Proheat M50 G-II PCM Manuel utilisateur

G-II PCM SERVICE MANUAL

M50, M80/90 & M105/125

SERIAL NUMBERS

G-II PCM MODEL HEATERS: 705000 – TO DATE

AND ALL MODELS EQUIPPED WITH A

G-II REPLACEMENT PCM

Rev. C

CONTENTS

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

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

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

C. PROHEAT CONTROL MODULE (PCM) TYPE ............................ C-1

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

E. MODEL DESCRIPTIONS ............................................................ E-1

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

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

1.2 G-II PCM ELECTRICAL ............................................................. 1-8

1.3 TORQUE SPECIFICATIONS ....................................................... 1-9

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

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

2.2 THEORY OF OPERATION .......................................................... 2-4

2.3 MODES OF OPERATION .......................................................... 2-6

2.3.1 Standard Mode............................................................2-6

2.3.2 Preheat Mode............................................................. 2-7

2.3.3 Supplemental Mode.................................................... 2-8

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

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

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

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

4.1.2 START Diagnosti Code 1............................................ 4-5

4.1.3 FLAME OUT Diagnosti Code 2 .................................. 4-23

4.1.4 COOLANT FLOW Diagnosti Code3 ............................. 4-24

4.1.5 OVERHEAT Diagnosti Code 4.................................... 4-25

4.1.6 VOLTAGE Diagnosti Code 5...................................... 4-26

4.1.7 FLAME FAULT Diagnosti Code 6 ............................... 4-27

4.1.8 TEMP SENSOR/COOLANT FLOW

Diagnosti Code 7 .................................................... 4-27

4.1.9 FUEL SOLENOID VALVE Diagnosti Code 8 ................. 4-29

4.1.10 NOT USED Diagnosti Code 9.................................... 4-29

4.1.11 IGNITION MODULE Diagnosti Code 10 ...................... 4-30

4.1.12 COOLANT PUMP Diagnosti Code 11.......................... 4-31

4.1.13 MOTOR Diagnosti Code 12 ...................................... 4-32

4.1.14 AUXILIARY OUTPUT Diagnosti Code 13 ..................... 4-34

4.1.15 ACCESSORY/SWITCH OUTPUT Diagnosti Code 14 ..... 4-34

4.1.16 INDICATOR OUTPUT Diagnosti Code 15 .................... 4-35

4.1.17 SYSTEM CURRENT Diagnosti Code 16...................... 4-35

4.1.18 MOTOR SPEED SENSOR Diagnosti Code 17 .............. 4-35

4.1.19 CANbus ERROR Diagnosti Code 18 .......................... 4-35

PROHEAT M-SERIES G-II PCM SERVICE MANUAL

4.2 COMPONENT MECHANICAL OR ELECTRICAL PROBLEMS.......... 4-36

4.2.1 Fuel Nozzle .............................................................. 4-36

4.2.2 Fuel Solenoid Valve .................................................. 4-36

4.2.3 Fuel Regulator .......................................................... 4-36

4.2.4 Air Compressor......................................................... 4-36

4.2.5 Fuel Supply Pump ..................................................... 4-36

4.2.6 Ignition Ele trodes .................................................... 4-36

4.2.7 G-II PCM Fuse........................................................... 4-36

4.3 OPERATIONAL PROBLEMS..................................................... 4-36

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

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

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

5.3

ROTARY VANE COMPRESSOR SERVICE & VANES INSTALLATION

.... 5-7

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

ii PROHEAT M-SERIES G-II PCM SERVICE MANUAL

SAFETYA.

Throughout this manual, you will see notes labeled DANGER,WARNING,

CAUTION, and NOTICE to alert you to spe ial instru tions or pre autions

on erning a parti ular pro edure that would be hazardous if performed

in orre tly or arelessly.

Observe them arefully!

These safety alerts alone annot eliminate all hazards. Stri t omplian e

with these spe ial instru tions and ommon sense are major a ident

prevention measures.

DANGER

Imme iate hazar s that will result

in severe injury or eath.

WARNING

Hazar s or unsafe practices that

coul result in severe personal

injury or eath.

NOTICE

Information that is important to

proper installation or maintenan e,

but is not hazard-related.

CAUTION

Hazar s or unsafe practices that

coul result in minor injury or

pro uct or property amage.

A-1

PROHEAT M-SERIES G-II PCM SERVICE MANUAL

SAFETY CONSIDERATIONS

Exhaust

Inhalation of exhaust gas ( ontaining arbon monoxide) may ause severe personal

injury and/or death. Anyone suspe ted of suffering from CO inhalation should be

removed from the hazardous area and given medi al assistan e immediately.

Explosion Hazar

Do not operate heater where ombustible fumes or airborne parti les, su h as saw-

dust, are present.

Fuel

Exer ise extreme aution 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, su h as a blowtor h, around fuel.

Fire Hazar

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

Batteries

Wear hand and eye prote tion when working near batteries. Do not smoke or use open

flames near batteries.

Electrical

Ele tri sho k an ause severe personal injury, burns, and death. Before working on

any unit, dis onne t the batteries. Use only approved materials and methods when

working on the ele tri al system and follow lo al ele tri al odes. Never work with

ele tri ity in wet onditions or when you are feeling fatigued.

Poisons/Toxins

Fuel and oolant are toxi and in some ases, ar inogeni . Wear eye and hand

prote tion at all times. Remove ontaminated lothing immediately and wash

ontaminated skin. Do not breathe in vapors.

Moving/Hot Parts

Moving parts an ause severe injury and or death. Before working on any unit, shut it

off. Do not operate any unit until prote tive overs have been repla ed. Always ensure

bolts and lamps are orre tly torqued and se ured. Inspe t me hani al omponents

periodi ally for damage and orrosion.

Coolant

Never remove the filler ap when the engine is hot – es aping steam or s alding water

ould ause serious personal injury. The oolant level in the expansion tank should be

he ked at least weekly (more frequently in high mileage or arduous onditions). Always

he k the level when the system is cold. Uns rew the filler ap slowly, allowing the

pressure to es ape before removing ompletely. Never run the engine without oolant.

Prevent anti-freeze oming in onta t with the skin or eyes. If this o urs, rinse

immediately with plenty of water. Anti-freeze will damage painted surfa es.

Never top-up with salt water. Even when travelling in territories where the water supply

ontains salt, always ensure you arry a supply of fresh (rain or distilled) water.

California Proposition 65 Warning

Do not operate heater in garages or in other close or unventilate areas.

Diesel exhaust an some of its constituents are known to the State of California to

cause cancer, birth efects, an other repro uctive harm.

Electrical components in this pro uct may contain lea , a chemical known to the

State of California to cause cancer an birth efects an other repro uctive harm.

WARNING

DANGER

A-2 PROHEAT M-SERIES G-II PCM SERVICE MANUAL

INTRODUCTION

MODEL: M50, M80, M90,

M105, & M125 G-II PCM

This manual is provided to assist in troubleshooting and maintaining the

PROHEAT M-Series heater. They are designed for use on any diesel-equipped

vehi le in luding tru ks, buses (s hool, transit and oa h), onstru tion

equipment, off road equipment, military equipment and argo.

PROHEAT heaters are used for the following appli ations:

(1) Engine Blo k Heat – The PROHEAT will preheat an engine blo k to ensure

reliable starting in old weather. Its’ use throughout the year will redu e

engine wear aused by old starts.

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

the vehi le is operating to provide supplemental heat for the engine

and/or passenger ompartment.

(3) Cargo Heat – The PROHEAT an supply heat to individual ompartments

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

an existing heating system.

(4) Marine – Marine applications typically involve the

engineering an

installation of a complete hot-water

heating system of which PROHEAT

is only one component. SeaStar Solutions recommen s that only an

expert in marine hot-water heating systems install a PROHEAT for

marine applications. NOTE: It is the

installer’s responsibility to ensure

that an installation

complies with all applicable co es an regulations.

Figure B-1.

B-1

PROHEAT M-SERIES G-II PCM SERVICE MANUAL

B-2

PROHEAT CONTROL

MODULE (PCM) TYPE

The G-I Proheat Control Module (PCM) is no longer available has been repla ed

with the G-II PCM. The new G-II PCM in orporates a new dual mode analog/digital

temperature

sensor and advan ed Data Link software. Both styles an be

identified in the figures below.

THIS MANUAL COVERS ONLY THE G-II PCM.

Please see G-I PCM Service Manual (M50/M80) part number

SL9150. This can be foun by visiting www.proheat.com

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

G-I PCM G-II PCM

METRI-PACK

12052644 AUX

CONNECTOR

KEYING

7 PIN

DATA LINK

CONNECTOR

FOUR PIN

DUAL MODE

TEMPERATURE

SENSOR

CONNECTOR

METRI-PACK

12052641 AUX

CONNECTOR

KEYING

2 X TWO PIN

ANALOG

TEMPERATURE

SENSOR

CONNECTORS

6 PIN

DATA LINK

CONNECTOR

NO AIR FILTER

RETENTION

TANGS

AIR FILTER

RETENTION

TANGS

STATUS

INDICATOR

LIGHT

PROHEAT M-SERIES G-II PCM SERVICE MANUAL C-1

C-2 PROHEAT M-SERIES G-II PCM SERVICE MANUAL

DUAL MODE

TEMP SENSOR

STATUS

INDICATOR

LIGHT

DUAL MODE

HAS 4 PIN

CONNECTOR

G-II PCM

DUAL MODE

TEMP

SENSOR

ANALOG TEMP

SENSOR

NO STATUS

INDICATOR

LIGHT

ANALOG SENSOR

HAS 2 PIN

CONNECTOR

G-I PCM

ANALOG

TEMP

SENSOR

Figure C-2. G-II PCM can be identified on a heater by looking for the status indicator light.

Also the Dual Mode Temp Sensor has a 4 pin connector.

Figure C-3. G-I PCM can be identified on a heater by not having the status indicator light.

Also the Analog Temp Sensor has a 2 pin connector.

NOTICE

For ontinuity, all figures shown in this

manual will use a diaphragm ompressor

unless

where spe ial instru tions or

illustrations

are required

Figure D-2. Diaphragm Compressor Type.

COMPRESSOR TYPED.

The rotary vane ompressor is no longer available has been repla ed with the

diaphragm type. Both styles an be identified in the Figures below. Please refer

to the M-Series Parts Book at www.proheat. om for part numbers. This manual

overs both styles of ompressors and learly identifies the differen es

where appli able.

Figure D-1. Rotary Vane Compressor Type.

DIAPHRAGM COMPRESSOR

Serial Numbers:

700000 – To Date

Serial Numbers:

500000 – 699999

ROTARY VANE COMPRESSOR

D-1

PROHEAT M-SERIES G-II PCM SERVICE MANUAL

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