Proheat M80 User Manual

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Page 1

G-I PCM SERVICE MANUAL

M50/M80

SE R I AL NUMBER S

VANE CO M P RESSOR : 50 0 000 - 69 9 9 99

DI A P HRAGM C O MPRESS O R : 700000 - 70 4999

Rev. H

Page 2

CONTENTS

A. SAFETY .

SAFETY CONSIDERATIONS ..............................................................A-2

..................................................................................... A-1

B. INTRODUCTION ......................................................................... B-1

C. MODEL DESCRIPTIONS............................................................ C-1

D. COMPRESSOR TYPE ................................................................ D-1

1.0 TECHNICAL SPECIFICATIONS .................................................. 1-1

1.1 PHYSICAL .............................................................................. 1-2

1.2 ELECTRICAL........................................................................... 1-4

1.3 TORQUE SPECIFICATIONS ....................................................... 1-5

2.0 PRINCIPLES OF OPERATION ................................................... 2-1

2.1 COMPONENT DESCRIPTION .................................................... 2-1

2.2 MODES OF OPERATION .......................................................... 2-4

2.2.1 Standard Mode............................................................2-4

2.2.2 Preheat Mode............................................................. 2-5

2.2.3 Supplemental Mode.................................................... 2-6

3.0 MAINTENANCE TOOLS ............................................................. 3-1

4.0 TROUBLESHOOTING AND REPAIR........................................... 4-1

4.1 SYSTEM AND COMPONENT DIAGNOSTICS................................ 4-2

4.1.1 EXAMPLE PROHEAT BEHAVIOR ERROR – Code 1 ........... 4-2

4.1.2 START Diagnostic Code ............................................... 4-3

4.1.3 FLAME OUT Diagnostic Code ..................................... 4-26

4.1.4 COOLANT FLOW Diagnostic Code ............................... 4-27

4.1.5 OVERHEAT Diagnostic Code....................................... 4-29

4.1.6 VOLTAGE Diagnostic Code ......................................... 4-29

4.1.7 FLAME FAULT Diagnostic Code .................................. 4-31

4.1.8 TEMPERATURE SENSOR T1 Diagnostic Code .............. 4-31

4.1.9 FUEL SHUT-OFF VALVE Diagnostic Code...................... 4-34

4.1.10 TEMPERATURE SENSOR T2 Diagnostic Code .............. 4-35

4.1.11 IGNITION MODULE Diagnostic Code ........................... 4-35

4.1.12 COOLANT PUMP Diagnostic Code............................... 4-36

4.1.13 MOTOR Diagnostic Code ........................................... 4-37

4.1.14 AUXILIARY OUTPUT Diagnostic Code .......................... 4-38

4.1.15 SWITCH/TIMER POWER Diagnostic Code .................... 4-38

4.2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS.......... 4-39

4.2.1 Fuel Nozzle .............................................................. 4-39

4.2.2 Fuel Shut-off Valve .................................................... 4-39

4.2.3 Fuel Regulator .......................................................... 4-39

4.2.4 Air Compressor......................................................... 4-39

4.2.5 Fuel Supply Pump ..................................................... 4-39

4.2.6 Ignition Electrodes .................................................... 4-39

4.2.7 G-I PCM Fuse ........................................................... 4-39

4.3 OPERATIONAL PROBLEMS..................................................... 4-42

PROHEAT G-I PCM SERVICE MANUAL

Page 3

5.0 MAINTENANCE .

......................................................................... 5-1

5.1 WEEKLY MAINTENANCE .......................................................... 5-1

5.2 ANNUAL MAINTENANCE .......................................................... 5-2

5.3

ROTARY VANE COMPRESSOR SERVICE & VANES INSTALLATION

.... 5-6

6.0 PROHEAT WARRANTY .............................................................. 6-1

PROHEAT G-I PCM SERVICE MANUAL

Page 4

SAFETYA.

Throughout this manual, you will see notes labeled DANGER, WARNING, CAUTION, and NOTICE to alert you to special instructions or precautions concerning a particular procedure that would be hazardous if performed incorrectly or carelessly.

Observe them carefully!

These safety alerts alone cannot eliminate all hazards. Strict compliance with these special instructions and common sense are major accident prevention measures.

DANGER

Immediate hazards that will result in severe injury or death.

WARNING

Hazards or unsafe practices that could result in severe personal injury or death.

CAUTION

Hazards or unsafe practices that could result in minor injury or product or property damage.

NOTICE

Information that is important to proper installation or maintenance, but is not hazard-related.

PROHEAT G-I PCM SERVICE MANUAL

A-1

Page 5

SAFETY CONSIDERATIONS

WARNING

Exhaust

Inhalation of exhaust gas (containing carbon monoxide) may cause severe personal

injury and/or death. Anyone suspected of suffering from CO inhalation should be removed from the hazardous area and given medical assistance immediately.

Explosion Hazard

Do not operate heater where combustible fumes or airborne particles, such as sawdust, are present.

Fuel

Exercise extreme caution when working near fuel or fuel-filled equipment. Do not operate heater during fueling operations. In addition, do not smoke or handle open flame equipment, such as a blowtorch, around fuel.

Fire Hazard

Do not place any flammable items around the heater and exhaust pipe.

Batteries

Wear hand and eye protection when working near batteries. Do not smoke or use open flames near batteries.

Electrical

Electric shock can cause severe personal injury, burns, and death. Before working on any unit, disconnect the batteries. Use only approved materials and methods when working on the electrical system and follow local electrical codes. Never work with electricity in wet conditions or when you are feeling fatigued.

WARNING

DANGER

Poisons/Toxins

Fuel and coolant are toxic and in some cases, carcinogenic. Wear eye and hand protection at all times. Remove contaminated clothing immediately and wash contaminated skin. Do not breathe in vapors.

Moving/Hot Parts

Moving parts can cause severe injury and or death. Before working on any unit, shut it off. Do not operate any unit until protective covers have been replaced. Always ensure bolts and clamps are correctly torqued and secured. Inspect mechanical components periodically for damage and corrosion.

Coolant

Never remove the filler cap when the engine is hot – escaping steam or scalding water could cause serious personal injury. The coolant level in the expansion tank should be checked at least weekly (more frequently in high mileage or arduous conditions). Always check the level when the system is cold. Unscrew the filler cap slowly, allowing the pressure to escape before removing completely. Never run the engine without coolant.

Prevent anti-freeze coming in contact with the skin or eyes. If this occurs, rinse immediately with plenty of water. Anti-freeze will damage painted surfaces.

Never top-up with salt water. Even when travelling in territories where the water supply contains salt, always ensure you carry a supply of fresh (rain or distilled) water.

California Proposition 65 Warning

Do not operate heater in garages or in other closed or unventilated areas. Diesel exhaust and some of its constituents are known to the State of California to

cause cancer, birth defects, and other reproductive harm. Electrical components in this product may contain lead, a chemical known to the

State of California to cause cancer and birth defects and other reproductive harm.

A-2

PROHEAT G-I PCM SERVICE MANUAL

Page 6

INTRODUCTION

MODEL: M50/M80 G-I PCM

Figure B-1.

This manual is provided to assist in troubleshooting and maintaining the PROHEAT M-Series heater. They are designed for use on any diesel-equipped vehicle including trucks, buses (school, transit and coach), construction equipment, off road equipment, military equipment and cargo.

PROHEAT heaters are used for the following applications:

(1) Engine Block Heat – The PROHEAT will preheat an engine block to ensure

reliable starting in cold weather. Its’ use throughout the year will reduce engine wear caused by cold starts.

(2) Supplemental Heat (engine running) – The PROHEAT can be used while

the vehicle is operating to provide supplemental heat for the engine and/or passenger compartment.

(3) Cargo Heat – The PROHEAT can supply heat to individual compartments

as a stand-alone heating system, or it can provide supplemental heat to an existing heating system.

(4) Marine – Marine applications typically involve the

installation of a complete hot-water is only one component. SeaStar Solutions recommends that only an expert in marine hot-water heating systems install a PROHEAT for marine applications. NOTE: It is the that an installation

complies with all applicable codes and regulations.

heating system of which PROHEAT

installer’s responsibility to ensure

engineering and

PROHEAT G-I PCM SERVICE MANUAL

B-1

Page 7

B-2

PROHEAT G-I PCM SERVICE MANUAL

Page 8

G-II PCM G-I PCM

MET RI-PACK 1205264 4 AUX CONNECTOR KEYING

7 PIN DATA LINK CONNECTOR

FOUR PIN DUAL MODE TEMPERATURE SENSOR CONNECTOR

MET RI-PACK 12052641 A UX CONNECTOR KEYING

2 X TWO P IN ANA LOG TEMPERATURE SENSOR CONNECTORS

6 PIN DATA LINK CONNECTOR

NO AIR F ILTER RET ENT ION TANGS

AIR FILTER RET ENT ION TANGS

STATUS INDICATOR LIGHT

PROHEAT CONTROL MODULE (PCM) TYPE

The G-I Proheat Control Module (G-I PCM) is no longer available has been replaced with the G-II PCM. The new G-II PCM incorporates a new dual mode analog/digital temperature identified in the figures below. Please refer to the M-Series Parts Book at www.proheat.com for part numbers.

THIS MANUAL COVERS ONLY THE G-I PCM. Please see SL9157 for Service information on the G-II PCM.

sensor and advanced Data Link software. Both styles can be

Figure C-1. G-I PCM and G-II PCM.

PROHEAT G-I PCM SERVICE MANUAL

C-1

Page 9

C-2

PROHEAT G-I PCM SERVICE MANUAL

Page 10

COMPRESSOR TYPED.

NOTICE

For continuity, all figures shown in this manual will use a diaphragm compressor unless

where special instructions or

illustrations

are required

The rotary vane compressor is no longer available has been replaced with the diaphragm type. Both styles can be identified in the Figures below. Please refer to the M-Series Parts Book at www.proheat.com for part numbers. This manual covers both styles of compressors and clearly identifies the differences where applicable.

ROTARY VANE COMPRESSOR

Serial Numbers:

500000 – 699999

Figure D-1. Rotary Vane Compressor Type.

DIAPHRAGM COMPRESSOR

Serial Numbers:

700000 – To Date

Figure D-2. Diaphragm Compressor Type.

PROHEAT G-I PCM SERVICE MANUAL

D-1

Page 11

D-2

PROHEAT G-I PCM SERVICE MANUAL

Page 12

MODEL DESCRIPTIONSE.

MODEL : M80- 24V S

/N : XXX XXX POWER : 95 WATTS FUEL TY PE: DIE SEL MAX PRE SS: 2 BAR OPER. VOLT:

20-30 VDC

HEAT OUTPUT: 24.0 KW

NSTALLATION DATE :

07 08 09 10 11 12

ade bt Teleflex Canad a

Richmond B C Canada

PID 200101

Please refer to the M-Series Parts Book at www.proheat.com for detailed part descriptions and part numbers. Included in the parts book are optional features such as a timer, coolant pump and associated installation equipment and maintenance tools. The following information describes the general characteristics of M-Series models covered in this manual: Heat Output, G-I PCM CANbus, Voltage, Fuel Fitting optional configurations, and Air Intake optional configurations.

Heat Output:

G-I PCM:

Voltage:

50,000 BTU/hr or 80,000 BTU/hr (15 kW or 23 kW).

The M-Series is available in either a 50,000 BTU/hr or 80,000 BTU/hr (15 kW or 23 kW) model.

CANbus SAE J1939.

The M-Series Proheat Control Module (G-I PCM) is available with CANbus

SAE J1939.

12 V or 24 V.

The M-Series is available in either a 12 V (10 – 15 VDC) or 24 V (20 – 30 VDC) model.

PROHEAT G-I PCM SERVICE MANUAL

Figure E-1.

E-1

Page 13

SPLASH GUARD STR AIGHT 3" OD

STR AIGHT SNORKEL

2.25" (55 mm) OD

SNORKEL ELBOW

26° SNORKEL ELBOW

Fuel Fitting – Optional

Configurations

-4 JIC, NPT 1/8” and -4 Hose Barb.

There are fuel fitting options including JIC, NPT, hose barb and tight access. Refer to parts book at www.proheat.com.

Air Intake – Optional

Configurations

NOTICE

For continuity, all figures shown in this manual

will use a splash guard intake.

Figure E-2.

Splash Guard, Straight and Right Angle Snorkel Attachments.

The M-Series can be equipped with a splash guard, straight and right angle intake snorkels. Refer to parts book at www.proheat.com

E-2

Figure E-3. Air Intake Options.

PROHEAT G-I PCM SERVICE MANUAL

Page 14

1.0

TECHNICAL SPECIFICATIONS

M50 12V M50 24V M80 12V M80 24V

RATING BTU/hr (kW) 50,000 (15) 50,000 (15) 80,000 (23) 80,000 (23)

SYSTEM VOLTAGE

Nominal DC Voltage (Range) 12 (10 – 15) 24 (20 – 30) 12 (10 – 15) 24 (20 – 30)

CURRENT DRAW (MAX) Amps 9.5 5.2 8.5 5.2

FUEL CONSUMPTION US gal/hr (L/hr) 0.48 (1.8) 0.48 (1.8) 0.78 (2.95) 0.78 (2.95)

IGNITION TYPE Electronic Spark Ignition

COOLANT OUTPUT TEMPERATURE MAX. 185°F (85°C)

AMBIENT OPERATING TEMPERATURE -40°F to +122°F (-40°C to +50°C)

WEIGHT lbs (kg) 53 (24)

HEAT EXCHANGER CAPACITY US gal (l) 0.5 (2)

COOLANT SYSTEM Minimum Capacity US gal (l) 2.64 (10) 2.64 (10) 2.64 (10) 2.64 (10) Recommended Flow Rate Through

Heater US gpm (lpm) 5 (19) 5 (19) 7 (26.5) 7 (26.5)

DANGER

Do not use gasoline.

FUEL TYPES

COMPATIBLE Diesel (ULSD, #1, #2, Arctic), JP8, Jet A1

Bio Fuels - Contact Proheat www.proheat.com

SYSTEM OUTPUTS

AUXILIARY OUTPUT Same as System Voltage

Maximum 1 Amp draw (over-load shut-off protection) High-side switched

SWITCH/TIMER Same as System Voltage POWER Maximum 1 Amp draw (over-load shut-off protection)

High-side switched

COOLANT PUMP Same as System Voltage

Maximum 10 Amp draw (over-load shut-off protection) High-side switched

INDICATOR LIGHT Same as System Voltage

Maximum 1 Amp draw (over-load shut-off protection) High-side switched

SYSTEM INPUTS

SWITCH 10 – 30V

Standard Run Mode Preheat Run Mode Supplemental Run Mode

COOLANT PUMP 10 – 30V AUXILIARY Allows independent operation of Coolant Pump through

the Proheat Control Module

POWER 12 Volt or 24 Volt

PROHEAT G-I PCM SERVICE MANUAL

1-1

Page 15

EXHAUST (SEE NOTE 2 AND 4)

-4 JIC MALE FUEL INLET (INTERNAL FUEL FILTER) (SEE NOTE 5)

2.75 (70)

12.60 (320)

23.24 (590)

4.45

(113)

8.14 (207)

2.03 (52)

FRONT VIEW

6 x .41 (10)

BOTTOM VIEW

AIR INTAKE ALTERNATE SNORKELS AVAILABLE (SEE PAGE 1-3 )

3.23 (82)

3.98

(101)

SIDE VIEW

SERVICE SPACE REQUIREMENT (

MAY VARY SEE NOTE 3 & PAGE 1-3)

G-I PCM

5.39

(137)

8.58

(218)

7.63

(194)

REAR VIEW

4.33

(110)

5.90

(150)

4 x M8 x 1.25 MOUNTING PEM NUTS

HEAT EXCHANGER (SEE NOTE 6)

.75 (19)

10.13 (257)

9.00 (229)

5.77

(147)

T1 PRIMA RY TEMPERATURE SENSOR SEE NOTE 8

.55 (243)

TOP VIEW

2 SECONDARY TEMPERATURE SENSOR LOCATION (SENSOR NOT SHOWN) SEE NOTE 8

INLE T SEE NOTE 8

OUTLET SEE NOTE 8

2 x 1.50 (38)

.97 (50)

PHYSICAL1.1

NOTES:

1. DIMENSIONS ARE IN INCHES (MILLIMETERS IN BRACKETS).

2. TYPICAL EXHAUST CUTOUT 3.25" CENTERED ON EXHAUST.

3. SERVICE SPACE REQUIRED TO REMOVE BURNER HEAD AND COMBUSTION TUBE FOR PERIODIC INSPECTION AND CLEANING.

4. THE EXHAUST PIPE SHOULD HAVE A MINIMUM DIAMETER OF

2.75", A MAXIMUM LENGTH OF 5' AND HAVE NO MORE THAN 180° OF BENDS.

5. ALTERNATE FUEL INLET CONFIGURATIONS AVAILABLE, SEE PARTS BOOK FOR FURTHER INFORMATION.

6. ALTERNATE HEAT EXCHANGERS AVAILABLE, SEE PARTS BOOK FOR FURTHER INFORMATION.

7. SNORKEL HOSE REQUIRED FOR THIS AIR INTAKE OPTION. CONTACT TECH SUPPORT AT WWW.PROHEAT.COM LENGTH AND BEND RESTRICTIONS

THE INLET AND OUTLET CAN BE REVERSED WITH THE ADDITION OF A T2 SECONDARY TEMPERATURE SENSOR.

FOR

1-2

PROHEAT G-I PCM SERVICE MANUAL

Page 16

IR INTAKE OPTION:

3" OD SNORKEL SEE NOTE 7

AIR INTAKE OPTION:

2.25" OD ELBOW WITH

7° ADAPTER PLATE SEE NOTE 7

AIR INTAKE OPTION:

2.25" OD SNORKEL SEE NOTE 7

AIR INTAKE OPTION: 2.25" OD ELBOW SEE NOTE 7

CAN BE INSTALLED AT 0°, 90°, 180°, 270°

4.31 (617

)

.77

(

147

)

SERVICE

SPACE

REQUIREMENT

(SEE NOTE 3)

9.21 (234)

9.09 (637

)

.77

(

147

)

SERVICE

SPACE

REQUIREMENT

(SEE NOTE 3)

9.99 (254)

24.00 (610)

5.77

(147

)

SERVICE

SPACE

REQUIREMENT

(SEE NOTE 3)

8.90 (226)

24.80 (630)

5.77

(147)

SERVICE

SPACE

REQUIREMENT

(SEE NOTE 3)

9.70 (246)

90°

0°

270°

180°

NOTES:

1. DIMENSIONS ARE IN INCHES (MILLIMETERS IN BRACKETS).

2. TYPICAL EXHAUST CUTOUT 3.25" CENTERED ON EXHAUST.

3. SERVICE SPACE REQUIRED TO REMOVE BURNER HEAD AND COMBUSTION TUBE FOR PERIODIC INSPECTION AND CLEANING.

4. THE EXHAUST PIPE SHOULD HAVE A MINIMUM DIAMETER OF

2.75", A MAXIMUM LENGTH OF 5' AND HAVE NO MORE THAN 180° OF BENDS.

5. ALTERNATE FUEL INLET CONFIGURATIONS AVAILABLE, SEE PARTS BOOK FOR FURTHER INFORMATION.

PROHEAT G-I PCM SERVICE MANUAL

6. ALTERNATE HEAT EXCHANGERS AVAILABLE, SEE PARTS BOOK FOR FURTHER INFORMATION.

7. SNORKEL HOSE REQUIRED FOR THIS AIR INTAKE OPTION. CONTACT TECH SUPPORT AT WWW.PROHEAT.COM FOR LENGTH AND BEND RESTRICTIONS

THE INLET AND OUTLET CAN BE REVERSED WITH THE ADDITION OF A T2 SECONDARY TEMPERATURE SENSOR.

1-3

Page 17

ELECTRICAL1.2

GHF

ECD

INDICATOR OUTPUT (HIGH SIDE SWITCHED. DASH OR PROHEAT TOGGLE SWITCH LIGHT) (1 AMP MAX)

ENGINE RUN (ALTERNATOR SIGNAL)

SPRING CENTRED

DOUBLE THROW

MOMENTARY SWITCH.

LOCATED ON THE

DRIVERS CONSOLE.

RED

TIMER OPTION

GREEN

WHITE

BLACK

MECHANICS DISABLE

SWITCH MOUNTED IN A

PROTECTED LOCATION

LOCATED AS PER CUSTOMER

REQUEST OR OEM REQUIREMENT

OFF

SIGNAL FROM OEM HEATING SYSTEM TO

TURN ON COOLANT PUMP WHEN REQUIRED

FOR A REASON OTHER THAN WHEN THE

HEATER REQUIRES THE PUMP

POWER OUTPUT (CONSTANT POWER. TIMER/SWITCH REMOTE PANEL) (1 AMP MAX SHARED WITH P3-D)

MAIN SWITCH INPUT (STANDARD "ON" SIGNAL OR PREHEAT UNLATCH) (ACTIVE HIGH)

GROUND (INDICATOR GROUND) (1 AMP MAX)

GROUND (ACCESSORY OUTPUT GROUND) (1 AMP MAX)

PREHEAT SWITCH INPUT (ACTIVE HIGH)

SUPPLEMENTAL SWITCH INPUT (ACTIVE HIGH)

PUMP (COOLANT) SWITCH INPUT (ACTIVE HIGH)

O.E.M. SUPPLIED

BATTERY POSITIVE (FUSE/BREAKER 30 AMP)

BATTERY NEGATIVE (GROUND)

PROHEAT G-I PCM

30 AMP

FUSE

(-)

POWER

SUPPLY

(+)

VEHICLE

GROUND

INDICATOR

LIGHT

CDE

RS232 Rx

RS232 Tx

FACTORY USE (N/A)

GROUND (1 AMP MAX)

INDICATOR OUTPUT (1 AMP MAX)

CAN-H

CAN-L

SHIELD

ACCESSORY POWER OUTPUT (1 AMP MAX SHARED WITH P2-C)

COOLANT PUMP GROUND

COOLANT PUMP OUTPUT

GROUND (AUXILIARY OUTPUT) (1 AMP MAX)

AUXILIARY OUTPUT (HIGH SIDE SWITCHED) (1 AMP MAX)

GHF

ECD

CDE

PROHEAT G-I PCM

O.E.M. SUPPLIED

MAXIMUM

10 AMPS

COOLANT PUMP

OUTPUT

AUXILIARY

OUTPUT

DATALINK

CAN BUS

CONTROL

POWER

P2 - CONTROL (SWITCH)

METRI-PACK 150 SERIES, 8 PIN

NOTE 1

P1 - POWER

METRI-PACK 280 SERIES, 2 PIN

NOTE 2

P3 - DATALINK (DOWNLOAD)

METRI-PACK 150 SERIES, 6 PIN

NOTE 1

NOTE 3

P5 - AUX (OUTPUT)

METRI-PACK 150 SERIES, 2 PIN

NOTE 1

NOTE 3

PROHEAT G-I PCM

P4 - PUMP (COOLANT)

METRI-PACK 150 SERIES, 2 PIN

NOTE 1

NOTE 3

P8 - T1: TEMP SENSOR

P7 - T2: TEMP SENSOR

NOTE 3

P6 - CANBUS (OPTIONAL)

METRI-PACK 150 SERIES, 3 PIN

NOTE 1

NOTE 3

NOTES:

1/ 150 SERIES CONNECTOR ASSEMBLIES TO BE

USED WITH 18AWG WIRE WITH MAXIMUM

.1" INSULATION DIAMETER. WIRE MUST MEET

OR EXCEED SAE J1128 GPT SPECIFICATIONS.

2/ 280 SERIES CONNECTOR ASSEMBLIES TO BE

USED WITH 10AWG WIRE WITH MAXIMUM

.161" INSULATION DIAMETER. WIRE MUST

MEET OR EXCEED SAE J1128 GPT OR GXL.

3/ ALL UNUSED CONNECTIONS ON THE PCM ARE

SUPPLIED WITH SEAL PLUGS ON STANDARD

HEATERS.

LOCK

PART#

G-I PCM CONNECTOR WIRE SEAL

PART#

TERMINAL

PART#

CAVITY SEAL

PART#

----

12052850

P3-DATALINK (DOWNLOAD)

1204808612048074

12059168

12052848

12052634P4-PUMP (COOLANT) 120480861204807412052641

12052634P5-AUXILIARY 120480861204807412052641

12052845P6-CAN BUS 120480861204807412110293

15300014P1-POWER 120151931207741315300027

12066304

P2-CONTROL (SWITCH)

1204808612048074

12059168

12047937

CONNECTOR

PART#

1-4

PROHEAT G-I PCM SERVICE MANUAL

Page 18

TORQUE SPECIFICATIONS1.3

Solenoid Valve

• Lubricate O-ring with diesel fuel.

• Install solenoid valve by hand.

• Ensure poppet and spring remain in place during assembly.

• Torque solenoid valve to fuel block to 25 in. lbs. ± 3 in. lbs.

(2.8 Nm ± 0.3 Nm).

Regulator

• Install 2 o-rings on back side of regulator (not shown).

• Torque screws (2) to 75 in. lbs. ± 3 in. lbs. (8.5 Nm ± 0.3 Nm).

Fuel Delivery Block

• Ensure all three O-rings are in place.

• Torque screws (3) to 75 in. lbs. ± 7 in. lbs. (8.5 Nm ± 0.8 Nm).

Nozzle

• Lubricate O-ring on nozzle with diesel fuel.

• Torque nozzle to fuel block to 150 in. lbs. ± 10 in. lbs.

(16.9 Nm ± 1.1 Nm).

PROHEAT G-I PCM SERVICE MANUAL

Nozzle Assembly

• Torque nozzle to nozzle stem to 30 in. lbs. ± 3 in. lbs. (3.4Nm ± .3 Nm).

1-5

Page 19

Motor

• Rotate motor shaft until motor drops into fuel pump gear..

• Ensure correct alignment (refer to ‘Motor Replacement’ on page 4-25)

Torque bolts (4) to 75 in. lbs. ± 7 in. lbs. (8.5 Nm ± 0.8 Nm).

•

Blower Housing

• Torque bolts (2) to 75 in. lbs. ± 7 in. lbs. (8.5 Nm ± 0.8 Nm).

Ignition Module

• Torque screws (2) to 75 in. lbs. ± 7 in. lbs. (8.5 Nm ± 0.8 Nm).

Temperature Sensor

• Install O-ring onto sensor.

• Torque sensor to 100 in. lbs. ± 10 in. lbs. (11.6 Nm ± 1.1 Nm).

Burner Head/Heat Exchanger

• Torque bolts (2) to 100 in. lbs. ± 10 in. lbs. (11.6 Nm ± 1.1 Nm).

1-6

PROHEAT G-I PCM SERVICE MANUAL

Page 20

Enclosure Lid (Optional)

• Torque screws (4) to 100 in. lbs. ± 10 in. lbs. (11.6 Nm ± 1.1 Nm).

Fuel Filter Fitting

• Install O-ring onto fitting.

• Torque fitting to 100 ± 10 in. lbs. (11.3 ± 1.1 Nm).

Rotary Vane Compressor ONLY

Serial Numbers 500000 – 699999

• Install O-rings into burner flange.

• Install compressor into burner flange. (Ensure correct alignment—refer to

‘Compressor Replacement’ on page 4-15)

• Torque screws (2) to 75 in. lbs. ± 3 in. lbs. (8.5 Nm ± 0.3 Nm).

Diaphragm Compressor ONLY

Serial Numbers 70000 and above

• Install O-rings in to cylinder head and valve cover (not shown).

• Ensure connecting rod is at BDC and ensure the diaphragm is concentric

to the diaphragm opening (not shown).

• Torque to 27 in. lbs +/- 3 in. lbs using a crisscross pattern.

Relief Valve

Serial Numbers 600000 – 699999

– for Use with Rotary Vane Compressor ONLY

PROHEAT G-I PCM SERVICE MANUAL

• Torque to 25 in. lbs. ± 3 in. lbs. (2.8 Nm ± 0.3 Nm).

1-7

Page 21

1-8

PROHEAT G-I PCM SERVICE MANUAL

Page 22

2.0

PRINCIPLE OF OPERATION

2.1

Combustion Air Blower:

Motor:

Fuel Supply Pump:

Fuel Regulator:

Fuel Nozzle:

COMPONENT DESCRIPTIONS

Impeller-style blower driven by the Motor provides the principle combustion air.

Drives the Combustion Air Blower, Air Compressor and Fuel Supply Pump.

A positive displacement, gear-type pump that draws fuel from the vehicle fuel tank and supplies it to the Fuel Regulator. Pressure is regulated between 7 – 10 PSI by means of an internal relief valve. Fuel is re-circulated within the pump, therefore a fuel return line to the tank is not required.

Diaphragm-type pressure reducing valve. The Fuel Regulator drops the fuel supply pressure to atmospheric pressure (0 PSI).

Air-aspirating type burner nozzle. Compressed air flows through the air passages, exiting the nozzle in front of the fuel orifice creating a vacuum in the fuel supply. This draws fuel from the Fuel Regulator and the combined fuel/air mixture is atomized into the combustion chamber.

Fuel Shut-off Valve:

Air Compressor:

Air Relief:

Ignition Module:

G-I PCM:

(PROHEAT Control Module)

Combustion Tube:

Electrically operated solenoid valve which controls fuel flow to the Fuel Nozzle.

Diaphragm compressor that supplies air pressure to the Fuel Nozzle. Note that

older versions of M-Series use a rotary vane compressor. Refer to page D-1 for more information.

Regulates air pressure to the fuel nozzle.

For use with Rotary Vane Compressor ONLY Serial Numbers 600000 – 699999.

Electronic Ignition Module with plug-in electrode.

Electronic control module monitors the PROHEAT sensors, operating conditions, and controls the Motor and other devices. Diagnostics are utilized for both safety in operations and detection of component faults to aid in service and troubleshooting. The G-I PCM contains the flame sensor which senses the flame intensity. This information can be retrieved by a personal computer using PROHEAT Datalink software.

Directs the air supplied by the blower through a swirler into the combustion zone, mixing it with the atomized fuel/air mixture from the Fuel Nozzle.

PROHEAT G-I PCM SERVICE MANUAL

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Page 23

Heat Exchanger:

Coolant is circulated through the heat exchanger via the inlet and outlet

orts. Heat is transferred from the heat exchanger through the inner wall of

p the exchanger into the coolant. The exhaust gases are directed out through the exhaust port.

Temperature Sensor 1:

Temperature Sensor 2:

Coolant Pump:

Measures the coolant temperature near the outlet port of the heat exchanger and sends this information to the G-I PCM. This sensor also measures the inner heat exchanger surface temperature for an overheat condition. It must

be connected at all times for overheat protection.

For installations where the coolant flow through the heat exchanger is opposite of what is specified on page 1-2 and page 2-3.

Circulates coolant through the PROHEAT and vehicle heating system. Depending on the PROHEAT installation, it may be operated by the G-I PCM.

2-2

PROHEAT G-I PCM SERVICE MANUAL

Page 24

OUTLET

600000 – 699999

SERIAL NUMBERS

SENSOR 1

TEMPERATURE

ROTARY VANE COMPRESSOR

AIR RELIEF

HEAT EXCHANGER

AIR COMPRESSOR

INLET

TUBE

COMBUSTION

COMPRESSOR

BUILT IN AIR

FLANGE WITH

BURNER HEAD

REQUIRED

FOR REVERSE

COOLANT FLOW

(IF EQUIPPED)

SENSOR 2

TEMPERATURE

MOTOR

FUEL

NOZZLE

IGNITION

ELECTRODES

AIR FILTER

IGNITION MODULE

FUEL

VALVE

SHUT-OFF

FUEL REGULATOR

FUEL

PUMP

SUPPLY

COMBUSTION AIR BLOWER

G-I PCM (PROHEAT CONTROL MODULE)

PROHEAT G-I PCM SERVICE MANUAL

IN AIR COMPRESSOR

FLANGE WITH BUILT

BURNER HEAD

BLOWER HOUSING

2-3

Page 25

MODES OF OPERATION2.2

The Proheat Control Module (G-I PCM) has three modes of operation: Standard, Preheat and Supplemental. Depending on the installation, more than one mode may be wired for operation. The wired modes may be identified by referring to the installation wiring diagram to determine the G-I PCM pins on P2 Control that have been connected. This wiring diagram may be compared with the drawing in Section 1.2 Electrical. The following is a summary of the operation modes:

2.2.1

1. Switch “ON” Standard

Mode Signal

2. Precheck

Standard Heat Mode

• normal operation of the Proheat

• over-rides and drops out

preheat mode

• overrides supplemental mode

Preheat Mode

• similar to standard mode

Except: 90 minute

time out.

• activated via momentary contact push button switch with latching internal to the G-I PCM

Supplemental Heat Mode

• similar to standard mode except: coolant pump does not run when Proheat is not firing

• overrides and drops out

preheat mode

• 30 second signal required before mode enabled

• No delay required for mode switch off

STANDARD MODE

The ON/OFF switch lamp, timer lamp or OEM indicator (installation options) will light. If the coolant temperature is below 160°F (71°C) the PROHEAT enters Pre-check. If the coolant temperature is above 160°F (71°C) the PROHEAT enters Standby.

The G-I PCM performs self diagnosis checking sensors for correct range, electrical components for over-load and for a flame presence. Also during the first Pre-check, the Ignition Module sparks for five seconds to allow a service technician to visually check for a spark. If there are no errors indicated, the PROHEAT goes to Ignition.

2-4

3. Ignition

4. Full Output

5. Cool Down (Purge)

The Motor and Coolant Pump start first, followed by the ignition spark, and then Fuel Shut-off Valve opens. The Ignition Module sparks for 30 seconds during which time the flame sensor must detect a correct flame. At the end of the Ignition cycle the Flame Sensor checks the flame:

•

If the PROHEAT

•

If the PROHEAT does not detect proper flame, the PROHEAT enters Cool Down

(Purge). The PROHEAT will attempt to start again moving into Pre-check after Cool Down (Purge) Fault Shut Down.

The PROHEAT will continue in Full Output until the coolant temperature reaches 185°F (85°C) at the PROHEAT outlet Temperature Sensor. The PROHEAT closes the Fuel Shut-off Valve and goes into Cool Down (Purge).

The Motor and Coolant Pump continue to operate for three minutes. After three minutes, the Motor stops and the PROHEAT enters Standby. The PROHEAT will Cool Down (Purge) for three reasons:

• Coolant reaches 185°F (85°C).

• A fault is detected. Go to Section 4.0 Troubleshooting and Repair, page 4-1.

• The PROHEAT is operating in Ignition or Full Output when it is switched off.

detects proper flame, it enters Full Output.

. If the second start cycle fails, the PROHEAT will enter

PROHEAT G-I PCM SERVICE MANUAL

Page 26

CAUTION

Always ensure that the PROHEAT is allowed to Cool Down (Purge) for a full 3 minutes. Full Output, DAMAGE TO THE HEATER MAY OCCUR.

If the power is shut off without a proper Cool Down (Purge) during

6. Standby

7. Switch “OFF”

8. Fault Shut Down

2.2.2

1. Momentary Switch “ON” Preheat

Mode Signal

The Coolant Pump continues to circulate coolant throughout the system. When the coolant temperature drops below 160°F (71°C), the G-I PCM will enter the cycle starting at Pre-check. The PROHEAT will continue to repeat Steps 2 to 6 until it is switched “OFF.”

The ON/OFF switch lamp, timer lamp or OEM indicator (installation options) will turn off.

If the PROHEAT is in Full Output, it will Purge first and then shut “OFF”.

If the PROHEAT is in Standby, it will shut “OFF” immediately.

If the PROHEAT diagnostics sense a system or component fault, the PROHEAT will shut down all components and flash a fault code(s) which best represents the conditions. To reset the PROHEAT, it must be switched off and then on again.

NOTE: Damage may occur it the fault codes are ignored and the PROHEAT is

repeatedly switched off and on without addressing the problem.

PREHEAT MODE (ENGINE OFF)

2. Precheck

3. Ignition

4. Full Output

5. Cool Down (Purge)

•

If the PROHEAT

•

If the PROHEAT does not detect proper flame, the PROHEAT enters Cool Down (Purge). after Cool Down (Purge) enter Fault Shut Down.

The Motor and Coolant Pump continue to operate for three minutes. After three minutes, the Motor stops and the PROHEAT enters Standby. The PROHEAT will Cool Down (Purge) for three reasons:

• Coolant reaches 185°F (85°C).

• A fault is detected. Go to Section 4.0 Troubleshooting and Repair, page 4-1.

• The PROHEAT is operating in Ignition or Full Output when it is switched off.

detects proper flame, it enters Full Output.

The PROHEAT will attempt to start again moving into Pre-check

. If the second start cycle fails, the PROHEAT will

PROHEAT G-I PCM SERVICE MANUAL

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CAUTION

Always ensure that the PROHEAT is allowed to Cool Down (Purge) for a full 3 minutes. Full Output, DAMAGE TO THE HEATER MAY OCCUR.

If the power is shut off without a proper Cool Down (Purge) during

6. Standby

7. After 90 mins. or a Momentary

Switch “OFF"

Signal

8. Fault Shut Down

2.2.3

1. Supplemental Mode Signal "ON"

(Engine Running)

The ON/OFF switch lamp, timer lamp or OEM indicator (installation options) will turn off.

If the PROHEAT is in Full Output, it will Purge first and then shut “OFF”.

If the PROHEAT is in Standby, it will shut “OFF” immediately.

NOTE: Damage may occur it the fault codes are ignored and the PROHEAT is

repeatedly switched off and on without addressing the problem.

SUPPLEMENTAL MODE (ENGINE RUNNING)

The ON/OFF switch lamp, timer lamp or OEM indicator (installation options) will light after 30 seconds of contentiously receiving the signal. If the coolant temperature is below 160°F (71°C) the PROHEAT enters Pre-run. If the coolant temperature is above 160°F (71°C) the PROHEAT enters Supplemental Standby (coolant pump off). If the coolant pump is requested on via the coolant pump input (analog or CAN) the PROHEAT enters Standby (coolant pump on) and will move directly to Pre-check.

2-6

2. Pre-Run

3. Pre-check

4. Ignition

The coolant pump operates for 30 seconds to circulate coolant through the system. If the coolant temperature is above 160°F (71°C) at the end of 30 seconds, the pump shuts off and the PROHEAT returns to Supplemental Standby (coolant pump off). If the coolant temperature remains below 160°F (71°C) after 30 seconds, the PROHEAT goes to Pre-check (with the coolant pump on).

The Motor starts first, followed by the ignition spark, and then Fuel Shut-off Valve opens. The Ignition Module sparks for 30 seconds during which time the flame sensor must detect a correct flame. At the end of the Ignition cycle the Flame Sensor checks the flame:

• If the PROHEAT detects proper flame, it enters Full Output.

• If the PROHEAT does not detect proper flame, the PROHEAT enters Cool

Down (Purge). The PROHEAT will attempt to start again moving into Precheck after Cool Down (Purge). If the second start cycle fails, the

PROHEAT will enter Fault Shut Down.

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5. Full Output

6. Cool Down (Purge)

7. Supplemental Standby

(Coolant pump off)

7A. Standby

(Coolant pump on)

The Motor and Coolant Pump continue to operate for three minutes. After three minutes, the Motor and Coolant Pump stop and the PROHEAT enters

Supplemental Standby (coolant pump off). The PROHEAT will Cool Down (Purge) for three reasons:

• Coolant reaches 185°F (85°C).

• A fault is detected. Go to Section 4.0 Troubleshooting and Repair, page 4-1.

• The PROHEAT is operating in Ignition or Full Output when it is switched off.

CAUTION

Always ensure that the PROHEAT is allowed to Cool Down (Purge) for a full 3 minutes. Full Output, DAMAGE TO THE HEATER MAY OCCUR.

The Coolant Pump is “OFF” but the G-I PCM continuously monitors the coolant temperature. If the coolant temperature drops below 160°F (71°C), the G-I PCM will enter the cycle starting at Pre-run. The PROHEAT will continue to repeat Steps 2 to 6 until it is switched “OFF.”

If the coolant pump is requested on via the coolant pump input (analog or CAN) the PROHEAT enters Standby (coolant pump on). If the coolant temperature drops below 160°F (71°C) the PROHEAT will move directly to Pre-check (step 3).

If the coolant pump is no longer requested on via the coolant pump input (analog or CAN) the PROHEAT enters Supplemental Standby (coolant pump off).

If the power is shut off without a proper Cool Down (Purge) during

8. Supplemental

Mode Signal

Removed

(Engine off)

9. Fault Shut Down

The ON/OFF switch lamp, timer lamp or OEM indicator (installation options) will turn off.

If the PROHEAT is in Full Output, it will Purge first and then shut “OFF”.

If the PROHEAT is in Standby, it will shut “OFF” immediately.

NOTICE

There is no time delay to shut off the PROHEAT in Supplemental Mode.

NOTE: Damage may occur it the fault codes are ignored and the PROHEAT is

repeatedly switched off and on without addressing the problem.

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2-8

PROHEAT G-I PCM SERVICE MANUAL

Page 30

MAINTENANCE TOOLS3.0

The following list is the minimum recommended tools to properly service the M-Series. Please refer to the M-Series parts book at www.proheat.com for additional PROHEAT service tools and computer software.

Minimum Proheat Service Tools

1. Remote Start Switch (P/N PK0091)

2. Temperature Sensor (P/N 200302K for G-I PCM)

3. Test Gauge, Air Pressure Digital Manometer (P/N PK0036)

4. Test Gauge, Air/Fuel Pressure (P/N PK0067)

5. Test Gauge Adaptor (P/N PK0091)

Rotary Vane Compressor Models ONLY (SN 600000 to 699999)

NOTICE

Additional standard hand tools may be required. This list is not intended to be exhaustive.

Minimum Standard Hand Tools

• Digital Multimeter

• Ratchet – 3/8" drive

• Extension, 12" – 3/8" drive

• Socket, 13 mm – 3/8" drive

• Screw Driver, Flat Blade 1/4" blade

• Allen Key, 4 mm – 3/8" drive or extension T-handle

• Allen Key, 5 mm – 3/8" drive or extension T-handle

• Allen Key, 9/64"

• 2x Combination Wrench, 3/4"

• Combination Wrench, 5/8"

• Combination Wrench, 9/16”

• Combination Wrench, 7/16”

• Wire Brush

• Adjustable Wrench

• Vise Grip

• Torque Wrench 25 – 150 in. lbs. [2.8 – 17 Nm]

PROHEAT G-I PCM SERVICE MANUAL

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3-2

PROHEAT G-I PCM SERVICE MANUAL

Page 32

4.0

STEP 1

TROUBLESHOOTING AND REPAIR

Problems with the PROHEAT and its operation will be indicated in two ways:

PROHEAT Diagnostic Faults indicated by means of a flashing diagnostic code on a OEM indicator light (if equipped). Go to page 4-2.

Operational problems may not be identified with a flashing diagnostic code (e.g., blown fuse, obstructed coolant flow, air leaks in fuel supply line)

Go to page 4-42

Troubleshooting a Problem

Locate the PROHEAT, remove the enclosure lid if used and visually check for any problems with wiring harnesses, fuel leaks, coolant leaks, exhaust pipe damage and environmental condition.

STEP 2

STEP 3

STEP 4

Figure 4-1: Air Pressure — Digital Manometer, Remote Start Switch, Temperature Sensor, Fuel Pressure Test Gauge and Test Gauge Adaptor.

Check the diagnostic indicator light, and if it's flashing, determine the code based on page 4-2.

If no code is indicated, turn the PROHEAT off and then on again using the existing operational switches, timer or a PROHEAT remote start switch (PROHEAT P/N PK0091).

Let the PROHEAT attempt to start and/or operate. Observe the operation.

NOTE: The PROHEAT will always attempt to start twice, as long as the coolant temperature is below 160°F (71°C). If a fault is detected it will shut down, go through a Cool Down (Purge) and attempt a second start. After both attempts to start or operate, an indicator light will flash a diagnostic code. Go to page 4-2.

• If the indicator light flashes, count the number of flashes and refer to the troubleshooting diagnostic code description for that number on the following pages.

• If the PROHEAT runs but is not performing or operating correctly, consult the Operational Problems section,page 4-42.

Troubleshooting and Repair Tools Required

• Test Gauge, Air Pressure Digital Manometer (PROHEAT P/N PK0036) Allows the service technician to check the air compressor pressure to ensure correct fuel delivery.

• Remote Start Switch (PROHEAT P/N PK0091) Allows the service technician to work at the PROHEAT. Isolates the PROHEAT from the existing vehicle system controls and comes with a built-in indicator light.

• Temperature Sensor (PROHEAT P/N P/N 200302K G-I PCM) Allows the service technician to start a PROHEAT when the coolant temperature is greater than 160°F (71°C). To be used only for troubleshooting.

• Test Gauge, Air/Fuel Pressure (PROHEAT P/N PK0067) Allows the service technician to check the fuel pressure to ensure correct fuel delivery (can also be used for air pressure measurements).

• Test Gauge Adaptor (PROHEAT P/N PK0091) Rotary Vane Compressor Models ONLY (SN 600000 to 699999) Allows the service technician to measure the air compressor pressure and adjust the air relief at the same time.

PROHEAT G-I PCM SERVICE MANUAL

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4.1 SYSTEM AND COMPONENT DIAGNOSTICS

The G-I PCM continually monitors the PROHEAT operating conditions. If the G-I PCM detects a problem, the indicator light flashes a diagnostic code(s).

The diagnostic indicator light may be located:

• In the toggle of the ON/OFF Switch provided by PROHEAT (standard

installation kit).

• In the PROHEAT Timer manual ON light (red).

• In an OEM indicator light package.

• In the remote switch (PROHEAT P/N PK0091) used for troubleshooting.

NO. OF DIAGNOSTIC CODE CODE PAGE FLASHES DESCRIPTION NO.

1 Start 1 4-3

SYSTEM

DIAGNOSTICS

COMPONENT

DIAGNOSTICS

2 Flame Out 2 4-26

3 Coolant Flow 3 4-27

4 Overheat 4 4-29

5 Voltage 5 4-29

6 Flame Fault 6 4-31

7 Temperature Sensor T1 7 4-31

8 Fuel Shut-off Valve 8 4-34

9 Temperature Sensor T2 9 4-35

10 Ignition Module 10 4-35

11 Coolant Pump 11 4-36

12 Motor 12 4-37

13 Auxiliary Output 13 4-38

14 Switch Output 14 4-38

4-2

4.1.1

1. Switch “ON” Standard

Mode Signal

2. Precheck

EXAMPLE PROHEAT BEHAVIOR ERROR – CODE 1

The following is an example of M-Series PROHEAT behavior during an error. The following example shows the sequence of events when the PROHEAT is switched “ON” in the Standard Mode (a similar sequence of events occurs for Preheat and Supplemental Modes).

The G-I PCM performs self diagnosis checking sensors for correct range, electrical components for over-load and for a flame presence. Also during the first Precheck, the Ignition Module sparks for five seconds to allow a service technician to visually check for a spark. If there are no errors indicated, the PROHEAT goes to Ignition.

PROHEAT G-I PCM SERVICE MANUAL

Page 34

3. Ignition

he Motor and Coolant Pump start first, followed by the ignition spark, and

T then Fuel Shut-off Valve opens. The Ignition Module sparks for 30 seconds during which time the flame sensor must detect a proper flame. At the end of the Ignition cycle the Flame Sensor checks the flame:

• In this error example, the PROHEAT does not detect proper flame and the PROHEAT enters Error Detection – Cool Down (Purge).

4. Error

Detection –

Cool Down

(Purge)

5. Steps 2 to 4 are Repeated

6. Fault Shut Down

The flame sensor did not “see” a flame by 30 seconds after entering ignition: the fuel solenoid closes and the Motor and Coolant Pump continue to operate for three minutes.

Code 01 will flash on the ON/OFF switch lamp, timer lamp or OEM indicator (installation options). There will be one flash, pause and then one flash repeating on the ON/OFF switch lamp, timer lamp or OEM indicator. After 3 minutes, the Motor and Coolant Pump stops and the PROHEAT attempts to start again.

The PROHEAT always restarts after one error detection. After the 3 minute

Cool Down (Purge), the PROHEAT will go through Precheck, Ignition and the Error Detection – Cool Down (Purge) cycle one more time.

After two consecutive Code 1 errors, the PROHEAT goes into a Fault Shut Down state. No further start attempts will be made.

The ON/OFF switch lamp, timer lamp or OEM indicator light will continue to flash once, pause and repeat.

NOTE: In order to restart the heater, turn the switch “OFF” and back “ON”.

4.1.2

(1 Flash)

START Diagnostic Code 1

Indicates that the G-I PCM Flame Sensor did not detect a flame or the flame was too weak to be detected during the FULL 30 second ignition period.

Troubleshoot the Start diagnostic code based on the following symptoms:

1. Fuel System. Go to page 4-4 to page 4-17, Steps 1 through 7.

a) There is no fuel, fuel odor or atomized fuel coming from the exhaust pipe.

b) There is no hot exhaust coming from the exhaust pipe.

2. Ignition System. Go to page 4-20.

a) There is raw fuel and/or atomized fuel and a raw fuel odor coming

from the exhaust pipe.

b) There is no hot exhaust coming from the exhaust pipe.

G-I PCM (PROHEAT Control Module) Flame Sensor circuit. Go to page 4-22.

a) There is a flame and the combustion sounds good, the PROHEAT

appears to be operating normally.

No smoke, raw fuel odor or atomized fuel is coming from the exhaust pipe.

4. Motor and/or G-I PCM fault. Go to page 4-24.

a) The Motor is NOT running. Ignition and Coolant Pump are operating.

b) No smoke, raw fuel odor or atomized fuel coming from the exhaust pipe.

PROHEAT G-I PCM SERVICE MANUAL

4-3

Page 35

START: Fuel System Step 1

Fuel and fuel supply – Check:

(1 Flash)

NOTICE

When fuel system is open, the PROHEAT will smoke and stumble until the air is purged from the system. It may be required to cycle more than one time.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

a) Vehicle fuel level and/or for fuel gelling during cold weather.

b) Air leaks and/or restrictions in the fuel supply lines to the PROHEAT.

c) The PROHEAT operation when supplying fuel from a direct source.

Test Procedure – Supplying fuel from a remote source:

a) Remove the fuel supply line from the PROHEAT fuel inlet.

b) Using a length of fuel line connected from the PROHEAT fuel inlet to a

direct source of CLEAN fuel. Switch the PROHEAT on and operate for at least one complete cycle. Observe the operation.

If the PROHEAT functions correctly, the fault is in the vehicle fuel system. Check fuel lines, connections and routing back to fuel tank. Consult OEM for service requirements.

If a Start diagnostic code is indicated, the problem is in the PROHEAT fuel system. Proceed to Step 2.

FUEL INLET

WARNING

Flammable liquid and vapours.

FUEL CONTAINER

Figure 4-2: Remote Fuel Supply

4-4

PROHEAT G-I PCM SERVICE MANUAL

Page 36

START: Fuel System Step 2

PROHEAT fuel filter – Check:

(1 Flash)

WARNING

Flammable.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

a) For filter contamination and restrictions.

b) For damaged inlet fitting.

Test Procedure – Fuel filter inspection, cleaning and/or replacement:

a) Disconnect the fuel supply line at the PROHEAT.

b) Remove the fuel filter adapter and fuel inlet fitting located in the

burner head.

c) Remove O-ring and filter. Inspect for contamination and/or restrictions.

Clean filter using electrical contact cleaner or warm soapy water. Replace if necessary.

d) Inspect the O-rings for contamination and/or damage. Clean O-rings

with a cloth or replace as necessary.

e) Inspect and clean the filter cavity and O-ring seat as necessary using

contact cleaner.

f) Reinstall filter, O-rings and inlet adapter. Tighten the adapter until it

bottoms out against the face.

g) Reconnect the fuel supply line.

h) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

If a Start diagnostic code is indicated, proceed to Step 3.

Figure 4-3: Fuel Filter Assembly and Location

FILTER

O-RING

INLET FITTING TORQUE = 100 ± 10 in. lbs (11.3 ± 1.1 Nm)

ADAPTER TORQUE = SEE SECTION 1.3

THREAD SEALANT REQUIRED

PROHEAT G-I PCM SERVICE MANUAL

4-5

Page 37

START: Fuel System Step 3

Fuel Nozzle and Fuel Nozzle cavity – Check:

(1 Flash)

Figure 4-4: Nozzle Number Location. M80 nozzle shown.

MOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3

TEMP SENSOR 1

a) For Fuel Nozzle and O-ring damage and/or contamination.

b) For correct Fuel Nozzle for the PROHEAT BTU rating.

Test Procedure – Fuel Nozzle removal, inspection and cleaning or replacement:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back out the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise and remove.

d) Remove Fuel Nozzle. Verify the Fuel Nozzle number ensuring it is the

correct Fuel Nozzle for your PROHEAT model. See table below.

MODEL NUMBER

M50 30609-50

M80 30609-9

FUEL INLET

SWITCH INPUT

POWER

Figure 4-5: Burner Head Removal and Fuel Nozzle Removal

COOLANT PUMP

e) Disassemble, inspect, clean, and reassemble Fuel Nozzle.

NOTICE

Fuel Nozzle parts are a matched set and not interchangeable.

Fuel Nozzle disassembly, inspection, cleaning and reassembly:

• Hold the Fuel Nozzle stem lightly but firmly in a vise using soft jaws, take care not to cause damage. Disassembles in three pieces.

• Inspect Fuel Nozzle stem and O-ring for contamination and/or damage. Inspect and clean distributor fuel orifice (a soft bristled brush may be used) , air passages, head and stem with electrical contact cleaner or warm soapy water.

FUEL NOZZLE

TORQUE = SEE

SECTION 1.3

FUEL NOZZLE CAVITY

4-6

PROHEAT G-I PCM SERVICE MANUAL

Page 38

HOLD UPRIGHT TO ASSEMBLE

TORQUE = SEE SECTION 1.3

ARROWS

SHOW HOW TO

LOOSEN THE

NOZZLE

• Re-clamp the Fuel Nozzle stem lightly but firmly in a vise using soft jaws, take care not to cause damage. Reinstall the distributor and Fuel Nozzle head. Ensure that the distributor is seated correctly.

he Fuel Nozzle assembly is self-aligning.

FUEL AND AIR OUTLET ORIFICE

HEAD

FUEL NOZZLE ORIFICE

AIR PASSAGES

NOZZLE NUMBER M80 NOZZLE SHOWN

DISTRIBUTOR

LUBRICATE O-RING WITH DIESEL FUEL

Figure 4-6: Fuel Nozzle Assembly

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

AIR PASSAGES

STEM

O-RING

f) Inspect the Fuel Nozzle cavity and clean as necessary using electrical

contact cleaner cleaner or warm soapy water.

g) Reinstall the Fuel Nozzle using diesel fuel to lubricate O-ring.

h) Reinstall the burner head by mounting it against the heat exchanger face,

turning clockwise to engage the mounting ears on the bolts.

i) Tighten mounting bolts. See Section 1.3 for torque.

j) Reconnect the electrical harnesses and fuel supply line.

k) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

If a Start diagnostic code is indicated, proceed to Step 4.

PROHEAT G-I PCM SERVICE MANUAL

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Page 39

START: Fuel System Step 4

Fuel Shut-off Valve – Check:

(1 Flash)

NOTICE

It is recommended that the Fuel Regulator be serviced at the same time as the Fuel Shut-off Valve. Go

to page 4-11, Step 5.

a) Fuel Shut-off Valve and G-I PCM - electrical open circuit fault.

b) Valve plunger – mechanical fault. Test the PROHEAT operation; Fuel

Shut-off Valve plunger removed.

Procedure – Coil and G-I PCM – electrical fault:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back out the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise and remove.

MOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3

TEMP SENSOR 1

LOCK

FUEL INLET

MOUNTING EARS (2)

SWITCH INPUT

POWER

Figure 4-7: Burner Head Removal

COOLANT PUMP

d) Remove the Fuel Shut-off Valve connector. Use a small flat head

screwdriver to lift the connector locking tab, pulling up on the connector to remove.

G-I PCM FUEL SHUT-OFF VALVE CONNECTION

Figure 4-8: Connector Removal

4-8

Figure 4-9: G-I PCM Fuel Shut-off Valve Connection

PROHEAT G-I PCM SERVICE MANUAL

Page 40

WARNING

Shock hazard due to high voltage.

e) Measure the Fuel Shut-off Valve coil using a multimeter set to read Ohms.

If the coil measures between 35 and 45 Ohms, coil is OK. Go to:

• Fuel Shut-off Valve output voltage measurement.

• Procedure – Fuel Shut-off Valve – Mechanical function.

If the coil measures open circuit, coil is faulty. Replace the Fuel Shut-off Valve. Go to Fuel Shut-off Valve replacement, page 4-10.

Figure 4-10: Coil Electrical Resistance Measurement

Fuel Shut-off Valve output voltage measurement:

WARNING

To avoid the risk of shock and to ensure that the PROHEAT does not fire, disconnect the Ignition Module connector at the G-I PCM.

NOTICE

All PROHEAT external harnesses must be connected to ensure that the PROHEAT attempts to start after Pre-check.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

a) Reconnect the power, Temperature Sensor(s) and switch harnesses at

the G-I PCM.

b) Disconnect Ignition Module connector at the G-I PCM.

c) Switch the PROHEAT on and measure across pins A and B of the G-I PCM

Fuel Shut-off Valve connection.

If no voltage is measured, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

If the correct voltage (9 – 15 V) is measured, the G-I PCM is OK. Go to Procedure – Fuel Shut-off Valve – Mechanical function.

G-I PCM IGNITION MODULE CONNECTION

PROHEAT G-I PCM SERVICE MANUAL

Figure 4-11: G-I PCM Fuel Shut-off Valve Output Voltage Measurement

Procedure – Fuel Shut-off Valve – Mechanical function:

a) Using a flat head screwdriver hold the valve stem while loosening the coil

nut. Remove the coil.

4-9

Page 41

b) Loosen and remove the valve stem. Remove the O-ring, plunger and

spring. Save the parts.

c) Inspect the O-ring and plunger seat for contamination. Clean as

necessary using electrical contact cleaner cleaner. Reinstall the valve

tem and seal. DO NOT INSTALL THE PLUNGER AND SPRING.

) Reinstall the coil, coil nut and reconnect the Fuel Shut-off Valve to the G-I PCM.

) Reinstall the burner head by mounting it against the heat exchanger face,

turning clockwise to engage the mounting ears on the bolts.

f) Reconnect electrical harnesses and fuel supply line.

g) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

If the PROHEAT runs OK, the Fuel Shut-off Valve is faulty. Go to Fuel Shut-off Valve replacement.

If a Start diagnostic code is indicated, proceed to Step 5.

Flammable.

WARNING

Fuel Shut-off Valve replacement:

a) Using a flat head screwdriver, hold the stem in place while loosening the

coil nut. Remove the coil.

COIL NUT TORQUE = 25 in-lbs

± 3 in-lbs (3.4 Nm ± 0.3 Nm)

COIL

SCREWDRIVER SLOT TORQUE = 25 in-lbs

± 3 in-lbs (3.4 Nm ±

0.3 Nm)

STEM TORQUE = 25 in-lbs

± 3 in-lbs (3.4 Nm ±

0.3 Nm)

PLUNGER

O-RING

Figure 4-12: Fuel Shut-Off Valve Assembly

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

4-10

b) Loosen and remove the valve stem. Remove the O-ring, plunger and spring.

c) Inspect the O-ring and plunger seat in the fuel block for contamination.

Clean as necessary using plastic safe electrical contact cleaner cleaner.

d) Install the new valve stem and seal using a slot screwdriver.

e) Reinstall the coil, coil nut and reconnect the Fuel Shut-off Valve connector

at the G-I PCM.

f) Reinstall the burner head by mounting it against the heat exchanger face,

turning clockwise to engage the mounting ears on the bolts.

g) Reinstall electrical harnesses and fuel supply line.

h) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

PROHEAT G-I PCM SERVICE MANUAL

Page 42

START: Fuel System Step 5

Fuel Regulator – Check:

(1 Flash)

WARNING

DO NOT disassemble the regulator.

o user serviceable parts. Attempts

N to open or repair may lead to unsafe operation.

WARNING

Flammable.

MOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3

TEMP SENSOR 1

a) For damage and/or contamination and mechanical operation.

Procedure – Fuel Regulator removal, inspection and reinstallation:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back out the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise and remove.

d) Remove ignition electrode assembly. Use a flat head screwdriver to pry

the electrode assembly out.

e) Remove the flame shield. Rotate to match the mounting square.

f) Remove the Fuel Regulator (2) screws, Fuel Regulator and O-rings.

MOUNTING SCREWS (2) TORQUE = SEE SECTION 1.3

FLAME SHIELD

IGNITION ELECTRODE ASSEMBLY

FUEL INLET

MOUNTING EARS (2)

SWITCH INPUT

POWER

Figure 4-13: Burner Head Removal and Fuel Regulator Removal

COOLANT PUMP

g) Inspect O-rings and O-ring seats for contamination and/or damage.

Replace if necessary.

h) Reinstall regulator ensuring that the O-rings are seated properly.

i) Reinstall the burner head by mounting it against the heat exchanger face,

turning clockwise to engage the mounting ears on the bolts.

j) Reconnect the electrical harnesses and fuel supply line.

NOTICE

k) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

All plugs/harnesses must be reinstalled into the Proheat Control

If a Start diagnostic code is indicated, proceed to Step 6.

Module (G-I PCM) before heater goes back into service.

FUEL REGULATOR

PROHEAT G-I PCM SERVICE MANUAL

4-11

Page 43

START: Fuel System Step 6

(1 Flash)

Air Compressor – Check:

a) Air Compressor pressure and operation.

efore checking air pressure, remove, disassemble and clean Fuel

B Nozzle. Go to Fuel Nozzle disassembly, inspection, cleaning and reassembly, page 4-6.

Air Compressor filter check:

a) Remove blower housing (2) screws and blower housing.

b) Remove the Air Compressor filter. Inspect for contamination and replace

if necessary. Ensure filter is installed and seated properly.

MOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3

TEMP SENSOR 1

HOUSING SCREWS TORQUE = SEE SECTION 1.3

WARNING

To avoid the risk of shock and to ensure that the PROHEAT does not fire, disconnect the Ignition Module & Fuel Solenoid connector at the G-I PCM.

NOTICE

Leaving the Temperature Sensor(s) disconnected ensures that the burner head will only run in purge for a maximum of three minutes.

FUEL INLET

SWITCH INPUT

AIR FILTER

Figure 4-14: Burner Head and Blower Housing Removal

COOLANT PUMP

POWER

Test Procedure – Air Compressor pressure (all models):

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back out the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise and remove.

d) Remove Ignition Electrode Assembly. Use a flat head screwdriver to pry

the electrode assembly out.

e) Remove the Flame Shield. Rotate to match the mounting square.

f) Disconnect the Fuel Shut-off Valve and Ignition Module connectors at the

G-I PCM. This ensures that fuel will not spray and/or light during testing.

g) For Diaphragm Compressor pressure check and setting, please continue

below. For Rotary Vane Compressor pressure check and setting, please go to page 4-14.

4-12

PROHEAT G-I PCM SERVICE MANUAL

Page 44

WARNING

Connect power and switch only. DO NOT connect the temperature sensor.

DIGITAL MANOMETER (P/N PK0036)

Test Procedure – Air Compressor pressure (Diaphragm Compressor models):

h) Remove the plug to the air pressure measurement port.

i) Thread in the Pressure Gauge and torque to 25 in-lbs ±3 in-lbs (2.8 Nm

0.3 Nm) as shown in Figure 4-15.

) Connect Power Harness and Remote Switch to the G-I PCM.

k) Switch the PROHEAT on and observe the air pressure:

If the Air Compressor reading is out of range, ensure the air compressor filter is clean. See page 4-12.

MODEL AIR PRESSURE (DIAPHRAGM COMPRESSOR)

M50 6.0 ± 0.1 PSI (41.4 ± 0.7 kPa)

M80 2.9 ± 0.1 PSI (20.0 ± 0.7 kPa)

l) Adjust the air pressure if necessary by turning the screw as shown in

Figure 4-15.

If the pressure cannot be set to the correct setting, rebuild kits are available. See www.proheat.com for the latest parts manual SL9151 for more information.

Turn heater off. Wait until purge mode is complete (approximately 3 minutes).

PRESSURE ADJUSTMENT SCREW

DECREASE PRESSURE

INCREASE PRESSURE

FLAME

SHIELD

IGNITION

ELECTRODE

ASSEMBLY

DIAPHRAGM

COMPRESSOR

Figure 4-15: Air Pressure Test. Diaphragm Compressor Model.

n) Remove Pressure Gauge. Lubricate air measurement port plug o-ring with

diesel fuel and reinstall plug into fuel block. Torque to 25 in-lbs ±3 in-lbs (2.8 Nm ±0.3 Nm). Re-install the Flame Shield, the Ignition Ignition Electrode Assembly and Burner Head onto the Heat Exchanger.

PROHEAT G-I PCM SERVICE MANUAL

4-13

Page 45

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

o) Connect the Power, Overheat/Temperature Sensor and Coolant Pump

electrical connections to the heater Burner Had and reconnect the fuel line.

) Activate the heater with the remote switch and observe operation. The

heater should run smoothly with no smoke although there may be some hesitation initially due to air in the fuel line.

q) Remove the remote switch and re-connect the control connection.

If a Start diagnostic code is indicated, proceed to Step 7.

NOTICE

Ensure to orient burner head as shown in Figure 4-16 or an incorrect pressure measurement may be made.

WARNING

Connect power and switch only. DO NOT connect the temperature sensor.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

Test Procedure – Air Compressor pressure (Rotary Vane Compressor models):

h) Thread in Pressure Gauge Adapter hand tight as shown in Figure 4-16.

i) I

nstall pressure Relief Valve & Pressure Gauge on to Pressure Gauge Adapter.

j) Orient Burner Head similar to assembled on heater.

k) Connect Power Harness and Remote Switch to the G-I PCM.

l) Switch the PROHEAT on and observe the air pressure:

MODEL AIR PRESSURE (ROTARY VANE COMPRESSOR)

M50 6.2 ± 0.1 PSI (42.7 ± 0.7 kPa)

M80 3.2 ± 0.1 PSI (22.1 ± 0.7 kPa)

m) Adjust the air pressure if necessary by releasing the lock nut and turning

the pressure relief cap as shown in Figure 4-17.

If the pressure cannot be set to the correct setting, read Section 5.2. Rotary Vane Compressor Service and Vanes Installation to check operation. If required, replace rotary vane compressor as shown on page 4-15.

n) Tighten the lock nut to 50 in-lbs ±5 in-lbs (5.6 Nm ±0.6) and ensure the

air pressure did not change after tightening the lock nut.

o) Turn the heater off. Wait until purge mode is complete (approx. 3 minutes).

p) Remove the Pressure Gauge Adapter and Harness. Lubricate Air Pressure

Relief Valve O-ring with diesel fuel and re-install the Air Pressure Relief Valve in it’s original location. Torque to 25 in-lbs ±3 in-lbs (2.8 Nm ±0.3 Nm). Reconnect the Ignition Module and Fuel Solenoid connector to the G-I PCM. Re-install the Flame Shield, the Ignition Electrode Assembly and Burner Head onto the Heat Exchanger.

Connect the Power, Overheat/Temperature Sensor & Coolant Pump

electrical line.

r) Activate the heater with the remote switch and observe operation. The

heater should run smoothly with no smoke although there may be some hesitation initially due to air in the fuel line.

s) Remove the remote switch and re-connect the control connection.

connections to the heater Burner Head and reconnect the fuel

4-14

If a Start diagnostic code is indicated, proceed to Step 7.

PROHEAT G-I PCM SERVICE MANUAL

Page 46

DIGITAL MANOMETER (P/N PK0036)

FLAME

SHIELD

IGNITION

ELECTRODE

ASSEMBLY

PRESSURE

RELIEF VALVE

ROTARY VANE COMPRESSOR

PRESSURE GAUGE ADAPTER

Figure 4-16: Air Pressure Test. Rotary Vane Compressor Model.

PRESSURE RELIEF VALVE BODY

LOCK NUT

PRESSURE RELIEF CAP

Figure 4-17: Pressure Relief Valve adjustment.

Rotary Vane Air Compressor Removal and Reassembly:

a) Disconnect Motor, Fuel Shut-off Valve and Ignition Module connectors at

the G-I PCM. b) Remove blower housing (2) screws and blower housing. c)

Remove blower retaining snap ring and slide the blower off the Motor shaft. d) Remove the G-I PCM. e) Remove Motor (4) screws and slide the Motor shaft out of the Fuel

Supply Pump taking care not to damage the Fuel Supply Pump seal.

Note the Motor drive gear size and location for reassembly. f) Remove the Air Compressor gear retaining snap ring and gear. Inspect

gears and replace if necessary. If gears are worn out it is not necessary

to replace compressor (spin and check for mechanical interference). g) Remove Air Compressor (2) screws, Air Compressor, (2) O-rings and the

gear locating snap ring from the Air Compressor shaft. h) Install new Air Compressor; ensure that the O-ring and seats are clean

and dry. Assembly lubricant not required.

PROHEAT G-I PCM SERVICE MANUAL

4-15

Page 47

i) Reinstall gear locating snap ring, gear and gear retaining ring. j) Reinstall the Motor, with drive gear, take care to ensure that the Fuel

Pump seal is not damaged.

k) Reinstall the G-I PCM, blower, blower retaining snap ring, Air Compressor

ilter and blower housing.

l) Reconnect the Motor, Fuel Shut-off Valve and Ignition Module connectors

at the G-I PCM.

m) Check air pressure. Adjust if necessary to correct pressure setting.

o to page 4-12.

GEAR LOCATING SNAP RING

AIR COMPRESSOR SCREWS TORQUE = SEE SECTION 1.3

HOUSING SCREWS TORQUE = SEE SECTION 1.3

BLOWER HOUSING

BLOWER RETAINING SNAP RING

O-RING

G-I PCM

AIR COMPRESSOR

MOTOR

O-RING

DRIVE GEAR

AIR COMPRESSOR GEAR

AIR COMPRESSOR GEAR RETAINING RING

MOTOR SCREWS TORQUE = SEE SECTION 1.3

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

4-16

AIR COMPRESSOR FILTER

BLOWER

Figure 4-18: Air Compressor Replacement

n) Reinstall the flame shield and ignition electrode assembly to the G-I PCM. o) Reinstall the burner head by mounting it against the heat exchanger face,

turning clockwise to engage the mounting ears on the bolts. p) Reinstall electrical harnesses and fuel supply line. q) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

If a Start diagnostic code is indicated, proceed to Step 7.

PROHEAT G-I PCM SERVICE MANUAL

Page 48

START: Fuel System Step 7

Fuel Supply Pump – Check:

TEMP SENSOR 1

(1 Flash)

a) Fuel Supply Pump pressure and operation.

Test Procedure – Fuel Supply Pump pressure:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back out the burner head mounting (2) bolts five to six turns

d) Remove ignition electrode assembly. Use a flat head screwdriver to pry

e) Remove the flame shield. Rotate to match the mounting square.

MOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3

allowing enough room to rotate the burner head 15° counter-clockwise and remove.

the electrode assembly out.

FLAME SHIELD

IGNITION ELECTRODE ASSEMBLY

FUEL INLET

MOUNTING EARS (2)

SWITCH INPUT

POWER

Figure 4-19: Burner Head Removal and Fuel Pressure Test

WARNING

Flammable.

COOLANT PUMP

f) Disconnect the Fuel Shut-off Valve and Ignition Module connectors at the

G-I PCM. Ensures that fuel will not spray and/or light during testing.

g) Remove the Fuel Supply Pump test port plug and install test gauge.

h) Reconnect the power and switch harnesses at the G-I PCM.

WARNING

To avoid the risk of shock and to ensure that the PROHEAT does not fire, disconnect the Ignition Module connector at the G-I PCM.

i) Reconnect the fuel supply line.

j) Switch the PROHEAT on and read the fuel pressure (should be 5 – 10 PSI):

If the pressure is out of range, Go to Fuel Supply Pump cleaning, page 4-18.

If the pressure reads OK, review Fuel System troubleshooting, page 4-3.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

Leaving the Temperature Sensor(s)

disconnected ensures that the burner

head will enter purge mode and run

for a maximum of three minutes.

NOTICE

GAUGE (P/N PK0067)

FUEL SUPPLY PUMP TEST PORT

FUEL SHUT-OFF SOLENOID

PROHEAT G-I PCM SERVICE MANUAL

4-17

Page 49

PRESSURE RELIEF VALVE CAP TORQUE = 22 in-lbs ±2 in-ibs (2.5 Nm±0.2 Nm)

BALL BEARING

SPRING

BALL GUIDE

Figure 4-20: Pressure Relief Valve Cap

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

Fuel Supply Pump cleaning:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back out the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise

and remove.

d) Locate the pressure relief valve cap and remove with a slot screwdriver.

Careful not to lose any of the internal components that may fall out.

e) Remove the spring from the cavity.

f) Remove the ball bearing from the cavity.

g) Inspect and clean all components.

h) Inspect and clean the cavity. Pay close attention to the center hole in the

cavity for any debris or a damaged edge. The edge of the hole should be

smooth with no nicks, do not use any tool that may damage this edge as

this will cause loss of fuel pressure.

i) Place ball bearing back in cavity on the center hole.

j) Place spring back in hole with brass ball guide on top of ball bearing.

k) Install pressure relief valve cap.

l) Re-test the Fuel Supply Pump. Start from item 'e' in Test procedure –

Fuel Supply Pump pressure, page 4-17.

If the Fuel Supply Pump pressure tests OK, go to item 'm'.

If the Fuel Supply Pump pressure is still incorrect, go to Fuel Supply

Pump replacement

m) Reassemble the burner head.

n) Reinstall electrical harnesses and fuel supply line.

o) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

Fuel Supply Pump replacement:

a) Disconnect and remove the Ignition Module. Go to page 4-20.

b) Remove Fuel Nozzle. Go to page 4-6.

c) Remove Fuel Regulator. Go to page 4-11.

d) Disconnect and remove Fuel Shut-off Valve. Go to page 4-10.

e) Remove blower housing (2) screws and blower housing.

Remove blower retaining snap ring and slide the blower off the Motor shaft.

g) Disconnect the Motor connector at the G-I PCM. Remove the G-I PCM.

h) Remove Motor (4) mounting screws using a 4 mm Allen wrench.

i) Remove the Motor.

j) Rotary Vane Air Compressor Only — remove the Air Compressor gear

retaining snap ring and gear.

k) Rotary Vane Air Compressor Only — remove Air Compressor (2) screws,

Air Compressor, (2) O-rings from the Fuel Supply Pump.

l) Reinstall all components in reverse order to new Fuel Supply Pump.

m) Reinstall the burner head by mounting it against the heat exchanger face,

turning clockwise to engage the mounting ears on the bolts.

n) Reinstall electrical harnesses and fuel supply line.

o) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

4-18

PROHEAT G-I PCM SERVICE MANUAL

Page 50

FUEL REGULATOR

IGNITION MODULE

SCREWS (2)

NOZZLE

FUEL SHUT-OFF VALVE

BLOWER HOUSING

FUEL PUMP

HOUSING SCREWS TORQUE = SEE SECTION 1.3

G-I PCM

MOTOR SCREWS TORQUE = SEE SECTION 1.3

FLAME SHIELD

DRIVE GEAR

O-RING

IGNITION ELECTRODE ASSEMBLY

AIR COMPRESSOR GEAR

AIR COMPRESSOR GEAR RETAINING RING

MOTOR

BLOWER RETAINING SNAP RING

Figure 4-21: Fuel Supply Pump Removal

PROHEAT G-I PCM SERVICE MANUAL

AIR COMPRESSOR FILTER

BLOWER

4-19

Page 51

START: Ignition System

5/32" [4 mm]

3/4"

[19 mm]

17/32 "

[13.5 mm]

.173" [4.4 mm]

.935"

[23.5 mm]

1.055 "

[26.8 mm]

5/32" [4 mm]

5/8"

[15.9 mm]

13/32" [10.7 mm]

Ignition Module – Check:

(1 Flash)

WARNING

o not connect Temperature

D Sensor to avoid flame.

WARNING

Shock hazard due to high voltage.

a) Ignition Operation using Ignition mode.

b) Ignition Module and G-I PCM – electrical open circuit fault.

Test Procedure – Ignition service diagnostic:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back out the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise

and remove.

d) Check Electrodes for carbon bridging and/or damage. Replace if necessary.

MOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3

TEMP SENSOR 1

IGNITION ELECTRODE PID# 200801

ROTARY VANE COMPRESSOR:

500000 – 699999

IGNITION ELECTRODE PID# 200801-1

DIAPHRAGM OR ROTARY VANE COMPRESSOR:

500000 – TO DATE

Figure 4-22: Burner Head Removal and Ignition Electrode Removal

4-20

POWER

DIAPHRAGM OR ROTARY VANE COMPRESSOR:

FUEL INLET

MOUNTING EARS (2)

SWITCH INPUT

COOLANT PUMP

IGNITION ELECTRODE PID# 200802

700000 – TO DATE

PROHEAT G-I PCM SERVICE MANUAL

Page 52

WARNING

Keep blower housing on to avoid injury when Motor starts up.

NOTICE

ll plugs/harnesses must be rein-

A stalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

e) Reconnect the power and switch harnesses.

f) Switch the PROHEAT on and observe for a spark. Spark will continue for

five seconds.

If the spark is OK, reinstall the burner head and review Fuel System troubleshooting, page 4-3.

If there is no spark check G-I PCM ignition output voltage.

Test Procedure – G-I PCM ignition output voltage:

a) Disconnect the Ignition Module and the Fuel Shut-off Valve connectors

(ensure no flow) at the G-I PCM.

b) Reconnect all external harnesses at the G-I PCM.

c) Switch the PROHEAT on and measure across pins A and C of the G-I PCM

Ignition Module connection.

If the correct system voltage (12 or 24) is measured, then measure across pins A and B (should read system voltage during ignition).

If both of the measurements are correct, then replace Ignition Module. Go to Ignition Module replacement.

If either of these measurements are incorrect, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

LOCK

Figure 4-23: Connector Removal

(+) (-)

Figure 4-24: G-I PCM Ignition Module Connection Measurement

Ignition Module replacement:

a) Remove ignition electrode assembly. Use a flat head screwdriver to pry

the electrode assembly out.

b) Remove the flame shield. Rotate to match the mounting square.

c) Remove Ignition Module (2) mounting screws and Module.

PROHEAT G-I PCM SERVICE MANUAL

d) Reinstall the new Ignition Module.

e) Reinstall flame shield and electrode assembly.

4-21

Page 53

f) Reconnect Ignition Module connector at the G-I PCM.

IGNITION MODULE

SCREWS (2) TORQUE = SEE SECTION 1.3

FLAME SHIELD

Figure 4-25: Ignition Module Replacement

IGNITION ELECTRODE ASSEMBLY

START: G-I PCM Flame

Sensor Circuit

TEMP SENSOR 1

(1 Flash)

MOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3

Flame Sensor – Check:

a) Flame Sensor operation.

b) Combustion tube orientation.

Test Procedure – Flame Sensor circuit:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back off the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise

and remove.

FLAME SENSOR PORT

FUEL INLET

MOUNTING EARS (2)

SWITCH INPUT

POWER

Figure 4-26: Burner Head Removal and Flame Sensor Location

4-22

COOLANT PUMP

PROHEAT G-I PCM SERVICE MANUAL

Page 54

WARNING

To avoid the risk of shock and to ensure that the PROHEAT does not fire, disconnect the Ignition Module connector at the G-I PCM.

d) Disconnect the Ignition Module connector at the G-I PCM.

e) Check for contamination on the Flame Sensor. Clean if necessary using

electrical contact cleaner or warm soapy water.

f) Reconnect the power harness and the remote test switch with the switch

in the off position.

REMOTE TEST SWITCH IN OFF POSITION (P/N PK0091)

Figure 4-27: Remote Test Switch Connection

g) Place a finger over the sensor port located on the burner head flange.

The indicator light should go out. Remove your finger and shine a flashlight into the sensor, the remote switch indicator light should come on.

If the indicator light reacts correctly, the Flame Sensor is OK. Go to Test Procedure – Combustion Tube orientation.

If the indicator light does not react, the Flame Sensor is faulty. Go to G-I PCM replacement, page 4-41.

Test Procedure – Combustion Tube orientation:

a) Ensure that the combustion tube orientation boss is aligned with the

heat exchanger flange notch.

b) Ensure that the combustion tube 'slits' are clean.

HEAT EXCHANGER FLANGE NOTCH

ORIENTATION BOSS

PROHEAT G-I PCM SERVICE MANUAL

MOUNTING BOLTS TORQUE = SEE SECTION 1.3

Figure 4-28: Combustion Tube Orientation

4-23

Page 55

START: Motor and/or

G-I PCM fault

(1 Flash)

Motor or G-I PCM – Check:

a) Electrical function – Open circuit motor.

b) Electrical function – Open circuit G-I PCM.

CAUTION

O NOT connect Motor directly to

D batteries or another power source as it will damage the Motor.

LOCK

Figure 4-29: Connector Removal

Test Procedure – Open circuit Motor:

a) Disconnect the Motor connector at the G-I PCM.

b) Using a multimeter set for resistance (Ohms) measure across pins A and B.

c) Check for an open circuit.

If an open circuit is detected, go to Motor replacement, page 4-25.

If an open circuit is not detected, go to Test Procedure – Open circuit G-I PCM.

MOTOR

Figure 4-30: Motor Electrical Resistance Measurement

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

LOCK

Test Procedure – Open circuit G-I PCM:

a) Disconnect the Motor connector and Temperature Sensor 1 at the G-I PCM.

b) Reconnect the power and switch harnesses at the G-I PCM.

c) Switch the PROHEAT on and measure voltage across pins A and B of the G-

I PCM Motor connection.

If the correct nominal system voltage (12 or 24) is measured, the G-I PCM

is OK. Go to Test Procedure – Open circuit Motor.

If no voltage is measured, the G-I PCM is faulty. Go to G-I PCM replacement,

page 4-41.

MOTOR

G-I PCM MOTOR CONNECTION

Figure 4-31: Connector Removal

4-24

Figure 4-32: G-I PCM Motor Output Voltage Measurement

PROHEAT G-I PCM SERVICE MANUAL

Page 56

Motor replacement:

) Disconnect all harnesses at the G-I PCM.

) Disconnect the fuel supply line.

) Loosen and back out the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise and remove.

d) Remove blower housing (2) screws and blower housing.

e) Remove blower retaining snap ring and slide the blower off the

Motor shaft.

f) Disconnect the Motor connector at the G-I PCM.

g) Remove Motor (4) mounting screws using a 4 mm Allen wrench.

h) Remove the Motor. Take care when removing that the Fuel Supply Pump

seal is not damaged.

i) Remove the gear retaining snap ring and gear from the old Motor and

install on the new Motor.

j) Install the new Motor. Take care when installing the Motor shaft in the

Fuel Supply Pump seal. Lubricate with clean diesel fuel.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

SCREWS (2) TORQUE = SEE SECTION 1.3

k) Reinstall (4) screws.

l) Reconnect the Motor connector at the G-I PCM.

m) Reinstall the blower, blower retaining snap ring, Air Compressor filter and

blower housing.

'L'

BLOWER

ENSURE MOTOR IS ALIGNED IN

THE CORRECT POSITION.

POINTER OVER 'R' ON BURNER

HEAD WHEN G-I PCM

CONNECTORS ON RIGHT SIDE

MOTOR

G-I PCM

O-RING

GEAR RETAINING SNAP RING

MOTOR SCREWS TORQUE = SEE SECTION 1.3

'R'

DRIVE GEAR

PROHEAT G-I PCM SERVICE MANUAL

AIR COMPRESSOR FILTER

G-I PCM MOTOR CONNECTION

BLOWER RETAINING SNAP RING

Figure 4-33: Motor Replacement

4-25

Page 57

4.1.3

FLAME OUT Diagnostic Code 2

(2 Flashes)

Indicates that a flame was detected but it could not be maintained or after

eing established the flame went out before reaching the cycle off

b temperature of 185°F (85°C).

lame Out sequence:

a) A flame is detected during the Ignition period or during Full Output.

b) The flame goes out.

c) The ignition is switched on for a maximum of 10 seconds to try and

reestablish the flame (Ignition periods will be 10 seconds longer in cases where the Flame Out occurred during the Ignition period).

d) If the flame is not established the Flame Out diagnostic code is displayed.

A Flame Out diagnostic code distinguishes that:

a) A flame was detected therefore there was a spark and the Ignition

system works.

b) The flame was detected therefore the Flame Sensor works.

c) The fault is in the fuel supply system.

Troubleshoot the Flame Out diagnostic code based on:

1. Fuel supply to the PROHEAT. Go to page 4-4 & page 4-5, Step 1 & 2.

• Fuel tank pick-up.

• Fuel fittings.

• Fuel lines.

• OEM supplied filters and check valves.

2. PROHEAT fuel system.

• Fuel Supply Pump

• Air Compressor

• Fuel Regulator

• Fuel Shut-off Valve

3. Operational symptoms that may occur in conjunction with a Flame Out

code. Go to page 4-4 to page 4-17, Steps 1 to 7.

• Combustion hesitation or coughing.

• Backfiring.

• Smoke.

• Strong diesel fuel odor.

Go to page 4-6 to page 4-17, Steps 3 to 7.

4-26

PROHEAT G-I PCM SERVICE MANUAL

Page 58

4.1.4

COOLANT FLOW Diagnostic Code 3

(3 flashes)

COOLANT FLOW: Step 1

(3 Flashes)

WARNING

NEVER remove coolant lines when the engine is hot – escaping steam or scalding water could cause serious personal injury. Loosen the coolant line clamps slowly, allowing the pressure to escape before removing completely.

Indicates that the coolant temperature in the PROHEAT reached 185°F (85°C) within 90 seconds from the beginning of Ignition. There is coolant in the system but its flow rate is too low.

Troubleshoot the Coolant Flow diagnostic code based on:

1. Vehicle coolant system. Go to Step 1.

• The PROHEAT starts and runs for 90 seconds or less and shuts down with a Coolant Flow diagnostic code indicated.

2. Coolant Pump system electrical or mechanical fault. Go to Step 2.

• The PROHEAT starts and runs for 90 seconds or less and shuts down with a Coolant Flow diagnostic code indicated.

Vehicle coolant system – Check:

a) For restrictions and blockages in the coolant lines.

b) OEM system shut-off valves for correct operation.

c) For loose hose clamps – air introduced into the system.

d) Coolant line size, fittings. Are they too restrictive?

e) Direction of flow. Are the PROHEAT Coolant Pump and the engine Coolant

Pump pumping in the same direction when they are operating at the same time?

f) Coolant capacity. Is there enough coolant in the system? Go to Technical

Specifications, page 1-1.

g) PROHEAT location. Is the PROHEAT or Coolant Pump the high point in the

system? Coolant Pumps are not self-priming and a surge tank may be required.

COOLANT FLOW: Step 2

PROHEAT G-I PCM SERVICE MANUAL

(3 Flashes)

Coolant Pump and G-I PCM – Check:

a) G-I PCM electrical function.

b) Coolant Pump electrical function.

c) Coolant Pump mechanical function.

Test Procedure – Electrical:

a) Disconnect the Coolant Pump connector at the G-I PCM.

b) Using a multimeter set for voltage, switch the PROHEAT on and measure

across pins A and B on the G-I PCM Coolant Pump connection.

If the correct nominal system voltage (12 or 24) is measured, the G-I PCM is OK. Go to Procedure – Mechanical inspection and testing, page 4-28.

If no voltage is measured, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

4-27

Page 59

RED (+) BLACK (-)

Figure 4-34: G-I PCM Coolant Pump Output Voltage Measurement

WARNING

Procedure – Mechanical inspection and testing:

a) Connect the power directly to the Coolant Pump. Observe the operation.

If the Motor does not operate, replace the Coolant Pump.

4-28

PROHEAT G-I PCM SERVICE MANUAL

Page 60

4.1.5

OVERHEAT Diagnostic Code 4

(4 Flashes)

CAUTION

Repeatedly resetting the PROHEAT without resolving the Overheat diagnostic code will damage the heat exchanger.

4.1.6

(5 Flashes)

Indicates that the Temperature Sensor detected an inner heat exchanger surface temperature of 230°F (110°C) within 60 seconds after entering

Cool Down (Purge).

Troubleshoot the Overheat diagnostic code based on:

1. Lack of coolant, air or flow problems in the coolant system.

Go to page 4-27, Steps 1 and 2.

2. Faulty Temperature Sensor. Go to page 4-31.

3. Faulty G-I PCM Temperature Sensor circuit. Go to page 4-31.

To reset the PROHEAT, switch it off and then on again.

VOLTAGE Diagnostic Code 5

Indicates that the supply voltage to the G-I PCM is outside the operating range.

Operating Range:

• 12 volt PROHEAT – 10 to 15 volts.

• 24 volt PROHEAT – 20 to 30 volts.

VOLTAGE: Step 1

(5 Flashes)

VOLTAGE: Step 2

(5 Flashes)

Troubleshoot the Voltage diagnostic code based on:

1. Low voltage.

• Voltage supply is below the rated requirement.

• Poor or faulty electrical connections.

• Voltage supply source is OK. Voltage drop due to high amperage load while the PROHEAT is operating or trying to operate.

2. High voltage.

• Voltage supply is above the rated requirement while the vehicle engine is running.

High Voltage – Check:

The vehicle charging system. Consult the OEM for service requirements.

Low Voltage – Check:

a) System voltage supply source.

b) Wiring harnesses and connection points.

PROHEAT G-I PCM SERVICE MANUAL

4-29

Page 61

Procedure – Low voltage testing:

) Inspect the wiring harnesses and connections for corrosion and proper

fit. Clean if necessary.

b) Using a multimeter set for voltage, measure across the positive and

negative battery terminals or at the supply source.

If the voltage is below the required voltage, service the batteries and/or charging system as per OEM supplier recommendations.

If the voltage level is within the operating range, go to item 'c'.

TO PROHEAT

Figure 4-35: Voltage Measurement

c) Locate and measure across pins D and B in the G-I PCM Data Link

connection. Perform this with the PROHEAT off and then switched on.

If the voltage is within the operating range and a Voltage diagnostic code is indicated, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41

If the voltage falls below the required voltage when the Motor starts, check the wiring from the supply source to the PROHEAT G-I PCM.

G-I PCM DATALINK CONNECTION

RED (+)

4-30

BLACK (-)

Figure 4-36: G-I PCM Datalink Connection

PROHEAT G-I PCM SERVICE MANUAL

Page 62

4.1.7

FLAME FAULT Diagnostic Code 6

(6 Flashes)

4.1.8

(7 or 9 Flashes)

Indicates that:

1. The PROHEAT reached 185°F (85°C) cycled off and entered Cool Down (Purge). After 20 seconds a flame was still detected.

2. The PROHEAT was switched on and a flame (signal) was detected in Pre-check.

Troubleshoot the Flame Fault diagnostic code based on:

1. Fuel System fault. Go to page 4-6 to page 4-17, Steps 3 to 7.

2. G-I PCM Flame Sensor circuit. Go to page 4-22.

TEMPERATURE SENSOR T1 Diagnostic Code 7 and/or 9

Indicates an electrical fault in the Temperature Sensor.

Troubleshoot the Temperature Sensor diagnostic code based on:

Whether the PROHEAT is equipped with a single Temperature Sensor or dual Temperature Sensors.

TEMP SENSOR T1: Step 1

(7 or 9 Flashes)

NOTICE

The temperature sensor may be plugged into T2. The M-Series will operate if the temperature sensor is plugged into T1 or T2. If the sensor if plugged into T2, reverse the instructions as found in step a), b) and c). ie: T1 will become T2, etc.

Temperature Sensor and G-I PCM (single sensor) – Check:

a) Temperature Sensor and G-I PCM electrical function.

Test Procedure – Sensor and G-I PCM:

a) Remove Temperature Sensor connector from G-I PCM connection T1.

b) Remove the G-I PCM sealing plug from G-I PCM connection T2. Put

sealing plug into G-I PCM connection T1.

c) Reconnect the Temperature Sensor connector to G-I PCM connection T2.

d) Switch the PROHEAT on:

If a diagnostic code is indicated, the sensor is faulty. Go to Temperature Sensor replacement.

PROHEAT G-I PCM SERVICE MANUAL

Figure 4-37: Temperature Sensors

4-31

Page 63

Figure 4-38: Temperature Sensor Test

If after changing the Temperature Sensor a diagnostic code is still indicated, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

est Procedure – Temperature Sensor measurement:

a) Using a multimeter set for resistance, measure across pins A and B of

the sensor.

If the sensor measures out of range (see chart below), the sensor is faulty. Go to Temperature Sensor replacement.

NOTICE

If the resistance is below 1.363 k-Ohm or above 10706 k-Ohm then there will be a Code 7 and/or 9

RESISTANCE TEMP TEMP (k-Ohms) (°C) (°F)

8574.14 -50 -58

5932.78 -45 -49

4155.34 -40 -40

2943.30 -35 -31

2108.75 -30 -22

1527.54 -25 -13

1117.67 -20 -4

826.12 -15 5

616.27 -10 14

463.88 -5 23

352.16 0 32

269.70 5 41

208.14 10 50

161.82 15 59

126.80 20 68

99.99 25 77

79.42 30 86

63.49 35 95

51.07 40 104

RESISTANCE TEMP TEMP (k-Ohms) (°C) (°F)

41.31 45 113

33.62 50 122

27.52 55 131

22.63 60 140

18.71 65 149

15.55 70 158

12.98 75 167

10.89 80 176

9.17 85 185

7.75 90 194

6.59 95 203

5.62 100 212

4.81 105 221

4.13 110 230

3.56 115 239

3.08 120 248

2.68 125 257

4-32

PROHEAT G-I PCM SERVICE MANUAL

Page 64

TEMP SENSOR T1: Step 2

(7 or 9 Flashes)

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

Temperature Sensor and G-I PCM electrical (dual sensors) – Check:

a) Temperature Sensor and G-I PCM electrical function.

Test Procedure – Sensor and G-I PCM:

a) Remove Temperature Sensor connector from G-I PCM connection T1.

b) Remove Temperature Sensor connector from G-I PCM connection T2.

c) Swap the connectors. T1 to T2 and T2 to T1.

d) Switch the PROHEAT on:

If a Temperature Sensor T1 diagnostic code is now indicated, the sensor is faulty. Go to Temperature Sensor replacement.

If a Temperature Sensor T2 diagnostic code is still indicated, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

SECONDARY SENSOR (IF EQUIPED) TORQUE TO 50 in-lbs ±5 in-lbs (5.6 Nm±0.5 Nm)

WARNING

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

Figure 4-39: Temperature Sensors

MAIN SENSOR TORQUE = SEE SECTION 1.3

Temperature Sensor replacement:

a) Isolate the coolant system at the PROHEAT inlet and outlet ports for

minimal coolant loss using valves in the system or hose clamps.

b) Remove main sensor mount using a 1" wrench and/or secondary sensor

using a 13 mm wrench.

c) Reinstall the new sensor. Ensure that the O-ring and O-ring seat are

clean. Install the sensor until it bottoms out on the mounting boss.

PROHEAT G-I PCM SERVICE MANUAL

4-33

Page 65

4.1.9

FUEL SHUT-OFF VALVE Diagnostic Code 8

(8 Flashes)

WARNING

To avoid the risk of shock and to ensure that the PROHEAT does not fire, disconnect the Ignition Module connector at the G-I PCM.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

Indicates an electrical fault in the Fuel Shut-off Valve coil or in the G-I PCM Fuel Shut-off Valve circuit.

roubleshoot the Fuel Shut-off Valve diagnostic code based on:

Fuel Shut-off Valve Coil or PROHEAT G-I PCM electrical.

Test Procedure – Fuel Shut-off Valve and G-I PCM test:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back out the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise and remove.

d) Disconnect the Fuel Shut-off Valve connector at the G-I PCM.

e) Disconnect the Ignition Module connector at the G-I PCM

f) Reconnect the power, Temperature Sensor(s) and switch harnesses at

the G-I PCM.

g) Switch the PROHEAT on:

If a Fuel Shut-off Valve diagnostic code is NOT indicated and the PROHEAT attempts to operate, the Fuel Shut-off Valve is faulty. Go to Fuel Shut-off Valve replacement, page 4-10.

If the Fuel Shut-off Valve diagnostic code is still indicated, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

MOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3

TEMP SENSOR 1

FUEL INLET

MOUNTING EARS (2)

SWITCH INPUT

POWER

Figure 4-40: Burner Head Removal and Fuel Shut-off Valve Connection

COOLANT PUMP

FUEL SHUT-OFF VALVE CONNECTION

LOCK

4-34

PROHEAT G-I PCM SERVICE MANUAL

Page 66

4.1.10

TEMPERATURE SENSOR T2 Diagnostic Code 7 and/or 9

(7 or 9 Flashes)

4.1.11

(10 Flashes)

Go to Temperature Sensor T1 Diagnostic Code, page 4-31.

IGNITION MODULE Diagnostic Code 10

Indicates an over-load fault is detected.

Troubleshoot the Ignition Module diagnostic code based on:

Ignition Module and G-I PCM – electrical.

Test procedure – Ignition Module and G-I PCM:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back out the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise and remove.

d) Disconnect the Ignition Module connector at the G-I PCM.

e) Reconnect the power and switch harnesses at the G-I PCM.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

f) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

If an Ignition Module diagnostic code is NOT indicated and the PROHEAT attempts to operate, the Ignition Module is faulty. Go to Ignition Module replacement, page 4-21.

If the Ignition diagnostic code is indicated, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

MOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3

TEMP SENSOR 1

FUEL INLET

MOUNTING EARS (2)

PROHEAT G-I PCM SERVICE MANUAL

POWER

Figure 4-41: Burner Head Removal

SWITCH INPUT

COOLANT PUMP

4-35

Page 67

4.1.12

COOLANT PUMP Diagnostic Code 11

(11 Flashes)

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

Indicates an over-load fault is detected.

Troubleshoot the Coolant Pump diagnostic code based on:

oolant Pump and G-I PCM – electrical.

Test Procedure – Coolant Pump and G-I PCM test:

a) Disconnect the Coolant Pump at the G-I PCM.

b) Switch the PROHEAT on and observe for a diagnostic code.

If a Coolant Pump diagnostic code is NOT indicated and the PROHEAT operates, the Coolant Pump is faulty. Go to Coolant Pump replacement.

If the Coolant Pump diagnostic code is still indicated, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

WARNING

CAUTION

DO NOT run a coolant pump dry. Before starting the PROHEAT ensure that the Coolant Pump is flooded with coolant by opening all valves and running the engine until the air has been purged from the system (approximately 15 – 20 minutes). This will prevent Coolant Pump damage.

G-I PCM COOLANT PUMP CONNECTION

Figure 4-42: G-I PCM Coolant Pump Connection

Coolant Pump replacement:

a) Isolate the Coolant Pump using shut-off valves provided in the coolant

system or hose to minimize coolant loss.

b) Remove Coolant Pump.

c) Install new Coolant Pump.

4-36

PROHEAT G-I PCM SERVICE MANUAL

Page 68

4.1.13

MOTOR Diagnostic Code 12

(12 Flashes)

Indicates that an over-load fault is detected in precheck or during operation.

Troubleshoot the Motor diagnostic code based on:

1. Motor – mechanical.

2. Motor or G-I PCM – electrical.

Test Procedure – Motor mechanical function:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line. c) Remove blower housing (2) screws and blower housing. Look at blower

housing and blower for any rubbing marks.

If blower housing/blower rubbing is observed. Replace blower as it may have warped.

d) By hand, rotate the blower and feel for mechanical binding.

If mechanical interference is felt, isolate the Motor from the Fuel Supply Pump and Air Compressor by removing the Motor. Go to Motor replacement, page 4-25.

If the Motor spins freely and there are no obvious mechanical problems, check the Motor/G-I PCM electrical operation. Go to Test Procedure – G-I PCM Motor output voltage.

TEMP SENSOR 1

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

BLOWER

FUEL INLET

SWITCH INPUT

POWER

Figure 4-43: Motor Mechanical Check

COOLANT PUMP

Test Procedure – G-I PCM Motor output voltage:

a) Disconnect the Motor connector at the G-I PCM.

b) Reconnect the power and switch harnesses at the G-I PCM.

c) Switch the PROHEAT on.

If Motor diagnostic code is still indicated, G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

If Motor diagnostic code is no longer indicated, Motor is faulty. Go to Motor replacement, page 4-25.

PROHEAT G-I PCM SERVICE MANUAL

4-37

Page 69

4.1.14

AUXILIARY OUTPUT Diagnostic Code 13

(13 Flashes)

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

Indicates a short circuit fault in the harness or the device being operated by the Auxiliary Output.

roubleshoot the Auxiliary Output diagnostic code based on:

G-I PCM – electrical

Test procedure – G-I PCM Output Signal:

a) Disconnect the Auxiliary Output harness at the G-I PCM.

b) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

If the diagnostic code is not indicated the fault is in the harness or the driven device. Go to OEM for service requirements.

If the diagnostic code is still indicated, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

G-I PCM AUXILIARY OUTPUT CONNECTION

4.1.15

(14 Flashes)

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

4-38

Figure 4-44: Auxiliary Output Connector

SWITCH/TIMER POWER Diagnostic Code 14

Indicates a short circuit fault in harness or the device being operated by the Switch Output.

Troubleshoot the Switch/Timer Power diagnostic code based on:

Electrical switch circuit in the switch wiring.

Test procedure electrical, short circuit:

a) Remove the Switch Output harness at the G-I PCM.

b) Remote start the PROHEAT using the PROHEAT remote start switch

(PROHEAT P/N PK0091).

If the PROHEAT functions correctly, the fault is in the wiring from the PROHEAT back to the switch. See OEM recommended service requirements.

If the PROHEAT does not function, the G-I PCM is faulty. Go to G-I PCM replacement, page 4-41.

PROHEAT G-I PCM SERVICE MANUAL

Page 70

4.2

COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS

4.2.1

4.2.2

4.2.3

4.2.4

4.2.5

4.2.6

4.2.7

Fuel 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.

Air Compressor Go to page 4-12, Step 6.

Fuel Supply Pump Go to page 4-17, Step 7.

Ignition Electrodes Go to page page 4-20.

G-I PCM Fuse

Protects the G-I PCM against high current. When switched on, the PROHEAT will NOT start, attempt to start, or indicate a diagnostic code.

Troubleshoot a Blown Fuse based on:

1. Voltage supply to the PROHEAT.

2. Voltage at the output connections of the G-I PCM.

Test Procedure – Voltage supply:

a) Disconnect the power harness at the G-I PCM.

b) Using a multimeter set for voltage, measure across pins A and B of the

harness connector for system voltage.

If there is no voltage, check the OEM voltage supply. Consult OEM for service requirements.

If the correct voltage (system voltage 12 – 24) is measured, go to item 'c'.

PIN B – BLACK (-)

PIN A – RED (+)

Figure 4-45: Power Harness

PROHEAT G-I PCM SERVICE MANUAL

4-39

Page 71

c) Disconnect the Datalink harness at the G-I PCM. Using a multimeter set

for voltage, measure across pins D and B in the PCM Datalink connection.

If voltage is read and it is of the correct value, the fuse is OK.

If voltage is not present, check the G-I PCM fuse.

G-I PCM DATALINK CONNECTION

RED (+)

BLACK (-)

Figure 4-46: G-I PCM Datalink Connection

Procedure – G-I PCM fuse replacement:

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Loosen and back out the burner head mounting (2) bolts five to six turns

allowing enough room to rotate the burner head 15° counter-clockwise and remove.

d) Remove blower housing (2) screws and blower housing.

MOUNTING BOLTS (2) TORQUE = SEE SECTION 1.3

TEMP SENSOR 1

4-40

FUSE COVER AND FUSE

FUEL INLET

SWITCH INPUT

COOLANT PUMP

POWER

Figure 4-47: Burner Head Removal and Motor Mechanical Check

PROHEAT G-I PCM SERVICE MANUAL

Page 72

e) Remove the fuse cover and using needle nose pliers or a fuse removal

tool remove the fuse.

If the fuse is blown, replace the fuse and check the PROHEAT current draw. Go to page 4-29.

If the fuse is OK, the G-I PCM is faulty. Go to G-I PCM replacement below.

G-I PCM replacement:

a) Disconnect the Fuel Shut-off Valve and Ignition Module connectors at

the G-I PCM.

b) Remove the blower housing (2) screws and blower housing.

c) Remove the blower retaining snap ring and slide the blower off the

Motor shaft.

d) Remove the Air Compressor filter.

e) Disconnect the Motor connector at the G-I PCM. Remove the G-I PCM.

f) Reinstall the new PCM following items 'e' back to 'a'.

NOTICE

All plugs/harnesses must be reinstalled into the Proheat Control Module (G-I PCM) before heater goes back into service.

LOCK

g) Reconnect the burner head by mounting it against the heat exchanger

face, turning it clockwise to engage the mounting ears on the bolts.

h) Reconnect electrical harnesses and fuel supply line.

i) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

BLOWER SCREWS (2) TORQUE = SEE SECTION 1.3

G-I PCM

AIR COMPRESSOR FILTER

G-I PCM MOTOR CONNECTION

BLOWER RETAINING SNAP RING

Figure 4-48: Connector Removal

PROHEAT G-I PCM SERVICE MANUAL

Figure 4-49: G-I PCM Replacement

4-41

Page 73

OPERATIONAL PROBLEMS4.3

Problems with the PROHEAT and/or vehicle application that are not specifically defined but are observed during the operation of the PROHEAT and or vehicle coolant system. These fall into three categories:

1. Fuel Supply/Combustion. Go to page 4-3 to page 4-25, Steps 1 to 7.

• Smoke from the exhaust

• Excessive raw diesel odor.

• Backfiring and coughing during the combustion process.

• Low heat output.

2. Coolant system. Go to page 4-27, Steps 1 and 2.

• Short combustion cycles. The PROHEAT is turning on and off at very

short intervals.

• Low heat output in the vehicle system. Go to page 4-3 to page 4-25,

Steps 1 to 7.

4-42

PROHEAT G-I PCM SERVICE MANUAL

Page 74

MAINTENANCE5.0

NOTICE

The flame hours can be determined from the G-I PCM data download. PK0056 is required to download the G-I PCM data. See the parts book at www.proheat.com

Your PROHEAT has been designed to operate with a minimum of maintenance. To ensure the efficient operation of your heater an ANNUAL MAINTENANCE

TUNE-UP is recommended to be performed each year or every 1000 flame hours. In addition, weekly operation is recommended.

Proper maintenance will result in the following benefits:

• Maximum heat transfer to the coolant

• Minimum battery power draw

• Long term cost savings

• Increased reliability

Check the system annually before each heating season. There are several maintenance procedures you can perform to keep your heater in service. Read this section of the manual carefully.

PROHEAT G-I PCM SERVICE MANUAL

Figure 5-1.

WEEKLY MAINTENANCE5.1

Run the heater a minimum of once a week to keep new fuel in the heater’s critical components.

5-1

Page 75

ANNUAL MAINTENANCE5.2

1. Clean Heater Enclosure

• Clean any accumulated debris or dust from the components.

• Make sure the opening around the exhaust pipe is clear.

• Visually inspect all the components for wear or damage.

• Ensure that the burner air intake is clear.

• Do not pressure wash.

2. Check Exhaust System

• Check the exhaust system carefully. Clean as necessary.

• Make sure the exhaust pipe is vented safely away from the vehicle.

• Check the pipe for dents, restrictions or severely corroded areas.

• Replace the exhaust pipe and clamps if necessary.

• Ensure the exhaust pipe clamp is tight and the exhaust pipe

is secure.

HEAT EXCHANGER

FLANGE NOTCH

ORIENTATION BOSS

Figure 5-2: Heat Exchanger

WARNING

Shock hazard due to voltage.

3. Check Heat Exchanger

• Remove the burner head assembly and combustion tube to access

the inside of the heat exchanger.

• To maintain optimum heat output, clean any combustion deposits

that may have accumulated on the heat exchanger fins.

• Use a wire brush to loosen the deposits and a vacuum to suck

them out.

• Ensure exhaust pipe is clean and free from restriction.

4. Check Cooling System

• Check all heater hoses and connections for signs of leakage

or damage.

• Repair or replace as required.

5. Check Power Source

• Check the condition of the power source and connections.

The heater will not function properly with a faulty power source or corroded connections.

6. Check Fuel System

• Check the fuel system for damaged fuel lines or leakage.

• Make sure the clamps on the fuel lines are secure.

5-2

PROHEAT G-I PCM SERVICE MANUAL

Page 76

. Check Fuel Filter

• Remove and inspect filter. Clean or replace as necessary.

Clean O-ring and seat. Avoid cutting or scratching.

•

• Refer to page 4-5, Step 2.

FUEL FILTER

O-RING

Figure 5-3: Fuel Filter

HOLD UPRIGHT TO ASSEMBLE

TORQUE = SEE SECTION 1.3

LUBRICATE O-RING WITH DIESEL FUEL

8. Clean Nozzle

• Inspect Fuel Nozzle stem and O-ring for contamination and/or damage. Inspect and clean distributor (a soft bristled brush may be used), fuel orifice, air passages, head and stem with electrical contact cleaner or warm soapy water.

• DO NOT use a welding torch tip cleaner.

• Refer to page 4-6.

BLOW THIS DIRECTION WHEN USING COMPRESSED AIR.

Figure 5-4: Fuel Nozzle

PROHEAT G-I PCM SERVICE MANUAL

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9. Compressor Air Filter

• Replace inlet air filter annually or more often if dusty conditions are encountered.

Ensure the air filter is seated correctly.

•

• Refer to page 4-12, Step 6.

AIR FILTER

Figure 5-5: Air Filter

NOTICE

Inspect Proheat Control Module (G-I PCM)

to ensure that all connectors

have

plugs or have an electrical

connection.

10. Compressor

•

Important: Complete steps 8 and 9 prior to step 10 compressor check.

• Check the air pressure setting as described on page 4-12.

11. Electrical System

• Check the internal and the external wire harnesses for damage or corrosion. Replace if required.

12. Timer/Toggle Switch Supplemental/Preheat

• Check heater operation under specified heater on signals.

13. Operation Test

• Run the system for at least 15 minutes or until the heater cycles “OFF” and then “ON” again. Inspect the following during operation:

a) Combustion process.

• For smoke and raw fuel odor from the exhaust pipe.

• Fuel system leaks and corrosion.

• If there is a problem go to page 4-3 to page 4-31, Steps 1 to 7.

b) Coolant system:

• For leaks

• For correct system heating process. Go to page 4-27, Steps 1 and 2.

5-4

PROHEAT G-I PCM SERVICE MANUAL

Page 78

REPLACEMENT PARTS AND

TEST EQUIPMENT

PART # QTY DESCRIPTION

200610K 1 Filter, Air, Element

880035K 1 Fuel Filter

PK0067 1 Test Gauge, Air/Fuel Pressure

PK0091 1 Remote On/Off Switch

PK0071 1 Test Gauge Adapter. Rotary Vane

Compressor Models ONLY SN 600000 to 699999.

PK0036 1 Digital Manometer

PROHEAT G-I PCM SERVICE MANUAL

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5.3

ROTARY VANE COMPRESSOR SERVICE & VANES INSTALLATION

The rotary vane compressor may need service to clean and/or to replace the vanes. This can be indicated by a lack of compressor pressure (page 4-14) or noise. It is recommended to perform the following steps:

Step 1. Access the compressor and clean the air filter.

Step 2. Clean the rotary vane compressor.

Step 3. Test air compressor for proper pressure and operation. If pressure

and operation is not achieved, then proceed to Step 4.

Step 4. Replace vanes and test air compressor for proper pressure and

operation.

NOTICE

Prevent dirt and/or other contaminants from entering into the compressor intake port when cleaning.

1. Access the Compressor & Clean Air Filter

a) Disconnect all harnesses at the G-I PCM.

b) Disconnect the fuel supply line.

c) Disconnect the air intake hose (if required).

d) Loosen and back out the burner head mounting (2) bolts five to six

turns allowing enough room to rotate the burner head 15° counterclockwise and remove the Burner Head to a workbench.

e) Remove blower housing (2) screws and blower housing.

Remove the Air Compressor filter. Inspect for contamination and replace if necessary. Clean the filter cavity and the air passages using a dry cloth.

g) Remove ignition electrode assembly. Use a flat head screwdriver to

pry the electrode assembly out.

h) Remove the flame shield. Rotate to match the mounting square.

FLAME SHIELD

G-I PCM

HOUSING SCREWS (2)

5-6

AIR RELIEF

IGNITION

ELECTRODE

ASSEMBLY

MOUNTING BOLTS (2)

AIR FILTER

Figure 5-6: Access the Compressor and Air Filter

PROHEAT G-I PCM SERVICE MANUAL

Page 80

WARNING

Failure to disconnect the ignition module will cause a spark that may

ause a fire. Ensure to disconnect

c ignition module.

NOTICE

Use only non-petroleum based flushing solvents such as GAST AH255B, I-chem electronics cleaner AF ICA363 or non-flammable electrical contact cleaner available

from any automotive

supplies store.

CAUTION

Wear eye protection during the cleaning process.

2. Clean the Rotary Vane Compressor

a) Remove the nozzle and air relief (see figure 5-6). If the nozzle stem

looks black, clean as shown on page 4-6 or replace the nozzle.

) Disconnect the ignition module connector. Ensure that the

temperature sensor is disconnected as well.

) Remove the air filter and blower (see figure 5-6).

d) Connect the power cable and remote on/off switch.

e) Turn on the switch. After 5 seconds, the motor should start to spin

and the switch should start to blink (The blink is due to the temperature sensor disconnections. See page 4-31 for more information.)

f) Using a non-flammable electrical contact cleaner or non-petroleum

based flushing solvent (DO NOT USE BRAKE CLEAN as it will damage the compressor)), spray directly into intake of compressor. Spray the cleaner and run the motor for at least 30 seconds to remove all of the vane dust and cleaner.

REMOVE AIR FILTER

REMOVE BLOWER

DISCONNECT TEMPERATURE SENSOR

DISCONNECT FUEL LINE

SPRAY CLEANER

DIRECTLY INTO AIR

COMPRESSOR INTAKE

REMOVE NOZZLE

DISCONNECT

IGNITION MODULE

REMOVE AIR RELIEF

PROHEAT G-I PCM SERVICE MANUAL

Figure 5-7: Compressor Cleaning

5-7

Page 81

g) Disconnect the power cable to remove power and stop motor.

h) Disconnect the remote on/off switch.

i) Reconnect ignition module connector.

) Reinstall the clean Fuel Nozzle using diesel fuel to lubricate o-ring.

k) Reinstall air relief (see Section 1.3 for torque).

) Reinstall flame shield and electrode.

m) Reinstall the air filter and blower.

n) Reinstall the blower housing.

3. Test Air Compressor

a) Test the air pressure setting as shown on page 4-14.

b) If pressure cannot be set correctly, proceed to step 4.

SCREW (3) DO NOT LOOSEN – SEE NOTICE

VANES (4)

BODY BORE & ROTOR

WEAR PLATE

9/64" HEX. HEAD SCREW (3)

END PLATE

5-8

Figure 5-8: Compressor Components

PROHEAT G-I PCM SERVICE MANUAL

Page 82

NOTICE

Use only non-petroleum based flushing solvents such as GAST AH255B Electrosolve Contact Cleaner or similar products available from any

utomotive supplies store.

NOTICE

DO NOT loosen the three screws holding the compressor body (figure 5-8), as it requires special tools to install the compressor body back in proper position.

NOTICE

The three holes in the plates are not equally spaced. Ensure their correct alignment to the compressor body (figure 5-8).

NOTICE

Never add oil to the compressor.

4. Replace the Vanes

) Remove three screws holding the compressor End Plate using a 9/64

hexagon key (refer to figure 5-8).

b) Remove the End Plate and the graphite Wear Plate (located behind the

luminum End plate) - refer to figure 5-8. Avoid damage to the end plate.

c) Before removing the old vanes from the rotor slots, check the direction

f the bevel edge so the new vanes are installed in the same manner.

d) Remove four old vanes from the slots in the compressor rotor. Turn

the compressor rotor by rotating the blower blade to enable better access to the vanes.

e) Spray body bore and rotor with non-petroleum based flushing solvent

(refer to figure 5-8). NO NOT USE BRAKE CLEAN.

f) Use a clean dry cloth to remove flushing solvent from parts.

g) Place new vanes in rotor slots in the proper beveled edge direction.

h) Place a sheet of emery cloth on a smooth flat surface and rub both

sides of the Wear Plate located behind the End Plate to remove any burrs. Use a clean dry cloth to remove any dust from the Wear Plate.

i) Remove old paint and clean the top surface of the compressor body

with a clean dry cloth. Do not leave scratches and scores.

j) Install the Wear Plate onto the compressor body and rotate to align all

three holes with the holes in the compressor body.

k) Repeat step (h) with the face of the metal End Plate. Use a clean dry

cloth to remove any dust from the metal plate and reinstall.

l) Replace the End Plate screws and tighten to 28–36 in-lbs (3.2–4.0 Nm).

m) Check that the unit rotates smooth turning the blower blade 2-3 times

n) Clean or replace the nozzle and the relief valve.

o) Replace the air filter.

p) Re-assemble heater burner head and check the air pressure (refer to

page 4-12).

q) Install Burner Head onto the Heat Exchanger and re-connect wires and

fuel line.

r) Switch the PROHEAT on and operate for at least one complete cycle.

Observe the operation.

s) There is a break-in period for the new vanes. After 100 hours of motor

operation or one month, repeat Steps 2 and 3.

PROHEAT G-I PCM SERVICE MANUAL

5-9

Page 83

5-10

PROHEAT G-I PCM SERVICE MANUAL

Page 84

PROHEAT WARRANTY6.0

NOTICE

This is a warranty summary. For the complete warranty manual, please go to www.proheat.com

Throughout this document references are made to SeaStar Solutions and Proheat which are operating names of Marine Canada Acquisition Inc. DBA SEASTAR SOLUTIONS and as such should be treated the same.

SeaStar Solutions warrants the PROHEAT Heater to be free of defects in material and workmanship under design usage and service conditions for two (2) years on parts and labour from the date of first installation. Replacement parts are covered for the remainder of the heater’s warranty or ninety (90) days, which ever is greater.

This warranty does not apply to damage or failure of the PROHEAT Heater or the vehicle into which it was installed due to improper installation, assembly, maintenance, abuse, neglect, accident, or the use of parts not supplied by SeaStar Solutions. Accessories supplied, but not

manufactured by SeaStar Solutions, shall be covered by the manufacturer’s warranty only and not subject to this warranty.

Non-standard installations, that is, those requiring a departure from published installation instructions, should not be undertaken without first having consulted SeaStar Solutions.

Coverage for warrantable parts, at the discretion of SeaStar Solutions will be made to the claimant in the form of repair, replacement or credit. Warranty labour payments will be made only to Registered PROHEAT Service Centres in accordance with the Standard Repair Times (SRT’s) as published by SeaStar Solutions.

Marine Installations

The purchaser and installer are advised that specific rules and regulations are in effect with respect to the installation of heaters in marine applications. These rules and regulations are enforced by regional and federal agencies and/or other agencies having jurisdiction. It is the installer’s responsibility to review and comply with all such rules and regulations.

In addition each marine installation must be inspected and approved by an Authorized PROHEAT Dealer. Only those installations which are approved, and so registered, will be eligible for warranty coverage of one (1) year on parts and labour.

THE WARRANTIES SET FORTH HEREIN ARE THE SOLE WARRANTIES MADE BY SEASTAR SOLUTIONS IN REGARD TO THE PROHEAT HEATER SYSTEM. SEASTAR SOLUTIONS MAKES NO OTHER WARRANTIES, EXPRESSED OR IMPLIED, OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

OWNER RESPONSIBILITIES

Before the expiration of the warranty, Owner must give notice to a Registered PROHEAT Dealer of failures, if any, considered to be warrantable and deliver the defective heater system to such dealer. Owner is responsible for the cost of all repairs made to the engine or equipment in which it is installed, other than the PROHEAT Heater system. Owner is responsible for lodging, meals and incidental costs incurred by the Owner as a result of a warrantable failure. Owner is responsible for “down-time” expenses, and all business costs and losses resulting from a warrantable failure.

SeaStar Solutions is not responsible for incidental or consequential damages.

Items Covered Under This Warranty

1. Basic Heater including combustion chamber components, fuel system components, air

compressor, ignition components, coolant pump, air blower.

2. Electrical controls provided by PROHEAT including cab mounted controls and PCM.

3. PROHEAT supplied accessories and mounting hardware.

Items Not Covered Under This Warranty

1. PROHEAT's no longer within the warranty period.

2. Normal wear and maintenance parts, including fuel filter, air filter, nozzle, and clamps.

3. Parts which malfunction due to improper installation, causing inadequacies in: air, fuel or

coolant flow; voltage due to wiring; shock or vibration protection.

4. Any progressive damage to the engine or vehicle arising out of failure of the PROHEAT.

5. PROHEATs which have been modified or use of non-standard parts not approved by SeaStar

Solutions.

6. PROHEATs that have been abused or damaged.

7. Travel time by a PROHEAT Dealer.

8. Diagnosis or repairs when caused by problems not directly related to the heater or due to

empty fuel tanks or poor fuel quality.

If you have any questions or concerns about the PROHEAT Warranty, contact your nearest PROHEAT Distributor or Proheat at (604) 270-6899.

PROHEAT G-I PCM SERVICE MANUAL

6-1

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6-2

PROHEAT G-I PCM SERVICE MANUAL

Page 86

Proheat Serial Number:

Installation Date:

Dealer:

Designed and Manufactured

in North America

SeaStar Solutions

3831 No.6 Road Richmond, B.C. Canada V6V 1P6

Tel: 604-270-6899 Fax: 604-270-7172

www.proheat.com

Proheat is a registered trademark of Marine Canada Acquisition Inc. and its subsidiary companies.

Printed in Canada 09/14 PID# SL9150H

Proheat M80 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual