Proheat M80 Service Manual
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Proheat M80 Service Manual

M series
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SERVICE MANUAL
M50/M80/M105

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Summary of Contents for Proheat M80

  • Page 1 SERVICE MANUAL M50/M80/M105...

  • Page 3: Table Of Contents

    CONTENTS A. SAFETY ..................A-1 SAFETY CONSIDERATIONS ..............A-2 B. INTRODUCTION ................B-1 1.0 TECHNICAL SPECIFICATIONS ...........1-1 1.1 PHYSICAL ................1-2 1.2 ELECTRICAL................1-3 2.0 PRINCIPLES OF OPERATION ............2-1 2.1 COMPONENT DESCRIPTION .............2-1 2.2 NORMAL OPERATING SEQUENCE..........2-4 3.0 TROUBLESHOOTING AND REPAIR ..........3-1 3.1 SYSTEM AND COMPONENT DIAGNOSTICS.........3-2 3.1.1 START Diagnostic Code..........3-3 3.1.2...

  • Page 5: Safety

    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 M-SERIES SERVICE MANUAL...

  • Page 6: Safety Considerations

    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. PROHEAT M-SERIES SERVICE MANUAL...

  • Page 7: Introduction

    PROHEAT heaters are used for the following applications: NOTE: It is the installer’s responsibility to ensure that an installation complies with all applicable codes and (1) Engine Block Heat – A PROHEAT will preheat an regulations. engine block to ensure reliable starting in cold weather.
  • Page 8 PROHEAT M-SERIES SERVICE MANUAL...

  • Page 9: Technical Specifications

    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 PROHEAT M-SERIES SERVICE MANUAL...

  • Page 10: Physical

    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 DEGREES OF BENDS. PROHEAT M-SERIES SERVICE MANUAL...

  • Page 11: Electrical

    POWER VEHICLE GROUND INDICATOR OUTPUT (HIGH SIDE SWITCHED. DASH OR PROHEAT TOGGLE SWITCH LIGHT) (1 AMP MAX) GROUND (INDICATOR GROUND) (1 AMP MAX) POWER OUTPUT (CONSTANT POWER. TIMER/SWITCH REMOTE PANEL) (1 AMP MAX SHARED WITH P3-D) GROUND (ACCESSORY OUTPUT GROUND) (1 AMP MAX) CONTROL MAIN SWITCH INPUT (STANDARD "ON"...
  • Page 12 PROHEAT M-SERIES SERVICE MANUAL...

  • Page 13: Principles Of Operation

    Ignition Module: Electronic Ignition Module with plug-in electrode. PCM: Electronic control module monitors the PROHEAT sensors, operating conditions, (PROHEAT Control Module) 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.
  • Page 14 1-2. This sensor also measures the inner heat exchanger surface temperature for an overheat condition. Coolant Pump: Circulates coolant through the PROHEAT and vehicle heating system. Depending on the PROHEAT installation, it may be operated by the PCM. PROHEAT M-SERIES SERVICE MANUAL...
  • Page 15 IGNITION MODULE TEMPERATURE HEAT EXCHANGER SENSOR 2 (IF EQUIPPED) FUEL NOZZLE FUEL FUEL SUPPLY SHUT-OFF PUMP VALVE AIR COMPRESSOR IGNITION ELECTRODES COMBUSTION AIR BLOWER BLOWER HOUSING TEMPERATURE SENSOR 1 COMBUSTION TUBE BURNER HEAD FLANGE MOTOR AIR FILTER PCM (PROHEAT CONTROL MODULE)

  • Page 16: Normal Operating Sequence

    ....If the PROHEAT is in Ignition or Full Output, it will Cool Down first, then shut OFF. If the PROHEAT is in Standby, it will shut OFF immediately.

  • Page 17: Troubleshooting And Repair

    If equipped with a diagnostic indicator light, and it is flashing, determine the code based on page 3-2. STEP 3 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). STEP 4 Let the PROHEAT attempt to start and/or operate.

  • Page 18: System And Component Diagnostics

    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).

  • Page 19: Start Diagnostic Code

    (1 Flash) Indicates that the PCM Flame Sensor did not detect a flame or the flame was too weak to be detected during the FULL ignition period (M50/M80/M105 – 30 second ignition period). Troubleshoot the Start diagnostic code based on the following symptoms: 1.
  • Page 20 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 NOTICE direct source of CLEAN fuel. Switch the PROHEAT on and operate for at least one complete cycle.
  • Page 21 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.
  • Page 22 Fuel Nozzle and Fuel Nozzle cavity – Check: (1 Flash) 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 PCM.
  • Page 23 Tighten mounting bolts. 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.
  • Page 24 Fuel Shut-off Valve – Check: (1 Flash) a) Fuel Shut-off Valve and PCM - electrical open circuit fault. b) Valve plunger – mechanical fault. Test the PROHEAT operation; Fuel Shut-off Valve plunger removed. NOTICE Procedure – Coil and PCM – electrical fault: a) Disconnect all harnesses at the PCM.
  • Page 25 To avoid the risk of shock and to b) Disconnect Ignition Module connector at the PCM. ensure that the PROHEAT does not c) Switch the PROHEAT on and measure across pins A and B of the PCM fire, disconnect the Ignition Module Fuel Shut-off Valve connection.
  • Page 26 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.
  • Page 27 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 6.
  • Page 28 Figure 3-12: Air Pressure Test h) Reconnect the power and switch harnesses at the PCM. Switch the PROHEAT on and read the air pressure: If the Air Compressor reading is out of range, go to Air Compressor filter check before attempting adjustment.
  • Page 29 Reconnect the Motor, Fuel Shut-off Valve and Ignition Module connectors at the PCM. m) Test the Air Compressor. Adjust if necessary to correct pressure setting. Go to items 'i', 'j' and 'k' in Test Procedure – Air Compressor pressure, page 3-12. PROHEAT M-SERIES SERVICE MANUAL 3-13...
  • Page 30 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.
  • Page 31 Reconnect the fuel supply line. To avoid the risk of shock and to Switch the PROHEAT on and read the fuel pressure (should be 3 – 12 PSI): ensure that the PROHEAT does not If the pressure is out of range, Go to Fuel Supply Pump cleaning, page 3-16.
  • Page 32 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. Fuel Supply Pump replacement: a) Disconnect and remove the Ignition Module.
  • Page 33 TORQUE = 75 in-lbs HOUSING SCREWS TORQUE = 75 in-lbs BLOWER HOUSING AIR COMPRESSOR GEAR AIR COMPRESSOR GEAR RETAINING RING MOTOR AIR COMPRESSOR FILTER BLOWER BLOWER RETAINING SNAP RING Figure 3-18: Fuel Supply Pump Removal PROHEAT M-SERIES SERVICE MANUAL 3-17...
  • Page 34 Figure 3-19: Burner Head Removal and Ignition Electrode Removal e) Reconnect the power and switch harnesses. WARNING Switch the PROHEAT on and observe for a spark. Spark will continue for Keep blower housing on to avoid five seconds. injury when Motor starts up.
  • Page 35 Switch the PROHEAT on and measure across pins A and C of the PCM Ignition Module connection. If the correct system voltage (12 or 24) is measured, then measure across pins B and C (should read 0 Volts). If both of the measurements are correct, then replace Ignition Module.
  • Page 36 Check for contamination on the Flame Sensor. Clean if necessary using To avoid the risk of shock and to electrical contact cleaner or warm soapy water. ensure that the PROHEAT does not Reconnect the power harness and the remote test switch with the switch fire, disconnect the Ignition Module in the off position.
  • Page 37 Test Procedure – Combustion Tube orientation: a) Ensure that the combustion tube orientation boss is aligned with the heat exchanger flange notch. HEAT EXCHANGER FLANGE NOTCH ORIENTATION BOSS MOUNTING BOLTS TORQUE = 100 in-lbs Figure 3-25: Combustion Tube Orientation PROHEAT M-SERIES SERVICE MANUAL 3-21...
  • Page 38 Disconnect the Motor connector and Temperature Sensor 1 at the PCM. b) Reconnect the power and switch harnesses at the PCM. c) Switch the PROHEAT on and measure voltage across pins A and B of the PCM Motor connection.
  • Page 39 GEAR RETAINING SNAP RING DRIVE GEAR MOTOR BLOWER SCREWS (2) TORQUE = 75 in-lbs MOTOR SCREWS TORQUE = 75 in-lbs AIR COMPRESSOR FILTER PCM MOTOR CONNECTION BLOWER RETAINING SNAP RING Figure 3-30: Motor Replacement PROHEAT M-SERIES SERVICE MANUAL 3-23...

  • Page 40: Flame Out Diagnostic Code

    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 3-4 and 3-5, Steps 1 and 2. • Fuel tank pick-up.

  • Page 41: Coolant Flow Diagnostic Code

    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.
  • Page 42 – escaping steam If the Motor does not operate, replace the Coolant Pump. or scalding water could cause serious personal injury. Loosen the coolant line clamps slowly, allowing the pressure to escape before removing completely. 3-26 PROHEAT M-SERIES SERVICE MANUAL...

  • Page 43: Overheat Diagnostic Code

    2. Faulty Temperature Sensor. Go to page 3-29. 3. Faulty PCM Temperature Sensor circuit. Go to page 3-29. To reset the PROHEAT, switch it off and then on again. CAUTION Repeatedly resetting the PROHEAT without resolving the Overheat diagnostic code will damage the heat exchanger.
  • Page 44 Figure 3-32: Voltage Measurement c) Locate and measure across pins D and B in the 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 PCM is faulty.

  • Page 45: Flame Fault Diagnostic Code

    1. The PROHEAT reached 185°F (85°C) cycled off and entered Cool Down. 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.
  • Page 46 Remove Temperature Sensor connector from PCM connection T1. b) Remove Temperature Sensor connector from 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.

  • Page 47: Fuel Shut-Off Valve Diagnostic Code

    WARNING Temperature Sensor replacement: a) Isolate the coolant system at the PROHEAT inlet and outlet ports for mini- NEVER remove coolant lines when mal coolant loss using valves in the system or hose clamps. the engine is hot – escaping steam or scalding water could cause b) Remove sensor using a 14 mm wrench.

  • Page 48: Temperature Sensor T2 Diagnostic Code

    Disconnect the Ignition Module connector at the PCM. e) Reconnect the power and switch harnesses at the PCM. 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.

  • Page 49: Coolant Pump Diagnostic Code

    Disconnect the Coolant Pump at the 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.

  • Page 50: Motor Diagnostic Code

    Test Procedure – PCM Motor output voltage: a) Disconnect the Motor connector at the PCM. b) Reconnect the power and switch harnesses at the PCM. c) Switch the PROHEAT on. If Motor diagnostic code is still indicated, PCM is faulty. Go to PCM replacement, page 3-39.

  • Page 51: Auxiliary Output Diagnostic Code

    Test procedure – PCM Output Signal: a) Disconnect the Auxiliary Output harness at the 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.

  • Page 52: Switch/Timer Power Diagnostic Code

    Remove the Switch Output harness at the 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.

  • Page 53: Component Mechanical Or Electrical Problems

    Go to page 3-18. 3.2.7 PCM Fuse Protects the 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.
  • Page 54 Remove blower housing (2) screws and blower housing. MOUNTING BOLTS (2) TORQUE = 100 in-lbs TEMP SENSOR 1 FUSE COVER AND FUSE FUEL INLET SWITCH INPUT COOLANT PUMP POWER Figure 3-44: Burner Head Removal and Motor Mechanical Check 3-38 PROHEAT M-SERIES SERVICE MANUAL...
  • Page 55 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 3-27. If the fuse is OK, the PCM is faulty. Go to PCM replacement.

  • Page 56: Operational Problems

    • Low heat output. 2. Coolant system. Go to page 3-25, 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 pages 3-4 to 3-15, Steps 1 to 7.

  • Page 57: Maintenance

    • Operating hours Annually: • Inspect and clean around the PROHEAT and exhaust system. • Inspect and clean external electrical connectors. • Test run the PROHEAT, letting it cycle at least once. Go to page 3-4, Sequence of Operation. Observe: 1.
  • Page 58 PROHEAT M-SERIES SERVICE MANUAL...

  • Page 59: Maintenance Tools

    MAINTENANCE TOOLS Minimum recommended tools. 1. PROHEAT remote switch (P/N PK0061) 2. Multimeter Repair tools required: • 4 mm – Allen wrench • 5 mm – Allen wrench • Small flat head screw driver • 5/8” wrench for nozzle removal •...
  • Page 60 PROHEAT Serial Number: Installation Date: Dealer: ® Teleflex Canada ® Energy Solutions Division Teleflex Canada 3831 No.6 Road Richmond, B.C. Canada V6V 1P6 Tel: (604) 270-6899 Fax: (604) 270-0137 Designed and Manufactured in North America Toll Free: 1-800-667-HEAT(4328) www.proheat.com © 2001 Teleflex Canada Printed in Canada Part # SL9150 Rev.

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M50M105

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