Idle Free Flex Operator's Handbook Manual

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Operator's

Handbook

Idle Free FLEX System

PN 701021

[REV A 3/18]

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Page 1 Operator’s Handbook Idle Free FLEX System PN 701021 [REV A 3/18]...
Page 2 Idle Free® and Vocational Heat Kit™ are trademarks of Idle Free Systems, Inc. The information, illustrations, and specifications contained in this publication are of the latest available at time of printing. Idle Free Systems reserves the right to alter the contents of this publication without prior notice. No part of this publication is to be electronically or mechanically reproduced, stored, or transmitted without expressed written permission of Idle Free Systems.
Page 3: Table Of Contents
Table of Contents Foreword Introduction Safety Operation Battery Management 11 Maintenance Troubleshooting Schematics Service Parts Warranty...
Page 4: Foreword
Please take a few minutes to read through this handbook and familiarize yourself with the basic principles of the Idle Free FLEX system. In addition to safety information, this handbook will equip you with the operational, management, and maintenance practices to maximize performance and product life.
Page 5: Introduction
Introduction Introduction This vehicle is equipped with the Idle Free FLEX system. The system is designed to reduce unnecessary engine idling, while maintaining the safety and comfort of the operator. Certain sections and components referenced throughout this handbook may or may not apply to this vehicle’s FLEX...
Page 6 Operator Interface The touchscreen is an intuitive interface for controlling the FLEX system. Centralized control placed in front of the driver promotes utilization. All buttons are pre-programmed and are self-explanatory in their function. The touchscreen powers up automatically when the truck’s ignition is turned “OFF”, reminding the...
Page 7: Safety
Safety Safety Safety is the priority and duty of the operator. Adhere to all safety notices and recommendations contained in manuals and decals. The warnings contained in this section pose a threat to both personal injury and/or equipment damage. Included with the kit are two decals that are installed in the vehicle.
Page 8 Safety WARNING ASHPYXIATION HAZARD Do not operate FFH in enclosed spaces or in presence of toxic materials, dust, or fumes. Ensure adequate ventilation. Ultracapacitor Engine Start Module WARNING ARCING HAZARD Do not short terminals. Do not connect in reverse polarity. Do not connect battery to “S+”...
Page 9 Safety WARNING DO NOT JUMP START Do not jump start to the “S+” circuit. Arcing and/or battery damage may result. Jump start only to batteries directly. Decals  Ensure the above decals are clearly visible to the operator.
Page 10: Operation
Operation Turn Your System On To use the Idle Free FLEX system, you MUST start by turning the truck’s ignition to the “OFF” position. The touchscreen now powers up and is the central control point. From the touchscreen you will control loads and monitor power consumption.
Page 11 Operation 1. Shut down engine (turn ignition “OFF”). 2. Turn coolant heater “ON” at touchscreen. 3. Adjust FAN and COOL/HEAT knobs on dash to control heat level 4. To turn off system turn ignition to “ON” position, or turn heat off on touch screen.
Page 12 Operation Ultracapacitor Engine Start Module The ESM retains electrical power in a bank of ultracapacitors. The actual ampacity of the ESM is rather small, less than 10% of a group 31 SLI battery. Yet, it has ability to discharge at an impressive 1,800 CCA. It also applies a higher than standard voltage to the starter, nominally 15.0 volts and up to 16.2 volts below 32°...
Page 13 Operation Touchscreen Press HEAT on the touchscreen to turn on coolant heater and heat controls on truck dash. On the truck’s dash use the FAN and Heat/Cool knob to manage the climate inside truck. Every system is unique depending on customer desires.
Page 14: Battery Management
Battery Management Battery Management Battery management is the key to success and longevity of the FLEX system. System runtime is proportional to battery performance. Deep cycle batteries are a consumable item and capacity reduction over time is to be expected. Unfortunately, many batteries have this deterioration accelerated through improper battery management.
Page 15: Maintenance
Maintenance Maintenance Fuel Fired Coolant Heater Annually □ Inspect heater body for damage or corrosion. □ Inspect wiring harness for damage, corrosion, or loose connections. □ Inspect air intake system for damage or restrictions. □ Inspect exhaust system for damage or restrictions. □...
Page 16 Maintenance Deep Cycle AGM Batteries Quarterly Batteries should be serviced on a quarterly basis using an “ABC” practice. ABC stands for Alternator-Battery-Connections. Poor alternators, underperforming batteries, and excessively corroded connections must be repaired or replaced. Alternator □ Inspect alternator for signs of stress or damage. □...
Page 17: Troubleshooting
The troubleshooting steps contained in this section are intended as a first approach by the operator to address common issues. For troubleshooting assistance, please contact Idle Free Technical Support. (920-206-9333) If any of these symptoms become persistent occurrences, the vehicle should be scheduled for service by a qualified technician.
Page 18 Troubleshooting Ultracapacitor Engine Start Module Symptom Possible Cause Resolution Vehicle cranks slow or Discharged ESM Test ESM for recharge not at all. status. Battery voltage too low Fully recharge vehicle batteries. Faulty ESM Test ESM for fault codes. Vehicle shuts down Battery voltage too low Fully recharge vehicle immediately after start.
Page 19 Troubleshooting Touchscreen Symptom Possible Cause Resolution Touchscreen does not Ignition switch Ensure ignition switch is turned to “OFF" power up Battery voltage too low Fully recharge batteries, voltage must be > 11.9 volts Replace fuse - in line Fuse blown with ignition relay and relay board under dash...
Page 20: Schematics
Schematics Schematics Fuel Fired Coolant Heater...
Page 21 Schematics Ultracapacitor Engine Start Module...
Page 22 Schematics Relay Module and Touchscreen...
Page 23: Service Parts
Service Parts Service Parts Genuine Idle Free service parts keep the VHK operating at full potential year after year. The list below contains common replaceable items. Please contact your local Idle Free dealership for ordering information. For help locating a dealership or identifying the proper part, please contact Idle Free Technical Support.
Page 24: Warranty
Warranty Warranty The FLEX system comes with a 2-year limited warranty. This warranty is backed nationwide by the Idle Free dealership network. Please contact your local Idle Free dealership to schedule warranty repairs. For help locating a dealership or identifying a warrantable failure, please contact Idle Free Technical Support.
Page 25 Idle Free Technical Support Phone: 920-206-9333 Fax: 920-206-6099 techsupport@idlefreesystems.com ©2018 Idle Free Systems Printed in USA...