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post #1 of 21 (permalink) Old 29-09-2009, 21:02 Thread Starter
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Leaking Cascade 2 water heater

Hi all

I have a 1996 Swift Kontiki with a Cascade 2 water heater. During a long trip recently I have noticed it leaking water from the Cowl. Its got a little worse and I would like to get it repaired. I have taken the Cowl off but water just seems to be seeping from the metal end of the heater. Im sorry but Im not very technical. I had a look on the Arcsystems site (found it in a similar thread here) and at the PDF manual and in the trouble shooting guide it says the following

Symptom - Water coming from Cowl
Cause - Pressure relief valve operating on temprature rise
Cure - Check pump pressure for high valve

Not sure what any of this means. We only got the van last year and were not aware we should drain it in winter although we did use it throughout the winter so Im not sure if its got frost damage.

We live in North Yorkshire and would like to get it fixed ASAP. Our nearest MH dealers are Catterick Caravans and Ropers Caravans but not had much to do with them in the past, will most dealers be able to sort this or can I do it myself?

Any feedback appreciated.
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post #2 of 21 (permalink) Old 29-09-2009, 21:24
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Have you checked the fusible plug ? Link below for pic and details

http://www.thecaravanspecialists.co....k=yes&P_ID=825


Mark
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post #3 of 21 (permalink) Old 29-09-2009, 21:33 Thread Starter
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Quote:
Originally Posted by CLS
Have you checked the fusible plug ? Link below for pic and details

http://www.thecaravanspecialists.co....k=yes&P_ID=825


Mark
Hi Mark

Thanks for the reply, cant get that link to work despite enabling cookies but I did find a pic of a fusible plug on the caravanspecialist site.

Really sorry but im none the wiser, where exactly should I be looking and what is the purpose of this plug.

Go easy on me, I know nothing!

Cheers
Barry
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post #4 of 21 (permalink) Old 29-09-2009, 21:42
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If it only leaks when hot it might be the valve but if its leaking when cold then I would check all the connections but I would suspect its had its day?

If it is only when hot perhaps the water is getting too hot. I have a vague memory of being able to set the hot water temperature on these, at least when running on electric. Check it and set to about 55C

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post #5 of 21 (permalink) Old 29-09-2009, 21:44
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Hi barryd

I have the same van and wter system as you.

We also had a leak this year it was the pressure valve which is on the outside under the plastic cowl at the top left on the heater.

This is a common fault im told, the plastic valve weakens over time and cracks causing leaks.

This valve changed its name from a pressure relief valve to a quick release or drain valve, because under pressure the tank itself would pop off before the valve would open thus making it useless.

So as its not really needed as a safty thing, you can try like I did ( and its still working fine) twist off the valve until it breaks off scary but its already bust so nothing to loose.

Once snapped off you will have a hole with the remains of the valve (plastic) find a screw/bolt that fits into the hole quite tight to blank it off.

Be very careful when you do this not to use to bigger screw/bolt the metal cast of the heater is not very strong and you dont want to crack it.

If you want to try and get the broken thread out and put a new valve in (about 10) you can use a hacksaw blade to cut it into bits but be careful not to get bits in the tank or cut the thread.

Do not use a stud extractor to get the plastic out it will crack the case.

I called Gary at Arc systems really helpful the Tel is 01159213175, they do an exchange for 60 if all goes wrong.

I hope I havent waffled on and hope this helps.

Chris

I d
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post #6 of 21 (permalink) Old 29-09-2009, 21:46 Thread Starter
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It seems to leak any old time, certainly not just when the water heater is on. If you turn the general water switch on every so often it the pump activates on its own like its feeding water through or there is a pressure problem, go outside and its dribbling away.
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post #7 of 21 (permalink) Old 29-09-2009, 21:48
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No problem , remove the plastic cover from the Carver Cascade then first check the pressure relief valve (top left) to see if water escapes from there when heating up. The fusible plug will be located in the centre of the the unit , an hexagonal head nut and check if water is leaking from there.


Mark
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post #8 of 21 (permalink) Old 29-09-2009, 21:51 Thread Starter
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Quote:
Originally Posted by chrisndeb
Hi barryd

I have the same van and wter system as you.

We also had a leak this year it was the pressure valve which is on the outside under the plastic cowl at the top left on the heater.

This is a common fault im told, the plastic valve weakens over time and cracks causing leaks.

This valve changed its name from a pressure relief valve to a quick release or drain valve, because under pressure the tank itself would pop off before the valve would open thus making it useless.

So as its not really needed as a safty thing, you can try like I did ( and its still working fine) twist off the valve until it breaks off scary but its already bust so nothing to loose.

Once snapped off you will have a hole with the remains of the valve (plastic) find a screw/bolt that fits into the hole quite tight to blank it off.

Be very careful when you do this not to use to bigger screw/bolt the metal cast of the heater is not very strong and you dont want to crack it.

If you want to try and get the broken thread out and put a new valve in (about 10) you can use a hacksaw blade to cut it into bits but be careful not to get bits in the tank or cut the thread.

Do not use a stud extractor to get the plastic out it will crack the case.

I called a company sorry forgotten the name but really helpful the Tel is 01159213175, they do an exchange for 60 if all goes wrong.

I hope I havent waffled on and hope this helps.

Chris

I d

Great info Chris, will have a look but I suspect this may be stretching my DIY capabilities. I have some rather clever neighbors though!

When you say that company do an exchange, can you clarify what they exchange for 60?

Thanks very much
Barry
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post #9 of 21 (permalink) Old 29-09-2009, 21:56
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Hi Barry

The exchange is the cast part of the heater, which would mean a strip down ie remove the heater.

Try what I said It works and its easy just be careful not to crack it.

Also a web site to have a look at for bits & advice www.preloved.co.uk

Good luck

Chris
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post #10 of 21 (permalink) Old 29-09-2009, 22:00 Thread Starter
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Quote:
Originally Posted by chrisndeb
Hi Barry

The exchange is the cast part of the heater, which would mean a strip down ie remove the heater.

Try what I said It works and its easy just be careful not to crack it.

Also a web site to have a look at for bits & advice www.preloved.co.uk

Good luck

Chris
So if I botch it then I can take it to bits, exchange it for 60 and then take all the bits in a box along to somebody who knows how to use a screwdriver?

Thanks very much will recruit engineering chap next door and have a go!

Barry
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