flush the tank with either air or water.
Whether using air or water pressure, it may be applied through the
inlet or outlet on the rear of the tank or the Pressure Temperature
Relief Valve. (If using the Pressure Temperature Relief Valve the
Support Flange must be removed). The pressure will force out the
remaining water and the corrosive particles.
If you use water pressure, pump fresh water into the tank with the
assistance of the on-board pump or use external water for 90
seconds to allow the fresh water to agitate the stagnant water on
the bottom of the tank and force deposits through the drain
opening. Continue repeating adding water and draining until the
particles have been cleared from the water remaining in the tank.
4. Replace the Drain Plug and close the Pressure Temperature Relieve
Valve. The approximately two quarts of water remining in the tank
after draining will not cause damage to the tank should freezing occur.
WINTERIZING (FLUSHING) INSTRUCTIONS
removing drain plug to flush tank.
• Turn off water heater and allow time for water to cool before
WARNING
SCALDING INJURY
WATER HEATER TANK CARE
Check main burner orifice.
Clean and adjust main burner.
Main burner and valve manifold must align with each other
Check electrode for cracked porcelain.
Check electrode for proper gap - 1/8” between electrode and
ground.
6. If module board functions intermittently, remove board and clean
terminal block with pencil eraser.
1.
2.
3.
4.
5.
HOW TO CLEAN ELECTRONIC IGNITION MODEL
1. Check main burner orifice and pilot assembly for contamination
(dirt, spider webs, etc.).
2. Clean main burner tube with small brush.
3. Main burner adjustment - open air shutter 1/4 way.
4. Low pilot flame. Check for contamination - if clean have the pilot
orifice replaced.
HOW TO CLEAN PILOT MODELS
Spiders, mud wasps, and other insects can build nests in burner tube.
This causes poor combustion, delayed ignition or ignition outside
combustion tube. Listen for a change in burner sounds or in flame
appearance from a hard blue flame to a soft lazy flame or one that is
very yellow. These are indications of an obstruction in burner tube
(FIG 9-C). Inspect and clean on a regular basis.
a. Remove air shutter screw (FIG 9-A) and slide air shutter (FIG 9-B)
down burner tube.
b. Run a flexible wire brush down burner tube (FIG 9-C) until it is
visible at end of burner tube.
c. Vacuum burner where it enters combustion tube.
d. Return air shutter to original position and replace screw.
e. The orifice, burner tube and shutter must be aligned so that the shutter is not
binding on the air tube.
PREVENTATIVE MAINTENANCE
5
A rotten egg odor (hydrogen sulfide) may be produced when the electro
galvanic action of the cladding material releases hydrogen from the
water. if sulfur is present in the water supply the two will combine and
produce an unpleasant smell.
1. Turn off main water supply. Drain the water heater tank and reinstall
drain plug. Remove the pressure-temperature relief valve. Mix
solution of 4 parts white vinegar to two parts water. With a funnel,
carefully pour solution into tank.
2. Cycle water heater with the above solution, letting it run under
normal operation 4-5 times.
3. Remove the drain plug and thoroughly drain all water from the tank.
Flush the water heater to remove any sediment. You may flush the tank
with air pressure or fresh water. pressure may be applied through either
the inlet or outlet valves on the rear of the tank or through the pressuretemperature relief valve coupling located on the front of the unit.
TO FLUSH TANK WITH AIR PRESSURE:
Insert your air pressure through the pressure-temperature relief valve
coupling. With the drain valve open, the air pressure will force the
remaining water out of the unit.
To flush tank with water pressure:
Fresh water should be pumped into the tank with either the onboard
pump or external water pressure. Continue this flushing process for
approximately 5 minutes, allowing the fresh water to agitate the
stagnant water on the bottom of the tank and forcing the deposits
through the drain opening.
4. Replace drain plug and pressure-temperature relief valve.
5. Refill tank with fresh water that contains no sulphur.
The Atwood water heater is designed for use in a recreation vehicle. If
you use your vehicle frequently or for long periods of time, flushing the
water heater several times a year will prolong the life of the storage tank.
FLUSHING TO REMOVE UNPLEASANT ODOR
TO REPLACE THE AIR GAP FOLLOW THESE STEPS:
1. Turn off main water supply (the pump or water hook up source).
2. Let water cool or let run until cool.
3. Open the hot water faucet closest to the water heater.
4. Pull handle of pressure temperature relief valve straight out and
allow water to flow until it stops.
5. Allow pressure temperature relief valve to snap shut; close faucet;
turn on water supply.
6. Turn on water heater and test.
• At least once a year manually operate pressure-temperature relief
valve (FIG 10).
When pressure-temperature relief valve discharges again, repeat above
procedure. For a permanent solution, we recommend one of the following:
• Install a pressure relief valve in cold water inlet line to water heater
and attach a drain line from valve to outside of coach. Set to relieve
at 100-125 PSI.
• Install a diaphragm-type expansion tank in cold water inlet line.
Tank should be sized to allow for expansion of approximately 15 oz.
of water and pre-charged to a pressure equal to water supply
pressure. These devices can be obtained from a plumbing
contractor or service center.
valve to establish air space. Storage water must be cool.
• Turn off water heater before opening pressure-temperature relief
SCALDING INJURY
WARNING
A Pressure Temperature Relief Valve, dripping while the water heater is
running, DOES NOT mean it is defective. During normal expansion of
water, as it is heated in the closed water system of a recreation
vehicle, the Pressure Temperature Relief Valve will sometimes drip. The
Atwood water heater tank is designed with an internal air gap at the
top of the tank to reduce the possibility of dripping. In time, the
expanding water will absorb this air and it must be restored.
pressure-temperature relief valve.
• Do not place a valve, plug or reducing coupling on outlet part of
EXPLOSION
WARNING
PRESSURE-TEMPERATURE RELIEF VALVE
Page 118 of 145
10
7
4
1
6 GAL. SHOWN
A
B
A
A
C
B
D
E
F
11
A
8
5
2
A
A
C
D
B
B
6
B
C
A
6 GALLON
B
E
C
11
B
A
9
A
6
D
E
E
B
A
6 GAL. SHOWN
3
A
C
C
F
D
10 GALLON
B
AVERTISSEMENTS IMPORTANTS POUR L'INSTALLATION
1. Poser le chauffe-eau par terre, dans le véhicule, avant de
construire les parois latérales. Le réservoir du chauffe-eau doit
toujours être positionné au même niveau que le bas de la découpe
de la paroi latérale (au sol ou sur un support surélevé).
2. L’ installation du chauffe-eau sur de la moquette doit se faire sur un
panneau en métal ou en bois de 7 ou 8 cm plus large et plus
profond que la taille totale de l'appareil.
3. Si l’appareil est installé dans un lieu où le branchement et les fuites
du réservoir risquent d’endommager les zones environnantes,
installer sous le chauffe-eau un système d'écoulement donnant vers
l'extérieur du véhicule.
4. Brancher les deux conduites d'eau de 1,27 cm NPT - sortie femelle
d'eau chaude (FIG 1-A) et entrée femelle d'eau froide (FIG 1-B), ainsi
que les conduites de gaz PL évasées de 0,95 cm (FIG 1-C).
a. Permettre une certaine flexibilité des conduites d'eau et de gaz
pour pouvoir tirer l’unité en avant, par le mur à 2,5 cm au-delà de
l’enveloppe extérieure (FIG 2).
b. Étanchéiser l'ouverture d’admission de la conduite de gaz en
glissant l’œillet (FIG 1-D) sur le tube de 9,5 mm (FIG 1-F) avant
de l'évaser (FIG 1-F). Faire passer la conduite de gaz et l’œillet
par l'ouverture du logement (FIG 1-C). Brancher le raccord
conique (FIG 1-E) et enfoncer l’œillet dans l'ouverture. Si la
conduite de gaz est déjà évasée, couper l’œillet d'un côté. Placer
l’œillet fendu sur la conduite de gaz et l'enfoncer dans l'ouverture.
c. Toujours mettre du lubrifiant de tuyau sur le filet, lorsqu’on relie
les accouplements d'eau chaude et d’eau froide. L’utilisation d’un
raccord en plastique adapté est préférable.
Cette méthode d’installation est l’une des plus répandue pour les
chauffe-eau. Il existe d’autres méthodes homologuées telles que les
installations de compartiment à bagages (Cf. MPD 90093) ou
d’encastrements (Cf. MPD 93948). Consulter votre inspecteur sur le
terrain, votre responsable de compte ou le service à la clientèle
Atwood pour toute question supplémentaire.
INSTALLATION GÉNÉRALE
• Véhicules de plaisance ANSI A119.2/NFPA 501C.
• Code national de carburant et de gaz ANSI Z223.1 et/ou codes d'installation
CAN/CGA B149. Norme fédérale de sécurité et de construction de maisons
mobiles, titre 24 CFR, partie 3280 ; lorsque cette norme n’est pas applicable,
utiliser la norme d’installation de maisons préfabriquées (Manufactured Home
Sites, Communities and Set-Ups), ANSI A255.1 et/ou la série CAN/CSA-Z240
MH, maisons mobiles.
• Code électrique national ANSI/NFPA No. 70 et/ou CSA C22.1.
• Caravanes de parc A119.5.
• Norme CSA de série Z240 RV, véhicules de plaisance.
USA ET CANADA - SUIVRE LES CODES NATIONAUX ET LOCAUX EN VIGUEUR - À DÉFAUT
DE CODES OU RÉGLEMENTATIONS LOCAUX, SE REPORTER AUX NORMES ACTUELLES DE :
• Installer dans les véhicules de plaisance uniquement. Les véhicules
de plaisance sont conçus comme résidences temporaires pour les
vacances, le camping ou les voyages ; ils fonctionnent de façon
autonome ou sont parfois remorqués par un autre véhicule.
• Tout l'air de combustion doit provenir de l'extérieur du véhicule de
plaisance et tous les produits de la combustion doivent être
évacués vers l'extérieur du véhicule de plaisance.
• NE PAS évacuer l'air du chauffe-eau par un système d'évacuation
servant à un autre appareil.
• NE PAS évacuer l'air du chauffe-eau vers un espace extérieur couvert.
• Protéger les matériaux de construction des gaz de carneau.
• IInstaller le chauffe-eau sur un mur extérieur, avec une trappe
d'accès donnant vers l'extérieur.
• NE modifier le chauffe-eau en AUCUNE façon.
• NE PAS modifier le chauffe-eau pour une mise à la terre positive.
• NE PAS faire d’essai diélectrique du chauffe-eau sans avoir
débranché l'allumage électronique (carte de circuit imprimé).
• NE PAS utiliser de chargeur de batterie pour alimenter le chauffeeau, même lors des essais.
11
B
41 cm
42,5 cm
DIMENSION DE LA DÉCOUPE
A
32 cm
40 cm
C
44,75 cm
52,4 cm
PROFONDEUR
Haut :
Bas :
0 cm
0 cm
décharge de type pression-température en conformité avec les normes
sur les soupapes de décharge et les mécanismes de coupure
automatique de l'alimentation en gaz pour systèmes à eau chaude
ANSI Z21.22.
LA SOUPAPE EST UN ELEMENT DE SÉCURITÉ ET NE DOIT PAS ÊTRE RETIRÉE SAUF EN
CAS DE REMPLACEMENT. Ce chauffe-eau est équipé d'une soupape de
sur la sortie de la soupape de décharge.
• NE PAS placer de robinet, de bouchon ou de raccord de réduction
AVERTISSEMENT
EXPLOSION
• La soupape ne se prête pas aux réparations, elle devra être remplacée.
• Toucher à la soupape risque de provoquer des brûlures.
• Toucher à la soupape annulera la garantie.
AVERTISSEMENT
BRÛLURES
SOUPAPE DE DÉCHARGE DE TYPE PRESSION-TEMPÉRATURE - (FIG 10)
11. Ouvrir l'alimentation en gaz et s’assurer que le chauffe-eau et les
différents raccords de gaz ne comportent pas de fuites, à l'aide
d'une solution de détection de fuites.
12. Remplir le réservoir du chauffe-eau ; vérifier que les différents
raccords ne comportent pas de fuites d’eau (FIG 1 A & B).
• NE PAS utiliser d'allumettes, de bougies ou toute autre source
d'allumage pour contrôler la présence éventuelle de fuites de gaz.
INCENDIE ET/OU EXPLOSION
AVERTISSEMENT
6. Suivre les marques et plier tous les rebords à 90º (FIG 3).
7. Pour éviter les fuites d'eau, appliquer du mastic tout autour de
l'ouverture, y compris dans les fentes de pliage (FIG 3-A). Il est
possible de substituer une bande adhésive de butyle au mastic
(2,54 cm x 0,3 cm).
8. Pousser l'unité contre le mastic, fixer les 4 équerres de fixation (FIG
4-A) au véhicule à l'aide de vis à tête ronde No.8, de 1,9 cm (nonfournies) ou l’équivalent. Terminer l'installation en insérant le même
type de vis No. 8 dans les orifices situés sur le bord du logement du
chauffe-eau. Check all gaskets, they must adher to the pan creating an
air tight seal.
9. Fixer la trappe d'accès (FIG 5).
a. Enfoncer l'axe de la charnière (FIG 5-A) dans le logement de la
charnière (FIG 5-B).
b. Faire glisser le couvercle (FIG 5-C) sur l'axe de la charnière.
c. Glisser l’axe de la charnière dans le couvercle, tout en l'enfonçant
dans le logement de la charnière (FIG 5-D).
REMARQUE : pour retirer l'axe de la charnière, soutenir le couvercle
d'accès et appuyer sur le coin de l'axe de la charnière, comme le
montre l’illustration FIG 5-E.
10. Débrancher l'unité et son robinet d'arrêt individuel de la conduite
d’alimentation en gaz lors de tout test de pression du système audelà de 3,4 kPa, 355 mm de colonne d'eau (C.E.). NE PAS régler
la pression d’admission au-delà du maximum indiqué sur la plaque
signalétique du clapet à gaz (330 mm C.E.). Isoler l'unité de la
conduite d'alimentation en gaz en fermant le robinet d'arrêt manuel
individuel lors de tout test de pression supérieur ou égal à 3,4 kPa.
Côtés : 0 cm
Arrière : 0 cm
DISTANCE MINIMALE PAR RAPPORT À TOUT MATÉRIAU
DE CONSTRUCTION COMBUSTIBLE
LITRES
15 - 22
38
CAPACITE
DÉCOUPE
5. Construire les parois latérales et découper l'ouverture. Cf. tableau et
FIG 2 A & B. Utiliser des montants de 2x2 (ou équivalent) pour
l'encadrement.
• Ne pas soulever, tirer ou pousser le tube du brûleur principal (FIG 3-F).
ATTENTION
ENDOMMAGEMENT DU PRODUIT
Page 119 of 145
(et Canada)
évite les blessures corporelles
et/ou les dommages matériels
ATTENTION
QUE FAIRE SI VOUS SENTEZ DU GAZ ?
• Evacuer TOUS les passagers du véhicule.
• Couper l'alimentation en gaz au niveau du réservoir ou à
la source.
• NE toucher AUCUN interrupteur électrique, n’utiliser ni le
téléphone, ni la radio à l'intérieur du véhicule.
• NE PAS démarrer le véhicule ou le générateur électrique.
• Contacter le fournisseur en gaz ou le technicien d’entretien
qualifié le plus proche pour effectuer toute réparation.
• S’il est impossible de joindre un fournisseur en gaz ou un
technicien d’entretien qualifié, contacter la caserne de
pompiers la plus proche.
• NE PAS ouvrir l'alimentation en gaz avant que la ou les
fuites soient réparées.
➤ Ne pas entreposer ni utiliser de carburant ou autres liquides et
vapeurs inflammables à proximité de cet appareil ou de tout
autre appareil.
• Ne pas suivre à la lettre les instructions contenues
dans ce manuel risque d’entraîner un incendie ou
une explosion et des dégâts matériels, des
blessures voire la perte de vie humaine.
INCENDIE OU EXPLOSION
AVERTISSEMENT
L'installation et l'entretien doivent être effectués par un technicien
d’entretien qualifié, un centre de service, un équipementier ou un
fournisseur de gaz.
évite les blessures corporelles
ou les accidents mortels
AVERTISSEMENT
Les symboles d'alerte de sécurité vous avertissent des dangers personnels
potentiels. Obéir à tous les messages de sécurité qui suivent ces symboles.
SYMBOLES D'ALERTE DE SÉCURITÉ
APPELS ET QUESTIONS D’ENTRETIEN
Les adresses et les numéros de téléphone des centres de
service agréés se trouvent sur notre site Internet à
http:/www.atwoodmobile.com ou composer le
574-264-2131 pour recevoir la liste par courrier.
La conception de ce chauffe-eau a été homologuée par
l’Association canadienne de normalisation pour installation à
l'intérieur de véhicules de plaisance. Ce chauffe-eau n'a pas été
conçu pour usage sur bateaux.
ENGLISH, FRANCAIS
9
10
..................................10
DIMENSIONS ......................................................10
POIDS ................................................................10
IDENTIFICATION DU MODÈLE
........................................................13-15
......................12-13
H
6
AA - 8
E/P
Allumage électronique ou rallumage
de la veilleuse
Révision (NUMÉRO)
Elément chauffant (À VIS OU À BOULON)
Capacité de 15, 22 ou 38 litres
Échangeur de chaleur du moteur
Combiné gaz et électricité (CA)
Gaz (PROPANE)
- SI VOTRE NUMÉRO DE MODÈLE N'APPARAÎT PAS SUR LA LISTE Les numéros reflétant une révision plus ancienne pourront être le
3, 4, 6, 7, 8 ou 9 (_ _ _ _ _ - X _)
C
l
15
LITRES
38 LITRES
22 LITRES
TOUS MODÈLES
DIMENSIONS
22
LITRES
38
LITRES
HAUTEUR
38 LITRES
22 LITRES
11,34 KG
14,5 KG
POIDS A L'ENVOI
G6A-7
GC6AA-8P
G10-2
GC10-2
GC6AA-8
GH6-7
G10-2P
GC10-2P
G6A-8E
GCH6A-9E
G10-3E GCH10A-3E
GC6AA-9E
GH6-8E
GC10A-3E
GH10-3E
P SUR LE MODÈLE NO. - VOIR LES EXPLICATIONS CI-DESSUS
H SUR LE MODÈLE NO. - VOIR LES EXPLICATIONS CI-DESSUS
E SUR LE MODÈLE NO. - VOIR LES EXPLICATIONS CI-DESSUS
C SUR LE MODÈLE NO. - VOIR LES EXPLICATIONS CI-DESSUS
40.6 CM 31.8 CM
40.6 CM 39.4 CM
LARGEUR
Allumage de
G4-7
la veilleuse
Allumage
électronique
Rallumage de la veilleuse
Échange de chaleur
Allumage électronique
Combinaison gaz-électricité
TYPE
EXPLICATION DU NUMÉRO DE MODÈLE
Quel que soit votre numéro de révision, les présentes instructions sont
généralement valables pour votre unité. Pour toute question, contacter votre
distributeur, un centre de service Atwood ou le service à la clientèle Atwood.
G
EXPLICATION DU NUMÉRO DE MODÈLE (EXEMPLE)
............................................................................16
SCHÉMAS ÉLECTRIQUES ............................................................8-9
IDENTIFICATION DES PIÈCES ..........................................................6
SCHEMAS ELECTRIQUES ................................................................7
FIGURES 1-11
Allumage électronique
Électrique
CHAUFFE-EAU ENTRETIEN
Allumage électronique
Rallumage de la veilleuse
Combinaison gaz-électricité
CHAUFFE-EAU FONCTIONNEMENT DE LA VEILLEUSE
Installation du câblage pour l'allumage électronique
Installation du câblage pour le rallumage de la veilleuse
Échangeur de chaleur
Combinaison gaz-électricité
INFORMATIONS SUR LA SÉCURITÉ
............................................11-13
CHAUFFE-EAU INSTALLATION GÉNÉRALE ......................................11-12
CHAUFFE-EAU
En vigueur à partir du 19/11/07
•Installation •Fonctionnement •Entretien
15 – 22 – 38 LITRES
CHAUFFE EAU AU
PROPANE LIQUIDE (PL)
MPD 93756
COMBINAISON gazélectricité
RALLUMAGE DE
VEILLEUSE
ALLUMAGE
ÉLECTRONIQUE
COMBO gas/electric
PILOT RELIGHT
SPARK IGNITION
BLACK
Manual Reset
High Temperature
Limit Switch
Fixed Thermostat
BLEU
( 3 )-VERT
Fil de masse
VERT
VERT
MARRON
NOIR
Masse
NOIR
(3) (2)
7
Interrupteur limiteur
haute température à
réarmement manuel
Thermostat fixe
Fil de haute tension
vers l’électrode
du brûleur
Élement
( 2 )-BLANC
( 1 )-NOIR
Fil neutre
MARRON
Interrupteur
Module d’étincelle
Décharger
et détecter
(4)
Coupure thermique Interrupteur
à distance
(6)
Voyant lumineux
de non allumage
Thermostat de
commande à température fixe
MARRON
(3) (2)
CAUTION
BATTERY
ELECTRICAL DAMAGE
BL
U
BR GRE E
OW EN
N
(6
(4 )
(3 )
(2 )
)
REMOTE
SWITCH
INTERRUPTEUR
À DISTANCE
(6
(4 )
(3 )
(2 )
)
ATTENTION
DOMMAGES ÉLECTRIQUES
BATTERIE
BATTERY
V
ROU ERT
GE
BATTERIE
• Lors de la réparation des commandes, étiqueter tous
les fils avant de les déconnecter.
• Après toute réparation, vérifier au bon fonctionnement
de l'unité.
12 V c. c.
BL
E
BR VER U
UN T
GRE
RED EN
• Label all wires before disconnecting when servicing controls.
• Verify proper operation after servicing.
12 volt DC
SCHÉMAS ÉLECTRIQUES
Interrupteur
ECO
Fil de phase
VERT
ROUGE
BLACK
Ground
Switch
Les lignes en pointillés sont
branchées par le client
ROUGE
Électrovannes
à gaz
( 2 )-WHITE
GREEN
GREEN
BROWN
High Voltage Lead
to
Burner Electrode
Element
( 3 )-GREEN
Ground Lead
( 1 )-BLACK
Spark
Module
Common Lead
Hot Lead
GREEN
RED
BROWN
Thermal Cut-Off
(4)
Non-Ignition
Light
(6)
Fixed Temperature
Control Thermostat
BROWN
BLUE
ECO
Switch
Spark & Sense
RED
Remote
Switch
WIRING DIAGRAMS
Dotted lines are wired by customer
Gas Solenoid
Valves
RED
ROUGE
NUMERO DE BROCHURE
GREEN
VERT
MPD 56281
LP GAS
DROP-IN COOKTOPS
9
D, DA, DA-PE Except HP Models
PROTECTED BY U.S. PATENTS D393,774, D393,567, D393,501, D393,502
ENGLISH
•Installation •Operation •Maintenance
Effective 12/13/07
SAFETY ALERT SYMBOLS
WARNING
Safety Symbols alerting you to potential personal safety hazards.
Obey all safety messages following these symbols.
WARNING
avoid possible
injury or death
CAUTION
avoid possible
injury and/or property damage
FOR YOUR SAFETY
READ ALL INSTRUCTIONS BEFORE OPERATING APPLIANCE
Installer:
Consumer:
Provide these instructions to the consumer.
Keep documents for future reference.
WARNING
FIRE OR EXPLOSION
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
• Open windows.
• DO NOT touch any electrical switch, or use any phone or radio in
vehicle.
• Extinquish any open flame.
• Evacuate ALL persons from vehicle.
• Shut off gas supply at gas container or source.
• DO NOT start vehicle’s engine or electric generator.
• Contact nearest gas supplier or qualified Service Technician for
repairs.
• If you cannot reach a gas supplier or qualified Service Technician,
contact the nearest fire department.
• DO NOT turn on gas supply until gas leak(s) has been repaired.
FOR YOUR SAFETY
➤ Do not store or use gasoline or other flammable vapors and liquids
in the vicinity of this or any other appliance.
WARNING
• Improper installation, adjustment, service or maintenance can
cause injury, property damage or death. Refer to this manual. For
assistance or additional information, consult a qualified installer,
service agency, manufacturer or the gas supplier.
WARNING
EXPLOSION OR FIRE
• Shut off all gas appliances and pilot lights when refueling gasoline
tanks, LP tanks or when vehicle is in motion.
• Atwood/Wedgewood gas operated cooking appliances are for use
with LP gas only, and for installation in recreational vehicles only
(e.g. travel trailers, motor homes, tent campers, etc.).
CARBON MONOXIDE POISONING
• Do not use any cooking appliance for space heating because of
potential danger to occupants of the vehicle and damage to operating components of the cooktop.
• A window or air vent should be open slightly while using any cooking appliance. Gas flame consumes oxygen which must be
replaced to assure proper combustion.
NOTE TO CONSUMER:
Have the installer or dealer show you where the main gas shut off
valve is located so that you will know how and where to turn off the
gas supply when necessary.
CONTENTS
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Cabinet & Counter Cut Out Chart . . . . . . . . . . . . . . . . . . . .2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
INSTALLATION
Appliance intended for use inside or temporary use outside the recreational vehicle. Appliance for use only with recreational vehicle with
which it is supplied. Do not store appliance outdoors. Electronic
Ignition models are for indoor use only.
Installation must conform with local codes or in the absence of local
codes, with the American National Standard for Recreational Vehicles,
ANSI/A119.2 and Article 551, ANSI/NFPA 70. In Canada, installation
must conform with CSA Z240.4.2-M.
WARNING
FIRE, EXPLOSION, BURN INJURY
CARBON MONOXIDE POISONING
• The cooking appliance must be completely separated and/or
sealed from other air moving or air consuming devices such as,
but not limited to, furnaces, microwave ovens, clothes dryers,
cooling fans and doors or drawers in common cabinets. Failure
to do so will affect the appliance(s) combustion air supply by
creating either a negative or positive draft.
• NEGATIVE DRAFT caused by air moving appliances may draw
the top burner flame down into or toward the cooktop resulting
in cooktop damage, burn hazard, explosion possibility and/or
carbon monoxide buildup.
• POSITIVE DRAFT may blow out the top burner flame during use
resulting in an explosion and/or fire hazard and/or injury to the
occupants of the vehicle.
• Do not operate the appliance in excessive windy conditions as
this may cause a negative or positive draft.
Page 120 of 145
8. Turn on the gas supply.
1. For proper operation of your cooking appliance:
THE CABINET MUST BE
• properly constructed.
• squared to the countertop and cabinet face
THE OPENING IN CABINET MUST BE
• level from side to side and front to rear
2. The cabinet opening must be constructed so that no combustible
material can be placed next to the cooktop sides. If there is a gap
between the cooktop and an adjacent cabinet, the gap must be closed
prior to installing the cooktop.
WARNING
EXPLOSION OR FIRE
• Do not use matches, candles or other sources of ignition to test
fittings and gas lines for leaks.
9. Check all connections for gas leaks using a non-corrosive leak
detection fluid. Do not use a soap and water solution. Leak test in
excess of 8 oz. per square inch (1/2 psi) of air pressure will invalidate warranty.
WARNING
10. a. D-26SV: Attach cam lock fastener (supplied) to a bracket constructed by the manufacturer (not supplied). Determine area to
mount bracket in upper portion of van that is secure and unobstructed. Unfold the cover and guards to determine the location of the
keyhole shaped slot in the upper guard. Attach assembly.
Apply control label to counter before installing burner knobs.
b. Drop-In: Remove the cooktop top and burner grates from packaging
and install grates:
FIRE
• 30 inches is the minimum vertical distance to combustible material above the cooktop stove. This distance may be reduced by
using non-combustible construction in accordance with Table 26.7.2 in ANSI A119.2.
3. Cabinet dimensions needed for each model are shown in CABINET &
COUNTER CUT OUT CHART. The cabinet cut-out must be located
with respect to the minimum clearances to combustible materials as
noted. When planning the location consider curtains or other combustible materials installed around the cooktop.
4. When the cabinet has been prepared according to the dimensions
given and the gas line is in place, remove the cooktop from its
packaging and position the cooktop in the opening.
5. Verify that the cooktop is level from side to side and front to rear.
6. Drop-In: Secure the burner box assembly in place with wood
screws (not supplied).
D26-SV: Slip right hand of unit under counter so that the valve
shafts protrude through the two 1˝ diameter holes in the counter.
Secure to the counter with (4) sheet metal screws (not supplied).
D26-SLG: Drop unit into cutout, secure to counter with (4) #6 flat
head wood screws (not supplied).
7. Make the gas connection. All openings in the cabinetry around the
gas line must be closed at time of installation. DA-PE models with
electronic ignition: Complete the electrical connections as shown in
the WIRING DIAGRAM. For galley slide-out applications, it is highly
recommended that the negative 12 volt connection be connected
directly to the battery. Voltage supply must be between 9 and 13
VDC. Appliance electrical rating is 12VDC, 0.6A during sparking.
11. a. SINGLE & DUAL RECTANGULAR WIRE grate models
3 burner Install the rubber feet on corner grate legs, and install
the grates on the stove top. From the underside of the cooktop,
install the spring clips over the protruding grate legs. Squeeze
the edges of the clips together and slip over the ends of the
burner grate as needed.
2 burner Install rubber feet on corner grate legs. From the top,
press spring clips into holes of cooktop. Install grate onto cooktop, engaging middle legs into spring clips.
b. ROUND WIRE grate models squeeze opposite sides of the grate together and insert the
legs into the holes in the stove top from above the stove top.
c. STAMPED STEEL grate models place one side of the grate in the burner well, ensuring that the
clip engages the emboss in the side. Gently press the other end
of the grate downward to “snap” the grate into place.
12. REPLACE THE COOKTOP TOP
Drop-In: Position the cooktop top in place; install the thumb
screws (supplied) through the cooktop top. Tighten securely. On
DAS models, press the top downward until it “snaps” in place
on both sides. Slide the knobs over the valve stems to complete
the installation. Your cooktop is now ready for operation.
CAUTION
PRODUCT DAMAGE HAZARD
• Connect to 12VDC service only.
• Do not connect to a circuit fused for more than 3 amps.
• Do not hi-pot cooktop unless electronic ignition system has
been disconnected.
FM
IN
D .
G
MIN
.
A
CABINET &
COUNTER
CUT OUT
CHART
D
M
E N.
I
M
C
CUT OUT DIMENSIONS
◆Minimum dimension
EM
.
CM
B E MIN
.
IN.
IN.
MIN
.
J
D-26SLG
Models D, DA
D, DA Models - 2 Burners
D , DA Models - 3 Burners
D-26SLG
D-26SV
IAM
A
B
11-5/8˝
16-1/16˝
19˝
11-5/8˝
16-3/8˝
19-3/16˝
14-1/8˝
16-3/8˝
C
2-1/4˝ ◆
2-1/2˝ ◆
5/8˝ ◆
4-3/8˝ ◆
I
A
H
D-26SV
D
3-1/8˝
3-1/8˝
4-1/2˝
3-1/8˝
ETE
C MIN
A
B
1" D
MIN
.
B
F IN.
FM
IN
D .
G
E
◗
◗
◗
◗
3/4˝
2-3/8˝
3/4˝
1˝
F
◆
◆
◆
◆
4-3/4˝
4˝
2-3/4˝
1-1/8˝
◆
◆
◆
◆
G
H
I
J
3˝
4-1/4˝
3-1/4˝
4-3/4˝
2-1/4˝
◗ Overall depth of cooktop
2
Page 121 of 145
R
1. Check that gas is on at shutoff valve.
BURNER OPERATION
2. LIGHTING Top Burners:
a. All burner controls operate counter-clockwise and must be
pressed inward (toward the cooktop) to turn ON or LITE. Do not
attempt to light more than one burner at a time.
b. IMMEDIATELY light the burner by holding a lit match or a handheld spark igniter designed for this purpose near the burner ports.
c. To extinguish the top burner flame, turn the appropriate burner
knob clockwise to OFF.
WARNING
BURN INJURY, FIRE AND/OR EXPLOSION
• Do not heat unopened containers. They could explode. The hot contents may cause burns and container particles may cause injury.
• Do not use the cooktop for warming or heating the vehicle. You could
be burned or injured, or a fire could start.
• Do not store flammable materials on, in, or near cooktop. Any fumes
can create an explosion and/or fire hazard.
• Do not operate cooktop if it is damaged or not working properly.
• Know where your vehicle’s main LP gas shutoff is located.
• Verify sufficient gas supply before attempting to light any top burner. Air in
the gas supply line will significantly delay burner ignition, and a burner
may light unexpectedly as the air in the line clears out and is replaced by
LP gas; this unexpected ignition may burn you. Air may be introduced into
the supply line when the vehicle gas bottle is replaced, during servicing of
other gas appliances, etc.
• If any burner should extinguish (after initially lighting or due to accidental
blow-out), turn all burner knobs clockwise to OFF and WAIT FIVE (5)
MINUTES before again attempting to light the burner.
• Do not touch top burners, burner grates, or areas near top burners during
and after use. Do not let clothing or other flammable materials contact top
burners or areas near top burners until they have sufficient time to cool.
• Pans must be large enough to contain food. Heavy splattering or spillovers
left on the cooktop can ignite and burn you.
• Be sure that glass cooking utensils are safe for use on the cooktop. Only
certain kinds of glass utensils are suitable for surface or top burner use
without breaking due to sudden changes in temperature.
• Never leave top burners unattended. A boil over may result, causing smoke
or grease spillovers that may ignite.
• Turn pan handles inward, but not over other top burners. This reduces the
chance of burns due to bumping pan.
• Grease is flammable. Never allow grease to collect around top burners or
on cooktop surface. Wipe spillovers immediately.
• Do not use water on grease fires. Never pick up a flaming pan. Smother a
flaming pan with a tight-fitting lid or cookie sheet. Flaming grease outside
of the pan can be extinguished with baking soda or a multipurpose dry
chemical or foam-type fire extinguisher.
• Use care when lighting a top burner by hand. If the burner lights
unexpectedly, or your hand is close to burner, you may be burned.
• Burner flame should not extend beyond the edge of the cooking
utensil. The flame could burn you and cause poor cooking results.
• Control knobs must be turned OFF when not cooking. Someone
could be burned or a fire may start if a burner is accidentally left ON.
• Do not touch top burners, burner grates, or areas near top burners during
and after use. Do not let clothing or other flammable materials contact top
burners or areas near top burners until they have sufficient time to cool.
• Pans must be large enough to contain food. Heavy splattering or spillovers
left on the cooktop can ignite and burn you.
• Be sure that glass cooking utensils are safe for use on the cooktop. Only
certain kinds of glass utensils are suitable for surface or top burner use
without breaking due to sudden changes in temperature.
• Never leave top burners unattended. A boil over may result, causing smoke
or grease spillovers that may ignite.
• Turn pan handles inward, but not over other top burners. This reduces the
chance of burns due to bumping pan.
• Grease is flammable. Never allow grease to collect around top burners or
on cooktop surface. Wipe spillovers immediately.
• Do not use water on grease fires. Never pick up a flaming pan. Smother a
flaming pan with a tight-fitting lid or cookie sheet. Flaming grease outside
of the pan can be extinguished with baking soda or a multipurpose dry
chemical or foam-type fire extinguisher.
• Use care when lighting a top burner by hand. If the burner lights
unexpectedly, or your hand is close to burner, you may be burned.
• Burner flame should not extend beyond the edge of the cooking
utensil. The flame could burn you and cause poor cooking results.
• Control knobs must be turned OFF when not cooking. Someone
could be burned or a fire may start if a burner is accidentally left ON.
LIGHTING Top Burners with electronic ignition:
a. Turn the appropriate burner knob counterclockwise to ON or
LITE. This will automatically activate the ignition system, and all
burners will begin to spark repeatedly. This is the “clicking” sound
you will hear. The burner will light within five (5) seconds.
b. To extinguish the top burner flame, turn the appropriate burner
knob clockwise to OFF.
c. If 12 VDC power is not available to the ignition module for any reason, the top burners may be lit manually. See instructions in
“Lighting Top Burners”.
CAUTION
PRODUCT DAMAGE HAZARD
• Do not cook with the control knob set in the LITE position.
Damage to the ignition module and burner electrodes may result.
• Do not use oversized cookware. The pan should not be more than
one inch larger than the burner grate. The maximum pan size is a
10-inch skillet. Oversized cookware will cause excessive heat
build-up in the stove top and will result in damage to the burner
grate, burner and cooktop.
• Do not use a broiler pan, griddle, or any other large utensil which
covers more than one (1) top burner at a time. This will create
excessive heat which may cause melting, sooting or discoloration
damage to the burner grates, cooktop top, or utensils.
• Do not leave an empty utensil, or one which has boiled dry, on a
hot top burner. The utensil could overheat and damage the utensil
or the cooking appliance.
STORAGE
Dry all surfaces and burner box, then spray surfaces with PAM or oil
base substance to preserve the surface from rusting during storage.
Before using, clean oil off surface of appliance.
MAINTENANCE
The owner’s cooking habits and cleanliness will affect the operation
of the cooktop. Proper installation and care will help keep your cooktop looking and operating like new. Most cleaning can be performed
using normal household items.
WARNING
BURN INJURY, FIRE AND/OR EXPLOSION
• All controls must be OFF, the cooktop cool before cleaning.
• All cooktop surfaces, burner grates and burners must be cool
before cleaning or disassembling cooktop.
• Do not use oven cleaners, bleach, or rust removers on the
cooktop or burner grates.
• Do not obstruct the flow of combustion and ventilation air.
• Keep appliance area clear of combustible materials, gasoline
and other flammable vapors and liquids.
CONNECTION DIAGRAM FOR ELECTRONIC IGNITION MODELS
12 volt
Burner Valve Switches
Battery
R
+
–
R
R
G
G
W
Connector
Ignition
Module
R = RED Wire
G = GREEN Wire
W = WHITE Wire
= Wire Connection
- - = Wired by Installer
W
Top Burners
3
Page 122 of 145
2. To remove the burner grates:
a. On models with round wire grates, squeeze opposite sides of
the grate together and lift free of the cooktop top.
b. On 2 burner models with rectangular wire grates, pull grate
straight up releasing them from spring clips.
c. On 3 burner models with rectangular wire grates, remove the
cooktop top (see Step 1 above). From the underside of the
cooktop top, remove the clips from the grates by squeezing the
ends of the clips together to release the tension on the grate.
d. On models with stamped steel grates, pull up on one end of
grate to “unsnap” it from cooktop.
e. Replacement is a reversal of the above procedure.
CAUTION
PRODUCT DAMAGE HAZARD
• Clean all surfaces quickly after boil overs or spillovers.
• Use warm soapy water only to clean the burner grates, cooktops, painted surfaces, porcelain surfaces, stainless steel surfaces and plastic items on your cooktop. Do not use grit or acidtype cleaners.
• Do not use steel wool or abrasive cleaners, they will damage
your cooktop. Use only non-abrasive plastic scrubbing pads.
• Do not allow foods containing acids (such as lemon or tomato
juice, or vinegar) to remain on porcelain or painted surfaces.
Acids may remove the glossy finish. Wipe up egg spills when
cooktop is cool.
• Do not wash warm porcelain surfaces. Allow porcelain to cool
before cleaning. You may burn yourself, or porcelain may crack.
• Pitting and discoloration will result if spills are allowed to remain
for any length of time on stainless steel.
• Do not allow spillovers to remain on burner caps. Caps could be
permanently stained if spillovers are not cleaned up promptly.
ALL COOKTOPS
If any of the burner ports or the orifices are clogged, carefully clean
with a toothpick. Never use a wire brush or metallic item for cleaning
burner ports or orifices. Never use any brush which may “shed” bristles, which may become lodged in the orifice or burner ports and
cause a fire or explosion.
DROP-IN COOKTOPS:
1. To remove the stove top:
a. Remove the two (2) side screws, if provided, from the cooktop.
Lift the cooktop clear of the burner box. Replacement is a
reversal of this procedure.
b. On DA models, pull the knobs straight up, removing them from
the valve stems, before removing the stove top.
c. On DAS models, remove knobs, then “unsnap” top by inserting
finger(s) in valve stem openings and pulling up.
COOKING APPLIANCE LIMITED WARRANTY
4. Return parts must be shipped to Atwood Mobile Products “prepaid”. Credit for
shipping costs will be included with the warranty claim. The defective parts
become the property of Atwood Mobile Products and must be returned to the
Consumer Service Department, Atwood Mobile Products, Greenbrier Operations,
6320 Kelly Willis Road, Greenbrier, TN 37073 USA.
5. This warranty applies only if the unit is installed according to the installation instructions provided and complies with local and state codes.
6. The warranty on replacement parts is the unused portion of the original warranty
period.
7. Damage or failure resulting from misuse (including failure to seek proper repair
service) misapplication, alterations, water damage or freezing are owner’s responsibility.
8. Atwood does not assume responsibility for any loss of use of vehicle, loss of time,
inconvenience, expense for gasoline, telephone, travel, lodging, loss or damage to
personal property or revenues. Some States do not allow the exclusion or limitation
of incidental or consequential damages, so the above limitations or exclusions may
not apply to you.
9. Any implied warranties are limited to two (2) years. Some States do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to
you. This warranty gives you specific legal rights and you may also have other rights,
which may vary, from State to State.
10. Replacement parts purchased outside the original cooking warranty carry a 90 day
warranty. This includes the part at no charge and reasonable labor charges to
replace it.
This Atwood product is designed for use in recreation vehicles for the purpose as
stated in the ‘data plate’. Any other use, unless authorized in writing by the Atwood
Engineering Department, voids the warranty. Atwood/Wedgewood Vision Products
include range/oven, drop-in, slide-in and high pressure stoves.
Atwood Mobile Products warrants to the original owner and subject to the below
mentioned conditions, that this product will be free of defects in material or workmanship for a period of two years from the original date of purchase. Atwood’s liability
hereunder is limited to the replacement of the product, repair of the product, or
replacement of the product with a reconditioned product at the discretion of the manufacturer. This warranty is void if the product has been damaged by accident, unreasonable use, neglect, tampering or other causes not arising from defects in material
workmanship. This warranty extends to the original owner of the product only and is
subject to the following conditions:
1. For two years from the date of purchase Atwood warrants that this product will be
free of defects in material and workmanship with the exceptions noted below. This
warranty includes reasonable labor charges required to remove and replace the
part. Service calls to the customer’s location are not considered part of these
charges and are therefore the responsibility of the owner.
2. This warranty does not cover the following items classified as normal maintenance
and/or customer damage.
a. Damage, discoloration or scratches to porcelain enamel or other finishes from
improper use and care.
b. adjustment of gas pressure
c. cleaning or adjustment of any burners
d. cleaning or replacement of burner orifices
e. cleaning or adjustment of pilot and thermocouple
f. damage to glass
g. products purchased for commercial, industrial or rental use.
3. In the event of warranty claim the owner must contact in advance either an authorized Atwood Service Station or the Atwood Service Department. Warranty claim
service must be performed at an authorized Atwood Service Station (a list will be
provided at no charge) or as approved by the Atwood Service Department Atwood
Mobile Products, 1120 North Main, Elkhart, IN 46514 USA.
Phone 574-264-2131.
4
Page 123 of 145
D-21 / D-26
D-26 SLG
D-26 SV
1
12
12
11
11
11
12
13
13
15
15
17
17
14
18
18
19
19
24
20
26
15
17
24
27
25
25
28
29
18
19
20
26
20
28
29
25
28
30
WEDGEWOOD DROP-IN’S
D-21 / D-26
D-26 SV
D-31
D-26SLG
12
11
2
13
9
10
15
17
18
21
23
D-21 / D-31
22
26
27
5
24
25
28
29
5
Page 124 of 145
DROP-IN COOKTOP
PARTS IDENTIFICATION
PIÈCES DÉTACHÉES TABLE DE CUISSON ENCASTRABLE
ITEM
D-21
D-26
D-26SV
D-26SLG
D-31
DA-21
DA-31
DA-31PE
DESCRIPTION
1 ................................................56204 ..................................................................................................COVER
2 ...... 53304 ..........53304..........53304 ..................................................................................................DESIGNER GRATE
5 ......51007 (2)..............................................51007 (3) ........................................................................MEDALLION GRATE
6 ..........................................................................................53436 ........................................................STAMPED STEEL GRATE
7..............................................................................................................53437 ........53437 ..................STAMPED STEEL GRATE, REAR
8..............................................................................................................53438 ........53438 ..................STAMPED STEEL GRATE, FRONT
9 ......53008 (4) ......53008 (4)....53008 (4)....53008 (8) ........................................................................GRATE BOOT
10 ......53301 (2) ......53301 (2)....53301 (2)....50005 (4) ........................................................................GRATE CLIP
11 ......52537............52537..........52537 ........52537 ............52016 ........52016 ....................................THUMB SCREW (2)
12 ......52434............52434..........52434 ........52434 ............52434 ........52434 ....................................WASHER, NYLON (2)
13 ......✵ ..................✵ ................52444 ........✵ ....................✵ ................✵ ..............✵ ..........................COOK TOP
14 ............................51443 ......................................................................................................................COOKTOP & COVER ASBLY
15 ......53000 (2) ......53000 (2)....53000 (2)....53000 (3) ......56129 (2) ..56129 (3) ..56129 (3)..............BURNER KNOB
17 ......52539............52437..........52437 ........52540 ............57700 ........57051 ........57050 ..................CONTROL LABEL (BLACK)
18 ......52516 ..............................52523 ........52524 ............52516 ........52523 ........52523 ..................MANIFOLD COVER
19 ......56073............56077..........56075 ................................56212 ........................................................BURNER, LEFT
20 ......56074............56078..........56076 ................................56213 ........................................................BURNER, RIGHT
21....................................................................56083 ..............................56215 ........56234 ..................BURNER, LEFT REAR
22....................................................................56082 ..............................56214 ........56235 ..................BURNER, LEFT FRONT
23....................................................................56084 ..............................56216 ........56233 ..................BURNER, RIGHT REAR
24 ......52294............52294..........52294 ........52294 ............52294 ........52294 ........52294 ..................BRASS FITTING
25 ......51062............51062..........51062 ........51062 ............51062 ........51062 ........51062 ..................REGULATOR
26 ......56090 (2) ......56090 (2)........................56090 (1) ......56090 (2) ..56090 (1) ..53114 (1)..............VALVE, 6500 BTUH
27 ................................................56089 (2)....56089 (2) ........................56089 (2) ..53124 (2)..............VALVE, 5200 BTUH
28 ......56079............56079..........56079 ........56080 ............56079 ........50160 ........50160 ..................MANIFOLD PIPE
29 ......56091 (2) ......56091 (2)....56091 (2)....56091 (3) ......56091 (2) ..56091 (3) ..56091 (3)..............BOLT FOR VALVE
30 ................................................56205 ..................................................................................................FRAME
31 ..............................................................................................................................51410 (4)..............CLIP, TOP
32 ..............................................................................................................................56162 ..................12V IGNITION MODULE
33 ..............................................................................................................................57055 (3)..............VALVE IGNITION SWITCH
N/S ............................................................................................................................57622 ..................WIRING HARNESS
N/S ............................................................................................................................56184 ..................ELECT. IG GROUND LEAD
N/S ............................................................................................................................57621 ..................ELECT. IG ELECTRODES LEAD
COUVERCLE
GRILLE DESIGN
GRILLE EN MÉDAILLON
GRILLE EN TÔLE
GRILLE EN TÔLE, ARRIÈRE
GRILLE EN TÔLE, AVANT
EMBOUT DE GRILLE
ETRIER DE GRILLE
VIS À PAPILLON
(2)
RONDELLE EN NYLON
(2)
TABLE DE CUISSON
TABLE DE CUISSON AVEC COUVERCLE
BOUTON DE COMMANDE DE BRÛLEUR
ETIQUETTE DE COMMANDE (NOIR)
COUVRE-SOUPAPE
BRÛLEUR, GAUCHE
BRÛLEUR, DROIT
BRÛLEUR, ARRIÈRE GAUCHE
BRÛLEUR, AVANT GAUCHE
BRÛLEUR, ARRIÈRE DROIT
RACCORD EN LAITON
RÉGULATEUR
SOUPAPE,
SOUPAPE,
6500 BTUH
5200 BTUH
TUYAU DE COLLECTEUR
BOULON DE SOUPAPE
CHÂSSIS
ETRIER, SUPÉRIEUR
MODULE D’ALLUMAGE
COMMUTATEURS DE LA VALVE
CABLE AVEC CONNEXION
ÉLECTRONIQUE FIL DE MASSE
ÉLECTRONIQUE CABLE
◆ order by color / iquer couleur
N/S not shown in illustration / non-représenté
DA-21
7
6
DA-31 / DA31PE
8
11
11
12
12
13
13
15
18
ATWOOD DROP-IN’S
17
17
15
18
21
23
22
19
24
25
29
24
20
25
29
28
31
26
27
28
DA-31PE
32
6
Page 125 of 145
LITERATURE NUMBER
.1%
L.P. GAS
ON DEMAND
WATER HEATER
Models
OD45, OD50, OD55
ENGLISH - FRANÇAIS
t*OTUBMMBUJPOt0QFSBUJPOt.BJOUFOBODF
Effective ..1
5IJTXBUFSIFBUFSEFTJHOIBTCFFODFSUJGJFECZUIF$BOBEJBO
4UBOEBSET"TTPDJBUJPOGPSJOTUBMMBUJPOJOSFDSFBUJPOWFIJDMFT This
water heater is not for use in marine applications.
Explanation of Model Number:
OD_____________________ On Demand
45________________ Input in 1000’s Btu
01__________ Generation
SERVICE CALLS & QUESTIONS
-PDBUJPOBOEQIPOFOVNCFSTPGRVBMJGJFE4FSWJDF$FOUFSTDBO
CFGPVOEBUPVSXFCTJUFIUUQXXXBTLGPSBUXPPEDPNPSDBMM
UPMPDBUFB4FSWJDF$FOUFS
mCRITICAL INSTALLATION WARNINGS
s )NSTALLINRECREATIONVEHICLESONLY26SARERECREATIONVEHICLES
DESIGNEDASTEMPORARYLIVINGQUARTERSFORRECREATIONCAMPING
ORTRAVELUSEHAVINGTHEIROWNPOWERORTOWEDBYANOTHERVEHICLE
SAFETY ALERT SYMBOLS
4BGFUZ4ZNCPMTBMFSUJOHZPVUPQPUFOUJBMQFSTPOBMTBGFUZIB[BSET
0CFZBMMTBGFUZNFTTBHFTGPMMPXJOHUIFTFTZNCPMT
mWARNING
BWPJEQPTTJCMF
JOKVSZPSEFBUI
mCAUTION
BWPJEQPTTJCMF
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s !LLCOMBUSTIONAIRMUSTBESUPPLIEDFROMOUTSIDETHE26ANDALL
PRODUCTSOFCOMBUSTIONMUSTBEVENTEDTOOUTSIDETHE26
s $/./4VENTWATERHEATERWITHVENTINGSYSTEMSERVINGANOTHER
APPLIANCE
s $/./4VENTWATERHEATERTOANOUTSIDEENCLOSEDPORCHAREA
s 0ROTECTBUILDINGMATERIALSFROMmUEGASEXHAUST
s )NSTALLWATERHEATERONANEXTERIORWALLWITHACCESSDOOROPENINGTO
OUTDOORS
mWARNING
'*3&03&91-04*0/
s $/./4MODIFYWATERHEATERINANYWAY
ÊÊUÊÊÊvÊ̅iʈ˜vœÀ“>̈œ˜Êˆ˜Ê̅ˆÃʓ>˜Õ>ÊˆÃʘœÌÊvœœÜi`Ê
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s $/./4()0/4WATERHEATERUNLESSELECTRONICIGNITIONSYSTEM
CIRCUITBOARDHASBEENDISCONNECTED
s $/./4USEBATTERYCHARGERTOSUPPLYPOWERTOWATERHEATEREVEN WHENTESTING
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Do not install close to opening door or under room slide-out where
the vent or inlet louvers can be obstructed.
WHAT TO DO IF YOU SMELL GAS
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—
Local codes or, in the absence of local codes, the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 and/or CSA B149.1, Natural Gas and
Propane Installation Code.
—
Local codes or, in the absence of local codes, the Standard on
Recreational Vehicles, NFPA1192 and/or CAN/CSA-Z240 RV.
1/"1/Ê,iµÕˆÀi“i˜ÌÃ
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OEM and Aftermarket – Unit can be installed in Atwood, Suburban and Girard
openings. Unit can also be installed through the wall from exterior, or prior to
erecting wall into place at OEM manufacturing facility.
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Atwood 6 Gallon Opening
Suburban 6 Gallon Opening
Atwood 10 Gallon Opening*
Suburban 10 Gallon Opening*
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RVBMJGJFEJOTUBMMFSTFSWJDFBHFODZPSUIFHBTTVQQMJFS
12.7 H x 16.25 W x 17.62 D
12.7 H x 12.7 W x 19.2 D
15.75 H x 16.2 W x 20.6 D
16.2 H x 16.2 W x 20.5 D
*Door/Adapter Kit Required
Page 126 of 145
GENERAL INSTALLATION
&SFDUUIFTJEFXBMMTBOEDVUUIFPQFOJOHPSPSJFOUUIF
QSFGBCSJDBUFEPQFOJOH'SBNFXJUIuYuMVNCFSPS
FRVJWBMFOU
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NOTE:1BSUTCBHHFEBOEJODMVEFEXJUIUIFVOJUJODMVEFDPSOFS
GJMMFSCSBDLFUTGMVFTDSFFOBOEDPWFSIPMFCVTIJOH
$PSOFS#SBDLFUT
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DVUPVUCZUIFGMPPSPSBSBJTFEGMPPS
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PGNFUBMPSXPPEVOEFSUIFVOJUJTBEEFEBOEFYUFOET
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An “air tight” seal must be the final result.
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Damage voids the Warranty!
Page 127 of 145
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FOR REPLACEMENT PARTS:
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UIBUNBJOUBJOTQFSJPEJDJOTQFDUJPOPGQSPEVDUPGMJTUFE
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4VQQMZ4ZTUFNT"/4*;$4"7BMWFNVTUIBWF
NBYJNVNTFUQSFTTVSFnot to exceed 100 psi.
(BT.BOJGPMEQSFTTVSFUBQPOCVSOFSBTTFNCMZ
Model Btu
Manifold Pressure
#UV
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#UV
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#UV
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mWARNING
WIRING INSTRUCTIONS
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The appliance, when installed, must be electrically grounded
in accordance with local codes or, in the absence of local
codes, with the National Electrical Code, ANSI/NFPA 70
and/or the CSA C22.1, Canadian Electrical Code.
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&91-04*0/
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m
THIS VALVE IS A SAFETY COMPONENT AND MUST
NOT BE REMOVED FOR ANY REASON OTHER THAN
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CAUTION
&-&$53*$"-%"."(&
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;$4"
Page 138 of 180
Page 128 of 145
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ELECTRONIC IGNITION MAINTENANCE
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Winter Operation and Winterizing Water Heater
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Atwood regarding the OPTIONAL Freeze Protection Kit.
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Winter Operation:
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0QFOUIFQSFTTVSFSFMJFGWBMWFCZMJGUJOHUIFIBOEMFUPBž
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TIPVMECFUVSOFEUPUIFi46..&3u
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UVSOPGGUIFi0/0'uQPXFSTXJUDI
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A Note About “Navy Showers” When Dry Camping
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Winterizing Procedure:
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Page 129 of 145
8"5&3)&"5&31"354-*45
17
19
20
18
21
3
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ITEM
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4
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12
5
13
6
14
15
8
9
PART #
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11
16
DESCRIPTION
PART #
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Page 130 of 145
TROUBLESHOOTING
.PTUQSPCMFNTBSFFBTJMZSFNFEJFECZDPOTVMUJOHUIFUSPVCMF
TIPPUJOHHVJEF*GQSPCMFNTTUJMMQFSTJTUDPOUBDU"UXPPEPSBO
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BOZXPSLJOWPMWJOHUIFHBTTZTUFN
"QFSJPEJDWJTVBMDIFDLPGUIFCVSOFSGMBNFTTIPVMECFEPOF
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FYDIBOHFS5IFSFTIPVMECFCMVFGMBNFXJUINJOJNVNPSOP
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#FTVSFUIBUUIFQPXFSWFOUGBOIBTWPMUTUPJUXIFO
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"UXPPEPSZPVSOFBSFTUBVUIPSJ[FETFSWJDFSFQSFTFOUBUJWF
No Water Flows From Tap When Tap is Turned on.
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NOTE: The heater is dormant until it senses water
flow. When a water tap is turned on to at least .5 GPM
the burner will fire until water flow is turned off and
the heater again goes dormant.
)PUBOEDPMEXBUFSMJOFTDPOOFDUFEUPIFBUFSBSF
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Heater Does Not Come On When The Water is turned
on. (Power vent not running)
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BOEDPMEXBUFSWBMWFTBGUFSVTJOH
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There Is No Ignition When Water Is On (Power vent is
running)
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Burner Turns On But Temperature Fluctuates
Erratically.
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"UXPPE
Heater Comes On But Rapidly Cycles On And Off.
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Burner Ignites But Water Temperature Is Too Low
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UFDIOJDJBO
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EJBNFUFSVOEFSJODIPVUTJEFEJBNFUFS
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$IFDLUIFIFBUFSEPPSMPVWFSTBOEGMVFQJQFGPSBJSGMPX
PCTUSVDUJPOTBOEDMFBO
Page 131 of 145
$IFDLUIBUUIFiTVNNFSXJOUFSuWBMWFJTJOUIFQSPQFS
QPTJUJPOGPSUIFUFNQFSBUVSFPGUIFJODPNJOHXBUFS
Water Temperature Too Low at Lower Water Flow
Rates
$IFDLUIBUUIFiTVNNFSXJOUFSuWBMWFJTJOUIFQSPQFS
QPTJUJPOGPSUIFUFNQFSBUVSFPGUIFJODPNJOHXBUFS
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UPUIFMPXFSGMPXXIFOUVSOJOHPOBXBUFSGBVDFU5IJTXJMM
CSJOHUIFHBTGMPXUPUIFSFRVJSFEIJHIFSTFUUJOH
Water Temperature Is Too Hot or No Temperature
Control.
'VFMUBOLSFHVMBUPSJTTFUUPPIJHIBOENBOJGPMEQSFTTVSF
BTEFTDSJCFEBCPWF)BWFUIFSFHVMBUPSDIFDLFECZB
RVBMJGJFEUFDIOJDJBO
$IFDLUIBUUIFiTVNNFSXJOUFSuWBMWFJTJOUIFQSPQFS
QPTJUJPOGPSUIFUFNQFSBUVSFPGUIFJODPNJOHXBUFS
8BUFSGMPXUPPMPXGPSJODPNJOHXBUFSUFNQFSBUVSF
Low Heat Rise and Excessive Water Flow Is Required
To Trigger Water Heater
*GZPVGJOEUIBUZPVSIFBUFSSFRVJSFTFYDFTTJWFGMPXUPBDUJWBUFJU
NVDIPWFSHBMMPOQFSNJOVUF
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$IFDLUIBUWBMWFTBOEGBVDFUTBSFDMPTFEXIFOOPUJOVTF
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LFFQUIFIFBUFSGSPNGVODUJPOJOHQSPQFSMZ
#FTVSFUIBUUIFCZQBTTWBMWFBUUIFXBUFSQMVNCJOH
DPOOFDUJPOTJTJOUIFiPGGuQPTJUJPO"OPQFOWBMWFDBO
BMTPQFSNJUXBUFSUPCZQBTTIFBUFSDBVTJOHJUOPUUPGJSF
If any problem persists, contact an authorized service
center or Atwood.
"5800%8"5&3)&"5&3-*.*5&%
8"33"/5:
"UXPPE.PCJMF1SPEVDUTXBSSBOUTUPUIFPSJHJOBMPXOFSBOETVCKFDU
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EFGFDUTJONBUFSJBMPSXPSLNBOTIJQGPSBQFSJPEPGUXPZFBSTGSPNUIF
PSJHJOBMEBUFPGQVSDIBTF"UXPPETMJBCJMJUZIFSFVOEFSJTMJNJUFEUP
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PGUIFQSPEVDUXJUIBSFDPOEJUJPOFEQSPEVDUBUUIFEJTDSFUJPOPGUIF
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'PSBQFSJPEPGUXPZFBSTGSPNUIFEBUFPGQVSDIBTF"UXPPE
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BOESFQMBDFUIFQBSU
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PGUIFTFDIBSHFTBOEBSFUIFSFGPSFUIFSFTQPOTJCJMJUZPGUIF
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OPSNBMNBJOUFOBODF
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TUBUFDPEFT
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PGUIFPSJHJOBMXBSSBOUZQFSJPEPSOJOFUZ
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UIFBCPWFMJNJUBUJPONBZOPUBQQMZUPZPV5IJTXBSSBOUZHJWFT
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XIJDIWBSZGSPNTUBUFUPTUBUF
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Page 132 of 145
“Quad II Diaphragm”
Models4406 Series
Automatic Water System Pump
With Internal Bypass Valve
Model 4406 Series
FEATURES
•
•
•
•
•
•
Self-Priming
Dry Running
Soft, Noise Absorbing Mounts
IAPMO listed, 12 Volt Model
CSA listed, 12 Volt Model
CE Models Available (d.c.)
3.5
(90)
3.44
(87)
SPECIFICATIONS
3.25
(82)
Motor: Permanent Magnet, Ball Bearing.
Pump: Four chamber diaphragm design; Self-priming
up to 6 ft. suction lift; Pump able to run dry
without damage; Removable port to hose
connectors.
Note:
The built-in bypass valve eliminates the need
for an accumulator tank. Do not install in a
system with an accumulator tank. The tank
will interfere with the internal bypass valve.
Pump Series
4406-XXX
Dimensions - Inches (mm)
Height
Width
Length
3.75 (95)
6.3 (160)
8.2 (208)
Weight
lb. (kg)
3.9 (1.8)
MODEL*
VOLTS
AMP DRAW
@ 10 psi (0.7 bar)
FLOW
GPM (l/min)
PRESSURE SWITCH
MAX psi (bar)
4406-143
4406-343**
4406-043**
12V dc
24V dc
115V ac
3.9
2.0
0.4
3.3 (12.5)
3.3 (12.5)
3.3 (12.5)
35 (2.4)
35 (2.4)
35 (2.4)
* CE fully suppressed models are identified by a prefix “R” and a CE mark on the label. (i.e. R4406-143).
Self Declaration Of Conformance (SDOC) is available upon request.
**Not listed with IAPMO or CSA
OPERATION
With pump switch off, and battery fully charged, fill water
tank, open all faucets then turn pump switch on. Water
will begin to flow, when water is free of air, turn faucets
off, remember you are filling the water heater and the
toilet and shower lines. When all valves are shut off
pump will stop. Should pump fail to stop, turn switch off
and see the trouble shooting guide.
This motor pump unit is equipped with a thermal
overload protection device. In the unlikely event the
motor overheats, the pump will shut off. Turn off power
to pump until motor cools.
Page 133 of 145
City Water
Inlet
Water
Heater
C
Water
Tank
Check
Valve
A
Autofill Tank Valve,
Plumb to Tank
B
Do Not Plumb Autofill
to Pump Suction Line
Flojet Inlet
Strainer
INSTALLATION
STEP I
Remove shipping plugs from Quad pump ports. Some
water from factory testing may spill out.
STEP 2
Install inlet A and discharge B port connectors. Firmly
push slide clips C forward to lock port connectors in
place.
STEP 3
Slide rubber mounts fully into 4 mounting tracks.
STEP 4
Mount pump vertically, with pump head down or
horizontally in an accessible location. If mounting
vertically, motor up, attach motor mounts first, then
pump head mounts, while supporting weight of pump.
STEP 5
Use 1/2” I.D. flexible hose (preferably braided or
reinforced). Use hose clamps on the slip-on barb hose
connectors.
STEP 6
Install no less than 3/8” I.D. hose for feed lines to
fixtures. Use high pressure hose on all city water lines.
STEP 7
Install a Flojet strainer in an accessible location (for
inspection and cleaning) between the tank and pump
inlet. This strainer or equivalent is required for pump
warranty to be valid.
NOTE: Do not use with an accumulator tank.
Black (–)
Red (+)
(+)
(–)
Fuse
Switch
Battery
WIRING
STEP I
Use 14 gauge stranded wire to 20’, 12 gauge to 50’,
from power source.
STEP 2
Use a 10-15 amp rated on-off switch on the (+) positive
(red) motor lead.
STEP 3
Install 10-15 amp fuse or breaker between the power
source and the positive lead for the -143 models and a
4 amp fuse for -343 models.
Page 134 of 145
TROUBLESHOOTING
WARNING: BEFORE SERVICING PUMP, TURN OFF PUMP AND DRAIN WATER FROM SYSTEM!!
Failure to Prime - Motor operates, but no pump discharge
• Restricted intake or discharge line
• Air leak in intake line
• Debris in pump
• Punctured pump diaphragm (pump leaking)
• Crack in pump housing
Pump Fails to Turn Off After All Fixtures Are Closed
• Empty water tank
• Insufficient voltage to pump (low battery)
• Punctured pump diaphragm (pump leaking)
• Discharge line leak
• Defective pressure switch
Motor falls to turn on
• Loose wiring connection
• Pump circuit has no power
• Blown fuse or open thermal protector
• Pressure switch failure
• Defective motor
Low Flow and Pressure
• Air leak at pump intake
• Accumulation of debris inside pump and plumbing
• Worn pump bearing (excessive noise)
• Punctured pump diaphragm (pump leaking)
• Defective motor
Pulsating Flow - Pump cycles on and off
• Restricted pump delivery. Check discharge lines, fittings and
valves for clogging or undersizing.
1
9
2
8
3
5
4
7 Includes items 1 thru 4
Quite often when a pump is worn or defective the one failed component has overburdened others. To avoid frequent aggravating
repairs, Flojet offers service kit assemblies making repairs as quick and easy as possible.
DISASSEMBLE
REASSEMBLE
Upper Housing
1. Remove switch (9). Disconnect switch wires.
Motor
1. Reassemble lower housing assembly (4) to motor. (Follow
steps 4 to 10.)
Diaphragm
2. Lower housing is assembled with:
• Flat side of diaphragm and outer pistons facing motor
• Hex stem of inner pistons must be aligned into hex holes in
outer pistons (4).
• Outer pistons must be aligned with alignment slots on cam
assembly making sure screw holes align in cam assembly,
otherwise diaphragm will leak.
3. Tighten cam piston screws partially, center piston in
diaphragm, then tighten screws securely (18 in. lbs. torque)
Lower Housing
4. Reassemble lower housing assembly (4) to motor.
5. Retighten set screw securely. Set screw head must be
positioned facing motor covering seam (indentation).
(Positioning of this screw is critical to avoid misalignment and
subsequent diaphragm damage.)
Upper Housing, Check Valve
6. Reassemble upper housing (1) and slide clips (8)
7. Properly seat O-Ring in check valve assembly (2) and check
if ferrules and screen are in place on upper housing (1)
8. Install check valve (2) into upper housing (1) and push in.
9. Assemble on to lower housing (4), align 4 screws on to motor
by rotating lower housing (4) if necessary to align feet.
10. Tighten screws evenly to 30 in. lbs. torque.
Pressure Switch
1. Place switch against front of pump (9), insert screws and take
care not to cross thread or strip out threads in housing.
2. Reconnect wires.
Upper Housing
2. Loosen but do not remove four pump head screws and
carefully remove upper housing assembly (1)
3. Inspect check valve (2) for debris
4. Reassemble new upper housing (1)
Check Valve Assembly
Follow step 2
3. Replace check valve (2)
4. Reassemble upper housing (1)
Lower Housing, Diaphragm, Motor
Follow step 2, then slide rubber foot from mounting track.
3. Rotate lower housing (4) so mounting notch opening on lower
housing exposes set screw which holds bearing housing to
shaft.
4. Loosen this set screw by inserting wrench 1/8” Allen wrench
into mounting notch opening. Then, slide lower housing (4) off
motor shaft.
Diaphragm Cont’d 5.
5. Loosen four cam piston screws with Phillips head screw
driver and pull apart cam from inner pistons. (Pistons should
always be replaced when a new diaphragm is installed.)
Motor Cont’d
5. Replace Motor
Page 135 of 145
AUTOMATIC WATER SYSTEM PUMP SERVICE PARTS
KEY#
DESCRIPTION
0 Service Kit*
1 Upper Housing With Clips
2 Check Valve Assembly
3 Diaphragm Assembly (includes screws)
4 Lower Housing Assembly
5 Motor
Motor CE Models
Motor 115 Volt a.c.
6 Quad Port x 1/2” HB. Straight
Quad Port x 5/8” HB. Straight
Quad Port x 3/4” HB. Straight
7 Pump Head Assembly
8 Side Clips (pair)
9 Switch, Pressure
MODEL#
4406-343
20409-043
20404-000
20407-030
20403-040
20419-001
2019-009A
R2019-008A
—
20381-002
20381-003
20381-006
20406-001A
20408-000
02090-104
4406-143
20409-043
20404-000
20407-030
20403-040
20419-001
2009-034A
R2009-034A
—
20381-002
20381-003
20381-006
20406-001A
20408-000
02090-104
4406-043
20409-043
20404-000
20407-030
20403-040
20419-001
—
—
2029-044A
20381-002
20381-003
20381-006
20406-001A
20408-000
02090-104
*Service Kit includes #2, #3, #8 and drive cam assembly.
ACCESSORIES
QUICK CONNECT PORT SYSTEM
20381-000
20381-002
QUAD PORT x
QUAD PORT x
1/2" MALE QEST. 1/2" HOSE BARB
STRAIGHT
STRAIGHT
20381-003
20381-026
20381-008
20381-009
20381-024
QUAD PORT x
QUAD PORT x
QUAD PORT x
QUAD PORT x
QUAD PORT x
5/8" HOSE BARB 10/13mm HOSE BARB 1/2" MALE QEST. 1/2" HOSE BARB 10/13mm HOSE BARB
STRAIGHT
90 ELBOW
STRAIGHT
90 ELBOW
90 ELBOW
The above part numbers are packaged with 2 fittings per bag.
STRAINERS
Pump Series
Strainer Number
Inlet
Outlet
4406-XXX
1740-012
1740-002
1740-004
1740-014
1/2 Barb
1/2 Barb
1/2 M Qest
1/2 M Qest
Quad Port
1/2 Barb
1/2 M Qest
Quad Port
Screen
40
40
40
40
Mesh
Mesh
Mesh
Mesh
WARRANTY
RETURN PROCEDURE
FLOJET warrants this product to be free of defects in material
and/or workmanship for a period of two years after purchase by
the customer from FLOJET. During this two year warranty period,
FLOJET will at its option, at no charge to the customer, repair or
replace this product if found defective in material or workmanship,
with a new or reconditioned product, but not to include costs of
removal or installation.
Prior to returning any product to FLOJET, call customer service for
an authorization number. This number must be written on the
outside of the shipping package. Place a note inside the package with an explanation regarding the reason for return as well
as the authorization number. Include your name, address and
phone number.
This is only an overview of our limited warranty. If you would like a
copy of our warranty, please call or write FLOJET.
U.S.A.
Flojet
20 Icon
Foothill Ranch, CA 92610-3000
Tel: (949) 859-4945
Fax: (949) 859-1153
© Copyright 2001, ITT Industries
UNITED KINGDOM
Jabsco/Flojet
Bingley Road, Hoddesdon
Hertfordshire EN11 OBU
Tel: +44 (0) 1992 450145
Fax: +44 (0) 1992 467132
Printed in U.S.A.
CANADA
Fluid Products Canada
55 Royal Road
Guelph, Ontario N1H 1T1
Tel: (519) 821-1900
Fax: (519) 821-2569
All Rights Reserved
JAPAN
NHK Jabsco Company Ltd.
3-21-10, Shin-Yokohama
Kohoku-Ku, Yokohama, 222
Tel: 045-475-8906
Fax: 045-475-8908
GERMANY
Jabsco GmbH
Oststrasse 28
22844 Norderstedt
Tel: +49-40-53 53 73-0
Fax: +49-40-53 53 73-11
Form: 81000-233
02/02
Page 136 of 145
Page 137 of 145
Page 138 of 145
12 Volt 10 Amp SOLAR CHARGE
CONTROLLER
Item 60031
Item 60021
U ser’s Manual
Notice D’utilisation
Page 139 of 145
12 Volt 10 Amp Solar Charge Controller
Maintain 12V batteries in a fully charged state
IMPORTANT SAFETY AND OPERATION INSTRUCTIONS
SAVE THESE INSTRUCTIONS
The charge controller is designed to protect your 12 Volt Lead-acid
battery from being overcharged as well as prevent discharge of the
battery during nighttime. This controller reduces overall system
maintenance and prolongs the battery life. The LCD Display will
display the battery voltage (60031 only). This controller is designed to
work with all makes of 12 Volt solar panels.
This manual contains important safety and operation instructions for
the 12 Volt 10 Amp Solar Charge Controller (Item# 60031, and
60021). Keep this manual with or near the controller at all times.
WARNINGS- Working with Batteries
RISK OF EXPLOSIVE GAS – Working in the vicinity of a lead acid battery is dangerous.
Lead acid batteries contain hydrogen-oxygen gases that can cause explosion and
sulfuric acid that can cause severe burns. Always work in a well ventilated area.
DO NOT SMOKE, OR ALLOW A SPARK OR A FLAME IN THE VICINITY OF A
BATTERY!
Remove personal metal items such as rings, necklaces, watches, and bracelets when
working with a battery. Be extra cautious to reduce risk of dropping a metal tool on to
the battery. The battery may spark or short circuit.
NEVER CHARGE A FROZEN BATTERY
If battery acid contacts skin or clothing, wash immediately with soap and water. If acid
enters the eye, IMMEDIATELY FLOOD EYE WITH RUNNING COLD WATER for at
least 10 minutes. GET MEDICAL ATTENTION IMMEDIATELY.
• CAUTION: DO NOT EXCEED THE UNIT’S VOLTAGE AND CURRENT RATINGS:
Solar array voltage - MAXIMUM INPUT 23 Volts.
Charging current - MAXIMUM INPUT 12 Amps.
Failure to comply with above warnings may lead to explosion, and or severe injury.
BE SURE TO DISCONNECT THE CONTROLLER FROM BATTERY AND SOLAR
ARRAY BEFORE PERFORMING ANY MAINTENANCE OR CLEANING
DO NOT DISSASSEMBLE THE CONTROLLER
INSTALLATION SHOULD BE PERFORMED BY A QUALIFIED PERSON
DO NOT DEVIATE FROM WIRING INSTRUCTIONS
Page 140 of 145
CONTROLLER DIMENSIONS
60031 Shown
FEATURES
• Digital Meter (60031 only) –
Battery voltage is shown digitally.
• Protect and Maintain battery –
Protect batteries from overcharging and maintains
batteries in fully charged state.
• Safety circuit protection –
Reverse polarity protection
• Reverse leakage protection – Protect batteries from discharge by solar panel
• Temperature Protection–
Over temperature protection and auto-resume
• Status Lights –
Easy reading LED indicators.
• Mounting Options –
Panel mounting / wall mounting.
INSTALLATION
The solar controller is designed to be panel mounted or wall mounted.
Installation
• Panel Mounted - The charge controller may be mounted flush with the wall.
Flush mounting requires a rectangular cutout in the mounting surface with sufficient space (2-3
inches) behind to accommodate the controller and wiring.
• Wall Mounted - The charge controller may also be mounted to the wall without making a
cutout. The controller will be raised from the wall; this is the quickest and easiest
mounting procedure.
Recommended Battery Capacity: 12V 35AH minimum.
CONNECTION PROCEDURES (refer to Connection diagram)
• Connect the solar panel positive side to the solar controller ARRAY + (this is marked by a
“+” tag) using a suitable wire (Be careful DO NOT short circuit the solar array.)
• Connect the solar panel negative side to the solar controller ARRAY – (this is marked by a
“-“ tag) with a suitable wire.
• Connect the battery positive side to the solar controller BATTERY positive side (this is
indicated by a red collar) with either the provided “O” rings or a suitable wire (you may
strip the “O” rings from the wire without voiding your warranty).
• Connect the battery negative side to the solar controller BATTERY NEGATIVE – with a
suitable wire.
Page 141 of 145
CONNECTION DIAGRAM
60031 Shown
Wire size: - Refer to the “WIRE SIZE” chart below to determine the minimum size wire
needed for each connection. When using heavy stranded wire, you may need to divide the
ends into two groups and straddle the screw on the terminal block.
Any wiring variation of size or length can affect performance of the charge controller
Length of Wire
AWG
Battery Connection
Distance round trip (wiring
provided)
< 0.9m (3ft)
18
Solar Array Connection
Distance round trip
6m (20ft) 9m (30ft) 12m (40ft)
16
14
12
OPERATION
Once properly mounted and connected the charge controller will start charging immediately given
adequate solar power. The 12 Volt 10 Amp Solar Charge Controller is based on a three stage
charging algorithm, Bulk Charge Mode, Constant Voltage Mode and Float Mode.
• PWM constant-voltage regulation to prevent heating and excessive battery gassing. Pulse
charging restores full battery capacity.
• Float mode: When the battery was fully charged, the battery voltage will reduce to a lower
regulated voltage, in which maintains the battery at full charged state safely.
NOTE: The Solar Charge Controller will not initiate charge cycle if battery voltage is less than 4.0
Volts.
Page 142 of 145
SPECIFICATIONS
Technical Specifications
PARAMETERS
UNITS
ELECTRICAL:
Normal input (solar cell array voltage)
Volt
Max. input solar cell array voltage
Volt
Peak charging current:
Amps
Current Consumption when connected 12V Array
(Battery not present)
Current Consumption when connected 12V battery
(Array not present)
CHARGING CHARACTERISTICS
Max. Bulk charging current
Constant voltage for Lead-acid battery
Float mode voltage
LCD METER DISPLAY: (60031 only)
Min. LCD Display Voltage
Max. LCD Display Voltage
PROTECTION:
Over temperature protection starting at (Stop charging)
Over temperature protection reset at (Restart Charging)
MECHANICAL
Controller Dimension
Controller overall Height
Net weight
ENVIRONMENTAL CHARACTERISTIC:
Operation temperature
Storage temperature
Operation humidity range
DATA
17~22
23
12
mA
55 max.
mA
10 max.
Amps
Volt
Volt
10
14.4 +/-0.4
13.5+/-0.4
Volt
Volt
6.0 +/-0.4
19.0 +/-0.4
ºC/°F
ºC/°F
>85/>185
<65/<149
mm
mm
g
125 (L) x 65(W)
Approx. 27
Approx. 300
ºC/°F
ºC/°F
-5 to 50 / 23 to 122
-10 to70 / 14 to 158
0 to 80% RH
MONITORING
LED Indicator
The 3 LEDs indicate charging status. These functions are described below.
Solar Power Indication (POWER LED - red)
ON:
OFF:
Indicates solar panel properly connected and solar power supplied normally.
No power available or insufficient voltage to active charge controller.
Charging status
CHARGING LED - blue;
“Float/Maintaining” CHARGE COMPLETE LED - green
LED
Status
Charging
Bulk
Charge
ON
Charge Complete
“Float/Maintaining”
OFF
Conditions
Indicates the battery is charging,
power from the solar array passes
unrestricted through to the battery.
Page 143 of 145
Solar
power
Weak
Flashing
OFF
Indicates the solar panel voltage
is too low (insufficient sunlight)
Float
Charge
OFF
ON
Indicates full charge reached, a
small “Float” charge continues to
optimize battery when you need
Digital LCD meter (60031 only)
A digital LCD meter is available on this controller; it will continuously display battery
voltage.
MAINTENANCE
1. Ensure all wire connections are sound and free from corrosion. Tighten the terminal block
screws of the array connections.
2. Visual check of solar array and battery output cabling for signs of overheating, damage and
cracking.
If any wires show damage, replace with a new wire immediately.
3. The above maintenance is recommended to be carried out at least every 3 months
TROUBLE SHOOTING
Battery won’t charge:
• Solar array may be sized incorrectly. A panel with a larger output is required. You may
add on to existing panels by wiring additional panels in parallel with the existing panel.
• Usage may be too high. The battery is being drawn upon at a faster rate than the solar
array is able to produce. A secondary battery may be used, by physically switching the
batteries out and allowing one battery to supply power while the other is being charged.
• Battery may be too small. In this case it may appear the battery is not charging however
it is the reserve that is depleting too quickly. A battery with a larger capacity may be
required. A secondary battery may be used, by physically switching the batteries out and
allowing one battery to supply power while the other is being charged. A second battery
may also be added to the existing battery by wiring the additional battery in parallel to the
existing battery. The charge controller need only be connected to one of the batteries in
this case.
• The battery may be bad. Small level of charge or discharge will greatly affect the battery
voltage. Battery needs replacing.
• Wires may be incorrectly hooked to the charge controller. Ensure the wires are
connected in parallel to the controller and to the correct terminals.
Solar Panel has no output:
• The solar panel may be seriously affected by the angle of the panel with regards to the
sun, and environmental factors. Ensure the surface is clean and free of dust and build
up; a clean damp rag may be used to clear the panel of dust. Do not use soap or
solvents of any kind. Cloudy conditions will affect the output of the solar panel.
• Wires may be incorrectly hooked to the charge controller. Ensure the wires are
connected in parallel to the controller and to the correct terminals. Please refer to the
Connection Procedures portion of this manual.
Warranty
This product is covered by a 1 year limited warranty. Sunforce Products Inc warrants to the original
purchaser that this product is free from defects in materials and workmanship for the period of one year from
date of purchase
To obtain warranty service please contact Sunforce Products for further instruction, at
1-888-478-6435 or email [email protected] Proof of purchase including date, and an explanation
of complaint is required for warranty service.
Page 144 of 145