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Recommended Pre-Season Maintenance For HYDRONIC Heaters
Before the cold weather arrives, it is recommended that your HYDRONIC 4 / 5 or 10 heaters receive a preseason check. Please use the recommended tools and follow the procedures as outlined in the heater manual while removing and reinstalling the different heater components. Pre‐season maintenance will make sure that your heater(s) are clean, free running and ready for a trouble free season.
The heaters should be inspected and repaired by an Espar trained mechanic, as follows:
1. Check all electrical connections from the heater to the batteries. Check for wear and abrasion along the length of the harnesses. Repair or replace the harness whenever the harness insulation is broken or damaged. Check the battery connections. Clean any corrosion at the terminals. Replace the battery terminals if the corrosion is severe. Check the fuse for corrosion and the correct rating.
2. Check all clamps and hoses. Replace as required.
3. Check the condition of the exhaust system. Check for holes and breaks in the exhaust piping. Replace the exhaust as necessary.
4. Check the fuel pump filter ‐ clean or replace as necessary. For heaters with external fuel pumps, ensure mounting angle of the fuel pump is in between 15‐35o. An incorrectly mounted fuel pump may lead to excessive carbon issues. Check the fuel lines for possible leaks, loose clamps, etc. Once the entire fuel system has been checked and any issues corrected, it is advisable to do a fuel quantity check.
5. Check and clear clogged weep holes on the side of the heater body. Look for any indication of coolant leakages. If leakage is suspected then remove cover with water pump assembly and inspect and replace “O” rings on water pump housing. Closely inspect the heater waterjacket for leakages and replace “O” ring between waterjacket and heat exchanger. If the waterjacket is cracked, replace it.
6. Remove and replace the glow pin screen. Make sure that the new screen is installed correctly as outlined in the repair manual for the heater.
7. Remove and check the glow pin. If it shows signs of dissimilar color or if the glow pin is in any way distorted, replace it.
8. The coolant pump should be removed and the impeller checked for damage. Any dirt or metal particles on the impeller magnet should be removed and the cavity in the pump should also be cleaned. Please Note: coolant pumps are not covered by warranty if the vehicle’s coolant system is excessively contaminated. Refer to Technical Circular 250.
9. Remove the flame tube and check the condition of the flame tube end. The flame tube should be light brown in color with no excessive carbon on the end of the flame tube. Check for carbon build up on the burner “nose” at the cold end of the flame tube. Any carbon covering the air slots should be removed. Check the inside of the heat exchanger and scrape any loose carbon out from between the fins in the heat exchanger. Re‐install the flame tube replacing all gaskets.
10. Re‐assemble the heater and test operation. The heater should be bench tested for 15‐20 minutes before returning the heater to the vehicle.
11. Regardless of the season, run the heater every month for a minimum period of 15 minutes. This will help the heater to burn away any combustion residue in the burner chamber and prevent corrosion in the waterjacket and decay of “O”rings.
Recommended Pre-Season Maintenance For AIRTRONIC Heaters
It is recommended that the AIRTRONIC heaters receive a pre-season check-up to make sure that the heaters are ready for a trouble-free cold weather season. Always use the recommended tools and follow the procedures as outlined in the manual while removing and reinstalling the heater components.
The heaters should be inspected and repaired by an Espar trained mechanic, as follows:
1. Before initial operation ensure that the heater is not being subjected to external loads by heavy objects being placed over it. This may cause damage to the heater parts and affect its normal operation. Ensure that sufficient clearances, as recommended in the heater manual are being maintained around the heater, even while the vehicle is in operation.
2. Check the return air inlet port and hot air outlet port for any blockages. Inspect the length of ducting for any damage and replace as necessary. Ensure all ducting connections are secure. Discourage heat sensitive materials from being placed too close to the heater, ducting components or hot air outlet ports.
3. Check all electrical connections from the heater to the batteries. Check for wear and abrasion along the length of the harnesses. Repair or replace the harness whenever the harness insulation is broken or damaged. Check the battery connections. Clean any corrosion at the terminals. Replace the battery terminals if the corrosion is severe. Check the fuse for corrosion and the correct rating.
4. Remove the glow pin and if necessary, clean it. If the glow pin shows signs of dissimilar color or distortions, replace it. Inspect the glow pin wires for damage and if necessary, replace it. Remember to clean the glow pin chamber and ensure glow pin ventilation hole is clear of any obstructions, than replace the glow pin.
5. Regardless of its condition, remove and replace the glow pin screen every pre-season. Make sure that the new screen is installed correctly. Install the new screen.
6. Check the condition of the exhaust pipe. Look for any holes or breaks in the exhaust piping. Replace if necessary. Ensure the exhaust pipe is securely located and correctly routed.
7. Check the condition of the combustion air intake tube. Clear any blockages. If damaged, replace it. Ensure that the combustion air intake tube is securely located and correctly routed.
8. Ensure mounting angle of the fuel pump is in between 15-35 degrees. An incorrectly mounted fuel pump may lead to excessive carbon issues. Check the fuel lines for possible leaks, loosened clamps, etc., inspect the filter on the suction side fuel pump filter, clean or replace as necessary. Once the entire fuel system has been checked and any issues corrected, it is advisable to do a fuel quantity check.
9. If the fuel quantity result is above specification, then it will be a cause for excessive carbon issues and the fuel pump should be replaced. If the fuel quantity result is within specifications, but on the higher side, then any possible excessive carbon issues may be corrected by increasing the mounting angel of the fuel pump to the near vertical position. If fuel quantity result is below specification, then it is recommended that the fuel pump may be replaced only if the heater repeatedly flames out during operation.
10. If there are complaints about the heater smoking excessively during operation then remove and check the condition of the burner. The burner should be light brown in color. Clean any carbon build up inside the burner tube. Check the inside of the heat exchanger and scrape out any loose carbon.
11. When reassembling the burner and the heat exchanger use a new thermal insulator. Likewise, when reassembling the blower motor assembly use a new blower gasket.
12. Reassemble the heater and test operation. The heater should be bench tested for 15-20 minutes before returning the heater to the vehicle.
13. Regardless of the season, run the heater every month for a minimum period of 15 minutes. This will help the heater to burn away any combustion residue in the burner chamber. It will ensure that the fuel in the lines to the heater does not gel and solidify and that the heater will start reliably when heating season arrives.
See attached link for details – ESPAR_Technical April20
With over 55 years experience Arctic Traveler Canada is a proven and trusted specialist in mobile climate control. We carry a variety of mobile heating solutions to complement your Commercial, Industrial, Construction, Mining or Agriculture application. From 16-65,000 BTU’s, our Cabin, Headliner and Rooftop heaters will supplement your Gas or Diesel needs and provide hours of comfort.
ESPAR Engine, Cabin & Cargo Heaters – Gas or Diesel operated air & coolant heaters.
|Airtronic series – From the smallest on the market D2 to the 27,300 BTU’s D8, ESPAR uses innovative heating technology to provide great comfort and warmth for every application, with pleasant temperatures prevailing on cabin entry.
Hydronic series – 7,170-17,755 BTU – Fuel-powered water heater used to heat the cabin and or the engine and to de-ice the windows (defrost). The heater’s compact design, with its integrated water pump and fuel metering pump (in the diesel version), saves time when installing the heater.
REDDOT Auxiliary Heaters. Among the most Versatile and maintenance free
|R250 series 16-30 BTU’s – Round tube and fin design allows heater mounting in any position, using multi-position leg brackets or flush mount frame. The compact size, simple plumbing and high output are ideal in any application.
R290 & R295- Single or Double Blower – 20-35,000 BTU’s – The big brother of the pair with two high performance three-speed motor blower assemblies, delivers where it’s needed most.
R3500– 49,000 BTU’s – This crew cab heater was designed to be able to heat larger cabs in extreme conditions. Its low profile and heavy duty construction allows for use in various applications.
ATC Heaters – Versatile and maintenance free
|892059 – 27,000 BTU’s , 892041 – 40,000 BTU’s, 892002 – 65,000 BTU’s|
Available in 12V & 24V, these auxiliary heaters are designed to heat larger cabs in extreme conditions. With a high performance 3 speed blower assembly, compact size, simple plumbing, heavy duty construction and high output, these heaters deliver where it counts and are ideal in any application.
Quick Heater Service Tip from Reddot
- When the status is “heater fan doesn’t work,” check the ground connection for rust, paint, grime, or some other obstruction at the terminus.
- If the motor doesn’t have a ground wire, its mount serves as a ground connection. Make sure nothing impedes the mount’s ground path.
- Use a multimeter to make sure you’re getting full voltage to the motor. Once you know the voltage is adequate, you can then look for worn brushes, dirty squirrel-cage fans, damaged fan blades, and other more typical motor problems.