Home

installation, service and owner`s manual models: xl900

image

Contents

1. INSTALLATION SERVICE AND OWNER S MANUAL MODELS XL900 XL1500 CONTENTS 1 2 INTRODUCTION ua aa a o ds o i OPERATING YOUR PROHEAT HEATER 1 1 TECHNICAL SPECIFICATIONS ENCLOSURE DIMENSIONS 5 ne Aue een 2 1 HEATER DIMENSIONS a Hate 2 3 INSTALLATION LOCATING THE HEATER Sansibar 32 MOUNTING THE HEATER An ee 34 EXHAUST PIPE 5 0 200 3 6 PLUMBING THE SYSTEM aiii 3 7 General Considerations r 3 7 Option A Engine Heat or Supplemental Heat 3 8 Option B Engine amp Sleeper 3 9 Engine Connection Details 3 11 WIRING amp ELECTRICAL 3 13 General Considerations ed oto Pr metet 3 13 Power Connection to Batteries 3 14 Timer Connections aueh 3 15 ON OFE SWIECA ee ee ralla 3 16 Sleeper Heater Wiring Details 3 17 Option A OEM Heater 6 Proheat Thermostat 3 18 Option B OEM Heater 6 Thermostat 3 19 Option C Auxiliary Sleeper Heater 3 20 Option D Relay Sleeper 3 17 FUEL SYSTEM ac ne ih ias 3 21 General Considerations nr 3 21 Option A X OR X
2. USED IN SERIES READ AMP FIGURE 1 REMOTE ON OFF SWITCH 952925 24 INCHES FIGURE 2 Teleflex eleflex Canada Energy Solutions Division Teleflex Canada 3831 No 6 Road Tel 604 270 6899 Fax 604 270 0137 1994 Reproduction in any form electronic print or otherwise is encouraged providing Richmond B C Web www proheat com the PROHEAT logo watermark is visible on Canada Email proheat proheat com the reproduction and credit is given to V6V 1P6 Toll Free 800 667 HEAT 4328 Teleflex Energy Solutions 8 10 PROHEAT OWNER S MANUAL Description Service Bulletin 968228 May 1994 Update Notice for Mark Air Compressor Filters MARKI TIE ROD 90 El LBOW Z MARKII AIR FILTER ELEMENT AIR FILTER ELEMENT E TO COMPRESSOR FIGURE 1 FIGURE 2 Purpose Parts Instructions Converting Mark heater air 1 936227 Filter Air Assembly Remove the old filter assembly by compressor filter configuration MKII c w element unscrewing the tie rod at the 90 to the Mark Il air compressor filter 1 936829 Clamp cushioned elbow Replace the 90 elbow configuration 1 842123 Elbow 3 16 hose with elbow part 842123 The new configuration provides x 1 8 greater protection for the filter 1 842020 Hose Air amp Fuel dou 222 Menus E a
3. etr to Diesel 1 2 Kerosene Coolant 150 to 185 F 65 to 85 heater Enclosure Dimensions XL900 12 W x 11H x 20 AL inches 318 x 280 x 521 mm XL1500 12 W x 11H x 22L inches 318 x 280 x 559 mm Weight Heater only XL900 40 Ibs 18 kg XL1500 41 Ibs 18 5 kg Weight with Enclosure XL900 55 lbs 25 kg XL1500 56 5 Ibs 26 kg Operating Temperature Range 40 to 122 F 40 to 50 C Heat Exchanger Capacity 1 quart U S 97 litre 9 1 2 241 mm 11 4 31 mm 8 1 2 35 8 216 mm 92 mm A 17 16 36 mm 12 1 2 318 mm LENGTH OF XL900 20 1 2 521 mm XL1500 22 559 mm es Figure 2 1 Enclosure Dimensions typical to all models TECHNICAL SPECIFICATIONS 2 1 Figure 2 2 Heater Dimensions XL900 2 2 PROHEAT OWNER S MANUAL Figure 2 3 Heater Dimensions XL1500 TECHNICAL SPECIFICATIONS 2 3 INSTALLATION 3 0 INSTALLATION There are seven major steps that must be completed to successfully install the PROHEAT heater 1 LOCATING THE HEATER 0er 3 2 to 3 3 2 MOUNTING THE HEATER eee 34 to 35 3 EXHAUST PIPE ns 3 6 4 PLUMBING THE SYSTEM uo HH nn 3 7 to 3 9 5 WIRING ELECTRICAL CONNECTIONS 3 13 to 3 20 CR
4. 6 1 Heat Exchanger u rn 6 2 Exhaust System ii cit endete do c ee oaa 6 2 Electrical System nn ee 6 3 MR d eO ERO VR ERR EET 6 3 Clean aeree rennen 64 Compressor Air Filter 2 74 414 nn 64 Cooling System ee 64 Fuel an 65 Vehicle Batteries r 65 Operation TEST a U aa 6 5 PCM Pin ut Details 6 6 PROHEAT Wiring 6 7 PROHEAT Sleeper Fan Wiring Details 6 8 Ta WARRANTY hy elles 7 1 8 APPENDICES Service Bulletin 951321 _ r 8 1 AL een 8 3 HOOT 12 8 5 a days 8 7 9008229 8 9 2009072 MEE 8 11 21010 01 ade 8 13 SB0003 sie cn 8 15 PROFEAT PROHEAT Model XL 900 XL1500 INTRODUCTION HH Hig This manual is provided to assist an authorized PROHEAT dealer to install and service a PROHEAT heater it is also a detailed owners manual Although trucks have been used in the examples applications for PROHEAT are by no means limited to trucks PROHEAT heaters are designed to be used on any diesel equipped vehicle including trucks buses school transit and coach con
5. YES CLEAN SENSOR IF NECESSARY AND RESTART DISCONNECT OLD SENSOR CONNECT TEST SENSOR HOLD UP TO INSPECTION PORT RESTART AFTER 60 SEC IS THERE A START ERROR 9 YES IS THERE A SPARK CHECK IGNITION CHECK FUEL SYSTEM SYSTEM PAGE 5 17 PAGE 5 28 1 CHECK MAIN HARNESS FOR OPEN CIRCUIT REPLACE IF NECCESSARY gt TRY WITH NEW CONTROLLER REPLACE IF NECCESSARY AFTER 60 SEC IF THERE IS A START ERROR GO TO FUEL SYSTEM TROUBLE SHOOTING amp REPAIR 5 9 5 10 7 Temp Sensor A TEMP TEMPERATURE SENSOR ERROR indicates a short or open circuit in the temperature sensor wiring or the coolant temperature is out of range below 58 F 50 C or above 266 F 130 C The resistance of the temperature sensor is proportional to temperature Check Temperature Sensor ERROR INDICATED a Inspect wiring for short or open circuits b Test the sensor to see if it is defective Test Procedure a Connect a multimeter adjusted to measure resistance to the temperature sensor as per Figure 5 4 The polarity of the sensor connections to the multimeter is not important b Measure the sensor resistance versus temperature under the following conditions at room temperature in a freezer in boiling water c Compare the measured values against the graph Figure 5 5 If values do not approximately match then the s
6. CX11 LOCKWASHER CAP SCREWS Figure 3 7 Mounting Tray 508 mm n 3 76 mm Dia 5 127 mm 5 127 mm CENTRELINE OF ENCLOSURE 12 306 mm 8 13 16 223 mm 3 4 20 mm MOUNTING HOLES 4 REQUIRED 5 127 mm n 11 16 427 mm 15 8 45 mm Figure 3 8 XL900 Enclosure Base Dimensions 3 4 OWNER S MANUAL m tt 7 8 556 mm 1 5 8 45 mm 4 n m 3 76 mm Dia 5 127 mm 5 127 mm CENTRELINE OF ENCLOSURE m d 8 13 16 53 4 146 mm 223 mm 3 4 20 mm MOUNTING HOLES REQUIRED 5 127 mm n n haa 11 16 427 mm PEA 15 8 45 mm Figure 3 9 XL1500 Enclosure Base Dimensions OPTI ON B Heater supplied without an enclosure mount in an existing enclosure on the vehicle ie tool box Heater supplied with an auxiliary mounting plate 1 Ensure that the proposed enclosure is big enough for the heater 12 x 11H x 20 AL inches 318 x 280 x521 mm 2 Using the indicated dimensions drill the 4 mounting holes and exhaust pipe clearance hole 3 Ensure that the combustion tube can be removed for service Minimum of 5 1 2 from fan end casting face is required D 178 mm p 51 2 140 mm ue 1 19 mm 2 m i 1 3 76 mm Dia O 25 mm ES 8 1 2 216 mm CENTRELINE OF ENCLOSURE
7. 5 0 ON FUNCTION _ ERRORS COMPONENT FAULTS On TROUBLE SHOOTING amp REPAIR NR N 10 11 12 13 TROUBLE SHOOTING amp REPAIR The trouble shooting guide is divided into four sections Function Errors Errors displayed on the PCM function display will cause the heater to shut down These errors are usually the result of a component problem It is possible to have two or more errors displayed at the same time A function error may be displayed in conjunction with a component error Component Faults This section covers the individual heater components In many cases there is a corresponding indicator light on the PCM function display The indicator light only indicates an electrical problem NOT a mechanical failure Component problems can also cause Function Errors NOTE A sleeper fan error 13 will not shut the PROHEAT down and heat to the engine will be maintained Components This section includes the electrode gap fuse nozzle and fuel regulator Operational Problems Problems that are not specifically described in the Function or Component errors sections NOTE Always let the heater run through two cycles when trouble shooting The heater will attempt one restart after any function or component error The heater will not start if it is in a purge cycle or if the coolant temperature is above 150 F 65 C A CONTINUOUSLY FLASHING ON INDICATOR indicates a proble
8. See Figure 5 7 Symptom Fuel pump is not pumping PUMP NOT PULSING ERROR INDICATED Check Fuel pump wiring See PROHEAT wiring diagram page 6 8 a Is the fuel pump wire shorted to ground Check wire harness from pump connection back to the PCM for pinched or abraded wire touching the PROHEAT chassis b For defective pump See Test Procedure Figure 5 6 If the pump tests OK replace the PCM Symptom Fuel pump pulsing rapidly NO ERROR INDICATED NOTE Rapid pulsing indicates air in system lack of fuel Check Fuel flow a The fuel level Is the PROHEAT pickup below fuel level b Fora blocked or pinched fuel line For air leaks suction and pressure lines d For gelling fuel Symptom Fuel pump not pumping PUMP NOT PULSING NO ERROR INDICATED Check Fuel System a For restrictions in fuel lines b Nozzle and fuel strainer for blockage See page 5 26 c For defective pump See Test Procedure Figure 5 6 d For defective regulator See page 5 27 e That the PCM functions See page 5 14 Check Electrical connections to Fuel Pump a That the fuel pump body is grounded to PROHEAT chassis b That ground wire is connected See Figure 5 7 c The voltage at the fuel pump positive terminal nominally 12 or 24 volts Power will be present ONLY during Start or Full Output mode See Figure 5 6 PROHEAT OWNER S MANUAL TROUBLE SHOOTING amp REPAIR Test procedure Indicates if there is flow to reg
9. that the installation complies with all applicable Coast Guard regulations 1 0 Regular use of your PROHEAT throughout the year will improve its reliability Weekly operation is recommended OPERATING YOUR PROHEAT HEATER OPERATING YOUR PROHEAT HEATER Engine Heat Only 1 Switch the toggle switch located in the vehicle dash to ON The switch will light and the heater will fire It will continue to fire until the coolant reaches 185 F 85 C at the heater outlet and then cycle off When the coolant temperature falls below 150 F 65 C at the heater inlet it will refire and repeat the cycle It will continue to cycle until a the heater is switched off b the heater runs out of fuel c the vehicle battery voltage drops below 10 5 volts or d an error occurs and the switch light flashes See Trouble Shooting amp Repair section 5 NOTE The PROHEAT may be operated if the engine is running or not running 2 When engine preheat is no longer required switch the PROHEAT heater OFF Engine and Sleeper Heat 1 Switch the toggle switch located in the vehicle dash to The switch will light and the heater will fire It will continue to fire until the coolant reaches 185 85 C at the heater outlet and then cycle OFF When the coolant temperature falls below 150 F 65 C at the heater inlet it will fire and repeat the cycle It will continue to cycle until a the heateris sw
10. 3 6 PROHEAT OWNER S MANUAL Figure 3 11 Maximize Cross flow You Choose ES INSTALLATION Plumbing the System GENERAL CONSIDERATIONS Coolant flow must be maintained throughout the coolant system under all conditions Keep engine inlet and outlet ports as far apart as possible to maximize cross flow through engine Ensure that no sharp kinks or bends exist in the hoses which may restrict coolant flow Avoid high points in the hose routing to prevent air traps Forsystems requiring more than 50 feet of coolant line consult factory for coolant pump recommendations For plumbing the system use Y NPT pipe fittings or bigger ID heater hose meeting SAE 3087 specifications NOTE Use of silicone hose requires special hose clamps Shut off valves are not required at the engine inlet and outlet connections but may be used if desired They should be left open at all times so that the heater may be operated periodically throughout the year Select Your Plumbing Option OPTION A Engine heat or supplemental heat The PROHEAT heats the engine block only NOTE When the engine block is preheated you will have nearly instant heat from the dash heat exchanger OPTION B Engine and sleeper heat The PROHEAT heats the engine block and the sleeper NOTE Plumbing the PROHEAT through the dash fan is not recommended 3 7 WARNING Allow the engine to cool down prior to opening the radiator cap
11. If power is connected to the PCM with the fuse in place the light on the PCM function display panel will light for 1 second and then go out This is normal NOTE Ensure the battery terminals are clean and free of corrosion If they are not remove and clean them Prior to re attachment grease them with electrically conductive grease d M 2 7 S 4 f p pH lo y j RED POSITIVE STRIP WIRE AS SHOWN AND CRIMP TO TERMINAL 20 3 16 POWER SUPPLY HARNESS BLACK NEGATIVE Figure 3 18 Power Connection to Battery PROHEAT OWNER S MANUAL The switch input circuit should only be used to supply power to the ON OFF switch and the TIMER oras a Signal to trip a relay Failure to follow this installation practice will result in damage to the NOTE The PCM must be reset power disconnected and reconnected when changing from a timer to a switch or from a switch to a timer Connecting a switch and a timer in the same circuit will cause the indicator light to flash incorrectly INSTALLATION Timer Connections TIMER BLACK SWITCH INPUT HARNESS TO KEYSWITCH OPTIONAL Black wire Ground Red wire Power White wire Operational signal from heater Green wire ON Signal to heater Grey wire Keyswitch backlighting optional Figure 3 19 Timer Connections The switch input circuit sh
12. KIT o be pe on Poe 951321 951528 967121 967329 968228 969023 SB0001 SB0003 SB0010 8 1 8 2 PROHEAT OWNER S MANUAL Service Bulletin 951321 October 1993 Description International Trucks with sleeper under passenger seat Plumbing AUXILIARY HEATER OEM HEATING SYSTEM SUPPLY Purpose The OEM system is designed for use while the engine is running For trucks using a PROHEAT or other fuel powered heater a low current draw auxiliary heater is recommended for maximum battery life NOTE Use separate air ducting for auxiliary heater DO NOT connect into OEM ducting Teleflex Canada Tel 604 270 6899 1993 Reproduction in any form electronic 3831 No 6 Road Fax 604 270 0137 print or otherwise is encouraged providing Richmond B C Web www proheat com the PROHEAT logo watermark is visible on o Teleflex Canaqa Canada Email proheat proheat com the reproduction and credit is given to Energy Solutions Division V6V 1 6 Toll Free 800 667 HEAT 4328 Teleflex Energy Solutions 8 4 PROHEAT OWNER S MANUAL PZOHEAT Service Bulletin 951528 October 1993 Description FLOW INDICATOR Coolant Flow Indicator TK9002 FLOW Part TK9002 Purpose The Coolant Flow Indicator is a service tool used to troubleshoot and test for possible flow and air problems in the coolant flow path Flow direction during heater
13. Opening the radiator cap when the engine is hot may cause serious injury OPTION A Instructions for Options A and B 1 Remove the radiator cap to release the system pressure Drain the coolant system 3 Plumb the system as per Figure 3 12 engine or supplemental heat or Figure 3 14 engine or sleeper heat 4 Add engine coolant to the system as per the specific engine manufacturer s recommendations and re install the radiator cap NOTE Plumbing the PROHEAT through the dash fan is not recommended Engine Heat or Supplemental Heat NOTE Specific engine DASH HEATER connection details by manufacturer and model PLA can be found at the end of ic this section RETURN TO ENGINE ESA SUPPLY PROHEAT ENGINE Figure 3 12 Engine Heat or Supplemental Heat I I LI J NOTE coolant systems where the return from the Proheat is plumbed to the bottom of the main coolant supply line from the radiator to engine pump the return line must be moved to avoid loss of heat through the radiator RETURN TO ENGINE SUPPLY TO PROHEAT ENGINE ENGINE RETURN TO ENGINE SUPPLY TO PROHEAT 3 8 Figure 3 13 Correct Return Line Plumbing PROHEAT OWNER S MANUAL OPTION B Engine and Sleeper For best results these vehicles should use an auxiliary heater See Service Bulletin 951321 for details International with single heater
14. BIG CAM Ina ea NT BIG CAM IV N14 iiis enr rere aene DETROIT DIESEL SERIES Dita umasa cold 3 vili A O OO 3 wiii MACK P 34x 3 11 CATERPILLAR EN LO amv Am 8 SAE TUBE FITTING NOTE The Caterpillar 3116 requires this fitting to connect the PROHEAT supply and return lines to the engine ports ENGINE CONNECTION DETAILS SUPPLY TO PROHEAT ALTERNATE SUPPLY TO PROHEAT les AA M JD X RA E RETURN FROM PROHEAT Caterpillar 3116 SUPPLY TO PROHEAT RETURN FROM PROHEAT Caterpillar 3176 CATERPILLAR RETURN FROM PROHEAT Caterpillar 3306 A AM RETURN FROM PROHEAT SUPPLY TO PROHEAT co al Caterpillar 3406 PROHEAT OWNER S MANUAL CATERPILLAR RETURN FROM PROHEAT Caterpillar 3408 ENGINE CONNECTION DETAILS 3 iii Z zt gt gt LEFT SIDE RIGHT SIDE CUMMINS Cummins B SERIES OWNER S MANUAL 3 iv CUMMINS ENGINE CONNECTION DETAILS TS ars JC l gt TH t ui I RETURN FROM PROHEAT ins KTA1150 CUMMINS SUPPLY TO PROHEAT
15. Figure 3 36 Fuel Line Connection Detail PROHEAT OWNER S MANUAL INSTALLATION First Time Start Up 1 Inspect the entire installation for loose bolts loose hoses and hose clamps loose wires and wire connections kinked or pinched hoses or wires battery connection for correct polarity and coolant supply and return location on the engine gt 2220730 Fill the vehicle cooling system with coolant as per owner s manual or engine manufacturer s recommendations 3 Place dash heater control in the full hot position Turn air conditioning off NOTE If shut off valves are installed make sure they are fully open 4 Start the vehicle engine and run it at a fast idle for 5 to 10 minutes to purge air from the heater and coolant system While the engine is running a make sure the coolant is flowing freely b inspect hoses and fittings for leaks c check the coolant level in the radiator and add coolant as necessary Shut the engine off Connect the power harness The ON light on the PCM function display will light for one second and then go out Start the PROHEAT heater using the On Off switch The indicator lamp should be lit with a solid red light Go to the heater and observe its operation Sequence of Events a Coolant temperature must be less than 150 65 C b ON light on PCM should be lit c You should hear the blower compressor and fuel pump start Looking through the inspection
16. OFF because the OEM system uses a constantly running fan 3 A valve in the sleeper heater coolant line regulates the flow and must be fully opened when the Proheat is running 4 Prevent possible backfeeding on ground side switched systems TELEFLEX IS NOT RESPONSIBLE FOR CHANGES IN SLEEPER FAN SYSTEMS BY ORIGINAL EQUIPMENT MANUFACTURING COMPANIES OPTION A Figure 3 22 Thermostat Location Make sure the vehicle ignition is switched OFF Mount the isolator in the sleeper fan motor area to a solid surface with the screw provided Cut OEM wire to sleeper fan motor and connect isolator in series Connect using 1 4 inch spade connectors provided See Figure 3 23 Wire end from resistor pack connected to isolator terminal marked ignition Wire end from sleeper fan motor connected to isolator terminal marked fan Locate Proheat thermostat in central area of sleeper approximately 12 above the bunk Avoid direct air flow from sleeper fan ducts See Figure 3 22 Remove the adjusting knob and face cover Mark and drill mounting holes Mount thermostat using the screws provided See Figure 3 24 Route sleeper fan harness from PCM to Proheat thermostat Cut to length Connect white wire to terminal 1 of the thermostat Use fork terminal provided Black wire not used Route a wire from terminal 2 of the thermostat to the isolator terminal marked Heater Connect using fork and spade terminal provided Can be cu
17. XL900 24 0 75 2 00 amps 24volts Teleflex XL1500 12 1 50 4 00 amps 12 volts Teleflex XL1500 24 0 75 2 00 amps 24volts Teleflex XL900 12 1 00 2 50 amps 12 volts Johnson XL900 24 0 50 1 25 amps 9 24 volts Johnson 5 19 12 Blower ABLOWER ERROR indicates an open circuit in the wire harness a short in the wire harness between the positive and negative leads or an internal short in the motor This component is ground side switched in the PCM NOTE An RPM check was added to the PCM for Serial C13000 and CAUTION greater This feature is constantly measuring the blower RPM and Wh bl fail will give an error should it fall below the necessary RPM to ema rial maintain sufficient combustion air the combustion chamber must be checked for carbon build up Symptom Blower not running ERROR INDICATED and cleaned as necessary Check Blower wiring amp function a That blower is connected to harness correctly See PROHEAT wiring diagram page 6 8 b The connector pins for damage or corrosion c Harness for pinched or abraded wires d Test blower If it tests OK replace PCM See Figure 5 12 and Test Procedure Symptom Blower not running NO ERROR INDICATED Fuse blown in PCM Check Blower function a Harness for pinched or abraded wires Positive lead must not short to ground b Check motor for internal short See Figure 5 1
18. a small blunt pin in the regulator vent hole and GENTLY depress the diaphragm inside c Fuel should flow out of the fuel line If there is no fuel flow the regulator is plugged NOTE Should a fuel regulator fail the combustion chamber must be checked for carbon build up and cleaned as necessary FUEL REGULATOR VENT HOLE BLUNT PIN TO DEPRESS DIAPHRAGM SJ UNDER VENT HOLE Figure 5 17 Fuel Regulator Test TROUBLE SHOOTING amp REPAIR 5 27 5 28 Step 1 Step 2 Step 3 Fuel System AIR INTAKE NOZZLE FUEL STRAINER COMPRESSED AIR 7 TO 10 PSI AIR FILTER ADAPTER AIR COMPRESSOR FUEL ee FUEL PICK UP Li qp FUEL 5 PSI SUCTION FUEL REGULATOR POSITIVE TERMINAL FUEL TANK Figure 5 18 Fuel System Schematic Is there fuel in the tank Start the Proheat The heater will try to start twice Wait until it has gone through two cycles approx 10 minutes The Proheat diagnostic system will tell you what it thinks is wrong While it is running observe for Is there a flame Yes means there is ignition and fuel See Is the ignition turning off No go to step 3 Is the ignition light turning off Yes then the Flame Sensor sees a flame No then the flame is either too weak or the Flame Sensor and or circuit is faulty See Flame Sensor page 5 9 in the Service Manual Does the Fuel Pump work This component must be tested before proceedi
19. bridging from the ignition electrode to the combustion tube NOTE A spark should be visible across the gap between the ignition electrode and the combustion tube Symptom Heateris Backfiring Backfiring is usually caused by a severe restriction of combustion air or air in the fuel line Check Inlet Air Flow a Is a blower error displayed page 5 20 b The blower operation is it turning is it turning slowly For restrictions at the fan inlet port and in the exhaust system OWNER S MANUAL 2 Flame Out TROUBLE SHOOTING amp REPAIR Check Fuel System a Is fuel level low b Air leaking into fuel system Symptom visible flame No spark The heater shuts down after the 60 second ignition period Check Ignition System a Check for a poor electrical connection between the ignition coil and the high tension lead Check for a poor electrical connection between the electrode and the high tension lead c Inspect the electrode gap Check for carbon bridging from the ignition electrode to the combustion tube Inspect the primary electrical connections to ignition coil and coil function page 5 16 Is the heater chassis ground wire attached The ground is connected to the boss located near the fuel pump Figure 5 7 b oa D A FLAME OUT Error occurs when the heater has started successfully but is unable to maintain a steady flame If during the run mode the flame senso
20. form electronic 3831 No 6 Road Fax 604 270 0137 print or otherwise is encouraged providing Richmond B C Web www proheat com the PROHEAT logo watermark is visible on Canada Email proheat proheat com the reproduction and credit is given to V6V 1P6 Toll Free 800 667 HEAT 4328 Teleflex Energy Solutions SB0003 Page 2 of 2 GROUND RING TERMINAL BLACK WITH GREEN STRIPE FIGURE 2 END VIEW FIGURE 1 5o SLEEPER FAN 3 B 3 A 3 A POWER 12V 24V 3 AMP LIMIT 3 B GROUND 2D e SWITCH OUTPUT 9 2 A POWER 12V 24V OUTPUT 09 2 B GROUND 2 C N 2 B 2 C ON SIGNAL TO HEATER 2 D INDICATOR 12V 24VOLTS CNN v 1 A POWER O 1 A POWER 12V 24V IMPUT gt 1 B GROUND 1 C USED Veleflex mm Teleflex Canada Energy Solutions Division Teleflex Canada 3831 No 6 Road Richmond B C Canada V6V 1P6 Tel 604 270 6899 Fax 604 270 0137 Web www proheat com Email proheat proheat com Toll Free 800 667 HEAT 4328 1995 Reproduction in any form electronic print or otherwise is encouraged providing the PROHEAT logo watermark is visible on the reproduction and credit is given to Teleflex Energy Solutions Service Bulletin SB0010 September 1997 Description Fuse Holder Kit Part 490001K PurpoSe There is now available a replacement fuse hold
21. ikha 7 9 Cummins L10 RETURN FROM PROHEAT SGT SA D pase OS T u SUPPLY CUMMINS Cummins NT BIG CAM IV N14 3 vii ENGINE CONNECTION DETAILS DETROIT DIESEL RETURN FROM PROHEAT q SUPPLY TO PROHEAT Detroit Diesel SERIES 60 RETURN FROM PROHEAT SUPPLY TO PROHEAT Detroit Diesel 6V92 8V92 MACK ENGINE CONNECTION DETAILS RETURN FROM PROHEAT SUPPLY TO PROHEAT LOCATED BEHIND THE COOLANT CONTAINER Mack E6 amp E7 NOTE It will be necessary to move the supply line for Proheat toward the back of the engine on the coolant manifold to ensure full engine heating Figure 3 16 Test Battery WARNING Do not use on positive ground vehicles If repairs to the vehicle require welding disconnect the Proheat power cable at the PCM This will prevent damage to the Proheat electronics Vehicles using ground side battery disconnect switches must install an in line 10 amp fuse on the internal harness Teleflex part PK 0310 This will prevent damage to the harness and PCM refer to service bulletin SB 0003 INSTALLATION Wiring amp Electrical Connections GENERAL CONSIDERATIONS Prior to installation of the PR
22. in the heat exchanger Check Coolant Flow a Is there coolant in the system b Determine if there is a blockage or air in the plumbing The compressor and fuel pump are wired in series with the overheat breaker The breaker contains a normally closed thermo switch When the thermostat reaches the preset temperature the contacts open shutting the compressor and fuel pump off and instantly shutting the heater down It can not be restarted until the breaker is manually reset To reset the breaker remove the rubber cap on the top of the overheat breaker and press the red reset button underneath If the breaker will not reset allow the heater to cool Breaker trips at 286 F 141 C Test Procedure a Connect a multimeter adjusted to measure resistance to the overheat breaker connector See Figure 5 2 The sensor should be normally closed Only if the sensor has tripped should it be open circuit POLARITY RED RESET BUTTON Mails NOT IMPORTANT a A 5 eo SPRING lt 6 gt 2 a du Figure 5 2 Overheat Sensor Test 5 5 5 6 5 Voltage Error A VOLTAGE ERROR indicates that the supply voltage to the heater is out of the normal operating range Voltage ranges 12 volt heater 10 5 to 15 0 volts 24 volt heater 20 0 to 30 0 volts Check Vehicle Voltage a Heater voltage must be within the specified range See following page for procedure to measure heater
23. low current draw and free flow during engine operation IT IS NOT SELF PRIMING The pump must be flooded and the system must be purged of all air for it to operate Do not run dry PRINCIPLE OF OPERATION 4 1 4 2 6 PCM 7 Hour Meter Utilizes a microprocessor to monitor operating conditions and control outputs to the motors and fuel pump It has powerful diagnostics to assist in trouble shooting One of the key features is the PCM Function Display on the front of the PCM which has LEDs to indicate function errors or component faults The Sleeper Fan output has a special current limiting feature which if used limits the current draw of the sleeper heater fan to 3 amps This is done to control the total current draw on the vehicles batteries PCMs Serial 10001 to C12999 sleeper fan output does not turn on until coolant temperature reaches 100 38 C PCMs Serial C13000 and greater sleeper fan turns on when the heater is switched or timed on The PCM reads supply voltage and internally adjusts for 12 or 24 volt systems NOTE The PROHEAT PCM s unique in that it uses ground side switching for the blower compressor coolant pump and ignition coil The positive wire to the motors and ignition coil will show voltage even when the heater is switched off LOCATED ON END PLATE Figure 4 2 LEDs will light to indicate error Switch or Timer ON light in dash will flash to indicate er
24. path of coolant flow from the heater In these cases the gauge may read significantly lower than actual coolant temperature Backfiring occurs when there is air in the fuel supply lines Check a Fuel level in tank is the pick up submerged b Air leaks are all the fuel line clamps tight c For severely restricted combustion air blockage at the blower inlet in the combustion chamber or in the exhaust system PROHEAT OWNER S MANUAL MAINTENANCE 6 0 MAINTENANCE ANNUAL MAINTENANCE Your PROHEAT heater has been designed to operate with a minimum of maintenance Check the system annually before each heating season There are several maintenance procedures you can perform to keep your heater in service Read this section of the manual carefully Always return to your authorized PROHEAT dealer for major maintenance Your PROHEAT dealer has the specialized equipment necessary to keep your PROHEAT in new condition Clean Heater Enclosure Remove the heater enclosure cover and blow out the compartment with compressed air Clean any accumulated debris or dust from the components Make sure the opening around the exhaust pipe is clear Visually inspect all the components for wear or damage Figure 6 1 PROHEAT Heater amp Enclosure NOTE Running the heater year round is a good maintenance practice 6 1 Heat Exchanger Exhaust System 6 2 To maintain optimum heat output clean any combustion depos
25. port you should see a spark and flames d The spark will stop after 5 to 60 seconds and the heater will continue to run NOTE If the indicator lamp in the ON OFF switch flashes upon initial start up wait The heater will attempt a re start in 3 minutes In some cases it takes longer for the fuel pump to prime the empty fuel lines during the initial start This is usually the case if the fuel lines are long If the light continues to flash after the re start then there is a problem The Trouble Shooting amp Repair section of this manual will assist you in correcting the problem 8 Once the heater is started it will continue to run until the coolant temperature reaches 185 F 85 C at heater outlet then it will shut off NOTE The vehicle dash temperature gauge may read significantly less depending on the location of the sender unit on the engine Sequence of Events for Shut Down a Fuel pump and compressor shut off b The blower will run for 3 minutes on purge cycle then shut off c The water pump will continue to run 9 The heater will restart when the coolant temperature falls below 150 F 65 C at heater inlet as long as the on off switch is left on 10 If the vehicle has been equipped with the sleeper heat option then a Adjust the PROHEAT sleeper thermostat to highest heat position b The sleeper heat exchanger fan will start blowing warm air NOTE PCMs Serial C10001 to C12999 sleeper fan output doe
26. to handle sleeper fan motor electrical current draw 5 Route sleeper fan harness from PCM to Proheat thermostat Cut to length Connect white wire to terminal 1 of the thermostat 6 Route wire from terminal 2 of the thermostat to relay 1 can be cut from left over wire harness Ground the relay using Proheat sleeper fan ground wire black OEM THERMOSTAT VEHICLE CONSTANT POWER FUSE 15 AMP SOURCE PANEL i e CIGARETTE LIGHTER ae RELAY 1 STANDARD 112 OR 24 30 AMP PROHEAT EM FAN THERMOSTAT a cl RESISTOR ASSEMBLY NOTE MAY OR MAY NOT BE LOCATED INSIDE SLEEPER HEATER ASSEMBLY SLEEPER FAN BO Geli HARNESS SLEEPER HEATER ASSEMBLY FAN MOTOR SINGLE WINDING TYPE Figure 3 26 Option B INSTALLATION 3 19 OPTION C F Make sure the vehicle ignition is switched OFF 2 Locate the auxiliary heater in a suitable area of the vehicle Install plumbing and air duct connections as per the manufacturer s recommendations 3 Locate the Proheat thermostat in a central area of the sleeper approximately 12 above the bunk Avoid direct air flow from sleeper fan ducts See Figure 3 22 4 Remove the adjusting knob and face cover Mark and drill mounting holes Mount thermostat using the screws provided See Figure 3 24 5 Route sleeper fan hamess from PCM to Proheat thermostat Cut to length Connect white wire to terminal 1 of the thermostat using
27. u REA 5 127 mm 7 1 2 191 1 25 mm Sore 5 127 mm Figure 3 9 XL900 amp XL1500 Base Mounting Plate Dimensions INSTALLATION 3 5 Exhaust Pipe Connection 1 Push the exhaust pipe through the hole in the enclosure and onto the exhaust outlet port of the heater Ensure that the pipe is pushed onto the spigot at least 1 38 mm 2 Route the exhaust pipe such that a It does not rest against or be directed toward any parts of the vehicle that may be damaged by heat i e brake lines seals wires rubber hoses b Debris and snow will not plug the outlet C Moisture from combustion will drain out of the pipe d It does not face forward WARNING 3 Disassemble the exhaust pipe clamp and apply anti seize compound Exhaust gases must not enter the to the threads 2 en i exnaust pipe 4 Assemble the exhaust clamp over the exhaust pipe clamp goes Way IOM VENICE inside the enclosure and tighten the nuts NOTE 1 exhaust pipe should not exceed 5 ft and have no more than 180 degrees of bends The bends must be formed for best results Do not use 90 degree welded pipe to turn corners NOTE For installations requiring special exhaust systems consult your PROHEAT Dealer Use formed elbows Tiya CLAMP U BOLT APPLY ANTI SEIZE COMPOUND TO THREADS Do not use welded 90 elbows Figure 3 10 Exhaust Pipe
28. 2 and Test Procedure Symptom Blower turning slowly NO ERROR INDICATED Check Blower function a For fan blade rubbing on housing b For fan blade slipping on motor shaft 5 20 PROHEAT OWNER S MANUAL Test Procedure a Connect the blower to a power supply of the rated voltage Does it turn If not replace the blower Measure the blower motor resistance Using a multimeter measure the resistance across the blower connector pins If resistance shows an open circuit or an internal short circuit then replace the blower assembly c Measure blower current Use test lead part 967422 as described on Service Bulletin 967329 in Appendix b Figure 5 12 Blower Test CURRENT DRAW XL900 12 25 0 75 amps 12 volts XL900 24 10 0 25 amps 24 volts XL1500 12 90 1 50 amps 12 volts XL1500 24 40 0 75 amps 24 volts TROUBLE SHOOTING amp REPAIR 5 21 5 22 13 Sleeper Fan A SLEEPER FAN ERROR indicates an electrical short in the sleeper fan wiring harness electrical connections or fan motor This error will not shut the heater down and heat to the engine will be maintained An open circuit will not display an error Symptom Sleeper Heater fan not turning ERROR INDICATED Check Sleeper Heater system a The wiring connections and polarity b For an electrical short from the positive wire to the negative wire For an electrical short from the posit
29. 7 6 8 PROHEAT OWNER S MANUAL WARRANTY PROHEAT WARRANTY Teleflex warrants the PROHEAT Heater to be free of defects in material and workmanship under design usage and service conditions for two 2 years on parts and one 1 year on labour from the date of first installation Replacement parts are covered for the remainder of the heater s warranty or ninety 90 days which ever is greater This warranty does not apply to damage or failure of the PROHEAT heater or the vehicle into which it was installed due to improper installation assembly maintenance abuse neglect accident or the use of parts not supplied by Teleflex Accessories supplied but not manufactured by Teleflex shall be covered by the manufacturer s warranty only and not subject to this warranty Non standard installations that is those requiring a departure from published installation instructions should not be undertaken without first having consulted Teleflex Coverage for warrantable parts at the discretion of Teleflex will be made to the claimant in the form of repair replacement or credit Warranty labour payments will be made only to Registered Proheat Service Centres in accordance with the Standard Repair Times SRT s as published by Teleflex MARINE INSTALLATIONS The purchaser and installer are advised that specific rules and regulations are in effect with respect to the installation of heaters in marine applications These rules and regulat
30. AT will Purge for 3 reasons the coolant reaches 185 F 85 C there is a function error or component fault See Troubleshooting amp Repair page 5 1 the PROHEAT is operating at Full Output when it is shut OFF 4 5 Function and Component Errors 4 6 The microprocessor in the PCM continually monitors all the PROHEAT systems If the internal diagnostics discover a problem an error message will be displayed on the PCM function display The remote on off switch or timer red on light will also flash an error code followed by a pause and then repeated the number of flashes correspond to the numbered error code eg 5 flashes indicates a VOLTAGE ERROR See diagram below for a complete list of error flash codes If this occurs refer to the troubleshooting section to assist in problem diagnosis START ERROR ON FLAME OUT COOLANT FLOW an OVERHEAT VOLTAGE ERROR FLAME SENSOR TEMP SENSOR PONENT FUEL PUMP COMPRESSOR IGNITION COIL COOLANT PUMP BLOWER SLEEPER FAN ERROR NO TYPE OF ERROR NO OF FLASHES 1 Start 1 2 Flame Out 2 3 Coolant Flow 3 4 Coolant Overheat 4 5 Voltage High Low 5 6 Flame Sensor 6 7 Temperature Sensor 7 8 Fuel Pump 8 9 Compressor 9 10 Ignition Coil 10 11 Coolant Pump 11 12 Blower Combustion 12 13 Sleeper Fan 13 Function Display Panel Detail amp Error Flash Codes PROHEAT OWNER S MANUAL
31. C Web www proheat com the PROHEAT logo watermark is visible on mu Teleflex Canada Canada Email proheat proheat com the reproduction and credit is given to Energy Solutions Division V6V 1 6 Toll Free 800 667 HEAT 4328 Teleflex Energy Solutions 8 8 PROHEAT OWNER S MANUAL Description The PROHEAT wiring system uses sealed connectors for resistance to corrosion and greater reliability The following test leads are required for troubleshooting Parts 967921 967422 Test Lead Test Lead Blower only 952925 Remote Test Lead Instructions 1 Test Lead 967921 is used for measuring voltage resistance continuity or amperage and can be used on all components except for the blower Direct voltage can be applied to the compressor and water pump by wiring from a remote power source to the spade connections 2 Test Lead 967422 is used for measuring voltage resistance continuity or amperage and is used for the blower circuit only Direct voltage can be applied to the blower by wiring from a remote power source to the connectors 3 The 952925 Remote On Off switch allows the service technician to plug into the heater at the switch input of the PCM This allows the heater to be turned On Off at the unit NOTE This Service Bulletin supercedes Service Bulletin 951621 Service Bulletin 967329 May 1994 USE SPADE CONNECTORS TO TEST VOLTAGE RESISTANCE OR CONTINUITY
32. Filter Compressor Cooling System Check all heater hoses and connections for signs of leakage or damage Repair or replace as required 6 4 PROHEAT OWNER S MANUAL Fuel System Vehicle Batteries Operation Test MAINTENANCE Check the fuel system for damaged fuel lines or leakage Make sure the clamps on the fuel lines are secure HOSE CLAMP GROMMET FUEL LINE FUEL TANK FUEL LINE FUEL PICK up Figure 6 7 Fuel Line Clamp Check the condition of the batteries and the power connections The heater will not function properly with weak batteries or corroded connections If you are unsure of their condition load test them and replace them as required Clean terminals to remove all corrosion Figure 6 8 Test Battery Run the system for at least 15 minutes or until the heater cycles off and then on again Alternate the thermostat for the sleeper heater if connected between the lowest and highest settings to ensure that the sleeper heater fan cycles ON and OFF 6 5 SLEEPER FAN 3 A POWER 12V 24V 3 AMP LIMIT 3 B GROUND SWITCH OUTPUT 2 A POWER 12V 24V OUTPUT 2 B GROUND 2 C ON SIGNAL TO HEATER 2 D INDICATOR 12 24VOLTS POWER 1 A POWER 12V 24V INPUT 1 8 GROUND 1 USED Figure 6 9 PCM Pin out Diagram 6 6 PROHEAT OWNER S MANUAL Figure 6 10 PROHEAT Wiring Diagram MAINTENANCE 6
33. IFICATION E WASHER FUEL SENDER PORT IN TANK Figure 3 32 This option requires a permanent modification to the fuel tank Select the location for the fuel pick up in the vehicle fuel tank Ensure sufficient clearance above the tank to get the fuel pick up into the tank Drill a 1 diameter hole in the tank NUT WASHER GASKET 42 lt GASKET WASHER x DRILL 1 DIA HOLE IN FUEL TANK 227 Figure 3 33 Installation 3 4 CLEAR Figure 3 34 For some situations where the fuel pick up is too far from the bottom of the tank an extension from left over fuel line can be added peg CUT BOTTOM OF FUEL PICKUP AT AN ANGLE 3 4 CLEAR OF BOTTOM OF TANK Figure 3 35 Fuel Pick up Depth 1 Determine the depth of the fuel tank at the desired fuel pick up location Cut the fuel pick up 3 to 4 inches shorter as shown in Figure 3 35 2 Install the pick up into the fuel tank as per selected option 3 Route the fuel line from the heater to the fuel pick up Ensure the fuel line is well secured and will not abrade 4 Attach the fuel line to the heater fuel pump fitting and the fuel pick up with hose clamps Lubricating the fittings with fuel may ease the installation effort HOSE CLAMP GROMMET FUEL LINE FUEL TANK d FUEL LINE FUEL PICK up
34. NPT Port en 3 22 Option B Existing Blank Fuel Sender Cover Plate 3 23 Option C Hole Drilled into Fuel 3 23 Installation aa kN IH 3 24 FIRST TIME STARTUP ea 3 25 PRINCIPLES OF OPERATION GENERAL DESCRIPTION 26d jute P heces 4 1 NORMAL OPERATING 45 TROUBLE SHOOTING amp REPAIR ON Indicator Light u a ul uuu uy 5 1 FUNCTION ERRORS EA 5 2 Stant ananas tela apan uk 5 2 Flame Out bun RE ns 5 3 Coolant Flow orco ao 54 AA een 55 anne neu 5 6 COMPONENT FAULTS nee 5 8 Flame SENSOR e 5 8 Temperature Sensor 5 10 FU PU aaa tss defe datus 5 12 Al Compres Ol casn ot at Ota ake dan Su ae nett 5 14 Koj iy Coll 5 16 Coolant PUITID a u qaa rue 5 18 O du ons 5 20 Sleeper see 5 22 COMPONENTS 5 23 Electrode Gap ER 5 23 PUS RR EEE SER 5 24 NOZZE na AH 5 26 Fuel Regulator oom meret ex mere teen 5 27 FUEL SYSTEMS u uk aa 5 28 Clara 5 28 OPERATIONAL PROBLEMS una 5 30 Smoking EXHAUST pe eb piede de 5 30 LOW Heat DOUEDULE u xao wa kasa teed 5 30 Engine Temperature Gauge 5 30 DT 5 30 6 MAINTENANCE Annual Maintenance 6 1 Clean Heater Enclosure
35. OEM OR AUXILIARY SLEEPER HEATER 2 a 69 HEATER RETURN TO ENGINE SOLENOID VALVE Pd OEM COMBO HEATERS ONLY NORM ALLY OPEN Wu SUPPLY TO PROHEAT Hcr NOTE Specific engine connection details by manufacturer and model can be found at the end of this section Figure 3 14 Engine and Sleeper Heat NOTE Vehicles equipped with a combination heater air conditioner the heater unit will have a solenoid operated shut off valve Typically this valve is normally open with the truck engine turned off and the key removed See Figure 3 15 for plumbing Due to the many options available in vehicle heating and air conditioning systems the installer should be looking for any restrictions that may affect coolant flow with vehicle ignition in the OFF position For vehicles with solenoid valves in the normally closed position Western Star INSTALLATION SLEEPER HEATER DASH HEATER SOLENOID VALVE NORMALLY CLOSED A SUPPLY TO PROHEAT ENGINE Figure 3 15 3 9 ENGINE CONNECTION DETAILS Engine Connection Details CATERPILLAR CNET 34 Sl Ta a od nie 34 O 341 e ea en dro 341 3408 MEE CUMMINS A ak 34v FG DOP NE KIALSO Cl e ete eta CERO Y pa a Pe pa CHR cd kta Dit Sas 3 vi NT
36. OHEAT Heater system ensure that the vehicle batteries are in good condition The system will not provide satisfactory performance with weak batteries Do not kink or abrade wires when routing them through the vehicle during installation Ensure wires are well supported and secured with tie wraps Do not use acid core solder when making solder connections Major Electrical Connections Required a Power connection to page 3 14 b Timer Connection iut cara a Feed page 3 15 C Sleeper heater connections page 3 17 to 3 19 TO SLEEPER FAN XL900 ONLY TO BATTERIES TO ON OFF SWITCH N AND OR TIMER Figure 3 17 Major Electrical Connections PROHEAT 12 volt systems should not use power split from a 24 volt system This will cause uneven charging of the batteries Power Connection to Batteries 1 Route wire harness from PCM to the battery Cut the harness to length as required 2 Strip outer wire jacket of harness back to expose the positive red and negative black leads Strip the leads as shown and crimp the ring tongue terminals supplied to the wires Connect the leads to the battery terminals See Figure 3 17 3 Leave power harness disconnected See Figure 3 17 Do not install until coolant pump system has been purged of air See First Time Start up page 3 25 NOTE
37. Pick up Installation Option OPTION A Fuel pick up to be installed in an existing or NPT port in fuel tank OPTION B Fuel pick up to be installed in an existing blank fuel sender cover plate OPTION C Fuel pick up to be installed in a hole drilled into the fuel tank OPTION A Do not use teflon tape as this will contaminate the heater and engine fuel system Locate an existing pipe thread port in the vehicle fuel tank and select the or NPT portion of the fuel pick up that fits into that port Apply a pipe sealant paste to the fuel pick up pipe threads prior to installation FUEL PICKUP EXISTING PORT IN FUEL TANK 1 4 NPT A FUEL ak Figure 3 30 NPT Port FUEL PICKUP EXISTING PORT IN FUEL TANK 1 2 NPT FUEL TANK Figure 3 31 V NPT Port PROHEAT OWNER S MANUAL OPTION B OPTION C To prevent fuel system contamination do not allow drill chips to fall into the fuel tank when drilling the hole WARNING Drilling the fuel tank may not be acceptable in some jurisdictions Do not drill the fuel tank on passenger carrying vehicles such as school buses INSTALLATION Locate an existing blank fuel sender port in the vehicle fuel tank Remove the cover plate drill a 1 diameter hole and install the fuel pick up as shown NUT 4 WASHER A GASKET I COVER PLATE SUPPLIED WITH FUEL TANK e REQUIRES MOD
38. UEL SYSTEM sans ne 3 21 to 3 24 7 FIRST TIME START UP een a 3 25 to 3 26 NOTE The installation details described in this manual may not cover all of the application possibilities In these cases this manual should be used as a guideline only If additional installation information is required please contact your PROHEAT Dealer regarding your specific application Prior to the installation of your PROHEAT consult your engine owner s manual or engine manufacturer for any restrictions that may apply to plumbing into the engine coolant system 3 1 You Choose I gt Caution 00 Do not weld PROHEAT heater mounting brackets to the vehicle frame If repairs to the vehicle require welding disconnect the Proheat power cable at the PCM This will prevent damage to the Proheat electronics WARNING Never locate the heater inside the vehicle cab See Figure 3 2 3 2 Locating the Heater Select Your Location The most suitable location for mounting the heater will vary depending on the type of vehicle Recommended mounting locations are Behind the cab across the frame rails 1 On either side of the frame rails 2 In existing enclosure on the vehicle step or toolbox 3 Figure 3 1 Recommended Mounting Positions GENERAL CONSIDERATIONS Never mount the heater to two separate parts of the vehicle Avoid mounting the heater to fenders or areas of e
39. be reset power disconnected and reconnected when changing from a timer to a switch or from a switch to a timer Connecting a switch and a timer in the same circuit will cause the indicator light to flash incorrectly OWNER S MANUAL You Choose gt INSTALLATION Sleeper Heater Wiring Details These installation options allow the operator to 1 2 Run the Proheat with the ignition key in the OFF position Return full control to the OEM system in normal operation mode Select One of the Following Wiring Options OPTION A OPTION B OPTION C OPTION D NOTE Limits the power provided to the sleeper fan motor to 3 AMPS With this system the total electrical draw is controlled by Proheat Note For larger systems in the latest model trucks this may not provide enough fan speed and therefore Option B C or D should be used Used in larger sleepers requiring greater fan speed to provide sufficient air movement to the sleeper This allows the driver to select the fan speed Used when a dedicated auxiliary heater is required Wiring schematics of specific trucks may be available in service bulletins Contact your dealer or Proheat Technical Department for information Used when climate control systems in sleepers require one or more of the following features to be controlled 1 Higher fan speed for greater air movement 2 Aseparate thermostat is required to turn the sleeper fan motor ON and
40. check Ignition Full Output Purge Standby Switch 0ff PRINCIPLE OF OPERATION Normal Operating Sequence The switch or timer lamp and the PCM ON LED will light The PROHEAT goes to Precheck The PCM performs a short self diagnostics cycle This takes several seconds checking components for proper ranges short circuits and open circuits If there are no errors indicated the PROHEAT goes to Start The blower starts first followed by the coolant pump ignition spark air compressor and fuel pump The ignition electrode sparks until the flame sensor sees a flame 5 seconds minimum to 60 seconds maximum Once the flame sensor sees a flame the PROHEAT goes to Full Output The PROHEAT runs at Full Output until the coolant temperature reaches 185 F 85 C at the PROHEAT outlet At this time the PROHEAT shuts the flame off and goes to Purge The air compressor and fuel pump shut off immediately The blower and coolant pump continue to run After 3 minutes the blower stops and the PROHEAT goes to Standby The coolant pump circulates the coolant through the system until the temperature drops to 150 65 C at the PROHEAT inlet then it will enter Precheck and repeat steps 2 5 The PROHEAT will continue to repeat steps 2 5 until it is Switched OFF If PROHEAT is in Full Output it will Purge first then shut OFF If PROHEAT is in Standby it will shut OFF immediately Note The PROHE
41. drawing too much fuel into the system Discolored and or distorted flame sensor Exhaust odor and haze Fuel combustion sound uneven flame noise Normal looking flame Heavy carbon buildup in the combustion chamber A faulty blower may also cause a flame sensor to discolor and or distort Other possible symptoms are blower fan distortion carbon build up in the fan end casting and combustion chamber and an extremely yellow flame See Service Manual for further information 1 Check combustion chamber and clean if necessary 2 Install a pressure gauge Teleflex 0060 in line as shown 3 Start Proheat Air pressure reading should fall within the range listed below while measuring the voltage at the coil as described in the service manual 4 If the compressor does not read within the range listed in the chart replace the compressor 5 If the compressor reads within the range listed in the chart check the combustion air blower as noted Coil Volts 10 5 11 0 11 5 12 0 12 5 13 0 13 5 14 0 P S I Range 4 8 6 8 5 0 7 0 5 4 7 4 5 8 7 8 6 1 8 1 6 3 8 3 6 5 8 5 6 6 8 6 LINE NOZZLE AIR INLET 175 Teleflex e mm Teleflex Canada Energy Solutions Division Teleflex Canada Tel 604 270 6899 1995 Reproduction in any form electronic 3831 No 6 Road Fax 604 270 0137 print or otherwise is encouraged providing Richmond B C Web www pro
42. e is located near the nozzle just out of the air fuel mixture path During the ignition sequence the spark jumps the gap between the electrode and the combustion tube igniting the air fuel mixture Spark duration varies from 5 to 60 seconds depending on conditions Measures coolant temperature at the outlet port of the heat exchanger Protects the heater from damage should it be operated without coolant The overheat breaker monitors the surface temperature of the heat exchanger casting When the temperature reaches 286 F 141 C the breaker kicks out This shuts off the power to the fuel pump and air compressor stopping the heater The breaker can be reset by pushing down on the red button located under the rubber cap Photo electrically measures the intensity of the flame It is the flame sensor that signals to the PCM that the heater is burning properly Is used to switch the heater on and off It has an indicator lamp that displays a red light when switched on A flashing red light indicates an error and one of the LEDs on the PCM function display will be lit See page 6 6 for details Is used to switch the heater on and off It can do this manually or by a preset time and day It has an indicator lamp that displays a red light when switched or timed on A flashing red light indicates an error and one of the LEDs on the PCM function display will be lit See page 6 6 for details PROHEAT OWNER S MANUAL Switch On Pre
43. e regulator from the system Start the heater and if there is still a fuel problem then it has to be in the Compressor or Nozzle PLACE THIS LINE IN A CONTAINER OF FUEL MAINTAIN FUEL LEVEL AT CENTRE OF THE REGULATOR REMOVE FUEL LINE FROM REGULATOR Figure 5 19 Eliminating Fuel Pump and Regulator from system Step7 Is Fuel Nozzle contaminated See Nozzle page 5 26 Clean the nozzle with a cleaner degreaser which will wash contamination out the back end of the nozzle 5 29 5 30 COMPLAINT Smoking exhaust Smelly exhaust fumes Low heat output Engine temperature gauge reads low Backfiring OPERATIONAL PROBLEMS Heater Operational Problems that are not specifically described in the function or component errors section These symptoms are usually an indication of an extremely rich air fuel mixture Check a Is the PROHEAT connected to the correct voltage See page 5 6 b Is the blower functioning Is the air inlet restricted c Is the compressor functioning See page 5 14 d Is the exhaust restricted e Is ita new heater New heaters may smoke for 15 minutes as oil is burned off the exhaust pipe This is normal If the heater appears to be functioning properly but the driver complains of low heat this is often indicative of a coolant flow restriction See section on Coolant Flow Error page 5 4 Depending on its location the engine temperature sensor may not be directly in the
44. ensor is defective and must be replaced Figure 5 4 Temperature Sensor Test OWNER S MANUAL Temperature Temperature Centigrade Farenheit 150 140 I 1 1 1 1 130 120230 130 C 266 OUT OF RANGE UPPER LIMIT I 1 I I I 1 120 JERE 100 90 fm 200 15410 85 185 F UPPER SET POINT 80 1 1 I I I a 170 13549 65 C 150 P LOWER SET POINT 290 140 50 40 110 30 20 80 10 En 10 20 20 30 10 40 50 f sso 50 C 58 F OUT OF RANGE LOWER LIMIT 0 60 70 400 600 800 1000 1200 1400 1600 1800 2000 2200 Resistance Ohms Q Figure 55 Coolant Temperature Sensor Graph NOTE Room temperature 70 F 20 C Resistance 9500 Boiling water 212 F 100 C Resistance 1700Q TROUBLE SHOOTING amp REPAIR 5 11 5 12 8 Fuel Pump A FUEL PUMP ERROR indicates an electrical short circuit between the positive wire to the pump and the chassis ground The PCM will NOT detect an open circuit When the fuel pump is operating properly you can feel it pulse approximately 1 2 pulses per second This indicates that the other components in the system ie compressor fuel regulator and nozzle are functioning NOTE The body of the fuel pump is grounded to the PROHEAT chassis The PROHEAT chassis is grounded through the PCM bya black green wire attached to the PROHEAT ground boss
45. er kit for controllers that have a faulty fuse holder Symptoms Timer resetting due to interruption of power Flashing 12 00 Proheat operating intermittently Works one day but not the next Fuse holder loose in the controller housing Fuse holder cap not locking in place falling out Random error codes Instructions Should the Proheat have some of the above symptoms the fuse holder should be checked and replaced if necessary This replacement kit include a fuse holder assembly and installation instructions Use the above part when ordering the kit Teleflex Canada Tel 604 270 6899 1995 Reproduction in any form electronic 3831 No 6 Road Fax 604 270 0137 print or otherwise is encouraged providing Richmond B C Web www proheat com the PROHEAT logo watermark is visible on o Teleflex Canaqa Canada Email proheat proheat com the reproduction and credit is given to Energy Solutions Division V6V 1P6 Toll Free 800 667 HEAT 4328 Teleflex Energy Solutions 8 20 PROHEAT OWNER S MANUAL PROHEAT Serial Number Installation Date Dealer 115 Teleflex e mm Teleflex Canada Energy Solutions Division Teleflex Canada 3831 No 6 Road Richmond B C Canada V6V 1P6 Tel 604 270 6899 Fax 604 270 0137 Designed and Manufactured in North America www proheat com 1993 Teleflex Canada Printed in Canada Part 925824 1 Revised 97 07 16
46. es without correcting the problem can damage the PCM 5 24 If when the heater is switched on the heater does not run and the ON light does not light check the fuse in the PCM The fuse will blow if there is a short to ground in a positive lead or internally for the following components ON OFF switch Coolant Pump Air Compressor Blower Ignition Coil Reversing polarity at the battery will also cause the fuse to blow This will not harm the PCM Check Heater wiring a Check polarity of battery connections b Test the internal wire harness for short circuits Sf fe GROUND ON fs HEAT EXCHANGER PIN LOCATIONS MOLDED INTO CONNECTOR HARNESS TO COMPONENTS NH COOLANT PUMP Figure 5 14 Internal Wire Harness Test The opposite page describes the test procedure for a blown fuse with power connected and the PROHEAT switched off OWNER S MANUAL Check for correct battery polarity Remove Fuse Disconnect from PCM Internal Wire Harness 18 Pin Connector Switch Harness Replace Fuse 15 amp only Yes Fuse Blown Test Procedure with Power Connected and Proheat Switched Off NOTE Ensure positive wire from the PCM to the ignition coil does not ground NOTE A short circuit in the sleeper fan ou
47. heat com the PROHEAT logo watermark is visible on Canada Email proheat proheat com the reproduction and credit is given to V6V 1P6 Toll Free 800 667 HEAT 4328 Teleflex Energy Solutions 8 16 PROHEAT OWNER S MANUAL PROFEAT Me Description Purpose Test Procedure Recommended thod of Protection Page 1 of 2 Service Bulletin SB0003 June 1995 Ground Side Battery Disconnect This service bulletin includes troubleshooting steps and protection recommendations from damage that may occur when attempting an engine start while the ground side battery disconnect switch is in the open position A Proheat is typically connected directly to the batteries so that it can be used to preheat the coolant when the ground side battery disconnect switch is open If the operator driver attempts to start the engine with this switch open the entire electrical current from the starter motor attempts to pass through the proheat internal wiring harness Without adequate fuse protection the Proheat ground circuit in the internal harness and or controller will be damaged The symptoms may include a START error or FLAME OUT error The fuel pump will not operate if the Proheat ground circuit has been damaged resulting in intermittent operation of the Proheat 1 Start the Proheat Check that the fuel pump is running Approximately 20 to 40 pulses per minute can be felt or heard Check for voltage at the fuel pump
48. hort to ground b Check motor for internal short See Figure 5 11 and Test Procedure Symptom Coolant pump not pumping NO ERROR INDICATED Check Coolant Pump function a If the impeller is turning freely If not replace pump Symptom Coolant pump turning slowly NO ERROR INDICATED Check Heater operation a If the heater is switched on but the coolant is between 150 F 65 C and 185 F 85 C at the heater outlet then for models Serial C10001 C12900 the pump runs at 50 current draw Models Serial C13000 and greater will be running at full current draw under the same conditions Symptom Coolant pump leaking Check Leak location a Hose clamps Tighten if necessary b Pump housing seal Replace pump if required PROHEAT OWNER S MANUAL TROUBLE SHOOTING amp REPAIR Test procedure a Connect coolant pump directly to the rated voltage 12 24 volts and see if it runs If not replace the pump b Measure coolant pump motor resistance Using a multimeter measure the resistance across the coolant pump connector pins If resistance shows an open circuit or an internal short circuit replace the coolant pump c Measure coolant pump current Use test lead part 967921 as described on Service Bulletin 967329 in Appendix u um D LT iT Figure 5 11 Coolant Pump Test MODEL CURRENT DRAW PUMP TYPE XL900 12 1 50 4 00 amps 12 volts Teleflex
49. igure 5 7 c Read the voltage with heater running or trying to run NORMAL VOLTAGE RANGES 12 volt heater 10 5 to 15 0 volts 24 volt heater 20 0 to 30 0 volts Figure 5 3 Heater Voltage Measurement TROUBLE SHOOTING amp REPAIR 5 7 5 8 6 Flame Sensor Component Faults A FLAME SENSOR ERROR indicates an electrical short circuit in the flame sensor wiring or a flame sensor failure It will not indicate an open circuit The flame sensor is an optical device which sees the flame If the sensor lens is dirty or has an open circuit it can not see the flame and results in either a START ERROR or a FLAME OUT Check Flame Sensor a Inspect the flame sensor wiring for a short circuit b Inspect the flame sensor lens for cleanliness c Testthe flame sensor See opposite page PROHEAT OWNER S MANUAL START UNIT IS THERE STOP UNIT YES AFLAME SENSOR CODE DISCONNECT SENSOR START UNIT IS THERE A FLAME SENSOR CODE 9 CHECK MAIN 55 FOR A SHORT CIRCUIT REPLACE IF NECCESSARY y TRY WITH NEW CONTROLLER REPLACE IF NECCESSARY REPLACE SENSOR CHECK FLAME QUALITY DOES FUEL PUMP PULSE REPLACE SENSOR Flame Sensor Test Procedure IS THERE A FLAME 9 SENSOR 60 5 IS THERE A START ERROR
50. ion components coolant pump air blower 2 Electrical controls provided by PROHEAT including cab mounted controls and PCM 3 PROHEAT supplied accessories and mounting hardware Items Not Covered Under This Warranty 1 Heaters no longer within the warranty period 2 Normal wear and maintenance parts including fuel filter air filter nozzle and lamps 3 Parts which malfunction due to improper installation causing inadequacies in air fuel or coolant flow voltage due to wiring shock or vibration protection 4 Any progressive damage to the engine or vehicle arising out of failure of the PROHEAT Heater unit Heaters which have been modified or use of non standard parts not approved by Teleflex Heaters that have been abused or damaged Travel time by a PROHEAT dealer Diagnosis or repairs when caused by problems not directly related to the heater or due to empty fuel tanks or poor fuel quality S ANO n If you have any questions or concerns about the PROHEAT Warranty contact your nearest PROHEAT Distributor or Teleflex Canada Ltd at 1 800 667 4328 8 0 APPENDICES CONTENTS INTERNATIONAL TRUCKS COOLANT FLOW INDICATOR BLOWER REGULATOR SERVICE TIP See TEST LEADS sera UPDATING MARK I AIR COMPRESSOR FILTERS AIR COMPRESSOR PRESSURE TEST 4 ern OVER FUELING a een GROUND SIDE BATTERY DISCONNECT FUSE
51. ions are enforced by the Department of Transportation and or other agencies having jurisdiction It is the installer s responsibility to review and comply with all such rules and regulations In addition each marine installation must be inspected and approved by an Authorized PROHEAT Dealer Only those installations which are approved and so registered will be eligible for warranty coverage of one year on parts and labour THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY TELEFLEX IN REGARD TO THE PROHEAT HEATER SYSTEM TELEFLEX MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED OR OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OWNER RESPONSIBILITIES Before the expiration of the warranty Owner must give notice to a registered PROHEAT dealer of failures if any considered to be warrantable and deliver the defective heater system to such dealer Owner is responsible for the cost of all repairs made to the engine or equipment in which it is installed other than the PROHEAT Heater system Owner is responsible for lodging meals and incidental costs incurred by the Owner as a result of a warrantable failure Owner is responsible for downtime expenses and all business costs and losses resulting from a warrantable failure TELEFLEX IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAM AGES Items Covered Under This Warranty 1 Basic Heater including combustion chamber components fuel system components air compressor ignit
52. isassemble nozzle as shown in figure 5 15 c Use a degreaser to thoroughly wash the separate parts d Dislodging contaminates in the distributor counterbore can be done by lightly hand spinning a drill bit 0 060 dia and then washing See figure 5 16 DO NOT use a tip cleaner in the fuel orifice e Reassemble nozzle and torque to 30 inch pounds f Using compressed air for cleaning should only be applied in the direction indicated See figure 5 15 g Lubricate O ring with diesel fuel and re install nozzle in fan end NOTE See step 6 of Fuel Troubleshooting section page 5 29 to confirm that the nozzle is functioning correctly All nozzles parts are matched do not interchange PROHEAT OWNER S MANUAL DRILL BIT 0 060 Figure 5 16 Fuel Nozzle Distributor Cleaning Fuel Regulator fuel regulator reduces the fuel pressure supplied by the fuel pump from 5 psi 0 34 Bar down to atmospheric pressure Compressed air flowing through the nozzle creates a venturi effect which siphons fuel from the regulator If the compressed air flow through the nozzle stops the regulator closes shutting off the fuel flow Check Fuel Regulator a Ensure that the vent hole in the regulator is not plugged b Ensure that all fuel line connections are tight Check the clamps Test Procedure a Disconnect the fuel line at the nozzle fuel inlet fitting and place it in a container b Start the heater Insert
53. itched off the heater runs out of fuel the vehicle battery voltage drops below 10 5 volts or an error occurs and the switch light flashes See Trouble Shooting Repair section 5 NOTE The PROHEAT may be operated if the engine is running or not running 2 For sleeper heat set the thermostat in the sleeper to the desired temperature If the set temperature is higher than the temperature in the sleeper the fan will cycle ON When the air reaches the set temperature the fan will cycle OFF The fan will cycle ON and OFF to maintain the set temperature NOTE PCMs Serial C10001 to C12999 sleeper fan output does not turn on until coolant temperature reaches 100 F 38 C PCMs Serial C13000 and greater sleeper fan turns on when the heater is switched or timed on 3 When engine and or sleeper preheat is no longer required switch the PROHEAT heater off 2 0 TECHNICAL SPECIFICATIONS MODEL HEAT OUTPUT VOLTS CURRENT FUEL RATE COOLANT FLOW BTU hr kw Nominal Amps Gal hr I hr Gal min min range XL900 12 30 000 12 6 0 0 27 1 0 8 0 30 9 0 10 5 15 XL900 24 30 000 24 3 0 0 27 1 0 8 0 30 9 0 20 30 XL1500 12 50 000 12 10 0 0 45 1 7 8 0 30 15 0 10 5 15 XL1500 24 50 000 24 5 0 0 45 1 7 8 0 30 15 0 20 30 WARNING Ignition Type Electronic spark ignition Do not use gasoline
54. its that may have accumulated on the heat exchanger fins Remove ignition lead from ignition electrode Remove blower connector Remove the 3 bolts securing the fan end assembly Remove the fan end assembly and combustion tube to access the inside of the heat exchanger Use a wire brush to loosen the deposits and an air hose to blow them out COMBUSTION TUBE Figure 6 2 Heat Exchanger Fins Access Check the exhaust system carefully Make sure the exhaust pipe is vented safely away from the vehicle cab Check the pipe for dents restrictions or severely corroded areas Replace the exhaust pipe and clamps if necessary Ensure the exhaust pipe clamp is tight OWNER S MANUAL Electrical System Fuel Strainer MAINTENANCE Check the internal and the external wire harnesses for damage Replace if required Figure 6 3 Wire Hamesses Remove and inspect strainer Clean or replace as necessary FUEL STRAINER Figure 64 Fuel Strainer 6 3 Clean Air Intake Check the combustion air inlet screen for restrictions Clean as required AIR INLET SCREEN Figure 65 Air Intake Compressor Air Filter The air compressor is fitted with an inlet air filter to ensure clean air is supplied to the nozzle Replace annually or more often if dusty conditions are encountered AIR FILTER ELEMENT MARKII AIR FILTER ELEMENT Figure 66 Air
55. ive wire to the chassis Test sleeper heater fan See Test Procedure Symptom Sleeper Heater fan not turning NO ERROR INDICATED Check Sleeper Heater system a The wiring connections and polarity b Test sleeper heater fan See Test Procedure Symptom Sleeper Heater system has low air flow NO ERROR INDICATED Check Sleeper Heater system a Air ducting b Use Test Procedure items e and f to determine if PROHEAT is Supplying enough power to drive the sleeper fan Test Procedure a Disconnect sleeper fan harness b Restart the PROHEAT If there is still an error replace the PCM c Check for correct voltage at the sleeper fan output on the PCM See page 6 7 d Reconnect sleeper fan harness Start the PROHEAT e Check for voltage at the thermostat isolator if used and the sleeper fan motor The power to the sleeper heater fan is regulated by voltage in the PCM It will read low when trying to drive the sleeper fan f Connect sleeper heater fan motor directly to a remote power source of the rated voltage 12 24 volts Does the motor run PROHEAT OWNER S MANUAL Electrode Gap TROUBLE SHOOTING amp REPAIR Components MARK Il only The electrode gap is factory set and should not require adjustment 1 8 3 16 E Figure 5 13 Electrode Gap Detail 5 23 Fuse Repeated replacement of the fuse or using incorrectly rated fus
56. m in the PCM Check Heater PCM function a Switch the heater ON OFF switch in the dash to OFF Reset the PCM by removing the power connection for 10 seconds and then re installing it If the ON light continues to flash replace the PCM 5 1 5 2 1 Start Error Function Errors A START ERROR Indicates that the flame sensor did not see a flame during the 60 second ignition period If the Start Error is displayed switch the heater to OFF and then ON to restart Observe the heater operation through the inspection window Symptom flame is visible The heater shuts down after the 60 second ignition period Check Flame Sensor a Inspect for an open circuit in the wiring b Inspect the lens for cleanliness page 5 8 Check Fuel System c Is there a restriction in the fuel system d Is the nozzle or filter screen plugged e Is the fuel pump operating page 5 12 f Fora defective pressure regulator page 5 27 g Is the compressor functioning page 5 14 h What type of fuel is being used Symptom flame visible The spark continues for the 60 second ignition period The heater shuts down after the 60 second ignition period Check Fuel System a 15 there a restriction in the fuel system Is the nozzle or filter screen plugged c Is the fuel pump operating page 5 12 For a defective pressure regulator page 5 27 Is the compressor functioning page 5 14 f For carbon
57. nd reduces noise level 3 16 ID 1 ft fo the around aie located Update configuration requires at the EE of the heater the following parts Use part 842020 to join the filter assembly to the 90 elbow on the compressor head Cut the hose to length Leave some slack in the hose Teleflex Canada Tel 604 270 6899 1994 Reproduction in any form electronic B Teleflex 3831 No 6 Road Fax 604 270 0137 print or otherwise is encouraged providing Richmond B C Web proheat the PROHEAT logo watermark is visibl e mm Teleflex Canada Canada ERisllipraheat aura the sha credi i aent a Energy Solutions Division V6V 1 6 Toll Free 800 667 HEAT 4328 Teleflex Energy Solutions 8 12 PROHEAT OWNER S MANUAL Service Bulletin 969023 March 1996 Description Air Compressor Pressure Test Kit Teleflex Part PK0060 REMOVE FILTER ELEMENT lt Lp gt gt PSU 9 LINE NOZZLE AIR INLET GAUGE amp PK0060 gt K MW LINE FROM COMPRESSOR Purpose This tool is used to check for proper air fuel delivery through the nozzle Instructions Install the pressure gauge Teleflex part PK0060 in line at the air inlet to the nozzle as shown above Perform this test with the compressor filter installed and removed This will check the filter for restrictions Readings that are above the pressure ratings indicate a blocked ai
58. ng with further troubleshooting While running the Proheat check for a pulsing fuel pump by feel or sound Check for power to the fuel pump positive terminal See figure 5 18 Disconnect the fuel line at the inlet to the regulator Start the Proheat Check fuel flow Approx 1 2 litre in 60 seconds Run the fuel pump using remote electrical power take power from the ignition coil positive post Check the Proheat internal harness ground wire for open circuit See wiring diagram page 6 7 of Service Manual PROHEAT OWNER S MANUAL Step4 Does the Regulator work Disconnect the fuel line at the fuel inlet fitting hold the line at the same level as the inlet Start the heater there should be no fuel flow This indicates that the regulator is holding the fuel pressure Lightly push on the regulator diaphragm use a blunt tool fuel should flow from the line NOTE A regulator that is stuck open will produce a rich flame Blockage in the regulator needle valve seat will produce a lean flame Step5 Does the Compressor work e Check the pressure output as described in the Service Manual page 5 14 Step6 Isolate the Nozzle and Compressor Split the fuel system by drawing fuel from a remote source To do this disconnect the fuel line at the outlet of the fuel regulator put this end into a small container of fuel that is about the same level as the regula tor centre This will eliminate the fuel pump and th
59. on Coil WARNING The PROHEAT chassis is grounded from the PCM as shown in Figure 5 10 Ensure the ground is securely connected Failure to ensure a proper ground may result in electrical shock An IGNITION COIL ERROR indicates an open circuit in the wire harness a short in the wire harness between the positive and negative leads or an internal short in the coil The fuse will blow if there is a short to ground in the positive lead or the coil This will not cause an ignition coil error The ignition coil is the easiest place to measure the voltage on the heater This component is ground side switched in the PCM Symptom No spark at the electrode ERROR INDICATED Check Coil wiring a Inspect the wiring harness to ensure the ring terminals are secured to the coil Make sure the polarity is correct b Inspect for broken or abraded wires in the wire harness c Test coil See Figure 5 10 Symptom No spark at the electrode NO ERROR INDICATED Check High tension wires and electrode a Inspect the high tension lead between the coil and the electrode b Inspect the ground lead between the second electrode and the heater chassis c Is the electrode gap adjusted correctly See page 5 23 for Electrode Gap Detail NOTE If a coil error occurs and no fault is found in the coil and wiring then the PCM must be checked PROHEAT OWNER S MANUAL TROUBLE SHOOTING amp REPAIR Test procedure a Measure ignition coil
60. operation or during engine operation can then be observed FIGURE 1 FLOW INDICATOR SLEEPER FAN TK9002 OTHER POSSIBLE LOCATIONS FLOW INDICATOR FIGURE 2 Teleflex Canada Tel 604 270 6899 O 1993 Reproduction in any form electronic B 3831 No 6 Road Fax 604 270 0137 print or otherwise is encouraged providing Richmond B C Web www proheat com the PROHEAT logo watermark is visible on mu Teleflex Canada Canada Email proheat proheat com the reproduction and credit is given to Energy Solutions Division V6V 1 6 Toll Free 800 667 HEAT 4328 Teleflex Energy Solutions 8 6 PROHEAT OWNER S MANUAL Service Bulletin 967121 March 1994 Description Bilower Regulator Service Tip In the event that either the combustion blower or the fuel regulator should fail it is advisable to check the Heat Exchanger for carbon build up This will require the removal of the combustion tube as described in the service manual Page 6 2 Heat Exchanger Carbon build up is caused by rich fuel mixture which is symptomatic of A INHIBITED COMBUSTION AIR FLOW Combustion blower failure Blocked air intake Blocked exhaust B OVER FUELING Pressure regulator failure Blocked nozzle Excessive compressor output Teleflex Canada Tel 604 270 6899 1994 Reproduction in any form electronic B 3831 No 6 Road Fax 604 270 0137 print or otherwise is encouraged providing Richmond B
61. ould only be used to supply power to the ON OFF switch and the TIMER oras a signal to trip a relay Failure to follow this installation practice will result in damage to the DASH 1 2 DIA HOLE SWITCH LABEL x e NUT ON OFF SWITCH ON OFF Switch Connections l Select a suitable location in the vehicle dash for the ON OFF switch NOTE Many dash panels have switches which are not utilized It may be convenient to remove one and replace it with the PROHEAT switch 2 Drill a 7 diameter hole through the dash for the switch Make sure you have clearance behind the dash for the switch wires and connections Install the switch as per the diagram See Figure 3 20 gt lt 3 16 5 mm GROUND 2 51 x ON POWER EOM B OFF 4 B ON SIGNAL INDICATOR Figure 3 20 ON OFF Switch Assembly Figure 3 21 ON OFF Switch Connections 3 Route the switch wire harness from the PCM to the dash panel You will have to pass the wire harness through the vehicle firewall If possible use an existing hole If not you will have to make one Use a grommet to prevent the wire from being damaged when it is passed through the hole 4 Cut the harness to length 5 Strip outer wire jacket of harness back to expose the 4 wires Strip the wires as shown and crimp the supplied spade terminals 6 Connect the terminals to the switch as shown See Figure 3 21 NOTE The PCM must
62. power terminal 2 If the fuel pump does not operate ground the body of the fuel pump directly to the battery negative post using a wire Restart the Proheat If the fuel pump runs and the Proheat starts then the problem is in the ground wire Note Itis possible to get a partial ground for the fuel pump if the exhaust pipe is contacting the machine frame and the ground side battery disconnect switch is closed 3 To locate the fault in the ground circuit first check the internal harness The ground wire is black with a green stripe Remove the 18 pin connector from the controller and check for continuity between the ground pin Pin C3 and the ring terminal See Figure 1 over If a fault is found replace the harness Next check the controller by measuring for continuity between pin C3 on the controller 18 pin connector and pin B at the power harness connector See Figure 2 4 the fuel pump did not run in step 2 refer to Fuel Pump Start error and Flame Out error in the troubleshooting section of the Service Manual 1 Install a 10 amp in ine fuse on the ground wire black with green stripe of the Proheat harness Proheat Part PK0310 2 Ensure that the Proheat exhaust pipe does not contact vehicle chassis 3 If possible rewire the disconnect switch to the positive side of the battery Teleflex e mm Teleflex Canada Energy Solutions Division Teleflex Canada Tel 604 270 6899 1995 Reproduction in any
63. r does not see a flame the ignition is switched on immediately If the flame is not re established within 10 seconds the heater will shut down and the FLAME OUT ERROR will be displayed The heater will go into the purge mode and attempt to restart in 3 minutes If the flame fails to reignite on the second attempt a START ERROR will be displayed on the function control panel If however the flame sensor senses enough of a flame during the ignition mode it will enter the run mode During the run mode if the flame sensor fails to see a flame then the FLAME OUT ERROR will be displayed Check Fuel System a Is there a restriction in the fuel system b Is the nozzle or filter screen plugged C Is the fuel pump operating page 5 12 d For a defective pressure regulator page 5 27 e Is the compressor functioning page 5 14 f What type of fuel is being used 5 3 3 Coolant Flow A COOLANT FLOW ERROR is displayed when the coolant temperature reaches 185 F 85 C in less than one minute after ignition This indicates that the coolant flow is severely restricted or blocked This feature aids in detecting coolant flow problems that can degrade the PROHEAT performance An in line flow indicator is a valuable troubleshooting tool used to Figure 5 1 a Check the coolant flow and direction b Check for air in the system c Check for restrictions caused by the truck systems ie Shuttle valves manual valves air opera
64. r passage in the nozzle and would show up as a lean flame If the pressure reads OK and the flame is lean check the nozzle fuel passage See Nozzle page 5 26 in the PROHEAT Service Manual Readings that are below the rated pressure indicate a problem with the compressed air system This would show up as a lean flame or wet carbon build up in the PROHEAT combustion chamber due to improper mixing of the fuel See Air Compressor page 5 14 in the PROHEAT Service Manual At FULL OUTPUT the pressure readings should be within the following limits XL900 6 9 psi 12 24 volts XL1500 8 11 psi O 12 24 volts 115 Teleflex e mm Teleflex Canada Energy Solutions Division Teleflex Canada 3831 No 6 Road Tel 604 270 6899 Fax 604 270 0137 1994 Reproduction in any form electronic print or otherwise is encouraged providing Richmond B C Web www proheat com the PROHEAT logo watermark is visible on Canada Email proheat proheat com the reproduction and credit is given to V6V 1P6 Toll Free 800 667 HEAT 4328 Teleflex Energy Solutions 8 14 PROHEAT OWNER S MANUAL Description Production note Cause Symptoms Note Instructions Service Bulletin SB0001 March 1995 OVER FUELING Some 1994 production heaters may have this over fueling condition Mid February 1995 and forward do not have high pressure compressors and are preset at the factory High compressor output
65. resistance Use a multimeter to measure the resistance across the positive and negative terminals The resistance should be less than 1 ohm If resistance is open circuit or 0 ohms short circuit then replace the ignition coil Note Remove positive and negative wires from the coil when testing Figure 5 9 Ignition Coil Test 7 WIRE FROM PCM 7 CHASSIS GROUND BOSS Figure 5 10 PROHEAT Ground Boss 5 17 5 18 11 Coolant Pump A COOLANT PUMP ERROR indicates an open circuit in the wire harness a short in the wire harness between the positive and negative leads or an internal short in the motor This component is ground side switched in the PCM The coolant pump is not self priming Ensure that the coolant system has been purged of air by running the vehicle engine for at least ten minutes following installation or service Do not run dry Symptom Coolant pump not running ERROR INDICATED Check Coolant Pump wiring amp function a That coolant pump is connected to harness correctly See PROHEAT wiring diagram page 6 8 b The connector pins for damage or corrosion c Harness for pinched or abraded wires d Test pump If it tests OK replace PCM See Figure 5 11 and Test Procedure Symptom Coolant pump not running NO ERROR INDICATED Fuse blown in PCM Check Coolant Pump function a Harness for pinched or abraded wires Positive lead must not s
66. ror also See page 6 6 Optional hour meter used to log running time Teleflex part PK0051 PROHEAT OWNER S MANUAL A ar N 2 d H 22 2 Pd Figure 4 3 8 Nozzle 9 Fuel Strainer 10 Blower 11 Inspection Port 12 Heat Exchanger PRINCIPLE OF OPERATION An air fuel aspirating type spray nozzle The compressed air flows through the nozzle at high speed creating a venturi effect This siphons fuel from the regulator and combines it with the air creating an extremely fine mist which is sprayed out the nozzle into the combustion chamber The nozzle determines the air fuel ratio Filters the fuel prior to entering the nozzle reducing nozzle blockage Uses an impeller type fan to supply approximately 9096 of the combustion air at low pressure It is also used to cool and purge the combustion chamber during the 3 minute shut down sequence Allows visual inspection of the combustion process and is invaluable for reducing time spent on troubleshooting and servicing the heater A two part cast aluminum housing Coolant will typically rise 10 to 15 F 6 to 8 C in temperature as it passes through the heat exchanger depending on the flow rate 4 3 4 4 13 14 15 16 17 18 Ignition Electrode Coolant Temperature Sensor Over Heat Breaker Flame Sensor ON OFF Switch not shown 7 Day Timer not shown The electrod
67. s not turn on until coolant temperature reaches 100 F 38 C PCMs Serial C13000 and greater sleeper fan turns on when the heater is switched or timed on 11 Switch the ON OFF switch to OFF The red light will go out and the heater will purge for three minutes 12 Inspect the installation again for leaks 13 Install the enclosure cover 14 TO ENSURE FULL WARRANTY COVERAGE COM PLETE THE WARRANTY CARD AND MAIL TO TELEFLEX CANADA LTD PROHEAT OWNER S MANUAL 4 0 PRINCIPLE OF OPERATION GENERAL DESCRIPTION gt Z lt 0 if Y Q oo El MS T up 4 2 Figure 4 1 1 Fuel Pump A constant pressure variable flow pump supplies fuel at 5 psi to the fuel regulator Under normal conditions it will pulse approximately 1 to 2 times per second On initial start up with a dry fuel line it will pulse rapidly until fuel pressure reaches 5 psi it will then slow to its normal rate 2 Fuel Regulator Reduces fuel to atmospheric pressure Siphoning action from the nozzle draws fuel from the regulator Without this siphoning there is no fuel flow 3 Air Compressor A diaphragm type compressor supplies air to the fuel nozzle 4 Ignition Coil An automotive type ignition coil supplies high voltage to the ignition electrode sparking to the combustion tube 5 Coolant Pump Circulates the engine coolant An impeller style pump is used because of its
68. struction equipment off road equipment military equipment and cargo PROHEAT heaters are used in the following applications 1 Engine Block Heat PROHEAT will preheat an engine block to ensure reliable starting in cold weather At the same time it may be used throughout the year to reduce the wear associated with cold starts Cab or Sleeper Heat engine off PROHEAT will supply heat to the cab or sleeper Drivers can sleep in comfort not only in the cold of winter but also in the spring and fall when the weather is miserable Substantial savings through reduced fuel consumption and engine wear can be obtained by not idling the engine during these times 3 Supplemental Heat engine running as the efficiency of modern diesel engines are improved there is no longer adequate reject heat available to heat the vehicle s interior This is particularly true for buses PROHEAT can be used while the vehicle is operating to provide supplemental heat for the interior 4 Cargo Heat PROHEAT can be used to provide heat to protect valuable cargo such as produce or beverages from damage due to freezing Marine Marine applications typically involve the engineering and installation of a complete hot water heating system of which PROHEAT is only one component Teleflex recommends that only an expert in marine hot water heating systems install a PROHEAT on a boat It is the installer s responsibility to ensure
69. t from left over wire harness Note For large sleepers this MAY NOT provide enough fan speed and therefore option B C or D should be considered See wiring diagram detail page 6 8 Option A MUST BE BOLTED TOA METAL SURFACE FOR HEAT SINKING Tee PANEL Thermostat Wire Connection Detail Screw Wire Colour 1 White from PCM f i i 2 White to isolator 3 Notused 4 Not used OEM THERMOSTAT OEM FAN RESISTOR ASSEMBLY ISOLATOR IGNITION on ONTROL NOTE MAY OR MAY NOT BE LOCATED INSIDE SLEEPER HEATER FAN OEM SLEEPER ASSEMBLY wami HEATER ASSEMBLY N HEATER PROHEAT PROHEAT 4 anay EE WIRE BLACK WIRE CONNECTION NOT USED DETAIL SLEEPER FAN FAN MOTOR SINGLE WINDING TYPE HARNESS Figure 3 24 Thermostat Installation 3 18 Figure 3 25 Sleeper Heater Wiring Detail Option A PROHEAT OWNER S MANUAL Make sure the vehicle ignition is switched OFF OPTION B Locate the Proheat thermostat in a central area of the sleeper approximately 12 above the bunk Avoid direct air flow from sleeper fan ducts See Figure 3 22 3 Remove the adjusting knob and face cover Mark and drill mounting holes Mount thermostat using the screws provided See Figure 3 24 4 Install relay 1 always between OEM sleeper fan control and OEM thermostat Note The constant power supply wire must be of sufficient size
70. ted valves Check Coolant Flow a Coolant Lines For restrictions and blockages Are clamps tight Shut off Valves Ensure that shut off valves are open and functioning properly c Fittings Fittings must be at least 1 2 NPT or larger Avoid using 90 fittings where possible Coolant Flow Direction The PROHEAT must be plumbed so that the PROHEAT coolant pump is pumping the coolant in the same direction as the engine coolant pump PROHEAT can be used when the engine is running Coolant Pump Does the pump function properly page 5 18 f Coolant System Capacity The coolant system must contain at least 3 gallons 11 litres of coolant If the system contains less it may heat up in less than 1 minute causing a COOLANT FLOW ERROR Sleeper Heater Many OEM sleeper heaters are combined with an air conditioning system The solenoid shut off valve used to cut off coolant flow during the air conditioning mode must be open when using the PROHEAT Refer to section 3 9 b Q KD SLEEPER FAN OTHER POSSIBLE LOCATIONS Figure 5 1 Flow Indicator TK9002 PROHEAT OWNER S MANUAL 4 Overheat Do not reset the Overheat breaker until the cause of the overheat condition has been determined TROUBLE SHOOTING amp REPAIR An OVERHEAT ERROR is displayed when the overheat breaker has tripped shutting the heater down This occurs if the heater has been started with little or no coolant
71. the fork terminal provided Black wire is not used 6 Route a wire from terminal 2 of the thermostat to an appropriate wire on the sleeper fan motor Make a splice connection and seal the splice with tape or heat shrink Note The electrical power and operation in this option is controlled by the Proheat See Option B should a relay be required to provide more electrical power Thermostat Wire Connection Detail Screw Wire Colour 1 White from PCM 2 White to sleeper heater 3 Not used 4 Not used PCM SLEEPER FAN HARNESS THERMOSTAT AUXILIARY SLEEPER HEATER SPLICE WIRES GROUND FAN MOTOR ORANGE MULTIPLE WINDING TYPE RED NOT USED Figure 3 27 Option C PROHEAT OWNER S MANUAL Do not use fuel lines and pick up tubes less than 1 8 ID or greater than 3 16 ID Failure to use the correct line size may result in heater malfunction Fuel System GENERAL CONSIDERATIONS Use s ID fuel line between the fuel tank and heater meeting SAE 30R7 supplied with kit Ensure fuel lines are well secured and will not abrade Ensure clamps are secure at fuel pump and fuel pick up Figure 3 28 Do not kink or pinch fuel line when routing lines You Choose I gt INSTALLATION 50 MAXIMUM LENGTH OF FUEL LINE lt gt 10 MAXIMUM RISE Figure 3 29 Fuel Supply Height Requirement Select Your Fuel
72. tlet will not blow the fuse An error will be indicated on the PCM This will not shut the heater down No Replace PCM Yes Disconnect all components from Internal Wire Harness 10 Connections See NOTE Reconnect Internal Wire Harness 18 Pin Connector Reconnect Switch Harness Yes No Replace Internal Wire Harness Reconnect Components Check Switch Harness and Connections for Short Circuit One at a time Yes No Check Component as per Trouble Shooting Guide TROUBLE SHOOTING amp REPAIR Component OK 5 25 5 26 Nozzle The nozzle and the compressor regulate the fuel air mixture A set orifice size allows a certain amount of fuel and air to flow through the distributor See Figure 5 12 Problems in the nozzle can cause poor burning This will be indicated by START ERRORS or FLAME OUT ERRORS on the PCM function display Check Nozzle a Inspect the wire mesh filter located in the fuel inlet fitting for blockage or debris b Inspect the nozzle for blockage c Clean or replace nozzle as necessary STEM NO NICKS IN O RING NOZZLE COUNTER BORE pes CE 9 TURN CLOCKWISE In TO DISASSEMBLE HOLES amp GROOVES CLEAR TURN COUNTER CLOCKWISE APPLY COMPRESSED AIR DISASSEMBLE IN THIS DIRECTION Figure 5 15 Fuel Nozzle Detail Nozzle Cleaning Procedure a Remove nozzle from fan end b D
73. ulator inlet a Remove fuel supply line at the regulator Place this end into a container b Start the PROHEAT Pump will operate at full output c Measure the fuel flow Flow should be greater than 0 13 US GPM 0 5 min at 12 Volts The fuel pump can be operated remotely by disconnecting the PROHEAT power supply and connecting the pump directly to 12 volts See Figure 5 6 FUEL FLOW gt FROM FUEL TANK TO CONTAINER THE BODY OF THE FUEL PUMP GROUND IS GROUNDED TO THE HEATER CHASSIS POWER SUPPLY POST 12 VOLT SUPPLY LOCATED ON THE BOTTOM OF THE PUMP FLOW RATE GREATER THAN 0 13 USGPM 0 5 l min AT 12 VOLTS Figure 5 6 Fuel Pump Test 7 GROUND WIRE TO PCM SFT ALS 7 CHASSIS GROUND BOSS gt 9 Figure 5 7 PROHEAT Ground Boss 5 13 9 Compressor COMPRESSOR ERROR indicates an open circuit in the wire harness a Short in the wire harness between the positive and negative leads or an internal short in the motor This component is ground side switched in the PCM Symptom Check Air Compressor not running ERROR INDICATED Air Compressor wiring amp function a That compressor is connected to harness correctly See PROHEAT wiring diagram page 6 8 b Check the connector pins for damage or corrosion c Harness for pinched or abraded wires d Test compressor If it tests OK replace PCM See Figure 5 8 and Test Procedure S
74. voltage Note Bad connections may show full voltage under no load conditions but not under full load With the heater off measure the voltage Then switch the heater on and measure the voltage again If the voltage drop is more than one volt check the vehicle battery connections and the power connection at the PCM b Ifthe measured voltage is higher than the specified range then check the voltage regulator on the vehicle Note If the vehicle batteries are marginal starting the vehicle while the heater is running may a Drop the voltage enough to cause a voltage error b Cause random component errors brown out To re set the PCM switch the heater to OFF and then back ON at the dash toggle switch If the problem continues load test the batteries to confirm their condition PROHEAT OWNER S MANUAL Heater Voltage Measurement The positive terminal of the ignition coil is always hot relative to the heater chassis ground as long as power is connected to the heater This is the supply voltage to the heater Test Procedure a Locate the rubber boot on the end of the ignition coil and peel it back to expose the positive and negative terminals Select the DC volts range of a multimeter and connect as per Figure 5 3 The positive lead of the multimeter should be attached to the positive coil lead The negative lead of the multimeter should be attached to the heater chassis at the PROHEAT ground boss F
75. xcessive vibration Do not mount the heater directly to the engine COOLANT OUT FUEL IN T d 5 IN MINIMUM CLEARANCE 6 Figure 32 Figure 3 3 Allow minimum 6 clearance for hose connections PROHEAT OWNER S MANUAL INSTALLATION Heater must be mounted below the highest point in the cooling system HIGHEST POINT IN COOLING SYSTEM HEATER MUST BE MOUNTED BELOW HIGHEST POINT za PROHEAT ENGINE OR RADIATOR Figure 34 Height Requirement Mounting the PROHEAT heater in an enclosure Figure 3 5 Adequate Air Flow Do not locate the heater in an airtight enclosure Ifthe heater is to be mounted in an enclosure other than the PROHEAT enclosure adequate air flow must be provided to ensure proper combustion Heater must be mounted within 5 of horizontal as shown Figure 3 6 Mounting Angle 3 3 Mounting the Heater Select Your Mounting Option OPTION A Heater supplied with an enclosure 1 Remove the enclosure cover 2 Drill the 4 mounting holes and exhaust pipe clearance hole 3 Using the bolts supplied fasten the enclosure to the mounting tray or brackets 4 Ensure that the combustion tube can be removed for service Minimum of 5 1 2 from fan end casting face is required NOTE Use anti seize compound on the fasteners to prevent galling and corrosion 4 5 1 x X 11 2 TN WE
76. ymptom Check Air Compressor not running NO ERROR INDICATED Fuse blown in PCM Air Compressor function a Harness for pinched or abraded wires Positive lead must not short to ground b Motor for internal short See Figure 5 8 and Test Procedure Symptom Check 5 14 Air Compressor running NO ERROR INDICATED No low air flow Air flow a Air filter for cleanliness For blocked air line to nozzle inlet For blocked nozzle See Nozzle page 5 26 Air compressor as described in Service Bulletin 969023 in Appendix Perform this with filter in place and then without filter on PROHEAT OWNER S MANUAL TROUBLE SHOOTING amp REPAIR Test procedure a Connect air compressor directly to a power source of the rated voltage 12 24 volts and see if the motor runs If not replace the compressor b Measure air compressor motor resistance Use a multimeter to measure the resistance across the compressor assembly connector pins If resistance shows an open circuit or an internal short circuit replace the compressor assembly Measure air compressor current Use test lead part 967921 as described on Service Bulletin 967329 in Appendix Figure 5 8 Co mpressor Test MODEL CURRENT DRAW XL900 12 3 50 5 00 12 volts XL900 24 1 50 3 00 24volts XL1500 12 5 50 7 00 12 volts XL1500 24 3 00 4 50 24volts 5 15 10 Igniti

Download Pdf Manuals

image

Related Search

Related Contents

Philips Docking Entertainment System DCM230  Kenmore 362.72221 Range User Manual  TDSHーBA東芝堂光灯器具ホ-ムラィ離取扱説明書  Sony TRINITRON KV-T29SN81 User's Manual  Podium Plus Data Analysis Software User Manual  Kensington SP17 Classic Laptop Sleeve - 17"/43.2cm  Cisco Systems 10005 ESR Installation Manual  Pauline Emery Master Project Final - Infoscience  RTDAQ Real-Time Data Acquisition Software  dvr belvedere - ICS "Monsignor Gagliano" Altavilla Milicia  

Copyright © All rights reserved.
DMCA: DMCA_mwitty#outlook.com.