ProCom Heating PCK80T Manuel utilisateur

IMPORTANT: Read and understand this manual before

assembling, starting or servicing heater. Improper use

of heater can cause serious injury. Keep this manual for

future reference.

Never use heater in living or sleeping areas.

Heater is suitable for outdoor use and for use on com-

bustible oors.

PORTABLE FORCED AIR HEATER

KEROSENE/DIESEL HEATER WITH BUILT-IN THERMOSTAT

OWNER’S MANUAL

PCK80T - 80,000 BTU/HR

Questions, problems, missing parts? Before returning to your retailer, call

our customer service department at 1-866-573-0674, 7:30 am - 4:15 pm CST,

Monday through Friday or email customerservice@usaprocom.com

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160177-01C2

2. Fueling

a) Personnel involved with fueling shall be

qualied and thoroughly familiar with

the manufacturer's instructions and

applicable regulations regarding the

safe fueling of heating units.

b) Only the type of fuel specied on the

heater's data plate shall be used.

c) All ame shall be extinguished and the

heater allowed to cool, prior to fueling.

d) During fueling, all fuel lines and fuel-

line connections shall be inspected for

leaks. Any leaks shall be repaired prior

to returning the heater to service.

e) At no time shall more than one day's

supply of heater fuel be stored inside

a building in the vicinity of the heater.

Bulk fuel storage shall be outside the

structure.

f) All fuel storage shall be located a mini-

mum of 25 feet (762 cm) from heaters,

torches, welding equipment and similar

sources of ignition (exception: fuel res-

ervoir integral with heater unit or any

authorized auxiliary tank connected to

heater unit).

g) Whenever possible, fuel storage shall

be conned to areas where oor pen-

etrations do not permit fuel to drip onto

or be ignited by a re at lower elevation.

h) Fuel storage shall be in accordance

with the authority having jurisdiction.

3. Use only the electrical voltage and fre-

quency specied on model plate.

4. Heater is suitable for outdoor use.

5. Heater must be grounded. Use only a

properly grounded three-wire extension

cord. Plug into grounded outlet only.

6. Use only in areas free of ammable va-

pors or high dust content.

WARNING: This product

contains and/or generates

chemicals known to the State

of California to cause cancer or

birth defects or other reproduc-

tive harm.

IMPORTANT: Read this owner’s

manual carefully and completely

before trying to assemble,

operate or service this heater.

Improper use of this heater can

cause serious injury or death

from burns, fire, explosion,

electrical shock and carbon

monoxide poisoning.

DANGER: Carbon monoxide

poisoning may lead to death!

Carbon Monoxide Poisoning: Early signs of

carbon monoxide poisoning resemble the u,

with headaches, dizziness and/or nausea. If

you have these signs, the heater may not be

working properly. Get fresh air at once! Have

heater serviced. Some people are more af-

fected by carbon monoxide than others. These

include pregnant women, persons with heart

or lung disease or anemia, those under the

inuence of alcohol and those at high altitudes.

Make certain you read and understand all

warnings. Keep this manual for reference. It

is your guide to safe and proper operation of

this heater.

1. Use only kerosene, #1/#2 diesel/fuel oil,

JET A or JP-8 fuels to avoid risk of re or

explosion. Never use gasoline, oil from

crank cases, naphtha, paint thinners,

alcohol or other highly ammable fuels.

SAFETY

TABLE OF CONTENTS

Safety ........................................................ 2

Unpacking.................................................. 3

Assembly ................................................... 3

Product Identication and Label Locations ... 4

Specications ............................................ 5

Fuels .......................................................... 5

Ventilation .................................................. 5

Operation ................................................... 6

Operation with Portable Generator ............ 7

Storing, Transporting or Shipping .............. 7

Preventative Maintenance Schedule ......... 7

Troubleshooting ......................................... 8

Service Procedures ................................... 9

Wiring Diagram ........................................ 15

Technical Service..................................... 15

Accessories ............................................. 15

Parts ........................................................ 16

Replacement Parts .................................. 19

Warranty .................................................. 20

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3160177-01C

SAFETY

UNPACKING

7. Minimum clearance from any combustible

materials: 8 feet (244 cm) from hot air

outlet, 6 feet (183 cm) from top, and 4

feet (120 cm) from sides and inlet.

8. Locate heater on a stable and level sur-

face while hot or operating or a re may

occur.

9. Heater is acceptable for use on ooring

such as wood (a combustible material).

10. Use only in well vented areas. Before

using heater, provide at least a 3 ft

2

(2800 cm

2

) opening of fresh, outside air

for each 100,000 Btu/Hr (30 kw) of rating.

11. Keep children and animals away from

heater at all times.

12. Never start heater when combustion

chamber is hot or if fuel has accumulated

in combustion chamber.

13. This heater is equipped with a thermostat.

Heater may start at anytime.

14. Never leave a heater plugged in without

adult supervision if children or animals are

likely to be present.

15. Use caution when moving or storing

heater when fuel tank contains fuel. Fuel

spillage can occur.

16. Use heater only in accordance with lo-

cal ordinances and codes. Canadian

residents should refer to CSA standard

B139, Installation Code for Oil Burning

Equipment for recommended installation

practice.

17. Never use gasoline, crankcase drainings,

naphtha, paint thinners, alcohol or other

highly ammable fuels.

18. Never use heater where gasoline, paint

thinner or other highly ammable vapors

are present.

19. Never use heater in living or sleeping

areas.

20. Never move, handle, refuel or service a

hot, operating or plugged-in heater.

21. Never attach duct work to front or rear of

heater.

22. Heaters used in the vicinity of tarpaulins,

canvas or similar enclosure materials shall

be located a safe distance from such ma-

terials. The recommended minimum safe

distance is 10 feet (304.8 cm). It is further

recommended that these enclosure ma-

terials be of a re retardant nature. These

enclosure materials shall be securely fas-

tened to prevent them from igniting or from

upsetting the heater due to wind action.

23. Unplug heater when not in use.

24. Never block air inlet (rear) or air outlet

(front) of heater.

25. Warning to New York City Residents

For Use Only At Construction Sites in

accordance with applicable NYC codes.

26. Never use external fuel sources or tanks

that are not specically designed for use

with this heater.

Figure 1 - Wire Guard Moved to Locked

Position

1. Remove all packing items applied to

heater for shipment.

2. Remove all items from carton.

3. Check items for any shipping damage. If

heater is damaged call ProCom Heating,

Inc. at 1-866-573-0674 for replacement

parts before returning to dealer.

ASSEMBLY

WIRE GUARD

All Models

Grasp wire guard from top of shell and pull

towards front of heater until it locks into place

in slots on both sides of upper shell.

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160177-01C4

PRODUCT IDENTIFICATION AND LABEL LOCATIONS

Fueling Label

Part No. 160168-01

Warning Label

Part No. 160110-01

Operating Label

Part No. 160173-02

Maintenance Label

Part No. 160175-01

Caution Label

Part No. 160172-01

Figure 2 - Product Identication & Label Locations

CSA/Control Label

Part No. 160111-02

NY, MA and CA

Information Label

Part No. 160169-01

Right Side

Left Side

Hot Air

Outlet

Thermostat

Knob

Wire

Guard

Top Handle

Fuel Tank

Cold Air

Inlet

Power

Cord

Fuel Cap

Fuel

Gauge

Hot Air

Outlet

Serial

Number

Label

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5160177-01C

SPECIFICATIONS

VENTILATION

Example: A 80,000 Btu/Hr (23.4 kw) heater

requires one of the following:

• a two-car garage door [16 feet (4.88 meter)

opening] raised 2.2" (5.6 cm)

• a single-car garage door [9 feet (2.74 me-

ter) opening] raised 3.3" (7.4 cm)

• two, 30" (76.2 cm) windows raised 6.2"

(13.9 cm)

FUELS

• noticeable odor

• additional fuel lter maintenance

* Use of #2 diesel/fuel oil in extreme cold

temperatures may require nontoxic anti-icer

additives.

Do not use fuels heavier than No. 2 grade

or heavy oils such as oil drained from crank-

cases. These heavy oils will not ignite properly

and will contaminate the heater.

IMPORTANT: Use a KEROSENE ONLY (blue)

or DIESEL ONLY (yellow) storage container.

Be sure storage container is clean. Foreign

matter such as rust, dirt or water will cause the

ignition control assembly to shut down heater.

Foreign matter may also require heater's fuel

system to be frequently cleaned.

PCK80T

Output Rating 80,000 Btu/Hr

Fuel Use only kerosene, #1/#2 diesel*/fuel oil,

JET A or JP-8 fuels

Fuel Tank Capacity 5.5 gal/20.8 L

Fuel Consumption (per hr) 0.60 gal/2.3 L

Pump Pressure 3.8 PSI (hot)

Electric Requirements 120 V/60 HZ

Amperage (Normal Run) 2.5

Typical Motor Speed 3400 RPM

Motor 1/4 hp

Shipping Weight 42 lbs/19 kg

Heater Weight without Fuel (approx) 36 lbs/16.3 kg

WARNING: Use only kero-

sene, #1/#2 diesel/fuel oil, JET

A or JP-8 fuels to avoid risk

of re or explosion. Never use

gasoline, oil drained from crank-

cases, naphtha, paint thinners,

alcohol or other highly am-

mable fuels.

Use only kerosene, #1/#2 diesel*/fuel oil,

JET A, JP-8 fuels. Heavier fuels such as No.

2 fuel oil, No. 2 diesel fuel may also be used

but will result in:

WARNING: Provide a fresh air

opening of at least three square

feet (2,800 square cm) for each

100,000 BTU/HR rating. Provide

extra fresh air if more heaters

are being used. The minimum

ventilation requirements must

be followed to avoid risks as-

sociated with carbon monoxide

poisoning. Make certain these

requirements are met prior to

operating heater.

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160177-01C6

C

160111-02

5,567,144 D663,812

D663,813

D663,815

Standards/normes/Normas:

UL 733 - Fourth Edition

CSA-B140.0-03

CSA B140.8-1967

CSA C22.2 No.3-M1988

ASSEMBLED IN THE USA BY:

ASSEMBLE AUX ETATS-UNIS PAR:

ENSAMBLADA EN LOS EE.UU.POR:

PROCOM HEATING, INC.

2800 GRIFFIN DRIVE

BOWLING GREEN, KY 42101

40

50

60

70

80

90

THERMOSTAT F

THERMOSTATO F

O

START/RUN

ENCIENDA/OPERACION

DEMARRE/MARCHE

`

STANDBY

IMPORTANT: Review and un-

derstand the warnings in the

Safety section, pages 2 and 3.

They are needed to safely oper-

ate this heater. Follow all local

ordinances and codes when

using this heater.

TO START HEATER

1. Follow all ventilation and safety information.

2. Locate heater to provide maximum circu-

lation of the heated air. Follow all location

requirements noted in Safety, pages

2 and 3.

3. Fill fuel tank with fuel and attach fuel cap.

Use only kerosene, #1/#2 diesel/fuel oil,

JET A or JP-8 fuels to avoid risk of re or

explosion. Never use gasoline, oil drained

from crank cases, naphtha, paint thinners,

alcohol or other ammable fuels.

4. Plug heater’s power cord into approved,

grounded, three-wire extension cord.

Extension cord must be at least 6 feet

(1.8 m) long.

Extension Cord Size Requirement

• 6 to 10 feet (1.8 to 3 m) long, use 18

AWG (0.75 mm

2

) rated cord

• 11 to 100 feet (3.3 to 30.5 m) long, use

16 AWG (1.0 mm

2

) rated cord

• 101 to 200 feet (30.8 to 61 m) long, use

14 AWG (1.5 mm

2

) rated cord

5. Plug extension cord into standard 120

volt/60 hertz, 3-prong grounded outlet.

6. Turn thermostat knob to the desired tem-

perature setting.

If thermostat set temperature is higher

than the surrounding air temperature,

heater should ignite immediately. If heater

thermostat set temperature is lower than

surrounding air temperature, heater will

not ignite. Exposure to direct sunlight

or extreme cold may affect temperature

reading and/or thermostat operation.

The LED will ash for 8 seconds before

ignition. The LED will remain on during

heater operation, even if the heater is

cycled off by the thermostat. The LED will

ash rapidly if the heater shuts down for

any reason (Example: If out of fuel).

WARNING: This heater is

equipped with a thermostat.

Heater may start at any time.

TO STOP HEATER

1. Turn thermostat knob counterclockwise

to STANDBY.

2. Unplug heater when not in use.

TO RESET HEATER

1. Wait two minutes before restarting.

2. Turn thermostat knob to STANDBY for 10

seconds, then restart heater.

OPERATION

Figure 3 - Controls Display

Thermostat Knob

LED Light

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7160177-01C

Ground Wire (#10 AWG -

Stranded-Copper)

Copper

or Brass

Grounding

Point

Figure 4 - Typical Generator Grounding

Method (Generator construction may

vary from that shown)

PREVENTATIVE MAINTENANCE SCHEDULE

WARNING: Never service heater while it is plugged in, operating

or hot. Severe burns and electrical shock can occur.

OPERATION WITH PORTABLE GENERATOR

Alternator

Ground Lug

WARNING: Before operating

heater or any appliance from a

portable generator, verify that

generator has been properly con-

nected to earth ground. Improper

grounding or failure to ground

generator can result in electro-

cution if a ground fault occurs.

Refer to owner’s manual supplied

by generator manufacturer for

proper grounding procedures.

Operating voltage range of heater is 95 to 135

Volts. Prior to plugging heater into generator

output voltage should be veried (if generator

is equipped with automatic idle feature, output

voltage should be measured with generator

running at full speed). If voltage does not

STORING, TRANSPORTING OR SHIPPING

3. Properly dispose of old and dirty fuel.

Check with local automotive service sta-

tions that recycle oil.

4. If storing, store heater in dry place. Make

sure storage place is free of dust and

corrosive fumes.

IMPORTANT: Do not store kerosene over

summer months for use during next heating

season. Using old fuel could damage heater.

measure in this range heater should not be

plugged into generator.

Refer to Operation, page 6, for starting, stop-

ping and resetting heater procedures.

Note: If shipping, transport companies require

fuel tanks to be empty.

1. Remove excess fuel from tank using a si-

phon pump. Drain remaining fuel through

ller neck by tipping heater to the rear.

2. If any debris is noted in old fuel, add 1 or 2

quarts of clean kerosene to tank, stir and

drain again. This will prevent excess debris

from clogging lters during future use.

Item How Often How To

Fuel tank Clean every season or as needed. See Storing, Transporting, or

Shipping, above.

Air output and

lint lters

Replace every 500 hours of operation or

once a year.

See Air Output, Air Intake and

Lint Filters, page 10.

Air intake lter Wash and dry with soap and water every 500

hours of operation or as needed.

See Air Output, Air Intake and

Lint Filters, page 10.

Fuel lter Clean twice a heating season or as needed. See Fuel Filter, page 11.

Fan blades Clean every season or as needed. See Fan, page 10.

Motor Not required/permanently lubricated.

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160177-01C8

TROUBLESHOOTING

WARNING: Never service heater while it is plugged in, operating

or hot. Severe burns and electrical shock can occur.

WARNING: High voltage! Unplug heater before servicing.

FAULT CONDITION POSSIBLE CAUSE REMEDY

Motor does not start eight sec-

onds after heater is plugged in.

1. No power to heater.

2. Thermostat setting is too

low.

3. Bad electrical connection

between motor and ignition

control assembly or igni-

tion control assembly and

power cord.

4. Binding pump rotor.

5. Defective ignition control

assembly.

6. Defective motor.

1. Check circuit breaker in

electrical panel.

2. Turn thermostat knob to a

higher setting.

3. Check all electrical connec-

tions. See Wiring Diagram,

page 15.

4. If fan does not turn freely,

see Pump Rotor, page 14.

5. Replace ignition control as-

sembly. See Ignition Control

Assembly, page 13.

6. Replace motor.

Motor starts and runs but

heater does not ignite.

1. No fuel in tank.

2. Pump pressure incorrect.

3. Dirty fuel lter.

4. Obstruction in nozzle.

5. Water in fuel tank.

6. Bad electrical connection

between ignitor and ignition

control assembly.

7. Defective ignitor.

8. Defective ignition control

assembly.

1. Fill tank with kerosene.

2. See Pump Pressure Ad-

justment, page 11.

3. See Fuel Filter, page 11.

4. See Nozzle Assembly,

page 13.

5. Drain and ush fuel tank

with clean kerosene. See

Storing, Transporting, or

Shipping, page 7.

6. Check electrical connec-

tions. See Wiring Diagram,

page 15.

7.

Replace ignitor, see page 12.

8. Replace ignition control as-

sembly. See Ignition Control

Assembly, page 13.

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9160177-01C

TROUBLESHOOTING

WARNING: High voltage! Unplug heater before servicing.

FAULT CONDITION POSSIBLE CAUSE REMEDY

Heater ignites but ignition

control assembly shuts heater

off after a short period of time.

1. Pump pressure incorrect.

2. Dirty air intake, air output,

and/or lint lter.

3. Dirty fuel lter.

4. Obstruction in nozzle.

5. Photocell assembly not

properly installed (not see-

ing the ame).

6. Dirty photocell lens.

7. Bad electrical connection

between photocell and

ignition control assembly.

8. Defective photocell.

9. Defective ignition control

assembly.

1. See Pump Pressure Ad-

justment, page 11.

2. See Air Output, Air Intake,

and Lint Filters, page 10.

3. See Fuel Filter, page 11.

4. See Nozzle Assembly,

page 13.

5. Make sure photocell boot is

properly seated in bracket.

6. Clean photocell lens.

7. Check electrical connec-

tions. See Wiring Diagram,

page 15.

8. Replace photocell.

9. Replace ignition control as-

sembly. See Ignition Control

Assembly, page 13.

SERVICE PROCEDURES

Figure 5 - Upper Shell Removal

WARNING: To avoid risk of

burn and electrical shock, never

attempt to service heater while it

is plugged in, operating, or hot.

UPPER SHELL REMOVAL

1. Remove screws along each side of heater

using 5/16" nut-driver. These screws at-

tach upper and lower shells together. See

Figure 5.

2. Lift upper shell off.

3. Remove fan guard.

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160177-01C10

Motor

Shaft

Setscrew

Figure 6 - Fan, Motor Shaft, and

Setscrew Location

Motor

Shaft

Back of Flat on

Motor Shaft

1.82"

Motor

Shaft

Length

Fan

Setscrew

Touching

Back of Flat

on Motor

Shaft

Figure 7 - Fan Cross Section

Fan

Motor

AIR OUTPUT, AIR INTAKE AND

LINT FILTERS

1. Remove upper shell (see Figure 5, page 9).

2. Remove lter end cover screws using

5/16" nut-driver (see Figure 8).

3. Remove lter end cover.

4. Replace air output and lint lters.

5. Wash or replace air intake lter.

6. Replace lter end cover.

7. Replace fan guard and upper shell.

IMPORTANT: Do not oil lters.

Air Intake

Filter

Lint Filter

Filter

End

Cover

Air Output

Filter

Figure 8 - Air Output, Air Intake, and Lint

Filters

SERVICE PROCEDURES

FAN

IMPORTANT: Remove fan from motor shaft

before removing motor from heater. The

weight of the motor resting on the fan could

damage the fan pitch (see Figure 6).

1. Remove upper shell (see Figure 5, page 9).

2. The fan is located with the set screw in

contact with the back of at on motor as

shown in Figure 7.

3. Use 1/8" Allen wrench to loosen setscrew

which holds fan to motor shaft (see Fig-

ure 6).

4. Slip fan off motor shaft.

5. Clean fan using a soft cloth moistened

with kerosene or solvent.

6. Dry fan thoroughly.

7. Place setscrew on flat of shaft.

Tighten setscrew firmly (40-50 inch-

pounds/4.5-5.6 n-m).

8. Replace fan guard and upper shell.

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11160177-01C

SERVICE PROCEDURES

PUMP PRESSURE

ADJUSTMENT

1. Remove pressure gauge plug from lter

end cover (see Figure 9).

2. Install 0-15 PSI pressure gauge.

3. Start heater (see Operation, page 6). Al-

low heater to reach operating temperature

(approx. 10 minutes).

4. Adjust pressure. Turn relief valve to right

to increase pressure. Turn relief valve to

left to decrease pressure. See specica-

tions in Figure 10 for correct pressure.

5. Remove pressure gauge. Replace pres-

sure gauge plug in lter end cover.

Figure 9 - Pressure Gauge Plug Removal

Pressure

Gauge

Plug

Pressure

Gauge

Figure 10 - Adjusting Pump Pressure

Relief

Valve

Pump

Model Pressure

80 3.8 PSI

Fuel Filter, Bushing,

and Lower Fuel Line

Upper Fuel Line

Side

Cover

Figure 11 - Fuel Filter Removal

FUEL FILTER

1. Remove side cover screws using 5/16"

nut-driver.

2. Remove side cover.

3. Pull upper fuel line off fuel lter neck (see

Figure 11).

4. Carefully pry bushing, fuel lter, and lower

fuel line out of fuel tank (see Figure 11).

5. Wash fuel lter with clean fuel and replace

in tank.

6. Attach upper fuel line to fuel lter neck.

7. Replace side cover.

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160177-01C12

IGNITOR

1. Remove upper shell and fan guard (See

Upper Shell Removal, page 9.

2. Remove fan (see page 10).

3. Remove the control side cover with a

5/16" nut driver. Remove side cover (see

Figure 12).

4. Disconnect ignitor wires from ignition

control assembly (see Figure 12). Pull

the ignitor wires up through the hole in

the lower shell.

5. Disconnect fuel line hose and air line

hose. Remove photocell from photocell

bracket (see Figure 12).

6. Remove combustion chamber. Stand

combustion chamber on end with nozzle

adapter bracket on top (see Figure 13).

7. Remove ignitor screw with a 1/4" nut

driver. Carefully remove ignitor from

nozzle adapter bracket.

CAUTION: Do not bend or

strike ignitor element. Handle

with care.

8. Carefully remove replacement ignitor from

packing.

9. Carefully guide ignitor into opening in

nozzle adapter bracket. Do not strike

ignitor element. Attach ignitor to nozzle

adapter bracket with screw using a 1/4"

nut driver. Torque 0.90 to 1.69 N-m (8 to

15 in-lbs) Do not over torque.

10. Replace combustion chamber.

11. Route the ignitor wires back down through

the hole in the lower shell. Connect wires

to the ignition control assembly (see Fig-

ure 12).

12. Replace control side cover.

13. Connect and route fuel line hose and air

line hose to nozzle adapter assembly.

14. Replace photocell in photocell bracket.

15. Replace fan (see page 10).

16. Replace fan guard and upper shell (see

pages 9 and 10).

SERVICE PROCEDURES

Photocell

Bracket

Ignitor

Ignitor Screw/

Washer Assembly

Nozzle

Adapter

Bracket

Ignitor

Element

Combustion

Chamber

Nozzle Adapter

Bracket Opening

Figure 13 - Ignitor SP002-01

Replacement

Figure 12 - Disconnecting Ignitor Wires

from Ignition Control Assembly

Photocell

Bracket

Air Line

Hose

Fuel

Line

Hose

Combustion

Chamber

Photocell

Assembly

Ignitor

Nozzle Adapter

Bracket

Ignition

Control

Assembly

Side Cover

Ignitor

Wire

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13160177-01C

Figure 14 - Removing Air and Fuel Line

Hoses

Fuel Line

Hose

Air Line

Hose

Nozzle/

Adapter

Assembly

Combustion

Chamber

Photocell

Bracket

Nozzle

Adapter

Bracket

NOZZLE ASSEMBLY

1. Remove upper shell (see Upper Shell

Removal, page 9).

2. Remove fan (see Fan, page 10).

3. Remove fuel and air line hoses from

nozzle assembly (see Figure 14).

4. Turn nozzle assembly 1/4 turn to left and

pull toward motor to remove (see Figure

15).

5. Place plastic hex-body into vise and

lightly tighten.

6. Carefully remove nozzle from the nozzle

adapter using 5/8" socket wrench (see

Figure 16).

7. Blow compressed air through face of

nozzle. This will free any dirt in nozzle

area.

8. Inspect nozzle sleeve for damage.

9. Replace nozzle into nozzle adapter until

nozzle seats. Tighten 1/3 turn more using

5/8" socket wrench 4.5 to 5.1 N-m (40 to

45 in-lbs). See Figure 16.

10. Attach nozzle assembly to burner strap

(see Figure 15).

11. Attach fuel and airline hoses to nozzle

assembly.

12. Replace fan (see Fan, page 10).

13. Replace fan guard and upper shell (see

Upper Shell Removal, page 9).

Figure 15 - Removing Nozzle/Adapter

Assembly

Nozzle/

Adapter

Assembly

Combustion

Chamber

Figure 16 - Nozzle and Nozzle Adapter

Nozzle Face

Nozzle

Nozzle Sleeve

Nozzle

Adapter

Air Line

Fitting

Fuel Line

Fitting

SERVICE PROCEDURES

IGNITION CONTROL ASSEMBLY

WARNING: High voltage!

1. Unplug heater.

2. To expose the ignition control assembly,

remove the control panel side cover

screws using 5/16" nut-driver.

3. Remove old ignition control assembly.

Install new ignition control assembly (see

Figure 12, page 12).

4. Replace control panel side cover.

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160177-01C14

PUMP ROTOR

(Procedure if Rotor is Binding)

1. Remove upper shell (see Upper Shell

Removal, page 9).

2. Remove filter end cover screws using

5/16" nut driver (see Figure 17).

3. Remove filter end cover and air filters.

4. Remove pump plate screws using 5/16"

nut-driver.

5. Remove pump plate.

6. Remove rotor, insert, and blades (see

Figure 18).

7. Check for debris in pump. If debris is

found, blow out with compressed air.

8. Install insert and rotor.

9. Check gap on rotor. Adjust to

0.076/0.101 mm (0.003"/0.004") if needed

(see Figure 18).

Note: Rotate rotor one full turn to ensure

the gap is 0.076/0.101 mm (0.003"/0.004")

at tightest position. Adjust if needed.

10. Install blades, pump plate, air filters, and

filter end cover.

11. Replace fan guard and upper shell (see

Upper Shell Removal, page 9).

12. Adjust pump pressure (see Pump Pres-

sure Adjustment, page 11).

Note: If rotor is still binding, proceed as

follows.

13. Perform steps 1 through 6.

14. Place fine grade sandpaper (600 grit) on

flat surface. Sand rotor lightly in “figure 8”

motion four times (see Figure 19).

15. Reinstall insert and rotor.

16. Perform steps 10 through 12.

Figure 17 - Rotor Location

Pump

Plate

Insert

Rotor

Blade

Filter

End

Cover

Air

Intake

Filter

Air Output Filter

Gap Adjusting

Screw

Rotor

Blade

0.003"/0.004"

(0.076-0.101 mm)

Gap Measured

With Feeler

Gauge

Gap Adjusting Screw

Figure 18 - Gap Adjusting Screw

Locations

Sandpaper

Figure 19 - Sanding Rotor

SERVICE PROCEDURES

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15160177-01C

WIRING DIAGRAM

ST002-01

AIR GAUGE KIT

Special tool to check pump pressure.

0-15 PSI gauge. 3/8" NPT pipe thread.

ST001-01

IGNITION CONTROL ASSEMBLY/

PHOTOCELL TESTER

Special tool used to test the ignition control

assembly and photocell.

ACCESSORIES

Purchase these accessories from your local dealer. If they can not supply these accessories,

contact ProCom Heating, Inc. at 1-866-573-0674 for information. You can also write to the

address listed on the back page of this manual.

TECHNICAL SERVICE

You may have further questions about installation, operation, or troubleshooting. If so, contact

ProCom Heating, Inc. at 1-866-573-0674. When calling, please have your model and serial

numbers of your heater ready.

You can also visit ProCom Heating, Inc.’s web site at www.usaprocom.com.

Photocell

Blue

White

Power Plug

120V/60Hz

Thermostat

Control

Green

Red

Black

Yellow/White

Photocell

Heater Control Assembly

Temp.

Ignitor

Motor Return

AC Neutral (N)

120V (L1)

Motor Main

Motor

www.usaprocom.com

160177-01C16

PARTS

MODEL PCK80T

12

13

19

20

22

21

22

28

23

24

25

26

14

16

29

10

15

17

18

3

27

4

5

6

9

7

8

11

1

2

www.usaprocom.com

17160177-01C

PARTS

MODEL PCK80T

This list contains replaceable parts used in your heater. When ordering parts, be sure to pro-

vide correct model and serial numbers (from model plate), and part number and description

of desired part.

ITEM PART NO. DESCRIPTION QTY

1 160075-01 Guard Wire 1

2 160101-01 Shell Screw 8

3 160050-01GY Upper Shell, Painted 1

4 160134-01 Combustion Chamber Assy. 1

5 160051-01GY Lower Shell, Painted 1

6 see detail, pg 19 Nozzle Bracket Assembly

7 160011-01 Fan 1

8 see detail, pg 18 Motor/Pump Assembly

9 see detail, pg 18 Photocell/Bracket Assembly

10 160043-01 Motor Mounting Bracket 1

11 160066-01 Fan Guard 1

12 160012-02 Fuel Filter 1

13 160034-01 Fuel Tube Bushing 1

14 160060-01 Small Shell Bracket 2

15 160021-01 Power Supply Cord 1

16 160013-01 Strain Relief Bushing 1

17 160056-01 Right Side Cover 1

18 160087-01 Clip, Nut, #10, .08 Wall 6

19 160055-01 Left Side Cover 1

20 160139-01GY Fuel Tank Assy., Small 1

21 160005-01 Fuel Gauge 1

22 160020-02 LED Ignition Control Assy. 1

23 160030-01 Vented Fuel Cap Assy. 1

24 160030-03 Vented Fuel Cap Gasket 1

25 160031-01 Plastic Filler Neck 1

26 160036-01 Filler Neck Gasket 1

27 160083-01 Shell Heat Shield 1

28 160027-01 Control Knob 1

29 160149-01 Handle 1

PARTS AVAILABLE - NOT SHOWN

160037-01 Airline Tubing 1

160039-01 Upper Fuel Line 1

160038-01 Lower Fuel Line 1

www.usaprocom.com

160177-01C18

1

16

15

14

13

12

18

17

11

10

9

8

7

6

5

4

3

2

PHOTOCELL ASSEMBLY

1

2

3

ITEM PART # DESCRIPTION QTY

1 160041-03 Photocell Bracket 1

2 160092-02 Screw, 6-32 x .38 2

3 160016-01 Photocell Assembly 1

ITEM PART # DESCRIPTION QTY

1 160001-01 Motor 1

2 160023-01 Rotor Insert 1

3 160003-01 Pump Rotor 1

4 160006-01 Pump Body 1

5 160088-01 Screw, 10-32 x .62 2

6 160007-01 Pump Cover 1

7 160009-01 Lint Filter 1

8 160008-01 Output Filter Assembly 1

9 160010-01 Intake Filter 1

10 160057-01 Filter End Cover 1

11 160025-01 Adjusting Screw 1

12 160024-01 Pipe Plug 1

13 160090-01 Screw, 10-32 x 1.0 3

14 160089-01 Screw, 10-32 x 1.12 6

15 160029-01 90° Nylon Elbow 1

16 160004-01 Pump Blade 4

17 160052-01 Pressure Relief Spring 1

18 160053-01 Steel Ball 1

PARTS

MOTOR AND PUMP ASSEMBLY

MODEL PCK80T

www.usaprocom.com

19160177-01C

PARTS

NOZZLE ASSEMBLY

MODEL PCK80T

ITEM PART # DESCRIPTION QTY

1 160028-01 Nozzle Adapter 1

2 160042-01 Nozzle Adapter Bracket 1

3 160102-01 Screw, 10-16 x .38 2

4 160002-01 Ignitor 1

5 160093-01 Belleville Washer 1

6 160092-01 Screw, 6-32 x .88 1

7 160040-32 Nozzle Assembly 1

REPLACEMENT PARTS

Contact authorized dealers of this product.

If they can’t supply original replacement

parts, call ProCom Heating, Inc. toll free at

1-866-573-0674 for referral information.

When calling have ready:

• Your name

• Your address

• Model and serial number of your heater

• How heater was malfunctioning

• Type of gas used (Propane/LP or Natural

gas/NG) and Propane/LP tank size

• Purchase date

• Place of purchase

Usually, we will ask you to return the defective

part to the factory. You may be asked to supply

proof of purchase.

Note: Use only original replacement parts. This will protect your warranty coverage for parts

replaced under warranty.

PARTS UNDER WARRANTY

PARTS NOT UNDER WARRANTY

Contact authorized dealers of this product.

If they can’t supply original replacement

part(s) call ProCom Heating, Inc. toll free at

1-866-573-0674 for referral information.

When calling have ready:

• Model and serial number of your heater

• The replacement part number

REGISTER YOUR PRODUCT AT WWW.USAPROCOM.COM

PROCOM HEATING, INC. LIMITED WARRANTIES

New Products – Outdoor Heating

Standard Warranty: ProCom Heating, Inc. warrants this new product and any parts thereof to be free from

defects in material and workmanship for a period of one (1) year from the date of rst purchase from an

authorized dealer provided the product has been installed, maintained and operated in accordance with

ProCom Heating, Inc.’s warnings and Instructions.

For products purchased for commercial, industrial or rental usage, this warranty is limited to 90 days from

the date of rst purchase.

Factory Reconditioned Products

Limited Warranty: ProCom Heating, Inc. warrants factory reconditioned products and any parts thereof to

be free from defects in material and workmanship for a period 30 days from the date of rst purchase from an

authorized dealer provided the product has been installed, maintained and operated in accordance with ProCom

Heating, Inc.’s warnings and Instructions. No return will be authorized. Parts will be provided to repair the product.

Terms Common to All Warranties

The following terms apply to all of the above warranties:

Always specify model number and serial number when contacting the manufacturer. To make a claim under

this warranty, the bill of sale or other proof of purchase must be presented.

This warranty is extended only to the original retail purchaser when purchased from an authorized dealer,

and only when installed by a qualied installer in accordance with all local codes and instructions furnished

with this product.

This warranty covers the cost of part(s) required to restore this product to proper operating condition and

an allowance for labor when provided by a ProCom Heating, Inc. Authorized Service Center or a provider

approved by ProCom Heating, Inc. Warranty parts must be obtained through authorized dealers of this

product and/or ProCom Heating, Inc. who will provide original factory replacement parts. Failure to use

original factory replacement parts will void this warranty.

Traveling, handling, transportation, diagnostic, material, labor and incidental costs associated with warranty

repairs, unless expressly covered by this warranty, are not reimbursable under this warranty and are the

responsibility of the owner.

Excluded from this warranty are products or parts that fail or become damaged due to misuse, accidents,

improper installation, lack of proper maintenance, tampering or alteration(s).

This is ProCom Heating, Inc.’s exclusive warranty, and to the full extent allowed by law; this express war-

ranty excludes any and all other warranties, express or implied, written or verbal and limits the duration of

any and all implied warranties, including warranties of merchantability and tness for a particular purpose to

one (1) year on new products and 30 days on factory reconditioned products from the date of rst purchase.

ProCom Heating, Inc. makes no other warranties regarding this product.

ProCom Heating, Inc.’s liability is limited to the purchase price of the product and ProCom Heating, Inc.

shall not be liable for any other damages whatsoever under any circumstances including direct, indirect,

incidental, or consequential damages.

Some States do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of

incidental or consequential damages, so the above limitation or exclusion may not apply to you.

This warranty gives you specic legal rights, and you may also have other rights which vary from state to state.

WARRANTY

KEEP THIS WARRANTY

Model (

located on product or identication tag

) _____________________________

Serial No. (

located on product or identication tag

) __________________________

Date Purchased ______________________________________

Keep receipt for warranty verication.

160177-01

Rev. C

02/16

ProCom Heating, Inc.

Bowling Green, KY 42101

www.usaprocom.com

1-866-573-0674

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