MAINTENANCE CHECKLIST & SCHEDULE FOR THE IDH RANGE

Size: px

Start display at page:

Download "MAINTENANCE CHECKLIST & SCHEDULE FOR THE IDH RANGE"

Cory Cummings
5 years ago
Views:

1 MAINTENANCE CHECKLIST & SCHEDULE FOR THE IDH RANGE INDUSTRIAL DIESEL HEATERS Details about recommended maintenance checks, components brief and how to check and replace parts as part of the maintenance program.

2 CONTENTS 1) Maintenance schedule.. 2 2) How to identify waxing problems. 2 3) Blending diesel fuel. 2 4) Components brief ) To check or replace fuel line. 5 6) To check or replace fuel filter.. 5 7) To check or replace air line. 5 8) To check or replace magic eye sensor (flame out protection sensor). 5 9) To check or replace fuel nozzle 6 10) To check or replace control board ) To check or replace capacitor. 7 12) To check or replace ignition transformer.. 7 1

3 RECOMMENDED MAINTENANCE SCHEDULE Due to poor quality diesel available in some regions in Australia and the continuous winter diesel problems we face each year such as wax crystallising which can lead to fuel line blockages etc, regular maintenance and adhering to our strict guidelines that include storing & preventative wax crystallising options is strongly recommended to ensure the best performance and longevity of our Diesel Heaters. All diesel fuel contains wax. It is considered an important diesel component because of its high cetane value. Normally the wax is a liquid in the fuel, however, when diesel fuel gets cold enough the wax starts to crystallise (i.e. solidify). If the temperature is sufficiently low, enough crystals will form to block the fuel filter, fuel line or nozzle. HOW TO IDENTIFY WAXING PROBLEMS If wax has formed in a diesel fuel then it will block fuel lines and filters, it is visible as a white/yellow deposit or cloud in the fuel. The heater will be hard to start or will not start due to fuel starvation. PART CHECK LOOK FOR REPLACE FUEL LINE Every 2 months Cracks or blockages Every 12 months FUEL FILTER Every 20 days Cracks or blockages Every 12 months FUEL NOZZLE Every 20 days Blockages Every 12 months AIR LINE Every 2 months Cracks Every 12 months * High frequent use or when used in colder regions will need to be checked on a more regular basis ** Replacements parts are readily available BLENDING DIESEL If you are in low temperature regions such as Alpine/highland/inland or unseasonably cold weather, a diesel blend with kerosene may provide some relief to lower the cloud point. PART NO. TANK SIZE (L) DIESEL (L) KEROSENE (L) IDH IDH IDH

4 COMPONENTS BRIEF Combustion chamber Combustion chamber with flame steady plate Flame steady plate Fuel line, Air line & Fuel filter Fuel nozzle Control board 3

5 A. Combustion chamber B. Spark plug C. Fan blade D. Motor E. Electric air pump F. Air intake filter G. Air output filter H. Fuel tank I. Control board J. Air line K. Fuel filter L. Flame steady plate M. Fuel nozzle G A. Burner assembly B. Air line C. Fuel line D. Flame steady plate E. Spark plug lead F. Spark plug G. Magic eye 4

Please ensure the heater is turned off and unplugged from the power source before doing any service work. FUEL LINE & FUEL FILTER 2. Remove side cover (not switch side) 3.

Remove fuel line, check for cracks around where the clips go or where the line passes through the body & check for waxing, If cracks or waxing is found replace line 5.

6 Please ensure the heater is turned off and unplugged from the power source before doing any service work. FUEL LINE & FUEL FILTER 2. Remove side cover (not switch side) 3. Remove clips securing fuel line to adaptor plate & fuel filter 4. Remove fuel line, check for cracks around where the clips go or where the line passes through the body & check for waxing, If cracks or waxing is found replace line 5. Pull fuel filter up and out of tank, check & make sure filter is clean & clear 6. Reassemble following steps 1-6 in reverse AIR LINE 2. Remove side cover (not switch side) 3. Remove rear grill 4. Remove clips holding air line to motor and adaptor plate 5. Remove air line, check for cracks around where the clips go or where the line passes through the body, if cracks found replace 6. Reassemble following steps 1-5 in reverse MAGIC EYE SENSOR 2. Pull magic eye out located besides spark plug 3. Using either tissue paper, soft cloth or cotton bud, gently clean the sensor inside the plug 4. Reassemble following steps 1-3 in reverse 5

7 Please ensure the heater is turned off and unplugged from the power source before doing any service work. FUEL NOZZLE (IDH50) 2. Remove clips securing fuel line & air line to the unit, then disconnect both lines 3. Remove earth wire from combustion chamber 4. Remove blue wire from thermostat, disconnect the red & earth wire from solenoid valve which is located above the spark plug 5. Disconnect spark plug lead from spark plug 6. Disconnect the magic eye located beside the spark plug 7. Pull combustion chamber out 8. Undo remaining screws holding the adaptor plate to chamber & turn adaptor plate over & remove fuel nozzle 9. Check the O ring on the end of the fuel nozzle for wear & make sure nozzle tip is not blocked To unblock fuel nozzle use a needle or fine wire or replace fuel nozzle 10. Reassemble following steps 1 8 in reverse FUEL NOZZLE (IDH20/30) 2. Remove clips securing fuel line & air line to the unit, then disconnect both lines 3. Disconnect spark plug lead 4. Disconnect magic eye sensor 5. Remove earth wire from combustion chamber 6. Pull combustion chamber out 7. Undo remaining screws holding spark plug housing to rear of chamber & remove fuel nozzle 8. Check the O ring on the end of the fuel nozzle for wear & make sure nozzle tip is not blocked To unblock fuel nozzle use a needle or fine wire or replace fuel nozzle 9. Reassemble following steps 1-7 in reverse 6

8 Please ensure the heater is turned off and unplugged from the power source before doing any service work. Control Board 1. Remove side panel on the power cord side using a Y piece or fine flat head screw driver 2. Pull side panel out 3. Remove control board pay particular attention as to where the wires go (refer to photo) 4. Check fuse located in green box on the board 5. Reassemble following steps 1-4 in reverse Start up capacitor 1. Remove side cover, power cord side 2. Pull side cover out 3. Disconnect start up capacitor from control 4. Reassemble following steps 1-3 in reverse Ignition transformer 1. Remove side cover, power cord side 2. Pull side cover out 3. Disconnect spark plug lead from transformer 4. Disconnect transformer from control board 5. Reassemble following steps 1-4 in reverse 7

HVF110, 210, 310, 410HD

342 N. Co. Rd. 400 East Valparaiso, IN 46383 219-464-8818 Fax 219-462-7985 www.heatwagon.com Installation and Maintenance Manual Please retain this manual for future reference. HVF110, 210, 310, 410HD