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Van Conversion Manual

1. E BLOWER MOTOR 8 5 RESISTOR BLOCK s s HI BLOWER MOTOR MED PRO AIR CONNECTOR AT D PILLAR 14 GA ORN 14 GA BLK 16 5 2 amp gt lt 8 8 242 S SUR iba 14 ORN 14 GA 14 GA VEL RO AIR CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN WITHOUT PERMISSION IN WRITING ROM PRO LLC TO USER SPECIFICALLY REFERRING THIS DRAWING RV X SIGNATURES DATE TRE EN 20 000099 DRAWN K F S 10 27 98 PRO AIR LL C REAR HEAT COOL WIRE SCHEMATIC CHECKED CWM 11 19 98 MEA AIRTECH amp 1100 SERIES SCAE 1 1 0 SEE X x X X X 731 C R 6 ELKHART IN 46514 LET NO REVISION BY pae APPROVED MRZ 11 19 98 Lind ASTRO W YF7 SEED 2 1 ProAir LLC 4 6 PARTNO 40 000 100 NOIES O E CONNECTION 1 HARNESS 125 INSULATED WIRE IN FUSE BOX UNDER DASH EQUIVALENT TO SAE SPECIFICATION 31128 TYPE GXL 2 BLOWER MOTOR MAXIMUM 20 GA GRY 1 INGITION DRAW HIGH 12 AMP 20 BLK GROUND MEDIUM 8 AMP LOW 5 3 DASHED WIRE DENOTES WIRES 14 GS CORN POWER 4 WIRE HARNESS ROUTED W
2. LLC CUSTOMER SERVICE MANUAL 1999 AirTech H C POWER PACK ASSEMBLY PART NUMBER 60 000 587 60 000 587 POWER ASS Y N 03 000 042 HEAT COIL 95 03 000 043 EVAPORATOR COIL 60 000 287 O RING 05 000 141 EXPANSION VALVE 60 000 287 O RING CA 68 000 005 BLOWER MOTOR W SEAL nN 101 000 091 RESISTOR 1 9A 98CS110 CUSTOMER SERVICE MANUAL DODGE POWER PACK 1100 SERIES ASSEMBLY PART NUMBER 66 000 014 66 000 014 POWER PACK 557 01000 091 RESISTOR 05 000 141 EXPANSION VALVE 60 000 287 O RING KIT 68 000 005 BLOWER MOTOR W SEAL 03 000 037 COIL HEAT COOL 60 000 287 O RING KIT ProAir LLC 98mkcs04 1 9B T o 77 ESECLE V LLC CUSTOMER SERVICE MANUAL Lengths and fittings may vary depending on the chassis ProAir unit serial number and model number should provide a reference point to correctly identify hose assemblies 98cs01 Section 2 0 Ford Econoline Van ProAir Unit L ocation Although location may vary by converter the ProAir unit is usually located on the driver s side rear corner insidetheinterior wall A C and heater hoses are routed over the wheel well insidetheinterior wall and drop through the f
3. RD E MN MEDIUM gt gt BLOWER MOTOR 14 GA YEL 12 L O E M SWITCH INSTALLED 2 W 57X PACKAGE BLOWER MOTOR PROAIR SWITCH INSTALLED RESISTOR BLOCK GND W 57L PACKAGE RO AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING REV SIGNATURES DATE TITLE DN 7 7 98 REAR HEAT COOL WIRE SCHEMATIC 40 000 021 PRO AIR LLC 2 ET 2 CHECKED 11 19 98 X x S X X Tingga 28731 CR ELKHART IN 46514 GE SEENOTE MS SER 1 bE 3 ProAir LLC 2 6B 40 000 018 REV 1 40 000 018 SIZE A 3 WIRE HARNESS ROUTED WITH HOSES WIRING OF SWITCH PLUG FOR PLUMBERS VAN PART NO a LOCATION ORN YEL WIRE INSERT SIDE OF SEE CONNECTOR SHOWN PRO AIR CONNECTOR GRN WIRE NOT USED AT REAR UNIT ot 14 GA GRN FRONT FAN SWITCH e LOW 14 CA YEL 18 CA YEL MOUNTED P d MEDIUM 14 GA RD 18 GA RD IN DASH 18 ORN 18 ORG 14 GA BLK
4. PRO CONNECTOR AT D PILLAR e Z gl a 4432 S Of sz 5 8 lt lt lt 15 ANP S 6 6 6 6 FUSE ee 14 ORN 14 GA WHT 14 GA WHT t 46514 7 RESISTOR BLOCK MED DRIVERS SDE REAR GRN WHT NOT USED CORNER OF VAN 4 IN LO gt gt z BLOWER MOTOR ula z 44 8 96 gt 5 5 5 14 GA ORN 14 GA ORN 14 GA RD 18 YEL RED 18 YELRED 42 18 GA YEURED Eu 87A 87 85 4 LOW FAN MEDIUM FAN HIGH FAN MOTOR RELAY MOTOR RELAY MOTOR RELAY 20 AMP 20 20 AMP 30 86 30 86 L L C 14 GA BLK 14 GA BLK 14 GA BLK 18 GA ORN 18 GA RED 18 GA RED 18 GA YEL 18 GA YEL 18 GA YEL C R GND AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING REV X SIGNATURES DATE TITLE PART NO 40 000 085 DRAWN 5 10 22 98 XO All REAR HEAT COOL WIRE SCHEMATIC SCALE Lo CWM 11 19 98 AIRTECH amp 1100 SERIES 1 1 0 X X 28731 USAGE SHET 1 OF 1 LET NO REVISION BY DATE APPROVED MRAZ 11 19 98 DODGE W HBC ProAir LLC PART NO 40 000 086 NOTES 1 HARNESS 125 INSULATE
5. For Chrysler vehicles ProA ir offers a switching option called L ast Touch Switch Control LTSC This system gives driver and passenger control of the rear fan through an electronic module Blower speeds are changed based on inputs given by either the front or rear switch whichever switch was last used is the one that changes the blower speed The driver s control switch has master shutoff of the system it must be in a position other than off for the rear switch to work The module is located near the rear unit The following pages contain wiring diagrams and installation instructions for the various modules Please contact ProA ir s customer service department for diagnosis or questions regarding this system ProAir LLC 1 7A NOTES 1 HARNESS 125 INSULATED WIRE EQUIVALENT TO SAE SPECIFICATION J1128 GXL 2 BLOWER MOTOR MAXIMUM AMP DRAW HIGH 12 MEDIUM 8 AMP LOW 5 AMP 3 DASHED WIRE DENOTES O E WIRES 4 WIRE HARNESS ROUTED WITH HOSES OEM CONNECTOR AT B PILLAR PART NO 40 000 087 22 GA RED ORN 18 GA YEL RED OEM d FRONT FAN 16 GA BLK LT BLU 18 GA YEL SWITCH 1 MOUNTED IN 16 GA BLK ORN i 18 RED DASH 1 18 ORN 14 GA
6. 11 19 98 X x X 28731 C R 6 ELKHART IN 46514 USAGE SHEET 1 OF 1 LET NO REVISION BY APPROVED MRZ 11 19 98 CMT W O YF7 ProAir LLC 3 6B General Motors G van GMT600 Last Touch Switch Control With or Without YF7 For General M otors vehicles ProAir offers a switching option called Last Touch Switch Control LTSC This system gives driver and passenger control of the rear fan through an electronic module Blower speeds are changed based on inputs given by either thefrontor rear switch whichever switch was last used is the one that changes the blower speed The driver s control switch has master shutoff of the system it must be in a position other than off for the rear switch to work The module is located near the rear unit The following pages contain wiring diagrams and installation instructions for the various modules Please contact ProA ir s customer service department for diagnosis or questions regarding this system ProAir LLC 3 7A NOTES 1 HARNESS 125 INSULATED WIRE EQUIVALENT TO SAE SPECIFICATION J1128 GXL 2 BLOWER MOTOR MAXIMUM AMP DRAW HIGH 12 MEDIUM 8 AMP LOW 5 3 DASHED WIRE DENOTES O E WIRES 4 WIRE HARNESS ROUTED WITH HOSES OFF GROUND RO AIR
7. 2000 General Motors Astro Safari Diagnosis Flow Chart Cooling Concerns w YF7 STEP 5 STEP 5 STEP 7 Recapture refrigerant from system using standard factory STEP 8 Call ProAir Customer Service Check auxiliary hoses for visible kinks or pinched areas Check hoses core and expansion valve for procedures blockage NOT OK Go to Step 5A NOT OK Go to Step 7A STEP 7A STEP 5A Repair as needed and Repair hoses and re check system recharge system using standard factory procedures Re check operation ProAir LLC 4 4B General Motors Astro Safari Diagnosis Flow Chart Cooling Concerns w o YF7 NOTES 1 Keep in mind the rear unit s performance is dependent on a properly operating dash system Rear A C temperatures should be checked at closest louver to ProAir unit The rear unit fan speed should be set on MEDIUM The vehicle s control head must be set to MAX A C The vehicle s temperature control lever should be at the max cold position The vehicle should be running above idle when performing cooling tests 1500 rpm s valve STEP 4 Check A C tee i i K Verify 221 RN Verify 2 de UE OK installation and location Go Step 5 Go to Step 2 Go to Step 3 En Go to Step 4 for correct assembly of dash system of rear system position water valve See factor ti 4 4D y connection should
8. DEFROST or FLOOR DEFROST mode the air conditioner continues to cycle and circulate refrigerant throughout the system output of rear heat will be moderated the DEFROST or FLOOR DEFROST position ProAir Unit R equirements This ProA ir unit contains Refrigerant 134a R 134a DO NOT add or replace with Refrigerant 12 R 12 F reon Adding R 12 to an R 134a system may cause component damage or poor A C system performance Use only PAG polyalkylene glycol synthetic lubricant within an R 134a system System Capacities ProMirRearUnit OEMDasUnt Tol Refrigerant 134a TUE R 134a 1100 62 oz 3 88 1b Refrigerant 134a 4 0 PAG lubricant 54H or GM equivalent all units 3 oz 8 oz 11 oz A nti freeze USE GM S DEX COOL COOLANT ONLY DEX COOL A dd approximately gallon of a 50 50 mixture of anti freeze and water all units to the van s cooling system when installing a ProAir rear unit NOTE Therefrigerant capacity for the ProAir rear unit should not be confused with the factory auxiliary rear unit which requires 24 oz 1 50 Ib of R 134a and is stated on the OE M sticker in the engine compartment on the front evaporator housing The ProAir sticker is located in this same area ProAir LLC 3 0 GENERAL MOTORS G VAN GMT600 FACTORY CONNECTION POINTS General Motors has procided for upfitters OEM connection points to interface with O
9. ProAir LLC 1 0 DODGE B VAN FACTORY CONNECTION POINTS W HBC The Chrysler Motor Corporation has provided for upfitters OEM connection points to interface with OEM heating cooling and electrical systems This package is labeled HBC 777 FOE DE OEM LIQUID LINE CONNECTION LOCATED AT PASSENGER SIDE BY OEM DASH UNIT P m x OEM SUCTION LINE CONNECTION LOCATED BY RADIATOR FILL OEM WATER LINE CONNECTIONS LOCATED BEHIND THE SUCTION CONNECTION d OEM SWITCH LOCATION AT THE DASH OEM ELECTRICAL CONNECTION LOCATED AT THE B PILLAR VAC LINE CONNECTION ProAir LLC 1 1 98mkcs01 DODGE B VAN FACTORY CONNECTION POINTS W O HBC For vehicles without the HBC package the locations for A C and heat connections are shown below OEM LIQUID LINE CONNECTION W O THE OEM SUCTION LINE CONNECTION W O THE HBC PACKAGE BY DASH HEATER HBC PACKAGE ABOVE FAN SHROUD ELECTRICAL CONNECTIONS FOR VEHICLES OEM WATER LINE CONNECTIONS W O THE W O THE HBC PACKAGE ARE MADE UNDER HBC PACKAGE UNDER THE HOOD THE HOOD SWITCH PANEL SHOWING LOCATION OF AUXILIARY SWITCH FOR UNITS W O THE HBC PACKAGE ProAir LLC 1 2 98mkcs02 Chrysler Dodge B Van Diagnosis Flow Chart Heat Concerns w HBC NOTES 1 Rear heat temperatures should be ch
10. Repair openin circuit between D pillar and relay Inoperative relay Replace medium speed relay No ground signal to resistor Repair open wire to resistor No ground signal out of resistor Replace resistor No ground signal to motor plug Repair open in wire or connector at motor plug No High Speed No ground signal to relay Repair open in circuit between D pillar and relay Inoperative relay Replace high speed relay No ground signal to resistor Repair open wire to resistor No ground signal to motor plug Repair open in wire or connector at motor plug Motor RunsContinuously 1 Stuck relay Replace relay Improperly wired connector Check connector Rewire harness Shorted wire Check for screw in harness M ismatched Blower 1 Incorrectly wired harness wires to OEM motor 1 Replace affected harness or connectors Speeds harness or resistor plug according to wiring diagram ProAir LLC 3 5B General Motors G van GMT600 Electrical Concerns Test Procedures Without YF7 Possible C ause Solution o l ProAir harness disconnected from OEM plug Reconnected and secure to prevent reoccurrence 2 ProAir harness disconnected from rear resistor harness 2 Reconnected and secure to prevent reoccurrence 3 Resistor plug disconnected from motor plug Reconnected and secure to prevent reoccurrence 4 Noor inadequate chassis ground Check wire terminal end and reground to chassis 5 6 No Bl
11. 18 GA YEL RD 14 CA WHT 14 WHT 5 GND lt 15 AMP FUSE x 14 CA ORN 14 CA WHT 14 CA ORN FUSE LOCATED 18 IN DRIVERS FUSE BLOWER MOTOR MED 14 GA RD SIDE REAR RESISTOR BLOCK E MN CORNER OF NOTE VAN 1 MUST BE FUSED WITH 15 AMP FUSE OR CIRCUIT BREAKER IF IGNITION R Q SOURCE WILL NOT HANDLE 15 AMPS ING 1o 14 GA YEL BLOWER MOTOR E o E USE POWER RELAY OPTIONAL 12 VOLT LJ lt 5 0 oo OPTIONAL POWER i az c RELAY B 4 5 595 9 FACTORY SS END 14GA BLK 86 L 85 16GA ORN IGNITION SOURCE 15 AMP IDOL FUSE 1 87 14GA RD TO ge 14 YEL 14 ORN TERMINAL 87 ON SNCH 18 GA YEL RD 18 GA YEL RD 18 GA YEL RD 12 VOLT BATTERY 87A 87 85 87A 87 85 87A 87 85 1 MEDIUM FAN HIGH FAN aL uM AL mee 30 20 AMP 30 30 14 CA BLK 14 CA BLK 14 GA BLK 18 CA ORG m 18 GA RD 18 CA RD LOCATED IN 18 CA YEL 18 CA YEL 18 CA YEL DRIVERS SIDE REAR CORNER OF GND AN Has AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING oe REAR HEAT COOL WIRE SCHEMATIC PARTNO DRAWN K F S 4 16 98 Q AIRTECH amp 1100 SERIES a own une PRO AIR LL
12. Diagnosis Flow Chart Heat Concerns w YF7 STEP 6 STEP 5 Check for correct OEM OK Check for kinked or OK STEP 7 OK STEP 8 water valve Normally Go to Step 6 pinched healer nose Go to Step 7 Check auxiliary Pieter Go to Step 8 open operation from OEM lines to core for blockage ProAir rear unit Call ProAir Customer Service NOT OK Go to Step 5A NOT OK Go to Step 6A NOT OK Go to Step 7A STEP 5A STOP This is an OEM part STEP 6A Remove kink or pinch STEP 7A Replace plugged Repair as necessary re check operation heater core Re check operation covered under GM warranty See Dealer for repair ProAir LLC 3 3B General Motors G Van GMT600 Diagnosis Flow Chart Heat Concerns w o YF7 NOTES 1 Rear heat temperatures should be checked at closest louver to ProAir unit 2 The rear unit fan speed should be set on HIGH 3 The vehicle must be at operating temperature 4 The vehicle should be running above idle when performing heat tests 1500 rpm s 5 The vehicle s control head must be set on floor mode for correct water valve operation STEP 2 STEP 3 STEP 1 Check coolant level Check for vacuum at 4 Check for correct water Verify proper operation Check coolant ProAir water valve No M Go to Step 2 Go to Step 3 Go to Step 4 Y of rear unit temperature Shou
13. 20 ft lb and the liquid line to 12 ft lb 3 Recharge the system according to factory procedures with the correct amounts of Pag Oil and R134a refrigerant 1100 COIL MINIMAX COIL AIRTECH COIL AIRTECH 11 COIL ProAir LLC 98mkrr02 5 2A LLC CUSTOMER SERVICE MANUAL REMOVE AND REPLACE INSTRUCTIONS HEAT COIL AirTech and MiniMax REMOVAL 1 Crimp off the heater hoses close to the power pack 2 Loosen the worm gear clamps and pull the hoses off the coil nipples 3 remove the two screws holding the coil plate to the case 4 Pull the coil out of the case REPLACE 1 Reverse the above procedure 2 Torque the worm gear clamps to 30 in Ib 3 Check the coolant level and add if necessary AIRTECH HEAT COIL MINIMAX HEAT COIL AIRTECH II HEAT COIL 5 2B 98csrr02 CUSTOMER SERVICE MANUAL REMOVE AND REPLACE INSTRUCTIONS BLOWER MOTOR REMOVE 1 Disconnect the wire harness at the motor plug 2 Remove the screw holding the motor retainer bracket to the front of the case 8 3 Slide the motor out from the bottom motor retainer REPLACE 1 Reverse the above procedure RESISTOR REMOVE 1 Disconnect the wire harness plug from the resistor 2 Remove the two screws holding the resistor to the case lid REPLACE 1 Reverse the above procedure 249 LA 207 REMOVE
14. 4 connections NOT OK Go to Step 4A NOT OK Go to Step 3A NOT OK Go to Step 2A STEP 4A Check fittings for proper connection and torque STEP 3A Check factory vacuum tee connection Yellow line under dash STEP 2A Review operating OK Re check operatio OK Re check operatio procedures and re check system WARNING DO NOT disconnect fittings without NOTE No vacuum at OEM yellow line in A C mode is an OEM problem Consult Dealer for repairs recapturing refrigerant using standard shop procedures ProAir LLC 3 4A 2000 General Motors G Van GMT600 Diagnosis Flow Chart Cooling Concerns w YF7 STEP 5 STEP 5 STEP 7 Recapture refrigerant from system using standard factory STEP 8 Call ProAir Customer Service Check auxiliary hoses for visible kinks or pinched areas Check hoses core and expansion valve for procedures blockage NOT OK Go to Step 5A NOT OK Go to Step 7A STEP 7A Repair as needed and recharge system using standard factory procedures Re check operation STEP 5A Repair hoses and re check system ProAir LLC 3 4B General Motors G Van GMT600 Diagnosis Flow Chart Cooling Concerns w o YF7 NOTES 1 Rear A C temperatures should be checked at closest louver to ProAir unit The rear unit fan speed should be set on MEDIUM The vehicle s control head must be set
15. Consult Dealer for repair and repair previous splice area Re check operation ProAir LLC 1 3A STEP 5 Check ProAir water valve operation Normally open NOT OK Go to Step 5A STEP 5A Remove water valve and check operation Replace if flow is blocked with no vacuum present 2000 Chrysler Dodge B Van Diagnosis Flow Chart Heat Concerns w HBC STEP 6 Check for kinked or pinched heater hose from Factory lines to ProAir rear unit NOT OK Go to Step 6A STEP 6A Remove kink or pinch Repair as necessary re check operation OK Go to Step 7 ProAir LLC 1 3B STEP 7 OK STEP 8 Check auxiliary heater Go to Step 8 core for blockage Call ProAir Customer Service NOT OK Go to Step 7A STEP 7A Replace plugged heater core Re check operation Chrysler Dodge B Van Diagnosis Flow Chart Heat Concerns w o HBC NOTES 1 Rear heat temperatures should be checked at closest louver to ProAir unit 2 The rear unit fan speed should be set on HIGH 3 The vehicle must be at operating temperature 4 The vehicle should be running above idle when performing heat tests 1500 rpm s 5 The vehicle s control head must be set on floor mode for correct water valve operation STEP 2 STEP 3 STEP 1 OK Check coolant level OK Check for vacuum at OK Check e walter OK Verify proper operatio
16. Diagnosis Flow Chart Cooling Concerns w 57X STEP 5 STEPS STEP 7 Check auxiliary hoses OK 2 Check hoses core and OK for visible kinks or Go to Step 6 y 9 Go to Step 7 expansion valve for Go to Step 8 standard factory pinched areas procedures blockage NOT OK Go to Step 5A NOT OK Go to Step 7A STEP 7A STEP 5A Repair as needed and Repair hoses and re check system recharge system using standard factory procedures Re check Operation ProAir LLC 2 4B STEP 8 Call ProAir Customer Service STEP 1 Verify proper operation of dash system NOT OK Go to Step 1 STEP 1A Diagnose dash concerns before making repairs to rear system NOTE Follow standard diagnosis procedures for determining inoperative A C system factory or auxiliary units OK Go to Step 2 Ford Econoline Van Diagnosis Flow Chart Cooling Concerns w o 57X NOTES Keep in mind the rear unit s performance is dependent on a properly operating dash system Rear A C temperatures should be checked at closest louver to ProAir unit The rear unit fan speed should be set on MEDIUM The vehicle s control head should be set in the MAX A C mode The vehicle s temperature control lever should be at the cold position The vehicle should be running above idle when performing cooling tests 1500 rpm s 1 2 3 4 5 6 STEP 2 Verify proper operation of
17. LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING PART NO 40 000 093 GM OEM CONNECTORS AT D PILLAR REAR AUXILIARY A C BLOWER SPEED CONTROL CIRCUITS YEL LOW 18 GA YEL TAN MED 18 GA TAN ORG HIGH 18 ORN BRN ING 18 GA BRN us RED 12V DC 14 GA RED BLK GROUND 14GA BLK REAR AUXILIARY AIC FEED amp GROUND HARNESS CONNECTION POINT AT LAST TOUCH MODULE 18 GRN 18 BLK z a ME a mox sus q lt lt 1 1 9 0 0 9 9 2 sm 2 2 BLOWER MOTOR x BLOWER MOTOR MED RESISTOR BLOCK PRO AIR CONNECTOR AT D PILLAR 14 GA ORN li GN LO y al 2 58658646 2 x x 444 5 6 5 5 5 5 a alz 2 2 2 S lt x 555 14 CA ORN 18 CA BLU 14 GA RD 18 GA YEL LOW 14 CA YEL 18 GA BRN MEDIUM e 15 AMP HIGH LAST TOUCH MODULE 18 YEL 18 YEL 18 GA BRN PASSENGER REAR 18 GA RD 18 GA RD 18 GA YEL CONTROL SWITCH 18 GA ORN 18 GA ORN 18 GA BLU ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING REV X SIGNATURES DATE TITLE PART NO 40 000 093 DRAWN K F S 10 26 98 PRO AIR LL C REAR HEAT COOL WIRE SCHEMATIC x CHG GM OEM CONNECTORS D PILLAR KFS 5 8 00 CHECKED 11 19 98 AIRTECH amp 1100 SERIES SCALE 1
18. ProAir LLC 2 5 Ford Econoline Electrical Concerns Test Procedures With 57X or 57L Possible C ause Solution 0 0 No Blower Speeds No 12V signal from OEM source 1 Consult OEM manual for diagnosis of this circuit No 12V power on motor plug 2 Repair openin circuit from source to connection M otor plug disconnected 3 Reconnect and secure to prevent reoccurrence 1 No Low Speed Open circuit on yellow wire Check yellow wire from ProAir connector to resistor Repair open in line Loose resistor connection 2 Check connection terminal R epair as necessary Inoperative resistor 3 Replace resistor No M edium Speed Open circuit on red wire 1 Check red wire from ProAir connector to resistor Repair open in line Loose resistor connection 2 Check connection terminal Repair as necessary Inoperative resistor 3 Replaceresistor No High Speed Open circuit on orange wire 1 Check orange wire from ProAir connector to resistor Repair open in line No ground to relay 2 Check ground source Reground if necessary Inoperative high blower relay 3 Replacerelay No ignition power to relay 4 Check for open circuitin pink wire or open relay connection Repair open in line Motor RunsContinuously 1 Stuck high speed relay 1 Replace relay Red yellow or orange wire shorted to ground 2 Isolate each circuit to determine cause Repair short to ground M ismatched Blower 1 Incorrectly wired harness wires to OEM mo
19. SCREWS ProAir LLC 98mkrr04 5 3 BERR CUSTOMER SERVICE MANUAL REMOVE AND REPLACE INSTRUCTIONS RELAY REMOVE 1 Disconnect the wire harness plug from the relay 2 Remove the phillips drive screw from the relay 3 Remove the relay REPLACE 1 Reverse the above procedure REMOVE SCREW HERE THERMAL EXPANSION VALVE REMOVE 1 Connect a refrigerant recapturing recycling machine to the service valves and recover the refrigerant from the system according to factory procedures 2 Remove the refrigerant tape covering the expansion valve and coil fitting 3 Disconnect the liquid hose from the expansion valve with a 5 8 open end wrench at the valve and a 3 4 open end wrench a the hose fitting 4 Remove the bulb clamp from the coil suction tube 5 Disconnect the expansion valve from the coil with a 5 8 open end wrench and a 7 8 open end wrench REPLACE 1 Reverse the above procedure tighten the fittings to 12 ft lb BULB CLAMP ORIENTATION OF BULB CLAMP ON THE SUCTION TUBE IS CRITICAL PLACE BULB AT THE FOUR O CLOCK POSITION AS SHOWN END VIEW OF TUBE ProAir LLC 98mkrr03 5 4 CUSTOMER SERVICE MANUAL REMOVE AND REPLACE INSTRUCTIONS HEATER HOSE REMOVE 1 Loosen the radiator cap to relieve pressure on the system 2 Position a catch basin under the OEM heater hose c
20. WIRE DENOTES WIRES FORD OEM CONNECTOR L_ 87 14 ORN AT D PILLAR 30 L 87A 18 ORN 18 ORN 18 RD WHT HIGH 18 RD 18 GA RD 212214 GA BLUWHT e MOTOR RELAY ze 5 9 20 18 CA YEL 18 CA YEL gt 14 GA YEL RD ALL RELAYS 2 mcm 1 85 86 18 GA RD 18 CA YEURD 18 YEURD 18 GA YEURD SIDE REAR 14 CA WHT 14 CA WHT 10 CA YEL BLK CORNER OF j e e Sis dU CAE as 2187 14 GA RD 15 AMP C FUSE FUSE LOCATED MEDIUM FAN IN DRIVERS MOTOR RELAY SIDE REAR FORD OEM WIRE 20 CORNER HARNESS ROUTED VAN FROM B PILLAR Bc TO D PILLAR ag 235 85 86 18 GA YEL z EE 20204 gos 2 lt lt lt 2 2 2 30 87 14 GA YEL 9 TA pt Bom L 87A LOW FAN a a 18 GRN 18 GA GRN x MOTOR RELAY al 20 555 lt FORD WIRE 5 HARNESS ROUTED FROM B PILLAR TO DASH 14 GA YEL rU 14 GA RD 2 8 14 ORN z 10 GA YEL BLK ER 1 amp NIU EN 14 18 CA YEL RD Sees lt e 2 2 Eo Pale 14 0 Fae zzi lt lt i GND SWITCH 5 6866 lt lt MOUNTED DIODE HOT IGN HOT CI ow OCIO 9 e ON SIDEWALL OFF gt T OFF gt 14 GA RD MED
21. Wiring Diagrams with and without YF7 Diagnosis Flowchart Airflow Concerns Power Pack Exploded Parts View MiniMax and 1100 Hose Assemblies Repair Procedures Power Pack Coil Evaporator and Heater all models Blower Resistor Relay Expansion Valve Heater Hose Assemblies Refrigerant Hose Assemblies Warranty Statement ProAir Warranty Procedures Technical Information Bulletins TIBs ProAir LLC Section 1 0 Chrysler Dodge B Van ProAir Unit Location Although location may vary by converter the ProAir unit is usually located on the driver s side rear corner inside the interior wall A C and heater hoses are routed over the wheel well inside the interior wall and drop through the floor behind the gas fill they are then routed forward into engine compartment See page 1 1 or 1 2 Factory Connection Points The air ducts also attach to the unit at this point and continue up the wall into the ceiling CAUTION Located near the unit and built into the wall is a vent which must be kept clear to maintain adequate airflow through the evaporator Do not block off this vent Also the louvers in the ceiling must be partially open while the unit is operating If the louvers are completely closed air backup will result in possible damage to the blower assembly ProAir Unit Operation The rear air conditioning system will function with the dash mode control positioned in one of the air conditioning settings The rear heatin
22. be closed No points W O YF7 coolant to rear NOT OK NOT OK NOT OK NOT OK Go to Step Go to Step Go to Step Go to Step 1 2 4 TA STEP 2 STEP 3A Diagnose dash Review operating ProAir water valve must OK Recharge system OK concerns before procedures and be connected to Yellow Re check according to factory Re check making repairs to rear re check system OEM vacuum line operatio procedures operatio System below the radio WARNING NOTE DO NOT disconnect Follow standard fittings without diagnosis procedures recapturing the for determining refrigerant using inoperative A C system standard shop factory or auxiliary procedures units ProAir LLC 4 4 2000 General Motors Astro Safari Diagnosis Flow Chart Cooling Concerns w o YF7 STEP 5 STEP 5 STEP 7 Recapture refrigerant from system using standard factory STEP 8 Call ProAir Customer Service Check auxiliary hoses for visible kinks or pinched areas Check tees hoses core and expansion procedures valve for blockage NOT OK Go to Step 5A NOT OK Go to Step 7A STEP 7A Repair as needed and recharge system using Repair hoses and standard factory re check system procedures Re check operation STEP 5A ProAir LLC 4 4D General Motors Astro Safari Electrical Concerns With or Without YF7 With Y F7 the Astro Safari vans are equipped with OEM wiring from the dash mounted switch to the driver s side under
23. customer service department for procedures to access these components ProAir LLC 4 8 2 LLC CUSTOMER SERVICE MANUAL ASTRO SAFARI MINIMAX POWER PACK ASSEMBLY PART NUMBER 66 000 015 66 000 015 POWER PACK ASSEMBLY 68 000 005 BLOWER MOTOR W SEAL 05 000 141 EXPANSION VALVE 60 000 287 O RING KIT 01 000 091 RESISTOR 03 000 055 HEAT COIL 03 000 036 EVAPORATOR COIL 60 000 287 O RING KIT 4 9A m are m imr CUSTOMER SERVICE MANUAL ASTRO SAFARI POWER PACK 1100 SERIES ASSEMBLY PART NUMBER 66 000 012 66 000 012 Power pack ass y 01 000 091 Resistor 05 000 141 Expansion valve 60 000 287 O ring kit 03 000 037 Coil heat cool 60 000 287 O ring kit 68 000 005 Blower motor w seal ProAir LLC 4 9B 98mkcs13 T o 77 ESECLE V LLC CUSTOMER SERVICE MANUAL Lengths and fittings may vary depending on the chassis ProAir unit serial number and model number should provide a reference point to correctly identify hose assemblies 4 10 98cs01 Section 5 0 Repair Procedures In our ongoing effort to improve our product we at ProAir use the valuable data we receive from our inspection of returned warranty parts As a result we require the return of the following wa
24. fittings without recapturing the refrigerant using standard shop procedures 2000 General Motors G Van GMT600 Diagnosis Flow Chart Cooling Concerns w o YF7 STEP 5 STEP 5 STEP 7 Recapture refrigerant from system using standard factory STEP 8 Call ProAir Customer Service Check auxiliary hoses for visible kinks or pinched areas Check tees hoses core and expansion procedures valve for blockage NOT OK Go to Step 5A NOT OK Go to Step 7A STEP 7A Repair as needed and recharge system using Repair hoses and standard factory re check system procedures Re check operation STEP 5A ProAir LLC 3 4D General Motors G van GMT600 Electrical Concerns With of Without YF7 GMT 600 vans are equipped with OEM wiring from the dash mounted switch to the driver s side D pillar of the van Start diagnosis of electrical concerns at the D pillar connectors The electrical system GMT 600 vehicles is 12 volts DC The switching to the auxiliary unit is done on the ground side of the circuit When starting diagnosis of the electrical concern disconnect the ProA ir harness from the OEM harness and check the chassis connectors for the following inputs Black Connector Red wire 12V DC battery positive Black wire Chassis ground Gray Connector Brown wire 12V DC ignition switched with key Yellow wire Grounded in low speed on auxiliary dash switch Tan wire Grounded in medium spe
25. rear system NOT OK Go to Step 2A STEP 2A Review operating procedures and re check system OK Go to Step 3 STEP 3 Check water valve operation when in A C OK Go to Step 4 mode max cold position Water valve should be closed No coolant to rear NOT OK Go to Step 3A STEP 3A Check vacuum line from water valve to OEM connection under dash for cuts or pinched areas Check OEM blue line for vacuum in A C modes OK Re check operation NOTE No vacuum at OEM blue line in A C mode is an OEM problem Consult Dealer for repairs ProAir LLC 2 4C STEP 4 Check auxiliary connections at condenser liquid line and compressor suction line for proper connection points See page 2 2 for details NOTO Go to Step 4A STEP 4A Make connections as shown on page 2 2 WARNING DO NOT disconnect fittings without recapturing refrigerant using standard shop procedures Go to Step 5 OK 2 4D OK Re check operatio 2000 Ford Econoline Van Diagnosis Flow Chart Cooling Concerns w o 57X STEP 5 STEPS STEP 7 Check auxiliary hoses OK 2 Check hoses core and OK for visible kinks or Go to Step 6 y 9 Go to Step 7 expansion valve for Go to Step 8 standard factory pinched areas procedures blockage NOT OK Go to Step 5A NOT OK Go to Step 7A STEP 7A STEP 5A R
26. receive payment on these warranty claims 6 ProAir reserves the right to deny any claims without the proper documentation or claims that were for improper repairs Service management is responsible for implementing controls to eliminate improper or unnecessary repairs and providing accurate information on the claims This includes a complete and clear description of the vehicle s concern and required repairs ProAir 28731 County Road 6 Elkhart Indiana 46514 219 264 5494 800 338 8544 Updated 13 October 2000 J Docs Warranty Forms Procedur Doc BE LLC TECHNICAL INFORMATION BULLETIN LUBRICATING O RINGS It is very important that all o rings be lubricated just prior to installation It is equally important to use the proper oil for lubricating o rings You must use a Mineral Oil to lubricate o rings The purpose of oiling o rings is to allow the o ring seat properly without rolling twisting or pinching CAUTION Never use PAG oil polyalkylene glycol to lubricate o rings PAG oil is soluble in water retains moisture and will cause joints to corrode and seize ProAir LLC 28731 County Road 6 Elkhart IN 46514 uc em ame TECHNICAL INFORMATION BULLETIN mee REVIEW OF PROAIR UNIT OPERATING INSTRUCTIONS 1 Rear auxiliary air conditioning will function with the dash mode control positioned in the Max A C or NORM location These are the settings where maximum cooling wi
27. wear of service items shall not be considered defects under this warranty This warranty does not cover customer lost time vehicle towing vehicle rental or lodging This warranty does not include consequential damages and ProAir shall not be responsible for any such damages ProAir does not make and does not authorize any person to make for it any warranty other than the foregoing warranty Such other warranties if any as may be imposed or implied by law are limited in duration to the duration of this written warranty Some states do not allow limitations on how long an implied warranty lasts nor do they allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply This warranty gives specific legal rights and other rights which vary from state to state This warranty does not cover loss of refrigerant unless the loss is a direct result of a defect covered by this warranty ProAir LLC 28731 County Road 6 Elkhart Indiana 46514 Telephone 219 264 5494 800 338 8544 Fax 219 264 2194 ProAir LLC 6 0 ProAir Warranty Procedures 1 The repair facility must contact ProAir by calling 219 264 5494 or 800 338 8544 ask for the customer service department The following information is required ProAir serial number and model number vehicle serial number mileage retail purchase date and retail customer s name The installers of ProAir s air conditioning units apply an
28. 1 0 Pam m 2l GUT MUT 111998 29731 CR 6 ELKHART IN 46514 ProAir LLC 3 7B NOTES PRO AIR CONNECTOR PART NO 40 000 094 1 HARNESS 125 INSULATED WIRE AT A PILLAR EQUIVALENT TO SAE SPECIFICATION J1128 TYPE GXL 2 BLOWER MOTOR MAXIMUM 20 GA GRY INGMON DRAW HIGH 12 20 GA BLK GROUND MEDIUM 8 AMP LOW 5 AMP 14 GA ORN POWER SOURCE 3 DASHED WIRE DENOTES O E WIRES 4 WIRE HARNESS ROUTED WITH HOSES 20 GA GRY BLK NOT USED OFF 2 Low 16 BLU 18 YEL FRONT SWITCH MEDIUM 16 GA RED 1 18 RED MOUNTED IN e DASH 7 HIGH 16 GA WHT i 18 ORN HARNESS CONNECTION POINT UNDER DASH 14 RED 14 RED 14 GA RED 14 CA RED 16 GA ORN mms HARNESS CONNECTION POINT 14 GA BLK AT LAST TOUCH MODULE GND 18 GA GRN 18 GA GRN 18 GA GRN 87A 87 85 i 1 POWER RELAY BLOWER MOTOR GND ill LUE RESISTOR BLOCK 30 86 ME HI z 14 GA RD x 9 amp a 2 o S 8 16 GA ORN lt lt lt lt lt lt 5 5 5 9 BLOWER MOTOR 15 EE FUSE MED 14 G
29. 18 GA GRN 18 GA GRN 18 GRN 1 1 1 1 GND ill BLOWER MOTOR RESISTOR BLOCK x 9 9 a 8 E ME a Sie HI x zx lt 9 6 0 0 0 EAE BLOWER MOTOR MED Y PRO AIR CONNECTOR AT D PILLAR 9 14 ORN 14 BLK li END 2 LO l al al gt a 2 8 41444 6 6 ol 6 9 9 g 8 2 3 2 2 2 lt x x 6 5 9 14 ORN 18 CA BLU OFF 14 GA RD 18 YEL e 14 CA YEL 18 GA BRN 15 FUSE e HIGH 18 YEL 18 YEL 18 GA BRN GROUND PASSENGER REAR 18 RD 18 GA RD 18 GA YEL CONTROL SWITCH 18 GA ORN 18 ORN 18 BLU LAST TOUCH MODULE RO AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING liza a ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING RV X SIGNATURES DATE PART 40 000 101 DRAWN KES 10 27 98 PI LL C REAR HEAT COOL WIRE SCHEMATIC AIRTECH amp 1100 SERIES SCALE 1 0 SIZE 11 19 98 X 28731 C R 6 ELKHART IN 46514 USAGE SHEET 1 OF 1 TS NO Wi DATE APPROVED MARZ 11 19 98 ASTRO W amp W O YF7 amp LAST TOUCH SW ProAir LLC 4 7B General Motors Astro Safari Airflow Concerns The first step in diagnosing an
30. 1A Diagnose dash concerns before making repairs to rear system OK Re check operatio STEP 2A Review operating OK Re check operatio procedures and re check system NOTE Follow standard diagnosis procedures for determining inoperative A C system factory or auxiliary NOTE OEM water valve works off of temperature lever Consult Dealer Service for diagnosis of this part ProAir LLC 1 4A WARNING DO NOT disconnect fittings without recapturing the refrigerant using standard shop procedures 2000 Chrysler Dodge B Van Diagnosis Flow Chart Cooling Concerns w HBC STEP 5 SIE STEP 7 Recapture refrigerant expansion valve for standard factory blockage procedures STEP 8 Call ProAir Customer Service Check auxiliary hoses for visible kinks or pinched areas NOT OK Go to Step 5A NOT OK Go to Step 7A STEP 7A Repair as needed and recharge system using standard factory procedures Re check Operation STEP 5A Repair hoses and re check system ProAir LLC 1 4B Chrysler Dodge B Van Diagnosis Flow Chart Cooling Concerns w o HBC STEP 1 OK Verify proper operation Go to Step 2 of dash system NOT OK Go to Step 1 STEP 1A Diagnose dash concerns before making repairs to rear system NOTE Follow standard diagnosis procedures for determining inoperative
31. 5 SIDE REAR 4 LOW FAN p MEDIUM FAN 4 HIGH FAN CORNER OF 1 MOTOR RELAY 1 MOTOR RELAY 1 MOTOR RELAY VAN 91 20 AMP 20 AMP 20 AMP 30 86 30 86 30 86 14 BLK 14 GA BLK 14 GA BLK 18 GA ORG e 18 GA RD 18 GA RD 18 GA YEL 18 GA YEL 18 GA YEL RO AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING REV ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING X SIGNATURES DATE TME PART NO DRAWN K F S 4 17 98 PRO AIR LL C REAR HEAT COOL WIRE SCHEMATIC 20080022 CWM 11 19 08 5 AIRTECH amp 1100 SERIES SCALE 1 0 A RERO x X APPROVED 7 11 19 98 28731 C R6 ELKHART IN 46514 USAGE FORD VAN W 57X amp 57L amp NO REAR SW SHEET 1 OF 1 ProAir LLC 2 6A 18 GA YEURD NOTES 1 HARNESS 125 INSULATED WIRE EQUIVALENT TO SAE SPECIFICATION 41128 GXL 2 FORD VAN W 57X amp 57L AND REAR PASSENGER FAN CONTROL SWITCH 3 BLOWER MOTOR MAXIMUM PART NO 40 000 021 DRAW HIGH 12 CRM 1 85 86 18 ORN 4 DASHED
32. 8 Remove the power pack REPLACEMENT 1 Reverse the above procedure 2 When re connecting the hoses torque the suction hose to 20 ft Ibs and the hose to 12 ft lb and the heater hose clamps to 30 10 65 3 Be sure to put the proper amounts of Pag Oil and R134a refrigerant back into the system 1100 SERIES POWER PACK AirTech POWER PACK AirTech II POWER PACK 5 1 98csrr01 g HERK CUSTOMER SERVICE MANUAL REMOVE AND REPLACE INSTRUCTIONS EVAPORATOR COIL REMOVE 1 Connect a refrigerant recapturing recycling machine to the service valves and recapture the refrigerant from the system according to factory procedures 2 Remove the screws attaching the duct adapter to the case lid 3 Remove the refrigerant tape around the coil fittings at the hoses 4 Disconnect the liquid hose with 5 8 open end wrench and a 3 4 open end wrench 5 Disconnect the suction hose with a 7 8 open end wrench on the hoses fitting a a 1 1 16 wrench on the coil fitting 6 Loosen the worm gear clamps from the heater hoses and remove the heater hoses 7 Remove the screw that fastens the case lid bracket to the wall 8 Disconnect the wire harness from the resistor and unscrew the relays at the lid 9 Remove the four spring clips attaching the lid to the case bottom 10 Remove the coil from the case bottom REPLACE 1 Reverse the above procedure 2 Torque the suction line to
33. A RD 14 CA ORN 14 CA BLK PRO AIR CONNECTOR GND AT D PILLAR 1 LO x o amp HO SE E E 12 VOLI D C BATIERY Xx g lt lt 5 E 2 5 6 6 5 5 5 18 GA GRN O 9 aia ia 14 GA ORN 18 GA BLU OFF 14 GA RD 18 GA YEL LOW 14 CA YEL 18 GA BRN MEDIUM e 15 AMP FUSE e HIGH 18 YEL 18 YEL 18 GA BRN GROUND PASSENGER REAR 18 GA RD 18 GA RD 18 GA YEL CONTROL SWITCH 18 GA ORN 18 ORN 18 BLU LAST TOUCH MODULE RO AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING REV X SIGNATURES DATE TITLE PART NO 40 000 094 DRAWN K F S 10 26 98 PRO AIR LL REAR HEAT COOL WIRE SCHEMATIC SCALE 1 0 SIZE CHECKED CWN 1119 98 AIRTECH amp 1100 SERIES 121 0 A X X 28731 C R 6 ELKHART IN 46514 USAGE SHET 1 OF 1 TS NO Wi DATE APPROVED MARZ 11 19 98 GMT W O 7 amp LAST TOUCH SW ProAir LLC 3 7C General Motors GMT600 G van Airflow Concerns The first step in diagnosing any concern is to get as specific as possible with it In order to help prevent misdiagnosis and ineffective costly repairs categorize the airflow concern into one of the following general
34. A C system factory or auxiliary units NOTES 1 Rear A C temperatures should be checked at closest louver to ProAir unit The rear unit fan speed should be set on MEDIUM The vehicle s control head must be set to MAX A C The vehicle s temperature control lever should be at the max cold position 3 Check water valve STEP 2 operation when in A C OK Go to Step 3 mode max cold position Water valve should be closed No coolant to rear Verify proper operation of rear system NOT OK Go to Step 3A NOT OK Go to Step 2A STEP 3A ProAir water valve should be connected to brown OEM vacuum line behind glove compartment STEP 2A Review operating procedures and re check system NOTE OEM water valve works off temperature lever Consult Dealer Service for diagnosis of this part ProAir LLC 1 4C Keep in mind the rear unit s performance is dependent on a properly operating dash system The vehicle should be running above idle when performing cooling tests 1500 rpm s OK Go to Step 4 OK Re check operatio STEP 4 Check A C tee installation and location OK Go to Step 5 1 4D for correct assembly See factory connection points W O HBC NOT OK Go to Step 4A STEP 4A Install tee s correctly Recharge system according to factory procedures OK Re check oper
35. AirTech H C POWER PACK ASSEMBLY PART NUMBER 60 000 587 60 000 587 POWER ASS Y N 03 000 042 HEAT COIL 95 03 000 043 EVAPORATOR COIL 60 000 287 O RING 05 000 141 EXPANSION VALVE 60 000 287 O RING CA 68 000 005 BLOWER MOTOR W SEAL nN 101 000 091 RESISTOR 3 9A 98CS110 ABRED ADIER CUSTOMER SERVICE MANUAL GM GMT600 POWER PACK 1100 SERIES ASSEMBLY PART NUMBER 66 000 011 66 000 011 Power pack ass y 101 000 091 Resistor 95 05 000 141 Expansion valve 60 000 287 O ring kit 03 000 037 Coil heat cool 60 000 287 O ring kit 68 000 005 Blower motor w seal ProAir LLC 98mkcs10 3 9B T o 77 ESECLE V LLC CUSTOMER SERVICE MANUAL Lengths and fittings may vary depending on the chassis ProAir unit serial number and model number should provide a reference point to correctly identify hose assemblies 98cs01 Section 4 0 General Motors Astro Safari Van ProAir Unit L ocation Although location may vary by converter the ProAir unit is usually located on the driver s side rear corner insidetheinterior wall A C and heater hoses are routed over the wheel well inside the interior wall and drop through the floor behind t
36. BLK 12 GA RED GRN M WHT BATTERY e 22 GRNWHT GRN WHT NOT USED e Z a amp 89 alg S O a S amp GND x za lt 6 6 o 9 9 e HARNESS CONNECTION POINT AT LAST TOUCH MODULE 18 GRN 18 18 PRO AIR CONNECTOR AT D PILLAR GND ill 8 amp z 1 Z ME a sos ss HI x 414144 9 0 6 9 81068 BLOWER MOTOR BLOWER MOTOR MED RESISTOR BLOCK PRO AIR CONNECTOR AT D PILLAR 14 GA ORN li GN LO z H gt gt 9 3 a z lt 5 5 5 5 5 9 za 2 2 2 2 S lt x 5 5 9 14 CA ORN 18 CA BLU OFF 14 GA RD 18 GA YEL LOW 14 CA YEL 18 GA BRN MEDIUM e 15 AMP e HIGH FUSE LAST TOUCH MODULE 18 YEL 18 YEL 18 GA BRN GROUND PASSENGER REAR 18 GA RD 18 GA RD 18 GA YEL CONTROL SWITCH 18 GA ORN 18 GA ORN 18 GA BLU RO AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING x SIGNATURES DATE PART 40 000 087 DRAWN K F S 10 23 98 All 2 LL C REAR HEAT COOL WIRE SCHEMATIC AIRTECH amp 1100 SERIES SCALE 1 0 SIZE 11 19 98 150 A X X X 28731 C R 6 ELKHART IN 46514 USAGE SHEET 1 OF 1 NO
37. D z 2 2 amp HI a lt lt lt lt _ 15 AMP 0 0 0 9 9 FUSE ES SE es 14 CA ORN 14 CA RED 14 CA RED La BLOWER MOTOR MED RELO WER MOIDI DRIVERS SIDE REAR CORNER OF VAN BLOWER MOTOR a z S 510 5 5 amp x z z 14 ORN 14 CA ORN CA TAN 18 BRN 18 BRN 18 BRN 87A 87 85 87A 85 5 LOW FAN D MEDIUM FAN HIGH FAN MOTOR RELAY MOTOR RELAY MOTOR RELAY 20 20 20 30 86 30 86 14GA BLK 14 GA BLK 14 GA BLK 18 GA ORN 18 TAN 18 GA TAN 18 GA YEL 18 GA YEL 18 GA YEL RO AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING REV X SIGNATURES DATE TITLE PART NO 40 000 091 DRAWN K F S 10 26 98 XO LL C REAR HEAT COOL WIRE SCHEMATIC AIRTECH amp 1100 SERIES SCALE 1 0 SIZE 11 19 98 x X X 28731 C R 6 ELKHART IN 46514 LET NO BY Dag APPROVED MRZ 11 19 98 GE GMT PEE poer d ProAir LLC PART NO 40 000 092 NOTES 1 HARNESS 125 INSULATED WIRE EQUIVALENT TO SAE SPECIFICATION J1128 TYPE GXL 2 BLOWER MOTOR MAXIMUM AMP DRAW 14 GA RED HIGH 12 AMP MEDIUM 8 AM
38. D WIRE EQUIVALENT TO SAE SPECIFICATION J1128 TYPE GXL 2 BLOWER MOTOR MAXIMUM DRAW HIGH 12 AMP HARNESS ROUTING PRO AIR CONNECTOR MEDIUM 8 AMP FROM SWITCH TO PILLAR AT D PILLAR DASHED WIR FRONT FAN 3 DASHED WIRE DENOTES O E WIRES ONT 7 oW bie Gave MOUNTED IN DASH e MEDIUM 16 GA RED i 18 GA RED 1 7 HIGH 16 GA ORN i 18 GA ORN 14 GA BLK ES a lt 14 GA BLK 87A 187 85 4 POWER RELAY 30 86 16 GA ORN ING POWER 20 GA RED 8 0 lt M 15 AMP BLOWER MOTOR 8 5 14 GA BLK li 216 F4 lt POS NEG 9 GND BLOWER MOTOR 12 VOLT D C BATIERY RESISTOR BLOCK HI 2 18 ORN MED 18 GA RED LO 18 GA YEL RO AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING ROM PRO AR LLC TO USER SPECIFICALLY REFERRING THIS DRAWING Rev X SIGNATURES DATE TE PART NO 40 000 086 DRAWN K F S 10 23 98 LL REAR HEAT COOL WIRE SCHEMATIC AIRTECH amp 1100 SERIES SCALE 1 0 SIZE _ 11 19 98 X x X 28731 C R 6 ELKHART IN 46514 USAGE SHEET 1 OF 1 LET NO REVISION BY pae MRZ 11 19 98 DODGE W 0 HBC ProAir LLC 1 6B Chrysler Dodge B van Last Touch Switch Control With or Without HBC
39. EM heating cooling and electrical systems This package is labeled YF7 and consists of the following OEM LIQUID LINE PRO AIR HOSE CONNECTION OEM WATER LINE CONNECTIONS AT B PILLAR tep OEM SUCTION LINE CONNECTION AT ENGINE COMPRESSOR OEM WTR VLV AT PA DE UNDER VAN OEM VACUUM CONNECTION LOCATION UNDER ZO THE DASH AT THE PASSENGER SIDE ELECTRICAL CONNECTIONS AT D PILLAR DRIVERS SIDE INSTRUMENT PANEL SWITCH LOCATION lt VACUUM TEE LOCATION ProAir LLC 98mkcs09 3 1 GMT600 FACTORY CONNECTION POINTS W O YF7 General Motors has provided for upfitters on vehicles without the connector package the connections shown below for the refirgerant hoses and heater hoses LIQUID LINE CONNECTION POINT W O SUCTION LINE CONNECTION POINT W O CONNECTOR PACKAGE CONNECTOR PACKAGE HEATER HOSE CONNECTIONS AND WATER VALVE INSTALLTION W O CONNECTOR PACKAGE CUT OFF FLAT CONN amp TAPE BACK THE GRAY BLACK WIRE RESISTOR PLUG MOTOR PLUG GRD ELECTRICAL CONNECTIONS ON VEHICLES W O CONNECTOR PACKAGE 3 2 98cs31a General Motors G Van GMT600 Diagnosis Flow Chart Heat Concerns w YF7 NOTES 1 Rear heat temperatures should be checked at closest louver to ProAir unit The rear unit fan speed should be set on HIGH The vehicle must be at operating temperature The vehicle shoul
40. ITH HOSES 20 GA GRVIBLK NOTUSED PRO AIR CONNECTOR AT A PILLAR OFF LOW 16 GA BLU 14 YEL FRONT FAN f SWITCH MEDIUM 16 GA RED 14 GA RED MOUNIED IN DASH 7 HIGH 16 GA WHT 14 GA ORN BLOWER MOTOR RESISTOR BLOCK Z ol a ME 8 E HI Xx zx ox 0 9 BLOWER MOTOR MED PRO AIR CONNECTOR AT D PILLAR 14 GA ORN 14 GA BLK m LO 9 8 gt gt te Ed Ed lt lt lt o6 9 xx muc 14 GA ORN 14 GA RD 14 GA YEL RO AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING X SIGNATURES DATE PART NO 40 000 100 DRAWN K F S 10 27 98 PRO AIR LL REAR HEAT COOL WIRE SCHEMATIC AIRTECH amp 1100 SERIES SCALE 1 0 SIZE cHecKeD 1179 98 Iz A X X X 28731 C R 6 ELKHART IN 46514 USAGE SHEET 1 OF 1 LET NO REVISION BY pae APPROVED MRZ 11 19 98 ASTRO W O YF7 ProAir LLC 4 6B General Motors Astro Safari Last Touch Switch Control With or Without YF7 For General M otors vehicles ProAir offers a switching option called Last Touch Switch Control LTSC This system gives driver and passenger control of the rear fan through an electronic module Blower speeds are changed based on inputs given by either thef
41. OEM LIQUID LINE VALVE AT THE RIGHT OF ACCUMULATOR OEM ELECTRICAL CONVENIENCE CTR BELOW DASH AT FIREWALL ProAir LLC 4 1 FACTORY SWITCH LOCATION 98mkcs12 ASTRO SAFARI CONNECTION POINTS W O YF7 General Motors has provided for upfitters on vehicles without the connector package the connections shown below for the refrigerant hoses and heater hoses OEM LIQUID LINE CONNECTION W O YF7 OEM SUCTION LINE CONNECTION W O YF7 LOCATED BY ACCUMULATOR LOCATED AT ACCUMULATOR OEM WATER LINE AND WATER VALVE OEM VACUUM LINE CONNECTION LOCATED CONNECTIONS LOCATED UNDER HOOD BEHIND RADIO General Motors Astro Safari Diagnosis Flow Chart Heat Concerns w YF7 NOTES 1 Rear heat temperatures should be checked at closest louver to ProAir unit The rear unit fan speed should be set on HIGH The vehicle must be at operating temperature The vehicle should be running above idle when performing heat tests 1500 rpm s 2 3 4 5 The vehicle s control head must be set on floor mode for correct water valve operation STEP 4 Check for vacuum at OK Go to Step 5 4 3B STEP 3 1 OEM connection OK STEP2 OK Check coolant OK Voll wvacutm ling Verify proper operation Go to Step 2 Check coolant level Go to Step 3 temperature Should Go to Step 4 of rear unit under dash passenger be at least 180deg F side No vacuum cont
42. P WIRE AT TWO PIN GRAY LOW 5 AMP 3 DASHED WIRE DENOTES WIRES S COMER AR 4 WIRE HARNESS ROUTED WITH HOSES PRO AIR CONNECTOR AT A PILLAR 20 GA GRY INGITION 20 GA YEL 20 GA BLK GROUND 14 GA ORN POWER 14 GA RED 20 GA GRY BLK NOT USED a g 16 GA BLU 14 GA VEL 4 FRONT FAN SWITCH MEDIUM 16 GA RED 14 CA RED 5 MOUNTED IN e DASH 7 HIGH 16 GA WHT 14 GA ORN 14 GA BLK II BLOWER MOTOR RESISTOR BLOCK amp a 87 87 85 E VE 2 xz gt S 6 POWER RELAY 3 l 9 30 86 BLOWER MOTOR MED 16 CORN 2 PRO AIR CONNECTOR g ING POWER AT D PILLAR LO gt gt e 14 ORN 14 GA BLK exon Luen 2 v zl o ogg a gt x lt 8 did o o0 9 4 010 S BORD POS GND 14 ORN 14 GA RD 12 VOLT D C BATTERY 14 GA YEL RO LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING ROM PRO LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING X SIGNATURES DATE TRE PART NO 40 000 092 DRAWN KFS 10 26 98 PI O LL REAR HEAT COOL WIRE SCHEMATIC AIRTECH amp 1100 SERIES SCALE 1 0 SIZE
43. ProAir Customer Service Manual Release Date 30 November 2000 Mission Statement ProAir is a leading manufacturer distributor and installer of air conditioning and heating systems to the specialty vehicle industry Our mission is to continually improve our product and services in order to meet our customers needs This will allow us to prosper as a business We are dedicated and committed to Providing the employees of ProAir with a quality work life Supplying our customers with a superior product excellent service and a competitive price Maintaining technological advancement and leadership Expanding and distributing our products worldwide Forming a partnership and long lasting relationship with our suppliers Profitability which will allow us to survive and grow Conducting business in an ethical and accountable manner ProAir has designed this manual to assist in diagnosing and servicing our rear heat cool units We have organized it by chassis specific sections Within each of these sections we have included ProAir requirements and factory connection points concern categories heating cooling electrical and airflow wiring schematics system diagnosis flowcharts exploded view diagrams and parts lists You will also find sections on replacement repair procedures technical information bulletins and our warranty statement Please refer to the table of contents for further details Although we have designed this manual fo
44. REVISION BY DATE APPROVED M RZ 11 19 98 DODGE W HBC amp LAST TOUCH SW ProAir LLC 1 78 PART NO NOTES 40 000 088 1 HARNESS 125 INSULATED WIRE EQUIVALENT TO SAE SPECIFICATION 11128 GXL 2 BLOWER MOTOR MAXIMUM WIRE HARNESS ROUTED SWITCH TO UNIT PRO AIR CONNECTOR AMP DRAW AT A PILLAR HIGH 12 AMP OFF MEDIUM 8 AMP FRONT FAN LOW 5 AMP SWITCH LOW 16 CA BLU 18 YEL 3 DASHED WIRE DENOTES WIRES MOUNTED IN DASH MEDIUM 16 GA RED 18 RED HIGH 16 GA WHT 18 ORN 16 GA GRN GND ul 14 CA RED 14 CA RED 14 CA RED 14 CA RED 14 CA BLK He GND 87A 187 85 HARNESS CONNECTION POINT AT LAST TOUCH MODULE 9 18 GRN 18 GRN 18 GRN 9 0 e eene 30 86 16 GA ORN ING POWER ATLICHTER eno 1 9 BLOWER MOTOR x RESISTOR BLOCK al o a E a zo HI X S 5 5 X 515555 9 15 S o x c FUSE Fu es BLOWER MOTOR MED a e 8 PRO AIR CONNECTOR AT D PILLAR 0 e z a 5 v lt z POS NEG 8 a 14 GA ORN 14 BLK Hos EX x zx 9 9 e 12 VOLT D C BATIE
45. RY Xx lt 010 9 14 CA ORN 18 GA BLU OFF 14 GA RD 18 YEL LOW 14 GA YEL 18 GA BRN MEDIUM e 15 FUSE e HIGH 18 YEL 18 GA YEL 18 GA BRN GROUND PASSENGER REAR 18 GA RD 18 GA RD 18 GA YEL CONTROL SWITCH 18 GA ORN 18 GA ORN 18 GA BLU LAST TOUCH MODULE RO AIR LLC CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL DISCLOSED HEREON NEITHER THIS DRAWING NOR ANY PRODUCTION THEREOF MAY BE USED TO MANUFACTURE ANYTHING SHOWN HEREON WITHOUT PERMISSION IN WRITING 1271 ROM PRO AIR LLC TO USER SPECIFICALLY REFERRING TO THIS DRAWING RE lt SIGNATURES DATE PART 40 000 088 DRAWN K F S 10 23 98 All 2 LL REAR HEAT COOL WIRE SCHEMATIC AIRTECH amp 1100 SERIES SCALE 1 0 SIZE _ 11 19 98 X X X 28731 C R 6 ELKHART IN 46514 USAGE SHEET 1 OF 1 LET NO REVISION BY DNE APPROVED MRZ 11 19 98 DODGE W O HBC amp LAST TOUCH SW ProAir LLC 1 7C 1999 DODGE W HBC LAST TOUCH SWITCH CONTROL Connect the harness from the rear switch P N 01 000 050 to the mating flat plug at the LTSC module Connect the green wire from this harness to the black wire with the spade connector from the short jumper harness Plug the short jumper harness into the gray connector on the module and into the 10 harness which goes to the front Plug the harness numbered 01 000 087 into the rem
46. Wiring Diagrams with and without HBC Diagnosis Flowchart Airflow Concerns Power Pack Exploded Parts View AirTech and 1100 Hose Assemblies Ford Econoline ProAir Requirements Factory Connection Points with 57X Factory Connection Points without 57X Diagnosis Flowchart Heat Concerns with and without 57X Diagnosis Flowchart Cooling Concerns with and without 57X Diagnosis Flowchart Electrical Concerns with 57X or 57L Wiring Diagrams Diagnosis Flowchart Airflow Concerns Power Pack Exploded Parts View AirTech and 1100 Hose Assemblies General Motors G van GMT600 ProAir Requirements Factory Connection Points with YF7 Factory Connection Points without YF7 Diagnosis Flowchart Heat Concerns with and without YF7 Diagnosis Flowchart Cooling Concerns with and without YF7 Diagnosis Flowchart Electrical Concerns with and without YF7 Wiring Diagrams Last Touch Switch Control Including Wiring Diagrams with and without YF7 Diagnosis Flowchart Airflow Concerns Power Pack Exploded Parts View AirTech and 1100 Hose Assemblies General Motors Astro Safari ProAir Requirements Factory Connection Points with YF7 Factory Connection Points without YF7 Diagnosis Flowchart Heat Concerns with and without YF7 Diagnosis Flowchart Cooling Concerns with and without YF7 Diagnosis Flowchart Electrical Concerns with and without YF7 Wiring Diagrams Last Touch Switch Control Including
47. aining flat connector at the module and into the motor and resistor at the power pack 01 000 087 LTSC MODULE 01 000 050 GRAY CONNECTOR 8 JUMPER HARNESS B PILLAR CONNECTION ProAir LLC 17D Itsdgw 1999 DODGE W O HBC LAST TOUCH SWITCH CONTROL Connect the harness from the rear switch 01 000 050 to the mating flat plug at the LTSC module Connect the green wire from this harness to the green wire from the wire harness that goes to the front Plug the harness to the front into the gray connector on the module and route it to the front alongside the van wall under the drivers seat in the OEM wire channel At the end cut off the black plug and then butt connect the wires to the switch harness matching the colors The red wire is connected to the red w white wire in the switch harness The other end of this red white wire is connected to the red wire with the spade connector from the power relay harness Plug the harness numbered 01 000 087 into the remaining flat connector at the module and into the motor and resistor at the power pack 201 000 087 01 000 050 WIRE HARN TO FRONT RED CUT OFF THIS CONN HERE RED WIRE W SPADE CONN FROM POWER RELAY HARNESS BLK GRD RED WHT TO DASH SWITCH 1 7E Itsdgwo Chrysler Dodge B van Airflow Concerns The first step in diagnosing any concern is to get as specific as possible with it In order to help prevent misdiagnosis and ineffec
48. areas Inadequate airflow front or rear louvers Inadequate airflow left or right louvers Inadequate airflow all louvers The following prechecks will help in diagnosis of the airflow concern Is air inlet blocked Remove debris or obstruction Is blower inoperative on low medium and or high Refer to electrical concerns section for specific chassis Is blower wheel not intact Refer to blower replacement in repair section 15 evaporator core iced up Refer to cooling concerns section for specific chassis Is there debris on blower wheel or coil Clean and prevent reoccurrence Is there inadequate airflow out of top of unit with duct Check for blocked inlet disconnected Check for debris on core Check for blower concern If any problems exist with these prechecks they must be rectified before removing interior panels to check the ductwork Repair procedures for the above concerns can be found in the specific chassis sections of this manual If all the above prechecks are all right then check all louvers for obstructions fabric tape hole cutouts etc If louvers are unobstructed it will be necessary to access duct hose crossover and wall extensions to determine the cause of the inadequate airflow Consult conversion company s customer service department for procedures to access these components ProAir LLC 3 8 LLC CUSTOMER SERVICE MANUAL 1999
49. atio WARNING DO NOT disconnect fittings without recapturing the refrigerant using standard shop procedures 2000 Chrysler Dodge B Van Diagnosis Flow Chart Cooling Concerns w o HBC STEP 6 STEP 5 STEP 7 Recapture refrigerant Check tees hoses from system ising core and expansion Standard factory valve for blockage procedures STEP 8 Call ProAir Customer Service Check auxiliary hoses for visible kinks or pinched areas NOT OK Go to Step 5A NOT OK Go to Step 7A STEP 7A Repair as needed and recharge system using Repair hoses and standard factory re check system procedures Re check operation STEP 5A ProAir LLC 1 4D Chrysler Dodge B van Electrical Concerns With HBC Chrysler vans that come with the HBC upfitter s package are equipped with OEM wiring from the dash mounted switch to the driver s side pillar of the van Start diagnosis of electrical concerns at the B pillar connector The electrical system on Chrysler vehicles uses as 12 volt DC signal The switching to the auxiliary unit is done on the ground side of the circuit When starting diagnosis of the electrical concern disconnect the ProA harness fromthe OEM harness and check the chassis connector for the following inputs White 6 pin connector Red wire with green tracer 12V DC ignition switched with key Red wire with grey tracer 12V DC battery positive These conditions must bemet in order for the au
50. d be running above idle when performing heat tests 1500 rpm s 2 3 4 5 The vehicle s control head must be set on floor mode for correct water valve operation STEP 1 OK STEP 2 OK proper operation Go to Step 2 Check coolant level Go to Step 3 of rear unit NOT OK Go to Step 2A NOT OK Go to Step 1A STEP 2A Fill to correct level with proper coolant Purge STEP 1A Refer to ProAir owner s operating guide for air from system Check for leaks and re test system correct operation of rear unit Verify operation and re check temperature STEP 3 Check coolant temperature Should be at least 180deg F NOT OK Go to Step 3A STEP 3A Run vehicle at 1500 rpm s for 10 minutes Re check operation NOT OK Go to Step 3B STEP 3B STOP This is an OEM problem Consult Dealer for repair ProAir LLC 3 3A STEP 4 Check for vacuum at OEM connection OK OK 5 Go to Step 4 Yellow vacuum line Go to Step 5 under dash passenger 3 3B side No vacuum continue to step 5 NOT OK Go to Step 4A STEP 4A Check dash control for OK OK ol Complete correct operation in Re check P floor mode OEM water operatio valve should be open NOT OK Go to Step 4B STEP 4B STOP This is an OEM control head problem Consult Dealer for repair 2000 General Motors G Van GMT600
51. dash area at the convenience center Without Y F7 an OEM harness and switch are installed thus making the wiring setup and its diagnosis identical to vehicles with Y F 7 Start diagnosis of electrical concerns at the connector located at the convenience center described above The electrical system on A stro Safari vehicles is a standard 12 volt DC system This means that the dash switch sends 12 volt signals to the unit in order to switch blower speeds W hen starting diagnosis of the electrical concern disconnect the ProA ir harness from the OEM connector and check the chassis connectors for the following inputs Black Connector Blue wire 12V DC in low speed on auxiliary switch Red wire 12V DC in medium speed on auxiliary switch White wire 12V DC in high speed on auxiliary switch These conditions must be met in order for the auxiliary unit to operate To diagnose any problems with the OEM wiring consult dealer service manuals If all inputs are present from the OEM system reconnect the ProA ir harness to the OEM plugs and continue checking at the rear unit See next page If the following test procedures do not lead you to the correction please contact ProA for further assistance ProAir LLC 4 5A General Motors Astro Safari Electrical Concerns Test Procedures With or Without YF7 Possible C ause Solution 1 Reconnected and secure to prevent reoccurrence Reconnected and secure to p
52. e component damage or poor A C system performance Use only PAG polyalkylene glycol synthetic lubricant within an R 134a system System Capacities ProMirRearUnit OEM Dah Unit Refrigerant 134a ETE R 134a 1100 3 13 1b Refrigerant 134a 1340 nia 50 oz 3 13 1b PAG lubricant 54H or GM equivalent all units 3 oz 8 oz 11 oz A nti freeze USE GM S DEX COOL COOLANT ONLY DEX COOL A dd approximately gallon of a 50 50 mixture of anti freeze and water all units to the van s cooling system when installing a rear unit NOTE Therefrigerant capacity for the ProAir rear unit should not be confused with the factory auxiliary rear unit which requires 12 oz 0 75 Ib of R 134a and is stated on the OE M sticker in the engine compartment on the front evaporator housing The ProAir sticker is located in this same area ProAir LLC 4 0 ASTRO SAFARI FACTORY CONNECTION POINTS General Motors has provided for upfitters OEM connection points to interface with OEM heating cooling and electrical systems This package 15 labeled YF7 and consists of the following OEM WATER LINE CONNECTIONS AT B PILLAR OEM VAC LINE CONNECTION BELOW RADIO OEM WATER VALVE UNDER THE ACCUMULATOR OEM SUCTION LINE CONNECTION AT COMP OEM LIQUID LINE CONNECTION NEAR TRANS TURN VALVE COUNTER CLOCKWISE TO OPEN
53. ecifically if the customer changed the temperature control in the slightest off cold then the ProAir water valve would open and hot water would start flowing to the rear unit ProAir LLC 28731 County Road 6 Elkhart IN 46514 BER LLC TECHNICAL INFORMATION BULLETIN HOSE CLAMPS GM VANS W YF7 WATER LINE CONNECTIONS There is a slight tendency for coolant leakage at the joint where the auxiliary hoses attach to the OEM aluminum lines To ensure a completely sealed connection two worm gear clamps on each hose will be used The positioning of the clamps and the tightening screw are critical The tightening screws must be positioned 180 from each other and facing in the same direction as shown in the illustration below Tighten the worm gear screws to 30 in Ib of torque The hoses from the rear auxiliary unit should be pushed onto the OEM aluminum lines a minimum of 2 1 2 To achieve maximum sealing place the clamps 1 4 to 3 8 apart 1 4 3 8 ProAir LLC 28731 County Road 6 Elkhart IN 46514
54. ecked at closest louver to ProAir unit 2 The rear unit fan speed should be set on HIGH 3 The vehicle must be at operating temperature 4 The vehicle should be running above idle when performing heat tests 1500 rpm s 5 The vehicle s control head must be set on floor mode for correct water valve operation STEP 4 Check for vacuum at STEP 3 OK STEP 2 OK Check coolant OK Go to Step 2 Check coolant level Go to Step 3 temperature Should Go to Step 4 be at least 180deg F OK Go to Step 5 1 3B STEP 1 ProAir water valve No vacuum continue to Step 5 Verify proper operation of rear unit NOT OK Go to Step 4A NOT OK Go to Step 3A NOT OK Go to Step 2A NOT OK Go to Step 1 STEP 4 Check for correct vacuum connection STEP 1A Refer to ProAir owner s STEP 2A STEP 3A Fill to correct level with operating guide for Run vehicle at 1500 correct operation of ive 2 m rpm s for 10 minutes pe PONDUS Re check ST irom System Re check rear unit p p operatio rear unit Verif ear unit Verify vacuum line connected to door motor Water valve should be open for leaks and re test system operation operation and re check temperature NOT OK Go to Step 3B NOT OK Go to Step 4B STEP 4B Re connect vacuum line to correct location STEP 3B STOP This is an OEM problem
55. ed on auxiliary dash switch Orange wire Grounded in high speed on auxiliary dash switch These conditions must be met in order for the auxiliary unit to operate diagnose any problems with the OEM wiring consult dealer service manuals If all inputs are present from the OEM system reconnect the ProA ir harness to the OEM plugs and continue checking at the rear unit See next page If the following test procedures do not lead you to the correction please contact ProA for further assistance ProAir LLC 3 5A General Motors G van GMT600 Electrical Concerns Test Procedures With or Without YF7 Possible Cause No Blower Speeds 15A fuse at unit blown Replace fuse Check for short in system No battery voltage at fuse connector Repair open wire or connector at D pillar M otor lead disconnected Reconnect and secure to prevent reoccurrence No ground signal to terminal 30 of relays Repair open wire or connector at D pillar No ground at motor Repair open relay connection or replace relay Inoperative motor Replace motor assembly NoLow Speed No ground signal to relay Repair open in circuit between D pillar and relay Inoperative relay Replace low speed relay No ground signal to resistor Repair open wire to resistor No ground signal out of resistor Replace resistor No ground signal to motor plug Repair open in wire or connector at motor plug No M edium Speed No ground signal to relay
56. efore if you encounter this same concern or one similar to it you may find it helpful to look first at the following areas Check all fittings for leaks Look for loose connections leaking o rings leaking expansion valve and poor crimps from the hose fittings Also check hoses for leaks cuts damage etc Illustrated below is an evaporator coil for an AirTech power pack The arrows indicate the three joints which should be carefully checked for leaks before ordering a new coil from ProAir AirTech II sub assembly ProAir LLC 28731 County Road 6 Elkhart IN 46514 EDEDED AH HED 1c Ir Rear auxiliary heating will function to its maximum potential with the dash mode control positioned in the FLOOR or HEAT location FLOOR or HEAT refers to OEM mode selector not the temperature control This is the setting where maximum heating will be achieved OEM SWITCH LOCATION AT THE ProAir installs a second water valve to control the flow of coolant to the rear unit independently of the front This is a normally open water valve opposite of the factory water valve OEM WATER LINE CONNECTIONS LOCATED BEHIND THE SUCTION CONNECTION ProAir routes the vacuum line from the ProAir water valve through the firewall just to the right of the OEM dash unit to a brown line If the vacuum source were run in conjunction with the OEM valve the rear air conditioning would be compromised Sp
57. ep 7 ProAir LLC 2 3B STEP 7 OK STEP 8 Check auxiliary heater Go to Step 8 core for blockage Call ProAir Customer Service NOT OK Go to Step 7A STEP 7A Replace plugged heater core Re check operation Ford Econoline Van Diagnosis Flow Chart Heat Concerns w o 57X NOTES 1 Rear heat temperatures should be checked at closest louver to ProAir unit 2 The rear unit fan speed should be set on HIGH 3 The vehicle must be at operating temperature 4 5 STEP 3 Verif pani ration OK STEP 2 OK Check coolant 2 Jnd Go to Step 2 Check coolant level Go to Step 3 temperature Should 5 be at least 180deg F NOT OK NOT OK NOT OK Go to Step Go to Step Go to Step 1A 2A 3A STEP 1A STEP 2A Refer to ProAir owner s Fill to correct level with STEP 3A operating guide for proper coolant Purge Run vehicle at 1500 correct operation of air from system Check rpm s for 10 minutes rear unit Verify for leaks and re test Re check operation operation and re check System temperature NOT OK Go to Step 3B STEP 3B STOP This is an OEM problem Consult Dealer for repair ProAir LLC 2 3C The vehicle should be running above idle when performing heat tests 1500 rpm s The vehicle s control head must be set on floor mode for correct water valve operation STEP 4 Check for vacuum at OK Go to Step 5 2 3D OK Go to Step 4 ProAir water va
58. epair as needed and Repair hoses and re check system recharge system using standard factory procedures Re check Operation ProAir LLC 2 4D STEP 8 Call ProAir Customer Service Ford Econoline Electrical Concerns With 57X or 57L The Econoline vans are equipped with OEM wiring from the dash mounted auxiliary fan switch to the driver s side D pillar location Start diagnosis of electrical concerns at the OEM connector The electrical system on Econoline vehicles is 12 volts DC The switching to the auxiliary unit is done on the ground side of the circuit W hen starting diagnosis of the electrical concern disconnect the ProA ir harness from the OEM harness and check the chassis connector for the following inputs Gray Connector Green wire with whitetracer Grounded in 1st position low 1 on auxiliary switch Y ellow wire with red tracer Grounded in 2d position low 2 on auxiliary switch Blue wire with white tracer Grounded in 3d position medium on auxiliary switch Red wire with white tracer Grounded in 4th position high on auxiliary switch Y ellow wire with black tracer 12V DC battery hot Y ellow wire with red tracer 12V DC ignition hot If all inputs are present from the OEM system reconnect the ProAir harness to the OEM connector and continue checking at the rear unit See next page If the following test procedures do not lead you to the correction please contact ProA ir for further assistance
59. eration OK Go to Step 7 ProAir LLC 1 3D STEP 7 OK STEP 8 Check auxiliary heater Go to Step 8 core for blockage Call ProAir Customer Service NOT OK Go to Step 7A STEP 7A Replace plugged heater core Re check operation Chrysler Dodge B Van Diagnosis Flow Chart Cooling Concerns w HBC NOTES 1 Keep in mind the rear unit s performance is dependent on a properly operating dash system Rear A C temperatures should be checked at closest louver to ProAir unit The rear unit fan speed should be set on MEDIUM The vehicle s control head must be set to MAX A C The vehicle s temperature control lever should be at the max cold position The vehicle should be running above idle when performing cooling tests 1500 rpm s 014 In STEP 3 Check water valve STEP 1 STEP2 operation when in A C Verify proper operation Verify proper operation mode max cold G wi 4 Check OEM to Auxiliary of dash system Col iene of rear system CUO SIPS position Water valve connections should be closed No coolant to rear OK Go to Step 5 1 4B STEP 4 NOT OK Go to Step 4A NOT OK Go to Step 3A NOT OK Go to Step 2A NOT OK Go to Step 1 STEP 3A ProAir water valve should be connected to brown OEM vacuum line behind glove compartment STEP 4A Check fittings for proper connection and torque STEP
60. es without the connector package the connections shown below for the refrigerant hoses and heater hoses SUCTION FITTING AND HOSE CONNECTION 22 LIQUID CONNECTION Refrigerant hose connection points on vehicles without the Heater hose connections on vehicles without the connector package connector package located between battery and radiator Water wyes should be installed as shown in heater lines to heater core OEM HARNESS CONNECTOR VACUUM LINE LOCATION FOR SWITCH AT D PILLAR INSTALLATION CONNECTION On vehicles without the connector package a switch must be Wire harness from the power pack will plug into the OEM harness installed in the dash at the location shown at the D pillar The vacuum line connection is made at the B pillar ProAir LLC 2 2 98csfwo Ford Econoline Van Diagnosis Flow Chart Heat Concerns w 57X NOTES 1 Rear heat temperatures should be checked at closest louver to ProAir unit The rear unit fan speed should be set on HIGH The vehicle must be at operating temperature The vehicle should be running above idle when performing heat tests 1500 rpm s 2 3 4 5 The vehicle s control head must be set on floor mode for correct water valve operation STEP 4 OK Go to Step 5 2 3B STEP 3 STEP 1 heck for v m STEP 2 Check coolant OK Check Vac um at Verify proper operation ProAir water valve No Go to Step 2 Check coolant level Go to Step 3
61. found in the specific chassis sections of this manual If all the above prechecks are all right then check all louvers for obstructions fabric tape hole cutouts etc If louvers are unobstructed it will be necessary to access duct hose crossover and wall extensions to determine the cause of the inadequate airflow Consult conversion company s customer service department for procedures to access these components ProAir LLC 2 7 LLC CUSTOMER SERVICE MANUAL 1999 AirTech H C POWER PACK ASSEMBLY PART NUMBER 60 000 587 60 000 587 POWER ASS Y N 03 000 042 HEAT COIL 95 03 000 043 EVAPORATOR COIL 60 000 287 O RING 05 000 141 EXPANSION VALVE 60 000 287 O RING CA 68 000 005 BLOWER MOTOR W SEAL nN 101 000 091 RESISTOR 2 8A 98CS110 CUSTOMER SERVICE MANUAL 1 FORD ECONOLINE POWER PACK 1100 SERIES ASSEMBLY PART NUMBER 66 000 009 66 000 009 POWER PACK ASS Y 101 000 091 RESISTOR 05 000141 EXPANSION VALVE 60 000 287 O RING KIT 68 000 005 BLOWER MOTOR W SEAL 03 000 037 HEAT COOL 60 000 287 O RING KIT ProAir LLC 98mkcs07 2 8B T o 77 ESECLE V LLC CUSTOMER SERVICE MANUAL Lengths and fittings may var
62. g system will function to its maximum potential with the dash mode control positioned in the HEAT location Verify that the unit is not cool only it must be a heat cool unit When the dash mode control is positioned in the DEFROST mode the air conditioner continues to cycle and circulate refrigerant throughout the system The output of rear heat will be moderated in the DEFROST position ProAir Unit Requirements This ProAir unit contains Refrigerant 134a R 134a DO NOT add or replace with Refrigerant 12 R 12 F reon Adding R 12 to an R 134a system may cause component damage or poor A C system performance Use only PAG polyalkylene glycol synthetic lubricant within an R 134a system System C apacities Fluids ProAirRearUnit OEM Dash Unit Total R 134a 1100 10 oz 0 63 Ib 34 oz 2 13 Ib 44 02 2 75 Ib R 134a AirT ech amp 12 oz 0 75 Ib 34 oz 2 13 Ib 46 oz 2 88 Ib PAG lubricant 54L or Chrysler Equivalent all units 3072 8 oz 11 02 A dd approximately gallon of a 50 50 mixture of anti freeze and water A nti freeze all units to the van s cooling system when installing a ProAir rear unit NOTE The refrigerant capacity for the ProAir rear unit should not be confused with the factory auxiliary rear unit which requires 12 oz 0 75 10 of R 134a and is stated on the OEM sticker in the engine compartment on the front evaporator housing The ProAir sticker is located in this same area
63. he gas fill The two heater hoses are routed forward to the driver s side B pillar and theliquid and suction hoses arerouted forward into the engine compartment See page 4 1 or 4 2 Factory Connection Points The air ducts also attach to the unit at this point and continue up the wall into the ceiling CAUTION Located near the unit and built into the wall is a vent which must be kept clear to maintain adequate airflow through the evaporator D o not block off this vent Also the louvers in the ceiling must be partially open while the unit is operating If the louvers are completely closed air backup will result in possible damage to the blower assembly ProAir Unit Operation Therear air conditioning system will function with the dash mode control positioned in one of the air conditioning settings The rear heating system will function to its maximum potential with the dash mode control positioned in the FLOOR location Verify that the unit is not cool only it must be a heat cool unit When the dash mode control is positioned in the DEFROST or FLOOR DEFROST mode the air conditioner continues to cycle and circulate refrigerant throughout the system The output of rear heat will be moderated in the DEFROST or FLOOR DEFROST position ProAir Unit Requirements This ProA ir unit contains Refrigerant 134a R 134a DO NOT add or replace with Refrigerant 12 R 12 F reon A dding R 12 to an R 134a system may caus
64. installation sticker to the passenger side door jamb The information on this sticker tells what model unit was installed the unit s se rial number date of installation and the installers assigned numbers This in formation is very helpful when requesting warranty parts or technical assistance 2 Describe the problem or type of warranty repair needed Our customer service specialists are trained on ProAir s units and can aid you in diagnosing the problem 3 If parts are needed ProAir reserves the right to supply any and all warranty parts 4 All warranty parts are shipped on a memo no charge billing and are sent the same day if possible An authorization number accompanies the replacement parts Also noted on the memo billing is our labor allowance for the repair labor allowances are based on ProAir s flat rate standards multiplied by the repair facility s standard retail labor rate defective parts shall be returned to ProAir shipping charges by the most economical method may be added to the cost of the repair No warranty claims will be paid without the return of defective parts 5 Warranty claims submitted to ProAir must include the following ProAir authorization number ProAir serial number vehicle serial number mileage and authorized labor amount ProAir does not pay tax or miscellaneous shop supplies All claims must be submitted within 180 days of the date of repair and all parts must be returned in order to
65. inue to Step 5 NOT OK Go to Step 4A NOT OK Go to Step 3A NOT OK Go to Step 2A NOT OK Go to Step 1A STEP 2A Fill to correct level with proper coolant Purge STEP 4A Run Check dash control for correct operation in rpm s for 10 minutes Complete Hsorrada Watek Re check operation valve should be open STEP 1A Refer to ProAir owner s operating guide for OK Re check operatio air from system Check for leaks and re test system correct operation of unit Verify operation and re check temperature NOT OK Go to Step 4B NOT OK Go to Step 3B STEP 4B STOP STEP 3B STOP This is an OEM control head problem Consult Dealer for repair This is an OEM problem Consult Dealer for repair ProAir LLC 4 3 2000 General Motors Astro Safari Diagnosis Flow Chart Heat Concerns w YF7 STEP 6 STEP 5 STEP 7 STEP 8 Check for correct OEM OK Ene for kinked or OK pinched heater hose Check auxiliary heater Call ProAir Customer water valve Normally Go to Step 6 Go to Step 7 Go to Step 8 from Factory lines to core for blockage Service open operation ProAir rear unit NOT OK Go to Step 5A NOT OK Go to Step 6A NOT OK Go to Step 7A STEP 5A STOP This is an OEM part STEP 6A Remove kink or pinch STEP 7A Replace plugged Repair as
66. ir as necessary re check operation OK Go to Step 7 ProAir LLC 3 3D STEP 7 Check auxiliary heater core for blockage NOT OK Go to Step 7A STEP 7A Replace plugged heater core Re check operation OK Go to Step 8 STEP 8 Call ProAir Customer Service General Motors G Van GMT600 Diagnosis Flow Chart STEP 1 OK Verify proper operation Go to Step 2 of dash system NOT OK Go to Step 1 STEP 1A Diagnose dash concerns before making repairs to rear system NOTE Follow standard diagnosis procedures for determining inoperative A C system factory or auxiliary units Cooling Concerns w YF7 NOTES 1 Keep in mind the rear unit s performance is dependent on a properly operating dash system Rear A C temperatures should be checked at closest louver to ProAir unit The rear unit fan speed should be set on MEDIUM The vehicle s control head should be set in the MAX A C mode The vehicle s temperature control lever should be at the cold position The vehicle should be running above idle when performing cooling tests 1500 rpm s 3 Check water valve operation when in OK STEP 4 Check OEM to Auxiliary OK Go to Step 5 3 4B STEP 2 OK Go to Step 3 A C mode max cold position Water valve should be closed No coolant to rear Verify proper operation of rear system Go to Step
67. its Cooling Concerns w YF7 NOTES 1 Keep in mind the rear unit s performance is dependent on a properly operating dash system Rear A C temperatures should be checked at closest louver to ProAir unit The rear unit fan speed should be set on MEDIUM The vehicle s control head should be set in the MAX A C mode The vehicle s temperature control lever should be at the cold position The vehicle should be running above idle when performing cooling tests 1500 rpm s STEP 3 Check OEM water valve operation when in OK A C mode max cold position Water valve should be closed No coolant to rear STEP 4 Verify that OEM liquid line valve is open OK Go to Step 5 4 4B STEP 2 OK Go to Step 3 Verify proper operation of rear system Go to Step 4 CCW rotation Check OEM to Auxiliary connections NOT OK Go to Step 4A NOT OK Go to Step 3A NOT OK Go to Step 2A STEP 4A Check fittings for proper connection and torque STEP 3A Check factory vacuum tee connection Yellow line under radio STEP 2A Review operating OK Re check operatio OK Re check operatio procedures and re check system WARNING DO NOT disconnect fittings without NOTE No vacuum at OEM yellow line in A C mode is a factory problem Consult Dealer for repairs discharging system using standard factory procedures ProAir LLC 4 4A
68. ld vacuum continue to installation be at least 180deg F Step 5 NOT OK Go to Step Go to Step NOT OK Go to Step 2A 3A Go to Step 1A 2 2A STEP 3A STEP 1A Fill to correct level with Check for correct STEP 4A Refer to ProAir owner s proper coolant Purge i OK Drai li rating guide for air from system Run OK VACUUM connection rain Coon system EET operation of vehicle at 1500 rpm s Complete Yellow vacuumiline Recheck Reposition water Ys p below dash passenger operatio Refill and re check rear rear unit Verify for 10 minutes side Water valve must unit operation operation and re check Re check rear unit temperature operation NOT O Go to Step Go to Step 3B 2B STEP 3B STEP 2B Re connect vacuum _ STOP line to correct location This is an OEM and repair previous problem Consult splice area Re check Dealer for repair operation ProAir LLC 3 3C OK Go to Step 5 3 30 2000 General Motors G Van GMT600 Diagnosis Flow Chart Heat Concerns w o YF7 STEP 5 Check ProAir water valve operation Normally open NOT OK Go to Step 5A STEP 5A Remove water valve and check operation Replace if flow is blocked with no vacuum present STEP 6 Check for kinked or pinched heater hose from Factory lines to ProAir rear unit NOT OK Go to Step 6A STEP 6A Remove kink or pinch Repa
69. ll be achieved from the rear unit 2 Rear auxiliary heating will function to its maximum potential with the dash mode control positioned in the FLOOR or HEAT location FLOOR or HEAT refers to vehicles OEM mode selector not the temperature control This is the setting where maximum heating will be achieved 1998 FORD CLIMATE CONTROLS MAXIMUM HEAT FLOOR MODE HEAT FLOOR MODE 1998 GM CLIMATE CONTROLS GMT M amp L VANS MAXIMUM COOLING MAX A C ProAir LLC 28731 County Road 6 Elkhart IN 46514 ar EE e LLC TECHNICAL INFORMATION BULLETIN 98 99 ASTRO SAFARI SUCTION HOSE ROUTING The suction hose assembly for 98 99 Astro Safari has been re configured to improve the installation Included in the new kit are a new bracket and fasteners for securing the hose Installation techniques must be altered slightly from prior methods The first step is to remove the center console engine cover Remove and retain the screw covers Remove the Torx screws and the 13mm nuts at the bottom brackets and the 15mm nuts at the top Remove the engine cover and set it aside Push the transfer case vent hose towards the center of the van as far as possible all wheel drive vans only Remove the bolt at the rear corner drivers side of the intake manifold which holds the bracket for plug wires Position the bracket as shown and re insert the bolt Screw the rear corner of the new bracket down to the existi
70. loor behind the gas fill The two heater hoses are routed forward to the driver s side B pillar and theliquid and suction hoses arerouted forward into the engine compartment See page 2 1 or 2 2 Factory Connection Points The air ducts also attach to the unit at this point and continue up the wall into the ceiling CAUTION Located near the unit and built into the wall is a vent which must be kept clear to maintain adequate airflow through the evaporator Do notblock off this vent Also thelouvers in the ceiling must be partially open while the unit is operating If the louvers are completely closed air backup will result in possible damage to the blower assembly ProAir Unit Operation Therear air conditioning system will function with the dash mode control positioned in one of the air conditioning settings The rear heating system will function to its maximum potential with the dash mode control positioned in the FLOOR location Verify that the unit is not cool only it must be a heat cool unit When the dash mode control is positioned in the DEFROST mode the air conditioner continues to cycle and circulate refrigerant throughout the system The output of rear heat will be moderated in the DEFROST position ProAir Unit Requirements This ProA ir unit contains Refrigerant 134a R 134a DO NOT add or replace with Refrigerant 12 R 12 F reon A dding R 12 to an R 134a system may cause component damage or poor A C system perf
71. lve No vacuum continue to Step 5 NOT OK Go to Step 4A STEP 4A Check dash control for correct operation in floor mode Water valve should be open OK Re check operatio OK Complete NOT OK Go to Step 4B STEP 4B STOP This is an OEM control head problem Consult Dealer for repair 2000 Ford Econoline Van Diagnosis Flow Chart Heat Concerns w o 57X STEP 6 STEPS STEP 7 STEP 8 Check for ProAir water 4 ProAir rear unit Check auxiliary heater OK Call ProAir Customer valve operation Go to Step 6 Go to Step 7 y Go to Step 8 Service Check for proper water wye installation page Normally open core for blockage NOT OK Go to Step 5A NOT OK Go to Step 7A Go to Step 6A STEP 5A Remove water valve and check operation STEP 6A Remove kink or pinch STEP 7A Replace plugged heater core Re check operation Replace if flow is blocked with no vacuum present Repair as necessary re check operation ProAir LLC 2 3D Ford Econoline Van Diagnosis Flow Chart Cooling Concerns w 57X NOTES 1 Keep in mind the rear unit s performance is dependent on a properly operating dash system 2 Rear A C temperatures should be checked at closest louver to ProAir unit 3 The rear unit fan speed should be set on MEDIUM 4 The vehicle s control head should be set in the MAX A C mode 5 The vehicle s
72. n Go to Step 2 Check coolant Go to Step 3 ProAir water valve No Go to Step 4 Go to Step 5 of rear unit temperature Should vacuum continue to installation 1 3D be at least 180deg F Step 5 Go to Step Go to Step Go to Step Go to Step 1 2 4 STEP 2A STEP 3A STEP 1A Fill to correct level with 2 STEP 4A Refer to ProAir owner s behind glove cooling apu operating guide for vehicle at 1500 rpm s Complete compartment Brown 2 correct operation of for 10 minutes vacuum line connected operatio eni andreicheck rear Sal unit Verify Re check rear unit to door motor Water unit operation operation valve should be open NOT OK NOT O Go to Step Go to Step 2B 3B STEP 2B STOP Re connect vacuum This is an OEM line to correct location problem Consult and repair previous Dealer for repair Splice area Pe Check operation ProAir LLC 1 3C STEP 5 Check ProAir water valve operation Normally open NOT OK Go to Step 5A STEP 5A Remove water valve and check operation Replace if flow is blocked with no vacuum present 2000 Chrysler Dodge B Van Diagnosis Flow Chart Heat Concerns w o HBC STEP 6 Check for kinked or pinched heater hose from Factory lines to ProAir rear unit NOT OK Go to Step 6A STEP 6A Remove kink or pinch Repair as necessary re check op
73. n wire to resistor No ground signal out of resistor Replace resistor No ground signal to motor plug Repair open in wire or connector at motor plug No High Speed No ground signal to relay Repair open ground at floor near unit Inoperative relay Replace high speed relay No ground signal to resistor Repair open wire to resistor No ground signal to motor plug Repair open in wire or connector at motor plug Motor RunsContinuously 1 Stuck relay Replace relay Improperly wired connector Check connector Rewire harness Shorted wire Check for screw in harness M ismatched Blower 1 Incorrectly wired harness wires to motor 1 Replace affected harness or connectors Speeds harness or resistor plug according to wiring diagram ProAir LLC 1 5B Chrysler Dodge B van Electrical Concerns Without HBC Chrysler vans that do not come with the H BC upfitter s package are equipped with ProA ir wiring from the dash mounted switch to the unit mounted on the driver s side T he ProAir wiring consists of three harnesses 1 a relay harness to carry the system s power requirements 2 a main harness routed from the auxiliary switch location to the rear unit and 3 a blower motor resistor harness attached directly to the unit This electrical system uses a 1 2 volt DC signal This means that the dash switch sends 12 volt signals to the rear unit in order to switch blower speeds W hen starting diagno
74. ne XE B moro KS SaO oto linea USAGE 1999 FORD W O 57X 57L PLUMBERS SHEET 1 OF 1 NOTES 1 HARNESS 125 INSULATED WIRE EQUIVALENT TO SAE SPECIFICATION J1128 TYPE GXL 2 BLOWER MOTOR MAXIMUM AMP DRAW HIGH 12 MEDIUM 8 AMP LOW 5 AMP Ford Econoline Airflow Concerns The first step in diagnosing any concern is to get as specific as possible with it In order to help prevent misdiagnosis and ineffective costly repairs categorize the airflow concern into one of the following general areas Inadequate airflow front or rear louvers Inadequate airflow left or right louvers Inadequate airflow all louvers The following prechecks will help in diagnosis of the airflow concern Is air inlet blocked Remove debris or obstruction Is blower inoperative on low medium and or high Refer to electrical concerns section for specific chassis Is blower wheel not intact Refer to blower replacement in repair section 15 evaporator core iced up Refer to cooling concerns section for specific chassis Is there debris on blower wheel or coil Clean and prevent reoccurrence Is there inadequate airflow out of top of unit with duct Check for blocked inlet disconnected Check for debris on core Check for blower concern If any problems exist with these prechecks they must be rectified before removing interior panels to check the ductwork Repair procedures for the above concerns can be
75. necessary re check operation covered under GM warranty See Dealer for repair heater core Re check operation ProAir LLC 4 3B General Motors Astro Safari Diagnosis Flow Chart Heat Concerns w o YF7 NOTES 1 Rear heat temperatures should be checked at closest louver to ProAir unit 2 The rear unit fan speed should be set on HIGH 3 The vehicle must be at operating temperature 4 The vehicle should be running above idle when performing heat tests 1500 rpm s 5 The vehicle s control head must be set on floor mode for correct water valve operation STEP 2 STEP 3 STEP 1 OK Check coolant level OK Check for vacuum at OK Check e ware Verify proper operation Check coolant ProAir water valve No CN Go to Step 2 Go to Step 3 Go to Step 4 Y of rear unit temperature Should vacuum continue to installation be at least 180deg F Step 5 NOT O NOT O NOT OK Go to Step Go to Step NOT OK Go to Step 2A 3A Go to Step 1A 4A STEP 2A STEP 1A Fill to correct level with muU STEP 4A Refer to ProAir owner s proper coolant Purge operating guide for air from system Run OK vacuum connection OK Drain cooling System correct operation of vehicle at 1500 rpm s Complete below radio Yellow Re check Re position water Y s rear unit Verify for 10 minutes vacuum line connected operatio Refill and re check rear to control head Water unit operation operation and
76. ng OEM bracket with a self tapping screw at the pilot hole Route the hose up from below in front of the paired fuel lines by the new bracket Remove the protective caps and lubricate the fitting and start threading it on the OEM fitting Put a 3 4 linestake on the hose and screw it to the new bracket as shown with a 10 x 3 8 hex screw Install a 10 piece of 3 4 convoluted tubing on the hose just below the linestake as shown Pull back the floor insulation locate and mark a spot on the floor 6 from the floor duct directly towards the driver side Run a 14 x 1 self piercing screw down through the floor here Below the floor put a 3 4 linestake on the hose and secure it to this screw with the nut provided When securing the hose it must be pulled reasonable tight when being clamped in place Do not allow the hose to sag or droop or come in contact with any sharp hot or moving components The third linestake secures the hose to the cross member at the rear of the transmission Finish assembly by torquing the Aeroquip fitting to 40 ft Ib while using a backup wrench LOCATION FOR 14 X 1 SELF PIERCING SCREW AT FLOOR CHANNEL CONVOLUTED TUBING ProAir LLC 28731 County Road 6 Elkhart IN 46514 Bere AE NEST ir TECHNICAL INFORMATION BULLETIN AirTech Evaporator Coil ProAir has received back many AirTech cores that had no refrigerant leaks even though each had been diagnosed by the repair facility as leaking Ther
77. oAir warrants every AirTech MiniMax and 1100 series unit produced by ProAir and used in a van conversion to be free from defects in material and workmanship under normal use for a period of thirty six 36 months or thirty six thousand 36 000 miles whichever comes first If a repair or adjustment under the warranty is required the product should be taken to an authorized ProAir service center or if possible taken to the original installer The owner s registration certificate should be presented The repairing service center must contact ProAir by calling 219 264 5494 or 800 338 8544 asking for the customer service department and describing the type of warranty repair needed If warranty parts are needed ProAir reserves the right to replace them No warranty claims will be paid without the return of defective parts to ProAir If the ProAir service center is too far away the customer may find a repairing facility nearby and contact ProAir We will attempt to allow the repair facility authorization to address the concern This warranty does not cover any product which has been subject to misuse neglect alteration accident improper installation or improper maintenance or which has been repaired outside of an authorized ProAir service center in any way so as to affect adversely its performance or reliability This warranty does not cover material or labor used in normal maintenance services or the replacement of service items Normal
78. onnection point to cotain theanti freeze 3 Loosen the worm gear clamp at the OEM connection point and pull the end of th hose off to drain the lines 4 Loosen or remove any linestakes 5 Loosen the worm gear clamp on the hoses at the power pack and remove the hose REPLACE 1 Reverse the above procedure 2 Tighten the hose clamps to 30 in Ib 3 Re silicone around the heater hose at the floor grommet TYPICAL WORM GEAR CLAMP AT THE HEATER HOSES ProAir LLC 98mkrr05 5 5 CUSTOMER SERVICE MANUAL REMOVE AND REPLACE INSTRUCTIONS REFRIGERANT HOSE REMOVAL 1 Connect a refrigerant recycling machine to the service ports and recapture the refrigerant according to factory procedures 2 Remove the refrigerant tape from around the hose fitting at the evaporator 3 Mark the locations of the ty raps for later replacement and remove 4 Loosen the screws at the linestakes 5 Using a primary and a back up wrench disconnect the hose at the evaporator and at the OEM connection point 6 Remove the hose REPLACEMENT 1 Reverse the above procedure 2 Suction hose fittings 1 2 must be torqued to 20 ft Ibs and liquid hose fittings 5 16 must be torqued to 12 ft Ibs 3 Be sure and replace all ty raps and tighten all linestakes to prevent hoses from chafing or sagging ProAir LLC 98mkrr06 5 6 ProAir 3 Year 36 000 Mile Limited Warranty Pr
79. ormance Use only PAG polyalkylene glycol synthetic lubricant within an R 134a system System Capacities ProMirRearUnit OEM Dah Unit Refrigerant 134a ess m Refrigerant 134a fs AirTech PAG lubricant Daphne H ermetic Oil FD46X G all units 302 9 oz A dd approximately gallon of a 50 50 mixture of anti freeze and water A nti freeze all units to the van s cooling system when installing a ProAir rear unit NOTE Therefrigerant capacity for the ProAir rear unit should not be confused with the factory auxiliary rear unit which requires 20 oz 1 25 Ib of R 134a and is stated on the OE M sticker in the engine compartment on the driver s side radiator support The sticker is located in this same area ProAir LLC 2 0 FORD ECONOLINE FACTORY CONNECTION POINTS Ford Motor Company has provided for upfitters OEM connection points to interface with OEM heating cooling and electrical systems These packages are labeled 57L and 57X OEM REFRIGERANT HOSE CONNECTION POINTS W VALVES OEM WATER LINE CONNECTIONS BELOW FLOOR OEM REFRIGERANT AND HEATER HOSE CONNECTIONS OEM ELECTRICAL CONNECTOR BEHIND THE B PILLAR OEM VACUUM CONNECTION AT B PILLAR OEM SWITCH LOCATION 99 FORD DASH SHOWING SWITCH LOCATION ProAir LLC 98mkcs06 2 1 FORD ECONLINE FACTORY CONNECTION POINTS W O 57L AND 57X Ford Motor Company has provided for upfitters on vehicl
80. ower Speeds Inoperative motor Replace motor No power from relay harness to switch harness Diagnoserelay power harness See page 3 2 for weston 1 Open circuit in yellow wire or connector s 2 resistor R eplace resi stor No Medium Speed 1 Opencircuit in red wire or connector s Check circuit Repair connector or open wire 2 Inoperative resistor Replace resistor No High Speed 1 Open circuit orange wire or connector s 1 Check circuit Repair connector or open wire M ismatched 1 Incorrectly wired harness wiresto OEM motorharness 1 Replace affected harness connectors Blower Speeds or resistor plug according to wiring diagram ProAir LLC 3 5C 3 6 PART NO 40 000 091 NOTES GM OEM CONNECTORS 1 HARNESS 125 INSULATED WIRE PILLAR EQUIVALENT TO SAE SPECIFICATION J1128 GXL 2 BLOWER MOTOR MAXIMUM REAR AUXILIARY A C BLOWER DRAW SPEED CONTROL CIRCUITS HIGH 12 MEDIUM 8 AMP LOW 5 3 DASHED WIRE DENOTES O E WIRES YEL LOW 18 4 WIRE HARNESS ROUTED WITH HOSES MED 18 GA TAN ORG HIGH 18 GA ORN BRN IGN 18 GA BRN BLK GROUND 14GA BLK RED 12V DC 14GA RED REAR AUXILIARY AIC FEED amp GROUN
81. r the current model year you will find that it also applies to GM vans both GMT600 and Astro Safari from the 1996 model year on to Ford vans from the 1996 model year on and to Dodge vans from the 1998 model year on When using this manual please keep in mind the following ProAir s rear unit serves as an auxiliary system to the front factory unit If the factory unit heating or air conditioning does not work correctly the symptoms will appear in the ProAir unit also Repairs made to the factory system will in turn allow the ProAir unit to perform properly again We have designed this manual to cover the vast majority of concerns encountered in the field However it does not address every possible concern that may occur In some instances you will need to contact ProAir for further assistance Please feel free to do so whenever you wish ProAir LLC 28731 County Road 6 Elkhart Indiana 46514 Telephone 219 264 5494 Fax 219 264 2194 ProAir LLC Section 1 0 1 1 1 2 1 3 1 4 5 6 Section 6 0 Section 7 0 Section 8 0 Customer Service Manual Table of Contents Chrysler Dodge B van ProAir Requirements Factory Connection Points with HBC Factory Connection Points without HBC Diagnosis Flowchart Heat Concerns with and without HBC Diagnosis Flowchart Cooling Concerns with and without HBC Diagnosis Flowchart Electrical Concerns with and without HBC Wiring Diagrams Last Touch Switch Control Including
82. re check Re check rear unit tb temperature operation valve must be open NOT O NOT OK Go to Step Go to Step 3B 2B STEP 3B STEP 2B Re connect vacuum STOP line to correct location This is an OEM and repair previous problem Consult splice area Re check Dealer for repair operation ProAir LLC 4 3C OK Go to Step 5 4 3D STEP 5 Check ProAir water valve operation Normally open NOT OK Go to Step 5A STEP 5A Remove water valve and check operation Replace if flow is blocked with no vacuum present Heat Concerns w o YF7 STEP 6 Check for kinked or pinched heater hose from Factory lines to ProAir rear unit NOT OK Go to Step 6A STEP 6A Remove kink or pinch Repair as necessary re check operation OK Go to Step 7 ProAir LLC 4 3D STEP 7 Check auxiliary heater core for blockage NOT OK Go to Step 7A STEP 7A Replace plugged heater core Re check operation OK Go to Step 8 2000 General Motors Astro Safari Diagnosis Flow Chart STEP 8 Call ProAir Customer Service General Motors Astro Safari Diagnosis Flow Chart STEP 1 OK Verify proper operation Go to Step 2 of dash system NOT OK Go to Step 1 STEP 1A Diagnose dash concerns before making repairs to rear system NOTE Follow standard diagnosis procedures for determining inoperative A C system factory or auxiliary un
83. revent reoccurrence Reconnected and secure to prevent reoccurrence 1 ProA harness disconnected from rear resistor harness 2 Resistor plug disconnected from motor plug 3 No or inadequate chassis ground 4 Check wire terminal end and reground to chassis Inoperative motor 5 Replace motor Low Speed 1 Opencircuit in yellow wire or connector s Check circuit Repair connector or open wire 2 Inoperative resistor 2 Replaceresistor 1 Check circuit Repair connector or open wire 2 resistor 2 Replaceresistor No High Speed 1 Open circuit in orange wire or connector s 1 Check circuit Repair connector or open wire M ismatched 1 Incorrectly wired harness wiresto OEM motor harness 1 Replace affected harness connectors Blower Speeds or resistor plug according to wiring diagram No Blower Speeds 1 ProAir harness disconnected from OEM plug 2 3 4 5 ProAir LLC 4 5B PART NO 40 000 099 NOTES 1 HARNESS 125 INSULATED WIRE EQUIVALENT TO SAE SPECIFICATION J1128 TYPE GXL 2 BLOWER MOTOR MAXIMUM AMP DRAW HIGH 12 MEDIUM 8 AMP GM OEM CONNECTORS LOW 5 AMP AT A PILLAR 3 DASHED WIRE DENOTES O E WIRES 4 WIRE HARNESS ROUTED WITH HOSES REAR AUXILIARY A C BLOWER SPEED CONTROL CIRCUITS 16 GA BLU LOW 114 YEL 16 RED MED 14GA RED 16 GA WHT HIGH 14 GA ORN
84. rontor rear switch whichever switch was last used is the one that changes the blower speed The driver s control switch has master shutoff of the system it must be in a position other than off for the rear switch to work The module is located near the rear unit The following pages contain wiring diagrams and installation instructions for the various modules Please contact ProA ir s customer service department for diagnosis or questions regarding this system ProAir LLC 4 7 NOTES 1 HARNESS 125 INSULATED WIRE EQUIVALENT TO SAE SPECIFICATION O E CONNECTION IN FUSE BOX UNDER DASH PART NO 40 000 101 J1128 GXL 20 GA GRY IGNITION 2 BLOWER MOTOR MAXIMUM 7 DRAW TA 20 GA BLK GROUND MEDIUM 8 AMP 1 LOW 5 AMP 14 ORN 14 CA BLK m END 14 ORN POWER 3 DASHED WIRE DENOTES O E WIRES 4 WIRE HARNESS ROUTED WITH HOSES 20 GRY BLK NOT USED PRO AIR CONNECTOR OFF AT A PILLAR ae LOW 16 GA BLU GA YEL FRONT FAN MEDIUM 16 RED 18GA RED SWITCH 7 f MOUNTED IN e HCH 16 GA WHT i 18 GA ORN 14 GA ORN WITH YF7 THE OEM LSA RED HARNESS IS USED HARNESS CONNECTION POINT AT LAST TOUCH MODULE
85. rranty parts before we issue payment on the claim power packs evaporator coils heater coils expansion valves water valves blower motors resistors relays wiring harnesses hose assemblies fittings switches arule we require the return of all warranty parts with the exceptions of fuses hose clamps o rings and other small miscellaneous components If you feel uncertain whether to return a particular part please contact us for additional information ProAir LLC 5 0 CUSTOMER SERVICE MANUAL REMOVE AND REPLACE INSTRUCTIONS POWER PACK REMOVAL 1 Connect a refrigerant recapturing recycling machine to the service valves and recapture the refrigerant form the system according to factory procedures 2 Disconnect the wire harness connectors to the blower motor resistor and unscrew the relays 3 Disconnect the suction hose with a 7 8 open end wrenchy on the hose fitting and a 1 1 16 open end wrench as a backup on the coil fitting 4 Disconnect the liquid hose with a 5 8 open end wrench on the hose fiting and a 3 4 open end wrench on the thermal expansion valve as a back up 5 Loosen the radiator cap to relieve pressure on the system 6 Clamp the hoses off and loosen the worm gear clamps at the heater hoses and remove the hoses 7 Remove the screws holding the duct adapter to the case lid and the screws holding the mounting brackets to the floor and the wall
86. sis of the electrical concern begin by accessing the auxiliary fan switch and check for ignition power on thered wire to the terminal marked B Y ou must have this ignition source for the rear blower to operate This source is generated from the relay harness mounted under the hood next to the battery The relay harness gets its signal at the OEM lighter connection located above the ProA ir auxiliary switch If the following test procedures do not lead you to the correction please contact ProA for further assistance ProAir LLC 1 5C Chrysler Dodge B van Electrical Concerns Test Procedures Without HBC Possible C ause Solution No Blower Speeds No Low Speed No M edium Speed No High Speed No ignition source to switch check fuse Inoperative switch Switch disconnected from harness M ain harness disconnected from resistor harness M otor unplugged No ground to motor Inoperative motor Inoperative switch Open connection or circuit in yellow wire from dash to rear unit Inoperative resistor Inoperative switch Open connection or circuitin red wirefrom dash to rear unit Inoperative resistor Inoperative switch Open connection or circuit in orange wire from dash to rear unit 1 2 Check ignition connection at lighter Check relay under hood Check battery connection to relay and fuse Replace switch Reconnect and secure to prevent reoccurrence Reconnect and secure to pre
87. temperature Should Go to Step 4 of rear unit vacuum continue to be at least 180deg F Step 5 NOT OK Go to Step 4A NOT OK Go to Step 3A NOT OK Go to Step 2A NOT OK Go to Step 1A STEP 2A Fill to correct level with proper coolant Purge STEP 4A Run Check dash control for correct operation in rpm s for 10 minutes Complete foor moda Water Re check operation 5 valve should be open STEP 1A Refer to ProAir owner s operating guide for OK Re check operatio air from system Check for leaks and re test system correct operation of rear unit Verify operation and re check temperature NOT OK Go to Step 4B NOT OK Go to Step 3B STEP 4B STOP STEP 3B STOP This is an OEM control head problem Consult Dealer for repair This is an OEM problem Consult Dealer for repair ProAir LLC 2 3 2000 Ford Econoline Van Diagnosis Flow Chart Heat Concerns w 57X STEP 6 Check for kinked or STEP 5 Check for ProAir water OK valve operation Go to Step 6 Normally open pinched heater hose from Factory lines to ProAir rear unit NOT OK Go to Step 5A NOT OK Go to Step 6A STEP 5A Remove water valve and check operation STEP 6A Remove kink or pinch Replace if flow is blocked with no vacuum present Repair as necessary re check operation OK Go to St
88. temperature control lever should be at the cold position 6 The vehicle should be running above idle when performing cooling tests 1500 rpm s STEP 3 Check water valve operation when in A C OK mode max cold Go to Step 4 position Water valve p should be closed No coolant to rear STEP 4 Check OEM to Auxiliary connections Make OK Go to Step 5 2 4B STEP 1 OK STEP 2 OK Verify proper operation Go to Step 2 Verify proper operation Go to Step 3 of dash system of rear system sure OEM and ProAir Valves are open CCW rotation NOT OK Go to Step 4A NOT OK Go to Step 3A NOT OK Go to Step 2A NOT OK Go to Step 1 STEP Check condition of vacuum line from water valve to OEM connection for cuts or pinched areas Check OEM blue line for vacuum STEP 1A Diagnose dash concerns before making repairs to rear system OK Re check operatio STEP 2A Review operating OK Re check operatio STEP 4A Open valves procedures and re check system WARNING NOTE Follow standard diagnosis procedures for determining inoperative A C system factory or auxiliary units NOTE No vacuum at OEM blue line in A C mode is an OEM problem Consult Dealer for repairs ProAir LLC 2 4A DO NOT disconnect fittings without recapturing refrigerant using standard shop procedures 2000 Ford Econoline Van
89. tive costly repairs categorize the airflow concern into one of the following general areas Inadequate airflow front or rear louvers Inadequate airflow left or right louvers Inadequate airflow all louvers The following prechecks will help in diagnosis of the airflow concern Is air inlet blocked Remove debris or obstruction Is blower inoperative on low medium and or high Refer to electrical concerns section for specific chassis Is blower wheel not intact Refer to blower replacement in repair section 15 evaporator core iced up Refer to cooling concerns section for specific chassis Is there debris on blower wheel or coil Clean and prevent reoccurrence Is there inadequate airflow out of top of unit with duct Check for blocked inlet disconnected Check for debris on core Check for blower concern If any problems exist with these prechecks they must be rectified before removing interior panels to check the ductwork Repair procedures for the above concerns can be found in the specific chassis sections of this manual If all the above prechecks are all right then check all louvers for obstructions fabric tape hole cutouts etc If louvers are unobstructed it will be necessary to access duct hose crossover and wall extensions to determine the cause of the inadequate airflow Consult conversion company s customer service department for procedures to access these components ProAir LLC 1 8
90. to MAX A C The vehicle s temperature control lever should be at the max cold position STEP 3 Check water valve operation when in A C STEP 1 STEP 2 OK Go to Step 3 OK Go to Step 2 mode max cold position Water valve should be closed No coolant to rear Verify proper operation of rear system Verify proper operation of dash system NOT OK Go to Step 3A NOT OK Go to Step 2A NOT OK Go to Step 1 STEP 3A ProAir water valve must be connected to Yellow STEP 1A Diagnose dash concerns before making repairs to rear system STEP 2A Review operating OEM vacuum line below the dash on the passenger side procedures and re check system NOTE Follow standard diagnosis procedures for determining inoperative A C system factory or auxiliary units ProAir LLC 3 4C Keep in mind the rear unit s performance is dependent on a properly operating dash system The vehicle should be running above idle when performing cooling tests 1500 rpm s STEP 4 Check A C tee OK installation and location Go to Step 4 OK Go to Step 5 3 40 for correct assembly See factory connection points W O YF7 NOT OK Go to Step 4A STEP 4A Install tee s correctly Recharge system according to factory procedures OK Re check operatio OK Re check operatio WARNING DO NOT disconnect
91. tor 1 Replace affected harness or connectors Speeds harness or resistor plug according to wiring diagram ProAir LLC 2 5B PRO AIR JUMPER HARNESS TO OEM MID SWITCH CONNECTOR PART NO 40 000 022 NOTES 1 HARNESS 125 INSULATED WIRE EQUIVALENT TO SAE SPECIFICATION 4 i 9 BLOWER MOTOR MAXIMUM O E M 1 mem gev cereos pum B ANS MEDIUM 8 AMP W 57L PACKAGE H LOW 5 FORD OEM CONNECTOR 3 DASHED WIRE DENOTES O E WIRES LOW AT D PILLAR 2 GA GRN WHT s gt 12 GA GRN WHT OFF LOW 2 4 GA YEL RD gt gt 14 GA YEL RD 18 GA YEL MEDIUM 2 GA BLU WHT 5 12 GA BLU WHT 18 GA RD HIGH 8 RD WHT 53 18 GA RD WHT 18 GA ORG 14 GA WHT 12 GA BLK 18 GA YEL RD 2 0 GA YEL BLK gt gt 10 GA YEL BLK GND 8 YEL RD 18 GA YELRD FORD OEM WIRE HARNESS ROUTED FROM PILLAR TO D PILLAR E HOT IGN HOT 14 ORN A 14 GA WHT 14 GA ORN FUSE LOCATED IN DRIVERS BLOWER MOTOR MED 14 GA RD SIDE REAR RESISTOR BLOCK EME CORNER OF VAN Q Lo 14 GA YEL BLOWER MOTOR o gt O 122 5 5 66 a Boc lt 0 0 14 YEL 14 GA ORN 18 GA YEL RD 18 GA YEL RD 18 GA YEL RD ALL RELAYS 7 t LOCATED IN DRIVERS 87A 87 85 87A 87 85 87A 8
92. vent reoccurrence Reconnect and secure to prevent reoccurrence Reground unit Replace motor Replace switch Check circuit Repair or replace harness Replace resistor Replace switch Check circuit Repair or replace harness Replace resistor Replace switch Check circuit Repair or replace harness Motor Runs Continuously 1 Ignition feed connected to source 1 Diagnose under hood relay refer to diagram Incorrectly wired harness wires to OEM motor 1 Replace affected harness or connectors harness or resistor plug according to wiring diagram M ismatched Blower 1 Speeds ProAir LLC 1 5D 1 6A PART NO OEM CONNECTOR 40 000 085 AT B PILLAR NOTES 1 HARNESS 125 INSULATED WIRE EQUIVALENT TO SAE SPECIFICATION FOUVALENT 22 RED GRN 18 GA YEURED 2 BLOWER MOTOR MAXIMUM OEM AMP DRAW 16 CA BLK LT BLU 18 GA YEL SWITCH i MEDIUM 8 AMP MOUNTED IN 118 GA RED LOW 5 AMP DASH i 3 DASHED WIRE DENOTES O E WIRES 20 GA GRN 18 ORN WIRE HARNESS ROUTED WITH HOSES 14 GA BLK 14 GA WHT 22 GA GRN WHT GRNWHT NOT USED _ g E Gg ala 8 GND lt lt lt lt 55 9
93. xiliary unit to operate T o diagnose any problems with the OEM wiring consult dealer service manuals If all inputs are present from the OEM system reconnect the ProA ir harness to the OEM plugs and continue checking at the rear unit See next page If the following test procedures do not lead you to the correction please contact ProA ir for further assistance ProAir LLC 1 5A Chrysler Dodge B van Electrical Concerns Test Procedures With HBC Possible Cause Solution 0 0 No Blower Speeds 15A fuse at unit blown Replace fuse Check for short in system No battery voltage at fuse connector Repair open wire or connector at B pillar M otor lead disconnected Reconnect and secure to prevent reoccurrence No ground signal to terminal 30 of relays Repair open wire or connector at B pillar No ground at motor Repair open relay connection or replace relay Inoperative motor Replace motor assembly NoLow Speed No ground signal to relay Repair open circuit between B pillar and relay Inoperative relay Replace low speed relay No ground signal to resistor Repair open wire to resistor No ground signal out of resistor Replace resistor No ground signal to motor plug Repair open in wire or connector at motor plug No M edium Speed No ground signal to relay Repair open circuit between B pillar and relay Inoperative relay Replace medium speed relay No ground signal to resistor Repair ope
94. y concern is to get as specific as possible with it In order to help prevent misdiagnosis and ineffective costly repairs categorize the airflow concern into one of the following general areas Inadequate airflow front or rear louvers Inadequate airflow left or right louvers Inadequate airflow all louvers The following prechecks will help in diagnosis of the airflow concern Is air inlet blocked Remove debris or obstruction Is blower inoperative on low medium and or high Refer to electrical concerns section for specific chassis Is blower wheel not intact Refer to blower replacement in repair section 15 evaporator core iced up Refer to cooling concerns section for specific chassis Is there debris on blower wheel or coil Clean and prevent reoccurrence Is there inadequate airflow out of top of unit with duct Check for blocked inlet disconnected Check for debris on core Check for blower concern If any problems exist with these prechecks they must be rectified before removing interior panels to check the ductwork Repair procedures for the above concerns can be found in the specific chassis sections of this manual If all the above prechecks all right then check all louvers for obstructions fabric tape hole cutouts etc If louvers are unobstructed it will be necessary to access duct hose crossover and wall extensions to determine the cause of the inadequate airflow Consult conversion company s
95. y depending on the chassis ProAir unit serial number and model number should provide a reference point to correctly identify hose assemblies 98cs01 Section 3 0 General Motors G Van GMT600 ProAir Unit L ocation Although location may vary by converter the ProAir unit is usually located on the driver s side rear corner inside the interior wall A C and heater hoses drop through the floor at this point with the liquid hose and the two heater hoses routed to the driver s side B pillar and the suction hose routed forward into the engine compartment See page 3 1 or 3 2 Factory Connection Points The air ducts also attach to the unit at this pointand continue up the wall into the ceiling CAUTION Located near the unit and built into the wall is a vent which must be kept clear to maintain adequate airflow through the evaporator D o not block off this vent Also the louvers in the ceiling must be partially open whilethe unitis operating If the louvers are completely closed air backup will result in possible damage to the blower assembly ProAir Unit Operation Therear air conditioning system will function with the dash mode control positioned in one of the air conditioning settings The rear heating system will function to its maximum potential with the dash mode control positioned in the FLOOR location Verify that the unit is not cool only it must be a heat cool unit When the dash mode control is positioned in the

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