Proheat M80 - Manual (Page 2)

PROHEAT G-I PCM SERVICE MANUAL i
CONTENTS
A. SAFETY ...................................................................................... A-1
SAFETY CONSIDERATIONS ..............................................................A-2
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