Procom PCK80T User manual

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 [e-mail]

www.usaprocom.com 160177-01B2
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 andcompletely
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

www.usaprocom.com 3160177-01B
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 ft2
(2800 cm2) 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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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
Top Handle
Fuel Tank
Cold Air
Inlet
Power
Cord
Fuel Cap
Fuel
Gauge
Hot Air
Outlet
Serial
Number
Label

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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,oildrained fromcrank-
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 afresh 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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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
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 mm2) rated cord
• 11 to 100 feet (3.3 to 30.5 m) long, use
16 AWG (1.0 mm2) rated cord
• 101 to 200 feet (30.8 to 61 m) long, use
14 AWG (1.5 mm2) 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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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
generatorhasbeenproperlycon-
nected toearth ground.Improper
grounding or failure to ground
generator can result in electro-
cution if a ground fault occurs.
Refertoowner’smanualsupplied
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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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-
ondsafterheater is pluggedin.
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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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
attempttoservice heaterwhileit
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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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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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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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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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 tur n 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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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

www.usaprocom.com 15160177-01B
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
Photocell
Blue
Blue
White
White
White
White
Power Plug
120V/60Hz
Thermostat
Control
Green
Green
Red
Black
Black
Yellow/White
Yellow/White
Photocell
Heater Control Assembly
Temp.
Temp.
Ignitor
Ignitor
Ignitor
Motor Return
AC Neutral (N)
120V (L1)
Motor Main
Motor

www.usaprocom.com 160177-01B16
PARTS
MODEL PCK80T
12
13
19
20
22
21
22
27
28
23
24
25
26
14
14
16
29
10
15
17 18
3
30
4
5
6
9
7
811
1
2

www.usaprocom.com 17160177-01B
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
1160075-01 Guard Wire 1
2160101-01 Shell Screw 8
3160050-01GY Upper Shell, Painted 1
4160134-01 Combustion Chamber Assy. 1
5 160051-01GY Lower Shell, Painted 1
6see detail, pg 19 Nozzle Bracket Assembly
7 160011-01 Fan 1
8see detail, pg 18 Motor/Pump Assembly
9see 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 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 160019-01 Thermostat Control 1
28 160027-01 Control Knob 1
29 160149-01 Handle 1
30 160083-01 Shell Heat Shield 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 160177-01B18
1
16
15 14
13
12
18 1711
10
9
8
7
6
5
4
3
2
PHOTOCELL ASSEMBLY
1
2
3
ITEM PART # DESCRIPTION QTY
1160041-03 Photocell Bracket 1
2160092-02 Screw, 6-32 x .38 2
3160016-01 Photocell Assembly 1
ITEM PART # DESCRIPTION QTY
1160001-01 Motor 1
2160023-01 Rotor Insert 1
3160003-01 Pump Rotor 1
4160006-01 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
9160010-01 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 19160177-01B
PARTS
NOZZLE ASSEMBLY
MODEL PCK80T
ITEM PART # DESCRIPTION QTY
1160028-01 Nozzle Adapter 1
2160042-01 Nozzle Adapter Bracket 1
3160102-01 Screw, 10-16 x .38 2
4160002-01 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
1-866-573-6074 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
1-866-573-6074 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. B
08/13
ProCom Heating, Inc.
Bowling Green, KY 42101
www.usaprocom.com
1-866-573-0674