Proheat M80 Manual de Serviço

G-I PCM SERVICE MANUALM50/M80SERIAL NUMBERSVANE COMPRESSOR: 500000 - 699999DIAPHRAGM COMPRESSOR: 700000 - 704999Rev. H

PROHEAT G-I PCM SERVICE MANUALD-1NOTICEFor continuity, all figures shown in thismanual will use a diaphragm compressorunlesswhere special instructions

PROHEAT G-I PCM SERVICE MANUALD-2

PROHEAT G-I PCM SERVICE MANUALE-1MODEL DESCRIPTIONSE.Please refer to the M-Series Parts Book at www.proheat.com for detailed partdescriptions and part

PROHEAT G-I PCM SERVICE MANUALE-2Splash Guard, Straight and Right Angle Snorkel Attachments.The M-Series can be equipped with a splash guard, straight

SYSTEM INPUTSSWITCH 10 – 30VStandard Run ModePreheat Run ModeSupplemental Run ModeCOOLANT PUMP 10 – 30VAUXILIARY Allows independent operation of Coola

PROHEAT G-I PCM SERVICE MANUAL1-2EXHAUST(SEE NOTE 2 AND 4)-4 JIC MALE FUEL INLET (INTERNALFUEL FILTER) (SEE NOTE 5)2.75 (70)12.60 (320)23.24 (590)4.45

PROHEAT G-I PCM SERVICE MANUAL1-3AIR INTAKE OPTION:3" OD SNORKEL SEE NOTE 7AIR INTAKE OPTION:2.25" OD ELBOW WITH27° ADAPTER PLATE SEE NOTE 7

PROHEAT G-I PCM SERVICE MANUAL1-4ELECTRICAL1.2BGHFECDAINDICATOR OUTPUT (HIGH SIDE SWITCHED. DASH OR PROHEAT TOGGLE SWITCH LIGHT) (1 AMP MAX)ENGINE RUN

PROHEAT G-I PCM SERVICE MANUAL1-5TORQUE SPECIFICATIONS1.3Solenoid Valve• Lubricate O-ring with diesel fuel.• Install solenoid valve by hand.• Ensure p

PROHEAT G-I PCM SERVICE MANUAL1-6Ignition Module• Torque screws (2) to 75 in. lbs. ± 7 in. lbs. (8.5 Nm ± 0.8 Nm).Blower Housing• Torque bolts (2) to

PROHEAT G-I PCM SERVICE MANUALiCONTENTSA. SAFETY ... A-1SAFETY CONS

PROHEAT G-I PCM SERVICE MANUAL1-7Enclosure Lid (Optional)• Torque screws (4) to 100 in. lbs. ± 10 in. lbs. (11.6 Nm ± 1.1 Nm).Fuel Filter Fitting• Ins

PROHEAT G-I PCM SERVICE MANUAL1-8

PROHEAT G-I PCM SERVICE MANUAL2-1PRINCIPLE OFOPERATIONCOMPONENT DESCRIPTIONSImpeller-style blower driven by the Motor provides the principle combustio

PROHEAT G-I PCM SERVICE MANUAL2-2Coolant is circulated through the heat exchanger via the inlet and outletports. Heat is transferred from the heat exc

PROHEAT G-I PCM SERVICE MANUAL2-3BLOWER HOUSINGFUELSUPPLYPUMPFUEL REGULATORFUELNOZZLEFUELSHUT-OFFVALVEBURNER HEADFLANGE WITH BUILTIN AIR COMPRESSORIGN

PROHEAT G-I PCM SERVICE MANUAL2-4MODES OF OPERATION2.2The Proheat Control Module (G-I PCM) has three modes of operation: Standard,Preheat and Suppleme

PROHEAT G-I PCM SERVICE MANUAL2-5CAUTIONAlways ensure that the PROHEAT is allowed to Cool Down (Purge) for a full 3minutes.If the power is shut off wi

PROHEAT G-I PCM SERVICE MANUAL2-6The Coolant Pump continues to circulate coolant throughout the system.When the coolant temperature drops below 160°F

PROHEAT G-I PCM SERVICE MANUAL2-7CAUTIONAlways ensure that the PROHEAT is allowed to Cool Down (Purge) for a full 3minutes.If the power is shut off wi

PROHEAT G-I PCM SERVICE MANUAL2-8

PROHEAT G-I PCM SERVICE MANUALii5.0 MAINTENANCE ... 5-15.1 WEEKLY MAINTENANCE .

PROHEAT G-I PCM SERVICE MANUAL3-1MAINTENANCE TOOLS3.0The following list is the minimum recommended tools to properly service theM-Series. Please refer

PROHEAT G-I PCM SERVICE MANUAL3-2

PROHEAT G-I PCM SERVICE MANUAL4-1TROUBLESHOOTINGAND REPAIR4.0Problems with the PROHEAT and its operation will be indicated in two ways:1.PROHEAT Diagn

PROHEAT G-I PCM SERVICE MANUAL4-24.1.14.1 SYSTEM AND COMPONENTDIAGNOSTICSThe G-I PCM continually monitors the PROHEAT operating conditions. If the G-I

PROHEAT G-I PCM SERVICE MANUAL4-3START Diagnostic Code 1Indicates that the G-I PCM Flame Sensor did not detect a flame or the flamewas too weak to be

PROHEAT G-I PCM SERVICE MANUAL4-4Fuel and fuel supply – Check:a) Vehicle fuel level and/or for fuel gelling during cold weather.b) Air leaks and/or re

PROHEAT G-I PCM SERVICE MANUAL4-5PROHEAT fuel filter – Check:a) For filter contamination and restrictions.b) For damaged inlet fitting.Test Procedure

PROHEAT G-I PCM SERVICE MANUAL4-6Fuel Nozzle and Fuel Nozzle cavity – Check:a) For Fuel Nozzle and O-ring damage and/or contamination.b) For correct F

PROHEAT G-I PCM SERVICE MANUAL4-7• Re-clamp the Fuel Nozzle stem lightly but firmly in a vise using softjaws, take care not to cause damage. Reinstall

PROHEAT G-I PCM SERVICE MANUAL4-8Fuel Shut-off Valve – Check:a) Fuel Shut-off Valve and G-I PCM - electrical open circuit fault.b) Valve plunger – mec

PROHEAT G-I PCM SERVICE MANUALA-1SAFETYA.Throughout this manual, you will see notes labeled DANGER, WARNING,CAUTION, and NOTICE to alert you to specia

PROHEAT G-I PCM SERVICE MANUAL4-9e) Measure the Fuel Shut-off Valve coil using a multimeter set to read Ohms.If the coil measures between 35 and 45 Oh

PROHEAT G-I PCM SERVICE MANUAL4-10b) Loosen and remove the valve stem. Remove the O-ring, plunger andspring. Save the parts.c) Inspect the O-ring and

PROHEAT G-I PCM SERVICE MANUAL4-11Fuel Regulator – Check:a) For damage and/or contamination and mechanical operation.Procedure – Fuel Regulator remova

PROHEAT G-I PCM SERVICE MANUAL4-12Air Compressor – Check:a) Air Compressor pressure and operation.Before checking air pressure, remove, disassemble an

PROHEAT G-I PCM SERVICE MANUAL4-13PRESSURE ADJUSTMENT SCREWDECREASEPRESSUREINCREASEPRESSUREFLAMESHIELDDIAPHRAGMCOMPRESSORIGNITIONELECTRODEASSEMBLYFigu

o) Connect the Power, Overheat/Temperature Sensor and Coolant Pumpelectrical connections to the heater Burner Had and reconnect the fuel line.p) Activ

PROHEAT G-I PCM SERVICE MANUAL4-15Figure 4-17: Pressure Relief Valve adjustment.PRESSURE RELIEF CAPLOCK NUTPRESSURE RELIEFVALVE BODYPRESSUREGAUGEADAPT

AIR COMPRESSORSCREWSTORQUE = SEESECTION 1.3O-RINGAIRCOMPRESSORGEAR LOCATINGSNAP RINGPROHEAT G-I PCM SERVICE MANUAL4-16i) Reinstall gear locating snap

PROHEAT G-I PCM SERVICE MANUAL4-17Fuel Supply Pump – Check:a) Fuel Supply Pump pressure and operation.Test Procedure – Fuel Supply Pump pressure:a) Di

PROHEAT G-I PCM SERVICE MANUAL4-18Fuel Supply Pump cleaning:a) Disconnect all harnesses at the G-I PCM.b) Disconnect the fuel supply line.c) Loosen an

PROHEAT G-I PCM SERVICE MANUALA-2SAFETY CONSIDERATIONSExhaustInhalation of exhaust gas (containing carbon monoxide) may cause severe personalinjury an

PROHEAT G-I PCM SERVICE MANUAL4-19IGNITION MODULESCREWS (2)NOZZLEFLAME SHIELDIGNITIONELECTRODEASSEMBLYFUEL PUMPFUEL SHUT-OFF VALVEFUEL REGULATORFigure

PROHEAT G-I PCM SERVICE MANUAL4-20Ignition Module – Check:a) Ignition Operation using Ignition mode.b) Ignition Module and G-I PCM – electrical open c

PROHEAT G-I PCM SERVICE MANUAL4-21e) Reconnect the power and switch harnesses.f) Switch the PROHEAT on and observe for a spark. Spark will continue fo

PROHEAT G-I PCM SERVICE MANUAL4-22f) Reconnect Ignition Module connector at the G-I PCM.Flame Sensor – Check:a) Flame Sensor operation.b) Combustion t

PROHEAT G-I PCM SERVICE MANUAL4-23d) Disconnect the Ignition Module connector at the G-I PCM.e) Check for contamination on the Flame Sensor. Clean if

PROHEAT G-I PCM SERVICE MANUAL4-24Motor or G-I PCM – Check:a) Electrical function – Open circuit motor.b) Electrical function – Open circuit G-I PCM.T

PROHEAT G-I PCM SERVICE MANUAL4-25Motor replacement:a) Disconnect all harnesses at the G-I PCM.b) Disconnect the fuel supply line.c) Loosen and back o

PROHEAT G-I PCM SERVICE MANUAL4-26FLAME OUT Diagnostic Code 2Indicates that a flame was detected but it could not be maintained or afterbeing establis

PROHEAT G-I PCM SERVICE MANUAL4-27COOLANT FLOW Diagnostic Code 3Indicates that the coolant temperature in the PROHEAT reached 185°F (85°C)within 90 se

PROHEAT G-I PCM SERVICE MANUAL4-28Procedure – Mechanical inspection and testing:a) Connect the power directly to the Coolant Pump. Observe the operati

PROHEAT G-I PCM SERVICE MANUALB-1INTRODUCTIONMODEL: M50/M80 G-I PCMThis manual is provided to assist in troubleshooting and maintaining thePROHEAT M-S

PROHEAT G-I PCM SERVICE MANUAL4-29VOLTAGE: Step 2(5 Flashes)OVERHEAT Diagnostic Code 4Indicates that the Temperature Sensor detected an inner heat exc

PROHEAT G-I PCM SERVICE MANUAL4-30Procedure – Low voltage testing:a) Inspect the wiring harnesses and connections for corrosion and properfit. Clean i

PROHEAT G-I PCM SERVICE MANUAL4-31FLAME FAULT Diagnostic Code 6Indicates that:1. The PROHEAT reached 185°F (85°C) cycled off and entered Cool Down(Pur

PROHEAT G-I PCM SERVICE MANUAL4-32If after changing the Temperature Sensor a diagnostic code is stillindicated, the G-I PCM is faulty. Go to G-I PCM r

PROHEAT G-I PCM SERVICE MANUAL4-33Temperature Sensor replacement:a) Isolate the coolant system at the PROHEAT inlet and outlet ports forminimal coolan

PROHEAT G-I PCM SERVICE MANUAL4-344.1.9(8 Flashes)Figure 4-40: Burner Head Removal and Fuel Shut-off Valve ConnectionFUEL SHUT-OFF VALVECONNECTIONLOCK

PROHEAT G-I PCM SERVICE MANUAL4-35TEMPERATURE SENSOR T2 Diagnostic Code 7 and/or 9Go to Temperature Sensor T1 Diagnostic Code, page 4-31.IGNITION MODU

PROHEAT G-I PCM SERVICE MANUAL4-36COOLANT PUMP Diagnostic Code 11Indicates an over-load fault is detected.Troubleshoot the Coolant Pump diagnostic cod

PROHEAT G-I PCM SERVICE MANUAL4-37MOTOR Diagnostic Code 12Indicates that an over-load fault is detected in precheck or during operation.Troubleshoot t

PROHEAT G-I PCM SERVICE MANUAL4-384.1.15(14 Flashes)SWITCH/TIMER POWER Diagnostic Code 14Indicates a short circuit fault in harness or the device bein

PROHEAT G-I PCM SERVICE MANUALB-2

PROHEAT G-I PCM SERVICE MANUAL4-39Fuel Nozzle Go to page 4-6, Step 3.Fuel Shut-off Valve Go to page 4-8, Step 4.Fuel Regulator Go to page 4-11, Step 5

PROHEAT G-I PCM SERVICE MANUAL4-40c) Disconnect the Datalink harness at the G-I PCM. Using a multimeter setfor voltage, measure across pins D and B in

PROHEAT G-I PCM SERVICE MANUAL4-41e) Remove the fuse cover and using needle nose pliers or a fuse removaltool remove the fuse.If the fuse is blown, re

PROHEAT G-I PCM SERVICE MANUAL4-42Problems with the PROHEAT and/or vehicle application that are notspecifically defined but are observed during the op

PROHEAT G-I PCM SERVICE MANUAL5-1MAINTENANCE5.0Your PROHEAT has been designed to operate with a minimum of maintenance.To ensure the efficient operati

PROHEAT G-I PCM SERVICE MANUAL5-21. Clean Heater Enclosure• Clean any accumulated debris or dust from the components.• Make sure the opening around th

BLOW THIS DIRECTIONWHEN USINGCOMPRESSED AIR.PROHEAT G-I PCM SERVICE MANUAL5-37. Check Fuel Filter• Remove and inspect filter. Clean or replace as nece

PROHEAT G-I PCM SERVICE MANUAL5-49. Compressor Air Filter• Replace inlet air filter annually or more often if dusty conditionsare encountered.•Ensure

PROHEAT G-I PCM SERVICE MANUAL5-5REPLACEMENT PARTS ANDTEST EQUIPMENTPART # QTY DESCRIPTION200610K 1 Filter, Air, Element880035K 1 Fuel FilterPK0067 1

PROHEAT G-I PCM SERVICE MANUAL5-6The rotary vane compressor may need service to clean and/or to replace thevanes. This can be indicated by a lack of c

PROHEAT G-I PCM SERVICE MANUALC-1PROHEAT CONTROLMODULE (PCM) TYPEC.The G-I Proheat Control Module (G-I PCM) is no longer available has been replacedwi

PROHEAT G-I PCM SERVICE MANUAL5-72. Clean the Rotary Vane Compressora) Remove the nozzle and air relief (see figure 5-6). If the nozzle stemlooks blac

PROHEAT G-I PCM SERVICE MANUAL5-8g) Disconnect the power cable to remove power and stop motor.h) Disconnect the remote on/off switch.i) Reconnect igni

PROHEAT G-I PCM SERVICE MANUAL5-9NOTICEDO NOT loosen the three screwsholding the compressor body (figure5-8), as it requires special tools toinstall t

PROHEAT G-I PCM SERVICE MANUAL5-10

PROHEAT G-I PCM SERVICE MANUAL6-1PROHEAT WARRANTY6.0Throughout this document references are made to SeaStar Solutions and Proheat which are operatingn

PROHEAT G-I PCM SERVICE MANUAL6-2

Proheat Serial Number:Installation Date:Dealer:Printed in Canada 09/14 PID# SL9150HDesigned and Manufacturedin North AmericaSeaStar Solutions3831 No.6

PROHEAT G-I PCM SERVICE MANUALC-2