INSTALLATION AND SERVICE MANUAL PROHEAT …

1 SAF .. A-1B.. B-1C. MO DEL DESCRIP TI .. TEC HNI CAL SP ECI FIC .. PHY SI CA L X4 5 .. ELEC TRI CAL X45 .. TO RQU E SP ECI FIC ATI ON S .. OPERATING YO UR PR .. INS TALL ATIO .. LO CA TIN G TH E HEATE R ..1 Se lect Your Lo ca tio n ..2 Ge ne ral co nsid er ation ..3 Mo unt in g the Proh ea t Heat er in an En clos ure .. MOUN TIN G TH E HEATE ..1 Op tio n A Hea ter Wit h Enclos ure ..1 Op tio n B Hea ter Wit hou t Enclos ure .. EXHA UST PI PE CON NECTIO .. PLUM BI NG TH E SYS TE ..1 Ge ne ral Cons id er atio ns ..2 Op tio n A Engin e Hea t or Supp le me nta l He ..3 Op tio n B Engin e and Sle ep er Hea .. WIR IN G & ELE CTR ICAL CONNECTI ONS.

2 3-1 .1 Ge ne ral Cons id er atio ns .. 3-1 .2 Po we r Connect io n to Bat ter ie s .. 3-1 .3 TimerCo nnect io ns (Op tion al) .. 3-1 .4 On /Off Swit ch Con nect io .. 3-1 .5 Sle ep er Fa n Mode l Heater Wir ing Deta ils .. 3-1 .6 Op tio n A OEM Hea ter & Proh ea t Th ermo sta .. 3-1 .7 Op tio n B OEM Hea ter & Th er mo sta .. 3-1 .8 Op tio n C Auxilia ry Slee per .. 3-1 .9 Op tio n D Auxilia ry Slee per Heater Cu rr ent .. 3-1 .1 0 Auxilia ry In put Mode l Heat er WiringDe ta ils .. 3-1 .1 1 Opt ion A Pr eh ea t Mo de Supp lemen ta l Mod e Ope ra ti . 3-1 .1 2 Opt ion B Pr eh ea t an d Su pp lem en ta l Mod .. 3-2 .1 3 Opt ion C St and ard Mode & Su ppleme nta l Mod e.

3 3-2 FU EL SYSTE .. 3-2 .1 Ge ne ral Cons id er atio ns .. 3-2 .2 Op tio n A 1/4 " or 1/ 2" NPT Po rt .. 3-2 .3 Op tio n B Exist in g Bla nk Fue l Sende r Co ver Pla .. 3-2 .4 Op tio n C Hole Drille d in to Fu el Ta nk .. 3-2 .5 Ins ta lla tio n .. 3-2 FIR ST TIM E STA RTUP .. 3-2 PRIN CI PLESOF OP .. 4-14-1 GE NER AL DE SCR IP TIO .. 4-14-2 MO DES OF OPE RATIO ..1 St an dard Mod e All Mod els ..2 Pr eh ea t Mode Aux Inp ut Mod els Only ..3 Su pp le mental Mod e Au x In put Mod els On ly .. TRO UBL ESHOOTI NG & REPA ..1 Tr oub le shoo ting a Prob le ..2 Exam ple Prohe at Behavio r Error Cod e 01 .. 5-25-1 OPE RATI ON IND IC ATO RS, FUN CTION & CO MPONENTDIAG NO STIC S.

4 1 Ope ratio n Ind icat ors ..2 Func tio n Dia gno st ics .. 5-501 Sta .. 5-502 Flam e .. 5-1503 Coo lan t Flo w .. 5-1604 Over hea .. 5-1705 Volt age .. 5-185. Com po ne nt Dia gn os tics .. 5-1906 Flam e Sens or .. 5-1907 Tem p Sens or .. 5-2108 Fue l Pu .. 5-2309 Com pre sso r .. 5-2310 Ign itio n Coil .. 5-2511 Coo lan t Pump .. 5-2712 Blow .. 5-3013 Slee pe r Fa n .. 5-3214 Hou r Mete r (Auxilia ry Output).. 5-335-2 CO MP ONE NT ME CHA NIC AL OR .. 5-345. Fue l No zz le .. 5-345. Fue l Regu lat .. 5-345. Air Com pr es .. 5-345. Fue l Pu mp .. 5-345. Ignitio n Ele ct ro de .. 5-345. Coola nt .. 5-345. Blow er .. 5-345. Fus e .. 5-355-3 OP ER ATIO NA L PROBLEM.

5 5-375. Smo king exh au st .. 5-375. Low he at out put .. 5-375. Enginete mperature ga uge rea ds low .. 5-375. Backfir ing .. MA IN TENANC .. 6-16-1 WE EK LY MA IN TENANCE .. 6-16-2 AN NU AL MA IN TE NANCE .. 6-16. Clean He at er Enclo sur e and Air In ta ke .. 6-26. Check Exh aus t Syst em .. 6-36. Check Heat Excha nger .. 6-36. Clean Fla me Sen so r .. 6-46. Check Co olin g Sy stem .. 6-46. Check Ba tteries .. 6-46. Check Fue l Syste .. 6-56. Check Fue l Filt er .. 6-56. Clean No zz le .. 6-66. 0 ReplaceComp res sor Air Filt er .. 6-66. 1 Ch eck Ele ct rica l Sy stem .. 6-76. 2 Ch eck Air Pr ess ure .. 6-86. 3 Ch eckMo des of Op era ti on Swi tch , Time r or OE M Sig na 6-87.

6 0 APP ENDI .. 7-1Bu lletin s 951 528 , 967329 , SB0003, PB0034,SB00628. 0 .. 8-1iiPROHEAT INST ALLATION & SERVICESA FETYThr ough out th is man ual, you will se e note s la be ledDANGER,WARNING,CAU TIO NandNOTICEto ale rt you to sp ecial ins tructions or preca utio nscon cern ing a par ticula r proce du re tha t wo uld be haza rd ous if pe rfo rm edinco rre ctly or car eles sly .Obser ve them car efully !The se sa fet y alert s alo ne ca nno t eliminate all haza rds . Strictcom plia ncewith th ese specialins tru ct ion s and co mmonse ns e are ma jo r accide ntpr ev ent ion meas ur es .DA NGERImm edi at e haz ar ds tha t wi ll re su ltin seve re inj ur y or dea NGHa zar ds or unsa fe pra cti ce s thatcou ld re sult in severe perso na lin ju ry or deat for mat ion tha t is im porta nt topro per ins talla tion or main ten an ce ,but is not haz ar d-re lat ed.

7 CAUTIONHa zar ds or unsa fe pra cti ce s thatcou ld re sult in mi nor inju ry orpr odu ct or pr oper ty dam CTI ON A. SA FE TYExha ustInh al at ion of exha ust gas (containing carbon monoxide) may causesev ere personalinj ury an d/o r deat h. Anyo ne su sp ectedof sufferingfrom CO inhalationshouldberem oved from the hazardous area an d givenmedicalas sion Hazar dDo no t oper ate heater wh ere combustiblefu me s or airborneparticles,suc h as saw -dust , are pre sen rc ise ext re me cautionwhenworkingnear fuel or fuel-filledeq notoper at e heat er du ring fuelingop addition, do not smokeor ha ndle ope nflam e eq uipm en t, such as a blo wtorch, aroundfue e Hazar dDo no t plac e an y flammableit ems aroundthe heaterand exha ust r han d and eye protectionwhenwo rkin g near not smokeor use openflam es ne ar ba tt ri calElec tric sh oc k can cau se severepersonal injury,burns,and uni t.

8 Disc on ne ct the only app ro ved materialsand me thodswhenwor ki ng on th e ele ctricalsystemand follow local r work withele ctr icity in wet cond itio ns or whenyou are fe eling sons/To xinsFue l and coo lant are toxic and in somecase s, ca rcin an d handpro tec tion at all clothingimmediatelyan d wa shcon tam inat ed skin . Do not breathein va ng/H ot Par tsMov ing/ho t par ts can cau se severeinjuryan d or an y unit,sh ut it of f. Do no t op erateany unit until protectivecov ers have bee n replaced. Alwaysensur e bolt s and clampsare co rrectlytorquedand pect mechanicalcom -pone nt s per iod ic ally fo r damagean d ntNev errem ove the filler cap whenth e engineis hot escapingsteamor scald ing watercou ld ca use ser iou s personal e coolantlev el in th e expansion tank shou ld bech eck ed at least weekly(morefrequentlyin hig h mileageor arduousconditions).

9 Alw ay sche ck the le velwh en the systemis cold. Unscrewthe fille r cap slowly,allowingthepre ssur e to esc ape beforeremovingcomplete ly. Ne ver ru n the enginewit hout nt ant i- fre eze comingin contactwith the skin or eyes. If th is occurs,rin seimmed ia tely wit h plentyof da ertop -u p wit h salt whentrav ellingin territorieswherethe wa ter supplycon tai ns sa lt, alwaysen sure you carry a supp ly of fresh(rain or distilled) for nia Proposition65 WarningDo no t op era te hea ter in ga ragesor in otherclosed or unventilatedare sel exh austan d someof its constituents are knownto the Stateof Ca lifo rnia tocausecance r, birth defects,and oth er ct ricalcom pon entsin this pro ductmay containlead,a che mic al knownto theSt at e of Calif orniato causeca nceran d birthdefectsand otherreproduct ive FE TY CONSIDERATIONSWAR NI NGWAR NI NGWAR NI NGWA RNINGWA RNINGWAR NI NGWA RNINGWAR NI NGWAR NI NGDAN GERA-2 PROHEAT INST ALLATION & SERVICEThis man ual is prov ided to assi st an authorized PROHEATde ale r to installand servicea PROHEAT he at er.

10 Althou ghtru cks hav e beenusedin the examples, ap plicationsforPR OHEA T are by no meanslimit ed to trucks . PROHEAThe at ers are designedto be use d on any dies el eq uippedvehi cl e including:tr ucks,buse s (sch ool, transitand co ach),con stru ction equipment,off ro ad equip men t, militaryeq uip me nt and HE AT heatersare used in th e follo wing application s:(1) Eng ine BlockHea t PROHEATwil l preheatan eng ineblo ck to ens ur e reliablestartingin cold we e sa me time it may be used thro ugh ou t the yea r tore du ce th e wea r as so ci ate d wit h cold sta rts.(2 )Ca b or Slee per Heat (e ngine off) PROHEAT will supplyhe at to the cab or sleep er. Dri ve rs can slee p in comfortnot only in the cold of winte r but also in th e sprin gand fall whenthe wea the r is miser bsta ntia lsav ings throug h red uce d fue l con sumption an d enginewea r ca n be obtainedby no t id ling the engine.